Removal Of Hydrostatic Unit From A Separated System; Motor Removal; Pump Removal; Installation Of Hydrostatic Unit In A Separated - Kohler K91 Owner's Manual

REMOVAL OF HYDROSTATIC UNIT
FROM A SEPARATED SYSTEM
MOTOR REMOVAL
1.
Remove the nuts from the two bolts securing
the top section of the motor to the transaxle.
Remove the two
1/2"
and two
3/8"
cap screws
that hold the manifold pad to the motor and
tie up the manifold so it will clear the motor
pad.
2.
Jack the tractor up under the frame and remove
the
left rear wheel for working space. Place
an oil drain pan under the motor and transaxle
to catch oil as the motor i s removed. To remove
the motor, remove the top corner motor-to-case
bolt nuts and the two lower motor-to-case cap
screws which thread into the case.
PUMP REMOVAL
1.
2.
3.
5 .
6.
7.
8.
9.
To remove the hydrostatic pump, disconnect
the head lamp wires and remove the hood,
grille and shroud assemblies. Disconnect and
remove the battery and disconnect the PTO rod
trunnion from the clutch bar.
Disconnect the fuel and suction lines from the
engine and the coil wire from the coil. Next,
disconnect the throttle arm ball joint and the
choke wire assembly from the carburetor and
engine.
Disconnect the cable from the starter and re-
move the four
x''
bolts holding the engine to
the frame.
Pull the engine straight forward until
the
coupling slides from the pump shaft spline.
It is not necessary to lift the engine from the
frame.
If,
however, you would
like
to get
it
completely out of the way, disconnect the
DC
wire from the voltage regulator connector and
the engine will be freed to move as desired.
Remove the right console panel, together with
the battery supports.
Disconnect all three control rods.
The
upper
forward rod is connected to the speed control
lever linkage.
The
long rod coming up from the
bottom
i s
connected to the brake pedal shaft
arm at the bottom. At the top it is connected
to the neutral plate so that when the brake
pedal is pushed down, the control shaft i s
brought to neutral, just as it i s when operated
by the speed control lever. On some models,
a third rod at the rear connects
the
neutral
plate and the parking brake lever.
Remove the four
5/16"
cap screws holding the
front manifold pad to the pump pad. As the
two rear screws have elastic stop nuts on the
top, it will
be
necessary to hold them while
removing the screws. An oil drain pan should
be
placed under this area, since there will be
some oil loss.
Where an "Allen'' type screw i s used, a
5/16"
hex with a
3/8"
drive socket i s recommended.
If
none i s
available, one can be fabricated by
welding a piece of hex stock to a
3/8"
drive
socket.
Disconnect the hydraulic
lift
tubes, located at
the top of the pump, from their fittings. Discon-
nect the temperature sending unit wire. Remove
the two
5/16"
bolts and nuts that hold the rear
pump bracket to the steering gear support.
After removing the bolt that attaches the front
pump bracket to the left side panel, the pump
and ,brackets may
be
removed.
If
a new pump
i s to, be installed, carefully change
the
brackets
and linkage from the old pump to the new
Pump-
INSTALLATION OF HYDROSTATIC
UNIT IN A SEPARATED SYSTEM
PUMP INSTALLATION
Place a small amount of clean grease in the mani-
fold plate seal ring recesses and on the seal rings
themselves. Next, place
a small O-ring in each of the
low pressure port recesses and a large O-ring in each
of the larg'e high pressure port recesses. Then place
a square section type back up ring over the top of
each of the large O-rings, centering them as closely as
possible.
To facilitate alignment of the pump to the manifold
pad, fabricate two aligning pins by cutting the heads
off
two
3/8-16
bolts to make two studs, each two inches
long. Saw 'a screwdriver slot in the end and taper
the ends as shown. Screw the aligning pins into the
FIG. 20.
O-ring Ports
two front threaded holes in the pump pad. Install the
pump by placing
it
carefully in position. Insert the
aligning pins into
the
front manifold holes as
the
pump i s lowered into place.
FIG. 21.
Aligning Pins
27