Simplicity AGCO Allis 500 Series Service And Repair Manual Download Page 85

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7 Electrical System Service

Troubleshooting Flow Chart

Check voltage regulator.

Refer to Engine Manual.

Replace the defective
engine component(s).

Component Tests OK

Component
Fails Test

Check alternator.

Refer to Engine Manual.

Replace the defective
engine component(s).

Done

Component
Fails Test

Battery over-charging:

Summary of Contents for AGCO Allis 500 Series

Page 1: ......

Page 2: ...nts 4 1 4 10 5 Belt Replacement 5 1 5 8 6 Common Service Procedures 6 1 6 10 7 Electrical System Service 7 1 7 30 8 Steering Component Service 8 1 8 10 9 Drive Controls Service 9 1 9 16 10 Transmissio...

Page 3: ...Manual Content 1 4 Safety Rules 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 F...

Page 4: ...four basic types are referred to through out this manual and denoted by their transmission When a service procedure is specific to a certain model that model will be identified as one of the groups l...

Page 5: ...t 1693333 Regent 14HP Hydro Export 1693335 Regent 16HP Gear Export 1693337 Regent 16HP Hydro Export 1693339 514G 14HP Gear 1693341 514H 14HP Hydro 1693343 516H 16HP Hydro 1693345 2514G 14HP Gear 16933...

Page 6: ...ining 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...

Page 7: ...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...

Page 8: ...rage 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 s...

Page 9: ...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 10: ...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 11: ...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 devi...

Page 12: ...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 13: ...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 14: ...ic Charging Regulated 9 amp DC charging circuit Air Cleaner Tri Clean Fuel Tank High Density polyurethane construction 2 gallons 7 57 liters of regular grade leaded or non leaded gasoline Muffler Simp...

Page 15: ...7 MPH 7 5 km h Rev 1 4 MPH 2 2 km h Differential Bevel Gear Type Axle Shaft 75 in Continuous Torque 225 ft lbs Output Drawbar Rating 16 HP 300 lbs 14 HP 321 lbs Maximum Weight 525 lbs on Axle Tuff To...

Page 16: ...in 36 cm Fuel Tank Material Non Corrosive Polyethylene Capacity 2 Gallons 7 5 L DIMENSIONS Tractor Overall Length 68 in 172 cm Overall Width 36 in 92 cm Height At Steering Wheel 41 in 104 cm To Top o...

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: ...1 16 1 General Information Notes...

Page 19: ...2 1 2 Troubleshooting Table of Contents SECTION CONTENTS Troubleshooting Troubleshooting Chart 2 2 Troubleshooting Common Mowing Problems 2 4 SECTION 2 TROUBLESHOOTING...

Page 20: ...r broken Visually check wiring replace broken or 7 frayed wires Tighten loose connections 9 Solenoid or starter motor faulty Repair or replace 7 10 Safety interlock switch Replace as needed 7 11 Spark...

Page 21: ...e speed too slow Always mow at full throttle N A looking 2 Ground speed too fast Slow down N A 3 Blades are dull Sharpen or replace blades 3 6 4 Mower drive belt slipping Clean or replace belt as nece...

Page 22: ...16 Blades are installed incorrectly Reinstall the blades correctly 6 Stepped Cutting Streaking Streaking Streaking is when thin strips of uncut grass are left behind the mower Streaking is usually cau...

Page 23: ...rectly 4 Blades are dull or worn Sharpen or replace the blades 3 6 Blades are damaged Replace the blades 6 Deck is clogged with grass clippings Clean out the deck N A Deck shell is damaged Repair or r...

Page 24: ...2 Troubleshooting Notes 2 6...

Page 25: ...Engine Oil Filter 3 4 Check Change Air Filter 3 4 Replace Spark Plug 3 4 Lubricate Rear Axles 3 5 Sharpen Balance Mower Blades 3 6 Tuff Torq K 56 Transmission Service 3 7 Hydro Gear 0500 0650 Transmis...

Page 26: ...5 Clean any dirt or grass from cylinder head cooling fins engine housing and air cleaner element 6 Cover air cleaner and exhaust outlet tightly with plastic or other waterproof material to keep out mo...

Page 27: ...ge First Use Each Use 5 Hours 25 Hours 100 Hours Fall Check Safety Interlock System 3 11 Check Tractor Brakes Check Mower Blade Stopping Time 3 11 See Before Before Every Every Every Spring NORMAL CAR...

Page 28: ...Leave room in the tank for fuel expansion Refer to your engine manual for gasoline recommendations Install and hand tighten the gas cap CAUTION Never use gasoline containing METHANOL gaso hol containi...

Page 29: ...ured washers may be missing or doubled This is adjusted on a tractor by tractor basis during assembly to allow a small amount of axle end play 6 Lubricate the axle shaft with anti seize compound or li...

Page 30: ...Reinstall each blade with the tabs pointing up toward deck as shown in Figure 10 Secure with a capscrew spring washer and hex washer be certain the hex washer is aligned with the hex shaft Use a woode...

Page 31: ...e and drain the transmission Figure 12 5 Replace the drain plugs and fill the transmission with oil up to the top notch see Figure 11 inset 6 Replace the spring and fill plug Reinstall the battery See...

Page 32: ...ery terminal cleaner until shiny 5 Reinstall the battery in the battery compartment and secure with the battery hold down rods C and bat tery clamp D 6 Reattach the battery cables positive cable first...

Page 33: ...t linkage Generally all moving metal parts should be oiled where contact is made with other parts Keep oil and grease off belts and pulleys Remember to wipe fittings and sur faces clean both before an...

Page 34: ...ting Location Inside hub of wheel Wheel shown removed from axle for visual clarity Front Wheel Grease Fitting Figure 19 PTO Electric clutch The Clutch Anchor Tab is Covered by A Plastic Cap and Does N...

