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Simplicity Coronet Series Service & Repair Manual

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  • Page 3: Table Of Contents

    Repair Manual Contents This manual is divided into the sections listed below. Please see the first page of each section for the specific contents of that section. Section Description Start Page End Page General Information ......1-1 —...
  • Page 4 1 General Information Table of Contents SECTION CONTENTS Models Covered Models & Identification..............1-2 Introduction Introduction .................. 1-4 Manual Content ................1-4 Safety Rules Safety Rules - General Operation..........1-5 Safety Rules - Service And Maintenance ........1-7 General Repair Information Bearings &...

  • Page 5: Models Covered

    1 General Information Models Covered In This Manual MODELS COVERED & IDENTIFICATION NUMBERS This manual contains service information for the models listed below (and similar models produced after this man- ual’s printing). Consult the Identification Tag located on the rider frame for the manufacturer’s identification num- ber and serial number.
  • Page 6 1 General Information Models Covered In This Manual Mower Decks Mfg. No. Mfg. No. Description Description 1692126 30" Mower 1694053 30” Mower 1692127 30" Mower 1692545 34” Mower 1692128 34" Mower 1693168 34” Mower (Export) 1692172 30" Mower 1692545 34” Mower 1692173 30"...

  • Page 7: Introduction

    1992 through 1998, and whenever neces- Covers removal, disassembly, inspection, and repair of sary, includes inset illustrations or other references to Simplicity serviceable hydro transmissions. help identify previous part designs and alternative ser- 10. Gear Transmission Repair vice procedures.

  • Page 8: 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 9 1 General Information Safety Rules CHILDREN GENERAL SAFETY Tragic accidents can occur if the operator is not alert to All WARNING, CAUTION, and instructional messages the presence of children. Children are often attracted to appearing in decals on the rider and mower being ser- the unit and the mowing activity.

  • Page 10: General Information

    Simplicity dealer ing equipment, grinders, or burning smoking materi- before proceeding. Never attempt a repair that you’re als.
  • Page 11 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 12 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 13: 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 14: 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 15: Specifications

    1 General Information Specifications Specifications Stroke 2.53 In. (64mm) Displacement 21.82 Cu. In. (357 cc) Electrical 12 Volt, 200 Cold Cranking Amps, 23 min. ENGINE System Reserve Capacity Ignition Electronic, Solid State, Maintenance Free 9 HP I/C — Briggs & Stratton Air Cleaner Pre-cleaner, Paper Element Air Filter Horsepower...
  • Page 16 1 General Information Specifications Lubrication Full Pressure Lube with Oil Filter Oil Capacity 4 Pints (1.9 L) CHASSIS Fuel Capacity 2 Gal. (7.57 L) Frame Heavy Gauge , Deep Drawn Steel Muffler Quiet Compact, Low Back Pressure Front Axle Self-Leveling Quick Hitch Seat Deck Lightweight Polymer Alloy 16 HP Command™...

  • Page 17: Torque Specifications

    1 General Information Hardware Identification Torque Specifications Hardware Identification & Torque Specifications Common Hardware Types Torque Specification Chart Hex Head Capscrew FOR STANDARD MACHINE HARDWARE (Tolerance ± 20%) Washer Hardware Lockwasher Marks Grade Carriage Bolt SAE Grade 2 SAE Grade 5 SAE Grade 8 Hex Nut in/lbs...
  • Page 18 2 Troubleshooting Table of Contents SECTION CONTENTS Troubleshooting Troubleshooting the Rider............2-2 Troubleshooting the Mower............2-3 2 - 1...

  • Page 19: Troubleshooting

    2 Troubleshooting Rider 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 20 2 Troubleshooting Mower Troubleshooting Rider Troubleshooting Cont. PROBLEM CAUSES REMEDIES Rider 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.
  • Page 21 2 Troubleshooting Notes 2- 4...
  • Page 22 3 Maintenance Table of Contents SECTION CONTENTS A. Storage Temporary ................3-2 Long Term ................3-2 Starting After Long Term Storage .......... 3-3 B. Preventive Maintenance Chart ........3-3 C. Maintenance & Adjustments Tire Pressure ................3-3 Engine Oil Level ..............3-5 Engine Oil Filter ..............

  • Page 23: Storage Temporary

    3 Maintenance Storage WARNING Never store a rider, 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 24: Starting After Long Term Storage

    3 Maintenance Storage / Chart Starting After Long Term Storage Before starting the rider after it has been stored for a long period of time, perform the following steps: 1. Remove the blocks from under the rider. 2. Install the battery if it was removed. 3.
  • Page 25 3 Maintenance Engine *2387 Figure 1. Engine Compartment - Typical NAME FUNCTION Fuel Tank 2 gal. (7.6L) see-through tank for fuel level reading. Ignition Switch Starts and stops the engine. Battery 12 volt, 340 amp battery recharged by engine alternator Throttle/Choke Cable Controls engine speed and choke position.

  • Page 26: Engine Oil Level

    3 Maintenance Engine C. ENGINE MAINTENANCE FUEL FILTER ENGINE OIL LEVEL DANGER Engine oil level must be checked at regular intervals to Do not remove fuel filter when engine is hot, as ensure that engine oil is maintained at a level that will spilled gasoline may ignite.

