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Simplicity Broadmotor Series Service & Repair Manual

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MANUFACTURING, INC.
500 N Spring Street / PO Box 997
© Copyright 2001 Simplicity Manufacturing, Inc.
Port Washington, WI 53074-0997 USA
All Rights Reserved. Printed in USA.
Rev 4/2001
TP 500-2493-00-BM-SMA

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Table of Contents

Troubleshooting

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Summary of Contents for Simplicity Broadmotor Series

  • Page 1 MANUFACTURING, INC. 500 N Spring Street / PO Box 997 © Copyright 2001 Simplicity Manufacturing, Inc. Port Washington, WI 53074-0997 USA All Rights Reserved. Printed in USA. Rev 4/2001 TP 500-2493-00-BM-SMA...
  • Page 2 Repair Manual Contents This manual is divided into the sections listed below. Please click hyperlink to access the specific contents of that section. General Information ......1-1 — 1-14 Troubleshooting .

  • 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 IDENTIFICATION TAG LOCATIONS MODELS COVERED & IDENTIFICATION NUMBERS This manual contains service information for the models listed below. Consult the Identification Tag located on the tractor frame for the manufac- turer’s identification number and serial number. Always use the manufacturer’s identification num- Mower Deck Tractor...

  • Page 5: Introduction

    1 General Information Introduction Since part numbers are subject to change and may vary INTRODUCTION by model year and manufacturing number, all parts in This manual is divided into sixteen major sections of ser- this manual are referred to by general description. vice information required for the models specified.

  • 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 unit, severe personal injury or death to you, or bystanders, or damage to property or equipment. This mowing deck is capable of amputating hands and feet and throwing objects.
  • Page 7 1 General Information Safety Rules Slope Operation Continued TRANSPORTING AND STORAGE Children WARNING Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the unit and the mowing activity. When transporting this tractor on an open trailer, Never assume that children will remain where you last saw them.

  • Page 8: Safety Rules - Service And Maintenance

    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 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 Size Of in/lbs...

  • Page 14: Specifications

    1 General Information Specifications NOTE: Specifications are correct at time of printing and are subject to change without notice. ENGINE 14 HP & 16 HP Briggs & Stratton Vanguard 16 HP Kohler Make Briggs & Stratton Make Kohler Model Vanguard™ V-Twin Model Command™...
  • Page 15 1 General Information Specifications CONTROLS: 50” MOWER: 12 GA. Steering 15" (38 cm) Steering Wheel Effective Cutting System: Gear and Sector, 1.25 turns Lock to Width 50 in Mower - 50 in (127 cm) Lock Overall Width Clutch/ Location: Right Front with Deflector 50 in Mower - 62 in (157.5 cm) Brake Pedal...
  • Page 16 1 General Information Notes 1 - 14...
  • 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 While normal care and regular maintenance will extend To avoid serious injury, perform maintenance on the life of your equipment, prolonged or constant use the tractor or mower only when the engine is may eventually require that service be performed to stopped and the parking brake engaged.
  • Page 19 2 Troubleshooting Mower Troubleshooting Tractor Troubleshooting Cont. Tractor drive belt slips. 1. Brake is out of adjustment. See Adjustments Section. 2. Pulleys or belt greasy or oily. Clean as required. 3. Belt stretched or worn. Replace with new belt. 4. Idler pulley pivot bracket Remove idler pulley bracket, clean and lubricate.
  • 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 Long Term Storage ..........3-2 Maintenance Schedule ..........3-3 Checking Tire Pressures........3-3 Check / Change Transmission Oil......3-4 Accessing the Engine ...........3-5 Fuel Filter Replacement ........3-5 Oil & Filter Change ..........3-5 Check / Change Air FIlter ........3-5 Inspect &...

  • Page 22: Temporary

    3 Maintenance Storage STORAGE WARNING Temporary Storage (30 Days Or Less) Never store the unit, with gasoline in engine or Remember, the fuel tank will still contain some gasoline, so fuel tank, in a heated shelter or in enclosed, never store the unit indoors or in any other area where fuel poorly ventilated enclosures.

  • Page 23: Maintenance Schedule

    3 Maintenance Schedule MAINTENANCE SCHEDULE & PROCEDURES The following schedule should be followed for normal care of your tractor and mower. You will need to keep a record of your operating time. Determining operating time is easily accomplished by multiplying the time it takes to do one job by the number of times you’ve done the job, or you can install the optional hour meter.

  • Page 24: Check / Change Transmission Oil

    3 Maintenance Check / Change Transmission Oil CHECK / CHANGE TRANSMISSION OIL The transmission oil should be checked before each use, and changed at the intervals shown or if it has become discolored from overheating or contamination. Service Interval: After initial 50 Hrs, then every 250 Hrs. FULL Oil Capacity: Apx.

  • Page 25: Accessing The Engine

    3 Maintenance Engine Service Undo Hood Straps (Both Sides) and Lift Hood to access Engine Figure 4. Engine Access Figure 5. Engine Compartment -Kohler Single Cylinder Engine A. Battery D Oil Fill/Dipstick B. Oil Filter E. Fuel Filter (Not Shown C.

  • Page 26: Lubrication

    Use grease fittings when present. Disassemble parts to apply grease to moving parts when grease fittings are not present. Not all greases are compatible. Simplicity Lithium Grease is recommended, automotive-type lithium grease may be used when this is not available.

  • Page 27: Lubricate Rear Axles

    3 Maintenance Lubricate Rear Axles Figure 11. Mower Lubrication Points Figure 10. Arbor Lubrication Points LUBRICATE REAR AXLES We recommend removing the rear wheels and lubricat- ing the axle shafts yearly. This prevents the wheel from seizing onto the axle shaft, making future service easier. 1.

  • Page 28: Battery Maintenance

    3 Maintenance Battery Maintenance BATTERY MAINTENANCE WARNING Checking the Battery Fluid Be careful when handling the battery. Avoid Note: Does not apply to maintenance-free batteries. spilling electrolyte. Keep flames and sparks away 1. Raise the hood to access battery. from the battery. 2.

  • Page 29: Servicing The Mower Blades

    3 Maintenance Mower Blade Service / Blade Brake Check SERVICING THE MOWER BLADES 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 4x4 Wood Block injury.

  • Page 30: Perform Safety Checks

    3 Maintenance Perform Safety Checks PERFORM SAFETY CHECKS WARNING Mower Blade Stopping Check Disengage the PTO, stop the engine, set the parking Mower blades and mower drive belt should come to a brake, and wait for moving parts to stop before leav- complete stop within five seconds after the electric clutch ing operator's position for any reason.

  • Page 31: Blade Brake Check

    3 Maintenance Perform Safety Checks Blade Brake Check SAFETY Mower blades and mower drive belt should come to a INTERLOCK SYSTEM complete stop within five seconds after electric PTO switch is turned off. 1. With tractor in neutral, PTO disengaged and operator This unit is equipped with safety interlock switches in seat, start the engine.
  • Page 32 3 Maintenance Notes 3 - 12...
  • Page 33 4 Adjustments Table of Contents SECTION CONTENTS Steering Wheel Adjustment ........4-2 Steering Gear Adjustment ........4-2 PTO Clutch Adjustment PTO Clutch Adjustment..............4-3 Blade Brake Check ...............4-3 Brake Spring Adjustment ........4-4 Foot Pedal Height Adjustment ......4-4 Cruise Control Release Adjustment ....4-5 Internal Neutral Adjustment........4-5 Transmission Purging ...........4-6 Mower Leveling Front-to-Back &...

  • Page 34: Steering Wheel Adjustment

    4 Adjustments Steering System Adjustments WARNING Before beginning any service work, turn the PTO off, set the parking brake, turn the ignition switch off, remove the key, disconnect the spark plug wires, and disconnect the negative battery cable. STEERING WHEEL ADJUSTMENT 1.

