TM2349 John Deere Lawn Tractor Select X700 X720 X724 X728 04780
2019-04-21
: John-Deere John-Deere-Lawn-Tractor-Select-X700-X720-X724-X728-Tm2349-04780 John-Deere-Lawn-Tractor-Select-X700-X720-X724-X728-TM2349-04780
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JOHN DEERE WORLDWIDE COMMERCIAL & CONSUMER EQUIPMENT DIVISION September 2005 John Deere Select Series™Tractors Ultimate™ Series X700, X720, X724 and X728 TM2349 SEPTEMBER 2005 TECHNICAL MANUAL North American Version Litho In U.s.a. INTRODUCTION Manual Description Introduction This technical manual is written for an experienced technician and contains sections that are specifically for this product. It is a part of a total product support program. The manual is organized so that all the information on a particular system is kept together. The order of grouping is as follows: • Table of Contents • Specifications and Information • Identification Numbers • Tools and Materials • Component Location • Schematics and Harnesses • Theory of Operation • Operation and Diagnostics • Diagnostics • Tests and Adjustments • Repair • Other Safety Specifications and Information Engine (Liquid-Cooled) Electrical Power Train Hydraulics Steering Note: Depending on the particular section or system being covered, not all of the above groups may be used. Brakes The bleed tabs for the pages of each section will align with the sections listed on this page. Page numbering is consecutive from the beginning of the Safety section through the last section. Attachments We appreciate your input on this manual. If you find any errors or want to comment on the layout of the manual please contact us. Miscellaneous All information, illustrations and specifications in this manual are based on the latest information at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT© 2005 Deere & Co. John Deere Worldwide Commercial and Consumer Equipment Division All rights reserved Previous Editions COPYRIGHT© Introduction SAFETY Handle Fluids Safely - Avoid Fires Safety Be Prepared For Emergencies Recognize Safety Information MIF This is the safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe servicing practices. MIF Understand Signal Words A signal word - DANGER, WARNING, or CAUTION - is used with the safety-alert symbol. DANGER identifies the most serious hazards. • When you work around fuel, do not smoke or work near heaters or other fire hazards. • Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual. • Make sure machine is clean of trash, grease, and debris. Replace Safety Signs • Be prepared if a fire starts. • Keep a first aid kit and fire extinguisher handy. • Do not store oily rags; they can ignite and burn spontaneously. • Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone. Use Care In Handling And Servicing Batteries MIF Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement. MIF Safety - 1 SAFETY Prevent Battery Explosions such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. • Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine. • Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. Use Care Around High-pressure Fluid Lines • Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F). Avoid High-Pressure Fluids Prevent Acid Burns • Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid acid burns by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. MIF 3. Avoiding breathing fumes when electrolyte is added. Escaping fluid under pressure can penetrate the skin causing serious injury. 4. Avoiding spilling or dripping electrolyte. 5. Use proper jump start procedure. Avoid injury from escaping fluid under pressure by stopping the engine and relieving pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. 3. Flush your eyes with water for 10 - 15 minutes. 4. Get medical attention immediately. If acid is swallowed: 1. Drink large amounts of water or milk. 2. Then drink milk of magnesia, beaten eggs, or vegetable oil. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. Avoid Heating Near Pressurized Fluid Lines 3. Get medical attention immediately. Wear Protective Clothing MIF MIF Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Safety - 2 SAFETY Service Machines Safely Support Machine Properly and Use Proper Lifting Equipment MIF Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. MIF Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts. Use Proper Tools Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards. Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches. Use only service parts meeting John Deere specifications. If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual. Lifting heavy components incorrectly can cause severe injury or machine damage. Follow recommended procedure for removal and installation of components in the manual. Work In Clean Area Before starting a job: Park Machine Safely 1. Clean work area and machine. 2. Make sure you have all necessary tools to do your job. 3. Have the right parts on hand. 4. Read all instructions thoroughly; do not attempt shortcuts. Using High Pressure Washers MIF Before working on the machine: 1. Lower all equipment to the ground. Directing pressurized water at electronic/electrical components or connectors, bearings, hydraulic seals, fuel injection pumps or other sensitive parts and components may cause product malfunctions. Reduce pressure and spray at a 45 to 90 degree angle. 2. Stop the engine and remove the key. 3. Disconnect the battery ground strap. 4. Hang a “DO NOT OPERATE” tag in operator station. 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 by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil. Safety - 3 SAFETY Work In Ventilated Area Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos. Keep bystanders away from the area. Service Tires Safely MIF Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension. If you do not have an exhaust pipe extension, open the doors and get outside air into the area. MIF Warning: California Proposition 65 Warning Gasoline engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Explosive 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 correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel. Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. Remove paint before welding or heating: If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available. Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts. Avoid Harmful Asbestos Dust Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer. Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated. Safety - 4 SAFETY Avoid Injury From Rotating Blades, Augers And PTO Shafts Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, 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 the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment. Dispose of Waste Properly MIF Keep hands and feet away while machine is running. Shut off power to service, lubricate or remove mower blades, augers or PTO shafts. Service Cooling System Safely Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer. Live With Safety MIF Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off machine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. Handle Chemical Products Safely MIF Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields. MIF Safety - 5 SAFETY Safety - 6 SPECIFICATIONS & INFORMATION TABLE OF CONTENTS Specifications & Information Table of Contents Fastener Torques..............................................9 Metric Fastener Torque Values ......................9 Inch Fastener Torque Values .......................10 O-Ring Seal Service Recommendations ......11 Face Seal Fittings With Inch Stud Ends Torque ..........................................................11 Face Seal Fittings With Metric Stud Ends Torque ..........................................................12 O-Ring Face Seal Fittings ............................13 O-Ring Boss Fittings ....................................13 Straight Fitting or Special Nut Torques ........14 Metric Fastener Torque Value - Grade 7 (Special) .......................................................14 General Information........................................14 Gasoline .......................................................14 Gasoline Storage..........................................15 4 - Cycle Gasoline Engine Oil ......................15 Break-In Engine Oil - 4-Cycle Gasoline........15 Hydrostatic Transmission and Hydraulic Oil.16 Gear Case Oil...............................................16 Gear Transmission Grease ..........................17 Alternative Lubricants...................................17 Synthetic Lubricants .....................................17 Anti-Corrosion Grease..................................17 Mower Spindle Grease.................................17 Lubricant Storage .........................................17 Mixing of Lubricants .....................................18 Oil Filters ......................................................18 Coolant Specifications ...................................18 Gasoline Engine Coolant..............................18 Gasoline Engine Coolant Drain Interval .......19 Serial Number Locations ...............................19 Product Serial Number .................................19 Gasoline Engine Serial Number Location ....19 Specifications & Information Table of Contents - 7 SPECIFICATIONS & INFORMATION TABLE OF CONTENTS Specifications & Information Table of Contents - 8 SPECIFICATIONS & INFORMATION FASTENER TORQUES Fastener Torques Metric Fastener Torque Values 4.8 9.8 10.9 4.8 8.8 9.8 10.9 12.9 4.8 8.8 9.8 10.9 12.9 10 5 12 10 10 12.9 12 10 10 5 5 Property Class and Nut Markings 12.9 8.8 10 Property Class and Head Markings 12 MIF Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9 Lubricated a Dry a Lubricated a Dry a Lubricated a Dry a Lubricated a Dry a SIZE N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft M6 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5 M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35 M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70 M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120 M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 109 M16 100 73 125 92 190 140 240 175 275 200 350 225 320 240 400 300 M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410 M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580 M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800 M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000 M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500 M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000 M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750 M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500 DO NOT use these hand torque values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only and include a ±10% variance factor. Check tightness of fasteners periodically. DO NOT use air powered wrenches. When bolt and nut combination fasteners are used, torque values should be applied to the NUT instead of the bolt head. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. a “Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means plain or zinc plated (yellow dichromate Specification JDS117) without any lubrication. Fasteners should be replaced with the same grade. Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. Tighten toothed or serrated-type lock nuts to the full torque value. Reference: JDS - G200. Specifications & Information Fastener Torques - 9 SPECIFICATIONS & INFORMATION FASTENER TORQUES Inch Fastener Torque Values 5 1 or 2b SAE Grade and Head Markings 8 5.2 5.1 8.2 No Marks 5 2 SAE Grade and Nut Markings 8 No Marks MIF Grade 1 Grade 2b Grade 5, 5.1 or 5.2 Grade 8 or 8.2 Lubricated a Dry a Lubricated a Dry a Lubricated a Dry a Lubricated a Dry a SIZE N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft 1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5 5/16 7.7 5.5 10 7 12 9 15 11 20 15 25 18 28 21 35 26 3/8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46 7/16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75 1/2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115 9/16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160 5/8 67 50 85 62 105 78 135 100 170 125 215 160 215 160 300 225 3/4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400 7/8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650 1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1-1/8 470 300 510 375 470 300 510 375 900 675 1150 850 1-1/4 570 425 725 530 570 425 725 530 1300 950 1-3/8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550 1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350 DO NOT use these hand torque values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only and include a ±10% variance factor. Check tightness of fasteners periodically. DO NOT use air powered wrenches. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. 1300 975 1450 1075 1850 1350 1650 1200 2050 1500 2600 1950 head. Tighten toothed or serrated-type lock nuts to the full torque value. a “Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means plain or zinc plated (yellow dichromate Specification JDS117) without any lubrication. Fasteners should be replaced with the same grade. Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. b “Grade 2” applies for hex cap screws (Not Hex Bolts) up to 152 mm (6 in.) long. “Grade 1” applies for hex cap screws over 152 mm (6 in.) long, and for all other types of bolts and screws of any length. When bolt and nut combination fasteners are used, torque values should be applied to the NUT instead of the bolt Reference: JDS - G200 Specifications & Information Fastener Torques - 10 SPECIFICATIONS & INFORMATION O-RING SEAL SERVICE O-Ring Seal Service Recommendations Face Seal Fittings With Inch Stud Ends Torque Stud End Tube Nut Stud Straight and Tube Nut Swivel Nut Locknut Tube Nut Stud End 90 Swivel Elbow and Tube Nut 90 Adjustable Stud Elbow Bulkhead Union and Bulkhead Locknut MIF Nominal Tube OD/Hose ID Face Seal Tube/Hose End Metric Tube OD Inch Tube OD Thread Size Tube Nut/ Swivel Nut Torque Bulkhead Lock Nut Torque Thread Size Straight Fitting or Lock Nut Torque mm Dash Size in. mm in. N•m N•m lb-ft in. N•m lb-ft 5 -3 0.188 4.76 3/8-24 8 6 6 -4 0.250 6.35 7/16-20 12 9 8 -5 0.312 7.94 1/2-20 16 12 10 -6 0.375 9.52 11/16-16 24 18 24 18 9/16-18 24 18 12 -8 0.500 12.70 13/16-16 50 37 46 34 3/4-16 46 34 16 -10 0.625 15.88 1-14 69 51 62 46 7/8-14 62 46 19 -12 0.750 19.05 1-3/16-12 102 75 102 75 1-1/16-12 102 75 22 -14 0.875 22.22 1-3/16-12 102 75 102 75 1-3/16-12 122 90 25 -16 1.000 25.40 1-7/16-12 142 105 142 105 1-5/16-12 142 105 32 -20 1.25 31.75 1-11/16-12 190 140 190 140 1-5/8-12 190 140 38 -24 1.50 38.10 2-12 160 217 160 1-7/8-12 217 160 9/16-18 16 217 lb-ft 12 O-Ring Stud Ends 12 9 Note: Torque tolerance is +15%, -20% Specifications & Information O-Ring Seal Service Recommendations - 11 SPECIFICATIONS & INFORMATION O-RING SEAL SERVICE Face Seal Fittings With Metric Stud Ends Torque Stud End Tube Nut Groove For Metric Identification Stud Straight and Tube Nut Swivel Nut Locknut Tube Nut Groove For Metric Identification Stud End 90 Swivel Elbow and Tube Nut 90 Adjustable Stud Elbow Bulkhead Union and Bulkhead Locknut MIF Nominal Tube OD/Hose ID Face Seal Tube/Hose End Metric Tube OD Inch Tube OD Thread Size Hex Size Tube Nut/ Swivel Nut Torque mm Dash in. Size mm in. mm N•m lb-ft N•m lb-ft mm 6 -4 0.250 6.35 9/16-18 17 16 8 -5 0.312 7.94 12 O-Ring Stud Ends, Straight Fitting or Lock Nut Bulkhead Lock Nut Torque 12 9 Thread Size Hex Steel or Size Gray Iron Torque mm Aluminum Torque N•m lb-ft N•m lb-ft M12X1.5 17 21 15.5 9 6.6 M14X1.5 19 33 24 15 11 10 -6 0.375 9.52 11/16-16 22 24 18 24 18 M16X1.5 22 41 30 18 13 12 -8 0.500 12.70 13/16-16 24 50 37 46 34 M18X1.5 24 50 37 21 15 16 -10 0.625 15.88 1-14 30 69 51 62 46 M22X1.5 27 69 51 28 21 -12 0.750 19.05 1-3/16-12 36 102 75 102 75 M27X2 32 102 75 46 34 22 -14 0.875 22.22 1-3/16-12 36 102 75 102 75 M30X2 36 25 -16 1.000 25.40 1-7/16-12 41 142 105 142 105 M33X2 41 158 116 71 52 M38X2 46 176 130 79 58 28 32 -20 1.25 31.75 1-11/1612 50 190 140 190 140 M42X2 50 190 140 85 63 38 -24 1.50 38.10 2-12 60 217 160 217 160 M48X2 55 217 160 98 72 Note: Torque tolerance is +15%, -20% Specifications & Information O-Ring Seal Service Recommendations - 12 SPECIFICATIONS & INFORMATION O-RING SEAL SERVICE O-Ring Face Seal Fittings 2. Put hydraulic oil or petroleum jelly on the O-ring (B). Place electrical tape over the threads to protect O-ring from nicks. Slide O-ring over the tape and into the groove (A) of fitting. Remove tape. A D C B E A MIF 1. Inspect the fitting sealing surfaces (A). They must be free of dirt or defects. 2. Inspect the O-ring (B). It must be free of damage or defects. MIF 3. For angle fittings, loosen special nut (D) and push special washer (C) against threads so O-ring can be installed into the groove of fitting. 3. Lubricate O-rings and install into groove using petroleum jelly to hold in place during assembly. 4. Turn fitting into the boss by hand until special washer or washer face (straight fitting) contacts boss face and O-ring is squeezed into its seat. 4. Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place. 5. To position angle fittings (E), turn the fitting counterclockwise a maximum of one turn. Important: Avoid Damage! DO NOT allow hoses to twist when tightening fittings. Use two wrenches to tighten hose connections; one to hold the hose, and the other to tighten the swivel fitting. 6. Tighten straight fittings to torque value shown on chart. For angle fittings, tighten the special nut to value shown in the chart while holding body of fitting with a wrench. 5. Tighten fitting or nut to torque value shown on the chart per dash size stamped on the fitting. O-Ring Boss Fittings 1. Inspect boss O-ring boss seat. It must be free of dirt and defects. If repeated leaks occur, inspect for defects with a magnifying glass. Some raised defects can be removed with a slip stone. A B MIF Specifications & Information O-Ring Seal Service Recommendations - 13 SPECIFICATIONS & INFORMATION GENERAL INFORMATION Straight Fitting or Special Nut Torques Thread Size a Torquea Number of Flatsb N•m lb-ft 3/8-24 UNF 8 6 2 7/16-20 UNF 12 9 2 1/2-20 UNF 16 12 2 9/16-18 UNF 24 18 2 3/4-16 UNF 46 34 2 7/8-14 UNF 62 46 1-1/2 1-1/16-12 UN 102 75 1 1-3/16-12 UN 122 90 1 1-5/16-12 UN 142 105 3/4 1-5/8-12 UN 190 140 3/4 1-7/8-12 UN 217 160 1/2 General Information Gasoline 4 - Cycle Engines c FLAMMABLE, Caution: Avoid Injury! Gasoline is HIGHLY handle it with care. DO NOT refuel machine while: indoors, always fill gas tank outdoors; machine is near an open flame or sparks; engine is running, STOP engine; engine is hot, allow it to cool sufficiently first; smoking. Help prevent fires: fill gas tank to bottom of filler neck only; be sure fill cap is tight after fueling; clean up any gas spills IMMEDIATELY; keep machine clean and in good repair - free of excess grease, oil, debris, and faulty or damaged parts; any storage of machines with gas left in tank should be in an area that is well ventilated to prevent possible igniting of fumes by an open flame or spark, this includes any appliance with a pilot light. Torque tolerance is ± 10 percent. bTo To prevent fire or explosion caused by STATIC ELECTRIC DISCHARGE during fueling: be used if a torque wrench cannot be used. After tightening fitting by hand, put a mark on nut or boss; then tighten special nut or straight fitting the number of flats shown. Metric Fastener Torque Value - Grade 7 (Special) Size Steel or Gray Iron Torque Aluminum Torque N•m (lb-ft) N•m (lb-ft) M6 11 (8) 8 (6) M8 24 (18) 19 (14) M10 52 (38) 41 (30) M12 88 (65) 70 (52) M14 138 (102) 111 (82) M16 224 (165) 179 (132) • ONLY use a clean, approved POLYETHYLENE PLASTIC fuel container and funnel WITHOUT any metal screen or filter. To avoid engine damage: • DO NOT mix oil with gasoline; • ONLY use clean, fresh unleaded gasoline with an octane rating (anti-knock index) of 87 or higher; • fill gas tank at the end of each day's operation to help prevent condensation from forming inside a partially filled tank; • keep up with specified service intervals. Use of alternative oxygenated, gasohol blended, unleaded gasoline is acceptable as long as: • the ethyl or grain alcohol blends DO NOT exceed 10% by volume or • methyl tertiary butyl ether (MTBE) blends DO NOT exceed 15% by volume RFG (reformulated) gasoline is acceptable for all machines designed for use of regular unleaded fuel. Older machines (that were designed for leaded fuel) may see some accelerated valve and seat wear. Specifications & Information General Information - 14 SPECIFICATIONS & INFORMATION GENERAL INFORMATION • SAE 10W-40 - API Service Classifications SG or higher; • SAE 5W-30 - API Service Classification SG or higher; • SAE 10W-30 - API Service Classifications SG or higher; • SAE 30 - API Service Classification SC or higher. SAE 10W-40 MIF SAE 5W-30 Important: Avoid Damage! California Proposition 65 Warning: Gasoline engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. -40 -22 -4 14 -40 -30 -20 -10 32 F 0 C 50 68 86 104 122 10 20 30 40 50 SAE 10W-30 Gasoline Storage SAE 30 Important: Avoid Damage! Keep all dirt, scale, water or other foreign material out of gasoline. Keep gasoline stored in a safe, protected area. Storage of gasoline in a clean, properly marked (“UNLEADED GASOLINE”) POLYETHYLENE PLASTIC container WITHOUT any metal screen or filter is recommended. DO NOT use de-icers to attempt to remove water from gasoline or depend on fuel filters to remove water from gasoline. Use a water separator installed in the storage tank outlet. BE SURE to properly discard unstable or contaminated gasoline. When storing the machine or gasoline, it is recommended that you add John Deere Gasoline Conditioner and Stabilizer (TY15977) or an equivalent to the gasoline. BE SURE to follow directions on container and to properly discard empty container. 4 - Cycle Gasoline Engine Oil Use the appropriate oil viscosity based on the expected air temperature range during the period between recommended oil changes. Operating outside of these recommended oil air temperature ranges may cause premature engine failure. The following John Deere oils are PREFERRED: Break-In Engine Oil - 4-Cycle Gasoline Important: Avoid Damage! ONLY use a quality breakin oil in rebuilt or remanufactured engines for the first 5 hours (maximum) of operation. DO NOT use oils with heavier viscosity weights than SAE 5W-30 or oils meeting specifications API SG or SH, these oils will not allow rebuilt or remanufactured engines to break-in properly. The following John Deere oil is PREFERRED: • BREAK - IN ENGINE OIL. John Deere BREAK - IN ENGINE OIL is formulated with special additives for aluminum and cast iron type engines to allow the power cylinder components (pistons, rings, and liners as well) to “wear-in” while protecting other engine components, valve train and gears, from abnormal wear. Engine rebuild instructions should be followed closely to determine if special requirements are necessary. John Deere BREAK - IN ENGINE OIL is also recommended for non-John Deere engines, both aluminum and cast iron types. • PLUS - 4 - SAE 10W-40; The following John Deere oil is also recommended: • TORQ - GARD SUPREME - SAE 5W-30. • The following John Deere oils are also recommended, based on their specified temperature range: • TURF - GARD - SAE 10W-30; • PLUS - 4 - SAE 10W-30; • TORQ - GARD SUPREME - SAE 30. TORQ - GARD SUPREME® - SAE 5W-30. If the above recommended John Deere oils are not available, use a break-in engine oil meeting the following specification during the first 5 hours (maximum) of operation: • SAE 5W-30 - API Service Classification SE or higher. Other oils may be used if above John Deere oils are not available, provided they meet one of the following specifications: Specifications & Information General Information - 15 SPECIFICATIONS & INFORMATION GENERAL INFORMATION Important: Avoid Damage! After the break-in period, use the John Deere oil that is recommended for this engine. Gear Case Oil Use the appropriate oil viscosity based on the air temperature ranges. Operating outside of these recommended oil air temperature ranges may cause premature gear case failure. BREAK-IN OIL -40 -22 -4 14 -40 -30 -20 -10 32 F 50 68 86 104 122 0C 10 20 30 40 50 SAE 5W-30 Important: Avoid Damage! ONLY use a quality oil in this gear case. DO NOT mix any other oils in this gear case. DO NOT use BIO-HY-GARD® in this gear case. The following John Deere gear case oil is PREFERRED: • Hydrostatic Transmission and Hydraulic Oil Use the appropriate oil viscosity based on these air temperature ranges. Operating outside of these recommended oil air temperature ranges may cause premature hydrostatic transmission or hydraulic system failures. Important: Avoid Damage! Mixing of LOW VISCOSITY HY - GARD® and HY - GARD® oils is permitted. DO NOT mix any other oils in this transmission. DO NOT use engine oil or “Type F” (Red) Automatic Transmission Fluid in this transmission. DO NOT use BIO-HY-GARD® in this transmission. GL-5 GEAR LUBRICANT® - SAE 80W-90. The following John Deere gear case oil is also recommended if above preferred oil is not available: • GL-5 GEAR LUBRICANT® - SAE 85W-140. Other gear case oils may be used if above recommended John Deere gear case oils are not available, provided they meet the following specification: • API Service Classification GL - 5. SAE 80W-90 -40 -22 -4 14 -40 -30 -20 -10 32 F The following John Deere transmission and hydraulic oil is PREFERRED: • LOW VISCOSITY HY-GARD® - JDM J20D. The following John Deere oil is also recommended if above preferred oil is not available: • HY-GARD® - JDM J20C. Other oils may be used if above recommended John Deere oils are not available, provided they meet one of the following specifications: • John Deere Standard JDM J20D; • John Deere Standard JDM J20C. HY-GARD J20C -40 -22 -4 14 -40 -30 -20 -10 32 F 50 68 86 104 122 0C 10 20 30 40 50 Low Viscosity HY-GARD J20D Specifications & Information General Information - 16 0 C 50 68 86 104 122 10 20 30 40 50 SAE 85W-140 SPECIFICATIONS & INFORMATION GENERAL INFORMATION Gear Transmission Grease Anti-Corrosion Grease Use the following gear grease based on the air temperature range. Operating outside of the recommended grease air temperature range may cause premature gear transmission failure. This anti-corrosion grease is formulated to provide the best protection against absorbing moisture, which is one of the major causes of corrosion. This grease is also superior in its resistance to separation and migration. Important: Avoid Damage! ONLY use a quality gear grease in this transmission. DO NOT mix any other greases in this transmission. DO NOT use any BIO GREASE in this transmission. The following John Deere gear grease is PREFERRED: • NON-CLAY HIGH-TEMPERATURE EP GREASE® JDM J13E4, NLGI Grade 2. The following anti-corrosion grease is preferred: • DuBois MPG-2™ Multi-Purpose Polymer Grease M79292. Other greases may be used if they meet or exceed the following specification: • Other greases may be used if above preferred John Deere grease is not available, provided they meet the following specification: • John Deere Standard JDM J13A2, NLGI Grade 1. J13A2 NLGI Grade 1 John Deere Standard JDM J13E4, NLGI Grade 2. -40 -22 -4 14 -40 -30 -20 -10 32 F 50 68 86 104 122 0C 10 20 30 40 50 J13E4 NLGI Grade 2 Mower Spindle Grease -40 -22 -4 14 -40 -30 -20 -10 32 F 50 68 86 104 122 0C 10 20 30 40 50 This premium, multi-purpose grease is specially formulated as a high-temperature, extreme-pressure grease, especially effective in rolling contact applications. The following water resistant grease is preferred: • Alternative Lubricants Use of alternative lubricants could cause reduced life of the component. If alternative lubricants are to be used, it is recommended that the factory fill be thoroughly removed before switching to any alternative lubricant. Multi-Purpose SD Polyurea Grease - TY6341. The following multi-purpose grease may also be used: • Multi-Purpose HD Lithium Complex Grease - TY24416. Other greases may be used if they meet or exceed the following specification: • John Deere Standard JDM J13E4, NLGI Grade 2. Synthetic 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 manual. The recommended air temperature limits and service or lubricant change intervals should be maintained as shown in the operator’s manual, unless otherwise stated on lubricant label. Avoid mixing different brands, grades, or types of oil. Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements. Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance. J13E4 NLGI Grade 2 -40 -22 -4 14 -40 -30 -20 -10 32 F 50 68 86 104 122 0C 10 20 30 40 50 Lubricant Storage All machines operate at top efficiency only when clean lubricants are used. Use clean storage containers to handle all lubricants. Store them in an area protected from dust, moisture, and other contamination. Store drums on their sides. Make sure all containers are properly marked as to their contents. Dispose of all old, used containers and their contents properly. Specifications & Information General Information - 17 SPECIFICATIONS & INFORMATION COOLANT SPECIFICATIONS Mixing of Lubricants Coolant Specifications In general, avoid mixing different brands or types of lubricants. Manufacturers blend additives in their lubricants to meet certain specifications and performance requirements. Mixing different lubricants can interfere with the proper functioning of these additives and lubricant properties which will downgrade their intended specified performance. Gasoline Engine Coolant The engine cooling system when filled with a proper dilution mixture of anti-freeze and deionized or distilled water provides year-round protection against corrosion, cylinder or liner pitting, and winter freeze protection down to -37°C (-34°F). The following John Deere coolant is PREFERRED: Oil Filters Important: Avoid Damage! Filtration of oils is critical to proper lubrication performance. Always change filters regularly. The following John Deere oil filters are PREFERRED: • AUTOMOTIVE AND LIGHT TRUCK ENGINE OIL FILTERS. • COOL-GARD® PRE-DILUTED SUMMER COOLANT (TY16036). This coolant satisfies specifications for “Automobile and Light Duty Engine Service” and is safe for use in John Deere Lawn and Grounds Care/Golf and Turf Division equipment, including aluminum block gasoline engines and cooling systems. The above preferred pre-diluted anti-freeze provides: Most John Deere filters contain pressure relief and antidrainback valves for better engine protection. • adequate heat transfer Other oil filters may be used if above recommended John Deere oil filters are not available, provided they meet the following specification: • corrosion-resistant chemicals for the cooling system • compatibility with cooling system hose and seal material • ASTB Tested In Accordance With SAE J806. • protection during extreme cold and extreme hot weather operations • chemically pure water for better service life • compliance with ASTM D4656 (JDM H24C2) specifications If above preferred pre-diluted coolant is not available, the following John Deere concentrate is recommended: • COOL-GARD® CONCENTRATED SUMMER COOLANT CONCENTRATE™ (TY16034). If either of above recommended engine coolants are available use any Automobile and Light Duty Engine Service ethylene glycol base coolant, meeting the following specification: • ASTM D4985 (JDM H24A2). Read container label completely before using and follow instructions as stated. Specifications & Information Coolant Specifications - 18 SPECIFICATIONS & INFORMATION SERIAL NUMBER LOCATIONS Important: Avoid Damage! To prevent engine damage, DO NOT use pure anti-freeze or less than a 50% anti-freeze mixture in the cooling system. DO NOT mix or add any additives/conditioners to the cooling system in Lawn and Grounds Care/Golf and Turf Division equipment. Water used to dilute engine coolant concentrate must be of high quality - clean, clear, potable water (low in chloride and hardness Table 1) is generally acceptable. DO NOT use salt water. Deionized or distilled water is ideal to use. Coolant that is not mixed to these specified levels and water purity can cause excessive scale, sludge deposits, and increased corrosion potential. Property Requirements Total Solids, Maximum 340 ppm (20 grns/gal) Total Hardness, Maximum 170 ppm (10 grns/gal) Chloride (as Cl), Maximum 40 ppm (2.5 grns/gal) Sulfate (as SO4), Maximum 100 ppm (5.8 grns/gal) Serial Number Locations Product Serial Number A M55444 The 13-digit product identification number (A) is located on the right-hand side frame, just below engine compartment. Gasoline Engine Serial Number Location Mix 50 percent anti-freeze concentrate with 50 percent distilled or deionized water. This mixture and the pre-diluted mixture (TY16036) will protect the cooling system down to 37°C (-34°F) and up to 108°C (226°F). A Certain geographical areas may require lower air temperature protection. See the label on your anti-freeze container or consult your John Deere dealer to obtain the latest information and recommendations. A Gasoline Engine Coolant Drain Interval When using John Deere Pre-Diluted (TY16036) Automobile and Light Duty Engine Service coolants, drain and flush the cooling system and refill with fresh coolant mixture every 36 months or 3,000 hours of operation, whichever comes first. MX13637 Engine serial number (A) is located on the valve cover or on the front of the engine crankcase. When using John Deere Concentrate (TY16034) Automobile and Light Duty Engine Service coolants, drain and flush the cooling system and refill with fresh coolant mixture every 24 months or 2,000 hours of operation, whichever comes first. If above John Deere Automobile and Light Duty Engine Service coolants are not being used; drain, flush, and refill the cooling system according to instructions found on product container or in equipment operator’s manual or technical manual. Specifications & Information Serial Number Locations - 19 SPECIFICATIONS & INFORMATION SERIAL NUMBER LOCATIONS Specifications & Information Serial Number Locations - 20 ENGINE - GAS (LIQUID-COOLED) TABLE OF CONTENTS Engine - Gas (Liquid-Cooled) Table of Contents Specifications .................................................23 General Specifications .................................23 Tests and Adjustments Specifications..........23 Repair Specifications....................................24 Torque Specifications (Alphabetical)............25 Special or Required Tools ............................26 Component Location......................................27 Engine (FD671D) .........................................27 Engine (FD750D) .........................................28 Theory of Operation .......................................29 Cooling System Operation ...........................29 Fuel and Air System Operation ....................30 Fuel Injection Air System Components and Operation (FD750D).....................................30 Fuel Pressure Regulator Operation (FD750D)......................................................31 Governor Operation......................................31 Lubrication System Operation ......................32 Throttle Body Operation (FD750D) ..............33 Diagnostics .....................................................34 Engine Diagnosis .........................................34 Engine Tests ................................................38 Tests and Adjustments ..................................40 Throttle Lever Adjustment ............................40 Throttle Cable Adjustment............................40 Choke Adjustment (FD671D) .......................41 Governor Adjustment ...................................41 Low Idle Speed Adjustment..........................42 High Idle Speed Adjustment.........................42 Compression Test ........................................43 Valve Clearance Adjustment ........................43 Crankcase Vacuum Test ..............................44 Engine Oil Pressure Test .............................46 Fuel Pump Flow Test for Carburetor (FD671D)......................................................47 Fuel Pump Pressure Test for Carburetor (FD671D)......................................................47 Fuel Pump Pressure Test For Fuel Injection (FD750D)......................................................48 Bleed Fuel System (FD750D) .....................49 Fan Belt Tension Adjustment .......................49 Thermostat Test ...........................................50 Cooling System Test ....................................50 Radiator Bubble Test....................................51 Radiator Cap Pressure Test ........................ 51 Water Pump/Alternator Drive Belt Adjustment................................................... 51 Repair.............................................................. 52 Thermostat Removal and Installation .......... 52 Fan Belt Removal and Installation ............... 53 Cooling Fan and Bracket Removal and Installation.................................................... 53 Coolant Pump Removal and Installation...... 54 Radiator Removal and Installation............... 56 Muffler Removal and Installation ................. 58 Air Cleaner Removal and Installation .......... 58 Carburetor Removal and Installation (FD671D) ..................................................... 60 Throttle Body Removal and Installation (FD750D) ..................................................... 62 Fuel Injector Removal and Installation (FD750D) ..................................................... 63 Fuel Pressure Regulator Removal and Installation (FD750D) .............................................. 64 Cylinder Head Removal and Installation...... 65 Intake Manifold Removal and Installation (FD671D) ..................................................... 66 Intake Manifold Removal and Installation (FD750D) ..................................................... 67 Starting Motor Removal and Installation...... 69 Starter Motor Disassembly and Assembly... 69 Starting Motor Inspection............................. 71 Engine Removal and Installation ................. 73 Flywheel Removal and Installation .............. 77 Push Rod/Rocker Arm Removal and Installation.................................................... 77 Valve Train Removal and Installation .......... 79 Crankcase Cover Removal and Installation. 80 Crankcase Cover Inspection........................ 82 Governor Assembly Removal and Installation.................................................... 82 Piston Removal and Installation .................. 84 Inspect Piston and Cylinder ........................ 87 Cylinder Bore Honing................................... 89 Camshaft/Tappet Removal and Installation 90 Camshaft Disassembly and Inspection ....... 91 Crankshaft Removal and Replacement ...... 92 Crankshaft Inspection .................................. 92 Connecting Rod Inspection.......................... 94 Breather Valve Removal and Installation..... 95 Oil Pump Removal and Installation.............. 95 Oil Pump Inspection..................................... 96 Engine - Gas (Liquid-Cooled) Table of Contents - 21 ENGINE - GAS (LIQUID-COOLED) TABLE OF CONTENTS Oil Screen Removal and Installation ............98 Engine - Gas (Liquid-Cooled) Table of Contents - 22 ENGINE - GAS (LIQUID-COOLED) SPECIFICATIONS Specifications General Specifications Engine General Specifications: Engine Use (FD671D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X700 Engine Use (FD750D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X720, X724, and X728 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kawasaki Model Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD671D Model Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD750D Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745 cm3 (45.5 cu-in.) Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 mm (3.07 in.) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 mm (3.07 in.) Compression Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8: 1 Compression Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Automatic Crankshaft Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal (Counterbalanced) Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressurized by Positive Displacement Pump Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 kPa (40 psi minimum) Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cartridge Type, Full Flow, Spin-On Filter Crankcase Capacity (With Filter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 L (1.9 qt) Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled Cooling System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 L (4.2 qt) Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Element replaceable paper Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Horizontal; discharge frame side Maximum Angle of Operation (With Full Crankcase): Continuous (All Directions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20° Intermittent (All Directions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35° Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable (In-Line Type) Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electromagnetic Pump (In-Tank Type) Fuel Shut-Off Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replaceable (Below Carburetor Float Bowl) Carburetor (FD671D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Float type, fixed main jet, two barrel Fuel Injection (FD750D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Simultaneous port fuel injection Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK BPR4ES Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V - 20 amps with regulator Tests and Adjustments Specifications Engine: Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75 mm (0.030 in.) Fan Belt Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 19 mm (0.48 - 0.75 in.) Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Oil Pressure (Minimum at 1250 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 kPa (40 psi) Cylinder Compression (Minimum, with Engine Warm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620 kPa (90 psi) Engine - Gas (Liquid-Cooled) Specifications - 23 ENGINE - GAS (LIQUID-COOLED) SPECIFICATIONS Fuel/Air System: Slow Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1600 ± 25 rpm Fast Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3550 ± 25 rpm Repair Specifications Cylinder Head: Cylinder Head Flatness (Maximum Warp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 mm (0.002 in.) Valves and Valve Lifters: Valve Clearance (Intake/Exhaust Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Valve Stem Runout (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 mm (0.002 in.) Valve Stem OD (Exhaust and Intake, Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.94 mm (0.273 in.) Valve Guide ID (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.08 mm (0.279 in.) Valve Spring Free Length (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.0 mm (1.22 in.) Valve Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45° Push Rod Runout (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm (0.02 in.) Crank shaft: Crankshaft Journal Bearing ID: Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.14 mm (1.659 in.) Crankshaft Journal OD (Minimum) PTO Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.935 mm (1.651 in.) Flywheel Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.935 mm (1.651 in.) Crankshaft Runout (TIR) (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) Crankpin OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.95 mm (1.573 in.) Crankpin Width (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.5 mm (1.83 in.) Connecting Rod: Twist (Maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm over 100 mm (0.006 over 3.94 in.) Bend (Maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm over 100 mm (0.006 over 3.94 in.) Connecting Rod Big End Width (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.35 mm (0.88 in.) Camshaft: Bearing ID Maximum (Crankcase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing ID Maximum (Crankcase Cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Journal Diameter: PTO Side (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel Side (Minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cam Lobe Height (Minimum): Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.081 mm (0.791 in.) 20.081 mm (0.791 in.) 19.927 mm (0.785 in.) 19.927 mm (0.785 in.) 33.594 mm (1.323 in.) 33.594 mm (1.323 in.) Oil Pump: Inner and outer rotor clearance (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 mm (0.012 in.) Outer rotor OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.47 mm (1.593 in.) Outer rotor thickness (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.830 mm (0.781 in.) Pump Housing inside diameter (Maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.801 mm (1.606 in.) Pump Housing depth (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.230 mm (0.797 in.) Pump Shaft outside diameter (Minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.923 mm (0.4300 in.) Pump Shaft bearing inside diameter (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.072 mm (0.436 in.) Engine - Gas (Liquid-Cooled) Specifications - 24 ENGINE - GAS (LIQUID-COOLED) SPECIFICATIONS Relief Valve Spring length (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.50 mm (0.77 in.) Cylinder Bore, Pistons and Rings Cylinder Bore ID: New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.00 mm (3.071 in.) Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.08 mm (3.074 in) Cylinder Bore Out of Round (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.056 mm (0.0022 in.) Piston Pin Bore ID (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.080 mm (0.751 in.) Piston Pin OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.960 mm (0.747 in.) Top and Middle Compression Ring-To-Groove Side Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Piston Ring Thickness (Top, Second) (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40 mm (0.055 in.) Top and Second Ring End Gap (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.04 in.) Oil Ring End Gap (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 mm (0.05 in.) Piston OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.70 mm (3.059 in.) Torque Specifications (Alphabetical) Note: Use appropriate torque wrench which will read within the inch pound range given, or convert inch pounds to foot pounds as follows: Inch-pounds/12 = Foot-pounds Air Cleaner Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 N•m (87 lb-in.) Camshaft Breather Chamber Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.) Carburetor to Manifold Mounting Bolts and Nuts (FD671D). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (106 lb-in.) Throttle Body and Intake Pipe Mounting Bolts (FD750D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (106 lb-in.) Choke Valve Screw (FD671D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.95 N•m (8.4 lb-in.) Throttle Valve Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.90 N•m (8.0 lb-in.) Water Temperature Sensor (FD750D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.) Vacuum Sensor (FD750D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 N•m (87 lb-in.) Control Panel Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 N•m (52 lb-in.) Crankcase Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.) Cylinder Head Bolts (Silicone Sealant Applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Float Chamber Mounting Screw (Carburetor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (18 lb-in.) Oil Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (221 lb-in.) Engine Flywheel Cover Bolt (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 N•m (61 lb-in.) Cooling Fan Shaft Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.) Flywheel Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 N•m (41 lb-ft) Fuel Shut Off Solenoid Valve (FD671D) Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N•m (61 lb-in.) Float Chamber Mounting Screw (FD671D) Carburetor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (17 lb-in.) Governor Arm Clamp Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (69 lb-in.) Ignition Coil Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 N•m (30 lb-in.) Intake Manifold Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.) Muffler Flange Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.) Main Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 N•m (6 lb-in.) Oil Pump Cover Plate Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 N•m (52 lb-in.) Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (132 lb-in.) Rocker Arm (Valve Clearance) Adjusting Locknuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Rocker Arm Bracket Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.) Rocker Cover Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 N•m (61 lb-in.) Engine - Gas (Liquid-Cooled) Specifications - 25 ENGINE - GAS (LIQUID-COOLED) SPECIFICATIONS Connecting Rod Cap Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.) Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (221 lb-in.) Starter Motor Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.) Voltage Regulator Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 N•m (30 lb-in.) Special or Required Tools Special or Required Tools Tool Name Tool No. Tool Use Photo Tachometer JT05719 Slow and fast idle adjustment Cylinder Leakdown Tester JT03502 Cylinder leakdown test Crankcase Vacuum Test Kit JT03503 Crankcase vacuum check Connector Hose Assembly Pressure Gauge Assembly JT03349 JT03017 JT03344 Oil pressure test Compression Gauge JDM59 Cylinder compression test Fuel Pump Pressure Test Kit JDG356 Fuel pump pressure test - FD671D engines Fitting Pressure Gauge 0-400 kPa (0-60 psi) Fuel Hose JDG41 JTO7032 Fuel pump pressure test - FD750D engines Tension Gauge JDST28 Fan belt tension check Cooling System Pressure Pump Radiator Test Kit D05104ST JDG692 Radiator cap and cooling system pressure tests Lapping Tool Valve lapping Engine - Gas (Liquid-Cooled) Specifications - 26 ENGINE - GAS (LIQUID-COOLED) COMPONENT LOCATION Component Location Engine (FD671D) C D B A E F J G I H MX14278 A- Throttle Cable B- Governor Arm C- Coolant Temperature Sensor D- Coolant Hose E- Fuel Shutoff Solenoid F- Ignition Module #1 Cylinder G- Ignition Module #2 Cylinder H- Starting Motor I- Engine Frame Ground J- Spark Plug #2 Cylinder Note: Number 1 cylinder is on same side of engine as oil filter. Engine - Gas (Liquid-Cooled) Component Location - 27 ENGINE - GAS (LIQUID-COOLED) COMPONENT LOCATION Engine (FD750D) E D R C G H B A I J P O K N M MX14312 A- Engine Coolant Temperature Sensor B- #2 Cylinder Fuel Injector C- Air Temperature Sensor D- Vacuum Pressure Sensor E- Fuel Pressure Relief Screw F- #1 Cylinder Fuel Injector G- Engine Coolant Temperature Sensor H- Engine Oil Pressure Switch (RH Side) I- Fuel Shutoff Solenoid L J- Ignition Module #1 Cylinder K- Ignition Module #2 Cylinder L- Wiring Harness Connector M- Wiring Harness Connector N- Starting Motor Solenoid O- Frame Ground P- Spark Plug #2 Cylinder Note: Number 1 cylinder is on same side of engine as oil filter. Engine - Gas (Liquid-Cooled) Component Location - 28 ENGINE - GAS (LIQUID-COOLED) THEORY OF OPERATION Theory of Operation Cooling System Operation F D C G B A E H K J I MX14217 A- Radiator B- Cooling Fan C- Radiator Cap, maintains radiator pressure at 78 - 98 kPa (11.3 - 14.2 psi) D- Thermo Switch, detects at 111°C (232°F) E- Bypass Tube F- Engine Body G- Water Pump (Impeller) H- Jiggle Valve I- Drain Plug J- Valve, One Way K- Thermostat, fully open at 95°C (203°F) Function: The coolant pump circulates coolant through the cooling system, drawing hot coolant from the engine block, and circulating it through the radiator for cooling. System Operation: The impeller-type coolant pump draws coolant from the bottom of the radiator when the thermostat is open, or from the bypass when the thermostat is closed. Coolant from the water pump flows to the water jackets in block, up through cylinder heads, intake manifold, past the coolant temperature sensor and thermostat. When the engine temperature is below approximately 82°C (180°F), the thermostat is closed and coolant is directed back to the water pump through bypass hose to be recirculated. This allows the engine to warm up to operating temperature quickly. When the engine temperature is approximately 82°C (180°F), the thermostat begins to open and is fully open at 95°C (203°F). Coolant from the water jackets and cylinder heads now flow through the thermostat to the radiator, which is cooled by the radiator fan. The fan is driven by a belt off the crankshaft pulley. If the engine coolant temperature raises to 111°C (232°F), a thermo switch detects this, and turns on a warning light on the dash, warning you of a potentially dangerous overheating situation. The radiator cap maintains a pressure of 78 - 98 kPa (11.3 - 14.2 psi) inside the radiator, which actually raises the boiling point of the coolant. The radiator cap contains a pressure valve and a vacuum valve. When the coolant is hot and pressure is above 98 kPa (14.2 psi), the pressure valve opens, allowing some coolant to flow to the recovery tank. After the engine is stopped, the coolant cools and the pressure inside the radiator decreases. The pressure difference between the radiator and recovery tank forces the vacuum valve open and some coolant from the recovery tank flows back to the radiator. Engine - Gas (Liquid-Cooled) Theory of Operation - 29 ENGINE - GAS (LIQUID-COOLED) THEORY OF OPERATION Fuel and Air System Operation Fuel Injection Air System Components and Operation (FD750D) Function: The fuel system supplies fuel to the engine for combustion. The air intake system filters air needed for combustion. A B C A A B D C F E MX14223 MX14324 The fuel tank holds the fuel pick-up and fuel sensor assembly. The carburated engine has a fuel pump mounted to the side of the engine The fuel pick-up (A) consists of a fuel pick-up tube and a float type fuel sensor. The fuel pump draws fuel through the fuel pump screen. Low pressure fuel from the fuel pump flows through the fuel shut-off valve and in-line fuel filter to the carburetor. Fuel pressure is maintained at the carburetor inlet needle until the float allows more fuel in the bowl. The fuel injected engine has pressurized fuel supplied to the engine. The fuel pick-up (B) consists of a fuel pick-up tube with an in-line electric fuel pump (C). System Operation - Fuel Injection: An electric fuel pump (C) mounted inside the fuel tank provides pressurized fuel to the carburetor. The fuel pump uses the fuel for lubrication and cooling. The fuel shutoff solenoid shuts off fuel to the main jet, preventing gas fumes from escaping into the air for emission control, while the fuel cap is vented for releasing any increased pressure within the fuel tank. The ignition delay module is used with the fuel shut-off solenoid to prevent backfire. The ignition delay module allows the spark plugs to fire for one additional second after the key switch is turned off to burn any remaining fuel in the cylinder. When the key switch is turned off, the fuel shut-off solenoid is de-energized. Air enters the air filter though the side panel screen and air filter inlet hose. The breather hose vents crankcase fumes into the carburetor for burning to decrease emissions. A- Fuel Injectors B- Fuel Pressure Regulator C- Air Temperature Sensor D- Water Temperature Sensor E- Vacuum Pressure Sensor F- Thermo Switch Function: The fuel injection system supplies pressurized fuel to the fuel injectors for combustion. The air intake system filters air needed for combustion. System Operation: An electric fuel pump mounted inside the fuel tank provides pressurized fuel to the fuel injectors (A). The fuel pump uses the fuel for lubrication and cooling. The fuel pump and fuel injectors are controlled by the fuel injection module computer. The controller monitors engine operating and environmental conditions to calculate the amount of fuel to inject. The fuel pump draws fuel through the fuel pump screen. High pressure fuel from the fuel pump flows through the in-line fuel filter to the fuel pressure regulator (B) and fuel injector. The fuel injector is a solenoid operated type valve with single point injection. Fuel is injected into the throttle body when the solenoid is energized by the controller. Fuel pressure is controlled by the fuel pressure regulator. The regulator is an overflow type regulator that maintains fuel pressure at the fuel injector at a constant 175 kPa (25 psi). Excess fuel flows through the regulator valve and fuel return hose to the fuel tank. The fuel shutoff solenoid shuts off fuel to the main jet, preventing gas fumes from escaping into the air for emission control, while the fuel cap is vented for releasing any increased pressure within the fuel tank Engine - Gas (Liquid-Cooled) Theory of Operation - 30 ENGINE - GAS (LIQUID-COOLED) THEORY OF OPERATION The throttle control lever, which is connected to the throttle lever and the governor lever, controls engine rpm. The governor lever is connected to the throttle valve inside the throttle body. Slow idle is adjusted by turning the slow idle stop screw and fast idle is adjusted by moving the throttle control plate. Air enters the air filter through the side panel screen and air filter inlet hose. The primary and secondary elements filter the air before entering the throttle body. The breather hose vents crankcase fumes into the throttle body for burning to decrease emissions. A small amount is always present due to some restriction of air movement through the filter elements. The vacuum increases as the filter elements become plugged. Fuel Pressure Regulator Operation (FD750D) Function: Maintains a constant differential in pressure between fuel pressure at the injector and air pressure in the throttle body. Therefore, the amount of fuel injected is determined by the opening time of the injector. B E- Inlet from Injector F- Return to Tank G- Fuel Chamber H- Valve I- Diaphragm System Operation: The pressure regulator is an overflow type of regulator. The spring chamber is connected to the throttle body to insure that they are operating at the same air pressure. High pressure fuel from the injector flows to the pressure regulator inlet and fills the fuel chamber. A hose from the vacuum inlet is connected to the intake manifold. This allows the air pressure in the spring chamber and intake manifold to be equal. When intake manifold vacuum increases, the spring chamber vacuum also increase and overcomes spring tension, allowing the diaphragm to move upward. With the valve connected to the diaphragm, the valve moves upward and allows more fuel to flow out of the outlet and return to the fuel tank. This lowers the fuel pressure. As intake manifold vacuum decreases, the spring chamber vacuum decreases and the spring returns the diaphragm to the original position. The valve restricts fuel flow to return and fuel pressure increases. C Governor Operation A System Operation: I D H E G F M45334 A- To Throttle Body B- Spring C- Spring Chamber D- Valve Support The governor controls engine speed. Governed engine speed is a balance between governor spring tension, set by the throttle control, and actual engine speed, countered by centrifugal force of the governor flyweights. As tension is applied to governor spring, governor linkage opens carburetor/fuel injection throttle shaft and plate, increasing engine rpm. As the engine speed increases, flyweight assembly (driven by the crankshaft gear) pushes on governor arm, rotating governor shaft and lever, moving throttle shaft, closing throttle plate slightly and reducing rpm to governed operating speed. If a heavy load is encountered, engine speed drops, as does the governor assembly speed. Flyweights retract and allow shaft arm to move governor shaft and lever in opposite direction to open throttle plate and allow more air into venturi to draw in more fuel until engine peak operating speed is recovered. Springs provide a smooth yet responsive transitional control. Important: Avoid Damage! Flyweight assembly shaft is pressed into crankcase cover and is not serviceable. Therefore, if it is damaged or pulled loose, the crankcase cover MUST BE replaced. Engine - Gas (Liquid-Cooled) Theory of Operation - 31 ENGINE - GAS (LIQUID-COOLED) THEORY OF OPERATION Lubrication System Operation D E F C A B G O N I J M H L K System Operation: Pressure oil from the relief valve flows to the oil filter (N). The filter contains a bypass valve, which opens if the element becomes plugged to insure engine lubrication. A positive displacement gerotor pump (L) is used to pressurize the lubrication system. The lubrication system is protected by an oil pressure relief valve (M), low pressure switch (O), and an oil filter (N) with bypass. An oil pressure switch (O) mounted above the oil filter turns on a warning light if oil pressure is below 98 kPa (14.2 psi). Filtered pressure oil flows through a passage in the oil sump to the crankshaft main bearing (J) (PTO side). The oil pump (L) draws oil from the sump through a filter screen (K). Pressure oil from the pump flows to the oil pressure relief valve (M). Oil pressure reading should be 276 kPa (40 psi) minimum. If oil pressure exceeds 310 kPa (45 psi), the relief valve (M) opens allowing oil to return to sump. The relief valve is not adjustable. Drilled passages in the crankshaft (I) distribute oil from the main bearing to the connecting rod (G) journals and crankshaft main bearing (H) (flywheel side). A drilled passage in the connecting rods allows oil from the connoting rod journal to lubricate the piston (F) and cylinder walls and camshaft (B), tappets (C), governor gear (A), water pump gear (D) and rocker arms and valves (E). MX14218 Engine - Gas (Liquid-Cooled) Theory of Operation - 32 ENGINE - GAS (LIQUID-COOLED) THEORY OF OPERATION Throttle Body Operation (FD750D) D E C B F G A H A I J MX14223 A- Fuel Injectors B- Fuel Inlet C- Fuel Pressure Regulator D- Vacuum Hose E- Fuel Return Hose F- Fuel Pressure Relief Screw G- Air Temperature Sensor H- Water Temperature Sensor I- Vacuum Pressure Sensor J- Thermo Switch Excess fuel not used by the injector flows through the pressure regulator (C) back to the fuel tank. The FD750D has an extra passage [fuel pressure relief screw (F)] in the throttle body that allows for a means to relieve the fuel pressure in the fuel lines before any work is done on the system. Function: Injects and atomizes the fuel into the intake air for the proper combustion. System Operation: An electric fuel pump, controlled by the computer, supplies fuel to the inlet (B) of the throttle body to the injector. The fuel pressure regulator holds the fuel under pressure in the injectors (A). The computer receives signals from the throttle sensor and other sensors then controls the time the injector is open. The injector injects the atomized fuel into the throat of the throttle body. Engine - Gas (Liquid-Cooled) Theory of Operation - 33 ENGINE - GAS (LIQUID-COOLED) DIAGNOSTICS Diagnostics Symptom: Engine Starting Problems Problem Cause - Solution Engine Diagnosis c extremely Caution: Avoid Injury! Engine radiator fluid is hot during operation. The engine may start to rotate at any time. Keep hands away from all moving parts when testing. Symptom: Engine Starting Problems Problem Cause - Solution 1. Engine will not crank? a. No: Go to next step. 2. Engine will not start; plug wet? a. No: Go to next step. b. Yes: Battery weak or discharged. Fusible link defective. Check key switch or wiring. Starter solenoid defective. Starter motor defective. b. Yes: Mixture too rich. Clean under engine shrouding. Check spark plug gap and spark (see Electrical section). Inlet needle and seat sticking (FD671D engine). Clean carburetor (FD671D engine). 3. Engine is hard to a. No: For additional tests, see start when cold? “Engine Tests” on page 38. b. Yes: Mixture too rich. Mixture too lean. Clean under engine shrouding. Choke is not completely shut, adjust choke (FD671D engine). Inlet needle and seat sticking (FD671D engine). Clean carburetor (FD671D engine). 4. Engine cranks but will not start? a. No: Go to next step. b. Yes: Battery weak or discharged. Fuel shut-off valve closed (in-line valve). Fuel shut-off solenoid not allowing fuel into main jet (FD671D engine). Fuel shut-off solenoid not allowing fuel into fuel injector (FD750D engine). Improper use of choke (FD671D engine). Float level too high (FD671D engine). Check spark (See Electrical section). Weak or faulty spark plug. Faulty high tension leads. Faulty ignition module (FD671D engine). Faulty fuel injection module (FD750D engine). Faulty ignition coil. Faulty pulsar coil. Contaminated fuel or faulty fuel supply system. Defective fuel pump. Air being drawn in through a hole in fuel line(s). Clogged fuel line or filter. Fuel tank vent line clogged. Air filter restricted. Defective head gasket. Cylinder head loose. Broken valve spring. Warped cylinder head. Poor compression. Worn piston/piston rings stuck or not seated. Worn cylinder bore. Worn or burned valves, or improper clearance. Engine - Gas (Liquid-Cooled) Diagnostics - 34 ENGINE - GAS (LIQUID-COOLED) DIAGNOSTICS Symptom: Engine Performance Problems Problem Cause - Solution 1. Loss of power? a. No: Go to next step. b. Yes: Low oil level. Too much oil in crankcase. Carburetor out of adjustment (FD671D engine). Air/Fuel passages plugged. Carbon deposits in exhaust pipe/ muffler. Carbon deposits in combustion chamber. Weak or faulty spark plug. Faulty high tension leads. Faulty ignition module (FD671D engine). Faulty fuel injection module (FD750D engine). Faulty ignition coil. Faulty pulsar coil. Contaminated fuel or faulty fuel supply system. Defective fuel pump. Air being drawn in through a hole in fuel line(s). Clogged fuel line or filter. Fuel tank vent line clogged. Vapor lock. Air filter restricted. Defective breather valve. Cylinder head loose. Mixture too lean. Check and clean air cleaner. Adjust idle mixture and check engine performance (FD671D engine). Choke is not completely open, adjust choke (FD671D engine). Clean carburetor (FD671D engine). Worn or burned valves, or improper clearance. Broken valve spring. Warped cylinder head. Defective head gasket. Poor compression. Worn piston/piston rings stuck or not seated. Worn cylinder bore. Symptom: Engine Performance Problems Problem Cause - Solution 2. Engine runs erratically? a. No: Go to next step. 3. Engine misses at high rpm? a. No: Go to next step. b. Yes: Carburetor out of adjustment (FD671D engine). Lack of coolant. Governor linkage out of adjustment. Faulty governor spring. Governor gear assembly binding or broken. Check spark (See Electrical section). Carburetor flange loose or leaking at gasket (FD671D engine). Throttle body flange loose or leaking at gasket (FD750D engine). Carburetor body and throttle shaft worn (FD671D engine). Throttle body and throttle shaft worn (FD750D engine). Weak or faulty spark plug. Faulty high tension leads. Faulty ignition module (FD671D engine). Faulty fuel injection module (FD750D engine). Faulty ignition coil. Faulty pulsar coil. Contaminated fuel or faulty fuel supply system. Defective fuel pump. Air being drawn in through a hole in fuel line(s). Clogged fuel line or filter. Fuel tank vent line clogged. Vapor lock. Oil leakage around governor shaft. Defective oil seal. b. Yes: Check spark (See Electrical section). Weak or faulty spark plug. Faulty high tension leads. Faulty ignition module (FD671D engine). Faulty fuel injection module (FD750D engine). Faulty ignition coil. Faulty pulsar coil. Carburetor out of adjustment (FD671D engine). Clogged fuel line or filter. Fuel tank vent line clogged. Defective fuel pump. Warped cylinder head. Engine - Gas (Liquid-Cooled) Diagnostics - 35 ENGINE - GAS (LIQUID-COOLED) DIAGNOSTICS Symptom: Engine Performance Problems Problem Cause - Solution Symptom: Engine Performance Problems Problem Cause - Solution 4. Engine misses at low rpm? 9. Spark plug fouled black? a. No: Go to next step. 10. Spark plug burned white? a. No: Go to next step. 11. Runs better without air cleaner? a. No: Go to next step. 12. Runs worse when warm? a. No: Go to next step. 13. Engine overheats? a. No: Go to next step. 14. Engine backfires? a. No: Go to next step. a. No: Go to next step. b. Yes: Carburetor out of adjustment (FD671D engine). Air/Fuel passages plugged. Air being drawn through carburetor or intake manifold flanges (FD671D engine). Air being drawn through throttle body or intake manifold flanges (FD750D engine). Incorrect timing gear alignment. Check spark (See Electrical section). Weak or faulty spark plug. Faulty high tension leads. Faulty ignition module (FD671D engine). Faulty fuel injection module (FD750D engine). Faulty ignition coil. Faulty pulsar coil. Worn or burned valves, or improper clearance. Warped cylinder head. 5. Engine rpm low a. No: Go to next step. or engine stalls? b. Yes: Battery weak or discharged. 6. Engine speed a. No: Go to next step. unstable (surging)? b. Yes: Mixture too lean. Clean under engine shrouding. Adjust idle mixture and check engine performance (FD671D engine). Clean carburetor (FD671D engine). 7. Engine is sluggish? 8. Black, smoky exhaust? a. No: Go to next step. b. Yes: Mixture too rich. Check and clean air cleaner. Adjust idle mixture and check engine performance (FD671D engine). Choke is not completely open, adjust choke (FD671D engine). Clean carburetor (FD671D engine). a. No: Go to next step. b. Yes: Check spark plug gap and spark (see Electrical section). Mixture too rich. Check and clean air cleaner. Choke is not completely open, adjust choke (FD671D engine). b. Yes: Check spark plug gap and spark (see Electrical section). Mixture too rich. Check and clean air cleaner. Adjust idle mixture and check engine performance (FD671D engine). Choke is not completely open, adjust choke (FD671D engine). Inlet needle and seat sticking (FD671D engine). b. Yes: Check spark plug gap and spark (see Electrical section). Mixture too lean. Clean under engine shrouding. Clean carburetor (FD671D engine). b. Yes: Mixture too rich. Check and clean air cleaner. b. Yes: Mixture too rich. Check and clean air cleaner. Adjust idle mixture and check engine performance (FD671D engine). Choke is not completely open, adjust choke (FD671D engine). Inlet needle and seat sticking (FD671D engine). b. Yes: Mixture too lean. Clean under engine shrouding. Water pump nylon impeller defective. b. Yes: Carburetor out of adjustment (FD671D engine). Check spark (See Electrical section). Faulty pulsar coil. Air being drawn in through a hole in fuel line(s). Cylinder head loose. Warped cylinder head. Defective head gasket. Intake valve burned or sticking. Engine - Gas (Liquid-Cooled) Diagnostics - 36 ENGINE - GAS (LIQUID-COOLED) DIAGNOSTICS Symptom: Engine Performance Problems Problem Cause - Solution Symptom: Engine fuel/oil/coolant problems Problem Cause - Solution 15. Engine knocks? a. No: Go to next step. 2. Excessive oil consumption? a. No: Go to next step. 16. Engine overheats? a. No: For additional tests, see “Engine Tests” on page 38. 3. Excessive fuel consumption? a. No: Go to next step. b. Yes: Excessive engine load. Faulty ignition module (FD671D engine). Faulty fuel injection module (FD750D engine). Contaminated fuel or faulty fuel supply system. Defective head gasket. b. Yes: Lack of coolant. Excessive engine load. Fan belt slippage. Defective radiator hose or clamp. Improper or defective radiator cap. Broken or missing fan shroud. Defective radiator. Loose stud bolts and cap screw. Cracked or porous casting. Damaged water pump seals. Improperly installed gasket. Warped cylinder head. Broken valve spring. Defective head gasket. Worn or burned valves, or improper clearance. Symptom: Engine fuel/oil/coolant problems Problem Cause - Solution 1. Coolant leakage? a. No: For additional tests, see “Engine Tests” on page 38. b. Yes: Lack of coolant. Improper or defective radiator cap. Defective radiator hose or clamp. Defective radiator. Cracked or porous casting. Loose stud bolts and cap screw. Engine overheating. Damaged water pump seals. Improperly installed gasket. Cylinder head loose. b. Yes: Too much oil in crankcase. Incorrect oil viscosity. Drain-back in breather chamber plugged. Defective breather valve. Worn valve stems(s) or valve guide(s). Plugged oil ring groove. Poor compression. Worn piston/piston rings stuck or not seated. Worn cylinder bore. b. Yes: Check spark (See Electrical section). Weak or faulty spark plug. Faulty high tension leads. Faulty ignition module (FD671D engine). Faulty fuel injection module (FD750D engine). Faulty ignition coil. Faulty pulsar coil. Improper use of choke (FD671D engine). Air filter restricted. Carburetor out of adjustment (FD671D engine). Float level too high (FD671D engine). Cylinder head loose. Broken valve spring. Worn or burned valves, or improper clearance. Poor compression. Worn piston/piston rings stuck or not seated. Worn cylinder bore. Engine - Gas (Liquid-Cooled) Diagnostics - 37 ENGINE - GAS (LIQUID-COOLED) DIAGNOSTICS Engine Tests section. No: Check valve guides and stems. Test Procedure - A: 8. Is fuel is reaching injectors (FD750D)? (Crack fuel injection lines at injectors. Crank engine. Be sure fuel shutoff solenoid has pulled in. Fuel leaks out.) Test Conditions: • Machine parked on level surface. Yes: Go to next step. • PTO Switch off • Key switch off unless indicated otherwise. • Spark plug connected to D-05351ST Spark Tester No: No fuel present: Check fuel shutoff valve is open, fuel level in tank, inspect filter/separator element. Test fuel pump. 9. Check flywheel and starting motor: Minimum cranking rpm within specification? Engine 1. When checking dipstick, oil at proper level and viscosity? No leakage? Clean oil and filter? Yes: Go to next step. No: Change oil and inspect for source of contamination. No: Change oil filter. Yes: Go to next step. No: See “Starter Amp Draw Test” in Electrical section. 10. Carburetor choke and governor linkage, (FD671D). Linkage not binding and adjusted correctly? Yes: Go to next step. No: Repair, replace or adjust linkage. No: Check gaskets, seals, plugs, cylinder head, block, and intake manifold and breather. 2. Air filter outlet hose not cracked; clamps tight? Yes: Go to next step. No: Replace hose and/or tighten clamps. 