Sabre 1338 Gear Technical Manual Download Page 1

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Sabre Lawn Tractor

38–Inch and 46–Inch (96 cm and 117 cm)

Models: 1338 Gear

John Deere Consumer Products Group

TM–GX10131 (Mar–97)

LITHO IN U.S.A. (New)

1538 Hydro
15538 Gear

1646 Hydro

1538 Gear

1638 Hydro
1646 Gear

Technical Manual

15538 Hydro

1546 Gear

www.servicemanualall.com
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Summary of Contents for 1338 Gear

Page 1: ...dels 1338 Gear John Deere Consumer Products Group TM GX10131 Mar 97 LITHO IN U S A New 1538 Hydro 15538 Gear 1646 Hydro 1538 Gear 1638 Hydro 1646 Gear Technical Manual 15538 Hydro 1546 Gear www servic...

Page 2: ...e used Each section will be identified with a symbol rather than a number The groups and pages within a section will be consecutively numbered We appreciate your input on this manual If you find any e...

Page 3: ...nts coolants paints and adhesives A Material Safety Data Sheet MSDS provides specific details on chemical products physical and health hazards safety procedures and emergency response techniques Check...

Page 4: ...attention immediately USE SAFE SERVICE PROCEDURES WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job Prolonged exposure to loud noise can cause impairmen...

Page 5: ...o not attempt shortcuts ILLUMINATE WORK AREA SAFELY Illuminate your work area adequately but safely Use a portable safety light for working inside or under the machine Make sure the bulb is enclosed b...

Page 6: ...sive separation of a tire and rim parts can cause serious injury or death Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job Always maintain the corr...

Page 7: ...SAFETY 1 6 3 5 97 www servicemanualall com...

Page 8: ...GASOLINE STORAGE 8 LUBRICANT SPECIFICATIONS 8 ENGINE OIL 8 GREASE 9 ALTERNATIVE LUBRICANTS 9 SYNTHETIC LUBRICANTS 9 OIL FILTERS 9 LUBRICANT STORAGE 9 SERIAL NUMBER LOCATIONS 10 TRACTOR IDENTIFICATION...

Page 9: ...Champion RJ 19 LM 15 16 Hp M78543 Champion RC 12 YC Spark Plug Air Gap 0 76 mm 0 030 in Battery Type BCI Group U1 Battery Cranking Amps 230 amps at 0 C 32 F Battery Cold Cranking Amps 190 amps at 0 C...

Page 10: ...everse 0 4 24 km hr 0 2 62 mph Brake Type Single External Disc Brake With Friction Pucks Lubrication 10W30 Engine Oil Class CD Reservoir Internal Capacity 1 6 L 3 4 pt Power Train K51 Transmission Gea...

Page 11: ...e Wing Lift Height 40 3 mm 1 57 0 12 in Overall Cutting Width 965 mm 38 in Overall Width w o discharge chute 1026 mm 40 4 in Drive Type Single V Belt With Spring Tension Idler Spindle Lubrication None...

Page 12: ...lbs Trailer Tongue Weight Maximum 22 6 kg 50 lbs Steering Type Manual Pinion Sector Axle Pivot Hub Shim Adjustable Lubrication Multipurpose Grease Lubrication Interval 10 hrs Maximum Toe In 6 mm 0 24...

Page 13: ...ies for hex cap screws over 152 mm 6 in long and for all other types of bolts and screws of any length Size Grade 1 Grade 2b Grade 5 5 1 or 5 2 Grade 8 or 8 2 Lubricateda Drya Lubricateda Drya Lubrica...

Page 14: ...8 Class 10 9 Class 12 9 Lubricateda Drya Lubricateda Drya Lubricateda Drya Lubricateda Drya Nm lb ft Nm lb ft Nm lb ft Nm lb ft Nm lb ft Nm lb ft Nm lb ft Nm lb ft M6 4 7 3 5 6 4 4 9 6 6 11 5 8 5 13...

Page 15: ...mower is stored for the winter add gasoline storage stabilizer to the fuel Follow directions on can CAUTION Handle fuel with care it is highly flammable DO NOT refuel machine Indoors Always fill fuel...

Page 16: ...C LUBRICANTS Synthetic lubricants may be used in John Deere equipment if they meet the applicable performance requirements industry classification and or military specification as shown in this group...

Page 17: ...ICATION NUMBER Tractor identification number plate A is located on the rear of frame or under seat ENGINE SERIAL NUMBER Tractor engine serial number sticker B is located on fan shroud A A B GEAR TRANS...

Page 18: ...ER MATERIALS 3 REPAIR 4 ENGINE REMOVAL 4 ENGINE INSTALLATION 5 The engines used on Sabre products are warranted by the manufacturer Briggs Stratton Corporation Please refer to the Owners Manual suppli...

Page 19: ...CONTENTS CONTINUED ENGINE 3 2 2 11 97 Page www servicemanualall com...

Page 20: ...est 13 Horsepower REPAIR MANUAL For Single Cylinder 4 Cycle Engines 15 Horsepower REPAIR MANUAL For Single Cylinder 4 Cycle Engines 16 Horsepower REPAIR MANUAL For Single Cylinder 4 Cycle Engines SERV...

Page 21: ...hose to carburetor 6 Loosen clamp C to disconnect throttle cable D Capscrews Capscrews Heat Shield And Nut B C D A E 7 Disconnect hose clamp E and slide fuel line off of hose barb on carburetor 8 Dis...

Page 22: ...round connector on capscrew installed in step 2 and secure with washer and nut 4 Install other three capscrews washers and nuts Torque to 32 N m 24 lb ft 5 If muffler was removed inspect muffler flang...

Page 23: ...rminal F 9 Connect two 2 harness connectors H Capscrew F H 10 Connect and adjust throttle cable C to obtain full throttle and choke when lever is full forward and idle when lever is rearward 11 Connec...