  • Page 35: Pto Clutch Adjustment

    4 Adjustments PTO Clutch Adjustment Figure 5. Adjust PTO Clutch A. Window B. Adjustment Nut C. Feeler Gauge Figure 4. PTO Clutch Adjustment A. Adjustment Window (Qty. 3, one shown) B. Adjustment Nuts PTO CLUTCH ADJUSTMENT WARNING Check the PTO clutch adjustment after the initial 50 hour To avoid serious injury, perform adjustments only break-in period and then after every 250 hours of opera- with engine stopped, key removed and tractor on...

  • Page 36: Brake Spring Adjustment

    4 Adjustments Brake Spring & Foot Pedal Adjustment BRAKE SPRING ADJUSTMENT 1. Disengage the PTO, stop the engine, block the wheels, and remove the ignition key. DO NOT engage the parking brake. 2. Remove the mower deck (see Mower Deck Removal). 3.

  • Page 37: Cruise Control Release Adjustment

    4 Adjustments Cruise Control & Neutral Adjustment CRUISE CONTROL RELEASE NOTE: Idler ADJUSTMENT Assembly Removed for See Figure 8. Illustration 1. Stop the tractor, shut off the PTO, turn off the engine, Purposes. and remove the key. DO NOT engage the parking brake.

  • Page 38: Transmission Purging

    4 Adjustments Transmission Purging TRANSMISSION PURGING Purge the transmission if the unit is excessively noisy or lacks drive in forward or reverse. 1. Elevate the rear end of the tractor using a chain hoist or floor jack. Support the rear of the unit using jack- stands.

  • Page 39: Mower Leveling

    4 Adjustments Mower Leveling WARNING Before checking mower, shut off PTO and engine. Allow all moving parts to stop. Remove ignition key, then disconnect the spark plug wire and fasten it away from the spark plug. MOWER LEVELING If the cut is uneven, the mower may need leveling. Unequal or improper tire pressure may also cause an uneven cut.
  • Page 40 4 Adjustments Notes 4 - 8...
  • Page 41 5 Belt Replacement Table of Contents SECTION CONTENTS Transmission Drive Belt Replacement Remove the Old Belt ..............5-2 Install the New Belt ...............5-2 Mower Belt Replacement 38” Mower Drive Belt Replacement ..........5-3 44” & 50” PTO Belt Replacement..........5-4 44” & 50” Arbor Drive Belt Replacement........5-5 5 - 1...

  • Page 42: Transmission Drive Belt Replacement

    TRANSMISSION DRIVE BELT REPLACEMENT NOTE: Be sure to use only genuine Simplicity replace- ment parts. REMOVE THE OLD BELT See Figure 1. 1. Turn off the PTO, stop the engine, and block the tires.

  • Page 43: Mower Belt Replacement

    BELTS OVER PULLEYS. MOWER BELT REPLACEMENT 38” Mower Drive Belt Replacement 1/8” Gap NOTE: Be sure to use only genuine Simplicity replace- ment parts. 1/8” Gap NOTE: It is not necessary to remove the mower to install a new belt. However, for easier access mower can be removed.

  • Page 44: 44" & 50" Pto Belt Replacement

    BELTS OVER PULLEYS. 44” & 50” PTO Belt Replacement 1/8” Gap NOTE: Be sure to use only genuine Simplicity replace- ment parts. NOTE: It is not necessary to remove the mower to install a new belt. However, for easier access mower can be removed.

  • Page 45: 44" & 50" Arbor Drive Belt Replacement

    To avoid damaging belts, DO NOT PRY BELTS OVER PULLEYS. 44” & 50” Arbor Drive Belt Replacement NOTE: Be sure to use only genuine Simplicity replace- ment parts. 1. Park the tractor on a smooth, level surface such as a concrete floor.
  • Page 46 5 Belt Replacement Notes 5 - 6...
  • Page 47 6 Common Service Procedures Table of Contents SECTION CONTENTS Mower Deck Removal & Installation Removing the Mower Deck ............6-2 Installing the Mower Deck .............6-3 Mower Blade Removal & Installation Removal ..................6-4 Installation ..................6-4 Elevating the Tractor Elevating Rear End for Safe Service..........6-5 Elevating Front End for Safe Service ..........6-5 Rear Wheel Removal &...

  • Page 48: Mower Deck Removal & Installation

    6 Common Service Procedures Mower Removal & Installation Figure 2. Lift Arms (Viewed from underneath right side of tractor) A. Mower Lift Arm C. Flat Washer B. Tractor Lift Arm D. Safety Clip Figure 1. Raising & Lowering Mower A. Mower Lift Lever B.

  • Page 49: Installing The Mower Deck

    6 Common Service Procedures Mower Removal & Installation Figure 6. Mower Hitch A. Tractor Hitch Brackets Figure 5. Raising & Lowering Mower B. Spring-Loaded Lever A. Mower Lift Lever B. Mower Height Adjuster WARNING Engage parking brake, disengage PTO, stop engine and remove key before attempting to install or remove the mower.

  • Page 50: Mower Blade Removal & Installation

    6 Common Service Procedures Mower Removal & Installation MOWER BLADE REMOVAL & INSTALLATION WARNING 4x4 Wood Block 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 51: Elevating The Tractor

    6 Common Service Procedures Elevating the Tractor ELEVATING THE TRACTOR 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 52: Rear Wheel Removal & Installation

    6 Common Service Procedures Rear Wheel Removal & Installation REAR WHEEL REMOVAL & INSTALLATION 1. Remove the key and disconnect the spark plug wire while working on the unit. 2. Engage the parking brake and block the front wheels. 3. Using a jack or chain hoist positioned at the center of the rear frame, carefully jack the unit up until the rear tires are approximately 1"...

  • Page 53: Front Removal & Installation

    6 Common Service Procedures Front Wheel & Wheel Bearing Removal & Installation FRONT WHEEL REMOVAL & Retaining ring INSTALLATION Hubcap 1. Using a flat blade screwdriver, pop off the plastic hub retainer cap to gain access to the retaining ring. 2.

  • Page 54: Battery Service

    6 Common Service Procedures Battery Service 6. Charge the battery until fully charged (i.e. until the WARNING specific gravity of the electrolyte is 1.250 or higher and the electrolyte temperature is at least 60° F). The Keep open flames and sparks away from the best method of making certain a battery is fully battery;...
  • Page 55 6 Common Service Procedures Battery Service THIS HOOK-UP FOR NEGATIVE GROUND VEHICLES Starter Starter Switch Switch Jumper Cable Starting Discharged Vehicle Vehicle Battery Battery Jumper Cable To Ground Engine Block MAKE CERTAIN VEHICLES DO NOT TOUCH Figure 17. Battery Jump Starting Diagram WARNING WARNING For your personal safety, use extreme care when...

  • Page 56: Battery Removal & Installation

    6 Common Service Procedures Burnishing the Electric PTO Clutch BATTERY REMOVAL & INSTALLATION Removing the Battery WARNING When removing battery cables, DISCONNECT THE NEGATIVE (-) CABLE FIRST and positive (+) cable last. If not done in this order, the positive terminal can be shorted to the frame by a tool.
  • Page 57 7 Electrical System Service Table of Contents GENERAL INFORMATION Section Contents ................. 7-2 System Description...............7-2 Principles of Operation ..............7-3 Safety Interlock System ............... 7-3 Checking Out the System ............7-3 Model Variation Notes ..............7-3 EXPLODED VIEW DIAGRAMS Exploded View Diagrams..............7-4 IGNITION SWITCH SERVICE BULLETIN Bulletin ..................7-8 LINEAR DIAGRAMS...

