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REPAIR

ELECTRICAL

3/5/97

4 - 27

REPAIR

IGNITION SWITCH REMOVAL &
INSTALLATION

1. Remove rear retaining screws (A) and Bracket (B).

NOTE: Front bracket (F) does not have to be removed.

2. Remove ignition switch connector (C).
3. Check and/or replace ignition switch as required.
4. Install new switch and replace cover by inserting

lugs (D) into slots (E). Secure from underside of
tractor fender with two screws (A) and bracket (B).
DO NOT overtighten screws, they are threaded
into plastic.

B

A

F

C

D

E

SEAT SWITCH REMOVAL &
INSTALLATION

NOTE: Seat switch connector has an internal spring

which will short cavities of connector together
when it is disconnected from seat switch. This
prevents operator from defeating seat switch
by leaving connector disconnected.

1. Tilt seat forward.
2. Disconnect connector (A).
3. Rotate switch assembly (B) counterclockwise to

remove switch from seat pan.

4. Depress tabs (D) of cover and remove.
5. Unsnap switch (C) from housing.
6. Assemble in reverse order of disassembly.

A

B

C

D

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Содержание 1338 Gear

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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