  • Page 27: Spark Plug

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

  • Page 28: Maintenance

    3 Maintenance Mower Blade Service Figure 4. Balancing The Blade LOOSEN Figure 3. 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 29: Lubricating The Rider

    3 Maintenance Lubrication LUBRICATION Lubricating the Rider Lubricate the rider as shown in Figures 7 through 15. 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.
  • Page 30 3 Maintenance Lubrication *2388B *2402 Figure 10. Brake Pedal Pivot Point Figure 13. Rider Lubrication Points - Rear Half (Gear Model Shown) *2390 Figure 11. Rider Lubrication Points - Front Half Figure 14. Front Axle Lubrication Points *2397 Note: On 30” mower, grease fitting is on topside of deck.
  • Page 31 3 Maintenance Maintenance Records 3- 10...
  • Page 32 4 Adjustments Table of Contents SECTION CONTENTS Brake Adjustment ............4-2 Gear Models..............4-2 Hydro Models ..............4-2 Neutral Adjustment All Models................4-3 Return to Neutral Adjustment Hydro Only ................ 4-3 Idler Pulley / Clutch Adjustment All Models................4-4 Steering Gear Adjustment ...........

  • Page 33: Brake Adjustment

    4 Adjustments Brake Adjustment WARNING 2 9/16" – 2 5/8" To avoid serious injury, perform adjustments only with engine stopped, key removed and rider on level ground. BRAKE ADJUSTMENT Brake Adjustment - Gear Models 1. Place the transmission in gear and release the park- ing brake.

  • Page 34: Hydro Models

    4 Adjustments Neutral Adjustments NEUTRAL ADJUSTMENT *2510-2 Perform the following adjustment if the rider travels for- ward or backward with the ground speed control lever positioned in the neutral gate. 1. Position the rider on flat, level ground and start the engine.

  • Page 35: Idler Pulley / Clutch Adjustment

    4 Adjustments Clutch / Steering Adjustments IDLER PULLEY / *2425 CLUTCH ADJUSTMENT Perform the following adjustment if the rider drive belt does not completely declutch when the clutch/brake pedal is depressed. 1. To inspect the belt, start the engine and apply the parking brake.

  • Page 36: Adjustments

    4 Adjustments Mower Adjustments *2399 Figure 9. Leveling The Mower Side-to-Side A. Nut C. Rear Rollers B. Eccentric Nut MOWER ADJUSTMENTS If the cut is uneven, the mower may need leveling. Unequal or improper tire pressure may also cause an uneven cut.

  • Page 37: Front-To-Back Leveling

    4 Adjustments Mower Adjustments Front-To-Back Leveling *2397 1. Make sure mower is level side-to-side and that rear rollers are on the ground. 2. Position blade(s) front-to-back. Measure the distance from the ground to front tip of blade(s), and from ground to rear tip of blade(s). On 30”...

  • Page 38: Mower Cutting Height Adjustment

    4 Adjustments Mower / PTO Clutch / Transmission Adjustments Figure 13. Release Lever (Located Under Back of Rider PURGING AIR FROM Figure 12. HYDRO TRANSAXLE A. Mower Lift Lever B. Quadrant Air may become trapped in the inlet hydraulic filter or C.
  • Page 39 4 Adjustments Notes 4 - 8...
  • Page 40 5 Electrical Troubleshooting Table of Contents 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 Checking Out The System General....................5-3 Test Series ..................5-3 Electrical System Exploded View Diagram ......5- 1.

  • Page 41: System Description

    5 Electrical Troubleshooting General Information - Theory INTRODUCTION Cranking System THE CRANKING SYSTEM IS COMPOSED OF: Tools Needed the ignition switch, the solenoid, the safety interlock sys- • VOM (Volt-Ohm meter, multi-meter, or equivalent) tem, and the starter. • Test Light. •...

  • Page 42: Checking Out The System General

    5 Electrical Troubleshooting General Information - Testing CHECKING OUT THE SYSTEM “No Continuity” is a broken circuit. In this manual no continuity is determined with a VOM set to measure General Ohms. No continuity will register as infinite Ohms. Both the ignition and charging systems are internal to the “Battery Voltage”...
  • Page 43 5 Electrical Troubleshooting Electrical System Gear units only On Later Models Ref. No. 2, 3, 4, 15, 19, 42, and 44 are not used. Later Model Seat Switches are Mounted Inside the Seat Assembly. Torque to 30-36 in. lbs. Hydro units only Clutch 5, 18 Starter...

  • Page 44: Electrical Troubleshooting

    5 Electrical Troubleshooting Electrical System ELECTRICAL SYSTEM Ref. Qty. Description Ref. Qty. Description COVER, Terminal CABLE, Battery, Ground SPRING SWITCH, PTO, Electric Clutch SPRING WIRING HARNESS CLIP ADAPTER PLUG, Engine CABLE, Battery to Solenoid MODULE, Interlock TUBE, Vent SWITCH, Ignition WIRE ASSY.