3. Air filter elements not plugged? Air filter housing sealed; no dirt tracking inside filter element? Yes: Go to next step. 11. Carburetor - fuel filter, fuel pump, and carburetor bowl drain screw (key switch on), (FD671D). Fuel level increases in filter? Fuel pump operating - listen for humming sound near fuel cap? Fuel present in float bowl when screw is opened? Yes: Go to next step. No: See “Shutoff Circuit Diagnosis” in the Electrical section. No: Test fuel pump pressure and flow. No: Replace element or housing. 4. Air filter restriction indicator not leaking? Yes: Go to next step. No: Replace indicator. 5. Does fuel shutoff solenoid pull in and stay in when key is returned to “ON”? (Listen for clicking as key is cycled.) No: Check carburetor for debris. 12. Fuel injection pump static timing test, (FD750D). Timing should be correct? (Remove pump as the LAST possible solution.) Yes: Go to next step. Yes: Go to next step. No: Have injection pump static timing adjustment performed by a qualified service repair shop. See “Tests and Adjustments” in this section. No: If solenoid will not pull in and hold in, see Fuel Shutoff Solenoid Circuit Diagnosis in Electrical section. 13. Carburetor/Throttle body (engine running). Low idle at 1550 rpm? High idle at 3600 rpm? 6. Check hand throttle control lever linkage. Full movement of governor control arm from idle to full speed? Yes: Go to next step. Yes: Go to next step. No: Repair; replace or adjust linkage. 7. Check intake and exhaust valves. Valve clearance within specification (engine cold)? Valves not sticking? No: See “Low Idle Speed Adjustment” on page 42 and “High Idle Speed Adjustment” on page 42 in this section. 14. Engine runs smoothly through out rpm range with low smoke and good power? Yes: Go to next step. Yes: Go to next step. No: Adjust governor. No: Adjust valves. See “Tests and Adjustments” in this 15. Test oil pressure switch port. Minimum oil pressure Engine - Gas (Liquid-Cooled) Diagnostics - 38 ENGINE - GAS (LIQUID-COOLED) DIAGNOSTICS within specifications? smelling; no water in fuel? Yes: Go to next step. Yes: Go to next step. No: Test engine oil pressure. (See “Engine Oil Pressure Test” on page 46 in this section.) No: Drain and clean fuel tank. Add fresh fuel. 16. Thermostat opening temperature within specifications? Yes: Go to next step. 2. Fuel pump filter and in-line filter free of debris? No: Replace filters. Yes: Go to next step. No: Perform thermostat opening test. See “Tests and Adjustments” in this section. 3. Fuel hoses not cracked or leaking? Yes: Go to next step. 17. Muffler not restricted? No: Replace. Yes: Go to next step. 4. Fuel hose clamps tight? No: Replace muffler. Yes: Go to next step. 18. When performing cylinder compression test: Cylinder compression within specification? Pressure difference between cylinders within specification? No: Replace or tighten. Yes: Engine tests completed. 5. Fuel tank does not have vacuum? Yes: Fuel tank, pump, lines and filter tests completed. No: Replace vented fuel cap. No: Rebuild engine. Coolant tank and radiator 1. Coolant level between marks on tank when engine is warm? Coolant in radiator full to top? Yes: Go to next step. No: Add proper coolant mix. 2. Coolant not contaminated with oil, fuel or discolored brown? Yes: Go to next step No: Drain and flush system. Check for source of contamination. 3. Radiator screen free of debris? Yes: Go to next step. No: Clean or replace. 4. Hoses not cracked or leaking; clamps and radiator cap tight? Yes: Go to next step. No: Pressure test radiator and cap. 5. Water pump/alternator belt tight; not glazed or cracked? Yes: Go to next step. No: Replace and adjust belt tension. 6. Fan blades not damaged or warped? Yes: Coolant tests completed. No: Replace fan. Fuel tank, pump, lines and filter 1. Fuel level correct; not contaminated or stale Engine - Gas (Liquid-Cooled) Diagnostics - 39 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS Tests and Adjustments Throttle Cable Adjustment Throttle Lever Adjustment Reason: To insure that the throttle lever cable moves the governor linkage from slow to fast idle position. Reason: To achieve smooth throttle lever movement with enough tension to maintain throttle setting. Procedure: Test Equipment: • A Spring Scale Procedure: 1. Connect a scale near the end of the throttle lever. 2. Move throttle lever to slow idle position. B E D C MX14227 Picture Note: FD671D engine shown; FD750D engine does not have choke assembly parts (A). 1. Set the throttle lever in the slow idle position. Check that the throttle control lever (D) contacts the idle speed adjustment screw (E) at the slowest throttle lever setting. A MX14234A 3. Adjust friction disks by tightening or loosening lock nut (A) until throttle lever movement in forward direction is 18 35 N (4 - 8 lb force). Note: Make sure throttle cable is not binding or stuck. 2. If the throttle control lever (D) is not touching the screw (E) at the slowest setting, loosen the throttle cable clamp (C). Pull throttle cable (B) to left. When the control lever contacts the control plate idle adjustment screw, retighten the cable clamp. 3. Set the throttle lever to the fastest idle position and check that the throttle control lever is advancing to the full open position. 4. If the control lever is not advancing to the fully open position, loosen the cable clamp and readjust cable. 5. If the cable cannot be adjusted to obtain a fully open throttle lever position at fastest idle while maintaining contact with the adjustment screw at lowest idle position, it will be necessary to adjust the control plate idle speed adjustment screw. 6. Turn the idle adjustment screw (E) clockwise until it contacts the throttle control lever when set in the slow idle position. After completing the idle screw adjustment, check to make certain the motor is maintaining a 1550 RPM governed low idle setting. Follow the Low Idle Speed Adjustment sequence in this chapter if corrections are necessary. Engine - Gas (Liquid-Cooled) Tests and Adjustments - 40 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS Choke Adjustment (FD671D) Governor Adjustment Reason: Reason: To make sure the choke plate is fully closed when the choke lever is in the full choke position. Correct adjustment also makes sure choke is completely open in the fast idle position. To make sure the governor shaft contacts the flyweight plunger when the engine is stopped. Procedure: Note: Adjust throttle cable before adjusting governor linkage. Procedure: Note: Adjust throttle cable before adjusting choke. Note: It is not necessary to remove the throttle or choke cables from the governor plate assembly to reach the governor arm. The governor plate can be swung away with the cables installed when accessing the governor arm components. 1. Remove air cleaner assembly. 2. Move choke lever forward to full choke position and check that choke butterfly in carburetor is fully closed. B A B C D A C MX14227 3. If adjustment is necessary, loosen the choke cable clamp (A) and move the cable (B) to obtain a fully closed position. Retighten the cable clamp. 4. Release the choke lever and make certain the return spring (C) on the governor control plate is returning the choke butterfly to the fully open position. 5. Reinstall air cleaner assembly and check choke operation while starting machine. MX14227 Picture Note: FD671D engine shown; FD750D engine does not have choke assembly parts (D). 1. Loosen bolt (A), and fully turn the bracket (B) counterclockwise and hold it there. 2. Turn the top end of the governor arm (C) counterclockwise to fully open the carburetor/EFI throttle valve and tighten the bolt (A). Engine - Gas (Liquid-Cooled) Tests and Adjustments - 41 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS Low Idle Speed Adjustment High Idle Speed Adjustment Reason: Reason: To set engine slow idle mixture rpm. To set engine high idle mixture and rpm. Equipment: Equipment: • • JTO5719 Photo Tachometer JTO5719 Photo Tachometer Procedure: Procedure: 1. Disconnect all external loads from engine. Note: High idle speed adjustment should be made after the low idle speed adjustment is performed. 2. Put reflective tape on blower housing screen. 3. Start and run engine at MEDIUM idle for five minutes. c careful Caution: Avoid Injury! Engine will be HOT. Be not to burn skin. c Caution: Avoid Injury! Always keep hands clear of moving parts. 1. Start and run engine at MEDIUM idle for five minutes. Important: Avoid Damage! Do Not adjust high idle speed with air cleaner removed. A D B C E A B C MX14227 Picture Note: FD671D engine shown; FD750D engine does not have choke assembly parts (D). D MX14226 2. Loosen the lock nut (C), and unscrew the high idle set screw (B) a few turns. Picture Note: FD671D engine shown; FD750D engine does not have choke assembly parts (E). 3. Use a photo tachometer to check engine rpm at the blower housing screen. 4. Move throttle lever on dash to idle position. Hold the throttle lever (A) on the carburetor in the closed position, turn governor arm (C) clockwise all the way. 4. Move the throttle lever on dash to obtain the a 3600 RPM high idle speed and leave it there. 5. Adjust the low idle speed screw (B) until the engine idles at 1450 rpm (carburetor idle rpm). Use the photo tachometer to check engine rpm at the blower housing screen. 6. Release the throttle lever and adjust the low idle speed set screw (D) on the control plate to obtain a 1550 rpm governed low idle speed. 5. Turn the high idle set screw (B) so that the end of it just touches the speed control lever (A). Tighten the lock nut (C). 6. Recheck the idle speed and readjust if necessary. Specifications: High idle setting . . . . . . . . . . . . . . . . . . . . . . . . . 3550 rpm Carburetor idle setting. . . . . . . . . . . . . . . . . . . . 1450 rpm Governed idle setting . . . . . . . . . . . . . . . . . . . . 1600 rpm Engine - Gas (Liquid-Cooled) Tests and Adjustments - 42 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS Note: For high altitude operation above 4000 feet, use high altitude carburetor kit, to prevent over rich fuel mixture and black exhaust smoke. Compression Test Reason: To determine the condition of pistons, rings, cylinder walls and valves. 6. Crank hot engine until highest compression reading is obtained. 7. Record pressure readings for each cylinder. Test Equipment: • Important: Avoid Damage! DO NOT overheat starting motor during test. Starter duty is 5 seconds one, 10 seconds off. Additionally, if throttle lever is left in slow idle position (air flow into carburetor restricted), compression could read up to 483 kPa (70 psi) below specification. Specifications: JDM59 Compression Gauge Minimum Compression . . . . . . . . . . . . . 620 kPa (90 psi) Procedure: 1. Adjust valve clearance to 0.15 mm (0.006 in.) with engine at top dead center (TDC) compression stroke. Engine must be “cold” (shop temperature, about 60 - 85°F (16 - 30°C). See “Valve Clearance Adjustment” on page 43 for procedure. Note: Be sure the battery is fully charged before performing procedure. 2. Run engine until it reaches operating temperature (thermostat opens, and both radiator hoses hot). Results: • If pressure readings are above specification, adjust valves and check fuel and intake air systems. Check exhaust for restriction. • If pressure readings are below specification, squirt clean engine oil into cylinders and repeat test. • If pressure increases significantly, check piston rings and cylinder walls for wear or damage. • If pressure does NOT increase after retest, check for leaking valves, valve seats or cylinder head gaskets. • Install spark plugs and reconnect ignition coils when finished with testing procedure. Valve Clearance Adjustment A Reason: Check and adjust valve clearance for proper engine operation. B MX14235 3. Stop the engine, remove both spark plugs, and ground leads to block or use a spark tester (B). 4. Attach the compression gauge assembly (A) firmly into one plug hole. 5. Put throttle lever in fast idle (wide open) position. On FD671D engines, choke must be properly adjusted and fully open. Air filter must be clean. Important: Avoid Damage! Perform valve clearance measurement or adjustment when the engine is at room temperature, 16 - 27°C (60 - 80°F). Proper valve clearance is essential for the engine to operate properly. Check valve clearance for each cylinder separately. Procedure: 1. Remove spark plugs. 2. Remove valve covers. 3. Turn the crankshaft clockwise until piston, visible in the spark plug hole, is at TDC (top dead center) of the compression stroke. Engine - Gas (Liquid-Cooled) Tests and Adjustments - 43 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS B Crankcase Vacuum Test C A Reason: #1 #2 To measure the amount of crankcase vacuum, to ensure the crankcase is not pressurized. A pressurized crankcase will force oil to leak past the seals. Equipment: MX14236 4. Align the flywheel magnet (B) with #1 ignition coil (C) and #2 ignition coil (A). 5. Both intake and exhaust valves will be closed and the rocker arms will be loose. If one rocker arm is tight, the piston is on the exhaust stroke and the crankshaft must be turned another revolution (360 degrees). • JTO5697 U-Tube Manometer Test Kit; or, • JT03503 Crankcase Vacuum Test Kit Procedure 1: Important: Avoid Damage! Test must be run with the engine at normal operating temperature, if not, test will be inaccurate. DO NOT use more than 3 feet of manometer tubing. If a longer hose is used the readings will be inaccurate. 1. Park machine on level surface. 2. Raise engine hood and remove dipstick. Check dipstick/ oil fill cap and O-ring for cracks or damage, replace as necessary. D 3. Install appropriate size rubber plug in dipstick tube. E 4. Insert barbed fitting in rubber plug so that clear line to fitting (A) can be connected at a later step. Important: Avoid Damage! DO NOT make connection between U-Tube Manometer clear line and engine crankcase BEFORE engine is running or fluid in manometer could be drawn into crankcase. 5. Attach manometer magnets to a solid metal surface. F MX14237 A B 6. Loosen the lock nut (D) and valve clearance adjustment bolt (E). 7. Insert a 0.15 mm (.006 in.) feeler gauge (F) between rocker arm and valve stem, and turn the adjusting bolt (E) until the thickness gauge begins to bind between the rocker arm and valve stem end. 8. Holding the adjusting bolt, tighten the locknut to 11 N•m (96 lb-in.). Repeat for either exhaust or intake valve. 9. Repeat procedure for other cylinder. Specifications: Valve Clearance (at 16 - 27°C (60 - 80°F). . . . . . . . . . . 0.15 mm (0.006 in.) Nut Torque. . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Spark Plug Torque . . . . . . . . . . . . . . 25 N•m (221 lb-in.) M88761 6. Open top valves (A) and (B) one turn. Engine - Gas (Liquid-Cooled) Tests and Adjustments - 44 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS Important: Avoid Damage! Repeat test at least three times for accuracy. To repeat test, remove the manometer tube from top of manometer at “A”. DO NOT remove manometer tube from engine. Perform step #7 then reattach manometer tube to side “A”. Continue with step #10. C 11.Remove line from manometer before stopping engine. Then remove dipstick hose connection and install dipstick. Procedure 2: M88762 7. Zero the manometer by sliding the ruled scale up or down so “0” (C) is located where water level on both sides is even. 8. Hold finger over rubber plug hole to keep oil from spraying out. Start engine, move the throttle lever to fast idle (3400 rpm) and allow engine to reach operating temperature. 1. Park machine on level surface. 2. Raise engine hood and remove dipstick. Check dipstick/ oil fill cap and O-ring for cracks or damage, replace as necessary. 3. Install appropriate size rubber plug in dipstick tube. 4. Insert barbed fitting in rubber plug so that clear line to fitting can be connected at a later step. Important: Avoid Damage! DO NOT make connection between test gauge and rubber plug BEFORE engine is running at FAST idle or gauge damage may result. 9. Quickly attach clear line from manometer to rubber plug in dipstick opening. After test reading is made, DO disconnect test gauge WHILE engine is running at FAST idle to prevent damage to gauge. D 5. Hold finger over rubber plug hole to keep oil from spraying out. Start engine, move the throttle lever to fast idle and allow engine to reach operating temperature. 6. Connect gauge, clear line, and barbed fitting to rubber plug. 7. Record crankcase vacuum reading. Gauge should show a minimum vacuum of 10.2 cm (4 in.) of water movement. 8. Disconnect barbed fitting, clear line, and gauge from rubber plug while engine is running at FAST idle. Hold finger over rubber plug hole to keep oil from spraying out. 9. Move throttle to SLOW idle and turn engine OFF. 10.Remove rubber plug and install dipstick. Specification: E Minimum Crankcase Vacuum at 3400 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 cm (4 in. water) Results: M88764 Picture Note: Example: 3 + 3 = 6 in. of vacuum 10.Record vacuum reading. Gauge should show a minimum vacuum of 10.2 cm (4 in.) of water movement. The reading is obtained by adding (D) and (E) water movement from “0” position. If crankcase vacuum does not meet specification, check the following: Note: A new engine may have low vacuum readings due to the fact that the rings are not seated. • Seals and gaskets for leakage Engine - Gas (Liquid-Cooled) Tests and Adjustments - 45 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS • Rocker arm cover O-ring for leakage • Rings, piston, and cylinder bore for wear or damage E Engine Oil Pressure Test Reason: To determine condition of lubrication system. C D Equipment: • JT03344 Pressure Gauge Assembly • JT03349 Connector • JT03017 Hose Assembly c HOT. Caution: Avoid Injury! Engine components are Be careful not to touch, especially the exhaust pipe or muffler while making adjustments. Wear protective eye glasses and clothing. Procedure - Preliminary Check: 1. Park machine on level surface. 2. Turn key switch OFF. Allow engine to cool. 3. Move forward/reverse pedals to NEUTRAL position. 4. Engage parking brake and raise hood. MX14242 8. Install JT03349 Connector (C). 9. Install JT03017 Hose Assembly (D) and JT03344 pressure gauge assembly (E). 10.Monitor oil pressure while cranking engine. If no oil pressure is present discontinue cranking engine. Determine and correct cause before running engine. Important: Avoid Damage! If pressure reading is below 69 kPa (10 psi), STOP ENGINE IMMEDIATELY and determine cause. Procedure- Engine Running: 5. Check engine oil level, bring oil level to full mark. 1. Start and Run engine at medium idle for five minutes to heat engine oil to normal operating temperature. 2. Run engine at fast idle (3350 rpm) and check oil pressure. Gauge should read a minimum oil pressure of 276 kPa (40 psi). B Results: • If oil pressure reading is BELOW specifications, inspect or replace the following: A - Oil pressure relief valve spring worn or broken - Oil pressure relief valve stuck or broken. - Oil pump worn or damaged MX14241 6. Disconnect oil pressure switch wiring lead (B). 7. Remove oil pressure switch (A). - Oil pump suction screen or oil passages plugged - Connecting rod and main bearing journals excessively worn. - Connecting rod and main bearing journals excessively worn. - Oil filter plugged. Specifications: Minimum Oil Pressure . . . . . . . . . . . . . . 276 kPa (40 psi) Oil Pressure Switch Torque . . . . . . . 15 N•m (132 lb-in.) Engine - Gas (Liquid-Cooled) Tests and Adjustments - 46 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS Fuel Pump Flow Test for Carburetor (FD671D) Reason: Fuel Pump Pressure Test for Carburetor (FD671D) To determine proper fuel flow from transfer pump. Reason: Test Equipment: To check condition of fuel pump and determine fuel pressure. • Graduated container Test Equipment: Procedure: • JDG356 Fuel Pump Pressure Test Kit Procedure: 1. Engage parking brake. B A A B MX15403 C 1. Disconnect fuel supply hose (A) from carburetor (B) and put end in a graduated cylinder. 2. Turn key switch on for 10 seconds. DO NOT start engine. Results: • If fuel flow is below 300 mL (10 oz)/10 seconds, check fuel pump filter, in-line filter, hoses, and fuel shutoff valve for debris or restrictions. Replace filters; then test again. • If fuel flow is still below 300 mL (10 oz)/10 seconds, replace fuel pump. MX15403 2. Loosen clamp (A), and disconnect fuel supply hose (C) from fuel filter (B). 3. Connect fuel pump pressure test kit to end of supply hose (C). 4. Turn key switch on. DO NOT start engine. Observe pressure reading. Results: • If fuel pressure is below 10 kPa (1.5 psi), check fuel pump filter, in-line filter, hoses, and fuel shutoff valve for debris or restrictions. Replace filters; then test again. • If pressure is still below 10 kPa (1.5 psi), replace fuel pump. Engine - Gas (Liquid-Cooled) Tests and Adjustments - 47 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS Fuel Pump Pressure Test For Fuel Injection (FD750D) Reason: B D To check condition of fuel pump and fuel pressure regulator which determines fuel pressure. C Test Equipment: • JT07032 400 kPa (60 psi) Pressure Gauge • JDG41 1/4 M NPT X 1/8 ID Barbed Fitting • Fuel Hose and Hose Clamps A Procedure: 1. Engage park brake. Put PTO in OFF position. Note: Be sure the battery is fully charged. A MX31772 A- Fuel Line from Pump/Filter B- From Relief Screw on Throttle Body C- Excess Pressure Return from Pressure Regulator D- Main Return Line to Fuel Tank 3. Disconnect the fuel line (B) from the tee fitting. 4. Cap the tee fitting open port with a short piece of fuel line and fuel line cap. 5. Install the pressure gauge into the fuel relief line (B). 6. Tighten the hose clamp in the correct position. MX15401/MX15402 Picture Note: Left side of engine shown. 2. Loosen the fuel pressure relief screw (A) to relieve the high pressure in the return fuel hose; Do Not close it at this time, leave open. c fuel. Caution: Avoid Injury! Be prepared for spilling Wipe up any fuel immediately. DO NOT try to start engine with the fuel hoses disconnected. Note: The fuel pump will run for two seconds and then shut off. 7. Turn the key to the RUN position and read fuel pressure. 8. Fuel pressure should be 172 - 186 kPa (25 - 27 psi). • If fuel pressure is higher than specified, check fuel return hose for sharp bends, kinking or clogging or; vacuum hose for air leaks. • If fuel pressure is much lower than specified, inspect for fuel line leakage or clogs in fuel filter or fuel pump. If the inspection turns out good, replace entire pressure regulator or fuel pump. See “Fuel Pressure Regulator Removal and Installation (FD750D)” on page 64 in this section, or “Fuel Pump/Fuel Gauge Sensor Removal and Installation” on page 461 in the Miscellaneous section. 9. Remove pressure gauge. 10.Connect the fuel relief hose to the tee fitting and clamp it. 11.Tighten the fuel pressure relief screw (A). Engine - Gas (Liquid-Cooled) Tests and Adjustments - 48 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS Bleed Fuel System (FD750D) B Reason: When the engine is run out of fuel, injection components fail, or fuel system opened, this procedure purges air from fuel system. A Procedure: Note: This procedure should not be necessary, but may be used when the engine does not start after ten seconds of trying. MX14230 A 1. Use JDST28 Belt Tension Gauge (B) to check belt (A) tension midway between fan and drive sheaves. Belt tension should be between 25 kg (55 lb) and 40 kg (88 lb). If belt tension is below 18 kg (40 lb), adjust or replace the belt. See full specifications below. D C MX15401/MX15402 F Picture Note: Left side of engine shown. 1. Loosen the pressure release screw (A). E Note: Cycling the key switch is necessary because power is supplied to the fuel pump for only a few seconds. 2. With screw loosened, cycle the key switch back and forth (on-off, on-off). Do not turn the engine over. 3. After the system has been “refueled”, tighten the relief screw (A). MIF 2. If the tension gauge is not available, apply moderate pressure (F) to belt between driveshaft sheave (D) and fan pulley (E). Belt should deflect inward (C) as follows: Specifications: Fan Belt Tension Adjustment Belt Tension Measurement Slacks Reason: 25 kg (55 lb) force and 12 mm (0.47 in.) deflection To keep proper tension on belt to drive cooling fan. 40 kg (88 lb) force and 9 mm (0.35 in.) deflection Test Equipment: 18 kg (40 lb) force and 17 mm (0.67 in.) deflection (adjust or replace belt) • JDST28 Belt Tension Gauge Procedure: Results: c clothing Caution: Avoid Injury! Fingers or loose can get caught in rotating parts. Park safely, stop engine, wait for all moving parts to stop, and allow engine to cool before servicing. • If deflection is not within specifications, disconnect drive shaft and remove outer sheave half of fan drive pulley. Remove shim(s) to increase belt tension or add shim(s) to decrease tension. If proper belt tension cannot obtained, replace belt. See “Fan Belt Removal and Installation” on page 53 for procedure and component explode for adjustment. Engine - Gas (Liquid-Cooled) Tests and Adjustments - 49 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS Thermostat Test Cooling System Test Reason: Reason: To determine opening temperature of thermostat. To inspect cooling system for leaks. Equipment: Equipment: • Thermometer • D05104ST Cooling System Pressure Pump • Glass Container • JDG692 Radiator Pressure Test Kit (Adapters) • Heating Unit Procedure: c thermostat Caution: Avoid Injury! DO NOT allow or thermometer to rest against the side or bottom of glass container when heating water. Either may rupture if overheated. Procedure: 1. Remove thermostat. See “Thermostat Removal and Installation” on page 52. c boiling Caution: Avoid Injury! Coolant may be above temperature and under pressure in --cooling system. DO NOT remove pressure cap when system is hot. Escaping steam will burn unprotected skin. Always wear protective clothing and goggles when servicing cooling system M87350 1. Check cooling system is cool and squeeze top radiator hose to check system pressure has dropped. M82122a 2. Suspend thermostat and a thermometer in a container of water. 3. Heat and stir the water. Observe opening action of thermostat and compare temperatures with specifications. 4. Remove thermostat and observe its closing action as it cools. 2. Remove cap. Top off coolant if low. Wet the cap sealing surfaces with water or coolant to prevent pressure leaks. Attach D05104ST pressure pump to radiator filler neck. c procedure, Caution: Avoid Injury! During testing do not exceed the pressure for which the system was designed. The maximum pressure is 102.7 kPa (14.9 psi). Specifications: 3. Pressurize system with tester to 60 kPa (8.7 psi). Begin Opening . . . . . . . . . . . 80.5 - 83.5° C (177- 182° F) Fully Open . . . . . . . . . . . . . . . . . . . . . . . . . 95° C (203° F) Minimum Lift Height Above 95° C (203° F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 mm (0.31 in.) 4. Check for leaks throughout cooling system. Results: • If thermostat does not open according to specifications, replace. • If closing action is not smooth and slow, replace thermostat. Results: • Pressure should hold to specifications. If pressure decreases, check for leaks. Repair leaks or replace parts as necessary. • If leakage continues after all external leaks have been stopped, a defective head gasket, cracked block, or cylinder head may be the cause. Engine - Gas (Liquid-Cooled) Tests and Adjustments - 50 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS Radiator Bubble Test 2. Attach adapter to D05104ST pressure pump. Reason: 3. Apply pressure. Pressure valve in cap should open according to specification. To determine if compression pressure is leaking past head gaskets and into cooling system. Specification: Procedure: Relief Valve Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . 78 - 98 kPa (11.3 - 14.2 psi) 1. With coolant at proper level and radiator cap tight, start and run engine to bring it to operating temperature. Results: 2. Disconnect overflow hose from coolant recovery tank. • If cap leaks, relieve pressure and retighten cap. Test again. Replace cap if pressure is not within specification. Water Pump/Alternator Drive Belt Adjustment Reason: To keep proper tension on belt to drive water pump and alternator. To prevent shortened belt and bearing life. Equipment: M55592a • JDG529 or JDST28 Belt Tension Gauge • Straight Edge Procedure: 1. Park machine safely. See Parking Safely in the Safety Section. 3. Put end of hose in a container of water. 4. Check for bubbles coming from hose. 2. Allow engine to cool. Results: • 3. Raise hood. If bubbles are present, replace head gaskets. Radiator Cap Pressure Test Reason: To test radiator cap for operating in correct pressure range. Test Equipment: • D05104ST Cooling System Pressure Pump • JDG692 Radiator Pressure Test Kit (Adapters) Procedure: MIF 4. Check belt tension between water pump and alternator using Belt Tension Gauge and a straight edge. Belt Tightening Specifications: Applied Force . . . . . . . . . . . . . . . . . . . . 98 N (22 lb-force) Deflection . . . . . . . . . . . . . 10 - 15 mm (0.400 - 0.600 in.) Results: T6333AX 1. Install radiator cap on appropriate adapter. If deflection is not within specifications: • Adjust belt tension. Engine - Gas (Liquid-Cooled) Tests and Adjustments - 51 ENGINE - GAS (LIQUID-COOLED) REPAIR Repair Adjusting Belt Tension: Thermostat Removal and Installation A 1. Park machine with park brake ON, transmission in NEUTRAL, and engine OFF. c boiling Caution: Avoid Injury! Coolant may be above temperature and under pressure in --cooling system. DO NOT remove pressure cap when system is hot. Escaping steam will burn unprotected skin. Always wear protective clothing and goggles when servicing cooling system B 2. Allow engine to cool before servicing cooling system. Squeeze top radiator hose to verify the system pressure has dropped before opening radiator cap. MX34242 1. Loosen adjusting bolt (A). 2. Loosen alternator bolts (B). 3. Place container under cooling system drain and open valve. Open radiator cap to speed up draining. Drain only enough coolant to lower coolant level below thermostat housing. 3. Push alternator inward to loosen belt, and outward to tighten belt. 4. Tighten bolts. D B A 5. Check belt tension. C A A E F MX15403 4. Loosen the hose clamps (A), and remove the three coolant hoses. 5. Unscrew the mounting bolts (C), and remove the thermostat body, enough to remove final clamp and hose (D). Remove thermostat body from engine. B G E F H MX14243 Engine - Gas (Liquid-Cooled) Repair - 52 ENGINE - GAS (LIQUID-COOLED) REPAIR 6. Remove the bolts (E), and separate the thermostat upper body (B) from the lower body (F). 6. Loosely install belt between sheave halves and start installing the three outer sheave-retaining nuts (E). 7. Remove thermostat (G) from upper body (B). Test or replace thermostat. See “Thermostat Test” on page 50. 7. Install and tighten mounting nuts (E) to 15 N•m (130 lbin.). 8. When installing thermostat, replace gasket (G) with a new one. 8. Install driveshaft, and tighten mounting cap screws (A) to 20 N•m (15 lb-ft). 9. Tighten bolts (E) to 10 N•m (87 lb-in.). 9. Check and adjust fan belt tension. See “Fan Belt Tension Adjustment” on page 49. Fan Belt Removal and Installation 10.Install and tighten spark plugs to 25 N•m (18 lb-ft). Note: Disconnect and remove spark plugs to allow for easy flywheel rotation during outer sheave half installation. Specifications: 1. Remove spark plugs. Note: Rotate outer sheave half as nuts are tightened to allow belt to center in sheave halves. Sheave Mounting Nuts (E). . . . . . . . . 15 N•m (130 lb-in.) Driveshaft Mounting Bolts (A). . . . . . . . 20 N•m (15 lb-ft) Spark Plug Torque . . . . . . . . . . . . . . . . . 25 N•m (18 lb-ft) Cooling Fan and Bracket Removal and Installation Important: Avoid Damage! Bearings are a press fit. Remove only if being replaced. To avoid pinching fan belt between flywheel and outer sheave half, rotate flywheel while tightening outer sheave half mounting cap screws. A B C F c 182°C Caution: Avoid Injury! DO NOT heat oil over (360°F). Oil fumes or oil can ignite above 193°C (380°F). Use a thermometer. DO NOT allow a flame or heating element to come in direct contact with the oil. Heat the oil in a wellventilated area. D E M81225a A- Mounting Cap Screws B- Outer Sheave Half C- Fan Belt D- Shim E- Mounting Nuts F- Drive Shaft G F C D E B 2. Remove three (3) cap screws (A) holding drive shaft (F) onto outer sheave half (B). H A I 3. Remove three (3) nuts (E) holding outer sheave half (B) and shim (D) to inner sheave half attached to flywheel. 4. Remove fan belt (C). Remove shim (D) if belt is to be tightened. Leave shim in if installing a new belt. O P D N J M L K 5. Install fan belt. MX14252 Note: Rotate sheave assembly as nuts are tightened to allow belt to center in sheave halves and not be pinched in an off-center position. A- Washer B- Snap Ring C- Bracket Engine - Gas (Liquid-Cooled) Repair - 53 ENGINE - GAS (LIQUID-COOLED) REPAIR • Note the position of different lengths of bolts so they can be installed in their original positions. D- Bearing (2 used) E- Mounting Flange F- Pulley G- Cap Screw H- Flanged Nut I- Fan J- Stud K- Pulley (outer half) L- Shim(s) M- Fan Belt N- Cap Screw O- Spacer P- Nut E 10 5 4 G 2 1 9 6 7 3 8 F 1. Heat mounting bracket (C) with bearings (D) in hot oil to remove bearings. Tap bearings from mounting bracket. 2. Install bearings using a bushing, bearing and seal driver set and press. 3. Assemble fan (I), and belt sheave (F) to mounting flange (E) and install fan assembly to engine. Tighten hardware to standard torque specifications. 4. Install fan belt, shim(s) (L), and outer sheave half (K) to flywheel. Tighten flange nuts (H) to 15 N•m (130 lb-in.). 5. Adjust belt tension. See “Fan Belt Tension Adjustment” on page 49. MX14253 2. Loosen the hose clamp (F) and disconnect the water hose (G) at the coolant inlet port of the water pump (E). 3. Unscrew the water pump bolts in the order shown, and remove the water pump assembly. Disassembly: Note: Do not attempt to remove the mechanical seal (F), oil seal (D), and O-Ring (J), unless they are to be replaced. A Coolant Pump Removal and Installation B Removing: C 1. Remove muffler. See “Muffler Removal and Installation” on page 58. N D E B F A G A H C M L K J I MX14256 D MX14253 A- Bolt, M8, 80 mm (3.15 in.) B- Bolt, M8, 45 mm (1.77 in.) C- Bolt, M8, 60 mm (2.36 in.) D- Bolt, M8, 30 mm (1.18 in.) A- Pump Gear B- Dowel Pin C- Washer D- Claw Washer E- Oil Seal F- Drainage Outlet Passage G- Mechanical Seal Cartridge H- Mating Ring Engine - Gas (Liquid-Cooled) Repair - 54 ENGINE - GAS (LIQUID-COOLED) REPAIR Pump Specifications: I- Cup Gasket J- Pump Shaft K- O-Ring L- Dowel Pin M- Impeller N- Pump Housing Shaft OD (Minimum). . . . . . . . . . . . . 9.94 mm (0.391 in.) Housing Shaft Bore/ID (Maximum) 10.09 mm (0.397 in.) Installing: B C N D B G A L A M O J E MX14255 K MX14255 1. Remove pump gear (A). 2. Remove dowel pin (B), washer (C), claw washer (D). 1. Remove the old gasket from pump cover and pump housing. Important: Avoid Damage! Do not get the sealant into the water line hole on the crankcase or the crankcase cover. Note: Mechanical seal (G) is sealed into place and will be difficult to remove. If mechanical seal parts are damaged, replace the seal as a set. 2. Apply sealant bead to the mating surfaces of the pump cover and pump housing. 3. Drive mechanical seal assembly (G) and remove oil seal (K) from the housing (N). Note: Recall position of different lengths of bolts (in removal procedure above). • If the mechanical seal (G) is damaged, the coolant leaks through the seal, and drains through the drainage outlet passage (F). • If the oil seal (E) is damaged, the engine oil drains through the drainage oil passage (F). Important: Avoid Damage! Check impeller for material break- down or deterioration. Replace the complete coolant pump if impeller is damaged. Flush cooling system to remove debris and add new coolant. 4. Remove dowel pin (L) from the pump shaft (J), and remove impeller (M). 5. Measure outside diameter of shaft (J). If less than specification or if it shows any signs of corrosion, replace it. 6. Measure pump shaft bore in housing (N). Replace housing if greater than specifications. 7. Inspect all parts for wear or damage. Replace as necessary. A 10 5 6 D 8 1 4 3 9 7 2 C MX14253 3. Install the mounting bolts, and tighten them in the order shown to 20 N•m (15 lb-ft). 4. Install hose (D) and hose clamp (C) to the coolant inlet port of the water pump cover (A). Note: When installing impeller assembly to housing, coat mating surfaces with clean water. Engine - Gas (Liquid-Cooled) Repair - 55 ENGINE - GAS (LIQUID-COOLED) REPAIR Radiator Removal and Installation G H c boiling Caution: Avoid Injury! Coolant may be above temperature and under pressure in --cooling system. DO NOT remove pressure cap when system is hot. Escaping steam will burn unprotected skin. Always wear protective clothing and goggles when servicing cooling system. I J K Note: Cooling system capacity is approximately 2.8 L (3.0 qt). 1. Drain coolant. L MX14398 B A 6. Loosen clamp (G), and remove air cleaner hose (H) from air cleaner housing. 7. Loosen throttle cable clamp at throttle linkage and move throttle cable (K) from top of radiator shroud (L). Note: There is also a choke control cable equipped on FD671D engines that will need to be moved in order to move radiator shroud. C D 8. Remove bolts and nuts (J) on both sides of machine. Move radiator shroud (L) towards front of machine, over engine fan. E 9. Remove four screws (I) holding radiator to pedestal, and remove radiator from machine. F MX14397 Picture Note: FD750D engine shown 2. Remove hoses (B and F). 3. Remove side panel (A) and side panel on opposite side of machine. 4. Remove recovery tank (C). 5. FD750D engine: Remove screw holding bracket for fuel filter (E) and fuel line (D). Move fuel filter and fuel lines toward engine to be able to move radiator shroud forward. c toCaution: Avoid Injury! Reduce compressed air less than 210 kPa (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection. 10.Check radiator for debris lodged in fins. Clean radiator using compressed air or pressure washer. 11.Inspect radiator for bent fins, cracks and damaged seams. Repair as necessary. Engine - Gas (Liquid-Cooled) Repair - 56 ENGINE - GAS (LIQUID-COOLED) REPAIR C B D E A F P G O H A I N K M K J L MIF A- Hose Clamp B- Radiator Hose (Return) C- Screw (3 used D- Radiator Shroud E- Filler Cap F- Radiator G- Overflow Hose H- Bracket I- Clip, Oil Radiator Mount J- Foam Pad K- Clip L- Screen M- Flange Nut N- Screw O- Radiator Hose (Supply) P- Support Bracket Installation is done in the reverse order of removal. • Close drain valve and fill radiator with proper coolant to top of filler neck. • Start engine and allow it to reach proper operating temperature. Check radiator, hoses and connections for leaks. Adjust coolant level in recovery tank. Engine - Gas (Liquid-Cooled) Repair - 57 ENGINE - GAS (LIQUID-COOLED) REPAIR Muffler Removal and Installation F 1. Disconnect headlight connector and remove hood. 2. Disconnect and remove battery. G G MX16206 8. Unscrew the four (4) flange nuts (G), and remove the spring washers and engine hook (F) on No. 1 cylinder side. A B I MX14370 Picture Note: Battery shield, right side view. H 3. Remove two cap screws (A) securing side brackets of battery shield to frame and two nuts (B) securing hood brackets to frame. D I E MX16207 9. Remove the four (4) bolts (I) on the muffler bracket and take off the muffler assembly (H). C 10.Remove the gaskets. MX14374 4. Remove cap screw (C) that secures battery shield to top of frame. 5. Compress positive battery cable retainer clip (D) and separate cable from battery shield. 6. Loosen two cap screws that secure slotted mounting holes in battery shield to back of frame at locations marked (E). 7. Lift and remove battery shield. 11.Inspect the exhaust pipe or muffler for dents, cracks, rust or holes. check for breaks in seems and loose internal components. Replace muffler if any considerable damage is found. 12.Clean the exhaust pipe flanges to the exhaust port gasket surfaces, and install new gaskets each time the muffler is installed. Note: To prevent mis-threading, finger tight the flange nuts first. Next tighten the bolts on the muffler bracket. 13.Install the muffler, engine hook, spring washers, and nuts. Tighten nuts (G) to 20 N•m (180 lb-in.). Engine - Gas (Liquid-Cooled) Repair - 58 ENGINE - GAS (LIQUID-COOLED) REPAIR Air Cleaner Removal and Installation F- Paper Filter G- Case H- Cap Screw I- Case J- Gasket K- Grommet L- Air Temperature Sensor, FD750D only M- Clamp N- Hose O- Cap Screw P- Vacuum Sensor, FD750D only Q- Bracket R- Cap Screw S- Seal T- Stud B C A D E F 1. Inspect precleaner and paper element for dirt and dust. 2. Clean precleaner if necessary by washing in warm, soapy water. 3. Rinse in clean water. Squeeze to remove water. 4. Let air dry. G Important: Avoid Damage! DO NOT wash paper element. Clean or replace paper element as necessary. T S 5. Apply 30 mL (1 oz) of clean engine oil to precleaner. Squeeze to distribute oil evenly and to remove excess oil. H 6. Tap paper element gently to remove dust. R 7. Replace element if oily, dirty or damaged. I Q 8. Apply Thread Lock and Sealer (Medium Strength) on mounting screws before installation. 9. When installing breather hose, Make certain hose end is fully seated in the air cleaner base and the hose is not kinked. P J O K M N M L MX14261 Picture Note: FD750D air cleaner assembly shown A- Nut B- Washer C- Cover D- Wing Nut E- Foam Filter Engine - Gas (Liquid-Cooled) Repair - 59 ENGINE - GAS (LIQUID-COOLED) REPAIR Carburetor Removal and Installation (FD671D) c flammable Caution: Avoid Injury! Gasoline is extremely and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke, and make sure the area is well ventilated and free from any source of flame or sparks. Disassembly and Assembly: D C B E A Removing: 1. Remove air cleaner and related parts. See “Air Cleaner Removal and Installation” on page 58. 2. Remove radiator. See “Radiator Removal and Installation” on page 56. F L 3. Remove cooling fan and fan belt. See “Cooling Fan and Bracket Removal and Installation” on page 53. K C A D J I G H MX16197 B MX16196 4. Turn the fuel shut off valve to the off position. 5. Drain the carburetor. 6. Disconnect the fuel tube at the fuel inlet joint (A) of the carburetor. 7. Disconnect the solenoid valve lead terminal. 8. Unscrew the intake pipe and carburetor mounting bolts (B). 9. Unhook the throttle (C) and choke link rod (D) at the ends of their arms while pulling off the carburetor. A- Spring B- Pilot Screw C- Limiter D- Cover Assembly E- Pilot Jet F- Choke Valve Assembly G- Throttle Valve Assembly H- Float Chamber Assembly I- Main Jet (L) J- Main Jet (R) K- Float Assembly L- Screw 1. Refer to the illustration shown for disassembly and assembly. Important: Avoid Damage! Do Not clean holes or passages in the carburetor body with sharp objects such as wire or small drill bits. • There are several passage plugs (ball plugs) in the carburetor body. Do not remove them. • Before disassembly, mark the outside of the choke valve and throttle valves for assembling them. Engine - Gas (Liquid-Cooled) Repair - 60 ENGINE - GAS (LIQUID-COOLED) REPAIR c and Caution: Avoid Injury! When cleaning rubber plastic carburetor parts, use a cleaning • If the float position is not correct, bend the tab as required for correct adjustment. solvent with a high flash point that will not damage the components. 2. Inspect moving parts such as shafts, choke and throttle plates etc. for wear or damage. Replace if necessary. 3. Check the carburetor body and float chamber for cracks, nicks or other damage. Replace components as necessary. 4. Remove all rubber and plastic parts from the carburetor. Soak all metal carburetor parts in cleaning solvent for a maximum of 1/2 hour. 5. Spray all internal passages and jets in the carburetor body with a spray carburetor cleaner to verify that passages and jets are open. S T MX16199 9. Inspect the float valve for excessive wear or damage. Important: Avoid Damage! Rinse carburetor body in warm water immediately after using carburetor cleaning solvent or spray to neutralize corrosive action of cleaner on aluminum. • The tip should be smooth, without any grooves, scratches, or tears (S). The rod at the opposite end of the needle should move smoothly when pushed in and released. 6. Rinse carburetor with warm water and dry with compressed air. Do Not use rags or paper to dry parts as lint may plug holes or passages. • If either the valve or the valve seat is worn or damaged (T), replace the float assembly and carburetor as a set. 7. Inspect all parts for wear or damage, replace as necessary. 8. Clean and check the float level as follows: c the Caution: Avoid Injury! Do not push down on float (K) during float level checking. K N O M 10.Replace the pilot screw in accordance with the following procedure, if necessary: • Carefully mark the position of the pilot screw limiter on the carburetor body so that it can be installed and set to its original position later. • Remove the limiter, being careful not to turn the pilot screw at this time. • Turn the pilot screw clockwise and count the number of turns until screw is gently seated in the pilot passage. Record the number of turns needed to close the screw. • Q Turn out the pilot screw to replace it with a new one. U V P R MX16198 • With the float (K) assembly installed onto the carburetor body (R), hold the carburetor upside down at an eye level. Gently support the float with a finger and bring it down slowly so that the float arm tab (P) just touched the float valve (O). The float arm surface (N) should be parallel (M) with the carburetor body mating surfaces (Q). MX16200 11.Inspect the tapered portion (V) of the pilot screw (U) for wear or damage. • If the pilot screw is worn or damaged on the taper portion of it, replace it. Engine - Gas (Liquid-Cooled) Repair - 61 ENGINE - GAS (LIQUID-COOLED) REPAIR • Check the spring for a weakened condition; replace it, if necessary. 12.Install the new pilot screw until the screw is gently seated. Then open the screw the same number of turns as recorded prior to removal. • Align the limiter with the mark on the carburetor body to install, taking care not to turn the pilot screw. Throttle Body Removal and Installation (FD750D) Removing: c flammable Caution: Avoid Injury! Gasoline is extremely and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke, and make sure the area is well ventilated and free from any source of flame or sparks. Installing: C A D 1. Remove air cleaner and related parts. See “Air Cleaner Removal and Installation” on page 58. 2. Remove radiator. See “Radiator Removal and Installation” on page 56. 3. Remove cooling fan and fan belt. See “Cooling Fan and Bracket Removal and Installation” on page 53. B 4. Remove fan mounting holder. 5. Turn the fuel shut off valve to the OFF position. MX16196 1. Clean the mating surfaces of the carburetor, insulator and intake pipe, and fit new gaskets. c pressurized Caution: Avoid Injury! Release of fluids from fuel system can cause serious injuries. Relieve fuel system pressure before servicing. Important: Avoid Damage! Take care not to bend the throttle (C) and choke (D) link rods during installation. C B D E 2. Install the gaskets, insulator, carburetor and intake pipe with mounting bolts (B), and tighten them to 12 N•m (106 lb-in.). 3. Install fuel tube at the fuel inlet joint (A). F E A G I F H MX16210 6. Loosen the fuel pressure relief screw (B) to relieve the high pressure in the return fuel hose (C), and then tighten it. MX16201 • Be sure the fuel tube clip ends (F) face toward the intake manifold (E) as shown. 4. Adjust idle speed. 7. Disconnect the fuel return hose (C). 8. Disconnect the inlet fuel hose (D) coming from the fuel pump, and the fuel return hose (E), and drain all the fuel in the hoses into a suitable container. 5. Install remaining components reverse of removal. Engine - Gas (Liquid-Cooled) Repair - 62 ENGINE - GAS (LIQUID-COOLED) REPAIR 9. Disconnect the breather hose (H). Note: Recall position of longer and shorter cap screws when removing throttle body assembly. 10.Unscrew the intake pipe and throttle body assembly long mounting bolts (F), short mounting bolts (I), and nuts (G). 11.Unhook the throttle link rod (A) at both ends before pulling off the throttle body assembly and fuel pressure regulator. Disassembly and Assembly: Note: Do not attempt to remove the throttle valve and shaft unless they appear to be damaged. Note: Take care not to bend the throttle link rod during installation. 2. Install the gaskets, throttle body assembly, and intake pipe with mounting bolts and tighten them to 12 N•m (106 lb-in.). 3. Install remaining fuel hoses and be sure they are clamped securely in place. 4. Adjust idle speed. See “Low Idle Speed Adjustment” on page 42. Fuel Injector Removal and Installation (FD750D) c flammable Caution: Avoid Injury! Gasoline is extremely and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke, and make sure the area is well ventilated and free from any source of flame or sparks. K J Procedure: c pressurized Caution: Avoid Injury! Release of fluids from fuel system can cause serious L injuries. Relieve fuel system pressure before servicing. M MX16211 1. Remove the screws (M), and remove the throttle valves (K). 1. Turn the fuel shut off valve to the OFF position. 2. Relieve fuel line pressure: 2. Remove the circlip (L), and pull out the throttle shaft (J). 3. Before assembling, thoroughly clean the throttle body of dirt by applying compressed air. A Note: Replace the dust seal of the throttle shaft with a new one. 4. Apply engine oil to the new dust seal and insert the throttle shaft (J). 5. Install the throttle shaft into the throttle body. Note: After tightening screws (M), be sure that the throttle valves are positioned properly, and the throttle shaft moves freely without any irregularities. 6. Install the throttle valves (K). Applying a non-permanent locking agent to the screws (M), secure valves with screws. Tighten screws to 0.9 N•m (8 lb-in.). MX15401, MX15402 a. Loosen fuel pressure relief screw (A) on left side of machine to relieve pressure. b. Tighten relief screw. Installing: 3. Remove air cleaner and related parts. See “Air Cleaner Removal and Installation” on page 58. 1. Clean the mating surfaces of the throttle body assembly and intake pipe, and install new gaskets. 4. Remove radiator. See “Radiator Removal and Installation” on page 56. Engine - Gas (Liquid-Cooled) Repair - 63 ENGINE - GAS (LIQUID-COOLED) REPAIR 5. Remove cooling fan and fan belt. See “Cooling Fan and Bracket Removal and Installation” on page 53. 14.Securely place the projections (E) of the injector cap into the holes (F) of the intake. 6. Remove fan mounting holder. 15.Connect the injector connector and injector cap. 7. Remove throttle body assembly. See “Throttle Body Removal and Installation (FD750D)” on page 62. 16.Install the throttle body, control panel assembly, radiator, and air cleaner assemblies reverse of removal. Fuel Pressure Regulator Removal and Installation (FD750D) C B 1. Remove air cleaner assembly. See “Air Cleaner Removal and Installation” on page 58. c pressurized Caution: Avoid Injury! Release of fluids from fuel system can cause serious injuries. Relieve fuel system pressure before servicing. D C MX16215 A 8. Remove the injector cap (B). 9. Disconnect the injector connector (C). B D Important: Avoid Damage! Never drop the injector, especially on a hard surface. This can permanently damage the injector. 10.Pull out the fuel injector (D) from the intake manifold. Note: Take care not to damage the injector inserts when they are pulled from the throttle body. MX14288 11.Inspect injector for damage and test injector. See “Fuel Injector Test - X720/X724/X728” on page 225 in the Electrical section. 12.Before assembly, replace any seals and O-Rings with new ones. Apply engine oil to the seal(s) and O-Ring(s). E 2. Loosen the fuel pressure relief screw (A) to relieve the high pressure in the return fuel hose, and then tighten it. 3. Remove vacuum hose (B) and fuel return hose (C). 4. Remove two bolts (D) and remove the regulator. 5. Check the vacuum tube hose (B), fuel return hose (C) and O-Ring for brittleness, cracks, or damage, and replace if necessary. F 6. Apply engine oil to the O-Ring. 7. Install fuel pressure regulator, vacuum hose (B) and clamp, and fuel return hose (C) and clamp. 8. Tighten the two bolts (D). MX16217 13.Install the injector into the intake manifold. Engine - Gas (Liquid-Cooled) Repair - 64 ENGINE - GAS (LIQUID-COOLED) REPAIR Cylinder Head Removal and Installation (G). If it is not at TDC, turn the flywheel clockwise one turn (360°). Removing: 1. Remove radiator and it’s bracket. 2. Remove air cleaner and carburetor assemblies See “Carburetor Removal and Installation (FD671D)” on page 60 or See “Throttle Body Removal and Installation (FD750D)” on page 62. 3. Remove muffler. See “Muffler Removal and Installation” on page 58. • When setting the flywheel a TDC of the #2 cylinder, turn the flywheel magnet (F) clockwise from position at TDC. of #1 cylinder to the #2 ignition coil (E). If it is not at TDC, turn the flywheel clockwise one turn (360°). Important: Avoid Damage! Cylinder head can be warped during removal if the correct head bolt removal procedure is not followed. 3 4. Remove intake manifold. See “Intake Manifold Removal and Installation (FD671D)” on page 66 or “Intake Manifold Removal and Installation (FD750D)” on page 67. 1 B A 6 5 A C 4 2 D MX11613 MX16112 5. Remove spark plug(s) (D). 6. Unscrew the eight (8) rocker cover mounting bolts (A), and remove the left (B) and right (C) covers and gaskets. Note: No. 1 cylinder is the left cylinder when sitting in the drivers seat, No. 2 cylinder is the right. 8. Loosen the cylinder head bolts 1/4 turn in the sequence shown. Repeat the sequence until all bolts are removed and lift off the cylinder head assembly. Note: If removing push rods, Mark each rod for assembly in original location. 9. Clean the mating surfaces of the cylinder heads and cylinder of all old gasket material and sealing compound. Installing: F E #2 1. Install push rods in their original positions if removed. See “Push Rod/Rocker Arm Removal and Installation” on page 77. G #1 F E #2 G #1 MX14236 7. Before removing the cylinder head, the piston should be set to TDC (Top Dead Center) on the intake stroke for the cylinder you are working on. This can be determined by the position of the flywheel magnet (F) in relation to the coils. • When setting the flywheel a TDC of the #1 cylinder, align the flywheel magnet (F) with the #1 ignition coil MX14236 2. Set the cylinder you are working on to TDC of intake power stroke. Engine - Gas (Liquid-Cooled) Repair - 65 ENGINE - GAS (LIQUID-COOLED) REPAIR • When setting the flywheel a TDC of the #1 cylinder, align the flywheel magnet (F) with the #1 ignition coil (G). If it is not at TDC, turn the flywheel clockwise one turn (360°). • When setting the flywheel a TDC of the #2 cylinder, turn the flywheel magnet (F) clockwise from position at TDC of #1 cylinder to the #2 ignition coil (E). If it is not at TDC, turn the flywheel clockwise one turn (360°). • 3 N•m (27 lb-in.) • 15 N•m (11 lb-ft) • 27 N•m (20 lb-ft) 7. Check valve clearance and adjust if necessary. See “Valve Clearance Adjustment” on page 43. 8. Install gasket and rocker cover, tightening rocker cover mounting bolts to 6.9 N•m (61 lb-in.). 9. Install spark plugs, intake manifold, muffler, carburetor, air cleaner, and radiator in reverse order of disassembly. H I Intake Manifold Removal and Installation (FD671D) Removing: 1. Remove air cleaner assembly. See “Air Cleaner Removal and Installation” on page 58. I A MX16114 3. Install the two alignment pins (I) in the cylinder head assemblies (if removed). Important: Avoid Damage! Cylinder head gaskets (H) are coated with sealing agents. Gasket leaks could occur if the sealing compound is scratched or damaged. D 4. Position new gaskets (H) on the cylinders. 5. Lower the cylinder head, with push rods aligned under the rocker arms. 4 6 C B MX16110 2. Remove muffler and two cap screws (C) securing control panel. 3. Remove the control panel assembly (B), while unhooking the governor spring (D) end loop at the panel bracket. 4. Clear the choke link rod end (A) form the choke lever. 1 2 5. Remove carburetor. See “Carburetor Removal and Installation (FD671D)” on page 60. 6. Drain the coolant in the engine. 5 3 MX11613 6. Install the cylinder head bolts, noting the position of different length bolts. Tighten in the sequence shown above. Use a torque wrench and tighten in the following steps to prevent warping the head: Engine - Gas (Liquid-Cooled) Repair - 66 ENGINE - GAS (LIQUID-COOLED) REPAIR 8 6 3.0 N•m (27 lb-in.) at a time, until the torque on each bolt is 20 N•m (15 lb-ft). 4. Fill engine coolant. E 5. Install the carburetor, control panel assembly, and air cleaner assembly reverse of removal. 2 4 3 Intake Manifold Removal and Installation (FD750D) 1 Removing: 5 7 F MX16111 c pressurized Caution: Avoid Injury! Release of fluids from fuel system can cause serious injuries. Relieve fuel system pressure before servicing. 7. Unscrew the manifold mounting nuts in numerical sequence, 1/4 turn at a time, until all bolts are loose. 8. Remove the manifold (E) and gaskets (F). 9. Inspect the intake manifold for signs of cracks or porous spots. Fuel stains on the surface of the manifold often indicate a suspect area. Inspect the manifold gasket mounting surfaces for burned areas or nicks and gouges. Replace the intake manifold if it is cracked, or the gasket mounting surfaces are damaged to the point they will not seal properly with new gaskets. Visually inspect the coolant passage in the manifold for deposits or corrosion in layer inside the passage; clean the passage if necessary. 10.Clean all old gasket residue off the mating surfaces of the intake manifold and the cylinder heads. Install new gaskets. 1. Remove air cleaner assembly. See “Air Cleaner Removal and Installation” on page 58. 2. Drain the coolant in the engine, and remove radiator. See “Radiator Removal and Installation” on page 56. B A C D Installing: E F 8 6 MX16214 E 3. Remove two cap screws (B) and bracket (A). 2 4 3 4. Remove two cap screws (E) securing control panel. 5. Clear the throttle link rod end (C) from the choke lever. 6. Remove the control panel assembly (D), while unhooking the governor spring (F) end loop at the panel bracket. 1 5 F 7. Remove throttle body assembly. See “Throttle Body Removal and Installation (FD750D)” on page 62. 7 MX16111 1. If removed, install the cylinder heads on each cylinder and tighten the head bolts. See “Cylinder Head Removal and Installation” on page 65. 2. Place new gaskets (F) on each mating surface, and install the manifold (E). 3. Tighten the manifold mounting bolts in sequence above, Engine - Gas (Liquid-Cooled) Repair - 67 ENGINE - GAS (LIQUID-COOLED) REPAIR Installing: I H 5 G 3 8 2 L J K 4 1 7 6 MX16215 8. Disconnect fuel injector leads (J), water temperature lead (G), vacuum sensor lead (H), and thermo switch lead (I). 5 3 1. If removed, install the cylinder heads on each cylinder and tighten the head bolts. See “Cylinder Head Removal and Installation” on page 65. 2. Place new gaskets on each mating surface, and install the manifold (L). 8 2 MX16216 L 3. Tighten the manifold mounting bolts in sequence above, 3.0 N•m (27 lb-in.) at a time, until the torque on each bolt is 20 N•m (15 lb-ft). I H 7 1 4 G 6 MX16216 9. Unscrew the manifold mounting nuts in numerical sequence, 1/4 turn at a time, until all bolts are loose. J 10.Remove the manifold (L) and gaskets. 11.Inspect the intake manifold for signs of cracks or porous spots. Fuel stains on the surface of the manifold often indicate a suspect area. Inspect the manifold gasket mounting surfaces for burned areas or nicks and gouges. Replace the intake manifold if it is cracked, or the gasket mounting surfaces are damaged to the point they will not seal properly with new gaskets. Visually inspect the coolant passage in the manifold for deposits or corrosion in layer inside the passage; clean the passage if necessary. 12.Clean all old gasket residue off the mating surfaces of the intake manifold and the cylinder heads. Install new gaskets. K MX16215 4. Connect fuel injector leads (J), water temperature lead (G), vacuum sensor lead (H), and thermo switch lead (I). 5. Fill engine coolant. 6. Install the throttle body, control panel assembly, radiator, and air cleaner assembly reverse of removal. Engine - Gas (Liquid-Cooled) Repair - 68 ENGINE - GAS (LIQUID-COOLED) REPAIR Starting Motor Removal and Installation 1. Disconnect battery negative terminal (-). 2. Pull back the rubber boot and remove the lead (A) from the starter motor to the solenoid. C A B C B MX11971 MX14279 3. Unscrew the mounting nuts (B) and remove the solenoid assembly (C). 2. Disconnect battery terminal and leads from starting motor solenoid terminal (B). D F 3. Disconnect switch lead (A) from starting motor. 4. Remove the two (2) mounting bolts (C) and pull the starter motor from the engine. G E 5. Clean the starter motor and engine mounting flanges to ensure good electrical contact when installing starter. If corrosion is evident on either machined mounting surface, clean the area with emery cloth or sandpaper. 6. Install the starter, and two mounting bolts (C). Tighten mounting bolts to 20 N•m (180 lb-in.). G 7. Install all electrical leads in reverse order of removal. Install negative battery terminal (-). Starter Motor Disassembly and Assembly 1. Remove the starter motor from the engine. See “Starting Motor Removal and Installation” on page 69. MX11972 4. Pull the rubber insert (D) from the starter motor and remove the pinion gear cover (E). Slip the actuating arm (F) from the pinion gear. Remove the motor through bolts (G). H A I MX11973 5. Pull the armature (H) from the yoke (I). MX11970 Engine - Gas (Liquid-Cooled) Repair - 69 ENGINE - GAS (LIQUID-COOLED) REPAIR T T L L M J K MX11974 MX11974 6. Separate the front stopper (J) from the rear stopper (K) and remove the front stopper from the armature shaft. Push the rear stopper down the shaft and remove the snap ring (L). Pull the rear stopper and pinion gear (M) from the armature shaft. 9. Before beginning assembly apply a small amount of electric grease to the indicated areas (T) of the armature shaft. Obtain a new snap ring (L). Assemble the pinion gear on the armature shaft with the new snap ring and install the pinion assembly and actuating arm. Slide the yoke over the armature. U N O MX11979 MX11975 7. Pull the end cover (N) from the yoke and remove the insulator (O). 10. Inspect the solenoid rubber boot (U) for visible damage (hole, rips, dry rot etc.); replace if necessary. V S P W Q N R MX11975 MX11976 8. Remove the brush springs (P) from the brush holder (Q). Separate the brushes (R) from the holder and remove the holder from the yoke (S). 11. Install the brush assembly and insulator on the yoke. Fit the notch (V) in the (-) lead grommet onto the projection (W) on the end cover (N). Install the end cover. Engine - Gas (Liquid-Cooled) Repair - 70 ENGINE - GAS (LIQUID-COOLED) REPAIR Starting Motor Inspection 1. Disassemble starter. See “Starter Motor Disassembly and Assembly” on page 69. X A Y MX11981 12. Grease the pinion gear fork fingers, and set the pinion gear fork so that the fingers fit into the groove in the gear. Fit the notch (Y) in the yoke onto the projection (X) on the pinion gear fork. Install the through bolts through the rear cover and thread into the pinion gear cover. Z MX11984 2. Measure length of brush (A). If any brush is shorter than 6 mm (0.24 in.), replace all brushes. Inspect the brush springs for any distortion or damage. Replace if necessary. C MX11979 B 13. Engage the hook (Z) on the starter solenoid with the pinion gear fork. Install the solenoid mounting nuts. 14. Install the solenoid to starter motor lead. Install the starter assembly onto the engine. See “Starting Motor Removal and Installation” on page 69. MX11980 3. Inspect the surface of the commutator. If the surface is scratched or dirty, polish it with very fine emery cloth (B) and then clean out the grooves (C). D E F MX11987 Engine - Gas (Liquid-Cooled) Repair - 71 ENGINE - GAS (LIQUID-COOLED) REPAIR 4. Measure the depth of the grooves between the commutator segments (D). If groove depth is less than 0.2 mm (0.008 in.) undercut the insulating mica (E) to the standard depth (F) of 0.5 to 0.8 mm (0.012 to 0.031 in.) using a thin file. If grooves are only dirty, clean them carefully and measure depth before cutting the mica. 7. Set a multimeter to the R x 1 ohm position and check the resistance between each segment and all others. If the armature winding resistance registers either infinite or much greater than 0 ohms the starter motor should be replaced. MX11991 MX11988 5. Measure the commutator outside diameter at several points. If the diameter is less than 27 mm (1.06 in.) replace the armature with a new one. 8. With the multimeter in the R x 1 ohm position measure the resistance between the armature shaft and the commutator. If the resistance is less than infinite, the armature is shorted and must be replaced. G MX11989 6. Support the armature in an alignment jig at each end of the shaft as shown. Position a dial indicator perpendicular to the commutator. Rotate the armature slowly and read the commutator runout. If runout is more than 0.4 mm (0.016 in.) replace the armature. MX11992 9. Place the armature on a growler (G) and hold a thin metal strip (e.g. a hack saw blade) on top of the armature. Turn on the growler and rotate the armature one complete turn. If the metal strip vibrates, the windings are internally shorted to each other and the starter must be replaced. MX11990 Engine - Gas (Liquid-Cooled) Repair - 72 ENGINE - GAS (LIQUID-COOLED) REPAIR 12.Remove the pinion clutch and turn it by hand. The clutch should turn freely counterclockwise, and lock up and not turn in a clockwise direction. If the clutch does not operate correctly or is noisy when freewheeling, replace it. + Engine Removal and Installation Prepare Machine: • Park machine safely. See “Park Machine Safely” in the SAFETY section. - • Allow engine to cool. • Open hood. MX11998 10.With the multimeter in the Rx 1k ohm position, measure the resistance between the positive brushes and starter motor yoke. If resistance is less than infinite on any brush, the brush is shorted and the complete yoke assembly must be replaced. Removing: 1. Disconnect headlight connector and remove hood. 2. Remove radiator cap and drain coolant into a clean container. 3. Disconnect and remove upper and lower radiator hoses. 4. Loosen clamp and remove air cleaner intake hose. 5. Disconnect and remove battery. - - MX12000 11.With the multimeter in the Rx 1 ohm position, measure the resistance between the negative brushes and starter motor yoke. If resistance is less than infinite on any brush, the brush is shorted and the complete yoke assembly must be replaced. A B MX14370 Picture Note: Battery shield, right side view. 6. Remove two cap screws (A) securing side brackets of battery shield to frame and two nuts (B) securing hood brackets to frame. MX14440 Engine - Gas (Liquid-Cooled) Repair - 73 ENGINE - GAS (LIQUID-COOLED) REPAIR H L D E K G C P I O M R N MX14374 Q 7. Remove cap screw (C) that secures battery shield to top of frame. J 8. Compress positive battery cable retainer clip (D) and separate cable from battery shield. MX14376 9. Loosen two cap screws that secure slotted mounting holes in battery shield to back of frame at locations marked (E). 10.Lift and remove battery shield. 11.Remove right side lift bracket and muffler. See “Muffler Removal and Installation” on page 58. Picture Note: Fuel injected engine, left side. 13.Disconnect the wiring harness plug-in connectors (G, H, I, J) and bullet connector (K). Note: The carburated engine will have fewer connectors than the fuel injected engine shown. 14.Remove the retaining bolt at the rear of the left cylinder head, remove wire harness J-clip and disconnect ground wire (L). 15.Disconnect positive battery cable (M) and power lead bundle (N) at the starting motor terminal and unplug solenoid wire (O). 16.Disconnect the engine ground strap (P) and the main wiring harness ground wire bundle (Q) by removing the left front engine mount bolt (R), washer and nut. F S T U MX14375 12.Install lift bracket (F) back onto right side muffler flange studs. Use two muffler flange nuts as spacers, then bracket, then two remaining nuts to secure bracket to studs. This will prevent damage to valve cover from lifting hook during removal and installation. MX14378 Picture Note: Throttle cable and shield, fuel injected engine. 17.Remove two cap screws retaining throttle linkage shield (S) and remove shield. Engine - Gas (Liquid-Cooled) Repair - 74 ENGINE - GAS (LIQUID-COOLED) REPAIR 18.Loosen throttle cable clamp (T) and disconnect cable (U). W Y V MX15401, MX14502 MX15403 Picture Note: Carburated engine fuel lines. 19.Disconnect and plug the fuel supply line (V) and fuel return line (W) on carburated engine. Picture Note: Fuel pressure relief screw, fuel injected engine. 21.Release fuel pressure by loosening pressure relief screw (Y), then tighten screw. Z X X AA X AB MX13614 AC 20.Remove the three cap screws (X) at the rear of the drive coupler and disconnect drive shaft from engine sheave. Note: Fuel lines may be pressurized on the fuel injected engine. Relieve pressure prior to servicing fuel lines or components. AC MX16001 Picture Note: Fuel injected engine, right side. 22.Disconnect and plug the fuel return line (Z), and disconnect the supply line quick-coupler (AA) at the top of the fuel filter (AB), on the fuel injected engine. 23.Remove the two right side engine mount bolts (AC), washers and nuts, and the left rear motor mount bolt, washer and nut. 24.Detach any hydraulic lines that may be supported by Jclips or other hardware connected to the bottom of the engine. Engine - Gas (Liquid-Cooled) Repair - 75 ENGINE - GAS (LIQUID-COOLED) REPAIR Note: If no spreader bar is available, remove air cleaner assembly and cover fuel injection air intake hole with a clean shop rag to prevent entry of foreign objects. 9. Secure any hydraulic hoses, if removed in an earlier step, to appropriate hardware attached to the bottom of the engine. 10.Secure wire harness J-clip and ground wire to back of left cylinder head with retaining bolt and tighten. AD 11.Connect main wire harness plug-in connectors and bullet connector to the corresponding engine connectors. 12.Connect the main wiring harness power lead bundle and positive battery cable to the starter terminal, and connect the solenoid plug. 13.Connect and adjust throttle cable. See “Throttle Cable Adjustment” on page 40. 14.Install throttle cable shield. 15.Remove the right side lift bracket and four flange nuts from the muffler flange studs. 16.Install new muffler gaskets. 17.Install the muffler and the right side lifting bracket in their original locations and tighten mounting hardware. See “Muffler Removal and Installation” on page 58. 18.Install battery shield and attach positive battery cable retainer clip. 19. Install battery and connect positive battery cable. MX16004 25.Connect engine hoist to lift hooks on engine using spreader bar (AD) with lift chains to avoid damage to air cleaner during removal. 20.Install and tighten upper and lower radiator hoses. 21.Replace radiator coolant. 22.Install hood and connect headlight plug. 23.Connect negative battery cable. 26.Lift engine slightly and pull away from radiator to clear shroud and fuel filter, then remove engine from machine. Installing: 1. Lower the engine so that it rests slightly on the engine mounts. 2. Align the engine and mounts, then install the two right side and the left rear engine mount bolts, washers and nuts finger tight. 3. Lower engine fully, disconnect hoist from engine lifting brackets and remove hoist. 4. Route ground wire bundle from main wiring harness to original position by left front engine mount. 5. Install engine ground strap and ground wire bundle from main wiring harness with left front engine mount hardware, tighten hardware finger tight. 6. Tighten all engine mount bolts to 50 N•m (37 lb-ft). 7. Align drive coupler with engine sheave, install drive coupler mounting bolts and tighten to 40 N•m (30 lb-ft). 8. Unplug and connect fuel return hose and connect fuel supply hose quick-coupler to fuel filter. Engine - Gas (Liquid-Cooled) Repair - 76 ENGINE - GAS (LIQUID-COOLED) REPAIR Flywheel Removal and Installation Specification: Flywheel Bolt . . . . . . . . . . . . . . . . . . . . . 56 N•m (41 lb-ft) Procedure: 1. Park machine safely. See Parking Machine Safely in Safety section. Push Rod/Rocker Arm Removal and Installation 2. Remove engine from machine. See “Engine Removal and Installation” on page 73. Removing: 3. Remove plastic cover surrounding lower half of flywheel, and outer sheave attached to flywheel. 1. Set the piston on the cylinder you are working on at top dead center (TDC) of the power stroke. 2. Remove rocker covers. See “Cylinder Head Removal and Installation” on page 65. C B A B A C B A E D D MX16077 4. Hold flywheel with strap and remove flywheel bolt (A). 5. Thread a flywheel puller into the pulling holes (B) and remove the flywheel. 6. To remove stator coil, see “Stator Replacement” on page 230 in the Electrical section. 7. To remove ignition coil, see “Ignition Coil Replacement and Adjustment” on page 230 in the Electrical section. 8. Align the flywheel keyway with the key on the crankshaft and install flywheel. MX11613 3. Remove the valve clearance adjusting nuts (A), washers, and bolts (C). 4. Remove the rocker arms (E), along with collars (D), to provide access to the push rods (B). Pull out the push rods and mark each rod so it can be installed in the original position during reassembly. G C F F MX16115 MX16079 5. Remove two bolts (F) and rocker arm bracket (G). 9. Install spring washer (C) as shown. 