Page 24: ...OPERATION 12 IGNITION CIRCUIT TEST POINTS 14 CHARGING HEADLIGHT CIRCUIT OPERATION 16 CHARGING CIRCUIT DIAGNOSIS 17 HEADLIGHTS CIRCUIT DIAGNOSIS 18 TESTS AND ADJUSTMENTS 20 BATTERY TEST 20 CHARGE BATT...

Page 25: ...CONTENTS CONTINUED ELECTRICAL 4 2 2 11 97 Page www servicemanualall com...

Page 26: ...on Minimum 30 K Ohms Secondary Plug Wire And Core 7 9 10 85 K Ohms Air gap 0 2 0 3 mm 0 008 0 012 in Spark Plug Type 13 HP TY6129 Champion RJ 19 LM 15 and 16 HP M78543 Champion RC 12 YC Gap 0 76 mm 0...

Page 27: ...L column to repair the malfunction The detailed tests or adjustments referred to in the IF NOT NORMAL column are located at the end of that group The system diagram that accompanies each test procedur...

Page 28: ...G BATTERY 220 RED BLK ENGINE CONNECTOR 15A M 451 YEL WHT 940 WHT 120 BLK 110 BLK 945 WHT BLK 941 WHT 700 PUR BLADE IGNITION MODULE SPARK PLUG DRIVE SEAT COIL 1 0 0 OFF SEAT 1 ON SEAT 1 0 0 OFF 1 ON 0...

Page 29: ...UR WHT 705 PUR 945 WHT 942 WHT BLK BLADE 8mm 5 16 Eyelet GROUND 8mm 5 16 BATTERY POSITIVE 200 RED 100 BLK 401YEL 941 WHT 700 PUR IGNITION SWITCH SOLENOID POSITIVE SOLENOID GROUND 1 0 5 B L K 2 0 1 R E...

Page 30: ...TION ELECTRICAL 3 5 97 4 7 COMPONENT LOCATION Headlights Starter Solenoid Fuel Shut Off Solenoid Starter Motor Spark Plug Blade Battery Seat Switch Brake Drive Switch Ignition Switch Switch www servic...

Page 31: ...ing Circuit Diagnosis See Ground Circuit Tests Test battery and connections See Ignition Circuit Tests See Charging Circuit Tests See Starter Solenoid Test See Seat Switch Tests See headlight circuit...

Page 32: ...the end of the blade drive lever shaft It is used to prevent the engine from cranking if the blade drive is engaged With the blade drive lever disengaged blade drive switch plunger depressed current f...

Page 33: ...h purple wire Battery voltage Test purple wire back to ignition switch 7 Blade Drive Switch purple white wire Battery voltage Check Blade Drive Switch and lever 8 Park brake switch purple white wire B...

Page 34: ...UR 700 PUR Red 100 Black 2 16 401 YEL 4 200 RED BRAKE SWITCH BLADE DRIVE FUEL SHUTOFF SOLENOID STARTER RELAY SOLENOID IGNITION BATTERY STARTER 705 PUR WHT 12 13 9 705 PUR WHT 7 SWITCH 941 WHT 710 PUR...

Page 35: ...rimary coil of the ignition module by electromagnetic induction When the primary current builds to its highest level the ignition module induces high voltage current into the secondary coil This high...

Page 36: ...0 1 0 1 0 0 1 2 IGNITION MODULE E1 SPARK PLUG COIL FUEL SOLENOID SHUT OFF OPTIONAL 100 BLACK 110 BLACK 401 942 WHITE YELLOW 941 WHITE 941 WHITE 942 WHITE 940 WHITE 940 WHITE 945 WHITE BLACK 946 BLACK...

Page 37: ...e connector 940 white wire wiring harness side of connector Infinite resistance Check that blade drive switch plunger is being fully depressed by blade drive lever Infinite resistance Check that brake...

Page 38: ...te Black 945 White Black 940 White White 941 942 White 942 White 100 Black 940 White S4 Blade Drive Switch Key Switch 2 1 1 1 1 2 2 2 Engine Connector 1 3 3 3 3 2 3 3 945 White Black 942 White 940 Whi...

Page 39: ...pole stator mounted under the flywheel inducing alternating current into the stator coils Alternating current is routed to the headlamp bulbs anytime the engine is running through the 451 Yel Wht wir...

Page 40: ...connector 451 Yel Wht connector at engine cover 11 8 13 2 DC voltage Check headlamp bulbs See Briggs Stratton engine manual for charging system repair Test Conditions Meter negative lead grounded to...

Page 41: ...1 Headlamps Bulbs are lit whenever engine is running Check for burned out bulbs 2 Yellow White wire at headlamp socket connector 12 14 Volts AC Test ground circuit Go to step 3 3 Yellow White wire at...

Page 42: ...L 3 5 97 4 19 Engine Connector 3 Black 220 Red Black 1 120 Black Yel Wht 2 Headlight Harness 5 7 120 Black 451 YEL WHT Headlight Harness 3 451Yel Wht 2 Red 451 Yellow White TO ENGINE TO CHASSIS 4 www...

Page 43: ...charge battery at 10 amp rate All cells more than 1 225 with less than 50 point variation load test battery More than 50 point variation replace battery CHARGE BATTERY Reason To increase battery char...

Page 44: ...E B A Procedure 1 Turn load knob of tester clockwise until amperage reading A is equal to a Cold cranking amperage rating use blue scale OR b Three times ampere hour rating use black scale 2 Hold for...

Page 45: ...ual for electrical system repair A Black Wire B STARTER SOLENOID TEST Reason To determine if starter solenoid or starter is defective Equipment Jumper wire Connections 1 Put transaxle in neutral Move...

