Broadmoor Series Service & Repair Manual

Service &

Rep

air Man

ual

Bro

adm

oo

r Series

MANUFACTURING, INC.

500 N Spring Street / PO Box 997Port Washington, WI 53074-0997 USA

© Copyright 2001 Simplicity Manufacturing, Inc.All Rights Reserved. Printed in USA.

Rev 4/2001TP 500-2493-00-BM-SMA

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Repair Manual ContentsThis manual is divided into the sections listed below.

Please click hyperlink to access the specific contents of that section.

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 — 1-14

2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 — 2-4

3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 — 3-12

4 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 — 4-8

5 Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 — 5-6

6 Common Service Procedures . . . . . . . . . . . . . . . . . . . 6-1 — 6-10

7 Electrical System Service. . . . . . . . . . . . . . . . . . . . . . . 7-1 — 7-34

8 Steering & Front Wheel Repair . . . . . . . . . . . . . . . . . . 8-1 — 8-14

9 Drive Controls Service. . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 — 9-8

10 Hand Controls Service. . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 — 10-6

11 Transmission Removal & Installation. . . . . . . . . . . . 11-1 — 11-8

12 Transmission Tear Down . . . . . . . . . . . . . . . . . . . . . . . 12-1 — 12-16

14 Seat Deck & Fuel Tank Service . . . . . . . . . . . . . . . . . . 14-1 — 14-8

15 PTO Clutch Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1 — 15-6

16 Mower Deck Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1 — 16-22

13 Hood & Dashboard Service . . . . . . . . . . . . . . . . . . . . . 13-1 — 13-8Not

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1 General InformationTable of Contents

SECTION CONTENTS

Models CoveredModels & Identification................................................................. 1-2

IntroductionIntroduction .................................................................................. 1-3

Manual Content ........................................................................... 1-3

Safety RulesSafety Rules - General Operation................................................ 1-4

Safety Rules - Service And Maintenance .................................... 1-6

General Repair InformationBearings & Bushings ................................................................... 1-9

Belts & Pulleys............................................................................. 1-9

Electrical Parts ............................................................................. 1-9

Fasteners & Hardware............................................................... 1-10

Genuine Replacement Parts...................................................... 1-10

Hydraulic Parts .......................................................................... 1-10

Paint........................................................................................... 1-10

Required Tools & Equipment..................................................... 1-10

Systems Checks ........................................................................ 1-10

Torque Specifications ................................................................ 1-11

Specifications..............................................................................1-12

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1 General InformationModels Covered In This Manual

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1693052 Broadmoor, 14HP Hydro1693054 Broadmoor, 16HP Hydro1693056 Broadmoor, 16HP V Hydro1693058 1614H, 14HP Hydro1693060 1616H, 16HP Hydro1693062 1616VH, 16HP V-Twin Hydro1693064 2616H, 16HP Hydro1693066 2616VH, 16HP V-Twin Hydro1693068 Broadmoor, 14HP Hydro (Export)1693070 Broadmoor, 16HP Hydro (Export)1693072 Broadmoor, 16HP V Hydro (Export)1693275 Broadmoor, 18HP V Hydro1693277 1618H, 18HP V-Twin Hydro1693279 2618H, 18HP V-Twin Hydro1693281 Broadmoor, 18HP V Hydro (Export)1693351 Broadmoor, 14HP Hydro1693353 Broadmoor, 16HP Hydro1693355 Broadmoor, 16HP V Hydro1693358 Broadmoor, 14HP Hydro (Export)1693360 Broadmoor, 16HP Hydro (Export)1693362 Broadmoor, 16HP V Hydro (Export)1693365 1614H, 14HP Hydro

1693367 1616H, 16HP Hydro1693369 1616VH, 16HP V-Twin Hydro1693372 2615H, 16HP Hydro1693374 2616VH, 16HP V-Twin Hydro1693580 Broadmoor, 16HP Hydro1693592 Broadmoor, 16HP V Hydro1693594 Broadmoor, 16HP V Hydro (Export)1693596 1615H, 16HP Hydro1693598 2616H, 16HP Hydro1693600 Broadmoor, 18HP V Hydro1693602 1618H, 18HP V-Twin Hydro1693604 2618H, 18HP V-Twin Hydro1693613 Broadmoor, 18HP V Hydro (Export)1693617 1616VH, 16HP V-Twin Hydro1693622 2616VH, 16HP V-Twin Hydro1693662 Broadmoor, 16HP Hydro (Export)1693817 Broadmoor, 16HP V Hydro1693819 Broadmoor, 16HP V Hydro (Export)1693821 1616VH, 16HP V-Twin Hydro1693823 2616VH, 16HP V-Twin Hydro

Tractors

Mower Decks

1692682 38” Mower Deck1692682 38” Mower Deck1692683 38” Mower Deck1692683 38” Mower Deck1692683 38” Mower Deck1692683 38” Mower Deck1692684 44” Mower Deck1692684 44” Mower Deck1692685 44” Mower Deck1692685 44” Mower Deck1692685 44” Mower Deck1692685 44” Mower Deck

1693170 38” Mower Deck (Export)1693170 38” Mower Deck (Export)1693171 44” Mower Deck (Export)1693171 44” Mower Deck (Export)1693267 50” Mower Deck1693267 50” Mower Deck1693283 50” Mower Deck (Export)1693283 50” Mower Deck (Export)1693284 50” Mower Deck1693284 50” Mower Deck1693284 50” Mower Deck1693284 50” Mower Deck

Mower DeckIdentification Tag

TractorIdentification Tag

IDENTIFICATION TAG LOCATIONS

AMERICAN MODELSCE MODELS

SSAAMMPPLLEE

SSAAMMPPLLEE

MODELS COVERED &IDENTIFICATION NUMBERSThis manual contains service information for themodels listed below. Consult the IdentificationTag located on the tractor frame for the manufac-turer’s identification number and serial number.

Always use the manufacturer’s identification num-ber and serial number when ordering parts or doc-umentation. Attachments are not covered in thismanual. Refer to the attachment operator’s man-ual or authorized dealer for service information.

Transmissions are identified by identification num-ber tags located on the transmission casing.

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1 General InformationIntroduction

INTRODUCTIONThis manual is divided into sixteen major sections of ser-vice information required for the models specified.These sections are:

1. General Information

2. Troubleshooting

3. Maintenance

4. Adjustments

5. Belt Replacement

6. Common Service Procedures

7. Electrical System Service

8. Steering & Front Wheel Repair

9. Drive Controls Service

10. Hand Controls Service

11. Transmission Removal & Installation

12. Transmission Tear Down

13. Hood and Dashboard Service

14. Seat Deck & Fuel Tank Service

15. PTO Clutch Service

16. Mower Deck Repair

Since part numbers are subject to change and may varyby model year and manufacturing number, all parts inthis manual are referred to by general description.Specific part number information may be found in therespective Parts Manual for the unit being serviced.Always use the manufacturing number that appears onthe Identification Tag of the unit you are servicing toidentify component part numbers.

MANUAL CONTENTThis manual is intended primarily for use by dealer ser-vice personnel as a technical reference manual or as acompliment to normal service training.

While the information in this manual has been developedto permit mechanics and service technicians to performmost service procedures quickly and effectively, it isassumed that those using this manual will have someoutdoor power equipment service experience or otherbasic power equipment service training with similar typesof products.

In addition, it is assumed that all those performing ser-vice on these units are familiar with the general princi-ples of operation of these units, and understand all oper-ating controls, safety instructions, and normal handlingprecautions for servicing large, high horsepower ridingtractors and mowers.

Engine information is available from the appropriateengine manufacturer in a separate service manual.

General engine information and basic engine trou-bleshooting information is provided, but is intended forgeneral guidance only. The engine manufacturer’s man-ual should be always be consulted first before makingany major adjustments, part changes, or other majorrepairs.

This manual includes all relevant service information formodel years 1990 through 1995, and whenever neces-sary, includes inset illustrations or other references tohelp identify previous part designs and alternative ser-vice procedures.

The service techniques in this manual also assume thatthe person providing service has access to a standardassortment of mechanic’s hand tools, and approachesmost disassembly and repair procedures with availabilityof these basic tools in mind. Whenever specialized orcustom tools are available to save time, reduce effort, orimprove overall service efficiency, the most effective saferepair method available should be utilized.

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1 General InformationSafety Rules

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GENERAL OPERATION• Read, understand, and follow all instructions in the manual and on

the unit before starting.• Only allow responsible adults, who are familiar with the instruc-

tions, to operate the unit (local regulations can restrict operatorage).

• Clear the area of objects such as rocks, toys, wire, etc., whichcould be picked up and thrown by the blade(s).

• Be sure the area is clear of other people before mowing. Stop unitif anyone enters the area.

• Never carry passengers.• Do not mow in reverse unless absolutely necessary. Always look

down and behind before and while travelling in reverse.• Be aware of the mower discharge direction and do not point it at

anyone. Do not operate the mower without either the entire grasscatcher or the deflector in place.

• Slow down before turning.• Never leave a running unit unattended. Always disengage the

PTO, set parking brake, stop engine, and remove keys before dis-mounting.

• Turn off the PTO switch to disengage the blades when not mowing.• Stop engine before removing grass catcher or unclogging chute.• Mow only in daylight or good artificial light.• Do not operate the unit while under the influence of alcohol or

drugs.• Watch for traffic when operating near or crossing roadways.

• Use extra care when loading or unloading the unit into a trailer ortruck.

• Data indicates that operators, age 60 years and above, areinvolved in a large percentage of riding mower-related injuries.These operators should evaluate their ability to operate the ridingmower safely enough to protect themselves and others from injury.

• Keep in mind the operator is responsible for accidents occurring toother people or property.

• All drivers should seek and obtain professional and practicalinstruction.

• Always wear substantial footwear and trousers. Never operatewhen barefoot or wearing sandals.

• Before using, always visually check that the blades and blade hard-ware are present, in-tact, and secure. Replace worn or damagedparts.

• Never operate the machine with defective guards, or without safetyprotective devises in place.

• Disengage attachments before: refuelling, removing an attachment,making adjustments (unless the adjustment can be made from theoperator’s position).

• When the machine is parked, stored, or left unattended, lower thecutting means unless a positive mechanical lock is used.

• Follow the manufacturer’s recommendation for wheel weights orcounterweights.

SLOPE OPERATION

Slopes are a major factor related to loss-of-control and tip-over accidents,which can result in severe injury or death. All slopes require extra caution.If you cannot back up the slope or if you feel uneasy on it, do not operateon it.

Control of a ride-on machine sliding on a slope will not be regained by theapplication of the brake. The main reasons for loss of control are: insuffi-cient tire grip on the ground, speed too fast, inadequate braking, the typeof machine is unsuitable for it’s task, lack of awareness of the ground con-ditions, incorrect hitching and load distribution.

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.The triangle in text signifies important cautions or warnings which must be followed.

WARNINGNever operate on slopes greater than 17.6 percent(10°) which is a rise of 3-1/2 feet (106 cm) vertically in20 feet (607 cm) horizontally. When operating on slopes use additional wheelweights or counterweights. See your dealer todetermine which weights are available andappropriate for your unit. Select slow ground speed before driving onto slope.In addition to front and rear weights, use extra cautionwhen operating on slopes with rear-mounted grasscatcher.Mow UP and DOWN the slope, never across theface, use caution when changing directions and DONOT START OR STOP ON SLOPE.

Do• See your authorized dealer for recommendations of wheel weights

or counterweights to improve stability. • Mow up and down slopes, not across.• Remove obstacles such as rocks, tree limbs, etc.• Watch for holes, ruts, or bumps. Uneven terrain could overturn the

unit. Tall grass can hide obstacles.• Use slow speed. Tires may lose traction on slopes even through

the brakes are functioning properly. Choose a low gear so that youwill not have to stop or change speeds while on the slope.

• Use extra care with grass catchers or other attachments. Thesecan change the stability of the unit.

• Keep all movement on the slopes slow and gradual. Do not makesudden changes in speed or direction.

• Always keep unit in gear especially when traveling downhill. Whenclutching, release clutch slowly.

Do Not• Do not start or stop on a slope. If tires lose traction, disengage the

blade(s) and proceed slowly straight down the slope.• Do not turn on slopes unless necessary, and then, turn slowly and

gradually downhill, if possible.• Do not mow near drop-offs, ditches, or embankments. The mower

could suddenly turn over if a wheel is over the edge of a cliff orditch, or if an edge caves in.

• Do not mow on wet grass. Reduced traction could cause sliding.• Do not try to stabilize the unit by putting your foot on the ground.• Do not use grass catchers on steep slopes.• Do not mow slopes you cannot back up.• Do not shift to neutral and coast down hill.

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Slope Operation ContinuedChildrenTragic accidents can occur if the operator is not alert to the presence ofchildren. Children are often attracted to the unit and the mowing activity.Never assume that children will remain where you last saw them.

• Keep children out of the mowing area and under the watchful careof another responsible adult.

• Be alert and turn unit off if children enter the area.• Before and during reverse operation, look behind and down for

small children.• Never carry children. They may fall off and be seriously injured or

interfere with safe unit operation.• Never allow children to operate the unit.• Use extra care when approaching blind corners, shrubs, trees, or

other objects that may obscure vision.

TOWING• Never allow children or others in or on towed equipment.• Tow only with a machine that has a hitch designed for towing. Do

not attach towed equipment except at the hitch point.• Follow the manufacturer’s recommendations for weight limit for

towed equipment and towing on slopes.• On slopes, the weight of the towed equipment may cause loss of

traction and loss of control.• Travel slowly and allow extra distance to stop.• Do not shift to neutral and coast down hill.

TRANSPORTING AND STORAGE

• Always observe safe refueling and fuel handling practices whenrefueling the tractor after transportation or storage.

• Always follow the engine manual instructions for storage prepara-tions before storing the tractor for both short and long term periods.

• Always follow the engine manual instructions for proper start-upprocedures when returning the unit to service.

• Never store the unit or fuel container inside where there is an openflame or pilot light, such as in a water heater. Allow unit to coolbefore storing.

EMISSIONS• Engine exhaust from this product contains chemicals known, in

certain quantities, to cause cancer, birth defects, or other repro-ductive harm.

• Look for the relevant Emissions Durability Period and Air Indexinformation on the engine emissions label.

WARNINGWhen transporting this tractor on an open trailer,make sure unit is facing forward, toward the directionof travel. If tractor is facing backward, wind lift couldcause damage to the hood.

SERVICE AND MAINTENANCE• Use extra care in handling gasoline and other fuels. They are flam-

mable and vapors are explosive.a) Use only an approved container.b) Never remove gas cap or add fuel with the

engine running. Allow engine to cool before refueling. Do not smoke.

c) Never refuel the unit indoors.• If fuel is spilled, do not attempt to start the engine but move the

machine away from the area of spillage and avoid creating anysource of ignition until fuel vapors have dissipated.

• Replace all fuel tank caps and fuel container caps securely.• Never fill containers inside a vehicle or on a truck bed with a plastic

bed liner. Always place containers on the ground away from yourvehicle before filling.

• Remove gas-powered equipment from the truck or trailer and refuelit on the ground. If this is not possible, then refuel such equipmenton a trailer with a portable container, rather than from a gasolinedispenser nozzle.

• Keep nozzle in contact with the rim of the fuel tank or containeropening at all times until fueling is complete. Do not use a nozzlelock-open device.

• If fuel is spilled on clothing, change clothing immediately.• Maintain or replace safety and instruction labels as necessary.• Never run a unit in an enclosed area.• Keep nuts and bolts, especially blade attachment bolts, tight and

keep equipment in good condition.• Never tamper with safety devices. Check their proper operation

regularly and make necessary repairs if they are not functioningproperly.

• Keep unit free of grass, leaves, or other debris build-up. Clean upoil or fuel spillage.

• Stop and inspect the equipment if you strike an object. Repair, ifnecessary, before restarting.

• Never make adjustments or repairs with the engine running unlessspecified otherwise in the engine manufacturer’s manual.

• Grass catcher components are subject to wear, damage, and dete-rioration, which could expose moving parts or allow objects to bethrown. Frequently check components and replace with manufac-turer’s recommended parts, when necessary.

• Mower blades are sharp and can cut. Wrap the blade(s) or weargloves, and use extra caution when servicing them.

• Check brake operation frequently. Adjust and service as required.• Use only factory authorized replacement parts when making

repairs.• Always comply with factory specifications on all settings and

adjustments.• Only authorized service locations should be utilized for major ser-

vice and repair requirements.• Never attempt to make major repairs on this unit unless you have

been properly trained. Improper service procedures can result inhazardous operation, equipment damage and voiding of manufac-turer’s warranty.

• On multiple blade mowers, take care as rotating one blade cancause other blades to rotate.

• Do not change engine governor settings or over-speed the engine.Operating the engine at excessive speed can increase the hazardof personal injury.

• Disengage drive attachments, stop the engine, remove the key,and disconnect the spark plug wire(s) before: clearing attachmentblockages and chutes, performing service work, striking an object,or if the unit vibrates abnormally. After striking an object, inspectthe machine for damage and make repairs before restarting andoperating the equipment.

• Never place hands near the hydro pump cooling fan when the trac-tor is running. Cooling fan is located on top of the transaxle

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SERVICE AND MAINTENANCE

The service information provided in this manual is intend-ed to provide you with the knowledge required to performa wide range of service procedures on the listed equip-ment.

While appropriate safety reminders and safety warningshave been included here and elsewhere in this manual tohelp promote the use of safe service techniques, youmust also observe all appropriate shop safety ruleswhenever performing these procedures.

No single manual, including this one, can include everypossible warning or safety instruction necessary to guar-antee complete safety - you must apply your commonsense and knowledge of shop and power equipmentsafety whenever performing service, whenever workingaround others who are operating, servicing, or handlingequipment, and whenever you are present in a workenvironment where hand or power tools, shop equip-ment, or outdoor power equipment may be present.

This includes taking the necessary safety precautions tohelp ensure a safe workplace, exercising reasonablecare to avoid unsafe acts, and being alert for potentialhazards as you move about the workplace or engage invarious service activities.

If you encounter a service situation involving the use ofan unfamiliar tool, procedure, or part, and rereading theappropriate section of this manual does not provide theinformation you want, contact your Simplicity dealerbefore proceeding. Never attempt a repair that you’renot sure about, since help is usually never more than justa phone call away.

Practicing safe service procedures not only helps protectyou and those you work around, it also contributes toproviding safe, reliable equipment .

Personal Protective Equipment• Wear protective safety glasses whenever using hand

or power tools, shop equipment, and whenever work-ing under power equipment to protect your eyes fromfalling debris and small parts.

• Wear safety goggles or full face protection when han-dling battery electrolyte fluid, or when performinggrinding or sharpening operations that producesparks or flying debris. Extensive grinding mayrequire the use of protective sleeves and an apron.

• Wear work gloves when handling sharp surfacessuch as mower blades, or when working aroundsharp edges. Never wear gloves that are loose fittingor that have tie straps, as these could cause yourhands to get caught by rotating parts, resulting inserious injury. Chemical-resistant Rubber gloves arerecommended when handling or pouring battery elec-trolyte.

• Steel-toe safety shoes are highly recommended toprotect feet from falling tools, heavy parts, and othershop equipment.

Fuel Handling Safety• Always use extra care when handling gasoline -

gasoline is highly flammable, and gasoline vaporsare explosive as well as toxic if inhaled.

• Never store fuel indoors, or refuel a unit indoors.Gasoline vapors can easily travel unseen to distantsources of ignition such as pilot lights or open flameson water heaters, furnaces, stoves, or other gasoperated appliances, sparks from electric motors orother electrically-operated tools and equipment, weld-ing equipment, grinders, or burning smoking materi-als. Contact with these or any other sources of igni-tion will cause an explosion and/or fire, serious per-sonal injury, and damage to property and equipment.

• Never transfer gasoline from one container to anotherunless the containers are connected by an approvedgrounding strap. Hand or power operated transferpumps can generate a static charge of electricity,causing dangerous sparking and ignition of fuel orfuel vapors. Always follow the pump manufacturer’ssafety and operating instructions.

• Use only approved containers for fuel, and alwayshandle the container with extreme care to avoidspillage or leaking of explosive vapors.

• Never smoke or allow others in the area to smokewhile refilling the fuel tank, or when handling gaso-line cans. Make sure any smoking materials that hadbeen in use in the area are fully extinguished beforeopening a fuel can or starting refueling .

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Exhaust Gas Safety• Internal combustion engines produce and exhaust

Carbon Monoxide (CO), an odorless, colorless, gasthat causes dizziness, nausea, flu-like symptoms,unconsciousness, or even brain damage or death, ifbreathed for prolonged periods.

• If exposed to Carbon Monoxide gas, get to a fresh airsource immediately and seek medical attention. COcan build up in your blood, and can cause lingeringsymptoms or permanent damage if left untreated.

• Operate the unit outdoors or in a well ventilated area,or pipe exhaust gases out of the work area to an out-side location where the exhaust can be dissipatedsafely away from doors, windows, air conditioners, orother potential sources of outside-air intake that couldpermit reentry of hazardous fumes.

• Never enter an enclosed area where an engine hasbeen running and exhaust gases have been allowedto collect. Open adjacent windows or doors first topermit outside air to ventilate the area, and allow suf-ficient time for a complete air exchange to occur.

Battery/Electrolyte Safety• Lead-Acid batteries use an electrolyte containing sul-

phuric acid, a highly corrosive liquid that can causesevere chemical burns if allowed to come into contactwith skin, or blindness if allowed to contact your eyes.Always wear approved eye goggles or a full faceshield and protective gloves when handling elec-trolyte or filling the battery.

• Lead-acid batteries also produce hydrogen, a color-less, highly explosive gas that can be easily ignitedby a single spark. Charging the battery incorrectly orhooking up jumper cables improperly can causesparking, and must be avoided. Always follow rec-ommended battery charging and jumper cable pro-cedures.

• When removing or installing battery cables, discon-nect the negative cable FIRST, and reconnect itLAST. If not done in this order, the positive terminalcould be accidentally shorted to the frame by a tool,creating a dangerous spark that can ignite nearbyfuel vapors or escaping hydrogen gas from the battery.

• Keep battery securely fastened in position with venttube directed down and out of battery compartment.Replace battery if electrolyte leakage occurs. Makesure the battery vent tube is properly installed, and isnot plugged with clippings or other debris. Replacethe vent tube if cracked, damaged, or missing fromunit.

• Old batteries should be disposed of by recycling.

Electrical System Safety• Loose connectors, worn wires, damaged wire insula-

tion, and loose termination hardware can causesparks, short-circuits, and erratic equipment opera-tion. Always check wiring for damage, and makeappropriate repairs before placing unit back into oper-ation.

• Use care when working around exposed terminals toprevent short-circuiting the electrical system.Sparking, electric shocks, and damage to the systemmay result from accidental contact between terminalsand metal hand tools.

Elevating Unit Safely• Always support unit on approved jack stands when

working on an elevated unit, and keep unit fromrolling by engaging parking brake and placing wheelchocks behind wheels still on floor or work table.

• Secure unit to work-surface of scissor-lift worktablesor other powered lift tables in accordance with themanufacturer’s instructions. Unsecured units mayroll unexpectedly while work is being done, causinginjuries.

• Never work under an elevated unit unless it is proper-ly supported by jack stands, locked from rolling withwheel chocks or equivalent, and you can quicklyescape from under the unit in an emergency using arolling device such as a mechanic’s creeper.

• Always protect your eyes from falling debris or smallparts by wearing approved safety glasses or goggles.

• Remove the ignition key and disconnect the sparkplug wires before working under a unit. Accidental orinadvertent starting could result in serious injuries.

Proper Tool Use• Use power and hand tools only for the use that they

were designed. Never alter or modify tools, or impro-vise using tools that are not suitable for the job athand.

• Keep all hand and power tools in good repair, and putthem away when done to avoid cluttering the workarea. Use extra care when using corded toolsaround moving or rotating parts such as belts andpulleys, since the cord could get caught and suddenlypull the tool, or you, into the area of moving parts.

• Always check the unit to ensure that all hand andpower tools and tool attachments have beenremoved from the unit after use. Small tools and toolattachments left on the equipment can fall into thecutting path when the unit is placed into service, andbecome a hazard to bystanders if struck by mowerblades.

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Work Area Safety• Always keep the work area clear of clutter from dis-

carded parts, and debris from parts boxes or packag-ing materials. Small parts, hardware items, and otherdebris or refuse left lying around can become slip,trip, and fall hazards if not removed and discarded ofproperly.

• Always observe general shop safety rules for house-keeping, and tend to oil spills and other spilled fluidspromptly to prevent slip and fall injuries.

• Allow sufficient work area around the equipment youare working on to permit comfortable working posi-tions. Never put yourself in a position that would pre-vent you from escaping quickly in the event of emer-gencies such as sudden shifts in equipment position,fire, or other situations requiring an immediate reac-tion on your part.

Compressed Air Safety• Always use care when using compressed air to blow

dirt and debris off equipment - always direct the airblast away from yourself and others in the area, andprotect your eyes with safety glasses to prevent injuryfrom particles that may blow back toward your face.

• Never use high pressure air directly against your skinto clean dirt and debris - the air pressure could actu-ally force foreign material or fluids into your skin,causing serious injuries.

• Use care when filling tires - lawn and garden tractorsutilize low pressure tires, and over-pressurization ishazardous to you and anyone who operates theequipment with improper tire pressures. Always con-sult the air pressure recommendations for the unitinvolved before adding additional air to the tires.

Grease & Lubricant Safety• Normal service and maintenance involves the use of

oils and greases that could present a fire hazard ifnot handled properly. Always dispose of oily ragsproperly to prevent fires caused by spontaneouscombustion.

• Spilled lubricants pose dangerous slip hazards andmust be taken care of immediately. Wipe up spillscarefully, or use absorbent materials to soak upspilled fluids. Always dispose of rags, paper towels,and other saturated absorbents properly.

• Store oils and greases away from flame or other igni-tion sources. Petroleum-based fluids can be ignitedby smoking materials and sparks - always treat oilsand greases as potentially flammable materials.Always cap oil and grease containers when doneusing, and store or dispose of properly.

General Servicing Safety• Always check safety devices and switches for proper

operation - never alter these devices or make tempo-rary or makeshift repairs. Use only factory-autho-rized parts and procedures, and check newly-installed parts for proper operation.

• Make sure all hardware items are properly tightened,especially blade attachment bolts. Replace any hard-ware that appears damaged.

• Check brake operation, and adjust or repair asrequired. Always comply with factory specificationson settings and adjustments.

• Check grass catcher components for wear, damage,or deterioration, and replace with factory authorizedparts if necessary.

• Always make repairs using factory authorizedreplacement parts only. Using parts that don’t meetfactory specifications can result in sudden or prema-ture failures, poor or erratic equipment performance,and potential safety hazards to operators andbystanders.

• Always comply with factory specifications on settingsand adjustments when installing new parts, makingrepairs, or performing routine service procedures.

• Always test repairs before releasing units to cus-tomers, paying special attention to any items that aresafety-related. Correct any problems noted, and re-check to ensure that the problems have been fullyremedied.

• Make sure all safety and operating instruction decalsare legible, properly located, and securely attached.Replace any decals that can’t be read or are in dan-ger of falling off.

• Always advise equipment owners of any potentialoperating or safety problems that may be arising dueto anticipated wear, and request that the owneraddress the problem before a hazard develops.

• Never allow a unit to be placed back into service if aserious safety or operating problem is evident.Advise the owner of the problem and the possiblehazards associated with the problem, and requestpermission to correct the deficiencies.

• Use extreme care when working on older models thatdo not have all of the latest safety devices andswitches. Disengage the PTO and transmissionbefore starting the unit, or commencing repairs.

• Always use care when removing or installing parts toprevent damage from dropping or rough handling.Support heavy parts properly to prevent damage orpersonal injury to yourself and others.

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1 General InformationRepair Information

GENERAL REPAIR INFORMATIONIn addition to providing specific repair procedures for theequipment listed at the beginning of this section, thismanual provides the following additional general instruc-tions for dealing with repairs to various types of compo-nents.

This information is designed to help you deal more effec-tively with these components by providing basic serviceknowledge and other useful tips.

Bearings & Bushings

Roller bearings, ball bearings, and bushings are used toprovide support to rotating shafts and other parts such asgears, pulleys, and sprockets that are used to transmitrotary motion. Over time, bearings and bushings mayrequire additional lubrication to transmit this rotarymotion with minimal friction, or may need replacementdue to normal operation and wear. Normal service forbearings and bushings includes removal, cleaning,inspection, lubrication, and replacement.

REMOVAL

Most bearings and bushings used on the listed equip-ment can be easily removed by following the appropriatedetailed procedures found throughout this manual. Careshould always be exercised to avoid scratching or dam-aging the bearing or bushing, the mounting shaft, andsurrounding components. Bearing or bushing removal isusually necessary when excessive play or wobble isnoticed on the part it supports, when unusual noise orvibration is apparent, or when a burning smell is presentat the bearing location.

CLEANING

Sealed bearings and bushings can be cleaned by carefulwiping with a cloth. Bearings with one-sided or remov-able shields and plain bushings can be cleaned byimmersion in safety solvent, and brushing with a partcleaning brush. Oil-impregnated bushings, and bushingsmade of nylon or other synthetic materials, can becleaned with safety solvents, or wiped clean, but shouldnot be immersed in solvent for periods longer than thatnecessary to remove heavy or caked-on build-ups ofgrease. All petroleum-based solvents are flammable, soappropriate precautions regarding flames, sparks, andother ignition sources should always be observed.Gasoline should never be used because of its volatilityand its highly toxic nature.

INSPECTION

Once cleaned, bearings can be properly inspected forwear, scratches, visible damage such as corrosion,cracked seals or scorching, and rough, or noisy, opera-tion. Bushings can be visually checked for scratches,uneven wear, or other visual damage.

LUBRICATION

After passing inspection, bearings and bushings shouldbe lubricated in accordance with factory specifications,and reinstalled according to the appropriate installationinstructions. New bearings and bushings must also beproperly lubricated before use. For optimal performance,and as a practical preventive maintenance measure,bearings and bushings used in pairs or multiple setsshould all be replaced at the same time.

Belts & PulleysBelts and pulleys transmit rotary motion from powersources to work components, providing the force neededto drive transmissions, operate mower decks, and powervarious attachments. This continual use eventuallycauses belts to wear out, and over time may also requirethe replacement of pulleys and pulley bearings.

Belt wear and various types of damage are easilychecked by visual examination, which is covered ingreater detail elsewhere in this manual. Pulleys mayalso be checked visually for wear or apparent damage,but pulley bearings usually require removal, cleaning,and inspection to determine if replacement is required.

Belt and pulley life can be optimized by making sure thatproper belt tension and alignment are observed whenbelts are installed. Proper belt tension and alignmentshould also be maintained by performing periodic checksand adjustments. In addition, only factory authorizedreplacement belts will minimize problems caused bysize, thermal instability, and variations in quality.

Electrical PartsThe electrical parts used on these units has been specif-ically engineered for outdoor power equipment, and isdesigned to provide years of reliable operation. As withall electrical components and systems, electrical con-tacts must be kept clean and dry, and all terminationsmust be securely fastened or connected. Also, all elec-trical components, wiring, and connectors should be peri-odically inspected for corrosion, signs of excessive heatbuild-up, or other damage that signals that it is time torepair or replace the item.

Specific procedures for electrical troubleshooting andmost common repairs is covered in separate sections ofthis manual.

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Fasteners & HardwareAll hardware and fasteners used in this equipment mustmeet factory specifications for SAE grade, size, andtorque, and must be kept securely tightened. Lockinghardware that degrades with use should be replacedwhen service is performed in affected areas. Alwaysobserve factory specifications for torque, or consult thetorque chart for torque information.

Genuine Replacement Parts

Only factory authorized replacement parts should beused when making repairs or performing routine mainte-nance. The use of parts that do not meet stringent facto-ry specifications can cause poor performance, prematurefailures, and lead to potential safety hazards. In addition,the use of non-factory authorized replacement parts willvoid your warranty.

Hydraulic PartsHydraulic parts are adversely affected by dirt and conta-mination, and care must be exercised when performingservice on these parts to prevent foreign material fromentering. Specific service information appears else-where in this manual, and all precautions and proce-dures must be followed when repairing or servicing theseparts.

PaintThe paint on outdoor power equipment provides for anattractive appearance, as well as a barrier to corrosioncaused by exposure to moisture in the environment.Scratches, abrasions, and other damage to painted sur-faces should be repaired promptly to prevent the forma-tion of rust and premature part failure. Factory suppliedpaints are available that provide both an accurate colormatch and superior corrosion resistance.

Required Tools & EquipmentAll repairs in this manual can be accomplished with stan-dard mechanic’s hand tools. The use of appropriatepower tools such as impact wrenches and power driversmay aid in part removal and replacement, but care mustbe exercised to avoid causing damage to componentsfrom excessive tightening. Transmission service, steer-ing service, tire and wheel service, and service to com-ponents located under the frame also requires the use ofa jack with suitable capacity, and jack stands to supportthe unit being worked on.

Systems ChecksIn addition to performing individual component service,components affected by related parts changes shouldalso receive attention at the time service is performed.Examples of this include part replacements that are partof a safety device, electrical components, transmissioncomponents, and pulleys that are part of the same powerdelivery system. Giving attention to related parts willhelp ensure that the parts most likely to be affected bythe wear of similar or nearby parts, or parts subjected tothe same amount of stress or wear, are given appropri-ate attention before a failure can occur.

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Torque Specification ChartFOR STANDARD MACHINE HARDWARE (Tolerance ± 20%)

HardwareGrade

SAE Grade 2 SAE Grade 5 SAE Grade 8

Size Of in/lbs in/lbs in/lbsHardware ft/lbs Nm. ft/lbs Nm. ft/lbs Nm.