10.Install and tighten the flywheel bolt. 11.Install engine into machine. Engine - Gas (Liquid-Cooled) Repair - 77 ENGINE - GAS (LIQUID-COOLED) REPAIR Inspection: H D J I MX16116 • Clean the rocker arms and inspect the push rod and valve stem contact points (I). If the contact surfaces are excessively worn or show signs of galling or surface flaking, replace the rocker arm. • Measure the inside diameter of the rocker arm bearing (B) at several points using a dial bore gauge or inside micrometer. If the inside diameter is more than the service limit, replace the rocker arm. MX16117 • Measure the inside diameter (J) of the rocker arm collar (D) with a micrometer at several points of the bearing of the rocker arm. If the outside diameter is less than the service limit, replace the rocker arm collar. Rocker Arm Collar Outside Diameter: Service Limit. . . . . . . . . . . . . . . . . . . 10.91 mm (0.43 in.) Rocker Arm Bearing Inside Diameter: Service Limit . . . . . . . . . . . . . . . . . . 11.05 mm (0.435 in.) Installing: 1. Set the piston at TDC on the cylinder you are working on before beginning push rod installation. G F MX11799 • Inspect the push rods for damage or excessive runout. Place each push rod in V blocks set as near to the ends of the rod as possible. Set up a dial gauge at the center point of the push rod. Turn the rod to measure the runout. Check the difference between the highest and lowest dial readings to determine runout. If this figure exceeds 0.5 mm (0.02 in.) the push rod must be replaced. F MX16115 2. If removed, install bracket (G) and two bolts (F). Tighten bolts to 22 N•m (16 lb-ft). Engine - Gas (Liquid-Cooled) Repair - 78 ENGINE - GAS (LIQUID-COOLED) REPAIR 6. Insert the washer (Q) onto the bolt (C), and insert the bolt into the hole at the right side of the bracket and through the collar installed with the rocker arm. K 7. Install the nut (A) onto the bolt and tighten the nut temporarily. 8. Apply clean engine oil to the rocker arm pivot seat area and the contact points on the arm when reinstalling the rocker arms. Perform a valve clearance adjustment as detailed in the Engine Tests and Adjustments section of this manual. 9. Install rocker covers. Valve Train Removal and Installation L Procedure: 1. Remove cylinder head. See “Cylinder Head Removal and Installation” on page 65. M Note: When removing valve train, mark all parts so they can be reinstalled in their original position. C B A N B MX11802 3. Install each push rod (K) in its original position by inserting the end of the rod so it is sliding along the inside wall of the crankcase (L). Position the push rod on the tappet (M). A D 4. Check that both intake and exhaust push rods on the cylinder you are assembling are at the lowest position on the cam lobes (N). If not, turn the flywheel clockwise one turn (360o) and reset the piston at TDC of the power stroke. MX11613 G 2. Remove valve clearance adjusting nuts (A), bolts (B) and associated hardware to remove rocker arms (D). O 3. Remove rocker arm bracket (C). F P A E G C D E H Q MX16117 5. Insert the collar (D) into the rocker arm hole so that the groove (P) of the collar faces upward, then set them on the bracket (O), positioning the push rod ends onto the rocker arm detents. Engine - Gas (Liquid-Cooled) Repair - 79 MX16119 ENGINE - GAS (LIQUID-COOLED) REPAIR 4. Support the valve heads inside the combustion chamber with a suitable block such as a piece of wood. 5. Remove the spring retainer (E) by pushing down with your thumbs and removing the collets (G). 6. Remove the spring (H) and valve (F). Note: Bottom spring retainer (J) can only be removed with stem seal. Crankcase Cover Removal and Installation Procedure: 1. Remove engine from machine. See “Engine Removal and Installation” on page 73. 2. Drain engine oil. I J A B K MX16110 MX16120 7. Remove the stem seals (I). Stem seal replacement is not mandatory on a low hour engine, but is recommended, particularly if a new valve has been installed. Note: Valve guides (K) are not replaceable. If a valve guide is damaged or worn beyond maximum specifications, the head casting must be replaced. 3. Remove governor control panel (B) and governor arm (A). See “Governor Assembly Removal and Installation” on page 82. 4. Remove rocker covers. See “Cylinder Head Removal and Installation” on page 65. 3 C 6 8. Check to see if the valve seats properly in the valve seat. If not, resurface the valve seat and/or replace the valve. 7 10 9. Install new stem seals if necessary. 10.Apply engine oil to the valve stem to avoid damaging the valve stem seal. Install the valve and check for smooth operation in the valve guide. Replace valve if valve binds in guide, or guide to stem clearance is excessive. 11.Install valve spring, collets and spring retainer on the valve. 9 8 4 D 1 5 2 D MX16129 12.Install rocker arm bracket (C). 13.Apply clean engine oil to the rocker arm at the spherical pivot seat, and the points where the arm contacts the push rod and the valve stem end. 14.Install the rocker arm (and associated hardware) on the rocker arm bracket, and tighten the bolt and nut temporarily. Perform a valve adjustment as detailed in Valve Clearance Inspection and Adjustment in the Engine Tests and Adjustments section. 5. Remove the ten (10) cover mounting bolts and remove the crankcase cover (C) from the crankcase. There are two knock points (D) on the cover where a plastic or wood mallet can be used to gently tap the cover loose. 6. Remove the crankcase cover gasket and any gasket residue from both the cover and the crankcase mating area. Engine - Gas (Liquid-Cooled) Repair - 80 ENGINE - GAS (LIQUID-COOLED) REPAIR c cover Caution: Avoid Injury! Clean the crankcase and in a well ventilated area where no sparks or flames are present including appliance pilot lights. Never use gasoline or a low flash-point solvent to clean parts. A fire or explosion could result. 7. Clean the mating surfaces of the cover and the crankcase using a high flash point solvent. Blow out the oil passage in the cover using compressed air. 8. Replace the crankshaft PTO oil seal if necessary. Note the following while replacing this seal: 9. Check to see that the O-Rings (L) are in place on the crankcase as shown above. 10.Apply silicone sealant bead (J), 1 - 2 mm (0.04 - 0.08 in.) wide, to mating surface (K) of the crankcase (in areas shown above). c into Caution: Avoid Injury! Do not get the sealant the oil line hole (M) on the crankcase or crankcase cover. 11.Check that the crankshaft dowels (N) are in place on the crankcase and install a new gasket on the crankcase. Important: Avoid Damage! If one cover bolt at a time is tightened completely, the cover could be warped. F 8 C E 5 4 I G H 1 2 3 MX11847 • The crankshaft PTO oil seal is installed with the marks (E) facing out. Press the new seal into the cover until it is flush with the flange surface (F). Pack high temperature grease (H) into the space between the seal lip (G) and the dust lip (I). K 7 10 6 9 MX16129 12. Install the crankcase cover (C). Noting the different length of bolts, tighten the bolts 1/2 turn at a time in the sequence shown, and to a final torque of 22 N•m (16.0 lbft) when all bolts are tight. 13.Install rocker covers. See “Cylinder Head Removal and Installation” on page 65. J J 14.Remove governor control panel and governor arm. See “Governor Assembly Removal and Installation” on page 82. 15.Fill engine with approximately 1.8 L (1.9 qt) of oil. J 16.Install engine onto machine. See “Engine Removal and Installation” on page 73. N L M N MX16130 Engine - Gas (Liquid-Cooled) Repair - 81 ENGINE - GAS (LIQUID-COOLED) REPAIR Crankcase Cover Inspection 4. Disassemble remaining parts, and visually inspect for wear or damage; replace, as necessary. Procedure: K A J G H B F I E L D MX16135 1. Drain engine oil and remove the crankcase cover. See “Crankcase Cover Removal and Installation” on page 80. 2. Measure the inside diameter (A) of the PTO shaft bearing at several points. This bearing is not replaceable. If it is damaged, or the inside diameter is more than 42.09 mm (1.66 in.) the crankcase cover must be replaced. M 3. Install crankcase cover. See “Crankcase Cover Removal and Installation” on page 80. A MX14226 Picture Note: FD671D engine shown; FD750D engine does not have choke assembly parts (L). 4. Replace engine oil. Governor Assembly Removal and Installation Governor Arm Removal and Installation: 5. Insert the bracket (G) onto the governor shaft (H) to the bottom of the woodruff are of the shaft, and tighten the clamp nut (D) to 8 N•m (69 lb-in.). 6. Install the control panel assembly, and connect the bracket with the governor spring (M). B 7. Install the end of throttle link rod (B) with the link spring (J) around it into the governor arm hole (I) and the other end into the carburetor throttle lever (K) hole. A 8. Install the governor arm (A) on the bracket (G) with the bolt (F) and washer by turning the bolt counterclockwise so the projection of the bracket fits into the governor arm hole (E). 9. Loosen the bolt (F), and fully turn the bracket (G) counterclockwise and hold it there. D C MX16110 Picture Note: FD671D engine shown; FD750D engine does not have choke assembly. 10.Turn the top end of the governor arm (A) counterclockwise to fully open the carburetor throttle valve and tighten the bolt (F). 1. To remove the governor arm, remove governor control panel (C). 2. Loosen the clamp nut (D) and take off the governor arm (A). 3. Clear the throttle link rod (B) from the governor arm and choke lever. Engine - Gas (Liquid-Cooled) Repair - 82 ENGINE - GAS (LIQUID-COOLED) REPAIR Governor Removal and Installation: c governor Caution: Avoid Injury! Do not remove the assembly unless it is necessary. Once it has been removed, it must be replaced. 1. Remove crankcase cover. See “Crankcase Cover Removal and Installation” on page 80. Note: To avoid damage to the surface of crankcase cover, use suitable soft mats (C) as shown below. 6. Spin the governor assembly by hand and check that the flyweights operate freely and the center sleeve moves outward. Governor Shaft Removal and Installation: 1. Remove camshaft. See “Camshaft/Tappet Removal and Installation” on page 90. 2. Unscrew the governor arm clamp nut, and remove the governor arm. See “Governor Arm Removal and Installation:” on page 82. C B C A B A MX16193 MX16191 2. Remove the governor assembly (A) with the sleeve (B) by prying the gear with two proper size screw drivers. 3. Remove the circlip (B) on the governor shaft (C), and remove the governor shaft and washer (A). Note: Replace the oil seal only if the lip shows signs of leakage or it has been damaged. If the oil seal is removed, install it after the shaft (C) is installed. 3. Remove the thrust washer. B E A F C F D D E MX16194 MX16192 4. Install thrust washer (C). 5. Fit the sleeve (B) into the governor assembly (A), and install them as a set. Note: The sleeve (B) and the governor assembly (A) cannot be installed separately. Push the set onto the shaft (E) until inner flange (F) snaps into the groove (D) securely. A 4. The oil seal (E) must be assembled with the seal lip towards inside of the engine. 5. Press in the oil seal approximately 1.0 mm (0.04 in.) (D) flush or below the crankcase surface (F). Engine - Gas (Liquid-Cooled) Repair - 83 ENGINE - GAS (LIQUID-COOLED) REPAIR Important: Avoid Damage! Note location of the arrow mark (F) on the piston head in relation to the “Made in Japan” mark on the connecting rod. The “Made in Japan” mark (D) on the No. 1 cylinder (C) connecting rod must be face to face with the “Made in Japan” mark (E) on the No. 2 cylinder (G) connecting rod. Keep components together as a matched set. C B A F MX16193 D 6. Apply engine oil to the governor shaft (C). E 7. Insert the governor shaft into the crankcase and washer (A). 8. Fit the circlip (B) securely into the groove of the governor shaft (C), as shown above. 9. Check that the governor shaft moves freely in its operating range. Piston Removal and Installation G C MX16123 4. Push the connecting rod end up into the cylinder, and pull the piston and connecting rod assembly out the top of the cylinder. Removing: 1. Remove cylinder heads. See “Cylinder Head Removal and Installation” on page 65. F 2. Remove the crankcase cover and the camshaft. See “Camshaft/Tappet Removal and Installation” on page 90. E A A MX11819 B I MX16122 H 3. Turn the crankshaft to expose the connecting rod cap bolts (A). Remove the bolts and take off the connecting rod caps (B). MX16124 Engine - Gas (Liquid-Cooled) Repair - 84 ENGINE - GAS (LIQUID-COOLED) REPAIR 5. Remove one of the piston snap rings (I) with a needle nose pliers (H). M 6. Push the piston pin out the side where the snap ring was removed and remove the piston from the rod. 7. Remove the top and second rings with piston ring pliers. N J MX11822 3. Install the scraper ring (N) in the second groove with the notch facing down. 4. Install the compression ring (M) in the first groove with the bevel facing down. MX11820 8. If piston ring pliers are not available, carefully spread the ring opening with your thumbs and push up on the back side of the ring (J) to remove it. P O R 9. Remove the 3-piece oil ring using the thumb method. P Q O Installing: 1. Inspect and clean the piston and rings before installation. See “Inspect Piston and Cylinder” on page 87. Q R L MX11823 K 5. Orient the ring gaps on the piston as shown: • O - piston arrow mark • P - top ring and upper steel rail end gaps • Q - 30o - 45o • R - second ring and lower steel rail end gaps F MX11821 2. Install a new oil control ring on the piston in the following sequence: D • Install the expander (K) in the oil ring groove with the ends (L) touching together, not overlapping. • Install the upper and lower steel rails. Rails are interchangeable and do not have an up or down orientation. C E G MX16123 6. Apply fresh engine oil to the piston pin and assemble the piston for the #1 cylinder (C) with the arrow mark (F) facing away from the “Made in Japan” mark (D) on the Engine - Gas (Liquid-Cooled) Repair - 85 ENGINE - GAS (LIQUID-COOLED) REPAIR connecting rod. 7. Apply fresh engine oil to the piston pin and assemble the piston for the #2 cylinder (G) with the arrow mark (F) facing the “Made in Japan” mark (E) on the connecting rod. W S T X MX16127 MX16125 11..Insert the piston and rod assembly in the cylinder bore with the arrow mark on the piston (W) facing the flywheel (X). Lightly tap the top of the piston with a plastic mallet (V) to insert the piston assembly in the bore. 8. Fit new piston pin snap rings to both pistons. Align the snap ring gap (S) so it does not align with the piston pin hole notch (T). Y AA Important: Avoid Damage! Do Not reuse piston pin snap rings. Weakened and deformed snap rings could fall out causing engine damage. Use only new snap rings when reinstalling pistons. Z AB 9. Apply fresh engine oil to the piston skirt and cylinder bore. AC AA AC Y U U Z MX11830 12.Apply engine oil to the inner surface (Y) of the connecting rod big end (Z) and caps (AA). V MX16126 10..Use a piston ring compression tool (U) to compress the piston rings. Important: Avoid Damage! The connecting rod and rod big end cap are machined as a matched set. They must be replaced as a set in their original position on the crankshaft. 13.Align the rods on the crankshaft, and install the big end rod caps in their original position. 14.Apply a small amount of engine oil to the thread (AB) and seating surface of the rod cap bolts. Install bolts (AC) and tighten to 21 N•m (186 lb-in.). 15.Install the camshaft and the crankcase cover. See “Camshaft/Tappet Removal and Installation” on page 90. Engine - Gas (Liquid-Cooled) Repair - 86 ENGINE - GAS (LIQUID-COOLED) REPAIR 16.Install cylinder heads. See “Cylinder Head Removal and Installation” on page 65. C Inspect Piston and Cylinder Procedure: A MX11833 4. Check piston ring grooves for wear by inserting a new ring in the piston and measuring the clearance between piston and ring with a feeler gauge (C). Wear should not exceed: • Top and Second Ring - 0.15 mm (0.006 in.) MX11831 1. Remove the piston and piston rings. See “Piston Removal and Installation” on page 84. Important: Avoid Damage! Never attempt to clean carbon deposits with the piston in the engine. Carbon particles will fall between the piston and cylinder and could damage crankshaft bearings and seals. If piston ring groove clearance is greater than specified, replace the piston. Note: The three piece oil ring is difficult to measure for ring groove clearance. Check both ring and piston groove visually for damage or wear and replace either component as necessary. 2. Scrape carbon deposits off the piston head (A) using an appropriate scraper that will not gouge or scratch the piston. c edges Caution: Avoid Injury! The top and bottom of the ring may be extremely sharp. D B MX11834 5. Worn rings normally show visual evidence of wear such as surface scratches or an extremely shiny sealing surface. If you are considering reusing rings measure the following: MX11832 • Ring Thickness - Use a micrometer to measure at several points around the ring (D). The minimum service limit for both the top and second ring is 1.40 mm (0.055 in.). If any measurement is less than the service limit, replace the entire set of rings. 3. Clean the piston ring grooves (B) with a broken ring or a suitable tool. Engine - Gas (Liquid-Cooled) Repair - 87 ENGINE - GAS (LIQUID-COOLED) REPAIR compartment (H). If coolant leakage appears in the push rod compartment, replace the crankcase. E F • Check the cylinder head gasket. If coolant is leaking through gasket surfaces, check the gasket surfaces (I) for traces of the leakage, and check to make sure the cylinder head and block surfaces are smooth, clean and level. MX16128 • Piston Ring End Gap - Use the piston to push each piston ring (E) into the cylinder bore to a point close to the bottom of the cylinder bore. Measure the gap (F) between the ends of the ring with a feeler gauge. Top and Second Ring End Gap - 1.00 mm (0.04 in.) service limit Oil Ring End Gap - 1.2 mm (0.05 in.) service limit If any measurement is greater than the service limit, replace the entire set of rings. J MX11838 7. Measure the outside diameter of the piston pin with a micrometer at several points (J). If the outside diameter is less than 18.96 mm (0.747 in.) the piston pin must be replaced. H K G I MX11839 MX16149 6. Inspect the crankcase for an accumulation of dust, scale, and lime in the water jacket (G). If this accumulation is observed, flush the cooling system. 8. Measure the inside diameter of the piston pin with a dial bore gauge at several points (K) on both sides of the piston. If the inside diameter is greater than 19.08 mm (0.751 in.) the piston must be replaced. Note: A cracked or porous casting is not visible to the eye. If evidence of leakage of coolant from any suspected area is found, replace the crankcase. L • Inspect the crankcase for coolant leakage outside the water jacket. Small leaks may appear only as rust, corrosion or stains, due to evaporation. If this is observed, tighten bolts and/or replace the cylinder head gasket. • Inspect the crankcase for coolant leakage into the engine. Leakage occurs through a loose cylinder head, cracked or porous casting, and through the push rod Engine - Gas (Liquid-Cooled) Repair - 88 MX11840 ENGINE - GAS (LIQUID-COOLED) REPAIR 9. Measure the inside diameter of the connecting rod small end with a dial bore gauge (L) at several points. If the inside diameter is greater than 19.06 mm (0.75 in.) the piston must be replaced. 13.If any of the cylinder bore measurements are greater than the following service limits, the cylinder must be bored and honed (see Resizing Cylinder Bore and Cylinder Bore Honing). If cylinder bores are within specifications and show no signs of damage, new piston rings may be fitted provided the cylinder bores are honed. This will restore the proper cross hatch angle in the cylinder bores ensuring proper lubrication and piston ring rotation. • Standard Cylinder Bore Inside Diameter: 78.00 mm (3.071 in.) • Standard Cylinder Bore Service Limit: 78.08 mm (3.074 in.) N M • Standard Cylinder Bore Out-of-Round Service Limit: 0.056 mm (0.022 in.) Cylinder Bore Honing MX11841 10.Measure the outside diameter of the piston (M) at a point (N), 11 mm (0.43 in.) up from the bottom of the piston and 90 degrees from the piston pin hole. If the outside diameter is less than 77.7 mm (3.06 in.), the piston must be replaced. Procedure: Note: To produce the proper cross hatch finish use a drill speed of approximately 200 rpm and 40 - 60 strokes per minute. Lubricate hone liberally to prevent build up on finishing stones. A M86885 O M86883 11.Clean the cylinder and inspect the bores for scoring, signs of seizure or ridges at the top or bottom of the cylinder. 12.Measure the cylinder inside diameter (O) using a dial bore gauge. Measure the cylinder front to back and side to side at the following points: • 10 mm (0.394 in.) from top of cylinder • 10 mm (0.394 in.) from bottom of cylinder • 55 mm (2.165 in.) from top of cylinder 1. The cylinder finish, (Cross Hatch) should be applied when reconditioning a cylinder bore. The finishing stones will produce the correct cross hatch necessary for proper lubrication and piston ring rotation. The correct hatch angle is approximately 45° (A). 2. It is recommended that the cylinder bores be reconditioned to restore the cross hatch when new piston rings are to be installed in a cylinder that is within specification. Be careful not to hone oversize. Engine - Gas (Liquid-Cooled) Repair - 89 ENGINE - GAS (LIQUID-COOLED) REPAIR Important: Avoid Damage! Ensure that the entire cylinder and crankcase are thoroughly cleaned after honing. First wash the cylinder and crankcase carefully in a solvent such as kerosene or commercial solvent. Then thoroughly wash cylinder and crankcase using a stiff brush with soap and hot water. Rinse thoroughly with hot running water. Repeat washing and rinsing until all traces of honing grit are gone. Honing grit is highly abrasive and will cause rapid wear to all of the internal components of the engine unless it is completely removed. 3. When cylinder and crankcase have been thoroughly cleaned, use a white rag or napkin and wipe the cylinder bore. If honing grit is present, it will appear as a grey residue on rag. If any honing grit is evident, re-wash and rinse entire cylinder and crankcase and check again. When cleaning is complete, oil cylinder bore to prevent rusting. Camshaft/Tappet Removal and Installation C MX16139 7. Remove the tappets (C) and mark them for reinstallation. 8. Before reinstalling tappets and camshaft apply fresh engine oil to: • Tappet Journals Procedure: • Camshaft Journals 1. Remove engine and drain oil. See “Engine Removal and Installation” on page 73. • Cam Lobe Surface • Camshaft Gear 2. Remove crankcase cover. See “Crankcase Cover Removal and Installation” on page 80. 9. With the crankcases turned upside down, install the tappets in their original positions. 3. Remove rocker covers. See “Cylinder Head Removal and Installation” on page 65. 4. Place the piston at Top Dead Center (TDC) for the cylinder you are working on. D A E B MX16141 10.Slide the camshaft into position in the crankcase, aligning the punch marks on the crankshaft gear (D) and camshaft gear (E). MX16113 5. Remove rocker arms (B) and push rods (A). See “Push Rod/Rocker Arm Removal and Installation” on page 77. 6. Turn the crankcase up side down so that tappets fall away from cam lobes. Pull the camshaft out of the crankcase. 11.Install crankcase cover with a new gasket. 12.Install pushrods and check valve clearances before reinstalling rocker covers. See “Valve Clearance Adjustment” on page 43. 13.Install remaining components in the order they were removed. Fill engine with new oil. Engine - Gas (Liquid-Cooled) Repair - 90 ENGINE - GAS (LIQUID-COOLED) REPAIR Camshaft Disassembly and Inspection Procedure: E A MX16144 B MX16142 5. Measure both camshaft journals (E) at several points around the journal circumference. If any journal is worn less than the service limit, replace the camshaft. 1. Inspect camshaft gear (A) for pitting, fatigue cracks, burrs or uneven wear due to improper tooth contact. Replace camshaft if necessary. F Important: Avoid Damage! Damaged or worn cam lobes usually indicate damaged tappets. Check tappets when replacing camshaft. 2. Check the top of the cam lobes (B) for signs of uneven wear, grooving, pitting or flaking of hardened wear area. Replace camshaft if any of these conditions exist. C MX16145 6. Measure inside diameter (F) of the camshaft bearing bore in crankcase at several points. This bearing is not serviceable, so it will be necessary to replace the crankcase if the inside diameter is greater than the service limit. B D E G MX16143 3. Remove the spring (C) from the ACR (Automatic Compression Release) assembly. DO NOT attempt to remove the ACR weight. If the ACR weight (D) is damaged, or does not swing freely when shaking the cam, the camshaft must be replaced. 4. Measure the height of each cam lobe (B), if less than service limit replace camshaft. MX16146 7. Measure inside diameter (G) of the camshaft bearing bore in crankcase cover at several points. This bearing is Engine - Gas (Liquid-Cooled) Repair - 91 ENGINE - GAS (LIQUID-COOLED) REPAIR not serviceable, so it will be necessary to replace the crankcase cover if the inside diameter is greater than the service limit. 5. Pull the crankshaft (A) out of the crankcase. It may be necessary to tap on the crankshaft with a wood or plastic mallet to loosen the crankshaft. 8. Install a new spring on the ACR assembly. 6. Before installing the crankshaft, clean the crankshaft journals and the crankcase bearing surfaces thoroughly. 9. Install the camshaft in the crankcase. See “Camshaft/ Tappet Removal and Installation” on page 90. Cam Lobe Height: 7. Pack high temperature grease into the crankcase oil seal. Service Limit Intake . . . . . . . . . IN 33.594 mm (1.323 in.) Service Limit Exhaust . . . . . . EX 33.594 mm (1.323 in.) 8. Apply engine oil to the crank journals and bearing surfaces and carefully insert crank (A) into the main bearing and oil seal in the crankcase. Camshaft Journal Diameters: 9. Install pistons and rods on crankshaft (see Piston Removal/Replacement). PTO Side . . . . . . . . . . . . . . . . . . . . 19.927 mm (0.785 in.) Flywheel Side . . . . . . . . . . . . . . . . 19.927 mm (0.785 in.) Camshaft Bearing Bores: Crankcase Camshaft Bore . . . . . . 20.081 mm (0.791 in.) Crankshaft Cover Camshaft Bore 20.081 mm (0.791 in.) Crankshaft Removal and Replacement 10.Install camshaft and tappets. See “Camshaft/Tappet Removal and Installation” on page 90. 11.Install a new crank oil seal if necessary in the crankcase cover. Install the crankcase cover. See “Crankcase Cover Removal and Installation” on page 80. Crankshaft Inspection Procedure: Procedure: 1. Remove engine and drain oil. See “Engine Removal and Installation” on page 73. 2. Remove flywheel. See “Flywheel Removal and Installation” on page 77. c toCaution: Avoid Injury! Used tappets are mated their camshaft lobes. Mark them for installation in the same bore they were removed from. 3. Remove camshaft and tappets. See “Camshaft/Tappet Removal and Installation” on page 90. 1. Remove crankshaft. See “Crankshaft Removal and Replacement” on page 92. 2. Clean the crankshaft and connecting rods with a high flash point solvent and dry with compressed air. 3. Inspect the teeth of the crankshaft gear for fatigue cracks, pitting or signs of uneven tooth contact. Replace crank gear if necessary. 4. Inspect the crankshaft and connecting rod bearing surfaces for excessive wear, uneven contact or gouging and scratching. Components should be replaced if any of these conditions exist. 4. Remove connecting rod and piston assemblies. See “Piston Removal and Installation” on page 84. A A MX16148 MX16147 5. Measure the crankpin outside diameter (A) at several points around the circumference. If the crankpin diameter is less than the service limit at any point, replace the crankshaft. Engine - Gas (Liquid-Cooled) Repair - 92 ENGINE - GAS (LIQUID-COOLED) REPAIR C B D F MX16150 MX16148 6. Measure the crankpin width (C) at several points with a dial caliper. If crankpin width exceeds the service limit at any point, replace the crankshaft. 9. Measure the inside diameter (F) of the crankshaft journal bearing on the crankcase at several points. Replace the journal bearing if the inside diameter is more than the service limit. 7. Measure the flywheel side (B) and PTO side (D) main journals at several points. If either journal is less than the service limit, the crankshaft must be replaced. H I G E J MX16151 MX11892 8. Measure the crankshaft runout. Set the crankshaft in a flywheel alignment jig or on V blocks. Set up dial gauges (E) at both bearing journals. Turn the crankshaft slowly by hand and measure the runout. The difference between the highest and lowest dial gauge reading is the amount of runout. If the measurement at either journal exceeds the service limit, the crankshaft must be replaced. 10.The journal bearing (G) is press fit into the crankcase (I). • Remove the oil seal on the crankcase. (Note: The oil seal should be replaced once removed.) • Place the crankcase on a support block (J), with the oil seal side up. • Using a bushing tool (H), drive out the bearing as shown. Specifications: Crankpin Outside Diameter (Service Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.950 mm (1.573 in.) Crankpin Width (Service Limit) . . . . 46.50 mm (1.83 in.) Crank Main Journal PTO Side (Service Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.935 mm (1.651 in.) Crank Main Journal Flywheel Side (Service Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.935 mm (1.651 in.) Crank shaft Runout (Service Limit) 0.05 mm (0.002 in.) Crankcase Journal Bearing Inside Diameter (Service Limit) . . . . . . . . . . . . . . . . 42.14 mm (1.659 in.) Engine - Gas (Liquid-Cooled) Repair - 93 ENGINE - GAS (LIQUID-COOLED) REPAIR Connecting Rod Inspection Procedure: 1. Remove pistons and connecting rods. See “Piston Removal and Installation” on page 84. F B G MX11901 A MX16152 2. Measure the connecting rod big end width (A) with a micrometer or dial caliper. If the measurement is less than the service limit, the rod must be replaced. 3. Apply a light film of oil to the threads of the cap bolts. Install the rod cap and the cap bolts and tighten the bolts to 21 N•m (180 lb-in.). Measure the inside diameter (B) of the big end at several points with a telescoping gauge or inside micrometer. If the inside diameter is greater than the service limit, the rod and cap must be replaced. C 6. Measure connecting rod twist. With the big end mounted in V blocks, hold the connecting rod horizontally and measure the amount that the small end arbor varies (F) from being parallel with the surface plate over a 100 mm length (G). If twist exceeds the service limit the rod and cap must be replaced. 7. Install the connecting rods and pistons. See “Piston Removal and Installation” on page 84. Specifications: Connecting Rod Big End Width Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.35 mm (0.88 in.) Connecting Rod Big End Inside Diameter Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.055 mm (1.577 in.) Connecting Rod Bend Service Limit . . . . . . . . . . . . . . . . . . . . . . 0.15. mm (0.006 in.) over 100 mm (3.94 in.) Connecting Rod Twist Service Limit . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) over 100 mm (3.94 in.) D E MX11898 4. Measure connecting rod bend. Insert an arbor the same size as the big end through the connecting rod big end. Insert an arbor (D) 100 mm (3.397 in.) (E) or longer the same diameter as the small end through the connecting rod small end. Place V blocks on a surface plate, and support the big end arbor in the V blocks. 5. Hold the small end of the rod straight up vertically and measure from the surface plate to the small end arbor on both sides of the connecting rod. Measurement must be taken at a point that is exactly 100 mm (3.397 in.) apart. The difference between the two measurements determines the rod bend (C). If the connecting rod bend exceeds the service limit the rod and rod cap must be replaced. Engine - Gas (Liquid-Cooled) Repair - 94 ENGINE - GAS (LIQUID-COOLED) REPAIR Breather Valve Removal and Installation Procedure: 5. To install assembly, align the center of the valve seat with the center of the reed valve (E) and back plate (D), then tighten the mounting screw (C). 1. Remove engine from machine. See “Engine Removal and Installation” on page 73. 6. Before installing cover, be sure the drain hole (F) does not accumulate any debris. 7. Install a new cover gasket (A) and install cover (B). Tighten four breather valve cover mounting bolts to 20 N•m (180 lb-in.). A Oil Pump Removal and Installation Procedure: 1. Remove crankcase cover. See “Crankcase Cover Removal and Installation” on page 80. B A MX16153 2. Remove the four (4) bolts holding the breather cover (B) to the crankcase. 3. Inspect gasket (A) for damage, and replace if necessary. C B D MX16156 2. Remove two cap screws (B) holding oil screen filter (A) onto crankcase cover. E F MX16154 4. Unscrew the mounting screw (C), and remove the back plate (D) and reed valve (E). C • Inspect the reed valve (E) for breakage, hair cracks or distortion. Replace valve if any signs of wear or damage are present. • Inspect the back plate (D) for damage or a rough contact surface. Replace if necessary. • Inspect the valve seating surface for nicks, burrs, scratches or fretting. If damage or wear is evident, remove the reed valve and backing plate and clean the surface with fine emery paper. D MX16155 3. Remove the remaining three (3) bolts (C) holding the oil pump assembly (D) to the crankcase cover and remove pump assembly. Note: The mounting screw (C) is self-tapping. Be aware that mis-threading or overtightening the screw will strip the female threads and ruin the hole. Engine - Gas (Liquid-Cooled) Repair - 95 ENGINE - GAS (LIQUID-COOLED) REPAIR 9. Install the relief valve and ball in the crankcase cover, then install the pump parts assembly into the cover. C F E G 10.Install the pump assembly into the crankcase cavity making certain to align the 6 mm diameter hole (L) in the cover plate with center of the relief valve. Put the oil screen filter in position, and install the five (5) mounting bolts tightening to 6 N•m (52 lb-in.). 11.Install the crankcase cover with a new gasket. See “Crankcase Cover Removal and Installation” on page 80. Oil Pump Inspection Procedure: M H L J K I MX11912 4. Remove the relief valve ball (I) and spring (J) from the crankcase cover. 5. The pump can be disassembled by removing the pin (M) and separating the pump gear (E) from the pump shaft (H) and the cover plate (K). 6. Remove the inner (G) and outer rotor (F) from the pump cavity. 7. Assemble the pump in reverse order of disassembly. 8. Fill the rotor housing in the crankcase cover with fresh oil for initial lubrication. Note: When installing the pump parts assembly, align the 6 mm diameter hole (L) on the cover plate with the center of the relief valve. A MX16157 1. Remove the oil pump assembly from the crankcase cover. See “Oil Pump Removal and Installation” on page 95. Visually inspect the pump gear, inner and outer rotor and cover plate for wear or damage. Replace components as necessary. 2. Install inner and outer rotor in crankcase cavity and check clearance between inner and outer rotor with a feeler gauge. Take this measurement at the point where the high point of the inner rotor meets the high point of the outer rotor (A). If the clearance exceeds the service limit replace the inner and outer rotors as a set. B C C MX16158 L D MX16155 3. Measure the thickness (B) of the outer rotor with a micrometer at several points. If the thickness is less than the service limit at any point, replace the inner and outer rotors. Engine - Gas (Liquid-Cooled) Repair - 96 ENGINE - GAS (LIQUID-COOLED) REPAIR 4. Measure the outside diameter (C) of the outside rotor at several points with a micrometer. If the rotor diameter is less than the service limit, replace the inner and outer rotor as a set. H D MX16161 E F MX16159 5. Measure the inside diameter (E) of the pump housing with an inside micrometer at several points. If the inside diameter of the cover is greater than the service limit the crankcase cover must be replaced. 6. Measure the depth (D) of the pump housing with a depth micrometer at several points. If any measurement is greater than the service limit the crankcase cover must be replaced. 7. Measure the inside diameter (F) of the pump shaft bearing in the crankcase cover at several points with an inside micrometer. If the inside diameter exceeds the service limit at any point it will be necessary to replace the crankcase cover. 9. Remove the relief valve spring and steel ball from the crankcase cover. Clean the valve seat and valve components with a high flash point solvent, and blow any foreign particles out of the seat with compressed air. Inspect the steel ball for wear or dimpling. Replace the steel ball and spring if any wear or damage is evident. 10.Measure the free length (H) of the spring with a vernier caliper. If the free length of the spring is less than the service limit, replace the spring. 11.Install oil pump assembly in crankcase cover. See “Oil Pump Removal and Installation” on page 95. Specifications: Inner to Outer Rotor Clearance (Service Limit) (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 mm (0.012 in.) Outer Rotor Outside Diameter (Service Limit) (C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40.47 mm (1.593 in.) Outer Rotor Thickness (Service Limit) (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.830 mm (0.781 in.) Pump Housing Inside Diameter (Service Limit) (E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.801 mm (1.606 in.) Pump Housing Depth (Service Limit) (D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.230 mm (0.797 in.) Pump Shaft Outside Diameter (Service Limit) (G) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.923 mm (0.4300 in.) Pump Shaft Bearing Inside Diameter (Service Limit) (F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.072 mm (0.436 in.) Spring Free Length (H) . . . . . . . . . . 19.50 mm (0.77 in.) G MX16160 8. Measure the outside diameter (G) of the pump shaft with a micrometer at several points. If the diameter is less than the service limit, replace the pump shaft. c ventilated Caution: Avoid Injury! Clean parts in a well area using a high flash point solvent. Make certain no spark or flame such as pilot light is near the work area. Engine - Gas (Liquid-Cooled) Repair - 97 ENGINE - GAS (LIQUID-COOLED) REPAIR Oil Screen Removal and Installation Procedure: 1. Remove the crankcase cover. See “Crankcase Cover Removal and Installation” on page 80. A B MX16156 2. Remove two cap screws (B) holding oil screen filter (A) onto crankcase cover. c ventilated Caution: Avoid Injury! Clean parts in a well area using a high flash point solvent. Make certain no spark or flame such as pilot light is near the work area. A C MX16163 3. Clean the oil screen (C) with a high flash-point solvent and remove any particles stuck to it. Check the screen carefully for any damage, or metal particles that might indicate internal engine damage. If the screen is damaged, replace entire oil screen filter (A). 4. Install the pipe on the oil pump assembly with the two cap screws. Tighten the cap screws to 6 N•m (52 lb-in.). 5. Install crankcase cover. See “Crankcase Cover Removal and Installation” on page 80. Engine - Gas (Liquid-Cooled) Repair - 98 ELECTRICAL TABLE OF CONTENTS Electrical Table of Contents General Information......................................103 Reading Electrical Schematics...................103 Theory of Operation Information ................104 Diagnostic Information................................104 Wire Color Abbreviation Chart....................104 Common Circuit Tests................................105 Conductors For 12 Volt Circuits .................105 Specifications ...............................................107 General Specifications ...............................107 Test and Adjustment Specifications ...........107 Repair Specifications..................................108 Special or Essential Tools ..........................109 Other Materials...........................................110 Component Location....................................111 Right Side...................................................111 Left Side .....................................................112 Engine Components (FD671D) ..................113 Engine Components (FD750D EFI) ...........114 Instrument Panel ........................................115 Schematics and Harnesses .........................116 Schematic and Wiring Harness Legend X700 ...........................................................116 Schematic And Wiring Harness Legend X720/X724/X728 ........................................117 Electrical Schematic - X700 Carbureted (1 of 2) ........................................................119 Electrical Schematic - X700 Carbureted (2 of 2) ........................................................120 W1 Main Wiring Schematic - 720/X724/X728 EFI (1 of 2) .................................................121 W1 Main Wiring Schematic - 720/X724/X728 EFI (2 of 2) .................................................122 Liquid Cooled EFI Schematic (1 of 2).........123 Liquid Cooled EFI Schematic (2 of 2).........124 W1 Main Wiring Harness - X700 Carbureted (1 of 2) ........................................................125 W1 Main Wiring Harness - X700 Carbureted (2 of 2) ........................................................126 W1 Main Wiring Harness - X720/X724/X728 EFI (1 of 2) .................................................127 W1 Main Wiring Harness - X720/X724/X728 EFI (2 of 2) .................................................128 W2 Engine Wiring Harness - X700.............129 W2 Engine Wiring Harness - X720/X724/ X728 EFI.................................................... 130 W2 Engine Wiring Harness Circuit Schematic X720/X724/X728........................................ 131 W3 Headlight Wiring Harness.................... 132 W4 Rear Wiring Harness ........................... 132 W5 PTO Option Wiring Harness................ 132 W6 Auxiliary Alternator Wiring Harness..... 133 W6 Auxiliary Alternator Wiring Harness Circuit Schematic .................................................. 134 A2 EFI Module Pin and Signal Location .... 135 W1 Main Wiring Harness Color Codes X700 .......................................................... 136 W1 Main Wiring Harness Color Codes X720/X724/X728 EFI ................................. 137 W2 Engine Wiring Harness Color Codes X700 .......................................................... 138 W2 Engine Wiring Harness Color Codes X720/X724/X728........................................ 138 W3 Headlight Wiring Harness Color Codes ........................................................ 138 W4 Rear Lights Wiring Harness Color Codes ........................................................ 138 W5 PTO Option Wiring Harness Color Codes ........................................................ 139 W6 Auxiliary Alternator Wiring Harness Color Codes............................................... 139 Operation and Diagnostics ......................... 140 Power Circuit Operation - X700 ................. 140 Power Circuit Electrical Schematic - X700 141 Power Circuit Diagnosis - X700 ................. 143 Power Circuit Operation - X720/X724/ X728 .......................................................... 149 Power Circuit Electrical Schematic - X720/ X724/X728 EFI .......................................... 151 Power Circuit Diagnosis - X720/X724/ X728 EFI.................................................... 154 Cranking Circuit Operation - All Models..... 161 Cranking Circuit Electrical Schematic All Models .................................................. 162 Cranking Circuit Diagnosis - All Models..... 163 Charging Circuit Operation - All Models (Standard Configuration) ........................... 164 Charging Circuit Operation - All Models (With Auxiliary Alternator) .......................... 164 Charging Circuit Electrical Schematic All Models .................................................. 165 Electrical Table of Contents - 99 ELECTRICAL TABLE OF CONTENTS Charging Circuit Diagnosis - All Models (Standard Configuration) ............................167 Charging Circuit Diagnosis - All Models (With Optional Alternator)...........................167 Ignition Circuit Operation - X700 ................168 Ignition Circuit Electrical Schematic - X700169 Ignition Circuit Diagnosis - X700 ................171 Ignition Circuit Operation - X720/X724/X728 EFI..............................................................173 Ignition Circuit Electrical Schematic - X720/ X724/X728 EFI ...........................................174 Ignition Circuit Diagnosis - X720/X724/ X728 EFI ....................................................176 PTO/RIP Circuit Operation - All Models .....177 PTO/RIP Circuit Electrical Schematic All Models...................................................179 PTO/RIP Circuit Diagnosis - All Models .....181 Display Panel Circuit Operation All Models...................................................185 A1 Display Panel Pin and Signal Location 187 Lights Circuit Operation - All Models ..........188 Lights Circuit Electrical Schematic All Models...................................................189 Lights Circuit Diagnosis - All Models ..........190 Power Port Circuit Operation - All Models..192 Power Port Circuit Electrical Schematic All Models...................................................192 Power Port Circuit Diagnosis - All Models..193 Fuel Pump and Fuel Shutoff Circuit Operation X700 ...........................................................194 Fuel Pump and Fuel Shutoff Circuit Electrical Schematic - X700 .......................................195 Fuel Pump and Fuel Shutoff Circuit Diagnosis X700 ...........................................................196 Fuel Pump and Fuel Injector Circuit Operation - X720/X724/X728 ......................................197 Fuel Pump and Fuel Injector Circuit Electrical Schematic - X720/X724/X728 ....................198 Fuel Pump and Fuel Injector Circuit Diagnosis - X720/X724/X728 ......................................200 Fuel Injection Sensor and Diagnostic Circuit Operation - X720/X724/X728 .....................203 Fuel Injection Sensor and Diagnostic Circuit Electrical Schematic - X720/X724/X728.....206 Tests and Adjustments ............................... 208 Common Circuit Tests ............................... 208 Ground Circuit Tests.................................. 208 Battery Voltage and Specific Gravity Test . 208 Battery - Charge ........................................ 209 Battery - Load Test .................................... 210 Regulated Amperage and Voltage Test..... 211 Regulated Voltage Test ............................. 211 Unregulated Voltage Test (Standard Configuration) ............................................ 212 Unregulated Voltage Test (Optional Auxiliary Alternator) .................................................. 212 Stator Resistance Test (Standard Configuration) ............................................ 213 Alternator Resistance Test (Optional Auxiliary Alternator) .................................................. 213 Starting Motor Condition ............................ 214 Starter Solenoid Test ................................. 214 Starting Motor Amp Draw Test .................. 215 Starting Motor No-load Amperage and RPM Test................................................... 215 Starting Motor Field Windings Test............ 216 Starter Armature Test ................................ 216 Engine Coolant Temperature Sensor Test 216 Engine Oil Pressure Switch Test ............... 217 Lights Switch Test...................................... 217 PTO/RIP Switch Test................................. 218 Relay Test.................................................. 218 Power Port Switch Test ............................. 219 Key Switch Test ......................................... 219 Seat Switch Test........................................ 220 Brake Switch Test and Adjustment............ 220 RIO Switch Test......................................... 221 RIO Switch Adjustment.............................. 222 Fuse Test................................................... 222 PTO Solenoid Test (Standard Front PTO). 222 PTO Switch Test (Optional Rear PTO Installed) .................................................... 223 Fuel Shutoff Solenoid Test - X700............. 224 Diode Test ................................................. 224 Fuel Tank Sensor Test .............................. 224 Fuel Injector Test - X720/X724/X728......... 225 Fuel Injection Module Test - X720/X724/ X728 .......................................................... 225 Vacuum Pressure Sensor Test - X720/X724/ X728 .......................................................... 226 Air Temperature Sensor Test - X720/X724/ X728 .......................................................... 227 Electrical Table of Contents - 100 ELECTRICAL TABLE OF CONTENTS Coolant Temperature Sensor Test - X720/ X724/X728..................................................227 Spark Plug Gap Test ..................................228 Spark Plug Gap Adjustment .......................228 Ignition Coil Test ........................................229 Spark Test ..................................................229 Repair.............................................................230 Ignition Coil Replacement and Adjustment 230 Stator Replacement....................................230 Alternator Removal, Inspection, and Installation (Optional).............................................231 Electrical Table of Contents - 101 ELECTRICAL TABLE OF CONTENTS Electrical Table of Contents - 102 ELECTRICAL GENERAL INFORMATION General Information Reading Electrical Schematics S1 Key Switch B Wht Wht Red Red X1 F2 15 Amp Fuse S1 M 6 800 Pink X3 A D K2 Ignition Relay D C Start 210 Red X2 X3 On Off SeatSeat S2 Seat Switch 414 Yel/ Blk Run 3 Off L F3 15 Amp Fuse K F1 Fusible Link 215 Org 721 Pur W1 Shielded Ground G M1 Starting Motor M Blk E 2 J X3 4 1 5 2 E W2 Engine Wiring Harness T1 Ignition X5 Yel/Wht Coil I X3 710 Pur H Red G1 Battery 5 3 X2 S 1 K1 Start Relay 1 B 4 H B E1 Spark Plug F X3 X4 Yel/ Wht Yel/Wht Yel/ Wht Wht F 805 Pnk Blk/Yel T2 Ignition Coil N E2 Spark Plug O C 105 Blk mif The schematic is made up of individual circuits laid out in a sequence of related functions. It is formatted with all power wires (A) across the top and all ground wires (B) across the bottom. Current flow is generally from top to bottom through each circuit and component. All components are shown in the off position. The diagram does not list connector (C) information unless needed to avoid confusion. If the connector is shown, the number next to it is the terminal pin location (D) in the connector. Each component is shown by a symbol (E), its name (F), and an identification code (G). The identification code contains a device identifying letter (H) and number (I). The identifying letter is always the same for a specific component, but the identifying numbers are numbered consecutively from upper left to lower right. The terminal designation (J) is placed directly inside or outside the symbol next to the connecting wire path. Switch positions (K) are also placed directly inside or outside the symbol. The solid line (L) shows the position the switch is currently in and dash lines (M) represent other switch positions. The circuit number (N) and wire color (O) of the wires are Electrical General Information - 103 ELECTRICAL GENERAL INFORMATION Wire Color Abbreviation Chart shown directly next to the wire path. The same component name and identification code are used consistently on all diagrams in this section. Components can be easily cross-referenced. Theory of Operation Information The theory of operation stories divide the electrical system into individual circuits by function. Each circuit is isolated from the main wiring schematic and only shows the components that are used in it. The story contains information on function, operating conditions, and theory of operation. The circuit schematics are drawn with the components in the operating position, with the power, or battery positive, into them across the top and the ground, or battery negative, across the bottom. Diagnostic Information The diagnostic procedures is used to test the complete circuit regardless of the problem or complaint. Select a symptom or system from the quick check or troubleshooting chart and follow the test procedures under that heading. The diagnostic procedure lists: • Test conditions • Test sequence • Test location • Normal reading • Check or test to perform if reading is not normal When performing the test or check, be sure to set your machine up to the TEST POINT/PROCEDURES listed in the first column and follow the sequence carefully. The middle RESULTS column gives the reading or condition that should be obtained in BOLD print. If the results of the test or check are not normal, perform the test, check, or adjustment listed below the BOLD print. The system diagram that accompanies each test procedure is drawn to resemble machine components. The leader line points to the exact point the test is to be made. Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue Brn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown Grn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green Gry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gray Org. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange Pnk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink Pur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tan Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow Blk/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black/White Blu/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue/White Brn/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brown/White Brn/Yel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown/Yellow Dk Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Blue Dk Brn/Lt Grn . . . . . . . . . . . . . Dark Brown/Light Green Dk Brn/Red . . . . . . . . . . . . . . . . . . . . . . Dark Brown/Red Dk Brn/Yel . . . . . . . . . . . . . . . . . . . . . Dark Brown/Yellow Dk Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Green Lt Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Blue Lt Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Green Org/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange/White Pnk/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink/Black Pur/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Purple/White Red/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Black Red/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/White Wht/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Black Wht/Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Red Yel/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Black Yel/Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Red Yel/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yellow/White Electrical General Information - 104 ELECTRICAL GENERAL INFORMATION Common Circuit Tests Shorted Circuit: M85600 MIF A shorted circuit may result in the wrong component operating (i.e. improper wire-to-wire contact). To test for a shorted or improperly wired circuit: 1. Turn component switch ON. 2. Start at the controlling switch of the component that should not be operating. 3. Follow the circuit and disconnect wires at connectors until component stops operating. 4. Shorted or improper connections will be the last two wires disconnected. High Resistance or Open Circuit: M85601 MIF High resistance or open circuits usually result in slow, dim or no component operation (i.e. poor, corroded, or disconnected connections). Voltage at the component will be low when the component is in operation. To test for high resistance and open circuits: 1. Check all terminals and grounds of the circuit for corrosion. 2. If terminals are not corroded or loose, the problem is in the component or wiring. Grounded Circuit: M85602 MIF Grounded circuits usually result in no component operation or a blown fuse. Conductors For 12 Volt Circuits Electrical General Information - 105 ELECTRICAL GENERAL INFORMATION Stranded Conductors For 12 Volt Circuits SAE Wire Size (Gauge) 20 18 16 14 12 10 Metric Wire Size (MM) 0.5 0.8 1.0 2.0 3.0 5.0 Typical Stranding 7 X 28 16 X 30 19 X 29 19 X 27 19 X 25 19 X 23 Minimum Conductor Area In Circular Mils 1072 1537 2336 3702 5833 9343 Electrical General Information - 106 ELECTRICAL SPECIFICATIONS Specifications General Specifications Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Starter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Shift Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-amp Stator Battery: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BCI Group U1 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V Reserve Capacity @25A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Minutes Cold Cranking Amps @ 0° . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342 Headlights: Incandescent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Halogen Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.5 watt (optional) Tail Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 watt Bayonet Base Turn Signal/Hazard Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Cd/m2, Single Element, Type 1156 Instrument Panel Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 watt Bayonet Base Test and Adjustment Specifications Stator: Regulated Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 amps (minimum) at high idle Regulated Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 volts DC (maximum) Unregulated Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 VAC (minimum) Stator Coil Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.11 - 0.18 ohms Auxiliary Alternator (Optional): Regulated Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 amps (minimum) at high idle Regulated Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 volts DC (maximum) Unregulated Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 VAC (minimum) Starter: Loaded Amp Draw/RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 amps (maximum) at 500 RPM No-Load Amps/RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 amps (maximum) at 6000 RPM No-Load RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6000 Minimum Ignition Coil: Primary Winding Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 - 3.6 k-ohms Secondary Winding Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 21 k-ohms Air Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 - 0.40 mm (0.010 - 0.016 in.) Engine Coolant Temperature Sensor: Variable Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 - 700 ohms Off to On Closing Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 - 114 °C (226 - 237°F) On to Off Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 197°C (214 - 225°F) Electrical Specifications - 107 ELECTRICAL SPECIFICATIONS Engine Oil Pressure Switch: (0.47 in.) Switch Opening Pressure . . . . . . . . . . . . . . . . . . 98 kPa (14.2 psi) Repair Specifications PTO Clutch Solenoid: Starter: Resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10 ohms Spark Plug: Minimum Brush Length . . . . . . . . . . . . . . . . . . . . 6.0 mm (0.24 in.) Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75 mm (0.030 in.) Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . NGK BPR2Es Fuel Gauge Sender: Resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approximately 6 - 103 ohms EFI Vacuum Pressure Sensor - X720/X724/X728: Left and Center Terminals . . . . . . . . . . . . . . . . . . 2986 3034 ohms Left and Right Terminals . . . . . . . . . . . . . . . . . . . 773 787 ohms Center and Right Terminals. . . . . . . . . . . . . . . . . 3774 3798 ohms Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . about 5 volts DC Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 4.9 volts DC depending on air pressure EFI Air Temperature Sensor - X720/X724/X728: Resistance at 0°C (32 °F) . . . . . . . . . . . . . . . . . . . 5.29 6.47 k-ohms Resistance at 20°C (68°F) . . . . . . . . . . . . . . . . . . 2.21 2.69 k-ohms Resistance at 80°C (176°F) . . . . . . . . . . . . . . . . . 133 163 ohms EFI Coolant Temperature Sensor - X720/X724/X728: Resistance at 20°C (68°F) . . . . . . . . . . . . . . . . . . 2.21 2.69 k-ohms Resistance at 80°C (176°F) . . . . . . . . . . . . . . . . . 292 354 ohms Resistance at 110°C (230°F). . . . . . . . . . . . . . . . . 133 163 ohms Fuel Injectors - X720/X724/X728: Resistance at 20°C (68°F) . . . . . . . . . . . . . . . . . . 12.5 ohms RIO Switch: Air Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm Electrical Specifications - 108 ELECTRICAL SPECIFICATIONS Display Code Chart: Test Conditions Code • Brake on • PTO switch in RIO position (pulled out) • Key switch on Action Test Point Fault Cause Depress brake pedal. S8 brake switch, 765 Pur wire, 504 Yel wire, and switched power circuits. S8 brake switch OK. Turn key switch to start. S1 key switch, 720 Pur wire, 591 Yel wire, switched and unswitched power circuits. S1 key switch OK. Operator on seat. S4 seat switch, 800 Pnk wire, 502 Yel wire, and switched power circuits. S4 seat switch OK. Pull up RIP switch. S3 PTO/RIP switch, 754 Blu wire, 501 Yel wire, and switched power circuits. S3 PTO/RIP switch OK (RIP position). Activate PTO switch. S3 PTO/RIP switch, 755 Blu wire, 501 Yel wire, and switched power circuits. S3 PTO/RIP switch OK (PTO position). Depress reverse pedal. S7 RIO switch, 772 Blu wire, 402 Yel wire, and switched power circuits. S7 RIO switch OK. Remove oil pressure sensor wire. B1 engine oil pressure switch and 620 Tan wire. B1 engine oil pressure switch OK. B2 engine water temperature Remove and ground coolant sensor and 310 Org wire. temperature switch wire. B2 engine water temperature switch OK. Turn on back S9 light switch, 400 Yel/Blu up light switch. wire, and switched power circuits. S9 light switch OK (back up lights position). **** Rear PTO jumper (if installed) Engage rear PTO. S6 rear PTO switch, 740 Blu wire, 520 and 521 Yel wires, and switched power circuits. S6 rear PTO switch OK. No action End of tests End of tests Special or Essential Tools Note: Order tools according to information given in the Electrical Specifications - 109 ELECTRICAL SPECIFICATIONS U.S. SERVICE-GARD™ Catalog or in the European Microfiche Tool Catalog (MTC). Special or Required Tools Tool Name Tool No. Tool Use Spark Tester D-05351ST Test ignition system and spark plugs. Current Gun Photo Tachometer JTO5712 JTO5719 Starting motor tests. Battery Tester JTO5685 Starting motor amp draw test and battery tests. Current Gun Battery Tester JTO5712 JTO5685 Regulated amp and voltage tests. Other Materials Other Material Part No. TY9374/ TY9375 Part Name Pipe sealant with Teflon™ Part Use Seal threads on temperature sensor and oil pressure switches. Note: Teflon™ is a registered trademark of the Du Pont Company. Electrical Specifications - 110 ELECTRICAL COMPONENT LOCATION Component Location Right Side C D E B A F G L N M J K H I MIF A- X13 Power Port B- S2 Power Port Switch C- S4 Seat Switch D- S1 Key Switch E- S9 Light Switch F- K1 Main Relay (EFI) G- E2 LH Headlight H- G1 Battery I- E1 RH Headlight J- F5 Fuse - (X720/X724/X728) K- S7 RIO Switch L- K2 Fuel Relay (EFI) M- S3 PTO/RIP Switch N- F6 Fuse Electrical Component Location - 111 ELECTRICAL COMPONENT LOCATION Left Side B A C D E F R Q P O G H I J L N MIF A- G1 Battery B- K3 Safety Relay (EFI) C- S9 Light Switch D- A1 Display Panel E- S3 PTO/RIP Switch F- B3 Fuel Gauge Sender G- E3 RH Tail Light H- E5 RH Backup Light I- Y2 PTO Clutch Solenoid J- V1 Diode K- S5 Front PTO Switch (optional) L- S6 Rear PTO Switch (optional) M- E6 LH Backup Light K M N- E4 LH Tail Light O- S8 Brake Switch P- N1 Voltage Regulator/Rectifier Q- N2 Voltage Regulator/Rectifier (optional) R- A2 EFI Module (EFI) Electrical Component Location - 112 ELECTRICAL COMPONENT LOCATION Engine Components (FD671D) A B C D H G E F MX14278 A- B2 Engine Coolant Temperature Sensor B- B1 Engine Oil Pressure Switch (RH Side) C- Y3 Fuel Shutoff Solenoid D- T2 Ignition Module E- T1 Ignition Module F- Y1 Starting Motor Solenoid G- W1 Frame Ground H- E1 Spark Plug Electrical Component Location - 113 ELECTRICAL COMPONENT LOCATION Engine Components (FD750D EFI) D E C F G B A H N M I L K MX14312 A- B4 Engine Coolant Temperature Sensor B- Y3 #1 Cylinder Fuel Injector C- B5 Air Temperature Sensor D- B6 Vacuum Pressure Sensor E- Y4 #2 Cylinder Fuel Injector F- B2 Engine Coolant Temperature Sensor G- B1 Engine Oil Pressure Switch (RH Side) J H- T2 Ignition Module I- T1 Ignition Module J- X2 Wiring Harness Connector K- X10 Wiring Harness Connector L- Y1 Starting Motor Solenoid M- W1 Frame Ground N- E1 Spark Plug Electrical Component Location - 114 ELECTRICAL COMPONENT LOCATION Instrument Panel B A C F C E H J I H G E F MX13564 A- Fuel Gauge B- Oil Pressure Indicator Light C- Coolant Temperature Gauge D- EFI Diagnostic Light (X720/X724/X728) E- Battery Discharge Indicator Light F- Hour Meter G- Rear PTO Indicator Light H- Reverse Implement Option (RIO) Indicator Light I- Front and Mid PTO Indicator Light J- Park Brake Indicator Light Electrical Component Location - 115 D ELECTRICAL SCHEMATICS AND HARNESSES Schematics and Harnesses Y2 - PTO Clutch Solenoid Y3 - Fuel Shutoff Solenoid Schematic and Wiring Harness Legend - X700 A1 - Display Panel J1 - A1 Display Panel B1 - Engine Oil Pressure Switch J2 - A1 Display Panel B2 - Engine Coolant Temperature Sensor B3 - Fuel Gauge Sender E1 - RH Headlight E2 - LH Headlight E3 - RH Tail Light E4 -LH Tail Light E5 - RH Back Up Light E6 - LH Back Up Light E7 - Spark Plug E8 - Spark Plug F1 - Fuse 15A F2 - Fuse 15A F3 - Fuse 30A F4 - Fuse 20A F5 - Fuse 15A G1 - Battery G2 - Alternator G3 - Auxiliary Alternator (Option) M1 - Starting Motor M2 - Fuel Pump N1 - Voltage Regulator/Rectifier S1 - Key Switch S2 - Power Port Switch S3 - PTO/RIP Switch Connectors: J3 - A1 Display Panel X1 - W1 Main Wiring Harness to W4 Rear Wiring Harness X2 - W1 Main Wiring Harness to N1 Voltage Regulator/ Rectifier X3 - W1 Main Wiring Harness to W2 Engine Wiring Harness X4 - W1 Main Wiring Harness to W5 PTO Solenoid Wiring Harness X5 - Rear PTO Jumper X6 - M2 Fuel Pump to Fuel Pump Adaptor X13 - Power Port X14 - W6 Auxiliary Alternator (Option) Wiring Harness to G3 Auxiliary Alternator X15 - W6 Auxiliary Alternator (Option) Wiring Harness to N1 Voltage Regulator/Rectifier X16 - W6 Auxiliary Alternator (Option) Wiring Harness to N2 Voltage Regulator/Rectifier X17 - Auxiliary Alternator (Option) Wiring Harness to W2 Engine Wiring Harness Wiring Harnesses: W1 - Main Wiring Harness W2 - Engine Wiring Harness W3 - Headlight Wiring Harness W4 - Rear Wiring Harness W6 - Auxiliary Alternator Wiring Harness (Option) S4 - Seat Switch S5 - Front PTO Switch S6 - Rear PTO Switch (Option) S7 - RIO Switch S8 - Brake Switch S9 - Light Switch T1 - Ignition Coil T2 - Ignition Coil V1 - PTO Diode W1 - Frame Ground Y1 - Starting Motor Solenoid Electrical Schematics and Harnesses - 116 ELECTRICAL SCHEMATICS AND HARNESSES Schematic And Wiring Harness Legend X720/X724/X728 S8 - Brake Switch A1 -Display Panel T1 - Ignition Coil A2 - Electronic Fuel Injection Module (EFI) T2 - Ignition Coil B1 - Engine Oil Pressure Switch V1 - PTO Diode B2 - Engine Coolant Temperature Sensor W1 - Frame Ground B3 - Fuel Gauge Sender W2 - Frame Ground B4 - EFI Engine Coolant Temperature Sensor Y1 - Starting Motor Solenoid B5 - EFI Air Temperature Sensor Y2 - PTO Clutch Solenoid B6 - EFI Vacuum Pressure Sensor Y3 - #1 Cylinder Fuel Injection Solenoid E1 - RH Headlight Y4 - #2 Cylinder Fuel Injection Solenoid E2 - LH Headlight Connectors: E3 - RH Tail Light J1 - A1 Display Panel E4 - LH Tail Light J2 - A1 Display Panel E5 - RH Back Up Light J3 - A1 Display Panel E6 - LH Back Up Light X1 - W1 Main Wiring Harness to W4 Rear Wiring Harness E7 - Spark Plug E8 - Spark Plug X2 - W1 Main Wiring Harness to N2 Voltage Regulator/ Rectifier F1 - Fuse 15A X3 - W1 Main Wiring Harness W2 Main Wiring Harness F2 - Fuse 15A X4 - W1 Main Wiring Harness to W5 PTO Solenoid Wiring Harness F3 - Fuse 30A F4 - Fuse 20A F5 - Fuse 10A F6 - Fuse 15A G1 - Battery G3 - Auxiliary Alternator (Option) G2 - Alternator K1 - Main Relay K2 - Fuel Pump Relay K3 - Safety Relay M1 - Starting Motor M2 - Fuel Pump N1 - Voltage Regulator/Rectifier S1 - Key Switch S2 - Power Port Switch S3 - PTO/RIP Switch S4 - Seat Switch S9 - Light Switch X5 - Rear PTO Jumper X6 - W1 Main Wiring Harness to M2 Fuel Pump X7 - W1 Main Wiring Harness to W3 Headlight Wiring Harness X8 - W1 Main Wiring Harness to X10 EFI Connector X9 - W1 Main Wiring Harness to X10 EFI Connector X10 - W1 Main Wiring Harness to A2 EFI Module X11 - A2 EFI Module to X10 Connector X12 - X10 Connector to T1 and T2 Ignition Coils X13 - Power Port X14 - W6 Auxiliary Alternator (Option) Wiring Harness to G3 Auxiliary Alternator X15 - W6 Auxiliary Alternator (Option) Wiring Harness to N1 Voltage Regulator/Rectifier X16 - W6 Auxiliary Alternator (Option) Wiring Harness to N2 Voltage Regulator/Rectifier X17 - Auxiliary Alternator (Option) Wiring Harness to W2 Engine Wiring Harness S5 - Front PTO Switch S6 - Rear PTO Switch (Option) S7 - RIO Switch Electrical Schematics and Harnesses - 117 ELECTRICAL SCHEMATICS AND HARNESSES Wiring Harnesses: W1 - Main Wiring Harness W2 - Engine Wiring Harness W3 - Headlight Wiring Harness W4 - Rear Wiring Harness W5 - PTO Solenoid Wiring Harness W6 - Auxiliary Alternator Wiring Harness Electrical Schematics and Harnesses - 118 ELECTRICAL SCHEMATICS AND HARNESSES Electrical Schematic - X700 Carbureted (1 of 2) S1 Key Switch Off Run Start 593 Yel 402 Yel 591 Yel S2 401 Yel A S1 204 Red B G M S4 Seat Switch 402 Yel 520 Yel Off On 130 Blk 502 Yel 940 Wht / 941 Wht 800 Pnk 401 Yel 520 Yel F1 F2 B A 15A D C 15A F3 E F4 30A G 20A F H 400 Yel/Blu 400 Yel/Blu 593 Yel 500 Yel 500 Yel 505 Yel 204 Red 200 Red S-3 504 Yel 503 Yel S-5 594 Yel 501 Yel 591 Yel 410 Yel 209 Red 503 Yel 410 Yel 592 Blu 505 Yel 201 Red X1 202 Red 941 Wht 720 Pur S-1 212 S-2 Fuse Links S2 Power Port Switch 720 Pur 213 B Y1 Start Solenoid M1 Start Motor Pnk 209 Red A J2-B J2-K J1-E J3-D J3-A J3-H A1 Display Panel J3-B S3 PTO/RIP Switch Off N1 Voltage Regulator/ Rectifier F5 Fuse 15A On 511 Yel 3 Red S RIP* 756 Blu C U M 125 Blk X2 Off On Red 756 Blu 594 Yel J1-A 6 754 Blu 5 757 Blu 8 4 755 Blu 7 2 501 Yel 754 Blu J1-B 755 Blu J1-C J1-L J2-A 1 940 Wht 942 Wht X2 X3 A G1 Battery X13 Power Port 595 Brn/Wht V1 PTO Diode G 3 U 100 Blk X4 X3 B Blk 757 Blu 590 Brn/Yel G2 Alternator 125 Blk 758 Blu 116 Blk 130 Blk Y2 PTO Clutch Solenoid X4 115 Blk S-4 135 Blk E7 Spark Plug E8 Spark Plug 100 Blk 110 Blk 110 Blk W1 Ground T1 Ignition Coil Unswitched Power Switched Power MIF Electrical Schematics and Harnesses - 119 ELECTRICAL SCHEMATICS AND HARNESSES Electrical Schematic - X700 Carbureted (2 of 2) Neutral/Forward With Optional Rear PTO Reverse 402 Yel S7 RIO Switch 742 Blu/Wht S5 Front PTO Switch S6 Rear PTO Switch On 743 Pur 740 Blu 520 Yel 520 Yel S9 Light Switch 521 Yel 400 Yel/Blu 400 Yel/Blu 742 Blu/Wht On Off 740 Blu 521 Yel Off On On 772 Blu Off 450 Yel/Wht 455 Yel/Wht S-6 504 Yel S8 Brake Switch J1-G J1-S J2-F 459 Yel/Wht X7 (On) A1 Display Panel J1-D (Off) 765 Pur 504 Yel J2-C 810 Pnk F 810 Pnk X1 E J3-E E2 LH Headlight E1 RH Headlight 451 Yel/Wht 451 Yel/Wht J1-K E3 RH Taillight 815 Pnk 815 Pnk E4 LH Taillight X1 J1-H J1-M J2-J E5 RH Backup Light 900 Blk/Wht E6 LH Backup Light J3-F 650 Pnk/Blk 620 310 Tan Org X7 655 Pnk X3 X3 X5 651 Pnk/Blk 110 Blk X6 X1 X6 B1 Engine Oil Pressure Switch P 100 Blk t 0 Y3 Fuel Shutoff Solenoid M B2 Engine Water Temperature Sensor B3 Fuel Gauge Sender Q M2 Fuel Pump X6 X6 120 Blk 121 Blk 122 Blk 100 Blk 110 Blk 110 Blk MIF Electrical Schematics and Harnesses - 120 ELECTRICAL SCHEMATICS AND HARNESSES W1 Main Wiring Schematic - 720/X724/X728 EFI (1 of 2) S1 Key Switch Off Run Start 593 Yel 402 Yel 591 Yel S2 401 Yel A S1 206 Red B G M S4 Seat Switch 402 Yel Off On 502 Yel 520 Yel 401 Yel 800 Pnk F1 F2 B A D C 201 Red 30A G 20A 400 Yel/Blu 500 Yel 505 Yel 204 Red 15A F3 E F4 400 Yel/Blu 15A F 593 Yel 500 Yel 560 Red/Yel 501 Yel 220 Red S-7 H 200 Red S-3 504 Yel 503 Yel S-5 591 Yel 410 Yel 594 Yel 209 Red 503 Yel 410 Yel 592 Blu F5 10 Amp Fuse X1 202 Red 505 Yel 720 Pur S-1 212 S-2 Fuse Links 209 Red Red 756 Blu A Y1 Start Solenoid On J1-A J2-K J1-E J3-D J3-H J3-B S3 PTO/RIP Switch Off C 511 Yel 3 N1 Voltage Regulator/ Rectifier 221 560 Red Red/Yel U 6 754 Blu 5 757 Blu 8 4 755 Blu 7 2 501 Yel 754 Blu J1-B 755 Blu J1-C 1 J1-L 87a M 611 Brn 230 Red Off On S2 Power Port Switch G1 Battery X13 Power Port Blk RIP* X2 Red S B M1 Start Motor 125 Blk Pnk 720 Pur 213 756 Blu 594 Yel J2-B 100 Blk X2 595 Brn/Wht A 590 Brn/Yel F5 Fuse 15A B 30 85 86 170 Brn X4 V1 PTO Diode G2 Alternator 758 Blu 125 Blk 116 Blk 150 Blk S-4 Unswitched Power X10 233 Red/Blu X11 X9 110 Blk W1 Ground Y2 PTO Clutch Solenoid 87a X4 3 U 171 Brn 757 Blu K1 Main Relay X3 G 87 Switched Power MIF Electrical Schematics and Harnesses - 121 115 Blk 232 Red 231 Red K2 Fuel Pump Relay 87 30 85 86 100 Blk 110 Blk ELECTRICAL SCHEMATICS AND HARNESSES W1 Main Wiring Schematic - 720/X724/X728 EFI (2 of 2) S7 RIO Switch With Optional Rear PTO Neutral/Forward Reverse 402 Yel S5 Front PTO Switch 772 Blu 742 Blu/Wht S6 Rear PTO Switch On 520 Yel 743 Pur Off 742 Blu/Wht 740 Blu On Off 520 Yel 740 Blu 521 Yel 521 Yel S9 Light Switch 400 Yel/Blu 504 Yel 400 Yel/Blu 504 Yel Off On On 772 Blu 450 Yel/Wht J1-S J2-F S-6 455 Yel/Wht J1-G S8 Brake Switch A1 Display Panel 459 Yel/Wht X7 (On) F C (Off) J1-D E H J2-C J1-K J3-E E1 RH Headlight 765 Pur 810 Pnk 810 Pnk 451 Yel/Wht 451 Yel/Wht X1 815 Pnk 815 Pnk X1 J1-H 900 Blk/Wht E2 LH Headlight E6 LH Backup Light X7 J2-J J1-R J1-M J2-A J3-F K3 Safety Relay 785 Grn 310 Org 650 Pnk/Blk 620 Tan X3 139 Blk 87 30 85 86 E4 LH Taillight E3 RH Taillight 87a 670 Pur 110 Blk E5 RH Backup Light X6 X1 138 Blk P 651 Pnk/Blk 655 Pnk X6 910 Wht X8 100 Blk 110 Blk M M2 Fuel Pump B1 Engine Oil Pressure Switch X6 121 Blk t0 135 Blk Q B2 Engine Water Temperature Sensor B3 Fuel Gauge X6 Sender 120 Blk 100 Blk 110 Blk MIF Electrical Schematics and Harnesses - 122 122 Blk ELECTRICAL SCHEMATICS AND HARNESSES Liquid Cooled EFI Schematic (1 of 2) Blk X12 W2 Ground Y3 #1 Cylinder Fuel Injector Solenoid X10 Yel/Blu A 160 Blk B 330 Org Yel/Blu Blk/Wht Y4 #2 Cylinder Wht Fuel