Simplicity AGCO Allis 400 Series Service & Repair Manual Download

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5 Electrical Troubleshooting

Safety System Diagram

5 - 18

RED

BLUE

RED / BLACK

(B+)

RED / BLACK

BROWN

ORANGE

TAN

GREEN

RED / BLUE

BLACK / WHITE

WHITE / GREEN

BLUE / RED

YELLOW

BATTERY

BLACK

SEAT SWITCH

PTO SWITCH

PTO

IGINITION

SWITCH

TRANS. SWITCH - GEAR

CLUTCH/BRAKE PEDAL SWITCH - HYDRO

BLUE

MODULE

CONNECTOR

INTERLOCK

MODULE

CIRCUIT

BREAKER

SOLENOID

STARTER

Splice "A"

(10" from ignition switch)

IGNITION SWITCH

POSITION CIRCUIT MAKE

1.OFF

2. RUN

3. START

G & M

B & L

B & L & S

(BACK VIEW

OF SWITCH)

Coronet, 400, & 2400
Series - Typical

Summary of Contents for AGCO Allis 400 Series

Page 1: ......

Page 2: ......

Page 3: ...el Repair 6 1 6 4 7 Foot Controls Repair 7 1 7 8 8 Hand Controls Repair 8 1 8 10 9 Hydro Transmission Repair 9 1 9 20 10 Gear Transmission Repair 10 1 10 8 11 Belt Clutch Replacement 11 1 11 6 12 Mowe...

Page 4: ...s Safety Rules General Operation 1 5 Safety Rules Service And Maintenance 1 7 General Repair Information Bearings Bushings 1 10 Belts Pulleys 1 10 Electrical Parts 1 10 Fasteners Hardware 1 11 Genuine...

Page 5: ...P Gear 412 1692399 13 HP Hydro 413 1692489 8 5 HP Gear 2400 1692491 13 HP Hydro 2400 1692515 12 5 HP Hydro Coronet 1692517 12 HP Hydro COronet 1692519 12 HP Hydro 412 1692748 11 HP Gear Coronet 169275...

Page 6: ...92172 30 Mower 1692173 30 Mower 1692174 34 Mower 1692543 30 Mower 1692544 30 Mower 1692545 34 Mower 1692546 34 Mower 1693168 34 Mower Export 1692543 30 Mower 1692544 30 Mower Mfg No Description 169405...

Page 7: ...L 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...

Page 8: ...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...

Page 9: ...orage preparations when preparing the rider 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 st...

Page 10: ...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 slee...

Page 11: ...y 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 Lo...

Page 12: ...lways 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 devic...

Page 13: ...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 visua...

Page 14: ...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 acc...

Page 15: ...8 cc Construction Overhead Valve Cast Iron Sleeves Aluminum Crankcase Electrical 12 Volt 15 Amp Alternator Regulated Battery System 200 Cold Cranking Amps Ignition High Energy Electronic Ignition Air...

Page 16: ...on right side of seat deck Mower Cutting Infinite Height Control on Steering Column Height CHASSIS Frame Heavy Gauge Deep Drawn Steel Front Axle Self Leveling Quick Hitch Seat Deck Lightweight Polymer...

Page 17: ...washer Washer Carriage Bolt NOTES 1 These torque values are to be used for all hardware excluding locknuts self tapping screws thread forming screws sheet metal screws and socket head setscrews 2 Reco...

Page 18: ...2 1 2 Troubleshooting Table of Contents SECTION CONTENTS Troubleshooting Troubleshooting the Rider 2 2 Troubleshooting the Mower 2 3 SECTION 2 TROUBLESHOOTING...

Page 19: ...tor 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 C...

Page 20: ...d See Maintenance Section equally or properly Mower cut is rough looking 1 Engine speed too slow Set to full speed 2 Ground speed too fast Slow down 3 Blades are dull Sharpen or replace blades See Mow...

Page 21: ...2 Troubleshooting Notes 2 4...