Page 46: ...voltage is the same as when cranking 4 Read DC amperage on battery tester 5 Turn load knob fully counterclockwise Specifications Maximum starter amp draw 180 amps at 225 rpm Results If amperage is ab...

Page 47: ...SED Results If continuity is NOT correct replace switch C A D B BRAKE SWITCH ADJUSTMENT Reason To ensure proper that engine starts only when brake fully applied Procedure 1 Depress brake pedal and set...

Page 48: ...witch cover see Repair Section page 27 for Ignition Switch Removal Installation 4 Disconnect ignition switch connector NOTE Ignition switch terminals are identified to coincide with electrical schemat...

Page 49: ...g harness connector to isolate the wire or component and check resistance again Maximum allowable resistance in the circuit is 0 1 ohms Check both sides of connectors closely as disconnecting and conn...

Page 50: ...cket B DO NOT overtighten screws they are threaded into plastic B A F C D E SEAT SWITCH REMOVAL INSTALLATION NOTE Seat switch connector has an internal spring which will short cavities of connector to...

Page 51: ...nal 4 Remove battery hold down rubber strap from frame and lift battery from tractor 5 Starter solenoid is located under operator s seat in front of battery 6 Follow wiring above to remove and replace...

Page 52: ...PERATION 10 TRANSAXLE OPERATION 11 BRAKE SYSTEM OPERATION 12 DIAGNOSIS 13 TESTS AND ADJUSTMENTS 15 CLUTCH BRAKE LINKAGE TRACTION DRIVE ADJUSTMENT 15 SHIFT LINKAGE ADJUSTMENT 17 REPAIR 18 TRACTION DRIV...

Page 53: ...GEAR POWER TRAIN CONTENTS CONTINUED 5 2 3 5 97 www servicemanualall com...

Page 54: ...23 5th Gear 28 Spur Gear 14 Intermediate Shaft Drive Sprocket Gear 18 1st Gear 37 2nd Gear 35 3rd Gear 30 4th Gear 27 5th Gear 22 Combination Gear Idler Shaft 12 and 35 Differential Spur Gear 32 Diffe...

Page 55: ...27 N m 20 lb ft ReAr Axle Cap Screws Nuts To Frame 30 N m 22 lb ft ShIft Linkage Lock Nut 15 N m 11 lb ft OTHER MATERIALS Form In Place Gasket Silicone Sealant Never Seez PT506 or PT569 SERVICE PART K...

Page 56: ...stretched replace belt Clutch brake pedal linkage out of adjustment Clutch brake components worn bent or broken replace and adjust Shift lever and linkage bent worn out of adjustment or broken replace...

Page 57: ...Intermediate shaft 1st gear 37 teeth 64 Differential ring gear 32 teeth 21 Intermediate shaft 2nd gear 35 teeth 65 Differential bevel gear 15 teeth 22 Intermediate shaft 3rd gear 30 teeth 66 Retainin...

Page 58: ...67 66 65 75 76 77 79 78 80 81 83 82 84 87 86 85 73 72 74 64 63 62 61 59 38 40 41 39 42 43 44 45 24 23 22 21 20 19 18 17 8 7 5 4 3 2 1 Use Form In Place Gasket Silicone Sealant to seal housing halves...

Page 59: ...27 Flange nut M6 28 Park locking rod 29 Flange nut M8 30 Rolled pin M4x20 31 Safety wire 32 Washer 33 Brake rod compression spring 34 Brake compression spring strap 35 Flange nut M8 36 Adjustable idle...

Page 60: ...OMPONENT LOCATION SHIFT LINKAGE SYSTEM COMPONENT LOCATION 1 2 3 4 5 6 7 8 36 35 37 41 40 9 12 11 10 13 14 15 16 17 20 19 21 22 23 24 34 31 32 30 28 29 27 26 25 38 39 42 43 44 45 46 47 48 49 18 33 50 5...

Page 61: ...rank assembly pivots the tensioning sheave E moves rearward releasing drive belt tension This allows the engine A Clutch Pedal E Tensioning Sheave B Engine Drive Sheave F Bellcrank Assembly C Tensioni...

Page 62: ...e Gears E Cross Shaft Bevel Gears F Idler Shaft G Spur Gear H Shift Fork I Shift Keys J Intermediate Shaft K Drive Axles L Beveled Drive Gear M Differential Ring Gear N Idler Gear O Shift Collar A J B...

Page 63: ...Clutch Bellcrank and Tensioning Idler Assembly H Clutch Tensioning Spring A F E G B C D H N O Q P Transaxle Brake Assembly There is a small segment of pedal travel P that briefly allows the tractor to...

Page 64: ...If case seal is leaking reseal case 6 Perform brake test See tests and adjustments Mower holds on 17 slope and stops in 0 9 1 5 M 3 5 ft or less Go to step 7 and 8 7 Inspect brake pads disk Pads and...

Page 65: ...GEAR POWER TRAIN 5 14 2 12 97 1 2 4 5 10 11 2 2 8 7 9 www servicemanualall com...

Page 66: ...pe 17 2 Look for a steady pull in all three lower gears up the slope 3 If traction test fails in any or all of the three lower gears the belt tension must be adjusted BRAKE TEST 1 Drive or push tracto...

Page 67: ...pression spring bracket C and front edge of brake rod stop tabs D is 7 5 8 mm 0 30 0 32 in 6 Once above measurement is obtained cycle clutch brake pedal 7 Remeasure distance it should be the same This...

Page 68: ...all three lower gears 8 Install battery if removed REPEAT TEST DRIVE 1 Repeat test drive in at beginning of this section 2 If tractor fails either brake test inspect brake assembly components replace...

Page 69: ...ch to shift Re check for axle rotation in neutral steps 2 through 4 this section 10 Lower tractor to surface and remove blocks E F G I H Results Test drive tractor to ensure all forward and reverse ge...