  • Page 45: Checking The Power Supply / Fuel Solenoid A. Wiring

    5 Electrical Troubleshooting Battery & Cable Tests CHECKING THE POWER SUPPLY / WARNING FUEL SOLENOID To prevent accidental starting, disconnect and secure the spark plug wires before conducting any electrical tests. A. Check Wiring Condition and Tightness 1. Check all wires for cracked or worn insulation. WARNING 2.

  • Page 46: Battery Cables

    5 Electrical Troubleshooting Battery & Cable Tests HYDROMETER TEST WARNING 1. Remove the vent cap and check each cell using a Follow Battery charger manufacturer’s hydrometer. Replace the cap when finished. instructions. All cells should have a specific gravity of 1.27 or higher. If the cells vary by more than .

  • Page 47: Isolate Cranking And Safety Systems

    5 Electrical Troubleshooting System Isolation / Cranking System Tests ISOLATE CRANKING AND SAFETY SYSTEMS 1. Disconnect the spark plug wire(s) from the spark plug(s) to prevent accidental starting. 2. Remove the yellow connector (A, Figure 6) from the small solenoid post. 3.

  • Page 48: Test Power To Ignition Switch

    5 Electrical Troubleshooting Ignition Switch Tests B. Test Power to Ignition Switch NOTE: Some later model units use an ignition switch with a sixth terminal. The sixth terminal isolates the alternator from the rest of the electrical system dur- ing engine shut down. The remaining five terminals function exactly the same as five terminals switches and will not effect the test procedures contained in this section.

  • Page 49: Test Power To Solenoid

    5 Electrical Troubleshooting Ignition Switch / Solenoid Tests 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 0.3-3.0 ohms (continu- ity) on the multi-meter (see Figures 12-14). 9.

  • Page 50: 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 51: 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 19.Testing for Solenoid Short 5.

  • Page 52: Pto Interlock Switch

    5 Electrical Troubleshooting Safety Interlock System Tests 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 53: Seat Switch (Electrical)

    5 Electrical Troubleshooting Seat Switch / Clutch / Brake Switch Tests C. Test Seat Switch - Electrical (All Models) Early Model Seat NOTE: On later models the seat switch is mounted in the Switch Location seat. 1. Raise the seat deck and disconnect the harness plug. 2.

  • Page 54: Neutral Safety Switch (Electrical)

    5 Electrical Troubleshooting Neutral Safety Switch / Module / Misc.Tests F. Test Neutral Safety Switch - Electrical (Gear Models Only) NOTE: The neutral safety switch threads into the top of the transmission case and may be more easily tested if the transmission is removed.

  • Page 55: Power To Hour Meter

    5 Electrical Troubleshooting Hour Meter / PTO Clutch Tests B. Test Power to Hour Meter (Where Applicable) 1. Turn the ignition switch to RUN. 2. Set VOM to VDC. 3. Probe ground. Probe the positive wire (C, Figure 33) at the hour meter terminal. The VOM should read battery voltage.

  • Page 56: Wiring Diagram

    5 Electrical Troubleshooting Wiring Diagram Coronet, 400, & 2400 Series - Typical 5 - 17...

  • Page 57: Safety System Diagram

    5 Electrical Troubleshooting Safety System Diagram Coronet, 400, & 2400 Series - Typical 5 - 18...
  • Page 58 6 Wheel Repair Table of Contents SECTION CONTENTS Elevating Rear End for Safe Service ........6-2 Elevating the Front of the Unit For Safe Service .... 6-2 Rear Wheel Removal ..............6-3 Front Wheel Removal ..............6-4 Wheel Bearing Replacement ..........

  • Page 59: Elevating Rear End For Safe Service

    6 Wheel Repair Elevating the Unit ELEVATING REAR END FOR SAFE SERVICE 1. Remove the ignition key and disconnect spark plug wire to prevent accidental starting while working on the unit. 2. Engage the parking brake and block the front wheels. 3.

  • Page 60: Wheel Repair

    Hub Cap Spacer (AGCO-Allis & Massey Ferguson Models) Valve E-Ring Hub Cap (Simplicity Models) Figure 3. Rear Wheel Assembly REAR WHEEL REMOVAL NOTE: The assembly shown in Figure 3 may differ slightly from the assembly on your particular rider–specif- ically the number of washers used. Each rider is individ- ually checked and the necessary number of washers is used.

  • Page 61: Front Wheel Removal

    AGCO-Allis & Massey Ferguson Models 17 4 Ref. Qty. Description Ref. Qty. Description Bearing Hub Cap (Simplicity Models) Hub Cap (AGCO-Allis & Massey Ferguson Models) Grease Zerk Valve Tire Washer E-Ring Figure 5. Front Wheel Assembly FRONT WHEEL REMOVAL WHEEL BEARING REPLACEMENT Refer to Figure 5.
  • Page 62 7 Foot Controls Repair Table of Contents SECTION CONTENTS Foot Controls Diagram - Gear Models ........ 7-2 Foot Controls Diagram - Hydro Models ......7-4 Foot Pedal Pad Replacement ..........7-6 Foot Pedal Assembly & Front Clutch Rod Removal ..7-6 Idler Arm Assembly Removal - Gear Models ....