Page 35: ...f the tractor does not pass the test do not oper ate tractor See your authorized dealer Under no circumstance should you attempt to defeat the purpose of the safety system Figure 24 Tractor Mower Cont...

Page 36: ...3 Maintenance Maintenance Records 3 12...

Page 37: ...0500 0650 Models 4 3 Peerless Models 4 4 Neutral Adjustment Tuff Torq K 56 Models 4 5 Hydro Gear 0500 0650 Models 4 6 Peerless Models 4 6 Ground Speed Control Foot Pedal Adjustment Tuff Torq K 56 Mode...

Page 38: ...2 With the tractor parked on a level sur face adjust the brake rod nut A until spring B is compressed to a length of 1 69 1 75 1 11 16 to 1 3 4 3 Check the adjustment by backing the tractor up a hill...

Page 39: ...n axle nut B counter clockwise and recheck gap c If cotter pin was removed back off nut counter clockwise until the nearest slot is aligned with hole in threads Replace cotter pin 4 Adjustments Brake...

Page 40: ...n in the inset 3 To adjust clearance turn nut D clockwise to decrease the gap or turn nut counterclockwise to increase the gap Figure 5 Brake Adjustment Gear Models A Brake Rod D Adjustment Nut B Brak...

Page 41: ...e seat switch depress the clutch brake pedal and start the engine 6 Release the clutch brake pedal 6 Using an 8 mm wrench adjust neutral by turning the eccentric B Figure 7 7 Once neutral has been est...

Page 42: ...d of the cam slot and the stop pin will increase reverse speed and decrease forward speed Figure 8 Neutral Adjustment Hydro Gear 0500 A Nut C Cam Slot B Neutral Adjustment Rod D Stop Pin C D B A Viewe...

Page 43: ...ral Adjustment procedure before adjusting the Forward Speed If the unit does not reach top speed with the forward direction pedal fully depressed perform the following adjustment with the engine off a...

Page 44: ...10 12 psi 56 82 kPa SIDE TO SIDE LEVELING 1 With the mower installed place the tractor on a smooth level surface such as a concrete floor Turn the front wheels straight forward 2 Check for bent blade...

Page 45: ...t tips should be equal to rear tips or within 1 8 higher If not proceed to step 3 below 44 Mower Decks Measure the distance from the ground to the front tip of the front blade and rear tips of the rea...

Page 46: ...4 Adjustments Notes 4 10...

Page 47: ...dels 5 2 Belt Installation Tuff Torq K 56 Models 5 3 Belt Removal Hydro Gear 0500 0650 Models 5 4 Belt Installation Hydro Gear 0500 0650 Models 5 5 Belt Removal Peerless Gear Drive Models 5 6 Belt Ins...

Page 48: ...lt from the idler assembly 7 Remove the drive belt from the transmission input pulley C Figure 3 8 Disconnect the drag link A Figure 2 from the steer ing arm C 9 Unplug the wiring harness from the PTO...

Page 49: ...A Figure 4 2 Using the original hardware reinstall the PTO clutch A Figure 1 Torque the capscrew D to 50 ft lbs 3 Reconnect the PTO clutch wire harness 4 Route the belt through the frame and install i...

Page 50: ...nd remove the drive belt from the idler pulleys D 5 Unplug PTO clutch wire harness 6 Remove the capscrew D Figure 6 and remove the PTO clutch A 7 Disconnect the drag link A Figure 5 from the steer ing...

Page 51: ...g link A Figure 5 3 Rotate the belt B Figure 7 through the transmission pulley fan A and seat it in the pulley groove 4 Install the belt on the engine pulley see Figure 9 for belt routing 5 Install th...

Page 52: ...ley capscrew and belt guide E Figure 10 Remove the drive belt from the idler assembly pulleys 6 Remove the belt from the transmission input pulley B Figure 11 and rear idler pulley C 7 Disconnect the...

Page 53: ...e key 2 Remove the mower deck from the tractor See MOWER REMOVAL INSTALLATION Section 6 3 Elevate the front of the tractor see ELEVATING THE FRONT END FOR SAFE SERVICE Section 6 4 Engage the parking b...

Page 54: ...on the tractor 44 Mowers 1 Park the tractor on a level surface Disengage the PTO turn off the engine and set the parking brake Remove the key 2 Remove the mower deck from the tractor See MOWER REMOVAL...

Page 55: ...n Removal 6 5 Front Wheel Service Front Wheel Removal Installation 6 6 Wheel Bearing Replacement 6 6 Battery Service Disconnecting the Battery Cables 6 7 Removing Installing the Battery 6 7 Checking B...

Page 56: ...the release rod A Figure 3 and lifting the mower hitch off the tractor hitch Slide the mower deck out from under the right side of the tractor 6 Install the mower in reverse order of removal Note When...

Page 57: ...gned with the hex shaft Use a wooden block A to prevent blade rotation and torque the capscrew to 45 55 ft lbs 61 75 N m WARNING For your personal safety do not handle the sharp mower blades with bare...

Page 58: ...ing Front End for Safe Service 1 Remove the ignition key and disconnect spark plug wire to prevent accidental starting while working on the unit 2 Engage the parking brake and block the rear wheels 3...

Page 59: ...ed on a tractor by tractor basis during assembly to allow a small amount of axle end play 6 Lubricate the axle shaft with anti seize compound or lithium grease 7 Reinstall components in reverse order...

Page 60: ...of the rider see ELEVATING FRONT END FOR SAFE SERVICE this section 2 Remove the plastic hub cap Ref 8 9 Remove the e ring Ref 7 using a screwdriver 3 Remove the washer Ref 6 4 Remove the wheel assembl...