Injector Yel/Red Solenoid Brn Blk/Yel Yel/Red C 460 Yel Blk/Wht F 710 Pur G D 510 Blu E 610 Tan Org H 860 Pnk Red I Blk J Wht K 340 Grn L 240 Red Tan M 470 Yel Red/Blu Wht 950 Wht 170 Brn N Grn O 515 Blu Blu P 615 Tan Red Org Grn X9 Wht 233 Red/Blu 87a 232 Red M2 Fuel Pump X6 231 Red 655 Pnk 87 30 85 86 Blu 651 Pnk/Blk to M B4 Engine Coolant Temperature Sensor Blk/Yel Brn 910 Wht Red/Blu K2 Fuel Pump Relay X6 X8 Tan 121 Blk 100 Blk Switched Power 5 VDC Circuits W1 Ground MIF Electrical Schematics and Harnesses - 123 ELECTRICAL SCHEMATICS AND HARNESSES Liquid Cooled EFI Schematic (2 of 2) Blk Blk Blk Blk Blk E7 Spark Plug E8 Spark Plug T1 Ignition Coil T2 Ignition Coil X11 615 Tan A 515 Blu A1 Display Panel B C 470 Yel F C D 860 Pnk E F 710 Pur G 610 Tan H 160 Blk 330 Org I J 460 Yel 510 Blu 950 Wht A2 Electric Fuel Injection Module E H K L M 171 Brn N 340 Grn 240 Red O J1-L P J1-R 611 Brn 87a 785 Grn 670 Pur Org Grn to B5 Air Temperature Sensor Blk/Yel Blk/Yel Blk/Yel Red/Blu m 650 Pnk/Blk K3 Safety Relay X8 170 Brn Red J3-F 785 Grn B6 Vacuum Pressure Sensor Tan MIF Electrical Schematics and Harnesses - 124 87 30 85 86 ELECTRICAL SCHEMATICS AND HARNESSES W1 Main Wiring Harness - X700 Carbureted (1 of 2) 800 655 754 451 942 620 755 765 651 X5 Connector Fuel Pump Shutoff 410 772 815 941 900 740 650 756 J1 Connector to Instrument Cluster 505 135 591 720 J3 Connector to Instrument Cluster 742 810 310 503 J2 Connector to Instrument Cluster W1 Ground X3 to W2 Engine Wiring Harness M1 Starting Motor Fusible Links 595 590 310 620 213 S-2 100 940 942 212 650 655 Fuse Block F1 15A F2 15A F3 30A F4 20A S-1 110 S-6 202 201 Y1 Start Solenoid 720 504 110 455 765 X7 to W3 Headlight Wiring Harness MIF Electrical Schematics and Harnesses - 125 S8 Brake Switch 450 451 455 459 ELECTRICAL SCHEMATICS AND HARNESSES W1 Main Wiring Harness - X700 Carbureted (2 of 2) S1 Key Switch 130 940 941 204 593 S3 PTO/RIP Switch 501 511 755 591 401 757 511 756 754 S9 Light Switch 511 810 450 400 X2 to N1 Voltage Regulator/Rectifier 594 125 209 595 590 X6 to B3 Fuel Gauge Sender and M2 Fuel Pump 100 125 130 135 410 594 593 122 504 121 503 120 501 115 500 121 651 402 520 209 502 200 S-5 S-4 120 592 900 S-3 521 740 122 459 592 815 743 742 520 S6 Rear PTO S5 Front 521 Switch PTO Switch (Option) X1 to Rear Lights Wiring Harness S7 RIO Switch 502 772 402 116 V1 PTO Diode 758 757 758 X4 to Y2 PTO Clutch S4 Seat Switch 800 115 116 MIF Electrical Schematics and Harnesses - 126 ELECTRICAL SCHEMATICS AND HARNESSES W1 Main Wiring Harness - X720/X724/X728 EFI (1 of 2) 800 754 655 451 611 620 755 765 K2 Fuel Pump Relay 910 231 815 785 740 900 650 756 J1 Connector to Instrument Cluster K1 EFI Module Power Relay 560 230 505 135 591 720 J3 Connector to Instrument Cluster 742 810 150 221 139 138 310 503 220 J2 Connector to Instrument Cluster F5 Fuse 650 W1 Ground 651 X6 Connector 410 772 655 232 X2 to W2 Engine Wiring Harness M1 Starting Motor Fusible Links 213 595 100 670 K3 EFI Module Ground Relay 590 F1 15A F2 15A F3 30A F4 20A 310 620 212 X3 to W2 Engine Wiring Harness S-1 S-2 221 910 785 110 Fuse Block 670 202 X9 to W2 Engine Wiring Harness 201 170 233 611 171 S-9 Y1 Start Solenoid 720 A M 110 455 D P D X7 to W3 Headlight Wiring Harness X10 to W2 Engine Wiring Harness A P M A = 160 B = 330 C = 460 D = 510 E = 610 F = 710 G = plug H = 860 MIF Electrical Schematics and Harnesses - 127 I = 950 J = 170 K = 340 L = 240 M = 470 N = plug O = 515 P = 615 504 765 S8 Brake Switch ELECTRICAL SCHEMATICS AND HARNESSES W1 Main Wiring Harness - X720/X724/X728 EFI (2 of 2) S1 Key Switch S3 PTO/RIP Switch 501 511 206 755 593 757 511 756 591 754 401 511 S9 Light Switch X10 to A2 Electric Fuel Injection Module 450 160 810 400 330 610 460 710 510 860 470 950 171 S-8 206 220 340 204 240 515 615 X2 to N1 Voltage Regulator/Rectifier 594 125 595 590 S-7 230 231 X6 to B3 Fuel Gauge Sender and M2 Fuel Pump 232 233 S-6 209 450 451 455 459 135 125 100 150 138 139 410 594 593 560 122 504 121 503 120 501 115 500 121 651 402 520 209 502 200 S-5 S-4 120 592 900 S-3 521 740 122 459 592 815 743 742 520 S6 Rear PTO S5 Front PTO Switch 521 Switch (Option) X1 to Rear Lights Wiring Harness S7 RIO Switch 502 772 402 116 758 757 758 X4 to Y2 PTO Clutch S4 Seat Switch 800 115 116 MIF Electrical Schematics and Harnesses - 128 ELECTRICAL SCHEMATICS AND HARNESSES W2 Engine Wiring Harness - X700 Yel/Wht Y3 Fuel Shutoff Solenoid Wht X2 to W1 Main Wiring Harness T1 Ignition Coil Blk T2 Ignition Coil Blu/Red Wht Blk Yel Yel/Wht Blk Wht Blk B1 Engine Oil Pressure Switch (NC) Blu/Red G2 Alternator Yel B3 Engine Coolant Temperature Sensor MIF Electrical Schematics and Harnesses - 129 ELECTRICAL SCHEMATICS AND HARNESSES W2 Engine Wiring Harness - X720/X724/X728 EFI Dk Blk X2 to W1 Main Wiring Harness Lt Blk T1 Ignition Coil T2 Ignition Coil Yel Blu/Red Lt Blk Lt Blk Dk Blk Dk Blk Lt Blk B1 Engine Oil Pressure Switch (NC) Wht Blu/Red Yel/Blu G2 Alternator Y3 #1 Cylinder Fuel Injector Solenoid B5 Air Temperature Sensor Grn Blk Yel B2 Engine Coolant Temperature Sensor AB AB X12 Connector Blk/Yel B4 Engine Coolant Temperature Sensor Blk Blk/Wht Red W2 Ground Blu AB Brn X3 to W1 Main Wiring Harness Blk/Yel B6 Vacuum Pressure Sensor Blk/Yel Org Wht Tan X9 to W1 Main Wiring Harness AB Red/Blu A = 160 B = 330 C = 460 D = 510 E = 610 F = 710 G = plug H = 860 Y4 #2 Cylinder Fuel Injector Solenoid Wht Yel/Red I = 950 J = 170 K = 340 L = 240 M = 470 N = plug O = 515 P = 615 A M D P X10 to W1 Main Wiring Harness MIF Electrical Schematics and Harnesses - 130 ELECTRICAL SCHEMATICS AND HARNESSES W2 Engine Wiring Harness Circuit Schematic - X720/X724/X728 X2 to Main W1 Main Wiring Harness T1 Ignition Coil Blk T2 Ignition Coil Blk Dk Blk B3 Engine Coolant Temperature Sensor X12 Dk Blk Yel X8 to W1 Main Wiring Harness Blk Blu/ Red Red B5 Air Temperature Sensor Org Brn B1 Engine Oil Pressure Switch Blk/Yel Grn X11 to W1 Main Wiring Harness A B B4 Engine Coolant Temperature Sensor B6 Vacuum Pressure Sensor C Blk/Yel D Blu E F G H Blk/Yel I Lt Blk Lt Blk J Tan K Red/Blu L M Y3 #1 Cylinder Fuel Injector Solenoid N Yel/Blu O Wht P G2 Alternator Y4 #2 Cylinder Fuel Injector Solenoid Yel/Red Wht Blk/ Wht X9 to W1 Main Wiring Harness Blk/ Wht Wht W2 Ground MIF Electrical Schematics and Harnesses - 131 ELECTRICAL SCHEMATICS AND HARNESSES W3 Headlight Wiring Harness E1 RH Headlight Blk Blk X7 To W1 Main Wiring Harness Blk E2 LH Headlight Blk MIF W4 Rear Wiring Harness E4 Left Tail Light E6 Left Backup Light 110 800 E3 Right Tail Light 100 420 110 100 593 594 594 150 130 400 592 E5 Right Backup Light 820 150 130 120 593 S2 Accessory Switch X1 to Main Wiring Harness 12 VDC Power Port 800 820 592 A B D B C A 400 420 120 140 140 MIF W5 PTO Option Wiring Harness S6 Rear PTO Switch 790 520 740 790 X5 to W1 Main Wiring Harness 742 742 S5 Front PTO Switch 520 MIF Electrical Schematics and Harnesses - 132 740 ELECTRICAL SCHEMATICS AND HARNESSES W6 Auxiliary Alternator Wiring Harness 591 Brn 126 Blk 596 Brn X14 504 210 Yel Red 590 Brn 600 Brn 125 Blk X15 595 Brn 211 Red X16 595 Brn 600 Brn 126 Blk 521 Yel X17 Electrical Schematics and Harnesses - 133 504 Yel 125 Blk 596 Brn 210 Red 590 Brn 211 Red 591 Brn ELECTRICAL SCHEMATICS AND HARNESSES W6 Auxiliary Alternator Wiring Harness Circuit Schematic 125 Blk 125 Blk 504 Yel 504 Yel 210 Red 210 Red 590 Brn 590 Brn 600 Brn 600 Brn 595 Brn 595 Brn 521 Yel 126 Blk 211 Red 126 Blk 521 Yel 211 Red 591 Brn 596 Brn G G3 Alternator Electrical Schematics and Harnesses - 134 ELECTRICAL SCHEMATICS AND HARNESSES A2 EFI Module Pin and Signal Location P A O B N C M D L K E F J G H I A- 615 Tan -Engine Coolant Temp Sensor In B- 515 Blu - Air Temp Sensor In C- Not Used D- 470 Yel - Vacuum Pressure Sensor Operational Voltage E- 860 Pnk - Machine Interlock Safety Ground F- Not Used G- 710 Pur - EFI Module Ground H- 610 Tan - #2 Injector Control (Ground) I- 160 Blk - #2 Injector Control (Ground) J- 330 Org - EFI Module Ground K- 460 Yel - Fuel Pump Relay Control (Ground) L- 510 Blu - EFI Sensor Ground M- 950 Wht -Fault Light Out N- 171 Brn - Tach In O- 340 Grn -Vacuum Pressure Sensor In P- 240 Red - Power Out to Fuel Injectors Electrical Schematics and Harnesses - 135 ELECTRICAL SCHEMATICS AND HARNESSES W1 Main Wiring Harness Color Codes - X700 Size/No./Color Wire Connection Points Size/No./Color Wire Connection Points 1.0 505 Yel F2, J3 3.0 100 Blk W1, Splice (S-4) 0.8 511 Yel S3, S3 1.0 110 Blk W1, X7 0.8 520 Yel Splice (S-5), S5 0.8 115 Blk Splice (S-4), X4 0.8 521 Yel S5, S6 0.8 116 Blk V1, X4 3.0 590 Brn/Yel X3, X2 0.8 120 Blk Splice (S-4), X6 0.8 591 Pur S1, J2 0.8 121 Blk Splice (S-4), X6 3.0 592 Blu Splice (S-3), X1 3.0 122 Blk Splice (S-4), X1 0.8 593 Yel S1, Splice (S-5) 2.0 125 Blk Splice (S-4), X2 0.8 594 Yel Splice (S-5), X2 0.8 130 Blk Splice (S-4), S1 3.0 595 Brn/Wht X3, X2 0.8 135 Blk Splice, X3 0.8 620 Tan J1, X3 3.0 200 Red F4, Splice (S-3) 0.8 650 Pnk/Blk J3, X3 3.0 201 Red F3, Splice (S-1) 0.8 651 Pnk/Blk X5, X6 3.0 202 Red Splice (S-2), F4 0.8 655 Pnk X3, X5 3.0 204 Red F3, S1 1.0 720 Pur Y1, J3 3.0 209 Red Splice (S-3), X2 0.8 740 Blu S6, J1 1.0 212 Fusible Link Y1, Splice (S-1) 0.8 742 Blu/Wht S5, J2 1.0 213 Fusible Link Y1, Splice (S-2) 0.8 743 Pur Rear PTO Jumper 0.8 310 Org J2, X3 0.8 754 Blu S3, J1 2.0 400 Yel/Blu F1, S9 0.8 755 Blu S3, J1 3.0 401 Yel F1, S1 0.8 756 Blu S3, J3 0.8 402 Yel Splice (S-5), S7 0.8 757 Yel S3, X4 0.8 410 Yel Splice (S-5), J1 0.8 758 Blu X4, V1 1.0 450 Yel/Wht S9, Splice (S-6) 0.8 765 Pur J1, S8 0.8 451 Yel/Wht Splice (S-6), J1 0.8 772 Blu S7, J1 1.0 455 Yel/Wht Splice (S-6), X7 0.8 800 Pnk S4, J1 0.8 459 Yel/Wht Splice (S-6), X1 0.8 810 Pnk J2, S9 2.0 500 Yel F5, Splice (S-5) 1.0 815 Pnk J3, X1 0.8 501 Yel Splice (S-5), S3 0.8 900 Blk/Wht J1, X6 0.8 502 Yel Splice (S-5), S4 0.8 940 Wht Splice, X3 1.0 503 Yel Splice (S-5), J2 0.8 941 Wht J3, Splice 0.8 504 Yel Splice (S-5), S8 0.8 942 Wht X3, J1 Electrical Schematics and Harnesses - 136 ELECTRICAL SCHEMATICS AND HARNESSES W1 Main Wiring Harness Color Codes - X720/ X724/X728 EFI Size/No./Color Wire Connection Points 0.8 310 Org J2, X3 Size/No./Color Wire Connection Points 0.8 330 Org X10, X11 3.0 100 Blk W1, Splice (S-4) 0.8 340 Grn X10, X11 1.0 110 Blk W1, X7 2.0 400 Yel/Blu F1, S9 0.8 115 Blk Splice (S-4), X4 3.0 401 Yel F1, S1 0.8 116 Blk V1, X4 0.8 402 Yel Splice (S-5), S7 0.8 120 Blk Splice (S-4), X6 0.8 410 Yel Splice (S-5), J1 0.8 121 Blk Splice (S-4), X6 1.0 450 Yel/Wht S9, Splice (S-6) 3.0 122 Blk Splice (S-4), X1 0.8 451 Yel/Wht Splice (S-6), J1 2.0 125 Blk Splice (S-4), X2 1.0 455 Yel/Wht Splice (S-6), X7 0.8 135 Blk Splice (S-4), J2 0.8 459 Yel/Wht Splice (S-6), X1 1.0 138 Blk Splice (S-4), K3 0.8 460 Yel X10, X11 1.0 139 Blk Splice (S-4), K3 0.8 470 Yel X10, X11 0.8 150 Blk Splice (S-4), K1 2.0 500 Yel F2, Splice (S-5) 0.8 160 Blk X10, X11 0.8 501 Yel Splice (S-5), S3 0.8 170 Brn X10, Splice 0.8 502 Yel Splice (S-5), S4 0.8 171 Brn X11, Splice 1.0 503 Yel Splice (S-5), J2 3.0 200 Red F4, Splice (S-3) 0.8 504 Yel Splice (S-5), S8 5.0 201 Red Splice (S-1), F3 1.0 505 Yel F2, J3 3.0 202 Red Splice (S-2), F4 0.8 510 Blu X10, X11 5.0 204 Red F3, Splice (S-3) 0.8 511 Blu S3, S3 3.0 206 Red Splice (S-3), S1 0.8 515 Blu X10, X11 3.0 209 Red Splice (S-3), X2 0.8 520 Yel Splice (S-5), S5 2.0 212 Fusible Link Y1, Splice (S-1) 0.8 521 Blu S5, S6 1.0 213 Fusible Link Y1, Splice (S-2) 0.8 560 Red/Yel Splice (S-5), K1 1.0 220 Red Splice (S-7), F5 3.0 590 Brn/Yel X2, X3 1.0 221 Red F5, K1 0.8 591 Pur S1, J2 0.8 230 Red K1, Splice 3.0 592 Blu Splice (S-3), X1 0.8 231 Red Splice, K2 0.8 593 Yel S1, Splice (S-5) 0.8 232 Red Splice, K2 0.8 594 Yel X2, Splice (S-5) 0.8 233 Red/Blu Splice, X9 3.0 595 Brn/Wht X2, X3 0.8 240 Red X10, X11 0.8 610 Tan X10, X11 Electrical Schematics and Harnesses - 137 ELECTRICAL SCHEMATICS AND HARNESSES W2 Engine Wiring Harness Color Codes X700 Size/No./Color Wire Connection Points 0.5 Red/Blu X10, B6 Size/No./Color Wire Connection Points 0.5 Wht X10, Splice 0.5 Blk X2, G2 0.5 Wht Splice, X10 0.5 Blk X2, G2 0.5 Wht Splice, Y3 0.5 Wht X2, T1 0.5 Wht Splice, Y4 0.5 Wht X2, T2 0.5 Tan X10, B6 0.5 Yel/Wht X2, Y2 0.5 Grn X10, B5 0.5 Blu/Red X2, B1 0.5 Blu X10, B4 0.5 Yel X2, B3 W3 Headlight Wiring Harness Color Codes W2 Engine Wiring Harness Color Codes X720/X724/X728 Size/No./Color Wire Connection Points 0.5 Lt Blk X2, G2 0.5 Lt Blk X2, G2 0.5 Dk Blk X2, T1 0.5 Dk Blk X2, T2 0.5 Dk Blk X2, X24 0.5 Blu/Red X2, B1 0.5 Yel X2, B3 0.5 Yel/Blu X10, Y3 0.5 Blk/Wht X10, Splice 0.5 Blk/Wht Splice, W2 0.5 Blk/Wht X10, Splice 0.5 Brn X10, X8 0.5 Blk/Wht X10, Splice 0.5 Blk/Yel Splice, B4 0.5 Blk/Yel Splice, B5 0.5 Blk/Yel Splice, B6 0.5 Yel/Red X10, Y4 0.5 Org X10, X8 0.5 Red X10, X8 0.5 Blk X10, X12 Size/Color Wire Connection Points 0.8 Blk X7, E1 0.8 Blk X7, E2 0.8 Blk E1, X7 0.8 Blk E2, X7 W4 Rear Lights Wiring Harness Color Codes Size/No./Color Wire Connection Points 0.8 100 Blk Splice, E4 0.8 110 Blk Splice, E6 0.8 120 Blk Splice, X1 0.8 130 Blk Splice, E3 2.0 140 Blk X13, X1 0.5 150 Blk Splice, E6 0.8 400 Yel X1, E4 0.8 420 Yel X1, E3 2.0 592 Pnk X1, S2 2.0 593 Pnk S2, X13 0.8 800 Pur X1, E6 0.8 820 Pur X1, E5 Electrical Schematics and Harnesses - 138 ELECTRICAL SCHEMATICS AND HARNESSES W5 PTO Option Wiring Harness Color Codes Size/No./Color Wire Connection Points 0.8 520 Yel Splice (S-5), S5 0.8 740 Blu S6, J1 0.8 742 Pur Jumper 0.8 521 Yel S5, J2 W6 Auxiliary Alternator Wiring Harness Color Codes Size/No./Color Wire Connection Points 3.0 125 Blk X15, X16 3.0 126 Blk X17, W1 Ground 3.0 210 Red X15, X16 3.0 211 Red X17, Splice 1.0 212 Red Splice (Fusible Link), 212 0.8 504 Yel X15, X16 0.8 521 Yel X15, X17, 3.0 590 Brn X15, X16 3.0 591 Brn X17, X14 3.0 595 Brn X15, X16 3.0 596 Brn X17, X14 0.8 600 Brn X15, X16 Electrical Schematics and Harnesses - 139 ELECTRICAL OPERATION AND DIAGNOSTICS Operation and Diagnostics Power Circuit Operation - X700 Function: To provide unswitched and switched power to the primary electrical components whenever the battery is properly connected. The power circuits are divided among the unswitched power circuit, switched power circuits (key switch in run position), and secondary power circuits. The secondary power circuits become energized when switched power circuits energize signal wires to the A1 display panel, providing current paths to the secondary circuits. The secondary power circuits will not be energized if the A1 display panel fails. Operating Conditions, Unswitched Circuits: Voltage must be present at the following components with the key switch in the off position. • G1 battery positive terminal • M1 starting motor - B terminal • S1 key switch - B terminal • N1 voltage regulator/rectifier - X2 connector, 209 Red • F3 and F4 fuses • S2 power port switch The positive battery cable connects the battery to the starting motor. The starting motor bolt is used as the 12 volt DC tie point for the rest of the electrical system. These circuits are protected by the 212 and 213 fusible links and the F3 and F4 fuses respectively. The battery cables and the starting motor tie point connections must be good for the machine’s electrical system to work properly. Proper starting motor operation depends on the battery cables to carry high current. The ground cable connection is equally as important as the positive cable connection in maintaining electrical system integrity Operating Conditions, Switched Circuits: With the key switch in run position, PTO switch(es) in the off position, brake locked, and operator off the seat, switched voltage should be present at the following components: • S5 PTO/RIP switch - 501 and 511 Yel wires • S4 seat switch - 502 Yel wire • S7 RIO switch - 402 Yel wire • N1 voltage rectifier/regulator - X2 connector, 594 Yel wire • A1 display panel - J1 connector, 410 Yel wire • A1 display panel - J2 connector, 503 Yel wire • A1 display panel - J3 connector, 505 Yel wire • A1 display panel - J2 connector, 742 Blu/Wht wire (If rear PTO option not installed) • S6 rear PTO switch (rear PTO option installed) 520 Yel wire • S5 front PTO switch (rear PTO option installed) 521 Yel wire These circuits are controlled by the key switch and are protected by the F3 and F4 fuses and the unswitched circuits. With power now available at various locations on the machine, the electrical system is ready to perform the different functions of starting and running the engine, engine monitoring lights, the PTO clutch and the PTO system interlocks, and the headlights. The ground circuit is equally important as the power circuit connections. Proper systems operation depends on good wires and connections in order to carry the current needed to operate the various components. Operating Conditions, Secondary Switched Circuits: Secondary switched voltage must be present at the following components during the following conditions: Key switch in run position, transmission in neutral, PTO in off position, brake locked, and operator off seat: • S3 PTO/RIP switch - 756 Blu wire • Y3 fuel shutoff solenoid - 650 Pnk/Blk and 655 Pnk wires • M2 fuel pump - 651 Pnk/Blk wire • B3 fuel gauge sender - 900 Blk/Wht wire • B2 engine coolant temperature sensor - X3 connector, 310 Org wire • S1 key switch - terminal “A” • A1 display panel - J1 connector, 410 Yel wire • B1 engine oil pressure switch - X3 connector, 620 Tan wire • A1 display panel - J2 connector, 503 Yel wire • • A1 display panel - J3 connector, 505 Yel wire • F1 and F2 fuses These circuits are controlled by the A1 display panel and are protected by the fusible links and the F1, F2, F3, and F4 fuses. • S9 light switch - 400 Yel/Blu wire • S6 brake switch - 504 Yel wire S6 brake switch - 765 Pur wire Electrical Operation and Diagnostics - 140 ELECTRICAL OPERATION AND DIAGNOSTICS Power Circuit Electrical Schematic - X700 S1 Key Switch Off Run Start 593 Yel 402 Yel 591 Yel S2 401 Yel A S1 204 Red B G M S4 Seat Switch 402 Yel 520 Yel Off On 502 Yel 800 Pnk 401 Yel 520 Yel F1 F2 B A 15A D C F3 E F4 F 500 Yel 505 Yel 204 Red H 200 Red 15A 30A G 20A 400 Yel/Blu 400 Yel/Blu S-3 593 Yel 500 Yel 504 Yel 503 Yel S-5 594 Yel 501 Yel 410 Yel 209 Red 591 Yel J1-A J2-B 503 Yel 410 Yel 592 Blu 505 Yel 201 Red 209 Red A1 Display Panel 594 Yel 756 Blu 212 J1-E J3-D X1 202 Red S-1 J2-K S-2 Fusible Links Pnk A Red B Y1 Start Solenoid S U On J3-B S3 PTO/RIP Switch Off C 511 Yel 3 Red S2 Power Port Switch RIP* 756 Blu X2 Off On 213 M1 Start Motor 125 Blk N1 Voltage Regulator/ Rectifier 2 501 Yel 1 6 5 8 4 7 J2-A M 135 Blk 125 Blk G1 Battery Blk 100 Blk S-4 100 Blk Secondary Power Circuits W1 Ground Unswitched Power Switched Power Safety Circuits Switched Power MIF Electrical Operation and Diagnostics - 141 ELECTRICAL OPERATION AND DIAGNOSTICS With Optional Rear PTO (X5 Connector) Neutral/Forward Reverse 402 Yel S5 Front PTO Switch S7 RIO Switch 742 Blu/Wht 520 Yel Off 740 Blu 520 Yel S9 Light Switch Off On On 521 Yel 772 Blu 400 Yel/Blu 400 Yel/Blu 504 Yel S8 Brake Switch J1-G J1-S J2-F (On) A1 Display Panel (Off) 765 Pur J1-D 504 Yel F E 900 Blk/Wht J1-H J3-F J1-M J2-J 650 Pnk/Blk 620 310 Tan Org X3 655 Pnk X3 X5 651 Pnk/Blk X6 X6 B1 Engine Oil Pressure Switch P 100 Blk t0 Y3 Fuel Shutoff Solenoid M B2 Engine Water Temperature Sensor M2 Fuel Pump B3 Fuel Gauge Sender Q X6 X6 120 Blk 121 Blk S6 Rear PTO Switch On 743 Pur 100 Blk MIF Electrical Operation and Diagnostics - 142 742 Blu/Wht On Off 521 Yel A1 Display Panel (J2-F) 740 Blu A1 Display Panel (J1-S) ELECTRICAL OPERATION AND DIAGNOSTICS Power Circuit Diagnosis - X700 Yes: Go to next step. Test Procedure A: No: Check 200 Red wire, 592 Pnk wire, and X1 connector. Test Conditions: • Machine parked safely with park brake locked. • Key switch in off position. • Battery fully charged. • Follow procedure in sequence. • Ensure all circuit grounds are in good condition and have continuity. Unswitched Power Circuits: D E 15 15 B 30 20 A 1. Is battery voltage present at F4 20A fuse, 200 Red wire (A)? Yes: Go to next step. No: Check 213 fusible link, 202 Red wire and F4 fuse. Yes: Go to next step. 4. Is battery voltage present at N1 voltage regulator/ rectifier X2 connector Red wire (D)? If auxiliary alternator is installed, check for battery voltage at N2 voltage regulator/rectifier Red wire (E) as well. No: Check 212 fusible link, 201 Red wire, and F3 fuse. Yes: Go to next step. 2. Is battery voltage present at F3 30A fuse, 204 Red wire (B)? No: Check 209 and 200 Red wires and connections. C F 3. Is battery voltage present at S2 power port switch 592 Pnk wire (C)? 5. Is battery voltage present at S1 key switch, 204 Red wire (F)? Electrical Operation and Diagnostics - 143 ELECTRICAL OPERATION AND DIAGNOSTICS Yes: End of unswitched power circuit diagnosis. No: Check 204 Red wire and connections. Test Procedure B: 3. Is battery voltage present at S9 light switch, 400 Yel/ Blu wire (I)? Yes: Go to next step No: Check 400 Yel/Blu wire and connections. Test Conditions: • Machine parked safely with park brake locked. • Key switch in run position. • Follow procedure in sequence. • Ensure all ground circuits are in good condition and have continuity. Switched Power Circuits: J G 15 15 30 H 4. Is battery voltage present at A1 display panel, J3 connector 505 Yel wire (J)? Yes: Go to next step. 20 No: Check 505 Yel wire and connections. 1. Is battery voltage present F1 15A fuse, 400 Yel/Blu wire (G)? Yes: Go to next step. No: Test F1 fuse. No: Test S1 key switch. See “Key Switch Test” on page 219. K No: Check 401 Yel wire and connections. 2. Is battery voltage present at F2 15A fuse, 500 and 505 Yel wires (H)? 5. Is battery voltage present at A1 display panel, J1 connector 410 Yel wire (K)? Yes: Go to next step. Yes: Go to next step. No: Test F2 fuse. No: Check 500 Yel wire, S-5 splice, and 410 Yel wire and connections. I Electrical Operation and Diagnostics - 144 ELECTRICAL OPERATION AND DIAGNOSTICS M L O 6. Is battery voltage present at A1 display panel, J2 connector 503 Yel wire (L)? 9. If rear PTO option is installed - Is battery voltage present at S5 front PTO switch, 520 Yel wire (O)? Yes: Go to next step. Yes: Go to next step. No: Check 500 Yel wire, S-5 splice, and 503 Yel wire and connections. No: Check 500 Yel wire, S-5 splice, and 520 Yel wire and connections. 7. If rear PTO option is not installed - Is battery voltage present at A1 display panel, J2 connector 742 Blu/Wht wire? Yes: Go to next step. No: Check 500 and 520 Yel, 743 Pur, and 742 Blu/Wht wires and connections. P 10. If rear PTO option is installed - Is battery voltage present at S6 rear PTO switch, 521 Yel wire (P)? Yes: Go to next step. N No: Check 521 Yel wire and connections. 8. Is battery voltage present at S7 RIO switch, 402 Yel wire (N)? Yes: Go to next step. No: Check 500 Yel wire, S-5 splice, and 402 Yel wire and connections. Q 11. Is battery voltage present at S8 brake switch, 504 Yel wire (Q)? Yes: Go to next step. Electrical Operation and Diagnostics - 145 ELECTRICAL OPERATION AND DIAGNOSTICS No: Check 500 Yel wire, S-5 splice, and 504 Yel wire and connections. R T U 12. Is battery voltage present at S1 key switch, 593 Yel wire (R)? Yes: Go to next step. No: Check 500 Yel wire, S-5 splice, and 593 Yel wire and connections. S 14. Is battery voltage present at X2 connector of N1 voltage regulator/rectifier, 594 Yel wire (T)? If G2 auxiliary alternator is installed, check for battery voltage at N2 voltage regulator/rectifier, 521 Yel wire (U) as well. Yes: End of switched power tests. 13. Is battery voltage present at S3 PTO/RIP switch 501 and 511 Yel wires (S)? No: Check 500 Yel wire, S-5 splice, and 594 Yel wire and connections. If G2 auxiliary alternator is installed, check 521 Yel wire as well. Yes: Go to next step. No: Check 500 Yel wire, S-5 splice, 501 and 511 Yel wires and connections. V 15. Is battery voltage present at S4 seat switch, 502 Yel wire (V)? Electrical Operation and Diagnostics - 146 ELECTRICAL OPERATION AND DIAGNOSTICS Yes: Go to next procedure. No: Check 500 Yel wire, S-6 splice, and 502 Yel wire and connections. 2. If installed, engage rear PTO (S6 rear PTO switch in the on position). Is battery voltage present at A1 display panel J1 connector, 740 Blu wire (X)? Yes: Go to next step. Test Procedure C: No: Test S6 rear PTO switch. See “PTO Switch Test (Optional Rear PTO Installed)” on page 223. If OK, check 740 Blu wire and connections. Test Conditions: • Machine parked safely with park brake locked. • Key switch in run position, engine off. • Battery fully charged. Y • Component under test in active position. De-activate circuit when done testing. • Follow procedure in sequence. • Ensure all circuit grounds are in good condition and have continuity. Secondary Power Circuits: W 3. Close S4 seat switch (operator on seat). Is battery voltage present at A1 display panel J1 connector, 800 Pnk wire (Y)? Yes: Go to next step. No: Test S4 seat switch. If OK, check 800 Pnk wire and connections. 1. Place S5 front PTO switch in on position. Is battery voltage present at A1 display panel J2 connector, 742 Blu/Wht wire (W)? Z Yes: Go to next step. No: Test S5 front PTO switch. See “PTO Switch Test (Optional Rear PTO Installed)” on page 223. If OK, check 742 Blu/Wht wire and connections. 4. Place transmission in neutral (S7 RIO switch closed). Is battery voltage present at A1 display panel J1 connector, 772 Blu wire (Z)? Yes: Go to next step. No: Test S7 RIO switch. See “RIO Switch Test” on page 221. If OK, check 772 Blu wire and connections. X Electrical Operation and Diagnostics - 147 ELECTRICAL OPERATION AND DIAGNOSTICS No: Check 620 Tan wire and connections. If OK, replace A1 display panel. aa ac 5. Close S8 brake switch (brake pedal depressed). Is battery voltage present at A1 display panel J1 connector, 765 Pur wire (aa)? Yes: Go to next procedure. No: Test S8 brake switch. See “Brake Switch Test and Adjustment” on page 220. If OK, check 765 Pur wire and connections. 2. Is battery voltage present at X3 connector, 310 Org wire (AC) of B2 engine coolant temperature sensor? Yes: If necessary, test B2 engine coolant temperature sensor. See “Engine Coolant Temperature Sensor Test” on page 216. Go to next step. No: Check 310 Org wire and connections. If OK, replace A1 display panel. Test Procedure D: ad Test Conditions: • Machine parked safely with park brake locked. • Key switch in run position, engine off. • Battery fully charged. • Component under test in active position. De-activate circuit when done testing. • Follow procedure in sequence. • Ensure all circuit grounds are in good condition and have continuity. Sensor Circuits: 3. Is battery voltage present at B3 fuel gauge sender, X6 connector 900 Blk/Wht wire (AD)? Yes: If necessary, test B3 fuel gauge sender. See “Fuel Tank Sensor Test” on page 224. If OK, go to next procedure. No: Check 900 Blk/Wht wire and connections. If OK, replace A1 display panel. ab Secondary Switched Power Safety Circuits: Note: Due to the various combinations of the switched safety circuits, refer to the specific diagnostic procedures for that circuit in this section. 1. Is battery voltage present at X3 connector, 620 Tan wire (AB) of B1 engine oil pressure switch? Yes: If necessary, test B1 engine oil pressure switch. See “Engine Oil Pressure Switch Test” on page 217. If OK, go to next step. Electrical Operation and Diagnostics - 148 ELECTRICAL OPERATION AND DIAGNOSTICS Power Circuit Operation - X720/X724/X728 Function: To provide unswitched and switched power to the primary electrical components whenever the battery is properly connected. The power circuits are divided among the unswitched power circuit, switched power circuits (key switch in run position), and secondary power circuits. The secondary power circuits become energized when switched power circuits energize relays or modules providing current paths to the secondary circuits. The secondary power circuits will not be energized if the relays or modules controlling the current path(s) fail. Operating Conditions, Unswitched Circuits: Voltage must be present at the following components with the key switch in off position. • G1 battery positive terminal • M1 starting motor - B terminal • S1 key switch - B terminal • N1 voltage regulator/rectifier • F3, F4, F5, and F6 fuses • S2 power port switch • K1 EFI module power relay - 87 terminal, 221 Red wire • S9 light switch - 400 Yel/Blu wire • S8 brake switch - 504 Yel and 765 Pur wires • S5 PTO/RIP switch - 501 and 511 Yel wires • S4 seat switch - 502 Yel wire • S7 RIO switch - 402 Yel wire • N1 voltage rectifier/regulator - 594 Yel wire • K1 EFI module power relay - 560 Red/Yel wire • S5 front PTO switch (optional rear PTO installed) 521 Yel wire • S6 Rear PTO switch (optional rear PTO installed) 520 and 521 Yel wire These circuits are controlled by the key switch and are protected by the 212 fusible link and the F and F2 fuses. With power now available at various locations on the machine, the electrical system is ready to perform the different functions of starting and running the engine, engine monitoring lights, the PTO clutch and the PTO system interlocks, and the headlights. The ground circuit is equally important as the power circuit connections. Proper systems operation depends on good wires and connections in order to carry the current needed to operate the various components. The positive battery cable connects the battery to the starting motor. The starting motor bolt is used as the 12 volt DC tie point for the rest of the electrical system. These circuits are protected by the 212 and 213 fusible links and the F3 and F4 fuses. Operating Conditions, Secondary Switched Circuits: Secondary switched voltage must be present at the following components during the following conditions: Key switch in run position, transmission in neutral, PTO in off position, brake locked, and operator off seat: • K1 EFI module power relay - 230 Red wire The battery cables and the starting motor tie point connections must be good for the machine’s electrical system to work properly. Proper starting motor operation depends on the battery cables to carry high current. The ground cable connection is equally as important as the positive cable connection in maintaining electrical system integrity. • K2 fuel pump relay - 231 and 232 Red and 655 Pnk wires • X9 connector - 233 Red/Blu wire • M2 fuel pump - 651 Pnk/Blk wire • B1 engine oil pressure switch - 620 Tan wire • B2 engine water temperature sensor - 310 Org wire Operating Conditions, Switched Circuits: • B3 fuel gauge sender - 900 Blk/Wht wire With the key switch in run position, PTO switch in off position, brake locked, and operator off the seat, switched voltage should be present at the following components: • A1 display panel - 650 Pnk/Blk wire • A1 display panel - 611 Brn wire • K3 safety relay - 650 Pnk/Blk wire • Y3 and Y4 fuel injector solenoids - Wht wires • A2 EFI module - 240 Red wire • S1 key switch - terminals “A” and “S1” • A1 display panel - J1 connector, 410 Yel wire • A1 display panel - J2 connector, 503 Yel wire • A1 display panel - J3 connector, 505 Yel wire • A1 display panel - J2 connector, 742 Blu/Wht wire (If rear PTO option not installed) • B4 engine coolant temperature sensor (5 VDC or less) Blu wire • B5 air temperature sensor (5 VDC or less) - Grn wire • B6 vacuum pressure sensor (5 VDC or less) - Tan wire Electrical Operation and Diagnostics - 149 ELECTRICAL OPERATION AND DIAGNOSTICS These circuits are controlled by the key switch and their respective controlling components. They are protected by the unswitched and switched power fusible links and fuses. Electrical Operation and Diagnostics - 150 ELECTRICAL OPERATION AND DIAGNOSTICS Power Circuit Electrical Schematic - X720/X724/X728 EFI S1 Key Switch Off Run Start 402 Yel 593 Yel S1 S2 401 Yel A 206 Red B 402 Yel G M S4 Seat Switch Off On 502 Yel 520 Yel 401 Yel F1 F2 A C F3 E F4 201 Red B 400 Yel/Blu 15A D 500 Yel 505 Yel 204 Red 15A 30A G 20A F H 400 Yel/Blu 593 Yel 500 Yel 560 Red/Yel 501 Yel 220 Red S-7 200 Red S-3 504 Yel 503 Yel S-5 410 Yel 594 Yel 209 Red 503 Yel J1-E 505 Yel F5 10 Amp Fuse X1 202 Red J2-K 410 Yel 592 Blu J3-D 720 Pur S-1 212 S-2 Fuse Links 209 Red Red B On S Pnk S3 PTO/RIP Switch Off C 511 Yel 3 N1 Voltage Regulator/ Rectifier Red Y1 Start Solenoid M1 Start Motor RIP* A J3-H 125 Blk X2 720 Pur 213 594 Yel 221 560 Red Red/Yel U 2 501 Yel 1 6 754 Blu 5 8 4 7 J1-L 87a M 611 Brn 230 Red Off On S2 Power Port Switch 87 30 85 86 170 Brn X10 K1 Main Relay 233 Red/Blu G1 Battery 171 Brn X11 X9 87a Blk 125 Blk 150 Blk 231 Red K2 Fuel Pump Relay 100 Blk Switched Power Safety Circuits W1 Ground 232 Red Unswitched Power Secondary Power Circuits Switched Power Electrical Operation and Diagnostics - 151 87 30 85 86 100 Blk ELECTRICAL OPERATION AND DIAGNOSTICS With Optional Rear PTO (X5 Connector) S7 RIO Switch S5 Front PTO Switch Neutral/Forward Reverse 402 Yel S6 Rear PTO Switch On 520 Yel 742 Blu/Wht Off 743 Pur 742 Blu/Wht On Off 521 Yel 740 Blu 740 Blu 520 Yel 521 Yel A1 Display Panel (J2-F) 772 Blu 400 Yel/Blu 504 Yel 400 Yel/Blu 504 Yel J1-S J2-F J1-G S8 Brake Switch A1 Display Panel S9 Light Switch Off On On (On) F C (Off) J1-D E 765 Pur H J1-H 900 Blk/Wht J2-J J1-M J2-A J3-F K3 Safety Relay 650 Pnk/Blk 620 310 Tan Org 87a X3 139 Blk 87 30 85 86 X6 138 Blk P B1 Engine Oil Pressure Switch X8 910 Wht 100 Blk t0 Q B2 Engine Water Temperature Sensor 135 Blk B3 Fuel Gauge X6 Sender 120 Blk 100 Blk Electrical Operation and Diagnostics - 152 A1 Display Panel (J1-S) ELECTRICAL OPERATION AND DIAGNOSTICS X11 W2 Ground A B Y3 #1 Cylinder Fuel Injector Solenoid C X10 D A E B 330 Org Blk/Wht F C G D H E Y4 #2 Cylinder Fuel Injector Solenoid Wht I F 710 Pur G Blk/Wht J K H L I M J Wht K 340 Grn L 240 Red Tan M 470 Yel Red/Blu Wht A2 Electric Fuel Injection Module N O P N Grn O 515 Blu Blu P 615 Tan Grn to X9 Blu to B5 Air Temperature Sensor Blk/Yel B4 Engine Coolant Temperature Sensor Blk/Yel Red/Blu m Tan Electrical Operation and Diagnostics - 153 B6 Vacuum Pressure Sensor ELECTRICAL OPERATION AND DIAGNOSTICS Power Circuit Diagnosis - X720/X724/X728 EFI Yes: Go to next step. Test Procedure A: No: Check 200 Red wire, 592 Pnk wire, and X1 connector. Test Conditions: • Machine parked safely with park brake locked. • Key switch in off position. • Battery fully charged. • Follow procedure in sequence. • Ensure all circuit grounds are in good condition and have continuity. Unswitched Power Circuits: D E 15 15 B 30 20 A 1. Is battery voltage present at F4 20A fuse, 200 Red wire (A)? Yes: Go to next step. No: Check 213 fusible link, 202 Red wire and F4 fuse. 2. Is battery voltage present at F3 30A fuse, 204 Red wire (B)? Yes: Go to next step. No: Check 212 fusible link, 201 Red wire, and F3 fuse. 4. Is battery voltage present at N1 voltage regulator/ rectifier X2 connector Red wire (D)? If auxiliary alternator is installed, check for battery voltage at N2 voltage regulator/rectifier Red wire (E) as well. Yes: Go to next step. No: Check 209 and 200 Red wires and connections. C F 3. Is battery voltage present at S2 power port switch 592 Blu wire (C)? 5. Is battery voltage present at S1 key switch, 206 Red wire (F)? Electrical Operation and Diagnostics - 154 ELECTRICAL OPERATION AND DIAGNOSTICS Yes: Go to next step. No: Check 401 Yel wire and connections. No: Check 206 and 204 Red wires and connections. 2. Is battery voltage present at F2 15A fuse, 500 and 505 Yel wires (I)? Yes: Go to next step. No: Test F2 fuse. G J 6. Is battery voltage present at K1 main relay, 221 Red wire (G)? Yes: End of unswitched power circuit diagnosis. No: Check 204 and 220 Red wires, F5 10A fuse, and 221 Red wire and connections. 3. Is battery voltage present at S9 light switch, 400 Yel/ Blu wire (J)? Yes: Go to next step Test Procedure B: No: Check 400 Yel/Blu wire and connections. Test Conditions: • Machine parked safely with park brake locked. • Key switch in run position, • Follow procedure in sequence. • Ensure all ground circuits are in good condition and have continuity. Switched Power Circuits: K H 15 4. Is battery voltage present at A1 display panel, J3 connector 505 Yel wire (K)? 15 30 I 20 Yes: Go to next step. No: Check 505 Yel wire and connections. 1. Is battery voltage present F1 15A fuse, 400 Yel/Blu wire (H)? Yes: Go to next step. No: Test F1 fuse. No: Test S1 key switch. See “Key Switch Test” on page 219. Electrical Operation and Diagnostics - 155 ELECTRICAL OPERATION AND DIAGNOSTICS L O 5. Is battery voltage present at A1 display panel, J1 connector 410 Yel wire (L)? 8. Is battery voltage present at S7 RIO switch, 402 Yel wire (O)? Yes: Go to next step. Yes: Go to next step. No: Check 500 Yel wire, S-5 splice, and 410 Yel wire and connections. No: Check 500 Yel wire, S-5 splice, and 402 Yel wire and connections. N M P 6. Is battery voltage present at A1 display panel, J2 connector 503 Yel wire (M)? 9. If rear PTO option is installed - Is battery voltage present at S5 front PTO switch, 520 Yel wire (P)? Yes: Go to next step. Yes: Go to next step. No: Check 500 Yel wire, S-5 splice, and 503 Yel wire and connections. No: Check 500 Yel wire, S-5 splice, and 520 Yel wire and connections. 7. If rear PTO option is not installed - Is battery voltage present at A1 display panel, J2 connector 742 Blu/Wht wire (N)? Yes: Go to next step. No: Check 500 and 520 Yel, 743 Pur, and 742 Blu/Wht wires and connections. Q 10. If rear PTO option is installed - Is battery voltage present at S6 rear PTO switch, 521 Yel wire (Q)? Electrical Operation and Diagnostics - 156 ELECTRICAL OPERATION AND DIAGNOSTICS 13. Is battery voltage present at S3 PTO/RIP switch 501 and 511 Yel wires (T)? Yes: Go to next step. No: Check 521 Yel wire and connections. Yes: Go to next step. No: Check 500 Yel wire, S-5 splice, 501 and 511 Yel wires and connections. R 11. Is battery voltage present at S8 brake switch, 504 Yel wire (R)? U Yes: Go to next step. No: Check 500 Yel wire, S-5 splice, and 504 Yel wire and connections. V S 12. Is battery voltage present at S1 key switch, 593 Yel wire (S)? Yes: Go to next step. No: Check 500 Yel wire, S-5 splice, and 593 Yel wire and connections. 14. Is battery voltage present at X2 connector of N1 voltage regulator/rectifier, 594 Yel wire (U)? If G2 auxiliary alternator is installed, check for battery voltage at N2 voltage regulator/rectifier, 521 Yel wire (V) as well. Yes: End of switched power tests. No: Check 500 Yel wire, S-5 splice, and 594 Yel wire and connections. If G2 auxiliary alternator is installed, check 521 Yel wire as well. T Electrical Operation and Diagnostics - 157 ELECTRICAL OPERATION AND DIAGNOSTICS Test Procedure C: Test Conditions: • Machine parked safely with park brake locked. • Key switch in off position. • Battery fully charged. • Component under test in active position. De-activate circuit when done testing. • W 15. Is battery voltage present at S4 seat switch, 502 Yel wire (W)? Yes: Go to next procedure. No: Check 500 Yel wire, S-5 splice, and 502 Yel wire and connections. Follow procedure in sequence. • Ensure that A1 display panel, J2 connector 135 Blk wire has continuity to ground. • Ensure all circuit grounds are in good condition and have continuity. Secondary Power Circuits: Y X 16. Is battery voltage present at K1 main relay, 560 Red/Yel wire (X)? Yes: End of switched power diagnosis. No: Check 500 Yel wire, S-5 splice, and 560 Red/Yel wire and connections. 1. Is battery voltage present at K1 main relay, 230 Red wire (Y)? Yes: Go to next step. No: Check all connections on K1 main relay. If OK, test relay. aa Z 2. Is battery voltage present at K2 fuel pump relay, 231 (Z) and 232 (AA) Red wires? Yes: Go to next step. Electrical Operation and Diagnostics - 158 ELECTRICAL OPERATION AND DIAGNOSTICS No: Check 230, 231, and 232 Red wires and connections. ad ab 5. Is there continuity to between A2 EFI module, X11 connector 860 Pnk wire (AD) and ground? Yes: Go to next step. 3. Is battery voltage present at A2 EFI module X11 connector, 240 Red wire (AB)? No: Check 860 Pnk, Org, and 670 Pur wires, X11, X10, and X8 connectors and connections. If OK, test K3 safety relay. See “Relay Test” on page 218. Yes: Go to next step. No: Check 233 Red/Blu wire, X9 connector, Wht wire X10 connector, and 240 Red wire. ac ae 6. Is battery voltage present at X3 connector, 620 Tan wire (AE) of B1 engine oil pressure switch? 4. Is battery voltage present at A1 display panel, J3 connector 650 Pnk/Blk wire (AC)? Yes: Go to next step. Yes: If necessary, test B1 engine oil pressure switch. See “Engine Oil Pressure Switch Test” on page 217. If OK, go to next step. No: Check 620 Tan wire and connections. If OK, replace A1 display panel. No: Replace A1 display panel. Electrical Operation and Diagnostics - 159 ELECTRICAL OPERATION AND DIAGNOSTICS af 7. Is battery voltage present at X3 connector, 310 Org wire (AF) of B2 engine coolant temperature sensor? Yes: If necessary, test B2 engine coolant temperature sensor. See “Engine Coolant Temperature Sensor Test” on page 216. Go to next step. No: Check 310 Org wire and connections. If OK, replace A1 display panel. ag 8. Is battery voltage present at B3 fuel gauge sender, X6 connector 900 Blk/Wht wire (AG)? Yes: If necessary, test B3 fuel gauge sender. See “Fuel Tank Sensor Test” on page 224. If OK, go to next step. No: Check 900 Blk/Wht wire and connections. If OK, replace A1 display panel. Electrical Operation and Diagnostics - 160 ELECTRICAL OPERATION AND DIAGNOSTICS Cranking Circuit Operation - All Models Function: To energize the starting motor solenoid and engage the starting motor to crank the engine. Operating Conditions: • Key switch in start position. • Brake locked, switch closed. • PTO/RIP switch in off position. Theory of Operation: The starting motor is a solenoid shift design. The power circuit provides current to the S1 key switch and protects the cranking circuit with the 212 fusible link and F3 fuse. Current flows from the battery positive (+) terminal to the starter solenoid battery terminal, 212 fusible link, 201 Red wire, F3 fuse, 204 Red wire and to the key switch. With the key switch in the start position, the secondary power circuit is energized, thereby providing power to the the A1 display panel. At the same time, secondary power is provided to through the key switch over the 593 Yel wire and exiting the switch over the 591 Yel wire and providing a start signal to the A1 display panel. To provide the start signal, the following conditions must be met: • The S8 brake switch must be closed (brake pedal depressed), providing 12 VDC to the A1 display panel J1 connector over the 765 Pur wire. • The S3 PTO/RIP switch must be in the off position. This will prevent the 754 and 755 Blu wires (J1) from supplying power to the A1 display panel, thereby indicating that the PTO is off. The A1 display panel will then output power over the 720 Pur wire to he starting Y1 motor solenoid. The Y1 starting motor solenoid is engaged by current flowing through the coil windings, pulling the plunger inward. The plunger closes the solenoid main contacts. Current flows through the hold-in windings, keeping the solenoid engaged. With the solenoid main contacts closed, high current from the battery flows across the main contacts to the M1 starting motor causing it to turn. Electrical Operation and Diagnostics - 161 ELECTRICAL OPERATION AND DIAGNOSTICS Cranking Circuit Electrical Schematic - All Models S1 Key Switch Off Run Start 593 Yel 591 Yel S2 401 Yel A S1 206 Red (EFI) B G M 504 Yel S8 Brake Switch 401 Yel F1 A F2 C (On) B (Off) 15A D 15A F3 E 30A G 20A F H 504 Yel 500 Yel S-5 204 Red 765 Pur 501 Yel 591 Yel J2-B A1 Display Panel 201 Red J1-D F S-1 720 Pur J3-H 212 E RIP* Red Red B Y1 Start Solenoid M1 Start Motor S On 501 Yel Off 3 6 754 Blu 755 Blu M 2 1 C J1-B J1-C 5 8 4 7 S3 PTO/RIP Switch G1 Battery Blk W1 Ground MIF Electrical Operation and Diagnostics - 162 H ELECTRICAL OPERATION AND DIAGNOSTICS Cranking Circuit Diagnosis - All Models Test Procedure A: Yes: Test starting motor and solenoid. See “Starting Motor Condition” on page 214 and related tests. No: If all power circuits are OK and operating conditions are met, replace A1 display panel. Test Conditions: • Machine parked safely with park brake locked. • Key switch in start position. • PTO(s) off. • Battery fully charged. • Power circuits functioning properly. • Follow procedure in sequence. • Ensure that A1 display panel, J2 connector 135 Blk wire has continuity to ground. • Ensure all circuit grounds are in good condition and have continuity. Cranking Circuit: A 1. Is battery voltage present at A1 display panel, J2 connector 591 Yel wire (A)? Yes: Go to next step. No: Check 591 Yel wire and connections. If OK, test S1 key switch. See “Key Switch Test” on page 219. B 2. Is battery voltage present at Y1 starting motor solenoid, 720 Pur wire (B)? Electrical Operation and Diagnostics - 163 ELECTRICAL OPERATION AND DIAGNOSTICS Charging Circuit Operation - All Models (Standard Configuration) Charging Circuit Operation - All Models (With Auxiliary Alternator) Function: Function: To maintain battery voltage between 12.4 volts DC and 15 volts DC. To maintain battery voltage between 12.4 volts DC and 14.8 volts DC. Operating Conditions: Operating Conditions: The key switch must be in the run position, with the engine running, for the charging system to operate. The key switch must be in the run position, with the engine running, for the auxiliary charging system to operate. Theory of Operation: Theory of Operation: The main charging system components are the G1 battery, G2 alternator and the N1 voltage regulator/rectifier. Charging output is controlled by the regulator/rectifier. The status of the charge rate is indicated by the discharge light on the display panel. The auxiliary charging system components are the G1 battery, G3 alternator and the N2 voltage regulator/rectifier. Charging output is controlled by the regulator/rectifier. The status of the charge rate is indicated by the discharge light on the display panel. With the key switch in the run position, battery sensing circuit current flows from battery positive terminal to the starting motor terminal, 212 fusible link, F3 fuse, 204 Red wire, S1 key switch, 401 Yel wire, F2 fuse, 500 and 594 Yel wires, and the N1 voltage regulator/rectifier. The battery sensing circuit allows the voltage regulator/rectifier to monitor battery voltage. Note: If one of the two charging systems fail, the discharge indicator on the A1 display panel may not illuminate due to the functioning charging circuit supplying current to the battery. With the engine running, a rotating permanent magnet in the alternator induces AC current in the alternator stator coils. The AC current flows to the voltage regulator/rectifier. The voltage regulator/rectifier converts AC current to DC current needed to charge the battery. Current flows from the voltage regulator/rectifier to the battery positive (+) terminal through the 209 and 200 Red wires, F4 fuse, 202 Red wire and 213 fusible link. When the battery is fully charged, the voltage regulator/rectifier halts current flow to the battery. If the voltage on the sensing circuit falls below system usage or is insufficient to maintain a preset voltage, the A1 display panel will sense the lowered voltage and illuminate the discharge light. The ground circuit 125 and 100 Blk wires provide a path to ground for the voltage regulator/rectifier. With the key switch in the run position, battery sensing circuit current flows from battery positive terminal to the starting motor terminal, 212 fusible link, F3 fuse, 204 Red wire, S1 key switch, 401 Yel wire, F2 fuse, 500, 594, and 521 Yel wires, and the N2 voltage regulator/rectifier. The battery sensing circuit allows the voltage regulator/rectifier to monitor battery voltage. Note that at this point, dual charging systems are running in parallel but share the same voltage sensing circuit over the 521, 504, and 594 Yel wires. With the engine running, a rotating permanent magnet in the alternator induces AC current in the alternator stator coils. The AC current flows to the voltage regulator/rectifier. The voltage regulator/rectifier converts AC current to DC current needed to charge the battery. Current flows from the voltage regulator/rectifier to the battery positive (+) terminal through the 211, 209 and 200 Red wires, F4 fuse, 202 Red wire and 213 fusible link. When the battery is fully charged, the voltage regulator/ rectifier halts current flow to the battery. If the voltage on the sensing circuit falls below system usage or is insufficient to maintain a preset voltage, the A1 display panel will sense the lowered voltage and illuminate the discharge light. The ground circuit 126 Blk wire provides a path to ground for the voltage regulator/rectifier. Electrical Operation and Diagnostics - 164 ELECTRICAL OPERATION AND DIAGNOSTICS Charging Circuit Electrical Schematic - All Models Off Run Start S1 Key Switch 593 Yel S1 206 Red (EFI) B S-7 S2 401 Yel A M G 401 Yel F1 A F2 C B 15A D F3 E F4 201 Red 30A G 20A 593 Yel 500 Yel 500 Yel 505 Yel 204 Red 15A F S-5 594 Yel H 200 Red 202 Red S-1 212 S-2 Fusible Links 594 Yel 209 Red 125 Blk 503 Yel X2 213 A 410 Yel C 505 Yel Red B Y1 Start Solenoid M1 Start Motor S N1 Voltage Regulator/ Rectifier Red A1 Display Panel J2-K J1-E J3-D F U E M C H X2 595 Brn/Wht 590 Brn/Yel J2-A G1 Battery X3 G Blk G2 Alternator 3 U 125 Blk 135 Blk 100 Blk W1 Ground Unswitched Power Switched Power Electrical Operation and Diagnostics - 165 ELECTRICAL OPERATION AND DIAGNOSTICS Charging Circuit Electrical Schematic - All Models (With Optional Auxiliary Alternator) W1 Main Wiring Harness X2 125 Blk 125 Blk 594 Yel S-5 209 Red G 504 Yel 504 Yel 210 Red 210 Red 590 Brn 590 Brn 600 Brn 600 Brn 595 Brn 595 Brn X3 G2 Alternator U N1 Voltage Regulator/ Rectifier 521 Yel X2A 126 Blk 521 Yel 209 Red S-1 211 Red 591 Brn 596 Brn X3A G G3 Alternator U N2 Voltage Regulator/ Rectifier 125 Blk 126 Blk Electrical Operation and Diagnostics - 166 ELECTRICAL OPERATION AND DIAGNOSTICS Charging Circuit Diagnosis - All Models (Standard Configuration) Charging Circuit Diagnosis - All Models (With Optional Alternator) Test Procedure A: Test Procedure A: Test Conditions: Test Conditions: • Machine parked safely with park brake locked. • Machine parked safely with park brake locked. • Operator may be on or off seat. • Operator may be on or off seat. • Key switch in off position. • Key switch in off position. • PTO(s) off. • PTO(s) off. • Battery fully charged. • Battery fully charged. • Power circuits functioning properly. See “Power Circuit Operation - X700” on page 140 or See “Power Circuit Operation - X720/X724/X728” on page 149. • Power circuits functioning properly. See “Power Circuit Operation - X700” on page 140 or See “Power Circuit Operation - X720/X724/X728” on page 149. • • Perform standard configuration charging circuit diagnosis first. Follow procedure in sequence. • Ensure that A1 display panel, J2 connector 135 Blk wire has continuity to ground. • Follow procedure in sequence. • Ensure all circuit grounds are in good condition and have continuity. • Ensure that A1 display panel, J2 connector 135 Blk wire has continuity to ground. Note: If the discharge light is illuminated and no fault can be found with the power circuit and charging circuit, replace A1 display panel. • Ensure all circuit grounds are in good condition and have continuity. Charging Circuit: Note: If the discharge light is illuminated and no fault can be found with the power circuit and charging circuit, replace A1 display panel. Charging Circuit: B B A A 1. Is there continuity between X2 and X3 connectors, 595 Brn/Wht wire (A)? 1. Is there continuity between X2A and X3A connectors, 596 Brn wire (A)? Yes: Go to next step. Yes: Go to next step. No: Check 595 Brn/Wht wire and connections. Repair or replace as necessary. No: Check 596 Brn/Wht wire and connections. Repair or replace as necessary. 2. Is there continuity between X2 and X3 connectors, 590 Brn/Yel wire (B)? 2. Is there continuity between X2A and X3A connectors, 591 Brn wire (B)? Yes: See “Tests and Adjustments” on page 208 for alternator tests. Yes: See “Tests and Adjustments” on page 208 for alternator tests. No: Check 590 Brn/Yel wire and connections. Repair or replace as necessary. No: Check 591 Brn wire and connections. Repair or replace as necessary. Electrical Operation and Diagnostics - 167 ELECTRICAL OPERATION AND DIAGNOSTICS Ignition Circuit Operation - X700 Function: To control the ignition coils ability to create a spark while also controlling the fuel supply to the engine. Operating Conditions, Stopping Engine: • Key switch in off position, or, • Operator off seat with PTO engaged, and, • Park braked unlocked. Theory of Operation, Stopping Engine Theory of Operation, Running Engine The key switch is connected to the A1 ignition interlock module by soldered wire connections. The components are solid state and are not serviced separately except for the 15 amp fuses. Lines within the border of the A1 ignition interlock module except for key switch connections are circuit paths on the circuit board and are not wires in the harness. The ignition system is a transistor-controlled magneto design. Ignition timing is controlled by the transistor and is not adjustable. As the engine turns over the flywheel magnet induces current into the magneto ignition coil, which in turn produces current high enough to jump the spark plug(s) gap, creating spark to ignite the engine fuel/ air mixture. The engine is shut off by grounding the T1 and T2 ignition coils. With the ignition primary coil grounded, a spark cannot be produced. When the S1 key switch is in the off position, a path to ground is created through the key switch Wht wire (M) solder connection and back to the interlock module through the Wht wire (S2) solder connection. In addition the power circuit current flow is stopped at the key switch. This deenergizes the magneto relay providing a path to ground for ignition coil through the magneto relay. The magneto relay coil is energized by current from the seat switch circuit or brake circuit. If the operator gets off the seat (seat switch opens) with the PTO engaged without the park brake locked, current flow to the magneto relay coil is stopped. The seat switch or brake switch also energize the ignition relay. Whenever the ignition relay is de-energized, the fuel shutoff solenoid is also de-energized and fuel flow to the carburetor is stopped. Operating Conditions, Running Engine: • Key switch in run or start position, • Operator on seat, or, • Key switch in run or start position, • Operator off seat, • Park braked locked. Electrical Operation and Diagnostics - 168 ELECTRICAL OPERATION AND DIAGNOSTICS Ignition Circuit Electrical Schematic - X700 S1 Key Switch Off Run Start 402 Yel 593 Yel S1 204 Red B M S2 401 Yel A G S4 Seat Switch 402 Yel 520 Yel Off On 130 Blk 502 Yel 940 Wht / 941 Wht 800 Pnk 401 Yel 520 Yel F1 A F2 C B 15A D 15A F3 E 30A G 20A F 593 Yel 500 Yel 500 Yel 505 Yel 204 Red 504 Yel 503 Yel S-5 J1-A 410 Yel 501 Yel H 503 Yel 410 Yel 505 Yel 941 Wht 201 Red S-1 RIP* 212 On J2-K J1-E J3-D J3-A A1 Display Panel S3 PTO/RIP Switch Off 511 Yel 3 Red B S 2 Y1 Start Solenoid M1 Start Motor 501 Yel 1 6 754 Blu 754 Blu J1-B 755 Blu J1-C J1-L J2-A 5 8 4 755 Blu 7 940 Wht 942 Wht M X3 Blk 135 Blk Blk Blk G1 Battery Blk E7 Spark Plug E8 Spark Plug Blk 130 Blk T1 Ignition Coil 100 Blk W1 Ground T2 Ignition Coil 100 Blk Unswitched Power Switched Power Electrical Operation and Diagnostics - 169 ELECTRICAL OPERATION AND DIAGNOSTICS Neutral/Forward Reverse 402 Yel With Optional Rear PTO S7 RIO Switch 742 Blu/Wht S5 Front PTO Switch 743 Pur 740 Blu S6 Rear PTO Switch On 520 Yel 520 Yel Off 521 Yel 772 Blu S8 Brake Switch J1-G (On) A1 Display Panel J1-D (Off) 765 Pur 504 Yel F E J3-F 650 Pnk/Blk 655 Pnk X3 X5 651 Pnk/Blk X6 M Y3 Fuel Shutoff Solenoid On Off 521 Yel 504 Yel J1-S J2-F 742 Blu/Wht M2 Fuel Pump X6 121 Blk 100 Blk Electrical Operation and Diagnostics - 170 740 Blu ELECTRICAL OPERATION AND DIAGNOSTICS Ignition Circuit Diagnosis - X700 Test Procedure A: B Test Conditions: • Machine parked safely with park brake locked. • Key switch in off position. • PTO(s) off. • Battery fully charged. • Power circuits functioning properly. • Follow procedure in sequence. 2. Is there continuity between T1 and T2 ignition coil’s Wht wires and ground? • Ensure that A1 display panel, J2 connector 135 Blk wire has continuity to ground. Yes: Go to next procedure. • Ensure all circuit grounds are in good condition and have continuity. Ignition Off: No: Check Wht wires, X3 connector, and 940 Wht wire and connections. Test Procedure B: A Test Conditions: 1. Is there continuity between A1 display panel, J3 connector 941 Wht wire (A) and ground? Yes: Go to next step. • Machine parked safely with park brake locked. • Key switch in run position, engine off. • PTO(s) off. • Battery fully charged. • Power circuits functioning properly. • Follow procedure in sequence. • Ensure that A1 display panel, J2 connector 135 Blk wire has continuity to ground. • Ensure all circuit grounds are in good condition and have continuity. Ignition On: No: Check 941 and 940 Wht wires. No: Test S1 key switch. See “Key Switch Test” on page 219. C No: Test 130 Blk wire at S1 key switch for continuity to ground. 1. Is there continuity between A1 display panel, J3 connector 941 Wht wire (C) and ground? No: Go to next step. Electrical Operation and Diagnostics - 171 ELECTRICAL OPERATION AND DIAGNOSTICS Yes: Test S1 key switch. See “Key Switch Test” on page 219. Yes: Replace A1 display panel. If problems persist, test T1 and T2 ignition coils. See “Ignition Coil Test” on page 229. Electrical Operation and Diagnostics - 172 ELECTRICAL OPERATION AND DIAGNOSTICS Ignition Circuit Operation - X720/X724/X728 EFI Function: To control the ignition coils ability to create a spark while also controlling the fuel supply to the engine. With these signal present, the EFI module provides power to the T1 and T2 ignition coils over the 171 and 170 Brn wires, X10 connector, and the Blk wire to the coils. As the flywheel rotates, magnets located on the flywheel pass underneath the ignition coils and cause them to induce current to their respective spark plugs. Ignition timing is not adjustable. Operating Conditions, Stopping Engine: • Key switch in off position, or, • Operator off seat with PTO engaged, and, • Park braked unlocked. Theory of Operation, Stopping Engine: The engine is shut off by grounding the T1 and T2 ignition coils. With the ignition primary coil grounded, a spark cannot be produced. When the S1 key switch is in the off position, the power circuit current flow is stopped at the key switch. This deenergizes the A1 display panel thereby turning of the output signal to the K3 safety relay. This will also de-energize the K1 main relay turning off power to the A2 EFI module. Operating Conditions, Running Engine: • Key switch in run or start position, • Operator on seat, or, • Key switch in run or start position, • Operator off seat, • Park braked locked. Theory of Operation, Engine Running: When the key switch is in the run position, with the engine is running, power flows through the switched power circuit to the A1 display panel (See “Power Circuit Operation X720/X724/X728” on page 149). The A1 display panel outputs 12 VDC to the K3 safety relay over the 650 Pnk/Blk wire thereby energizing it and providing a path to ground for the A2 EFI module as long as this signal is present. This path is accomplished by the 138 and 139 Blk wires. This provides a path to ground over the 670 Pur wire, X8 connector, Org wire, X11 connector, and to the A2 EFI module. The key switch in the on position will also energize the K1 main relay which provides power to the A2 EFI module over the 230 Red and 233 Red/Blu wires. Electrical Operation and Diagnostics - 173 ELECTRICAL OPERATION AND DIAGNOSTICS Ignition Circuit Electrical Schematic - X720/X724/X728 EFI S1 Key Switch Off Run Start 402 Yel 593 Yel S1 206 Red B M S2 401 Yel A S4 Seat Switch 402 Yel G Off On 502 Yel 520 Yel 401 Yel F1 A F2 C F3 E F4 B 400 Yel/Blu D 500 Yel 505 Yel 204 Red 15A 15A 30A G 20A F 800 Pnk 593 Yel 500 Yel 560 Red/Yel 501 Yel 220 Red 504 Yel 503 Yel S-5 J1-A 410 Yel S-7 H 503 Yel 410 Yel 505 Yel F5 10 Amp Fuse 201 Red S-1 RIP* 212 On J2-K J1-E J3-D S3 PTO/RIP Switch Off 511 Yel 3 Red B S 221 560 Red Red/Yel Y1 Start Solenoid M1 Start Motor 2 501 Yel 1 6 754 Blu 754 Blu J1-B 755 Blu J1-C 5 8 4 755 Blu 7 87a M 230 Red 87 30 85 86 K1 Main Relay 233 Red/Blu G1 Battery Blk 150 Blk 100 Blk 100 Blk W1 Ground Unswitched Power Switched Power Electrical Operation and Diagnostics - 174 ELECTRICAL OPERATION AND DIAGNOSTICS With Optional Rear PTO S7 RIO Switch S5 Front PTO Switch Neutral/Forward Reverse 402 Yel Off 520 Yel 742 Blu/Wht S6 Rear PTO Switch On 742 Blu/Wht On Off 743 Pur 740 Blu 521 Yel 740 Blu 520 Yel 772 Blu Blk 521 Yel Blk Blk E7 Spark Plug 504 Yel 504 Yel E8 Spark Plug T1 Ignition Coil J1-G J1-S J2-F S8 Brake Switch A1 Display Panel C F Blk J1-D 765 Pur T2 Ignition Coil X10 A (On) B (Off) C D E F E H G H Red I 950 Wht J 170 Brn K 611 Brn J1-L X11 L J1-R M A N J3-F J2-A 785 Grn 670 Pur B O X8 C P D Red E Org F G 87a H I 139 Blk 650 Pnk/Blk 233 Red/Blu 87 30 85 86 J 138 Blk K Wht L M K3 Safety Relay 171 Brn Org X9 100 Blk 135 Blk 139 Blk Electrical Operation and Diagnostics - 175 N O P A2 Electric Fuel Injection Module ELECTRICAL OPERATION AND DIAGNOSTICS Ignition Circuit Diagnosis - X720/X724/X728 EFI Test Procedure A: X Test Conditions: • Machine parked safely with park brake locked. • Key switch in run position, engine off. • PTO(s) off. • Battery fully charged. • Power circuits functioning properly. • Follow procedure in sequence. 2. Is battery voltage present at T1 and T2 ignition coil Blk wires? • Ensure that A1 display panel, J2 connector 135 Blk wire has continuity to ground. • Ensure that A2 EFI module, X11 connector 710 Pur and 330 Org wires have continuity to ground. • Ensure all circuit grounds are in good condition and have continuity. Yes: Check ignition coil(s) air gap(s). See “Ignition Coil Replacement and Adjustment” on page 230. Yes: Check ignition coil(s) resistance. See “Ignition Coil Test” on page 229. Yes: Replace A2 EFI module. No: Check Blk wires, X12 connector, 170 Brn wire at X10 connector to splice. Ensure that continuity exists between 170 Brn wire and 611 Brn wire at A1 display panel. Ignition On: No: Replace A2 EFI module. X 1. Is battery voltage present at A1 display panel, J1 connector 611 Brn wire? Yes: Go to next step. No: Check 611 Brn wire at A1 display panel and 171 Brn wire at A2 EFI module. If power circuits all check out OK, replace A2 EFI module. Electrical Operation and Diagnostics - 176 ELECTRICAL OPERATION AND DIAGNOSTICS PTO/RIP Circuit Operation - All Models Without Optional Rear PTO Installed: Function: To provide power to energize the PTO clutch solenoid and visually alert the operator that the PTO is functioning. Operating Conditions: • Key switch in run position, • PTO/RIP switch on, • Operator on seat, or, • Park brake locked. Theory of Operation: With the S3 PTO/RIP switch in the on position, current flows from the switched 501 Yel wire through the switch to the 755 Blu wire to the A1 display panel. This will allow the operator engage the PTO. In order for the PTO to be engaged with the machine transmission in the neutral or forward positions, the A1 display panel must receive voltage over the 772 Blu wire out of the closed S7 RIO switch. The A1 display panel, J2 connector, receives PTO ‘on’ logic voltage, regardless of the S3 PTO/RIP switch position, at the 742 Blu/Wht wire by the switched power circuit. This will cause the display panel to output current over the 756 Blu wire to the S3 PTO/RIP switch. The power flows out of the switch over the 757 Blu wire to the Y2 PTO solenoid. The 115 and 100 Blk wires complete the path to ground, thereby energizing the clutch and activating the PTO. The parallel 758 Blu, V1 diode, and 116 Blk circuit prevents current from feeding back into other circuits on the machine due to the low impedance of the PTO clutch. Function: To provide power to energize the PTO clutch solenoid and visually alert the operator that the PTO(s) are functioning. • Key switch in run position, • PTO/RIP switch on, • Operator on seat, or, • Park brake locked. With the S3 PTO/RIP switch in the on position, current flows from the switched 501 Yel wire through the switch to the 755 Blu wire to the A1 display panel. This will allow the operator to then turn on the PTO switch to engage the desired PTO. In order for the PTO to be engaged with the machine transmission in the neutral or forward positions, the A1 display panel must receive voltage over the 772 Blu wire out of the closed S7 RIO switch. If the S5 front PTO switch is closed (on position), power will be sent to the A1 display panel via the 742 Blu/Wht wire. This will cause the display panel to output current over the 756 Blu wire to the S3 PTO/RIP switch. The power flows out of the switch over the 757 Blu wire to the Y2 PTO solenoid. The 115 and 100 Blk wires complete the path to ground, thereby energizing the clutch and activating the PTO. The parallel 758 Blu, V1 diode, and 116 Blk circuit prevents current from feeding back into other circuits on the machine due to the low impedance of the PTO clutch. Circuit Function - RIO (All Configurations): To provide a safety interlock with the machine being repositioned in reverse while the PTO is engaged, by deactivating the PTO circuit. If an operator chooses to keep the PTO engaged while operating the machine in reverse, a deliberate action must be taken by actuating the PTO/RIP switch momentarily while pressing the reverse pedal. Operating Conditions - RIO: • Key switch in the run position, • Operator on the seat, • PTO/RIP switch in the RIP (momentary) position while placing the machine in reverse. Theory of Operation - RIO: With Optional Rear PTO Installed: Operating Conditions: Theory of Operation: If the operator deems it necessary to operate the machine in reverse, the S3 PTO/RIP switch must be placed in the RIP position. This will maintain all of the circuits necessary for normal PTO operation as well as provide power to the A1 display panel over the 754 Blu wire. This signal indicates to the display panel that the operator intends to operate the PTO with the machine in reverse while the PTO is engaged. When the reverse pedal is pressed, it opens the S7 RIO switch and removes power from the 772 Blu wire to the A1 display panel. Once the machine is travelling in the reverse direction, the RIP switch my be released. When the operator resumes travel in the forward direction, the S7 RIO switch again closes it’s contacts, applying voltage to the display panel Electrical Operation and Diagnostics - 177 ELECTRICAL OPERATION AND DIAGNOSTICS over the 772 Blu wire. This resets internal circuitry in the display panel and the procedure will have to be repeated if the machine is to be operated in reverse again. Electrical Operation and Diagnostics - 178 ELECTRICAL OPERATION AND DIAGNOSTICS PTO/RIP Circuit Electrical Schematic - All Models S1 Key Switch 206 Red (EFI) S-7 Off Run Start S1 B M 402 Yel S2 401 Yel A S4 Seat Switch 402 Yel G Off On 502 Yel 520 Yel 401 Yel F1 A F2 C F3 E F4 800 Pnk B 15A D 500 Yel 505 Yel 204 Red 15A 30A G 20A F 504 Yel 503 Yel 500 Yel S-5 501 Yel 410 Yel H J2-B 503 Yel 410 Yel 505 Yel J1-A J2-K J1-E J3-D 201 Red J3-H 756 Blu S-1 756 Blu 212 RIP* On J3-B S3 PTO/RIP Switch Off 511 Yel 3 Red B S 5 757 Blu 8 4 755 Blu 7 2 Y1 Start Solenoid M1 Start Motor 6 754 Blu 501 Yel 1 754 Blu J1-B 755 Blu J1-C M 757 Blu X4 G1 Battery V1 PTO Diode Blk 758 Blu 116 Blk Y2 PTO Clutch Solenoid X4 115 Blk 100 Blk 100 Blk W1 Ground Unswitched Power Switched Power Electrical Operation and Diagnostics - 179 ELECTRICAL OPERATION AND DIAGNOSTICS S7 RIO Switch With Optional Rear PTO Neutral/Forward Reverse 402 Yel S5 Front PTO Switch 742 Blu/Wht 520 Yel 740 Blu 772 Blu 520 Yel Off 504 Yel 504 Yel J1-G S8 Brake Switch A1 Display Panel F (On) C (Off) J1-D E H 742 Blu/Wht On Off 521 Yel 521 Yel J1-S J2-F S6 Rear PTO Switch On 743 Pur 765 Pur J2-C J2-A 135 Blk 100 Blk Electrical Operation and Diagnostics - 180 740 Blu ELECTRICAL OPERATION AND DIAGNOSTICS PTO/RIP Circuit Diagnosis - All Models Test Procedure A (If Optional Rear PTO is Installed): No: Check 765 Pur wire and connections. If OK, test S8 brake switch. See “Brake Switch Test and Adjustment” on page 220. Test Conditions: D • Machine parked safely with park brake locked. • Transmission in neutral. • Key switch in run position, engine off. • PTOs off. • Operator on seat. • Battery fully charged. • Power circuits functioning properly. See “Power Circuit Operation - X700” on page 140 or See “Power Circuit Operation - X720/X724/X728” on page 149. • Follow procedure in sequence. • Ensure that A1 display panel, J2 connector 135 Blk wire has continuity to ground. • Ensure all circuit grounds are in good condition and have continuity. 4. Is battery voltage present at A1 display panel, J2 connector 742 Blu/Wht wire (D)? No: Go to next step. Yes: Test S5 front PTO switch. See “PTO Switch Test (Optional Rear PTO Installed)” on page 223. PTO(s) Off, Engine Off: B C E A 5. Is battery voltage present at A1 display panel, J1 connector 740 Blu wire (E)? 1. Is battery voltage present at A1 display panel, J1 connector 772 Blu wire (A)? Yes: Go to next step. No: Go to next procedure. Yes: Test S6 rear PTO switch. See “PTO Switch Test (Optional Rear PTO Installed)” on page 223. No: Check 772 Blu wire and connections. If OK, test S7 RIO switch. See “RIO Switch Test” on page 221. 2. Is battery voltage present at A1 display panel, J1 connector 800 Pnk wire? Yes: Go to next step. No: Check 800 Pnk wire (B) and connections. If OK, test S4 seat switch. See “Seat Switch Test” on page 220. 3. Is battery voltage present at A1 display panel, J1 connector 765 Pur wire (C)? Yes: Go to next step. Electrical Operation and Diagnostics - 181 ELECTRICAL OPERATION AND DIAGNOSTICS Test Procedure A (Without Rear PTO Installed): No: Check 765 Pur wire and connections. If OK, test S8 brake switch. See “Brake Switch Test and Adjustment” on page 220. Test Conditions: • Machine parked safely with park brake locked. • Transmission in neutral. • Key switch in run position, engine off. • PTO off. • Operator on seat. • Battery fully charged. D • Power circuits functioning properly. See “Power Circuit Operation - X700” on page 140 or See “Power Circuit Operation - X720/X724/X728” on page 149. • Follow procedure in sequence. • Ensure that A1 display panel, J2 connector 135 Blk wire has continuity to ground. 4. Is battery voltage present at A1 display panel, J2 connector 742 Blu/Wht wire (D)? • Ensure all circuit grounds are in good condition and have continuity. No: Go to next step. Yes: Test S5 front PTO switch. See “PTO Switch Test (Optional Rear PTO Installed)” on page 223. PTO Off, Engine Off: Test Procedure B (Any Configuration): B Test Conditions: C A 1. Is battery voltage present at A1 display panel, J1 connector 772 Blu wire (A)? Yes: Go to next step. No: Check 772 Blu wire and connections. If OK, test S7 RIO switch. See “RIO Switch Test” on page 221. 2. Is battery voltage present at A1 display panel, J1 connector 800 Pnk wire? Yes: Go to next step. • Machine parked safely with park brake locked. • Transmission in neutral. • Key switch in run position, engine off. • S3 PTO switch in on position. • S5 PTO switch in on position (If installed). • Operator on seat. • Battery fully charged. • Power circuits functioning properly. See “Power Circuit Diagnosis - X700” on page 143 or See “Power Circuit Operation - X720/X724/X728” on page 149. • Follow procedure in sequence. • Ensure that A1 display panel, J2 connector 135 Blk wire has continuity to ground. • Ensure all circuit grounds are in good condition and have continuity. No: Check 800 Pnk wire (B) and connections. If OK, test S4 seat switch. See “Seat Switch Test” on page 220. 3. Is battery voltage present at A1 display panel, J1 connector 765 Pur wire (C)? Yes: Go to next step. Electrical Operation and Diagnostics - 182 ELECTRICAL OPERATION AND DIAGNOSTICS S3 PTO/RIP Switch in On Position, S5 PTO Switch in On Position (If Rear Optional Rear PTO is Installed), Engine Off: F No: Test Y2 PTO solenoid and wiring. See “PTO Solenoid Test (Standard Front PTO)” on page 222. Test Procedure C (Any Configuration): Test Conditions: 1. Is battery voltage present at A1 display panel, J1 connector 755 Blu wire (F)? Yes: Go to next step. No: Check 755 Blu wire and connections. If OK, test S3 PTO/RIP switch. See “PTO/RIP Switch Test” on page 218. • Machine parked safely with park brake locked. • Transmission in neutral. • Key switch in run position, engine off. • S3 PTO switch in RIP position. • Front and rear PTO(s) engaged (If installed). • Transmission in reverse (S7 RIO switch open). • Operator on seat. • Battery fully charged. • Power circuits functioning properly. See “Power Circuit Operation - X700” on page 140 or See “Power Circuit Operation - X720/X724/X728” on page 149. • Follow procedure in sequence. • Ensure that A1 display panel, J2 connector 135 Blk wire has continuity to ground. • Ensure all circuit grounds are in good condition and have continuity. S3 PTO/RIP Switch in RIP Position, S5 PTO Switch in On Position (If Optional Rear PTO is Installed), Engine Off: H G 2. Is battery voltage present at X4 connector, 757 Blu wire (G)? Yes: Test V1 PTO diode. See “Diode Test” on page 224. If OK, go to next procedure. 1. Is battery voltage present at A1 display panel, J1 connector 754 Blu wire (H)? No: Check 757 Blu wire and connections. If OK, test S3 PTO/RIP switch. See “PTO/RIP Switch Test” on page 218. No: Go to next step. Yes: Test S7 RIO switch. See “RIO Switch Test” on page 221. No: If all test conditions have been met, replace A1 display panel. 3. Does Y2 PTO clutch engage? Yes: Go to next procedure. Electrical Operation and Diagnostics - 183 ELECTRICAL OPERATION AND DIAGNOSTICS I 2. Is battery voltage present at X4 connector, 757 Blu wire (I)? Yes: Test V1 PTO diode. See “Diode Test” on page 224. If OK, go to next procedure. No: Check 757 Blu wire and connections. If OK, test S3 PTO/RIP switch. See “PTO/RIP Switch Test” on page 218. No: If all test conditions have been met, replace A1 display panel. 