Page 70: ...3 Pull belt from around engine drive sheave G and past front belt guide H Pull belt under belt guide and around steering arm I 14 Rotate mower drive lever to allow belt to pass between lever J and swi...

Page 71: ...le idler D as shown H G I K J A B C D 5 Install drive belt through rear belt guide A and over transaxle drive sheave B 6 Install belt guides on clutch sheave and adjustable idler 7 Install park brake...

Page 72: ...o be released quickly from mower frame Protect your face eyes and hands before releasing spring C D F E 8 Remove clutch brake pedal by removing mounting nut G and pulling pedal through frame 9 Remove...

Page 73: ...er J Right Hand Bracket P Left Hand Bracket E Washer K Special Square Hole Washer F Cap Screw L Shift Lever A B C D E N M L K F I H G 16 N m 12 lb ft 15 N m 11 lb ft 15 N m 11 lb ft J 15 N m 11 lb ft...

Page 74: ...1 Tighten mounting hardware to the following specifications Front Hanger capscrews to frame 30 N m 22 lb ft Front transaxle cap screws to hangers 27 N m 20 lb ft Rear axle cap screws nuts to frame 30...

Page 75: ...ake disc is not contacting transaxle case 1 brake lever is not contacting its mounting bracket 2 top or bottom If so all worn components must be replaced E H F G Contact Points 1 2 1 Remove brake asse...

Page 76: ...l condition of assembly including the key and keyway and the drive sheave hub keyway 2 Check condition of pinion gear D look for wear pitting broken teeth etc 3 Grasp the input shaft and try to rock i...

Page 77: ...Grease 8 Clean and inspect bore If scratched or deformed replace upper case half Assemble Input Shaft Pinion Gear Assembly IMPORTANT DO NOT scratch or deform upper case half bore when installing need...

Page 78: ...shim thickness C needs to be changed 10 Install woodruff key F in shaft keyway L K I E J E C D F Shifter Disassembly 1 Lift shifter shaft B from lower case half mounting hole C and groove of shift col...

Page 79: ...0 026 in not scored nor discolored burnt Spacer C should be 0 630 x 1 00 x 0 169 in not scored nor discolored burnt Narrow combination gear E should have 35 good teeth and wide combination gear F shou...

Page 80: ...need to be added or worn components need to be replaced E I H A B D F Exploded View G C Intermediate Drive Shaft Disassembly 1 Lift both drive I and intermediate E shaft assemblies from transaxle cas...

Page 81: ...loration burnt Replace components as necessary 5 Replace seals I and F every time transaxle housing has been separated TRANSAXLE ASSEMBLY IMPORTANT Maintain absolute cleanliness when working on transa...

Page 82: ...ft groove 2 Install four keys in grooves of intermediate shaft and hold them so internal shift collar anchors A will seat in internal groove of collar B as it is installed on the shaft 3 Slide shift c...

Page 83: ...Install components on idler shaft in order shown N K J M L O P Q A B C D E F G Washers A and C should be 0 632 x 1 00 x 0 026 in Spacer B should be 0 630 x 1 00 x 0 169 in Narrow combination gear D s...

Page 84: ...1 Install shifter shaft rubber boot B 2 Coat detent balls C and springs D with Never Seez and install in case bores 3 Install and tighten set screws A until they are flush with top of mounting hole su...

Page 85: ...nd brake disc Install Drive Sheave and Shift Arm 1 Install woodruff key C in input shaft E 2 Install drive sheave D and fasten with snap ring F 3 Install shift arm A Tighten cap screw B to 16 N m 140...

Page 86: ...STEM OPERATION K51 20 TROUBLESHOOTING 21 DIAGNOSIS 24 DIAGNOSIS K55 26 DIAGNOSIS K51 28 TESTS AND ADJUSTMENTS 30 TRACTION DRIVE SYSTEM 30 DRIVE BELT ADJUSTMENT 31 TRANSPORT FREE WHEEL VALVE ADJUSTMENT...

Page 87: ...STAL LATION K55 39 POWER TRAIN LINKAGE SYSTEM REMOVAL INSTALLATION K55 40 TRANSAXLE REMOVAL AND INSTALLATION K55 41 TRANSAXLE DISASSEMBLY K55 42 TRANSAXLE ASSEMBLY K55 50 TRANSAXLE INSTALLATION K55 55...

Page 88: ...7 mm 0 28 in 7 mm 0 28 in Lubrication K 55 K 51 Oil Type 10W30 Engine Oil Class CD Factory Sealed Capacity 1 6 L 1 7 qt Factory Sealed Gear Ratios K 55 K 51 Forward 25 3 1 28 2 1 Reverse 25 3 1 28 2 1...

Page 89: ...5 mm 0 02 in N A Differential Cross Shaft To Bevel Pinion Gears Maximum 0 5 mm 0 02 in N A Brake Components Wear Tolerances K 55 K 51 Brake Disc Minimum 2 5 mm 0 1 in N A Brake Puck Minimum 8 mm 0 32...

Page 90: ...axle Housing Case Half Sealant K 55 K 51 Form In Place Silicone N A Gasket Sealant Pump Connector Pipe Plug Sealant K 55 K 51 Pipe Sealant With Teflon N A Approved Teflon Sealant Tape N A Lubrication...

Page 91: ...LH Axle Bushing 26 Shifter Shaft O Ring 74 Lower Case Housing 27 Shift Block 2 used 75 O Ring 28 Shifter Shaft 76 Drain Plug 29 Left Axle Shaft Thrust Washer 77 Cap Screw Self Tapping M8x30 17 used 3...

Page 92: ...5 46 47 48 49 50 51 53 54 55 56 52 57 58 59 60 62 63 64 65 66 67 37 36 35 34 33 32 31 30 29 71 70 69 68 84 86 85 87 88 89 90 91 92 96 93 95 94 81 78 77 76 75 82 83 28 61 74 27 N m 20 lb ft 57 N m 42 l...