Page 61: ...in Figure 17 7 Connect the black negative battery cable to the negative battery post Secure using the hardware shown in Figure 17 Checking Battery Voltage A voltmeter can be used to determine conditi...

Page 62: ...engine unless some mechani cal adjustment is made 10 After starting allow the engine to return to idle speed Remove the cable connection at the engine or frame Then remove the other end of the same c...

Page 63: ...when jump starting Never expose battery to open flame or electric spark battery action generates hydrogen gas which is flammable and explosive Do not allow battery acid to contact skin eyes fabrics o...

Page 64: ...r operation to release any trapped air that may cause damage to the internal transaxle parts 1 Park the tractor on a flat level surface and block the tires 2 Place the hydro release lever in the PUSH...

Page 65: ...ion and Replacement PTO Switch Headlight Switch 7 14 Key Switch 7 14 PTO Clutch 7 15 Foot Pedal Switches 7 15 Transmission Switch 7 15 Circuit Breaker 7 15 Solenoid 7 15 Seat Switch 7 16 Battery 7 16...

Page 66: ...ng procedures given in this section still apply System Description The tractor has three basic electrical circuits correspond ing to the three positions of the key switch START RUN and OFF START sends...

Page 67: ...lso prevent cranking if the ground speed control lever is out of neutral The engine will crank ONLY if ALL of the following con ditions are met the PTO is disengaged AND the parking brake is engaged g...

Page 68: ...ch To Engine Ground Bolt To Solenoid Yellow Hydro Models Transmission Neutral Safety Switch Gear Models Only 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 25 22 23 26 27 31 32 33 34 35 36 12 3...

Page 69: ...IRE ASSY Seat Switch 17 1 WIRING HARNESS Main 18 1 SWITCH Headlights 19 1 SWITCH PTO 20 2 CABLE Solenoid to Starter Battery to Ground 21 1 COVER Terminal 22 2 LOCKWASHER 5 16 23 2 NUT Hex 5 16 24 NF 2...

Page 70: ...Red Green Yellow To right rear engine mtg bolt To alternator To headlight To headlight To magneto fuel shut off Peerless Models To starter motor To clutch 22 21 23 35 6 13 14 To magneto Hydro Gear 050...

Page 71: ...Pedal N C Gray 17 1 SWITCH Pedal N O Black 18 3 TIE 19 1 CLIP Wire 20 1 COVER Terminal 21 2 NUT Hex 5 16 24 NF 22 2 LOCKWASHER 5 16 23 2 CABLE Solenoid to Starter Battery to Ground 24 1 WIRE ASSY 25...

Page 72: ...AL SWITCHES w PEDAL UP RED WHITE BLACK RED SPLICE D PURPLE PURPLE BLACK BLACK BLACK RED PURPLE GREEN BLACK BLACK GRAY BLACK BLACK BLACK BLACK YELLOW YELLOW RED TAN TAN BLUE RED TAN TAN RED RED BLACK L...

Page 73: ...H P N 1654634 STARTER B S SOLENOID P N 1685290 HEADLIGHT SWITCH P N 1703799 BATTERY P N 1685290 CIRCUIT BREAKER P N 1665238 N C SEAT SWITCH UNOCCUPIED P N 1714771 SPLICE A SPLICE B SPLICE C SPLICE D A...

Page 74: ...AKER P N 1665238 SOLENOID P N 1685290 MAGNETO PTO SWITCH P N 1714772 PEDAL SWITCHES w PEDAL UP RED WHITE RED WHITE PURPLE PURPLE PURPLE BLACK BLACK BLACK RED BLACK RED PURPLE GREEN BLACK RED BLACK BLA...

Page 75: ...P N 1654634 STARTER B S SOLENOID P N 1685290 HEADLIGHT SWITCH P N 1703799 BATTERY P N 1685290 CIRCUIT BREAKER P N 1665238 N C SEAT SWITCH UNOCCUPIED P N 1714771 SPLICE A SPLICE B SPLICE C SPLICE D ALT...

Page 76: ...osition When the key is turned to the START position current travels through the circuit breaker to the key switch and from there on to the safety switches When the PTO switch is turned off the clutch...

Page 77: ...ent from feeding back to the fuel shut off solenoid if the fuel shut off solenoid receives feed back current it may remain open and the engine may back fire NOTE Hydro Gear 0500 0650 models and Peerle...

Page 78: ...lock into place 6 Connect the wire harness to the back of the switch 7 Reinstall the cover removed in step 2 Figure 1 PTO Headlight and Key Switch Location PTO Switch Headlight Switch Key Switch Key...

Page 79: ...t and secure the negative battery cable See DISCONNECTING THE BATTERY CABLES Section 6 2 Disconnect the wires from the terminals 3 Remove the capscrew securing the body of the circuit breaker 4 Instal...

Page 80: ...Install a new switch in the seat pan Turn the switch assembly clockwise to lock into place 7 Reconnect the wire harness Battery See Figure 5 Refer to REMOVING AND INSTALLING THE BATTERY Section 6 Figu...

Page 81: ...ponent Tests OK Component Fails Test Check clean the battery cables and ground Refer to B Clean Ground Cable C Battery Tests Clean both ends of the negative battery cable Component Tests OK Component...

Page 82: ...grey pedal switch Refer to G Foot Pedal Switch Tests Replace the pedal switch Component Tests OK Component Fails Test Check the seat switch Refer to I Seat Switch Test Replace the seat switch Compone...

Page 83: ...ch Component Tests OK Component Fails Test Check the PTO switch Refer to F PTO Switch Test Replace the PTO switch Component Tests OK Component Fails Test Check the seat switch Refer to I Seat Switch T...