Page 22: ...erm Storage 3 3 B Preventive Maintenance Chart 3 3 C Maintenance Adjustments Tire Pressure 3 3 Engine Oil Level 3 5 Engine Oil Filter 3 5 Engine Air Filter 3 5 Fuel Filter 3 5 Spark Plug 3 6 Battery M...

Page 23: ...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 fin...

Page 24: ...or you can install the optional hour meter Before Before Every Every 25 Every 100 Spring Safety Items First Use Each Use 5 Hours Hours Hours Fall Check safety interlock system Check rider brakes Check...

Page 25: ...lutch Controls electric clutch for attachments Pull out to engage clutch push in to disen gage F Air Filter See engine manual for maintenance instructions G Oil Fill Dipstick Turn and remove to check...

Page 26: ...the air intake of the engine and must be cleaned or replaced every 25 hours of operation or more frequently when operating conditions are dusty Follow the engine manufacturer s recommendations for re...

Page 27: ...leaned 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...

Page 28: ...h the tabs pointing up toward deck as shown in Figures 5 6 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...

Page 29: ...teeth require the direct application of grease to all wear surfaces Use a small clean applicator brush or other means of applying and spreading the grease evenly Special care should be taken with bal...

Page 30: ...1 Rider Lubrication Points Front Half 2402 2390 NOTES 1 Unless specified use torque specifications shown on standard hardware torque specification chart 2 Grease locations indicated by grease gun symb...

Page 31: ...3 10 3 Maintenance Maintenance Records...

Page 32: ...stment Hydro Only 4 3 Idler Pulley Clutch Adjustment All Models 4 4 Steering Gear Adjustment 4 4 Steering Wheel Adjustment 4 4 Mower Adjustments 4 5 Side to Side Leveling 4 5 Front to Back Leveling 4...

Page 33: ...feeler gauge in gap and turn nut B clockwise until resistance is felt on the feeler gauge To increase gap turn nut B counter clockwise and recheck gap c If cotter pin was removed back off nut counter...

Page 34: ...nut A securely to 17 ft lbs On hydro models see Figure 4 Loosen the nut A that secures the front control rod B to the rear con trol rod C Control rod must move freely Move the ground speed control lev...

Page 35: ...slot in the idler arm assembly with the clutch brake pedal released If adjustment is required proceed to step 5 4 Loosen capscrew D and taptite screw E securing pivot plate A 5 Hydro Models Rotate the...

Page 36: ...r 3 on show scale Make sure mower lift lever is in down position 4 Loosen nut C Figure 11 so trailing arms are loose Mower must be resting on rollers with no weight on trailing arms 5 Make sure rear r...

Page 37: ...engthen level ing rod D To raise front of deck shorten leveling rod D When proper measurement is obtained tight en nut A against bracket then tighten jam nut E against nut A Transport Height Adjustmen...

Page 38: ...ING AIR FROM HYDRO TRANSAXLE Air may become trapped in the inlet hydraulic filter or closed loop passages of the hydro transaxle during assembly It is very important for proper operation to release an...

Page 39: ...4 Adjustments Notes 4 8...

Page 40: ...7 2 Isolate Cranking and Safety Systems 5 8 3 Testing the Cranking System A Test Circuit Breaker 5 8 B Test Power to Ignition Switch 5 9 C Test Ignition Switch 5 9 D Test Power to Solenoid 5 10 E Test...

Page 41: ...tion the igni tion circuit is open allowing the engine to run Charging System While the engine is running current flows from the alter nator through a rectifier to the positive battery post and charge...

Page 42: ...negative battery post or any other con ductive part of the frame For best results use the nega tive battery post as ground VOM is a volt ohm meter multi meter or equivalent VDC is volts of direct curr...

Page 43: ...11 20 46 25 14 29 1 39 37 1 13 30 24 7 8 45 9 23 36 34 26 41 43 16 6 12 35 40 32 33 47 31 27 28 22 10 5 18 To Clutch To Starter Gear units only Hydro units only Torque to 30 36 in lbs On Later Models...