3. Does Y2 PTO clutch engage? Yes: Go to next procedure. No: Test Y2 PTO solenoid and wiring. See “PTO Solenoid Test (Standard Front PTO)” on page 222. Electrical Operation and Diagnostics - 184 ELECTRICAL OPERATION AND DIAGNOSTICS Display Panel Circuit Operation - All Models Function - Instrument Panel: To inform the operator of various machine operating conditions. There are no serviceable components on the display panel. It must be replaced as an assembly. Operating Condition - Instrument Panel: The key switch must be in run or start position. Theory of Operation - Instrument Panel: The instrument panel receives current from the power circuit. Power is supplied to the instrument panel from the battery positive (+) terminal to the 212 fusible link, 201 Red wire, F3 fuse, 204 Red wire, and to the S1 key switch. Power then leaves the switch on the 401 Yel wire to the F2 fuse, and leaves the fuse on the 500 Yel wire to a common splice. From the splice, the 503 and 410 Yel wires provide switched power to the A1 display panel. From the F2 fuse, power is also sent to the display panel over the 505 Yel wire. The circuit traces on the instrument panel then supply current to the individual lights and gauges. The A1 display panel also contains logic circuits that control certain functions such as PTO, safety, and reverse lighting operations. In addition, the display panel outputs on-board diagnostic codes to aid in troubleshooting the machine. See “Display Code Chart:” on page 109. The ground path for the instrument panel is completed by the 135 and 100 Blk wires to frame ground. Function - Engine Oil Pressure Light: To alert operator of low engine oil pressure. Theory of Operation - Engine Oil Pressure Light: The engine oil pressure light circuit uses a pressure activated switch to provide a path to ground for the engine oil pressure light. The switch is closed when engine oil pressure is at or below 98 kPa (14.2 psi). If the engine is not running or engine oil pressure is at or below 98 kPa (14.2 psi), the B1 engine oil pressure switch will be closed. The engine oil pressure switch completes the path to ground and the engine oil pressure light comes on. When the engine starts and engine oil pressure increases above 98 kPa (14.2 psi), the engine oil pressure switch opens, breaking the path to ground and the light goes out. Function - Engine Coolant Temperature Gauge: Inform the operator of engine and coolant operating temperature. Theory of Operation - Engine Coolant Temperature Gauge: The B2 engine coolant temperature sensor is a variable resistor, providing a ground circuit path for the temperature gauge. As the engine coolant heats, the resistance decreases. As the resistance decreases, more current is allowed to flow across the B2 engine coolant temperature gauge causing the needle raise and indicate a higher temperature. The temperature gauge is part of the instrument panel. The engine coolant temperature sensor resistance is approximately 40 - 700 ohms. Function - Fuel Gauge: Inform the operator of the fuel level in the fuel tank. Theory of Operation - Fuel Gauge: The fuel level in the fuel tank is measured by the B2 fuel gauge sensor. The sensor is a variable resistor. The resistance is set by movement of a mechanical linkage connected to a float in the fuel tank. The 5 to 95 ohm variable resistance creates a variable voltage difference across the fuel gauge. The voltage difference ranges from approximately 5.72 VDC (fuel tank full) to approximately 0.87 VDC (fuel tank empty). The fuel gauge is part of the instrument panel. Function - Hour Meter: To record the number of hours the key switch is in the run position. The hour meter also displays on-board diagnostic codes for the X720/X724/X728 EFI models. See “Fuel Injection Sensor and Diagnostic Circuit Operation - X720/ X724/X728” on page 203 for more information. Theory of Operation - Hour Meter: The P1 hour meter counts the total number of hours the key switch is in the run position. The P1 hour meter receives power from the switched power circuit. Function - Brake Light: Inform the operator that the brake pedal is depressed or the park brake is engaged. Theory of Operation - Brake Light: The brake light will illuminate whenever the brake pedal is depressed or the park brake is engaged with the key switch in the on position. It is activated by the S8 brake switch and receives its power from the 504 Yel wire, and when closed (brake applied), and sends power over the 765 Pur wire to the brake light on the instrument panel. A path to ground is provided by the 135 Blk wire on the instrument panel and to frame ground. Electrical Operation and Diagnostics - 185 ELECTRICAL OPERATION AND DIAGNOSTICS Function - Discharge Light: To inform the operator if the battery is not charging. Theory of Operation - Discharge Light: The battery discharge light will illuminate when the battery is not receiving a sufficient charge from the charging circuit. See “Charging Circuit Operation - All Models (Standard Configuration)” on page 164 for more information. Function - PTO Light(s): To inform the operator that the PTO(s) are engaged. Theory of Operation: The PTO light(s) will illuminate when a PTO is engaged. See “PTO/RIP Circuit Operation - All Models” on page 177 for more information. Function - Fuel Injection System Error Light (EFI Models Only): To inform the operator that an error has occurred with the fuel injection system. Theory of Operation - Fuel Injection System Error Light (EFI Models Only): The light will flash a code or series of codes to inform the operator that there is a problem with the fuel injection system. See “Fuel Injection Sensor and Diagnostic Circuit Operation - X720/X724/X728” on page 203. Electrical Operation and Diagnostics - 186 ELECTRICAL OPERATION AND DIAGNOSTICS A1 Display Panel Pin and Signal Location C B A D ah ag af H G E ae I J F ad ac K L M ab aa A- J2-K 503 Yel, Switched Power In B- J2-J 310 Org, Coolant Temperature In C- J2-H, Not Used D- J2-G, Not Used E- J2-F 742 Blu/Wht, Front PTO In F- J1-S 740 Blu, Rear PTO In G- J1-R, 785 Grn (EFI Only), Fault Light In H- J1-P, Not Used I- J1-N, Not Used J- J1-M 620 Tan, Oil Pressure In K- J1-L 611 Brn (EFI) or 942 Wht (Carb), Tach In L- J1-K 451 Yel/Wht, Illumination In M- J1-J, Not Used N- J3-H 720 Pur, Start Out O- J3-G, Not Used P- J3-F 650 Pnk/Blk, Ignition Out (EFI) or Fuel Circuit Out (Carb) Z Y V X W N U O T P S Q R Q- J3-E 815 Pnk, Backup Lights Out R- J3-A 941 Wht, Ignition Out (Carb Only) S- J3-B 756 Blu, PTO Out T- J3-C, Not Used U- J3-D 505 Yel, Switched Power In V- J1-A 800 Pnk, Seat Switch In W- J1-B 754 Blu, RIO Overide In X- J1-C 755 Blu, PTO In Y- J1-D 765 Pur, Brake Switch In Z- J1-E 410 Yel, Switched Power In AA- J1-F, Not Used AB- J1-G 772 Blu, Reverse In AC- J1-H 900 Blk/Wht, Fuel Sender In AD- J2-A 135 Blk, Ground AE- J2-B 591 Pur, Start In AF- J2-C 810 Pnk, Back Up Lights In AG- J2-D, Not Used AH- J2-E, Not Used Electrical Operation and Diagnostics - 187 ELECTRICAL OPERATION AND DIAGNOSTICS Lights Circuit Operation - All Models Function: Provides current to the headlights, tail lights, backup lights, and instrument panel lights, in combinations depending upon the position the light switch or transmission (RIO switch). Operating Conditions: • Machine parked safely with park brake locked - key switch in run position, engine off. • Light switch in ‘on’ or ‘on with backup lights’ position, or, • Transmission in reverse. Theory of Operation: Power is provided to the S9 light switch through the unswitched and switched power circuits and is protected by the 212 fusible link and the F3 and F1 fuses. The 400 Yel/ Blu wire connects to the S9 light switch. The key switch must be in the run position in order for the lights to function. See “Power Circuit Operation - X700” on page 140 or “Power Circuit Operation - X720/X724/X728” on page 149. With the S9 light switch in the on position, current is provided to the 450 Yel/Wht wire which splices into the 451, 455, and 459 Yel/Wht wires. The 451 Yel/Wht wire supplies current to the A1 display panel to illuminate the display panel lights. The 135 and 100 Blk wires provide the ground from the display panel. The 455 Yel/Wht wire supplies current to the X7 connector to illuminate the E1 and E2 headlights. The ground is provided through the X7 connector to the 110 Blk wire and frame ground. The 459 Yel/Wht wire supplies current to the X1 connector to illuminate the E3 and E4 tail lights. The ground is provided through the X1 connector to the 122 and 100 Blk wires to frame ground. With the light switch in the ‘on with backup lights’ position, in addition to the display panel light, E1 and E2 headlights, and the E3 and E4 tail lights, current is provided to the to the E5 and E6 backup lights. The A1 display panel provides current via the 815 Pnk wire to the X1 connector and the backup lights. Ground is provided through the X1 connector and the 122 and 100 Blk wires to frame ground. The backup lights can also be activated by the S7 RIO switch. When the machine is placed in reverse and the RIO switch is opened, power over the 772 Blu wire to the A1 display panel is removed. This signals the display panel that the machine is travelling in reverse and the display panel will output voltage over the 815 Pnk wire to the E5 and E6 backup lights. Ground is provided by the 122 and 100 Blk wires to frame ground. Electrical Operation and Diagnostics - 188 ELECTRICAL OPERATION AND DIAGNOSTICS Lights Circuit Electrical Schematic - All Models S1 Key Switch 206 Red (EFI) S-7 Off Run Start S1 B M S2 401 Yel A G S9 Light Switch 401 Yel F1 A F2 C F3 E F4 Off On On B 400 Yel/Blu D 500 Yel F 204 Red 15A 15A 30A G 20A 450 Yel/Wht S-6 455 Yel/Wht 459 Yel/Wht X7 H S7 RIO Switch E1 RH Headlight Neutral/Forward 402 Yel 201 Red Reverse 772 Blu X1 810 Pnk E2 LH Headlight X1 451 Yel/Wht S-1 212 J1-G J2-C J1-K J3-E 815 Pnk E3 RH Taillight X7 110 Blk Red B S E4 LH Taillight Y1 Start Solenoid M1 Start Motor M E5 RH Backup Light A1 Display Panel E6 LH Backup Light X1 G1 Battery J2-A Blk 135 Blk 100 Blk 110 Blk W1 Ground Unswitched Power Electrical Operation and Diagnostics - 189 122 Blk ELECTRICAL OPERATION AND DIAGNOSTICS Lights Circuit Diagnosis - All Models No: Check 455 Yel/Wht wire and connections. Yes: Check headlight grounds. If OK, replace bulb(s). Test Procedure A: Yes: If bulb(s) do not illuminate, repair or replace W3 headlight wiring harness. Test Conditions: • Machine parked safely with park brake locked. • Key switch in off position. • S9 light switch in on position. • Battery fully charged. • Power circuits functioning properly. • Follow procedure in sequence. Yes: Go to next step. • Ensure that A1 display panel, J2 connector 135 Blk wire has continuity to ground. • Ensure all circuit grounds are in good condition and have continuity. Light Switch in On Position: C 3. Is battery voltage present at X1 connector, 459 Yel/Wht wire (C)? No: Check 459 Yel/Wht wire and connections. Yes: Check tail light grounds. If Ok, replace bulb(s). Yes: If bulb(s) do not illuminate, repair or replace W4 rear wiring harness. D A 1. Is battery voltage present at S9 light switch, 450 Yel/Wht wire (A)? Yes: Go to next step. No: Test S9 light switch. See “Key Switch Test” on page 219. 4. Is battery voltage present at A1 display panel, J1 connector 451 Yel/Wht wire (D)? Yes: If voltage is present and A1 display panel does not illuminate, replace display panel. AB Yes: Go to next procedure. No: Check 451 Yel/Wht wire and connections. B 2. Is battery voltage present at X7 connector, 455 Yel/Wht wire (B)? Electrical Operation and Diagnostics - 190 ELECTRICAL OPERATION AND DIAGNOSTICS Test Procedure B: Yes: Check tail light grounds. If OK, replace bulb(s). Test Conditions: Yes: If bulb(s) do not illuminate, repair or replace W4 tail light wiring harness. • Machine parked safely with park brake locked. Yes: Go to next procedure. • Key switch in off position. • S9 light switch in on with back up lights position. No: Check 815 Pnk wire and connections. If OK, replace A1 display panel. • Battery fully charged. • Power circuits functioning properly. • Follow procedure in sequence. Test Procedure C: Test Conditions: • Ensure that A1 display panel, J2 connector 135 Blk wire has continuity to ground. • Machine parked safely with park brake locked. • Key switch in off position. • Ensure all circuit grounds are in good condition and have continuity. • S9 light switch in on with back up lights position. • Battery fully charged. • Power circuits functioning properly. • Follow procedure in sequence. Light Switch in On with Back Up Lights Position: • Ensure that A1 display panel, J2 connector 135 Blk wire has continuity to ground. • Ensure all circuit grounds are in good condition and have continuity. Light Switch Off, Machine in Reverse: E G 1. Is battery voltage present at A1 display panel, J2 connector 810 Pnk wire (E)? No: Check 810 Pnk wire and connections. No: Test S9 light switch. “Lights Switch Test” on page 217. Yes: Go to next step. 1. Is battery voltage present at A1 display panel, J3 connector 815 Pnk wire (G)? F Yes: End of tests. No: Test S7 RIO switch. See “RIO Switch Test” on page 221. No: Check 772 Blu wire and connections from S7 RIO switch to A1 display panel J1 connector for battery voltage. No: Replace A1 display panel. 2. Is battery voltage present at X1 connector, 815 Pnk wire (F)? Electrical Operation and Diagnostics - 191 ELECTRICAL OPERATION AND DIAGNOSTICS Power Port Circuit Operation - All Models Function: Power Port Circuit Electrical Schematic - All Models Provides a receptacle to power small auxiliary electrical devices. F1 A Operating Conditions: F2 C • Key switch in on or off position F3 E • Power port switch in on position F4 B 15A D 15A 30A G 20A F H 200 Red S-3 Theory of Operation: 592 Blu The X13 power port will power small 12 VDC electrical devices up to 15A and is controlled by the S2 power port switch. Current to the S2 power port switch is provided by the 213 fusible link, 202 Red wire, F4 fuse, 200 Red and 592 Blu wires, and X1 connector to the switch. With the switch in the closed position (power on), current then flows through the F6 fuse and to the power port. Ground is provided by the 100 Blk wire to frame ground. This circuit is only completed if there is a device plugged into the power port receptacle. X1 202 Red S2 Power Port Switch S-2 Fuse Links Pnk Off On 213 Red B S Y1 Start Solenoid M1 Start Motor F5 Fuse 15A M A G1 Battery X13 Power Port B Blk 100 Blk S-4 Unswitched Power W1 Ground Electrical Operation and Diagnostics - 192 Switched Power ELECTRICAL OPERATION AND DIAGNOSTICS Power Port Circuit Diagnosis - All Models Test Procedure: Test Conditions: • Machine parked safely with park brake locked. • Key switch in off position. • S2 power port switch in on position. • Battery fully charged. • Power circuits functioning properly. • Follow procedure in sequence. • Ensure all circuit grounds are in good condition and have continuity. Power Port Circuit: A 1. Is battery voltage present at Red wire (A) of X13 power port? Yes: If ground circuit is OK, replace power port. No: Test F6 15A inline fuse. See “Fuse Test” on page 222. No: Test S2 power port switch. See “Power Port Switch Test” on page 219. No: Check wires and connections. Electrical Operation and Diagnostics - 193 ELECTRICAL OPERATION AND DIAGNOSTICS Fuel Pump and Fuel Shutoff Circuit Operation - X700 Function: To provide power to the fuel shutoff solenoid and the fuel pump to supply fuel to the engine. Operating Conditions: • Key switch in run or start position, • Operator on seat, or, • Key switch in run or start position, • Operator off seat, • Park braked locked. Theory of Operation: The fuel shutoff solenoid and fuel pump circuit is controlled by the A1 display panel in one of two ways: Current from the switched power circuit is supplied to the S4 seat switch from the 500 and 502 Yel wires. When the operator is on the seat, current flows across the seat switch to the 800 Pnk wire and into the A1 display panel. The display panel will then output voltage over the 650 Pnk/Blk wire to the X3 connector. This will engage the Y3 fuel shutoff solenoid, allowing the free flow of fuel. The solenoid is grounded through the engine. At the same time, the 655 Pnk wire, spliced at the X3 connector, carries power to the X5 connector, 651 Pnk/Blk wire, and finally the X6 connector at the M2 fuel pump. the pump is grounded through the X6 connector, and the 121 and 100 Blk wires to frame ground. With both the fuel pump and fuel shutoff solenoid energized, fuel is now able to flow to the carburetor and into the combustion chamber. Current can also be supplied to the A1 display panel through the S8 brake switch. Current from the switched power circuit is supplied to the S8 brake switch from the 500 and 504 Yel wires. When the brake is on, current flows across the brake switch to the 765 Pur wire. The 765 Pur wire supplies current to the A1 display panel. The display panel will then output voltage over the 650 Pnk/Blk wire to the X3 connector. This will engage the Y3 fuel shutoff solenoid, allowing the free flow of fuel. The solenoid is grounded through the engine. At the same time, the 655 Pnk wire, spliced at the X3 connector, carries power to the X5 connector, 651 Pnk/Blk wire, and finally the X6 connector at the M2 fuel pump. the pump is grounded through the X6 connector, and the 121 and 100 Blk wires to frame ground. Electrical Operation and Diagnostics - 194 ELECTRICAL OPERATION AND DIAGNOSTICS Fuel Pump and Fuel Shutoff Circuit Electrical Schematic - X700 S1 Key Switch Off Run Start S1 204 Red B M S2 401 Yel A G 401 Yel F1 A F2 C S4 Seat Switch B Off 15A D 500 Yel F 204 Red 15A F3 E 30A G 20A On S-5 500 Yel H 502 Yel 504 Yel S8 Brake Switch 201 Red (On) (Off) S-1 212 A1 Display Panel Fusible Link J1-D Red B S Y1 Start Solenoid M1 Start Motor 800 Pnk J1-A J3-F 650 Pnk/Blk M 655 Pnk X3 X5 651 Pnk/Blk X6 Y3 Fuel Shutoff Solenoid M G1 Battery M2 Fuel Pump Blk X6 121 Blk 100 Blk W1 Ground Unswitched Power Electrical Operation and Diagnostics - 195 504 Yel 800 Pnk ELECTRICAL OPERATION AND DIAGNOSTICS Fuel Pump and Fuel Shutoff Circuit Diagnosis - X700 B Test Procedure: Test Conditions: • Machine parked safely with park brake locked. • Key switch in on position, engine off. • Operator on seat. • PTO off. • Battery fully charged. • Power circuits functioning properly. • Follow procedure in sequence. 3. Is battery voltage present at 651 Pnk/Blk wire (B) of M2 fuel pump? • Ensure all circuit grounds are in good condition and have continuity. Fuel Circuit: Yes: Test M2 fuel pump. See fuel pump tests in Engine section. No: Check 655 Pnk wire, X5 connector, 651 Pnk/Blk wire, X6 connector and connections. A 1. Is battery voltage present at A1 display panel, J3 connector 650 Pnk/Blk wire (A)? Yes: Go to next step. No: If all operating conditions have been met, replace A1 display panel. 2. Does the Y3 fuel shutoff solenoid make an audible ‘click’ when the key switch is turned to the run position? Yes: If necessary, test Y3 fuel shutoff solenoid. See “Fuel Shutoff Solenoid Test - X700” on page 224. No: Check 650 Pnk/Blk wire, X3 connector, and Y3 fuel shutoff solenoid wires. If OK, test or replace fuel shutoff solenoid. Electrical Operation and Diagnostics - 196 ELECTRICAL OPERATION AND DIAGNOSTICS Fuel Pump and Fuel Injector Circuit Operation - X720/X724/X728 Function: To provide power to the fuel pump and fuel injectors to supply fuel to the engine. These circuits provide the inputs to the EFI module which in turn provides the proper output to the injectors. Operating Conditions: • Key switch in run or start position. • Operator on seat. The fuel pump and injectors can also be controlled by the S8 brake switch. Current from the switched power circuit is supplied to the S8 brake switch from the 500 and 504 Yel wires. When the brake is engaged (switch closed), current flows across the S8 brake switch to the 765 Pur wire and into the A1 display panel. The A1 display panel then outputs voltage to the 650 Pnk/Blk wire. The 650 Pnk/Blk wire supplies current to the K3 safety relay. The K3 safety relay closes and provides a path to ground for the A2 EFI module through the 860 Pnk, Org, and 670 Pur wires, K3 EFI module safety relay, 139 and 100 Blk wires to frame ground. Or, • Key switch in run or start position. • Operator off seat. • Park braked locked. Theory of Operation: The fuel pump and fuel injector circuit is controlled by the A2 electric fuel injection (EFI) module which is powered through the A1 display panel. Current from the switched power circuit is supplied to the S4 seat switch from the 500 and 502 Yel wires. When the operator is on the seat (switch closed), current flows across the seat switch to the 800 Pnk wire and into the A1 display panel. The A1 display panel then outputs voltage to the 650 Pnk/Blk wire. The 650 Pnk/Blk wire supplies current to the K3 safety relay. The K3 safety relay closes and provides a path to ground for the A2 EFI module through the 860 Pnk, Org, and 670 Pur wires, K3 EFI module safety relay, 139 and 100 Blk wires to frame ground. At the same time power is being supplied to the A2 EFI module through the K1 main relay. With the key in the run position, switched power is provided to the K1 main relay from the 500 Yel and 560 Red/Yel wires. This energizes the K1 main relay to supply unswitched power from the 212 fusible link, 201 Red wire, F3 fuse, 204 and 220 Red wires, F5 fuse, and 221 Red wire to the 230 Red and 233 Red/Blu wires to the X9 connector to the Wht wire in the W2 engine wiring harness. The Wht wire provides power to the Y3 and Y4 fuel injector solenoids and the 240 Red wire to the A2 EFI module. With power to the A2 EFI module, internal circuitry provides a ground circuit for the K2 fuel pump relay. The power input for the for the K2 fuel pump relay is provided from the K1 main relay and 230 and 231 and 232 Red wires. With the K2 fuel pump relay energized, current flows from the 231 Red wire to the 655 Pnk, X6 connector, and 651 Pnk/Blk wires to the M2 fuel pump. With the fuel pump, fuel injectors, and the EFI module energized, fuel is now able to be delivered into the combustion chamber. Electrical Operation and Diagnostics - 197 ELECTRICAL OPERATION AND DIAGNOSTICS Fuel Pump and Fuel Injector Circuit Electrical Schematic - X720/X724/X728 S1 Key Switch Off Run Start 593 Yel S1 206 Red B M 402 Yel 591 Yel S2 401 Yel A S4 Seat Switch 402 Yel G Off On 502 Yel 520 Yel 401 Yel F1 A F2 C F3 E F4 800 Pnk B 15A D 15A 30A G 20A 593 Yel 500 Yel 560 Red/Yel 500 Yel 505 Yel 204 Red F 504 Yel 503 Yel S-5 220 Red S-7 H 591 Yel 410 Yel J2-B 503 Yel 410 Yel 201 Red F5 10 Amp Fuse 202 Red S-1 212 505 Yel J1-A J2-K J1-E J3-D S-2 Fusible Links 213 Red B S 221 560 Red Red/Yel Y1 Start Solenoid M1 Start Motor 87a M 230 Red 87 30 85 86 233 Red/Blu K1 Main Relay G1 Battery K2 Fuel Pump Relay 87a Blk 231 Red 150 Blk 30 85 86 910 Wht 100 Blk 100 Blk W1 Ground 232 Red 655 Pnk 87 Unswitched Power Switched Power Electrical Operation and Diagnostics - 198 ELECTRICAL OPERATION AND DIAGNOSTICS With Optional Rear PTO S7 RIO Switch S5 Front PTO Switch Neutral/Forward Reverse 402 Yel S6 Rear PTO Switch On 520 Yel 742 Blu/Wht Off 742 Blu/Wht 743 Pur On Off 740 Blu 520 Yel 740 Blu 521 Yel 772 Blu 521 Yel X11 W2 Ground A B 504 Yel 504 Yel C X10 D A J1-G J1-S J2-F B 330 Org Brn C 460 Yel D S8 Brake Switch A1 Display Panel 765 Pur E F G H E Blk/Wht (On) C F Blk/Wht (Off) I F 710 Pur G J K H J1-D L I M J E N K H A2 Electric Fuel Injection Module O L 240 Red P M N O P Y3 #1 Cylinder Fuel Injector Solenoid Y4 #2 Cylinder Fuel Injector Solenoid 651 Pnk/Blk X6 Wht M2 M Fuel Pump X6 655 Pnk 121 Blk X8 910 Wht 100 Blk Brn 135 Blk Electrical Operation and Diagnostics - 199 X9 Wht ELECTRICAL OPERATION AND DIAGNOSTICS Fuel Pump and Fuel Injector Circuit Diagnosis - X720/X724/X728 Fuel Injector Control Circuit: Test Procedure A: Test Conditions: B • Machine parked safely with park brake locked. • Key switch in run position, engine off. • Operator on seat. • PTO off. • Battery fully charged. • Power circuits functioning properly. • No fault codes from on-board self diagnostics. • Follow procedure in sequence. • Ensure all circuit grounds are in good condition and have continuity. Fuel Pump Circuit: C 1. Is there continuity between A2 EFI module X11 connector, 710 Pur wire (B) and 330 Org wire (C) and ground? Yes: Go to next step. A No: Check 710 Pur wire, 330 Org wire, X10 connector and connections. 2. Is battery voltage present at Wht wires of Y3 and Y4 fuel injector solenoids? Yes: Go to next step. No: Re-check power circuits. Also, ensure that battery voltage is present at A2 EFI module, X11 connector 240 Red wire. 3. Is a problem suspected with one or both of the fuel injector solenoids? 1. Is battery voltage present at 651 Pnk/Blk wire (A) of M2 fuel pump? Yes: If ground circuit is OK, test or replace M2 fuel pump. See fuel pump tests in Engine section. No: Go to next procedure. Yes: Test fuel injector solenoid(s). See “Fuel Injector Test - X720/X724/X728” on page 225. No: Check fuel pump wiring, 651 Pnk/Blk wire, and 655 Pnk wire and connections. Electrical Operation and Diagnostics - 200 ELECTRICAL OPERATION AND DIAGNOSTICS EFI Module and Sensors: replace A2 EFI module. D E G 4. Is 2.26 - 2.5 VDC present at Blu wire (G) of B4 engine coolant temperature sensor? Yes: Go to next step. 1. Is continuity to ground present at A2 EFI module, X11 connector 460 Yel wire (D)? Yes: Go to next step. No: Check Blu wire, 615 Tan wire and connections. Test B4 engine coolant temperature sensor. See “Coolant Temperature Sensor Test - X720/X724/X728” on page 227. If OK, replace A2 EFI module. No: Check 460 Yel wire, Brn wire and connections. No: Re-check power circuits. See “Power Circuit Diagnosis - X720/X724/X728 EFI” on page 154. 2. Is there continuity between A2 EFI module, X11 connector 510 Blu wire (E) and ground? Yes: Go to next step. No: Check 510 Blu wire, X10 connector, Blk/Yel wire and connection. No: Replace A2 EFI module. H I 5. Is 3.5 - 3.8 VDC present measured at B6 vacuum pressure sensor Tan wire (H)? Yes: Go to next step. No: Check Tan wire, 470 Yel wire and connections. Test B6 vacuum pressure sensor. See “Vacuum Pressure Sensor Test - X720/X724/X728” on page 226. If OK, replace A2 EFI module. 6. Measure battery voltage at B6 vacuum pressure sensor. Red/Blu wire (I). Is voltage between 0.5 - 4.9 VDC? F 3. Is 2.26 - 2.5 VDC present at B5 air temperature sensor, Grn wire (F)? Yes: Go to next procedure. No: Replace B6 vacuum pressure sensor. Yes: Go to next step. No: Check Grn wire, 515 Blu wire and connections. Test B5 air temperature sensor. See “Air Temperature Sensor Test - X720/X724/X728” on page 227. If OK, Electrical Operation and Diagnostics - 201 ELECTRICAL OPERATION AND DIAGNOSTICS Test Procedure B: Test Conditions: • Machine parked safely with park brake locked. • Key switch in run position, engine running. • Operator on seat. • PTO off. • Battery fully charged. • Power circuits functioning properly. • No fault codes from on-board self diagnostics. • Follow procedure in sequence. • Ensure all circuit grounds are in good condition and have continuity. Fuel Injectors: I 1. Place a test light on a fuel injector Yel/Blu wire (I). Does the light rapidly pulse on and off? Repeat for other injector on Yel/Red wire. Yes: Remove fuel injectors and test. See “Fuel Injector Test - X720/X724/X728” on page 225. No: Check Yel/Red, 510 Blu wires and connections for Y4, #2 cylinder injector. No: Check Yel/Blu, 160 Blk wires, and connections for Y3, #1 cylinder injector. No: If wires are OK, replace A2 EFI module. Electrical Operation and Diagnostics - 202 ELECTRICAL OPERATION AND DIAGNOSTICS Fuel Injection Sensor and Diagnostic Circuit Operation - X720/X724/X728 Function: Provides the inputs to the EFI module which in turn provides the proper output to the injectors. The circuit integrity indicators (hour meter and EFI diagnostic light) display a code to provide a visual indication of circuit integrity. These fault codes will aid in the diagnosis of operational problems that may occur. Operating Conditions: the fuel injection diagnostic light will display all the fault codes that are detected by the EFI module starting with the lowest numbered code. When all the fault codes have been displayed, the hourmeter will be off for approximately 5 seconds and then the fault codes will repeat. The B4 coolant temperature, B5 air temperature and B6 vacuum pressure sensors are all resistance operated components that change their signal voltages to the EFI module. The fault codes for these components are based on the EFI module reading either a open or shorted circuit. This means that the EFI module is receiving either sensor voltage (5 VDC) or no voltage from the sensors. • Key in run or start position, Diagnostic Circuit Operation: • Engine running. During normal operation the display panel will illuminate all indicator lights for 2 seconds and the gauges will sweep. Then the light will not be illuminated. The hourmeter will begin to display a specific fault code when the input from any one or more sensors is not operating properly. If more than one fault exists, each fault will be displayed before the controller repeats the fault codes. Theory of Operation: Power is supplied to the electric fuel injection module when the key is in the run or start positions and the K1 main relay has been energized. At the same time the ground circuit is controlled by the K3 safety relay which is controlled by the A1 display panel and the A2 EFI module. When the operating conditions have been met, the fuel injector sensors provide the input to the EFI module so that the EFI module will provide the ground path for the injectors at the correct time and duration. The EFI module also has a self diagnostic mode that will display a code on the display panel if any of the three input sensors is not operating properly. When the circuit is operating normally, this light will remain off. If a fault exists, The EFI module has the capability to test on board circuits and display a message indicating that circuit’s status. The EFI module also has 4 different fault codes available to assist with diagnostics. If a code is displayed, this means that the EFI is receiving either battery voltage or no voltage from the sensor. Once a code has been read, it can be matched to the fault code chart. EFI Module On Board Circuit Status Code Chart: Fault Code Flash Sequence Test Point Fault Cause N/A B5 air temperature sensor Grn and Blk/Yel wires to A2 EFI module B5 air temperature sensor circuit malfunctioning. Circuit either open or shorted N/A B4 coolant temperature sensor, Blu and Blk Yel wires to A2 EFI module B4 coolant temperature sensor circuit malfunctioning. Circuit either open or shorted. N/A B6 vacuum pressure sensor, Tan, Red Blu, and Blk/Yel wires to A2 EFI module B6 vacuum pressure sensor circuit malfunctioning. Circuit either open or shorted. N/A EFI module air/fuel pressure calculation error. To reset: Stop engine, wait for fault indicator light to go off and fuel pump to stop (approximately 0.5 to 1 second). Start engine. Electrical Operation and Diagnostics - 203 ELECTRICAL OPERATION AND DIAGNOSTICS Fault Code Flash Sequence Test Point N/A Fault Cause EFI module air/fuel pressure calculation error. To reset: Stop engine, wait for fault indicator light to go off and fuel pump to stop (approximately 0.5 to 1 second). Start engine. N/A None End of tests. All sensors functioning normally. Display Code Chart: Test Conditions • Brake on • PTO switch in RIO position (pulled out) • Key switch on Code Action Test Point Fault Cause Depress brake pedal. S8 brake switch, 765 Pur wire, 504 Yel wire, and switched power circuits. S8 brake switch OK. Turn key switch to start. S1 key switch, 720 Pur wire, 591 Yel wire, switched and unswitched power circuits. S1 key switch OK. Operator on seat. S4 seat switch, 800 Pnk wire, 502 Yel wire, and switched power circuits. S4 seat switch OK. Pull up RIP switch. S3 PTO/RIP switch, 754 Blu wire, 501 Yel wire, and switched power circuits. S3 PTO/RIP switch OK (RIP position). Activate PTO switch. S3 PTO/RIP switch, 755 Blu wire, 501 Yel wire, and switched power circuits. S3 PTO/RIP switch OK (PTO position). Depress reverse pedal. S7 RIO switch, 772 Blu wire, 402 Yel wire, and switched power circuits. S7 RIO switch OK. Remove oil pressure sensor wire. B1 engine oil pressure switch and 620 Tan wire. B1 engine oil pressure switch OK. Electrical Operation and Diagnostics - 204 ELECTRICAL OPERATION AND DIAGNOSTICS Code Action Test Point Fault Cause B2 engine water temperature Remove and ground coolant sensor and 310 Org wire. temperature switch wire. B2 engine water temperature switch OK. Turn on back S9 light switch, 400 Yel/Blu up light switch. wire, and switched power circuits. S9 light switch OK (back up lights position). **** Rear PTO jumper (if installed) Engage rear PTO. S6 rear PTO switch, 740 Blu wire, 520 and 521 Yel wires, and switched power circuits. S6 rear PTO switch OK. No action End of tests End of tests Electrical Operation and Diagnostics - 205 ELECTRICAL OPERATION AND DIAGNOSTICS Fuel Injection Sensor and Diagnostic Circuit Electrical Schematic - X720/X724/X728 W2 Ground Y3 #1 Cylinder Fuel Injector Solenoid X10 Yel/Blu A 160 Blk B 330 Org Yel/Blu Blk/Wht Y4 #2 Cylinder Wht Fuel Injector Yel/Red Solenoid Brn Blk/Yel Yel/Red C 460 Yel Blk/Wht F 710 Pur G Org H 860 Pnk Red I D 510 Blu E 610 Tan 950 Wht J Wht K 340 Grn L 240 Red Tan M 470 Yel Red/Blu Wht N Grn O 515 Blu Blu P 615 Tan Red Org Grn X9 Wht 233 Red/Blu 87a 232 Red 655 Pnk 87 651 Pnk/Blk to B4 Coolant Temperature Sensor M Blk/Yel 30 Brn 910 Wht 85 M2 Fuel Pump X6 231 Red Blu 86 Red/Blu K2 Fuel Pump Relay X6 X8 100 Blk 5 VDC Circuits Tan 121 Blk W1 Ground Electrical Operation and Diagnostics - 206 ELECTRICAL OPERATION AND DIAGNOSTICS X11 615 Tan A 515 Blu A1 Display Panel B C 470 Yel F C D 860 Pnk E F 710 Pur G 610 Tan H 160 Blk 330 Org I J 460 Yel 510 Blu 950 Wht A2 Electric Fuel Injection Module E H K L M N 340 Grn 240 Red O J1-R P J3-F 785 Grn K3 Safety Relay X8 Org 785 Grn Grn to B5 Air Temperature Sensor Blk/Yel Blk/Yel Blk/Yel Red/Blu m 87a 785 Grn Red 650 Pnk/Blk B6 Vacuum Pressure Sensor Tan 5 VDC Circuits Electrical Operation and Diagnostics - 207 670 Pur 87 30 85 86 ELECTRICAL TESTS AND ADJUSTMENTS Tests and Adjustments Common Circuit Tests Shorted/Grounded Circuit: A shorted circuit on the ground side of a component (i.e. improper wire-to-wire or wire to ground contact) may result in improper component operation. A shorted circuit on the power side of a component or contact of two power circuits (i.e. improper wire-to-wire or wire to ground contact) may result in blown fusible link and fuses. To test for a shorted or improperly wired circuit: component to be tested that is closest to the battery negative terminal. Resistance reading must be very close to or the same as the battery negative terminal reading. Work backwards from the battery on the ground side of the problem circuit until the resistance reading increases above 0.1 ohms. The problem is between the last two test points. If a problem is indicated, disconnect the wiring 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 connecting may temporarily solve problem. Voltmeter Procedure: 1. Turn component switch ON. 1. Put transmission in neutral. Lock park brake. Put PTO switch in off position. Turn key switch to on position. 2. Start at the controlling switch of the component that should not be operating. 2. Connect voltmeter negative (black) lead to negative terminal of battery. 3. Follow the circuit and disconnect wires at connectors until components stop operating. 3. Put meter positive (red) lead on ground terminal of component to be tested. Be sure the component circuit is activated (key in run position, switches closed) so voltage will be present at the component. Record voltage. Voltage must be greater than 0 but less than 1 volt. Some components will have a very small voltage reading on the ground side and still be operating correctly. 4. Shorted or improper connections will be the last two wires disconnected. HIgh Resistance or Open Circuit: High resistance or open circuits usually result in slow, dim, or no component operation (i.e. poor, corroded, or severed connections). Voltage at the component will be low when the component is in operation. To test for high resistance and open circuits: 1. Check all terminals and ground connections of the circuit for corrosion. Results: • If resistance is above 0.1 ohms, check for open wiring, loose terminal wire crimps, poor connections, or corrosion in the ground circuit. • If voltage is 0, the component is open. 2. If terminals are not loose or corroded, the problem is in the component or wiring. • If voltage is greater than 1 volt, the ground circuit is bad. Check for open wiring, loose terminal wire crimps, poor connections, or corrosion in the ground circuit. Ground Circuit Tests Battery Voltage and Specific Gravity Test Reason: Reason: To check for opens, loose terminal wire crimps, poor connections, or corrosion in the ground circuit. The voltmeter method checks ground connections under load. To check voltage and determine condition of battery. Equipment: • Voltmeter or JTO5685 Battery Tester • • Hydrometer Procedure • Clean battery terminals and top of battery Ohmmeter or Voltmeter Ohmmeter Procedure: Equipment: 1. Turn key switch to OFF position. Lock park brake. 2. Connect ohmmeter negative (black) lead to negative (-) terminal of battery. Put meter positive (red) lead on negative terminal of battery and record reading. Reading should be 0.1 ohm or less. 3. Put meter red lead on ground terminal of circuit or Electrical Tests and Adjustments - 208 ELECTRICAL TESTS AND ADJUSTMENTS Procedure: c Caution: Avoid Injury! Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into the eyes. Avoid the hazard by: Filling batteries in a well-ventilated area, Wearing eye protection and rubber gloves, Avoiding breathing fumes when electrolyte is added. Avoid spilling or dripping electrolyte. Use proper jump-start procedure. If you spill acid on yourself: Flush your skin with water. Apply baking soda or lime to help neutralize the acid. Flush your eyes with water for 10 - 15 minutes. Get medical attention immediately. If acid is swallowed: Drink large amounts of water or milk. Then drink milk of magnesia, beaten eggs, or vegetable oil. Get medical attention immediately. 6. Use an hydrometer to check for a minimum specific gravity of 1.265 with less than 50 point variation in each cell at full charge at 26.7°C (80°F). Results: • Battery voltage less than 12.4 VDC, charge battery. • Battery voltage more than 12.4 VDC, test specific gravity. • All cells less than 1.175, charge battery at 10 amp rate. • All cells less than 1.225 with less than 50 point variation, charge battery at 10 amp rate. 1. Park machine safely with park brake locked. 2. Inspect battery terminals and case for breakage or cracks. 3. Check electrolyte level in each battery cell. Add clean, soft water as needed. If water added, charge battery for 20 minutes at 10 amps. 4. Remove surface charge by placing a small load on the battery for 15 seconds. D.C. AMPS MIF • All cells more than 1.225 with less than 50 point variation, load test battery. • More than 50 point variation: replace battery. Specifications: Minimum battery voltage . . . . . . . . . . . . . . . . .12.4 volts Minimum specific gravity . . . . . . . . . . . . . . . . . . . . . . 1.225 with less than 50 point variation D.C. VOLTS Battery - Charge Reason: To increase battery charge after battery has been discharged. Equipment: MIF • Battery charger (variable rate) 5. Check battery voltage with voltmeter or JTO5685 battery tester. Electrical Tests and Adjustments - 209 ELECTRICAL TESTS AND ADJUSTMENTS Battery - Load Test Procedure: Reason: To check condition of battery under load. Note: Charge battery before performing load test. Equipment: Battery Charger and Booster • JTO5685 Battery Tester Note: Use the procedures given with the tester. MIF 1. Connect variable rate charger to battery. Connections: Note: Maximum charge time at boost setting is 10 minutes. Allow an additional 5 minutes for each 10 degrees below 70 degrees F. B 2. Start charger at slow rate. Increase charge rate one setting at a time. Check charger ammeter after 1 minute at each setting. Maintain 10 amp charge rate. Use boost setting as necessary. D E C 3. Check if battery is accepting a 10 amp charge after 10 minutes at boost setting. A • Battery will not accept 10 amp charge after 10 minutes at boost setting: replace battery • Battery is accepting 10 amp charge after 10 minutes at boost setting, and battery did not need water: go to steps 6 and 7 • Battery is accepting 10 amp charge after 10 minutes at boost setting, but battery did need water or all cells were below 1.175: go to steps 4 and 5 Important: Avoid Damage! Decrease charge rate if battery gases or bubbles excessively or becomes too warm to touch. M49597 1. Turn load knob (A) of tester counter-clockwise to off. 2. Connect tester positive cable (B) to battery positive terminal. 3. Connect tester negative cable (C) to battery negative terminal. Procedure: 1. Turn load knob of tester clockwise until amperage reading is equal to: 4. Set charger at 15 - 25 amps. 5. Check specific gravity after 30 minutes (60 minutes for maintenance-free battery). Note: If battery was discharged at slow or unknown rate, charge at 10 - 15 amps for 6 - 12 hours (Maintenance-free battery: 12 - 24 hours). If battery was discharged at fast rate, charge at 20 - 25 amps for 2 - 4 hours (Maintenance-free battery: 4 - 8 hours). • More than 50 point variation between cells: replace battery • Less than 50 point variation between cells: go to steps 6 and 7 • Cold cranking amperage rating (blue scale). or • Three times ampere hour rating (black scale). 2. Hold for 15 seconds and turn load knob of tester off. 3. Read battery voltage. Results: • If the battery does not indicate 9.6 volts or more, replace battery 6. Continue charging battery until specific gravity is 1.230 - 1.265 points. 7. Load test battery. Electrical Tests and Adjustments - 210 ELECTRICAL TESTS AND ADJUSTMENTS Regulated Amperage and Voltage Test 6. Quickly turn load knob completely counter-clockwise (out) to off position. Reason: 7. Start and run engine at high idle. Battery voltage should read between 14.2 -14.8 VDC. To determine the regulated charging output of the alternator. 8. Turn load knob (A) clockwise (in) until voltage on tester voltage scale (B) reads 11 volts DC and look at current gun to see if output meets specifications. Note: Battery must be in a good state of charge. Equipment: 9. Quickly turn load knob (A) completely counterclockwise (out) to off position. • JTO5712 Current Gun • Voltmeter • JTO5685 Battery Tester 10.After load test, battery voltage (B) should return to the voltage level prior to test. Results: Procedure: • If current gun amp reading is below specification, test for unregulated voltage output. If unregulated voltage output test meets specifications and you have verified voltage to ground to regulator/rectifier(s), replace regulator/rectifier(s). 1. Park machine safely with park brake locked. 2. Raise hood. Important: Avoid Damage! Turn load knob (A) fully counterclockwise (out) into OFF position BEFORE making any test connections. • If at any time voltage increase exceeds 14.8 VDC, replace regulator/rectifier(s). Specifications (Standard): B A D.C. AMPS High Idle Voltage . . . . . . . . . . . . . . . . . . 14.2 - 14.8 VDC Minimum High Idle Amperage. . . . . . . . . . . . 13.5 Amps D.C. VOLTS Specifications (With Auxiliary Alternator): High Idle Voltage . . . . . . . . . . . . . . . . . . 14.2 - 14.8 VDC Minimum High Idle Amperage. . . . . . . . . . . . 33.5 Amps Regulated Voltage Test Reason: To determine regulated voltage output of the regulator/ rectifier. Equipment: • MIF 3. Connect JTO5712 Current Gun to voltmeter and put around red wire going to voltage rectifier/regulator. Set current gun for DC current. Voltmeter Procedure: 1. Park machine with park brake locked. 2. Raise hood. 3. Remove surface charge from battery by placing a small load on the battery for 15 seconds. 4. Connect battery tester to battery. Important: Avoid Damage! Perform these tests quickly to prevent damage to battery tester. DO NOT apply full load to battery for more than 5 - 10 seconds. 4. Set voltmeter to DC volts scale. 5. Turn load knob clockwise (in) until voltage on voltage tester scale reads 11 volts DC for 5 seconds only to partially drain battery. Electrical Tests and Adjustments - 211 ELECTRICAL TESTS AND ADJUSTMENTS B A A MIF B 5. Connect meter red lead (A) to positive battery terminal. 6. Connect meter black lead (B) to negative battery terminal. 7. Start and run engine at low idle. 8. Read meter while increasing engine speed to fast idle. Voltage should increase from battery voltage at low idle to maximum regulated voltage at fast idle. Important: Avoid Damage! Do not allow the battery voltage to exceed 15.5 volts DC or the battery and charging system will be damaged. Specifications: MIF 3. Disconnect connector (A) from voltage rectifier/ regulator. 4. Set voltmeter to AC volts. 5. Connect voltmeter to stator terminals (B). 6. Start and run engine at 3000 rpm. 7. Record stator voltage. Specification: Unregulated voltage (minimum) . . . . . . . . . . . . . 26 VAC Regulated voltage (maximum) . . . . . . . . . . . . .14.8 VDC Results: Results: • • If the DC voltage stays below the minimum specification, test unregulated voltage output. If ok, replace the voltage rectifier/regulator(s). Unregulated Voltage Test (Optional Auxiliary Alternator) • If the DC voltage goes above the maximum specification, replace the regulator/rectifier(s). Reason: If voltage is less than specification, replace stator. To determine charging output of the alternator. Unregulated Voltage Test (Standard Configuration) Reason: To determine charging output of the alternator stator. Test Equipment: • Test Equipment: • Voltmeter Procedure: 1. Park machine with park brake locked. 2. Raise hood. Voltmeter Procedure: 1. Park machine with park brake locked. 2. Raise hood. Electrical Tests and Adjustments - 212 ELECTRICAL TESTS AND ADJUSTMENTS A A B B MIF 3. Disconnect connector (A) from alternator. MIF 4. Set voltmeter to AC volts. 5. Connect voltmeter to alternator terminals (B). 3. Disconnect connector (A) from voltage rectifier/ regulator. 6. Start and run engine at 3000 rpm. 4. Set voltmeter to ohms. 7. Record alternator voltage. 5. Connect meter across terminals (B) of connector. Specification: 6. If reading is not within specification, replace stator. Unregulated voltage (minimum) . . . . . . . . . . . . . 26 VAC 7. Connect meter to either terminal (B) of alternator connector and to frame ground. Results: • 8. If meter does show continuity, replace stator. If voltage is less than specification, replace alternator. Stator Resistance Test (Standard Configuration) Reason: To determine if stator windings are open or grounded. Equipment: • Specification: Stator Resistance . . . . . . . . . . . . . . . . . . 0.11 - 0.18 ohms Alternator Resistance Test (Optional Auxiliary Alternator) Reason: To determine if alternator windings are open or grounded. Voltmeter Equipment: Procedure: • 1. Park machine safely with engine off and park brake locked. Procedure: 2. Raise hood. 1. Park machine safely with engine off and park brake locked. Voltmeter 2. Raise hood. Electrical Tests and Adjustments - 213 ELECTRICAL TESTS AND ADJUSTMENTS Starter Solenoid Test Reason: To determine if starter solenoid or starting motor is defective. Equipment: • Jumper wire Procedure: A 1. Put transmission in neutral. Lock park brake. Move key switch to off position. 2. Raise hood. 3. Disconnect and ground spark plug leads. B MIF 3. Disconnect connector (A) from auxiliary alternator. 4. Set voltmeter to ohms. A 5. Connect meter across terminals (B) of alternator. B 6. If reading is not within specification, replace alternator. C 7. Connect meter to either terminal of alternator connector and to frame ground. 8. If meter does show continuity, replace alternator. Specification: Alternator Resistance . . . . . . . . . . . . . .0.11 - 0.18 ohms Starting Motor Condition MX14279 1. The starting motor overheats because of: • Long cranking. • Armature binding. 4. Disconnect 720 Pur wire from starter solenoid terminal (A). 5. Connect jumper wire to positive battery terminal and briefly jump to starter solenoid terminal (A). 2. The starting motor operates poorly because of: • Armature binding. • Starting motor runs: solenoid is good, check cranking circuit. • Dirty or damaged starter drive. • • Badly worn brushes or weak brush springs. • Excessive voltage drop in cranking system. • Battery or wiring defective. • Shorts, opens, or grounds in armature. Note: Starting motor repair is limited to brushes, end caps, and starter drive. Fields in starting motor are permanent magnets and are not serviceable. If housing or armature is damaged, replace starting motor. Starting motor does not run: go to next step. 6. Remove red and black rubber boots from starter solenoid terminals (B and C). 7. Connect jumper wire between starter solenoid large terminals (B and C). • Starter runs: Replace solenoid. • Starting motor does not run: Check battery cables then replace starting motor. Electrical Tests and Adjustments - 214 ELECTRICAL TESTS AND ADJUSTMENTS Starting Motor Amp Draw Test Starting Motor No-load Amperage and RPM Test Reason: To determine the amperage required to crank the engine and check starter motor operation under load. Equipment: • Reason: To determine if starting motor is binding or has excessive amperage draw under no-load. Equipment: JTO5685 Battery Tester Procedure: 1. Put transmission in neutral. Lock park brake. Put key switch in off position. • JTO5712 Current Gun • JTO5719 Photo Tachometer Procedure: 2. Raise hood. 1. Remove starter from engine. 3. Disconnect and ground spark plug leads. Note: Check that battery is fully charged and of proper size to ensure accuracy of test. Important: Avoid Damage! Turn load knob (A) fully counterclockwise before making any test connections D.C. AMPS 2. Connect jumper cables to battery. D.C. VOLTS A M45864a A 3. Put screwdriver between gear and bendix drum (A) and pull outward. Install reflective tape on drum. 4. Connect negative cable to starter body. MIF 4. Connect JTO5685 Battery Tester to battery. 5. Connect positive cable to solenoid battery terminal. 6. Attach current gun to positive jumper cable. 5. Crank engine and read voltage. 6. Turn key switch to off position. Adjust load knob until battery voltage reads the same as when cranking. 7. Read amperage on meter. 8. Turn load knob fully counterclockwise. Important: Avoid Damage! Complete this test in 20 seconds or less to prevent starter damage. 7. Use jumper wire to briefly connect solenoid battery terminal and solenoid engagement terminal. 8. Measure starter amperage and rpm. Specification: Starter amp draw (maximum) . . . . . . . . . . . . . . 85 amps Specifications: Results: Starter amperage (maximum) . . . . 50 amps at 6000 rpm Starter rpm (minimum). . . . . . . . . . . . . . . . . . . . 6000 rpm • If amperage is above specification, check starting motor no load amperage draw to determine if starting motor is binding or damaged. Results: • If starting motor is good, check internal engine components for binding or damage. • If amperage or rpm is out of specification, check for binding or seizing bearings, sticking brushes, dirty or worn commutator. Repair or replace starter. Electrical Tests and Adjustments - 215 ELECTRICAL TESTS AND ADJUSTMENTS Starting Motor Field Windings Test Note: Field winding case is a tie point for many separate field coils. It may be difficult to detect one bad coil. If rpm was slow and armature tests are normal, replace field coil assembly. B while holding a hacksaw blade or steel strip on armature. The hacksaw blade will vibrate in area of short circuit. 2. Shorts between bars are sometimes caused by dirt or copper between bars. Inspect for this condition. 3. If test indicates short circuit in windings, clean the commutator of dust and fillings. Check armature again. If test still indicates short circuit, replace armature. A C (A) (B) M50112/M50113 D A- Test for grounds B- Test for open M57356 A- Field brushes (Continuity between brushes and to case) B- To solenoid C- Armature brushes (Continuity between brushes and solenoid lead. Open to case.) D- Starter case 4. Using an ohmmeter, test each individual armature winding for grounded or open circuits. Note: Armature windings are connected in parallel, so each commutator bar needs to be checked. 5. If either test fails, armature must be replaced. Engine Coolant Temperature Sensor Test Replace field coil if not according to specifications. Reason: Starter Armature Test To verify coolant temperature sensor is functioning properly. Equipment: Important: Avoid Damage! Do not clean armature with solvent. Solvent can damage insulation on windings. Use only mineral spirits and a brush. • Ohmmeter Procedure: Note: Perform test with engine at room temperature. 1. Park machine safely in neutral with park brake locked. 2. Raise hood. 3. Disconnect 310 Org wire from engine coolant temperature sensor. 4. Measure resistance between terminal and sensor body. 5. If resistance does not meet specification, replace coolant temperature switch. 6. Drain engine coolant and remove coolant temperature switch. mif 1. Locate short circuits by rotating armature on a growler Electrical Tests and Adjustments - 216 ELECTRICAL TESTS AND ADJUSTMENTS 3. Disconnect Blu/Red wire from engine oil pressure switch (A) located near oil filter. 4. Connect black lead of ohmmeter to engine block and red lead of ohmmeter to terminal of switch. 5. Measure resistance between terminal and engine block. A Results: • There should be continuity between terminal and ground. • If there is no continuity between terminal and ground; replace the oil pressure switch. M91295 7. Place sensor (A) in antifreeze solution heated to approximately 110°C (230°F). Measure resistance while sensor is heated. 8. If resistance does not meet specification, replace coolant temperature sensor. Note: Be sure to apply Pipe Sealant with TEFLON® to threads of switch anytime it is installed. TEFLON® is a registered trademark of the DuPont Company. Important: Avoid Damage! Do not allow connector of wire to contact the engine or frame as there will be voltage on it during the test. Specification: Variable Resistance . . . . . . . . . . . . . . . . . 40 - 700 ohms 1. Start and run engine. Engine Oil Pressure Switch Test 2. Measure resistance between terminal and engine block. Reason: Results: To determine the proper operation of the oil pressure switch. There should be no continuity between switch terminal and ground with the engine running. Equipment: • If the switch does have continuity to engine block (ground) with engine running, check engine oil pressure. • Ohmmeter • If oil pressure meets specification, replace the oil pressure switch. Procedure: Note: Perform test with engine at room temperature. 1. Park machine safely in neutral with park brake locked. 2. Raise hood. Lights Switch Test Reason: To verify terminal continuity is correct for each switch position. Equipment: • Ohmmeter or continuity tester Procedure: A 1. Park machine safely in neutral with park brake locked. 2. Raise hood. 3. Remove left side panel. 4. Disconnect lights switch connector. 5. Put light switch in off position. MX14287 Electrical Tests and Adjustments - 217 ELECTRICAL TESTS AND ADJUSTMENTS B A C B MIF C 6. Use and ohmmeter to test switch continuity in off, headlights on, and backup lights on positions. A G D Specifications: Switch PositionTerminal Continuity Off . . . . . . . . . . . . . . . . . . . . . . . . no continuity between terminals Headlights On . . . . . . . . . . . . . . . . . . . . . . . . . . . .A and B Backup lights on. . . . . . . . . . . . . . . . . . . . . . . . . .A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A and C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B and C E H G MIF 5. Use and ohmmeter to test switch continuity in off, on, and momentary (RIP) positions. Specifications: Results: To verify terminal continuity is correct for each switch position. Switch PositionTerminal Continuity Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D and F On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D and E Momentary (RIP). . . . . . . . . . . . . . . . . . . . . . . . . . A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D and E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G and H Equipment: Results: • All other possible combinations have infinite resistance. If any continuity is NOT correct, replace switch. • If continuity is not correct, replace lights switch. PTO/RIP Switch Test Reason: Ohmmeter or continuity tester Procedure: 1. Park machine safely in neutral with park brake locked. 2. Raise hood. 3. Disconnect PTO switch connector. 4. Put PTO switch in the off position. Relay Test Reason: To check relay terminal continuity in the energized and deenergized condition. Equipment: • Ohmmeter or continuity tester Procedure: 1. Park machine safely in neutral with park brake locked. 2. Raise hood. 3. Disconnect relay connector. 4. Check terminal continuity using an ohmmeter or continuity tester. Electrical Tests and Adjustments - 218 ELECTRICAL TESTS AND ADJUSTMENTS Power Port Switch Test (D)86 (B)30 Reason: To ensure that the power port switch will break the circuit when switched off to prevent inadvertent battery drain. Equipment: (C)85 (E)87 (A)87a • E Ohmmeter Procedure: A D 1. Park machine safely with park brake locked. 2. Disconnect power port switch connector. C B A MIF 3. With switch in off position, check for continuity across terminals (A). M56817 5. There should be continuity between terminals 87A (A) and 30 (B), and 85 (C) and 86 (D). 6. There should not be continuity between terminals 87 (E) and 30 (B). 7. Connect a jumper wire from battery positive (+) terminal to relay terminal 85 (C). Connect a jumper wire from relay terminal 86 (D) to ground (-). 8. There should be continuity between terminals 87 (E) and 30 (B). Results: • If continuity is not correct, replace relay. 4. With switch in on position, check for continuity across terminals (A). Specifications: Switch in off position. . . . . . . . . . . . . . . . . No Continuity Switch in on position . . . . . . . . . . . . . . . . . . . . Continuity Key Switch Test Reason: To verify key switch functions are operating properly. Equipment: • Ohmmeter or Continuity Tester Procedure: 1. Park machine safely. See “Park Machine Safely” on page 3 in the Safety section. 2. Open hood and remove storage tray. 3. Disconnect key switch connector. Note: DO NOT refer to markings stamped on terminals. Identify terminals by art keys ONLY. Terminal combinations other than those listed in chart should Electrical Tests and Adjustments - 219 ELECTRICAL TESTS AND ADJUSTMENTS NOT have continuity. E F A A MIF 4. Check continuity across seat switch connector terminals (A). There should be continuity. B D 5. Release the seat switch plunger. C 6. Check continuity across connector terminals. There should not be continuity. MIF 4. Use an ohmmeter to test switch continuity in OFF, RUN, and START positions. Switch Position Terminal Continuity: Seat switch plunger depressed . . . . . . . . . . . continuity Seat switch plunger released . . . . . . . . . . no continuity • OFF: A and B Results: • RUN: C and D • START: C and D • E and F • If the seat switch does not have continuity with the operator on the seat, check the seat switch bracket and spring for damage. • If the seat switch does not have continuity with the plunger depressed, replace the switch. Results: • Specifications: If any continuity is not correct, replace switch. Seat Switch Test Brake Switch Test and Adjustment Reason: Reason: To verify proper operation of seat switch. To make sure the brake switch has continuity when the brake pedal is depressed. Equipment: Equipment: • • Ohmmeter Ohmmeter Procedure: Procedure: 1. Park machine safely in neutral with park brake locked. 1. Park machine safely in neutral with park brake locked. 2. Disconnect seat switch connector. Note: Brake switch is located on left side of frame under footrest. 3. Depress the seat switch plunger. 2. Remove footrest. 3. Disconnect brake switch connector. Electrical Tests and Adjustments - 220 ELECTRICAL TESTS AND ADJUSTMENTS RIO Switch Test Reason: To make sure the RIO switch has proper continuity. Equipment: B • Procedure: A B Ohmmeter 1. Park machine safely in neutral with park brake locked. A MIF 4. Check continuity across terminals (A). Check continuity across terminals (B). Note: Be sure actuator (C) contacts switch plunger (plunger depressed) and not switch body. Note: RIO switch is located on right side of frame under footrest. 2. Remove footrest. 3. Disconnect RIO switch connector. C B A B A D MIF MIF Picture Note: NOTE: Side view shown 5. Release park brake pedal. 6. Check continuity across terminals. Be sure actuator does not contact switch plunger (plunger released). Specifications: Brake pedal depressed (plunger depressed) continuity between terminals . . . . . . . . . . . . . . . (A) only Brake pedal released (plunger released) continuity between terminals . . . . . . . . . . . . . . . (B) only Results: • 4. Press switch plunger and check continuity across terminals (A) and then check continuity across terminals (B). 5. Press switch plunger and check continuity across terminals. Specifications: Plunger depressed) continuity between terminals . . . . . . . . . . . . . . . (A) only Plunger released) continuity between terminals . . . . . . . . . . . . . . . (B) only Results: • If continuity is not correct, replace switch. • Adjust switch to specification if needed. If continuity is not correct, replace switch. • If actuator position is not correct, loosen cap screw (D). Depress brake pedal and lock park brake. Rotate actuator (C) until the switch plunger is depressed, but not bottomed out. The actuator must not contact the switch body. Hold actuator in position and tighten cap screw. Electrical Tests and Adjustments - 221 ELECTRICAL TESTS AND ADJUSTMENTS RIO Switch Adjustment Fuse Test Reason: Reason: To set the proper air gap so that the RIO switch is activated at the proper time. To verify that fuse has continuity. Equipment: Equipment: • • Ruler • Continuity tester Ohmmeter or continuity tester Procedure: 1. Park machine safely in neutral with park brake locked. Procedure: 2. Raise hood. 1. Stop engine and lock park brake. 3. Remove fuse from fuse holder. 2. Remove fender deck. A A B D C M49391 E 4. Check visually for broken filament (A). MX16074 3. Measure the gap between the bottom edge (A) of the spring and the bottom edge (B) of the RIO switch body. • The gap should be 12 mm (0.47 in.). 4. The bottom edge of the switch should be in line with the bottom edge of the spring. 5. Connect ohmmeter or continuity tester to each end of fuse. 6. Check for continuity. Results: • If continuity is not indicated, replace the fuse. 5. Slightly loosen the back nut (C) and then the front nut (D). PTO Solenoid Test (Standard Front PTO) 6. Position the RIO switch at the proper angle with a 12 mm (0.47 in.) gap. Reason: To verify that the solenoid is operating properly. 7. Tighten the nuts to 13.5 N•m (10 lb-ft) while maintaining the position of the switch. Equipment: 8. Perform RIO switch test. • 9. Install the fender deck. Procedure: Specifications: 1. Park machine safely in neutral with park brake locked. Ohmmeter or continuity tester Air Gap. . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm (0.47 in.) Torque . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 N•m (10 lb-ft) Electrical Tests and Adjustments - 222 ELECTRICAL TESTS AND ADJUSTMENTS PTO Switch Test (Optional Rear PTO Installed) Reason: To verify that mid and rear PTO switches function properly. Equipment: A • Ohmmeter or continuity tester Procedure: 1. Park machine safely in neutral with park brake locked. MX14285 2. Disconnect PTO solenoid connector (A) at rear of machine. C B B A C MX14286 M91222 3. Using an ohmmeter or continuity tester, check if continuity exists between solenoid terminals. 2. Locate rear PTO switches at rear left side of transaxle and disconnect front PTO switch connector (A) and rear PTO switch connector (B). Results: 3. Move PTO selector lever (C) to top position. • If resistance does not meet specifications, replace solenoid. PTO Solenoid Continuity: B to C . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 - 10.0 ohms Short to Case Test 1. Check for grounds or shorts by connecting tester to one coil terminal and the other to bare metal of coil case or frame. D Results: MIF • Replace fuel shutoff solenoid if continuity is present from either terminal to coil case. 4. Check for continuity between switch terminals (D) and compare to specification. Audibility Test: 5. Move PTO selector lever (C) to front position. 1. Connect PTO solenoid connector (A). 6. Check for continuity between switch terminals (D) and compare to specification. 2. Listen for click when PTO solenoid pulls in. Results: • If click when PTO solenoid pulls in is not heard, replace solenoid. 7. Move PTO selector lever (C) to bottom position. 8. Check for continuity between switch terminals (D) and compare to specification. Electrical Tests and Adjustments - 223 ELECTRICAL TESTS AND ADJUSTMENTS Replace switch if correct continuity can not be obtained. Front PTO Switch Continuity: PTO Lever Position . . . . . . . . . . . . Terminal Continuity Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No Continuity Middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuity Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuity 8. Remove jumper wire from the battery negative (-) terminal. Plunger should extend. Results: If plunger does not move, replace solenoid. Rear PTO Switch Continuity: PTO Lever Position . . . . . . . . . . . . Terminal Continuity Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuity Middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuity Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . No Continuity Diode Test Reason: To verify that diode has proper continuity. Equipment: Fuel Shutoff Solenoid Test - X700 • Reason: To determine if the fuel shutoff plunger retracts when the solenoid is energized. Ohmmeter or continuity tester Procedure: 1. Park machine safely in neutral with park brake locked. 2. Raise hood. Equipment: • 7. Connect a jumper wire from the battery negative (-) terminal to solenoid threads (B). Plunger should now retract with the solenoid energized. 3. Remove diode from connector. 2 jumper wires Procedure: 1. Park machine safely in neutral with park brake locked. 2. Raise hood. c from Caution: Avoid Injury! Keep gasoline away sparks, flame, or hot engine parts or personal injury can result. A B MIF 4. Connect ohmmeter red (+) lead to pin (A) of diode. 3. Remove drain screw and spring to drain gasoline from float bowl. 5. Connect ohmmeter black (-) lead to pin (B) of diode. Check for continuity. 4. Disconnect fuel shutoff solenoid connector. 6. Reverse test leads. Check for continuity. 5. Remove fuel shutoff solenoid, washer and float bowl. Results: Diode must have continuity in one direction only. Replace defective diode. A Fuel Tank Sensor Test B Reason: To make sure the fuel tank sensor resistance changes as the float is raised or lowered. C M82845 6. Connect a jumper wire from the battery positive (+) terminal to solenoid terminal (C). It may be necessary to push plunger (A) inward slightly for plunger to retract. Equipment: • Ohmmeter Note: It may be necessary to push plunger (A) inward slightly for plunger to retract. Electrical Tests and Adjustments - 224 ELECTRICAL TESTS AND ADJUSTMENTS Procedure: 1. Park machine safely in neutral with park brake locked. 2. Remove fender deck. 3. Disconnect fuel tank sensor connector. 4. Remove fuel tank sensor. A MIF 5. Measure resistance across fuel injector terminals (A). 6. Connect a jumper wire from battery negative terminal to one of the fuel injector terminals. 7. Briefly and repeatedly connect a jumper wire from battery positive terminal to the other fuel injector terminal. 8. The fuel injector must click each time the jumper wire contacts the terminal. A Specification: A Resistance at 20°C (68°F) . . . . . . . . . . . . . . . . 12.5 ohms Results: M46303a 5. Measure resistance across fuel tank sensor terminals with black and black/white wires (A). 6. Move sensor float arm up and down. 7. Meter must show resistance increase and decrease as float moves up and down. Resistance is the lowest when the float is in the lowest (empty) position. • If resistance does not meet specifications, check fuel injector operation before replacing the fuel injector. The tested resistance values may vary from the specifications due to type of meter used or temperature. • If the fuel injector does not click, replace the fuel injector. Fuel Injection Module Test - X720/X724/X728 Specification: Sensor resistance (approximately) . . . . . . .6 - 103 ohms Reason: To determine if fuel injection module is defective. Results: If the resistance does not change or does not meet the specifications, replace the fuel tank sensor. Fuel Injector Test - X720/X724/X728 Reason: Procedure: The fuel injection module is very sensitive to the type of meter used to check resistance. Due to variations in the meters, the best way to determine if the fuel injection module is good is to replace the questionable fuel injection module with a known good module. To verify fuel injector continuity and operation. Results: Equipment: • If the new fuel injection module does not solve the problem, check the other fuel injection components. • Ohmmeter Procedure: 1. Park machine safely in neutral with park brake locked. 2. Raise hood. 3. Remove air cleaner assembly. 4. Disconnect fuel injector connector. Electrical Tests and Adjustments - 225 ELECTRICAL TESTS AND ADJUSTMENTS Vacuum Pressure Sensor Test - X720/X724/ X728 Reason: To verify vacuum pressure sensor continuity and operation. Equipment: • Ohmmeter • Voltmeter G Procedure: F 1. Park machine safely in neutral with park brake locked. 2. Raise hood. E H 3. Remove air cleaner assembly. MX14288 7. Disconnect air pressure sensor hose (E). 8. Turn key switch to run position. Note: It will be necessary to remove the rubber seals around the wires to take the voltage readings. 9. Connect voltmeter negative lead to wire terminal (F). A 10.Connect voltmeter positive lead to wire terminal (G). 11.Measure input voltage. Voltage should be about 5 volts DC. 12.Connect voltmeter positive lead to wire terminal (H). 13.Measure output voltage. Voltage should be something less than 5 volts DC depending on air pressure. MX14288 4. Disconnect air pressure sensor connector (A). 14.Apply slight air pressure to sensor hose. Voltage should increase. 15.Apply slight vacuum to hose and voltage should decrease. Specifications: Terminal resistance (Approximation): Left (B) and center (C) . . . . . . . . . . . . . 2986 - 3034 ohms Left (B) and right (D) . . . . . . . . . . . . . . . . 773 - 787 ohms Center (C) and right (D) . . . . . . . . . . . . 3774 - 3798 ohms Input voltage (G). . . . . . . . . . . . . . . . . . .about 5 volts DC Output voltage (H . . . . . . . . . . . . . . . .3.46 - 3.82 volts DC depending on air pressure C B D MX14289 5. Measure resistance between left (B), center (C), and right (D) terminals on vacuum sensor. 6. Connect wire harness to air pressure sensor. Results: • If resistance does not meet specifications, check output voltage before replacing the air pressure sensor. The tested resistance values may vary from the specifications due to type of meter used or temperature. • If the output voltage does not increase or decrease, replace the air pressure sensor. Electrical Tests and Adjustments - 226 ELECTRICAL TESTS AND ADJUSTMENTS Air Temperature Sensor Test - X720/X724/ X728 terminals (B). Reason: Resistance at 0°C (32 °F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29 - 6.47 k-ohms Resistance at 20°C (68°F) . . . . . . . . . 2.21 - 2.69 k-ohms Resistance at 80°C (176°F) . . . . . . . . . . . 133 - 163 ohms To verify air temperature sensor continuity. Equipment: • Ohmmeter Specifications: Results: Procedure: 1. Park machine safely in neutral with park brake locked. 2. Raise hood. • If resistance does not meet specifications, replace the air temperature sensor. The tested resistance values may vary from the specifications due to type of meter used or temperature. 3. Remove air cleaner assembly. Coolant Temperature Sensor Test - X720/ X724/X728 Reason: To verify coolant temperature sensor continuity. Equipment: • A Ohmmeter Procedure: 1. Park machine safely in neutral with park brake locked. 2. Raise hood. 3. Remove air cleaner assembly. MX14290 4. Disconnect air temperature sensor connector (A). A MX14288 4. Disconnect coolant temperature sensor connector (A). 5. Measure resistance across coolant temperature sensor terminals. B MX14291 5. Measure resistance across air temperature sensor Electrical Tests and Adjustments - 227 ELECTRICAL TESTS AND ADJUSTMENTS Specifications: 2. Raise hood. Resistance at 20°C (68°F) . . . . . . . . . 2.21 - 2.69 k-ohms Resistance at 80°C (176°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292 - 354 ohms Resistance at 110°C (230°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133 - 163 ohms 3. Disconnect spark plug cap. Results: • If resistance does not meet specifications, replace the coolant temperature sensor. The tested resistance values may vary from the specifications due to type of meter used or temperature. Spark Plug Gap Test Spark plugs should not be burned, blistered, or have cracked insulator tips or badly eroded electrode. Make sure the plug is correctly gapped. Specification: Spark Plug (NGK BPR4ES) . . . . . . . 0.75 mm (0.030 in.) M48364 4. Measure resistance across spark plug cap terminals. Resistance should be about the same as marked on the spark plug cap. Specifications: Spark plug cap resistance. . . . . . . . . . . . marked on cap Note: Bending center wire or hitting plug with gapping tool can break insulator. Results: John Deere recommended plug is the best heat range for the engine application. • If resistance does not meet specification, replace spark plug cap. If hotter plug is used, go no more than (1) one range hotter. Spark Plug Gap Adjustment • For NGK plugs: the lower the number the hotter the plug. Reason: • For Champion Plugs: The higher the number the hotter the plug. To maintain the correct gap between the center electrode and the tab needed to produce a good spark. If spark plugs are burning improperly: Equipment: • Use known good grade and source of fuel. • Test fuel for alcohol content. Tester is available at an auto parts store. Alcohol content should be a maximum of 10%. This rating should be listed on service station pumps. • Try a different grade (octane) fuel, or a different fuel manufacturer. • With electronic ignition, check ground connections, ignition components, and a possible sheared flywheel key (unlikely). • Feeler gauge Procedure: Important: Avoid Damage! Do not clean spark plug with sand paper or abrasives. Engine scoring can result. 