Page 93: ...OCATION K51 1 Knob 2 1 4X20 Hex Jam Nut 3 Rod 4 E Ring 5 M6X30 Bolt 6 Snap Ring 7 Spacer 8 Sheave 9 Fan 10 Flnage Lock Nut 11 Lock Nut 12 Screw 13 Screw 14 Strap 15 Push Nut 16 Screw R H Side Screw L...

Page 94: ...ION HYDROSTATIC POWER TRAIN 2 12 97 6 9 COMPONENT LOCATION K51 1 4 New Case 27 4 31 4 N m 20 23 lb ft Used Case 22 5 27 4 N m 16 20 lb ft 11 11 2 3 6 5 8 9 7 10 11 14 11 11 17 12 15 14 16 13 www servi...

Page 95: ...Sheave K51 3 Arm K55 4 Arm K51 5 Bolt M8 x 45 6 Spring 7 Bushing 8 Cap Screw 9 Bolt K51 10 Spacer K51 11 Flange Nut M8 12 Lock Washer 13 Cap Screw 14 Sheave Engine 15 Bolt M8 x 45 16 Idler 17 Idler 1...

Page 96: ...ression Spring 11 Washer 12 Park Brake Lever 13 Extension Spring 14 Flange Nut 15 Rod Parking Brake 16 Cap Screw M8x35 K55 17 Lock Nut M8 K55 18 Brake Pedal K55 19 Pad 20 Shaft Brake K51 21 Strap Retu...

Page 97: ...r Bolt 15 Cap Screw M10x25 16 Cap Screw M8x25 17 Spacer 18 Flange Nut M8 19 Lock Nut 5 16 24 UNF 3B 20 Shift Link Ball Joint Assembly 21 Flange Nut M8 22 Mounting Stud M10x76 5 Top M8x40 Bottom 23 Shi...

Page 98: ...Gearshift Lever 4 Knob 5 Lock Nut 6 Strap 7 Roller 8 Bracket 9 Ball Joint 10 Stud Adjusting 11 Nut 5 16 12 Ball Joint 13 Bushing 14 Shoulder Bolt 15 Screw M10 x x25 16 Screw M8 x 25 17 Support 18 Loc...

Page 99: ...ots on the frame allowing the tension idler to move back into range B A F D C H E G D Used with K 51 Only TRANSAXLE AND SHIFT LINKAGE SYSTEM OPERATION Function The function of the transaxle is to tran...

Page 100: ...lock P because the pump pistons are not moving up and down as they rotate Therefore the motor cylinder block Q does not turn nor do the motor output shaft M differential assembly L or drive axles K an...

Page 101: ...washplate into reverse position With the pump swashplate angled in the opposite direction from the forward position the pump cylinder block pistons are pumping oil through the other side of the center...

Page 102: ...shifter bracket L This action moves the shifter bracket L and lever D back towards the neutral position At the same time this returns the shift linkage I into neutral position and the internal variab...

Page 103: ...forward forcing the cam roller J to roll up one of the ramp contours of shifter bracket K This action moves the shifter bracket and shifter lever L back towards the neutral position At the same time...

Page 104: ...system allows the operator to push the tractor while the engine is off transmission in or out of either forward or reverse and the brake released Major Components Internal center block relief valve as...

Page 105: ...rator to push the tractor while the engine is off transmission in or out of either forward or reverse and the brake released Major Components External over center actuating lever assembly Theory of Op...

Page 106: ...ode pushes hard Creeps in neutral Check or Solution Belt sheaves and idlers loose out of adjustment worn or damaged tighten replace or adjust properly Belt worn frayed glazed or stretched replace belt...

Page 107: ...filter plugged K55 Only Incorrect type or volume of lubricant used replace with correct type and volume K55 Only Note Initial leakage may be result of excessive factory rust preventive Clean case and...

Page 108: ...ot tight or bad seal Replace seal and Torque to15 N m 11lb ft K55 Only Transport free wheeling valves and linkage out of adjustment or damaged readjust or replace as necessary Engine performance probl...

Page 109: ...guides Adjust repair or replace components as needed 5 Hydro housing exterior No cracks leaks or loose hardware Tighten hardware Check warranty Repair or replace transaxle housing Replace any damaged...

Page 110: ...DIAGNOSIS HYDROSTATIC POWER TRAIN 2 12 97 6 25 5 6 1 3 4 2 9 7 6 8 8 K55 Shown Used with K51 Only www servicemanualall com...

Page 111: ...and working smoothly Adjust as needed Repair or replace as needed Test Conditions Tractor on level surface Front wheels blocked Engine OFF Rear wheels raised off surface with axle housings on jack sta...

Page 112: ...DIAGNOSIS HYDROSTATIC POWER TRAIN 2 12 97 6 27 1 2 3 4 6 5 www servicemanualall com...

Page 113: ...3 Neutral return linkage Neutral return linkage adjusted properly and working smoothly Adjust as needed Repair or replace as needed Test Conditions Tractor on level surface Front wheels blocked Engin...

Page 114: ...DIAGNOSIS HYDROSTATIC POWER TRAIN 2 12 97 6 29 1 2 3 4 5 6 www servicemanualall com...

Page 115: ...oo aggressively or tractor may tip over backwards while performing the test drive on a 17 slope 17 1 Test drive tractor to see if traction drive system pulls tractor up a 17 slope in lower 1 3 of forw...

Page 116: ...ver center position B 3 Watch closely that actuating pin E moves inward all the way and as lever snaps into over center position does not move outward at all 4 If actuating pin E does move outward loo...

Page 117: ...e creeps loosen front and rear jam nuts C of turnbuckle assembly D 6 Use flats E to turn threaded link use 1 4 turn increments clockwise to shorten turnbuckle length or counterclockwise to extend turn...

