Simplicity Pow'r Max 4040 Garden Tractor Manuals

Manuals and User Guides for Simplicity Pow'r Max 4040 Garden Tractor. We have 1 Simplicity Pow'r Max 4040 Garden Tractor manual available for free PDF download: Repair Manual

Simplicity Pow'r Max 4040 Repair Manual (133 pages)

Pow'r Max Series

Brand: Simplicity | Category: Tractor | Size: 7 MB

Table of Contents
3
Safety Rules
9
General Information
11
Battery Removal and Installation
11
Battery Water Level
11
Bearing Cleaning and Inspection
12
Battery Charging
12
Battery Winter Care
12
Recommended Torque Specifications for Hardware
13
Transmission Fluid and Filter
14
Viscous Coating VC-3
14
Brake Adjustment
15
Transmission Priming Procedure
15
Clutch Pedal Free Travel Adjustment
16
Clutch Belt Tension
16
Engine Description
19
Engine Removal
19
Engine Electrical Connections
19
Choke and Throttle Cable Connections
19
Engine Installation
21
PTO Runout Check
21
Removal and Installation of Wheel
22
Drop Housing Removal and Disassembly
22
Drop Housing Inspection and Repair
23
Drop Housing Assembly and Installation
23
Brakes
24
Brake Assembly Removal and Disassembly
25
Right Rear Axle Extension
25
Brake Assemby Outer Stationary Discs and Studs
25
Differential Output Shaft and Outer Rotating Disc
25
Disassembly of Brake Levers and Linkage
26
Brake Levers and Linkage Inspection and Repair
26
Brake Levers and Linkage Assembly
26
Brake Assembly Installation and Assembly
26
Brake Levers and Linkage Diagram
27
Power Train System
28
Clutch
28
Hydrostatic Transmission
28
Transmission
29
Power Train System Diagram
29
Three-Speed Gear Operation (Neutral Position)
30
Differential
31
Rear PTO
31
Clutch and Drive Shaft View
32
Clutch Disassembly
33
Drive Shaft Removal
34
Clutch Inspection, Cleaning and Repair
34
Clutch Assembly
34
Drive Shaft Installation
34
Transmission Removal and Disassembly
35
Seat Assembly Diagram
35
Hydrostatic Pump Inlet and Transmission Temperature Sending Unit
36
Transmission Case Covers Diagram
36
Shift Shaft Assemblies Diagram
37
Transmission Diagram
38
Transmission Inspection, Cleaning and Repair
39
Transmission Assembly
39
Transmission Installation
41
Differential Removal and Disassembly
42
Differential Inspection, Cleaning and Repair
42
Differential Assembly and Installation
42
Differential Diagram
43
PTO Drive Unit Removal
44
Oil Seal Instllation in Differential Support
44
Rear PTO Drive Unit Disassembly
45
PTO Drive Unit Inspection
46
PTO Drive Unit Assembly
47
PTO Drive Unit Installation
47
Final Drive
48
Drive Shaft Assembly Removal and Inspection
49
Intermediate Gear Assembly Removal and Inspection
49
Final Gear Assembly Removal and Inspection
50
Final Gear Assembly Installation
50
Final Gear Plug Installation
51
Final Drive Gear Installation
51
Final Gear Assembly Cap End Play
51
Intermediate Gear Installation
52
Final Gear Assembly Shimming Mechanism View
52
Locking Collar Installation
52
Correct Retaining Ring Installation
52
Drive Shaft Assembly Installation
53
Steering and Front Axle Assemblies
54
Steering Gear Removal
54
Steering Shaft, Gear, Hub and Spindle Assemblies Diagram
56
Steering Gear Disassembly
57
Removing Pitman Shaft Assembly
57
Steering Gear Inspection
58
Removing Worm Shaft and Ball Nut
58
Removing Lower Bearing Retainer
58
Pitman Shaft and Lash Adjuster View
58
Steering Gear Repairs
59
Removal Pitman Shaft Needle Bearing
