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Simplicity 1691766, Service & Repair Manual

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Simplicity 1691766 Service & Repair Manual Download Page 199

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7 Transmission Repair

7E Tuff Torq K210A

TUFF TORQ K210A SIX SPEED
TRANSAXLE

General

The Tuff Torq model K210A six speed gear transaxle is a
rugged and efficient gear drive transaxle using an auto-
motive style differential.

IMPORTANT: Cleanliness is a primary means of
assuring satisfactory life on new or repaired units.
Cleaning parts by using a solvent wash and air dry-
ing is usually adequate. As with any precision equip-
ment, all parts must be kept free of foreign materials
and chemicals.

Figure E-1.  Tuff Torq Model K210A Six Speed Gear Transaxle

• Protect all exposed sealing surfaces and open cavities

from damage and foreign material.

• Prior to removing and disassembling transaxle, the

tractor should be steam cleaned or blown with com-
pressed air before beginning any repairs. 

• It is recommended that all seals be replaced before

transaxle is reassembled. Lightly lubricate all seals
with a clean petroleum jelly prior to assembly.

• After transaxle is removed from the tractor, remove all

external components such as the brake arm, brake
actuating pins, control arm, cooling fan, input pulley,
and frame mounting hardware before separating case
halves.

Oil Capacity and Type: 124 oz. of 10W-30 Engine Oil

Summary of Contents for 1691766

Page 1: ...Service Repair Manual Landlord Series MANUFACTURING INC 500 N Spring Street PO Box 997 Port Washington WI 53074 0997 USA Copyright 1997 Simplicity Manufacturing Inc All Rights Reserved Printed in USA ...

Page 2: ......

Page 3: ... Rules General Operation 1 4 Safety Rules Service And Maintenance 1 6 General Repair Information Bearings 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 SECTION 1 GENERAL INFORMATION ...

Page 4: ...1692446 1716H 16HP Hydro 1692448 1718H 18HP Hydro 1692501 2718H 18HP Hydro 1692576 Landlord 18HP Hydro Tractors Mower Decks Mfg No Description 1691996 50 Mower Deck 1692026 44 Mower Deck 1692038 50 Mower Deck 1692035 44 Mower Deck 1692686 44 Mower Deck Mfg No Description 1692688 50 Mower Deck 1692689 50 Mower Deck 1692881 50 Mower Deck 1692882 50 Mower Deck 1693172 44 Mower Deck Export Figure 1 Tr...

Page 5: ... CONTENT This manual is intended primarily for use by dealer ser vice personnel as a technical reference manual or as a compliment to normal service training While the information in this manual has been developed to permit mechanics and service technicians to perform most service procedures quickly and effectively it is assumed that those using this manual will have some outdoor power equipment s...

Page 6: ...o 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 mow it Do Follow manufacturer s 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 Un...

Page 7: ... Always follow the engine manual instructions for storage preparations when preparing the tractor for both short and long term periods Always follow the engine manual instructions for proper start up procedures when returning the unit to service Never store the unit or fuel container inside where there is an open flame or pilot light such as in a water heater gas furnace or stove Allow unit to coo...

Page 8: ...safety goggles or full face protection when han dling battery electrolyte fluid or when performing grinding or sharpening operations that produce sparks or flying debris Extensive grinding may require the use of protective sleeves and an apron Wear work gloves when handling sharp surfaces such as mower blades or when working around sharp edges Never wear gloves that are loose fitting or that have ...

Page 9: ...erly installed and is not plugged with clippings or other debris Replace the vent tube if cracked damaged or missing from unit Old batteries should be disposed of by recycling Electrical System Safety Loose connectors worn wires damaged wire insula tion and loose termination hardware can cause sparks short circuits and erratic equipment opera tion Always check wiring for damage and make appropriat...

Page 10: ... always treat oils and greases as potentially flammable materials Always cap oil and grease containers when done using 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 op...

Page 11: ...xic nature INSPECTION Once cleaned bearings can be properly inspected for wear 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 should be lubricated in accordance with factory specifications and reinstalled a...

Page 12: ... caused 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 supplied paints are available that provide both an accurate color match and superior corrosion resistance Required Tools Equipment All repairs in this manual can be accomplished with stan dard m...

Page 13: ...102 0 120 163 2 170 231 2 5 8 11 90 122 4 150 204 0 220 299 2 5 8 18 100 136 180 244 8 240 326 4 3 4 10 160 217 6 260 353 6 386 525 3 4 16 180 244 8 300 408 0 420 571 2 7 8 9 140 190 4 400 544 0 600 816 0 7 8 14 155 210 8 440 598 4 660 897 6 1 8 220 299 2 580 788 8 900 1 244 0 1 12 240 326 4 640 870 4 1 000 1 360 0 NOTES 1 These torque values are to be used for all hardware excluding locknuts self...

Page 14: ...truction Cast Iron Sleeves Aluminum Crankcase Electrical 12 Volt 15 Amp Alternator Regulated System Battery 340 Cold Cranking Amps 41 min Reserve Capacity Industrial Rated Starter Motor Ignition Magnetron Electronic Ignition Air Cleaner Replaceable Paper with Oiled Foam Precleaner Lubrication Full Pressure Lube w Oil Filter Oil Capacity 2 Quarts 1 9 L Fuel Tank Material Non Corrosive Polyethylene ...

Page 15: ... Combination Clutch Brake Parking Brake Pedal Standard Equipment Gear Brake Location Right Front Pedal Gear Clutch Location Left Front Pedal Location Electric Mower Lift Lever switch on dash Manual Mower Lift Lever tractor right side PTO Clutch Electric Dash Mounted Ground Speed Lever Dash Mounted Ignition Key Switch on dash panel Throttle Lever and Choke Lever on dash panel Light Switch on dash p...

Page 16: ...8 cm Overall Width with Deflector 56 In 142 2 cm Weight 115 lbs 52 kg Variable Cutting Ht 1 3 6 in 2 5 to 91 cm Blade Arrangement Three Staggered Blades Mower Drive V Belt From Tractor PTO Pulley Spindle Bearings Lubricated and Sealed Ball Bearings Mower 50 Effective Cutting Width 50 In 127 cm Overall Width with Deflector 62 In 157 5 cm Weight 135 lbs 61 4 kg Variable Cutting Ht 1 3 6 In 2 5 to 91...

Page 17: ...2 1 2 Troubleshooting Table of Contents SECTION CONTENTS Troubleshooting Troubleshooting the Tractor 2 2 Troubleshooting the Mower 2 3 SECTION 2 TROUBLESHOOTING ...

Page 18: ...noid or starter motor faulty Repair or replace See Electrical Troubleshooting Section 10 Safety interlock switch or Replace as needed See Electrical module faulty Troubleshooting Section 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 14 Foot p...

Page 19: ...ed too slow Set to full speed 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 to...

Page 20: ...2 Troubleshooting Notes 2 4 ...

Page 21: ...Engine Oil Filter 3 4 Engine Air Filter 3 4 Fuel Filter Service 3 5 Spark Plug Service 3 6 Mower Blade Service 3 9 Lubrication Lubricating the Tractor 3 8 Lubricating the Mower 3 10 Tire Pressure 3 10 Check Add Transmission Oil Hydro Gear K216 Models 3 11 Tuff Torq K215 Models 3 11 Tuff Torq K210 Models 3 11 Change Transmission Oil Hydro Gear K216 Models 3 12 Tuff Torq K215 Models 3 13 Tuff Torq K...

Page 22: ...il that will be required when tractor is used again 2 Prepare the mower deck for storage as follows a Remove mower deck from the tractor b Clean underside of mower deck c Coat all bare metal surface with paint or light coat of 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 ...

Page 23: ...cord of your operating time Determining operating time is easily accomplished by multiplying the time it takes to do one job by the number of times you ve done the job or you can install the optional hour meter Safety Items Before Before Every Every Every 100 Spring First Use Each Use 5 Hours 25 Hours Hours Fall Check safety interlock system Check Tractor Brakes Check mower blade stopping time Aft...

Page 24: ... allowing oil level checks and fill ing to be performed using the same tube Engine Oil Filter The engine oil filter should be changed in accordance with the engine manufacturer s recommendations which is generally every 50 hours of operation or more fre quently when operating conditions are hot over 85 or dusty The oil filter removes abrasive particles and other conta minants from the oil keeping ...

Page 25: ...hoses and fuel filter to drain out as the hoses are disconnected and catch the fuel in the container 3 Observing the same fuel filter flow direction noted during removal install the new fuel filter in the fuel line by sliding the hoses onto the filter 4 Squeeze the tabs on the hose clamps together and slide the clamps into place over the fuel filter tubes to secure the fuel lines to the fuel filte...

Page 26: ...s should be inspected at the regular intervals specified in the engine manufacturer s owner s manual and cleaned or replaced as required Dirty worn or fouled spark plugs may cause hard start ing rough engine operation or loss of power and may contribute to premature starter failure from excessive cranking of the engine The spark plug s can be found by looking for the thick black spark plug cable s...

Page 27: ...up toward deck as shown in Figures 8 and 9 Secure with a cap screw D cup washer C and spline or hex washer B Use a wooden block to prevent blade rotation and torque capscrews to 50 70 ft lbs 67 95 N m LOOSEN Figure 6 Removing The Blade Figure 7 Balancing The Blade Figure 8 Installing The Blade Early Models A Wooden Block C Cup Washer B Spline Washer D Capscrew A D C B TIGHTEN Figure 8 Installing T...

Page 28: ...ed gear teeth steering gears require periodic lubrication with lithium grease When grease fittings are present a manual or pneumatic pressure feed grease gun should be utilized to inject enough grease through the fitting to fully permeate the enclosed area containing the bearings or other moving parts Plain bushings bearings axles without grease fittings and exposed gear teeth require the direct a...

Page 29: ...ease Fitting on Rear Shift Arm Figure 15 Front Axle Lubrication Points Figure 14 Lubrication Point Gear Models Transmission Control Rod Area Figure 16 PTO Electric clutch Lubrication Lubricate tab welded to underside of frame lightly whenever electric clutch is removed for service when drive belt is replaced or when a squeaking sound develops ...

Page 30: ...30 oil Brush any dirt and grass from the area to be lubricated and wipe lubrication points clean before applying oil This will ensure that oil can get into the area where it is required Avoid getting grease or oil on belts and pulley when applying lubricants and always wipe away excess oil and grease to prevent a rapid build up of dirt and debris from accumulating Figure 19 Lubricate Lift Arm Pivo...

Page 31: ...apacity 90 oz The transmission oil should be checked seasonally 1 Locate the fill plug dipstick 2 Remove the plug and check the oil level on the dip stick A Figure 22 Add oil if necessary 3 Replace the plug Tuff Torq K210 Models Oil Type 10W 30 Premium Engine Oil Oil Capacity 124 oz 1 Locate the fill plug dipstick 2 Remove the plug and check the oil level on the dip stick Add oil if necessary 3 Re...

Page 32: ...er and allow the oil to drain from the transaxle housing see Figure 24 2 Remove the two internal hex head screw retaining the filter base to the axle housing see Figure 25 3 Remove the filter base and gasket 4 Unscrew the filter base from the 7 16 SAE barbed fit ting and hose 5 Install the filter base and a new gasket with the two screws and torque the screws to 7 10 ft Ibs 4 Fill the transmission...

Page 33: ...ve and replace the oil filter see Figure 27 3 Reinstall the drain plug 4 Fill the transmission with new oil See Check Add Transmission Oil 5 Run the unit for 5 minutes and recheck the oil level Tuff Torq K210 Models Oil Type SAE 10W 30 Premium Engine Oil Oil Capacity 124 oz Change Interval The transmission oil should be changed when perform ing repair work or if the fluid has become discolored fro...

Page 34: ...3 14 3 Maintenance Notes ...

Page 35: ...6 3010L 4 5 Tuff Torq K210A Gear Models 4 5 Return to Neutral Adjustments Tuff Torq K215A 4 6 Hydro Gear 216 3010L 4 6 Clutch Brake Adjustment Hydros Tuff Torq K215A 4 7 Hydro Gear 216 3010L 4 7 Clutch Adjustment Gear Clutch Adjustment 4 8 Brake Adjustment Gear Brake Adjustment 4 8 Purging Air From Transaxle 4 8 PTO Electric Clutch Adjustment 4 9 Mower Adjustments Side to Side Leveling 4 10 Front ...