  • Page 58: General Information

    7 Electrical System Service General Information other components, related to the circuit, are operating WARNING properly. If several components malfunction at the same time, chances are the problem is in the fuse/breaker, Before beginning any service work, turn the PTO common splice, or ground connection that is common to off, set the parking brake, turn the ignition switch all the malfunctioning components.

  • Page 59: Principles Of Operation

    7 Electrical System Service General Information • OFF grounds the engine ignition coil through the igni- Safety Starting Sub-System tion switch, preventing ignition system sparking. The The safety starting sub-system will prevent the engine safety interlock module can also ground the ignition from cranking if any of the following conditions exist.

  • Page 60: Exploded View Diagrams

    7 Electrical System Service Exploded View Diagrams Electrical - Lower Harness See Engine Group To Upper Harness Briggs & Stratton Models Only Grommet - See Engine Group Electric Clutch Briggs & Stratton Models Only To Engine Ground Bolt. To Engine Fuel Shut-Off Solenoid, Briggs &...
  • Page 61 7 Electrical System Service Exploded View Diagrams Electrical - Lower Harness REF NO. QTY. DESCRIPTION HEADLIGHT ASSY. (Incl. Ref. Nos. 2, 3, 4, 5 & 6) LENS, Headlight BULB, Headlight, 12.8V BEZEL, Headlight HEAT SHIELD SOCKET, Bulb WIRE ASSY., Headlight SWITCH, Seat, Operator Present BUSHING, Snap, Small BUSHING, Snap, Large (Kohler Models Only)
  • Page 62 7 Electrical System Service Exploded View Diagrams Electrical - Upper Harness 38 39 To Lower Harness 5 5 5 21 21 Footnote Below Part List Figure 2. Exploded View Diagram – Upper Wiring Harness 7 - 6...
  • Page 63 7 Electrical System Service Exploded View Diagrams Electrical - Upper Harness REF NO. QTY. DESCRIPTION CAPSCREW, Plastite, #8-16 x 1/2 HOURMETER INTERLOCK SWITCH, Cruise/Parking Brake SWITCH, Headlight BULB, Indicator Light STRAP, Wire Retainer BOOT, Insulator BATTERY TRAY, Battery NUT, Plastic, 1/4-20 CABLE, Battery to Ground HOSE, Battery, Drain CAPSCREW, Hex Hd, 1/4-20 x 3/4...

  • Page 64: Bulletin

    7 Electrical System Service Wiring Diagram Service Bulletin 99-7 M A N U F A C T U R I N G , I N C . TOPIC: REPLACING PLASTIC BODIED IGNITION SWITCHES MODELS AFFECTED: Products Using Plastic Body Ignition Switches Field reports indicate failures of plastic ignition switches.

  • Page 65: Linear Diagrams

    7 Electrical System Service Linear Diagrams Wiring Diagram Note: Several different wiring harness- HOWEVER, all Broadmoor / 1600 / 2600 series electrical es and ignition switches have been used in the foot-con- systems use the same interlock module and function the trolled Broadmoor Series: early models used a two-piece same.

  • Page 66: Linear Circuit Diagrams

    7 Electrical System Service Linear Diagrams LINEAR CIRCUIT DIAGRAMS FUEL SOLENOID "D" SPLICE ACCESORIES SOLENOID PTO SWITCH (OFF POSITION) N.O. N.O. CIRCUIT N.C . BREAKER KEY SWITCH PEDAL SWITCH (START POSITION) (w/ PEDAL UP) SEAT SWITCH BATTERY N.O. or N.C. (UNOCCUPIED) N.O.
  • Page 67 7 Electrical System Service Ignition Switch Service Bulletin MAGNETO ALTERNATOR KEY SWITCH (OFF POSITION) INTERLOCK MODUEL Figure 6. Ignition Shutdown Linear Circuit Diagram IGNITION SHUTDOWN CIRCUIT See Figure 8. Ignition shutdown occurs when the ignition key switch is The interlock module can also ground the magneto turned to the “OFF”...

  • Page 68: Common "No Start" Circuit Tests

    7 Electrical System Service Common Circuit Tests "D" SPLICE ALTERNATOR SOLENOID N.O. N.O. CIRCUIT N.C . BREAKER PEDAL SWITCH SEAT SWITCH KEY SWITCH (w/ PEDAL DOWN) BATTERY (RUN POSITION) (OCCUPIED) N.O. or N.C. N.O. PTO SWITCH (OFF POSITION) Figure 7. Cranking Circuit Linear Diagram COMMON “NO START”...
  • Page 69 7 Electrical System Service Common Circuit Tests Figure 8. Electrical Component Locations 7 - 13...

  • Page 70: Safety Shut Down Test

    7 Electrical System Service Common Circuit Tests MAGNETO "D" SPLICE ALTERNATOR SOLENOID N.O. N.O. CIRCUIT N.C . BREAKER PEDAL SWITCH SEAT SWITCH KEY SWITCH (w/ PEDAL DOWN) BATTERY (RUN POSITION) (OCCUPIED) N.O. or N.C. N.O. PTO SWITCH (OFF POSITION) Figure 9. Safety Shutdown Circuit Linear Diagram Safety Shut Down Test 2.
  • Page 71 7 Electrical System Service Common Circuit Tests Figure 10. Electrical Component Locations MAGNETO KILL CIRCUIT TESTS 13. Set the VOM to Ohms (checking continuity). Turn the key switch to RUN. Disconnect the wire harness from the interlock module. 14. Connect the negative probe to ground. 15.

  • Page 72: Component Location And Replacement

    7 Electrical System Service Location and Replacement COMPONENT LOCATION AND REPLACEMENT NOTE: Most repairs do not require the dashboard to be removed for component replacement or service. If it is required, refer to appropriate section for dashboard ser- vice. Figure 12. Headlight Switch Replacement Dashboard C.
  • Page 73 7 Electrical System Service Location and Replacement Figure 15. Seat Switch Safety System A. Seat Switch C. Seat Figure 14. PTO Switch Replacement B. Wire Harness Dashboard C. PTO Switch B. Wire Harness D. Locking Tabs PTO SWITCH The PTO switch (C, Figure 14) is located in the dashboard (A) on the right-hand side of the steering wheel.
  • Page 74 7 Electrical System Service Location and Replacement PTO CLUTCH For replacement procedure, see PTO CLUTCH SER- VICE section. BRAKE PEDAL SWITCH The brake pedal switch is located under right side of frame, next to the pedal. 1. Disconnect and secure the negative battery cable, (see Section 6, COMMON SERVICE PROCE- DURES).
  • Page 75 7 Electrical System Service Location and Replacement INTERLOCK MODULE The safety interlock module (A, Figure 19) is located on the underside of the dashboard. 1. Disconnect and secure the negative battery cable, (see Section 6, COMMON SERVICE PROCE- DURES). 2. Label and disconnect the wire harness. 3.

  • Page 76: Troubleshooting

    7 Electrical System Service Troubleshooting Charts TROUBLESHOOTING Locate the problem you are having, then check all the components in the order listed. Engine will not turn over: Component Fails Test Loose, broken, or dirty Refer to A. Check/Clean Replace/repair damaged connectors or wiring.
  • Page 77 7 Electrical System Service Troubleshooting Charts Engine will turn over but will not start: Component Fails Test Check all wires and Refer to A. Check/Clean Replace components as connections. Wires and Connectors. required. Component Tests OK Component Fails Test Check the ignition switch. Refer to G.
  • Page 78 7 Electrical System Service Troubleshooting Charts Engine dies when brake pedal released: Component Fails Test Check the brake pedal Refer to L. Brake Pedal Replace the brake pedal switch. Switch Tests. switch. Component Tests OK Component Fails Test Check the seat switch. Refer to N.
  • Page 79 7 Electrical System Service Troubleshooting Charts Battery not charging: Component Fails Test Check battery. Refer to C. Battery Tests. Replace the battery. Component Tests OK Component Fails Test Check ground. Refer to B. Check/Clean Clean both ends of the Ground Cable. negative battery cable.