  • Page 63: Foot Controls Diagram - Gear Models

    7 Foot Controls Repair Foot Controls Diagram - Gear Models Transmission Carrier FOOT CONTROLS - GEAR MODELS See Rear Wheels Figure 1. Foot Controls - Gear Models 7- 2...
  • Page 64 7 Foot Controls Repair Foot Controls Diagram - Gear Models Foot Controls - Gear Models Ref. Qty. Description Ref. Qty. Description SPRING, Return NUT, Hex, Nylon Lock, 5/16-18 WASHER, 3/4 WASHER, Plain, 17/64 x 5/8 x 3/64 PULLEY, Idler SCREW, Hex Hd., 1/4-28 x 5/8 SPRING, Idler WASHER KLIPRING, 1/2...

  • Page 65: Foot Controls Repair

    7 Foot Controls Repair Foot Controls Diagram - Hydro Models Transmission Carrier FOOT CONTROLS - HYDRO MODELS See Electrical Group, Ref. No. 14 Hook spring (Ref. No. 3) here. See Rear Wheels & Tires pg. 36 & 37 Figure 2. Foot Controls - Hydro Models 7- 4...
  • Page 66 7 Foot Controls Repair Foot Controls Diagram - Hydro Models Foot Controls - Hydro Models Ref. Qty. Description Ref. Qty. Description SPRING, Return WASHER, Plain WASHER, 3/4 WASHER, Plain, 5/16 SPRING NUT, Hex, Lock, 5/16-18 PULLEY, Idler CAPSCREW, 5/16-18 x 1-3/4 SPACER, 25/64 x 5/8 x 11/16 CAPSCREW, Hex, 1/4-20 x 3/4 KLIPRING, 1/2...

  • Page 67: Foot Pedal Pad Replacement

    7 Foot Controls Repair Foot Pedal Assembly Service FOOT PEDAL PAD REPLACEMENT 1. Remove the worn foot pedal pad (A, Figure 3) using a large adjustable open-end wrench placed over the flats of the foot pedal arm (B) next to the pad. Tap the wrench with a hammer or rubber mallet to slide the pad off the arm.

  • Page 68: Idler Arm Assembly Removal - Gear Models

    7 Foot Controls Repair Idler Arm Assembly Removal - Gear Models IDLER ARM ASSEMBLY REMOVAL - GEAR MODELS 1. Remove the mower deck. See Mower Deck Repair. 2. Elevate the rear of the unit. See Elevating Rear End for Safe Service in Wheel Repair Section. 3.

  • Page 69: Idler Arm Assembly Removal - Hydro Models

    7 Foot Controls Repair Idler Arm Assembly Removal - Hydro Models IDLER ARM ASSEMBLY REMOVAL - HYDRO MODELS 1. Remove the mower deck. See Mower Deck Repair. 2. Elevate the rear of the unit. See Elevating Rear End for Safe Service in Wheel Repair Section. 3.
  • Page 70 8 Hand Controls Repair Table of Contents SECTION CONTENTS Knob Removal Ground Speed Control Knob Removal......... 8-4 Parking Brake Knob Removal ............8-4 Cutting Height Adjustment Knob Removal........8-4 ............. 8-5 Steering Wheel Removal ............8-5 Steering Shaft Removal ............8-5 Dash Shroud Removal ....
  • Page 71 8 Hand Controls Repair Hand Controls Assembly 24, 25 NOTE: Unless noted otherwise, use the standard hardware torque speci- fication chart. Figure 1. Dashboard Assembly 8- 2...
  • Page 72 8 Hand Controls Repair Hand Controls Assembly Front Column and Dash Ref. Qty. Description Ref. Qty. Description WASHER, Plain WASHER, 13/32 x 1-1/2 x 1/8 BUSHING WASHER, Plain, 17/32 x 1-1/4 x 7/64 SCREW, Hex, Flange, Taptite, 1/4-20 x 1/2 SPACER SCREW, Hex, Flange, Taptite, 1/4-20 x 3/4 TUBE, Steering...

  • Page 73: Knob Removal

    8 Hand Controls Repair Knob Removal GROUND SPEED Ground Speed CONTROL KNOB REMOVAL Control Knob 1. Remove the ground speed control knob 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”...

  • Page 74: Steering Wheel Removal

    8 Hand Controls Repair Steering Wheel / Shroud Removal STEERING WHEEL REMOVAL *2786 1. Using a punch, drive out the roll pin (C, Figure 4) securing the steering wheel (A) to the steering shaft. 2. Pull the wheel off the shaft. Install the steering wheel in reverse order.

  • Page 75: Hand Controls Repair

    8 Hand Controls Repair Ground Speed Control Adjustment NOTE: These parts are used on transmissions with S/N’s prior to 4000T0001. 15 14 Early Models NOTE: These parts are used on transmissions with S/N’s 4000T0001 and higher. Later Models 19 9 Figure 5.

  • Page 76: Ground Speed Control Lever Tension Adj

    8 Hand Controls Repair Ground Speed Control Adjustment Early Models NOTE: These parts are used on transmissions with S/N’s prior to 4000T0001. Ref. Qty. Description Ref. Qty. Description BREATHER ASSY. SCREW, Socket Hd. BUSHING, Rubber ACTUATOR PIN ARM, Bypass ARM, Brake SEAL WASHER, 7/16 x 7/8 x 1/16 PUCK, Dampener...
  • Page 77 8 Hand Controls Repair Throttle Control Repair Throttle (Engine Speed Control) Assembly 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.