Page 36: ...after adjustment Figure 1 Steering Gear Adjustment A Capscrews A IDLER PULLEY Hydro Gear 216 3010L Only See Figure 2 These units have an idler pulley installed near the transaxle The position of the pulley is pre set at the factory and does not require adjustment Early model year units may have pulley brackets with slotted pulley mounting holes If the belt does not disengage when the clutch brake ...

Page 37: ... be rotated with a pliers or use a 1 4 rod or 2 Phillips screwdriver inserted into hole in ball retainer 8 Tighten nut D securing ball retainer E 9 Depress clutch brake pedal fully and apply parking brake Turn the tractor engine off 10 Tighten both nuts securing the top and bottom of the speed control lever B C 11 Release the parking brake and restart the engine Run the engine at full throttle and...

Page 38: ...ing brake and start tractor Move the ground speed control lever from forward and reverse into the neutral gate 7 If there is minimal rotation of right rear axle slightly loosen nut E on hex adjuster Turn hex adjuster just slightly turn counterclockwise to correct forward rota tion and turn clockwise to correct reverse rotation until axle stops If there is more than slight rotation of rear axle rep...

Page 39: ...ar shift rod C 5 Move the shift lever so that it is positioned in the neutral gate 6 Tighten nut A securely 7 Check operation of unit for any movement with shift lever in neutral gate Perform the return to neutral adjustment refer to next page Figure 5 Neutral Adjustment A Nut B Idler Pivot Assembly C Rear Shift Rod D Idler Arm Assembly E Front Shift Rod WARNING When making adjustment keep hands h...

Page 40: ...C clamp if required Do not apply parking brake to hold pedal as pedal will not be held fully against footrest without free play 4 See Figure 8 Position shift lever just below neutral gate shift lever shaft should be centered on corner at start of reverse slot 5 Rotate the return to neutral cam C securely against the front clutch rod D There should be no gap between the clutch rod and cam at the co...

Page 41: ...Place a feeler gauge between the disc and one puck If the clearance is not properly set remove the cotter pin retaining the castle nut and set the correct clear ance by adjusting the nut Reinstall the cotter pin Figure 10 Brake Adjustment A Feeler Gauge B Adjustment Nut A B 3 Fully depress the clutch brake pedal and lock the parking brake by pulling up on the parking brake knob 4 See Figure 11 The...

Page 42: ... to the neutral gate 6 Place the hydro release lever A in the DRIVE posi tion 7 Drive the tractor at least five feet in the forward and reverse directions with full throttle and full ground speed Repeat this procedure three times in the for ward and reverse directions 8 Check oil level if applicable Repeat the above steps if tractor has noisy or erratic operation lack of performance after transmis...

Page 43: ...he rotor and armature faces The pulley must turn freely 7 If drag is encountered repeat the adjustment proce dure using care to ensure that the rivet joints are away from the adjustment windows before making any adjustments NOTE The actual air gap between the rotor and armature may vary from 005 to 023 even after per forming the adjustment procedure This is due to dimensional variations on compone...

Page 44: ...g Turn the blades front to back Measure the distance from the ground to front tip of center blade and from ground to rear tips of left hand and right hand blades Front tips should be 1 8 1 4 3 6 mm higher than rear tips For adjustment refer to Figure 17 1 To raise front of mower deck loosen front nut A and turn rear nut B against bracket C to shorten rod D 2 To lower front of mower deck loosen rea...

Page 45: ...afety Interlock System A PTO Interlock Switch 5 17 B Seat Switch Mechanical 5 17 C Seat Switch Electrical 5 18 D Clutch Brake Switch Mechanical 5 18 E Clutch Brake Switch Electrical 5 18 F Neutral Safety Switch Mechanical 5 19 G Neutral Safety Switch Electrical 5 19 H Interlock Module 5 20 5 Misc Tests A Headlights 5 20 B Power to Headlights 5 20 C Headlight Switch 5 21 D Hour Meter 5 21 E Power t...

Page 46: ...unning current flows from the alter nator through a rectifier to the positive battery post and charges the battery The circuit breaker normally closed opens if the circuit is shorted Cranking System Battery voltage is present at the B terminal of the igni tion switch at all times see Figure 8 Turning the igni tion switch to START supplies 12 volts to one of the sole noid coil terminals Current is ...

Page 47: ...d to measure DC voltage Ohms are units of resistance or the VOM setting used to measure resistance Continuity is an continuous unbroken circuit In this manual continuity is determined with a VOM set to mea sure Ohms Zero Ohms is true continuity However due to contact point corrosion and resistance within wires continuity may measure several Ohms No Continuity is a broken circuit In this manual no ...

Page 48: ...5 Electrical Troubleshooting Lower Wiring Harness 5 4 Figure 1 Lower Wiring Harness NOTE Use standard hardware torque specifications chart unless otherwise noted 9 7 4 8 10 3 2 14 6 1 11 5 13 6 12 ...

Page 49: ... Headlight 12 8V 5 1 TIE Cable 6 2 BUSHING Snap Small 7 1 LENS Headlight 8 1 BEZEL Headlight 9 1 HEADLIGHT ASSY Incl Ref Nos 3 4 7 8 10 10 2 HEAT SHIELD 11 1 WIRE ASSY Seat Switch and Lift 12 1 WIRE ASSY Engine Ground 13 1 HARNESS ASSY Lower 14 1 SWITCH Seat Operator Present REF NO QTY DESCRIPTION LOWER WIRING HARNESS ...

Page 50: ...ness 5 6 Figure 2 Main Wiring Harness NOTE Use standard hardware torque specifications chart unless otherwise noted 24 29 26 8 5 38 12 39 28 17 27 11 37 2 38 23 33 34 33 34 13 38 15 38 30 1 8 14 20 38 9 6 35 21 7 25 36 35 3 22 19 10 32 31 16 18 4 ...

Page 51: ...15 1 MODULE 16 1 TRAY Battery 17 1 COVER Key Switch 18 2 NUT Plastic 1 4 20 19 1 VENT Battery 20 1 STRAP Wire Retainer 21 2 ROD Battery Hold Down 22 1 SWITCH Lift 23 1 HOUR METER 24 1 SWITCH 25 1 CABLE Battery to Ground 26 1 SWITCH PTO Electric Clutch 27 2 KEY Ignition 28 1 ADAPTER Nut 29 1 HARNESS Wiring 30 1 HARNESS Upper 31 2 NUT Hex Full 1 4 20 32 2 LOCKWASHER 1 4 33 2 LOCKWASHER 5 16 34 2 NUT...

Page 52: ...5 Electrical Troubleshooting Electric Lift Motor 5 8 NOTE Use standard hardware torque specifications chart unless otherwise noted 7 4 3 8 9 12 11 2 1 5 10 6 Figure 3 Electric Lift Motor ...

Page 53: ...3 1 MOTOR KIT 12 VDC 4 1 GASKET Housing 5 1 SEAL Outer Tube Top 6 1 BALL SCREW ASSY 7 1 MOTOR GEARBOX ASSY 12 VDC 17 1 Ratio 8 1 BRUSH LEAD Red 9 1 BRUSH LEAD Black 10 1 SEAL Inner Tube Top 11 1 OUTPUT GEAR SLIP CLUTCH ASSY 12 1 GEAR ASSY 2nd 3rd REF NO QTY DESCRIPTION ELECTRIC LIFT MOTOR ...

Page 54: ...TEST BATTERY VOLTAGE 1 Test the battery voltage set VOM to VDC 2 Place one test probe of the VOM on the battery s positive post and one probe on the negative post Note and record the battery voltage as it will be refer enced in later tests 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 thr...

Page 55: ...d 1 Remove the negative battery cable from the battery and from the ground Clean the cable terminals and the engine ground with a wire brush until the metal is shiny 2 Remove the positive cable from the battery and sole noid Clean the terminals and solenoid post with a wire brush until the metal is shiny 3 Remove the cable going from the solenoid to the starter Clean the cable terminals solenoid p...

Page 56: ... INTERLOCK SYSTEM b If the starter does not turn the engine over pro ceed to part 3 TESTING THE CRANKING SYSTEM 5 Remove the jumper and reconnect the black yellow and green black connector to the solenoid 3 TESTING THE CRANKING SYSTEM For the following tests it is assumed that the battery is fully charged and all connections and wires are good A Test Circuit Breaker The circuit breaker A Figure 8 ...

Page 57: ...the plug from the ignition switch 2 Remove the ignition switch from the dash board 3 Set VOM to Ohms 4 With key switch in the OFF position connect test leads to terminals G and M There should be a read ing of 0 3 3 continuity on multi meter 5 Check all other connection combinations for no conti nuity G to M should be the only combination that has continuity all other connection combinations should...

Page 58: ... combinations for no conti nuity B to L B to S and L to S should be the only combinations that have continuity all other connec tion combinations should have no continuity Replace a switch that does not meet all of the above test results 10 Reinstall the ignition switch and reattach the plug B L OFF RUN START D Test Power to Solenoid 1 Unplug the blue white wire A Figure 16 from sole noid post 1 2...

Page 59: ... to the other small post and then touch it to the positive battery post The lead may arch to the battery post this is normal There should be a single audible click heard as the solenoid engages and the engine should turn over If no click is heard proceed to SOLENOID BENCH TEST If the solenoid clicks but the starter does not turn the engine over check the starter cable and the starter itself If the...

Page 60: ...gages 6 With the solenoid engaged 12 VDC to the small posts 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 wires and connectors G Test Power to Starter For this and all tests the ground speed control lever must be in the neutral gate the parking brake set and the PTO switch must be OFF Unplug and sec...

Page 61: ...h of the front row of termi nals The VOM should show continuity Terminals further apart 5 Move PTO switch to the ON position 6 Touch one probe to each of the back row of termi nals The VOM should show continuity 7 Touch one probe to each of the front row of termi nals The VOM should show no continuity B Test Seat Switch Mechanical 1 Tilt the seat forward and rest it against the steering wheel The ...

Page 62: ...ch Mechanical Later Models Only 1 Release the parking brake 2 Check the clutch brake switch The switch button should not be depressed 3 Set the parking brake 4 Check the clutch brake switch The switch button should be depressed E Test Clutch Brake Interlock Switch Electrical Later Models Only 1 Release the parking brake 2 Remove the plug from the clutch brake pedal inter lock switch 3 Set the VOM ...

Page 63: ...under the dashboard and may be easier to test if removed Use a 1 4 drive ratchet a 1 extension and 1 4 shallow sock et to remove the two plastite screws that secure the switch to the dashboard 1 Remove the wire harness plug 2 Place the ground speed control lever in neutral depress the switch 3 See Figure 33 Set the VOM to Ohms Touch one probe to each of the top row terminals and then the bottom ro...

Page 64: ...e is bad and must be replaced 5 MISCELLANEOUS TESTS A Test Headlight Bulbs 1 Remove the headlights from the headlight assembly by twisting the socket counterclockwise and pulling it out of the reflector assembly 2 Visually inspect the bulb If the element is burned out replace the bulb B Test Power to Headlight Circuit 1 Turn the ignition switch to ON RUN and the head light switch OFF 2 Set VOM to ...

Page 65: ...tery voltage If not check the switch and the continuity of all wires and connectors C Test Headlight Switch 1 Remove the plugs from the headlight switch 2 Set the VOM to Ohms 3 With the switch OFF probe both terminals The VOM should read no continuity 4 Turn the switch to ON The VOM should read conti nuity D Test Hour Meter Where Applicable The hour meter A Figure 40 can be easily tested by turnin...

Page 66: ...lt age If not check the key switch and all wires and connections 4 Probe ground Probe the black wire at the hour meter terminal The VOM should read battery volt age If not check the ignition switch all wires and connections and the hour meter F Inspect and Replace Dash Lights 1 Open the hood 2 Remove the dash lights A Figure 42 by twisting the socket counterclockwise and pulling it out of the dash...