Page 84: ...mponent Tests OK Component Fails Test Check circuit breaker Refer to D Circuit Breaker Test Replace the circuit break er Component Tests OK Component Fails Test Check ground Refer to B Check Clean Gro...

Page 85: ...t Check voltage regulator Refer to Engine Manual Replace the defective engine component s Component Tests OK Component Fails Test Check alternator Refer to Engine Manual Replace the defective engine c...

Page 86: ...old otherwise A Check Clean Wires and Connectors 1 Check all wires for cracked or worn insulation 2 Check all connectors terminals and receptacles for loose wires or corrosion Figure 8 Refer to the ex...

Page 87: ...ce vent cap when done 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 see Figure 11 N...

Page 88: ...56 mod els and Peerless models 1998 and later use the key switch pictured in Figure 14 TEST OFF POSITION 1 Remove the plug from the ignition switch 2 Remove the ignition switch from the control panel...

Page 89: ...tion switch 2 Remove the ignition switch from the control panel 3 Set VOM to Ohms 4 Early models see Figure 19 later models see Figure 20 With the key switch in the START position connect test leads t...

Page 90: ...is section 1 Pull the wire harness off the back of the switch 2 Place the PTO switch in the OFF position see Figure 22 3 Set VOM to Ohms Test the top middle and bottom rows of terminals A B and C Figu...

Page 91: ...th the brake pedal up not depressed probe the switch terminals The VOM should show no continuity 3 Depress the brake pedal and engage the parking brake 4 Probe the switch terminals The VOM should show...

Page 92: ...FF Unplug and secure the spark plug wire 1 Disconnect the yellow wire plug and black wire plug from the small posts of the solenoid 2 Connect a jumper lead from one small post to ground 3 Connect a ju...

Page 93: ...obes to the large posts Figure 30 The meter should read no continuity 4 See Figure 31 Probe the mounting base of the sole noid Probe one of the small posts and observe the VOM Now probe the other smal...

Page 94: ...nformation relating to engine components NOTE The fuel shut off solenoid is located on the bot tom of the carburetor float bowl see Figure 35 1 Turn the ignition switch from OFF to RUN There should be...

Page 95: ...Gear Removal 8 5 Upper Steering System Assembly Steering Gear Installation 8 6 Steering Shaft Installation 8 6 Steering Wheel Installation 8 7 Lower Steering System Disassembly Wheel Removal Wheel Be...

Page 96: ...mponent Service Steering System Components 8 2 2 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 14 18 14 7 16 7 13 7 Steering System Components Typical Figure 1 Steering S...

Page 97: ...6 9 1 CAPSCREW 3 8 16 x 1 1 4 10 1 WASHER 11 1 STEERING GEAR ASSY 12 1 DRAG LINK 13 3 NUT Hex Flange Lock 3 8 16 14 3 KLIPRING 15 1 ARM Steering LH 16 2 WASHER 17 2 SPINDLE ASSY 18 2 SPACER 19 1 PIN C...

Page 98: ...in the gas tank Leave the fuel line disconnected 3 Remove the two capscrews H Figure 3 securing the sides of the dashboard D to the bulkhead F 4 Remove the spring clips G securing the bottom of the da...

Page 99: ...r to Figure 4 1 Elevate the front of the tractor see ELEVATING FRONT END FOR SAFE SERVICE Section 6 2 Loosen the flange locknuts O Figure 4 and carriage bolts P 3 Separate the rear of the tie rod J fr...

Page 100: ...ront of the tractor see ELEVATING FRONT END FOR SAFE SERVICE Section 6 3 Insert the shaft C Figure 5 washer E bushing F and mounting plate G assembly through the frame 4 Secure the mounting plate G Fi...

Page 101: ...on 1 Turn the front wheels straight 2 Lubricate the steering shaft D Figure 7 with anti seize compound or lithium grease 3 Mount the wheel A on the shaft and install the roll pin C using a hammer and...

Page 102: ...2 Remove the wheel and tie rod see previous sec tions 3 Remove the snap ring G Figure 8 4 Using a punch and hammer drive the spindle M or N out through the steering arm H or P and out of the front ax...

Page 103: ...drag link D to the steering gear assem bly C using the original capscrew A washer B and nut E 3 Attach the front of the drag link D to the left steering arm H using the original carriage bolt F space...

Page 104: ...8 Steering Component Service Notes 8 10...

Page 105: ...moval 9 7 Brake Linkage Idler Assembly Installation 9 7 Hydro Gear 0500 0650 Models Foot Pedal Assembly Removal Installation 9 8 Brake Linkage Removal Installation 9 8 Idler Assembly Removal Installat...

Page 106: ...8 7 4 3 12 13 9 14 15 16 17 18 19 20 21 22 23 15 24 25 26 27 28 22 30 31 25 32 33 34 3 15 29 14 35 36 37 38 39 40 41 42 43 15 42 4 15 23 To Top of Frame To Lanced Notch in Top of Frame Figure 1 Drive...

Page 107: ...1 LOCKWASHER 3 8 19 1 WASHER Plain 3 8 20 1 GUARD 21 1 PULLEY Idler V 22 2 BUSHING 5 8 23 2 COTTER PIN 1 8 x 3 4 24 1 NUT Hex Flange Whiz 3 8 16 25 2 SPRING 26 1 PULLEY Backside Idler 27 1 BRACKET Id...

Page 108: ...brake pedal by twisting and pulling the pad 4 Refer to Figure 2 Remove the cotter pin and washer from the brake rod C and disconnect the brake rod from the brake pedal arm 5 Disconnect the transmissio...

Page 109: ...k absorber C Figure 4 Install in reverse order of removal After installation per form GROUND SPEED CONTROL FOOT PEDAL ADJUSTMENT procedure found in Section 4 9 Drive Controls Service Tuff Torq K 56 Mo...