  • Page 78: Throttle Control Repair

    8 Hand Controls Repair Throttle Control Repair THROTTLE CONTROL REPAIR Multi-Piece Throttle Service 1. Remove the wire clip securing the throttle cable (N, The throttle control is attached to the underside of the Figure 6) to the throttle lever by removing the truss seat deck.
  • Page 79 8 Hand Controls Repair Notes 8- 10...
  • Page 80 9 Hydro Transmission Repair Hydro-Gear 310-0500 SECTION CONTENTS ............9-7 Transmission Removal ..........9-9 Remove External Linkages ................9-10 Disassembly ..................9-14 Assembly ................. 9-20 Installation Identification Tags Here Figure 1 Hydro-Gear Model 0500 Hydrostatic Transaxle IMPORTANT: Cleanliness is a primary means of assuring satis- factory life on new or repaired units.
  • Page 81 9 Hydro Transmission Repair Hydro-Gear 310-0500 Hook on screw located on upper housing assembly. Hook end of spring (16) on screw located here. Figure 2 Hydro Gear Model 750 Hydrostatic Transaxle...
  • Page 82 9 Hydro Transmission Repair Hydro-Gear 310-0500 Ref. Qty. Description Ref. Qty. Description SEAL-LIP BLOCK-CYLINDER (MOTOR) ASSY. RING, Retaining ACTUATOR-BYPASS SEAL-LIP CENTER SECTION ASSEMBLY ARM-BYPASS SEAL-LIP .26 x .42 x .8 SET SCREW RING, Retaining PIN-ACTUATING WASHER WASHER, 7/16 x 7/8 x .060 OIL FILTER ELEMENT NUT, Hex, Lock, 5/16-24 BOLT, 5/16-18 x 1-3/4...
  • Page 83 9 Hydro Transmission Repair Hydro-Gear 310-0500 Hook spring, Ref. No. 2, here Attach to boss on RH underside of transmission. Torque to 80-100 in. lbs. Torque to 360-400 in. lbs. Figure 3. Transmission and Carrier...
  • Page 84 9 Hydro Transmission Repair Hydro-Gear 310-0500 Ref. Qty. Description Ref. Qty. Description SPRING NUT, Hex, Jam, 1/2-20 SPRING, Return WASHER, 5/16 SCREW, Taptite, 5/16-18 x 2-1/4 CAPSCREW, Hex Hd., 1/2-13 x 1-1/4 TRANSMISSION, Hydro WASHER, Plain, 13/32 x 1-1/4 x 1/16 BELT STOP NUT, Hex, Lock, 1/4-20 BUSHING, Rear...
  • Page 85 9 Hydro Transmission Repair Hydro-Gear 310-0500 Transmission Carrier See Electrical Group, Ref. No. 14 Hook spring (Ref. No. 3) here. Figure 4. Hydro Control Linkage...
  • Page 86 9 Hydro Transmission Repair Hydro-Gear 310-0500 Ref. Qty. Description Ref. Qty. Description SPRING, Return SPACER, Pivot WASHER, 3/4 TUBE SPRING LOCKWASHER, 5/16 PULLEY, Idler LOCKWASHER, 5/16 SPACER, 25/64 x 5/8 x 11/16 NUT, Hex, 5/16-18 KLIPRING, 1/2 NUT, Hex, 5/16-18 SPACER COTTER PIN, 7/64 x 3/4 PAD, Pedal...
  • Page 87 9 Hydro Transmission Repair Hydro-Gear 310-0500 NOTE: These parts are used on transmissions with S/N’s prior to 4000T0001. 15 14 NOTE: These parts are used on transmissions with S/N’s 4000T0001 and higher. 19 9 Figure 5. External Linkages...
  • Page 88 9 Hydro Transmission Repair Hydro-Gear 310-0500 NOTE: These parts are used on transmissions with S/N’s prior to 4000T0001. Ref. Qty. Description Ref. Qty. Description BREATHER ASSY. SCREW, Socket Hd. BUSHING, Rubber ACTUATOR PIN ARM, Bypass ARM, Brake SEAL WASHER, 7/16 x 7/8 x 1/16 PUCK, Dampener LOCKING STRAP SET SCREW...
  • Page 89 9 Hydro Transmission Repair Hydro-Gear 310-0500 Disassembly 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. 2. Remove the nut (A, Figure 6) securing the brake arm and remove the brake arm.
  • Page 90 9 Hydro Transmission Repair Hydro-Gear 310-0500 8. Lift the axle/differential assembly out of the upper housing. NOTE: It will be necessary to remove any burrs or rust from the axle ends prior to the removal of the two bronze bearings. Burrs and rust will damage the bearings and seals.
  • Page 91 9 Hydro Transmission Repair Hydro-Gear 310-0500 17. Remove the brake rotors and stators by sliding one at a time off the end of the splined motor shaft. 18. Inspect each side of both rotors for excessive wear or damage. 19. Inspect the rotor’s internal splines for excessive wear or damage.
  • Page 92 9 Hydro Transmission Repair Hydro-Gear 310-0500 24. Remove the motor block assembly from the motor Bypass Plate shaft and inspect for unusual wear or damage. The Goes Here pistons should fit with very little side clearance in the block bores, but must slide freely. NOTE: The correct bore diameter for the block is 0.6776”...
  • Page 93 9 Hydro Transmission Repair Hydro-Gear 310-0500 36. Reposition the housing and remove the input shaft lip seal from the housing bore. A hook type tool may be used to pry the seal out. Care must be taken to avoid damage to the housing bore, shaft sealing surface or bearing.