Page 44: ...2 1 WIRE ASSY PTO Clutch 23 1 BOOT Insulator 24 1 CABLE Solenoid to Starter 25 1 WIRE ASSY Neutral Switch Hydro model 26 1 CABLE Battery Ground 27 1 SWITCH PTO Electric Clutch 28 1 WIRING HARNESS 29 1...

Page 45: ...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 l...

Page 46: ...lenoid 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 post and starter post with a wire brush until the me...

Page 47: ...e 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 TESTING THE CRANKING...

Page 48: ...ge If not check the bat tery circuit breaker and all connections 4 Reinstall the ignition plug B L OFF RUN START C Test Ignition Switch 1 Remove the plug from the ignition switch 2 Remove the ignition...

Page 49: ...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 re...

Page 50: ...d 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 I...

Page 51: ...2 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 P...

Page 52: ...to the ON position 6 Touch one probe to each of the back row of termi nals The VOM should show continuity Figure 24 terminals closer together 7 Touch one probe to each of the front row of termi nals T...

Page 53: ...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 de...

Page 54: ...uld show no continuity G Interlock Module If all other switches connectors wires and cables have tested OK the interlock module is at fault and must be removed and replaced The module is not testable...

Page 55: ...clutch body from either terminal the clutch has an internal short and should be replaced to prevent damage to the engine Terminals Located On Back Side Clutch Body 5 Electrical Troubleshooting Hour M...

Page 56: ...UE BLACK WHITE BLACK WHITE BLACK WHITE WHITE GREEN WHITE GREEN BLUE RED BLUE RED BLUE RED YELLOW YELLOW YELLOW YELLOW YELLOW BATTERY BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK SEAT SW...

Page 57: ...WHITE GREEN BLUE RED YELLOW YELLOW YELLOW YELLOW YELLOW BATTERY BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK SEAT SWITCH PTO SWITCH PTO IGINITION SWITCH TRANS SWITCH GEAR CLUTCH BRAKE PEDAL SWITCH...

Page 58: ...e of Contents SECTION CONTENTS Elevating Rear End for Safe Service 6 2 Elevating the Front of the Unit For Safe Service 6 2 Rear Wheel Removal 6 3 Front Wheel Removal 6 4 Wheel Bearing Replacement 6 4...

Page 59: ...y working lifting device with a capacity suitable for the weight of the unit being serviced Always use a jack stand to support the unit while performing service and chock remaining wheels to prevent t...

Page 60: ...lly the number of washers used Each rider is individ ually checked and the necessary number of washers is used The wheel should be free to slide back and forth slightly Refer to Figure 3 1 Elevate the...

Page 61: ...er to Figure 5 1 Elevate the front of the rider see Elevating Front End for Safe Service 2 Remove the plastic hub cap Ref 8 9 Remove the e ring using a screwdriver see Figure 4 3 Remove the washer Ref...

Page 62: ...ontrols Diagram Gear Models 7 2 Foot Controls Diagram Hydro Models 7 4 Foot Pedal Pad Replacement 7 6 Foot Pedal Assembly Front Clutch Rod Removal 7 6 Idler Arm Assembly Removal Gear Models 7 7 Idler...

Page 63: ...ls 7 2 6 11 10 1 28 21 27 27 28 8 9 19 30 37 3 36 4 7 26 25 28 20 22 16 35 15 41 2 34 5 39 28 27 33 27 13 40 23 29 29 30 31 24 32 38 14 23 12 29 25 26 18 17 Transmission Carrier See Rear Wheels FOOT C...

Page 64: ...Idler Bracket 21 1 PIVOT SHAFT ASSY 22 1 SPACER Pivot 23 2 SPACER 24 1 LOCKWASHER 1 4 25 2 LOCKWASHER 5 16 26 2 NUT Hex 5 16 18 27 6 COTTER PIN 3 32 x 3 4 28 4 WASHER Plain 29 3 WASHER Plain 5 16 30...