8-32 19 2.1 30 3.4 41 4.68-36 20 2.3 31 3.5 43 4.910-24 27 3.1 43 4.9 60 6.810-32 31 3.5 49 5.5 68 7.71/4-20 66 7.6 8 10.9 12 16.31/4-28 76 8.6 10 13.6 14 19.05/16-18 11 15.0 17 23.1 25 34.05/16-24 12 16.3 19 25.8 27 34.03/8-16 20 27.2 30 40.8 45 61.23/8-24 23 31.3 35 47.6 50 68.07/16-14 30 40.8 50 68.0 70 95.27/16-20 35 47.6 55 74.8 80 108.81/2-13 50 68.0 75 102.0 110 149.61/2-20 55 74.8 90 122.4 120 163.29/16-12 65 88.4 110 149.6 150 204.09/16-18 75 102.0 120 163.2 170 231.25/8-11 90 122.4 150 204.0 220 299.25/8-18 100 136 180 244.8 240 326.43/4-10 160 217.6 260 353.6 386 525.03/4-16 180 244.8 300 408.0 420 571.27/8-9 140 190.4 400 544.0 600 816.07/8-14 155 210.8 440 598.4 660 897.61-8 220 299.2 580 788.8 900 1,244.01-12 240 326.4 640 870.4 1,000 1,360.0

Hex Head Capscrew

Hex Nut

Lockwasher

Washer

Carriage Bolt

NOTES1. These torque values are to be used for all hardware

excluding: locknuts, self-tapping screws, thread formingscrews, sheet metal screws and socket head setscrews.

2. Recommended seating torque values for locknuts:a. for prevailing torque locknuts - use 65% of grade 5

torques.b. for flange whizlock nuts and screws - use 135% of

grade 5 torques.3. Unless otherwise noted on assembly drawings, all torque

values must meet this specification.

Hardware Identification & Torque SpecificationsCommon Hardware Types

Screw, 1/2 x 2

BodyDiameter

BodyLength

InsideDiameter

Nut, 1/2”

NoMarks

3/85/161/4

1/2DIA.

7/16DIA.

Wrench & Fastener Size Guide

Standard Hardware Sizing

When a washer or nut is identified as 1/2”, this is theNominal size, meaning the inside diameter is 1/2 inch; if asecond number is present it represent the threads per inch

When bolt or capscrew is identified as 1/2 - 16 x 2”, thismeans the Nominal size, or body diameter is 1/2 inch; thesecond number represents the threads per inch (16 in thisexample, and the final number is the body length of thebolt or screw (in this example 2 inches long).

The guides and ruler furnished below are designed tohelp you select the appropriate hardware and tools.

01/4

3/41/2

11/4

3/41/2

21/4

3/41/2

31/4

3/41/2

4

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NOTE: Specifications are correct at time of printing and are subject to change without notice.

ENGINE14 HP & 16 HP Briggs & Stratton VanguardMake Briggs & StrattonModel Vanguard™ V-TwinHorsepower 16 HP @ 3600 rpmCylinder 2Bore 2.68 in (68 mm)Stroke 2.60 in (66 mm)Displacement 29.3 Cu. in (480 cc)Construction Overhead Valve, Cast-Iron Sleeves,

Aluminum CrankcaseElectrical System 12 Volt, 16 amp Alternator Regulated BatteryCapacity 340 Cold Cranking amps, 41 Min. Reserve

Industrial Rated Starter MotorIgnition Magnetron Electronic IgnitionAir Cleaner Ducted Paper Cartridge and Foam

Pre-cleanerLubrication Full Pressure Lube w/ Oil FilterOil Capacity 56 Oz. w/Filter (1.7 L)Muffler Quiet Compact, Low Back Pressure

16 HP Briggs & Stratton V-TwinMake Briggs & StrattonModel Intek™ V-TwinHorsepower 16 HP @ 3600 rpmCylinder 2Bore 2.97 in (76 mm)Stroke 2.89 in (73 mm)Displacement 40.0 Cu. in (656 cc)Construction Overhead Valve, Cast-Iron Sleeves,

Aluminum CrankcaseElectrical System 12 Volt, 9 amp Alternator Regulated BatteryCapacity 340 Cold Cranking amps, 41 Min. Reserve Ignition High Energy Electronic IgnitionAir Cleaner Ducted Paper Cartridge and Foam

Pre-cleanerLubrication Full Pressure Lube w/ Oil FilterOil Capacity 4 Pints w/Filter (1.9 L)Muffler Quiet Compact, Low Back Pressure

18 HP Briggs & Stratton VanguardMake Briggs & StrattonModel Vanguard™ V-TwinHorsepower 18 HP @ 3600 rpmCylinder 2Bore 3.03 in (77 mm)Stroke 2.64 in (67 mm)Displacement 38 Cu. in (624 cc)Construction Overhead Valve, Cast-Iron Sleeves,

Aluminum CrankcaseElectrical System 12 Volt, 16 amp Alternator Regulated BatteryCapacity 340 Cold Cranking amps, 41 Min. Reserve

Industrial Rated Starter MotorIgnition Magnetron Electronic IgnitionAir Cleaner Ducted Paper Cartridge and Foam

Pre-cleanerLubrication Full Pressure Lube w/ Oil FilterOil Capacity 2 Quarts w/Filter (1.9 L)Muffler Quiet Compact, Low Back Pressure

16 HP KohlerMake KohlerModel Command™ CV16SHorsepower 16 HP @ 3600 rpmCylinder 1Bore 3.55 in (90 mm)Stroke 2.64 in (67 mm)Displacement 26.0 Cu. in (426 cc)Construction Overhead Valve, Cast-Iron Sleeve,

Aluminum CrankcaseElectrical System 12 Volt, 15 amp Alternator Regulated Battery

12 Volt, 340 Cold Cranking amps,41 Min. Reserve Capacity

Ignition High Energy Electronic IgnitionAir Cleaner Ducted Paper Cartridge and Foam

Pre-cleanerLubrication Full Pressure Lube w/ Oil FilterOil Capacity 2 Quarts w/Filter (1.9 L)Muffler Quiet Compact, Low Back Pressure

TRANSMISSION:Type Tuff Torq K61

HydrostaticPump Variable Displacement Axial PistonMotor Fixed Displacement Reversible Axial PistonControl Single Lever Foot Pedal, Free-Wheeling

Lever for Manual Tractor MovementHydraulic Fluid 10w 30 Premium Engine Oil

External Oil ReservoirSpeeds Forward: 0 - 5.6 MPH (0 - 9.0 km/h)@ 3400 rpm Reverse: 0 - 3.2 MPH (0 - 4.8 km/h)Differential Bevel Gear with Controlled TractionAxle Shaft 1 inContinuous Torque 188 ft. lbs.OutputDrawbar Rating 251 lbs.Maximum Weight 629 lbs.on Axle

CHASSIS:Frame Heavy Steel Channel - 10-12 Gauge

Power Take-Off Point: FrontEngine Mounting: Above Front AxlePivot Point Location: Front Axle

Rear Wheels Tire Size: 20 x 10.00-8 Turf TypePneumatic Inflation Pressure: 6-8 psi (41-55 kPa)

Front Axle 1-3/4 in x 3 in 12 Ga. Fabricated TubeFront Wheels Tire Size: 15 x 6.00-6

Pneumatic Inflation Pressure: 12-15 psi (82-103 kPa)

Accessibility Hood Tips ForwardSeat Type: Bucket, High Back w/Quick Adjust,

Spring SuspensionAdjustable to Suit Different Size Operators

Turning Radius Inside Rear Tire: 16 in (40.6 cm)Fuel Tank Material: Non-Corrosive Polyethylene

Fuel Tank Gauge Built Into Filler CapCapacity: 4 Gallons (15.1 L)

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1 General InformationSpecifications

CONTROLS:Steering 15" (38 cm) Steering Wheel

System: Gear and Sector, 1.25 turns Lock to Lock

Clutch/ Location: Right FrontBrake Pedal Combination Clutch/Brake/Parking Brake

PedalLocation Mower Lift Lever: Right Side

PTO Clutch: Electric, Dash MountedHydrostatic Control-Single Lever Foot PedalIgnition Key Switch: On Lower Dash PanelThrottle Lever On Dash Panel and Choke Knob On Lower Dash PanelLight Switch: On Dash PanelSeparate Indicator Lights for SafetyInterlock Switch: Operator Present, PTO Disengaged,Low Oil Pressure Warning Light, Hourmeter

DIMENSIONS:Overall Length 70.25 in (178 cm)Overall Width 35 in (88.9 cm)Height To Top of Steering Wheel: 40 in (101.6 cm)

To Top of Engine Cover: 34 in (86.7 cm)Wheel Base 50.75 in (129 cm)Weight (apx..) Net: 424 lbs. (192 kg) w/o mower

536 lbs. (243 kg) w/mowerShipping: 575 lbs. (261 kg) w/o mower

687 lbs. (312 kg) w/mowerTractor Heightw/Snowcab 71.5 in (181 cm)

Tractor Lengthw/Snowthrower est. 98 in (249 cm)

Tractor Lengthw/Dozer Blade est. 94 in (239 cm)

50” MOWER: 12 GA.Effective CuttingWidth 50 in Mower - 50 in (127 cm)

Overall Widthwith Deflector 50 in Mower - 62 in (157.5 cm)

Weight 50 in Mower - 135 lbs. (61.4 kg)Variable Cutting Ht. 1.0 - 3.6 in (3.2 to 8.0 cm)Blade Arrangement Three Staggered BladesMower Drive V-Belt From Tractor Engine PTO Electric

ClutchSpindle Bearings Lubricated and Sealed Ball Bearings

Lube Fitting Provided

44” MOWER: 12 GA.Effective CuttingWidth 44 in Mower - 44 in (111.8 cm)

Overall Widthwith Deflector 44 in Mower - 56 in (142.2 cm)with Turbo 58" (147 cm)

Weight 44 in Mower - 112 lbs. (51 kg)Variable Cutting Ht. 1.0 - 3.6 in (3.2 to 8.0 cm)Blade Arrangement Three Staggered BladesMower Drive V-Belt From Tractor Engine PTO Electric



38” MOWER: 12 GA.Effective CuttingWidth 38 in Mower - 38 in (96.5 cm)

Overall Widthwith Deflector 38 in Mower - 49.5 in (125.7 cm)with Turbo 38 in Mower - 51.5 in (131 cm)

Weight 38 in Mower - 100 lbs. (45 kg)Variable Cutting Ht. 1.0 - 3.6 in (2.5 to 9.1 cm)Blade Arrangement Two BladesMower Drive V-Belt From Tractor Engine PTO Electric



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2 TroubleshootingTable of Contents

SECTION CONTENTS

Troubleshooting

Troubleshooting the Tractor ......................................................... 2-2

Troubleshooting the Mower.......................................................... 2-3

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TROUBLESHOOTINGWhile normal care and regular maintenance will extendthe life of your equipment, prolonged or constant usemay eventually require that service be performed toallow it to continue operating properly.

The troubleshooting guide below lists the most commonproblems, their causes and remedies.

Troubleshooting the TractorPROBLEM CAUSE REMEDYEngine will not turnover or start. 1. Brake pedal not depressed. Fully depress brake pedal.

2. PTO (electric clutch) switch Place in OFF position.in ON position.

3. Out of fuel. If engine is hot, allow it to cool, then refill the fuel tank.

4. Engine flooded. Push choke knob in (twin cylinder models) or move throttle control out of CHOKE position (single cylinder models).

5. Circuit breaker tripped. Wait one minute for automatic reset.Replace if defective.

6. Battery terminals require See Battery Maintenance Section.cleaning.

7. Battery discharged or dead. Recharge or replace.8. Wiring loose or broken. Visually check wiring & replace broken or

frayed wires. Tighten loose connections.9. Solenoid or starter motor faulty. See Electrical Troubleshooting Section.10. Safety interlock switch or See Electrical Troubleshooting Section.

module faulty.

11. Spark plug(s) faulty, fouled Clean and gap or replace. or incorrectly gapped. See engine manual.

12. Water in fuel. Drain fuel & refill with fresh fuel.13. Gas is old or stale. Drain fuel & replace with fresh fuel.

Engine starts hard or runs poorly. 1. Fuel mixture too rich. Clean air filter. Check choke adjustment (engine speed control).

2. Spark plug(s) faulty, fouled, or Clean and gap or replace. incorrectly gapped. See engine manual.

Engine knocks. 1. Low oil level. Check/add oil as required.2. Using wrong grade oil. See engine manual.

Excessive oil consumption. 1. Engine running too hot. Clean engine fins, blower screen andair cleaner.

2. Using wrong weight oil. See engine manual.3. Too much oil in crankcase. Drain excess oil.

Engine exhaust is black. 1. Dirty air filter. Replace air filter. See engine manual.2. Choke closed. Open choke.

Engine runs, but tractor will 1. Ground speed control pedals Depress pedals.not drive. not depressed.

2. Transmission release lever Move into drive position.in “push” position.

3. Drive belt is broken. See Drive Belt Replacement.4. Drive belt slips. See cause and remedy below.5. Brake is not fully released. See Brake Adjustment.

WARNINGTo avoid serious injury, perform maintenance onthe tractor or mower only when the engine isstopped and the parking brake engaged.

Always remove the ignition key, disconnect thespark plug wire and fasten it away from the plugbefore beginning the maintenance, to preventaccidental starting of the engine.

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2 TroubleshootingMower 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.

“frozen” in declutched position. Brake will not hold. 1. Brake is incorrectly adjusted. See Brake Adjustment.

2. Internal brake worn. See Transmission Teardown. Tractor steers hard or 1. Steering linkage is loose. Check and tighten any loose connections.handles poorly. See Steering Gear Adjustment.

2. Improper tire inflation. Check and correct.3. Front wheel spindle Grease spindles. See Lubricating the

bearings dry. Tractor.Drive belt does not stop when 1. Belt stops or belt tension See Adjustments Section.clutch/brake pedal depressed. out of adjustment.

Troubleshooting the MowerPROBLEM CAUSE REMEDYMower will not raise. 1. Lift link not properly attached Attach or repair.

or damaged.Mower cut is uneven. 1. Mower not leveled properly. See Mower Adjustment.

2. Tractor tires not inflated See Maintenance Section.equally or properly.

Mower cut is rough looking. 1. Engine speed too slow. Set to full throttle.2. Ground speed too fast. Slow down.3. Blades are dull. Sharpen or replace blades.

See Mower Blade Service.4. Mower drive belt slipping Clean or replace belt as necessary.

because it is oily or worn. 5. Check PTO (Electric Clutch) See Adjustments Section.

Adjustment.6. Blades not properly fastened See Servicing the Mower Blades.

to arbors.Engine stalls easily with 1. Engine speed too slow. Set to full throttle.mower engaged. 2. Ground speed too fast. Slow down.

3. Carburetor improperly adjusted. See Engine Manual.4. Cutting height set too low. Cut tall grass at maximum cutting

height during first pass.5. Discharge chute jamming Cut grass with discharge pointing toward

with cut grass. previously cut area.Excessive mower vibration. 1. Blade mounting screws Tighten to 45-55 ft.lbs. (61-75 N.m.).

are loose.2. Mower blades, arbors, Check and replace as necessary.

or pulleys are bent.3. Mower blades are out Remove, sharpen, and balance blades.

of balance. See Servicing the Mower Blades.4. Belt installed incorrectly. Reinstall Correctly.

Excessive belt wear or breakage. 1. Belt tension too tight. Adjust belt tension.2. Bent or rough pulleys. Repair or replace.3. Using incorrect belt. Replace with correct belt.

Mower drive belt slips 1. Idler pulley spring broken or not Repair or replace as needed.or fails to drive. properly attached.

2. Belt stops out of adjustment. Check belt stops.3. Mower drive belt broken. Replace drive belt.

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3 MaintenanceTable of Contents

SECTION CONTENTSStorage

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 & Replace Spark Plugs............................3-5

Lubrication .............................................................3-6

Lubricate Rear Axles.............................................3-7

Battery MaintenanceCheck Battery Fluid.......................................................................3-8

Clean Battery and Cables .............................................................3-8

Servicing the Mower Blades.................................3-9

Perform Safety ChecksFunctional Tests..........................................................................3-10

Dash Safety Lights Test ..............................................................3-10

Mower Blade Stopping Check.....................................................3-10

Seat Switch Connection ..............................................................3-10

Safety Interlock System Check ...................................................3-11

Blade Brake Check .....................................................................3-11 SECT

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WARNINGNever store the unit, with gasoline in engine orfuel tank, in a heated shelter or in enclosed,poorly ventilated enclosures. Gasoline fumes mayreach an open flame, spark or pilot light (such asa furnace, water heater, clothes dryer, etc.) andcause an explosion.

Handle gasoline carefully. It is highly flammableand careless use could result in serious firedamage to your person or property.

Drain fuel into an approved container outdoorsaway from open flame or sparks.

STORAGETemporary Storage (30 Days Or Less)Remember, the fuel tank will still contain some gasoline, sonever store the unit indoors or in any other area where fuelvapor could travel to any ignition source. Fuel vapor is alsotoxic if inhaled, so never store the unit in any structure usedfor human or animal habitation.

Here is a checklist of things to do when storing your unittemporarily or in between uses:

• Keep the unit in an area away from where children maycome into contact with it. If there’s any chance of unau-thorized use, disconnect the spark plug wires.

• If the unit can’t be stored on a reasonably level surface,chock the wheels.

• Clean all grass and dirt from the mower.

NOTE: If storing your tractor between winter snow removaljobs in a cold area, we suggest that you fill the fuel tank atthe completion of each job to prevent water condensation inthe fuel tank. Wait for engine to cool before filling tank.

Long Term Storage (Longer Than 30 Days)Before you store your unit for the off-season, read theMaintenance and Storage instructions in the Safety Rulessection, then perform the following steps:

1. Drain crankcase oil and refill with a grade of oil that willbe required when unit is used again.

2. Prepare the mower deck for storage as follows:

a. Remove mower deck from the unit.

b. Clean underside of mower deck.

c. Coat all bare metal surfaces with paint or light coatof oil to prevent rusting.

3. Clean external surfaces and engine.

4. Prepare engine for storage. See engine owner’s manual.

5. Clean any dirt or grass from cylinder head cooling fins,engine housing and air cleaner element.

6. Cover air cleaner and exhaust outlet tightly with plasticor other waterproof material to keep out moisture, dirtand insects.

7. Completely grease and oil unit as outlined in the NormalCare section.

8. Clean up unit and apply paint or rust preventative to anyareas where paint is chipped or damaged.

9. Be sure the battery is filled to the proper level with waterand is fully charged. Battery life will be increased if it isremoved, put in a cool, dry place and fully chargedabout once a month. If battery is left in unit, disconnectthe negative cable.

10. Drain fuel system completely or add a gasoline stabilizerto the fuel system. If you have chosen to use a fuel sta-bilizer and have not drained the fuel system, follow allsafety instructions and storage precautions in this man-ual to prevent the possibility of fire from the ignition ofgasoline fumes. Remember, gasoline fumes can travelto distant sources of ignition and ignite, causing risk ofexplosion and fire.

NOTE: Gasoline, if permitted to stand unused for extendedperiods (30 days or more), may develop gummy depositswhich can adversely affect the engine carburetor and causeengine malfunction. To avoid this condition, add a gasolinestabilizer to the fuel tank and run the engine a few minutes,or drain all fuel from the unit before placing it in storage.

STARTING AFTER LONG TERM STORAGEBefore starting the unit after it has been stored for a longperiod of time, perform the following steps.

1. Remove any blocks from under the unit.

2. Install the battery if it was removed.

3. Unplug the exhaust outlet and air cleaner.

4. Fill the fuel tank with fresh gasoline. See engine manual for recommendations.

5. See engine owner’s manual and follow all instructionsfor preparing engine after storage.

6. Check crankcase oil level and add proper oil if necessary. If any condensation has developed duringstorage, drain crankcase oil and refill.

7. Inflate tires to proper pressure. Check fluid levels.

8. Start the engine and let it run slowly. DO NOT run athigh speed immediately after starting. Be sure to runengine only outdoors or in well ventilated area.

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3 MaintenanceSchedule

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

* See the engine manufacturer's owner's manual.** Change original engine oil after first 5 hours of operation.

*** More often in hot (over 85° F: 30° C) weather or dusty operating conditions.**** Perform service after the first 50 hours of operation, then every 250 hours.

Tire Pressure

Front 12-15 psi (83-104 kPa)

Rear 6-8 psi (41-55 kPa) Figure 1. Checking Tire Pressure

CHECK TIRE PRESSURESTire Pressure should be checked periodically, and main-tained at the levels shown in the chart. Note that thesepressures may differ slightly from the “Max Inflation”stamped on the side-wall of the tires. The pressuresshown provide proper traction, improve cut quality, andextend tire life.

Before Before Every Every Every SpringSAFETY ITEMS First Use Each Use 5 Hours 25 Hours 100 Hours & Fall

Check Safety Interlock System

Check Tractor Brakes

Check Mower Blade Stopping Time

Before Before Every Every Every SpringNORMAL CARE ITEMS First Use Each Use 5 Hours 25 Hours 100 Hours & Fall

Check Tractor/Mower for loose hardware

Check Engine Air Filter *, ***

Check Engine Oil Level *

Change Engine Oil & Filter *, **, ***

Lubricate Tractor & Mower ***

Check Tire Pressure

Check Transmission Fluid

Change Transmission Fluid **** Every 250 Hours

Check/Adjust PTO Clutch **** Every 250 Hours

Check Fuel Filter

Clean Battery & Cables

Clean & Sharpen Mower Blades

Inspect Spark Plug(s) *

Lubricate Rear Axle Shafts Yearly

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CHECK / CHANGE TRANSMISSION OILThe transmission oil should be checked before each use,and changed at the intervals shown or if it has becomediscolored from overheating or contamination.

Service Interval: After initial 50 Hrs, then every 250 Hrs.

Oil Capacity: Apx. 3.5 Quarts

Oil Type: SAE 10W-30 with a minimum API rating of SG/CD.

Checking the Oil Level:

1. Locate the reservoir tank on the rear of the unit.Observe the oil level. Oil should be up to the FULLmark (see Figure 2). DO NOT OVERFILL. Emptyspace is required for heat expansion.

2. If necessary, clean the area surrounding the reservoircap, remove the cap, and add oil.

Changing the Transmission Oil:

1. Drain hydrostatic system by removing drain plug (seeFigure 3). Drain oil into a suitable container.

2. Reinstall the drain plug.3. Add oil a few ounces at a time until the reservoir is

filled to the FULL mark. DO NOT OVERFILL. Emptyspace is required for heat expansion.

4. Run tractor for several minutes and recheck thetransmission oil level. If the transmission is exces-sively noisy or unresponsive, perform the purgingprocedure found in the Service section.

FULL

Figure 2. Transmission Oil Reservoir

Full Mark

Figure 3. Transmission Drain Plugs

Do not allow dirt, water, or other debris toenter the reservoir. Even a small amount ofdirt can irreparably damage the transmission

DrainPlug

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3 MaintenanceEngine Service

Figure 5. Engine Compartment -Kohler Single Cylinder EngineA. Battery D Oil Fill/DipstickB. Oil Filter E. Fuel Filter (Not ShownC. Air Filter F. Throttle/Choke Cable

D

CB

AE

F

ACCESSING THE ENGINETo gain access to the engine, unhook the rubber straps(Figure 4) and tip the hood forward.

NOTE: For engine service item locations see Figure6 for models with Briggs & Stratton engines andFigure 5 for models with Kohler engines

FUEL FILTER REPLACEMENTThe fuel filter (E, Figures 5 & 6) is located in the fuel linebetween the fuel tank and the carburetor.If filter is dirty or clogged, replace as follows:1. Disconnect the negative battery cable.

2. Place a container below the filter to catch spilled fuel.

3. Using a pliers, open and slide hose clamps from fuelfilter.

4. Remove hoses from filter.

5. Install new filter in proper flow direction in fuel line.

6. Secure with hose clamps.

7. Reconnect the negative battery cable when finished.

D

C

B

A

E

G

F

Figure 6. Engine Compartment - Briggs & Stratton Twin Cylinder EnginesA. Battery E. Fuel FilterB. Oil Filter F. Throttle CableC. Air Filter G. Choke CableD Oil Fill/Dipstick

Figure 4. Engine Access

Undo HoodStraps (BothSides) and LiftHood to accessEngine

D

C

B

AE

OIL & FILTER CHANGERefer to engine manual for specific oil and filter recom-mendations and oil draining procedures.

CHECK / CHANGE AIR FILTERRefer to the engine manual for specific air filter serviceprocedures.

INSPECT & REPLACE SPARK PLUGSRefer to the engine manual for specific spark plugreplacement procedures.

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3 MaintenanceLubrication

3 - 6

Figure 8. Lubricating the Tractor

LUBRICATIONLubricate the unit at the locations shown in Figures 7-11as well as the following lubrication points.

Grease:• front axle pivot• front axle grease fittings• steering linkage• foot pedal• mower pivots• mower arbors • transmission idler assembly pivot

Use grease fittings when present. Disassemble partsto apply grease to moving parts when grease fittingsare not present.

Not all greases are compatible. Simplicity LithiumGrease is recommended, automotive-type lithiumgrease may be used when this is not available.

Oil:• hydro linkage • seat adjustment assembly• brake linkage • frame pivot points• mower deck height adjustment linkage

Generally, all moving metal parts should be oiledwhere contact is made with other parts. Keep oil andgrease off belts and pulleys. Remember to wipe fit-tings and surfaces clean both before and after lubri-cation.

Figure 9. Brake Pedal Pivot Point

Figure 7. Lubricate Steering Linkage

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3 MaintenanceLubricate Rear Axles

Figure 11. Mower Lubrication PointsFigure 10. Arbor Lubrication Points

LUBRICATE REAR AXLESWe recommend removing the rear wheels and lubricat-ing the axle shafts yearly. This prevents the wheel fromseizing onto the axle shaft, making future service easier.

1. Remove the key and disconnect the spark plugwire(s) 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 ofthe rear frame, carefully jack the unit up until the reartires are approximately 1" - 2" off the ground.

NOTE: For overall unit stability during service, do notjack rear end higher than required for wheel removal.

4. Support the rear of the unit on jack stands positionedunder the rear frame (see Figure 12).

5. Remove the plastic hub cap (G, Figure 13).

6. Remove e-ring (F) using a screwdriver.

7. Remove the washers (D) and wheel (C).

NOTE: Your axle assembly may differ slightly from theassembly pictured: washer (D, Figure 13) may be miss-ing or doubled. This is adjusted on a tractor by tractorbasis during assembly to allow a small amount of axleend-play.

8. Lubricate the axle shaft with anti-seize compound orlithium grease.

9. See Figure 13 for assembly. Reinstall components inreverse order of disassembly and lower the unit. Besure the key (H) is in place in the axle key-way.

Figure 12. Elevate the Rear End

Figure 13. Wheel and Axle AssemblyA. Washer E. Hub Cap RetainerB. Spacer F. E-RingC. Wheel G. Hub CapD. Washer H. Key

A

B

C

D

E

F

G

H

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3 MaintenanceBattery Maintenance

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BATTERY MAINTENANCE

Checking the Battery FluidNote: Does not apply to maintenance-free batteries.1. Raise the hood to access battery.

2. Remove the battery filler cap (See Figure 14). Fluidmust be even with the split ring full mark. If not, adddistilled water.

3. Reinstall the filler cap.

Cleaning the Battery and Cables1. Disconnect the cables from the battery, negative

cable first (B, Figure 14).

2. Remove the battery hold-down rods (C, Figure 14)and battery clamp (D) and battery.

3. Clean the compartment with a solution of bakingsoda and water.

4. Clean the battery terminals and cable ends with awire brush and battery terminal cleaner until shiny.

5. Reinstall the battery in the battery compartment, andsecure with the battery hold-down rods (C) and bat-tery clamp (D).

6. Reattach the battery cables, positive cable first (seeA, Figure 14)

7. Coat the cable ends and battery terminals with petro-leum jelly or non-conducting grease.

WARNINGBe careful when handling the battery. Avoidspilling electrolyte. Keep flames and sparks awayfrom the battery.

When removing or installing battery cables,disconnect the negative cable FIRST and reconnectit LAST. If not done in this order, the positiveterminal can be shorted to the frame by a tool.

D

B

A

C

Figure 14. BatteryA. Positive Battery TerminalB. Negative Battery TerminalC. Hold Down RodD. Battery Clamp

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3 MaintenanceMower Blade Service / Blade Brake Check

SERVICING THE MOWER BLADES

1. Remove mower from the tractor. See MowerInstallation & Removal.

2. Blades should be sharp and free of nicks and dents.If not, sharpen blades as described in following steps.

3. To remove blade for sharpening, use a wood block tohold blade while removing the blade mounting cap-screw (Figure 15).

4. Use a file to sharpen blade to fine edge. Remove allnicks and dents in blade edge. If blade is severelydamaged, it should be replaced.

5. Balance the blade as shown in Figure 16. Center theblade’s hole on a nail lubricated with a drop of oil. Abalanced blade will remain level.

6. Reinstall each blade with the tabs pointing up towarddeck as shown in Figure 17. Secure with a capscrew,spring washer and hex washer (be certain the hexwasher is aligned with the hex shaft). Use a woodenblock to prevent blade rotation and torque capscrewsto 45-55 ft.lbs. (61-75 N.m.).

WARNINGFor your personal safety, do not handle the sharpmower blades with bare hands. Careless orimproper handling of blades may result in seriousinjury.

WARNINGFor your personal safety, blade mountingcapscrews must each be installed with a hexwasher and spring washer, then securelytightened. Torque blade mounting capscrew to 45 - 55 ft. lbs. (61 - 75 N.m.)

Figure 16. Balancing The Blade

Workbench

Nail

LOOSEN

Figure 15. Removing the Blade

AD

CB

TIGHTEN

Figure 17. Installing The BladeA. 4x4 Wood Block C. Spring WasherB. Hex Washer D. Blade Bolt

4x4 Wood Block

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3 MaintenancePerform Safety Checks

3 - 10

PERFORM SAFETY CHECKS

Functional Tests1. Check the tractor for loose bolts, screws, nuts, etc.

2. Start the engine and check all controls for properoperation: ground speed control pedals, clutch/brakepedal, parking brake, throttle and choke cables, elec-tric PTO clutch, headlight switch, steering, attachmentlift, etc.

3. Stop the engine and check for fluid leaks: oil, gaso-line, coolant, or transmission oil.

4. If any control fails to operate properly during testing orseems to be out of adjustment, check and readjust itaccording to the following Adjustments section.

Dash Safety Lights TestCheck the operation of the tractor controls and dashsafety lights. With an operator in seat and ignition switchturned to ON (engine not running):

1. PTO Indicator Light (red) should go on and off withoperation of electric clutch switch.

2. The parking brake / cruise control lock light should goon when the parking brake / cruise control is activat-ed.

3. Headlight Indicator Light should go on when theheadlights are turned on.

4. Oil Pressure Indicator Light (red) should turn on andshould go out immediately after the engine starts.

Mower Blade Stopping Check Mower blades and mower drive belt should come to acomplete stop within five seconds after the electric clutchswitch is turned off.

With the tractor in neutral, the electric clutch switch dis-engaged, and an operator in the seat, start the tractorengine. Run the engine at full throttle. Engage the electricPTO clutch switch and wait several seconds. Disengageelectric clutch switch and check the time it takes for themower drive belt to stop.

If the mower drive belt does not stop within five seconds,adjust the PTO clutch according to the instructions in theElectric Clutch Adjustment section.

Seat Switch Connection Check that the seat switch (A, Figure 18) is connected tothe seat switch wire harness (B).

WARNINGDisengage the PTO, stop the engine, set the parkingbrake, and wait for moving parts to stop before leav-ing operator's position for any reason.

If the tractor does not pass the test, do not oper-ate tractor. Under no circumstance should youattempt to defeat the purpose of the safety system.

Figure 18. Seat SwitchA. Seat Switch B. Wiring Harness

A

B

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3 MaintenancePerform Safety Checks

SAFETY INTERLOCK SYSTEM

This unit is equipped with safety interlock switchesand other safety devices. These safety systems arepresent for your safety, do not attempt to bypasssafety switches, and never tamper with safetydevices. Check their operation regularly.

Operational SAFETY ChecksYour unit is equipped with a seat switch safety sys-tem. Check the seat switch operation every fall andspring with the following tests.

Test 1 — Engine should NOT crank if:• PTO switch is engaged, OR

• Brake pedal is not fully depressed (or parkingbrake is not engaged), OR

• There is no operator in the seat.

Test 2 — Engine SHOULD crank if:• PTO switch is NOT engaged, AND

• Brake pedal is fully depressed (or parking brakeis engaged), AND

• An operator is sitting in the seat.

Test 3 — Engine should SHUT OFF if:• Operator rises off seat with PTO engaged, OR

• Operator rises off seat with brake pedal NOTfully depressed (or parking brake disengaged).

Test 4 — Blade Brake Check

Mower blades and mower drive belt should come toa complete stop within five seconds after electricPTO switch is turned off (or operator rises off seat).If mower drive belt does not stop within five sec-onds, see your dealer.

NOTE: Once the engine has stopped, the PTOswitch must be turned off after the operator returnsto the seat in order to start the engine.

WARNINGIf the unit does not pass a safety test, do notoperate it. See your authorized dealer. Underno circumstance should you attempt todefeat the purpose of the safety interlocksystem.

Blade Brake CheckMower blades and mower drive belt should come to acomplete stop within five seconds after electric PTOswitch is turned off.

1. With tractor in neutral, PTO disengaged and operatorin seat, start the engine.

2. Look over the left-hand footrest at the mower drivebelt. Engage the PTO and wait several seconds.Disengage the PTO and check the amount of time ittakes for the mower drive belt to stop.

3. If mower drive belt does not stop within five seconds,see your dealer.

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3 MaintenanceNotes

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4 - 1

4 AdjustmentsTable 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 & Side-to-Side Leveling..........................................4-7

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4 AdjustmentsSteering System Adjustments

4 - 2

WARNINGBefore beginning any service work, turn the PTOoff, set the parking brake, turn the ignition switchoff, remove the key, disconnect the spark plugwires, and disconnect the negative battery cable.

STEERING WHEEL ADJUSTMENT1. Use a suitable punch to remove the roll pin at the

base of the steering wheel (see Figure 1).2. Pull down on the rubber boot to expose the two holes

in the steering shaft.3. Align the hole in the steering wheel with the appropri-

ate steering shaft hole and install the roll pin.NOTE: Steering wheel is factory installed with the roll pinin the bottom hole.

STEERING GEAR ADJUSTMENTIf there is excessive slack in the steering system, thesteering gear (A, Figure 3) backlash can be removed.1. See Figure 2. Loosen the two nuts and adjust the

bracket so the gear teeth are closely meshed.2. Tighten nuts after adjustment.