  • Page 94 9 Hydro Transmission Repair Hydro-Gear 310-0500 3. Install the pump shaft lip seal. 4. Reposition the upper housing and install the swash- plate cradle bearings. 5. Install the slot guide block onto the displacement con- trol shaft. 6. Install the swashplate assembly into the housing. The slot on the swashplate must engage the slot guide block on the swashplate control shaft.
  • Page 95 9 Hydro Transmission Repair Hydro-Gear 310-0500 11. Install the washers and a new lip seal onto the Retaining Ring splined end of the motor shaft. Install one washer on each side of the retaining ring. 12. Install the motor shaft into the center section. Seal Washers Figure 25.
  • Page 96 9 Hydro Transmission Repair Hydro-Gear 310-0500 16. Insert the three assembly bolts into the center section and press the center section down onto the aligning pins and pump input shaft until it is seated on mount- ing bosses. While holding the center section in posi- tion, torque the bolts evenly from 44 ft.
  • Page 97 9 Hydro Transmission Repair Hydro-Gear 310-0500 22. To install brake disks, first install a stator, then a rotor (hub to inside), then a stator, then a rotor (hub to inside), then two stators. 23. Install the brake bolt (with nut) into the upper housing. At this time make sure the pump and motor rotate freely.
  • Page 98 9 Hydro Transmission Repair Hydro-Gear 310-0500 28. Torque the retaining nut on the brake nut to 120–185 in-lbs. 29. Lubricate and install the brake pins into case and brake arm onto brake bolt. 30. Install the slotted bracket (see Figure 36) onto brake bolt with the slot aligned over the tab on transaxle.
  • Page 99 9 Hydro Transmission Repair Hydro-Gear 310-0500 If you have the necessary equipment the transmis- sion manufacturer suggests performing the following test: 38. Prior to adding oil to the transaxle, it is recommended that you test for leaks. This may be performed with a small hand pump or by using compressed air and a regulator.
  • Page 100 Figure 1 Peerless 915-016B Transaxle PEERLESS 915-016B NOTE: This transaxle is serviced by the manufacturer and not by Simplicity. The exploded parts view is shown here and in the parts manual for reference purposes only. Should service be required, contact an authorized Peerless Service Repair Dealer for technical data and repair specifications.
  • Page 101 10 Gear Transmission Repair Peerless 915-016B Figure 2. Peerless 915-016B Transaxle 10-2...
  • Page 102 10 Gear Transmission Repair Peerless 915-016B Ref. Qty. Description Ref. Qty. Description COVER, Transaxle WASHER, Flat BEARING, Needle LEVER, Brake CASE, Transaxle SCREW, Hex Hd., Flange, COUNTERSHAFT, (4-7/8" Long) Threadforming,1/4-20 x 1-1/4 GEAR, Spur (16 Teeth) SCREW, Hex Hd., Flange, GEAR, Spur (22 Teeth) Threadforming, 1/4-20 x 2-1/4 NUT, Lock, 5/16-24...
  • Page 103 10 Gear Transmission Repair Peerless 915-016B Wire-Form Belt Guide Used on Later Models Switch (15) connected to wires (2) using two small screws. Hook spring, Ref. No. 4, here. Figure 3 Peerless 915-016B Transaxle 10-4...
  • Page 104 10 Gear Transmission Repair Peerless 915-016B Ref. Qty. Description Ref. Qty. Description TRANSMISSION, 5-Speed (Gear) STRAP, Torque COVER, Terminal CARRIER ASSY. BELT STOP STRAP, Torque SPRING, Return WASHER, Plain, 5/16 KEY, Woodruff, #9 WASHER, Plain, 7/16 x 1-1/4 x 1/8 RING, Retaining CAPSCREW, Hex Hd., 1/2-13 x 1-1/4 SCREW, Hex Hd., 5/16-18 x 2-1/4...
  • Page 105 10 Gear Transmission Repair Peerless 915-016B Transmission Carrier See Rear Wheels & Tires p. 36 & 37. Figure 4. Transaxle Controls 10-6...
  • Page 106 10 Gear Transmission Repair Peerless 915-016B Ref. Qty. Description Ref. Qty. Description SPRING, Return SPACER WASHER, 3/4 LOCKWASHER, 1/4 PULLEY, Idler LOCKWASHER, 5/16 SPRING, Idler NUT, Hex, 5/16-18 KLIPRING, 1/2 COTTER PIN, 3/32 x 3/4 PAD, Pedal WASHER, Plain LEVER, Idler, Pulley WASHER, Plain, 5/16 ROD, Clutch, Rear NUT, Hex, Nylon Lock, 5/16-18...
  • Page 107 11 Belt & Clutch Replacement Table of Contents SECTION CONTENTS Belt Replacement Drive Belt Replacement - Hydro Models ........11-2 Drive Belt Replacement - Gear Models........11-3 Mower Belt Replacement - 30” Decks........11-4 Mower Belt Replacement - 34” Decks........11-4 Clutch Replacement Electric Clutch Replacement ............