Page 110: ...Parking Brake Rod G Washer H Bushing I Carriage Bolt J Rear Brake Rod K Idler Bracket Spring L Back Side Idler Pulley M Nut N Capscrew O V Idler Pulley P Belt Guide Q Washer R Lockwasher S Brake Sprin...

Page 111: ...ivot shaft Brake Linkage Idler Assembly Installation NOTE It is assumed that all brake linkage and idler assembly components have been removed Skip any instructions that do not apply to your repair 1...

Page 112: ...Removal Installation Refer to Figure 9 FRONT BRAKE ROD 1 Block the wheels and release the parking brake 2 Disconnect the brake spring E from the back of the parking brake lever C 3 Remove the cotter...

Page 113: ...Gear 0500 0650 Models Idler Assembly Removal Installation 1 Release the parking brake and block the wheels 2 Remove the parking brake return spring E Figure 9 3 Remove the idler bracket spring J 4 Rem...

Page 114: ...Cotter Pin Washer D Spacer E Washer F Lockwasher G Nut H Capscrew I Washer J Spring K Spacer L Washer M Spacer N Washer O Nut P Nut Q Pivot Lever R Speed Control Lever S Spacer T Cam Lever U Carriage...

Page 115: ...control rod B to the pivot lever Q Remove the rod Install in reverse order of removal After installation per form GROUND SPEED CONTROL FOOT PEDAL ADJUSTMENT procedure in Section 4 NEUTRAL ADJUSTMENT...

Page 116: ...Rod Guide D Parking Brake Lever E Washer F Parking Brake Rod G Brake Return Spring H Parking Brake Knob I Brake Return Spring J Brake Lever Transmission K Rear Brake Rod L Bushing M Carriage Bolt N I...

Page 117: ...con crete floor and block the wheels Do not engage the parking brake 2 Remove the brake return spring G Figure 11 3 Remove the idler assembly spring N 4 Remove the cotter pin and washer A from the fro...

Page 118: ...Lever C Spring D Cotter Pins E Pivot Shaft F Carriage Bolt G Capscrew H Lockwasher I Washer J Bushing K Carriage Bolt L Bell Crank Assembly M Nut N Nut O Lower Shift Link P Shift Lever Q Carriage Bolt...

Page 119: ...he lower shift link O Figure 13 from the bell crank L by removing the nut M and and carriage bolt T 4 Disconnect the rear brake rod K Figure 11 from the transmission 5 Engage the parking brake to slac...

Page 120: ...9 Drive Controls Service Notes 9 16...

Page 121: ...eral 10 4 Carrier Transmission Removal 10 4 Carrier Transmission Installation 10 6 Hydro Gear 0500 0650 Models General 10 9 Transmission Removal 10 9 Transmission Installation 10 11 Peerless Gear Driv...

Page 122: ...0 12 1 3 4 5 6 7 13 14 15 16 17 18 19 20 21 22 19 21 23 21 22 24 25 26 25 27 1 4 4 30 31 8 28 1 15 29 9 11 2 35 36 37 38 39 40 41 42 43 44 43 4 32 33 34 Figure 1 Transmission Carrier Assembly Tuff Tor...

Page 123: ...SCREW Brass Tipped 16 1 PULLEY ASSY 17 1 RETAINING RING 18 1 CAPSCREW 5 16 18 x 1 19 2 NUT Flange 1 2 13 2 Way Lock 20 1 SPACER 21 3 WASHER 1 2 22 2 CAPSCREW 1 2 13 x 1 1 2 23 1 BUSHING 24 1 BELT GUID...

Page 124: ...the idler assembly 5 Remove the taptite screw B Figure 3 from the right side end of the transmission belt guide A 6 Loosen the capscrew C securing the left end of the transmission belt guide A Pivot...

Page 125: ...nd back carrier mounting capscrews A 13 Using the floor jack lower the transmission and carri er assembly just enough to allow the carrier cap screws A Figure 6 and spacers C E to be easily removed 14...

Page 126: ...l screwdriver flex the clips just enough to get over the ridge in the studs C 16 Disconnect the brake return spring E Figure 7 17 Disconnect the brake link L Figure 7 from the trans mission brake leve...

Page 127: ...tud C The other end of the shock absorber is attached to the transmission con trol lever and foot pedal rod with the other stud after the carrier is installed in the frame 7 Attach the release valve l...

Page 128: ...guide B Figure 11 16 Release the parking brake and adjust the belt guide B Figure 11 so that it is positioned 1 4 1 8 away from the belt 17 Connect the transmission control rod D Figure 12 to the tra...

Page 129: ...washers and keys See REAR WHEEL INSTALLATION AND REMOVAL Section 6 3 Engage the parking brake to slacken the belt and remove the drive belt from the rear idler pulley A Figure 13 4 Release the parking...

Page 130: ...lower the transmission out of the frame see Figure 17 Be careful not to dam age the fan or release lever If desired the carrier assembly can be removed for inspection and lubrication Refer to Figure 1...

Page 131: ...sion bar into place 6 Install the two front mounting capscrews G Figure 15 Do not tighten at this time 7 Install the four rear mounting capscrews E Figure 15 and torsion bar retainers F Tighten all mo...

Page 132: ...h jackstands and the transmission with a hydraulic floor jack see Figures 4 and 5 2 Remove the rear wheels see REAR WHEEL INSTALLATION REMOVAL Section 6 3 Disconnect the wire harness from the neutral...

Page 133: ...er Figure 22 Peerless Shift Linkage A Upper Shift Link D Shift Lever B Bell Crank Assembly E Shift Shaft C Lower Shift Link 10 Transmission Removal Installation Peerless Gear Drive Units A B C D E A B...