  • Page 80: Component Tests

    7 Electrical System Service Component Tests COMPONENT TESTS WARNING General Before beginning any test, The following tests should be used in conjunction with ALWAYS: this sections troubleshooting flow charts to efficiently • Disconnect the spark plug wire. troubleshoot common electrical problems; however, if a •...

  • Page 81: Battery Tests

    7 Electrical System Service Component Tests C. Battery Tests WARNING GENERAL Be careful when handling the battery. Avoid If the battery is producing 12 volts and the battery cables spilling electrolyte. Keep flames and sparks away have continuity, the rest of the cranking system can be from the battery.

  • Page 82: Isolated Battery Voltage Check

    7 Electrical System Service Component Tests D. Isolated Battery Voltage Check See Figure 24. In some cases, a short in the wiring or another compo- nent could be causing a low level current draw on the battery. This would be indicated by a slow drain on the battery during times when the engine is off.
  • Page 83 7 Electrical System Service Component Tests IGNITION SWITCH POSITION CIRCUIT MAKE START 1. OFF G & M & A 2. RUN B & L & A 3. START B & L & S TERMINALS START START START Figure 26. Ignition Switch Tests – 6-Pin Steel Body (Later Models) TEST OFF POSITION TEST RUN POSITION 1.

  • Page 84: Test Solenoid

    7 Electrical System Service Component Tests H. 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.
  • Page 85 7 Electrical System Service Component 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 30.Testing for Solenoid Short 5.

  • Page 86: Pto Switch Test

    7 Electrical System Service Component Tests SWITCH TERMINALS (BACK OF SWITCH) PTO SWITCH CIRCUITS N.C . PTO Switch – OFF Position N.O. / N.C. N.O. Figure 32. PTO Switch Terminals Continuity A. Top N.C. Terminals B. Middle N.C. Terminals (Not Used) C.

  • Page 87: Cruise Control Switch Test

    7 Electrical System Service Component Tests K. Cruise Control Switch Test The cruise control switch has a N.O. contact and closes when the cruse control is engaged. SWITCH TESTS NOTE: It may be easier to test the switch if the switch is removed.

  • Page 88: Seat Switch Safety Interlock Test

    7 Electrical System Service Component Tests M. Seat Switch Safety Interlock Test Check the seat switch (B, Figure 38) with the following tests. Engine should shut off if: A. Operator rises off seat with the brake pedal NOT depressed. B. Operator rises off seat with electric clutch engaged.

  • Page 89: Circuit Breaker Test

    7 Electrical System Service Component Tests O. Circuit Breaker Test All circuit breakers are located under the dashboard. The circuit breaker resets itself automatically. If the circuit doesn’t come back on, check it immediately. See Figure The circuit breaker is connected to one of the small sole- noid posts along with the positive battery cable.
  • Page 90 7 Electrical System Service Notes 7 - 34...
  • Page 91 8 Steering & Front Wheel Repair Table of Contents SECTION CONTENTS General ..............8-2 Required Tools & Equipment........8-2 Elevating Front of Unit for Safe Service ....8-2 Front Wheel Repair Removal & Installation ..............8-3 Inspection..................8-3 Steering Group Assemblies - Complete ....8-4 Lower Steering Group LH Spindle Repair .................8-5 RH Spindle / Steering Arm Repair ..........8-7 Reassembly ..................8-8...

  • Page 92: General

    8 Steering & Front Wheel Repair General / Tools / Elevating Unit 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 93: Front Wheel Repair

    8 Steering & Front Wheel Repair Front Wheel Repair FRONT WHEEL REPAIR Retaining ring Removal & Installation Hubcap 1. Using a flat blade screwdriver, pop off the plastic hub retainer cap to gain access to the retaining ring. 2. Using a flat-blade screwdriver, remove the retaining ring and hubcap retainer.

  • Page 94: Steering Group Assemblies - Complete

    8 Steering & Front Wheel Repair Steering Group Assemblies STEERING GROUP ASSEMBLIES - COMPLETE Dash Upper Steering Group Frame Lower Dash Lower Steering Group Figure 5. Steering Group - Complete 8 - 4...

  • Page 95: Lower Steering Group

    8 Steering & Front Wheel Repair Lower Steering Group LOWER STEERING GROUP A. Clip Ring B. Washer Torque to C. Capscrew 22-40 Ft. Lbs. D. Spacer E. Rod End F. Washer G. Flange Nut H. Capscrew I. Drag Link J. Washer K.
  • Page 96 8 Steering & Front Wheel Repair Lower Steering Group 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 8). NOTE: A spacer is located over the capscrew threads in the rod opening to permit rotation of the steering arm.

  • Page 97: Rh Spindle / Steering Arm Repair

    8 Steering & Front Wheel Repair Lower Steering Group RH Spindle / Steering Arm Repair 1. Remove right front wheel using same procedure as used for left front wheel. (Figure 11) 2. Use a center punch to mark the relative assembled positions of the right hand steering arm, right hand spindle assembly, and the right side of the front axle assembly (Figure 11 and 12).

  • Page 98: Reassembly

    8 Steering & Front Wheel Repair Lower Steering Group 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 6. NOTE: If alignment marks are obscured during service or if parts are replaced, proper steering alignment can be performed later with wheels installed using the distance...

  • Page 99: Tie Rod Repair

    8 Steering & Front Wheel Repair Lower Steering Group 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 16).

  • Page 100: Upper Steering Group

    8 Steering & Front Wheel Repair Upper Steering Group UPPER STEERING GROUP 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 101: Steering Wheel Removal

    8 Steering & Front Wheel Repair Upper Steering Group Steering Wheel Removal 1. Later-model steering wheels are attached to the steering shaft assembly with a long spring pin. Use a pin punch and hammer to drive the spring pin out of the steering wheel and steering shaft assembly (Figure 19).

  • Page 102: Steering Shaft Removal

    8 Steering & Front Wheel Repair Upper Steering Group 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 21) just above bushing in the frame support.
  • Page 103 8 Steering & Front Wheel Repair Upper Steering Group 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 23).

  • Page 104: Drag Link Removal

    8 Steering & Front Wheel Repair Upper Steering Group Drag Link Removal Drag Link 1. See Figure 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 105 9 Torque Generator Repair Table of Contents SECTION CONTENTS Exploded View Diagram ........9-2 General Information..........9-3 Tear-Down and Reassembly Tear Down..................9-4 Reassembly ..................9-6 9 - 1...

  • Page 106: Exploded View Diagram

    9 Torque Generator Repair Exploded View Diagram Screw, Cap, (7) Housing, Power End Spring, Centering (for Standard Input Torque) (6) Housing, Power End (bearings, needle type) Ring, Retaining Washer Seal, Quad Ring, Retaining Seal, Shaft (Lip Type) Seal, Quad O-ring (2) Shaft, Power End Washer Drive, Power End...

  • Page 107: General Information

    9 Torque Generator Repair General Information GENERAL WARNING Before beginning any service work, turn the PTO off, set the parking brake, turn the ignition switch off, remove the key, disconnect the spark plug wire, and disconnect the negative battery cable. The following repair information may be used to inspect The following procedures may be used to completely dis- and/or repair the 217 Series or 227 Series Torque...