  • Page 108: Belt Replacement

    11 Belt & Clutch Replacement Drive Belt Replacement BELT REPLACEMENT Drive Belt Replacement - Hydro Models BELT REMOVAL 1. Remove the mower deck. See Mower Deck Repair section for instructions. 2. Block the front tires and elevate the rear of the unit. See Elevating the Rear End for Safe Service.

  • Page 109: Drive Belt Replacement - Gear Models

    11 Belt & Clutch Replacement Drive Belt Replacement Drive Belt Replacement - Gear Models BELT REMOVAL 1. Remove the mower deck. See Mower Deck Repair section for instructions. 2. Block the front tires and elevate the rear of the unit. See Elevating the Rear End for Safe Service.
  • Page 110 11 Belt & Clutch Replacement Mower Belt Replacement *2391 CAUTION To avoid damaging belts, do not pry belts over pulleys. Mower Belt Replacement - 30” See Figure 5. NOTE: Mower does not need to be removed to install a new belt. However, for easier access, the mower can be removed following steps listed under “Mower Removal and Installation”...

  • Page 111: Clutch Replacement

    11 Belt & Clutch Replacement Clutch Replacement CLUTCH REPLACEMENT Electric Clutch Replacement CLUTCH REMOVAL 1. Remove the mower deck. See Mower Deck Repair section for instructions. 2. Block the front tires and elevate the rear of the unit. See Elevating the Rear End for Safe Service. 3.
  • Page 112 11 Belt & Clutch Replacement Notes 11 - 6...
  • Page 113 12 Mower Deck Repair Table of Contents SECTION CONTENTS Explosion Diagrams ............30” Drive and Arbors - Early Models ........8-2 30” Drive and Arbors - Later Models ........8-4 30” Housing, Hitch, and Height Adjustment ......8-6 34” Drive and Arbors - Early Models ........8-8 34”...
  • Page 114 12 Mower Deck Repair 30" Mower Deck - Drive & Arbor, Early Models Torque to 50-70 Ft. Lbs. NOTE: Unless noted other- wise, use the standard hard- ware torque specification chart. Torque to 50-70 Ft. Lbs. Figure 1. 38" Mower Deck - Deck, Arbors & Blades 12- 2...
  • Page 115 12 Mower Deck Repair 30" Mower Deck - Drive & Arbor, Early Models 30" Mower Deck - Deck & Arbors, Early Models Ref. Qty. Description Ref. Qty. Description BEARING LOCKWASHER, 3/8 V-BELT, 73-7/64" LOCKWASHER, 7/16 COVER, Arbor Housing WASHER, Flat, 13/32 x 1 x 1/8 ADAPTER, Blade CAPSCREW, Hex Hd., 7/16-14 x 1-1/2, Gr.
  • Page 116 12 Mower Deck Repair 30" Mower Deck - Drive & Arbors, Later Models Torque to 50-70 Ft. Lbs. NOTE: Unless noted otherwise, use the standard hardware torque specification chart. Torque to 50-70 Ft. Lbs. Figure 2. 30" Mower Deck - Drive & Arbors, Later Models 12- 4...
  • Page 117 12 Mower Deck Repair 30" Mower Deck - Drive & Arbors, Later Models 30" Mower Deck - Drive & Arbors, Later Models Ref. Qty. Description Ref. Qty. Description V-BELT, 73-7/64" NUT, Hex, Flange, 9/16-18 WASHER, Spring NUT, Hex, 3/8 BLADE, Mower, 30" LOCKWASHER, 3/8 GRIP, Lever WASHER, Flat, 13/32 x 1 x 1/8...
  • Page 118 12 Mower Deck Repair 30" Mower Deck - Housing, Hitch, & Height Adjustment When assembled, attach spring (1) here. Figure 3. 30" Mower Deck - Housing, Hitch & Height Adjustment 12- 6...
  • Page 119 12 Mower Deck Repair 30" Mower Deck - Housing, Hitch, & Height Adjustment 30" Mower Deck - Housing, Hitch & Height Adjustment Ref. Qty. Description Ref. Qty. Description SPRING LOCKNUT, Hex, 3/8-16 RING, Retaining CAPSCREW, Hex, 3/8-16 x 1-1/4 SPACER CAPSCREW, Hex Hd., 3/8-16 x 1 BOLT, Shoulder WASHER, Flat...
  • Page 120 12 Mower Deck Repair 34" Mower Deck - Drive & Arbors - Early Models Torque to 50-70 Ft. Lbs. Torque to 50-70 Ft. Lbs. Attach the end of spring (Ref. No. 3) here. NOTE: Unless noted other- wise, use the standard hard- ware torque specification chart.
  • Page 121 12 Mower Deck Repair 34" Mower Deck - Drive & Arbors, Early Models 34" Mower Deck - Drive & Arbors -Early Models Ref. Qty. Description Ref. Qty. Description BEARING NUT, Hex, 3/8-16 V-BELT, 82-7/64" LOCKWASHER, 3/8 SPRING LOCKWASHER, 7/16 COVER, Arbor Housing CAPSCREW, Hex Hd., 3/8-16 x 2-1/2 WASHER, Spring CAPSCREW, Hex Hd., 7/16-14 x 1-1/4, Gr.