Page 65: ...39 24 48 23 43 13 11 4 5 52 3 20 46 49 42 53 2 6 12 7 37 21 38 51 41 25 34 34 44 17 46 47 27 37 40 50 45 28 19 33 31 36 30 32 30 32 18 Transmission Carrier See Electrical Group Ref No 14 See Rear Whee...

Page 66: ...turn Rear 28 1 SPACER Pivot 29 1 TUBE 30 2 LOCKWASHER 5 16 31 1 LOCKWASHER 5 16 32 2 NUT Hex 5 16 18 33 1 NUT Hex 5 16 18 34 6 COTTER PIN 7 64 x 3 4 35 3 WASHER Plain 36 1 WASHER Plain 37 2 WASHER Pla...

Page 67: ...Never use a heat gun or blow dryer if flammable vapors are present as the heating element could ignite the vapor and cause a fire or explosion Figure 3 Foot Pedal Pad Installation A Pad B Foot Pedal...

Page 68: ...r Model Underside A Idler Pulley B Drive Belt C Belt Guide A 2510 2 Figure 6 Idler Arm Gear Models A Idler Carriage Bolt B Clutch Rod C Idler Spring A B 6 Release the parking brake 7 Remove the cotter...

Page 69: ...iage bolt B Figure 8 and spacer that attach the idler arm assembly C to the frame and let the arm assembly hang on the belt 6 Note the position of the idler pulley belt guide relative to the idler arm...

Page 70: ...t Knob Removal 8 4 Steering Wheel Removal 8 5 Steering Shaft Removal 8 5 Dash Shroud Removal 8 5 Ground Speed Control Lever Replacement 8 5 Ground Speed Control Lever Tension Adj 8 7 Throttle Control...

Page 71: ...hboard Assembly 26 7 50 5 3 47 21 12 28 13 20 35 48 46 2 22 27 2 18 19 30 11 39 41 44 42 19 16 6 36 30 32 6 45 14 39 34 17 27 23 40 36 37 24 25 29 49 33 15 4 33 31 38 43 10 1 8 9 9 NOTE Unless noted o...

Page 72: ...ex Jam 1 4 20 28 2 COTTER PIN 29 1 CAPSCREW Hex Hd 5 16 18 x 1 1 2 30 2 WASHER Plain 1 4 31 1 CAPSCREW Hex Hd 3 8 16 x 2 32 2 CAPSCREW Hex 1 4 20 x 7 8 33 2 WASHER Plain 13 32 x 1 1 2 x 1 8 34 1 WASHE...

Page 73: ...t 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 2 Slide the knob off the shift lever and check for cracks or excessive wear...

Page 74: ...e the ground speed control lever knob 7 Remove the plastic upper dash panel by pushing it forward 8 Remove the capscrews Ref 39 Figure 1 securing the front dash shroud Ref 14 The capscrews are located...

Page 75: ...9 8 5 7 6 5 4 11 16 17 3 18 2 14 14 8 16 17 8 9 19 9 6 7 8 13 20 18 10 11 3 5 15 4 NOTE These parts are used on transmissions with S N s prior to 4000T0001 NOTE These parts are used on transmissions w...

Page 76: ...6 1 SET SCREW 7 1 ARM Control 8 1 SPRING 9 1 CUP WASHER 10 1 SCREW Socket Hd 11 2 ACTUATOR PIN 12 1 ARM Brake 13 1 WASHER 7 16 x 7 8 x 1 16 14 1 LOCKING STRAP 15 1 NUT Hex Lock 5 16 x 24 16 1 SEAL Lip...

Page 77: ...ttle Handle E Throttle Knob F Nylon Washer G Throttle Mounting Bracket H Washer I Esna Light Hex Locknut J Plain Washer 5 16 K Spring L Plastite Screw 1 4 20 x 5 8 M Nut Assembly 10 32 N Bowden Wire C...