Page 134: ...ws F Figure 25 Do not tighten at this time 5 Rotate the torsion bar into place 6 Install the two front mounting capscrews B Figure 25 Do not tighten at this time 7 Install the four rear mounting capsc...

Page 135: ...l safety switch C Figure 29 13 Reinstall the rear wheels see REAR WHEEL INSTALLATION AND REMOVAL Section 6 14 Perform the transmission neutral adjustment see NEUTRAL ADJUSTMENT Section 4 in necessary...

Page 136: ...10 Transmission Removal Installation Notes 10 16...

Page 137: ...oded View Diagrams 11 8 Transmission Removal 11 10 Brake Assembly Service 11 10 Remove External Components 11 10 Transmission Disassembly 11 11 Transmission Assembly 11 17 Install External Control Lin...

Page 138: ...11 Transmission Teardown Notes 11 2...

Page 139: ...ploded view diagram on page 4 Specifications Type Hydrostatic Tuff Torq K56 Pump Variable Displacement Axial Piston Motor Fixed Displacement Axial Piston Control Single Pedal Foot Control Free Wheelin...

Page 140: ...79 82 86 16 15 14 6 8 7 13 7 5 1 2 3 3 28 30 35 36 37 38 39 40 41 42 43 45 44 46 45 43 42 41 49 50 51 56 54 60 74 75 55 57 59 58 61 62 63 64 64 65 66 67 53 52 80 81 90 91 93 92 96 94 95 81 51 47 47 4...

Page 141: ...2 5 49 1 SHAFT Axle LH 50 1 SHAFT Reduction 51 2 WASHER 12x32x3 2 52 1 FINAL PINION 53 1 REDUCTION GEAR 54 1 WASHER 12x24x1 55 1 CYLINDER BLOCK Complete 56 1 CYLINDER BLOCK 57 5 PISTON 58 5 WASHER 11...

Page 142: ...11 Transmission Teardown Notes 11 6...

Page 143: ...external components such as the brake arm brake actuating pins control arm cooling fan input pulley and frame mounting hardware before separating the case halves Identification Tags Here HYDRO GEAR 05...

Page 144: ...e standard hardware torque specification chart Hook on screw located on upper housing assembly Hook end of spring 16 on screw located here 322 0650 ONLY 40 50 35 31 41 27 34 33 34 32 37 36 8 18 6 11 7...

Page 145: ...CK CYLINDER MOTOR ASSY 30 1 ACTUATOR BYPASS 31 1 CENTER SECTION ASSEMBLY 0500 Transaxle 31 1 CENTER SECTION ASSEMBLY 0650 Transaxle 32 1 SEAL LIP 26 x 42 x 8 33 1 RING Retaining 34 2 WASHER 35 1 OIL F...

Page 146: ...ission Removal See HYDRO GEAR 0500 0650 TRANSMISSION INSTALLATION REMOVAL Section 10 Brake Assembly Service The brake assembly components can only be serviced by separating the transmission case halve...

Page 147: ...her L 3 Remove the input pulley K HYDRO RELEASE LEVER 1 Remove the taptite screw A Figure 4 washer B spring C and washer D 2 Remove the nut E and remove the lever F VENT TUBE 1 Remove vent plug J Figu...

Page 148: ...e upper housing 7 Inspect the lower case half for damage Inspect the axle journal bearing pockets for excessive wear Inspect the brake rotor stator pocket for excessive wear NOTE Prior to reassembly t...

Page 149: ...for proper torque They should be torqued to 16 18 ft lbs 15 Inspect the journal bearings inside the differential housing for excessive wear by feeling the shafts for an unreasonable amount of play 16...

Page 150: ...ble but do not remove Several styles of check plates have been used some use one bolt some three and others have four The plate with four bolts should be torqued to 170 to 240 in lbs while the plate w...

Page 151: ...50 Models Only 28 Remove the two internal hex head capscrews retain ing the jackshaft to the housing with a 5 mm hex wrench and remove the jack shaft pinion gear assembly from the housing Figure 17 Ja...

Page 152: ...Assm Variable Swash Plate Washer Spring Figure 19 Remove Input Shaft Seal 36 Reposition the housing and remove the input shaft lip seal from the housing bore A hook type tool may be used to pry the s...

Page 153: ...sure to torque all 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 21 2 Install the pump input shaft assemb...

Page 154: ...ers onto the jack shaft Install the jackshaft assembly into the housing and torque the bolts to 120 in lbs to 170 in lbs Use Loc Tite solution on the bolts 10 Install the aligning pins A Figure 26a an...

Page 155: ...section Bypass Plate Figure 29 Install Motor Block Kit 14 Lubricate the running faces and install the motor block kit onto the motor shaft Figure 30 Position Center Section Assembly 15 Position the w...

Page 156: ...towards the pistons by compressing the piston springs and sliding the bearing assembly into place NOTE Use a wide thick putty knife or equivalent to compress the pistons and allow the bearing to be i...

Page 157: ...ws to 135 165 in lbs in the sequence shown in Figure 36 26 Wipe off all excess sealant from the seam of the housings 27 Check the bypass actuator and axle shafts for free dom of movement The axle shaf...

Page 158: ...9 2 NUT Hex Lock 5 16 x 24 10 1 SEAL Lip 11 1 SEAL Lip 12 1 RING Retaining 13 1 CASTLE NUT 5 16 24 14 2 PUCK Dampener 15 1 ARM Control 16 1 STUD 5 16 24 17 1 SPRING Helical Compression 18 1 COTTER PI...

Page 159: ...se opening with the plastic fitting removed from the case Oil level should be 1 3 4 to 2 below the top of the vent hole threads see Figure 41 Install Vent Tube 1 Install the tube fitting H Figure 42 i...