Figure 1. Steering Wheel Removal

Figure 2. Steering Gear Adjustment

Figure 3. Steering Gear AdjustmentA. Steering Gear

A

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4 AdjustmentsPTO Clutch Adjustment

WARNINGTo avoid serious injury, perform adjustments onlywith engine stopped, key removed and tractor onlevel ground.

PTO CLUTCH ADJUSTMENTCheck the PTO clutch adjustment after the initial 50 hourbreak-in period and then after every 250 hours of opera-tion. Also perform the following procedure if the clutch isslipping or will not engage, or if a new clutch has beeninstalled.

1. Remove key from ignition switch and disconnectspark plug wires to prevent the possibility of acciden-tal starting while the PTO is being adjusted.

2. See Figure 4. Note the position of the 3 adjustmentwindows (A) in the side of the brake plate and thenylock adjustment nuts (B).

3. Insert a .012”-.015” (2.5-4mm) feeler gauge (C)through each window, positioning the gauge betweenthe rotor face and the armature face as shown inFigure 5.

4. Alternately tighten the adjustment nuts (B, Figure 4)until the rotor face and armature face just contactsthe gauge.

5. Check the windows for an equal amount of tensionwhen the gauge is inserted and removed, and makeany necessary adjustments by tightening or loosen-ing the adjustment nuts.

NOTE: The actual air gap between the rotor and arma-ture may vary even after performing the adjustment pro-cedure. This is due to dimensional variations on compo-nent parts, and is an acceptable condition.

6. Check the mower blade stopping time. The mowerblades and mower drive belt should come to a com-plete stop within five seconds after the electric PTOswitch is turned off.


1. With parking brake engaged, PTO disengaged andan operator in the seat, start the tractor engine.


3. If the mower drive belt does not stop within five sec-onds, perform the PTO Clutch Adjustment. If the beltstill does not stop within 5 seconds, see your dealer.

AB

C

Figure 5. Adjust PTO ClutchA. WindowB. Adjustment NutC. Feeler GaugeFigure 4. PTO Clutch Adjustment

A. Adjustment Window (Qty. 3, one shown) B. Adjustment Nuts

AB

B

B

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4 AdjustmentsBrake Spring & Foot Pedal Adjustment

4 - 4

BRAKE SPRING ADJUSTMENT1. Disengage the PTO, stop the engine, block the

wheels, and remove the ignition key. DO NOTengage the parking brake.

2. Remove the mower deck (see Mower Deck Removal).

3. Locate the brake spring (A, Figure 6) and adjustmentnut (B).

4. With the parking brake disengaged check the brakespring (A) for movement.

There should be no more that .002” clearancebetween the spring (A) and the adjustment nut(B)–however, spring must NOT be compressed.

If this adjustment does not correct a braking prob-lem, replace the brake band assembly.

FOOT PEDAL HEIGHT ADJUSTMENT(FORWARD SPEED ADJUSTMENT)1. Disengage the PTO, stop the engine, block the

wheels, and remove the ignition key. DO NOTengage the parking brake.

2. Loosen the carriage bolt and nut (A, Figure 7).

3. Grab the transmission rod (B) with a pair of lockingpliers and pull it fully forward. This will require someeffort.

4. With the transmission rod (B) pulled fully forward, fullydepress the forward ground speed pedal. Hold bothfully forward.

5. Tighten the carriage bolt and nut (A).

Figure 6. Brake Adjustment NutA. Brake Spring B. Adjustment Nut

B A

Figure 7. Foot Pedal AdjustmentA. Carriage Bolt & NutB. Transmission Rod

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4 AdjustmentsCruise Control & Neutral Adjustment

INTERNAL NEUTRAL ADJUSTMENTThe neutral gate of the Tuff Torq K61 is established inter-nally and should not need to be adjusted. If the tractorcreeps forward or backward with the ground speed con-trol pedals at rest (neutral position) while the engine isrunning, perform the following adjustment:

1. Block the front tires.

2. Using an overhead chain hoist or hydraulic floor jack,elevate the rear end of the tractor so that the wheelsdo not contact the ground. Position jackstands underthe rear frame.

3. Using a 17 mm wrench loosen the neutral adjustmentjam nut (A, Figure 9).

4. Activate the seat switch, depress the brake pedal,and start the engine.

5. Release the brake pedal.

6. Using an 8 mm wrench adjust neutral by turning theeccentric (B, Figure 9) until the rear wheels do notcreep.

7. Once neutral has been established, hold the eccentric(B) in place and secure in position with the jam nut(A).

CRUISE CONTROL RELEASEADJUSTMENTSee Figure 8.

1. Stop the tractor, shut off the PTO, turn off the engine,and remove the key. DO NOT engage the parkingbrake.

2. Remove the mower deck.

3. Fully depress the forward ground speed control pedaland engage the cruise control.

4. Locate the cruise control release tabs (A) on thebrake cam (B) and cruise lock cam (C).

With the cruise control locked and the brake pedal atrest (disengaged) there should be 1/8” to 3/16” clear-ance between the two tabs. If not, proceed to step 5.

Depressing the brake pedal approximately 1” to 1-1/4”should cause the cams to contact each other releas-ing the cruise control. If not, proceed to step 5.

5. Loosen the cam adjustment bolt (D) and rotate thecruise lock cam (C) until there is 1/8” gap between thecruise release tabs (A).

Repeat step 4.

Figure 8. Cruise Control Release TabsA. Cruise Release Tabs C. Cruise Lock CamB. Brake Cam D. Cam Adj. Bolt

A

B

C D NOTE: IdlerAssemblyRemoved forIllustrationPurposes.

1/8” to 3/16”Gap

Figure 9. Neutral AdjustmentA. Jam Nut B. Eccentric

AB

8. Fully depress both the forward ground speed pedaland reverse ground speed pedal and check that itreturns to neutral and the rear wheels do not creep.

9. After adjustments have been completed, shut off theengine and lower the tractor.

10. Perform FOOT PEDAL ADJUSTMENT procedure.

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4 AdjustmentsTransmission Purging

4 - 6

TRANSMISSION PURGINGPurge the transmission if the unit is excessively noisy orlacks drive in forward or reverse.

1. Elevate the rear end of the tractor using a chain hoistor floor jack. Support the rear of the unit using jack-stands. Elevate the unit just high enough for the rearwheels to clear the ground.

2. Activate the seat switch, depress the clutch / brakepedal, and start the engine. After the engine hasstarted, set throttle to IDLE.

3. Release the brake pedal and fully depress the for-ward ground speed pedal.

4. While holding the ground speed control in forwardposition, engage and disengage the transmissionrelease valve lever (A, Figure 10) several times.

5. Fully depress the reverse ground speed pedal.

6. While holding the ground speed control in reverse,engage and disengage the transmission release valvelever (A) several times.

7. Engage the transmission release valve lever andstroke the transmission from full forward to fullreverse several times.

8. Lower the tractor and test run for several minutes.

Figure 10. Transmission Release LeverA. Release Lever (Engaged Position Shown)

A

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4 AdjustmentsMower Leveling

MOWER LEVELINGIf the cut is uneven, the mower may need leveling.Unequal or improper tire pressure may also cause anuneven cut. Make sure tire pressure is correct.

1. With the mower installed, place the tractor on asmooth, level surface such as a concrete floor. Turnthe front wheels straight forward.

2. Check for bent blades and replace if necessary.

3. Disengage the PTO. Place the mower in mid-cutposition. Arrange the mower blades so that they arepointing from side-to-side.

4. Measure the distance between the outside tips ofeach blade and the ground. If there is more than 1/8”(3mm) difference between the measurements oneach side, proceed to step 5. If the difference is 1/8”(3mm) or less, proceed to step 6.

5. See Figure 11. Loosen the outside nut (A). Turn theeccentric nut (B) to raise or lower left-hand side ofmower. When mower is level, hold the eccentric nutwhile tightening the outside nut.

NOTE: When using a turbo collection system, raise thedischarge side of the mower approximately 1/4” to com-pensate for turbo assembly weight. Check the level ofthe cut grass and adjust the 1/4” measurement as neces-sary for a smooth, even cut.

6. Arrange the blades so they face front-to-back.

7. On 38" deck, measure the distance from the groundto front tip and rear tip of the left and right-handblades.

On 44" and 50” decks, measure the distance from theground to the front tip of the center blade, and fromthe ground to rear tip of left-hand blade.

Front tips on all decks should be 1/8”-1/4” higher. Ifnot, proceed with steps 8 - 10.

8. See Figure 12. To raise front of mower deck, loosenfront nut (A) and turn rear nut (B) against bracket (C).

9. To lower front of mower deck, loosen rear nut (B) andbracket (C) will move backwards to lengthen rod.

10. Re-check measurement before tightening front nut(A) against bracket.

WARNINGBefore checking mower, shut off PTO and engine.Allow all moving parts to stop. Remove ignitionkey, then disconnect the spark plug wire andfasten it away from the spark plug.

Figure 11. Leveling The Mower Side-to-SideA. Outside Nut B. Eccentric Nut

Figure 12. Leveling The Mower Front-To-BackA. Front Nut C. Mower BracketB. Rear Nut D. Adjustment Rod

A

B

B C AD

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5 Belt ReplacementTable 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

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5 Belt ReplacementTransmission Drive Belt Replacement

5 - 2

WARNINGBefore beginning any service work, turn the PTOoff, set the parking brake, turn the ignition switchoff, remove the key, disconnect the spark plugwire, and disconnect the negative battery cable.

Figure 1. Transmission Drive Belt ReplacementA. Idler Assy. Spring D. Idler PulleysB. PTO Clutch Plug E. Steering ArmC. Crankshaft Bolt F. Brake Rod

A

F

E

D

B C

Figure 2. Brake RodA. Brake Rod C. Cotter PinB. Brake Lever

TRANSMISSION DRIVE BELTREPLACEMENTNOTE: 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.DO NOT engage the parking brake.

2. Remove the mower deck. See Removing the MowerDeck.

3. Disconnect the idler pulley assembly spring (A).

4. Unplug the PTO clutch wire plug (B).

5. Remove the crankshaft bolt (C) securing the PTOclutch to the crankshaft.

6. Remove the PTO clutch.

7. Disconnect the steering arm (E).

8. Loosen the idler pulleys (D) and remove the belt fromthe idler assembly.

9. Remove the belt from the engine drive pulley.

10. See Figure 2. Disconnect the brake rod (A) from thebrake lever (B) at the back of the transmission.

11. Rotate the belt through the blades of the input pulleyfan and remove the belt from the tractor.

INSTALL THE NEW BELT

12. Rotate the belt through the blades of the input pulleyfan and install onto input pulley.

13. See Figure 2. Reattach the brake rod (A) to the brakelever (B) at the back of the transmission.

14. See Figure 1. Install the belt onto the idler pulleys (D)and tighten the idler pulley hardware.

15. Install the belt onto the engine pulley.

16. See Figure 1. Reconnect the steering arm (E).

17. Reinstall the PTO clutch wire. Torque the crankshaftbolt (C) to 45-50 ft. lbs.

18. Reconnect the PTO clutch plug (C, Figure 1).

19. Reattach the idler assembly spring (A, Figure 1).

A

B

C

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5 Belt Replacement38” Mower Belt Replacement

MOWER BELT REPLACEMENT

38” Mower Drive Belt ReplacementNOTE: Be sure to use only genuine Simplicity replace-ment parts.

NOTE: It is not necessary to remove the mower to installa new belt. However, for easier access mower can beremoved.

Refer to Figure 3.

1. Park the tractor on a smooth, level surface such as aconcrete floor. Disengage the PTO, turn off theengine and lock the parking brake. Remove the key.

2. If mower is not removed, lower the mower lift andplace the mower in the lowest cutting position.

3. Push the idler arm (A) away from you to relieve belttension. Drop the belt from the PTO (electric clutch)pulley.

IMPORTANT: Note the position of all belt guides relativeto the belt and pulleys before loosening.

4. Loosen the two belt stop brackets (C) and idler pulleybelt guide (D).

5. Remove the old belt and replace with a new belt.Make sure V-side of belt runs in arbor pulley groovesand the flat backside runs against the idler pulley.

6. Position the belt stop brackets (C) in their originalpositions. There must be 1/8” clearance between thebelt stop and the pulleys.

7. Position the idler pulley belt guide (D) in its originalposition up against arm (A) so that there is a 1/8" gapbetween the pulley and belt guide.

8. Install mower on tractor if it was removed.

9. Run the mower under no-load condition for about 5minutes.

Figure 3. Mower Belt Routing - 38" Mower DeckA. Idler Pulley Arm C. Belt Stop BracketB. PTO Pulley D. Idler Pulley Belt Guide

To avoid damaging belts, DO NOT PRYBELTS OVER PULLEYS.

C

DA

CB

Left Side of Mower

1/8” Gap

1/8” Gap

1/8” Gap

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5 Belt Replacement44” & 50” Mower Belt Replacement

5 - 4


44” & 50” PTO Belt ReplacementNOTE: Be sure to use only genuine Simplicity replace-ment parts.

NOTE: It is not necessary to remove the mower to installa new belt. However, for easier access mower can beremoved.


2. If mower is not removed, place the mower in the low-est cutting position.

3. Push the idler arm (A, Figure 4) away from you torelieve belt tension. Drop the belt from the PTO (elec-tric clutch) pulley.

IMPORTANT: Note the position of all belt guides relativeto the belt and pulleys before loosening.

4. Loosen the nut and lockwasher securing idler pulleybelt guide (C, Figure 4).

5. See Figure 5. Remove three capscrews securingleft-hand arbor cover (D).

5. Remove the old belt and replace with a new one.Make sure the V-side of belt runs in the pulleygrooves.

7. See Figure 4. Position the idler pulley belt stop (C) inits original position so that there is a 1/8" gapbetween the pulley and belt stop.

8. See Figure 5. Reinstall the left-hand arbor cover (D).

9. Install mower on tractor if it was removed. Install belton PTO pulley.

10. Run the mower under no-load condition for about 5minutes.

Figure 5. Mower Deck - 44" & 50”A. UpstopB. Right-hand Arbor CoverC. SpringD. Left-hand Arbor CoverE. Capscrew

Figure 4. Mower Belt Routing - 44" & 50” Mower DeckA. Idler Pulley Arm C. Idler Pulley Belt GuideB. PTO Clutch Pulley D. Arbor Drive Pulley

1/8” Gap

FRONT

A

D

A

D

E

C

B

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5 Belt Replacement44” & 50” Mower Belt Replacement


44” & 50” Arbor Drive Belt ReplacementNOTE: Be sure to use only genuine Simplicity replace-ment parts.


2. Remove the mower from the tractor. See MowerRemoval in the Operation section.

3. See Figure 6. Remove the two capscrews securingupstop (A) and remove the upstop.

4. Remove the four capscrews securing the right-handarbor cover (B, Figure 6). Remove three capscrewssecuring left-hand arbor cover (D).

5. Using a pair of locking pliers or a spring puller,remove the idler pulley spring (C, Figure 6) from slotin deck.

6. Loosen capscrew (E, Figure 6) securing the idler pul-ley to the bracket. The belt can now be slippedbetween the pulley and idler bracket hub.

7. Install a new belt as shown in Figure 7. Make surethat V-side of belt runs in arbor pulley (A) groovesand flat side of belt runs against idler pulley (B).

8. Tighten the capscrew (E, Figure 6).

9. Reinstall spring (C, Figure 6) into its slot in mowerdeck.

11. Reinstall the left and right arbor covers (B and D,Figure 6) and upstop (A) using the original hardware.Be careful not to strip out the capscrews.

12. Install the mower onto the tractor.

FRONT

Figure 7. Mower Deck Drive Belt Routing - 44" & 50” DeckA. Arbor Drive Pulley (V-sided)B. Idler Pulley (Flat-sided)

A

A

A

B

Figure 6. Mower Deck - 44" & 50”A. UpstopB. Right-hand Arbor CoverC. SpringD. Left-hand Arbor CoverE. Capscrew

A

D

E

C

B

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6 Common Service ProceduresTable 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 & Installation......................6-6

Front Removal & Installation ................................6-7

Battery Service

Checking Battery Voltage..............................................................6-8

Charging a Completely Discharged Battery ..................................6-8

Jump Starting With an Auxiliary Battery........................................6-8

Battery Removal & Installation

Removing the Battery..................................................................6-10

Installing the Battery....................................................................6-10

Burnishing the Electric PTO Clutch...................6-10

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6 Common Service ProceduresMower Removal & Installation

6 - 2

MOWER DECK REMOVAL &INSTALLATIONRemoving the Mower Deck1. Park tractor on a hard, level surface such as a con-

crete floor. Turn off PTO switch and engine, removethe key and apply parking brake.

2. Place mower in the lowest cutting position using themower height adjuster (B, Figure 1).

3. Place the mower lift lever (A, Figure 1) in the lowestposition.

4. Disconnect the mower lift arm (A, Figure 2) from thetractor lift arm (B). Re-install washer and safety clip.

5. Remove belt from PTO pulley (B, Figure 3).

6. Turn wheels straight ahead. Pull back on spring-loaded lever (B, Figure 4) and lift mower hitch off ofthe tractor brackets.

7. Turn wheels fully left, and slide mower deck out rightside of tractor.

WARNINGEngage parking brake, disengage PTO, stopengine and remove key before attempting toinstall or remove the mower.

CAUTIONThe muffler and surrounding areas may be hot.

Figure 1. Raising & Lowering MowerA. Mower Lift Lever B. Mower Height Adjuster

Figure 2. Lift Arms (Viewed from underneath right side of tractor)A. Mower Lift Arm C. Flat WasherB. Tractor Lift Arm D. Safety Clip

Figure 4. Mower HitchA. Tractor Hitch BracketsB. Spring-Loaded Lever

A

B

Figure 3. Removing & Installing BeltA. Idler Arm B. PTO Pulley

B

A

C

D

A

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Figure 8. Removing & Installing BeltA. Idler Arm B. PTO Pulley

Figure 7. Lift Arms (Viewed from underneath right side of tractor)A. Mower Lift Arm C. Flat WasherB. Tractor Lift Arm D. Safety Clip

Figure 6. Mower HitchA. Tractor Hitch BracketsB. Spring-Loaded Lever

A

B

Installing the Mower Deck1. Park tractor, shut off PTO and engine, remove the

key and apply parking brake. Turn the wheels fully tothe left.

2. Place mower height adjuster (B, Figure 5) in the low-est cutting position. Place the mower lift lever in thelowest position, also. Slide mower deck under rightside of tractor so that mower hitch is aligned withfront tractor hitch.

3. See Figure 6. Turn wheels straight. Pull back on thespring-loaded lever (B) while lifting up on the mowerhitch. Install mower hitch onto tractor hitch brackets(A). When properly installed, the spring-loaded levershould seat fully underneath the brackets.

4. See Figure 7. Connect the mower lift arm (A) to thetractor lift arm (B) using the flat washer (C) and safetyclip (D).

5. See Figure 8. Move idler arm (A) to relieve belt ten-sion. Install belt onto the PTO pulley (B).

Figure 5. Raising & Lowering MowerA. Mower Lift Lever B. Mower Height Adjuster

CAUTIONThe muffler and surrounding areas may be hot.

WARNINGEngage parking brake, disengage PTO, stopengine and remove key before attempting toinstall or remove the mower.

B

A

B

A

C

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MOWER BLADE REMOVAL &INSTALLATION

Removal1. Remove mower from the tractor. See Mower

Installation & Removal.

2. To remove the blade use a wood block to hold theblade while removing the blade mounting capscrew(Figure 9).

Installation1. Reinstall each blade with the tabs pointing up toward

deck as shown in Figure 10. Secure with a capscrew,spring washer and hex washer (be certain the hexwasher is aligned with the hex shaft).

2. Use a wooden block to prevent blade rotation andtorque capscrews to 45-55 ft.lbs. (61-75 N.m.).

WARNINGFor your personal safety, do not handle the sharpmower blades with bare hands. Careless orimproper handling of blades may result in seriousinjury.

WARNINGFor your personal safety, blade mountingcapscrews must each be installed with a hexwasher and spring washer, then securelytightened. Torque blade mounting capscrew to 45 - 55 ft. lbs. (61 - 75 N.m.)

LOOSEN

Figure 9. Removing the Blade

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TIGHTEN

Figure 10. Installing The BladeA. 4x4 Wood Block C. Spring WasherB. Hex Washer D. Blade Bolt

4x4 Wood Block

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6 Common Service ProceduresElevating the Tractor

ELEVATING THE TRACTOR

Elevating Rear End for Safe Service1. Remove the ignition key and disconnect spark plug

wire to prevent accidental starting while working onthe unit.


3. Using a hydraulic or scissors jack positioned at thecenter of the rear frame assembly, carefully jack theunit up until the rear tires are approximately 1" - 2" offthe ground.

NOTE: For overall unit stability during service, do notjack rear end higher than required for tire removal.

4. Support the rear of the unit on jackstands positionedunder the rear frame.

Figure 11. Jacking Up the Tractor

Figure 12. Supporting the Rear of the Tractor

Figure 13. Supporting the Front of the Tractor

Elevating Front End for Safe Service1. Remove the ignition key, and disconnect spark plug

wire to prevent accidental starting while working onthe unit.

2. Engage the parking brake and block the rear wheels.

3. Position a hydraulic or scissors jack under the centerof the front axle and raise the front end up 1” to 2”.

NOTE: For overall unit stability during service, do notjack front end higher than required for tire removal.

4. Support the tractor by positioning jackstands underthe foot rests or frame.

DANGERPREVENT SERIOUS INJURY OR DEATH FROM FALLING UNIT

Always use a properly working lifting device witha capacity suitable for the weight of the unitbeing serviced.

Always use a jack stand to support the unit whileperforming service, and chock remaining wheelsto prevent the unit from rolling off the supports.

Never work under or around an elevated unit thatis not properly supported and secured in posi-tion with wheel chocks.

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6 Common Service ProceduresRear Wheel Removal & Installation

6 - 6

Figure 14. Wheel and Axle AssemblyA. Washer E. Hub Cap RetainerB. Spacer F. E-RingC. Wheel G. Hub CapD. Washer H. Key

A

B

C

D

E

F

G

HREAR WHEEL REMOVAL &INSTALLATION1. Remove the key and disconnect the spark plug wire

while working on the unit.


3. Using a jack or chain hoist positioned at the center ofthe rear frame, carefully jack the unit up until the reartires are approximately 1" - 2" off the ground.

NOTE: For overall unit stability during service, do notjack rear end higher than required for wheel removal.

4. Support the rear of the unit on jack stands positionedunder the rear frame.

5. Remove the plastic hub cap (G, Figure 14).

6. Remove e-ring (F, Figure 14) using a screwdriver.

7. Remove the washers (D) and wheel (C).

NOTE: Your axle assembly may differ slightly from theassembly pictured: washer (D, Figure 14) may be miss-ing or doubled. This is adjusted on a tractor by tractorbasis during assembly to allow a small amount of axleend-play.

8. Lubricate the axle shaft with anti-seize compound orlithium grease.

9. See Figure 14 for assembly. Reinstall components inreverse order of disassembly and lower the unit. Besure the key (H) is in place in the axle key-way.

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6 Common Service ProceduresFront Wheel & Wheel Bearing Removal & Installation

Figure 15. Front Wheel Retaining Ring

FRONT WHEEL REMOVAL &INSTALLATION1. Using a flat blade screwdriver, pop off the plastic hub

cap to gain access to the retaining ring.

2. Insert the tip of the flat blade screwdriver into thearea at the open end of the retaining ring, and twistthe blade against the retaining ring to force the retain-ing ring out of the groove (Figure 15).

3. With the retaining ring partially out of the groove,insert the blade tip between the retaining ring andspindle shaft, and pop the retaining ring out of thegroove.

4. Slide the wheel off the spindle shaft (Figure 16). Notethat the tire air valve and axle grease fitting are locat-ed on the inside of the wheel.

5. Wheel bearings are pressed into the wheel hub witha press fit and may be removed by pressing or dri-ving out.

6. Install in reverse order of removal.

Retaining ring

Hubcapretainer

Figure 16. Wheel And Assembly HardwareA. Air Valve D. Hubcap RetainerB. Grease Fitting E. HubcapC. Retaining Ring

AC

B

D

E

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6 Common Service ProceduresBattery Service

6 - 8

Checking Battery VoltageA voltmeter can be used to determine condition of bat-tery. When engine is off, the voltmeter shows batteryvoltage, which should be 12 volts. When engine is run-ning, the voltmeter shows voltage of charging circuitwhich normally is 13 to 14 volts.

A dead battery or one too weak to start the engine maynot mean the battery needs to be replaced. For example,it may mean that the alternator is not charging the bat-tery properly. If there is any doubt about the cause of theproblem, see your dealer. If you need to replace the bat-tery, follow the steps under Cleaning the Battery &Cables in the Regular Maintenance Section.

Charging a Completely Discharged Battery

1. Be aware of all the safety precautions you shouldobserve during the charging operation. If you areunfamiliar with the use of a battery charger andhydrometer, have the battery serviced by your dealer.

2. Add water sufficient to cover the plate (fill to the prop-er level near the end of the charge). If the battery isextremely cold, allow it to warm before adding waterbecause the water level will rise as it warms. Also, anextremely cold battery will not accept a normalcharge until it becomes warm.

3. Always unplug or turn the charger off before attach-ing or removing the clamp connections.

4. Carefully attach the clamps to the battery in properpolarity (usually red to [+] positive and black to [-]negative).

5. While charging, periodically measure the temperatureof the electrolyte. If the temperature exceeds 125° F(51.6° C), or if violent gassing or spewing of elec-trolyte occurs, the charging rate must be reduced ortemporarily halted to prevent battery damage.

WARNINGKeep open flames and sparks away from thebattery; the gasses coming from it are highlyexplosive. Ventilate the battery well duringcharging.

WARNINGDo not attempt to charge a frozen battery. Allowthe battery to warm to 60° F (15.5° C) beforeplacing on charger.

6. Charge the battery until fully charged (i.e. until thespecific gravity of the electrolyte is 1.250 or higherand the electrolyte temperature is at least 60° F). Thebest method of making certain a battery is fullycharged, but not over charged, is to measure thespecific gravity of a cell once per hour. The battery isfully charged when the cells are gassing freely at lowcharging rate and less than 0.003 change in specificgravity occurs over a three hour period.

Jump Starting With an Auxiliary (Booster) BatteryJump starting is not recommended. However, if it mustbe done, follow these directions. Both booster and dis-charged batteries should be treated carefully when usingjumper cables. Follow the steps below EXACTLY, beingcareful not to cause sparks. Refer to Figure 17.

1. Both batteries must be of the same voltage.

2. Position the vehicle with the booster battery adjacentto the vehicle with the discharged battery so thatbooster cables can be connected easily to the batter-ies in both vehicles. Make certain vehicles do nottouch each other.

3. Wear safety glasses and shield eyes and face frombatteries at all times. Be sure vent caps are tight.Place damp cloth over vent caps on both batteries.

4. Connect positive (+) cable to positive post of dis-charged battery (wired to starter or solenoid).

5. Connect the other end of same cable to same postmarked positive (+) on booster battery.

6. Connect the second cable negative (-) to other postof booster battery.

7. Make final connection on engine block of stalled vehi-cle away from battery. Do not lean over batteries.

8. Start the engine of the vehicle with the booster bat-tery. Wait a few minutes, then attempt to start theengine of the vehicle with the discharged battery.

9. If the vehicle does not start after cranking for thirtyseconds, STOP PROCEDURE. More than thirty sec-onds seldom starts the engine unless some mechani-cal adjustment is made.

10. After starting, allow the engine to return to idle speed.Remove the cable connection at the engine or frame.Then remove the other end of the same cable fromthe booster battery.

11. Remove the other cable by disconnecting at the dis-charged battery first and then disconnect the oppo-site end from the booster battery.

12. Discard the damp cloths that were placed over thebattery vent caps.

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6 Common Service ProceduresBattery Service

Figure 17. Battery Jump Starting Diagram

WARNINGAny procedure other than the preceding couldresult in:(1) personal injury caused by electrolyte squirtingout the battery vents, (2) personal injury or property damage due tobattery explosion, (3) damage to the charging system of the boostervehicle or of the immobilized vehicle.Do not attempt to jump start a vehicle having afrozen battery because the battery may rupture orexplode. If a frozen battery is suspected, examineall fill vents on the battery. If ice can be seen or ifthe electrolyte fluid cannot be seen, do notattempt to start with jumper cables as long as thebattery remains frozen.

WARNINGFor your personal safety, use extreme care whenjump starting. Never expose battery to open flameor electric spark – battery action generateshydrogen gas which is flammable and explosive.Do not allow battery acid to contact skin, eyes,fabrics, or painted surfaces. Batteries contain asulfuric acid solution which can cause seriouspersonal injury or property damage.When removing or installing battery cables,disconnect the negative cable FIRST andreconnect it LAST. If not done in this order, thepositive terminal can be shorted to the frame by atool.To avoid engine damage, do not disconnectbattery while engine is running. Be sure terminalconnections are tight before starting.

To StarterSwitch

StartingVehicleBattery

To Ground

To Starter Switch

DischargedVehicle Battery

EngineBlock

THIS HOOK-UP FOR NEGATIVE GROUND VEHICLES

MAKE CERTAIN VEHICLES DO NOT TOUCH

Jumper Cable

Jumper Cable

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6 Common Service ProceduresBurnishing the Electric PTO Clutch

6 - 10

FRONT

BATTERY REMOVAL & INSTALLATIONRemoving the Battery

1. Open the tractor hood by unlatching the rubber straphold-downs (A, Figure 18). Raise the hood.

2. The battery is shipped in the rear section of theengine compartment. Remove the hold-down rods(C) and hold-down bar.

3. Remove the battery from the compartment.

Installing the Battery

1. Carefully place the battery back in the engine com-partment (see Figure 18). Secure the battery usingthe hold-down rods (C) and hold-down bar.

2. Attach the red positive cable (B, Figure 19) and coverto the positive post as shown.

3. Attach the black negative cable (A, Figure 19) to thenegative post as shown.

4. Install the vent hose on the battery cap and route thehoses out of the bottom right side of the engine com-partment through the frame. Make sure the tubes goall the way through the frame and will not drip on anybelts, pulleys, or the mower deck. NOTE:Maintenance free batteries do not have a vent tube.

C

B

AD

C

Figure 19. Battery Cables & FillA. Negative CableB. Positive Cable & CoverC. Nut, Lockwasher, & WasherD. Capscrew

Figure 18. Engine Compartment Briggs & Stratton ShownA. Hood Strap C. Hold-Down RodsB. Vent Cap

AB

C

WARNINGWhen installing battery cables, CONNECT THEPOSITIVE (+) CABLE FIRST and negative (-) cablelast. If not done in this order, the positiveterminal can be shorted to the frame by a tool.

WARNINGWhen removing battery cables, DISCONNECTTHE NEGATIVE (-) CABLE FIRST and positive (+)cable last. If not done in this order, the positiveterminal can be shorted to the frame by a tool.

BURNISHING THE ELECTRIC PTOCLUTCHThis procedure should be performed on new units or ifthe PTO clutch has been replaced.

1. Select a safe area to operate the mower deck. Withthe drive in neutral, the PTO switch disengaged, andan operator in the seat, start the tractor engine. Runthe engine at full throttle.

2. Engage the PTO switch and run the deck for fifteenseconds. Disengage the PTO switch and wait for themower drive belt to stop.

3. Repeat step 2 above ten times, and then re-checkthe mower blade stopping time. (Stopping time mustbe five seconds or less.)

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7 Electrical System ServiceTable of Contents

GENERAL INFORMATIONSection Contents ......................................................................... 7-2System Description.......................................................................7-2Principles of Operation ................................................................ 7-3Safety Interlock System ............................................................... 7-3Checking Out the System ............................................................ 7-3Model Variation Notes ................................................................. 7-3

EXPLODED VIEW DIAGRAMSExploded View Diagrams..............................................................7-4

IGNITION SWITCH SERVICE BULLETINBulletin ..........................................................................................7-8

LINEAR DIAGRAMSLinear Circuit Diagrams ................................................................7-9

COMMON “NO START” CIRCUIT TESTSCranking Circuit Test ..................................................................7-12Safety Shut Down Test ...............................................................7-14

COMPONENT LOCATION AND REPLACEMENTComponent Location & Replacement .........................................7-16

TROUBLESHOOTINGTroubleshooting Flow Charts..................................................... 7-20

COMPONENT TESTSGeneral Testing Information .......................................................7-24A. Check/Clean Wires and Connectors .....................................7-24B. Check/Clean Ground Cable...................................................7-24C. Battery Tests .........................................................................7-25D. Isolated Battery Voltage Check .............................................7-26E. Charging Voltage Check........................................................7-26F. Interlock Module ....................................................................7-26G. Ignition Switch Tests..............................................................7-26H. Test Solenoid.........................................................................7-28I. Solenoid Bench Test .............................................................7-28J. PTO Switch Test....................................................................7-30K. Cruise Control Switch Test ....................................................7-31L. Brake Pedal Switch Tests......................................................7-31M. Seat Switch Safety Interlock Test..........................................7-32N. Seat Switch Test....................................................................7-32O. Circuit Breaker Test...............................................................7-33P. PTO Clutch ...........................................................................7-33Q. Headlight Switch Test............................................................7-33R. Fuel Solenoid Test.................................................................7-33S. Voltage Regulator .................................................................7-33T. Alternator ..............................................................................7-33 SE

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7 Electrical System ServiceGeneral Information

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GENERAL INFORMATIONThe electrical system is a 12-volt, negative ground type.Power for the lights and all electrical accessories is sup-plied by a lead/acid-type battery which is charged by thealternator.

This section covers the location, replacement, trou-bleshooting, and testing procedures for the various elec-trical components that are not associated with theengine. Information on the engine, alternator, ignitionsystem, and starter can be found in the engine manufac-turer’s instructions.

It should be noted that when portions of the electricalsystem are serviced, the negative battery cable shouldbe disconnected from the battery to prevent electricalshorts and/or fires.

Section ContentsSection 7 contains the following sub-sections:

General Information – General overview of the electricalsystem, principles of operation, and definitions of basicelectrical terms.

Exploded View Diagrams – Three-dimensional illustra-tions of the electrical system components.

Wiring Diagrams – Schematics of the electrical system.