  • Page 108: Tear-Down And Reassembly

    9 Torque Generator Repair Tear-Down Quad Seal Vise Jaws Output Shaft (top View) (power end) Up Housing (Standard) Washer Washer Shaft and Retaining Ring (power end) Housing (bearings—needle type) TEAR-DOWN AND REASSEMBLY Tear-Down 5. Remove both washers from the housing (power end), 1 To disassemble the torque generator, first support and re-position the housing with seal end up.
  • Page 109 9 Torque Generator Repair Tear-Down O-ring Drive Spacer Spacer Geroler Plate Valve Valve Housing Washer Housing — 227 Series O-ring Gerotor Sleeve Shaft Seal Spool Drive (can be Centering Springs Quad Seal Retaining Ring or Lip Seal) and Cross Pin O-ring 16.

  • Page 110: Reassembly

    9 Torque Generator Repair Reassembly Spring InstallationTool Alternate Method Plug O-ring Relief Valve Valve Housing Add One (for Relief Spring Springs Valve Option) at a Time 23. In preparation of installing the control spool and NOTE: Valve housing with inlet relief valve has one o- sleeve centering spring set, stand all springs on a ring on the plug.
  • Page 111 9 Torque Generator Repair Reassembly NOTE: Careful insertion of input shaft upon reassembly 26. Install the cross pin into the spool/sleeve. will prevent shaft seal damage (step 32). 27. Lubricate and install the washer into the valve hous- 32. With the washer still resting firmly in the valve hous- ing.
  • Page 112 9 Torque Generator Repair Reassembly Gerotor or Geroler Drive (power end) Quad Seal Housing (Standard) Washer Spacer Spacer Plate O-ring Washer Shaft and Retaining Ring (power end) 40. Lubricate and install the o-ring into the gerotor or Housing (bearings—needle type) Gerotor.
  • Page 113 10 Hand Controls Service Table of Contents SECTION CONTENTS Attachment Lift Lever Service Lift Lever Grip Replacement ............10-2 Upper Lift Rod Replacement............10-2 Lower Lift Rod Replacement............10-2 Engine Choke Control Choke Cable Replacement ............10-3 Throttle Control Service Throttle Knob Service..............10-4 Throttle Assembly Replacement ..........10-4 Parking Brake Control Service Knob Removal................10-5 Parking Brake Rod Replacement..........10-5...

  • Page 114: Attachment Lift Lever Service

    10 Hand Controls Service Attachment Lift Lever Service A. Bushing B. Lift Lever & Grip C. Upper Lift Rod D. Lift Plate E. Lower Lift Cam F. Washer & Locknut Side of G. Capscrew Lower Dash H. Nylon Bushing I. Spacer J.

  • Page 115: Engine Choke Control

    10 Hand Controls Service Choke Control Service ENGINE CHOKE CONTROL (SELECT UNITS) Choke Cable Replacement 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 2). For easiest Engine Choke service access, the battery should be removed from the Control...

  • Page 116: Throttle Control Service

    10 Hand Controls Service Throttle Control Service THROTTLE CONTROL SERVICE The throttle (engine speed) control is attached to the underside of the dashboard and may be accessed by raising the unit's hood. For greater access and improved work area, the battery may be removed from the unit. Throttle Knob Service The throttle knob (A, Figure 5) snaps onto the throttle control (C).

  • Page 117: Parking Brake Control Service

    10 Hand Controls Service Parking Brake Linkage A. Parking Brake Knob B. Dashboard C. Upper Brake Rod D. Parking Brake Cam E. Lower Brake Rod F. Lock Plate Bracket G. Pivot Shaft (Frame) Figure 6. Parking Brake Linkage PARKING BRAKE CONTROL SERVICE Knob Removal 1.
  • Page 118 10 Hand Controls Service Notes 10 - 6...
  • Page 119 11 Drive Controls Service Table of Contents SECTION CONTENTS Brake System Components ........2 General Information..........3 Parking Brake Mechanism ........3 Brake Component Replacement Rear Brake Rod Replacement ............3 Idler Assembly Service..............4 Brake Pedal Pad Replacement ............4 Brake Pedal Assembly Removal & Installation ........4 Differential Lock Control Service ......5 Shock Absorber Replacement.........5 Cruise Control System Components ......6...

  • Page 120: Brake System Components

    11 Drive Controls Service Brake System Components Brake System Components Hook Spring to hole in Frame above Transmission To Notch in Frame Figure 1. Brake System Components A. Parking Brake Rod G. Idler assembly M. Idler Pivot (Frame) B. Cruise/P-Brake Light Switch H.

  • Page 121: General Information

    11 Drive Controls Service Parking Brake System Service NOTE: Idler Assembly Removed for To Parking Illustration Brake Cam Purposes. 1/8” to 3/16” Figure 2. Cruise Control Release Tabs A. Cruise Release Tabs C. Cruise Lock Cam B. Brake Cam D. Cam Adj. Bolt GENERAL INFORMATION Hook Spring to Frame...

  • Page 122: Idler Assembly Service

    11 Drive Controls Service Idler Assembly and Brake Pedal Service To Parking Brake Cam Hook Spring Figure 5. Brake Pedal Assembly to Frame A. Brake Pedal Arm E. Brake Pedal Cam B. Bushings F. Brake Switch Actuator C. Clutch Rod G.

  • Page 123: Differential Lock Control Service

    11 Drive Controls Service Differential Lock and Shock Absorber Service DIFFERENTIAL LOCK CONTROL SERVICE (Select Models) Early models used a cable to actuate the transmission control arm. Later models used a rod. Replacement 1. Remove the hardware securing the seat deck (see Section 16 SEAT DECK SERVICE).

  • Page 124: Cruise Control System Components

    11 Drive Controls Service Cruise Control System Components Cruise Control System Components Figure 8. Drive System Components A. Parking Brake Rod G. Pivot M. Idler Pivot (Frame) B. Cruise/P-Brake Light Switch H. Brake Lever N. Lock Plate Bracket C. Parking Brake Cam I.

  • Page 125: Cruise Control Lock Mechanism

    11 Drive Controls Service Cruise Control Service NOTE: Idler Assembly Removed for To Parking Illustration Brake Cam Purposes. 1/8” to 3/16” Figure 9. Cruise Control Release Tabs A. Cruise Release Tabs C. Cruise Lock Cam B. Brake Cam D. Cam Adj. Bolt CRUISE CONTROL LOCK Hook Spring MECHANISM...

  • Page 126: Foot Pedal Assembly Service

    11 Drive Controls Service Foot Pedal Assembly Service FOOT PEDAL ASSEMBLY SERVICE Removal & Installation 1. Remove the washer, lockwasher, and nut (F, Figure 11) securing the transmission control rod (G) to the foot pedal assembly. 2. Remove the capscrew (D) and spacer (H). 3.
  • Page 127 12 Hand Controls Service Table of Contents SECTION CONTENTS Exploded View Diagrams Manual Lift Mechanism - 44” Models ..........12-2 Manual Lift Mechanism - 50” Models ..........12-4 Manual Lift Lever Service General ..................12-6 Latch Rod & Spring Replacement - All Manual Lift Models ..12-6 Lift Lever Removal - All Manual Lift Models........12-7 Lift Cable &...
  • Page 128 12 Hand Controls Service Exploded View Diagrams Manual Lift Mechanism - Models with 44” Mower Deck 12 - 2...
  • Page 129 12 Hand Controls Service Exploded View Diagrams Manual Lift Mechanism - Models with 44” Mower Deck REF NO. QTY. DESCRIPTION 1650157 BUTTON 1713995 GRIP 1918265 WASHER, 5/16 1676526 SPRING, Compression 1721866 QUADRANT & LEVER ASSEMBLY 1705249 SPACER 1922127 CAPSCREW, Hex Head, 5/16-18 x 1-3/4 1921977 CAPSCREW, Hex Head, 5/16-18 x 1-1/4 1919438...
  • Page 130 12 Hand Controls Service Exploded View Diagrams Manual Lift Mechanism - Models with 50” Mower Deck 12 - 4...
  • Page 131 12 Hand Controls Service Exploded View Diagrams Manual Lift Mechanism - Models with 50” Mower Deck REF NO. QTY. DESCRIPTION 1916951 NUT, 1/2-13 1916966 LOCKWASHER, 1/2-13 1924361 WASHER, 1/2 1722412 SPACER 1708559 PULLEY 1924359 WASHER, 1/2 1722343 PULLEY, Guide 1722411 SPACER 1960245 CAPSCREW, Hex Head, 1/2-13 x 3...