Page 67: ... 2 Set VOM to Ohms 3 Probe the clutch body with the negative test lead 4 Probe one of the connector terminals with the posi tive lead The VOM Should show no continuity 5 Probe the other connector terminal with the positive lead Again the VOM should show no continuity If the VOM shows continuity to the clutch body from either terminal the clutch has an internal short and should be replaced TEST ELE...

Page 68: ...ould go up 5 Reverse the connections on the battery and connect to the lift motor wires The lift should go down 6 Reconnect the lift motor wires to their original con nectors If the motor passes this test the problem lies in the wiring connections or switch TEST ELECTRIC LIFT SWITCH 1 Open the hood locate and remove the wire harness plug from the back of the electric lift switch 2 Remove the elect...

Page 69: ...GE BLACK ORANGE TAN TAN TAN TAN BLACK TAN BLACK TAN BLACK TAN BLACK TAN BLACK TAN G R E E N B L A C K GREEN BLACK GREEN WHITE GREEN GREEN GREEN GREEN WHITE BLUE WHITE BLUE WHITE BLUE WHITE BLACK WHITE PURPLE WHITE YELLOW YELLOW YELLOW BLACK BLACK YELLOW BLACK RED BLACK BLACK BLACK BLACK BLACK PURPLE P U R P L E BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK PINK BLACK PINK BLACK PINK ...

Page 70: ...CH TRANS SWITCH HARNESS PLUG UPPER HARNESS PLUG LOWER INTERLOCK MODULE SEAT SWITCH 4 1 2 3 4 1 2 3 4 1 2 3 5 6 7 8 5 6 7 8 5 6 7 8 SPLICE A SPLICE C BLACK BLACK BLACK WHITE WHITE RED RED RED B L A C K LOWER HARNESS PTO START START A LIGHT C E D S B M L G S B M L G R S IGNITION SWITCH POSITION CIRCUIT MAKE 1 OFF 2 RUN 3 START G M B L B L S NOTE SPLICE A 5 2 FROM HARNESS PLUG SPLICE B 6 5 FROM HARNE...

Page 71: ...Brake Pedal Assy Service Hydro Gear 216 6 42 Clutch Rod Service Hydro Gear 216 6 42 Brake Arm Brake Rod Service Hydro Gear 216 6 43 Idler Arm Assy Service Hydro Gear 216 6 44 Clutch Rod Service Hydro Gear 216 6 42 Lockout Lever Shift Pivot Assy Service 6 46 Clutch Rod Service Tuff Torq K215A Models 6 49 Clutch Rod Service Tuff Torq K215A Models 6 49 Clutch Brake Pedal Assy Service Tuff Torq K215A ...

Page 72: ... required for servicing these areas include 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 FOR SAFE SERVICE 1 Remove the ignition key and disconnect the spark plug wire to prevent accidental starting while working on unit 2 Remove mowing deck See Operator s Manual 3 Remove the hood assembl...

Page 73: ...General Repair 6A Steering Front Wheel Repair Figure A 2 Front Wheel Assemblies A Valve Stem Cap B Tire C Tube D Seal E Bearing F Cup G Wheel H Washers I Setscrew J Collar K Hub Cap K J I H E F G F E D A C B ...

Page 74: ...her damage that indicates that replacement of the spindle assem bly is necessary 8 Wipe off excessive grease from the cone bearings and clean them thoroughly with safety solvent Dry the bearings with a low pressure air stream and inspect carefully for signs of wear such as pitting score marks cracking or chipping Replace the bearing if necessary along with the mating bearing cup in the wheel hub 9...

Page 75: ...pair 6A Steering Front Wheel Repair Lower Steering Group Upper Steering Group Figure A 4 Steering Group Typical Assembly Frame Dash Shown For Component Position Reference Frame Dash Lower Dash STEERING GROUP ASSEMBLIES ...

Page 76: ...t Hand Spindle Repair 1 Remove the wheels as described previously under Front Wheel Repair 2 Using a flat blade screwdriver position the tip of the screwdriver blade at the open end of the steering arm clip ring and twist the blade against the clip ring to force the ring partially out of the groove Figure A 6 3 Insert the tip of the screwdriver blade in the gap between the inside edge of the clip ...

Page 77: ...by turning it clockwise looking at the end of the drag link shaft one or two turns with a 3 4 open end wrench and then unscrew the rod end by turning it counter clock wise NOTE When reinstalling the rod end be sure to adjust the length of the drag link arm so that the left and right spindle stops stop against the axle assembly with full left and right turns respectively See the adjustment proce du...

Page 78: ...lat blade screwdriver position the tip of the screwdriver blade at the open end of the steering arm clip ring and twist the blade against the clip ring to force the ring partially out of the groove Figure A 12 5 Insert the tip of the screwdriver blade in the gap between the inside edge of the clip ring and the spin dle shaft and pop the clip ring completely out of the groove 6 Slide the right hand...

Page 79: ... the distance between tires as a guide The distance between tires at the front should be 1 8 less than the distance between tires at the rear measured at the the outer edge of the tire tread when the wheels are pointed straight ahead This slight toe in is permanently set by the tie rod and is not adjustable 3 Before reassembling rod end hardware to left hand steering arm squirt a few drops of SAE ...

Page 80: ... Check the tie rod for cracks or other damage at the rod ends and replace if necessary Also the center portion of the tie rod must be straight to provide the correct 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 using new spacers or hardware if required Before installing the flanged lock nut squirt a few drops...

Page 81: ...ew UPPER STEERING GROUP ASSEMBLY I G J K G F E L K T K S R Q O P N M C D B A NOTE 4 gear teeth Apply Loctite 271 Torque to 20 30 ft lbs Torque to 17 23 ft lbs 2 places Early models used a capscrew washer nut in place of a roll pin C Figure A 17 Upper Steering Assembly To Rod End See Figure 4A 8 NOTES 1 Unless specified use torque specifications shown on standard hardware torque specification chart...

Page 82: ... Steering Wheel CURRENT MODELS 1B Later model steering wheels are attached to the steering shaft assembly with a long spring pin Use a pin punch and hammer to drive the spring pin out of the steering wheel and steering shaft assembly Figure A 19 2 Slide steering wheel up to remove from steering shaft assembly and note positioning of mounting holes for later reassembly Figure A 20 3 Inspect steerin...

Page 83: ...were held in place by the cotter pin Slide the washers off the shaft Figure A 22 Steering Mounting Plate A Nuts A 4 Loosen the nuts securing the steering mounting plate A Figure A 22 5 Slide the steering shaft assembly down and out of the bottom of the unit to remove for replacement Note Unit must be tipped up at this point to remove the shaft 6 Inspect steering shaft assembly and bushings for exc...

Page 84: ...place as required 7 Reassemble in reverse order of disassembly Apply a grease to the pitman arm shaft bushings and gear teeth Figure A 23 Disconnect Drag Link Ball Joint Drag Link Pitman Steering Arm Steering Gear Pitman Steering Arm Service 1 Tilt the unit up or place on an elevated work stand for access to the underside of the frame 2 Disassemble the drag link from the pitman arm by removing the...

Page 85: ... or two turns with a 3 4 open end wrench and then unscrew the rod end by turning it counter clockwise 4 Check the drag link for cracks or other damage and replace if required If the drag link is being replaced position the jam nuts on the new drag link in the approximate positions utilized on the old drag link 5 Inspect the rod ends for free movement rotation of the rod end bearing and replace the...

Page 86: ...6 General Repair 6A Steering Front Wheel Repair Notes 6 16 ...

Page 87: ... the end of the ground speed control lever NOTE Do not overheat the knob as this may distort the part or cause melting and could prevent a secure fit when reattaching the knob Use a low heat setting when using a heat gun and keep the gun 4 6 away from the knob while moving back and forth to provide even heat ing 1 Slide the knob off the ground speed control lever and check for cracks or excessive ...

Page 88: ...Washer E Torsion Spring F Plastic Bushing 1 2 Dia G Nylon Bushing 3 4 Dia H Washer 1 2 I Hex Locknut 5 16 18 J Washer 5 16 K Spring L Hex Nut 5 16 18 M Lockwasher 5 16 N Washer H T O Spacer P Stud 5 16 18 x 3 1 4 Q Carriage Bolt 1 4 20 x 3 4 R Washer 21 64 x 1 1 4 S Tension Bracket T Washer 1 4 U Lockwasher 1 4 V Hex Nut 1 4 20 W Shift Lever Assembly Figure B 3 Typical Ground speed control Lever A...

Page 89: ...ontrol lever may be in creased or decreased on later models by adjusting the tension on the ground speed control lever compression spring K Figure B 3 Later Model Ground speed control Lever Assembly The correct tension for proper ground speed control lever operation should be obtained when the adjustment locknut I Figure B 3 is torqued to 75 100 in lbs 1 Using a 1 2 deep socket with a 4 6 extensio...

Page 90: ... to the ground speed control lever 6 Check the ground speed control lever for smooth op eration Figure B 9 Ground speed control Lever Assembly Removal Ground Speed Control Lever Assembly Replacement The ground speed control lever assembly should be re placed if damaged or worn 1 Remove the steering wheel and steering shaft See Steering and Front Wheel Repair 2 From the underside of the unit remove...

Page 91: ...control lever assembly arm to the front transmission ground speed control rod linkage Figure B 11 6 The ground speed control lever assembly may now be removed from the unit and inspected for wear or damage Replace parts as required Refer to Figure B 3 for proper assembly sequence of parts 7 Reassemble parts in reverse order of disassembly Apply a light coating of grease to the inside diameter of a...

Page 92: ... shift lever rod to shift lever arm and set washers aside for reuse when reassembling rod 3 Safely elevate and support unit mower deck re moved for working access to transmission shift lever area 4 See Figure B 13 Remove capscrew hex nut wash ers and spacers connecting shift rod to speed control lever and remove shift rod from unit Inspect shift rod for wear or damage and replace as required 5 Rea...

Page 93: ...ront shift lever rod to shift lever arm and set washers aside for reuse when reassembling rod 3 Safely elevate and support unit See Elevating Unit for Safe Service and remove the mower deck for ac cess to transmission shift lever area 4 See Figure B 14 Remove capscrew hex nut wash ers and spacers connecting shift rod to shift lever and remove shift rod from unit Inspect shift rod for wear or damag...

Page 94: ...y Area Underside Of Unit 3 Safely elevate and support unit mower deck re moved for working access to idler arm assembly area and related shift linkage parts Figure B 16 Figure B 17 Remove Cotter Pin 4 See Figure B 17 After noting assembly position of front and rear clutch rods to ensure proper assembly when reassembling parts remove cotter pin and washer from front clutch rod 5 See Figure B 17 Dis...

Page 95: ...he groove on the pivot shaft and remove the idler arm assem bly from the unit by pulling it straight out and off the shaft See Foot Controls for specific idler arm as semblies and components used on various models Figure B 20 Lockout Lever Shift Pivot Assembly 8 See Figure B 20 Remove the hex nut that secures the lockout lever to the shift pivot assembly 9 Lift the rear shift rod off the screw thr...

Page 96: ...ot tube Replace the shift pivot assembly if worn or corroded 13 Check the front shift rod for cracks corrosion or other damage and replace if necessary Front Shift Rod Shift Pivot Front Rear Shift Rod Service Hydro Gear 216 3010L Models Figure B 22 Remove Hydro Control Lever A Hydro Control Lever B Hydro Shift Rod C Shock Absorber A B C 14 See Figure 23 Remove the nut washer spacer and carriage bo...

Page 97: ...Shock 4 1 SHOCK ABSORBER 5 1 LEVER Hydro Control 6 1 ROD Shift Rear 7 2 NUT Hex Fin 3 8 16 8 2 LOCKWASHER 3 8 9 3 LOCKWASHER 5 16 10 3 NUT Hex Fin 5 16 18 11 5 WASHER 11 32 x 3 4 x 1 16 19 20 21 Ref Qt Desc No 12 4 WASHER 11 32 x 1 x 1 8 13 1 CAPSCREW Hex Hd 5 16 18 x 3 4 14 2 CAPSCREW Hex Hd 5 16 18 x 2 15 1 NUT Hex Lock 10 32 16 3 NUT Hex Flange Lock 5 16 18 17 1 BOLT Carriage 5 16 18 x 1 1 4 18...