1. Scrape or wire brush deposits from spark plug. 2. Inspect spark plug for: Reason: • Cracked porcelain. To determine if spark plug cap is defective. • Pitted or damaged electrodes. Equipment: • A Ohmmeter Procedure: 1. Park machine safely in neutral with park brake locked. Electrical Tests and Adjustments - 228 ELECTRICAL TESTS AND ADJUSTMENTS MIF Spark Test 3. Check spark plug gap (A) using a feeler gauge. Set gap to specifications. Reason: 4. Install and tighten spark plug to specifications. Check overall condition of ignition system. Specifications: Equipment: Spark plug gap . . . . . . . . . . . . . . . . . 0.75 mm (0.030 in.) Spark plug torque . . . . . . . . . . . . . . . 25 N•m (221 lb-in.) • Ignition Coil Test 1. Brake locked. PTO(s) disengaged. D-05351ST Spark Tester Connections: Reason: A To determine condition of ignition coil windings. C Equipment: • Ohmmeter B Procedure: D 1. Put transmission in neutral. Put key switch in off position. 2. Remove spark plug cap from spark plug wire. 3. Disconnect wires from ignition coil terminal. MIF 2. Remove high tension lead (A) from spark plug and connect to spark tester (B). 3. Connect spark tester to spark plug. 4. Adjust spark tester gap to 4.2 mm (0.166 in.) with screw (C). C Important: Avoid Damage! Do not adjust spark tester gap beyond 5.0 mm (0.200 in.) as damage to ignition system components could occur. B A Procedure: MX16073 4. Measure primary coil resistance between laminations (A) and terminal (B). 5. Measure secondary coil resistance between laminations (A) and spark plug wire (C). Specifications: Primary coil resistance . . . . . . . . . . . . . 2.2 - 3.6 k-ohms Secondary coil resistance . . . . . . . . . . . . 13 - 21 k-ohms Results: 1. Turn key switch to start position and watch spark (D) at spark tester. If engine will start, watch spark with engine running. Specifications: • Steady, strong, blue spark. Results: • If spark is weak, or if no spark, install a new spark plug and test again. • If spark is still weak, or still no spark, run tests on individual components to find cause of malfunction. • If resistance does not meet specifications, replace the ignition coil. Electrical Tests and Adjustments - 229 ELECTRICAL REPAIR Repair Adjustment: Ignition Coil Replacement and Adjustment B B C C Removal: 1. Park machine safely. See “Park Machine Safely” on page 3 in safety section. B B C C MX14236 1. Place feeler gauge between ignition coil legs (C) and flywheel. 2. Hold ignition coil in place and tighten the mounting capscrews (B) to 3.4 N•m (30 lb-in.). A B 3. Check air gap again after tightening. Readjust if needed. Specifications: MX16073 Air Gap . . . . . . . . . . . . . . .0.25 - 0.40 mm (0.010 - 0.016 in.) Capscrew Torque . . . . . . . . . . . . . . . . 3.4 N•m (30 lb-in.) 2. Disconnect plug wire from spark plug. 3. Disconnect ignition lead from primary coil terminal (A). Stator Replacement Note: The charging system is a permanent magnet and stator design. As the flywheel rotates, a permanent magnet in the flywheel induces AC current in the stator windings. This current flows to the regulator-rectifier where it is converted to DC current needed to charge the battery. Component may differ from illustration. 4. Remove ignition coil mounting capscrews (B). Installation: Removal: 1. Park machine safely. See “Park Machine Safely” on page 3 in Safety section. 2. Remove engine from machine. See engine removal in appropriate engine section. A B A MX16073 1. Align ignition coil with mounting holes on crankcase. 2. Loosely install mounting capscrews (B). B 3. Connect ignition lead from primary coil terminal (A). 4. Connect plug wire to spark plug. MX16077 Electrical Repair - 230 ELECTRICAL REPAIR 3. Hold flywheel with strap and remove flywheel bolt (A). Specifications: 4. Thread a flywheel puller into the pulling holes (B) and remove the flywheel. Stator Capscrew . . . . . . . . . . . . . . . . . 3.4 N•m (30 lb-in.) Wire Clamp Capscrew . . . . . . . . . . . . 3.4 N•m (30 lb-in.) Flywheel Bolt . . . . . . . . . . . . . . . . . . . . . 56 N•m (41 lb-ft) Alternator Removal, Inspection, and Installation (Optional) Removal: C 1. Park machine safely. See “Park Machine Safely” on page 3 in Safety section. D D B MX16078 5. Remove the wire clamp (C). 6. Remove the four mounting capscrews (D) and remove stator from crankcase. A C Installation: D 1. Place stator over crankshaft and onto crankcase. MX36050 Align the four mounting holes with the threaded holes in the crankcase and the stator wires routed towards the clamp. 2. Disconnect alternator electrical connector (A). 2. Install and tighten the four capscrews. 3. Loosen alternator adjustment cap screw (B). Slide alternator towards engine. 3. Install and tighten the wire clamp. 4. Align the flywheel keyway with the key on the crankshaft and install flywheel. 4. Remove belt from alternator. 5. Remove adjustment cap screw, mounting cap screw (C), and spacer (D). F A MX36056 6. Remove alternator from machine. Note location of engine ground wire (F) for reassembly. MX16079 5. Install spring washer (A) as shown. 6. Install and tighten the flywheel bolt. 7. Install engine into machine. Electrical Repair - 231 ELECTRICAL REPAIR Disassembly and Inspection: J G MX56054 MX36051 1. Remove nut (G), lock washer, and washer from rear of alternator. Note: Rotor magnets will provide some resistance when separating rotor from alternator body. 2. Separate rotor from alternator body. 5. Remove two screws (J) securing stator to alternator case. Remove stator. 6. Inspect bearing for rough spots or looseness. Replace as necessary. Assembly and Installation: • Assembly is in the reverse of disassembly. • Installation is in the reverse of removal. • Adjust alternator belt tension. See Tests and Adjustments in the in the Engine section. H MX36053 3. Inspect rotor and magnets (H) for damage. Replace if necessary. I MX36055 4. Remove screw (I) securing stator wiring to rear of alternator case. Electrical Repair - 232 POWER TRAIN - HYDROSTATIC TABLE OF CONTENTS Power Train - Hydrostatic Table of Contents Specifications ...............................................235 General Specifications ...............................235 Test And Adjustment Specifications...........235 Repair Specifications..................................235 Special or Essential Tools ..........................236 Other Materials...........................................236 Component Location....................................237 Hydrostatic Power Train .............................237 Final Drive (MFWD)....................................239 Front Axle Gear Case (MFWD) ..................240 Front Axle Assembly (MFWD)....................242 Rear PTO Gear Case Assembly ................243 MFWD Output Shaft ...................................245 Theory of Operation .....................................247 Center Section and Directional Control Valves - Reverse System Operation ..........247 Transaxle Oil Flow System Operation........250 External Power Train System Operation ....253 Transaxle Internal System Operation.........254 Rear PTO Component Location and Operation - Optional ...................................258 540 Rear PTO ............................................259 Diagnostics ...................................................260 Hydrostatic Transmission Diagnosis ..........260 Mid-PTO System Diagnosis .......................262 Transaxle Diagnosis...................................263 Hydrostatic Transmission Test ...................264 Mid-PTO System Test ................................265 Transaxle Test............................................266 Tests and Adjustments ................................267 Hydraulic Oil Warm-Up Procedure .............267 Charge Pump Pressure Test......................267 Charge Pump Flow and Pressure Test - At Charge Pump .............................................268 Mid-PTO Engagement Pressure and Brake Test ............................................................270 Transaxle Neutral Adjustment ....................271 Transaxle Control Linkage Adjustment ......272 Transaxle Linkage Full Forward Adjustment .................................................273 Cruise Control Linkage Check and Adjustment .................................................273 Repair............................................................ 275 Foot Control Linkage Removal and Installation.................................................. 275 Shift Lever Linkage (MFWD) Removal and Installation.................................................. 278 Oil Cooler Removal and Installation .......... 279 Control Arm and Damper Removal and Installation ................................................. 280 Differential Lock Linkage Inspection .......... 281 Charge Pump Removal and Installation .... 282 Charge Pump Disassembly and Assembly 283 Directional Control Valves ......................... 284 Hydrostatic Pressure Relief Valve (45 Loader) Installation.................................................. 284 Drive Shaft Removal and Installation......... 285 PTO Solenoid Valve .................................. 286 PTO Relief Valve Removal and Installation.................................................. 287 PTO Relief Valve Disassembly, Inspection and Assembly ............................................ 287 PTO Brake Removal and Installation......... 288 PTO Brake Disassembly, Inspection and Assembly ................................................... 289 PTO Drive Train (Mid-PTO) Removal and Installation ................................................. 290 PTO Drive Train (Mid and Rear PTO) Removal and Installation ........................... 291 Rear PTO Removal and Installation .......... 294 Transaxle Removal and Installation........... 297 Differential Lock Shaft Disassembly and Assembly ................................................... 298 Differential (2-Wheel Drive) Disassembly and Assembly ............................................ 300 Differential (MFWD) Disassembly and Assembly ................................................... 301 PTO Clutch Disassembly, Inspection and Assembly ................................................... 302 MFWD Output Shaft Removal and Installation.................................................. 304 Hydrostatic Transmission 2-WD and MFWD........................................................ 306 Hydrostatic Pump Inspection ..................... 313 Transaxle Disassembly.............................. 314 Transaxle (Right Cover) Disassembly and Assembly ................................................... 316 Transaxle Case Inspection ........................ 317 Transaxle Assembly .................................. 317 Power Train - Hydrostatic Table of Contents - 233 POWER TRAIN - HYDROSTATIC TABLE OF CONTENTS Rear Axle Assembly (Two Wheel Steer Models) Removal and Installation ..............319 Rear Axle Assembly (Two Wheel Steer Models) Disassembly and Assembly..........319 Rear Axle Assembly (All Wheel Steer) Removal and Installation ............................321 Rear Axle Assembly (All Wheel Steer) Disassembly and Assembly .......................322 Knuckle Assembly (All Wheel Steer) Removal and Installation ............................323 Knuckle Housing Disassembly and Assembly....................................................323 Final Drive Cover Removal and Installation (MFWD)......................................................324 Final Drive Housing Removal and Installation (MFWD)......................................................326 Spindle Housing - (MFWD) ........................328 Drive Shaft Removal and Installation (MFWD)......................................................329 Mechanical Front Wheel Drive Removal and Installation - (MFWD) ................................329 Differential Input Housing - (MFWD) ..........331 Front Axle Housing Disassembly and Assembly....................................................332 Power Train - Hydrostatic Table of Contents - 234 POWER TRAIN - HYDROSTATIC SPECIFICATIONS Specifications General Specifications Transaxle Capacity: Two-Wheel Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 L (7.0 qt) All-Wheel Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 L (6.0 qt) Four-Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 L (7.0 qt) Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J20D Low Viscosity HY-GARD Front Axle: Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere GL5 Gear Lubricant (80W-90 Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 L (2.5 qt) Test And Adjustment Specifications Hydrostatic Transmission: Pump and Motor Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 mL (0.6 oz)/rev Charge Pump: Displacement (2-WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mL/rev (0.2 oz)/rev Displacement (MFWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 mL/rev (0.27 oz)/rev Charge Pressure Control Valve (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1958 kPa (284 psi) Charge Pressure Relief Valve (Implement Pressure) (minimum). . . . . . . . . . . . . . . . . . . . . . . . . . 63710 kPa (924 psi) Charge Pump Flow 2-WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 L/m (4.5 gpm) Minimum Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 L/m (3.4 gpm) Charge Pump Flow (MFWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.7 L/m (6.0 gpm) Minimum Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 L/m (4.5 gpm) PTO: PTO Pressure Control Valve (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14698 kPa (213 psi) PTO Circuit Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L/m (0.5 gpm) Repair Specifications Control Arm Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 N•m (54 lb-ft) PTO Solenoid Armature Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.) PTO Solenoid Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9 N•m (43 lb-in.) Transaxle Cover Cap Screws: Used Transaxle Case Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (221 lb-in.) Transaxle Cover Cap Screws: New Transaxle Case Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) PTO Output Shaft Retaining Cap Screws Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) PTO Shifter Shaft Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (221 lb-in.) PTO Ball Switches Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 N•m (25 lb-ft) PTO Clutch Pack Wear Clearance Between Plate and Bottom of Gear/Hub Groove . . . 2.7 mm (0.106 in.) maximum Charge Pump Cap Screws: Short Cap Screws Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (221 lb-in.) Long Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft) Hydrostatic Motor Seal Cap Depth below Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 mm (5/32 in.) Hydrostatic Center Valve Block: Directional Control Valves Torque. . . . . . . . . . . . . . . . . . . . . . . . . . 35 N•m (26 lb-ft) Power Train - Hydrostatic Specifications - 235 POWER TRAIN - HYDROSTATIC SPECIFICATIONS Bottom Suction Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 N•m (37 lb-ft) Charge Pressure Relief Valve Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (221 lb-in.) Mounting Cap Screws Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft) Axle Housing Cap Screws Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft) King Pin Cap Screws Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft) Transaxle to Frame Mounting Cap Screws and Nuts Torque . . . . . . . . . . . . . . . . . . . . . . . . 71 - 106 N•m (52 - 78 lb-ft) Differential Cap Screws Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 N•m (65 lb-ft) Drive Shaft Cap Screws Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft) Hydraulic Line Fittings Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (212 lb-in.) Special or Essential Tools Note: Order tools according to information given in the U.S. SERVICE-GARD™ Catalog or in the European Microfiche Tool Catalog (MTC). Special or Required Tools Tool Name Tool No. Tool Use Temperature Gauge JDG282 Used to test the hydraulic oil temperature. Solenoid Valve Socket JDG757A Used to install solenoid armature. Transmission Gear Spacer JDT39 Used to disassemble and assemble PTO clutch assembly. Bushing, Bearing and Seal Driver Set Used to service bearings and seals. Press Used to remove and install axle shaft and bearings. Snap Ring Pliers Set Used to remove snap rings. Knife-Edge Puller Used to remove bearings. Jack Stands Used to support machine. Lift Brackets or 8 mm Eyebolts Used to remove and install transaxle. Hoist Used to remove and install transaxle. Other Materials Other Material Part No. Part Name Part Use TY15130 John Deere Form-in-Place Gasket Seal mating surfaces of transaxle. TY6305/TY9485/#764 Cure primer Clean thread of sealing surfaces. TY9370/TY9477/#242 Thread Lock and Sealer (Medium Strength) To seal threads on control valve screws, spool detent, and small plugs. Power Train - Hydrostatic Specifications - 236 POWER TRAIN - HYDROSTATIC COMPONENT LOCATION Component Location Hydrostatic Power Train A B C D F G E H T I J S R K Q P L M O N Power Train - Hydrostatic Component Location - 237 POWER TRAIN - HYDROSTATIC COMPONENT LOCATION MX14200 A- Cruise Control Latch B- Forward Pedal C- Reverse Pedal D- RIO Switch E- Charge Pump F- Control Rod G- Control Valves H- Oil Fill Tube I- PTO Brake Cover J- PTO Solenoid K- Control Arm Damper L- Control Valve M- Differential Lock Shaft N- Rear Cover Plate O- Differential Lock Arm P- Brake Arm Q- Center Valve Block R- Motor Case Assembly S- Center PTO Shaft T- Drive Shaft Power Train - Hydrostatic Component Location - 238 POWER TRAIN - HYDROSTATIC COMPONENT LOCATION Final Drive (MFWD) J I H G D F K E D C A A B B C D L L E K F D G I H J MX14348 A- Spindle B- Sleeve C- Seal D- Snap Ring (4 used) E- Ball Bearing F- Case G- Gasket H- Final Gear I- Snap Ring J- Ball Bearing K- Gearbox L- Drain Plug Power Train - Hydrostatic Component Location - 239 L POWER TRAIN - HYDROSTATIC COMPONENT LOCATION Front Axle Gear Case (MFWD) C D B F A E L K M N G O M P Q H J J G R S T U V W X Y AD Z AA H AB AC Power Train - Hydrostatic Component Location - 240 I POWER TRAIN - HYDROSTATIC COMPONENT LOCATION MX14349 A- Washer B- Nut C- Cap Screw D- Cap Screw E- Bracket, Left F- Bracket, Right G- Gear Case, Front H- Stud I- Gear Box, Front Right J- Cap Screw (12 used) K- Sleeve L- Seal M- Ball Bearing N- Snap Ring O- Washer P- Gear Q- Shaft R- Sleeve S- Collar T- Seal U- Snap Ring V- Washer W- Bearing Race X- Needle Bearing Y- Washer Z- Snap Ring AA- Pinion, Final AB- Ball Bearing AC- Gear Box, Front Left AD- Pin (4 used) Power Train - Hydrostatic Component Location - 241 POWER TRAIN - HYDROSTATIC COMPONENT LOCATION Front Axle Assembly (MFWD) M N O L Q G F A B C B K J H R I G D E S H T U V W X AH AF Y AE Q AC P AD N AB AG Z AA O MX14350 A- Bolt B- Bushing (2 used) C- Washer D- Lock Nut E- Ball Bearing F- Gear, Differential (2) G- Shaft, Differential H- Pinion, Differential (2) I- Gear, Differential J- Ball Bearing K- Shaft, Right L- O-Ring (2) M- Axle Housing, Right N- O-Ring O- Ball Bearing P- O-Ring Q- Gear, Front R- Cap Screw (6 used) S- Ball Bearing T- Gear U- Input Shaft V- Bearing W- Seal X- Cover Y- Bolt Z- Bolt AA- Ball Bearing AB- Gear AC- Snap Ring AD- Ball Bearing AE- Dowel Pin AF- Drive Pinion AG- Differential Housing AH- Shaft, Left Power Train - Hydrostatic Component Location - 242 P POWER TRAIN - HYDROSTATIC COMPONENT LOCATION Rear PTO Gear Case Assembly B A C D E F G H L K I M J J N O Q P R M S U T AL V W X T Y M Z AK AJ AI AA AH AG AB AF AE AD AC Y Z MX14322 A- Snap Ring B- Spacer C- Snap Ring D- Bearing E- PTO Gear F- Needle Bearing G- Spline Collar H- Snap Ring I- Bushing J- Bolt K- O-Ring L- Cap M- Bearing (3 used) N- Gear, Rear PTO (35T) O- Bushing Power Train - Hydrostatic Component Location - 243 POWER TRAIN - HYDROSTATIC COMPONENT LOCATION P- Snap Ring Q- Ball Bearing R- Seal S- PTO Shaft T- Washer U- Gear, Rear PTO (29T) V- Idle Shaft, Rear PTO W- Gear, Rear PTO (14T) X- Cover Y- Bushing Z- Cap Screw AA- Pin AB- Cap Screw AC- Ball Bearing AD- Shaft, Rear PTO AE- Ball Bearing AF- Snap Ring AG- PTO Gear (20T) AH- Shift Collar AI- Snap Ring AJ- Cap Screw AK- Case, Rear PTO AL- O-Ring Power Train - Hydrostatic Component Location - 244 POWER TRAIN - HYDROSTATIC COMPONENT LOCATION MFWD Output Shaft B C A D G E F AB J Y I AA H K W L Z W Y V X O U T P S R Q O Power Train - Hydrostatic Component Location - 245 N M POWER TRAIN - HYDROSTATIC COMPONENT LOCATION MX14346 A- Spacer B- Strainer C- Motor Housing D- Motor Shaft E- Spring Pin F- Pin G- Arm H- Strap I- Screw J- O-Ring K- Shaft L- Shifter M- Spline Collar N- Shift Collar O- Ball P- Spring Q- Front Drive Shaft R- Ball Bearing S- Washer T- Sleeve U- Seal V- Gasket W- Locating Sleeve (2 used) X- Front Cover Y- Lock Washer Z- Bolt AA- Cap Screw AB- Bolt Power Train - Hydrostatic Component Location - 246 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION Theory of Operation Center Section and Directional Control Valves - Reverse System Operation the pump, going into a braking mode, and tries to overrun the pump. Closed loop pressure increases higher than the charge pressure, closing off the charge oil. Anti-cavitation valve then opens to make up oil lost through the pump, preventing pump cavitation. Note: Hydrostatic theory is not covered. See FOS Series Manuals. Function: The center section contains the closed loop passages between the variable displacement pump and the bidirectional, fixed displacement motor. It also contains the directional control valves. These valves control the flow of charge oil into the closed loop and block closed loop pressure from the charge circuit oil. System Operation: Charge oil from the charge pump enters the center section at port (C). Charge oil will open the closed loop check valve and enter the forward side of the closed loop when the reverse side has been pressurized by the hydrostatic pump. When the direction is reversed to provide forward direction, charge oil will then pressurize the reverse side of the closed loop. The variable displacement hydrostatic pump pressurizes the reverse side loop, causing the fixed displacement motor to rotate. The reverse directional check valve blocks the closed loop pressure oil from entering the charge circuit. The reverse directional check valve cartridge has a leak-off orifice. This orifice bleeds off a small amount of high pressure oil from the reserve closed loop back into the charge circuit. This provides for a wider neutral band to help prevent creep. This small leakage does not slow down reverse. Free-Wheeling: When the free-wheeling push pins are pushed down, the pins unseat the closed loop check valves, allowing oil flow created by the motor to escape into the charge circuit. This prevents oil pressure from building between the pump and motor, allowing the machine to be pushed. Anti-Cavitation Valves: These valves prevent cavitation of the motor during freewheeling or when the motor overruns the pump (machine going down hill). During free-wheeling, the free-wheeling valves are depressed and the engine is not turning the charge pump that supplies the charge oil. The hydrostatic motor pumps the closed loop oil out into the charge circuit; the anticavitation valves open, letting oil from the transaxle sump into the closed loop, preventing motor cavitation. When the machine goes down a hill, the motor becomes Power Train - Hydrostatic Theory of Operation - 247 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION D B C E A R F Q G P H O I N M Reverse Pressure Oil K Charge Pressure Oil Engagement Circuit Oil Pressure Free Oil L MIF Power Train - Hydrostatic Theory of Operation - 248 J POWER TRAIN - HYDROSTATIC THEORY OF OPERATION T U S AA V W Z AB X AK Y AI AJ AH AC AG AF AD Charge Pressure Oil Clutch Engagement Pressure Oil AE Lube Pressure Oil Pressure Free Oil Power Train - Hydrostatic Theory of Operation - 249 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION MIF A- Charge Pressure Relief Sump Passage B- Reverse Directional Control Valve C- Pressure Oil From Charge Pump D- Freewheeling Manual Push Pins E- Forward Directional Control Valve F- Closed Loop Check Valve G- Hydrostatic Pump H- Inlet To Charge Pump I- Forward Side Loop J- Anti-Cavitation Check Valves K- Screen L- Plugs M- Motor N- Reverse Loop O- Valve Plate Cooling Passage P- Return From Oil Cooler Q- Reverse Leakoff Orifice R- To PTO Engagement Solenoid S- Clutch Piston T- PTO Pressure Test Port U- PTO Engagement Solenoid V- PTO Brake W- Charge Pressure Relief Valve X- Charge Pressure Test Port Y- Lube Reduction Valve Z- Directional Valve - Forward AA- PTO Pressure Control Valve AB- Hydrostatic Motor AC- Directional Valve - Reverse AD- Return From Steering Valve and Control Valve To Sump AE- Transaxle Case AF- Hydraulic Oil Filter AG- Outlet To Steering Control Unit AH- Charge Pressure Control Valve AI- PTO Flow Orifice AJ- Charge Pump AK- Hydrostatic Variable Pump Transaxle Oil Flow System Operation Function: Provide pressure oil to charge and lubricate the hydrostatic transmission, operate the hydraulic system and engage the PTO clutch and brake. System Operation: The charge pump draws oil from the transaxle case, through the filter and provides pressure oil to outlet galley of the pump. Three valves control the flow and pressure from the pump. Charge Pressure Control Valve: If charge pressure is below 1910 kPa (277 psi), the charge pressure control valve will block oil flow from leaving the “OUT” port to the steering valve. This will insure priority oil flow to the lube reduction valve for transmission lubrication. When charge pressure is at a minimum of 1958 kPa (284 psi), it will allow oil flow out the “OUT” port to steering and hydraulic control valve. Charge Pressure Relief Valve: Charge pressure relief valve protects the hydraulic system and charge pump from excessive pressure. High pressure in the hydraulic circuit can be caused by an excessive load on the hydraulic outlets, or with nothing connected to the outlets when the control lever is moved. Lube Reduction Valve: The lube reduction valve has two functions: 1. If pressure in the lube and charge port exceeds 586 kPa (85 psi), it will close off the flow to the port, reducing lube and charge pressure. 2. This valve also has a small orifice that allows a small flow of oil to the engagement solenoid. Oil is available for clutch and brake engagement when PTO is engaged. Power Train - Hydrostatic Theory of Operation - 250 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION B C D A E F G H I AA J Z K L M Y N X O W P V Q R U T Charge Pressure Oil Clutch Engagement Pressure Oil Lube Pressure Oil Pressure Free Oil MIF Power Train - Hydrostatic Theory of Operation - 251 S POWER TRAIN - HYDROSTATIC THEORY OF OPERATION W B V Charge Pressure Oil Clutch Engagement Pressure Oil Lube Pressure Oil Pressure Free Oil I D M N J K O L P MIF A- Clutch and Brake Pressure Test Port B- PTO Engagement Solenoid Valve C- PTO Pressure Control Valve D- Passage to Solenoid E- Directional Valve - Forward F- Charge Pressure Relief Valve G- Directional Valve - Reverse H- Center Section I- Charge Pressure Test Port J- Lube Reduction Valve K- PTO Flow Orifice L- Return From Cooler To Sump M- Lube Passage To Hydrostatic Pump N- Out to Steering O- Charge Pressure Control Valve P- Charge Pump Q- Hydrostatic Motor R- To Charge Pump S- Filter T- Inlet From Case U- Transaxle Case V- Clutch Lube Passage W- Clutch Piston X- Brake Shoe Y- Brake Piston Z- Brake Spring AA- PTO Brake Power Train - Hydrostatic Theory of Operation - 252 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION External Power Train System Operation System Operation: The transaxle is a combination of a hydrostatic transmission, differential and axle assemblies. It also contains a hydraulic operated PTO clutch and brake with all associated drive train gears. The drive shaft connects the engine to the input shaft of the transaxle. The input shaft rotates the charge pump, hydrostatic pump and PTO clutch drive hub. These components provide the power to operate the transaxle. The transaxle is controlled by foot operated forward and reverse pedals. The pedal linkage is connected to the swash plate control lever that operates the internal swash plate shaft, controlling the direction and amount of output of the hydrostatic pump to the hydrostatic motor. The damper (shock absorber) provides for a smooth operation of the control linkage and also provides the pedal “feel”. The differential lock pedal and linkage are located on the left-hand side of the transaxle. When the pedal is depressed, the linkage holds the internal differential lock lever, collar and pins under spring tension. This is done because if the lock pins do not line up with the holes in the differential, the lock will not engage. When the holes do line up with the pins, the spring will force the pins to engage. The free-wheeling linkage is accessible from the right rear of the machine. When the linkage is moved up, the directional control valves are depressed, allowing the closed loop circuit to by-pass, allowing the machine to be pushed. Power Train - Hydrostatic Theory of Operation - 253 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION Transaxle Internal System Operation C B I D J K E F L G M H A N V O P U Q R T S MX11457 Power Train - Hydrostatic Theory of Operation - 254 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION Picture Note: Side View Shown A- PTO Electrical Engagement Solenoid B- PTO Clutch Hub and Gear C- Dip Stick D- PTO Piston E- PTO Clutch F- PTO Drive Gear G- Neutral Centering Spring H- Swash Plate I- Hydrostatic Pump J- Charge Pressure Relief Valve K- Charge Pressure Test Port L- Lube Reduction Valve M- Charge Pump N- Input Shaft O- Hydrostatic Motor P- Anti-Cavitation Valves Q- Input Pinion Gear R- Ring Gear S- PTO Output Shaft T- Left Axle U- PTO Driven Gear V- PTO Idler Gear Power Train - Hydrostatic Theory of Operation - 255 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION C B D A E F G H J I MX14458 Picture Note: Rear View Shown A- Brakes B- PTO Output Shaft C- Swash Plate Shaft D- Swash Plate Control Lever E- Differential Input Gear F- Differential Ring Gear G- Differential Bevel Pinions H- Differential Side Gears I- Differential Shift Collar and Pin J- Left Axle Power Train - Hydrostatic Theory of Operation - 256 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION Transaxle Operation: and pins lock the left-hand axle and side gear to the differential carrier, turning both axles at the same rate. The transaxle consists of an internal hydrostatic pump and external hydrostatic motor, differential assembly and a hydraulic PTO clutch and gearing to the PTO output shaft. PTO Operation: When the PTO is engaged, the electrical engagement solenoid allows pressure oil, supplied by the charge pump, to engage the PTO clutch and release the PTO brake. The PTO clutch is applied when pressure oil moves the PTO piston, squeezing the clutch disk together. With the disks locked together, power is then transmitted by the PTO clutch hub and gear, through the idler gear and driven gear and out the case through the output shaft. Whenever the engine is running, the drive shaft is turning the input shaft, charge pump and PTO drive gear. The charge pump provides charge and lubrication oil for the hydrostatic pump, motor and PTO clutch lube. It also provides pressure oil to operate the PTO clutch and supply oil for the steering valve and hydraulic control valve. See Steering and/or Hydraulics sections. The PTO brake is released at the same time the clutch is applied. Pressure oil moves the brake piston out against brake spring pressure, releasing the brake. When the PTO is shut off, the engagement solenoid blocks the pressure oil and the brake springs push the piston and brake shoe against the PTO clutch hub and gear. Frictional force stops the rotation of the PTO drive train. See “Transaxle Oil Flow System Operation” on page 250. The hydrostatic pump, controlled by the foot control linkage and swash plate, provides direction and speed of the closed loop pressure oil to the hydrostatic motor. The motor drives the input pinion gear. Power is then transmitted through the ring gear, differential input gear and differential ring gear. Differential action to the rear axles and wheels is provided through the bevel pinions and side gears. When the differential lock is engaged, the differential collar C B A D E F F G H I Q J K P O N M L Power Train - Hydrostatic Theory of Operation - 257 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION M55426a A- PTO Pressure Control Valve B- PTO Clutch, Hub and Gear C- PTO Clutch D- Hydrostatic Pump E- Charge Pressure Relief Valve F- Directional Control Valves G- Charge Pressure Test Port H- Lube Reduction Valve I- Input Shaft J- Charge Pressure Control Valve K- Neutral Centering Spring L- Neutral Adjustment Eccentric M- PTO Brake Piston N- PTO Brake Springs O- PTO Brake P- PTO Pressure Test Port Q- Damper (Shock Absorber) Rear PTO Component Location and Operation - Optional Function: To provide 540 rear PTO drive. Theory of Operation: The mid-PTO and the rear PTO kits, use a common power flow up to the shift collar. To have power to either or both PTO's the operator must be on the seat and PTO clutch must be engaged. Power is then transmitted from the input shaft through the clutch disks and out the clutch hub and gear, idler gear, PTO drive gear and into shift collar. The shift collar has three detented positions. It is moved by the shift fork that is controlled by the external shift lever. Rear PTO: When the shift collar is positioned in the rear detent (shift lever up), the collar connects and drives only the rear PTO drive gear. Power then flow through the reduction gear set and PTO output gear, out the rear coupler. A boss on the shift fork depresses the mid-PTO switch, turning off the mid-PTO indicator light on the dash. Mid- and Rear PTO: When the shift collar is in the middle detent position, the shift collar picks up both the rear and mid-PTO drive gears. Both PTO output shafts are powered. The shift fork boss is not depressing either of the PTO switches, leaving both PTO indicator lights on. Mid-PTO: When the collar is positioned in forward detent (shift lever down) the collar connects and drives only the mid-PTO shaft. A boss on the shift fork depresses the rear PTO switch and turns the indicator light on the dash off. Stationary PTO Operation: For the rear PTO to operate with operator off seat, a startup sequence must be followed: 1. Engine off. PTO switch off. PTO drive line connected and shields in place. 2. Park brake set. 3. Rear PTO lever positioned up for rear PTO operation. 4. Engine can be started with operator on or off seat. 5. Operator off seat. Pull PTO switch on. Note: If seat switch is activated by touching or sitting on seat, PTO will disengage. Repeat procedure to engage PTO. Power Train - Hydrostatic Theory of Operation - 258 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION 540 Rear PTO E F G H D I C B A Q P O J K N L M MX16044 A- Rear PTO Power Flow B- Rear PTO Shaft C- PTO Output Gear D- Idler Gear E- Clutch and Hub Gear F- Clutch Disk G- PTO Clutch Gear H- Input Shaft I- Common Power Flow to Shift Collar J- Mid-PTO Power Flow K- Mid-PTO Shaft L- PTO Drive Gear M- Mid-PTO Drive Gear N- Shift Collar O- Rear PTO Drive Gear P- Rear PTO Switch Q- Reduction Gear Set Power Train - Hydrostatic Theory of Operation - 259 POWER TRAIN - HYDROSTATIC DIAGNOSTICS Diagnostics Symptom: Hydrostatic Transmission Problems Problem Cause - Solution Hydrostatic Transmission Diagnosis 4. Too aggressive in reverse? a. No: Go to next step. 5. Slow forward under load, or speed drops when load is applied? a. No: Go to next step. Symptom: Hydrostatic Transmission Problems Problem Cause - Solution 1. Machine will not move on its own power? 2. Machine will not move. Wheels locked up. Can not be pushed? a. No: Go to next step. b. Yes: Free-wheeling linkage set for push or partially set. Control pedal linkage bent, binding or disconnected. Directional control valves leaking or stuck down. Brakes set or not releasing. See Brakes section. Anti-cavitation valves leaking or stuck open. Charge pump scored or worn. Pump or motor valve plates scored or worn. Filter pugged or suction side air leak. Check filter, charge pump or case seal. Charge pressure relief valve leaking. Seat valve or spring damaged. Drive shaft not turning pump input shaft or charge pump key sheared. a. No: Go to next step. b. Yes: Brakes set or not releasing. See Brakes section. 3. Will not move in one a. No: Go to next step. direction? b. Yes: Free-wheeling linkage set for push or partially set. Control pedal linkage bent, binding or disconnected. Directional control valves leaking or stuck down. Directional valve in wrong location. Anti-cavitation valves leaking or stuck open. Pump or motor valve plates scored or worn. Power Train - Hydrostatic Diagnostics - 260 b. Yes: Free-wheeling linkage set for push or partially set. Linkage damper (shock absorber) failed. Directional control valves leaking or stuck down. Pump or motor valve plates scored or worn. b. Yes: Forward pedal height needs to be adjusted. Free-wheeling linkage set for push or partially set. Control pedal linkage bent, binding or disconnected. Directional control valves leaking or stuck down. Drive shaft not turning pump input shaft or charge pump key sheared. Anti-cavitation valves leaking or stuck open. Directional valve in wrong location. Charge pump scored or worn. Pump or motor valve plates scored or worn. Filter pugged or suction side air leak. Check filter, charge pump or case seal. Engine performance is poor or not operating or set at correct operating speeds. See Engine diagnosis. POWER TRAIN - HYDROSTATIC DIAGNOSTICS Symptom: Hydrostatic Transmission Problems Problem Cause - Solution Symptom: Hydrostatic Transmission Problems Problem Cause - Solution 6. Erratic speed? 9. Transaxle or a. No: Go to next step. differential lock b. Yes: See “Hydrostatic problem or complaint? Transmission Test” on page 264. a. No: Go to next step. b. Yes: Free-wheeling linkage set for push or partially set. Linkage damper (shock absorber) failed. Control pedal linkage bent, binding or disconnected. Brakes set or not releasing. See Brakes section. Directional control valves leaking or stuck down Drive shaft not turning pump input shaft or charge pump key sheared. Anti-cavitation valves leaking or stuck open Charge pump scored or worn Pump or motor valve plates scored or worn Filter pugged or suction side air leak. Check filter, charge pump or case seal Charge pressure relief valve leaking. Seat valve or spring damaged Swash plate control shaft or bushing worn. Engine performance is poor or not operating or set at correct operating speeds. See Engine diagnosis 7. Machine will not stop? a. No: Go to next step. 8. PTO problem or complaint? a. No: Go to next step. 10. Transmission operating hot? a. No: Go to next step. 11. Hydraulic noise? a. No: Go to next step. b. Yes: Free-wheeling linkage set for push or partially set. Control pedal linkage bent, binding or disconnected. Brakes set or not releasing. See Brakes section. Neutral adjustment not correct. Anti-cavitation valves leaking or stuck open. Swash plate control shaft or bushing worn. b. Yes: For mid or rear PTO problems or complaints, see “Mid-PTO System Diagnosis” on page 262. Power Train - Hydrostatic Diagnostics - 261 b. Yes: Free-wheeling linkage set for push or partially set. Control pedal linkage bent, binding or disconnected. Brakes set or not releasing. See Brakes section. Neutral adjustment not correct. Oil cooler may be plugged with debris. Directional control valves leaking or stuck down. Anti-cavitation valves leaking or stuck open. Charge pump scored or worn. Pump or motor valve plates scored or worn. For mid or rear PTO problems or complaints, see “Mid-PTO System Diagnosis” on page 262. b. Yes: Free-wheeling linkage set for push or partially set. Brakes set or not releasing. See Brakes section. Neutral adjustment not correct. Drive shaft not turning pump input shaft or charge pump key sheared. Directional control valves leaking or stuck down. Anti-cavitation valves leaking or stuck open. Charge pump scored or worn. Pump or motor valve plates scored or worn. Filter pugged or suction side air leak. Check filter, charge pump or case seal. Charge pressure relief valve leaking. Seat valve or spring damaged. Swash plate control shaft or bushing worn. For mid or rear PTO problems or complaints, see “Mid-PTO System Diagnosis” on page 262. POWER TRAIN - HYDROSTATIC DIAGNOSTICS Symptom: Hydrostatic Transmission Problems Problem Cause - Solution 12. Gear noise, dependant on speed, direction of travel or during turn? a. No: Go through procedures in “Hydrostatic Transmission Test” on page 264 for additional tests. b. Yes: Brakes set or not releasing. See Brakes section. Drive shaft not turning pump input shaft or charge pump key sheared. Charge pump scored or worn. Pump or motor valve plates scored or worn. Filter pugged or suction side air leak. Check filter, charge pump or case seal. For mid or rear PTO problems or complaints, see “Mid-PTO System Diagnosis” on page 262. Symptom: Mid PTO Engagement Problems Problem Cause - Solution 3. PTO will not stay engaged? a. No: Go to next step. 4. Gear or bearing noise with PTO engaged? a. No: See “Mid-PTO System Test” on page 265. Mid-PTO System Diagnosis Symptom: Mid PTO Engagement Problems Problem Cause - Solution 1. PTO will not engage? 2. Engine stalls when PTO is engaged? a. No: Go to next step. b. Yes: Check engagement solenoid circuit. See Electrical section. PTO switch not working. PTO lube reduction valve orifice plugged. Engagement valve installed incorrectly. PTO pressure control valve faulty. PTO clutch piston leaking, input shaft seal leaking or clutch disk worn. Low charge pump output. PTO shaft, gear or bearing failure. b. Yes: Check engagement solenoid circuit. See Electrical section. Engagement valve installed incorrectly. PTO clutch piston leaking, input shaft seal leaking or clutch disk worn. PTO lube reduction valve orifice plugged. Low charge pump output. PTO pressure control valve faulty. b. Yes: PTO brake not releasing. Check brake piston, O-Rings. PTO brake springs faulty. Symptom: Mid PTO Speed Problems Problem Cause - Solution 1. PTO shaft slows down? a. No: Go to next step. 2. PTO shaft will not stop, or slow to stop? a. No: Go through procedures in “Mid-PTO System Test” on page 265 for additional tests. a. No: Go to next step. b. Yes: Excessive load on PTO output. Remove load. Use higher engine rpm. Check engine performance. Hydraulic circuit in relief. Remove restriction or load. PTO brake not releasing. Check brake piston, O-Rings. PTO shaft, gear or bearing failure. Power Train - Hydrostatic Diagnostics - 262 b. Yes: Excessive load on PTO output. Remove load. Use higher engine rpm. Check engine performance. PTO lube reduction valve orifice plugged. Low charge pump output. PTO pressure control valve faulty. PTO clutch piston leaking, input shaft seal leaking or clutch disk worn. b. Yes: Check engagement solenoid circuit. See Electrical section. Engagement valve installed incorrectly. PTO brake not releasing. Check brake piston, O-Rings. Excessive load on PTO output. Remove load. PTO brake springs faulty. POWER TRAIN - HYDROSTATIC DIAGNOSTICS Transaxle Diagnosis Symptom: Transaxle Noise Problems Problem Cause - Solution Symptom: Problem Cause - Solution 1. PTO complaint? a. No: Go to next step. b. Yes: See Mid-PTO or rear PTO diagnosis. See Transaxle Repair. 2. Hydrostatic transmission complaint? a. No: Go to next step. 3. Rear drive wheel are locked up; will not move directional pins down? a. No: Go to next step. b. Yes: Brakes are applied or misadjusted. See Brakes section. b. Yes: Brakes are applied or misadjusted. See Brakes section. Differential lock collar, pin or differential carrier failure. Check axle or differential gear failure. See axle or differential repair. See “Transaxle Test” on page 266. See “Repair” on page 275. 1. Ratcheting noise as a. No: Go to next step. machine moves? b. Yes: Brakes are applied or misadjusted. See Brakes section. Differential lock linkage is misadjusted. Differential is engaged. Check adjustment. Adjustment ok = repair differential lock. Differential lock collar, pin or differential carrier failure. Check axle or differential gear failure. See axle or differential repair. See “Repair” on page 275 for repair procedures. 2. Ratcheting noise as a. No: Go through procedures in machine turns? “Transaxle Test” on page 266 for additional tests. a. No: Go to next step. 4. Rear wheel freewheel; no transaxle b. Yes: Check axle or differential drive; hydraulic control gear failure. See axle or valve pins are up? differential repair. Differential lock collar, pin or differential carrier failure. See “Transaxle Test” on page 266. See “Repair” on page 275. 5. Differential lock will not engage? a. No: Go to next step. 6. Differential lock will not disengage? a. No: See “Transaxle Test” on page 266. b. Yes: Differential lock linkage is mis-adjusted. Differential lock collar, pin or differential carrier failure. See “Repair” on page 275. b. Yes: Brakes are applied or misadjusted. See Brakes section. Differential lock linkage is misadjusted. Differential is engaged. Check adjustment. Adjustment ok = repair differential lock. Differential lock collar, pin or differential carrier failure. See Repair section for repair procedures. Power Train - Hydrostatic Diagnostics - 263 b. Yes: Differential lock linkage is mis-adjusted. Differential is engaged. Check adjustment. Adjustment ok = repair differential lock. Differential lock collar, pin or differential carrier failure. Check axle or differential gear failure. See axle or differential repair. See Repair section for repair procedures. POWER TRAIN - HYDROSTATIC DIAGNOSTICS Hydrostatic Transmission Test Engine NOT running: 7. With free-wheeling lever disengaged (DOWN), machine stops after differential lock engages? No: Go to next step. Test Conditions: Yes: Differential bevel gears or axles will not push in either direction. • Park brake disengaged. Yes: Brakes are on or dragging. • Engine not running. Yes: Reverse orifice is plugged. • Machine on hard level surface. 8. With free-wheeling lever engaged (UP), machine pushes easily forward and backward? Hydrostatic Transmission 1. When checking transmission dipstick, correct type, viscosity of oil, and oil level? No signs of leaks from transaxle? Yes: Go to next step. No: Add or change hydraulic oil. Repair all external leaks. 2. Oil cooler/radiator intake screen and cooler fins free of debris and clean? Fins not bent? Yes: Go to next step. No: Free-wheel lever is bent, disconnected from LeftHand bracket, or not pushing directional control valve pins. Repair linkage. No: Check directional control valve pins for dirt or corrosion that would bind pins. No: Check brakes for dragging. 3. Hydraulic control levers return to neutral position? 9. Transmission control pedals (brakes disengaged) and linkage move smoothly with slight resistance to movement? (NOTE: Linkage will return slower at colder temperatures.) No free-play in linkage between pedals and swash plate shaft? Yes: Go to next step. Yes: Go to next step. No: Hydraulic control levers not in neutral; hydraulic system could be in relief. See Hydraulics section and check linkage for binding. No: Inspect linkage for bent, binding or looseness 4. With free-wheeling lever disengaged (DOWN), machine free-wheels in both directions? No: Disconnect control rod from swash plate arm. Check linkage for binding and repair. No: Go to next step. No: Linkage not binding - check swash plate shaft for binding or internal return/centering spring or swash plate bushing binding. Yes: Go to next step. No: Clean as required. Yes: Free-wheeling linkage not releasing directional control valve pins. No: If pedals do not return to neutral, disconnect damper (shock). Pedals should return sharply. 5. With free-wheeling lever disengaged (DOWN), machine pushes in reverse but not forward? 10. Transmission control pedals and linkage: With brake pedal engaged, forward and reverse pedal should be locked in neutral? (Engage free-wheeling lever and push machine to verify.) No: Go to next step. Yes: Go to next step. Yes: Directional control valves are installed in wrong ports. Switch valves around. No: Pedals not locked in neutral. See “Transaxle Control Linkage Adjustment” on page 272. Yes: Forward valve is leaking. Replace forward valve. No: Brakes not holding machine. See Brakes section and adjust. Yes: Directional control pins stuck down. 6. With free-wheeling lever disengaged (DOWN), machine free-wheels with brakes applied? No: Go to next step. Yes: Adjust brakes. (See Brakes section.) Yes: If brakes do not stop machine, check for the following: (NOTE: Push machine until differential lock engages.) Failed brake shaft or bearing, failed differential input gear or differential carrier, or check differential bevel gears. 11. To check cruise control lever and linkage (if equipped), push forward pedal slightly and set cruise. (Brake pedal released.) Does cruise control release when forward pedal is pressed and released or brake pedal is depressed? Yes: Hydrostatic transmission (engine OFF) checks completed. No: Check linkage for bent, binding or disconnected Power Train - Hydrostatic Diagnostics - 264 POWER TRAIN - HYDROSTATIC DIAGNOSTICS No: Check charge pressure relief valve for broken spring or debris. links. No: Check cam teeth for wear if cruise will not stay engaged. 5. Test charge pump pressure port. Is there charge pressure, but no drive? Engine running: No: Hydrostatic transmission (engine running) tests completed. Test Conditions: Yes: Replace directional control valves. • Start engine. • Release park brake. • Move machine to open area for driving test. Yes: Lube reduction valve stuck. Yes: Inspect pump and motor for wear. Yes: See “Hydrostatic Transmission Diagnosis” on page 260. Hydrostatic Transmission Yes: Anti-cavitation valve stuck open. 1. With parking brake applied, does machine have excessive noise when operated? Yes: See “Charge Pump Flow and Pressure Test - At Charge Pump” on page 268. No: Go to next step. Yes: Extreme wear of valve plates or rotating groups. Yes: Transmission neutral return linkage bolt is out of adjustment. 2. Test forward and reverse pedals. Drive machine forward, then stop. Reverse and stop. Does machine respond to pedal movement? (Gradual increase in speed FORWARD up to 13.2 km/h (8.2 mhp). Should stop within 2.2 - 4 m (7 - 10 ft) without using brake. Gradual speed increase; speed in REVERSE to 8.8 km/h (5.5 mph). Should stop within 1.2 - 1.8 m (4 - 8 ft).) Mid-PTO System Test Test Conditions: • Park brake disengaged. • Engine running approximately half throttle. Yes: Go to next step. • Deck or PTO driven implement installed. No: Check free-wheeling linkage if machine will not move or if hydrostatic is jerky. • PTO switch off. No: If machine still will not move, continue testing sequence. If machine does not stop within distance, check linkage for binding, replace dampener and retest. Mid-PTO No: Check swash plate shaft for binding, or neutral return spring weak or broken. 3. Are drive shaft cap screws tight? No wear or damage to splines? Drive shaft turning input shaft? Yes: Go to next step. A No: Tighten cap screws. Repair or replace as necessary M55440 4. Test charge pump pressure port. Is there charge pressure? 1. Is PTO shaft (A) turning? Yes: Go to next step. No: Go to next step. No: Check hydraulic oil level. Yes: Perform “Mid-PTO Engagement Pressure and Brake Test” on page 270. No: Replace hydraulic filter. Yes: Check brake springs, brake shoes, solenoid valve and clutch return spring. No: Check vent for plugging. No: Check charge pump seal. No: Check for sheared pump drive key. 2. With PTO switch on, brake off, and being on the seat, is PTO engaging? Power Train - Hydrostatic Diagnostics - 265 POWER TRAIN - HYDROSTATIC DIAGNOSTICS Transaxle Test Yes: Go to next step. No: Perform PTO engagement pressure test. See “MidPTO Engagement Pressure and Brake Test” on page 270. No: If there is no engagement, and/or no engagement pressure check: Electrical solenoid in Electrical section; PTO pressure control valve leaking to sump; Lube reduction valve orifice plugged; For no charge pressure. Perform “Charge Pump Flow and Pressure Test - At Charge Pump” on page 268.; Clutch or brake packing leaking; Packing on end of clutch hub shaft missing or leaking. 3. Observe PTO shaft. (Engine at full rpm; PTO on, then off.) Does PTO shaft and implement stop within four seconds? Yes: Go to next step. No: Check brake springs and brake facing. Repair PTO inertia brake. 4. Observe PTO shaft. (Engine at full rpm; PTO on.) Is PTO driving implement satisfactory under load? PTO clutch not slipping? No vibration? Test Conditions: • Park brake engaged. • Engine not running. Transaxle 1. When checking dipstick, oil at proper level and viscosity? Yes: Go to next step. No: Add or change hydraulic oil and filter. 2. Check transaxle (drive machine). No leaks? Transaxle engages in 0.5 - 1. 0 seconds? Yes: Go to next step. No: Replace leaking and worn seals. Yes: Mid-PTO test completed. 3. Differential lock engages within a short distance when differential lock pedal is depressed? (Machine wants to continue in a straight line. Differential lock will disengage when you release the traction pedal.) No: PTO pressure low; adjust pressure control valve. Yes: Go to next step. No: Check clutch disk for wear. (NOTE: Check lube passage in input shaft and in clutch input gear for blockage.) No: Check linkage springs and all linkage connections. Inspect differential and lock collar and pins. Check for broken differential shift fork return spring. No: Vibration: Disconnect implement drive shaft and operate PTO. Check shaft U-joints or implement for vibration. 4. Check differential and axles (jack one wheel off ground). During a turn, any noise from axles or differential? (AWS wheel hubs in knuckle housing should have movement (wobble)). No: Go to next step. Yes: Noise in the turn: Check all bearings then differential side gears and bevel pinions. 5. Check brake pedals. Any noise in differential when brakes are released and rear wheels are rotated? No: Transaxle test completed. Yes: Ratcheting noise: See “Brake/Differential Linkage Adjustment:” on page 391 in the Brakes section. Yes: Brakes adjusted properly - disassemble and repair transaxle. Power Train - Hydrostatic Diagnostics - 266 POWER TRAIN - HYDROSTATIC TESTS AND ADJUSTMENTS Tests and Adjustments Hydraulic Oil Warm-Up Procedure Reason: When making hydraulic tests the oil must be heated to normal operating temperature for the tests to be accurate. Test Equipment: • JDG282 Temperature Gauge Procedure: 1. Install JDG282 Temperature Gauge on transmission oil filter. Important: Avoid Damage! DO NOT overheat engine. 2. Apply park brake. Start engine and run at full throttle. 3. Move and hold hydraulic lever in implement raise position. c pressure Caution: Avoid Injury! Escaping fluid under can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable source. Such information is available from the Deere & Company Medical Department in Moline, Illinois, U.S.A. In the United States and Canada only, this information may be obtained by calling 1-800822-8262. 4. Periodically cycle all hydraulic functions to distribute heated oil. 5. Heat oil to operating temperature before performing tests. Charge Pump Pressure Test Reason: To determine charge pressure control valve operation and help determine condition of hydraulic charge pump. This also checks charge pump pressure relief valve operation and determines if there is sufficient pressure to operate implements. B Test Equipment: A MX35901 • JT05489 Connector, 7/16-20 x M 37° 1/2-20 M ORB • JT03017 Hose • JT03117-13790 kPa (2000 psi) Pressure Gauge Pressure Test Procedure: 4. Install connector, hose and pressure gauge to charge pressure test port (A). 5. Start engine and run at high idle. Do not operate steering or hydraulic control valves. 6. Observe gauge reading. This is charge pressure. Warm hydraulic oil to operating temperature before performing this test. When done “cold” or at shop temperature, most machines (especially when new) will likely be close to 3450 kPa (500 psi). 1. Park machine safely. See “Park Machine Safely” in the Safety section. 7. Move hydraulic control lever to raise or lower position. Hold until pump pressure is in relief. 8. Observe gauge reading and release control. This is charge pressure relief pressure (implement operation pressure). 2. Remove seat and fender deck. Specifications: 3. Attach seat switch and set up machine so engine can be run. Charge Pressure (minimum) . . . . . . 19588 kPa (284 psi) Charge Relief (Implement) Pressure (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6371 kPa (924 psi) Power Train - Hydrostatic Tests and Adjustments - 267 POWER TRAIN - HYDROSTATIC TESTS AND ADJUSTMENTS Results: Procedure: • If charge pressure is to specifications, 1958 kPa (284 psi) minimum, in transaxle, charge pressure control valve is operating properly. Note: To save time and help with diagnosis, perform charge pump flow and pressure test at hydraulic control valve quick disconnect fittings before performing this test. See “Charge Pump Pressure and Flow Test at Couplers” on page 351 in the Hydraulics section. • Note: Charge pressure gauge reading may be higher than specification due to cold oil temperature. Warm oil and retest. • If charge pressure is too high, and oil is at operating temperature, there is a potential problem with the charge pressure control valve, or a restriction in the system. See “Charge Pump Flow and Pressure Test - At Charge Pump” in the Hydraulic Power Train section.” • If relief pressure is within charge relief (implement) pressure specifications, 6371 kPa (924 psi) minimum, pump and charge pressure relief valve are in good condition. 1. Remove fender deck. Support fuel tank to one side. c pressure Caution: Avoid Injury! Escaping fluid under can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable source. Such information is available from the Deere & Company Medical Department in Moline, Illinois, U.S.A. In the United States and Canada only, this information may be obtained by calling 1-800822-8262. B MX14228 • If relief pressure is below 5881 kPa (853 psi), check charge pressure relief valve (B), shim relief pressure spring. If pressure cannot be increased, check charge pump for damage. 2. Disconnect the pressure and return line from the charge pump housing. Charge Pump Flow and Pressure Test - At Charge Pump Reason: To check condition of charge pump and setting of the charge pump relief valve. Isolates possible restrictions of flow in the steering control valve and/or hydraulic control valve. Test Equipment: • JT01765 Consumer Products Hydraulic Fitting Kit • JT05469 Flowcharter Kit • JT03216 Connector, 9/16-18 M 37° x 9/16-18 M ORB • JT03341 Elbow, 90° 9/16-18 M 37° x 9/16-18 F 37° • JT03342 Coupler, 3/4” F NPT x 9/16-18 F 37° M55420 Power Train - Hydrostatic Tests and Adjustments - 268 POWER TRAIN - HYDROSTATIC TESTS AND ADJUSTMENTS • D A B If there is no pump flow, check for: • Drive shaft not turning input shaft • Sheared charge pump drive key • Charge pressure control valve (E) stuck closed • If pump flow is below 13 L/m (3.4 gpm) for 2-WD machines, OR 17 L/m (4.5 gpm) for MFWD machines, foamy or erratic, match specifications by checking: C D M55421 A- ORB Connectors (removed from charge pump) B- JT03216 Connector, 9/16 - 18 M 37° x 9/16 - 18 F 37° C- JT03341 90° Elbow, 9/16 - 18 M 37° x 9/16 - 18 F 37° D- JT03342 Coupler, 3/4” F NPT x 9/16 - 18 F 37° • If O-Ring is damaged. • Hydraulic oil level; replace filter and repeat test. • Transaxle vent not plugged, filter seal for leaks. • Oil ring at inlet of charge pump for leak in case passage between filter and charge pump. • If dipstick is loose. 3. Remove the ORB fittings and install JT03216 and JT03341. Important: Avoid Damage! After connecting flowmeter, keep disconnected lines away from drive shaft. F 4. Connect flowmeter inlet hose to pump outlet (right-hand side). 5. Connect return hose of flowmeter to return port (lefthand side). Flow Test Procedure: 1. Open flowmeter control valve. 2. Start engine and run at wide open throttle. Oil must be at normal operating temperature. 3. Observe flowmeter reading. MX14228 • If pump flow is still below 13 L/m (3.45 gpm) for 2-WD machines, OR 17 L/m (4.5 gpm) for MFWD machines, match specifications by checking charge pressure relief valve (F) for damage or debris that could be holding valve open. • Replace pump and repeat test. Pressure Test Procedure: Results: • If pump flow is between 13 - 17 L/m (3.4 - 4.5 gpm) for 2-WD machines OR 17 - 22.7 L/m (4.5 - 6 gpm) for MFWD machines, pump is in good condition. E 1. Flowmeter still connected as in flow test. 2. Start engine and run at wide open throttle. 3. Slowly close flowmeter valve until maximum pressure is reached. Observe pressure reading. Results: • If pressure is 6371 kPa (924 psi) minimum, pump and valve are in good condition. • If pressure is below 5881 kPa (853 psi), shim charge pressure relief pressure spring. If pressure cannot be increased, check charge pump for damage. M55428 Power Train - Hydrostatic Tests and Adjustments - 269 POWER TRAIN - HYDROSTATIC TESTS AND ADJUSTMENTS G D A MX14180 B • If pump seems in good condition, check condition of lube reduction valve modulation orifice (G) for plugging. • Replace charge pump and repeat test. MX35902 2. Install JT05486 (B) and JT05483 (C) Connectors. 3. Install JT03017 Hose (D) with JT03115, 2758 kPa (400 psi) Pressure Gauge (A). Specifications: Charge Pump Flow (2-WD) . 13 - 17 L/m (3.4 - 4.5 gpm) Charge Pump Flow (MFWD) 17 - 22.7 L/m (4.5 - 6 gpm) Charge Pressure Relief Pressure (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6371 kPa (924 psi) 4. Run engine at wide open throttle. Mid-PTO Engagement Pressure and Brake Test Results: PTO Engagement Pressure Test Reason: To check for adequate clutch engagement pressure and brake release pressure. Test Equipment: • C JT05486 Connector, 1/4 M NPT x 7/16-20 M 37° • JT05483 Connector, 90° elbow, 7/16-20 M 37°, 7/16-20 F 37° Swivel • JT03017 Hose • JT03115 2758 kPa (400 psi) Pressure Gauge 5. With brake pedal released and operator on seat, engage PTO switch. 6. Observe pressure gauge. • If pressure is at or above 1420 - 1517 kPa (206 - 220 psi) engagement valve is operating and engagement pressure is OK. If there is a PTO engagement complaint, inspect clutch disk for wear. • If there is no pressure on gauge, see Electrical Section to check engagement solenoid and circuit. Inspect PTO engagement valve for proper installation, scoring, or damage to solenoid shaft. If solenoid is operating, check lube reduction valve orifice for plugging. Perform “Charge Pump Flow and Pressure Test - At Charge Pump” on page 268. Procedure: 1. Remove hex-plug upper right-hand port on rear transmission case. Important: Avoid Damage! Do not overtighten fittings. F E M55462 Power Train - Hydrostatic Tests and Adjustments - 270 POWER TRAIN - HYDROSTATIC TESTS AND ADJUSTMENTS • If pressure is low, perform same test on left-hand port opposite test port checked above and compare pressure differential. If different, check solenoid valve (F) for sticking or shim missing, or solenoid not functioning. If both pressures are low, check PTO pressure control valve (E). • If pressure is low, inspect PTO pressure control valve spring or seat for damage and valve for scoring. Add shims to increase pressure. If shims will not increase pressure, check lube reduction valve orifice. Perform “Charge Pump Flow and Pressure Test - At Charge Pump” on page 268. Procedure: c during Caution: Avoid Injury! Rear wheels will rotate adjustment or if transaxle is out of adjustment. Always support rear wheels with jackstands. Be cautious of rotating wheels. 1. Lift machine with a hoist and support rear wheels off the ground. 2. Support rear axle with jackstands. Mid-PTO Brake Test Reason: PTO brake is not stopping implement within five seconds. Also, insure PTO shaft does not rotate when PTO is off. A Procedure: 1. With implement installed, PTO on and engine at wide open throttle. 2. Shut PTO off. 3. Observe the time it takes for implement to come to complete stop. Results: • Implement stops within five seconds and stays stopped, PTO brake is OK. • Implement takes longer than specified time to stop or continues to run, check the following: - Size of the implement may be too large or requires its own brake. M55443 Picture Note: NOTE: Fender deck was removed to illustrate adjustment location. Adjustment can be made through right-hand side frame cutout (A). - Weak or broken brake springs. B - Worn brake shoe or scored PTO clutch hub and gear assembly. C - Weak or broken clutch piston return spring. - Engagement solenoid valve not releasing pressure, keeping clutch engaged. Transaxle Neutral Adjustment Reason: M55442 To ensure that machine does not creep when pedals are in neutral. Test Equipment: • Hoist • Jackstands (2) 3. Loosen lock nut (B). c when Caution: Avoid Injury! Use extreme caution doing this adjustment. Drive wheels are free to rotate. Note: If creep is intermittent, inspect transmission control linkage for binding or damage. Repair linkage before adjusting transmission neutral. 4. Have someone activate seat safety switch, or use a jumper wire to bypass the seat switch. 5. Start engine and run at low idle. Power Train - Hydrostatic Tests and Adjustments - 271 POWER TRAIN - HYDROSTATIC TESTS AND ADJUSTMENTS 6. With brakes disengaged, turn eccentric nut (C) forward and backward until rear wheels stop turning. 7. Tighten lock nut. Make sure adjustment did not change. If adjustment changes, use wrench from rear of machine to tighten lock nut. B A 8. Depress both forward and reverse speed pedals then release to verify adjustment. Repeat adjustment as necessary. C D 9. Lower machine to the ground. Remove seat switch jumper wire if used. Results: E • If neutral will not hold, turn eccentric 180° and repeat adjustment. • If drive wheels continue to rotate, check for worn or binding control linkage. Disconnect linkage and repeat adjustment. MX14384 • Wheels rotate after adjustment with control linkage disconnected. Check swash plate shaft bushing for binding or wear. Check neutral return spring, pump and motor valve plate wear. F c from Caution: Avoid Injury! Remove jumper wire seat switch if installed. G H I Transaxle Control Linkage Adjustment J Reason: To insure transmission returns to neutral and control pedals are locked in neutral when brake is set. K Procedure: N 1. Park machine safely. 2. Check transmission neutral adjustment and readjust if not correct. See “Transaxle Neutral Adjustment” on page 271. M L MX14163 3. Press brake pedal (A) and pull up on lever (B) to set parking brake. Be sure that brake pin (C) on brake shaft is in latch (D) and forward shaft (H) pin (N) aligns in slot (E). 4. Press forward (F) and reverse (G) pedals and check for movement. Pedals should remain locked in position. 5. Remove spring pin holding pivot onto forward shaft (H), and loosen jam nuts (M) on pivot (I), until pivot can be moved freely into slot on forward shaft (H). 6. Tighten jam nuts (M) on brake rod (K) to pivot (I), making sure leaf spring (J) is positioned correctly to press against RIO switch (L). Power Train - Hydrostatic Tests and Adjustments - 272 POWER TRAIN - HYDROSTATIC TESTS AND ADJUSTMENTS Transaxle Linkage Full Forward Adjustment Reason: To set forward pedal height to insure maximum forward speed. Procedure: • If reverse pedal (D) is not within specifications, loosen nuts (C) and move slotted front side of pedal up or down as needed. Tighten nuts. Cruise Control Linkage Check and Adjustment Reason: 1. Turn engine off. To ensure that cruise control will engage and disengage properly. First Procedure: 1. Put service-park brake in disengaged position, transaxle in neutral. A B A MX13638 2. Measure the distance (A) between the front side of forward pedal and top of pedestal and distance (B) between the front side reverse pedal and top of pedestal. Specifications: MX14396 Forward pedal to pedestal (A) . . . . . . 101.6 mm (4.0 in.) Reverse pedal to pedestal (B) . . . . . . 57.2 mm (2.25 in.) Results: 2. With engine not running, push down forward drive pedal and engage cruise control lever (A) in several locations and with forward pedal all the way down. Release cruise control lever. Results: • Drive pedal should remain in down position. D C E F MX14269 • If forward pedal (E) is not within specifications, loosen nuts (F) and move slotted front side (toward front of machine) of pedal up or down as needed. Tighten nuts. Power Train - Hydrostatic Tests and Adjustments - 273 POWER TRAIN - HYDROSTATIC TESTS AND ADJUSTMENTS Inspect linkage component for wear or damaged conditions. Replace as necessary. A F E B D C MX14163 A- Cruise Control Lever B- Control Rod C- Return Spring D- Cruise Control Stop E- Cruise Control Latch F- Cruise Control Disconnect Rod • If pedal will not stay engaged, check condition of teeth on cruise control latch (E) and stop (D). Replace if worn. Second Procedure: 1. Reset cruise control. 2. Engage service-park brake. Results: • Forward drive pedal should disengage. • If cruise control does not disengage, check hydrostatic control linkage adjustment or for a disconnected cruise control disconnect rod (F). Third Procedure: 1. Reset cruise control. 2. Tap forward pedal down and release. Results: • Cruise should disengage. • If cruise does not disengage check for binding pivots. Power Train - Hydrostatic Tests and Adjustments - 274 POWER TRAIN - HYDROSTATIC REPAIR Repair Foot Control Linkage Removal and Installation E A F C B D G H AR AT AS AQ B L AR I AO J AK K AP M N O AM AN AJ AK L AL AB AA Q AC AD Z AF R P X AE AF Y X AI S AD L X U W V R T AG U AH L Power Train - Hydrostatic Repair - 275 S POWER TRAIN - HYDROSTATIC REPAIR MX14417 A- Knob B- Spring Pin C- Washer D- Coupling E- Screw F- Rod, Cruise Control G- Plug H- Screw I- Seal J- Bushing K- Latch, Cruise Control L- Flange Nut M- Extension Spring N- Pad O- Pedal, Forward P- Flange Nut Q- Screw R- Screw S- Bracket T- Pad U- Pedal, Reverse V- Washer (6 used) W- Ball Bearing X- Bearing Support Y- Cotter Pin Z- Shaft, Forward AA- Carriage Bolt AB- Stop AC- Ball Bearing AD- Flange Nut AE- Washer AF- Carriage Bolt AG- Bracket (welded to frame) AH- Shaft, Reverse Pedal AI- Bearing Housing AJ- Arm, Transaxle AK- Spring Locking Pin AL- Rod, Control AM- Cap Screw AN- Strap AO- Switch, Stop AP- Lock Nut AQ- Leaf Spring AR- Nut AS- Pivot AT- Washer Removing: A F K AS AL AJ G M Z AK MX14163 1. Block machine wheels and release parking brake. Note: Remove cruise control linkage. Then, disassemble foot control linkage. 2. Remove extension spring (M) from forward shaft (Z) and cruise control latch (K). 3. Remove handle (A), and cotter pin holding cruise control rod (F) in position on machine. Lower rod assembly from under machine frame. 4. Remove spring locking pin (AK) and disconnect control rod (AL) from transaxle control arm (AJ). 5. To remove cruise control latch (K), remove plug (G) and cap screw/lock nut and associated parts holding it onto machine frame. 6. Remove spring locking pin and pivot (AS) from forward shaft (Z), and remove control rod (AL) and pivot from machine. Power Train - Hydrostatic Repair - 276 POWER TRAIN - HYDROSTATIC REPAIR 14.To remove bearing housing (AI), remove lock nut (AD), and inspect housing for wear or damage. Replace, as necessary. U Installing: P O S Z W S P AI L L Y AD S MX14269 7. Remove nuts (P) and bolts holding forward (O) and reverse (U) pedals onto brackets (S). Y X W V 8. Loosen nuts (L) and remove brackets (S) from both forward and reverse shafts. AG AH S AB MX14305 L W 1. After replacing all worn/damaged parts, install forward shaft (Z) and reverse shaft (AH) through welded frame bracket (AG). Z AC AD 2. Making sure all bearings (W) and supports (X and AI) are in place, install washer(s) (V) and cotter pins (Y) securing both forward and reverse shafts in place. AI Y S AD Y U X W V AH P AG S O S MX14305 9. Remove cotter pin (Y), washer(s) (V), and remove reverse (AH) and/or forward (Z) shaft. 10.Remove bearings (W), and inspect for damage or wear. Replace as necessary. 11.Bearing supports (X) are press fit into welded frame bracket (AG). If worn or damaged, replace. Press new support onto bracket. 12.To remove bearing (AC), remove lock nut (AD), and inspect bearing for wear or damage. Replace, as necessary. 13.To remove stop (AB), remove lock nut (L), and inspect stop for broken or worn teeth. Replace, as necessary. S L L P AD MX14269 3. Install brackets (S) onto forward and reverse shafts, and tighten nuts (L) securing brackets to shafts. 4. Install forward (O) and reverse (U) pedals onto brackets (S), and secure with nuts (P) and bolts. Power Train - Hydrostatic Repair - 277 POWER TRAIN - HYDROSTATIC REPAIR Shift Lever Linkage (MFWD) Removal and Installation A A B F C K AS D G E H AL F AJ G K J P I M Z M AK L O L N MX14163 5. Raise control rod (AL) into position, and secure pivot (AS) onto forward shaft (Z) with spring locking pin. 6. Raise control rod (AL) onto transaxle control arm (AJ), and secure with spring locking pin (AK). 7. Secure cruise control latch (K), with associated hardware, with cap screw and lock nut. Install plug (G). 8. Raise cruise control rod (F) into position, and secure onto end of cruise control latch (K) with cotter pin. Install handle (A). 9. Install extension spring (M) onto forward shaft (Z) and cruise control latch. 10.Set parking brake, and adjust foot control linkage. See “Transaxle Control Linkage Adjustment” on page 272. MX14347 A- Cap B- Lock Nut C- Knob D- Lever E- Torsion Spring F- Bolt G- Cap Screw H- Pivot I- Lock Nut J- Linkage K- Spring Locking Pin L- Washer (2 used) M- Stud N- Nut O- Lever P- Flange Nut 1. Pull off cap (A), and remove nut (B) and knob (C). 2. Remove fender deck. See “Fender Deck Removal and Installation” on page 459 in the Miscellaneous section. 3. Remove spring pin (K) and washer (L), and remove pin (M) from shift arm on hydrostatic transmission motor. 4. Remove lock nut (I), cap screw (G), and pivot (H) holding components to top of frame. 