Page 118: ...ing spring length distance E between flanged nut and top anchor washer and adjust to specification This will ensure shift lever will remain stationary wherever operator lets go of lever anywhere in sh...

Page 119: ...and remeasure distances each time until specified measurements are obtained 8 Brake lever travel H should not exceed 30 if it does measure brake components individually Specifications Brake lever hole...

Page 120: ...a 17 slope 30 Max C 2 Carefully test drive tractor to see if traction drive system pulls tractor steadily up a 17 slope in lower 1 3 of forward range 3 Look for a steady pull in all three lower gears...

Page 121: ...belt can be removed from adjustable idler Release tensioning idler and remove belt from tensioning idler and transaxle drive sheave Not Shown 6 Remove park brake lever from locking rod CAUTION Tensio...

Page 122: ...on Wear gloves and use a firm grip when stretching spring Yoke Arm 5 Pull tensioning idler rearward until belt can be removed from adjustable idler Release tensioning idler and remove belt from tensio...

Page 123: ...lt tension See DRIVE BELT ADJUSTMENT on page 31 8 Remove blocking and return tractor to level 9 Hook up battery and spark plug Engine Pulley Tension Idler Adjust Idler Belt Link Arm Yoke Arm Park Brak...

Page 124: ...ONING SYSTEM REMOVAL INSPECTION INSTALLATION K55 1 Remove mower deck 2 Remove Traction Drive Belt See TRACTION DRIVE BELT REMOVAL K55 on page 36 3 Thread one end of a three foot long piece of starter...

Page 125: ...Lock Nut M6 35 Washer 4 Lock Nut M10 36 Cotter Pin M3 2x20 5 Shift Link 37 Washer 6 Snap Ring 38 Brake Pedal Pad 7 Anchor waSher 39 Brake Pedal 8 Spring 40 Lock Nut M8 9 Friction Disc 41 Comp Spring S...

Page 126: ...mounting bracket 10 Remove two right side mounting cap screws and flange nuts L A H D C E G F B I J K L M N O 11 Pull transport lever N into over center position to remove two left hand mounting cap s...

Page 127: ...pected after performing all external checks and adjustments CALL SABRE SERVICE DEPARTMENT FOR AUTHORIZATION TO REPLACE TRANSAXLE ASSEMBLY IMPORTANT PAY CLOSE ATTENTION to the ORDER and ORIENTATION of...

Page 128: ...First inspect brake assembly for wear or damage check for brake disc contact points at case points 1 and 2 check for brake lever contact point at mounting bracket edge 3 If contact is detected replace...

Page 129: ...ousing cap screws B G H I A 2 Carefully separate transaxle housing into upper and lower case halves 3 Remove any gasket residue from both case halves 4 Inspect overall condition of components without...

Page 130: ...lock 10 If valve assemblies do not dislodge remove plug L and bleed port connector K and try using compressed air to dislodge valve assemblies 11 If valve assemblies still remain lodged depress check...

Page 131: ...Axle Side 1 Remove short axle side thrust washer A H A B C D E C F H I I A B C D Short Axle Side 2 Turn c ring D in its groove so gap C faces down to keep c ring from falling down inside case 3 Caref...

Page 132: ...es outside diameters 17 Replace components as necessary F G G G R IMPORTANT Axle shaft seals O must be replaced every time axles are remove Protect new seals by wrapping tape over splines and c ring g...

Page 133: ...per case 7 Carefully move and separate motor pump and center block assembly to workbench Remove Pump Input Shaft Assembly J N L O P Q M I K C A B C IMPORTANT Carefully remove components so case bore i...

Page 134: ...during re assembly A B C D E T F G H I J K M N S R O Q P L 1 Carefully separate motor and drive shaft components 2 Clean and inspect components individually once disassembled drive shaft seal A must...

Page 135: ...ft Assembly IMPORTANT Carefully install pump shaft assembly so case bore is not damaged 1 Assemble pump input shaft and carefully install it into upper case with snap ring C 2 Wrap tape around shaft s...

Page 136: ...ssemble motor drive shaft 2 Wrap tape over brake disc splines A before installing new seal with open lip to inside Remove tape once seal is installed 3 Install narrow thrust washer C into fixed swashp...

Page 137: ...thing is aligned properly then tighten three caps screws to 55 N m 40 lb ft Install Differential Axle Assembly 7 Wrap tape around short B and long E axle shaft splines and c ring grooves to protect ne...

Page 138: ...in lower case half bore G 5 Fasten actuating bracket I with e ring H 6 Be sure assembly is pushed all the way out before assembling transaxle case halves 7 Install clean or new magnet assembly K Asse...

Page 139: ...Used upper case 27 N m 20 lb ft 6 Install new o ring on drain plug F and tighten it to 24 N m 17 lb ft Install Brake Assembly F G E B 1 Install brake components to transaxle and using friction puck s...

Page 140: ...y from all obstructions check transmission oil Top of if required 2 Safely raise and block frame so that rear wheels are a minimum of 51 mm 2 in off the surface Chock front wheels 3 Run engine at SLOW...

Page 141: ...elease tension from spring Tension is now off traction drive system and it may be worked on safely 4 Use this drawing for complete repair of system CAUTION Bellcrank tensioning spring is under high te...

Page 142: ...M68954 Lock Nut 9 525 MM 1 20 M117048 Pivot 1 21 14H774 Nut 3 8 1 22 M120404 Spring 1 23 M115388 Rod 1 24 M120007 Strap Comp Spring 1 25 M78462 Compression Spring 1 26 24H1305 Washer 13 32 x 13 16 1 2...

Page 143: ...lley C CAUTION Large idler spring is under high tension Wear safety glasses and gloves when removing drive belt A B C Idler Spring 6 Remove drive belt from drive sheave and fan D 7 Remove drive wheels...