Page 160: ...sion perform the following adjustment procedures found in Section 6 PURGING AIR FROM TRANSAXLE After installing the transmission perform the following adjustment procedures found in Section 4 BRAKE BR...

Page 161: ...r blown with com pressed air It is recommended that all seals be replaced before transaxle is reassembled Lightly lubricate all seals prior to assembly After the transaxle is removed from the tractor...

Page 162: ...11 Transmission Teardown Peerless MST 205 515 11 26 NOTE Unless noted otherwise use the standard hardware torque specification chart Copyright 1997 Tecumseh Products Company All Rights Reserved...

Page 163: ...37 1 Brake Pad Plate 38 2 Brake Pad pkg of 2 39 2 Dowel Pin 40 1 Washer 41 1 Brake Lever 42 1 Screw 1 4 20 x 1 1 4 42A 1 Screw 1 4 20 x 2 1 4 43 1 Locknut 5 16 24 44 1 Brake Pad Holder 45 1 Spacer 46...

Page 164: ...11 Transmission Teardown Notes 11 28...

Page 165: ...s SECTION CONTENTS Exploded View Diagram Hood Assembly Typical 12 2 Hood Assembly Service Hood Removal 12 4 Hood Installation 12 4 Headlight Assembly Service Lightbulb Service 12 4 Headlight Assembly...

Page 166: ...Assembly Diagram 12 2 Screws Into Heat Shield Ref 17 of Engine Group 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 33 9 10 10 10 22 22 32 Hood Assembly Typical F...

Page 167: ...NEL Side LH Orange 16 1 PANEL Side LH Red 17 1 LIGHT BAR ASSY Incl Ref Nos 18 19 20 21 18 2 SOCKET Bulb 19 1 BEZEL 20 2 BULB 1156 21 1 LENS 22 10 NUT Hex Nylon Lock 1 4 20 23 1 GRILLE Orange 23 1 GRIL...

Page 168: ...zel 3 Remove and replace the light bulb Headlight Assembly Removal NOTE The hood can be left on the tractor for this proce dure 1 Remove the capscrews F Figure 3 and nuts D 2 Lift the hood A off the s...

Page 169: ...am Seat and Seat Deck Assembly Typical 13 2 Seat and Slide Assembly Service Seat Removal Installation 13 4 Seat Switch Replacement 13 4 Control Panel Service Control Panel Removal Installation 13 5 Se...

Page 170: ...at Deck Service Exploded View Diagram 13 2 1 2 3 4 5 6 7 8 9 10 9 12 11 13 9 14 15 17 16 20 21 22 23 18 19 24 25 26 27 28 29 25 26 27 29 Seat Seat Deck Assembly Typical Figure 1 Seat Seat Deck Assembl...

Page 171: ...2 STOP Seat Rubber 11 1 SEAT DECK Orange 11 1 SEAT DECK Red 12 2 NUT Tinnerman 13 4 NUT Hex Lock 5 16 18 14 1 GUARD Splash Pod 15 1 CONTROL POD Gear 16 1 CONTROL POD Hydro 17 3 SCREW Taptite 5 16 18 x...

Page 172: ...the three capscrews I Figure 2 washers H and spacers G securing the seat slide C to the hinge plate F 3 Remove the four whizlock capscrews D Figure 2 securing the seat pan A to the seat slide C Instal...

Page 173: ...plate are being removed as an assembly follow the seat switch wire harness down to the shrink wrap remove the shrink wrap and unplug the wire harness from the main harness 1 Disconnect the ignition sw...

Page 174: ...13 Seat Seat Deck Service Notes 13 6...

Page 175: ...nts SECTION CONTENTS PTO Clutch Tests Blade Brake Stopping Time Check 14 2 Electrical Tests 14 2 PTO Clutch Service PTO Clutch Removal Installation 14 3 PTO Clutch Adjustment 14 3 Burnishing the PTO C...

Page 176: ...clutch assembly CHECK CLUTCH FOR SHORT CIRCUITS 1 Set VOM to Ohms 2 Probe the clutch body with the negative test lead 3 Probe one of the clutch wire harness terminals with the positive lead The VOM s...

Page 177: ...procedure should be used whenever a new PTO clutch is installed The purpose of burnishing the PTO clutch is remove anti corrosion coatings and break in the clutch under controlled conditions 1 Select...

Page 178: ...14 PTO Clutch Service Notes 14 4...

Page 179: ...ever Knob 15 2 Parking Brake Knob 15 2 Throttle Control Knob 15 2 Pedal Pad Removal Installation Brake and Ground Speed Pedal Pad 15 3 Seat Bumper Removal Installation Seat Bumper Removal Installation...

Page 180: ...forth to provide even heat ing 2 Slide the knob off the ground speed control lever and check for cracks or excessive wear replace as nec essary Parking Brake Knob The parking brake knob A Figure 2 is...

Page 181: ...REMOVAL INSTALLATION 1 Tilt the seat forward 2 Remove the two capscrews A Figure 5 securing the top of the seat deck to the frame wrapper 3 Remove the seat bumper by sliding it out of the groove in t...

Page 182: ...mage the foam Figure 5 Seat Cover Early Models A Seat Cover B Seat Pan and Foam Assembly Figure 6 Seat Cover Later Models A Seat Cover and Foam Assembly B Seat Pan C Plastic Edging Clip A B A B C Late...

Page 183: ...Idler Arm Hitch Later Models 16 6 38 Mower Deck Height Adjustment Gauge Wheels 16 8 44 Mower Deck Housing Arbors Blades 16 10 44 Mower Deck Belt Idler Arm Hitch 16 12 44 Mower Deck Height Adjustment...