Page 78: ...ice 3 Remove the throttle lever from the throttle mounting bracket by unscrewing the hex locknut I Figure 6 from the carriage bolt C Keep the head of the car riage bolt against the throttle lever to k...

Page 79: ...8 Hand Controls Repair Notes 8 10...

Page 80: ...its Cleaning parts by using a solvent wash and air drying is usually adequate As with any pre cision equipment all parts must be kept free of foreign materials and chemicals Protect all exposed sealin...

Page 81: ...static Transaxle Hook on screw located on upper housing assembly Hook end of spring 16 on screw located here 40 50 35 31 41 27 34 33 34 32 37 36 8 18 6 11 7 12 16 53 42 49 38 48 24 43 44 39 5 14 13 17...

Page 82: ...CYLINDER PUMP ASSY 25 1 ARM Trunnion 26 1 GUIDE SLOT 27 1 SHAFT Motor 28 1 BEARING Thrust 42 x 68 x 16 29 1 BLOCK CYLINDER MOTOR ASSY 30 1 ACTUATOR BYPASS 31 1 CENTER SECTION ASSEMBLY 32 1 SEAL LIP 2...

Page 83: ...6 25 22 19 23 23 29 9 26 31 30 1 20 21 12 14 18 18 28 15 27 28 19 7 25 17 16 8 4 3 2 13 5 5 8 10 Hook spring Ref No 2 here Attach to boss on RH underside of transmission Torque to 360 400 in lbs Torqu...

Page 84: ...1 2 17 1 NUT Hex Jam 1 2 20 18 2 WASHER 5 16 19 2 CAPSCREW Hex Hd 1 2 13 x 1 1 4 20 1 WASHER Plain 13 32 x 1 1 4 x 1 16 21 1 NUT Hex Lock 1 4 20 22 1 WASHER Plain 17 32 x 1 1 4 x 5 64 23 2 NUT Hex Fl...

Page 85: ...34 22 16 38 35 34 15 26 14 39 24 48 23 43 13 11 4 5 52 3 20 46 49 42 53 2 6 12 7 37 21 38 51 41 25 34 34 44 17 46 47 27 37 40 50 45 28 19 33 31 36 30 32 30 32 18 Transmission Carrier See Electrical Gr...

Page 86: ...45 1 SCREW Taptite 1 4 20 x 5 8 46 3 NUT Hex Flange Whiz 1 4 20 47 1 CARRIAGE BOLT 1 4 20 x 7 8 48 1 CARRIAGE BOLT 5 16 18 x 1 49 1 CARRIAGE BOLT 5 15 18 x 2 3 4 50 1 CARRIAGE BOLT 3 8 16 x 2 1 4 51...

Page 87: ...13 12 10 9 8 5 7 6 5 4 11 16 17 3 18 2 14 14 8 16 17 8 9 19 9 6 7 8 13 20 18 10 11 3 5 15 4 NOTE These parts are used on transmissions with S N s prior to 4000T0001 NOTE These parts are used on transm...

Page 88: ...ssions with S N s prior to 4000T0001 1 1 BREATHER ASSY 2 1 BUSHING Rubber 3 1 ARM Bypass 4 1 SEAL 5 1 SET SCREW 6 2 ACTUATOR PIN 7 1 ARM Brake 8 3 WASHER 7 16 x 7 8 x 1 16 9 2 NUT Hex Lock 5 16 x 24 1...

Page 89: ...blade screwdrivers Use caution to prevent damage to the mating sealing surfaces as you separate the two halves NOTE The sealant will make the two halves difficult to separate 6 Remove the bottom case...

Page 90: ...reassembly 10 Inspect the bronze bearings for excessive wear The bearings should be 0 754 to 0 756 11 Inspect the axle ends for damage or excessive wear The axle ends should be 0 749 to 0 0750 Figure...