59
Installing Pitman Shaft Needle Bearing
60
Installing Worm Shaft Upper Bearing Race
60
Steering Gear Assembly
61
Filling Ball Circuits
61
Steering Gear Bench Adjustment
63
Steering Gear Installation
63
Steering Shaft Removal, Inspection, and Installation
64
Steering Shaft Assembly View
65
Drag Link Removal, Inspection, Installation and Adjustment
66
Drag Link and Tie Rod Diagram
66
Tie Rod Removal, Inspection, and Installation
67
Hub Removal, Inspection and Installation
67
Spindle Removal, Inspection and Installation
68
Hub and Spindle View
68
Front Axle Removal, Inspection and Installation
69
Front Axle Assembly View
70
Power Lift System
71
Hydraulic Control Valve Removal and Installation
72
Power Lift Hydraulic Flow Diagram
72
Power Lift System Removal and Installation
75
Hydraulic Cylinder Removal
76
Hydraulic Cylinder Installation
76
Oil Cooler Removal, Inspection and Installation
76
Electrical Wiring Diagram
77
Electrical System Description
79
Electrical System Checks
79
Wiring Harness
79
Battery Circuit
81
Battery Condition
81
Battery Wiring
82
Charging Circuit
83
Charging Circuit Check
85
No Charge Test
85
High Charge Rate Test
85
Flywheel Stator Check
85
Ignition Circuit Description
86
Ignition Circuit Check
86
Spark Plugs
86
Breaker Points and Condenser
86
Starting Circuit
87
Wiring Circuit
87
Ignition Switch
87
PTO Switch
89
Transmission Neutral Start Switch Adjustment
89
Lights and Hourmeter Circuit
91
Wiring Circuit Check
91
Engine Cranking Requirements
91
Starter Motor and Solenoid Condition
91
Pressure and Temperature Sending Unit Circuit
92
Light Switch
92
Lights and Hourmeter
92
Sending Units
93
PTO Circuit
94
Power Take-Off Circuit Diagram
94
Removal and Installation of Electrical Components
95
Electric Clutch
95
Starter and Flywheel Removal
95
Instrument Panel Component Removal
95
Front PTO Clutch Removal
96
Front PTO Clutch Installation
96
Circuit Breaker Removal and Installation
97
Fuse Removal and Installation
97
Transmission Neutral Start Switch Removal and Installation
97
Light Removal and Installation
98
Sending Unit Removal and Installation
98
Troubleshooting Guide
99
Fuel System
101
Fuel Tank and Fuel Guage Removal, Inspection and Installation
102
Air Cleaner Removal, Cleaning and Installation
102
Fuel System Components Diagram
103
Fuel Lines and Filter
105
Breather Tube Installation
105
Air Cleaner O-Ring Installation
105
Air Filter Removal
105
In-Line Hydrostatic Unit
107
Hydraulic Fluid Recommendations
107
Pump/Motor
108
Charge Pump and Check Valves
108
Control
108
Implement Relief Valve
109
Acceleration Valves
109
Circuit Flow Diagram
110
Testing
111
Hydrostatic Unit Troubleshooting
113
Removal and Installation
115
Selecting Proper Amount of Shim
118
Disassembly, Repair and Reassembly
119
Charge Pump
119
Three Transmission Sections
119
Charge Relief Valve
120
Major Disassembly and Repair
121
Separating the Three Main Sections
121
Shaft and Trunnion Seals
121
Motor Section
121
Disassembling Pump Section
123
Disassembling Center Section
124
Motor Section Reassembly
125
Pump Section Reassembly
125
Attaching Swashplate to Trunnion Shaft
125
Reassembling Center Section
126
Reassembling Three Main Sections
126
Priming Procedure
127
Testing after Repair
127
Connecting Motor Housing to Center Section
127

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