Linear Circuit Diagrams – Linear diagrams showingelectrical current path with the ignition switch in its threepositions.

Common “No Start” Circuit Tests – Linear diagramsand procedures for troubleshooting a tractor that won’tstart.

Component Location and Replacement – Location ofelectrical components and explanations of how toremove and replace them.

Troubleshooting Flow Charts – Checklist of componenttests to solve common electrical problems. Includes ref-erences to specific component test procedures.

Component Tests – Testing procedures for specificcomponents.

IntroductionBefore tackling any troublesome electrical circuit, firststudy the appropriate wiring diagrams to get a completeunderstanding of what makes up that individual circuit.Malfunctions can often be narrowed down by noting if


other components, related to the circuit, are operatingproperly. If several components malfunction at the sametime, chances are the problem is in the fuse/breaker,common splice, or ground connection that is common toall the malfunctioning components.

Electrical problems usually stem from simple causes,such as loose or corroded connections, a blown fuse, atripped circuit breaker, or a bad relay. Visually inspectthe condition of all fuses, wires, and connections in asuspected problem circuit before troubleshooting it.

Note: If testing instruments are going to be utilized, studythe diagrams ahead of time to plan where the necessaryconnections will be made in order to accurately pinpointthe trouble spot.

Before attempting to locate a problem with test instru-ments, use the wiring diagram(s) to decide where tomake the connections.

TYPICAL TOOLS NEEDED

• VOM (volt-ohm meter, multi-meter, or equivalent).• Test Light (circuit tester or continuity tester).• Jumper wires with alligator clips at both ends.• Power Supply (variable or 12VDC) or 12VDC Battery.• Hydrometer.• Wire Brush or Battery Terminal Brush.• Clean Pencil Eraser.• Standard Wrench Set.• Standard Socket Set.• Screwdriver Set.

System Description All Broadmoor / 1600 / 2600 Series tractors have threebasic electrical circuits that represent the different electri-cal functions of the tractor’s electrical system. Eachfunction corresponds to the three positions of the ignitionswitch: “START,” “ON,” and “OFF.”

• START sends battery power to two sub-circuits:

1) Sends power through the safety switches (PTO,foot pedal, PTO, and seat switches) to the #3 termi-nal of the interlock module. If all safety switches areclosed, the interlock module activates the solenoidsending power to the starter.

2) Sends power to the #7 terminal of the interlock mod-ule (activating the module) and fuel solenoid (openingthe fuel solenoid).

• RUN connects battery power to two sub-circuits:

1) Connects the alternator to the battery through theignition switch. The alternator coil feeds power backinto the battery for recharging.

2) Sends power to the fuel solenoid and PTO clutchcircuit.

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• OFF grounds the engine ignition coil through the igni-tion switch, preventing ignition system sparking. Thesafety interlock module can also ground the ignitioncoil through the #5 and #4 terminals.

Principles of Operation IGNITION SHUTDOWN SYSTEM

When the ignition switch is in the “START” or “RUN” posi-tion, the ignition circuit is open, allowing the engine torun.

When the ignition switch is turned to “OFF,” the engine isshut off by grounding the ignition coil.

CHARGING SYSTEM

While the engine is running, current flows from the alter-nator to the positive battery post and charges the battery.

CRANKING SYSTEM

The cranking system is composed of the ignition switch,the safety interlock switches, the PTO switch, thesolenoid, and the interlock module.

Cranking system current path:1. Current travels from the battery through the circuit

breaker, through the ignition switch, through the sole-noid, through the safety switches to the interlock mod-ule. A second wire connects the solenoid to the #1post of the inter lock module. If the safety switchesare closed, the module grounds the solenoid, crankingthe starter.

Safety Interlock SystemThe safety system is controlled by the interlock module.The safety switches are used to trigger the module.

Operator Present Sub-SystemThe operator present sub-system is designed to protectthe operator from injury if the operator would leave theseat.

1. Engine should shut off when the operator risesoff the seat if ANY of the following conditionsexist:A. Brake pedal is not depressed.B. PTO clutch switch is engaged.

2. Engine should remain on when the operator risesoff the seat ONLY if ALL of the following condi-tions are met:A. Brake pedal is fully depressed (or parking brake

set).B. Electric clutch switch disengaged.

7 Electrical System ServiceGeneral Information

Safety Starting Sub-SystemThe safety starting sub-system will prevent the enginefrom cranking if any of the following conditions exist.

1. Engine should NOT crank if ANY of the followingconditions exist:

A. PTO clutch switch is engaged.B. Brake pedal is not depressed.C. The operator is out of the seat.

2. Engine should crank ONLY if ALL of the followingconditions are met:

A. Electric clutch switch disengaged.B. Brake pedal is fully depressed (or parking

brake set).C. The operator is in the seat.

Checking Out the System BASIC ELECTRICAL TERMS

“Ground” is the negative battery post or any other con-ductive part of the frame. For best results, use the nega-tive battery post as ground.

“VOM” is a volt-ohm meter, multi-meter, or equivalent.

“VDC” is volts of direct current or the VOM setting usedto measure DC voltage.

“Ohm” is units of resistance or the VOM setting used tomeasure resistance.

“Continuity” is a continuous, unbroken circuit. In thismanual continuity is determined with a VOM set to mea-sure ohm. Zero ohm is true continuity. However, due tocontact point corrosion and resistance within wires, conti-nuity may measure a few ohm.

“No Continuity” is a broken circuit. In this manual nocontinuity is determined with a VOM set to measureohm. No continuity will register as infinite ohm.

“Battery Voltage” is the approximate voltage output ofthe battery. Keep in mind that “battery voltage” tested atany component will be slightly lower than “battery voltage”tested at the battery terminals due to resistance withinconnections and wires.

Model Variation NotesWIRE HARNESSES & IGNITION SWITCHES

Several different wiring harnesses and ignition switcheshave been used in the foot-controlled Broadmoor Series:early models used a two-piece main harness, later mod-els used a one piece main harness, six pin and five pinignition switches have both been used (see appropriateparts manual for specific information).

HOWEVER, all Broadmoor / 1600 / 2600 series electricalsystems use the same interlock module and function thesame.

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7 Electrical System ServiceExploded View Diagrams

7 - 4

Electrical - Lower Harness

Figure 1. Exploded View Diagram – Lower Wiring Harness

To Engine Ground Bolt.

See Engine Group

To Upper Harness

Grommet - See Engine Group

Briggs & Stratton Models Only

Briggs & Stratton Models Only

To Electric Clutch

To Engine Fuel Shut-Off Solenoid, Briggs & Stratton Models Only

To Oil Pressure Sending Unit, Briggs & Stratton Models Only

To Engine Harness Plug, Kohler Models Only

8

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1 1 HEADLIGHT ASSY. (Incl. Ref. Nos. 2, 3, 4, 5 & 6) 2 1 LENS, Headlight3 2 BULB, Headlight, 12.8V4 1 BEZEL, Headlight5 2 HEAT SHIELD6 2 SOCKET, Bulb7 1 WIRE ASSY., Headlight8 1 SWITCH, Seat, Operator Present9 2 BUSHING, Snap, Small

10 1 BUSHING, Snap, Large (Kohler Models Only)11 2 CABLE TIE12 1 WIRE ASSY., Seat Switch*13 1 WIRE HARNESS, Lower (Early Briggs & Stratton Models - See Footnote)13 1 WIRE HARNESS, Lower (Kohler Models)*13 1 WIRE HARNESS, Lower (Later Briggs & Stratton Models - See Footnote)14 1 WIRE ASSY., Engine Ground

Electrical - Lower Harness

REF NO. QTY. DESCRIPTION

Footnotes:

* Briggs & Stratton Model Wire Harness Note: The Briggs & Stratton models listed below use lower wire har-ness 1704377. All other Briggs & Stratton Models use lower wire harness 1718308.

1693052 S/N 00001-4961693056 S/N 00001-011691693058 S/N 00001-741693060 S/N 00001-1169

1693062 S/N 00001-2241693066 S/N 00001-511693068 S/N 00001-261693072 S/N 00001-28

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7 - 6

Electrical - Upper Harness

Figure 2. Exploded View Diagram – Upper Wiring Harness

1

23

37

555

45

4

67

1

8

9

10

12

13

14

15

16

11

17

18

1419

20

36

3536

3534

33

32

27

26

24

28

2121

1

2229

30

23311

To Lower Harness

25

38 39

24

See Footnote

Below Part List

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1 7 CAPSCREW, Plastite, #8-16 x 1/22 1 HOURMETER3 1 INTERLOCK SWITCH, Cruise/Parking Brake4 1 SWITCH, Headlight5 5 BULB, Indicator Light 6 1 STRAP, Wire Retainer7 1 BOOT, Insulator8 1 BATTERY9 1 TRAY, Battery

10 2 NUT, Plastic, 1/4-2011 1 CABLE, Battery to Ground12 1 HOSE, Battery, Drain13 2 CAPSCREW, Hex Hd, 1/4-20 x 3/414 4 WASHER, Plain, 1/415 2 LOCKWASHER, 1/416 2 NUT, Hex, 1/4-20 UNC17 1 HOLD DOWN, Battery18 2 ROD, Battery Hold Down19 1 COVER, Terminal20 1 CABLE, Solenoid to Starter21* 1 WIRE HARNESS, Main (Early Briggs & Stratton Models - See Footnote)21 1 WIRE HARNESS, Main (Kohler Models)21* 1 WIRE HARNESS, Main (Later Briggs & Stratton Models - See Footnote)22 1 SWITCH, PTO Electric Clutch23 1 CIRCUIT BREAKER24* 1 IGNITION SWITCH, 5-Pin Plastic Body (Early Briggs Models - See Footnote)24* 1 IGNITION SWITCH, 6-Pin, Plastic Body (Kohler Models and Later Briggs & Stratton Models -

See Footnote)25 1 WIRE ASSY, Lock Light (All Briggs & Stratton Models)26 1 NUT, Flange27 2 KEY, Ignition28 1 MODULE29 1 SWITCH, Interlock, Clutch/Brake Pedal30 1 WIRE ASSY.31 1 WIRE ASSY.32 1 SOLENOID33 2 CAPSCREW, Hex Washer Hd, Plastite, 1/4-20 x 1/234 1 CABLE, Battery to Solenoid35 2 LOCKWASHER, 5/1636 2 NUT, Hex, 5/16-2437 2 CAPSCREW, Taptite, #5-40 x 3/438 2 LOCKWASHER, 1/839 2 NUT, Machine Screw, #5-40

Electrical - Upper Harness


Footnotes:

* Briggs & Stratton Model Ignition Switch Note: The Briggs & Stratton models listed below use 5-pin plasticignition switch 1713845 and main wire harness 1715805. All other Briggs & Stratton Models use 6-pin plasticignition switch 1718305 & main wire harness 1718307.

1693052 S/N 00001-4961693056 S/N 00001-011691693058 S/N 00001-741693060 S/N 00001-1169

1693062 S/N 00001-2241693066 S/N 00001-511693068 S/N 00001-261693072 S/N 00001-28

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7 Electrical System ServiceWiring Diagram

7 - 8

TOPIC: REPLACING PLASTIC BODIED IGNITION SWITCHESMODELS AFFECTED: Products Using Plastic Body Ignition Switches

M A N U F A C T U R I N G ,I N C .

Service Bulletin99-7

Field reports indicate failures of plastic ignition switches. To correct these failures, replace plastic ignition switcheswith a metal switch kit 1686734. Switch kit 1686734 is a direct replacement for most 5-pin, and 6-pin metal and plas-tic bodied switches. NOTE: If equipped with 6-Pin, plastic bodied ignition switch 1718305 requires the tractor harnessto be rewired. See the following instructions for switch identification and rewiring instructions. NOTE: Ignition key for kit 1686734 is P/N 1717163.

WARNINGBefore beginning any service work turn off thePTO, set the parking brake, turn off the ignition,and disconnect the spark plug wire(s). Alsodisconnect the negative battery cable.

S

L

M

BG A

Figure 2. Label Wires & Remove from Harness

S

B

G

LM

Figure 3. Reinstall Wires Into Harness Connector

A

NOTICENOTE: 5-Pin switches do not use the “A” terminal. Inthose applications leave the boot on the “A” terminal.

Kit 1686734 is a direct replacement for several metalignition switches and requires no modification of thetractor’s wire harness.

This kit is also a direct replacement for several plasticignition switches with the following exception:

If kit 1686734 is used to replace 6-pin plastic ignitionswitch 1718305, the tractor ignition switch plug must berewired. Use the procedure below to identify your switchand, if necessary, to rewire the tractor harness.

Identify 1718305 SwitchThe 1718305 is a 6-pin, plastic bodied switch that can beidentified by the letters stamped into the switch bodynext to the terminals. If the terminal labels of yourignition switch match those in Figure 1, use the followingprocedure to rewire the tractor wire harness.

Rewire Ignition Switch Plug1. Remove the 5-pin main plug and single plug from the

back of the ignition switch.

2. Label the plug wires of the 5-pin plug as shown inFigure 2.

3. Using a small screwdriver, remove the wires from theplastic harness plug.

A S

G LMB

Figure 1. 1718305 Switch Terminal Marks

4. Reinstall the wires back into the plug in the positionsshown in Figure 3.

5. Install the new ignition switch and reconnect the mod-ified 5-pin main plug, and single plug.

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IGN

ITIO

NS

WIT

CH

1716

061

S

MB

L

A

G

BLACK BLACK BLACK BLACK

BLACK

BLA

CK

BLA

CK

BLA

CK

BLA

CK

BLA

CK

BLA

CK

BLA

CK

BLA

CK

BLA

CK

TAN

/BLA

CK

BLA

CK

BLA

CK

TAN

TAN

BLACK

BLACK/YELLOW

BLA

CK

BLACK BLACK

BLU

E

BLU

E

BLUE BLUE

BLUE

BLUE

BLUE

BLUE

BLUE

BLUE

BLUE

BLUE

BLUE

BLUE

BLUE

BLUE

BLU

E

BLU

EB

LUE

BLU

E

BLU

E

BLU

E

BLU

EB

LUE

BLU

E

BLU

E

BLU

EB

LUE

BLU

E

BLU

EB

LUE

BLU

E

BLU

EB

LUE

GR

EE

N/W

HIT

EG

RE

EN

/WH

ITE

GR

EE

N/W

HIT

E

BLU

E

BLU

EBLUE

BLACK

BLACK

BLACK

BLACK/YELLOW

BLACK

BLACK/YELLOW

BLUE

BLUE

BLU

E

BLU

EB

LUE

BLU

EB

LUE

BLU

E

BLU

E

PU

RP

LE/W

HIT

E

PURPLE/WHITE

RE

D

RE

DR

ED

RE

D

RE

D

RED

RED

RED

PU

RP

LE/W

HIT

EP

UR

PLE

/WH

ITE

PURPLE/WHITE

RE

D/W

HIT

E

RE

D/W

HIT

ER

ED

/WH

ITE

RED/WHITE

BLU

E/W

HIT

EB

LUE

/WH

ITE

BA

TT

ER

Y16

8521

5

CIR

CU

IT B

RE

AK

ER

1665

238

SO

LE

NO

ID16

8529

0B S

BLA

CK

GR

EE

N/B

LAC

K

GREEN/BLACK

GREEN/BLACK

BLACK/YELLOW

BLUE/WHITE

GREEN/WHITE

GR

EE

N/W

HIT

EG

RE

EN

/WH

ITE

GREEN/WHITE GREEN/WHITE

GREEN/WHITE

GR

EE

N/W

HIT

E

HE

AD

LIG

HT

S

STA

RT

ER

FU

EL

SH

UTO

FF

OIL

PR

ES

SU

RE

EN

GIN

E P

LU

G(K

OH

LE

R)

ALT

ER

NA

TOR

MA

GN

ETO

BR

IGG

S M

OD

EL

S

GR

AYG

RAY

GR

AYG

RAY

BLU

E

BLU

EB

LUE

BLUE

BLUE

BLUE/WHITE

PURPLE

PURPLE PURPLE PURPLE

PURPLE PURPLE

PU

RP

LEP

UR

PLE

PURPLE

PU

RP

LE

PU

RP

LEP

UR

PLE

PU

RP

LEP

UR

PLE

PU

RP

LEP

UR

PLE

PU

RP

LE

WHITE

WH

ITE

WHITE

WH

ITE

WH

ITE

WH

ITE

WH

ITE

WH

ITE

WH

ITE

WH

ITE

WH

ITE

WH

ITE

WH

ITE

WH

ITE

WH

ITE

WHITE

WHITE

WHITE WHITE

WHITE

WH

ITE

PTO

SW

ITC

H (

OF

F)

1716

332

LO

CK

SW

ITC

H16

6558

6

CR

UIS

EU

NLO

CK

ED

PTO

DIS

EN

GA

GE

D

YE

LLO

W

YELLOW

YE

LLO

W

OR

AN

GE

ORANGE

OR

AN

GE

/BLA

CK

ORANGE

PTO

LIG

HT

OIL

LIG

HT

N.O

. N.O

.

N.O

.N

.C.

N.O

.

(BA

CK

VIE

WO

F S

WIT

CH

)

LO

CK

LIG

HT

SE

AT

LIG

HT

HE

AD

LIG

HT

LIG

HT

FO

OT

SW

ITC

H17

2041

1

PE

DA

L U

P

A

C

B

87

65

12

34

LIG

HT

S O

FF

HO

UR

ME

TE

R17

1898

2

HE

AD

LIG

HT

SW

ITC

H17

0379

9

DC

LU

TC

H17

1766

4

SE

AT

SW

ITC

H17

0437

9IN

TE

RL

OC

K M

OD

UL

E17

0397

2

UN

OC

CU

PIE

D

IGN

ITIO

N S

WIT

CH

PO

SIT

ION

1. O

FF

2. R

UN

3. S

TAR

T

CIR

CU

IT M

AK

EG

& M

& A

B &

L &

AB

& L

& S

7 - 9

7 Electrical System ServiceLinear Diagrams

Wiring Diagram Note: Several different wiring harness-es and ignition switches have been used in the foot-con-trolled Broadmoor Series: early models used a two-piecemain harness, later models used a one piece main har-ness, six pin and five pin ignition switches have bothbeen used (see appropriate parts manual for specificinformation).

HOWEVER, all Broadmoor / 1600 / 2600 series electricalsystems use the same interlock module and function thesame.

Figure 3. Wiring Diagram

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7 Electrical System ServiceLinear Diagrams

7 - 10

CRANKING CIRCUIT

The cranking circuit is only active when the ignition keyswitch is in the start position.

Power is supplied through the circuit breaker to the B ter-minal of the ignition switch. When the switch is turned tothe start position, contacts are closed between the B - Lterminals and B - S terminals of the ignition switch.

SOLENOID

B

S

8 7 6 5

1 2 3 4

N.O.

SEAT SWITCH (UNOCCUPIED)

BATTERY

CIRCUITBREAKER

PTO SWITCH(OFF POSITION)

N.O.

N.O. or N.C.

N.C .

PEDAL SWITCH (w/ PEDAL UP)

N.O.

KEY SWITCH(START POSITION)

A M

LG

B S

FUEL SOLENOID

ACCESORIES

"D" SPLICE

Figure 4. Cranking Circuit Linear Diagram

The B - S connection applies power to the starter sole-noid, safety switches, and #3 terminal of the interlockmodule. If all controls are disengaged the safety switch-es allow current to pass through to the #3 terminal of themodule grounding the solenoid, activating the starter.

The B - L connection supplies power to activate the mod-ule and power the accessories.

LINEAR CIRCUIT DIAGRAMS

N.O.

SEAT SWITCH (UNOCCUPIED)BATTERY

CIRCUITBREAKER

A

M

L

G

B

S PTO SWITCH(OFF POSITION)

N.O.

N.O.

N.C .

KEY SWITCH(RUN POSITION)

8 7 6 5

1 2 3 4

ELECTRIC PTOCLUTCH

ALTERNATOR

Figure 5. PTO Circuit Linear Diagram

RUN POSITION

When the key is turned to the RUN position (after theengine has started) the battery, alternator, fuel solenoid,head lights, and PTO clutch are connected through thekey switch.

This multiple splice supplies alternator power to the bat-tery for charging and to the rest of the tractor electricalsystem to run the accessories and PTO clutch.

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7 - 11

7 Electrical System ServiceIgnition Switch Service Bulletin

KEY SWITCH(OFF POSITION)

AM

LG

B

S

INTERLOCKMODUEL

MAGNETO

8 7 6 5

1 2 3 4

ALTERNATOR

Figure 6. Ignition Shutdown Linear Circuit Diagram

IGNITION SHUTDOWN CIRCUIT

See Figure 8.

Ignition shutdown occurs when the ignition key switch isturned to the “OFF” position or the safety system kills theengine.

The key switch grounds the magneto through the “M” to“G” connection.

The interlock module can also ground the magnetothrough a #5 to #4 connection

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7 Electrical System ServiceCommon Circuit Tests

7 - 12

SOLENOID

B

S

8 7 6 5

1 2 3 4

N.O.

SEAT SWITCH (OCCUPIED)BATTERY

CIRCUITBREAKER


N.O.

N.O. or N.C.

N.C .

PEDAL SWITCH (w/ PEDAL DOWN)

N.O.


A M

LG

B S

"D" SPLICE

ALTERNATOR

A

E F G

J

K

HI

B

C

D

Figure 7. Cranking Circuit Linear Diagram

COMMON “NO START” CIRCUIT TESTSCranking Circuit Test

Perform the following tests if the starter will not crank theengine. The procedure below uses a VOM to show volt-age at specific switches. If a switch is not transmittingvoltage across itself, it is defective and should bereplaced.

Test Instrument: VOM set to VDC.Control positions:Brake Pedal - Depressed (parking brake set)PTO Switch - OFFSeat - OccupiedIgnition Switch - Start PositionBattery: Both terminals connected.Safety: Disconnect the lead from starter to prevent acci-dental cranking. Secure away from the frame.Procedure:

NOTE: Do not disconnect any of the switches or compo-nents being tested. Probe connectors from the back, orpartially remove the connecter to probe the componentterminals.

1. Disconnect the lead from the starter motor andsecure away from the frame.

2. Connect the negative terminal of the VOM to the neg-ative battery terminal.

3. Set the controls in the positions listed above.

4. Probe both sides of the circuit breaker (A, Figures 7& 8). There should be current at both terminals.

5. Probe the L and S terminals of the key switch con-nector (B, C). There should be current at both termi-nals.

6. Check for current at both of the small terminals of thesolenoid (D).

7. Check for current at the foot pedal switch (E).

8. Check for current at the normally closed terminals ofthe PTO switch (F).

9. Check for current at both seat switch terminals (G).

10. Check for current at the #1 and #7 terminal of theinterlock module (J). The #1 and #7 terminal mustreceive power for the module to activate.

11. Check for current at the #3 (H) terminal of the inter-lock module. A lack of current here means that thewire connecting the #3 terminal and the seat switch isbroken.

12. Check for current at the #4 (I) terminal. If current ispresent, the #4 grounding wire is defective. If no cur-rent is present replace the module.

13. If current is detected at all specified locations, theproblem lies in one of the areas listed below. SeeCOMPONENT TESTS for specific testing proce-dures:

* Defective Solenoid

• Defective Starter

• Defective Interlock Module

• Bad/Intermittent Ground

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7 - 13


A

F

J

H

KI

D

B

S

L

B

C

Figure 8. Electrical Component Locations

E

G

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7 - 14

SOLENOID

B

S

8 7 6 5

1 2 3 4

N.O.

SEAT SWITCH (OCCUPIED)BATTERY

CIRCUITBREAKER


N.O.

N.O. or N.C.

N.C .

PEDAL SWITCH (w/ PEDAL DOWN)

N.O.


A M

LG

B S

"D" SPLICE

ALTERNATOR

MAGNETO

A

E F G

J L

K

HI

B

C

D

Figure 9. Safety Shutdown Circuit Linear Diagram

Safety Shut Down TestPerform the following tests if the engine will not run withthe key switch in the run position, or if the safety kill sys-tem is malfunctioning.

NOTE: The logic of the interlock module allows the sameswitches used for the cranking circuit to serve the safetycircuit as well. Therefore, if the engine turns over, it islikely that the module is faulty or a wire is broken.

The procedure below uses a VOM to show voltage atspecific switches. If a switch is not transmitting voltageacross itself, it is defective and should be replaced.

Test Instrument: VOM set to VDC.Control positions:Brake Pedal - Depressed (parking brake set)PTO Switch - OFFSeat - OccupiedIgnition Switch - Start Position/Run PositionBattery: Both terminals connected.Safety: Disconnect the lead from starter to prevent acci-dental cranking. Secure away from the frame.Procedure:

NOTE: Do not disconnect any of the switches or compo-nents being tested unless instruction to do so. Probeconnectors from the back, or partially remove the con-necter to probe the component terminals.

SAFETY SWITCH TESTS

1. Disconnect the lead from the starter motor andsecure away from the frame.

2. Connect the negative terminal of the VOM to the neg-ative battery terminal.

3. Set the controls in the positions listed above.

4. Probe both sides of the circuit breaker (A, Figure 9 &10). There should be current at both terminals.

5. Probe the L and S terminals of the key switch con-nector (B, C). There should be current at both termi-nals.

6. Check for current at both of the small terminals of thesolenoid (D).

7. Check for current at the foot pedal switch (E).

8. Check for current at the normally closed terminals ofthe PTO switch (F).

9. Check for current at both seat switch terminals.

10. Check for current at the #7 terminal of the interlockmodule (J). The #7 terminal must receive power forthe module to activate.

11. Check for current at the #3 (H) terminal of the inter-lock module. A lack of current here means that thewire connecting the #3 terminal and the seat switch isbroken.

12. Check for current at the #4 terminal. If current is pre-sent, the #4 grounding wire is defective. If no currentis present replace the module.

Proceed to next page

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7 - 15


A

F

J

H

KI

D

B

S

L

B

C

Figure 10. Electrical Component Locations

E

G

MAGNETO KILL CIRCUIT TESTS

13. Set the VOM to Ohms (checking continuity). Turn thekey switch to RUN. Disconnect the wire harnessfrom the interlock module.

14. Connect the negative probe to ground.

15. Probe the #5 plug (L). The VOM should show nocontinuity. If the VOM shows continuity, the coil isbeing shorted to ground through a broken wire or thekey switch.

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7 - 16

7 Electrical System ServiceLocation and Replacement

COMPONENT LOCATION ANDREPLACEMENT

Figure 11. Dashboard ComponentsA. Headlight Switch C. PTO SwitchB. Ignition Key Switch D. Cruise Control Switch

(Inside Dashboard)

HEADLIGHT SWITCH

The headlight switch (A, Figure 11) is located in thedashboard on the left-hand side.

1. Disconnect and secure the negative battery cable,(see Section 6, COMMON SERVICE PROCE-DURES).

2. Unplug the wire harness (B, Figure 12) from the backof the switch (C).

3. From behind the dashboard, push in the locking tabs(D) and remove the switch as shown.

NOTE: Be careful to not press on the tabs that hold thecontact block to the switch rocker. The parts in the con-tact block are very small and could get lost if separated.

4. Install headlight switch in reverse order of removal.

Figure 12. Headlight Switch ReplacementA Dashboard C. Headlight SwitchB. Wire Harness D. Locking Tabs

B

3. Unplug the wire harness (B) from the back of the igni-tion key switch (C).

4. Remove the cap (F) using a screwdriver or pliers.

5. Remove the key switch nut (E) from the switch.

6. Remove the switch (C) from the back of the dash-board (A).

7. Reinstall ignition key switch in reverse order ofremoval.

C

CA

C

B

A

Figure 13. Ignition Key Switch ReplacementA Dashboard E. Key Switch NutB. Wire Harness F. CapC. Ignition Key Switch G. KeysD. Washer

G

A

AF

E

C

D

CB

NOTE: Most repairs do not require the dashboard to beremoved for component replacement or service. If it isrequired, refer to appropriate section for dashboard ser-vice.

D

D

IGNITION KEY SWITCH

The ignition key switch is located in the dashboard onthe right-hand side of the steering wheel.

1. Remove the key (G, Figure 13) from the switch if notalready done so.


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7 - 17


Figure 15. Seat Switch Safety SystemA. Seat Switch C. SeatB. Wire Harness

B

SEAT SWITCH


2. Tip the seat deck forward to access the bottom of theseat assembly.

3. Disconnect the wire harness (B, Figure 15) from theseat switch (A).

4. Remove the spring cover (A, Figure 16).

5. Remove the nut (B), washer (C), and spring (D).

6. Remove the seat switch from the switch mountingplate (E).

7. Install seat switch in reverse order of removal.

A

C

Figure 16. Seat Switch RemovalA. Spring Cover D. SpringB. Nut E. Switch Mounting PlateC. Washer

A

B

C

D

E

Figure 14. PTO Switch ReplacementA Dashboard C. PTO SwitchB. Wire Harness D. Locking Tabs

A

PTO SWITCH

The PTO switch (C, Figure 14) is located in thedashboard (A) on the right-hand side of the steeringwheel.


2. Unplug the wire harness (B, Figure 14) from the backof the switch (C).

3. From behind the dashboard, push in the locking tabs(D) and remove the switch as shown in Figure 14.

4. Install PTO switch in reverse order of removal.

B

A

C

C

D

D

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7 - 18

PTO CLUTCHFor replacement procedure, see PTO CLUTCH SER-VICE section.

BRAKE PEDAL SWITCHThe brake pedal switch is located under right side offrame, next to the pedal.1. Disconnect and secure the negative battery cable,

(see Section 6, COMMON SERVICE PROCE-DURES).

2. Elevate the front of the unit. (See Section 6, COM-MON SERVICE PROCEDURES, Elevating Front Endfor Safe Service.)

3. Label and disconnect the wire harness.

4. Squeeze the tabs on the side of the switch (A, Figure17) and push the switch up into the fame.

5. Install switch in reverse order of removal.

Figure 17. Brake Pedal SwitchA. Brake Pedal Switch

A

Figure 18. Circuit Breaker ReplacementA. Circuit BreakerB. Wires

CIRCUIT BREAKER

The circuit breaker (A, Figure 18) is located on theunderside of the dashboard.


2. Disconnect the wires (B) from the circuit breaker ter-minals.

3. Remove the screw securing the body of the circuitbreaker to the dashboard and remove the circuitbreaker.

4. Install circuit breaker in reverse order of removal.

NOTE: The circuit breaker posts are marked “BAT” and“AUX.” The BAT post should be connected to the batteryvia the solenoid. The AUX post should be connected tothe ignition switch.

AB

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7 - 19


INTERLOCK MODULEThe safety interlock module (A, Figure 19) is located onthe underside of the dashboard.1. Disconnect and secure the negative battery cable,


2. Label and disconnect the wire harness.

3. Remove the plastite screws (B) securing the module(A) to the underside of the dashboard.

4. Replace the module in the same orientation as theoriginal and install in reverse order.

VOLTAGE REGULATOR

The voltage regulator is installed on the engine as acomplete unit.

Refer to the engine manufacturer’s manual for specificinformation regarding engine component testing andreplacement.

IGNITION COIL (MAGNETO)


OIL PRESSURE SENSOR

All models contain an oil pressure sensor (sender) whichis located on the engine.


ALTERNATOR

All models contain an alternator to charge the batteryand supply the tractor with electrical energy during oper-ation.


To determine if the charging function of the alternator isoperating correctly, a basic check can be performed.Refer to the Battery Charging Voltage Test in this sec-tion.

Figure 19. Interlock ModuleA. Interlock ModuleB. Plastite Screws

A

B

B

FUEL SOLENOID

Refer to the tractor's specific engine manufacturer’sinstructions for service, repair, and replacement parts.

NOTE: Before beginning any work on the fuel pump orfuel solenoid, disconnect and secure the negative batterycable.

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7 - 20

Loose, broken, or dirtyconnectors or wiring.

Refer to A. Check/CleanWires and Connectors.

Replace/repair damagedwires or connectors.

Component Tests OK

ComponentFails Test

Battery connections dirty orloose, or worn battery.

Refer to C. Battery Tests. Replace/repair batterycables or replace battery.

Component Tests OK

ComponentFails Test

Dead battery. Refer to C. Battery Tests. Charge or replacebattery.

Component Tests OK

ComponentFails Test

Circuit Breaker Malfunction. Refer to O. Circuit BreakerTest.

Replace circuit breaker.

Component Tests OK

ComponentFails Test

Worn or malfunctioningignition switch

Refer to G. Ignition SwitchTests.

Replace ignition switch.

Component Tests OK

ComponentFails Test

Worn or failed solenoid. Refer to H. Solenoid Test. Replace solenoid.

Component Tests OK

ComponentFails Test

Worn or malfunctioningbrake pedal switch.

Refer to L. Brake PedalSwitch Tests.

Replace the brake pedalswitch.

ComponentFails Test

Engine will not turn over:

Loose, broken, or dirtyground connection. Refer to B. Check/Clean

Ground Cable.

Replace/repair damagedground connection.

Component Tests OK

ComponentFails Test

7 Electrical System ServiceTroubleshooting Charts

Worn or malfunctioning PTOswitch.

Refer to J. PTO SwitchTests.

Replace the PTO switch.

Component Tests OK

ComponentFails Test

Malfunctioning seat switch. Refer to N. Seat SwitchTests.

Replace seat switch.ComponentFails Test

Component Tests OK

Malfunctioning module. Refer to F. Interlock ModuleTests.

Replace interlockmodule.

ComponentFails Test

Done

Component Tests OK

TROUBLESHOOTING Locate the problem you are having, then check all thecomponents in the order listed.

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Check all wires andconnections.

Refer to A. Check/CleanWires and Connectors.

Replace components asrequired.

Component Tests OK

ComponentFails Test

Check the ignition switch. Refer to G. Ignition SwitchTests.

Replace the ignitionswitch.

Component Tests OK

ComponentFails Test

Check the PTO switch. Refer to J. PTO SwitchTest.


Component Tests OK

ComponentFails Test

Check the brake pedalswitch.



Component Tests OK

ComponentFails Test

Check the seat switch. Refer to N. Seat SwitchTest.

Replace the seat switch.

Component Tests OK

ComponentFails Test

Check the interlock module. Refer to F. Interlock ModuleTest.

Replace the interlockmodule.

Component Tests OK

ComponentFails Test

Done

Engine will turn over but will not start:

Check the engine ignitionsystem.