Page 91: ...ng the center section in the upper housing The bolts are sealed in with thread locking compound and may require the use of a breaker bar to loosen CAUTION The pump and motor piston springs may push th...

Page 92: ...wear or damage Figure 15 Center Section Motor Shaft Figure 16 Remove Pump Block Assembly 27 Remove the pump block assembly block thrust washer and spring from the input shaft and inspect for unusual w...

Page 93: ...l threaded parts to the recom mended torque levels and replace all o rings and shaft seals 1 Install the swash plate control shaft See Figure 20 2 Install the pump input shaft assembly and retaining r...

Page 94: ...ock spring onto the pump shaft NOTE To simplify the installation of the pump block wrap a rubber band snugly around the pistons This is intended to hold the pistons in their bores as the block kit is...

Page 95: ...e bypass plate small end first into the center section 14 Lubricate the running faces and install the motor block kit onto the motor shaft 15 Position the washers and seal and install the center secti...

Page 96: ...motor thrust bearing with the thicker race towards the pistons by compressing the piston springs and sliding the bearing assembly into place NOTE Use a wide thick puddy knife or equivalent to compres...

Page 97: ...e example NOTE The drawing may not be the same as the original factory sealant application but is the currently recom mended pattern Apply sparingly NOTE Use RTV or silicon sealer Do not put sealant o...

Page 98: ...36 onto brake bolt with the slot aligned over the tab on transaxle 31 Install washer and brake adjustment nut NOTE Two versions of the brake retainer nuts have been used Early production employed Nylo...

Page 99: ...ard for five seconds and then reverse for five seconds Do this three times in each direction NOTE It may be necessary to repeat these steps in the vehicle to fully purge the transaxle See Sec 2 Purgin...

Page 100: ...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 the transaxle the tractor s...

Page 101: ...90 20 22 2 66 2 32 12 69 28 6 4 49 18 7 76 77 76 47 23 8 9 67 8 29 10 65 61 63 59 58 57 56 17 26 14 13 31 48 23 33 34 65A 54 174 11 30B 52 30 51 30 50 30 45 39 44 37 38 36 38 14 15 16 26 13 31 161 85...

Page 102: ...ER Flat 41 1 LEVER Brake 42 1 SCREW Hex Hd Flange Threadforming 1 4 20 x 1 1 4 42A 1 SCREW Hex Hd Flange Threadforming 1 4 20 x 2 1 4 43 1 NUT Lock 5 16 24 44 1 HOLDER Brake Pad 45 1 SPACER 46 1 BRACK...

Page 103: ...e 3 Peerless 915 016B Transaxle 13 24 23 14 28 30 31 31 18 26 22 22 16 30 6 5 11 2 15 32 21 25 29 28 17 27 25 4 7 1 20 19 9 8 3 10 12 Hook spring Ref No 4 here Wire Form Belt Guide Used on Later Model...

Page 104: ...ITCH Ball 16 1 BUSHING Front 17 1 STRAP Torque 18 1 CARRIER ASSY 19 1 STRAP Torque 20 1 WASHER Plain 5 16 21 1 WASHER Plain 7 16 x 1 1 4 x 1 8 22 2 CAPSCREW Hex Hd 1 2 13 x 1 1 4 23 1 CAPSCREW Hex Hd...

Page 105: ...016B 10 6 6 11 10 1 28 21 27 27 28 8 9 19 30 37 3 36 4 7 26 25 28 20 22 16 35 15 41 2 34 5 39 28 27 33 27 13 40 23 29 29 30 31 24 32 38 14 23 12 29 25 26 18 17 Transmission Carrier See Rear Wheels Ti...

Page 106: ...3 4 40 1 CARRIAGE BOLT 5 16 18 X 1 1 4 41 2 KEY Ref Qty Description Ref Qty Description TRANSMISSION REMOVAL INSTALLATION 1 Remove the mower deck See Mower Deck Repair 2 Elevate the rear end see Eleva...