Page 98: ...he latch rod is pushed out of the lift lever latch 2 Pull the pin punch back out of the latch rod hole and slide the spring and push on nut off the end of the pin punch 3 Disengage the hook end of the spring from the lift lever assembly and visually inspect the spring for wear or damage Replace if necessary 4 Inspect the lift lever latch G Figures B 26 B 27 and replace if necessary The lift lever ...

Page 99: ...REMOVAL The entire lift lever assembly may be easily removed from the unit for bench inspection and repair 1 Remove the mower deck as described in Mower Deck Repair 2 Remove two 5 16 18 x 1 1 4 capscrews locknuts and spacers U I J Figure B 26 that secure the lift lever assembly to right side of the unit s frame Slide the lift guide bracket H Figures B 26 up and out of position between the frame an...

Page 100: ... Capscrew 5 16 18 x 1 1 4 U Roll Pin V Lift Tube Assembly W Clip Pin X Pin Y Hex Head Capscrew 3 8 16 x 2 1 2 Z Cable Guard AA Plastic Pulley BB Spacer CC Spacer DD Flange Lock Hex Nut 3 8 16 EE Lift Cable Assembly LIFT LEVER ASSEMBLY Models With 2 Lift Arms 44 50 Mower Decks Z Y V W X D K S Q J O N M L K T G U F I J H E B A Q P R Q C DD BB AA CC EE EE Note 1 NOTES 1 Insert capscrews S from right ...

Page 101: ...pect all parts for wear corrosion or dam age and replace as necessary Reassemble parts in reverse order of disassembly DOUBLE CABLE MANUAL LIFT TUBE ASSEMBLY REPLACEMENT 1 The lift tube assembly slides over the lift lever assem bly shaft and can be removed by simply sliding the lift tube away from the mounting bracket portion of the lift lever assembly Figure B 27 2 Check the lift tube assembly fo...

Page 102: ...1 SHAFT ASSM 5 1 SUPPORT Lift 6 1 SUPPORT Actuator 7 1 POWER LIFT ASSM 8 2 CHAIN 3 Link 2 CHAIN 4 Link 9 1 LIFT ARM ASSM 10 1 PIN Clevis 11 1 LIFT TUBE ASSM 12 1 WASHER Plain 13 1 PIN Cotter Ref Qt Desc No 14 4 WASHER Plain 15 9 NUT Hex Lock ESNA 5 16 18 16 2 NUT Hex Lock ESNA 3 8 16 17 2 CAPSCREW Hex Hd Whizlock 3 8 16 18 2 CAPSCREW Hex Hd 5 16 18 x 1 19 1 WASHER Plain 20 6 CAPSCREW Hex Hd 5 16 1...

Page 103: ...1 Remove the mower deck as described in Mower Deck Repair 2 Remove the safety clip 23 Figure 30 and the long clevis pin 1 to disconnect the power lift assembly 7 from the lift arm assembly 9 3 Disconnect the red and black motor wires 4 Remove the 3 1 4 long capscrew 21 securing the power lift assembly 5 Lift the power lift assembly 7 out the actuator brack et 2 for service Figure B 31 Mower With E...

Page 104: ...32 for a complete breakdown and assembly groupings The following procedure is for complete disassembly If complete disassembly is not required follow the instruc tions as far as needed For reassembly follow the in structions in reverse order 1 See FIgure 32 Remove the taptite capscrew 1 and remover the ball screws assembly 6 2 Remove the gear box cover screws 14 cover 15 and gasket 4 3 Remove the ...

Page 105: ... en gagement of the cable end with the choke lever re move the cable end from the choke lever Figure B 34 Figure B 35 Choke Cable Assembly 2 From inside the dashboard area unscrew the hex nut that secures the choke cable assembly to the dash and slide the choke cable and handle assembly out of the front of the dash 3 Inspect all parts for wear or damage and replace as required 4 Reassemble parts i...

Page 106: ...le Assembly Later Models Multi piece Throttle Assembly Throttle Engine Speed Control Throttle Engine Speed Control Assembly G E A F H I L P Q K J Throttle Engine Speed Control Service The throttle engine speed control is attached to the un derside of the dashboard and may be accessed by rais ing the unit s hood For greater access and improved work area the battery may be removed from the unit THRO...

Page 107: ...ad of the carriage bolt against the throttle lever to keep the bolt from turning while the locknut is being removed 4 Slide the carriage bolt and throttle lever out of the throttle lever mounting bracket catching the spring and washers as the carriage bolt is removed from the assembly 5 Check the throttle lever mounting bracket G Figure B 36 for wear or damage and remove and replace if necessary b...

Page 108: ...otter Pin From Parking Brake Rod Disengage From Brake Cam Parking Brake Rod Service 1 See Figure B 39 Remove the cotter pin from the lower end of the parking brake rod and after noting the correct installation position of the rod disengage it from the parking brake cam Lift the parking brake rod up and out of the lower dash frame area and in spect for wear or damage Replace as necessary Reassemble...

Page 109: ...rtion of the pad with a rubber mallet to make sure it is fully seated on the arm and won t come off when the pedal is depressed DANGER Never work on an elevated unit unless it is securely supported and wheels are firmly chocked to prevent the unit from rolling off or away from the supports DANGER Always obey all safety precautions for working around battery hazards such as electrolyte hydrogen gas...

Page 110: ... 3 23 22 31 10 37 41 20 32 47 39 38 34 19 11 21 29 30 46 16 1 17 24 32 31 36 27 28 33 25 28 27 2 39 42 42 40 4 26 6 32 35 32 31 15 13 43 42 42 9 45 43 42 12 14 44 18 5 44 Connect to inside RH side of frame Connect to tab on RH side of frame Figure C 3 Clutch Brake Controls Hydro Gear Models Clutch Brake Controls Hydro Gear Models ...

Page 111: ...D Parking Brake 23 KNOB 24 ROD Brake 25 BRACKET Idler 26 PULLEY 27 NUT Hex 3 8 16 28 LOCKWASHER 3 8 29 LOCKWASHER 5 16 30 NUT Hex Full 5 16 18 31 COTTER PIN 32 WASHER Plain 5 16 33 WASHER Plain 3 4 34 NUT Hex Nyloc 5 16 18 35 NUT Hex Esna 3 8 16 36 CAPSCREW Hex Hd 3 8 16 x 1 37 WASHER Plain 1 4 38 WASHER 13 32 x 1 1 4 x 1 16 39 WASHER Plain 3 8 40 CAPSCREW Hex Hd 3 8 16 x 3 1 4 41 COTTER PIN 1 16 ...

Page 112: ... may be left in place partially assembled Clutch Rod Service Hydro Gear 216 Models Refer to Figure C 3 for specific assembly and part loca tion information 1 Using a needle nose pliers remove the cotter pin that secures the clutch rod to the parking brake cam Figure C 4 2 Remove the cotter pin and washer that secure the rear end of the clutch rod to the idler arm assembly and brake arm Figure C 5 ...

Page 113: ... and brake arm see Figure C 7 Separate the brake arm from the clutch rod and idler assembly Figure C 9 Remove Brake Rod Cotter Pin Hex Lock Nut Brake Rod Spring Brake Rod Brake Arm Cotter Pin Brake Rod Figure C 7 Idler Arm Assembly Area Underside Of Unit Idler Arm Assembly Cotter Pin Brake Arm Clutch Rod Brake Rod Brake Spring Drive Spring 3 Remove the hex locknut from the brake rod Remove the bra...

Page 114: ... of the belt stop relative to the v pulley and then loosen the lock nut that secures the v pulley to the idler Slide the drive belt out of the gap between the pulley and belt stop 3 See Figure C 12 Slide the clip ring out of the groove on the pivot shaft and remove the idler arm assembly from the unit by pulling it off the shaft 4 Inspect the idler arm assembly for wear cracked pul leys or other d...

Page 115: ... PULLEY Idler Backside 5 WASHER Plain 3 8 6 NUT Hex Flange Whiz 3 8 16 7 PULLEY V Idler 8 BELT STOP 9 CLIP RING 5 8 10 WASHER 5 8 I D x 1 1 4 O D x 5 64 Thk REF NO DESCRIPTION Figure C 13 Idler Arm Assembly Hydro Gear K216 3010L Models 1 1 2 3 4 5 6 5 6 7 8 5 10 9 Idler Arm Assembly Hydro Gear K216 3010L Models ...

Page 116: ...his shifts the transmission into neutral and automatically repositions the shift lever into the neutral gate Visually inspect the lockout lever for wear cracks corrosion or other damage and replace if necessary See Figure C 16 for assembly location information 1 Remove the idler arm assembly see Idler Arm Assembly Service 2 Detach the rear shift rod see Figure C 14 from the lockout lever and remov...

Page 117: ...d Controls Section Rear Shift Rod See Hand Controls Section Lockout Lever Assm Idler Arm Assm Clutch Brake Pedal Assm Brake Rod Clutch Rod Brake Arm C 16 Transmission Control Linkage Overview Hydro Gear 216 Models Transmission Control Linkage Hydro Gear 216 3010L Models ...

Page 118: ...NOB Plastic 9 ROD Parking Brake 10 WASHER Plain 9 32 11 FITTING Grease 12 GROMMET 13 NUT Hex Full 3 8 16 14 IDLER ARM ASSY 15 PIN Cotter 16 WASHER 5 8 17 CLIP RING 5 8 18 WASHER Plain 13 32 19 PULLEY Flat Idler 20 CAPSCREW 3 8 16 x 2 21 PULLEY V 22 BELT STOP 23 SPRING Tension 24 ROD Clutch 25 ARM Foot Pedal 26 LOCKWASHER 3 8 27 NUT Hex Lock 3 8 16 28 WASHER REF NO DESCRIPTION Clutch Brake Controls...

Page 119: ...ly To Foot Pedal Arm Figure C 19 Clutch Rod and Idler Arm assembly Figure C 18 Clutch Brake Pedal Assembly Parts Typical Foot Pedal Arm Parking Brake Cam Return to Neutral Rod Clutch Rod 2 Remove the cotter pin and washer that secure the rear end of the clutch rod to the idler arm assembly see Figure C 19 3 Remove the clutch rod inspect and replace as neces sary The clutch rod must be straight bet...

Page 120: ... K215A Models See Figures C 21 for assembly and part location infor mation 1 Remove the mower deck and position the unit to per mit safe access to the foot control assembly parts 2 Using a socket wrench remove the locknut F that secures the foot pedal arm H to the brake pedal assembly A 3 Note the position of the brake pedal assembly A and foot pedal arm H and slide the brake pedal arm out of the ...

Page 121: ...llustration FRONT Idler Arm Assembly Service Tuff Torq K215A Models 1 Remove the mower deck to provide access to idler arm assembly components 2 Remove the tension spring E Figure C 22 2 Remove the brake rod as described in Brake Rod Service 3 Remove the clutch rod as described in Clutch Rod Service 5 Loosen the idler pulley M and remove the drive belt from the idler arm assembly 4 Remove the clip...

Page 122: ...o the transmission Remove the brake rod assembly Inspect the components for damage and replace as necessary Reinstall in reverse order of disassembly Figure C 24 Tuff Torq K215A Brake Rod Linkage A 5 16 18 ESNA Hex Locknut B Flat Washer C Compression Spring D Rod Guide Assembly E Brake Rod F Cotter Pin G Extension Spring H Plain Washer I Curved Spring Washer E F C B A D I A H G Note Unless specifi...

Page 123: ... when the ground speed con trol lever is moved the shock absorber may need to be replaced 1 See Figure C 25 Remove the hardware securing the shock absorber B 2 Remove the shock absorber B and manually pull the ends If little resistance is felt replace it A 2 SPACER B 1 SHOCK ABSORBER C 1 CAM CONTROL ASSY D 1 BRACKET E 1 LOCKWASHER 3 8 F 3 LOCKWASHER 5 16 G 2 NUT Hex 5 16 18 H 1 NUT Hex 1 2 20 I 2 ...