5. Disassemble components as necessary. Replace worn or defective parts and reassemble in reverse order. Power Train - Hydrostatic Repair - 278 POWER TRAIN - HYDROSTATIC REPAIR Oil Cooler Removal and Installation K N L A I J J O C M B H D G B E F MX14392 A- Selective Control Valve B- Fitting C- Hydraulic LIne D- Hose Clamp E- Clamp F- Screw G- Hydraulic LIne H- Hose I- Power Steering Control Valve J- Hose Clamp K- Oil Cooler L- Retainer M- Hose N- Hose Clamp O- Adapter Q P MX14393 1. Loosen and move clamp (D) slightly to remove hose (H) from hydraulic line (C), and drain transaxle (cooler) fluid into a clean container. 3. Remove side panel from instrument panel assembly, and pull handle (P) to remove screen (Q). 2. Loosen and move clamp (N) slightly to remove hose (M) from adapter (O) on transaxle, and drain transaxle (cooler) fluid into the same clean container as in step 1. Power Train - Hydrostatic Repair - 279 POWER TRAIN - HYDROSTATIC REPAIR Installation is done in the reverse order of removal. • If removed, tighten fittings on selective control valve (A) and power steering control valve (I) to specification. K R • Fill transaxle fluid up to appropriate level. Specifications: L Selective Control Valve Fittings . . . . . . 38 N•m (28 lb-ft) J M MX14394 4. Loosen and move clamps (J) on both sides of cooler and remove lines (M and H) from cooler (K). 5. Pull and turn fasteners (L) so that cooler assembly can be removed from radiator coolant frame (R). Control Arm and Damper Removal and Installation Note: Fuel tank can be removed for easier access to control arm and damper. A B D C J I E H E MX14183 A- Control Arm G F F B- Washer C- Main Cap Screw Power Train - Hydrostatic Repair - 280 POWER TRAIN - HYDROSTATIC REPAIR 4. Remove cap screw (C) and washer (B) from control arm. D- Foot Control Rod E- Spring Locking Pin F- Washer G- Damper H- Pivot Stud I- Clevis Pin J- Spring Locking Pin 5. Remove control arm. 6. Install control arm the same as removal, and install washer and cap screw. Tighten cap screw (C) to specification. 1. Remove spring locking pins (E) and washers (F) from both sides of damper (G). Note: If removed, use medium strength thread lock and sealer on pivot stud (H) threads. 7. Install damper with open end of clamp facing down. 2. Slide damper off of pivot stud (H) and clevis pin (I). Inspect and, if defective, replace damper as an assembly. 8. Install remaining washers and spring locking pins. 3. To remove control arm (A), remove spring locking pin (J) and disconnect foot control rod (D) from control arm. Specifications: Control Arm Cap Screw. . . . . . . . . . . . . 73 N•m (54 lb-ft) Note: Access to cap screw (C) is through hole in right frame. Differential Lock Linkage Inspection J I K C D E H G B A F MX14418 A- Pin B- Washer C- Rear Differential Lock Rod D- Differential Lock Arm E- Bushing F- Spring Locking Pin G- Torsion Spring H- Bushing I- Differential Lock Pedal Rod J- Knob K- Screw 1. Disassemble parts from differential lock linkage. 2. Inspect linkage components for wear or damaged conditions. Replace as necessary. 3. Install short leg of spring to the rear of arm. Power Train - Hydrostatic Repair - 281 POWER TRAIN - HYDROSTATIC REPAIR Charge Pump Removal and Installation Note: Approximate capacity of hydrostatic powertrain is 6.6L (7.0 qt) for two-wheel steering and 5.6L (6.0 qt) for all-wheel steering. 1. Remove fender deck. See “Fender Deck Removal and Installation” on page 459 in the Miscellaneous section. 2. Remove drain plug to drain oil from transaxle. 3. Remove drive shaft. See “Drive Shaft Removal and Installation” on page 285. • Tighten tube adapter (E) and adapter (B) to specification. • Tighten hose (A) to specification. Specifications: Short Cap Screws . . . . . . . . . . . . . . . . . 25 N•m (18 lb-ft) Long Cap Screw . . . . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft) Tube Adapter . . . . . . . . . . . . . 24 - 35 N•m (18 - 26 lb-ft) Hose . . . . . . . . . . . . . . . . . . . . 24 - 35 N•m (18 - 26 lb-ft) C B D A G E F G MX14308 4. Disconnect hose (A) and loosen clamp for hose (F) from pump housing (C). 5. Remove tube adapter (E) and adapter (B). 6. Remove two short (G) and one long (D) cap screw. Important: Avoid Damage! Do not drop pump gerotor (H) or lose key (I). Damage to machined surfaces will cause poor performance and premature failure. H I M81188 Installation is done in the reverse order of removal. • Tighten two short cap screws (G) to specification. • Tighten long cap screw (D) to specification. Power Train - Hydrostatic Repair - 282 POWER TRAIN - HYDROSTATIC REPAIR Charge Pump Disassembly and Assembly A G B F C E H D Y I X J W K L M V N L S R J T O U Q P MX14321 A- Cap Screw (2 used), M10 x 65 B- Plug C- O-Ring D- Pump Body E- Pressure Valve F- Spring G- O-Ring H- Plug I- Shims J- Pin K- O-Ring L- O-Ring M- O-Ring N- Outer Rotor O- Key P- Inner Rotor Q- O-Ring R- Plug S- Reducing Valve T- Spring U- Reducing Plug V- O-Ring W- Bushing X- Seal Y- Cap Screw, M10 x 105 Note: Charge pressure control valve and pressure reducing valve can be removed when the charge pump is in the machine. To inspect valve seats and bores, the pump must be removed. 1. Disassemble all parts of charge pump (D). 2. Inspect O-rings (C, K, L, M, and Q) for cuts or damage. Replace as necessary. Note: Pump gerotor (N and P), seal (X), body (D), and pressure reducing valve (S) parts must be replaced as a set. 3. Inspect gerotor charge pump parts (N- P). Replace parts if worn, chipped, scored or damaged. 4. Remove plug (U) to remove pressure reducing valve parts (V, S, and T). 5. Inspect parts for scoring, wear or damage. 6. Check small orifice in reducing valve (S) spool for obstruction. 7. Replace parts if necessary. 8. Remove plug (H) to remove charge pressure relief valve parts (E, F, G, and I). 9. Inspect parts for scoring, wear or damage. 10.Replace parts if necessary. Power Train - Hydrostatic Repair - 283 POWER TRAIN - HYDROSTATIC REPAIR 11.Inspect seal (X) and bushing (W) for wear or damage. 12.If bushing is removed, apply clean hydraulic oil to bushing and use a disk driver to install bushing to bottom of bore. C- Forward Control Valve D- O-Ring E- Backup Ring F- O-Ring 13.If seal is replaced, apply clean hydraulic oil to new seal. Install seal with open side into pump body. Push seal to bottom of bore. 1. Disassemble parts from directional control valves. 14.Apply clean hydraulic oil to all machined surfaces before assembly. 3. Plunger pin must move freely. 2. Inspect O-rings and backup rings for damage. 4. Internal valve must move freely when valve is shaken. 5. Make sure orifice and all passages are free of any obstruction. Directional Control Valves Removal: 1. Remove fuel tank. See “Fuel Tank Removal and Installation” on page 460 in the Miscellaneous section. Important: Avoid Damage! The reverse control valve must be installed in the left port. The control valve can be identified by a small orifice drilled into a land between the two sets of valve passageways. 6. Assemble parts. A Hydrostatic Pressure Relief Valve (45 Loader) Installation B M81180 2. Remove free-wheeling control lever (A). 3. Remove directional control valves (B). Installation: • Installation is done in the reverse order of removal. Specification: Important: Avoid Damage! The 45 loader is shipped complete with a hydrostatic pressure relief valve which must be installed in place of the transaxle’s forward control valve. The relief valve limits the peak hydrostatic pressures in the transaxle. This protects the transaxle from unnecessary stress for longer life. Operation of a front end loader on a machine without the transaxle hydrostatic pressure relief valve will void the machine warranty. If a 45 loader is taken off one machine and used on another, or another brand of loader is used, it is important that the loader machine be equipped with the transaxle relief valve. Directional Control Valves . . . . . . . . . . 35 N•m (26 lb-ft) Disassembly, Inspection and Assembly: A B A C D D E M81183 E F M81181ae A- Reverse Control Valve (with orifice) B- Orifice 1. Remove forward control valve and replace with hydrostatic pressure relief valve (A). 2. Tighten valve to specification. Power Train - Hydrostatic Repair - 284 POWER TRAIN - HYDROSTATIC REPAIR Specification: Disassembly, Inspection and Assembly: Pressure Relief Valve . . . . . . . . . . . . . . 35 N•m (26 lb-ft) A Drive Shaft Removal and Installation E Removing: 1. Remove fuel tank. See “Fuel Tank Removal and Installation” on page 460 in the Miscellaneous section. B B A D C M81172ae MX35901 2. Loosen cap screw (A). A- Cap Screws (2 used) B- Drive Shaft C- Cap Screws (3 used) D- Isolator E- Lube Fitting 1. Disassemble drive shaft. 2. Inspect U-joint for wear. 3. Inspect isolator for cracks or wear. B 4. Install isolator with bosses toward drive shaft. 5. Assemble drive shaft. Installing: C 1. Install drive shaft from under frame and attach to transaxle pump shaft. M81174 3. Remove three cap screws (C) to remove drive shaft (B) from under machine frame. 2. Raise front of drive shaft to engine pulley and tighten cap screws (C) to specification. 3. Tighten cap screw (A) to specification. Specifications: Drive Shaft to Engine Pulley Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft) Drive Shaft to Transaxle Cap Screw . . . 35 N•m (26 lb-ft) Power Train - Hydrostatic Repair - 285 POWER TRAIN - HYDROSTATIC REPAIR PTO Solenoid Valve 7. Place wave washer in case cover. Removal and Installation: Disassembly, Inspection and Assembly: Important: Avoid Damage! Do not bend, twist or damage solenoid armature. Do not damage machined surfaces or sharp edges of spool or sleeve. PTO will not function or will function erratically if spool, sleeve or armature is damaged. Note: Sleeve and spool must be replaced as a set. Important: Avoid Damage! Be sure large land (H) on sleeve and oil hole in spool are facing away from PTO case cover. A D B E C F F J H G I A M78316a M55442 1. Disconnect solenoid connector (F) from wiring harness. 2. Remove nut (A) and O-ring (B). A- Wave Washer B- Spool C- Sleeve D- O-Ring E- Flats F- Solenoid Armature G- Gasket H- Large Land on Sleeve I- Oil Hole J- Spring 1. Disassemble PTO solenoid valve. 2. Inspect parts for wear or damage. 3. Install spool into sleeve so the end with the oil hole is toward the large land on the sleeve. 4. Place spring into recess in end of spool. M81115a Picture Note: NOTE: Nut (A) and O-ring (B) were already removed in step 2. 5. Install sleeve assembly so smaller lands go into the PTO cover first. 6. Install gasket and O-ring. 3. Remove solenoid cover (C), O-ring (D), and solenoid coil (E). Note order and direction of valve components for reassembly. 4. Remove solenoid armature assembly using JDG757A Solenoid Valve Socket (N). 5. Carefully remove valve components from PTO cover. Note: Check bottom of bore for “wave” washer. 6. Clean and inspect parts for damage. Replace if necessary. Power Train - Hydrostatic Repair - 286 POWER TRAIN - HYDROSTATIC REPAIR PTO Relief Valve Removal and Installation F A K M81189a M81123 7. Use JDG757A Solenoid Valve Socket (K) to tighten solenoid armature (A) to specification. 1. Remove relief valve plug. 2. Install relief valve plug (A) and tighten to specification. Specifications: Solenoid Valve Armature. . . . . . . . . . 22 N•m (195 lb-in.) Valve Coil Plastic Nut. . . . . . . . . . . . . 4.9 N•m (43 lb-in.) Relief Valve Plug . . . . . . . . . . . . . . . . . . 25 N•m (19 lb-ft) L PTO Relief Valve Disassembly, Inspection and Assembly M N M78310 8. Slide solenoid coil (N) onto solenoid armature. Install Oring (L) and plastic nut (M) (do not tighten plastic nut at this time.) A B C D M78309 P 1. Disassemble PTO relief valve. 2. Check relief valve plunger and bore for scoring, nicks or burrs. Replace if necessary. 3. Install spring (B), gasket (C), relief valve plunger (A), and plug (D) in PTO cover. O M55442 9. Position solenoid coil wire leads (P) to the right and approximately 45° above horizontal. Important: Avoid Damage! When tightening plastic nut be sure to tighten nut to exact specifications. Nut has a very low torque. Any overtightening will damage the armature coil. 10.Tighten plastic nut (O) to specification. Power Train - Hydrostatic Repair - 287 POWER TRAIN - HYDROSTATIC REPAIR PTO Brake Removal and Installation Note: Approximate capacity of hydrostatic powertrain is 6.6 L (7.0 qt) for two-wheel steering and 5.7 L (6.0 qt) for all-wheel steering. c before Caution: Avoid Injury! Allow transaxle to cool draining fluid. Hot fluid can cause serious burns. B A C D MX35903 1. Remove plug to drain oil from transaxle. 2. Remove fuel tank (A). See “Fuel Tank Removal and Installation” on page 460 in the Miscellaneous section. 3. Remove hitch plate (D). Note: If rear PTO is installed, remove necessary rear PTO components before rear transaxle cover removal. See “Rear PTO Removal and Installation” on page 294. 4. Remove PTO solenoid harness (B) and rear transaxle cover (C). If optional rear PTO is installed (not shown above), remove rear PTO. See “Rear PTO Removal and Installation” on page 294. 5. Remove control arm damper, to gain access to three cap screws holding PTO brake cover to transaxle side cover. See “Control Arm and Damper Removal and Installation” on page 280. c spring Caution: Avoid Injury! PTO brake cover is loaded. Remove cap screws evenly to release spring force. 6. Installation is reverse of removal. Power Train - Hydrostatic Repair - 288 POWER TRAIN - HYDROSTATIC REPAIR PTO Brake Disassembly, Inspection and Assembly J K I F E B A G D H C D L M N MX14331 A- Collar, Brake Pin B- O-Ring C- Pin, PTO Brake D- Snap Ring (2 used) E- Piston F- Stopper G- Spring, Inner H- Spring, Middle I- Spring, Outer J- Cover K- Cap Screw (3 used) L- O-Ring M- PTO Brake Shoe N- PTO Clutch Assembly 2. Remove PTO clutch assembly (N) and brake shoe (M) together. Note: PTO brake pin, piston, springs, and O-Rings, etc., (parts C through I), must be replaced as a set. 3. Check pin and piston for burrs, scoring or wear. 4. Replace brake shoe if grooves in shoe contact surface are not visible. 5. Inspect O-rings for cuts or damage. 6. Inspect springs for cracks or damage. 7. Apply petroleum jelly to O-rings and seal on end of PTO clutch shaft. 8. Install piston assembly and clutch assembly. 9. Clean mating surface of cover and case. Be sure threaded holes are clean. 1. Carefully pull piston assembly from case using a pliers. Do not damage pin. 10.Apply a bead of John Deere Form-in-Place Gasket to cover mating surface. Power Train - Hydrostatic Repair - 289 POWER TRAIN - HYDROSTATIC REPAIR 1. Remove plug to drain oil from transaxle. Important: Avoid Damage! Be sure cover is aligned with transaxle case and installed within 3 mm (1/8 in.) of case before tightening cap screws. Major damage can occur to cover and/or case if cover is not installed properly before tightening cap screws. Q P Transaxle Cover Cap Screw Specifications: Used Transaxle Case . . . . . . . . . . . . . . 25 N•m (18 lb-ft) New Transaxle Case . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) R PTO Drive Train (Mid-PTO) Removal and Installation Note: Approximate capacity of hydrostatic powertrain is 6.6L (7.0 qt) for two-wheel steering and 5.6L (6.0 qt) for all-wheel steering. T S MX35903 Removing: 2. Remove fuel tank (P). 3. Remove hitch plate (S). c before Caution: Avoid Injury! Allow transaxle to cool draining fluid. Hot fluid can cause 4. Disconnect PTO solenoid harness (Q). 5. Remove rear transaxle cover (R) or transaxle cover plate (T). serious burns. E D A I C N B M O P I L F K G H J I MX16046 A- PTO Clutch Assembly B- Snap Ring C- Needle Bearing D- Washer E- Seal F- Needle Bearing G- Washer Power Train - Hydrostatic Repair - 290 POWER TRAIN - HYDROSTATIC REPAIR 8. Install transaxle drain plug. Refill transaxle with approximately 6.6L (7 qts) for two-wheel steer models and 5.6L (6 qts) for all-wheel steering models using JOHN DEERE LOW VISCOSITY HY-GARD™ (J20D as required) to cross-hatched area of dipstick. H- Cap Screw I- Ball Bearing J- Snap Ring K- Mid-Mount PTO Gear L- PTO Output Shaft M- Snap Ring N- PTO Idler Gear O- PTO Idler Shaft P- Washer Rear Cover Cap Screws Specifications: Used Transaxle Case . . . . . . . . . . . . . . . 25 N•m (18 lb-ft) New Transaxle Case. . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Internal Cap Screws. . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) 6. Remove PTO clutch assembly. Important: Avoid Damage! When removing snap ring (B), be sure not to lose needle bearing (C) or washers (D). 7. Remove PTO idler gear assembly. 8. Remove PTO gear. PTO Drive Train (Mid and Rear PTO) Removal and Installation Note: Approximate capacity of hydrostatic powertrain is 6.6L (7.0 qt) for two-wheel steering and 5.6L (6.0 qt) for all-wheel steering. Removing: 9. Left axle must be removed to remove PTO output shaft assembly. See “Rear Axle Assembly (Two Wheel Steer Models) Removal and Installation” on page 319. 10.Inspect ball bearings and needle bearing for smooth rotation. Note: Idler gear and shaft must be replaced as a set. c before Caution: Avoid Injury! Allow transaxle to cool draining fluid. Hot fluid can cause serious burns. 1. Remove plug to drain oil from transaxle. 11.Inspect gears and splines for missing or chipped teeth, wear or damage. Replace parts if necessary. W Installing: V 1. If replaced, install new needle bearing from inside case with bearing identification marks toward the inside of the case. Push bearing tight against shoulder in bore. 2. Install new seal with the open, spring side towards the inside of the case. X 3. Push seal against shoulder in bore. 4. Install mid-mount PTO gear so side with the longer center hub is towards bearing. 5. Clean mating surfaces of rear cover and case. Be sure threaded holes are clean and two O-rings are in position in rear cover. 6. Apply petroleum jelly to seal on shaft of PTO clutch assembly. 7. Apply a bead of John Deere Form-in-Place Gasket to cover mating surface. Important: Avoid Damage! Be sure cover is aligned with transaxle case and installed within 3 mm (1/8 in.) of case before tightening cap screws. Major damage can occur to cover and/or case if cover is not installed properly before tightening cap screws. Y AB AA AA Z MX14332 2. Remove fender deck and fuel tank (V). 3. Remove roll pin and rear PTO control rod (AB). 4. Remove rear PTO shield (X). 5. Remove hitch plate (Z). 6. Disconnect two PTO switch connectors (AA). 7. Remove rear PTO cover (Y). 8. Disconnect PTO solenoid harness (W). Power Train - Hydrostatic Repair - 291 POWER TRAIN - HYDROSTATIC REPAIR 9. Remove cap screws (AC) (9 used) to remove rear cover (AD). AC AD MX16048 A D S U B T E C P Q S R O N S M F G H L K J MX16047 A- PTO Clutch Assembly B- Snap Ring I C- Needle Bearing D- Washer E- Seal Power Train - Hydrostatic Repair - 292 POWER TRAIN - HYDROSTATIC REPAIR F- Snap Ring G- Spacer H- Ball Bearing I- Mid-Mount and Rear-Mount PTO Gear J- Needle Bearing K- Spline Collar L- Snap Ring M- Cap Screw (2 used) N- Washer O- Needle Bearing P- Washer Q- PTO Idler Shaft R- PTO Output Shaft S- Ball Bearing T- Snap Ring U- PTO Idler Gear 10.Remove PTO clutch assembly. Important: Avoid Damage! When removing snap ring (B), be sure not to lose needle bearing (C) or washers (D). 11.Remove PTO idler gear assembly. 12.Remove snap ring (L), spline collar (K), and remove mid-mount and rear-mount PTO gear assembly (I). 13.Left axle must be removed to remove PTO output shaft assembly. Inspect ball bearings and needle bearings for smooth rotation. 14.Inspect gears and splines for missing or chipped teeth, wear or damage. Replace parts if necessary. Installing: Important: Avoid Damage! Be careful not to get too much sealant in area of two upper O-rings in rear cover (AD). Sealant should be applied outside of the grooves surrounding each O-ring. DO NOT fill groove with sealant. Purpose of groove is to stop excess sealant from moving O-ring during reassembly. AC AD MX16048 1. Clean mating surfaces of rear cover (AD) and transaxle case. Be sure threaded holes are clean and two O-rings are in position in rear cover. 2. Apply petroleum jelly to seal on shaft of PTO clutch assembly. 3. Apply a bead of John Deere Form-in-Place Gasket to rear cover mating surface. Important: Avoid Damage! Be sure rear cover (AD) is aligned with transaxle case and installed within 4 mm (1/8 in.) of case before tightening cap screws (AC). Major damage can occur to cover and/or case if cover is not installed properly before tightening cap screws. 4. Carefully position the rear cover (AD) on the transaxle and onto the lower dowel pin. Use a pry bar between the PTO and frame to carefully move the PTO approximately 1.5 mm (1/16-in.) to the right to align the top of the cover with the upper dowel pin. Secure with cap screws (AC) (9 used). Rear Cover Cap Screw Torque Specifications: Used Transaxle Case . . . . . . . . . . . . . . . 25 N•m (18 lb-ft) New Transaxle Case. . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Internal Cap Screws. . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Power Train - Hydrostatic Repair - 293 POWER TRAIN - HYDROSTATIC REPAIR Rear PTO Removal and Installation W Note: Approximate capacity of hydrostatic powertrain is 6.6L (7.0 qt) for two-wheel steering and 5.6L (6.0 qt) for all-wheel steering. V Removing: c before Caution: Avoid Injury! Allow transaxle to cool draining fluid. Hot fluid can cause serious burns. X Y 1. Remove plug to drain oil from transaxle. AB AA Z AA MX14332 5. Apply a bead of John Deere Form-in-Place Gasket to PTO gear case (Y) mating surface. D 6. Shift PTO lever (AB) to the middle position. 7. Carefully position the PTO gear case assembly (Y) on the transaxle. Important: Avoid Damage! Be sure PTO gearbox cover (Y) is aligned with rear cover and installed within 4 mm (1/8 in.) of cover before tightening cap screws. Major damage can occur to both covers and transaxle case, if PTO cover is not installed properly before tightening cap screws. 8. Secure PTO to transaxle with cap screws. Rear PTO Gear Case Cap Screw Torque Specifications: Used Transaxle Case . . . . . . . . . . . . . . 25 N•m (18 lb-ft) New Transaxle Case . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) 9. Install shifter (AB), PTO shield (X), and hitch plate (Z). 10.Connect PTO switch connectors (AA). 11.Disconnect PTO solenoid harness (W). C E B F A H G H MX14332 2. Remove roll pin and rear PTO control rod (A). 3. Remove rear PTO shield (E). 4. Remove hitch plate (G). 5. Disconnect two PTO switch connectors (H). Note: Remember to install three different sized cap screws in original holes as removal. 6. Remove four M12 x 40 (D), two M8 x 110 (C), and three M8 x 50 (B) cap screws and PTO assembly (F). 12.Install transaxle drain plug. Refill transaxle with approximately 6.6L (7 qts) for two-wheel steer models and 5.6L (6 qts) for all-wheel steering models using JOHN DEERE LOW VISCOSITY HY-GARD™ (J20D as required) to cross-hatched area of dipstick. 13.Install any additional items removed prior to PTO. I J MX16048 Power Train - Hydrostatic Repair - 294 POWER TRAIN - HYDROSTATIC REPAIR 7. Remove snap ring (I) and drive gear set (J). Inspect parts and replace as necessary. 5. Inspect rear PTO case (C) components. Replace as necessary. Disassembly and Assembly: 6. Apply clean hydraulic oil to O-ring (D) before installation. 7. If shifter fork (N) was disassembled, install spring (O) and ball (P) in fork. While compressing ball and spring, install fork shaft (M). Be sure ball fits into grooves of shaft. C A 8. With fork groove of shift collar away from case, install shifter fork and collar. Be sure arm of shifter shaft (E) fits into slot of shifter fork. B Note: Install bearings with writing/numbers facing gears in cover assembly. Q E D F P O N R L M G AV MX16059 9. Remove bearing (Q) and bearing (R), noting markings on outer bearing races. I H U W V J L T S Q MX14325 1. Remove cover from PTO gear case (C). 2. Remove cap screw (A) and plate (B), and pull shifter shaft (E) from PTO gear case (C). Replace O-Ring (D). X Y R 3. Remove shift collar (F) and shifter fork (N) assembly together. 4. Remove tow relief valve (L) if necessary. Remove and replace O-rings (G through L). Note: If shift collar replacement is necessary, the rear PTO idler gear and rear PTO input gear (in the rear PTO cover) must be replaced also. The three gears are available as a set. Z AB AC AA AD MX16060 10.Remove rear PTO gear (S), and collar (T) from PTO shaft (U). Power Train - Hydrostatic Repair - 295 POWER TRAIN - HYDROSTATIC REPAIR Note: If rear PTO input gear (AB) replacement is necessary, the shift collar (F) (in the rear PTO case) and rear PTO idler gear (X) must be replaced also. The three gears are available as a set. Rear PTO gear (S) and rear PTO idler pinion (AC) must be replaced as a set. 11.Remove washer (AD), PTO idler pinion (AC), PTO input gear (AB). Remove idle shaft (AA), and bearing (Y) from cover. Press bearing from shaft. 12.Remove snap ring (Z), and PTO idler gear (X) from rear PTO shaft (V). 13.If necessary, remove ball switch (W) and O-Ring. M78313 • If removed, install O-rings and ball switches (W). DO NOT overtighten. Tighten to 34 N•m (25 lb-ft). Installing: 1. Clean mating surface of cover and gear case. Be sure threaded holes are clean. U AG W AF AE A AJ AH V B AI C MX16061 14.Remove snap ring (AE) and press bearing (AF) from PTO shaft (U). Inspect shaft for wear or damage, and replace if necessary. 15.Remove and replace oil seal (AG) from cover. Install new seal into cover with the closed side of the seal into the bore first. Use a disk driver to push seal to bottom of bore. Note: Recall writing/numbers on all outer bearing races, and install bearings in reverse order as removal. 16.Remove snap ring (AJ), and remove rear PTO input shaft (U) from cover. Remove bearing (AH) and large bearing (AI) from shaft. MX16048 2. If removed, install drive gear set (C) and snap ring (B). 3. Apply a bead of John Deere Form-in-Place Gasket to PTO cover to gear case, and gear case to transaxle (A) mating surfaces. Important: Avoid Damage! Carefully lower cover assembly onto case, making sure bearings fit into bores and gears mesh properly. Be sure cover is installed within 3 mm (1/8 in.) of case before tightening all cap screws to 25 N•m (18 lb-ft). Major damage can occur to cover and/or case if cover is not installed properly before tightening cap screws. 17.Inspect all parts and replace as necessary. Assembly is reverse order of disassembly. • Install bearings (AI and AH) on rear PTO input shaft (V) tight against shoulder. Power Train - Hydrostatic Repair - 296 POWER TRAIN - HYDROSTATIC REPAIR A G F H E B I D C K J K D E D MX14332 4. Install PTO assembly (I) on the two alignment bushings, and tighten four M12 x 40 (G), two M8 x 110 (F), and three M8 x 50 (E) cap screws to specification below. 5. Connect two PTO switch connectors (K). 6. Install rear PTO control rod (D), and roll pin. 7. Install rear PTO shield (H), and secure with four cap screws to specification below. MX14332 3. Remove fuel tank (A). See “Fuel Tank Removal and Installation” on page 460 in the Miscellaneous section. 4. If equipped, remove rear PTO shield (B), disconnect rear PTO control rod (C), and the two (2) PTO switch connectors (D). 5. Remove hitch plate (E). 8. Install hitch plate (J). 9. Install transaxle drain plug. Refill transaxle with approximately 6.6L (7 qts) for two-wheel steer models and 5.6L (6 qts) for all-wheel steering models using JOHN DEERE LOW VISCOSITY HY-GARD™ (J20D as required) to cross-hatched area of dipstick. F G Specifications: PTO Shield Cap Screws . . . . . . . . . . . . 54 N•m (40 lb-ft) M8 Bolts. . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (18 lb-ft) M12 Bolts. . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft) H Transaxle Removal and Installation MX35901 Removal: Note: Approximate capacity of hydrostatic powertrain is 6.6L (7.0 qt) for two-wheel steering and 5.6L (6.0 qt) for all-wheel steering. 6. Disconnect charge pump-to-steering valve hose (H) and oil cooler-to-charge pump hose (F). 7. Remove drive shaft (G) from transaxle. See “Drive Shaft Removal and Installation” on page 285. 1. Park machine safely, and disconnect negative battery cable. c before Caution: Avoid Injury! Allow transaxle to cool draining fluid. Hot fluid can cause serious burns. 2. Remove plug to drain oil from transaxle. Power Train - Hydrostatic Repair - 297 POWER TRAIN - HYDROSTATIC REPAIR M N I J MX35903 MX16087 13.Remove rear tires. 8. Disconnect brake linkage (I). 9. For AWS machines only, remove nut (J) and disconnect rear intermediate linkage. 14.Disconnect PTO solenoid connector (M). 15.Attach transaxle to a hoist. 16.Remove four cap screws (N) and lock nuts on both sides of transaxle, and carefully remove transaxle. 17.Repair transaxle as necessary. K Installation: Installation is done in the reverse order of removal. • Connect drive shaft while installing transaxle. • Tighten four transaxle mounting lock nuts to specification. Specifications: MX35903 10.Remove spring locking pin and washer, and disconnect differential lock linkage (K). Transaxle Mounting Lock Nuts . . . . . . . . . . . . . . . . . . . . . . . . 71 - 106 N•m (52 - 78 lb-ft) Differential Lock Shaft Disassembly and Assembly Disassembly: c compression. Caution: Avoid Injury! Springs are under Carefully remove roll pin and L release spring force slowly to prevent personal injury. MX16051 11.Disconnect foot control linkage (L). 12.Lift rear of machine, and install jack stands. Power Train - Hydrostatic Repair - 298 POWER TRAIN - HYDROSTATIC REPAIR G C D B F E C A A N H O M I L K J MX14317 A- Snap Ring (2 used) B- Spring C- Sleeve (2 used) D- Fork E- Shaft F- Spring G- Washer H- Roll Pin I- Shift Collar J- Cap Screw K- Plate L- Fulcrum, Differential Lock M- Washer N- Cotter Pin O- Seal 1. Remove roll pin (H), washer (G), and spring (F). 2. Remove snap rings (A), sleeves (C), spring (B), shaft (E), and fork (D). 3. Inspect shaft (E) and fork for wear or damage. Replace parts as necessary. Assembly: Assembly is reverse of disassembly. Note: Install long hub of fork towards transaxle. Power Train - Hydrostatic Repair - 299 POWER TRAIN - HYDROSTATIC REPAIR Differential (2-Wheel Drive) Disassembly and Assembly Disassembly: D C B G A I E J K F H J I L N O M MX14340 A- Ball Bearing B- Bevel Input Gear C- Final Pinion Shaft D- Ball Bearing E- Right Ball Bearing F- Final Gear G- Right Differential Gear H- Differential Carrier I- Pins (2 used) J- Pinion Gear (2 used) K- Left-Notched Differential Gear L- Differential Holder M- Cap Screws w/Washers (8 used) N- Differential Lock Collar O- Left Ball Bearing 1. Use a puller to remove left ball bearing from differential holder. 2. Inspect differential components. 3. Bearings must rotate free and smoothly. Replace as necessary. 4. Check differential components for wear or damage. If replacement is necessary, all parts must be replaced as set. 5. Inspect differential lock collar for wear or loose or sheared off pins. 6. Check differential holder (L) and carrier (H) for wear, cracks or damage. 7. Inspect final gear (F) for worn or damaged teeth. Note: Pinion gears (J) (2 used) and pins (I) (2 used) must be replaced as a set. Power Train - Hydrostatic Repair - 300 POWER TRAIN - HYDROSTATIC REPAIR 1. Install final gear on differential holder and carrier with the deeper offset of gear center away from the holder. Tighten eight differential cap screws (M) to specification. 8. Inspect ball bearings (A and D) for smooth rotation. Note: Final pinion shaft (C) and final gear (F) must be replaced as a set. Bevel input gear (B) and bevel input pinion (not shown) must be replaced as a set. 2. Install differential lock collar (N) and left bearing (O). Push bearing tight against shoulder of differential holder. 9. Check bevel input gear (B) and final pinion shaft (C) for worn or damaged condition. Replace parts as necessary. 3. Install remaining components. Specifications: Assembly: Differential Cap Screws . . . . . . . . . . . . . 88 N•m (65 lb-ft) Note: Use medium strength thread lock and sealer. Differential (MFWD) Disassembly and Assembly Disassembly: D C G i B A H J E L G F K J I M N O Q E P MX14341 A- Ball Bearing B- Bevel Input Gear C- Final Pinion Shaft D- Ball Bearing E- Ball Bearing (2 used) F- Differential Holder, Right G- Liner (2 used) H- Right Differential Gear I- Washer (2 used) J- Pinion Gear (2 used) K- Differential Pinion Shaft Power Train - Hydrostatic Repair - 301 POWER TRAIN - HYDROSTATIC REPAIR pinion shaft (K) must be replaced as a set. L- Left-Notched Differential Gear M- Final Gear N- Differential Holder, Left O- Washers (8 used) P- Cap Screws (8 used) Q- Differential Lock Collar 8. Inspect ball bearings (A and D) for smooth rotation. Note: Final pinion shaft (C) and final gear (M) must be replaced as a set. Bevel input gear (B) and bevel input pinion (not shown) must be replaced as a set. 1. Use a puller to remove ball bearings (E) from differential holders (F and N). 9. Check bevel input gear (B) and final pinion shaft (C) for worn or damaged condition. Replace parts as necessary. Assembly: 2. Inspect differential components. Note: Use medium strength thread lock and sealer. 3. Bearings must rotate free and smoothly. Replace as necessary. 4. Check differential components for wear or damage. If replacement is necessary, all parts must be replaced as a set. 5. Inspect differential lock collar for wear or loose or sheared off pins. 1. Install final gear on differential holder and carrier with the deeper offset of gear center away from the holder. Tighten eight differential cap screws (P) to specification. 2. Install differential lock collar (Q) and left and right bearings (E). Push bearing tight against shoulder of differential holder. 3. Install remaining components. 6. Check differential holders (F and N) and differential pinion shaft (K) for wear, cracks or damage. Specifications: 7. Inspect final gear (M) for worn or damaged teeth. Differential Cap Screws . . . . . . . . . . . . . 88 N•m (65 lb-ft) Note: Pinion gears (J), washers (I), and differential PTO Clutch Disassembly, Inspection and Assembly Disassembly: I H G F J E K D C B A L Q M R T S N P O Power Train - Hydrostatic Repair - 302 POWER TRAIN - HYDROSTATIC REPAIR M81113ae A- Ball Bearing B- Snap Ring C- Clutch Shaft D- Needle Bearing E- Washer F- O-Ring G- Piston H- Spring I- Washer J- Snap Ring K- Input Shaft Collar L- Snap Ring M- Thick Steel Plate N- Friction Plate O- Spring P- Pin Q- Steel Plate R- Clutch Gear/Hub S- Washer T- Seal Ring Transmission Gear Spacer (X) to compress spring (U) and washer (V) in a vise. Remove snap ring (W) and slowly release force of spring. 6. Remove remaining clutch parts. 7. Check bearings for smooth rotation. 8. Inspect clutch gear for worn or damaged teeth. 9. Check inner piston bore for scoring or wear. 10.Check steel plates for scoring, discoloration, warping or wear. 11.Replace worn or damaged springs. 12.Check input shaft collar for burrs, wear or damaged teeth or splines. 13.Check clutch pack wear. Assemble parts. 1. Remove PTO clutch assembly. See “PTO Brake Removal and Installation” on page 288. 2. Remove large snap ring (L) and thick steel plate (M). 3. Remove parts. Note: Friction plates, springs, steel plates and pins must be replaced as a set. 4. Replace clutch gear/hub if brake surface is badly scored or teeth are chipped or damaged. c force. Caution: Avoid Injury! Piston is under spring Use care during disassembly. M81186 14.Put clutch gear/hub on bench so steel and friction plates are against snap ring. Measure clearance between inner steel plate and bottom of clutch gear/hub. 15.If clearance measures 2.7 mm (0.106 in.) or more, replace PTO clutch plates. 16.Apply clean hydraulic oil to all parts. Assembly: U Assembly is done in the reverse order of disassembly. V W X M81124 5. Remove piston from clutch gear/hub. Use JDT39 Power Train - Hydrostatic Repair - 303 POWER TRAIN - HYDROSTATIC REPAIR MFWD Output Shaft Removal and Installation Removal: 1. Park machine safely, and remove negative battery cable. Note: Approximate capacity of hydrostatic powertrain is 6.6L (7.0 qt) for two-wheel steering and 5.6L (6.0 qt) for all-wheel steering. 1. Remove front wheel drive output shaft assembly from front wheel drive housing by driving assembly into housing from the front. Note: Front wheel drive output shaft has two spring loaded detent balls located under shift collar. Use care when removing shift collar from front wheel drive output shaft. Note that flat end of shift collar goes toward bearing. 2. Remove front drive shaft assembly. c before Caution: Avoid Injury! Allow transaxle to cool draining fluid. Hot fluid can cause H serious burns. 3. Drain transaxle. I B C A MX16020 D 2. Remove shift collar (I), detent balls, spring, and bearing (H) from front wheel drive output shaft. G F Note: Flat end of shift collar goes toward bearing. 3. Clean bearings in a suitable solvent. Dry with compressed air. E Important: Avoid Damage! DO NOT spin bearing using compressed air. Damage to bearing balls, cage, and races could result. MX16018 4. Remove spring pin (B) and washer, and remove end of linkage (A) off of shift arm (G). 5. Remove two long cap screws (C) and washers, cap screw (E) and washer, and three short cap screws (D) holding cover assembly (F) onto motor case. 4. Inspect bearings for discolored, burned, balls and/or races. Check balls and races for spalling or cracking. Roll bearing by hand to check for rough turning or excessive looseness or play between balls and races. Replace bearings as required. J Disassembly and Assembly: MX16034 5. Measure OD of bearing surface. If not within specifications, replace front wheel drive output shaft. 6. Measure ID of pilot hole. If not within specifications, replace front wheel drive output shaft. MX16019 7. Inspect sleeve (J) for wear. Replace, as necessary. Power Train - Hydrostatic Repair - 304 POWER TRAIN - HYDROSTATIC REPAIR 8. Inspect spines on front wheel drive output shaft and shift collar for damage. Replace as required. O M 9. Inspect groove in shift collar for scoring or damage. Replace as required. P Q N R Specifications: Front Wheel Drive Output Shaft: OD at Bearing . . . . . . . . . 24.98 - 25.0 mm (0.983 - 0.984 in.) ID Pilot Hole . . . . . . . . . . . 17 - 17.02 mm (0.669 - 0.670 in.) U T S MX16037 K 12.Use drift to drive out spring pin (S) and roll pin (T) securing pivot (U) to shaft. L 13.Slide shaft (R) from housing and pivot (U). 14.Replace O-Ring (Q) on shaft. 15.Remove washer (P) and inspect seal (O) for wear or damage. Replace, as necessary. 16.Measure shaft bore in housing. If not in specifications, replace housing. 17.Measure OD of shaft in bearing area. If not in specifications, replace shaft. MX16035 10.Slide bearing block (K) from pin (L) on shift arm. Replace if damaged or worn. M Specifications: Shaft OD . . . . . . . . . . . . . . . 16.93 - 17 mm (0.667 - 0.669 in.) Housing Shaft Bore ID . . . 17 - 17.043 mm (0.669 - 0.671 in.) Assembly and Installation: Assembly and installation of the front MFWD output assembly is carried out in reverse order of disassembly and removal. Replace the gasket, or use a thin bead of RTV silicone gasket maker between center case and front PTO output housing. N Tighten cap screws to specification. MX16036 11.Remove cap screw (M) securing keeper (N) to housing. Specification: Cap Screws. . . . . . . . . . . . 16 - 22 N•m (144 - 192 lb-in.) Power Train - Hydrostatic Repair - 305 POWER TRAIN - HYDROSTATIC REPAIR Hydrostatic Transmission 2-WD and MFWD Hydrostatic Transmission Removal: 1. Remove transaxle. See “Transaxle Removal and Installation” on page 297. 2. Remove charge pump. See “Charge Pump Removal and Installation” on page 282. Important: Avoid Damage! Do not drop or damage pump valve plate when removing center valve block assembly. Do not nick or scratch lapped or machined surfaces of the valve plates or cylinder block components. The slightest damage can cause poor performance. A B B C C M81104 Picture Note: 2-Wheel Drive Shown 1. Remove retaining ring (B), bevel input pinion (C), and ball bearing (A). 2. Inspect bearing for smooth rotation. Note: Bevel input pinion and bevel input gear must be replaced as a set. A 3. Check pinion for wear or damage. 4. Replace retaining ring if ring is distorted during removal. Hydrostatic Transmission Motor Disassembly and Assembly (2-Wheel Drive): M81182 Picture Note: 2-Wheel Drive Shown (MFWD similar) 3. Remove cap screws (A) and carefully remove center valve block (B) and motor assembly from transaxle. Important: Avoid Damage! Do not drop or damage motor valve plate when removing motor assembly. Do not nick or scratch lapped or machined surfaces of the valve plate or cylinder block components. The slightest damage can cause poor performance. 4. Replace gasket (C) if torn or damaged. Hydrostatic Transmission Motor Removal: Power Train - Hydrostatic Repair - 306 POWER TRAIN - HYDROSTATIC REPAIR B C D E G F I H A T J H S X J R Q W K P V N O N U MX14345 A- Cap Screw B- Seal Cap C- Snap Ring D- Snap Ring E- Washer F- Ball Bearing G- Motor Case H- Locating Sleeve (2 used) I- Motor Shaft J- Center Valve Block Assembly K- Locating Pin L- Motor Valve Plate M- Snap Ring N- Washer O- Spring P- Cylinder Block Q- Shim R- Piston Spring S- Piston T- Gasket U- Thick Thrust Plate M L V- Thrust Bearing W- Bushing X- Thin Thrust Plate 1. Remove two cap screws (A). Important: Avoid Damage! Keep pistons (S) matched with bore of cylinder block (P). Do not interchange motor pistons and valve plate (L) with pump pistons and valve plate. Pistons and cylinder blocks are a matched set. 2. Remove cylinder block assembly. Note: Motor rotating components must be replaced as a set. 3. Inspect rotating components: Note: Scoring is fine scratches or grooves cut into the highly machined surface. When the scratches can be detected by feel using a lead pencil or fingernail, the part must be replaced. 4. Check valve plate and cylinder block for grooves, scoring, discoloration or pitting. 5. Check for free movement of pistons in cylinder bore. Power Train - Hydrostatic Repair - 307 POWER TRAIN - HYDROSTATIC REPAIR 6. Check pistons for flat areas, scoring or discoloration. 11.Assemble parts in reverse order of removal. 7. Thrust bearing (V) must rotate freely. Note: Use petroleum jelly to hold valve plate in position. Note: Thin thrust plate (X), bushing (W) and motor case (G) must be replaced as a set. 8. Inspect thin thrust washer for wear or damage. Replace as necessary. Important: Avoid Damage! Do not damage ball bearing (F) when removing seal cap (B). 9. Remove seal cap (B) and snap ring (C) to remove shaft assembly components. 10.Inspect bushing (W), thrust bearing (V) and shaft (I) for wear or damage. Replace if necessary. Note: Apply John Deere Form-in-Place Gasket to outer edge of new seal cap. Install seal cap until cap is approximately 4 mm (5/32 in.) below surface of motor case. • Put motor valve plate (L) on center valve block. Make sure bronze surface is away from valve block and notch in valve plate fits on locating pin of valve block. Important: Avoid Damage! Pump and motor valve plates are not interchangeable. The pump valve plate has two leading grooves into two of the slotted ports. The motor valve plate (L) has no leading grooves. Note: Motor case will seem springy because the springs inside the cylinder block are being compressed. Hydrostatic Transmission Motor Disassembly and Assembly (MFWD): Apply clean hydraulic oil to all mating surfaces. B C D E G A F R H F Q V J P U O I N L T M L S MX14344 A- Cap Screw B- Snap Ring C- Snap Ring D- Ball Bearing E- Motor Case F- Locating Sleeve (2 used) G- Motor Shaft H- Center Valve Block Assembly I- Locating Pin J- Motor Valve Plate K- Snap Ring Power Train - Hydrostatic Repair - 308 K J POWER TRAIN - HYDROSTATIC REPAIR components. L- Washer M- Spring N- Cylinder Block O- Shim P- Piston Spring Q- Piston R- Gasket S- Thick Thrust Plate T- Thrust Bearing U- Bushing V- Thin Thrust Plate 11.Inspect bushing (U), thrust bearing (T) and shaft (G) for wear or damage. Replace if necessary. Note: Apply clean hydraulic oil to all mating surfaces. 12.Assemble parts in reverse order of removal. Note: Use petroleum jelly to hold valve plate in position. • Put motor valve plate (J) on center valve block. Make sure bronze surface is away from valve block and notch in valve plate fits on locating pin of valve block. 1. Remove front drive shaft assembly. See “Removal:” on page 304. Important: Avoid Damage! Do not drop or damage motor valve plate when removing motor assembly. Do not nick or scratch lapped or machined surfaces of the valve plate or cylinder block components. The slightest damage can cause poor performance. 2. Remove two cap screws (A). Important: Avoid Damage! Pump and motor valve plates are not interchangeable. The pump valve plate has two leading grooves into two of the slotted ports. The motor valve plate (J) has no leading grooves. Note: Motor case will seem springy because the springs inside the cylinder block are being compressed. Important: Avoid Damage! Keep pistons (Q) matched with bore of cylinder block (N). Do not interchange motor pistons and valve plate (J) with pump pistons and valve plate. Pistons and cylinder blocks are a matched set. 3. Remove cylinder block assembly. Note: Motor rotating components must be replaced as a set. 4. Inspect rotating components: Note: Scoring is fine scratches or grooves cut into the highly machined surface. When the scratches can be detected by feel using a lead pencil or fingernail, the part must be replaced. 5. Check valve plate and cylinder block for grooves, scoring, discoloration or pitting. 6. Check for free movement of pistons in cylinder bore. 7. Check pistons for flat areas, scoring or discoloration. 8. Thrust bearing (T) must rotate freely. Note: Thin thrust plate (V), bushing (U) and motor case (E) must be replaced as a set. 9. Inspect thin thrust plate (V) for wear or damage. Replace as necessary. Important: Avoid Damage! Do not damage ball bearing (D) when removing snap ring (B). 10.Remove snap ring (B) to remove shaft assembly Power Train - Hydrostatic Repair - 309 POWER TRAIN - HYDROSTATIC REPAIR Center Valve Block Disassembly and Assembly: S K J I L H M I G N H F O E P G D F Q E C R B D T C A B A AF W U V V X W AB Y AE AD AC Z MX14326 A- Holder B- Spring C- Ball D- Push Pin E- O-Ring F- Seal AA G- O-Ring H- Back-up Ring I- O-Ring J- Forward Check Valve K- Top Plug L- O-Ring M- O-Ring Power Train - Hydrostatic Repair - 310 POWER TRAIN - HYDROSTATIC REPAIR N- Washer O- Shim (0.5) P- Shim (0.2) Q- Spring R- Charge Pressure Relief Valve Plunger S- Reverse Check Valve T- Seat U- Center Valve Block V- Needle Bearing (2 used) W- Locating Pin (2 used) X- Pump Valve Plate Y- Anti-Cavitation Valve Body Z- Backup Ring AA- O-Ring AB- Ball AC- Ball Holder AD- Spring AE- Retainer AF- Motor Valve Plate Note: Remove motor assembly if necessary to inspect needle bearing. See “Hydrostatic Transmission Motor Removal:” on page 306. 1. Remove and inspect directional check valves. Important: Avoid Damage! The reverse check valve must be installed in the left port. The check valve can be identified by a small orifice drilled into a land between the two sets of valve passageways. 11.Replace center valve block if necessary. Note: Scoring is fine scratches or grooves cut into the highly machined surface. When the scratches can be detected by feel using a lead pencil or fingernail, the part must be replaced. 12.Inspect valve plate for grooves, scoring, discoloration or pitting. Important: Avoid Damage! Pump and motor valve plates are not interchangeable. The pump valve plate has two leading grooves into two of the slotted ports. The motor valve plate has no leading grooves. 13.Put pump valve plate on center valve block. Make sure bronze surface is away from valve block and notch in valve plate fits on locating pin of valve block. Note: Use petroleum jelly to hold valve plate in position. 14.Remove plug to inspect charge pressure relief valve parts. 15.Check plunger for nicks, wear or damage. 16.Inspect plunger seat in center valve block. Remove any obstructions and replace center valve block if seat is worn or damaged. Hydrostatic Transmission Motor Installation: Note: Replace retaining ring (D) if ring is distorted during removal. B 2. Replace locator pins if missing or damaged. 3. Inspect needle bearings for wear or damage. If bearings are replaced, install new bearings with the stamped end away from center valve block. 4. Push bearings into bore until end of bearing is approximately 3 mm (7/64 in.) above the surface of the valve block. A 5. Inspect anti-cavitation valve assemblies. Note: Screens may be located in bores of transaxle case. C D 6. Check suction screens for blockage. 7. Carefully pull anti-cavitation valve body from center valve block so as not to lose parts. 8. Replace parts as necessary. 9. Apply oil to O-rings and push assembly to bottom of bore. 10.Inspect center valve block where charge pump contacts block for scoring. E F M81104 Picture Note: 2-Wheel Drive Shown Power Train - Hydrostatic Repair - 311 POWER TRAIN - HYDROSTATIC REPAIR 1. Secure motor housing assembly (A) and gasket (F) to center valve block (B) and install ball bearing (C) and bevel input pinion (E). Secure with retaining ring (D). Hydrostatic Transmission Installation: Important: Avoid Damage! Do not drop or damage pump valve plate when removing center valve block assembly. Do not nick or scratch lapped or machined surfaces of the valve plates or cylinder block components. The slightest damage can cause poor performance. B C A M81182 Picture Note: 2-Wheel Drive Shown (MFWD similar) 1. Install gasket (C). 2. Install center valve block (B) and motor assembly to transaxle housing and secure with cap screws (A). Specifications: Mounting Cap Screws . . . . . . . . . . . . . 39 N•m (29 lb-ft) 3. Install charge pump. See “Charge Pump Removal and Installation” on page 282. 4. Install transaxle. See “Transaxle Removal and Installation” on page 297. Power Train - Hydrostatic Repair - 312 POWER TRAIN - HYDROSTATIC REPAIR Hydrostatic Pump Inspection A B C D E F G H I J MX16066 A- Washer B- Piston Spring (7 used) C- Snap Ring D- Cylinder Block E- Washer F- Spring G- Piston (7 used) H- Thick Thrust Plate I- Thrust Bearing J- Thin Thrust Plate Note: Pump rotating components must be replaced as a set. Thin thrust plate must be replaced as a set with the pump swash plate and bushing. 3. Check cylinder block for grooves, scoring, discoloration or pitting. Note: Scoring is fine scratches or grooves cut into the highly machined surface. When the scratches can be detected by feel using a lead pencil or fingernail, the part must be replaced. 4. Check for free movement of pistons in cylinder bores. Important: Avoid Damage! Keep pistons matched with bore of cylinder block. Do not interchange motor pistons and valve plate with pump pistons and valve plate. Pistons and cylinder blocks are a matched set. 5. Check pistons for flat areas, scoring or discoloration. Thrust bearing must rotate freely. For inspection of pump valve plate, refer to “Center Valve Block Disassembly and Assembly:” on page 310. 1. Spring is compressed. Apply an external force to compress spring farther before removing snap ring. Then slowly remove external force. 2. Remove parts from transaxle as necessary. Power Train - Hydrostatic Repair - 313 POWER TRAIN - HYDROSTATIC REPAIR Transaxle Disassembly 1. For AWS models, remove rear steering linkage. See “Rear Steering Linkage - All Wheel Steering” on page 383 in the Steering section. A B 2. Remove control arm damper. See “Control Arm and Damper Removal and Installation” on page 280. 3. Remove hydrostatic transmission and pump. See “Hydrostatic Transmission 2-WD and MFWD” on page 306. 4. Remove axle housings. See “Rear Axle Assembly (Two Wheel Steer Models) Removal and Installation” on page 319, and “Rear Axle Assembly (Two Wheel Steer Models) Disassembly and Assembly” on page 319, or “Rear Axle Assembly (All Wheel Steer) Disassembly and Assembly” on page 322. C 5. Remove brakes. See “Brakes Removal and Installation” on page 401 in the Brakes section. D A E M81089 Picture Note: With Rear PTO Option B 6. Remove PTO idler shaft assembly (C), snap ring (E), PTO gear (D) (or rear drive gear set). 7. Remove PTO brake shoe (B) and clutch (A). See “PTO Brake Removal and Installation” on page 288. C G H E I J F M D L M81088 K Picture Note: Without Rear PTO option MX16068 Power Train - Hydrostatic Repair - 314 POWER TRAIN - HYDROSTATIC REPAIR 8. Remove large snap ring (H) and input shaft assembly. 9. Remove large snap ring (L), small snap rings (G and K), washers (M and J), and ball bearing (I) from input shaft (F). N P O M81095 10.Lay transaxle on left side and remove sixteen (16) cap screws (N) attaching right cover assembly (O). Important: Avoid Damage! Bearing, washer and differential pinion located on top of differential assembly are loose. Do not drop or lose parts. M98231 11.Remove final pinion shaft ball bearing. Bearing may remain in cover assembly. 12.Lift final gear and differential assembly and differential lock shaft (P) from transaxle case together as an assembly. 13.Remove final pinion shaft assembly. Power Train - Hydrostatic Repair - 315 POWER TRAIN - HYDROSTATIC REPAIR Transaxle (Right Cover) Disassembly and Assembly G F E H I A B J K C L D B M A Q P N O MX16069 A- Swash Plate Bearing B- Washer C- Bushing D- Spring E- Cover F- Snap Ring G- Washer H- Cap Screw I- Washer J- Control Arm K- Nut L- Washer M- Pivot Stud N- O-Ring O- Eccentric Adjust Fulcrum P- Swash Plate Q- Fulcrum Cap Screw 3. Inspect transaxle cover components. 4. Check bushing, bearing and swash plate contact surfaces for wear or damage. Replace as necessary. 5. Inspect O-rings on swash plate and eccentric adjust fulcrum for cuts or damage. 6. Install spring so legs are crossed and each leg of spring fits into a groove of the fulcrum cap screw. 7. If swash plate bearing was removed, install new bearing until end of bearing is even with the inside surface of the cover. 8. Put petroleum jelly on all O-rings. Install swash plate assembly and remaining components. Note: Use medium strength thread lock and sealer. 1. Remove snap ring, nut and washers. 2. Pull swash plate from cover. Note: Pump swash plate, bushing, and thin thrust plate must be replaced as a set. Power Train - Hydrostatic Repair - 316 POWER TRAIN - HYDROSTATIC REPAIR Transaxle Case Inspection F B E A G M81099 M81097 7. Inspect PTO brake pin sleeve (E) for scoring or damage. Replace if necessary. 1. Remove front PTO shaft seal (B). 2. Inspect needle bearing (A) for wear or damage. Remove if necessary. Install new needle bearing from inside case with bearing identification marks toward the inside of the case. Push bearing tight against shoulder in bore. 8. Push sleeve out from inside of case. 9. Install new sleeve into case until flange of sleeve is tight against case. 3. Install new seal with the open, spring side towards the inside of the case. 10.Inspect swash plate bearing (G) for wear or damage. Replace if necessary. 4. Push seal against shoulder in bore. 11.Install new bearing using a disk driver. Push bearing to bottom of bore. 12.Inspect vent cap (F) for damage or obstructions. Replace as necessary. C Transaxle Assembly D A M81098 5. Replace differential lock shaft seal (C). Note: Differential lock plate (D) may have to be removed to install new seal. 6. Install new seal with the open, spring side towards inside of case. Push seal tight against bottom of bore. M98231 1. Apply clean hydraulic oil to all internal components. 2. Install final pinion shaft assembly (A) into transaxle case with bevel gear end in first. Power Train - Hydrostatic Repair - 317 POWER TRAIN - HYDROSTATIC REPAIR Important: Avoid Damage! Bearing and washer on top of differential assembly are loose. Do not drop or lose parts. D 3. Put fork of differential lock shaft into groove of collar on differential assembly. Install differential assembly and differential lock shaft together into transaxle case. 4. Install ball bearing. E C F H G M81088 Picture Note: Without Rear PTO Option D E B M81095 5. Apply a bead of John Deere Form-in-Place Gasket to mating surface of transaxle case. 6. Carefully lower right transaxle cover assembly (B) onto case while making sure bearings and shafts fit into bores properly. Make sure washer on swash plate does not fall out of position. Secure with sixteen (16) cap screws (C), and tighten to specification below. F Transaxle Case Cap Screw Torque Specifications: Used Transaxle Case . . . . . . . . . . . . . . 25 N•m (18 lb-ft) G New Transaxle Case . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) 7. Assemble bearing, washers and snap rings on input shaft. 8. Install input shaft assembly and large snap ring. H M81089 Picture Note: With Rear PTO Option Power Train - Hydrostatic Repair - 318 POWER TRAIN - HYDROSTATIC REPAIR 9. Install PTO brake shoe (E) and PTO clutch assembly (D). See “PTO Brake Removal and Installation” on page 288. 10.Install PTO idler shaft assembly (F), PTO gear (G) (or rear PTO gear on rear PTO option machines), and snap ring (H). 11.Install PTO drive train. See “PTO Drive Train (Mid and Rear PTO) Removal and Installation” on page 291. 12.Install brakes. See “Brakes Removal and Installation” on page 401 in the Brakes section. 13.Install axle housings. See “Rear Axle Assembly (Two Wheel Steer Models) Removal and Installation” on page 319. 14.Install hydrostatic transmission and pump. 15.Install control arm damper. See “Control Arm and Damper Removal and Installation” on page 280. 16.For AWS models, install rear steering linkage. See “Rear Steering Linkage- Installation” in the Steering section. Rear Axle Assembly (Two Wheel Steer Models) Removal and Installation B- Sleeve C- Seal D- Ball Bearing E- Snap Ring F- Axle Housing G- Cap Screw (2 used) H- Lock Nut (2 used) I- Bushing (2 used) J- Cap Screw (6 used) K- Washer L- Shaft 3. Remove two bolts (G) and nuts (I) holding axle housing (H) to frame. Note: Note position of two locator bushings (J) when removing axle housing. 4. Remove six cap screws (K) holding axle housing to transaxle housing, and remove axle assembly. 5. Clean axle housing and transaxle mating surfaces. Apply a bead of John Deere Form-in-Place Gasket to mating surface. 6. Repeat for other side if necessary. Removal: Installation: 1. Loosen rear wheel lugs and raise rear of machine by the frame. Installation is done in the reverse order of removal. Rear Axle Assembly (Two Wheel Steer Models) Disassembly and Assembly 2. Remove lugs and rear wheel. G A F B E D C B A I K J H C L M81196 MX16043 A- Snap Ring 1. Remove large snap ring (C) from groove of axle housing (A). Power Train - Hydrostatic Repair - 319 POWER TRAIN - HYDROSTATIC REPAIR 2. Use a press to remove axle shaft (B) from axle housing. 3. Remove remaining snap ring to remove axle shaft components. 4. Inspect axle shaft and housing for wear or damage. Replace parts as necessary. 5. Inspect bearing for smooth rotation. Replace if necessary. Note: Ball bearing is not pressed into housing. When placed in axle housing it may be loose. A clearance up to 0.38 mm (0.015 in.) is normal. D C 6. Install bearing, seal and snap ring into axle housing. Put spring-side of seal into housing first. E 7. Apply petroleum jelly to lips of seal and inner diameter of sleeve. 8. Install snap ring, washer and sleeve on axle shaft. Use a piece of pipe with a minimum inside diameter of 31 mm (13/16 in.) to push sleeve and washer tight against shoulder of shaft. Important: Avoid Damage! Do not use excessive force to install axle shaft. Axle housing may be cracked or damaged if too much force is used. MX14320 10.Install washer (E) and snap ring (C) on axle shaft. 11.Use a piece of pipe (D) with a minimum inside diameter of 31 mm (1-3/16 in.), maximum outer diameter of 43 mm (1-11/16 in.) and approximately 330 mm (13 in.) long to install snap ring. M81197 9. Install axle shaft assembly into axle housing using a press. Press shaft only until a rapid increase in pressure is noticed. Power Train - Hydrostatic Repair - 320 POWER TRAIN - HYDROSTATIC REPAIR Rear Axle Assembly (All Wheel Steer) Removal and Installation Removing: I A B H D G F E J K C L N P M O M L K I MX14233 A- Link Rod, Middle B- Bearing Housing C- Pivot Arm D- Left-Hand Axle E- Cap Screws F- Right-Hand Axle G- Axle Shaft H- Ball Bearing I- Drive Shaft, U-Joint J- Ball Bearing K- Case, Wheel Bearing L- Steering Arm M- Tie Rod (2) N- Cap, Pivot O- Pivot Plate P- Link Rod, Rear 1. Remove transaxle. See “Transaxle Removal and Installation” on page 297. 2. Remove left (D) and/or right (F) rear axle assemblies. Note: For AWS models, longer caps screws (E) are installed in the bottom three holes. 3. Clean axle housing and transaxle mating surfaces. 4. Repeat for other side if necessary. Installing: Note: Apply a bead of John Deere Form-in-Place Gasket to mating surfaces. Installation is done in the reverse order of removal. Note: For AWS models, remove rear steering linkage before removing transaxle. See “Rear Steering Linkage - All Wheel Steering” on page 383 in the Steering section. Power Train - Hydrostatic Repair - 321 POWER TRAIN - HYDROSTATIC REPAIR Rear Axle Assembly (All Wheel Steer) Disassembly and Assembly C D E F B A G K H J I M81121 1. Remove inner seal (C). 2. Remove large snap ring (D) to remove axle shaft (G) with ball bearing (F) and snap ring (E). Remove snap ring (E) if bearing or shaft must be replaced. 8. Install large snap ring. 9. Apply multi-purpose grease to lips of seal. Install seal so open, spring side of seal is towards bearing. Push seal against snap ring using a tube type driver. 3. Inspect axle components for cracks, wear or damage. Replace if necessary. 4. If bushing (A) and/or washer (B) was replaced, use a disk driver to install bushing until end of bushing is even with machined surface of axle housing (K). Apply multipurpose grease to inside diameter of bushing. 5. If ball bearing was replaced, push bearing to bottom of bore. 6. Install new lower king pin seal (I) with open side of seal away from ball bearing (J). Use a disk driver to push seal into bore until even with surface of axle housing. Apply multi-purpose grease to seal lips. Note: Do not lose locator sleeves (H) from axle housing. 7. Install axle shaft with bearing and snap ring in axle housing. Power Train - Hydrostatic Repair - 322 POWER TRAIN - HYDROSTATIC REPAIR Knuckle Assembly (All Wheel Steer) Removal and Installation C- Lubrication Fitting D- King Pin E- Knuckle Housing F- Seal G- Hub H- Washer I- Ring J- Cap K- Cap Screw L- Lock Washer B C A D E F 1. Remove upper and lower king pins. G 2. Pull knuckle housing from axle housing. H Installation is done in the reverse order of removal. I • Apply medium strength thread lock and sealer to threads of cap screws and washers. Specifications: L K J Mounting Cap Screws . . . . . . . . . . . . . . 54 N•m (40 lb-ft) M81120 • Apply multi-purpose grease to lube fitting until grease begins to appear at upper joint. A- Lock Washer B- Cap Screw Knuckle Housing Disassembly and Assembly B C D E A F G L H K J I M81122 Power Train - Hydrostatic Repair - 323 POWER TRAIN - HYDROSTATIC REPAIR 1. Remove seal cap (A), washer (B), snap ring (C) and Ujoint drive shaft (I). 2. Remove wheel hub (D) to disassemble remaining components. B 3. Inspect knuckle housing (E) components for cracks, wear or damage. Replace as necessary. Note: Inner ball bearing (F) is not press fit. 4. If inner ball bearing (F) was replaced, push new bearing to bottom of bore. Fill bearing and cavity with multipurpose grease. 5. Install snap ring (G). 6. Install bushing (K) against inner ball bearing (F). A C 7. Push outer ball bearing (J) tight against bushing (K). MX14359 Important: Avoid Damage! Open lip side of seal must face outward to prevent dust and moisture from getting into bearings. Push only on outer surface of seal. 8. Use a disk driver to push outer seal (L) (lip facing outward) into bore until even with the surface of knuckle housing (E). Important: Avoid Damage! Lip on seal must not be damaged or rolled over. 3. Drain the differential and remove drain plug (C) to drain either final drive housing. Note: Use a rubber hammer to loosen the cover (B). Do not force the cover off as damage may result. 4. Remove six cap screws (A). Remove the final drive cover (B) and hub shaft from the final drive housing. D 9. Use a disk driver to push inner seal (H) (seal lip facing outward) to bottom of bore. 10.Apply multi-purpose grease to seal lips. 11.Rotate wheel hub while installing into knuckle housing. Check while installing that seal lip is not rolled over. 12.Apply Dubois MPG-2 (M79292) grease (water repellent) to splines of U-joint drive shaft and slide into knuckle housing assembly. 13.Install remaining components. 14.Clean all threads of knuckle housing and cap screws with clean and cure primer. Final Drive Cover Removal and Installation (MFWD) Final Drive Cover Removal and Inspection: 1. Raise and safely support the front of the machine. 2. Remove the wheel and tire from the final drive requiring service. E MX14362 5. Remove the snap ring (E) from the hub shaft (D), and press hub shaft from the ring gear. Note: The oil wear sleeves in the front axle assembly are lined with rubber. Using heat to remove the sleeves will damage the rubber linings and will require replacement of the sleeves. Note: To service both of the front final drive assemblies, see “Front Wheel Removal and Installation” on page 462 in Miscellaneous section. Power Train - Hydrostatic Repair - 324 POWER TRAIN - HYDROSTATIC REPAIR F B H MX14364 MX14365 6. Inspect the oil seal wear sleeve (F) on the hub shaft for wear or damage. Inspect the seal, hub shaft, and cover. Replace any unserviceable parts. 8. Press the ring gear (H) from the inner race of the ball bearing inside the final drive cover (B). I J K G B MX14366 9. Remove the outer (I) and inner (J) snap rings on both sides of bearing (K), and press bearing out of final drive cover (B). Final Drive Cover Installation: MX14363 7. Remove the seal (G) from the cover. 1. Install the inner snap ring (J) onto the final drive cover (B). Press bearing (K) into housing and until it is seated against snap ring (J). Install second, outer snap ring (I) on the other side of bearing. Note: Use the correct puller and carefully remove and install the seal from the cover. Power Train - Hydrostatic Repair - 325 POWER TRAIN - HYDROSTATIC REPAIR D G E MX14362 MX14363 2. Install the seal (G) onto the cover. 4. Install the hub shaft (D) and snap ring (E). 5. Install the cover to the final drive case. Tighten six (6) cap screws in a cross pattern to specification. H Note: The final drives and axle housing fill very slowly. It may be necessary to open a drain plug to allow for a faster fill. BE CERTAIN to tighten the drain plug as soon as the gear lube reaches the drain hole. Allow the entire amount of gear lube to fill the housing. 6. Fill the housing with approved gear lube. Specifications: Final Drive Case Cover Cap Screws . . . . . . . . . . . . . . . . . . . . . 16 - 22 N•m (16 - 22 N•m (144 192 lb-in.) B MX14367 3. Press the ring gear (H) onto the inner race of the ball bearing inside the final drive cover (B). Final Drive Housing Removal and Installation - (MFWD) Removal and Inspection: C Note: Press the gear flush with the ball bearing inner race. DO NOT force the gear any further. B E D F G A H I J MX14359 Power Train - Hydrostatic Repair - 326 POWER TRAIN - HYDROSTATIC REPAIR 1. Drain the differential and final drive housing (I), and remove the final drive cover (J). See “Final Drive Cover Removal and Installation - (MFWD)” on page 324. N O 2. Remove cotter pin and castle nut (F) on machine tie rod (H) and remove tie rod from spindle arm (C). 3. Remove cotter pin and castle nut (E) and remove end of steering cylinder (G) from spindle arm (C). 4. Remove cap screw (B), long cap screw (D), and nuts/ washers (A). Remove the front spindle arm (C) from top spindle housing. 5. Remove seal and bearing from top of spindle housing, and, using a punch, tap top of drive shaft (M) to remove final drive housing assembly (I) from spindle housing. Q M P I MX14369 8. Remove snap ring (Q), washer (P), and bearing race (N), and inspect needle bearing (O) for wear or damage. If damaged, remove bearing and replace. R L K MX14368 6. Carefully remove collar (K), and seal (L) from final drive housing (I). Note: Note position of writing/numbers on bearings during removal and replace with same orientation. 7. Remove drive shaft (M) from final pinion and bearing seated in bottom of housing. MX14371 9. Remove the ring gear bearing (R) from the housing. 10.Inspect all the components of the final drive housing. Replace any unserviceable parts. Installation: 1. Press the ring gear bearing (R) into the housing. 2. With needle bearing (O) in place, install bearing and final pinion into bottom of final drive housing (I). Power Train - Hydrostatic Repair - 327 POWER TRAIN - HYDROSTATIC REPAIR 10.Install the housing cover (J). See “Final Drive Cover Installation:” on page 325. M Note: The final drives and axle housing fill very slowly. It may be necessary to open a drain plug to allow for a faster fill. BE CERTAIN to tighten the drain plug as soon as the gear lube reaches the drain hole. Allow the entire amount of gear lube to fill the housing. I 11.Fill the housing with approved gear lube. Spindle Housing - (MFWD) L Disassembly and Inspection: K 1. Remove the steering arm and final drive housing, along with spindle shaft. See “Final Drive Housing Removal and Installation - (MFWD)” on page 326. 2. Remove six cap screws holding spindle housing to differential housing. A MX14368 C 3. Seat bearing into bottom of housing, and press shaft (M) into bearing. B 4. Install seal (L) and collar (K) onto housing opening. 5. Raise assembly through spindle housing, while simultaneously orienting gear in spindle housing so final drive housing (I) mates fully with spindle housing. D 6. Install bearing and seal on top of spindle housing. F C B E E MX14372 3. Remove snap ring (C), washer (B), and bearing (D) from top of spindle housing (A). D 4. Remove gear (E) through the final drive opening of the housing. F G 5. Inspect the sleeve (F) on spindle housing for wear or damage. Replace as needed. A G H I J MX14359 7. Install the spindle arm (C) onto spindle housing. Secure assemblies with cap screw (B), long cap screw (D), and nuts/washers (A). 8. Install tie rod (H) onto end of spindle arm (C), and secure with castle nut (F) and cotter pin. 9. Install end of steering cylinder (G) onto arm of spindle, and secure with castle nut (E) and cotter pin. Power Train - Hydrostatic Repair - 328 MX14373 POWER TRAIN - HYDROSTATIC REPAIR 6. Inspect the steering arm and oil wear sleeve (G) for wear or damage. Replace as required. Assembly: 1. Remove nuts (C) and bolts. 2. Slide the drive shaft (A) toward the front of the machine, removing the rear drive shaft yoke from the differential drive shaft (B). 3. Slide drive shaft toward rear of machine to remove shaft from the differential input shaft. A C 4. Inspect all parts for wear or damage. Replace any unserviceable parts. B Note: The U-joint yokes are not serviced separately. If either yoke is damaged, replace the drive shaft. Installing: 1. Install front drive shaft yoke into differential input shaft as far forward as it will go. D E F MX14372 2. Slide rear drive shaft yoke onto differential drive shaft (B), until bolts can be installed. 1. Install bearing (D), washer (B), and snap ring (C) through top of spindle housing (A). 3. Install both bolts and tighten nuts (C). 2. Install gear (E) through the final drive opening of the housing, with the gear teeth facing toward the bottom of the spindle housing. Mechanical Front Wheel Drive Removal and Installation - (MFWD) 3. Install the spindle shaft, final drive housing, and steering arm. See “Final Drive Housing Removal and Installation (MFWD)” on page 326. Removal: Note: The final drives and axle housing fill very slowly. It may be necessary to open a drain plug to allow for a faster fill. BE CERTAIN to tighten the drain plug as soon as the gear lube reaches the drain hole. Allow the entire amount of gear lube to fill the housing. 2. Loosen front wheels and raise the front of the machine by the frame to allow front axle removal. 1. Remove the MFWD drive shaft. See “Drive Shaft Removal and Installation - (MFWD)” on page 329. 3. Remove both front wheels. A 4. Fill the housing with approved gear lube. Drive Shaft Removal and Installation (MFWD) Removing: B A B C D E C MX14359 4. Remove cotter pin and castle nut (B) from tie rod (D). Remove tie rod from steering arm (E). Repeat for other side of machine. 5. Remove cotter pin and castle nut (A) from steering cylinder (C) end. Remove steering cylinder end from steering arm. MX14379 Power Train - Hydrostatic Repair - 329 POWER TRAIN - HYDROSTATIC REPAIR A G F H B C D E C MX14359 MX16000 6. Remove the cotter pin and castle nut (H) from the steering cylinder end and lower cylinder (C), with hydraulic lines attached to cylinder. 7. Support the front axle (F) with a floor jack, and remove nut (G), washer, and bolt securing axle to frame. 8. Lower the axle from the frame with the floor jack. Set the axle on a workbench or blocks to drain and disassemble transaxle. Installation: 1. Set the axle on a floor jack beneath the machine. 2. Raise the axle into position. 5. Install steering cylinder (C) end to steering arm (E) and secure with castle nut (A) and cotter pin. 6. Install tie rod (D) to steering arm and secure with castle nut (B) and cotter pin. Repeat for other side of machine. 7. Install the tires. Tighten lugs to specification below. 8. Install the MFWD drive shaft. See “Drive Shaft Removal and Installation - (MFWD)” on page 329. 9. Lower the front of the machine. Note: The MFWD and axle housing fill very slowly. It may be necessary to open the drain plug to allow for a faster fill. BE CERTAIN to tighten the drain plug as soon as the gear lube reaches the drain hole. Allow the entire amount of gear lube to fill the housing. 10.Fill MFWD with approved gear lube. G Specifications: F Tire Lugs . . . . . . . . . . . . . . . . . . . . . . . . . 88 N•m (65 lb-ft) Tie Rod Ends . . . . . . . . . . . . . . . . . . . . . 53 N•m (39 lb-ft) H C MX16000 3. Slide the axle bolt through the frame and axle (F), and install washer and nut (G). 