Refer to Engine Manual. Replace components asrequired.

ComponentFails Test



Component Tests OK

ComponentFails Test

Check the fuel system. Refer to Engine Manual. Replace components asrequired.

Done

ComponentFails Test

Engine runs for a few seconds then dies: Not

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7 - 22

Check the brake pedalswitch.



Component Tests OK

ComponentFails Test

Done

Engine dies when brake pedal released:


Replace the seat switch.ComponentFails Test

Component Tests OK





Component Tests OK

ComponentFails Test

Done

Engine dies when PTO engaged:





Component Tests OK

ComponentFails Test

PTO clutch will not engage:



Component Tests OK

ComponentFails Test

Check the PTO clutch. Refer to P. PTO Clutch. Replace the PTO clutchassembly.

Done

ComponentFails Test

Check voltage regulator. Refer to Engine Manual. Replace the defectiveengine component(s).

Component Tests OK

ComponentFails Test

Check alternator. Refer to Engine Manual. Replace the defectiveengine component(s).

Done

ComponentFails Test

Battery over-charging:

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Check battery. Refer to C. Battery Tests. Replace the battery.

Component Tests OK

ComponentFails Test

Check circuit breaker. Refer to O. Circuit BreakerTest.

Replace the circuitbreaker.

Component Tests OK

ComponentFails Test

Check ground. Refer to B. Check/CleanGround Cable.

Clean both ends of thenegative battery cable.

Component Tests OK

ComponentFails Test

Check voltage regulator. Refer to Engine Manual. Replace the defectiveengine component(s).

Component Tests OK

ComponentFails Test

Check engine alternator. Refer to Engine Manual. Replace the defectiveengine component(s).

Component Tests OK

ComponentFails Test

Check ignition switch. Refer to G. Ignition SwitchTests.


Done

ComponentFails Test

Battery not charging:

Check charging voltage. Refer to E. ChargingVoltage Check.

Replace the defectiveengine component(s).

Component Tests OK

ComponentFails Test

Safety interlock malfunction:

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Figure 21. Testing Cable Continuity

Figure 20. Typical Wire Harness

Check forLoose Wires

InspectInsulation

Check forCorrosion

7 Electrical System ServiceComponent Tests

COMPONENT TESTSGeneralThe following tests should be used in conjunction withthis sections troubleshooting flow charts to efficientlytroubleshoot common electrical problems; however, if aspecific component is suspect, these tests can be usedindependently of the flow chart and of each other.

A. Check/Clean Wires and Connectors 1. Check all wires for cracked or worn insulation.

2. Check all connectors, terminals, and receptacles forloose wires or corrosion (Figure 20). Refer to theexploded view diagrams for wire harness locations.

B. Check/Clean Ground Cable1. Disconnect and secure the negative battery cable


2. Disconnect the other end of the negative batterycable (ground cable) from the engine.

3. Clean the battery and cable terminals with a wirebrush until the metal is shiny.

4. Using a VOM set to Ohm, test the continuity of thecable (Figure 21). The VOM should register no morethan 2-3 ohm.

5. Clean the negative battery post and engine groundwith a wire brush until the metal is shiny.

6. Reattach the negative cable to the engine block andthen the negative battery terminal.

WARNINGBefore beginning any test,ALWAYS:• Disconnect the spark plug wire.• Block the wheels.IN MOST CASES:• Engage the parking brake.• Turn the PTO switch OFF.• Turn the ignition switch OFF.• Place the ground speed control lever in

NEUTRAL (Peerless models only).If a test procedure requires a configuration otherthan the one listed above, instructions will be pro-vided in that specific procedure.Always reset the tractor to the configuration listedabove unless told otherwise.

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C. Battery TestsGENERAL

If the battery is producing 12 volts and the battery cableshave continuity, the rest of the cranking system can besystematically tested. However, a full test of the batteryincludes cleaning, testing battery charge (hydrometertest), and testing its ability to deliver current (heavy loadtest).

C-1 HYDROMETER TEST

1. Remove the vent caps (A, Figure 22).

2. Check each cell using a hydrometer.

3. All cells should have a specific gravity of 1.27 or high-er. If the cells vary by more than .050 points, chargethe battery and recheck.

If one or more cells read below 1.265, charge at 5 Amps, checking hourly. If the low cell or cells do notimprove within three hours of charging, replace thebattery.

4. Replace the cap when finished.

C-2 CHECK ELECTROLYTE LEVEL

1. Remove the battery vent cap (A, Figure 22) andmake sure the breather holes are open.

2. Check that fluid is even with the bottom of the splitrings (B, Figure 22). If not, fill with distilled water.Replace vent cap when done.

C-3 TEST BATTERY VOLTAGE

1. Test the battery voltage: set VOM to VDC.

2. Place one test probe of the VOM on the batteriespositive post and one probe on the negative post(see Figure 23). Note and record the battery voltageas it will be referenced in later tests. It should beapproximately 12 VDC.

C-4 HEAVY LOAD TEST

1. Follow the load tester manufacturer’s instructions;connect the battery tester to the battery.

2. Discharge the battery under a fixed load at threetimes the ampere-hour rating for approximately 15 seconds, then read the terminal voltage.

C-5 CLEAN BATTERY

1. Disconnect the battery cables.

2. Remove the battery from the battery compartment.

3. Remove dirt and corrosion with a solution of one partbaking soda and seven parts water.

WARNINGBe careful when handling the battery. Avoidspilling electrolyte. Keep flames and sparks awayfrom the battery.

When removing or installing battery cables,disconnect the negative cable FIRST and reconnectit LAST. If not done in this order, the positiveterminal can be shorted to the frame by a tool.

4. Clean the posts with a wire brush until the metal isshiny.

5. Reinstall battery and coat the terminals with petroleumjelly to prevent corrosion.

Figure 23. Check Battery Voltage - Air Cooled

Figure 22. Check Battery ElectrolyteA. Battery Cap B. Split-Ring

AB

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Figure 24. Check Battery Voltage

Figure 25. Interlock ModuleA. Interlock Module

D. Isolated Battery Voltage CheckSee Figure 24.

In some cases, a short in the wiring or another compo-nent could be causing a low level current draw on thebattery. This would be indicated by a slow drain on thebattery during times when the engine is off. The easiestway to check this is to check the voltage with the batteryinstalled, and then with the battery uninstalled (isolated).

Then reconnect the battery terminals with an amp meterin series with the battery and terminal. There should beno current draw off the battery when all accessories areoff and the ignition key switch is in the OFF position.

E. Charging Voltage CheckTo determine if the charging system is functioning prop-erly, check the battery voltage while the engine is run-ning. The charging system produces a slightly highervoltage than the battery so that the battery will rechargeand there is enough energy remaining to supply power tothe electrical systems.

F. Interlock Module Due to the complex circuitry and sensitivity of the electri-cal components that make up the interlock module, itcannot be feasible be tested. Test the switches, wires,and connections in the rest of the electrical system, thenreplace the module as a last resort. Bear in mind that amodule failure may be caused by another malfunctioningelectrical component. Therefore it is critical that the restof the electrical system be checked.


G. Ignition Switch TestsTo perform these tests, the ignition switch needs to beremoved from the dashboard.

TEST START POSITION

NOTE: To perform this test, the ignition key switch mayneed to be placed in a vice to hold the switch.See Figure 26.

1. Set VOM to Ohm.

2. Turn the key to the START position and hold it therefor the following steps.

3. Connect test leads to terminals B and L of the ignitionkey switch. The test meter should show continuity.

4. Connect test leads to terminals B and S of the igni-tion key switch. The test meter should show continu-ity

5. Connect test leads to terminals L and S of the ignitionkey switch. The test meter should show continuity.

A

6. Turn the key switch to the OFF position and repeatsteps 3, 4, and 5. With the key in the OFF position,the combinations listed above should show no conti-nuity.

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TEST RUN POSITION

1. Set VOM to Ohm.

2. Set the key switch to the RUN position for the follow-ing steps.

3. Connect test leads to terminals B and L. The testmeter should show continuity.

4. Connect test leads to terminals B and A. The testmeter should show continuity.

5. Connect test leads to terminals L and A. The testmeter should show continuity.

6. Turn the key switch to the OFF position and repeatsteps 3, 4, and 5. With the key in the OFF position,the combinations listed above should show no conti-nuity.

TEST OFF POSITION

1. Set VOM to Ohm.

2. Turn the ignition key switch to the OFF position.

3. Connect test leads to G and M. The test meter shouldshow continuity.

4. Connect test leads to G and A. The test meter shouldshow continuity.

5. Connect test leads to M and A. The test meter shouldshow continuity.

START

ON OFF

TERMINALS

B

M

L

S

B IGNITION SWITCH

POSITION

1. OFF

2. RUN

3. START

CIRCUIT MAKE

G & M & A

B & L & A

B & L & S

M

G

A

S

L

OFFRUN

START

B

L

OFFRUN

STARTA

G

OFFRUN

STARTA

Figure 26. Ignition Switch Tests – 6-Pin Steel Body (Later Models)

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H. Test SolenoidFor this, and all tests, the ground speed control levermust be in neutral, the parking brake set, and the PTOswitch must be OFF. Unplug and secure all spark plugwires. Read completely through the instructions beforeperforming this and all tests.

1. Disconnect the Green/Black & Black/Yellow plug (A,Figure 27) and Blue/White plug (B, Figure 27) fromthe small posts of the solenoid.

2. Connect a jumper lead from one small post toground.

3. Connect a jumper lead to the other small post andthen touch it to the positive battery post. The leadmay arch to the battery post–this is normal.

There should be a single audible “click” heard as thesolenoid engages and the engine should turn over. If noclick is heard, proceed to SOLENOID BENCH TEST. Ifthe solenoid clicks but the starter does not turn theengine over, check the starter cable and the starter itself.If the solenoid “clicks” rapidly or repeatedly, recheck thebattery and all connections for corrosion.

I. Solenoid Bench TestReplace a solenoid that does not pass all of the followingtests.

1. Identify and remove all wires from the solenoid.Remove the solenoid.

2. Set the VOM to the Ohms setting. Probe the smallposts of the solenoid (Figure 28). The VOM shouldread less than 10 Ohms.

7 - 28


Figure 29. Testing Solenoid Short

Figure 27. Solenoid LocationA. Green/Black & Black/Yellow PlugB. Blue/White Plug

Figure 28. Testing Solenoid Resistance

A

B

3. Connect the VOM probes to the large posts (Figure29). The meter should read no continuity.

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4. Probe the mounting base of the solenoid. Probesmall post #1 and observe the VOM. Probe post #2and observe the VOM. The VOM should read nocontinuity in both cases.


Figure 30.Testing for Solenoid Short

Figure 31. Testing Solenoid Continuity

12 VDC

5. Apply 12 VDC to the two small posts. There shouldbe an audible click as the solenoid engages.

6. With the solenoid engaged (12 VDC to the smallposts), measure the resistance at the two large posts.The VOM should read less than 10 ohms (continuity).

7. Correctly reinstall the solenoid and all related wiresand connectors.

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J. PTO Switch TestThe PTO switch is used in the PTO circuit and both safetyinterlock circuits: cranking and safety shutoff. To accom-modate these circuits, the PTO switch has four contactsactuated by the pull knob. The top and bottom contactsare common to all models covered in this manual. Themiddle N.O. (Normally Open) contacts are not used.

The N.C. contacts will be closed when the PTO switch isin the OFF position. Pulling up on the knob closes thecontacts, pushing down on the knob will open the con-tacts.

The N.O. contacts will be open when the PTO switch isin the OFF position. Pulling up on the knob opens thecontacts, pushing down on the knob will close the con-tacts these switches.

TEST PTO SWITCH

NOTE: You may want to remove the PTO switch fromthe control panel for testing. Refer to the PTO SwitchReplacement procedures located in this section.

1. Pull the wire harness off the back of the switch.

2. Place the PTO switch in the OFF position, knobpushed down (Figure 33).

3. Set VOM to Ohm. Test the top, middle, and bottomrows of terminals for continuity (Figure 33).

4. Place the PTO switch in the ON position, knob pulledup (Figure 34).

5. Set VOM to Ohm. Test the top, middle, and bottomrows of terminals for continuity (Figure 34).

Replace a switch that does not pass all tests.

PTO SWITCH CIRCUITS

N.O.

N.O. / N.C.

N.C .

SWITCH TERMINALS(BACK OF SWITCH)

Figure 32. PTO Switch TerminalsA. Top N.C. Terminals B. Middle N.C. Terminals (Not Used)C. Middle N.O. Terminals (Not UsedD. Bottom N.O. Terminals

A

B

D

Figure 33. Test PTO Switch – OFF Position

PTO Switch – ON Position

No Continuity

Continuity

Continuity

Figure 34. Test PTO Switch – ON Position

C

No Continuity

PTO Switch – OFF Position

Continuity

No Continuity

No Continuity

Continuity

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K. Cruise Control Switch Test The cruise control switch has a N.O. contact and closeswhen the cruse control is engaged.

SWITCH TESTS

NOTE: It may be easier to test the switch if the switch isremoved. See Component Location and Replacement forswitch removal procedures, earlier in this section.


2. Set VOM to Ohm. With the cruise control knob in thedisengages position (plunger not depressed) probethe switch terminals (see Figure 35). The VOMshould show continuity (zero ohm).

3. Engage the cruise control knob. Probe the switch ter-minals (see Figure 35). The VOM should show conti-nuity (closed).

4. Replace a switch that does not pass all tests.

Figure 35. Cruise Control Switch

L. Brake Pedal Switch Tests The foot pedal switch has two terminals and is a normal-ly open switch.

An N.O. contact is normally open, meaning that when thebrake pedal is at rest (up, not depressed) the switch isopen and will not conduct current. Depressing the brakepedal (or switch plunger) closes the switch.

SWITCH TESTS

NOTE: It may be easier to test the switch if the switch isremoved. See Component Location and Replacement forswitch removal procedures, earlier in this section.


2. Set VOM to Ohm. With the brake pedal up (plungernot depressed) probe the switch terminals (seeFigure 36). The VOM should show no continuity forN.O. contacts and continuity for N.C. contacts.

3. Depress the brake pedal and engage the parkingbrake.

4. With the brake pedal depressed (plunger depressed)Probe the switch terminals (see Figure 37). The VOMshould show continuity for N.C. contacts and no con-tinuity for N.O. contacts.


Figure 36. Brake Pedal Switch

Figure 37. Brake Pedal Switch

No Continuity

Continuity

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M. Seat Switch Safety Interlock TestCheck the seat switch (B, Figure 38) with the followingtests.

Engine should shut off if:

A. Operator rises off seat with the brake pedal NOTdepressed.

B. Operator rises off seat with electric clutchengaged.

Figure 39. Test Seat Switch

N. Seat Switch TestSee Figure 39.

All models have a N.O. (normally open) seat switch.When the seat is unoccupied, the switch is open and willnot conduct current. Sitting in the seat closes the switch.

1. Tilt the seat forward and pull the wire harness off theback of the switch.

2. Set VOM to Ohm. With the switch at rest (no operatorpushing down on the seat) probe the switch termi-nals. The VOM should show no continuity (open).

3. Press down in the middle of the seat to activate theswitch.

4. Probe the switch terminals. The VOM should showcontinuity


Figure 38. Seat Switch Safety SystemA. SeatB. Seat Switch

B

A

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No Continuity

Continuity

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Figure 41. Testing Driving Light Switch

Figure 40. Testing Circuit Breaker

O. Circuit Breaker TestAll circuit breakers are located under the dashboard. Thecircuit breaker resets itself automatically. If the circuitdoesn’t come back on, check it immediately. See Figure40.

The circuit breaker is connected to one of the small sole-noid posts along with the positive battery cable.

1. Set the VOM to VDC.

2. With the negative probe, touch ground.

3. Touch the positive probe to one post of the circuitbreaker, and then the other. Both posts should haveclose to full battery voltage going to them. If not,replace the breaker.

4. Set VOM to Ohm.

5. Disconnect the circuit breaker leads and probe bothcircuit breaker terminals. If the VOM reads 5 ohm ormore, replace the circuit breaker.

S. Voltage RegulatorThe voltage regulator is part of the engine, refer to theengine manufacturer’s operators manual for informationrelating to engine components. On some alternators thevoltage regulator is built in.

P. PTO ClutchRefer to PTO CLUTCH SERVICE section, for competePTO clutch testing information and replacement proce-dures.

Q. Headlight Switch Test1. If needed, remove the switch from the dashboard.

2. Set the VOM to Ohm.

3. With the switch in the OFF position, probe both termi-nals (Figure 34). The VOM should read no continuity.

4. Turn the switch to ON. The VOM should read conti-nuity.

R. Fuel Solenoid TestRefer to the engine manufacturer’s operators manual forinformation relating to engine components.

1. Turn the ignition switch from OFF to RUN. Thereshould be an audible “click” as the shut-off solenoidopens.

If there is no “click” use a VOM set to VDC. Test thevoltage between the solenoid lead and ground. Withthe ignition switch in the RUN position, the leadshould have 12 volts. If not, check the ignition switchand wiring.

If the solenoid is receiving 12 VDC and is not open-ing, replace the solenoid.

T. AlternatorRefer to the engine manufacturer’s operators manual forinformation relating to engine components.

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7 Electrical System ServiceNotes

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8 Steering & Front Wheel RepairTable of Contents

SECT

ION

8. S

TEER

ING

&FR

ONT

WHE

ELRE

PAIR

SECTION CONTENTSGeneral ...................................................................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

Tie Rod Repair ..............................................................................8-9

Upper Steering Group

Diagram.......................................................................................8-10

Steering Wheel Removal ............................................................8-11

Steering Shaft Removal ..............................................................8-12

Steering Gear / Pitman Arm Service ...........................................8-13

Drag Link Removal......................................................................8-14

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8 Steering & Front Wheel RepairGeneral / Tools / Elevating Unit

8 - 2

DANGERPREVENT SERIOUS INJURY OR

DEATH FROM FALLING UNIT

Always use a properly working lifting device witha capacity suitable for the weight of the unitbeing serviced.

Always use a jack stand to support the unit whileperforming service, and chock remaining wheelsto prevent the unit from rolling off the supports.

Never work under or around an elevated unit thatis not properly supported and secured in posi-tion with wheel chocks.

Figure 1. Elevate Front End Of Unit

GENERALServicing the lower steering mechanism and front wheelspindles should be performed with the front end of theunit elevated and supported evenly on both sides withjackstands.

Although service can be performed with the mowingdeck and hood assembly on the unit, removing the deckand hood assembly provides clear access to all lowersteering mechanism components and helps simplify thejob.

REQUIRED TOOLS & EQUIPMENTTools required for performing disassembly and assemblyin these areas include:

• socket wrench set• open end wrench set• Flat blade screwdriver• Metal striking hammer• Claw hammer, or pry bar• Center punch or carbide scribe• Torque wrench (0 - 75 ft. lbs.)

Specialized equipment required for servicing these areasinclude:

• Jackstands (2)• Scissor jack or hydraulic jack• Wheel blocks (2)• Grease gun w/Lithium-base automotive grease• Oil can (use SAE 30 weight oil)

ELEVATING FRONT OF UNIT FORSAFE SERVICE1. Remove the ignition key, and disconnect the spark

plug wire to prevent accidental starting while workingon unit.

2. Remove mowing deck. See Operator’s Manual.

3. Remove the hood assembly.

4. Engage parking brake, block the rear wheels, andusing a hydraulic or scissors jack positioned at thecenter of the front axle assembly, carefully jack theunit up until the front tires are approximately 1" - 2"off the ground (Figure 1).

NOTE: For overall unit stability during service, do notjack front end higher than required for adequate accessto steering and spindle components. Excessive eleva-tion may result in fuel leakage from gas tank or elec-trolyte leakage from battery vents.

5. Position jackstands at each end of front axle assem-bly and lower the unit slowly until jack stands fullysupport unit. Make sure the jackstands engage thebottom of the front axle assembly so that weight isevenly distributed on each of the jackstands.

6. Check the rear wheel blocks and make sure that theyare tight against the rear wheels to prevent rolling.

DANGER

Do not begin work on the unit unless it is stableand you are sure wheels are chock to preventrolling.

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8 Steering & Front Wheel RepairFront Wheel Repair

Figure 3. Front Wheel Retaining Ring - Broadmoor

FRONT WHEEL REPAIRRemoval & Installation1. Using a flat blade screwdriver, pop off the plastic hub

cap to gain access to the retaining ring.

2. Using a flat-blade screwdriver, remove the retainingring and hubcap retainer.

3. Slide the wheel off the spindle shaft (Figure 4). Notethat the tire air valve and axle grease fitting are locat-ed on the inside of the wheel.

4. Reinstall in reverse order of removal. Be sure toclean and lubricate the spindle shaft with lithiumgrease.

InspectionRemoval of the wheel provides an opportunity to inspectthe inside of the tire for sidewall damage, as well as tocheck inflation pressure. Also, visually check wheelbushings for wear or damage before reinstalling thewheel on the unit, and replace as required. Wheel bear-ings are pressed into the wheel hub with a press fit andmay be removed by pressing or driving out.

Retaining ring

Hubcapretainer

Figure 4. Wheel And Assembly HardwareA. Air Valve D. Hubcap RetainerB. Grease Fitting E. HubcapC. Retaining Ring

AC

B

D

E

Figure 2. Front Wheel Assembly

A. WasherB. TireC. Inner Tube (Optional)D. Ball BearingE. Valve Stem and CapF. Wheel AssemblyG. Hub Cap RetainerH. Retaining RingI. Hub Cap

A

B

C

D

F

DG

HI

E

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8 Steering & Front Wheel RepairSteering Group Assemblies

8 - 4

Lower Steering Group

Upper Steering Group

Figure 5. Steering Group - Complete

Frame

Dash

Lower Dash

STEERING GROUP ASSEMBLIES - COMPLETE

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8 Steering & Front Wheel RepairLower Steering Group

LOWER STEERING GROUP

Figure 6. Lower Steering Assembly

Figure 7. Remove Clip Ring

LH Spindle Repair1. Remove the wheels as described previously under

Front Wheel Repair.

2. Using a flat blade screwdriver, position the tip of thescrewdriver blade at the open end of the steering armclip ring, and twist the blade against the clip ring toforce the ring partially out of the groove (Figure 7).

3. Insert the tip of the screwdriver blade in the gapbetween the inside edge of the clip ring and the spin-dle shaft, and pop the clip ring completely out of thegroove.

NOTE: To index steering wheel,loosen the drag link nuts and adjustdrag link (I) so that full left hand turnand full right hand turn have equalplay (full turn must hit spindle stop).Torque nuts to 13 ft. lbs.

Clip Ring

Steering ArmAssembly

Torque to22-40 Ft. Lbs.

Torque to22-40 Ft. Lbs.

A

G

A

B

QA

S

D

I

R

J

B

P

O

N

L

M

K

C F

G

F

E

D

H

A. Clip RingB. WasherC. CapscrewD. SpacerE. Rod EndF. WasherG. Flange NutH. CapscrewI. Drag LinkJ. WasherK. SpindleL. Tie RodM. Carriage BoltN. SpacerO. Arm Assy.P. Flange Lock nutQ. Steering Arm Assy.R. Carriage BoltS. Spacer

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Figure 10. Remove Spindle Shaft Bushings

Punch marks

Figure 8. Remove Rod End

Figure 9. Inspect Rod End

4. Using a 9/16" socket and 9/16" open end or boxwrench, remove the capscrew/washer and flangedhex nut that secure the steering arm assembly to therod end (Figure 8).

NOTE: A spacer is located over the capscrew threads inthe rod opening to permit rotation of the steering arm.Damage to the spacer or washer caused by excessivetightening or wear may adversely affect steering, so besure to inspect these parts and replace them if neces-sary before reassembly.

5. The rod end is screwed onto the drag link arm and issecured in place with a 1/2-20 jam nut.

RodEnd

Drag LinkSteeringArm

SteeringArm Rod

End

SteeringArm

Bushing

6. Inspect the rod end for free movement/rotation of therod end bearing, and replace the rod end if necessary(Figure 9).

7. To remove the rod end, loosen the jam nut by turningit clockwise (looking at the end of the drag link shaft)one or two turns with a 3/4" open-end wrench, andthen unscrew the rod end by turning it counter-clock-wise.

NOTE: When reinstalling the rod end, be sure to adjustthe length of the drag link arm so that the left and rightspindle stops stop against the axle assembly with full leftand right turns respectively. See the adjustment proce-dures section for complete details.

8. Tap the left hand steering arm assembly up off thespindle shaft with a hammer to remove it from theaxle/spindle shaft assembly.

NOTE: It will be helpful to mark the relative positions ofthe steering arm, splined spindle shaft, and shaft housingwith punch marks to simplify realignment later (SeeFigure 10).

9. Tap the top of the splined spindle shaft down with afew light hammer blows, and remove the spindleshaft from the bottom of the axle assembly housing,noting alignment.

10. With the spindle shaft removed, the bushings can beremoved and inspected for signs of wear (Figure 10).Use a brass drift or punch to tap out the bushingsfrom opposite ends of the housing. Replace thebushings if worn, scored, or cracked.

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RH Spindle / Steering Arm Repair1. Remove right front wheel using same procedure as

used for left front wheel. (Figure 11)

2. Use a center punch to mark the relative assembledpositions of the right hand steering arm, right handspindle assembly, and the right side of the front axleassembly (Figure 11 and 12).

Figure 12. Disassemble Tie Rod From RH SteeringArm

Figure 11. Right Front Spindle Assembly

Figure 13. Remove Retaining Ring

4. Using a flat blade screwdriver, position the tip of thescrewdriver blade at the open end of the steering armclip ring, and twist the blade against the clip ring toforce the ring partially out of the groove (Figure 13).

5. Insert the tip of the screwdriver blade in the gapbetween the inside edge of the clip ring and the spin-dle shaft, and pop the clip ring completely out of thegroove.

6. Slide the right hand spindle assembly straight downto remove it from the front axle assembly. Inspectparts and replace as required. Grease spindle bush-ings as described earlier in left side disassemblyinstructions.

Clip Ring

3.Remove the hex nut and carriage bolt securing theright hand steering arm to the tie rod (Figure 12).

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Figure 15. Grease Wheel Bushings

Figure 14. Lubricate Rod End Spacer

Rod End Spacer

Rod End

Reassembly1. Reassemble parts in the reverse order of disassem-

bly, using particular care to realign the steering armassembly, spindle assembly, and axle housing.

2. Observe torque specifications on Figure 6.

NOTE: If alignment marks are obscured during serviceor if parts are replaced, proper steering alignment can beperformed later with wheels installed using the distancebetween tires as a guide. The distance between tires atthe front should be 1/8" less than the distance betweentires at the rear (measured at the the outer edge of thetire tread) when the wheels are pointed straight ahead.This slight toe-in is permanently set by the tie rod, and isnot adjustable.

3. Before reassembling rod end hardware to left handsteering arm, squirt a few drops of SAE 30 weight oilon the outer surface of the spacer (Figure 14).

4. Before reinstalling the wheel and related hardware,grease the spindle bushings using the grease fittingon the front axle assembly (Figure 15). Use a lithium-base, automotive-quality grease such as that provid-ed with the optional Grease Gun Kit.

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8 - 9


Tie Rod Repair1. The tie rod can be removed by disassembling the

flanged hex lock nuts and carriage bolts that securethe tie rod to the left and right steering arm assem-blies (Figure 16). Use care when removing the hard-ware to prevent the internal spacers from falling out.

2. Check the spacer for signs of excessive wear, dam-age, or flattening due to over-tightening of the assem-bly hardware, and replace if required. (The spacerallows the steering arms to pivot freely at the tie rodjoint.)

3. Check the tie rod for cracks or other damage at therod ends, and replace if necessary. Also the centerportion of the tie rod must be straight to provide thecorrect center-to-center distance for wheel alignment.If the tie rod is bent, replace the tie rod.

4. Reassemble the tie rod to the steering arms usingnew spacers or hardware if required. Beforeinstalling the flanged lock nut, squirt a few drops ofSAE 30 weight oil around the spacer (Figure 17).

5. Tighten the lock nut securely, but do not over-tightenas this will damage the spacer and may prevent freerotation of the steering arms.

Figure 17. Lubricate Tie Rod/Steering Arm Spacer

Figure 16. Tie Rod/ LH Steering Arm AssemblyA. Flanged Hex Lock Nut C. Carriage BoltB. Spacer

C

B

A

Spacer

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8 Steering & Front Wheel RepairUpper Steering Group

8 - 10

A. CapB. Steering WheelC. Pin, 5/16 x 2D. TubeE. Steering ShaftF. Cotter PinG. Washer, 49/64H. Washer

I. Carriage Bolt, 3/8-16 x 1J. Nut, Flange Lock, 3/8-16K. BushingL. Capscrew, 5/16-18 x 1-1/2M. SpacerN. Nut, 5/16-18O. Capscrew, 3/8-16 x 1-3/8P. Pitman Arm

Q. KeyR. Screw, Taptite, 5/16-18 x 1S. Sector Mounting PlateT. Steering Gear Assy. HubU. Square Head Set Screw

UPPER STEERING GROUP

I

G

J

K

G

F

E

LK

T

K

S

R Q

O

P

N

M

CD

B

A

NOTE 4

(gear teeth) Apply Loctite#271. Torqueto 20-30 ft.lbs.

Torque to 17-23ft.lbs. (2 places)

Early models used acapscrew, washer & nutin place of a roll pin (C).

Figure 18. Upper Steering Assembly

To Rod End - See Figure 48

NOTES:

1. Unless specified, use torque specifications shown on standard hardware torque specification chart.

2. Grease locations indicated by grease gun symbol:

3. Oil locations indicated by oil can symbol:

4. Pitman arm shaft (P) should protrude 9/16" above top of steering gear assembly hub (T).

Grease bushings "K"(3 places)

H

U

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8 - 11


Steering Wheel Removal 1. Later-model steering wheels are attached to the

steering shaft assembly with a long spring pin. Use apin punch and hammer to drive the spring pin out ofthe steering wheel and steering shaft assembly(Figure 19).

Figure 19. Remove Steering Wheel Spring PinLater Models

Figure 20. Remove Steering Wheel

2. Slide steering wheel up to remove from steering shaftassembly, and note positioning of mounting holes forlater reassembly (Figure 20).

3. Inspect steering wheel and hardware for wear ordamage, and replace as required. Reassemblesteering wheel to steering shaft assembly, or proceedto next step if steering shaft is to be serviced.

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Figure 21. Remove Cotter PinA. Cotter Pin

ASteering Shaft RemovalNOTE: Unit must eventually be tipped up to remove theshaft.

1. Remove the steering wheel as shown in the steeringwheel removal section.

2. Remove the cotter pin from the steering shaft (A,Figure 21) just above bushing in the frame support.

3. Locate the washers that were held in place by thecotter pin. Slide the washers off the shaft.

Figure 22. Steering Mounting PlateA. Nuts

A

4. Loosen the nuts securing the steering mounting plate(A, Figure 22).

5. Slide the steering shaft assembly down and out ofthe bottom of the unit to remove for replacement.Note: Unit must be tipped up at this point to removethe shaft.

6. Inspect steering shaft assembly and bushings forexcessive wear or damage. Replace if required.

7. Install the steering shaft assembly in the reverseorder of removal and apply a liberal coating of greaseto the steering shaft and drive gear.

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Figure 25. Remove Steering Arm Assembly

90°

4. Turn the steering arm assembly mounting plate 90*to allow the assembly to be removed as a unit. Pullthe assembly straight out. See Figure 25.

5. The steering arm assembly may be disassembledby removing the the two square head bolts (U,Figure 18) from the gear assembly.

6. Inspect all parts for excessive wear or damage andreplace as required.

7. Reassemble in reverse order of disassembly.Apply a grease to the pitman arm shaft, bushings,and gear teeth. Note the placement of the shaftkey for correct gear orientation.

Figure 23. Disconnect Drag Link Ball Joint

Drag Link

Pitman Steering Arm

Steering Gear / Pitman Steering Arm Service1. 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 byremoving the capscrew, washers, spacer, andflanged hex lock nut (Figure 23).

Figure 24. Remove Hex Capscrews

Pitman Steering Arm

3. Remove taptite hex head capscrews that secure pit-man steering arm/assembly to underside of unit(Figure 24).

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Figure 26. Disassemble Rod End From Steering Arm

Figure 27. Disassemble Rear Drag Link Rod EndFrom Pitman Steering Arm

Drag Link Removal1. See Figure 26. Using a 9/16" socket and 9/16" open

end or box wrench, remove the capscrew, washerand flanged hex nut that secure the steering armassembly to the front rod end on the drag link. (Forunits equipped with early style drag links, see Figure6 for correct hardware and assembly).

2. Disassemble rear drag link rod end from pitman armby removing capscrew, washers, spacer, and flangedhex lock nut (Figure 27).

3. Remove the drag link rod ends by first loosening thejam nuts. Turn the jam nuts clockwise (looking at theend of the drag link shaft) one or two turns with a 3/4"open-end wrench, and then unscrew the rod end byturning it counter-clockwise.

4. Check the drag link for cracks or other damage, andreplace if required. If the drag link is being replaced,position the jam nuts on the new drag link in theapproximate positions utilized on the old drag link.

5. Inspect the rod ends for free movement/rotation ofthe rod end bearing, and replace the rod ends if nec-essary.

6. Reassemble the rod ends to the drag link, andreassemble the drag link to the unit in the reverseorder of disassembly. Do not tighten the jam nutsuntil final spindle stop adjustments have been made.

NOTE: When reinstalling the rod ends, be sure toadjust the overall length of the drag link arm so that theleft and right spindle stops stop against the axle assem-bly with full left and right turns respectively. See theadjustment procedures section for complete details.