Page 124: ...nal Control Cam O Ball Retainer P 1 4 20 Hex Nut Q 1 4 Lockwasher R Self locking Tie S 1 4 Flat Washer T Spacer U Detent Support Bracket V 8 mm 1 25 x 19 mm Capscrew W 6 mm 1 0 Hex Nut X Speed Control Lever Y 1 4 20 x 3 4 Carriage Bolt Z Neutral Return Cam AA Retaining Ring AB Return to neutral Rod AC Cotter Pin AD Plain Washer AE Spring AF Ball AG 5 16 18 x 1 3 4 Carriage Bolt AH 1 4 20 ESNA Lock...

Page 125: ...rectional Control Cam U Control Support Bracket V Spacer W 1 4 Lube Fitting X 8 mm 1 25 x 19 mm Capscrew Y 6 mm 1 0 Hex Nut Z Speed Control Lever AA 1 4 20 x 2 Carriage Bolt AB Neutral Return Cam AC Retaining Ring AD Spacer AE 5 16 18 x 1 3 4 Carriage Bolt AF Return to neutral Rod AG Cotter Pin AH 5 16 18 ESNA Locknut AI Plain Washer AJ 3 8 16 x 1 1 4 Hex Capscrew AK Flat Washer AL Shift Rod AM Ny...

Page 126: ...6 Brake Compression Spring 7 Nyloc Nut 8 Plain Washer 9 Bushing 10 Torsion Spring 11 Knob 12 Parking Brake Rod 13 Parking Brake Cam 14 Flat Washer 15 Foot Pedal Arm 16 Flat Washer 17 Lock Nut 18 Plain Washer 19 Transmission Assembly REF NO DESCRIPTION REF NO DESCRIPTION 1 2 9 9 10 11 12 3 3 14 13 18 15 16 17 19 Brake Control Linkage Tuff Torq K210A Models ...

Page 127: ... parking brake cam 13 Front and Rear Brake Rod Assembly Service Tuff Torq K210A Models Refer to Figure C 28 for specific assembly and part information 1 Remove the mower deck to gain easier access to brake control parts 2 Remove the cotter pin and washer 3 8 that attach the rear brake rod 5 to the transmission Detach the rod from the transmission 3 Remove the cotter pin and washer 3 18 that attach...

Page 128: ... RING 5 8 18 WASHER Plain 13 32 Qty 6 on early models only 19 PULLEY Flat Idler 20 CAPSCREW Hex 3 8 16x2 3 4 21 PULLEY V 22 GROMMET 23 SPRING Drive 24 SPRING Torsion 25 ARM Foot Pedal 26 LOCKWASHER 3 8 27 NUT Hex Lock 3 8 16 28 BRAKE PEDAL ASSY L H REF NO DESCRIPTION REF NO DESCRIPTION Figure C 29 Clutch Linkage NOTE Belt Stop Ref No 11 must be indexed directly to the side of the frame or slightly...

Page 129: ... in revers order of removal Rear Clutch Rod Service Tuff Torq K210A Models Refer to Figure C 29 for specific assembly and part information 1 Remove the mower deck to gain easier access to the clutch controls 2 Remove the cotter pin 6 and washer 5 that attach the rear clutch rod 1 and extension spring 7 to the transmission Detach the rod NOTE The extension spring may be under tension remove careful...

Page 130: ...6 60 6 General Repair 6C Foot Controls Repair ...

Page 131: ...hood assembly is removed access is gained to both the hood and the dash for inspection or repair Hood removal is recommended prior to removal of the dash Figure D 1 Tractor Overview Hood and Grille A B C D F G E Hood Grille Removal 1 Unlatch the rubber hood strap G Figure D 2 on each side of the hood and raise the hood to its upright posi tion Figure D 2 Hood Assembly Parts A Air Duct E Side Panel...

Page 132: ...tion perform Steps 1 through 5 in reverse order Figure D 4 Hood Hinge Assembly A Clip B Pivot Spacer Hood Hinge 2 Disconnect the headlight wire harness at the two pin connector D Figure D 3 located near the oil fill tube on the right side of the engine Thread the wire har ness out through the engine lift bracket and remove it from the speed clip attaching the harness to the hood Figure D 3 Headlig...

Page 133: ...un and keep the gun 4 6 away from the knob while moving back and forth to provide even heat ing 4 Slide the knob off the ground speed control lever and check for cracks or excessive wear and replace as necessary 5 Unscrew the parking brake knob from the parking brake rod Figure D 6 WARNING Never use a heat gun or blow dryer if flammable vapors are present as the heating element could ignite the va...

Page 134: ...ing a 3 8 nut driver or 3 8 socket with a 6 exten sion bar remove the two whizlock capscrews with washers that secure the rear of the dash to the lower dash Use care to avoid dropping the washers as the screws are removed This location also uses captive pal nuts to simplify disassembly Figure D 9 Figure D 10 Disconnect Starter Cable At Solenoid 10 Disconnect the starter cable from the solenoid usi...

Page 135: ...ween the halves and use a gentle prying motion to separate the connector Figure D 12 NOTE Do not use excessive force when prying the con nector apart as this could crack the plastic connector housing Apply light pressure on opposite sides of the connector and gradually work the connector apart The electrical connectors used on these units are designed to withstand continuous vibration and may requ...

Page 136: ...per and Lower Wire Harness Connectors A 2 Wire connector B 8 Wire Connector B A 15 Locate the two wires that go from the upper wire har ness to the safety switch located at the base of the clutch pedal Disconnect the two wire connector B Figure D 15 at the clutch pedal end and thread the wire up through the body of the tractor Figure D 15 Wire Connection A Upper harness B 2 Wire Connector Landlord...

Page 137: ...the hole in the throttle lever Position the throttle cable out of the way so that it does not interfere with shift lever and lift lever service 17 See Figure D 17 On models equipped with a choke loosen the choke cable clamp on the engine using a screwdriver Note the position of the choke lever and the engagement of the cable end in the choke lever Throttle Lever Figure D 17 Remove Choke Cable From...

Page 138: ...f the dash assembly from the unit Choke Lever 19 Carefully lift the dash assembly up and away from the lower dash steering column and shift lever assem bly As the dash assembly is lifted it may be helpful to move the shift lever forward and backward slightly 20 After the dash assembly is fully separated from the unit set it aside carefully to prevent damage to elec trical components Figure D 19 Da...

Page 139: ...arness back through the hole in the seat deck it comes through 4 Remove the two nuts connecting the seat assembly to the seat deck 5 Remove the seat assembly from the seat deck Figure E 1 Disconnect Operator Present Switch A Safety Switch B Speed Clip 6 For replacement of the Operator Present Seat Switch remove a spring cover A Figure E 3 from one of the seat springs Remove the nut B from the carr...

Page 140: ...connecting the seat deck to the deck supports 6 Remove the seat deck 7 For seat deck installation follow removal steps in reverse order Figure E 4 Removal of Front Bolts Figure E 5 Removal of Top Bolts Fuel Tank Removal 1 Remove the seat and deck before removing the gas tank Refer to the Seat and Deck Removal section 2 Using a pliers loosen the clip holding the gas line to the tank and slide it do...

Page 141: ...el assemblies Figure F 1 Rear Wheel Assembly Retaining ring must be properly seated in groove of rear axle Apply anti seize lubri cant to axle before assembly I H G F B A E D C A Rear Tire B Tube Optional C Washer D Spacer E Rim Assembly F Washer Hub Cap Retainer G Washer H Retaining Ring I Hub Cap J Valve Stem Cap J ...

Page 142: ... unit up until the rear tires are approximately 1 2 off the ground NOTE For overall unit stability during service do not jack rear end higher than required for tire removal 3 Support the rear of the unit on jackstands positioned under each foot rest Figure F 2 Jacking and Supporting Tractor REAR WHEEL REMOVAL LATE MODELS 1 Elevate the rear end See previous section 2 Remove the plastic dust cover 5...

Page 143: ...ction 7 31 Reconditioning Replacement of Parts 7 31 Transaxle Repair 7 32 Removal 7 32 Hydro Pump Removal 7 36 Hydro Pump Installation 7 36 Axle Carrier Assemble 7 37 Filter Base Removal Installation 7 38 Transaxle Disassembly 7 38 Transaxle Assembly 7 41 Transaxle Installation 7 45 7D Sauer Sundstrand BDU 10L 258 Hydrostatic Pump General 7 47 Exploded View Diagrams 7 48 Minor Repair 7 49 Shaft Se...

Page 144: ...e As with any precision equip ment all parts must be kept free of foreign materials and chemicals Protect all exposed sealing surfaces and open cavities from damage and foreign material Prior to removing and disassembling transaxle the tractor should be steam cleaned or blown with com pressed air before beginning any repairs It is recommended that all seals be replaced before transaxle is reassemb...

Page 145: ...ning External 19 Bearing 20 Housing Transaxle Left 21 Screw Taptite 22 Shaft Axle Left 23 Plug 24 O Ring 25 Shaft Cam Lever Brake 26 Bolt w Washer 27 Cover Brake 28 Ring Retaining External 29 Shoe Set Brake 30 Ring Retaining External 31 Drum Brake 32 Brake Assy 33 Gear Set Idle 35 Bearing 36 Gear Final Shaft 24 Tooth 37 Shaft Final Pinion 38 Seal 39 Shim Set 40 Bearing 41 Reduction Shaft Assy 42 B...

Page 146: ...ng a 10 mm socket 3 Loosen but do not remove the neutral detent mount ing plate This will give socket clearance at the pump mounting bolt head 4 Remove four capscrews holding hydrostatic pump to gear case using a 13 mm socket 5 Separate hydrostatic pump from gear case Set aside carefully so as not to damage splined output shaft Note There is an O ring seal between these compo nents that should be ...

Page 147: ...ng and linings and replace them 9 Remove the retaining ring that secures the brake drum on the shaft 10 The brake drum cam lever shaft and cover bore all have wear tolerances that should be inspected on units showing high hours of use Specifications Brake drum I D 3 197 3 205 in Cam lever shaft O D 0 707 0 709 in Cover bore I D 0 709 0 710 in Shaft to bore clearance max 0 020 in 11 If you have not...

Page 148: ...a soft mallet or arbor press to remove the axle from the ball bearing 17 Check worn axles for proper O D at the differential bushing area and outer needle bearing area Specifications Axle O D at bushing area 0 982 in Axle O D at needle bearing area 1 180 in 18 Check the needle bearings for wear To replace the retaining ring is removed before driving the old bear ing out 19 Do not bottom a new bear...

Page 149: ...lined end with the seal Install the axle into the housing 22 The inner ball bearing has a light press fit onto the axle Use a driver that contacts the full race surface to avoid damaging the bearing 23 Remove the final pinion shaft assembly and differen tial assembly together from the case 24 Remove the reduction shaft assembly and idle shaft assembly from the case 25 The idle shaft is a press fit...

Page 150: ...o avoid distorting the bearing bore below 27 To service either the motor gear or bearing remove the retaining ring and press apart 28 Inspect bearings and gears on the reduction shaft assembly The backlash of the spiral bevel gear and motor gear is controlled by shim washers between the cover side ball bearing and the bore in the cover If any of the drive components on these two shafts are changed...

Page 151: ...ing If worn parts appear questionable tolerances can be checked according to specifications Specifications Idle shaft O D 0 866 in Gear I D 1 103 in Washer thickness 0 094 0 102 in 30 Inspect the final pinion shaft and bearings for wear 31 Loosen and remove six bolts and nuts from differen tial assembly Do not reuse this hardware Always use new parts here 32 As you disassemble the differential not...

Page 152: ...ons Pinion gear I D 0 553 in Pinion shaft O D 0 550 in Pinion washers min 0 020 in Thrust washers min 0 020 in Gear to shaft clearance max 0 016 in 34 Bushings in the differential housings are also service able They come installed in service replacement housings 35 Apply thread locking compound to the new hardware and torque the nuts in a crossing pattern to prevent distortion Torque 17 21 ft lbs ...

Page 153: ...ect the seal Be careful not to contact the splined end with the seal Install the axle into the housing Replace the axle and seat the bearing on the axle 38 Install a thrust washer retaining ring and the second thrust washer to secure the axle 39 Install the reduction shaft and idler gear and shaft together Be sure the flat on the idler shaft lines up with the tab in the case 40 Install the final p...