  • Page 132: Manual Lift Lever Service

    12 Hand Controls Service Manual Lift Lever Service WARNING Before beginning any service work, turn the PTO off, set the parking brake, turn the ignition switch off, remove the key, disconnect the spark plug wire, and disconnect the negative battery cable. MANUAL LIFT LEVER SERVICE General Two different manual lift mechanisms have been used on...

  • Page 133: Lift Lever Removal - All Manual Lift Models

    12 Hand Controls Service Manual Lift Lever Service Lift Lever Removal - All Manual Lift Models The entire lift lever assembly may be easily removed 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 regarding mower deck removal if necessary), or: 2.

  • Page 134: Lift Cable & Pulley Replacement

    12 Hand Controls Service Manual Lift Lever Service Lift Cable & Pulley Replacement FRONT NOTE: The right side pulley is secured with a lockwasher and nut instead of a C-clip. IMPORTANT NOTE: For both lift cables, the mower cle- vis pin (D) is installed from right to left; the tractor lift cle- vis pin (B) is installed from left to right.

  • Page 135: Engine Choke Control (Select Units)

    12 Hand Controls Service Choke Control Service ENGINE CHOKE CONTROL (SELECT UNITS) Choke Cable Replacement 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 5). For easiest service access, the battery should be removed from the unit.

  • Page 136: Throttle Control Service

    12 Hand Controls Service Throttle & Parking Brake Control Service THROTTLE CONTROL SERVICE The throttle (engine speed) control is attached to the underside of the dashboard and may be accessed by raising the unit's hood. For greater access and improved work area, the battery may be removed from the unit.

  • Page 137: Hydraulic Lift Control Service

    12 Hand Controls Service Hydraulic Lift Control Service HYDRAULIC LIFT CONTROL SERVICE Lift Control Knob Replacement 1. Clear the area around the mower deck or attachment and cycle the lift valve lever (A, Figure 11) to relieve any pressure in the system and lower the attachment. 2.
  • Page 138 12 Hand Controls Service Notes 12 - 12...
  • Page 139 13 Hood & Dashboard Service Table of Contents SECTION CONTENTS Exploded View Diagrams All Models..................13-2 Hood & Dashboard Removal Remove the Hood ...............13-4 Remove the Battery ..............13-4 Remove the Dashboard ..............13-5 Hood & Dashboard Installation Reinstall Dashboard..............13-7 Reinstall the Battery ..............13-8 Reinstall the Hood...............13-8 13 - 1...
  • Page 140 13 Hood & Dashboard Service Exploded View Diagram Hood, Grille & Dash Group 12 1 12 1 35 31 10 10 8 13 - 2...
  • Page 141 13 Hood & Dashboard Service Exploded View Diagram Hood, Grille, & Dash Group REF NO. QTY. DESCRIPTION PAL NUT, 1/4-20 AIR DUCT MOLDING, Air Duct PLUG, Hole, Electric Lift DASH ASSY. DASH, Lower WASHER, Plain, 1/4 CAPSCREW, Hex Flange Hd, Whizlock, 1/4-20 x 5/8 BUSHING, Nylon CAPSCREW, Taptite, 1/4-20 x 1/2 SUPPORT, Bulkhead, LH...

  • Page 142: Remove The Hood

    13 Hood & Dashboard Service Hood & Battery Removal HOOD & DASH REMOVAL WARNING Before beginning any service work turn off the PTO, set the parking brake, turn off the ignition, and disconnect the spark plug wire(s). Remove the Hood 1.

  • Page 143: Remove The Dashboard

    13 Hood & Dashboard Service Battery & Dashboard Removal Remove the Dashboard 1. Using a punch, remove the roll pin from the steering shaft (Figure 4). Remove the steering wheel and flex collar. Figure 4. Remove Steering Wheel 3. Unscrew the parking brake knob from the parking brake rod.
  • Page 144 13 Hood & Dashboard Service Dashboard Removal 5. Using a 3/8" nut-driver remove the two whizlock cap- screws and washers that secure the rear of the dash to the lower dash (Figure 7). Figure 7. Remove Rear Dash Mounting Screws 6.

  • Page 145: Hood & Dashboard Installation

    13 Hood & Dashboard Service Dashboard & Battery Installation 8. Disconnect the throttle cable and choke cable from the engine (Figure 10). 9. Carefully lift the dash assembly away from the lower dash. HOOD & DASHBOARD INSTALLATION Reinstall Dashboard 1. Reattach the throttle and choke controls to the engine (Figure 10).

  • Page 146: Reinstall The Battery

    13 Hood & Dashboard Service Battery & Hood Installation FRONT Figure 13. Battery Cables - Air Cooled Models A. Negative Cable D. Capscrew B. Positive Cable & Cover E. Vent Hose C. Nut, Lockwasher, & Washer Figure 12. Engine Compartment - Air Cooled Models A.
  • Page 147 14 Transmission Tear-Down Contents SECTION CONTENTS Exploded View Diagrams K71..................... 14-2 General Information Introduction ................14-6 Specifications ................14-6 Disassembly Preparation................. 14-7 Disassembly................14-7 Assembly Preparation................14-14 Disassembly................14-14 14 - 1...
  • Page 148 14 Transmission Tear-Down Exploded View Diagrams 95/99 86/88 86/88 86/88 1/20 30 29 14 - 2...

  • Page 149: Exploded View Diagrams

    14 Transmission Tear-Down Exploded View Diagrams K71 Hydrostatic Transmission REF NO. QTY. DESCRIPTION CASE SET, (K71E Only, See Ref. 20 for K71G) BEARING, 28 x 15 TAPER PLUG, 1/8, (K71E Only) BORE PLUG, 17, (K71E Only) CAP, Oil, 20 FILTER FITTING SEAL BEARING...
  • Page 150 14 Transmission Tear-Down Exploded View Diagrams 95/99 86/88 86/88 86/88 1/20 30 29 14 - 4...
  • Page 151 14 Transmission Tear-Down Exploded View Diagrams K71 Hydrostatic Transmission REF NO. QTY. DESCRIPTION PACKING, 6.1 PIN, 3.2 x 21 BOLT, 8 x 45 SWASH PLATE COMPLETE BEARING COMPLETE WASHER SPRING (N/C) SHAFT (BYPASS) LEVER (BYPASS) RING SPRING PACKING PIN, 3.0A*20 CONTROL LEVER BOLT PIN, 6.0A x 50...

  • Page 152: General Information

    14 Transmission Tear-Down General Information / Specs GENERAL INFORMATION Introduction There are presently 3 variations of the K-71 transaxle being used. The K-71E has a differential lock, automatic controlled traction, and a charge pump that in addition to maintain- ing the closed loop of oil between the pump and motor, allows the unit to have hydraulic lift and power steering.