Page 107: ...NTS Belt Replacement Drive Belt Replacement Hydro Models 11 2 Drive Belt Replacement Gear Models 11 3 Mower Belt Replacement 30 Decks 11 4 Mower Belt Replacement 34 Decks 11 4 Clutch Replacement Elect...

Page 108: ...e the belt 9 Separate the front and rear shift rods D and E Figure 2 10 Loosen the transmission control linkage D Figure 1 11 Unplug the electric clutch 12 Remove the drive belt BELT INSTALLATION 13 I...

Page 109: ...d B Figure 3 9 Disconnect the PTO clutch electrical connector 10 Remove the drive belt BELT INSTALLATION 11 Install the new drive belt over the engine pulley and transmission pulley 12 Reconnect the P...

Page 110: ...stallation in the Mower Deck Repair Section If mower is not removed place mower in lowest cutting position 1 Push idler pulley arm A Figure 6 away from you to relieve belt tension Remove belt from idl...

Page 111: ...utch 6 Hold the flats with a wrench and remove and retain the capscrews and lockwasher from the end of the crankshaft 7 Remove the clutch CLUTCH INSTALLATION 8 Lubricate the crankshaft with anti seize...

Page 112: ...11 6 11 Belt Clutch Replacement Notes...

Page 113: ...tment 8 6 34 Drive and Arbors Early Models 8 8 34 Drive and Arbors Later Models 8 10 34 Housing Hitch and Deflector 8 12 34 Height Adjustment 8 14 Mower Removal and Installation 8 16 Arbor Repair 8 17...

Page 114: ...38 Mower Deck Deck Arbors Blades 2 29 27 37 21 9 28 20 28 10 35 34 23 34 26 25 36 24 12 33 11 33 7 32 18 1 14 1 22 15 19 3 17 16 8 6 4 13 5 30 31 NOTE Unless noted other wise use the standard hard war...

Page 115: ...SHER Shim 18 1 ARBOR HOUSING ASSY Incl Ref No 19 19 1 FITTING Grease 20 1 IDLER Backside 21 1 PULLEY ASSY 7 55 64 Dia 22 1 GASKET Foam 23 1 PULLEY ASSY Idler 6 Dia 24 1 LEVER ASSY 25 1 NUT Hex 3 8 26...

Page 116: ...ss noted otherwise use the standard hardware torque specification chart 23 24 1 15 21 35 29 27 9 27 4 33 32 12 32 13 6 26 25 27 34 31 5 31 30 7 11 8 19 10 18 17 22 3 14 2 28 16 20 Figure 2 30 Mower De...

Page 117: ...EY 16 1 SHIELD Grass Lower 17 1 COVER Arbor Housing 18 1 SPACER 19 1 ARBOR HOUSING ASSY Incl Ref No 8 20 1 SHAFT Arbor 5 53 64 21 1 HUB Pulley 1 3 16 22 1 WASHER Cupped 23 2 WASHER Belleville 24 1 NUT...

Page 118: ...itch Height Adjustment 20 6 21 9 21 17 14 35 37 39 13 26 24 25 15 5 4 30 19 7 18 32 33 19 11 23 22 30 36 31 8 36 2 4 34 7 18 32 28 32 3 1 27 12 38 16 38 29 10 When assembled attach spring 1 here Figur...

Page 119: ...SY Mower 18 2 PLATE Pivot Support 19 2 SUPPORT ASSY Roller 20 2 BAR Mower Transport 21 3 JAMNUT Hex 1 2 13 22 2 NUT Hex 3 8 16 23 2 LOCKWASHER 24 2 LOCKWASHER 5 16 25 2 NUT Hex 5 16 18 26 2 WASHER Fla...

Page 120: ...35 30 2 37 34 19 28 34 7 10 33 3 29 39 24 8 4 1 25 13 1 17 14 11 26 28 27 38 18 31 29 39 23 8 4 1 25 13 14 1 17 18 9 33 36 16 15 20 12 22 5 6 21 20 32 5 6 15 16 12 32 Attach the end of spring Ref No...