Page 154: ...around the entire perimeter of the case Avoid applying the sealer too heavily as it may be squeezed into the case cavity Be sure the dowel pins are in their bores 43 Torque the cover screws using a crossing pattern Torque for a new case is different than a used assembly New case 20 23 ft lbs Used case 17 20 ft lbs 44 Install a new seal on the reduction shaft 45 Push down on the motor gear and chec...

Page 155: ...screw Torque screw New case 20 23 ft lb Used case 17 20 ft lb 48 Return the oil supply and return hoses to their ports Remember the spacers on the oil fitting bolts Install the drain plug and free wheeling latch Next are the bearing spacer and O ring at the motor gear 49 Install the O ring and spacer on the gear case before placing the hydrostatic pump in position 50 Install hydrostatic pump on ge...

Page 156: ...o hydrostatic pump mount bolts Figure A 36 Tighten Neutral Detent Mount Plate 52 Install O ring hose fittings on side outlet and bottom inlet of hydrostatic pump 53 Transaxle hydraulic fluid capacity is approximately 5 8 quarts 54 Purge the transaxle See Adjustment Section for the purging procedure Figure A 37 Install O Ring Hose Fittings ...

Page 157: ...ore transaxle is reassembled Lightly lubricate all seals with a clean petroleum jelly prior to assembly After transaxle is removed from the tractor remove all external components such as the brake arm brake actuating pins control arm input pulley and frame mounting hardware before separating case halves Figure B 1 Sauer Sundstrand Hydrostatic Drive Unit BDU 21L 207 Fluid required to replenish the ...

Page 158: ...r Section 7 O Ring Rubber 8 Housing Charge Pump 9 Geroter Assembly 10 Spring 11 Ball 12 Pin 13 Boss Plug with O Ring 14 Screw M8x20 15 Screw M8x35 16 Pipe Plug 17 O Ring Rubber 18 Check Valve Kit 19 Spring 20 Check Valve Plug 21 Ball 22 Bypass Valve Kit 23 Bypass Valve Spool 24 Bypass Plug 25 O RIng 26 Spring 27 O Ring 28 Plug 29 Poppet Orifice 30 Check Valve Kit 31 Overhaul Seal Kit includes part...

Page 159: ...er Block Motor 33 Piston 34 Spring Helical 35 Washer Spring Seat 36 Plug 37 Pin Straight Headless 38 Gasket Center Section 42 Plug Check Valve 43 O Ring 44 Ball 45 Spring Helical 46 Plug 47 Screw Socket Head 48 Screw Socket Head 50 Washer Thrust 52 Plug 53 O Ring 54 Spring Helical 55 Spool Bypass 56 Plug Bypass 57 O Ring 58 Nameplate 59 Plug 60 Spring Helical 62 O Ring 63 Housing Charge Pump 64 Ge...

Page 160: ...amage and foreign material It is recommended that all O rings be replaced Lightly lubricate all O rings with clean petroleum jelly prior to assembly Plug Fitting Torques If any plugs were removed from the housing center sec tion or end cap during servicing they should be torqued as indicated in the accompanying tables ITEM TORQUE Housing Plugs Drains 29 to 50 ft lbs 3 4 16 or 7 8 14 O Ring 39 to 6...

Page 161: ... the pump block spring may push the shaft partially out of the housing Do not attempt to pull the shaft out of the hous ing Internal parts could move out of alignment or fall into the transmission requiring major disassembly of the unit Figure B 6 Retaining Ring Removal Figure B 7 Lip Seal Removal INSTALLATION 1 Inspect the sealing area on the shaft for rust wear or contamination Polish the sealin...

Page 162: ...r section or end cap for damage or for eign material 4 Lay the transmission or pump on its side and reinstall the check ball or poppet spring and plug with O ring into the center section or end cap Be certain the check ball does not fall into the closed loop pas sage 5 Torque the plug to 15 to 35 ft lbs 28 to 47 Nm 6 Turn the unit over and repeat for the other check valve Figure B 9 Check Valve Re...

Page 163: ...removed from the transaxle assembly See Section 7A for instructions on separating the hydro pump from the transaxle Important The correct charge pump orientation is deter mined by the rotation of the pump shaft clockwise or counter clockwise Before removing the charge pump make note of or mark its position to simplify the reassembly process 1 Using a 5 or 6 mm internal hex wrench remove the two 2 ...

Page 164: ...ermined by the orienta tion of the charge pump cover on the center section or end cap The cast flat on the cover indicates the orienta tion see figure B 12 5 Install the charge pump cover and O ring The charge relief valve spring must enter the recess in the cover 6 Install the charge pump cover screws Torque the 5 mm screws to 84 to 120 in lbs 9 8 to 13 6 Nm Torque the 6 mm screws to 138 to 180 i...

Page 165: ... oil as possible can be drained from the housing Disassembly Procedures Prior to performing major repairs on the BDU remove the external components as described in the Minor Repairs section of this manual These include the following Bypass Valve Charge Check Valves and Charge Pump Assembly 1 Using a 6 mm internal hex wrench remove the eight screws which retain the center section to the housing The...

Page 166: ...reusable 12 Remove the bearing spacer washer 13 Remove the pump shaft assembly from the housing 14 Inspect the splines on the shaft for damage or unusu al wear 15 Inspect the bearing Replacement of the assembly is recommended if any damage or excessive wear is found 16 Remove the displacement control shaft from the housing 17 Remove the displacement control shaft lip seal from the housing Care mus...

Page 167: ...l threaded parts to the recommended torque levels 2 Replace all o rings gaskets and shaft seals CAUTION Most parts have critical high tolerance surfaces Care must be exercised to prevent damage to these surfaces during assembly Protect exposed surfaces openings and ports from damage or foreign material 3 Install the displacement control shaft 4 Install the pump shaft assembly into the housing 5 In...

Page 168: ... the motor thrust bearing into the housing NOTE It will be necessary to have a DRY journal bear ing to prevent a hydraulic lock while installing the motor shaft 14 Install the motor shaft cylinder block kit Use caution to prevent damage to the journal bearing while guid ing the shaft into position Once installed it will be necessary to hold the assembly in position until the center section has bee...

Page 169: ...ion housing supplements the cooling flow Charge check valves in the center section are used to control the makeup flow of fluid to the low pressure side of the loop A spool type bypass valve is utilized in the hydro pump to permit moving the vehicle by hand for short distances at low speeds 2mph without starting the engine The bypass valve is activated manually by the tractor s tow valve on the re...

Page 170: ... Gear 216 3010L Hydrostatic Transaxle 14 28 27 47 32 26 27 28 38 22 34 36 38 44 61 35 40 59 21 18 37 19 20 58 53 15 56 46 45 17 25 24 57 64 43 54 60 51 58 48 23 53 58 52 49 49 9 50 58 39 33 16 41 47 55 1 3 29 6 2 10 911 63 62 30 7 31 13 41 4 5 8 23 57 24 25 17 42 33 5 ...

Page 171: ... 1 GEAR Reduction 14T 38T 35 1 FINAL DRIVE PINION ASSY Item Qty Description 36 1 JACK SHAFT 37 1 O RING 38 2 WASHER 5 8 I D X 1 5 32 O D 39 1 WASHER 7 8 I D X 1 1 2 O D 40 2 BOLT Hex Hd 5 16 18 x 3 1 2 41 4 LOCKNUT Hex 5 16 18 42 11 BOLT Hex Gr 5 5 16 18 x 1 2 43 7 CAPSCREW Hex Gr 5 5 16 18 x 1 44 1 WASHER Differential 1 2 45 1 BOLT Shoulder 46 1 ARM Freewheel Actuating 47 2 SEAL Oil 5 8 x 1 x 1 4...

Page 172: ...selected for use by the factory and is recommended for normal operating temperatures Another alternative that will provide excel lent all climate performance is a synthetic engine oil such as 5W30 Mobil 1 The grease used in the manufacture of HYDRO GEAR products is a Rykon Premium Grease and should be substituted for with equivalent products such as Chemplus 1 LP only if it is not available in you...

Page 173: ...xle bore in the end cap for unusual wear 4 Check the bolts for proper torque of 25 32 ft lbs 5 If damage or unusual wear is found in any of the com ponents replacement of the entire assembly is rec ommended REDUCTION GEAR JACK SHAFT BRAKE SHAFT ASSEMBLY 1 Inspect the internal splines of the reduction gear and the splines on the jack shaft for wear 2 Inspect the bearing surfaces at the end of the j...

Page 174: ...t See Elevating the Rear End for Safe Service 2 Remove the seat and seat deck See Seat Deck Removal 3 Remove the rear wheels See Rear Wheel Removal 4 Push side buttons on fuel tank out of seat support channels and slide fuel tank forward Note Alternative method is to loosen capscrews securing seat supports 5 On later models with longer fuel tank slide clamp down and remove fuel line Position fuel ...

Page 175: ... securing hydro control lever to hydro shift rod Position rod out of the way and replace hardware Figure C 6 Remove Hydro Control Lever A Hydro Control Lever B Hydro Shift Rod C Shock Absorber A B C A Shock Absorber B Capscrew 5 16 18 x 2 C Washer 3 4 O D D Spacer Long E Washer 1 O D F Locknut 5 16 18 G Hydro Control Lever H Hydro Shift Rod Rear I Spacer Short J Capscrew 5 16 18 x 3 4 K Screw Grad...

Page 176: ...ansaxle Remove the lock nuts from front torque strap Leave the torque strap on the transaxle 14 Release park brake Remove cotter key and washer holding brake rod to transaxle brake lever Figure C 8 Remove Brake Rod Figure C 9 Drain Transaxle Oil 15 Remove oil filter and allow all oil to drain into pan Reinstall filter ...

Page 177: ...mounting straps and linkages clear frame 19 Remove all external components from transaxle case Torque strap Hydro control lever Bypass valve actuating lever Hydro fill tube Figure C 12 Remove Transaxle Figure C 11 Remove Axle Bolts 17 Remove axle mounting bolts from left and right side frame ...

Page 178: ... should slide freely away from the transaxle If necessary carefully pry the two compo nents apart by applying pressure with a long straight blade screw driver Use caution to avoid damaging either component 6 Remove and discard the O ring and quad ring used to seal between the pump and transaxle Figure C 13 Oil Lines Fittings and Filter Removal Figure C 14 Remove Pump From Axle Assembly Hydro Pump ...

Page 179: ... the shaft for rust wear or contamination Polish the sealing area on the shaft if necessary INSTALLATION 1 Lubricate the new seal with petroleum jelly 2 Fill the washer pocket area with Rykon Premium Grease or an equivalent product such as Chemplus 1 LP 3 Install washer aligning notches with ribs in pocket of main housing Install washer on top of notched washer 4 Install O ring onto axle mounting ...

Page 180: ...9 Remove Axle Assembly Bolts Figure C 20 Recommended Bolt Torque Sequence 7 6 9 11 13 12 4 1 8 10 3 5 2 Filter Base Removal and Installation Note Replacement of the filter base gasket can be accomplished with the transaxle still in tractor but will require draining oil from transaxle Note Do not remove the hose from the barbed fitting while changing filter bases Screw the new filter base on to the...

Page 181: ...ng separated so that it remains in the left hand hous ing lower half Figure C 21 Separate Housing Halves 5 Remove the final drive pinion assembly and washer A B C Replacement of complete assemblies is recommended 6 Remove the differential assembly and triangular washer if present from the housing Note Later model differential assemblies do not use triangular washer Discard washer if installing new...

Page 182: ...on Gear A B 8 Removal of the input shaft assembly will require applying pressure onto the end of each bearing retainer while lifting the assembly from the housing the top bearing retainer has a wave style spring washer in it to make up any end play The use of gasket sealant in this area may make it difficult to remove this assembly without the use of a pry tool as shown 9 Press the input pinion as...

Page 183: ...d The assembly should slide freely into place when the splines are properly aligned 6 Install the brake shaft assembly coupling end down 7 To install the reduction gear jackshaft it will be neces sary to position the reduction gear and one washer below the reduction gear then slide the jackshaft through them and into position 8 Install the second washer on top of the reduction gear Note If the jac...