Page 144: ...uckle Tighten lock nut to specification 6 Install drive belt over transaxle drive sheave and fan H I I L H Rear Axle 7 Pull idler arm towards transaxle and install drive belt onto idler pulley 8 Insta...

Page 145: ...A in groove on input shaft and fan lower retainer B with flat side towards fan A B C D A B 2 Install drive sheave and fan fan retainer C with flat side towards fan and c clip D TRANSAXLE INSTALLATION...

Page 146: ...ING Page 2 11 97 7 1 CONTENTS STEERING COMPONENT LOCATION 3 STEERING 3 SERVICE EQUIPMENT AND TOOLS 4 REPAIR 4 STEERING GEAR REMOVAL 4 REPLACE PEDESTAL BUSHINGS 5 ADJUST STEERING BACKLASH 5 www service...

Page 147: ...NOTES STEERING 7 2 2 11 97 www servicemanualall com...

Page 148: ...ATION STEERING Cotter Pin Washer Washer Tie Rod Steering Link Bushing Washer Sector Arm Pinion Shaft C Clip Washers Bushing Bushing Washer Cotter Pin Washer Bushing Steering Wheel Retainer Bolt Washer...

Page 149: ...tor 2 Remove fuel tank and dash panel See FUEL TANK AND DASH PANEL REMOVE AND INSTALL on page 5 in MISCELLANEOUS Section 3 Remove cotter pin and washer from end of steering tie rod Name Use Inside Pul...

Page 150: ...ssembly 9 Remove snap ring and washer s H 10 Remove sector gear shaft G 11 Replace worn or damaged parts as necessary 12 Adjust steering backlash see Adjust Steering Backlash later in this section M51...

Page 151: ...6 Install and fasten tie rods Long leg of tie rod is installed in axle spindle 7 Install steering wheel on top of steering shaft D and fasten with mounting hardware 8 Turn steering left to right seve...

Page 152: ...997 7 TESTS AND ADJUSTMENTS 8 SPINDLE BRAKE ADJUSTMENT 8 MOWER BELT TENSION ADJUSTMENT 8 DECK LEVELING SIDE TO SIDE 9 DECK LEVELING FRONT TO REAR 10 READJUSTING SUSPENSION TO OBTAIN 1 4 INCH CUT HEIGH...

Page 153: ...NOTES ATTACHMENTS 8 2 2 14 97 www servicemanualall com...

Page 154: ...necessary for smooth engagement with latch 4 Install and adjust mower deck 5 Install battery Lift Lever Lift Assist Spring Lift Lever Lock Lift Arm LH Lift Arm RH Latch Quadrant Latch Slotted Holes La...

Page 155: ...Idler 30 Spacer 31 Carriage Bolt M8X35 32 Rod RH Brake 33 Belt Guide 34 Washer 35 Lock Nut M8 36 Spring Locking Pin 37 Rod Front Draft 38 Ball Leveling 39 Washer 40 Capscrew 41 Blade 42 Washer 43 Was...

Page 156: ...6 Label Danger 37 Screw M8x20 38 Cap Screw M8x80 39 Washer 21 64 x 1 15 32 x7 64 40 Pad Brake W Spring 41 Lock Nut M6 42 Screw M8x12 Self Tapping 43 Nut Push On 44 Lock Nut M8 45 Hinge 46 Torsion Spri...

Page 157: ...ring Locking Pin 37 Rod Front Draft 38 Ball Leveling 39 Washer 40 Bolt M10x45 41 Blade 42 Washer 43 Washer 44 Bolt 45 Deflector 46 Spacer 47 Wheel Gage 48 Screw M10x70 49 Bolt 50 Capscrew 51 Screw M8x...

Page 158: ...COMPONENT LOCATION ATTACHMENTS 3 5 97 8 7 www servicemanualall com...

Page 159: ...Deck 1 17M 36 Bolt Carriage M8x40 37 Guide Belt 38 Screw M8x12 39 Bolt Carraige M10x45 40 Rod Front Draft 41 Ball Leveling 42 Lock Nut M10 43 Deflector 44 Blade 45 Washer 46 Washer 47 Bolt 48 Cap Scr...

Page 160: ...d every time the belt tension is adjusted Belt tension should be adjusted if required before brakes are adjusted 2 3 mm 0 078 0 118 Adjustment Nut Brake 5 Measure distance from brake surface to pulley...

Page 161: ...ctor on a hard level surface 2 Stop engine and remove key Disengage blade drive 3 Check tire pressure 14 PSI Front Tire 10 PSI Rear Tire 4 Adjust cutting height to middle position 5 Turn left blade by...

Page 162: ...djusting Nut J Bolt Rear Draft Arm Front Blade Tip Rear Blade Tip Rear Blade Tip 1 Turn blades to point front to rear 2 Measure height from level surface to front and rear blade tips Turn blades 180 a...

Page 163: ...tailed in DECK LEVELING SIDE TO SIDE and DECK LEVELING FRONT TO BACK sections Shown from right hand side of tractor REPAIR MOWER DECK REMOVAL 1 Stop engine engage park brake disengage blade drive 2 Pl...

Page 164: ...ear Draft Arm Rear Draft Pin Guide Rod Belt Guard Tensioning Pulley 6 Reinstall belt guard and tighten cap screws securely 7 Install mower deck on tractor See MOWER DECK INSTALLATION on page 13 8 Adju...

Page 165: ...e hands between lift lever and frame while adjusting Guide Rod Center Draft Arm Rear Draft Arm Between Guide Rod And Plate Rear Draft Arm Rear Draft Pin Guide Rod 5 Raise front of draft arms to align...

Page 166: ...w small washer and belleville washer to remove blade s 4 Remove spindle bearing guard s I and mounting hardware K to remove spindle assembly J INSTALLATION NOTE Spindles are not serviceable The spindl...