  • Page 153: Disassembly

    14 Transmission Tear-Down Disassembly WARNING Before beginning any service work, turn the PTO off, set the parking brake, turn the ignition switch off, remove the key, disconnect the spark plug wire, and disconnect the negative battery cable. DISASSEMBLY Preparation Drain the transaxle oil, thoroughly clean the transmis- sion, and put it on a stand.
  • Page 154 14 Transmission Tear-Down Disassembly 6. Use a 5mm allen wrench to remove the allen plug to Allen plug gain access to the roll pin that holds the shift fork in place for the differential lock. Roll Pin 7. Use an appropriate punch and hammer to drive the roll pin towards the front.
  • Page 155 14 Transmission Tear-Down Disassembly Figure 7. Remove Differential Retainers Figure 9. Remove Differential Assembly Figure 8. Remove C-Rings 11. Remove the differential: • Lift out the axle retainer (Figure 7) on either side of the differential, then pull the axles out slightly. Use a magnet to remove the axle c-rings (Figure 8) and Pinion Assy.
  • Page 156 14 Transmission Tear-Down Disassembly Charge Pump Bolts Bearing Snap Ring Seal Axle Figure 12. Charge Pump Removal Figure 11. Axle Removal Inspect Running Surfaces for Wear 12. Remove the axles (Figure 11) from the upper case. Examine the components for any signs of damage or wear, and replace as needed.
  • Page 157 14 Transmission Tear-Down Disassembly 16. Using a 14mm socket, loosen and remove the three bolts that retain the center section. Remove the Note Letter brake assembly bolts and brake assembly. Before on Fixed Center Section lifting and removing the center section from the upper Swash Plate Bolts case, be sure to note the letter on the fixed swash-...
  • Page 158 14 Transmission Tear-Down Disassembly A. Piston, Washer, & Spring Do not disassemble B. Motor Block the center section. C. Center Section D. Release Valve Pin E. Pump Block F. Bearing and Races G. Swashplate H. Motor Shaft I. Bearing J. Gear Figure 16.
  • Page 159 14 Transmission Tear-Down Disassembly A. Double Roll Pin B. Control Arm C. Side Cover Bolts (7) D. Side Cover E. Spring F. Variable Swash Plate G. Race (Thin) H. Bearing I. Race (Thick) J. Seal K. Snap Ring L. Input Shaft M.

  • Page 160: Assembly

    14 Transmission Tear-Down Assembly 24. In needed, remove the bypass lever and shaft. Remove the snap ring from the shaft being careful of Bypass the spring force behind it. The lever can be removed Lever from the shaft by simply pulling it from the shaft. 25.
  • Page 161 14 Transmission Tear-Down Assembly A. Double Roll Pin B. Control Arm C. Side Cover Bolts (7) D. Side Cover E. Spring F. Variable Swash Plate G. Race (Thin) H. Bearing I. Race (Thick) J. Seal K. Snap Ring L. Input Shaft M.
  • Page 162 14 Transmission Tear-Down Assembly 8. Install the center section and motor assembly. This procedure will require a number of things to be done in the proper sequence. Be sure to pre-lubricate parts before or as you assemble them, as it can make assembly easier and prevent any damage dur- ing assembly.
  • Page 163 14 Transmission Tear-Down Assembly Note Letter on Fixed Center Section Swash Plate Bolts Brake Assembly Bolts Figure 22. Center Section Installation Figure 23. Center Section Bolts See Figure 21. • Using hand pressure only, push the center section straight down (Figure 22). At the same time com- •...
  • Page 164 14 Transmission Tear-Down Assembly Drive Pin Charge Pump Bolts Dots Figure 25. Charge Pump Removal Charge Pump Valve and Spring Bearing Implement Relief Valve & Spring Snap Ring Seal Axle Figure 24. Charge Pump Installation Figure 26. Axle Installation 10. If not already done so, install the axle bearings and 9.

  • Page 165: Disassembly

    14 Transmission Tear-Down Assembly Figure 28. Install Differential Assembly Pinion Assy. DO NOT Disassemble Figure 29. Install C-Rings Figure 27. Differential Assembly Figure 30. Install Differential Retainers 13. Install the differential assembly. • See Figure 27. Install the slider, collar, and gear on the left side of the differential gear.
  • Page 166 14 Transmission Tear-Down Assembly 14. See Figures 31 & 32. Assemble the intermediate gear assembly and install into the upper case. Be sure the flats on bushing line up with the housing. Also be sure the bevel on gear is facing the center of the transaxle.
  • Page 167 14 Transmission Tear-Down Assembly 19. Install the internal oil filter (B, Figure 34) and its cap (A), being sure that the seal end of the filter is installed first. NOTE: Install the brake assembly now, if not done already. Figure 34. Internal Transmission Filter Service A.
  • Page 168 14 Transmission Tear-Down Notes 14 - 22...
  • Page 169 15 PTO Clutch Service Table of Contents SECTION CONTENTS General ..............15-2 Troubleshooting...........15-2 Adjustment Adjustment Procedure..............15-3 Blade Brake Check ..............15-3 PTO Clutch Electrical Tests (Bench Tests) Check Resistance ...............15-4 Check for Short Circuits ..............15-4 Check Engagement..............15-4 PTO Clutch Replacement Removal ..................15-5 Installation ...................15-5 Burnishing the Electric PTO Clutch ....15-5 15 - 1...

  • Page 170: General

    15 PTO Clutch Service General / Troubleshooting GENERAL TROUBLESHOOTING The Ogura electric PTO clutch used on the Broadmoor / Use the following procedure to check and replace a 1600 / 2600 series is very sensitive to initial wear, and defective clutch: therefore must be adjusted at it’s 50/250 hour service 1.

  • Page 171: Adjustment

    15 PTO Clutch Service Adjustment Figure 2. Adjust PTO Clutch A. Window B. Adjustment Nut C. Feeler Gauge Figure 1. PTO Clutch Adjustment A. Adjustment Window (Qty. 3, one shown) B. Adjustment Nut PTO CLUTCH ADJUSTMENT WARNING Check the PTO clutch adjustment after the initial 50 hour To avoid serious injury, perform adjustments only break-in period and then after every 250 hours of opera- with engine stopped, key removed and tractor on...

  • Page 172: Pto Clutch Electrical Tests (Bench Tests)

    15 PTO Clutch Service Electrical Tests Figure 3. Checking PTO Clutch Resistance Figure 4. Checking PTO Clutch for Shorts PTO CLUTCH ELECTRICAL TESTS (BENCH TESTS) Check Resistance See Figure 3. 1. Unplug the PTO clutch wire harness. 2. Using a volt/ohm meter (VOM) set to measure resis- tance (ohms), probe PTO clutch wire harness termi- nals.

  • Page 173: Pto Clutch Replacement

    15 PTO Clutch Service Replacement / Burnishing PTO CLUTCH REPLACEMENT Removal Refer to Figure 6. 1. Remove the mower deck, block the wheels, and dis- engage the parking brake. 2. Disconnect the electrical harness. 3. Remove the capscrew, lockwasher, and hex washer securing the clutch to the crank shaft.
  • Page 174 15 PTO Clutch Service Notes 15 - 6...
  • Page 175 16 Mower Deck Service Table of Contents SECTION CONTENTS Exploded View Diagrams 38” Mower Deck - Housing, Arbors, & Blades......16-2 38” Mower Deck - Belt & Hitch Group .........16-4 38” Mower Deck - Height Adjustment & Roller Group....16-6 44” & 50” Mower Decks - Housing, Arbors, & Blades ....16-8 44 &...

  • Page 176: 38" Mower Deck - Housing, Arbors, & Blades

    16 Mower Deck Service 38” Mower Deck - Housing, Arbors, & Blades Torque to 50-70 ft. lbs. Apply gasket former to this surface if foam gasket is not used. 27 27 27 Viewed From Bottom Torque to 45-55 ft. lbs. 16 - 2...
  • Page 177 16 Mower Deck Service 38” Mower Deck - Housing, Arbors, & Blades 38” Mower Deck - Housing, Arbors & Blades 38” Mower Deck - Housing, Arbors & Blades REF NO. QTY. DESCRIPTION NUT, Hex Flange, 9/16-8 WASHER, Belleville PULLEY, LH HUB ADAPTER, Pulley COVER, Arbor Housing BEARING...