Page 184: ...e 15 Place the input shaft assembly into the lower bearing retainer Note The bearing retainers are reversible and inter changeable Take care to position both so that the input shaft is aligned with the center of the input pinion assem bly Because of the high rpm that these assemblies will run any mis assembly will cause very noisy operation and rapid failure Figure C 27 Input Shaft Assembly A Reta...

Page 185: ...osition the right hand housing assembly and apply the liquid gasket onto the housing face A small bead of the sealant around the outer part of the housing face will be sufficient Note Prior to applying new sealant the old sealant must be cleaned from all surfaces Note A small recess on the right hand housing face is designed to catch a limited amount of sealant as it is squeezed out from between t...

Page 186: ...1 ft lbs in pattern as shown in figure C 31 Figure C 31 Recommended Bolt Torque Sequence 21 Install the two torque strap mounting bolts and lock nuts Torque each to 13 17 ft lbs Note Always use care during assembly procedures to avoid damage to lip seals 22 Install a new lip seal into the right hand housing axle bore and install the right hand axle carrier assembly see Axle Carrier section 23 Inst...

Page 187: ...o lever 9 11 ft lbs 3 Inspect drive belt before reinstallation If wear if noted replacement is recommended at this time 4 When reinstalling rear hydro shift rod belt must be positioned around idler pulley and above shift rod as shown in figure C 48 before assembling shift rod to hydro lever 5 Purge air from the transaxle See Purging Air From Transaxle in the Adjustments section 6 Perform the follo...

Page 188: ...7 46 7 Transmission Repair 7C Hydro Gear 216 3010L ...

Page 189: ...placed before transaxle is reassembled Lightly lubricate all seals with a clean petroleum jelly prior to assembly After transaxle is removed from the tractor remove all external components such as the brake arm brake actuating pins control arm input pulley and frame mounting hardware before separating case halves Figure D 1 Sauer Sundstrand Hydrostatic Drive Unit BDU 10L Fluid required to replenis...

Page 190: ...7 48 7 Transmission Repair 7D Sauer Sundstrand BDU 10L 258 14 15 12 11 16 17 13 19 26 4 18 23 21 20 5 7 8 29 31 6 32 33 28 28 32 33 27 17 9 13 22 18 25 24 10 9 1 2 3 30 22 34 ...

Page 191: ...m Bypass Passage Plug 56 to 50 ft lbs 1 16 27 Pipe 6 4 to 16 Nm Loop Plugs 15 to 35 ft lbs 9 16 18 O Ring 20 to 47 Nm Inlet Fitting Plug 8 to 20 ft lbs 7 16 20 O Ring 11 to 27 Nm Figure D 3 Sauer Sundstrand Hydrostatic Drive Unit BDU 10 L Figure D 4 Minor Repairs 7 49 7 Transmission Repair 7D Sauer Sundstrand BDU 10L 258 Item Qty Description 1 1 SPACER 2 1 SEAL 3 1 RETAINING RING 4 1 SEAL 5 1 SEAL...

Page 192: ...ially out of the housing Do not attempt to pull the shaft out of the hous ing Internal parts could move out of alignment or fall into the transmission requiring major disassembly of the unit 3 Inspect the sealing area on the shaft for rust wear or contamination Polish the sealing area on the shaft if necessary Figure D 5 Retaining Ring Removal Figure D 6 Lip Seal Removal INSTALLATION 4 Lubricate t...

Page 193: ...check valve plug with a 1 4 internal hex wrench 2 Remove the valve spring and check ball from the transmission center section or pump end cap CAUTION Do not allow the check balls to fall into the closed loop passages in the center section or end cap 3 Inspect the check balls and mating seats in the cen ter section or end cap for damage or foreign material 4 Lay the transmission or pump on its side...

Page 194: ...f valve spring and ball 6 Inspect the gerotor assembly charge pump cover and spacer plate for abnormal wear damage or foreign material Inspect the charge relief valve ball and spring Inspect the charge relief valve seat in the center section for damage or foreign material ASSEMBLY 1 Prior to reassembly of the charge pump apply a small quantity of petroleum jelly to the l D O D and faces of the ger...

Page 195: ...mbly Procedures Prior to performing major repairs on the BDU remove the external components as described in the Minor Repairs section of this manual These include the following Bypass Valve Charge Check Valves Charge Pump Assembly 1 Using a 6 mm internal hex wrench remove the eight screws which retain the center section to the housing The internal springs of the pistons should separate the center ...

Page 196: ...splines on the shaft for damage or unusu al wear 14 Inspect the bearing Replacement of the assembly is recommended if any damage or excessive wear is found 15 Remove the displacement control shaft from the housing 16 Remove the displacement control shaft lip seal from the housing Care must be taken to avoid damage to the housing bore 17 Inspect the housing for damage 18 Inspect the control shaft j...

Page 197: ...to the recommended torque levels 2 Replace all o rings gaskets and shaft seals CAUTION Most parts have critical high tolerance surfaces Care must be exercised to prevent damage to these surfaces during assembly Protect exposed surfaces openings and ports from damage or foreign material 3 Install the displacement control shaft 4 Install the pump shaft assembly into the housing 5 Install the bearing...

Page 198: ...to position Once installed it will be necessary to hold the assembly in position until the center section has been installed 16 Check to see that the piston springs are centered in the cylinder block bores If necessary position them with a small screwdriver Use caution to avoid dam age to the cylinder block face 17 Install the filter spring washer and new filter element 18 Install the two aligning...

Page 199: ...gure E 1 Tuff Torq Model K210A Six Speed Gear Transaxle Protect all exposed sealing surfaces and open cavities from damage and foreign material Prior to removing and disassembling transaxle the tractor should be steam cleaned or blown with com pressed air before beginning any repairs It is recommended that all seals be replaced before transaxle is reassembled Lightly lubricate all seals with a cle...

Page 200: ...7 58 7 Transmission Repair 7E Tuff Torq K210A Figure E 2 Tuff Torq Model K210A Six Speed Transaxle Exploded View ...

Page 201: ...am Lever 46 Brake Assembly Includes Part Nos 41 45 47 Bolt includes washer 48 Roll Pin 49 Fitting 50 Plug Seal 51 Seal TC 52 Bearing Needle 53 Ring Internal Snap 54 Seal TC 55 Housing Transmission R H 56 Shaft Axle R H 57 Bearing 58 Washer 59 Ring Internal Snap 60 Cap Oil 61 Packing 62 Screw 63 Washer 64 Ring Internal Snap 65 Bearing 66 Housing Transmission L H 67 Packing 68 Plug 69 Screw Self Thr...

Page 202: ...k return spring from inter lock lever on front left side of transaxle 4 Remove cotter pin and washer holding shift interlock rod to interlock lever Figure E 4 Remove Shift Interlock Linkage 5 Depress clutch pedal and remove transaxle drive belt from input shaft pulley on top of transaxle 6 Remove nut and washer holding ball joint to transaxle shift lever 7 Remove cotter pin and washer holding brak...

Page 203: ... floor jack under center of transaxle housing 11 Remove four nuts from capscrews holding transaxle to frame 12 Carefully lower the transaxle to the ground making sure the mounting straps and linkages clear the frame To reinstall follow the removal procedure in reverse order Figure E 6 Remove Transaxle Mounting Hardware Disassembly 1 Drain the transaxle oil if not done already Drain Plug Figure E 7...

Page 204: ...e interlock lever and remove interlock lever from shaft 7 Remove fourteen capscrews holding transaxle case halves together 8 Carefully pry the case halves apart using t pry points NOTE The case was silicone sealed at the factory and will not separate easily Do not damage case by applying excess pressure at pry point NOTE When separating case halves do not lose differ ential case washer or bearing ...

Page 205: ...move axle shaft seal 6 figure E 14 and internal snap ring under seal 7 12 Clean case in solvent and blow dry Figure E 14 Axle Shaft Removal 9 Remove washer from axle shaft Remove external snap ring and second washer next to roller bearing Drive axle shaft out of case with soft mallet Remove roller bearing from case Figure E 13 Remove Reduction Shaft Seal Cap 10 Remove reduction shaft end seal cap ...

Page 206: ...he compo nents as you remove them NOTE Do not lose track of the washers and shims on these shafts as they are removed from the case The shims may remain in the bores or stick to the bear ings as the shafts are removed Figure E 15 Remove Major Components Figure E 16 Remove Input Shaft 15 Remove left axle shaft assembly the same way the right hand assembly was removed 16 Remove the shift arm from th...

Page 207: ...n 3 16 Ball 3 8 Ball 3 16 Ball Roll Pin 3 16 Ball 18 Using a three way puller remove the 35 tooth spiral bevel gear and roller bearing from end of reduction shaft 19 Use puller to remove roller bearing from opposite end of reduction shaft Remove five reduction gears from reduction shaft and pull shaft from chain sprocket 20 Remove bearing from shift shaft and remove gears in order shown below Do n...

Page 208: ... remove the conical spring compress the spring washers with a C clamp remove the roll pins and remove the shift keys from the collar 21 Remove neutral collar washer sprocket chain and shifter from shift shaft Neutral Collar Washer Sprocket Shifter Shift Fork 23 Remove eight bolts and nuts holding differential housing together NOTE Nuts are installed with Loctite at the factory ...

Page 209: ...t the input shaft components for wear or dam age Figure E 25 Input Shaft Components A B C A D E F A Roller Bearing B Input Shaft C Collar D Sleeve E Washer F Internal Retaining Ring Figure E 24 Remove Axle Shaft Needle Bearing Needle Bearing Internal Snap Ring Axle Seal 3 Measure the differential housing A Bushing Inside Diameter New 27 97 28 15 mm Maximum 28 45 mm B Differential Case ID 25 05 25 ...

Page 210: ... 08 mm B Shift Fork Thickness 5 7 5 9 mm Shift Fork Width 8 05 8 15 mm Shift Fork to Shift Arm Pin Clearance New 0 05 0 186 mm Maximum 1 0 mm 8 Measure fork shaft and case in the following areas Fork Shaft OD 16 957 17 000 mm Fork Shaft to Shift Fork Clearance 0 040 0 123 mm Case Bore ID at Fork Shaft 17 016 17 043 mm Fork Shaft to Case Bore Clearance New 0 016 0 086 mm Maximum 0 5 mm Fork Shaft E...

Page 211: ...rm passes through transaxle case Range Arm Case Bore 17 016 17 043 mm Range Arm to Case Bore Clearance New 0 16 0 086 mm Maximum 0 5 mm D C 15 Measure brake components as follows A Brake Drum ID A Figure E 33 88 2 88 4 mm Brake Cam lever Shaft OD 19 947 20 000 mm Cam lever Shaft End Float 0 0 43 mm Cam lever Shaft Bore ID in Brake Cover 20 020 20 053 mm Cam lever to Cover Clearance New 0 02 0 106 ...

Page 212: ...shifter by placing two conical springs C and washers B onto shift collar E A B C E D F D F 3 Compress washer and conical spring with C clamp Install shift key F into inside groove of shift collar 4 Install roll pin D through shift collar and shift fork Repeat for other two shift forks 5 Install ring spring A over roll pins to retain Figure E 35 Assemble Input Shaft FIgure E 37 Install Shift Key In...

Page 213: ...ll reduction shaft chain sprocket A onto roller chain already around shift shaft sprocket from step 8 above 10 Slide reduction shaft B through reduction shaft chain sprocket A 11 Install reduction shaft collar C and press 35 tooth spiral cut ring gear D and roller bearing E onto end of reduction shaft B 12 Install 62 tooth shift gear F onto shift shaft G against neutral collar 13 See figure 4m 20 ...

Page 214: ... shaft A in following order B 14 Tooth Reduction Gear C 18 Tooth Reduction Gear D 23 Tooth Reduction Gear E 26 Tooth Reduction Gear F 32 Tooth Reduction Gear 17 Press roller bearing G onto end of reduction shaft Figure E 41 Assemble Reduction Shaft A C D E F B G 18 Install pinion gear set and washers onto pinion shaft 19 Set differential washer and gear into case Set pinion shaft and gears into no...

Page 215: ...lls Spring Roll Pin Shift Fork Fork Shaft 25 Assemble brake cam lever shaft A Figure E 45 to brake cover B and secure with retaining ring C NOTE Coat cam lever shaft with grease 26 Install brake spring D to brake shoes E and install shoes to cam lever A Figure E 45 Assemble Brake Components NOTE Install new needle bearing in case if needed See step one of inspection section for procedure 27 Instal...