Page 184: ...tom 10 2 2 8 11 1 2 2 3 4 5 6 7 7 8 9 10 12 13 14 15 16 17 17 18 18 19 19 22 23 24 22 23 24 25 26 27 27 28 29 30 30 32 33 31 34 35 11 9 7 7 6 36 35 34 5 37 38 15 14 13 1 20 21 29 39 39 39 39 25 25 25...

Page 185: ...16 18 x 1 1 2 17 2 WASHER 18 2 SHAFT Arbor 19 2 SHIELD Grass Lower 20 1 BLADE Mower 16 1 8 21 1 BLADE Mower 22 1 4 22 2 WASHER Hex 23 2 WASHER Spring 24 2 CAPSCREW Hex Hd 7 16 14 x 1 25 7 SCREW Taptit...

Page 186: ...Deck Belt Idler Arm Hitch Early Models 16 4 Figure 2 Belt Idler Arm Hitch Early Models 1 2 3 4 6 7 2 8 9 10 10 11 12 13 14 15 16 17 18 19 20 21 Hook Spring Ref 20 here when assembled Hook Spring Ref...

Page 187: ...HUB Insert 6 1 ARM Clutch 7 1 SPRING 8 1 CAPSCREW Hex Hd 3 8 16 x 1 3 4 9 1 SPACER Idler Arm 10 2 WASHER 11 1 CAPSCREW 3 8 16 x 1 1 4 12 2 NUT Hex Lock 3 8 16 13 2 WASHER Plain 3 8 I D 14 2 SPACER 15...

Page 188: ...r Arm Hitch Later Models 16 6 Hook Spring Ref 24 here when assembled Hook Spring Ref 9 to capscrew nut when assembled 1 2 3 4 5 6 7 8 9 10 14 11 12 13 15 16 10 17 18 19 21 22 23 24 26 2 12 11 1 2 25 2...

Page 189: ...PRING 10 3 LOCKNUT 3 8 16 11 2 WASHER 12 2 BUSHING 13 1 FITTING Grease 14 1 CLUTCH LEVER ASSY Not Serviced Separately 15 1 SPACER 16 1 LOCKNUT Flange 3 8 16 2 Way Lock 17 2 WASHER Plain 3 8 I D 18 2 S...

Page 190: ...eck Height Adjustment Gauge Wheels 16 8 44 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 16 19 1 20 21 22 23 1 24 25 26 27 28 27 4 29 30 4 31 32 33 8 34 35 36 37 18 38 39 38 40 41 38 38 9 1 42 43 Figure 4...

Page 191: ...17 1 SPRING 18 2 NUT Flange Lock 3 8 19 1 STRAP 20 1 ECCENTRIC 21 1 WASHER Flat 5 16 22 1 LOCKWASHER 5 16 23 1 NUT 5 16 18 24 1 NUT Hex 3 8 25 1 LOCKWASHER 3 8 26 1 NUT Adjuster 27 4 SPACER 28 2 ARM...

Page 192: ...lbs Apply gasket former to this surface if foam gasket Ref 10 is not used Torque screws to 50 70 ft lbs 1 2 2 3 4 5 6 7 8 9 10 11 12 13 14 14 15 16 17 18 19 20 21 23 24 14 25 26 27 28 29 30 31 32 33 3...

Page 193: ...tite 5 16 18 x 3 4 15 3 WASHER 16 1 SHAFT Arbor LH 17 3 SHIELD Grass Lower 18 3 BLADE Mower 16 1 8 19 3 WASHER Hex 20 3 WASHER Spring 21 3 CAPSCREW Hex Hd 7 16 14 x 1 22 1 SHAFT Arbor RH 23 1 HOUSING...

Page 194: ...tch 16 12 Arbor Drive Pulley Arbor Drive Pulley Arbor Drive Pulley Engine Pulley Tensioning Idler Pulley Hook Spring Ref 25 here when assembled 2 3 4 5 6 7 8 9 10 11 12 13 14 1 15 13 3 17 18 19 20 21...

Page 195: ...r 8 1 LOCKWASHER Spring 3 8 9 1 NUT Hex 3 8 16 10 1 NUT Hex Flange Lock 3 8 16 11 1 SPRING 12 1 NUT Hex Center Lock 3 8 16 13 2 WASHER 14 1 SPACER Idler Arm 15 1 CAPSCREW 3 8 16 x 1 1 4 16 2 CAPSCREW...

Page 196: ...ent Gauge Wheels 16 14 48 1 2 3 4 5 6 4 7 8 9 10 11 12 13 14 17 18 20 1 15 16 21 1 1 4 30 4 22 23 24 18 17 7 25 26 27 28 29 29 30 31 32 33 34 35 36 37 34 33 32 34 38 39 39 40 41 42 16 43 44 45 43 46 4...

Page 197: ...WASHER 5 16 19 1 CAPSCREW Hex Hd 5 16 18 x 3 4 20 1 QUADRANT 21 1 ARM ASSEMBLY Rocker 22 2 STRAP 23 1 ECCENTRIC 24 1 WASHER 25 1 NUT Hex 3 8 26 1 WASHER Lock 3 8 27 1 NUT Adjuster 28 1 CARRIAGE BOLT 3...

Page 198: ...y on the idler arm and secure with the original hardware Make sure the correct quantity of washers spacers are placed above and below the pulley 4 Align the belt guide in its original position so that...

Page 199: ...C D E F G H I J K M N O P Q R S T L A Flange Hex Nut B Belleville Washer C Pulley D Adapter Hub E Arbor Housing Cover F Upper Bearing G Sleeve Spacer 44 Only H Arbor Spacer I Lower Bearing J Foam Gask...

Page 200: ...e arbor housing and cover with RTV or silicon sealer Torque nuts to 50 70 ft lbs A B C D E F G H I J K M N O P Q R S T L A Flange Hex Nut B Belleville Washer C Pulley D Adapter Hub E Arbor Housing Cov...

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