  • Page 122 12 Mower Deck Repair 34" Mower Deck - Drive & Arbors, Later Models Torque to 50-70 Ft. Lbs. Torque to 50-70 Ft. Lbs. Torque to 50-70 Ft. Lbs. Figure 5. 34" Mower Deck - Drive & Arbors, Later Models 12- 10...
  • Page 123 12 Mower Deck Repair 34" Mower Deck - Drive & Arbors, Later Models 34" Mower Deck - Drive & Arbors, Later Models Ref. Qty. Description Ref. Qty. Description V-BELT, 82-7/64" WASHER SPRING WASHER, Belleville WASHER, Spring NUT, Hex, Flange, 9/16-18 SPACER NUT, Hex, 3/8-16 SCREW, Taptite, 5/16-18 x 3/4...
  • Page 124 12 Mower Deck Repair 34" Mower Deck - Housing, Hitch, & Deflector When assembled, attach spring (Ref. No. 1) here. Figure 6. 34" Mower Deck - Housing, Hitch & Deflector 12- 12...
  • Page 125 12 Mower Deck Repair 34" Mower Deck - Housing, Hitch, & Deflector 44" Mower Deck - Height Adjustment & Rollers Ref. Qty. Description Ref. Qty. Description SPRING LOCKNUT, Hex, 3/8-16 SPACER CAPSCREW, Hex Hd., 3/8-16 x 1-1/4 SPACER CAPSCREW, Hex Hd., 3/8-16 x 1 SPACER WASHER, Flat, 3/8 HOUSING ASSY., 34"...
  • Page 126 12 Mower Deck Repair 34" Mower Deck - Height Adjustment Spacer (Ref. No. 7) 17 16 goes between 2 welded tabs on Ref. No. 8.on both sides NOTE: Unless noted other- wise, use the standard hard- ware torque specification chart. Figure 7.
  • Page 127 12 Mower Deck Repair 34" Mower Deck - Height Adjustment 34" Mower Deck - Height Adjustment Ref. Qty. Description Ref. Qty. Description RING, Retaining WASHER, Plain, 5/16 BOLT, Shoulder, 3/8-16 WASHER, Flat, 1/2 SPACER, Roller WASHER, Flat, 5/8 PIN, Locking NUT, Flange Lock, 3/8 ROLLER SCREW, Taptite, 5/16-18-5/8...
  • Page 128 12 Mower Deck Repair Mower Removal & Installation *2396 Figure 8. Mower Removal/Installation (34” mower shown) A. Idler Pulley Arm Lift Cable B. Idler Pulley Lift Hook C. PTO (Electric Clutch) Pulley Rear Trailing Arms MOWER REMOVAL AND INSTALLATION WARNING NOTE: Perform mower installation on a hard, level sur- Stop engine and remove key while performing face such as a concrete floor.
  • Page 129 12 Mower Deck Repair Mower Removal & Installation 30” Mower *2390 Figure 9. Mower Hitch A. Lever C. Rider Hitch Brackets B. Mower Hitch 5. Remove mower hitch (B, Figure 9) from rider hitch brackets(C) by pulling spring-loaded lever (A) forward and lifting up on hitch.
  • Page 130 12 Mower Deck Repair Arbor Repair Capscrew Taptite Lockwasher Screws Heavy Washer Pulley Upper Grass Shield Blade Figure 12. Spindle Removal Adapter 5. From the bottom of mower deck, remove the six Taptite hex screws retaining the spindle flange to the Figure 13.
  • Page 131 12 Mower Deck Repair Arbor Repair 5. Using a pair of small screwdrivers, pry apart the upper and lower arbor housings. Figure 15. Split Arbor Housing 6. Remove the arbor shaft assembly from the lower housing. Upper Housing 7. Support the inner race of the bearing, and using a soft face hammer, drive the shaft from the bearing.
  • Page 132 12 Mower Deck Repair Arbor Repair Arbor Assembly - Early Model Arbors 1. While supporting the bearing’s inner race, drive the Capscrew shaft into the bearing until it seats on the shoulder of the shaft. Repeat for second bearing. 2. Install the arbor assembly into the lower housing. Lockwasher Pack the housing with multipurpose grease.
  • Page 133 1. Grip the arbor shaft (Ref. 12,) in a soft-jaw vice and (Ref. 7). remove the hex nut (Ref. 1) and belleville washers 3. Fill the housing with Simplicity Multi-Purpose Lithium (Ref. 2). Grease or equivalent. 2. Remove the the pulley (Ref. 3) and spacer (Ref. 4).
  • Page 134 12 Mower Deck Repair Arbor Repair IDLER PULLEY REPAIR Refer to Figures 1, 2, 4, and 5 for assembly diagrams. 1. Remove mower deck (see Mower Removal and Installation). 2. Remove the nut and capscrew securing the idler pul- ley to the clutch lever. Note the location and quantity of spacers and wash- ers above and below Idler when removing the cap- screw.

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