Page 216: ...er bearing on end of shift shaft 34 Install washer on case side of roller bearing or alter natively into bearing bore in right side transaxle case Figure E 49 Install Bearing Roller Bearing Washer Figure E 50 Install Gear Cluster 35 Install reduction shaft fork shaft and shift shaft sub assembly into right side transaxle case NOTE Be sure fork shaft washers remain on shaft 36 Install left side tra...

Page 217: ...her and external retaining ring 49 Tap on inside edge of axle shaft to drive axle shaft and retaining ring against roller bearing 50 Install washer on axle shaft against retaining ring 51 Repeat steps 48 50 for right side transaxle case Figure E 51 Install Reduction Shaft Shims 47 Remove gear cluster from case Do not lose right side bearing washer 44 Measure backlash of input shaft to reduction sh...

Page 218: ...ssembly into right side transaxle case and onto axle shaft spline 53 Install gear cluster assembly and fork shaft together into right side case being sure roller chain remains in place and shift shaft washer is in bearing bore Fit fork shaft into case bore being sure washer remains on shaft between retaining ring and case and shift fork is in shift collar groove Figure E 54 Install Gear Cluster Fi...

Page 219: ...sealing cap and retainer to left side case and secure with self tapping screw Retaining Screw Torque New Case 2 8 3 2 Kg m Used Case 2 3 2 8 Kg m 64 Install drain plug with new seal Drain Plug Torque 3 0 5 0 Kg m Drain Plug 65 Press new brake shaft seal into case 66 Install brake drum on brake shaft and secure with retaining ring 67 Install brake cover assembly into transaxle case and secure with ...

Page 220: ...ds on case vent if removed and apply Loctite to threads Case Vent Tightening Torque 0 8 1 2 Kg m Seal Cap Case Vent 70 Install input shaft seal and drive into place 71 Install input shaft pulley and retainer Check for excessive end play on input shaft pulley Input Shaft Pulley End Play 0 08 0 53 mm 72 Fill transaxle with 3 5 3 9 Liters of SAE 10w 30 engine oil Input Shaft Pulley ...

Page 221: ... 8 Height Adjustment Rollers 50 8 10 Mower Deck Repair Mower Removal Installation 8 12 PTO Belt Replacement 8 13 Arbor Drive Belt Replacement 8 13 Idler Pulley Service 8 14 Arbor Repair Arbor Assembly Removal All Models 8 15 Arbor Disassembly Early Models 8 16 Arbor Assembly Installation Earl Models 8 18 Arbor Disassembly Later Models 8 19 Arbor Assembly Later Models 8 19 SECTION 8 MOWER DECK REPA...

Page 222: ...Deck Deck Arbors Blades 33 31 37 19 6 2 1 27 9 1 10 40 31 37 18 6 2 1 27 9 1 10 15 15 29 30 38 25 26 29 30 23 32 22 38 39 35 16 36 14 13 3 8 5 4 34 8 14 13 3 5 4 24 17 28 17 28 20 20 21 35 7 11 12 24 Apply gasket former to this surface if foam gasket Ref No 27 is not used ...

Page 223: ...OUSING ASSY Arbor Bottom Incl Ref Nos 15 20 16 1 COVER Arbor 17 3 BLADE Mower 44 18 1 PULLEY ASSY 19 2 PULLEY ASSY Deck Drive 20 3 GREASE FITTING 21 1 COVER Arbor 22 1 CLAMP 23 1 SPRING 24 1 PLUG Hole 25 1 DEFLECTOR Plastic 26 1 ROD Deflector Front 27 3 GASKET Foam 28 3 BLADE Mower 50 29 2 NUT Hex 1 4 20 30 2 LOCKWASHER 1 4 31 3 LOCKWASHER 7 16 32 1 WASHER Plain 5 16 33 2 CAPSCREW Hex Hd 7 16 14 x...

Page 224: ...asket former to this surface if foam gasket Ref 12 is not used Apply gasket former to this surface if foam gasket Ref 12 is not used Torque nuts to 50 70 ft lbs 1 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 2 5 38 7 8 9 10 11 12 13 14 16 17 18 19 20 21 22 23 17 24 19 20 21 22 23 25 26 16 27 28 29 30 31 32 33 34 35 36 37 34 33 29 27 ...

Page 225: ...3 4 17 3 WASHER 18 1 SHAFT Arbor LH 19 3 SHIELD Grass Lower 20 3 BLADE Mower 16 1 8 21 3 WASHER Hex 22 3 WASHER Spring 23 3 CAPSCREW Hex Hd 7 16 14 x 1 24 2 SHAFT Arbor Center RH 25 1 MOWER HOUSING ASSY Mower Orange 25 1 MOWER HOUSING ASSY Mower Black 26 1 COVER Arbor 27 2 CARRIAGE BOLT 1 4 20 x 7 8 28 2 NUT Push On 29 2 WASHER Plain 30 1 CLAMP 31 1 WASHER Plain 5 16 32 1 SPRING 33 2 LOCKWASHER 1 ...

Page 226: ...21 21 26 11 26 26 8 8 12 12 26 15 4 20 21 26 10 19 10 9 28 26 26 9 10 16 6 27 3 10 25 1 29 17 14 29 2 23 26 22 25 24 3 13 Attach mower leveling adjustment rod Ref No 18 page 54 and Ref No 19 page 56 Connect spring here Figure 3 Clutch and Support Groups All Models ...

Page 227: ... ASSY 13 1 V BELT Deck Drive 50 14 1 ROD Latch 15 1 LEVER ASSY Idler Incl Qty 2 Ref No 10 16 1 LEVER ASSY Idler Arm Incl Qty 2 Ref No 10 17 1 HITCH ASSY 18 1 V BELT Mower Drive 50 19 1 SPRING 20 3 NUT Hex 3 8 16 21 3 LOCKWASHER 3 8 22 2 NUT Hex Lock 3 8 16 23 2 CAPSCREW Hex Hd 3 8 16 x 1 1 2 24 1 CAPSCREW Hex Hd 3 8 16 x 3 1 2 25 2 WASHER 26 15 WASHER 5 16 27 1 CARRIAGE BOLT 3 8 16 x 1 1 2 28 2 CA...

Page 228: ...36 5 36 8 36 2 19 17 43 40 32 21 40 27 28 34 37 23 38 18 2 36 33 15 8 36 11 39 30 22 29 31 6 7 41 24 1 26 43 13 43 26 16 4 20 12 36 36 36 36 36 36 36 Attach mower leveling adjustment rod Ref No 18 to bottom hole in mower hitch assembly Ref No 17 page 52 Figure 4 Height Adjustment Roller Groups 44 ...

Page 229: ...t 19 1 CRANK Cutting Height 20 1 WASHER Detent 21 1 INDICATOR Cutting Height 22 1 BRACKET Cutting Height 23 2 SPACER 24 1 ARM ASSY Mower 25 1 KNOB Height Crank 26 2 NUT Hex Jam 1 2 13 27 2 NUT Hex Hd 3 8 16 28 2 LOCKWASHER 29 2 LOCKWASHER 5 16 30 2 NUT Hex 5 16 18 31 1 COTTER PIN 32 1 WASHER Flat 5 16 33 2 CAPSCREW Hex Hd 5 16 18 x 1 1 4 34 1 CAPSCREW Hex Hd Truss 3 8 16 x 1 3 4 35 1 WASHER Plain ...

Page 230: ... 18 29 30 31 41 5 6 23 1 26 27 28 19 34 37 20 38 36 21 36 26 13 16 4 10 17 32 40 40 36 7 7 7 7 7 7 7 7 24 36 22 11 28 27 8 35 3 36 24 36 7 36 2 Attach mower leveling adjustment rod Ref No 19 to bottom hole in mower hitch assembly Ref No 17 page 52 Figure 5 Height Adjustment Roller Groups 50 ...

Page 231: ...Height 19 1 ROD Adjustment 20 1 SPACER 21 1 TRUNNION 22 1 SHAFT ASSY Roller 50 23 1 ARM ASSY Mower 24 3 SPACER 25 1 KNOB Height Crank 26 2 NUT Hex Jam 1 2 13 27 2 NUT Hex Hd 3 8 16 28 2 LOCKWASHER 29 2 LOCKWASHER 5 16 30 2 NUT Hex 5 16 18 31 1 COTTER PIN 32 1 WASHER Flat 5 16 33 2 CAPSCREW Hex 5 16 18 x 1 1 4 34 1 CAPSCREW Hex 3 8 16 x 1 3 4 35 1 WASHER Plain 1 2 36 10 WASHER 37 1 WASHER Plain 38 ...

Page 232: ... lift cable A from the lift pulley B Electric lift models see Figure 8 a Remove the safety clips D and disconnect the clevis pins C F from the lift chains 6 Turn wheels straight ahead Pull back on spring loaded lever B Figure 9 and lift mower hitch off of the tractor brackets A 7 Turn wheels fully left and slide mower deck out right side of tractor WARNING Stop engine and remove key Do not engage ...

Page 233: ...key 2 Remove the mower deck as described in Mower Removal and Installation 3 See Figure 11 Remove the two capscrews securing the upstop A and remove the upstop 4 Remove the four additional capscrews securing the right hand arbor cover B 5 Remove the three capscrews securing left hand arbor cover D and remove the cover 6 Using a piece of rope and pliers remove the idler pul ley spring C from the sl...

Page 234: ...idler pulley B Figure 13 service remove the PTO Belt as described in PTO Belt Service For arbor drive idler pulley H service remove the arbor drive belt as described in Arbor Drive Belt Service Figure 13 Idler Assembly A Belt Stop Bracket B PTO Idler Pulley C Idler Lever D Carriage Bolt 1 3 4 E Idler Arm F Carriage Bolt 1 1 2 G Idler Arm Spring H Arbor Drive Idler Pulley I Idler Lever Spring C B A...

Page 235: ...ess arbors 3 Remove the PTO and arbor drive belts See PTO and Arbor Drive Belt Replacement 4 Remove mower blade from the spindle to be rebuilt See Mower Blade Service Figure 14 Remove Belt Guard 5 From the bottom of mower deck remove the six Taptite hex screws retaining the spindle flange to the mower deck 6 Remove the arbor assembly from the deck Figure 15 Spindle Removal Taptite Hex Screws ...

Page 236: ... ARBOR DISASSEMBLY EARLY MODELS 1 Grip the blade adapter in a soft jaw vise Remove the cap screw securing the drive pulley to blade shaft 2 Remove the cap screw lock washer heavy washer pulley and upper grass shield 3 Remove the arbor from the vise Using a small screw driver remove the collar from the blade end of the arbor shaft Capscrew Lockwasher Heavy Washer Pulley Upper Grass Shield Blade Ada...

Page 237: ...e bearing and using a soft face hammer drive the shaft from the bearing Repeat with other bearing NOTE If the bearing is seized onto the shaft more force can be applied by inserting a punch down the bolt hole of the shaft and driving with a hammer 8 Remove the foam gasket 9 Inspect the arbor shaft for damaged splines and dam age to the bearing race area Replace if damaged If the bearings are not a...

Page 238: ...t for smooth easy rotation of bearings NOTE New bearings will feel stiff but will still rotate smoothly 4 Assemble the shim washer lower grass shield and blade adapter on the blade end of the arbor shaft Secure with the collar NOTE The blade end of the arbor shaft has recessed spines to hold the collar 5 Assemble the upper grass shield and pulley on top of the arbor shaft Secure with the heavy was...

Page 239: ...er Grass 14 1 BLADE Mower 16 1 8 15 2 WASHER Hex 16 2 WASHER Spring 17 2 CAPSCREW Hex Hd 7 16 14 x 1 Ref Qty Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Figure 21 Late Model Arbor Assembly Arbor Assembly Late Model Arbors Refer to Figure 21 for the following instructions 1 Install the washer Ref 11 on the arbor shaft Ref 12 Install the washer cup side down 2 Install the shaft and washer ...

Page 240: ...8 20 8 Mower Deck Repair Notes ...

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