Page 167: ...Blade Blade Bolt Washer Concave side MUST face blade Small Lock Large Cupped GAGE WHEEL ADJUSTMENT This unit has been equipped with gage wheels to minimize scalping by the mower deck when mowing uneve...

Page 168: ...ON 3 FUEL TANK AND DASH PANEL 3 REPAIR 4 FRONT WHEELS REMOVAL INSTALLATION 4 REAR WHEELS REMOVAL INSTALLATION 4 FRONT WHEEL BEARING REPAIR 4 FRONT AXLE REMOVAL 5 FRONT AXLE INSTALLATION 5 FRONT AXLE R...

Page 169: ...NOTES MISCELLANEOUS 9 2 3 5 97 www servicemanualall com...

Page 170: ...3 Dash Panel 4 Clip Nut 2 used 5 Screw 6 used 6 Fastener Grommet 4 used 7 Hose Clamps 6 used 8 Screw 9 Fuel Delivery Hose Typical 10 Fuel Shut Off Valve 11 Fuel Filter 12 Flange Screw 13 Nylock Nut 1...

Page 171: ...on axle and install snap ring 10 Install plastic cap A Washer Snap Ring Cap Two 2 Washer REAR WHEELS REMOVAL INSTALLATION 1 Safely lift and support tractor 2 Remove plastic cap C E ring D gear or snap...

Page 172: ...to axle long leg in axle spindle 5 Connect draft arms to axle M55893 D C B A C Lock Nut Washer Pivot Washer Bushing Cap Screw Vehicle Frame Bushing 1997 FRONT AXLE REPAIR 1 Remove axle See FRONT AXLE...

Page 173: ...screw securing switch cam to rod CAUTION Gasoline is explosive Do not expose to flame or spark Serious injury can result Catch or wipe up any spilled fuel immediately Spring Rod Cap Screw Blade Drive...

Page 174: ...all lever on end of throttle cable assembly 22 Align fuel hose with slot M overflow tube with frame hole N throttle cable with hole P and dash panel steering shaft hole with steering shaft O as you in...

Page 175: ...steering shaft 29 Install steering wheel and fasten with cap screw and lock nut 30 Assemble spacer switch cam spring rod on tension lever end Line up holes in shaft and cam and Secure with cap screw...

Page 176: ...n Bulletins Service Information Bulletin No 96 001 3 Service Information Bulletin No 96 002 4 Service Information Bulletin No 96 003 5 Service Information Bulletin No 96 008 6 Service Information Bull...

Page 177: ...CONTENTS CONTINUED Service Information Bulletins 9 2 3 5 97 Page S www servicemanualall com...

Page 178: ...is warm up procedure SABRE has implemented a removable decal on the console of all SABRE lawn tractors A sample of this decal is below Whenever possible the consumer should be given instruction by the...

Page 179: ...elow and then re tightening the mounting bolts On the 46 mower deck also loosen the center spindle mounting bolts push it forward and retighten the mounting bolts Service Note TORQUE SPINDLE MOUNTING...

Page 180: ...of the drive belt can cause the belt to contact the bushing resulting in a chattering noise Although this chattering noise produces no functional problems it can be eliminated by the installation of...

Page 181: ...veling Gauge P N TY15272 as an aid in leveling deck Additional Information Anytime the tension rod is adjusted it is important that the spindle brake clearances be checked to ensure proper clearances...

Page 182: ...38 Mower Deck Adjuster Figure 1 Tension Rod Jam Nut 20 23 mm 0 87 in 46 Mower Deck Tension Rod Adjuster Figure 2 SERVICE NOTE Whenever the tension rod is adjusted always check spindle brake pad to pul...

Page 183: ...art of frame weldment remove and re install the jacksheave belt keeper on the front side of the bracket mounting flats See Figure 3 below Turn Page Page 3 of 4 Figure 3 FRONT Engine Jacksheave 25 mm 1...

Page 184: ...operly oriented belt keepers can result in thrown belts premature belt wear or breakage Page 4 of 4 Figure 4 Engine Sheave Belt Routing both decks Belt Guides Mower Drive Belt Tractor Engine Pulley Fi...

Page 185: ...pulley remove play from mounting bolt by pushing pulley toward the belt guide before tightening retaining nut Additional Information Belt guide should be at a 90 degree angle to the idler arm If the...

Page 186: ...surface Paper element may not show evidence of oil wicking if examined only from the outside Solution Replace paper air filter element and file warranty through SABRE only if this condition is found...

Page 187: ...SERVICE INFORMATION BULLETINS 10 12 3 5 97 S www servicemanualall com...

Page 188: ...4 10 Gear Power Train 5 13 Headlight Circuit 4 18 Hydrostatic Power Train 6 24 Hydrostatic Power Train K51 6 28 Hydrostatic Power Train K55 6 26 E Electrical AC Voltage Output Test 4 22 Battery Chargi...

Page 189: ...Install 5 34 Gear Ratios Specifications 5 4 Gear Tooth Specifications 5 3 Idler Assembly Installation 5 32 Idler Gear Disassembly 5 28 Idler Gear Inspection 5 28 Intermediate Drive Shaft Inspection 5...

Page 190: ...ification 6 3 Brake Assembly Removal K55 6 43 Brake Components Wear Tolerance 6 4 Brake Torque Rating Specification 6 3 Breather Valve Assembly Removal K55 6 43 Case Halves Assembly K55 6 53 Case Halv...

Page 191: ...Plug Specifications 4 3 Specifications 2 2 Spindle Brake Adjustment 8 8 Starter Amp Draw Test 4 23 Solenoid Test 4 22 Specifications 4 3 Stator Specifications 4 3 Steering Backlash Adjustment 7 5 Colu...

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