Drag Link

Drag Link

Pitman Steering Arm

Steering Arm

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9 - 1

9 Torque Generator RepairTable of Contents

SECTION CONTENTS

Exploded View Diagram........................................9-2

General Information...............................................9-3

Tear-Down and Reassembly

Tear Down.................................................................................... 9-4

Reassembly ..................................................................................9-6

SECT

ION

9. T

ORQU

EGE

NERA

TOR

REPA

IRNot

for R

eprod

uctio

n

9 Torque Generator RepairExploded View Diagram

9 - 2

2017

1413

1511

89

109

21

94

322

6

15

2

9

162a

700

7

12

15 Pin

14 Spool

13 Sleeve

1 Screw, Cap, (7)

Plate, Spacer

9 Seal, O-ring (4)

11 Drive, Control End

Housing, Valve (for Inlet Relief Valve)12a

Housing, Power End2

Washer

Seal, Quad

Ring, Retaining

7 Drive, Power End

3

4

5

8

Shaft, Power End6

10 Gerotor

Washer22

Relief Valve S/A26

Plug27

O-ring28

Spacer, Spring (for Increased Input Torque) (4)30

Key, Woodruff (2)700

Spring, Centering (for Standard Input Torque) (6)

Ring, Retaining

Seal, Quad

Seal, Shaft (Lip Type)

O-ring (2)

16

17

18

19

Washer20

Plate, Spacer21

18a

12a

26

2728

30

18a

18

Housing, Valve12

OUT

INAUX

Housing, Power End (bearings, needle type)2a

19

OUTOUT

INAUX IN

AUX

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9 - 3

9 Torque Generator RepairGeneral Information

OUT

IN

AUX

OUT

IN

AUX

GENERAL

The following repair information may be used to inspectand/or repair the 217 Series or 227 Series TorqueGenerator. The 217 Series was used in the Landlord /1700 / 2700 Series tractors equipped with power steer-ing.

Tools Required:

- Ratchet Wrench

- 5/16 inch thin walled 12 point drive or 6 point drive(E10) socket

- Small screwdriver (6,3 mm [1/4 inch] flat blade)

- Small breaker bar or ratchet wrench

- Torque wrench (28 Nm [250 in-lb] capacity)

The following procedures may be used to completely dis-assemble and reassemble the 217, and 227 SeriesTorque Generators.

It is recommended that the torque generator be thor-oughly cleaned before any repairs are attempted. Whencleaning, be sure all open ports are sealed.

Although not all drawings show the torque generator in avise or on a bench, we recommend that you followinstructions in the steps as to the placement of partswhether it be in a vice or on the bench.


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9 Torque Generator RepairTear-Down

9 - 4

Output Shaft(power end) Up

Vise Jaws(top View)

OUTIN

AUX Key

Cap Screw

Housing and Shaft Assembly

TEAR-DOWN AND REASSEMBLYTear-Down1 To disassemble the torque generator, first support

the unit in a vertical position with the seven capscrews up and control end shaft down.

NOTE: When a bench vise is used to support the torquegenerator, do not to use excessive clamping pressure onthe control housing. Excessive pressure can distort thehousing. When using a vise, CLAMP ACROSS PORTFACE SIDES ONLY.

2. With the torque generator firmly supported, use a 6point drive socket wrench and remove seven capscrews (early production units used 12 point drivescrews).

3. Remove the housing (power end) and shaft assem-bly.

4. Turn the housing and shaft assembly over andremove the shaft with retaining ring in place.

NOTE: In most cases it is not necessary to remove theretaining ring from the shaft.

Quad Seal

Housing (Standard)

Housing (bearings—needle type)

Washer

Washer

Shaft and Retaining Ring(power end)

OUT

IN

AUX Drive(power end)

O-ringSpacer Plate

Gerotor or Geroler

5. Remove both washers from the housing (power end),and re-position the housing with seal end up. Usesmall screwdriver or similar tool to remove quadseal from the housing. Housing with two bearing sets(needle type) use the same output shaft, quad seal,washers, and retaining ring as the standard housing,however if bearings are to be replaced they are notsold separately as replacement parts.

6. Use a small screwdriver or similar tool to remove o-ring from the spacer plate.

7. Remove spacer plate from the gerotor or Gerotor.

8. Remove drive (power end) from the gerotor orGerotor.

9. Remove o-ring from the gerotor or Gerotor.

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9 - 5

9 Torque Generator RepairTear-Down

NOTE: Remove the gerotor or Gerotor, try to keep allparts together, Gerotor has 7 rolls to retain along with thestar (step 10).

10. Remove the gerotor or Gerotor.

11. Remove the spacer (217 Series will not have thisspacer).

12. Using a small screwdriver or similar tool, remove theo-ring from the spacer plate.

13. Remove spacer plate from the valve housing.

14. Again using a small screwdriver or similar tool,remove o-ring from the valve housing.

15. Remove the control end drive from the spool/sleeveassembly in the valve housing.

OUT

IN

AUX

OUT

IN

AUX

ValveHousing —227 Series

Valve Housing — 217 SeriesO-ring

Spacer Plate

O-ring

O-ring

SpacerPlate

Geroler

Gerotor

O-ring Drive

Drive

Spacer

16. Re-position valve housing, shaft horizontal andremove the spool/sleeve assembly.

17. Re-position valve housing shaft end up. Use a smallscrewdriver or similar tool to remove shaft seal.

18. Remove the washer from spool/sleeve assembly.

OUT

IN

AUX

SleeveSpoolCentering SpringsRetaining Ringand Cross Pin

Valve Housing Washer

Shaft Seal(can beQuad Sealor Lip Seal)

19. To separate spool from the sleeve, the cross pinmust be removed. To remove the cross pin, use asmall screwdriver or similar tool and push pin fromthe spool/sleeve.

20. With cross pin removed, push spool forward to disen-gage the control spool and centering springs from thesleeve.

NOTE: To prevent possible loss of the (six) centeringsprings, cover the control spool and springs with a cleanshop towel when pushing springs from the spool. Thiswill help contain springs in one location (step 21).

21. Remove centering springs from the control spool(and if applicable, four spring spacers). Retaining ringon spool need not be removed if no damage is appar-ent.

6 Springs and 4 Spacersfor Increased Input Torque

Spool (Special for Increased Input Torque)

6 Springs(Standard)

Spool and Retaining Ring

Pin

Sleeve

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9 Torque Generator RepairReassembly

9 - 6

NOTE: Valve housing with inlet relief valve has one o-ring on the plug. After o-ring replacement, install reliefvalve and plug into valve housing and torque plug to 41-46 Nm [30-34 lb-ft].

ReassemblyReplace all worn and damaged parts, also a good ser-vice policy is to replace all seals. Lubricate all seals withpetroleum jelly, and also lubricate all mating surfaceswith good clean hydraulic fluid for ease of reassemblyand to provide instant lubrication between rotating partsat start-up.

22. Lubricate the spool and install it into the sleeve, alignthe centering spring opening of the spool with thespring notches in the sleeve.

OUT

IN

AUX

Plug O-ring Relief Valve Valve Housing(for ReliefValve Option)

6 Springs and 4 Spacersfor Increased Input Torque

Spool (Special for Increased Input Torque)

6 Springs(Standard)

Spool and Retaining Ring

Pin

Sleeve

23. In preparation of installing the control spool andsleeve centering spring set, stand all springs on aclean flat surface with the notched side of the center-ing spring pointed down. Next place centering springswith arched side of each set of three pointing towardeach other as shown above.

24. To install centering springs, first insert spring installa-tion tool through spring openings in the spool/sleeve.Insert one end of the entire centering spring set (withnotched side toward the spool/sleeve) into the springinstallation tool. Compress extended ends of the cen-tering spring set and push springs into thespool/sleeve (do not pull on the spring tool), installa-tion tool will guide the springs through the spool andsleeve. Increased Input torque spring package has 4spring spacers 2 on each of the out sides of the sixsprings.

NOTE: When spring installation tool is not available, thecentering springs may be installed by hand. First installtwo (2) outside springs and add the others one at a timein between previously installed outside springs.

25. With spring set installed, center spring sets within thesleeve and push down on the spool until top of thecentering springs are flush with upper surface of thesleeve.

Spring InstallationTool

Springs

Alternate Method

Add OneSpringat a Time

OUT

IN

AUX

SleeveSpoolCentering SpringsRetaining Ringand Cross Pin

Valve Housing Washer

Shaft Seal(can beQuad Sealor Lip Seal)

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9 - 7


26. Install the cross pin into the spool/sleeve.

27. Lubricate and install the washer into the valve hous-ing.

NOTE: The input shaft seal has had two different config-urations and both seal types (Quad or Lip), have beenaddressed in the steps below.

28. In preparation of installing the quad seal, first installthe spool/sleeve assembly into the valve housingbackwards, shaft end up. Carefully retain thespool/sleeve and washer assembly in the valve hous-ing, and turn the assembly over, support it on a cleanflat surface. Temporarily installing these shaft parts inthe valve housing in the opposite direction from whichwas originally intended will create a groove or pocketinto which the quad seal can be easily installed fromthe input end of the valve housing.

29. Quad Seal Lubricate and install the quad seal in itsseat.

30. Quad Seal After seal installation, make sure the sealis not twisted. Turn the valve housing over andremove the spool/ sleeve assembly.

31. Lip seal Insert this seal into valve housing (withoutshaft installed) from the inside and guide it with yourfinger all the way into the seal groove, the seal lipmust be positioned so it is towards the inside of thevalve housing.

OUT

IN

AUX

OUT

IN

AUX

217 Series

227 Series

O-ringSpacer Plate

O-ring

O-ring

Spacer PlateO-ring Drive

Drive

NOTE: Careful insertion of input shaft upon reassemblywill prevent shaft seal damage (step 32).

32. With the washer still resting firmly in the valve hous-ing, lubricate the spool/sleeve assembly and carefullyinstall it in the valve housing shaft end down.

33. Lubricate the valve housing o-ring and install it intothe valve housing.

34. Install the control end spacer plate, aligning the capscrew holes and porting passages with the matchingholes in the control valve housing.

35. Lubricate and install the o-ring in the groove locatedin the spacer plate.

36. The preferred method of drive installation is to markthe drive with a felt tip pen, as shown here. Mark thesplined end of the drive, from tooth-to-tooth, with aline that parallels the slotted end of the drive. Thismethod helps assure proper alignment of the driveand gerotor or Gerotor star (meter section).

37. Install the drive, make sure you fully engage the sloton the end of the drive with the cross pin in the spooland sleeve assembly.

38. This illustration (above) shows the correct relation-ship of the spool/sleeve assembly cross pin and thegerotor or Gerotor star for proper torque generatortiming.

39. With the o-ring groove side of the outer ring facingupward, install the gerotor or Gerotor by aligning anytwo star valleys with the previously marked drive.After engaging the gerotor or Gerotor star with themarked drive, rotate the outer ring of the gerotor orGerotor to align with the threaded holes in the valvehousing.

Gerotor GerolerStarValley

Drive(Marked)

Pin

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9 - 8

40. Lubricate and install the o-ring into the gerotor orGerotor.

NOTE: Spacer is used only with 227 Series (step 41).

41. Install the spacer in the Gerotor star.

42. Lubricate and install the drive into the gerotor orGerotor star.

NOTE: The spline on one end of the drive is not as thickas the other and this thinner spline end must be installedinto the gerotor or Gerotor star.

43. Lubricate and install the spacer plate, with the sealgroove side facing upward. Install by aligning the capscrew holes with the matching holes in the gerotor orGerotor.

44. Lubricate and install the o-ring in the groove locatedin the spacer plate.

OUT

IN

AUX

Drive(powerend)

O-ringSpacer Plate

Gerotor or Geroler

Spacer

45. Lubricate and install the quad seal in the groovelocated in the power end housing.

46. After installing, make sure the quad seal is not twist-ed and is firmly seated in its groove.

47. With the quad seal installed, turn the power endhousing over and support it in an upright position(surface with seven mounting holes up). Lubricateand install the first washer by aligning the bump onthe washer with the matching recess in the powerend housing.

48. Lubricate and install the second washer in the powerend housing.

NOTE: Careful reassembly will prevent shaft seal dam-age when pushing the power end shaft into place (step49).

49. Lubricate and install the power end shaft in the hous-ing.

50. Before engaging the power end housing assembly,align the input and output shaft keyways and crossholes. Spline on the drive and the spline in the powerend shaft should line up. With the power end assem-bly installed, rotate housing to align cap screw holes.

51. Install the cap screws and torque in a crisscrosssequence to 23 Nm [200 in-lb].

52. The torque generator is now ready for test and instal-lation.

Quad Seal

Housing (Standard)

Housing (bearings—needle type)

Washer

Washer

Shaft and Retaining Ring(power end)

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10 - 1

10 Hand Controls ServiceTable 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

SECT

ION

10. H

AND

CONT

ROLS

SERV

ICE

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10 Hand Controls ServiceAttachment Lift Lever Service

10 - 2

ATTACHMENT LIFT LEVER SERVICEThe attachment lift system is only used to lift the mowerdeck.

Lift Lever Grip ReplacementThe lift lever grip is press fitted to the lift lever (B, Figure1). To remove the grip, twist it while pulling it off thelever. To install a new grip, lubricate the lift lever withsoapy water and press the grip onto the lever.

Upper Lift Rod ReplacementNOTE: The lift lever (B, Figure 1) and related parts maybe more easily accessed with the battery removed.

1. Remove the hardware securing the lift lever (B,Figure 1).

2. Disconnect the left lever (B) from the upper lift rod(C).

3. Rotate the lift rod (C) out of the upper lift cam (L) andremove from the bottom of the tractor. Install inreverse order of removal.


Figure 1. Attachment Lift System

B

C

A

K

H

L

M NO

P

J

D

E

F

Q

G

I

H

Side ofLower Dash

A. BushingB. Lift Lever & GripC. Upper Lift RodD. Lift PlateE. Lower Lift CamF. Washer & LocknutG. CapscrewH. Nylon BushingI. SpacerJ. Washers &

Nylock NutK. Brake PedalL. Upper Lift CamM. Lower Lift RodN. CapscrewO. Brake Pedal ArmP. Switch ActuatorQ. Clutch Rod

Lower Lift Rod Replacement.1. Disengage the parking brake.

2. Remove the washer and locknut (F, Figure 1) secur-ing the lower lift cam (E).

3. Separate the lower lift rod (M) and lower lift cam (E).

4. Separate the lower lift rod (M) from the upper lift cam(L). Install in reverse order of removal.

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10 - 3

10 Hand Controls ServiceChoke Control Service

Figure 2. Engine Choke Control Location

ENGINE CHOKE CONTROL (SELECT UNITS)Choke Cable ReplacementOn units with a dash-mounted engine choke control, thecontrol is a push-pull button mounted on the lower leftportion of the dash assembly (Figure 2). For easiestservice access, the battery should be removed from theunit.

Figure 3. Disconnect Choke Cable At Engine

1. Loosen the choke cable clamp on the engine using aphillips head screwdriver, and after noting theengagement of the cable end with the choke lever,remove the cable end from the choke lever (Figure3).

Figure 4. Choke Cable Assembly

2. From inside the dashboard area, unscrew the hex nutthat secures the choke cable assembly to the dash,and slide the choke cable and handle assembly outof the front of the dash.

3. Inspect all parts for wear or damage, and replace asrequired.

4. Reassemble parts in reverse order of disassembly.

5. Check engine choke linkage for proper engagementwith cable, and smooth operation of choke. Seeengine manufacturer's instructions for completechoke adjustment instructions.


Choke Cable Choke Handle

LockwasherHex Nut

To Engine

Choke Lever

Cable End

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10 Hand Controls ServiceThrottle Control Service

10 - 4

THROTTLE CONTROL SERVICEThe throttle (engine speed) control is attached to theunderside of the dashboard and may be accessed byraising the unit's hood. For greater access and improvedwork area, the battery may be removed from the unit.

Throttle Knob ServiceThe throttle knob (A, Figure 5) snaps onto the throttlecontrol (C). The knob can be removed by pulling itstraight off the control lever. To install it may be neces-sary to drive the knob on with a rubber mallet.

Throttle Assembly ReplacementThe throttle control is not adjustable and is serviced asan assembly.

1. Remove the throttle knob (A, Figure 5) by pulling itstraight off.

2. Unscrew the plastite screws (B) securing the one-piece throttle assembly (C) to the underside of thedashboard, and remove the one-piece throttle/cableassembly.

3. Inspect the assembly for wear or damage andreplace as required.

4. Reassemble in reverse order of disassembly.

Figure 5. Throttle AssemblyA. Throttle KnobB. Plastite ScrewsC. Throttle Assembly

A

B

C

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10 - 5

10 Hand Controls ServiceParking Brake Linkage

PARKING BRAKE CONTROLSERVICEKnob Removal1. The parking brake rod is threaded. Unscrew the

parking brake knob from the parking brake rod.(Figure 7)

Figure 7. Unscrew Parking Brake Knob

Figure 8. Remove Cotter Pin From Parking BrakeRod & Disengage From Brake Cam

Parking Brake Rod Replacement1. Remove the cotter pin (Figure 8) from the lower end

of the parking brake rod (C, Figure 6), and after not-ing the correct installation position of the rod, disen-gage it from the parking brake cam. Lift the parkingbrake rod up and out of the lower dash/frame area,and inspect for wear or damage. Replace as neces-sary. Reassemble in reverse order of removal.

Cotter Pin

A

B

C

DE

F

G

Figure 6. Parking Brake Linkage

A. Parking Brake KnobB. DashboardC. Upper Brake RodD. Parking Brake CamE. Lower Brake RodF. Lock Plate BracketG. Pivot Shaft (Frame)

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10 Hand Controls ServiceNotes

10 - 6

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11 - 1

11 Drive Controls ServiceTable 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

Cruise Control Lock Mechanism .............................7

Cruise Component Replacement

Plate and Pad Replacement.............................................................7

Lock Plate Replacement ..................................................................7

Foot Pedal Assembly Service

Removal and Replacement ..............................................................8

SECT

ION

11. D

RIVE

CONT

ROLS

SERV

ICE

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11 Drive Controls ServiceBrake System Components

11 - 2

Hook Spring to hole in Frame above Transmission

To Notch in Frame

Brake System Components

Figure 1. Brake System ComponentsA. Parking Brake RodB. Cruise/P-Brake Light SwitchC. Parking Brake CamD. Brake PedalE. Foot Pedal ArmF. Clutch Rod

G. Idler assemblyH. PivotI. Brake LeverJ. Brake SpringK. Brake Arm ExtensionL. Brake Return Spring

M. Idler Pivot (Frame)N. Lock Plate BracketO. Plate and Pad AssemblyP. Cruise RodQ. Rear Brake RodR. Cruise Lock Pivot (Frame)

A

D

E

F G

H

I

O

N

J

MR L

K

C

B

P

Q

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11 Drive Controls ServiceParking Brake System Service

GENERAL INFORMATIONThe braking system and ground speed control systemare both linked through the lock plate bracket (B, Figure3) and pivot plate (O). These two parts disengage thecruise mechanism and lock the parking brake. Lockingeither mechanism triggers the parking brake / cruiseswitch (B, Figure 1) and illuminates the indicator light inthe dashboard.

PARKING BRAKE LOCK MECHANISMTo lock the parking brake, first the brake pedal isdepressed, rotating the pivot plate (O, Figure 3) andbrake lever (P) past the locking plate bracket (B) (clock-wise from top). Second the parking brake/cruise knob ispulled up, rotating the locking plate (B) (clockwise fromtop) so that the cruise release tabs (A, Figure 2) movepast each other. At this point, letting up on the brakepedal allows the cruise release tabs to contact eachother back to back, locking the pivot plate (O, Figure 3)and bracket lever (P) in the engaged position.Depressing the brake pedal gives the cruise lock tabs (A,Figure 2) enough clearance to rotate past each other,and allows the parking brake knob to be depressed, dis-engaging the parking brake.

Hook Spring to Frame

To Parking Brake Cam

RA

Q

C

P

OB

D

E

M

K

N

L

/J

I

GH

F

Figure 3. Idler Assembly DetailA. Cruise Pivot (Frame) J. Washer & NutB. Lock Plate Bracket K. V-Idler PulleyC. Cruise Rod L. SpacerD. Brake Pedal Spring M. Washers, 3/8E. Clutch Rod N. Idler PlateF. Washer, 3/8 Plain O. Pivot PlateG. Backside Idler Pulley P. Brake LeverH. Washer & Nut Q. Plate & Pad Assy.I. Idler Assembly Spring R. Idler Pivot (Frame)


A

B


1/8” to 3/16”Gap

BRAKE COMPONENT REPLACEMENTRear Brake Rod Replacement1. Disconnect the brake return spring (L, Figure 1) from

the rear frame bolt.

2. Remove the cotter pin and washer securing the rear ofthe rod to the brake arm extension (K).

3. Remove the nut and spacer securing the brake rodguide to the brake lever (I).

4. Remove the nut and brake spring from the rod, andreplace the rod.

5. Install in reverse order of removal. Be sure to performthe brake spring adjustment found in Section 4ADJUSTMENTS.

WARNINGBefore beginning any service work, turn the PTOoff, set the parking brake, turn the ignition switchoff, remove the key, disconnect the spark plugwires, and disconnect the negative battery cable.

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11 Drive Controls ServiceIdler Assembly and Brake Pedal Service

11 - 4



RA

Q

C

P

OB

D

E

M

K

N

L

/J

I

GH

F

Figure 4. Idler Assembly DetailA. Cruise Pivot (Frame) J. Washer & NutB. Lock Plate Bracket K. V-Idler PulleyC. Cruise Rod L. SpacerD. Brake Pedal Spring M. Washer, 3/8E. Clutch Rod N. Idler PlateF. Washer, 3/8 Plain O. Pivot PlateG. Backside Idler Pulley P. Brake LeverH. Washer & Nut Q. Plate & Pad Assy.I. Idler Assembly Spring R. Idler Pivot (Frame)

Idler Assembly ServiceThe idler assembly (N, Figure 4) is not attached to thebrake lever (P). The idler assembly is rotated by contactbetween the pivot plate (O) and the stud on the top theidler plate (N) next to the pivot hole. The idler assemblyis under tension from the spring (I). If the idler assemblywill not return to normal position when the brake isreleased, remove and clean the assembly, and clean anydebris or corrosion from the pivot (R).

1. Block the wheels and engage the parking brake.

2. Loosen the hardware securing the backside idler pul-ley (G, Figure 4). Remove the belt from the pulleyassembly.

3. Disengage the parking brake.

A

B

D

C

F

G

E

Figure 5. Brake Pedal AssemblyA. Brake Pedal Arm E. Brake Pedal CamB. Bushings F. Brake Switch ActuatorC. Clutch Rod G. LocknutD. Frame

4. Remove the clip and washer from the frame pivot pin(R).

5. Remove and inspect the idler assembly. Check thepulleys for rough rotation or wobbling.

6. Install in reverse order of removal.

Brake Pedal Pad ReplacementThe brake pedal pad is glued to the brake arm. Toremove the pad, twist it while pulling. Use a chemicaladhesive to glue the new pedal pad to the brake armsuited to bonding metal to rubber.

Brake Pedal Assembly Removal &Installation1. Engage the parking brake - this releases tension on

the brake pedal assembly.

2. Remove the locknut (G, Figure 5).

3. Slide the brake pedal arm (A) out of the frame (D)and brake pedal cam (E). While the pedal assemblyis removed DO NOT disengage the parking brake.

4. Install in reverse order of assembly.

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11 Drive Controls ServiceDifferential Lock and Shock Absorber Service

DIFFERENTIAL LOCK CONTROLSERVICE(Select Models)Early models used a cable to actuate the transmissioncontrol arm. Later models used a rod.

Replacement

1. Remove the hardware securing the seat deck (seeSection 16 SEAT DECK SERVICE).

2. Disconnect the cable or rod (C, Figure 7) from thetransmission control lever (B) or pedal. Inspect andreplace as necessary.

3. Remove the C-clip securing the diff lock pedal to theframe stud.

4. Remove the pedal assembly. Inspect and replace asnecessary.

5. Install in reverse order of removal. Perform the differ-ential lock cable adjustment found in Section 4ADJUSTMENTS.

SHOCK ABSORBER REPLACEMENTThe shock absorber dampens the foot pedal, preventingjerky starts and stops.

1. Remove the hardware securing the mounting bracketsecuring the rear of the shock absorber (K, Figure 8).

2. Remove the hardware securing the front of the shock(K) to the transmission control lever (L).

Figure 7. Diff Lock Pedal and CableA. C-ClipB. Transmission Control LeverC. Cable or Rod

Figure 6. Diff Lock PedalA. Pedal Knob

A

A

B

C

Rear Wheel Removedfor Clarity

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11 Drive Controls ServiceCruise Control System Components

11 - 6

Cruise Control System Components

Figure 8. Drive System ComponentsA. Parking Brake RodB. Cruise/P-Brake Light SwitchC. Parking Brake CamD. Ground Speed Pedal Assy.E. Sift RodF. Idler Assembly

G. PivotH. Brake LeverI. Plate & Pad AssyJ. Release LeverK. Shock AbsorberL. Trans. Control Lever

M. Idler Pivot (Frame)N. Lock Plate BracketO. Lock PlateP. Lock Plate RetainerQ. Shock Mounting Bracket

A

D

E

F

G

H

I

O

N

JM

L

K

Q

C

B

P

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11 Drive Controls ServiceCruise Control Service

CRUISE CONTROL LOCKMECHANISMTo engage the cruise control, first the ground speedpedal must be depressed. This moves the lock plate (O,Figure 8) forward. Second the parking brake / cruiseknob is pulled up rotating the plate and pad assembly (Q,Figure 10) (clockwise from top) into the lock plate (O,Figure 8). The lock plate is pinned between the pad andframe, and the transmission’s return-to-neutral springprovides the tension to lock the mechanism. Depressingthe ground speed pedal moves the lock plate forward,allowing the pivot plate to rotate back to disengagedposition; or depressing the brake pedal rotates the brakecam (B, Figure 9), causing the cruise release tabs (A) tocontact each other, rotating the plate and pad out oflocked position, releasing the lock plate.

If the cruise control will not engage or release properly,the components should first be cleaned and lubricated.If this does not rectify the problem, replace any worncomponents.

CRUISE COMPONENTREPLACEMENTPlate and Pad Replacement1. Block the wheels. Disengage the parking brake.

2. Disconnect the idler assembly return spring (I, Figure10).

3. Disconnect the brake pedal spring (D, Figure 10).

4. Remove the cotter pin and washer securing the rearof the clutch rod (E) to the brake lever (P).



RA

Q

C

P

OB

D

E

M

K

N

L

/J

I

GH

F

Figure 10. Idler Assembly DetailA. Cruise Pivot (Frame) J. Washer & NutB. Lock Plate Bracket K. V-Idler PulleyC. Cruise Rod L. SpacerD. Brake Pedal Spring M. Washer, 3/8E. Clutch Rod N. Idler PlateF. Washer, 3/8 Plain O. Pivot PlateG. Backside Idler Pulley P. Brake LeverH. Washer & Nut Q. Plate & Pad Assy.I. Idler Assembly Spring R. Idler Pivot (Frame)


A

B


1/8” to 3/16”Gap

5. Remove the locknut and washers securing the cruiseassembly (B, Q, Figure 10) to the cruise pivot (A).

6. Inspect and replace parts as needed. Install inreverse order of installation. If the lock plate bracket(B) and plate and pad assembly (Q) are separated,perform the cruise control adjustment in Section 4ADJUSTMENTS.

Lock Plate Replacement1. Block the wheels and disengage the parking brake.

2. Remove the lock plate retainer (P, Figure 8).

3. Loosen the hardware securing the ground speedpedal assembly (D, Figure 8). Remove and replacethe lock plate (O). Install in reverse order of removal.

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11 Drive Controls ServiceFoot Pedal Assembly Service

11 - 8

FOOT PEDAL ASSEMBLY SERVICERemoval & Installation1. Remove the washer, lockwasher, and nut (F, Figure

11) securing the transmission control rod (G) to thefoot pedal assembly.

2. Remove the capscrew (D) and spacer (H).

3. Remove the ratchet fasteners (A) and foot rest pad.

4. Remove the capscrews (C), washers, and nuts (E)securing the foot pedal assembly (J).

5. Disconnect the friction plate (I) from the foot pedalassembly (J) and remove the assembly.

6. Install in reverse order of removal. Check the footpedal height adjustment per the procedure found inSection 4 ADJUSTMENTS.

A

B

D

J

F

H

I

G

C

E

Figure 11. Foot Pedal AssemblyA. Ratchet FastenersB. Foot Pedal PadC. CapscrewD. CapscrewE. Washer & NutF. Washer, Lockwasher, & NutG. Transmission Control RodH. SpacerI. Friction Lock Plate AssemblyJ Foot Pedal Assembly

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12 - 1

12 Hand Controls ServiceTable 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 & Pulley Replacement.................................................12-8

Engine Choke Control (Select Units)

Choke Cable Replacement .........................................................12-9

Throttle Control Service

Throttle Knob Service................................................................12-10

Throttle Assembly Replacement ...............................................12-10

Parking Brake Control Service

Knob Removal...........................................................................12-10

Parking Brake Rod Replacement..............................................12-10

Hydraulic Lift Control Service

Lift Control Knob Replacement .................................................12-11

Lift Control Lever Replacement.................................................12-11

SECT

ION

12. H

AND

CONT

ROLS

SERV

ICE

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12 Hand Controls ServiceExploded View Diagrams

12 - 2

Manual Lift Mechanism - Models with 44” Mower Deck

4

2

6

6

5

1

3

3

10

10

78

9

9

9

9

20

18

23

15

15

21

19

22

17

1112

1112

16

1314

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1 1650157 1 BUTTON2 1713995 1 GRIP3 1918265 2 WASHER, 5/164 1676526 1 SPRING, Compression5 1721866 1 QUADRANT & LEVER ASSEMBLY6 1705249 3 SPACER7 1922127 1 CAPSCREW, Hex Head, 5/16-18 x 1-3/48 1921977 1 CAPSCREW, Hex Head, 5/16-18 x 1-1/49 1919438 6 LOCKNUT, ESNA, 5/16-18

10 1722320 2 PIN, Cotter Locking11 1922755 2 WASHER, 3/812 1708298 2 PIN, Round Head, Drilled, 3/8 x 113 1960033 1 HAIR PIN, Clip14 1911386 1 WASHER, 3/415 1923325 4 CAPSCREW, Hex Head, 5/16-18 x 7/816 1704712 1 BRACKET17 1721869 1 TUBE & ARMS ASSEMBLY18 1704713 1 BRACKET & PINS ASSEMBLY19 1704715 1 BRACKET20 1934953 1 PUSH NUT, 5/1621 1927609 1 ROLL PIN, 3/8 x 122 1721999 1 LATCH23 1721959 1 ROD



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12 - 4


12

18

16

20

20

13

19

15

17

17

14

14

2122

28

28

28

28

26

30

23

29

29

25

27

24

31

11

32

3433

1

7

7

5

5

10

2

8

8

4

4

6

6

3

3

11

9

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1 1916951 1 NUT, 1/2-132 1916966 1 LOCKWASHER, 1/2-133 1924361 2 WASHER, 1/24 1722412 2 SPACER5 1708559 2 PULLEY6 1924359 2 WASHER, 1/27 1722343 2 PULLEY, Guide8 1722411 2 SPACER9 1960245 1 CAPSCREW, Hex Head, 1/2-13 x 3

10 1703805 1 RING, Klipring11 1708298 4 PIN, Round Head, Drilled, 3/8 x 112 1722436 2 CABLE13 1922755 2 WASHER, 3/814 1722320 4 PIN, Cotter Locking15 1650157 1 BUTTON16 1713995 1 GRIP, Black17 1918265 2 WASHER, 5/1618 1676526 1 SPRING, Compression19 1722413 1 QUADRANT & LEVER ASSEMBLY20 1705249 3 SPACER21 1922127 1 CAPSCREW, Hex Head, 5/16-18 x 1-3/422 1921977 1 CAPSCREW, Hex Head, 5/16-18 x 1-1/423 1721959 1 ROD24 1721999 1 LATCH25 1927609 1 ROLL PIN, 3/8 x 126 1934953 1 PUSH NUT, 5/1627 1704715 1 BRACKET28 1919438 8 LOCKNUT, 5/16-1829 1923325 4 CAPSCREW, Hex Head, 5/16-18 x 7/830 1704713 1 BRACKET & PINS ASSEMBLY31 1709926 1 TUBE & ARMS ASSEMBLY32 1704712 1 BRACKET33 1911386 1 WASHER, 3/434 1960033 1 PIN, Hair



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12 Hand Controls ServiceManual Lift Lever Service

12 - 6

MANUAL LIFT LEVER SERVICEGeneralTwo different manual lift mechanisms have been used onthe foot pedal controlled Landlord / 1700 / 2700 series.Models with a 44” mower use a duel chain lift, modelswith a 50” mower use a duel lift cable.

Latch Rod & Spring Replacement - All Manual Lift ModelsSee Figure 1.

The latch rod (G) fits inside the hollow lift lever assemblytube (E) and is secured in place with a pushnut (J).

1. Remove the grip (B).

2. Remove the button (A), washers (C), and spring (D).

3. Using a 5/16" pin punch and hammer, tap the end ofthe latch rod (G) back through the pushnut (J) andlatch (H).

4. Drive out the roll pin (I) and remove the latch (H).

5. Rotate the lever (E) forward and remove the latch rod(G).


Figure 1. Lift Lever LatchA. Button F. QuadrantB. Grip G. Latch RodC. Washers H. LatchD. Spring I. Roll PinE. Lift Lever J. Pushnut

A

B

C

D

E

F

G

H

I

J

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12 - 7


Lift Lever Removal - All Manual Lift ModelsThe entire lift lever assembly may be easily removedfrom the unit for bench inspection and repair:

1. If desired, remove the mower deck from the unit (seeMower Deck repair section for specific instructionsregarding mower deck removal if necessary), or:

2. Remove the locknuts (D, Figure 2) and spacers (C)securing the side and bottom of the U-bracket (B).

3. Remove the hair pin clip (F) and washer from the leftside of lift rod.

4. Slide the lift lever assembly straight off the bracketand pin assembly (E).

5. The lift lever assembly may now be moved to a work-bench for additional inspection and any required ser-vicing.

A

HC

G

BC

D

E

F

D

Figure 2. Lift Lever Assembly - 44” ModelsA. Lift Lever Assy.B. U-Bracket Assy.C. SpacersD. 5/16-18 LocknutsE. Bracket & Pin Assy.F. Hair Pin ClipG. 5/16-18 x 1-1/4 CapscrewH. 5/16-18 x 1-3/4 Capscrew

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12 - 8

Lift Cable & Pulley ReplacementNOTE: The right side pulley is secured with a lockwasherand 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. The pins must beinstalled in this orientation for proper clearance.