Page 121: ...rease 19 1 IDLER Backside 20 2 ADAPTER Blade 21 1 BLADE Mower Small 14 27 64 22 1 BLADE Mower Large 19 3 16 23 1 PULLEY ASSY Small Blade 24 1 PULLEY ASSY Large Blade 25 2 GASKET Foam 26 1 LEVER ASSY 2...

Page 122: ...ls 31 2 28 27 17 25 19 20 10 21 8 7 30 29 37 33 20 13 21 8 26 33 5 22 18 11 15 3 32 15 3 12 35 5 23 18 14 6 13 26 34 9 27 28 1 16 24 19 34 4 36 10 Figure 5 34 Mower Deck Drive Arbors Later Models Torq...

Page 123: ...x 16 1 PULLEY 3 3 4 17 1 PULLEY 5 18 2 SHIELD Grass Lower 19 2 COVER Arbor Housing Assy 20 2 SPACER 21 2 ARBOR HOUSING ASSY Incl Ref No 8 22 1 SHAFT Arbor 5 53 64 23 1 SHAFT Arbor 6 33 64 24 1 HUB Pul...

Page 124: ...pair 34 Mower Deck Housing Hitch Deflector 15 16 25 10 9 8 15 16 17 7 25 26 14 4 14 11 22 21 3 23 5 19 21 2 12 1 23 18 20 24 24 6 13 Figure 6 34 Mower Deck Housing Hitch Deflector When assembled attac...

Page 125: ...LECTOR Plastic 10 1 ROD Deflector 11 1 TRUNNION 12 1 ROD Adjustment 13 1 HITCH ASSY 14 3 JAMNUT Hex 1 2 13 15 2 NUT Hex 1 4 20 16 2 LOCKWASHER 1 4 17 1 WASHER Flat 5 16 18 2 LOCKNUT Hex 3 8 16 19 2 CA...

Page 126: ...er wise use the standard hard ware torque specification chart 13 17 16 18 7 8 26 4 23 25 14 15 6 11 1 24 5 20 3 20 5 2 19 22 12 10 22 20 3 9 6 21 21 15 14 2 19 20 5 24 1 Spacer Ref No 7 goes between 2...

Page 127: ...VER Arbor 11 1 BRACKET Roller Bar 34 12 1 PLATE Support RH 13 2 BAR Mower Transport 14 2 NUT Hex 3 8 15 2 LOCKWASHER 3 8 16 2 LOCKWASHER 5 16 17 1 NUT Hex 5 16 18 18 2 WASHER Plain 5 16 19 2 WASHER Fl...

Page 128: ...ieve belt tension On right hand side of 30 mower pull idler pulley arm to relieve belt tension 3 With belt tension relieved remove belt from idler pul ley B Figure 8 and PTO pulley C Removing belt rel...

Page 129: ...the rear and rear trailing arms F Figure 8 are posi tioned above rear torsion bar Figure 9 Mower Hitch A Lever C Rider Hitch Brackets B Mower Hitch 2390 Figure 10 Mower Belt Pattern A PTO Pulley B Arb...

Page 130: ...rew securing the drive pulley to blade shaft Figure 13 2 Remove the cap screw lock washer heavy washer pulley and upper grass shield Figure 13 3 Remove the arbor from the vise Using a small screw driv...

Page 131: ...nd 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...

Page 132: ...ower housing assembly align the pins and clamp together Check the shaft for smooth easy rotation of bearings NOTE New bearings will feel stiff but will still rotate smoothly 4 Assemble the shim washer...

Page 133: ...s 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 18 Late Model Arbor Assembly Arbor As...

Page 134: ...on and quantity of spacers and wash ers above and below Idler when removing the cap screw Also note the position of the belt guide 3 Place the new Idler assembly on the clutch lever and secure with th...

Page 135: ......

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