  • Page 178: 38" Mower Deck - Belt & Hitch Group

    16 Mower Deck Service 38” Mower Deck - Belt & Hitch Group Hook Spring to Belt Guide Hook Spring {Ref 22} here when assembled. 16 - 4...
  • Page 179 16 Mower Deck Service 38” Mower Deck - Belt & Hitch Group 38” Mower Deck - Belt & Hitch Group 38” Mower Deck - Belt & Hitch Group REF NO. QTY. DESCRIPTION V-BELT CAPSCREW, Hex Hd, 3/8-16 x 2-3/4 GUARD, Belt WASHER, Plain, 3/8 SPACER IDLER PULLEY (Incl.

  • Page 180: 38" Mower Deck - Height Adjustment & Roller Group

    16 Mower Deck Service 38” Mower Deck - Height Adjustment & Roller Group GREASE 3 3 3 23 23 24 GREASE Note: Attach mower levelling adjustment rod (Ref. 45) 44 18 to bottom hole in mower hitch assembly {See 38" Mower Deck - Clutch &...
  • Page 181 16 Mower Deck Service 38” Mower Deck - Height Adjustment & Roller Group 38” Mower Deck - Height Adjustment & Roller Group REF NO. QTY. DESCRIPTION NUT, Hex Flange Lock, 1/2-13 SHAFT ASSY., Roller WASHER, Plain, 1-1/4 ROLLER SPACER BAR, Roller NUT, Adjuster LOCKWASHER, 3/8 NUT, Hex, 3/8-16...
  • Page 182 16 Mower Deck Service 44” & 50” Mower Deck - Housing, Arbors & Blades Torque nuts to 50-70 ft. lbs. 38 38 Apply gasket former to this surface if foam gasket is not used. 27 27 Torque screws to 45-55 ft. lbs. 16 - 8...

  • Page 183: 44" & 50" Mower Decks - Housing, Arbors & Blades

    16 Mower Deck Service 44” & 50” Mower Decks - Housing, Arbors, & Blades 44” & 50” Mower Decks - Housing, Arbors & Blades 44” & 50” Mower Decks - Housing, Arbors & Blades REF NO. QTY. DESCRIPTION NUT, Hex Flange, 9/16-8 WASHER, Belleville PULLEY HUB, Double Pulley, LH Arbor...

  • Page 184: 50" Mower Decks - Belt & Hitch

    16 Mower Deck Service 44” & 50” Mower Decks - Belt & Hitch Movable Idler Pulley Engine Pulley Arbor Drive Pulley Arbor Drive Pulley Arbor Drive 7 7 7 7 Pulley Movable Arbor Drive Idler Pulley Pulley Arbor Drive Pulley Mount Hitch Assembly using upper holes...
  • Page 185 16 Mower Deck Service 44” & 50” Mower Decks - Belt & Hitch 44” & 50” Mower Decks - Belt & Hitch REF NO. QTY. DESCRIPTION HITCH ASSY. ROD, Latch GRIP, Lever NUT, Hex, 3/8-16 LOCKWASHER, 3/8 BELT STOP, Idler WASHER, Plain, 13/32 SPACER PULLEY, Idler (Incl.

  • Page 186: 44" Mower Deck - Height Adjustment & Rollers

    16 Mower Deck Service 44” Mower Deck - Height Adjustment & Rollers 12 12 GREASE 17 17 43 43 GREASE Note: Attach mower levelling adjustment rod (Ref 46) to bottom hole in mower hitch assembly. {See 44" & 50" Mower Deck - Belt, Clutch & Support Group.} 16 - 12...
  • Page 187 16 Mower Deck Service 44” Mower Deck - Height Adjustment & Rollers 44” Mower Deck - Height Adjustment & Rollers REF NO. QTY. DESCRIPTION NUT, Hex, 3/8-16 LOCKWASHER, 3/8 NUT, Adjuster SHAFT ASSY, Roller, 44” (Incl. Ref. Nos. 8, 9 & 11) SLIDE WASHER, Plain, 1/2 BOLT, Shoulder, 3/8-16...

  • Page 188: 50" Mower - Height Adjustment & Rollers

    16 Mower Deck Service 50” Mower - Height Adjustment & Rollers GREASE 17 17 43 43 GREASE Note: Attach mower levelling adjustment rod (Ref 46) to bottom hole in mower hitch assembly. {See 44" & 50" Mower Deck - Belt, Clutch & Support Group.} 16 - 14...
  • Page 189 16 Mower Deck Service 50” Mower - Height Adjustment & Rollers 50” Mower - Height Adjustment & Rollers REF NO. QTY. DESCRIPTION NUT, Hex, 3/8-16 LOCKWASHER, 3/8 NUT, Adjuster SHAFT ASSY, Roller, 50” (Incl. Ref. No. 11) SLIDE WASHER, Plain, 1/2 BOLT, Shoulder, 3/8-16 NUT, Hex Flange, 3/8-16 SPACER...

  • Page 190: Mower Deck Repair

    16 Mower Deck Service Idler Pulley Service MOWER DECK REPAIR WARNING Before beginning any service work, turn the PTO off, set the parking brake, turn the ignition switch off, remove the key, disconnect the spark plug wire, and disconnect the negative battery cable. Mower Removal &...

  • Page 191: Idler Pulley Service - 44" & 50" Decks

    16 Mower Deck Service Idler Pulley Service Movable Idler Pulley Engine Pulley Arbor Drive Arbor Drive Pulley Pulley Arbor Drive Arbor Drive Pulley Pulley Movable Idler Pulley A. Belt Stop Bracket B. PTO Idler Pulley C. Idler Lever D. Carriage Bolt, 1-3/4 E.

  • Page 192: Arbor Repair

    16 Mower Deck Service Arbor Repair Figure 4. Mower Deck - 38” Mower A. Belt Guides Figure 5. Mower Deck - 44" & 50” A. Right-hand Arbor Cover B. Left-hand Arbor Cover ARBOR REPAIR Taptite Arbor Assembly Removal - All Models Screws 1.

  • Page 193: Arbor Disassembly - 38" Mowers

    16 Mower Deck Service Arbor Disassembly - 38” Mowers Torque nuts to 50-70 ft. lbs. A. Flange Hex Nut B. Belleville Washer C. Pulley D. Adapter Hub E. Arbor Housing Cover F. Upper Bearing G. Arbor Spacer H. Lower Bearing I.

  • Page 194: Arbor Assembly - 38" Mowers

    16 Mower Deck Service Arbor Assembly - 38” Mowers Torque nuts to 50-70 ft. lbs. A. Flange Hex Nut B. Belleville Washer C. Pulley D. Adapter Hub E. Arbor Housing Cover F. Upper Bearing G. Arbor Spacer H. Lower Bearing I.

  • Page 195: Arbor Disassembly - 44" & 50" Mowers

    16 Mower Deck Service Arbor Disassembly - 44” & 50” Mowers Torque nuts to 50-70 ft. lbs. A. Flange Hex Nut B. Belleville Washer C. Pulley D. Adapter Hub E. Arbor Housing Cover F. Upper Bearing G. Sleeve Spacer (44" Only) H.

  • Page 196: Arbor Assembly - 44" & 50" Mowers

    8. Install the lower grass shield and mower blades as 38” decks do not use the sleeve spacer (G). described in Section 6, COMMON SERVICE 3. Fill the housing with Simplicity Multi-Purpose Lithium PROCEDURES. Grease or equivalent. NOTE: The arbor shaft may have up to 1/8" of end-play.

This manual is also suitable for:

Agco allis 1600 seriesMassey ferguson 2600 series

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