The right and left lift cable pulley assemblies are assem-bled to the sides of the frame, and are accessiblethrough the rear wheel wells.

1. Detach the lift cable (C, Figure 3) from the mowerand lift lever arm.

2. Remove the c-clip (F, Figure 4), washer (E), andspacer (D).

3. Slide the pulley out so that the cable clears the cableguide. Or remove and replace the pulley.

4. Install in reverse order of removal. Orient the cableas shown.

Figure 3. Mower Lift - 50” Manual Lift ModelsA. Hair Pin ClipB. Clevis Pin (Inserted Left to Right)C. Lift CableD. Clevis Pin (Inserted Right to Left)E. Hair Pin Clip & WasherF. Mower Lift Arm

C

B

D

A

E

F

FRONT

AB

H

C D E F

G

Figure 4. Lift Cable ReplacementA. Spacer E. Washer, LargeB. Cable Guide F. C-ClipC. Pulley G. CableD. Spacer H. Washer, Small

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12 - 9

12 Hand Controls ServiceChoke Control Service

Figure 5. Engine Choke Control Location

ENGINE CHOKE CONTROL (SELECT UNITS)Choke Cable ReplacementOn units with a dash-mounted engine choke control, thecontrol is a push-pull button mounted on the lower leftportion of the dash assembly (Figure 5). For easiestservice access, the battery should be removed from theunit.

Figure 6. Disconnect Choke Cable At Engine

1. Loosen the choke cable clamp on the engine using aphillips head screwdriver, and after noting theengagement of the cable end with the choke lever,remove the cable end from the choke lever (Figure6).

Figure 7. Choke Cable Assembly

2. From inside the dashboard area, unscrew the hex nutthat secures the choke cable assembly to the dash,and slide the choke cable and handle assembly outof the front of the dash.

3. Inspect all parts for wear or damage, and replace asrequired.

4. Reassemble parts in reverse order of disassembly.

5. Check engine choke linkage for proper engagementwith cable, and smooth operation of choke. Seeengine manufacturer's instructions for completechoke adjustment instructions.


Choke Cable Choke Handle

LockwasherHex Nut

To Engine

Choke Lever

Cable End

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12 Hand Controls ServiceThrottle & Parking Brake Control Service

12 - 10

THROTTLE CONTROL SERVICEThe throttle (engine speed) control is attached to theunderside of the dashboard and may be accessed byraising the unit's hood. For greater access and improvedwork area, the battery may be removed from the unit.

Throttle Knob ServiceThe throttle knob (A, Figure 8) snaps onto the throttlecontrol (C). The knob can be removed by pulling itstraight off the control lever. To install it may be neces-sary to drive the knob on with a rubber mallet.

Throttle Assembly Replacement1. Remove the throttle knob (A, Figure 8) by pulling it

straight off.

2. Unscrew the plastite screws (B) securing the one-piece throttle assembly (C) to the underside of thedashboard, and remove the one-piece throttle/cableassembly.

3. Inspect the assembly for wear or damage andreplace as required.

4. Reassemble in reverse order of disassembly.

Figure 8. Throttle AssemblyA. Throttle KnobB. Plastite ScrewsC. Throttle Assembly

A

B

C

PARKING BRAKE CONTROLSERVICEKnob Removal1. The parking brake rod is threaded. Unscrew the

parking brake knob from the parking brake rod.(Figure 9)


Figure 10. Remove Cotter Pin From Parking BrakeRod & Disengage From Brake Cam

Parking Brake Rod Replacement1. See Figure 10. Remove the cotter pin from the lower

end of the parking brake rod, and after noting the cor-rect installation position of the rod, disengage it fromthe parking brake cam. Lift the parking brake rod upand out of the lower dash/frame area, and inspect forwear or damage. Replace as necessary.Reassemble in reverse order of removal.

Cotter Pin

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12 - 11

12 Hand Controls ServiceHydraulic Lift Control Service

Figure 11. Control Valve ReplacementA. KnobB. Control LeverC. 5/16-18 x 1-1/4 CapscrewD. Flat WasherE. SpacerF. Flange NutG. Washer and Cotter PinH. Control Lever Link

A

B

C

DE F

H

G

HYDRAULIC LIFT CONTROL SERVICELift Control Knob Replacement1. Clear the area around the mower deck or attachment

and cycle the lift valve lever (A, Figure 11) to relieveany pressure in the system and lower the attachment.

2. Remove the knob (A, Figure 11) by pulling it straightoff the control lever (B). To install, press the newknob onto the lever.

Lift Control Lever ReplacementNOTE: For easier access, you may want to remove thebattery first.

1. Clear the area around the mower deck or attachmentand cycle the lift valve lever (A, Figure 11) to relieveany pressure in the system and lower the attachment.

2. Disconnect the control lever link (H) from the controllever (B) by removing the cotter pin and washer (G).

3. Remove the capscrew (C), flat washer (D), spacer(E) and nut (F).

4. Remove and replace the lever (B). Install in reverseorder of removal.

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12 Hand Controls ServiceNotes

12 - 12

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13 - 1

13 Hood & Dashboard ServiceTable of Contents

SECTION CONTENTS


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

SECT

ION

13. H

OOD

&DA

SHBO

ARD

SERV

ICE

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13 Hood & Dashboard ServiceExploded View Diagram

13 - 2

25

24

26

30

29

17

12

23 27

6

910

12

13

15

16

3

8

8 7

8 21

28

1

10108

121

353132

11

810

14

1222

181920

5

4

2

121

Hood, Grille & Dash Group

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13 Hood & Dashboard ServiceExploded View Diagram

1 10 PAL NUT, 1/4-202 1 AIR DUCT3 1 MOLDING, Air Duct 4 1 PLUG, Hole, Electric Lift 5 1 DASH ASSY. 6 1 DASH, Lower7 2 WASHER, Plain, 1/48 20 CAPSCREW, Hex Flange Hd, Whizlock, 1/4-20 x 5/89 1 BUSHING, Nylon

10 7 CAPSCREW, Taptite, 1/4-20 x 1/211 1 SUPPORT, Bulkhead, LH12 10 NUT, Hex Nylon Lock, 1/4-2013 1 SUPPORT, Bulkhead, RH14 1 BULKHEAD15 1 GROMMET, Wire Harness16 1 GROMMET, Bulkhead 17 1 SIDE PANEL ASSY., LH18 2 STRAP, Hood19 2 WASHER, Special20 2 NUT, Hex Nylon Lock, #10-2421 1 GRILLE22 2 HINGE, Hood23 2 SPACER, Hood24 2 SPACER25 2 PIVOT, Hood26 2 CAPSCREW, Taptite, 5/16-18 x 127 2 CLIP, Hairpin28 2 CAPSCREW, Taptite, 5/16-18 x 5/829 1 SIDE PANEL ASSY30 1 HOOD31 2 PLUG32 1 CAPSCREW, Taptite, 1/4-20 x 3/8

Hood, Grille, & Dash Group


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13 Hood & Dashboard ServiceHood & Battery Removal

13 - 4

HOOD & DASH REMOVAL

Remove the Hood1. Tip the hood forward.

2. Disconnect the wire harness from the headlights.

3. Remove the retaining clip (A, Figure 1) and spacer(B).

4. Lift the hood assembly off the frame pivots.

Remove the Battery1. Disconnect the negative battery cable (A, Figure 2)

from the negative battery post.

2. Disconnect the positive battery cable (B) from thepositive battery post.

3. Remove the hold-down rods (A, Figure 3) and hold-down bar.

4. Remove the battery from the compartment.

Figure 1. Remove HoodA. Retaining ClipB. Spacer

B

WARNINGBefore beginning any service work turn off thePTO, set the parking brake, turn off the ignition,and disconnect the spark plug wire(s).

A

WARNINGBattery Safety Rules: Be careful when handling the battery. Avoid

spilling electrolyte. When removing or installing battery cables,

disconnect the negative cable FIRST andreconnect it LAST. If not done in this order, thepositive terminal can be shorted to the frameby a tool.

Battery acid causes severe burns. Avoid contact with skin.

Wear eye protection while handling battery. To avoid an explosion, keep flames and sparks

away from battery, especially while charging.

Figure 3. Engine Compartment - Air Cooled ModelsA.Hold-Down Rods

A

FRONT

Figure 2. Battery Cables - Air Cooled ModelsA. Negative Cable D. CapscrewB. Positive Cable & Cover E. Vent Hose C. Nut, Lockwasher, & Washer

C

BE

A

D

D

C

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13 - 5

13 Hood & Dashboard ServiceBattery & Dashboard Removal

Remove the Dashboard1. Using a punch, remove the roll pin from the steering

shaft (Figure 4). Remove the steering wheel and flexcollar.

Figure 4. Remove Steering Wheel


Figure 6. Remove Front Dash Mounting Screws

3. Unscrew the parking brake knob from the parkingbrake rod. (Figure 5)

4. Remove the whizlock capscrews from the lower frontcorners of the dash using a 3/8” box wrench (Figure6). These screws fasten into captive pal-nuts in thedash.

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13 Hood & Dashboard ServiceDashboard Removal

13 - 6

5. Using a 3/8" nut-driver remove the two whizlock cap-screws and washers that secure the rear of the dashto the lower dash (Figure 7).

Figure 7. Remove Rear Dash Mounting Screws

Figure 8. Disconnect Starter Cable At Solenoid

Solenoid

Figure 9. Gently Pry Connector Apart WithScrewdriver

6. Disconnect the starter cable from the solenoid(Figure 8).

7. Label and disconnect all necessary wire harness con-nectors (Figure 9).

NOTE: If the connector cannot be separated by using agentle flexing motion on each of the two halves, insert asmall, flat-blade screwdriver between the halves, anduse a gentle prying motion to separate the connector. Itmay also be necessary to soften the connector with ahair dryer.

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13 - 7

13 Hood & Dashboard ServiceDashboard & Battery Installation

8. Disconnect the throttle cable and choke cable fromthe engine (Figure 10).

9. Carefully lift the dash assembly away from the lowerdash.

HOOD & DASHBOARDINSTALLATIONReinstall Dashboard1. Reattach the throttle and choke controls to the engine

(Figure 10). Refer to the engine manual for specificinstructions and adjustments.

2. Reconnect all wire harnesses and plugs.

3. Reconnect the starter cable to the solenoid (Figure8).

4. Reinstall the two whizlock capscrews securing therear of the dash to the lower dash (Figure 7).

5. Secure the upper dash to the lower dash using theoriginal hardware (Figure 6).

6. Reinstall the parking brake knob (Figure 11).

Figure 10. Choke & Throttle Cables

Figure 11. Parking Brake Knob

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13 Hood & Dashboard ServiceBattery & Hood Installation

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Figure 12. Engine Compartment - Air Cooled ModelsA. Hood Strap C. Hold-Down RodsB. Vent Cap

A B

C

FRONT

Figure 13. Battery Cables - Air Cooled ModelsA. Negative Cable D. CapscrewB. Positive Cable & Cover E. Vent HoseC. Nut, Lockwasher, & Washer

C

BE

A

D

D

C

Figure 14. HoodA. Retaining ClipB. Spacer

B

A

WARNINGBattery Safety Rules: Be careful when handling the battery. Avoid

spilling electrolyte. When removing or installing battery cables,

disconnect the negative cable FIRST andreconnect it LAST. If not done in this order, thepositive terminal can be shorted to the frameby a tool.

Battery acid causes severe burns. Avoid contact with skin.

Wear eye protection while handling battery. To avoid an explosion, keep flames and sparks

away from battery, especially while charging.

Reinstall the Battery1. Carefully place the battery back in the engine com-

partment (see Figure 12). Secure the battery usingthe hold-down rods (C) and hold-down bar.

2. Attach the red positive cable (B, Figure 13) and coverto the positive post as shown.

3. Attach the black negative cable (A, Figure 13) to thenegative post as shown.

4. Install the vent hose (if equipped) on the battery capand route the hoses out of the bottom right side of theengine compartment through the frame. Make surethe tubes go all the way through the frame and willnot drip on any belts, pulleys, or the mower deck.

Reinstall Hood1. Rest the hood assembly on the pivot bolts. Tilt the

hood forward.

2. Install the spacers (B, Figure 14) on the pivot bolts.

3. Secure the spacers (B) with retaining clips (A).

4. Close the hood to check the fit between the hood anddashboard. If the fit must be adjusted, loosen thehardware securing the dashboard and shift theassembly.

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14 Transmission Tear-DownContents

SECTION CONTENTS


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

SECT

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14 Transmission Tear-DownExploded View Diagrams

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1 1 CASE SET, (K71E Only, See Ref. 20 for K71G)2 2 BEARING, 28 x 153 1 TAPER PLUG, 1/8, (K71E Only)4 1 BORE PLUG, 17, (K71E Only)5 1 CAP, Oil, 206 1 FILTER7 1 FITTING8 1 SEAL9 2 BEARING

10 2 SEAL11 1 SCREW, Tapping, 8 x 2512 18 SCREW, Tapping13 1 SCREW, Tapping, 8 x 4514 2 BOLT, 8 x 75”15 3 RING, 4716 2 BOLT, 10 x 1217 2 PACKING, P1818 1 MAGNET COMPLETE19 1 MAGNET, Disk20 1 CASE SET (B), (K71G Only, See Ref. 1 for K71E)21 1 SEALANT22 1 CASE, Lower23 1 WASHER, Seal 1024 2 PIPE, 13 x 11.325 1 CENTER CASE COMPLETE26 1 VALVE, (A-1 SET)27 2 VALVE, (A-2 SET)28 2 KNOCK PIN, 15.5 x 3029 1 PLUG, 16 x 2530 1 PACKING31 2 PIN, 8 x 1432 1 PIN, 3 x 9.833 3 BOLT, 10 x 7534 1 FILTER35 1 CAP, (M40)36 1 PACKING37 2 CYLINDER BLOCK COMPLETE38 1 PUMP SHAFT39 2 RING, 1740 1 BEARING, 630341 1 HOUSING42 1 BEARING, 5120743 2 BLOCK44 1 WASHER, 18 x 31 x 145 1 SHAFT MOTOR46 1 BEARING47 1 MOTOR GEAR48 1 SNAP RING, 2049 1 RING, E1550 1 PUMP CASE S/A51 1 PUMP CASE COMPLETE52 1 CHECK BALL RETAINER53 1 HOLDER, (SEAT)54 1 VALVE, (IMP COMPLETE)55 2 PLUG56 1 VALVE, (CHARGE COMPLETE)57 1 PLUG, PT 1/858 2 CONNECTOR59 2 PACKING, P16

K71 Hydrostatic Transmission


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60 2 PACKING, 6.161 1 PIN, 3.2 x 2162 3 BOLT, 8 x 4563 1 SWASH PLATE COMPLETE64 1 BEARING COMPLETE65 2 WASHER66 1 SPRING (N/C)67 1 SHAFT (BYPASS)68 1 LEVER (BYPASS)69 1 RING70 1 SPRING71 2 PACKING72 1 PIN, 3.0A*2073 1 CONTROL LEVER75 1 BOLT76 1 PIN, 6.0A x 5077 1 PIN, 3.5A x 5078 1 WASHER, 1079 1 SIDE COVER SET, (Includes Ref. 2, 80 & 81)80 2 PACKING, P1481 2 PACKING, P2882 1 FULCRUM, (ECCENT)83 1 WASHER84 1 NUT 1285 2 PIN, 8 x 1686 2 DIFF GEAR KIT, (K71E Only, See Ref. 88 for K71G)87 1 FINAL GEAR88 2 DIFF GEAR KIT, (K71G Only, See Ref. 86 for K71E)89 1 SHAFT, (F PINION)90 1 REDUCTION GEAR91 1 BUSHING, 1592 1 BEARING, 6203SH293 1 AXLE SHAFT L94 1 AXLE SHAFT R95 1 COLLAR, (Diff. Lock), (K71E Only, See Ref. 99 for K71G)96 2 THRUST WASHER97 2 RING98 2 BUSHING99 1 COLLAR, (K71G Only, See Ref. 95 for K71E)100 1 BRAKE KIT101 1 PACKING, G35102 1 SPRING, (RETURN)103 1 SEAL, TC173007104 1 ARM, (BRAKE)105 2 BOLT, 8 x 25106 1 PIN, 6.0A x 4.0107 2 FORK, (Diff. Lock), (K71E Only)108 2 SHAFT, (Diff. Lock), (K71E Only)109 1 SPRING, (Diff. Lock), (K71E Only)110 1 ARM, (Diff. Lock), (K71E Only)111 1 COLLAR, (STOP), (K71E Only)112 1 SLIDER, (Diff. Lock), (K71E Only)113 1 WASHER, 17 x 32 x 3, (K71E Only)114 1 PACKING, 1A P12.5, (K71E Only)115 2 PIN, 6.0A*32, (K71E Only)116 2 PIN, 3.5A x 32, (K71E Only)

K71 Hydrostatic Transmission


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14 Transmission Tear-DownGeneral Information / Specs

14 - 6

Specifications:Type K71 Tuff TorqPump Variable Displacement Axial PistonMotor Fixed Displacement Reversible Axial PistonHydraulic Fluid 1.2 Gallons (4.6L) 10W30 CD Oil,

not including Oil Reservoir and External 10 Micron Filter

Control Foot Control, Free-Wheeling Lever for Manual Tractor Movement, ContinuouslyVariable, Forward & Reverse, without Brakingor Gear Changing

Speeds Forward: 0 - 6.6 MPH (0 - 10.6 km/h)@ 3400 rpm Reverse: 0 - 3.1 MPH (0 - 5 km/h)Differential Bevel Gear Type with Controlled TractionAxle Shaft 1 inContinuous Torque 405 ft. lbs.OutputDrawbar Rating 440 lbs.Maximum Weight 728 lbs.on Axle

GENERAL INFORMATIONIntroductionThere are presently 3 variations of the K-71 transaxlebeing used.

The K-71E has a differential lock, automatic controlledtraction, 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.

The K-71G has no differential lock, but does have auto-matic controlled traction, and a charge pump whichallows the unit to have hydraulic lift and power steering.

The K-71J has no differential lock, but does have auto-matic controlled traction, and a charge pump. Thecharge pump in this unit is of a different style and will notprovide hydraulic lift or power steering.

Some unique features of this transmission include:

• An internal wet brake.

• The transaxle case is divided into two sections whichresults in a number of benefits. Most particulatecontamination from the gear train is kept away fromthe sensitive components of the hydro. The transaxlecase is strengthened, and the unit is quieter in opera-tion. Oil also gets a chance to cool as it flowsbetween sections.

• There are three filters in this transaxle. The first isthe main filter within the hydro section that filters theoil prior to it being circulated through the rotatinggroups. The second separates the two sections ofthe transmission and keeps particulate contaminationaway from the hydro section. The third is the spin onfilter under the seat deck.

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14 Transmission Tear-DownDisassembly

DISASSEMBLYPreparationDrain the transaxle oil, thoroughly clean the transmis-sion, and put it on a stand. We suggest partially tappingsome of the unused case holes and using 1/2” bolts tosupport the front of the transmission. Use 5/16” rod tosupport the rear.

Note that a majority of the hardware is metric, but thereare some SAE sizes as well. Be sure to handle partswith care so as not to damage any components, espe-cially when working in the center section area (pump andmotor group).

Disassembly1. Loosen and remove the plastic plug (A, Figure 1) at

the lower front of the unit. Remove the filter (B).

2. Remove the 2 auxiliary hydraulic fitting adapters (C,Figure 1).

3. See Figure 2. Remove the case bolts, noting as yougo the varying length of the bolts (there are two longbolts, one medium length bolt, and 18 short bolts.There are two oil drain plugs. They can be distin-guished from the case bolts in that they have a seal-ing washer under them and require a 14mm socket.


Figure 1. Internal Transmission Filter ServiceA. Plastic Plug C. FittingsB. Internal Filter

AB

Figure 2. Case BoltsA. Long Bolts C. Drain PlugsB. Medium Bolt

Figure 3. Remove Lower Case

C

4. Separate the upper and lower case halves. Pry onlyat the pry-points. Remove any sealant left on themating surfaces.

5. Remove the lower case. Note a few items here.

• The magnet in the lower case will attract and holdmetal filings from the gear train.

• The small circular filter that separates the two casehalves from each other.

• Note that if the unit is equipped with the differentiallock, the mechanism is in the lower case.

A

B

C

Filter Disk (BehindCharge Pump)

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6. Use a 5mm allen wrench to remove the allen plug togain access to the roll pin that holds the shift fork inplace for the differential lock.

7. Use an appropriate punch and hammer to drive theroll pin towards the front. Be sure that the pin isbeing driven straight forward, and not down into thecase.

8. Pull the shaft out along with the spring, spacer andfork. Replace damaged parts as required.

9. Reassemble the shaft and case using a new o-ring.Be sure the new o-ring is lubricated and that the leveris oriented downward. Install the roll pin from theplug opening. Once installed be sure the roll pindoes not interfere with the case as it rotates duringoperation.

Figure 4. Remove Diff Lock ShaftA. Roll Pin

Figure 5. Remove Intermediate Gear Assy.

Figure 6. Intermediate Gear Assembly

10. Lift out the intermediate gear assembly.Disassemble and examine the components for anysigns of abnormal wear or damage. Note also theorientation of the bushing flats in the upper case andnotice that there is a slight bevel to the large gearthat faces the center of the transaxle.

BushingFlats

Beveled Edge

Allen plug

Roll Pin

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11. Remove the differential:

• Lift out the axle retainer (Figure 7) on either side ofthe differential, then pull the axles out slightly. Use amagnet to remove the axle c-rings (Figure 8) andcontinue to pull out the axles until they clear the dif-ferential.

• Lift the differential assembly out (Figure 9).Disassemble the gears and examine for any signs ofdamage or excessive wear. Note that not all theparts are serviced individually. Refer to current partsinformation for details.

• Do not disassemble the small pinion assemblies forany reason. They are not serviceable and the frictionor torque settings are factory established. Tamperingwith these will adversely affect the automatic con-trolled traction performance.

• Remove the bushings from the housing. Inspect forwear. Note the orientation of the bushings and thatboth are the same.

Figure 7. Remove Differential Retainers

Figure 10. Differential Assembly

Figure 8. Remove C-Rings

Figure 9. Remove Differential Assembly

Pinion Assy.DO NOTDisassemble

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12. Remove the axles (Figure 11) from the upper case.Examine the components for any signs of damage orwear, and replace as needed.

13. See Figure 11. To remove the axle bearing(s), firstremove the seal. Then remove the snap ring andcarefully drive the bearing out being careful not to hitthe balls or their cage. Examine it carefully for anysigns of damage or wear. It should turn over freelywith no roughness.

14. Remove the small round filter that separates the twosections of this transmission.

15. Using a 12mm socket, loosen and remove the threebolts that hold the charge pump housing in place(Figure 12). Carefully lift & remove the housing fromthe center section (Figure 13). Remove the rotorsand inspect for wear or damage. Any unusualscratches or wear will require replacement.

• The charge and implement relief valves can beremoved and inspected. Be careful not to mix up thesprings between the two valves. Note that theplungers and springs are different sizes and will notinterchange (implement spring is heavier). Againlook for any signs of gouges on the valve itself ordamage to the springs, replacing as needed. Be sureto keep track of the ball check valve if it was removedfor cleaning.

Figure 11. Axle Removal

Figure 12. Charge Pump Removal


Seal

Snap Ring

Bearing

Axle

Charge Pump Bolts

Inspect RunningSurfaces for Wear

Charge PressureValve and Spring

Ball Check Valve

Implement ReliefValve & Spring

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16. Using a 14mm socket, loosen and remove the threebolts that retain the center section. Remove thebrake assembly bolts and brake assembly. Beforelifting and removing the center section from the uppercase, be sure to note the letter on the fixed swash-plate. It must be reassembled with that letter facingup. If assembled incorrectly, the unit will run back-wards.

Figure 14. Center Section Bolts

Figure 15. Center Section Removal

Center SectionBolts

Note Letteron FixedSwash Plate

BrakeAssemblyBolts

17. Carefully lift the center section up and out of theupper case. The fixed swashplate, motor rotatinggroup, and shaft can now be separated. Use carewhen handling all these parts.

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18. Inspection and evaluation (see Figure 16).

• Inspect the motor shaft (H), bearing (I) and gear (J).If replacing the bearing, note that the seal is towardthe gear. Examine the motor shaft for damage to thesplines and bearing. Examine the thrust bearing andraces (F). Note that the thrust bearing race with thelettering on it goes in the swashplate (G). Any form ofdamage here would require replacement of all theparts

• Examine the rotating groups carefully. Be sure toreinstall the pistons (A) in the same bore they wereremoved from. Also make sure the washer insideeach piston is accounted for. Make sure the pistonsand bores in the motor block are free of scratches.Pistons should move up and down smoothly and eas-ily in their bores. Also look at the bottom of the cylin-der block where it contacts the center section: makesure there is no excessive scratching or wear.Caution: under no circumstances should you everremove the snap ring that retains the center spring inthe rotating groups. The spring is under considerableforce and can easily cause serious injury.

• Closely examine the running surfaces of the centersection and charge pump for any signs of excessivewear, damage or scratches. If you can feel scratcheswith a sharp pencil or fingernail on any of these sur-faces, they should be replaced.

• Remove and inspect the release valve pin (D).

Figure 16. Center Section

H

G

I

JF

E

B

C

D

A

A A. Piston, Washer, & SpringB. Motor BlockC. Center SectionD. Release Valve PinE. Pump BlockF. Bearing and RacesG. SwashplateH. Motor ShaftI. BearingJ. Gear

Do not disassemblethe center section.

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19. See Figure 17. Remove the thrust bearing races (G,I) and bearing (H) from the variable swashplate (F).Be sure not to use any form of pry tool to get theseparts out, use a magnet. The race in the plate itselfmay not come out easily during disassembly due tothe residual oil holding it in. It can be removed laterwhen the swashplate is removed. Inspect the bearingand races for signs of wear or damage and replaceas needed. Also notice that the thinner of the tworaces (G) goes in the swashplate.

20. Remove the input shaft (L) by first removing the seal(J) and snap ring (K). Inspect the shaft for signs ofdamage to the splines, running surfaces, and bearing.Do not remove the bearing unless it is damaged.

21. Remove the control arm (B) by driving out the doubleroll pin (A) that holds it in place then remove the arm.

22. Using a 12mm socket, loosen and remove the 7 bolts(C) that hold the side cover (D) in place. Note thatthere are two points where a pry tool can be insertedto break the seal of the sealant used. The variableswashplate can then be removed with the side plate.

23. Remove the swashplate (F).

• Carefully disengage the spring (E) from the neutraleccentric and slide it out. Disengage the spring fromthe anchor on the swashplate.

• Inspect the bushings in the side plate and the trans-mission case. Replace if they appear damaged orthe swashplate does not operate smoothly.

• The neutral eccentric can be removed if needed byusing a 17mm socket and loosening the jam nut thatretains it. Note the two o-rings that form the seal.

Figure 17. Input Shaft & Variable Swash Plate

FG

H

I

E

L

B

C

D

A

J

K

M

A. Double Roll PinB. Control ArmC. Side Cover Bolts (7)D. Side CoverE. SpringF. Variable Swash PlateG. Race (Thin)H. BearingI. Race (Thick)J. SealK. Snap RingL. Input ShaftM. Pin (Drives Charge Pump)

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14 Transmission Tear-DownAssembly

14 - 14

24. In needed, remove the bypass lever and shaft.Remove the snap ring from the shaft being careful ofthe spring force behind it. The lever can be removedfrom the shaft by simply pulling it from the shaft.

25. The brake can be removed if needed by looseningthe two bolts.

ASSEMBLYPreparationBe sure to replace all seals and o- rings with new parts.Have a supply of SG/CD 10W-30 engine oil to lubricateparts as they are assembled and petroleum jelly to lubri-cate seals. DO NOT use grease. Petroleum jelly willdissolve in the transmission oil without contaminating it.To seal the case halves, use automotive type RTV sili-cone sealer.

Assembly1. Figure 18. Reinstall the bypass shaft and lever

assembly, lubricating the o-rings with petroleum jelly.Reinstall the spring and snap ring, being sure it'sseated completely in it's groove. Be sure the flat sideof the snap ring faces up. To be sure you have theshaft installed correctly, you can install just the centersection, and the release valve pin (D, Figure 14) andoperate the bypass. You should see the pin come upout of the center section. If not the shaft is in back-wards and can be removed and reinstalled easily atthis point.

2. Reinstall the brake mechanism lightly lubricating itand the o-ring. Be sure to install with the lever goingdown as we are looking at the upper transmissioncase.

NOTE: For ease of assembly, you may wish to delayinstallation of the brake assembly until after the centersection has been installed.

Figure 18. Bypass & Brake

Snap ring

Brake Components

BypassLever

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Figure 19. Input Shaft & Variable Swash Plate

FG

H

I

N

E

L

B

C

D

A

J

K

M

A. Double Roll PinB. Control ArmC. Side Cover Bolts (7)D. Side CoverE. SpringF. Variable Swash PlateG. Race (Thin)H. BearingI. Race (Thick)J. SealK. Snap RingL. Input ShaftM. Pin (Drives Charge Pump)N. Pump Rotating Group

3. Assemble the centering spring (E) to the variableswashplate (F), being careful of the spring. Assemblethe neutral eccentric to the side plate being sure tolubricate the o-rings. Put the swashplate into the sideplate along with the thrust washer going between thespring and plate. Be sure to seat the spring correctly.

4. Apply sealant to the side plate (D) and assemble theunit to the upper case. Torque the bolts (C) to 16-18ft. lbs (21-24 NM).

5. Reinstall the input shaft (L) and snap ring (K), makingsure the snap ring gets fully seated, and that the flatmost side of the snap ring faces up.

6. Assemble the variable swash plate bearing (H) andraces (G, I) with the thin race (G) going in first, thenthe bearing and the thick race (I) last. The thick raceprovides the needed support and back up for the pis-tons.

7. Install the pump rotating group (N). To do this easily,put a rubber band around the pistons, then make asecond loop around the block. Once installed, besure that the pistons are in their bores correctly bypushing down on the cylinder block and making sureit works smoothly. Be sure to remove the rubberband. If the center section binds, one or more of thepistons may have come out of their bore and therotating group will have to be removed to correct.

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8. Install the center section and motor assembly. Thisprocedure will require a number of things to be donein the proper sequence. Be sure to pre-lubricateparts before or as you assemble them, as it canmake assembly easier and prevent any damage dur-ing assembly.

• Drop the stationary brake plate in place. Notice thatit is tapered and the tapered end goes into the topcase.

StationaryBrake Plate

Figure 20. Stationary Brake Plate

Figure 21. Center Section

H

G

I

JKF

E

B

C

D

A

A A. Piston, Washer, & SpringB. Motor BlockC. Center SectionD. Release Valve Pin & WasherE. Pump BlockF. Bearing and RacesG. SwashplateH. Motor ShaftI. BearingJ. GearK. Brake Rotor

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See Figure 21.

• Assemble the thrust bearing package (F), beingsure to put the race with the writing on it in the fixedswashplate (G) first, then the bearing and other race.If desired, petroleum jelly can be used to help holdthe parts in place.

• Assemble the motor output shaft (H), motor rotatinggroup (E, A), fixed swashplate (G) and brake rotor (K)together. If desired, a rubber band can be used tohold the pistons in the motor rotating group. Onceassembled the rubber band will have to be cut toremove it.

• Apply some petroleum jelly to the center section tohold the pin and washer (D) that lifts the motor rotat-ing group off the center section. You may also wantto apply some to the locating bosses to make assem-bly easier.

• Be sure that the bypass shaft is in the drive positionbefore assembling the center section. If it is not, itcan catch the pin (D) and damage these parts Use asmall screwdriver to push the pin all the way in to pre-vent it from catching on the bypass shaft.

• Be sure the fixed swashplate (G) is oriented correct-ly noting the letter from disassembly.

• Using hand pressure only, push the center sectionstraight down (Figure 22). At the same time com-press the fixed swashplate in so it can drop into theupper case. Also pay attention to the motor outputshaft so that the bearing gets properly seated as well.Caution: at no time use the bolts for the center sec-tion to draw it down with out first seating it by hand.

• Insert the bolts (Figure 23) and draw them up even-ly, rotating the motor as you go. If it binds, stop,loosen the bolts and try again. If that does not correctthe problem, it may be necessary to remove the boltscompletely and retry the complete procedure. Onceseated, snug the bolts gently down.

• Operate the dump valve lever and you should seethe motor rotating group lift off the center section.

• Operate the pump by installing the input pulley androtating it. If it cannot be rotated there is a problemand the center section will need to be loosened orremoved to correct.

• Torque the bolts to 35-47 ft. lbs. (47-50 NM)

Figure 23. Center Section BoltsFigure 22. Center Section Installation

Center SectionBolts

Note Letteron FixedSwash Plate

BrakeAssemblyBolts

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9. See Figure 24. Install charge pump.

• Install drive pin.

• Install the pump rotors with the dots matching up.

• Carefully install the charge pump housing beingsure it does not bind. Turn the input pulley by hand ifyou need to line things up.

• See Figure 25. Torque the bolts that retain thehousing to 17-20 ft. lbs. (23-27 NM).


Figure 24. Charge Pump Installation

Charge Pump BoltsDrive Pin

Dots

Charge PumpValve and Spring

Implement ReliefValve & Spring

Figure 26. Axle Installation

Seal

Snap Ring

Bearing

Axle

10. If not already done so, install the axle bearings andsnap rings.

11. Install axle bushings in upper case. Note that bothbushings are the same.

12. Install axles.

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13. Install the differential assembly.

• See Figure 27. First assemble the smaller piniongears with the controlled traction mechanism into thefinal drive gear. Note that the small tabs should be inagainst the gear and not to the side.

• See Figure 27. Next install the larger side gearsbeing sure that if you have the differential lock, thatthe gear with the notches is on the left and goes intothe differential lock slider.

• See Figure 27. Install the collar into the slider withthe recess facing out.

• See Figure 27. Install the slider, collar, and gear onthe left side of the differential gear.

• See Figure 28. Install the entire differential assem-bly into the case lining up each sides axle one at atime.

• See Figure 29. Install the c-ring in each side with amagnet tool. Be sure they are in the proper groove.It is easy to install them next to the splines wherethey do not belong. The flat side should face in.

• See Figure 30. Install the retainers.

Figure 27. Differential Assembly

Pinion Assy.DO NOTDisassemble

Figure 30. Install Differential Retainers

Figure 29. Install C-Rings

Figure 28. Install Differential Assembly

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14. See Figures 31 & 32. Assemble the intermediategear assembly and install into the upper case. Besure the flats on bushing line up with the housing.Also be sure the bevel on gear is facing the center ofthe transaxle.

14. Install the small round filter into the upper case.

15. Line up the shift fork for the differential lock by cen-tering it over the boss for the axle bushing. Also besure the differential lock is unlocked, and the magnetis installed.

Figure 31. Remove Intermediate Gear Assy.

Figure 32. Intermediate Gear Assembly

BushingFlats

Beveled Edge

16. Apply a good quality automotive RTV silicone sealantto the sealing surfaces of the upper case. Be sure allsurfaces are clean and free of any old sealant.

17. See Figure 33. Carefully install the lower case to theupper case. Install the bolts and tighten evenly goingfrom the inside to the outside, just snugging them up.

18. You can test the differential lock by rotating one ofthe axle shafts while moving the differential lock leverforward. You should get to a point where it willengage then release. This may require help from anassistant due to the preload of the controlled tractionmechanism . If everything works normally, torque thebolts to 16-18 ft. lbs (21-24 NM).

Figure 33. Case BoltsA. Long Bolts C. Drain PlugsB. Medium Bolt

A

B

C

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14 - 21


19. Install the internal oil filter (B, Figure 34) and its cap(A), being sure that the seal end of the filter isinstalled first.

NOTE: Install the brake assembly now, if not donealready.

Figure 34. Internal Transmission Filter ServiceA. Plastic Plug C. FittingsB. Internal Filter

Figure 35. Install Control Arm

AB

C

20. See Figure 35. Carefully install the 2 o-rings over thecontrol shaft.

21. Install the control arm and the roll pin.

22. Using seal protectors, install new seals for the axleand input shaft.

23. Install the input pulley and retaining nut.

24. Install any accessory brackets or hardware beforereinstalling the transaxle into the tractor.

25. Reinstall the transmission (see TRANSMISSIONREMOVAL AND INSTALLATION Section). Fill withoil (see MAINTENANCE Section). Perform neutraladjustment (see ADJUSTMENTS Section).

O-RingsControlArm

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14 Transmission Tear-DownNotes

14 - 22

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15 - 1

15 PTO Clutch ServiceTable 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

SECT

ION

15. P

TOCL

UTCH

SERV

ICE

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15 PTO Clutch ServiceGeneral / Troubleshooting

15 - 2


GENERALThe Ogura electric PTO clutch used on the Broadmoor /1600 / 2600 series is very sensitive to initial wear, andtherefore must be adjusted at it’s 50/250 hour serviceintervals (see PTO CLUTCH ADJUSTMENTS, this sec-tion). If the clutch fails to engage, the first step is alwaysto perform the adjustment procedure contained in theoperator’s manual, and reproduced in this section.

If the clutch must be tested, it should be removed fromthe tractor to electrically isolate it.

New PTO clutches must be burnished (see procedure inthis section).

TROUBLESHOOTINGUse the following procedure to check and replace adefective clutch:

1. Check PTO clutch air gap. Perform clutch adjust-ment.

2. Remove the PTO clutch from the tractor and performelectrical tests.

3. After replacing the clutch, burnish and re-check theair gap.

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15 - 3

15 PTO Clutch ServiceAdjustment

WARNINGTo avoid serious injury, perform adjustments onlywith engine stopped, key removed and tractor onlevel ground.

PTO CLUTCH ADJUSTMENTCheck the PTO clutch adjustment after the initial 50 hourbreak-in period and then after every 250 hours of opera-tion. Also perform the following procedure if the clutch isslipping or will not engage, or if a new clutch has beeninstalled.

1. Remove key from ignition switch and disconnectspark plug wires to prevent the possibility of acciden-tal starting while the PTO is being adjusted.

2. See Figure 1. Note the position of the 3 adjustmentwindows (A) in the side of the brake plate and thenylock adjustment nuts (B).

3. Insert a .012”-.015” (2.5-4mm) feeler gauge (C)through each window, positioning the gauge betweenthe rotor face and the armature face as shown inFigure 2.

4. Alternately tighten the adjustment nuts (B, Figure 1)until the rotor face and armature face just contactsthe gauge.

5. Check the windows for an equal amount of tensionwhen the gauge is inserted and removed, and makeany necessary adjustments by tightening or loosen-ing the adjustment nuts.

NOTE: The actual air gap between the rotor and arma-ture may vary even after performing the adjustment pro-cedure. This is due to dimensional variations on compo-nent parts, and is an acceptable condition.

6. Check the mower blade stopping time. The mowerblades and mower drive belt should come to a com-plete stop within five seconds after the electric PTOswitch is turned off.

Figure 1. PTO Clutch AdjustmentA. Adjustment Window (Qty. 3, one shown) B. Adjustment Nut


1. With parking brake engaged, PTO disengaged andan operator in the seat, start the tractor engine.


3. If the mower drive belt does not stop within five sec-onds, perform the PTO Clutch Adjustment. If the beltstill does not stop within 5 seconds, see your dealer.

AB

B

B

AB

C

Figure 2. Adjust PTO ClutchA. WindowB. Adjustment NutC. Feeler Gauge

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15 PTO Clutch ServiceElectrical Tests

15 - 4

PTO CLUTCH ELECTRICAL TESTS(BENCH TESTS)Check ResistanceSee 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.

The VOM should read 2.5 ~ 3Ω. If the clutch resistanceis not within this range, replace the clutch assembly.

Check for Short CircuitsSee Figure 4.

1. Set VOM to Ohms.

2. Probe the clutch body with the negative test lead.

3. Probe one of the clutch wire harness terminals withthe positive lead. The VOM should show no continu-ity.

4. Probe the other connector terminal with the positivelead. Again, the VOM should show no continuity.

If the VOM shows continuity to the clutch body fromeither terminal, the clutch has an internal short andshould be replaced to prevent damage to the engine.

Figure 4. Checking PTO Clutch for Shorts

Figure 5. Testing PTO Clutch Electrical Operation

Figure 3. Checking PTO Clutch Resistance

Check EngagementSee Figure 5.

Connect the PTO clutch terminals to a 12 VDC powersupply such as a 12 volt battery.

An audible “click” should be heard as the clutchengages. If the clutch does not engage, replace it.

Reconnect the clutch wire connector after testing.

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15 - 5

15 PTO Clutch ServiceReplacement / Burnishing

Rounded Key

Pulley Assembly

Electric Clutch

Hold the hex washer and torque the capscrew to 45-50 ft. lbs.

Hex Washer

Lockwasher, 7/16

Capscrew, 7/16-20 x 4

Square Key

PTO CLUTCH REPLACEMENTRemovalRefer 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 washersecuring the clutch to the crank shaft.

4. Remove the clutch and square key. Note: belt ten-sion should keep the transmission belt pulley inplace.

InstallationRefer to Figure 6.

1. Lubricate the crankshaft with anti-seize compound.

2. Make sure the rounded key (FIgure 6) is installed asshown.

3. Install the square key.

4. Install the PTO clutch. Be sure the square key is inthe keyway. Be sure the clutch anchor is insertedinto the clutch body.

5. Secure with the 7/16-10 x 4” capscrew, lockwasher,and hex washer. Hold the hex washer with a wrenchand tighten the capscrew to 45-50 ft. lbs.

BURNISHING THE ELECTRIC PTOCLUTCHNew PTO clutches must be burnished to remove anti-corrosion coatings on the clutch components.

1. Select a safe area to operate the mower deck. Withthe drive in neutral, the PTO switch disengaged, andan operator in the seat, start the tractor engine. Runthe engine at full throttle.

2. Engage the PTO switch and run the deck for fifteenseconds. Disengage the PTO switch and wait for themower drive belt to stop.

3. Repeat step 2 above ten times, and then re-checkthe mower blade stopping time. (Stopping time mustbe five seconds or less. If not, readjust the clutch airgap.)

Figure 6. Clutch Assembly

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15 PTO Clutch ServiceNotes

15 - 6

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16 - 1

16 Mower Deck ServiceTable of Contents

SECTION CONTENTS


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 & 50” Mower Decks - Belt & Hitch........................................16-10

44” Mower Deck - Height Adjustment & Rollers ........................16-12

50” Mower - Height Adjustment & Rollers .................................16-14

Mower Deck Repair

Mower Removal & Installation...................................................16-16

Mower Drive Belt & PTO Belt Replacement..............................16-16

Idler Pulley Repair - 38” Decks .................................................16-16

Idler Pulley Service - 44” & 50” Decks ......................................16-17

Arbor Repair

Arbor Assembly Removal - All Models ......................................16-18

Arbor Disassembly - 38” Mowers ..............................................16-19

Arbor Assembly - 38” Mowers...................................................16-20

Arbor Disassembly - 44” & 50” Mowers ....................................16-21

Arbor Assembly - 44” & 50” Mowers .........................................18-22

SECT

ION

16. M

OWER

DECK

SERV

ICE

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16 Mower Deck Service38” Mower Deck - Housing, Arbors, & Blades

16 - 2

Viewed From Bottom

Torque to 50-70 ft. lbs.


Apply gasket former to this surface if foam gasket is not used.

1

2

3

4

5

6

7

8

910

11

12

13

14

1516

17

18

19

20

21

22

2324

25

26

2728

29

30

31

32

3334

35

36

37

38

1 2

22

4

28

36

3531

2725

25

25

27

2725

27

272727

2527

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16 - 3

16 Mower Deck Service38” Mower Deck - Housing, Arbors, & Blades

1 2 NUT, Hex Flange, 9/16-82 4 WASHER, Belleville3 1 PULLEY, LH4 2 HUB ADAPTER, Pulley5 2 COVER, Arbor Housing6 4 BEARING7 2 SPACER8 2 GASKET, Foam9 2 ARBOR HOUSING ASSY. (Incl. Ref. No. 10)

10 2 FITTING, Grease11 4 NUT, Hex, 5/16-1812 4 LOCKWASHER, 5/1613 4 WASHER, Flat, 5/1614 2 UPSTOP15 4 WASHER, 3/816 1 PULLEY, RH17 1 MOWER DECK HOUSING, 38” (Orange)17 1 MOWER DECK HOUSING, 38” (Charcoal Grey)18 2 WASHER19 2 SHAFT, Arbor20 2 SHIELD, Grass, Lower21 1 BLADE, Mower, 16-1/8”22 2 WASHER, Hex23 2 WASHER, Spring24 2 CAPSCREW, Hex, Hd, 7/16-14 x 1-1/425 4 CAPSCREW, Taptite, 5/16-18 x 1-1/226 1 BLADE, Mower, 22-1/4”27 8 CAPSCREW, Taptite, 5/16-18 x 3/428 2 CARRIAGE BOLT, 1/4-20 x 7/829 2 PLUG, Hole30 1 NUT, Push31 2 WASHER, Plain32 1 CLAMP33 1 WASHER, 5/1634 1 SPRING35 2 LOCKWASHER, 1/436 2 NUT, Hex, 1/4-20 UNC37 1 DEFLECTOR, Plastic38 1 ROD, Deflector, Front

38” Mower Deck - Housing, Arbors & Blades


38” Mower Deck - Housing, Arbors & Blades

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16 Mower Deck Service38” Mower Deck - Belt & Hitch Group

16 - 4

Hook Spring Ref 22 here when assembled.

Hook Spring to Belt Guide

1

2

3

4

56

7

910

1112

13

14

15

16

17

1819

20

21

22

23

2

17

16

44

4

88

13

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16 - 5

16 Mower Deck Service38” Mower Deck - Belt & Hitch Group

1 1 V-BELT2 2 CAPSCREW, Hex Hd, 3/8-16 x 2-3/43 1 GUARD, Belt4 4 WASHER, Plain, 3/85 1 SPACER6 1 IDLER PULLEY (Incl. Ref. 5)7 1 GRIP, Lever8 1 CLUTCH LEVER ASSY. (Incl. Ref. Nos. 9 & 16)9 1 FITTING, Grease

10 1 LOCKWASHER, 3/811 1 NUT, Hex, 3/8-1612 1 SPRING13 3 NUT, Hex Steel Lock, 3/8-1614 1 NUT, Hex Flange, 2-Way Lock, 3/8-1615 1 SPACER16 2 BUSHING17 2 WASHER, 3/818 2 WASHER, Plain, 13/3219 2 SPACER20 1 ROD, Latch21 1 HITCH ASSY.22 1 SPRING23 2 CAPSCREW, Hex Hd, 3/8-16 x 1-1/2


38” Mower Deck - Belt & Hitch Group38” Mower Deck - Belt & Hitch Group

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16 Mower Deck Service38” Mower Deck - Height Adjustment & Roller Group

16 - 6

GREASE

GREASE

Note: Attach mower levelling adjustment rod (Ref. 45) to bottom hole in mower hitch assembly See 38" Mower Deck - Clutch & Support group

11

2

34

33

55

4

4

333

6 78

9

1011

1214

133

44

15

161718

1920

21

23

25

2726

40

28

29

30

31

3233

34

3536

39

3732

38

32379

8

22

24

17

41

42

242323 24

43 27

44 1845

4647

18

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16 Mower Deck Service38” Mower Deck - Height Adjustment & Roller Group

1 2 NUT, Hex Flange Lock, 1/2-132 1 SHAFT ASSY., Roller3 6 WASHER, Plain, 1-1/44 8 ROLLER5 2 SPACER6 1 BAR, Roller7 1 NUT, Adjuster8 2 LOCKWASHER, 3/89 2 NUT, Hex, 3/8-16

10 1 SLIDE11 1 WASHER, Plain, 1/212 1 BOLT, Shoulder, 3/8-1613 1 NUT, Push14 1 WASHER, 5/815 1 CARRIAGE BOLT, 3/8-16 x 1-1/216 2 STRAP, Mower Arm Assy.17 6 CAPSCREW, Taptite, 5/16-18 x 3/418 5 WASHER, Plain, 13/3219 1 CLIP, Pin, Safety20 1 LINK ASSY., Lift21 1 COTTER PIN22 1 COTTER PIN23 4 NUT, Hex, 5/16-1824 4 LOCKWASHER, 5/1625 1 BRACKET, Cutting Height26 1 ARM, Rear, Mower, RH27 4 CAPSCREW, Hex Hd, 5/16-18 x 1-1/428 1 CRANK, Cutting Height29 1 KNOB30 1 PAL NUT31 1 TRUNNION, Threaded32 3 WASHER, 5/833 1 TRUNNION34 1 PIN, Roll, 1”35 1 WASHER, Detent36 1 STRAP, Trunnion Retainer37 2 NUT, Hex Jam, 1/2-1338 1 TRUNNION39 1 PIN, Clevis40 1 ARM ASSY., Mower41 1 INDICATOR, Cutting Height42 1 WASHER, Flat, 5/1643 1 PLATE, Support44 1 CAPSCREW, Hex Hd, 3/8-16 x 1-3/445 1 ROD, Adjustment46 1 SPACER47 1 NUT, Hex Flange, 3/8-16

38” Mower Deck - Height Adjustment & Roller Group


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16 Mower Deck Service44” & 50” Mower Deck - Housing, Arbors & Blades

16 - 8

Torque nuts to 50-70 ft. lbs.

Torque screws to 45-55 ft. lbs.

Apply gasket former to this surface if foam gasketis not used.

1

2

3

4

5

6

7

89

10

11

12

13

1415

16

17

18

19

20

21

2223

24

25

26 2727

2829

30

3132

33

34 35

36

37

3838

55

34

33 29

16

28

24

16

2

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16 - 9

16 Mower Deck Service44” & 50” Mower Decks - Housing, Arbors, & Blades

1 3 NUT, Hex Flange, 9/16-82 6 WASHER, Belleville3 1 PULLEY4 1 HUB, Double Pulley, LH Arbor5 3 PULLEY6 1 HUB, Double Pulley, LH Arbor7 3 COVER, Arbor Housing8 3 BEARING9 3 SPACER, Bearing Sleeve

10 3 SPACER11 3 BEARING12 3 GASKET, Foam13 3 ARBOR HOUSING ASSY. (Incl. Ref. No. 14)14 3 FITTING, Grease15 1 COVER, Arbor16 27 CAPSCREW, Taptite, 5/16-18 x 3/4 (Qty. 25 used on 44” Deck)17 3 WASHER18 1 SHAFT, Arbor (LH)19 3 SHIELD, Grass, Lower20 3 BLADE, Mower, 16-1/8”, 44” Deck20 3 BLADE, Mower, 18-1/8”, 50” Deck21 3 WASHER, Hex22 3 WASHER, Spring23 3 CAPSCREW, Hex, Hd, 7/16-14 x 1-1/424 2 SHAFT, Arbor (Center & RH)25 1 MOWER HOUSING ASSY., 44” Mower (Orange)25 1 MOWER HOUSING ASSY., 50” Mower (Orange)25 1 MOWER HOUSING ASSY., 44” Mower (Charcoal Grey)25 1 MOWER HOUSING ASSY., 50” Mower (Charcoal Grey)26 1 COVER, Arbor27 2 CARRIAGE BOLT, 1/4-20 x 7/828 2 NUT, Push29 2 WASHER, Plain30 1 CLAMP31 1 WASHER, 5/1632 1 SPRING33 2 LOCKWASHER, 1/434 2 NUT, Hex, 1/4-20 UNC35 1 ROD, Deflector, Front36 1 PLUG, Hole37 1 DEFLECTOR, Plastic38 2 HUB, Pulley, RH & Center Arbor

44” & 50” Mower Decks - Housing, Arbors & Blades


44” & 50” Mower Decks - Housing, Arbors & Blades

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16 Mower Deck Service44” & 50” Mower Decks - Belt & Hitch

16 - 10

Engine Pulley

Movable Idler Pulley

Arbor Drive Pulley

Arbor Drive Pulley

Arbor Drive Pulley

Arbor Drive Pulley

Arbor Drive Pulley


Mount Hitch Assembly using upper holes

3 45 6

7

8

9

7

77

4

578

9

1011

1112

13

15

14 16

777713

1117

14

11

18

19

20

18

21

22723

2425

1

2

26

27

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16 - 11

16 Mower Deck Service44” & 50” Mower Decks - Belt & Hitch

1 1 HITCH ASSY.2 1 ROD, Latch3 1 GRIP, Lever4 2 NUT, Hex, 3/8-165 2 LOCKWASHER, 3/86 1 BELT STOP, Idler7 14 WASHER, Plain, 13/328 2 SPACER9 2 PULLEY, Idler (Incl. Ref. 8)

10 1 NUT, Hex Flange, 2-Way Lock, 3/8-1611 4 BUSHING12 1 SPRING13 2 SPACER14 2 FITTING, Grease15 1 LEVER ASSY, Idler (Incl. Ref. Nos. 11 & 14)16 1 CARRIAGE BOLT, 3/8-16 x 217 1 LEVER ASSY, Idler Arm (Incl, Ref. Nos. 11 & 14)18 2 WASHER, 3/819 1 CARRIAGE BOLT, 3/8-16 x 1-1/220 1 SPRING21 1 CAPSCREW, Hex Hd, 3/8-16 x 3-1/222 2 NUT, Hex Steel Lock, 3/8-1623 2 SPACER24 2 CAPSCREW, Hex Hd, 3/8-16 x 1-1/225 1 SPRING26 1 V-BELT, Arbor Drive, 44” Deck26 1 V-BELT, Arbor Drive, 50” Deck27 1 V-BELT, Mower Drive, 44” Deck27 1 V-BELT, Mower Drive, 50” Deck

44” & 50” Mower Decks - Belt & Hitch


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16 Mower Deck Service44” Mower Deck - Height Adjustment & Rollers

16 - 12

12

13

Note: Attach mower levelling adjustment rod(Ref 46) to bottom hole in mower hitch assembly. See 44" & 50" Mower Deck - Belt, Clutch & Support Group.

GREASE

GREASE

1

234

56

78

9

10

11

98

1210

1210

1210

1210

1210

1210

1210

1212

10

11

19

20

21

39

294343

42 41

40

3837

36

22

23

2425

2627

18 1717

13

15

16

33

35

34

32

3128

29

30

29

28

1243

13

44

4513

47

48

46

14

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16 - 13

16 Mower Deck Service44” Mower Deck - Height Adjustment & Rollers

1 2 NUT, Hex, 3/8-162 2 LOCKWASHER, 3/83 1 NUT, Adjuster4 1 SHAFT ASSY, Roller, 44” (Incl. Ref. Nos. 8, 9 & 11)5 1 SLIDE6 1 WASHER, Plain, 1/27 1 BOLT, Shoulder, 3/8-168 2 WASHER, 5/89 2 SPACER

10 9 ROLLER11 2 NUT, Push12 12 WASHER, Plain, 1-1/413 9 WASHER, Plain, 13/3214 1 CLIP, Pin, Safety15 1 LINK ASSY, Lift16 1 COTTER PIN17 2 NUT, Hex Flange Lock, 1/2-1318 1 BAR, Roller19 1 CRANK, Cutting Height20 1 KNOB, Height Crank21 1 PAL NUT22 2 CAPSCREW, Hex Hd, 5/16-18 x 1-1/423 1 ARM, Rear, Mower, RH24 1 BRACKET, Cutting Height25 2 LOCKWASHER, 5/1626 2 NUT, Hex, 5/16-1827 1 COTTER PIN28 2 NUT, Hex Jam, 1/2-1329 5 WASHER, 5/830 1 TRUNNION31 1 PIN, Clevis32 6 CAPSCREW, Taptite, 5/16-18 x 3/433 1 CARRIAGE BOLT, 3/8-16 x 1-1/234 3 STRAP, Mower Arm Assy.35 1 ARM ASSY., Mower36 1 PIN, Roll, 1” Long37 1 WASHER, Detent38 1 TRUNNION39 1 TRUNNION, Threaded40 1 PLATE, Mower Support41 1 INDICATOR, Cutting Height42 1 WASHER, Flat, 5/1643 4 CAPSCREW, Taptite, 5/16-18 x 1-1/444 1 UP-STOP, Mower45 1 CAPSCREW, Hex Hd, 3/8-16 x 1-3/446 1 ROD, Adjustment47 1 SPACER48 1 NUT, Hex Flange, 3/8-16

44” Mower Deck - Height Adjustment & Rollers


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16 Mower Deck Service50” Mower - Height Adjustment & Rollers

16 - 14

12

13

Note: Attach mower levelling adjustment rod(Ref 46) to bottom hole in mower hitch assembly. See 44" & 50" Mower Deck - Belt, Clutch & Support Group.

GREASE

GREASE

1

234

56

78

9

1011

9

8

1210

10

10

10

10

10

1012

10

11

19

20

21

39

294343

42 41

40

38

37

36

22

23

2425

2627

181717

13

15

16

33

35

34

32

31

2812

30

12

28

1243

13

44

4513

47

48

46

14

912

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16 - 15

16 Mower Deck Service50” Mower - Height Adjustment & Rollers

1 2 NUT, Hex, 3/8-162 2 LOCKWASHER, 3/83 1 NUT, Adjuster4 1 SHAFT ASSY, Roller, 50” (Incl. Ref. No. 11)5 1 SLIDE6 1 WASHER, Plain, 1/27 1 BOLT, Shoulder, 3/8-168 1 NUT, Hex Flange, 3/8-169 3 SPACER

10 9 ROLLER11 2 NUT, Push12 10 WASHER, Plain, 1-1/413 9 WASHER, Plain, 13/3214 1 CLIP, Pin, Safety15 1 LINK ASSY, Lift16 1 COTTER PIN17 2 NUT, Hex Flange Lock, 1/2-1318 1 BAR, Roller19 1 CRANK, Cutting Height20 1 KNOB, Height Crank21 1 PAL NUT22 2 CAPSCREW, Hex Hd, 5/16-18 x 1-1/423 1 ARM, Rear, Mower, RH24 1 BRACKET, Cutting Height25 2 LOCKWASHER, 5/1626 2 NUT, Hex, 5/16-1827 1 COTTER PIN28 2 NUT, Hex Jam, 3/4-1129 3 WASHER, 5/830 1 TRUNNION31 1 PIN, Clevis32 6 CAPSCREW, Taptite, 5/16-18 x 3/433 1 CARRIAGE BOLT, 3/8-16 x 1-1/234 3 STRAP, Mower Arm Assy.35 1 ARM ASSY., Mower36 1 PIN, Roll, 1” Long37 1 WASHER, Detent38 1 TRUNNION39 1 TRUNNION, Threaded40 1 PLATE, Mower Support41 1 INDICATOR, Cutting Height42 1 WASHER, Flat, 5/1643 4 CAPSCREW, Taptite, 5/16-18 x 1-1/444 1 UP-STOP, Mower45 1 CAPSCREW, Hex Hd, 3/8-16 x 1-3/446 1 ROD, Adjustment47 1 SPACER48 1 NUT, Hex Flange, 3/8-16

50” Mower - Height Adjustment & Rollers


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16 Mower Deck ServiceIdler Pulley Service

16 - 16

MOWER DECK REPAIR

Mower Removal & InstallationSee Section 6 COMMON SERVICE PROCEDURES.

Mower Drive Belt & PTO Belt ReplacementSee Section 5 BELT REPLACEMENT

Idler Pulley Repair - 38” Decks1. Remove mower deck (see Mower Removal and

Installation).

2. Note the location and quantity of spacers and wash-ers above and below Idler when removing the cap-screw (A, Figure 2). Also note the position of the beltguide (B).

3. Remove the nuts (H) and capscrew (A) securing theidler pulley (E) to the clutch lever (F).

4. Place the new Idler assembly on the clutch lever andsecure with the capscrew and nut. Make sure the thecorrect quantity of washers/spacers are placed aboveand below the pulley.

5. Align the belt guide to its original position.

Figure 1. Idler Removal


Hook Spring to Belt Guide

Figure 2. 38” Idler AssemblyA. CapscrewB. Belt StopC. WashersD. SpacerE. Idler PulleyF. Idler Arm & GripG. LockwasherH. LocknutI. Spring

A

B

C

D

E

F

G

H

I

H

C

C

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16 Mower Deck ServiceIdler Pulley Service

Idler Pulley Service - 44” & 50” DecksInspect the idler pulleys by removing the belt and careful-ly rotating the pulley by hand. If the bearing has anoticeable “tick,” feels rough or gritty, or wobbles, itshould be replaced. New bearings may feel stiff but willrotate smoothly.

1. Remove the mower deck (see Mower Deck Removaland Installation).

2. For PTO idler pulley (B, Figure 3) service, remove thePTO Belt as described in PTO Belt Service. Forarbor drive idler pulley (H) service remove the arbordrive belt as described in Arbor Drive Belt Service.

3. Remove the nut and carriage bolt (D or F) securingthe idler pulley to the idler lever (C) or idler arm (E).

4. Install the new idler pulley by following steps 3through 1 in reverse order.

Engine Pulley


Arbor Drive Pulley

Arbor Drive Pulley

Arbor Drive Pulley

Arbor Drive Pulley


Figure 3. 44” & 50” Idler Arm Assemblies

C

B

A

D

E

F

G

H

I

A. Belt Stop BracketB. PTO Idler PulleyC. Idler Lever D. Carriage Bolt, 1-3/4E. Idler ArmF. Carriage Bolt, 1-1/2”G. Idler Arm SpringH. Arbor Drive Idler PulleyI. Idler Lever Spring

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16 Mower Deck ServiceArbor Repair

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ARBOR REPAIRArbor Assembly Removal - All Models1. Remove the mower deck (see Mower Deck Removal

and Installation).

2. Remove the belt guides or covers as required toaccess arbors (see Figures 4 & 5).

3. Remove the PTO and arbor drive belts. See PTOand Arbor Drive Belt Replacement.

4. Remove mower blade from the spindle to be rebuilt.See Mower Blade Service.

5. From the bottom of mower deck, remove the sixTaptite hex screws retaining the spindle flange to themower deck (Figure 6).

6. Remove the arbor assembly from the deck.

Figure 6. Spindle Removal

TaptiteHexScrews

Figure 4. Mower Deck - 38” MowerA. Belt Guides Figure 5. Mower Deck - 44" & 50”

A. Right-hand Arbor CoverB. Left-hand Arbor Cover

A

A

A

B

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16 Mower Deck ServiceArbor Disassembly - 38” Mowers

Arbor Disassembly - 38” MowersRefer to Figure 7 for the following procedure.

1. Remove the blade from the arbor to be serviced, andremove the arbor assembly from the mower deck(see previous procedures).

2. Remove the nut (A), washers (B), and pulley (C).

3. Remove the spacer (D).

NOTE: If the spacer is seized onto the arbor shaft, soakwith rust penetrant to separate. If the parts must beforced apart, thread the hex nut back onto the arbor shaftto protect the threads and tap the end of the arbor shaftwith a rubber mallet.


A. Flange Hex NutB. Belleville WasherC. PulleyD. Adapter HubE. Arbor Housing CoverF. Upper BearingG. Arbor SpacerH. Lower BearingI. Foam GasketJ. Arbor HousingK. Grease FittingL. Taptite ScrewM. WasherN. Arbor ShaftO. Lower Grass ShieldP. BladeQ. Hex WasherR. Spring WasherS. Capscrew

Figure 7. Arbor Assembly

4. Using a flat blade screwdriver, pry the arbor cover (E)off. Remove and discard the gasket (I).

5. Separate the arbor shaft (N), bearings (F, H), lowerhousing (K), and washer (N).

NOTE: Bearings (F & H) are identical.

Replace parts as required.


A

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DE

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16 Mower Deck ServiceArbor Assembly - 38” Mowers

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Arbor Assembly - 38” MowersRefer to Figure 8 for the following procedure.

1. Install the washer (M) on the arbor shaft (O) cup sidedown.

2. Install the shaft and washer assembly through the arborhousing (J), bearings (H and F), and spacer (G).

NOTE: 38” mower decks use two identical bearings (H & F).

3. Fill the housing with Multi-Purpose Lithium Grease.

4. Assemble the foam gasket (I), arbor housing cover(E), pulley hub adapter (D), pulley (C), bellevillewashers (B) and nut (A) as shown.

NOTE: If a new foam gasket (I) is not used, seal thearbor housing and cover with RTV or silicon sealer.

5. Align the alignment pins on the arbor housing (J) andcover (E) and press housing together.

6. Torque the hex nut (A) to 50-70 ft. lbs.


A. Flange Hex NutB. Belleville WasherC. PulleyD. Adapter HubE. Arbor Housing CoverF. Upper BearingG. Arbor SpacerH. Lower BearingI. Foam GasketJ. Arbor HousingK. Grease FittingL. Taptite ScrewM. WasherN. Arbor ShaftO. Lower Grass ShieldP. BladeQ. Hex WasherR. Spring WasherS. Capscrew


7. Install the arbor assembly in the deck shell andsecure with the six hex head taptite screws (see Figure 6).

8. Install the lower grass shield and mower blades asdescribed in Section 6, COMMON SERVICEPROCEDURES.

NOTE: The arbor shaft may have up to 1/8" of end-play.This is normal and acceptable.


A

CB

DE

G

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H

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16 Mower Deck ServiceArbor Disassembly - 44” & 50” Mowers

Arbor Disassembly - 44” & 50” MowersRefer to Figure 9 for the following procedure.

1. Remove the blade from the arbor to be serviced, andremove the arbor assembly from the mower deck(see previous procedures).

2. Remove the nut (A), washers (B), and pulley (C).

3. Remove the spacer (D).

NOTE: If the spacer is seized onto the arbor shaft, soakwith rust penetrant to separate. If the parts must beforced apart, thread the hex nut back onto the arbor shaftto protect the threads and tap the end of the arbor shaftwith a rubber mallet.


A. Flange Hex NutB. Belleville WasherC. PulleyD. Adapter HubE. Arbor Housing CoverF. Upper BearingG. Sleeve Spacer (44" Only) H. Arbor SpacerI. Lower BearingJ. Foam GasketK. Arbor HousingL. Grease FittingM. Taptite ScrewN. WasherO. Arbor ShaftP. Lower Grass ShieldQ. BladeR. Hex WasherS. Spring WasherT. Capscrew


4. Using a flat blade screwdriver, pry the arbor cover (E)off. Remove and discard the gasket (J).

5. Separate the arbor shaft (O), bearings (F and I),lower housing (K), and washer (N).

Replace parts as required.


A

CB

DE

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H

J

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ML

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16 Mower Deck ServiceArbor Assembly - 44” & 50” Mowers

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Arbor Assembly - 44” & 50” MowersRefer to Figure 10 for the following procedure.

1. Install the washer (N) on the arbor shaft (O) cup sidedown.

2. Install the shaft and washer assembly through the arborhousing (K), bearings (I and F), and spacers (H and G).

NOTE: 38” mower decks use two identical bearings. 44”decks use two different bearings and therefore require asleeve spacer (G) be used with the upper bearing (F).38” decks do not use the sleeve spacer (G).

3. Fill the housing with Simplicity Multi-Purpose LithiumGrease or equivalent.

4. Assemble the foam gasket (J), arbor housing cover(E), pulley hub adapter (D), pulley (C), bellevillewashers (B) and nut (A) as shown.

NOTE: If a new foam gasket (J) is not used, seal thearbor housing and cover with RTV or silicon sealer.


A. Flange Hex NutB. Belleville WasherC. PulleyD. Adapter HubE. Arbor Housing CoverF. Upper BearingG. Sleeve Spacer (44" Only) H. Arbor SpacerI. Lower BearingJ. Foam GasketK. Arbor HousingL. Grease FittingM. Taptite ScrewN. WasherO. Arbor ShaftP. Lower Grass ShieldQ. BladeR. Hex WasherS. Spring WasherT. Capscrew


5. Align the alignment pins on the arbor housing (K) andcover (E) and press housing together.

6. Torque the hex nut (A) to 50-70 ft. lbs.

7. Install the arbor assembly in the deck shell andsecure with the six hex head taptite screws (see Figure 5).

8. Install the lower grass shield and mower blades asdescribed in Section 6, COMMON SERVICEPROCEDURES.

NOTE: The arbor shaft may have up to 1/8" of end-play.This is normal and acceptable.


A

CB

DE

G

H

J

I

F

ML

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Documents

Broadmoor Series Service & Repair Manual