4. Raise steering cylinder (C) onto axle and secure with castle nut (H) and cotter pin. Power Train - Hydrostatic Repair - 330 POWER TRAIN - HYDROSTATIC REPAIR Differential Input Housing - (MFWD) 6. Remove the bearing (O) and transfer gear (M) from the input pinion shaft. Disassembly: Note: This procedure can be performed with the differential on the machine. Remove the drive shaft and follow the steps in this section. E 7. Remove the snap ring (P), the large bearing (L) and pinion drive shaft (K) from the differential housing (H). Note: Note location of writing/numbers on large bearing (L) during removal procedure. Assemble with writing/numbers toward transfer gear (M). 8. Remove the large bearing (L) from the input pinion shaft (K). 9. Remove cap screws (I) and separate right axle housing (J) from differential housing (H) (for installation procedure). D 10.Inspect all parts for wear or damage and replace as required. C B F A Assembly: E G MX16005 D 1. Remove the differential input drive housing (E). 2. Push the input shaft (C) out of the housing. 3. Remove bearing (A) and the transfer gear (B) from the input shaft. Note: Note location of writing/numbers on bearing (D) during removal procedure. Assemble with writing/ numbers toward transfer gear (B). B C A 4. Remove bearing (D) from input shaft (C). F G MX16005 5. Remove washer (G) and seal (F) from inside housing. 1. Invert the input housing (E) and install a new seal (F). Note: Note flange (N) on transfer gear (M), and install with flange toward the pinion drive shaft (K). 2. Place the transfer gear (B) and press the 2 bearings (A and D) onto the input shaft. 3. Place the thrust washer (G) on the upper bearing. 4. Install the input shaft (C) to the housing. The upper bearing must seat inside fully in the input housing. I H P K J L O N M MX16006 Power Train - Hydrostatic Repair - 331 POWER TRAIN - HYDROSTATIC REPAIR Front Axle Housing Disassembly and Assembly Disassembly/Inspection: I 1. Drain the differential and final drive housings, and remove the MFWD from the machine. See “Mechanical Front Wheel Drive Removal and Installation - (MFWD)” on page 329. H P J K B L O D A C N M E MX16006 L 5. Install the bearing (L) to the input pinion shaft (K), with writing/numbers facing the transfer gear (M). 6. Install the input pinion shaft (K) to the differential housing (H). J F K I 7. Install the large snap (P) ring to the differential housing. 8. Install transfer gear (M), with raised flange (N) towards input pinion shaft (K). O J G H MX16008 2. Separate the right axle housing (D) from the differential housing (B). M 3. Remove the bevel pinion gears (J), bevel pinion shaft (I) and bevel gear (K) from the left axle (C). K H 4. Remove the ring gear (G) and bevel gear (H) from right axle housing (D). 5. Remove O-Ring (L) from right axle housing. Note: Note any writing/numbers on bearings and assemble with correct orientation. MX16007 9. Install the upper bearing (O) to the input pinion shaft (K) until it contacts the splines of the input pinion shaft. Support the bottom of the input pinion shaft during installation. 10.Lubricate the bearings and gears. Seal the input housing. B 11.Install the input housing (I) to the differential housing (H). Note: The MFWD and axle housing fill very slowly. It may be necessary to open the drain plug to allow for a faster fill. BE CERTAIN to tighten the drain plug as soon as the gear lube reaches the drain hole. Allow the entire amount of gear lube to fill the housing. C M N O MX16009 12.Fill the housing with approved gear lube. Power Train - Hydrostatic Repair - 332 POWER TRAIN - HYDROSTATIC REPAIR 6. To remove right (F) and left (C) axles, remove spindle assemblies from axle housings. See “Spindle Housing (MFWD)” on page 328. Remove gear (M) and bearing (N) on outside of shafts (C and F). Remove bearing from gear. 7. Remove O-Ring (O) on both housing ends. 8. Remove the left axle (C) with inner bearing (A) from the differential housing (B). Remove bearing (A) from axle (C). 9. Remove the right axle inner bearing (E) and axle (F) from the right axle housing (D). 10.Inspect all parts for wear or damage. Replace as necessary. 3. Install bearing (N) onto gear (M), and install onto shaft (C) through differential housing (B). Repeat for right axle housing. 4. Install the inner axle bearing (E) to the right axle housing. 5. Install the bevel gear (K) to the left axle (C). 6. Install new O-Ring (L) onto right axle housing. 7. Install bevel gear (H) and ring gear (G) to the right axle. 8. Install the bevel pinion gears (J) to the bevel pinion shaft (I). 9. Install the bevel pinion shaft and gears to the differential. Assembly: Note: Be certain the differential gear assembly remains intact during this installation. Some adjustment may be required to mesh the gears so the housings will match up. 10.Install the right axle housing (D) to the differential housing (B). 11.Install spindle assemblies to axle housings. See “Spindle Housing - (MFWD)” on page 328. B C 12.Fill the housing with approved gear lube. O N M Note: The MFWD and axle housing fill very slowly. It may be necessary to open the drain plug to allow for a faster fill. BE CERTAIN to tighten the drain plug as soon as the gear lube reaches the drain hole. Allow the entire amount of gear lube to fill the housing. MX16009 1. Install new O-Ring (O) on both housing ends. B D A C E L J F K I J H G MX16008 2. Press bearing (A) onto shaft (C), and install shaft through differential housing (B). Power Train - Hydrostatic Repair - 333 POWER TRAIN - HYDROSTATIC REPAIR Power Train - Hydrostatic Repair - 334 HYDRAULICS TABLE OF CONTENTS Hydraulics Table of Contents Specifications ...............................................337 General Specifications ...............................337 Test and Adjustment Specifications ...........337 Repair Torque Specifications .....................338 Special or Essential Tools ..........................338 Other Materials...........................................338 Schematics....................................................339 Hydraulic Schematic - Power Train ............339 Component Location....................................340 Hydraulic System .......................................340 Operation and Diagnostics ..........................341 Hydraulic System .......................................341 Hydraulic Control Valve Operation Neutral........................................................342 Hydraulic Control Valve Operation - Raise.343 Hydraulic Control Valve Operation - Float..344 Hydraulic Control Valve Operation Regen.........................................................345 Lift Cylinder Shut-off Valve - Optional ........346 Hydraulic Diagnostics.................................346 Preliminary Hydraulic System Inspection ...349 Hydraulic System Tests..............................350 Tests and Adjustments ................................351 Hydraulic Oil Warm-Up Procedure .............351 Charge Pump Pressure and Flow Test at Couplers .....................................................351 Charge Pump Pressure Test......................352 Lift Cylinder Leakage Test..........................353 Control Valve Leakage Test .......................354 Repair.............................................................355 Lift Cylinder Removal and Installation ........355 Hydraulic Control Valve Removal and Installation ..................................................355 Hydraulic Control Valve..............................355 Hydraulic Control Levers and Linkage .......358 Hydraulics Table of Contents - 335 HYDRAULICS TABLE OF CONTENTS Hydraulics Table of Contents - 336 HYDRAULICS SPECIFICATIONS Specifications General Specifications Transaxle: Hydraulic Oil J20D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Low Viscosity HY-GARD Oil Capacity (Two-Wheel Steer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 L (7.0 qt) Oil Capacity (All-Wheel Steer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 L (6.0 qt) Hydraulic Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Use original John Deere filters Charge Pressure Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1958 kPa (284 psi) Charge Pump (Two-Wheel Drive): Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 cc/rev. Charge Pressure Relief Valve (Implement Pressure) (minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . 6371 kPa (924psi) Rated Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 L/m (4.5 gpm) Minimum Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 L/m (3.4 gpm) @ 3200 rpm Charge Pump (All-Wheel Drive): Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 cc/rev. Charge Pressure Relief Valve (Implement Pressure) (minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . 6371 kPa (924 psi) Rated Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.7 L/m (6.0 gpm) Minimum Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 L/m (4.5 gpm) @ 3200 rpm Hydraulic Control Valve: Leakage (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 cc/minute @ 6895 kPa (0.135 oz/minute @ 1000 psi) Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.635 cm (1/4 in.) ISO Hydraulic Lift Cylinder: Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.5 mm (2.5 in.) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.6 mm (4.0 in.) Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.4 mm (1.0 in.) Test and Adjustment Specifications Note: Make sure engine idle and wide-open throttle speeds are correct before performing any of the hydraulic tests. Charge (Implement) Pressure Relief (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6371 kPa (924 psi) Charge Pressure (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1958 kPa (284 psi) Lift Cylinder Leakage Test: Hydraulic Oil Temperature (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43°C (110°F) Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Slow idle Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No leakage Control Valve Leakage Test: Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Slow idle Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No more than a drip from “out” port of control valve Hydraulics Specifications - 337 HYDRAULICS SPECIFICATIONS Repair Torque Specifications Control Valve Mounting Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 16 N•m (8 - 12 lb-ft) End Cap Retaining Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (36 lb-in.) Spring Retainer Retaining Screw (Under End Cap). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (36 lb-in.) Detent Ball Retaining Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (36 lb-in.) Spool Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (36 lb-in.) Drain Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N•m (28 lb-ft) Lift Check Valves Cap Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (18 lb-ft) 90° Fitting to Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 - 49 N•m (24 - 36 lb-ft) Small Straight Fitting to Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 - 30 N•m (18 - 22 lb-ft) Large Straight Fitting to Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 - 49 N•m (24 - 36 lb-ft) Quick Couplers to Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 - 49 N•m (24 - 36 lb-ft) Special or Essential Tools Note: Order tools according to information given in the U.S. SERVICE-GARD™ Catalog or in the European Microfiche Tool Catalog (MTC). Special or Required Tools Tool Name Tool No. Tool Use Temperature Gauge JDG282 Used to measure hydraulic oil temperature. Quick Coupler AM102420 Used to connect pressure and flow test equipment. 9/16-18 M x 7/16-20 M 37° Orb JT031111 Used to connect pressure and flow test equipment. Hose JT03017 Used to connect pressure gauge to couplers during pressure tests. Pressure Gauge - 13790 kPa (2000 psi) JT03117 Used to measure hydraulic oil pressure. Consumer Products Hydraulic Fitting Kit JT01765 Used for Charge Pump Flow and Pressure Quick Test at Couplers. Flowmeter Kit JT05469 Used to measure flow rate of hydraulic oil. 1/4 Male Quick-Coupler AM102420 Used to connect flowmeter to work ports. Connector and 9/16-18 M 37° x 9/16-18 M Orb JT03216 Used to connect flowmeter to work ports. Coupler and 3/4” F NPT x 9/16-18 F 37° Orb Used to connect flowmeter to work ports. JT03342 Other Materials Other Material Part No. Part Name TY9370/ TY9477/#242 Loctite ® Products Thread Lock and Sealer (Medium Strength) AM132341 Control Valve Seal Kit AM100201 Load Check Valve Kit AM132340 Spool Spring Center Kit AM132338 Spool Detent Float Kit Part Use Used to seal threads on control valve screws, spool detent and small plugs. Hydraulics Specifications - 338 HYDRAULICS SCHEMATICS Schematics Hydraulic Schematic - Power Train X PTO Pressure Test Port PTO Shutoff Solenoid PTO Clutch 1469 kPa (213 psi) PTO Pressure Regulator Valve PTO Brake 6371 kPa (924 psi) Charge Pressure Relief Valve (Implement Pressure) Hydrostatic Variable Displacement Pump Charge Pump 19 L/minimum (0.5 gpm) Constant Anti-Cavitation Screen Pressure Reduction Valve Forward Directional Control Valve Test Port Charge Pressure Hydrostatic Fixed Displacement Motor 18 mL/rev (0.6 oz/rev) 18 mL/rev (0.6 oz/rev) Anti-Cavitation Check Valve 19588 kPa (284 psi) Reverse Directional Control Valve 2-WD 6 mL/rev (0.2 oz/rev) Charge Pressure Control Valve MFWD 8 mL/rev (0.27 oz/rev) Hydraulic Oil Filter Oil Cooler Hydraulic Control Valve Steering Valve Housing Auxiliary Control Spool Valve P T B T P Manual Steering Check Valve A Lift Cylinder Shutoff Valve (Option) B Steering Control Valve C D Lift Cylinder Lift Control Spool Valve Metering Pump R L Regen Kit Spool Extension (Option) Steering Cylinder MIF Hydraulics Schematics - 339 HYDRAULICS COMPONENT LOCATION Component Location Hydraulic System A C B D N K J M I L E F G A- Lift Cylinder B- Auxiliary Control Valve Lever C- Lift Control Valve Lever D- Oil Cooler E- Link Rods F- Hydraulic Couplers G- Hydraulic Control Valve H- Steering Cylinder I- Steering Valve J- MFWD Drive K- Hydrostatic Motor L- Charge Pump M- Oil Filter N- Transaxle Hydraulics Component Location - 340 H HYDRAULICS OPERATION AND DIAGNOSTICS Operation and Diagnostics pressure relief valve opens. The charge pressure relief valve opening pressure is the implement operation pressure. Hydraulic System Function: The hydraulic system provides fluid power to charge the hydrostatic pump and operate the power steering, lift cylinder and any optional auxiliary hydraulic attachments. System Operation: The hydraulic systems is an “open center” type system. In this type of system the charge pump provides a continuous flow of oil through a circuit that connects all of the controlling valves. If the valves are not operated, the flow of oil passes through the “open center” of each valve and then returns to the transmission case. In an open center circuit, the first controlling valve takes priority over the next valve downstream in the circuit. The charge pump draws hydraulic oil from the transaxle case, through the filter, then supplies a constant flow of oil to the steering valve and control valve. Return oil from the steering valve and hydraulic control valve is routed through the oil cooler then back to the transaxle case. The hydraulic control valve is controlled by two levers on the steering column. The top lever controls the lift spool that controls the flow of oil to and from the lift cylinder. The lower lever operates the auxiliary control spool valve, used to operate hydraulic implement equipment attached to the machine. An optional shutoff valve can be installed in the line running to the lift cylinder. When in the off position, the lift cylinder is blocked out of the system, allowing attachments requiring dual function controls to be operated without the deck or hitch moving up or down. See this section for operation, test and repair of the hydraulic control valve and charge pressure tests. See Power Train section for operation, test and repair of charge pump and valves. See Steering section for operation and test of the steering valve and cylinder. Hydraulic Pump and Motor Operation: The charge pump draws oil from the transaxle sump and provides charge oil to the center section. The charge pressure control valve maintains a minimum oil pressure, 1958 kPa (284 psi), in the center section. The charge pressure relief valve maintains sufficient system pressure, 6371 kPa (924 kPa) minimum, to operate implements. Charge oil in the transmission will open the closed loop check valve and enter the forward side of the closed loop when the reverse side has been pressurized by the hydrostatic pump. When the direction is reversed to provide forward direction, charge oil will then pressurize the reverse side of the closed loop. The variable displacement hydrostatic pump pressurizes the reverse side loop, causing the fixed displacement motor to rotate. The reverse directional check valve blocks the closed loop pressure oil from entering the charge circuit. The reverse directional check valve cartridge has a leak-off orifice. This orifice bleeds off a small amount of high pressure oil from the reserve closed loop back into the charge circuit. This provides for a wider neutral band to help prevent creep. This small leakage does not slow down reverse. Steering Valve Operation: The steering valve is an open center type valve. This valve consists of a self-centering fluid control valve (spool and sleeve) and a metering pump. The valve and pump are hydraulically and mechanically interconnected inside the valve. Pressure oil comes into the steering valve body at the inlet port from the charge pressure control valve. The oil then flows through inlet passage to a series of grooves, passages, and slots in the valve body, sleeve, and spool to come out the power beyond passage and power beyond port to go on to the lift system. The amount of oil that flows this way varies with the speed of the turn. All the oil will follow this path when the steering valve is in neutral. There will be some oil when a slow turn is made, and there will be less oil when a fast turn is made. No oil is available to the power beyond port when the steering is dead headed. When the valve is in neutral, the turn passages are closed. The oil in the steering cylinder and lines is trapped oil. The small amount of internal leakage oil will go out the return port as return oil back to the sump. If the implements or steering are not activated, the charge pump circulates oil through the steering control valve and the hydraulic control valve at or above the charge pressure control valve setting. When the steering and/or hydraulic control valves are activated, restrictions in the system cause the charge pressure to increase until the charge Hydraulics Operation and Diagnostics - 341 HYDRAULICS OPERATION AND DIAGNOSTICS Hydraulic Control Valve Operation - Neutral F B A B A D C C E T A P C D E I A B H D Charge Pressure Oil Return Oil C G Trapped Oil D MIF A- Return Springs B- Load Check Valve C- Auxiliary Spool D- Lift Spool E- Inlet F- Hydraulic Control Valve Housing G- Lift Cylinder H- Load Check Valve I- Outlet Port Location Function: The hydraulic control valve controls oil flow to the lift cylinder and the auxiliary hydraulic outlets (if equipped). When both spool valves are in the neutral position they block oil flow to the lift cylinder and to any attachments, holding them in the desired position. System Operation: open-center spools (the lift cylinder spool and the auxiliary spool). The lift spool (D) has three positions in the standard configuration, controlling the raising and lowering of the lift cylinder. It is spring-centered and is automatically returned to the neutral position when the lever is released. The fourth position is for the bucket regenerative function, which is available as a kit. See “Hydraulic Control Valve Operation - Regen” on page 345. When in the neutral position, charge oil passes through the “open center” passage and exits the valve housing at the “OUT” port. The auxiliary spool (C) is four-position, controlling the raise, lower, and neutral functions of the couplers connected to auxiliary equipment. It is springcentered and automatically returns to neutral, except when placed into the “float” position. See “Hydraulic Control Valve Operation - Float”. In neutral, the passages are blocked by the spools, there is no oil flow entering the work ports. No oil is allowed to enter or leave, hydraulically locking the lift cylinder or attached implement in position. The hydraulic control valve housing contains two separate, Hydraulics Operation and Diagnostics - 342 HYDRAULICS OPERATION AND DIAGNOSTICS Hydraulic Control Valve Operation - Raise B E A A F B A D C D F C T C P H A B Charge Pressure Oil Return Oil C G D D MIF A- Return Springs B- Load Check Valves C- Auxiliary Spool D- Lift Spool E- Hydraulic Control Valve Housing F- Inlet G- Lift Cylinder H- Load Check Valve Function: System Operation: As the control lever and linkage moves either of the spools toward the lift position, the open center passage is closed off, increasing inlet pressure at work port. When inlet pressure overcomes the pressure of the work port, and oil flow starts to move the load, the lift check valve opens. The lift check valve prevents the load from dropping before inlet pressure overcomes the load or if the hydraulic system should lose pressure. High pressure oil acting against the cylinder, makes the cylinder extend. The oil from the rod end of the cylinder returns though the work port to return oil and exits the control valve. Controls the flow of pressure oil to the piston side of lift cylinder and allows return oil from the cylinder to exit the valve housing. Hydraulics Operation and Diagnostics - 343 HYDRAULICS OPERATION AND DIAGNOSTICS Hydraulic Control Valve Operation - Float B E A B A D C C I A F T D F H P A B Charge Pressure Oil Return Oil C Trapped Oil G D MIF A- Return Springs B- Load Check Valve C- Auxiliary Spool D- Lift Spool E- Hydraulic Control Valve Housing F- Inlet G- Lift Cylinder H- Load Check Valve I- Detent Balls System Operation: When the shift linkage moves the control spool (C) into the "float" position (lever fully forward), it is held there by detent balls. The spool will remain in this position until it is manually brought back out of the detents. In the float position, the open center circuit is still open, allowing oil flow to exit the control valve and also to be available for the operation of the lift cylinder. Both pressure and return work ports are open to the return circuit. As the cylinder extends or retracts, oil is drawn from the return circuit. Function: In "float" position, the spool equalizes the pressure between both work ports, allowing oil to freely enter or leave the auxiliary cylinder. This allows the implement to follow or "float" with the contour of the ground. Hydraulics Operation and Diagnostics - 344 HYDRAULICS OPERATION AND DIAGNOSTICS Hydraulic Control Valve Operation - Regen B E A A B A D C C D I F T F H P J A B Charge Pressure Oil C Return Oil Trapped Oil G D D MIF A- Return Springs B- Load Check Valve C- Auxiliary Spool D- Lift Spool E- Hydraulic Control Valve Housing F- Inlet G- Lift Cylinder H- Load Check Valve I- Regen Bucket Kit (Option) J- Shutoff Valve (Option) Function: optional regen end cap (I), included in the regen kit. Going into regen, the charge pressure is going into area “C”. Return flow from area “D” gets blocked and is rerouted across the load check bridge (H) to area “C”. System Operation: The shift linkage moves the control spool (D) into the "regen" position (lever fully forward). The auxiliary outlet spool will not remain in this position unless held, and should return from regen position without locking. The lift cylinder shutoff valve (J) would typically be closed. The regen function would be used with the loader to increase the speed of the bucket dump. The bucket cylinders are connected to the C and D ports. In "regen" position the spool moves fully forward into the Hydraulics Operation and Diagnostics - 345 HYDRAULICS OPERATION AND DIAGNOSTICS Lift Cylinder Shut-off Valve - Optional Function: The shutoff valve is supplied with the front hitch kit. Its purpose is to lock the lift cylinder in a set position so when using the front coupler work ports, the deck or rear hitch will not move. This will provide a positive movement of the attachment. Symptom: Hydraulic Problems Problem Cause - Solution 2. Hydraulic system inoperative? Hydraulic Diagnostics Symptom: Hydraulic Problems Problem Cause - Solution 1. Mower will not lift? a. No: Go to next step. b. Yes: Shutoff valve is installed and is shut off. LIft linkage is binding or disconnected. Deck height adjustment is all the way up. Check hydraulic oil level. Replace filter. See “Charge Pump Pressure and Flow Test at Couplers” on page 351. Hydraulic line damaged, causing a restriction. Charge (implement) pressure relief valve setting incorrect. Hydraulic control spool valve scored. See “Control Valve Leakage Test” on page 354. Lift cylinder leaking. See “Lift Cylinder Leakage Test” on page 353. Air leak on suction side of charge pump. Transmission case vent plugged. Hydraulics Operation and Diagnostics - 346 a. No: Go to next step. b. Yes: Optional shutoff valve is installed and is shut off. LIft linkage is binding or disconnected. Deck height adjustment is all the way up. Check hydraulic oil level. Replace filter. See “Charge Pump Pressure and Flow Test at Couplers” on page 351. Hydraulic line damaged, causing a restriction. Charge (implement) pressure relief valve setting incorrect. Lift cylinder leaking. See “Lift Cylinder Leakage Test” on page 353. Air leak on suction side of charge pump. Transmission case vent plugged. Hydraulic oil contaminated. Flush, change oil and filter. HYDRAULICS OPERATION AND DIAGNOSTICS Symptom: Hydraulic Problems Problem Cause - Solution Symptom: Hydraulic Problems Problem Cause - Solution 3. Slow hydraulic functions? 5. Erratic operation of a. No: Go to next step. implement attached to b. Yes: Check hydraulic oil level. couplers? Replace filter. See “Charge Pump Pressure and Flow Test at Couplers” on page 351. Coupler tips worn or damaged. Replace couplers. Charge (implement) pressure relief valve setting incorrect. See “Control Valve Leakage Test” on page 354. Control valve spool not neutralizing. Check linkage for binding or repair valve. Lift cylinder leaking. See “Lift Cylinder Leakage Test” on page 353. Implement lift or operating cylinder is leaking. Air leak on suction side of charge pump. Lift cylinder not locked out. Transmission case vent plugged. Hydraulic oil contaminated. Flush, change oil and filter. Excessive load. 4. Low lift capacity? a. No: Go to next step. b. Yes: Check hydraulic oil level. Replace filter. See “Charge Pump Pressure and Flow Test at Couplers” on page 351. Tapered crankshaft sheave slipping on engine crankshaft. Hydraulic line damaged, causing a restriction. Coupler tips worn or damaged. Replace couplers. Charge (implement) pressure relief valve setting incorrect. Hydraulic control spool valve scored. See “Control Valve Leakage Test” on page 354. Control valve spool not neutralizing. Check linkage for binding or repair valve. Lift cylinder leaking. See “Lift Cylinder Leakage Test” on page 353. Implement lift or operating cylinder is leaking. Air leak on suction side of charge pump. Lift cylinder not locked out. Transmission case vent plugged. Hydraulic oil contaminated. Flush, change oil and filter. Excessive load. 6. Mower deck or attachment drops with control valve in neutral? a. No: Go to next step. b. Yes: See “Charge Pump Pressure and Flow Test at Couplers” on page 351. Charge (implement) pressure relief valve setting incorrect. Lift cylinder leaking. See “Lift Cylinder Leakage Test” on page 353. Implement lift or operating cylinder is leaking. Hydraulic oil contaminated. Flush, change oil and filter. Excessive load. Hydraulics Operation and Diagnostics - 347 a. No: Go to next step. b. Yes: Hydraulic control spool valve scored. See “Control Valve Leakage Test” on page 354. Control valve spool not neutralizing. Check linkage for binding or repair valve. Lift cylinder leaking. See “Lift Cylinder Leakage Test” on page 353. Implement lift or operating cylinder is leaking. Air leak on suction side of charge pump. HYDRAULICS OPERATION AND DIAGNOSTICS Symptom: Hydraulic Problems Problem Cause - Solution Symptom: Hydraulic Problems Problem Cause - Solution 7. Hydraulic noise? 8. Control levers stick, a. No: Go to next step. hard to operate, do not b. Yes: Optional shutoff valve is align? installed and is shut off. LIft linkage is binding or disconnected. Deck height adjustment is all the way up. Check hydraulic oil level. Replace filter. See “Charge Pump Pressure and Flow Test at Couplers” on page 351. Hydraulic line damaged, causing a restriction. Coupler tips worn or damaged. Replace couplers. Charge (implement) pressure relief valve setting incorrect. Hydraulic control spool valve scored. See “Control Valve Leakage Test” on page 354. Control valve spool not neutralizing. Check linkage for binding or repair valve. Lift cylinder leaking. See “Lift Cylinder Leakage Test” on page 353. Implement lift or operating cylinder is leaking. Air leak on suction side of charge pump. Lift cylinder not locked out. Hydraulic oil contaminated. Flush, change oil and filter. a. No: Go to next step. b. Yes: Check hydraulic oil level. Replace filter. See “Charge Pump Pressure and Flow Test at Couplers” on page 351. Hydraulic line damaged, causing a restriction. Tapered crankshaft sheave slipping on engine crankshaft causing chirping sound. Charge (implement) pressure relief valve setting incorrect. Control valve spool not neutralizing. Check linkage for binding or repair valve. Air leak on suction side of charge pump. Transmission case vent plugged. Hydraulic oil contaminated. Flush, change oil and filter. Excessive load. 9. Hydraulic oil foams? a. No: Go to next step. b. Yes: Check hydraulic oil level. Replace filter. See “Charge Pump Pressure and Flow Test at Couplers” on page 351. Air leak on suction side of charge pump. Hydraulic oil contaminated. Flush, change oil and filter. 10. Frequent failure of hydraulic line or ORings? Hydraulics Operation and Diagnostics - 348 a. No: Go to next step. b. Yes: See “Charge Pump Pressure and Flow Test at Couplers” on page 351. Charge (implement) pressure relief valve setting incorrect. Hydraulic oil contaminated. Flush, change oil and filter. Excessive load. HYDRAULICS OPERATION AND DIAGNOSTICS Symptom: Hydraulic Problems Problem Cause - Solution valve malfunction. 11. Hitch drops or will a. No: Go to next step. not hold implement up? b. Yes: Hydraulic control spool valve scored. See “Control Valve Leakage Test” on page 354. Control valve spool not neutralizing. Check linkage for binding or repair valve. Lift cylinder leaking. See “Lift Cylinder Leakage Test” on page 353. Implement lift or operating cylinder is leaking. No: Go to next step. 12. Mower will not lower? a. No: Go through procedures in “Preliminary Hydraulic System Inspection” on page 349. b. Yes: Optional shutoff valve is installed and is shut off. LIft linkage is binding or disconnected. Deck height adjustment is all the way up. Hydraulic line damaged, causing a restriction. Preliminary Hydraulic System Inspection 3. Oil Leakage? Yes: Repair cause. 4. Radiator screen, cooler, and radiator free of dirt and debris? No: Clean as required. Yes: Engine OFF preliminary checks completed. Test Conditions: • Start engine. • Operate ALL hydraulic functions. Hydraulic System - Engine Running (Preliminary Checks) 1. Quick and positive steering response? Full right to full left with only slight effort? Steering wheel does not drift when driving in straight line? Yes: Go to next step. No: See the Steering section for steering system diagnosis. 2. Lift cylinder control lever: Implement should raise and lower. Holds implement up for a reasonable time (4 minutes) when in neutral? Yes: Go to next step. No: See “Charge Pump Pressure and Flow Test at Couplers” on page 351 and “Control Valve Leakage Test” on page 354. If lift cylinder rod leaked down 25.4 mm (1 in.) in the 1 - 2 minute range, check for cylinder leakage first, then proceed with tests. Test Conditions: • Engine off. • Machine on hard level surface. Hydraulic System - Engine OFF (Preliminary Checks) 1. Hydraulic oil between marks on dipstick? Yes: Go to step 2. 3. Auxiliary hydraulic control lever: Adequate pressure and flow out of front couplers. Holds pressure to attachment when in neutral? Yes: Go to next step. No: Add John Deere Low Viscosity HY-GARD Transmission and Hydraulic Oil (J20D). Drain and replace. 2. John Deere Low Viscosity HY-GARD Transmission and Hydraulic Oil: Foamy, milky, metal particles noted, discolored or burned? No: Go to next step. Yes: Check for air leak and use of correct fluid. Yes: Check for water in oil. No: See “Control Valve Leakage Test” on page 354. 4. Positive transmission speed control response: control forward, neutral, and reverse? Yes: Go to next step. No: See the Power Train section for transmission and speed control linkage diagnosis. 5. Hydraulic oil filter replaced at normal service intervals or replaced to verify filter is not restricted? Yes: Go to next step. Yes: Check for mechanic failure. Yes: Check for causes of overheating: Plugged radiator, hydraulic control valve stuck, charge pressure relief No: Change hydraulic filter. 6. All hydraulic system checks normal? Hydraulics Operation and Diagnostics - 349 HYDRAULICS OPERATION AND DIAGNOSTICS No: Complaint not found and unable to duplicate complaint. Factory assistance for a dealer is available through the Dealer Technical Assistance Center (DTAC). No: Perform all the steps in “Hydraulic Diagnostics” on page 346. Perform tests and adjustments to isolate and repair the malfunction. Yes: Engine running preliminary checks completed. Yes: Go to next step. No: Perform “Lift Cylinder Leakage Test” on page 353. Replace cylinder. 7. Auxiliary couplers: Relief pressure within specification? Hydraulic flow within specification? Spool leakage within specification? Yes: Go to next step. No: Perform “Charge Pump Pressure and Flow Test at Couplers” on page 351 and/or perform “Control Valve Leakage Test” on page 354. Hydraulic System Tests 8. Hydrostatic transmission operates in forward and reverse? Returns to neutral and does not creep? Test Conditions: • Park brake engaged. • Engine not running. Yes: See the Power Train section for hydrostatic system diagnosis No: Hydraulic checks completed. Hydraulics 1. Hydraulic/transmission dipstick has proper level, viscosity, type and condition per the preliminary hydraulic checks? Yes: Go to next step. No: Drain and replace fluid and filter. 2. Transmission drive shaft is turning hydrostatic transmission input shaft? Yes: Go to next step. No: Repair as necessary. 3. Constant, foam free flow from charge pump? Pump flow within specification? Pressure relief valve in specification? Yes: Go to next step. No: Perform “Charge Pump Pressure and Flow Test at Couplers” on page 351. 4. Steering is responsive and turns quickly full right and left? Yes: Go to next step. No: See the Steering section for steering system diagnosis. 5. Hydraulic control valve (deck lift): Lifts and holds deck and hitch in the raised position? Control lever returns to neutral? Yes: Go to next step. No: Perform “Control Valve Leakage Test” on page 354. Check linkage for binding. Repair or replace control valve. 6. Hydraulic cylinders lift and hold implement in a raised position? No leakage at rod seal or connectors? Hydraulics Operation and Diagnostics - 350 HYDRAULICS TESTS AND ADJUSTMENTS Tests and Adjustments Pressure Test: Hydraulic Oil Warm-Up Procedure Reason: When making hydraulic tests the oil must be heated to normal operating temperature for the tests to be accurate. A Test Equipment: • JDG282 Temperature Gauge Procedure: 1. Install JDG282 Temperature Gauge on transmission oil filter. Important: Avoid Damage! DO NOT overheat engine. 2. Apply park brake. Start engine and run at full throttle. 3. Move and hold hydraulic lever in implement raise position. MIF 1. Locate hydraulic control valve on right side of machine frame. Install JT03117 pressure gauge into coupler (A). 2. Start and run engine at high idle. 4. Periodically cycle all hydraulic functions to distribute heated oil. 3. Move the auxiliary hydraulic control lever to the raise or lower position. 5. Heat oil to operational temperature, 38 - 49° C (100 120° F) typical. 4. Observe pressure gauge reading. Charge Pump Pressure and Flow Test at Couplers • If pressure is to charge relief (implement) pressure specifications, 6371 kPa (924 psi) minimum, pump and charge pressure relief valve are in good condition. Reason: To check condition of the charge pump and the charge pressure relief valve setting (implement operation pressure). This determines if there is sufficient oil pressure and flow to operate implements. Note: This test can be misleading if there is a malfunction of the steering valve, hydraulic control valve or lift cylinder. Results: • If there is no pressure, repeat test using different coupler. If pressure exists, replace coupler and repeat test. • If pressure is below 5881 kPa (853 psi), See “Charge Pump Pressure Test” on page 352. Flow Test: Pressure Test Equipment: • AM102420 Quick Coupler • JT031111 9/16-18 M x 7/16-20 M 37° Orb • JT03017 Hose • JT03117-13790 kPa (2000 psi) Pressure Gauge A B Flow Test Equipment: • JT01765 Consumer Products Hydraulic Fitting Kit • JT05469 Flowmeter Kit • AM102420 1/4 Male Quick-Coupler • JT03216 Connector and 9/16-18 M 37° x 9/16-18 M Orb • JT03342 Coupler and 3/4” F NPT x 9/16-18 F 37° Orb MIF 1. Connect flowmeter to work ports (A and B). Hydraulics Tests and Adjustments - 351 HYDRAULICS TESTS AND ADJUSTMENTS Charge Pump Pressure Test Flow Test Procedure: 1. Open flowmeter control valve. Reason: 2. Start engine and run at high idle. Oil must be at normal operating temperature. 4. Observe flowmeter reading. To determine charge pressure control valve operation and help determine condition of hydraulic charge pump. This also checks charge pump pressure relief valve operation and determines if there is sufficient pressure to operate implements. Results: Test Equipment: • If pump flow is between minimum and rated flow specification, pump is in good condition. • JT05489 Connector, 7/16-20 x M 37° 1/2-20 M ORB • JT03017 Hose • • JT03117-13790 kPa (2000 psi) Pressure Gauge 3. Move cylinder lift control lever to get oil flow through meter in correct direction. If there is no pump flow, check: • Drive shaft not turning input shaft • Sheared charge pump drive key • Charge pressure control valve stuck closed Pressure Test Procedure: • If pump flow is below minimum flow specification, foamy or erratic, check: • Hydraulic oil level • Charge pressure 1. Park machine safely. See “Park Machine Safely” in the Safety section. • Filter, replace and repeat test 2. Remove seat and fender deck. • Transaxle vent for plugging • Filter seal for leaks 3. Attach seat switch and set up machine so engine can be run. • Charge pressure relief valve for damage or debris that could be holding valve open • Charge pressure control valve for scoring or debris that could be holding valve closed • If pump flow is still below minimum flow specification, check: • O-ring at inlet of charge pump leaking • Leak in case passage between filter and charge pump • If problem cannot be found, perform flow and pressure test at charge pump to eliminate the possibility of the steering valve or hydraulic control valve malfunctioning, giving false test results. See the Hydrostatic Power Train section. • Warm hydraulic oil to operating temperature before performing this test. When done “cold” or at shop temperature, most machines (especially when new) will likely be close to 3450 kPa (500 psi). See “Hydraulic Oil Warm-Up Procedure” on page 351. Check charge pump for damage. Charge Pump (Two-Wheel Drive): Rated Flow . . . . . . . . . . . . . . . . . . . . . 17 L/m (4.5 gpm) Minimum Flow. . . . . . . . . 13 L/m (3.4 gpm) @ 3200 rpm c pressure Caution: Avoid Injury! Escaping fluid under can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable source. Such information is available from the Deere & Company Medical Department in Moline, Illinois, U.S.A. In the United States and Canada only, this information may be obtained by calling 1-800822-8262. Charge Pump (All-Wheel Drive): Rated Flow . . . . . . . . . . . . . . . . . . . . 22.7 L/m (6.0 gpm) Minimum Flow. . . . . . . . . 17 L/m (4.5 gpm) @ 3200 rpm Hydraulics Tests and Adjustments - 352 HYDRAULICS TESTS AND ADJUSTMENTS B B A MX14228 4. Install connector, hose and pressure gauge to charge pressure test port (A). • If relief pressure is below 5881 kPa (853 psi), check charge pressure relief valve (B), shim relief pressure spring. If pressure cannot be increased, check charge pump for damage. 5. Start engine and run at high idle. Do not operate steering or hydraulic control valves. Lift Cylinder Leakage Test 6. Observe gauge reading. This is charge pressure. Reason: 7. Move hydraulic control lever to raise or lower position. Hold until pump pressure is in relief. To determine if lift cylinder is leaking. MX14307 8. Observe gauge reading and release control. This is charge pressure relief pressure (implement operation pressure). Specifications: Charge Pressure (minimum) . . . . . . . 1958 kPa (284 psi) Charge Relief (Implement) Pressure (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6371 kPa (924 psi) Results: • If charge pressure is to specifications, 1958 kPa (284 psi) minimum, in transaxle, charge pressure control valve is operating properly. • Note: Charge pressure gauge reading may be higher than specification due to cold oil temperature. Warm oil and retest. • If charge pressure is too high, and oil is at operating temperature, there is a potential problem with the charge pressure control valve, or a restriction in the system. See “Charge Pump Flow and Pressure Test - At Charge Pump” in the Hydraulic Power Train section.” • If relief pressure is to charge relief (implement) pressure specifications, 6371 kPa (924 psi) minimum, pump and charge pressure relief valve are in good condition. c pressure Caution: Avoid Injury! Escaping fluid under can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable source. Such information is available from the Deere & Company Medical Department in Moline, Illinois, U.S.A. In the United States and Canada only, this information may be obtained by calling 1-800822-8262. First Procedure: 1. Remove any attachment that is mounted, including mower deck. 2. With deck lift arms in raised position, shut off engine. Hydraulics Tests and Adjustments - 353 HYDRAULICS TESTS AND ADJUSTMENTS Control Valve Leakage Test Reason: To determine the condition of spool valves and housing. Test Equipment: • Measuring tape or ruler Mower Deck Lift Spool Procedure: 1. Heat hydraulic oil to specifications. See “Hydraulic Oil Warm-Up Procedure” on page 351. A 2. Make sure mower deck is properly installed. B MX14432 3. Disconnect lift cylinder rod-end line (A) from control valve. Important: Avoid Damage! Hold control lever in the raised position before starting engine. Also be ready to shut off engine. If valve leaks, oil will flow out open port. 4. Move hydraulic control valve lever to "lift" position. 4. Move lift cylinder to maximum raise position (pull top lever fully back). 5. Shut off engine. 6. Measure height from level ground to mower deck attaching pin (the pin engaged in “V” slot at the end of the lift arms). 7. Wait approximately 12 minutes. 8. Measure pin height again. 5. Start engine. Operate at slow idle. 6. Observe cylinder rod-end line (A) for continuous oil leakage. Results: • If hydraulic oil continually leaks out of fitting, replace lift cylinder. • 3. Make sure that mower deck lift stop is at 1.0 inch (lowest) cut height position. If no leakage, go to Second Procedure. Results: • Mower deck should drop no more than 25 mm (1.0 in.) in 12 minutes. Front Quick Hitch Lift Cylinder Procedure: 1. Heat hydraulic oil to specifications. See “Hydraulic Oil Warm-Up Procedure” on page 351. Second Procedure: 2. Make sure front hitch is properly installed. 1. Shut off engine and connect line (B). 3. Whatever front implement is on machine (blade, broom, snowblower, etc.) can remain mounted. 2. Start engine and lower (retract) cylinder. 3. Shut off engine. Remove line (B). 4. Move hitch lift cylinder to maximum raise position (pull bottom lever fully back). 4. Hold control lever in the lower position. 5. Shut off engine. 5. Start engine and observe flow from line. 6. Measure height from level ground to quick pull pin at the front/top of the quick hitch. Results: • No leakage, cylinder is good. • Leakage, replace cylinder. 7. Wait approximately 7 minutes. 8. Measure pin height again. Results: • Attachment should drop no more than 25 mm (1.0 in.) in 7 minutes. Hydraulics Tests and Adjustments - 354 HYDRAULICS REPAIR Repair “Hydraulic Control Valve” on page 355. Lift Cylinder Removal and Installation Installing: Installation is done in the reverse order of removal. See “Lift Linkage Removal and Installation” on page 464. Important: Avoid Damage! Do not overtighten valve mounting bolts, valve spools may stick. Hydraulic Control Valve Removal and Installation • Tighten mounting bolt (B), and lock nut (H) to mounting bolt (G), to specification. Removing: • 1. Remove hood. Tighten hydraulic line fittings (A) to specification. • Install lower control arm (F) and hardware before installing upper control arm (D) and hardware onto valve assembly. H A Specifications: Control Valve Mount Cap Screw 11 - 16 N•m (8 - 12 lb-ft) Hydraulic Lines . . . . . . . . . . . . 4 - 30 N•m (18 - 22 lb-ft) B Hydraulic Control Valve Disassembly: A Important: Avoid Damage! Always use new O-rings. Damaged or used O-rings will leak. A MX11895 Picture Note: NOTE: Engine removed in photo for clarity. A B A 2. Remove hydraulic lines at fittings (A). 3. Remove bolt (B) connecting lower half of control valve to frame. C D G C B G F D C E MX11929 1. Remove two load check valves (B) and O-rings. E 2. Remove two small straight fittings (C) with O-rings. 3. Remove one large straight fitting (E) with O-ring. 4. Remove 90° fitting (D) with O-ring. F MX35900 5. Remove couplers (A) with O-rings. 4. Remove spring pin (C) from control arm (D). 6. Remove up/down float spool assembly (G). 5. Remove spring pin (E) from control arm (F). 7. Remove up/down spool assembly (F). 6. Remove (G) bolt and nut (H) connecting upper half of control valve to frame. Installation is done in the reverse order of removal. 7. Remove and make repairs to valve as necessary. See • Install and tighten 90° fitting (D) to specification. Hydraulics Repair - 355 HYDRAULICS REPAIR Note: O-rings (O) are located in spool bore at each end of control valve. The O-rings are serviced as a separate assembly and replaced as a kit only. The remaining parts (gasket (N), end cap (M), spring (R), spring retainer (S), and screw (T), except the spool (P) and washers (Q), are serviced as a separate assembly and are replaced as kits only. • Install and tighten small straight fittings (C) to specification. • Install and tighten large straight fitting (E) to specification. • Install and tighten couplers to specification. Load Check Valve: Installation is done in the reverse order of removal. J • Up/Down Float Spool Assembly: I Important: Avoid Damage! Spool and housing are matched and must be replaced as an assembly. Make sure spool is installed in original bore to ensure proper operation. Always use new O-rings. Damaged or used O-rings will leak. K H MX11931 1. Disassemble check valve assembly, which includes a cap (J), O-rings (I), spring (K), and check valve poppet (H). Installation is done in the reverse order of removal. • Tighten screws (L and T) to specification. Tighten cap to specification. Note: The quick-coupler assembly is serviced as a separate assembly and is replaced as a kit only. Up/Down Spool Assembly: 1. Apply thread lock and sealer (medium strength) to threads of screws. Note: O-rings are located in spool bore at each end of control valve. The O-rings (Y) are serviced as a separate assembly and replaced as a kit only. The steel ball is serviced and the end cap is serviced. The remaining parts, except the spool (Z), end cap (W) and steel ball (AB), are serviced as a separate assembly and are replaced as kits only. 2. Apply multi-purpose grease to spring (AA) after installed on spool. Important: Avoid Damage! Always use new O-rings. Damaged or used O-rings will leak. Y O U N Z X V W AA M P AB Q AC R L MX11933 S 3. Apply thread lock and sealer (medium strength) to threads of screws (AC) and two detent plugs (U). T MX11932 4. Apply multi-purpose grease to two springs (V) and balls (AB). 1. Disassemble up/down float spool assembly. Hydraulics Repair - 356 HYDRAULICS REPAIR Installation is done in the reverse order of removal. • Tighten detent ball retaining screws and detent plugs to specification. Specifications: 90° Fitting . . . . . . . . . . . . . . . . 33 - 49 N•m (24 - 36 lb-ft) Small Straight Fitting . . . . . . . 24 - 30 N•m (18 - 22 lb-ft) Large Straight Fitting . . . . . . . 33 - 49 N•m (24 - 36 lb-ft) Quick Couplers . . . . . . . . . . . . 33 - 49 N•m (24 - 36 lb-ft) Load Check Valve Cap . . . . . . . . . . . . . 24 N•m (18 lb-ft) Spool Assembly Screws . . . . . . . . . . . 4 N•m (36 lb-in.) Hydraulics Repair - 357 HYDRAULICS REPAIR Hydraulic Control Levers and Linkage A B B C E D F G M L H K J I I MIF Picture Note: Viewed from frame side of valve A- Knob B- Spring Pin C- Lift Control Valve Lever D- Auxiliary Control Valve Lever E- Pivot F- Screw G- Carriage Bolt H- Lock Nut E I- Spring Locking Pin J- Link K- Spool Valve L- Quick Coupler M- Dust Cap 1. Remove instrument panel to access control levers. See “Instrument Panel Removal and Installation” on page 463. 2. Inspect linkage for bent or damage parts. 3. Repair or replace. Hydraulics Repair - 358 STEERING TABLE OF CONTENTS Steering Table of Contents Specifications ...............................................361 General Specifications ...............................361 Test and Adjustment Specifications ...........361 Repair Specifications..................................361 Special or Essential Tools ..........................361 Component Location....................................362 Steering Components - Front Wheel Steer 362 Steering Components - All Wheel Steer.....363 Steering Components - All Wheel Steer Rear Axle....................................................364 Theory of Operation .....................................365 Steering System Operation ........................365 Steering Valve Operation - Neutral ............366 Steering Valve Operation - Turning............367 Steering Valve Operation - Manual ............368 Diagnostics ...................................................369 Steering Diagnosis .....................................369 Steering System Tests ...............................370 Steering Link Checks .................................371 Tests and Adjustments ................................372 Hydraulic Oil Warm-Up Procedure .............372 Steering Valve and Cylinder Leakage Test 372 Toe-In Adjustment Front Wheels................373 Toe-In Adjustment All Wheel Steering .......373 Repair.............................................................375 Steering Column Removal and Installation 375 Steering Valve Removal and Installation ...376 Steering Valve Disassembly and Assembly....................................................377 Steering Cylinder Removal and Installation ..................................................380 Front Axle Removal and Installation...........380 Front Axle Disassembly and Assembly ......381 Rear Steering Linkage - All Wheel Steering ......................................................383 Steering Intermediate Linkage - AWS ........385 Front and Rear Pivots ................................386 Steering Table of Contents - 359 STEERING TABLE OF CONTENTS Steering Table of Contents - 360 STEERING SPECIFICATIONS Specifications General Specifications Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Tilt Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Test and Adjustment Specifications Steering System Leakage: Oil Temperature (Typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43°C (110°F) Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fast Idle Maximum Turns with Constant Torque of 6.8 N•m (60 lb-in.) in Either Direction . . . . . . . . . . . . . . . . . . . . . . . . . 4 rpm Charge Pressure Control Valve (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1958 kPa (284 psi) Steering Valve System Pressure (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6371 kPa (924 psi) Toe-In Adjustment: Front Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6 mm (0.04 - 0.24 in.) Rear Tires (All Wheel Steer): Front-to-back difference from frame for each tire . . . . . . . . . . . . 0 - 10 mm (0 - 0.4 in.) Repair Specifications Hydraulic Line to Steering Valve Retainer Plate Cap Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Steering Valve Mounting Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (150 lb-in.) Steering Wheel Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N•m (28 lb-ft) Steering Valve End Cover Cap Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (150 lb-in.) Check Ball Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (150 lb-in.) Front Axle Pivot Cap Screw and Lock Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 N•m (150 lb-ft) Tie Rod Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 N•m (45 lb-ft) Rear Steering Link Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 N•m (125 lb-ft) Adjusting Nut Jam Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 N•m (50 lb-ft) Rear Steering Side Pivots Pivot Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 N•m (80 lb-ft) Rear Axle Pivot Bracket Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 N•m (67 lb-ft) 2WD Pivot Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 ± 40 N•m (147.5 ± 29.5 lb-ft) 4WD Pivot Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367 ± 73 N•m (271 ± 53.8 lb-ft) 2WD Steering Cylinder Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.5 ± 6.8 N•m (38 ± 5 lb-ft) 4WD Steering Cylinder Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.2 ± 9.5 N•m (40 ± 7 lb-ft) Special or Essential Tools Note: Order tools according to information given in the U.S. SERVICE-GARD™ Catalog or in the European Microfiche Tool Catalog (MTC). Special or Required Tools Tool Name Bushing, Bearing and Seal Driver Set Tool No. Tool Use Used to install seals and bushings. Steering Specifications - 361 STEERING COMPONENT LOCATION Component Location Steering Components - Front Wheel Steer B A D F G C A D E F G MX35904 A- Steering Cylinder B- Front Axle (Rear Wheel Drive) C- Front Axle (All Wheel Steering) D- Steering Control Unit (SCU) E- MFWD Drive Shaft F- Tie Rod G- Steering Arm Steering Component Location - 362 STEERING COMPONENT LOCATION Steering Components - All Wheel Steer C B D A N O M J L E F K I H G F MX35905 A- Steering Cylinder B- Front Axle (2 Wheel Drive Only on AWS) C- Tie Rod D- Steering Control Unit (SCU) E- Rear Tie Rod Pivot F- Rear Wheel Steering Arm G- Tie Rod (2) H- Link Rod, Rear I- Pivot Arm J- Bearing Housing K- Link Rod, Middle L- Bearing Housing M- Steering Arm, Front N- Link Rod, Front O- Steering Arm Steering Component Location - 363 STEERING COMPONENT LOCATION Steering Components - All Wheel Steer Rear Axle F B A E D G H C I J M L K I H F MX14233 A- Link Rod, Middle B- Bearing Housing C- Pivot Arm D- Axle Shaft E- Ball Bearing F- Drive Shaft, U-Joint G- Ball Bearing H- Case, Wheel Bearing I- Steering Arm J- Tie Rod (2) K- Cap, Pivot L- Pivot Plate M- Link Rod, Rear Steering Component Location - 364 STEERING THEORY OF OPERATION Theory of Operation 6371 kPa (924 psi) Steering System Operation Function: Offer hydraulic all wheel power steering for ease of operation. 1958 kPa (284 psi) System Operation: Pressure oil is supplied by the charge pump of the hydrostatic transmission to the inlet port of the steering valve. When the steering wheel is not turned, the oil flows directly through the valve and out to the hydraulic control valve. When the steering wheel is turned to make a left turn, the pressure oil is routed through the steering valve and out the left turn port. The oil then flows down left turn line to the rod end of the steering cylinder. The cylinder rod is pushed out, rotating the front steering arm to the right which pulls the left tie rod and spindle and pushes the right tie rod and spindle. This turns the front wheels to the left. The return oil from the head end of the cylinder is routed through right turn line to the right turn port of the steering valve. The oil is routed through the valve to the return port. On all wheel steer machines, linkage connects the front steering arm to the rear pivot, which allows the front and rear sets of wheels to pivot in opposite directions. When the front steering arm is rotated counterclockwise, the front link rod is pushed to the right which rotates the front steering arm clockwise. This moves the middle link rod, rear pivot arm, and rear link rod rearward. The rear pivot is rotated counterclockwise, which pushes the left rear tie rod, rear steering arm, rear spindle housing, and rear spindle hub and pulls the right side link. This turns the rear wheels to the right. With the front wheels turned to the left and the rear wheels turned to the right, a short turning radius is accomplished. Transaxle T Hydraulic Control Valve P P B T Steering Valve R When the steering wheel is turned to make a right turn, the pressure oil is routed the opposite way through the valve. The oil comes out the right port of the valve to the head end of the cylinder. The cylinder rod is pushed out and the front pivot plate rotates the opposite way. The return oil flows through the lines to the left port of the valve and out the return port. L Steering Cylinder Picture Note: Left Turn Shown The steering valve is designed to allow manual steering if the engine is not running or if there is a failure of the hydraulic pump. The tilt steering assembly allows the steering wheel to be adjusted for operator comfort. A spring loaded rod locks the steering column in different positions. Steering Theory of Operation - 365 STEERING THEORY OF OPERATION Steering Valve Operation - Neutral C D E B F G A H N I M Pressure Oil Return Oil L K Trapped Oil MIF A- Check Valve B- Return Port C- Valve Body D- Sleeve E- Sleeve Inlet Groove F- Spool Inlet G- Spool H- Power Beyond Slot I- Power Beyond Groove J- Feed Holes K- Inlet Passage L- Power Beyond Passage M- Inlet Port N- Power Beyond Port J sleeve) and a metering pump. The valve and pump are hydraulically and mechanically interconnected inside the valve. Pressure oil comes into the steering valve body at the inlet port. The oil then flows through inlet passage to a series of grooves, passages, and slots in the valve body, sleeve, and spool to come out the power beyond passage and power beyond port to go on to the lift system. The amount of oil that flows this way varies with the speed of the turn. All the oil will follow this path when the steering valve is in neutral. There will be some oil when a slow turn is made, and there will be less oil when a fast turn is made. No oil is available to the power beyond port when the steering is dead headed. When the valve is in neutral, the turn passages are closed. The oil in the steering cylinder and lines is trapped oil. The small amount of internal leakage oil will go out the return port as return oil back to the sump. Function: Controls oil flow to and from the steering cylinder. In neutral, the steering valve blocks oil flow to the cylinder, holding the wheels in a fixed position and allows oil to flow to the hydraulic system. System Operation: The steering valve is an open center type valve. This valve consists of a self-centering fluid control valve (spool and Charge oil enters the steering valve at normal charge pressure of 1958 kPa (284 psi) minimum, passes through the open center valve, then the oil cooler to return to sump. If the steering wheel is turned, oil restriction occurs, and the charge pressure increases. The charge pressure relief valve will open when the hydraulic pressure reaches 6371 kPa (924 psi) and pass excess oil to the sump. Steering Theory of Operation - 366 STEERING THEORY OF OPERATION Steering Valve Operation - Turning B C D E F G H I A J K L M Z N O Y P Q X Pressure Oil Return Oil R W Trapped Oil S T V U MIF A- Center of Spool B- Valve Body C- Spool D- Sleeve E- Spool Left Turn Slot F- Left Turn Passage G- Left Turn Groove H- Right Turn Passage I- Right Turn Groove J- Spool Outlet Slot K- Sleeve Outlet Holes L- Valve Body Passages M- Spool Right Turn Slot N- Sleeve Inlet Holes O- Gerotor Cavity (Reducing Volume) P- Gerotor Body Q- Gerotor Cavity (Enlarging Volume) R- Sleeve Inlet Groove S- Spool Inlet Groove T- Gerotor Gear U- Right Turn Port V- Feed Holes W- Inlet Passage X- Inlet Port Y- Return Port Z- Left Turn Port Function: Controls pressure oil flow to the proper end of the steering cylinder to turn the front wheels. System Operation: Pressure oil comes into the steering valve body at the inlet port. The oil then flows through inlet passage to a series of grooves, holes, slots, and passages to the gerotor. The steering wheel is turning which turns the gerotor gear in the gerotor body so that some of the cavities are enlarging in volume and the oil fills them. At the same time, some of the gerotor cavities are reducing in volume which feeds the pressure oil out to another series of passages, grooves, slots and holes. They provide a path to one of the steering ports (in this drawing the right turn port) and on to the steering cylinder. The gerotor controls the rate at which oil flows to the steering cylinder. The return oil coming back from the steering cylinder is routed into the other steering port (in this case, left turn) to the center of the spool. From the center of the spool the oil goes out the return port back to sump. Smooth turning is insured by the design of the gerotor. Its geometry causes it to fill and empty its cavities 6 times as fast as the steering wheel is being turned. Steering Theory of Operation - 367 STEERING THEORY OF OPERATION Steering Valve Operation - Manual C B E D A F G H I Z J K L Y M X N W Return Oil Trapped Oil Pressure Oil Suction Oil O V P U MIF A- Left Turn Passage B- Valve Body C- Spool D- Sleeve E- Spool Left Turn Slot F- Left Turn Groove G- Right Turn Groove H- Spool Outlet Slot I- Sleeve Outlet Holes J- Spool Right Turn Slot K- Sleeve Inlet Holes L- Valve Body Passages M- Gerotor Cavity (Reducing Volume) N- Gerotor Body O- Gerotor Gear P- Gerotor Cavity (Enlarging Volume) Q- Sleeve Inlet Groove R- Spool Inlet Groove S- Right Turn Port T- Inlet Holes U- Inlet Passage V- Inlet Port W- Check Valve X- Return Port Y- Return Passage Q T S R Z- Left Turn Port Function: Provides manual steer operation to make a left or right turn if hydraulic oil pressure and flow is not available. System Operation: When the hydraulic system is not operating, engine not running or hydraulic pump failure, it is still possible to steer the machine. The gerotor must create the pressure and flow necessary to move the steering cylinder as the steering wheel is being turned. As some of the gerotor cavities reduce in volume, pressure oil is forced out of the cavities through a series of passages, holes, grooves, and slots in the valve body, sleeve, and spool to one of the steering ports (in this drawing right turn). The pressure oil is then routed to the steering cylinder. The return oil from the steering cylinder returns in the other port (in this case the left turn port) through another series of passages, grooves, slots, and holes to the center of the spool. From the center of the spool the oil is routed to the return port. The return port is connected to the inlet port through the check valve. The check valve allows the oil from return port to be drawn back into the system. This suction oil is routed through the valve body, sleeve, and spool to gerotor cavities that are enlarging in volume. As the steering wheel is turned the enlarging volume cavities become the reducing volume cavities and the oil is transferred. Steering Theory of Operation - 368 STEERING DIAGNOSTICS Diagnostics Symptom: Steering Function Problems Problem Cause - Solution Steering Diagnosis Symptom: Steering Noise or Vibration Problem Cause - Solution 1. Steering shimmy or vibration? a. No: Go to next step. 2. Noise during turning? a. No: For additional procedures go to “Steering System Tests” on page 370. 1. Steers hard or no steering in BOTH directions? a. No: Go to next step. 2. Steers hard or no steering in ONE direction? a. No: Go to next step. b. Yes: Front axle spindles or front pivot plate binding; not lubricated. Front steering arm, rear pivot arm, or middle link rod binding. Front tie rods bent, loose, or toein not correct. Rear tie rods bent, loose, or toein not correct. Link rods bent, loose, or adjusted incorrectly. b. Yes: Steering cylinder has external or internal oil leakage. Steering cylinder lines restricted or leaking. Return lines to transmission and oil cooler restricted or leaking. Front axle spindles or front pivot plate binding; not lubricated. Rear spindle housing and rear pivot plate binding; not lubricated. b. Yes: Charge pressure relief valve not opening within specification. Steering cylinder has external or internal oil leakage. Steering valve has external or internal oil leakage. Steering cylinder lines restricted or leaking. Return lines to transmission and oil cooler restricted or leaking. Front axle spindles or front pivot plate binding; not lubricated. Rear spindle housing and rear pivot plate binding; not lubricated. Front steering arm, rear pivot arm, or middle link rod binding. Front tie rods bent, loose, or toein not correct. Rear tie rods bent, loose, or toein not correct. Link rods bent, loose, or adjusted incorrectly. b. Yes: Steering cylinder has external or internal oil leakage. Steering valve has external or internal oil leakage. Steering cylinder lines restricted or leaking. Front axle spindles or front pivot plate binding; not lubricated. Rear spindle housing and rear pivot plate binding; not lubricated. Front steering arm, rear pivot arm, or middle link rod binding. 3. Steering pulls in one a. No: Go to next step. direction? b. Yes: Steering cylinder has external or internal oil leakage. Steering valve has external or internal oil leakage. Front tie rods bent, loose, or toein not correct. Rear tie rods bent, loose, or toein not correct. Middle link rod bent, loose, or adjusted incorrectly. Steering Diagnostics - 369 STEERING DIAGNOSTICS Steering System Tests Symptom: Steering Function Problems Problem Cause - Solution 4. Steering wheel creeps? 5. Wheels turn on engine start-up? 6. Slow steering response? a. No: Go to next step. b. Yes: Steering cylinder has external or internal oil leakage. Steering valve has external or internal oil leakage. Test Conditions: • Machine parked on level surface. • Park brake engaged. a. No: Go to next step. • Steering cylinder (A) disconnected. b. Yes: Charge pressure relief valve not opening within specification. Steering cylinder has external or internal oil leakage. • Hydraulic oil at room temperature. • Engine running at fast idle. a. No: For additional procedures go to “Steering System Tests” on page 370. b. Yes: Charge pressure relief valve not opening within specification. Steering cylinder has external or internal oil leakage. Steering valve has external or internal oil leakage. Steering cylinder lines restricted or leaking. Return lines to transmission and oil cooler restricted or leaking. Front axle spindles or front pivot plate binding; not lubricated. Rear spindle housing and rear pivot plate binding; not lubricated. Front steering arm, rear pivot arm, or middle link binding. Steering 1. Steering wheel turns smoothly with no binding? Steering cylinder extends and retracts? (Maximum of 3 revolutions of steering wheel to fully extend cylinder. Compare steering effort with cylinder connected.) Yes: Go to next step. No: Steering cylinder does not move or wheel revolutions are more than 3, see “Steering Valve and Cylinder Leakage Test”. Steering wheel binds or will not lock in place, go to step 14. 2. Hydraulic checks: Pressure relief valve test port pressure setting to minimum specification 6371 kPa (924 psi)? Yes: Go to next step. No: See Charge Pump Flow and Pressure Test in the Hydraulic section. 3. Check steering cylinder. No external/internal oil leakage? Yes: Go to next step. No: See “Steering Valve and Cylinder Leakage Test” on page 372. 4. Check steering valve. No external/internal oil leakage? Yes: Go to next step. No: See “Steering Valve and Cylinder Leakage Test” on page 372. 5. Check steering lines. Not pinched, cracked or leaking? Yes: Go to next step. No: Replace as necessary. 6. Check return lines to transmission and oil cooler. Not restricted, pinched, cracked or leaking? Yes: End of steering tests. No: Replace as necessary. Steering Diagnostics - 370 STEERING DIAGNOSTICS Steering Link Checks steering rod repair. Replace if necessary. 8. Tires and wheels are correct size, matched circumference, and proper air pressure? Rims not bent? Tires running true (no wobble)? No excessive play in wheel hubs? Wheel bearings lubricated and not rough? Test Conditions: • Key switch in OFF position. • Front link rod disconnected. • Rear link rod disconnected. • Front wheels off ground for front axle check. • Rear wheels off ground for rear axle check. Yes: Go to next step. No: Replace as needed. Inflate tires to recommended pressure. 9. Rear weights or wheel weights have proper rear ballast? Yes: End of steering link tests. Steering Links 1. Front axle spindles and front pivot plate turns with little resistance? Axle bushings lubricated, no side freeplay? No: Add or subtract weights. See Operator's Manual. Yes: Go to next step. No: Repair axle, spindle, or plate. 2. Rear spindle housing and rear pivot plate turns with little resistance? Bearings lubricated, no side freeplay? Yes: Go to next step. No: Repair spindle housing or pivot plate. 3. Front steering arm, rear pivot arm and middle link rod turns with little resistance? Bearings not rough, no side freeplay? Yes: Go to next step. No: Repair steering arm, pivot arm, or link rod. 4. Front tie rods are not bent? Rod ends are tight? Toein is 1 - 6 mm (0.04 - 0.24 in.)? Yes: Go to next step. No: Replace if necessary. Adjust toe-in. 5. Rear tie rods are not bent? Rod ends are tight? Wheels are straight with pin through rear pivot plate? Yes: Go to next step. No: Replace if necessary. Adjust toe-in. 6. Steering cylinder ball joint is tight, not worn and properly lubricated? Rod not bent? Yes: End of steering tests. No: Replace if necessary. 7. Steering column and tilt assembly: Steering column not binding? Snap rings in place? Universal joint not binding or worn? Tilt assembly not binding? Spring holds latch rod in notch? Yes: Go to next step. No: Tilt steering wheel will not lock in place, or may lock in only one position or will not hold position, see tilt Steering Diagnostics - 371 STEERING TESTS AND ADJUSTMENTS Tests and Adjustments Hydraulic Oil Warm-Up Procedure Reason: When making hydraulic tests the oil must be heated to normal operating temperature for the tests to be accurate. Test Equipment: • JDG282 Temperature Gauge Procedure: 1. Install JDG282 Temperature Gauge on transmission oil filter. Important: Avoid Damage! DO NOT overheat engine. 2. Apply park brake. Start engine and run at full throttle. c pressure Caution: Avoid Injury! Escaping fluid under can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. 3. Move and hold hydraulic lever in implement raise position. 4. Periodically cycle all hydraulic functions to distribute heated oil. A 5. Heat oil to operational temperature [38 - 49° C (100 120° F) typical]. Steering Valve and Cylinder Leakage Test B Reason: To check the steering valve and cylinder for internal leakage. Test Equipment: • Torque Wrench • JT03375, 9/16 - 18 M ORFS x 7/16 - 20 M 37° Fitting • JT05484, 7/16 - 20 F 37° Cap Procedure: MX11934 3. Disconnect return hose (A) from the steering cylinder (B). 4. Cap return hose with JT03375 Fitting and JT05484 Cap. 1. Remove steering wheel cap. 5. Heat hydraulic oil to approximately 43°C (110°F). See “Hydraulic Oil Warm-Up Procedure” on page 372. 2. Turn wheels for a complete right turn. 6. Run engine at fast idle. 7. Using a torque wrench on steering wheel nut, turn steering wheel right with a constant torque of 6.8 N•m (60 lb-in.). 8. Observe the number of rotations of the steering wheel that occurs in one minute. Also observe leakage from cylinder return connector. Compare results to specifications. 9. Reinstall hose and tighten to 16 N•m (144 lb-in.). Steering Tests and Adjustments - 372 STEERING TESTS AND ADJUSTMENTS Results: 3. Mark the center (D) on the front of the tires. • If steering wheel rpm is more than 4 rpm, and there is leakage (steady stream) from the cylinder return connector, the steering cylinder is leaking. Replace cylinder. Repeat test. 4. Measure distance between marks (E) from front (F) of right front tire to front of left front tire. Record distance. • If steering wheel rpm is still more than 4 rpm, repair or replace steering valve. 5. Rotate the tires 180 degrees so the marks on the front of the tires are now on the rear of the tires. Measure distance between marks (G) from back of right front tire to back of left front tire. Record distance. Toe-In Adjustment Front Wheels 6. Distance (E) should be 1 - 6 mm (0.04 - 0.24 in.) less than distance (G). Reason: 7. Loosen tie rod nuts (H) and adjust tie rods equally to achieve the specified toe-in. Correct toe-in adjustment prevents tire wear and steering wander. Specification: Toe-In. . . . . . . . . . . . . . . . . . . . . 1 - 6 mm (0.04 - 0.24 in.) Procedure: Note: Toe-in cannot be adjusted with wheels off the ground or on an uneven surface. Toe-In Adjustment All Wheel Steering 1. Park machine on level surface. Reason: Note: Measuring point should be from center of tire, hub height. Correct toe-in adjustment prevents tire wear and steering wander. Front Wheel Procedure: Note: Toe-in cannot be adjusted with wheels off the ground or on an uneven surface. Be sure the jam nut and cotter pin are tight. Add washers if needed. H 1. Park machine on level surface. E C G A Note: Measuring point should be from center of tire, hub height. B H H F MIF E C 2. Inspect tie rod (A), front axle (B), and steering cylinder (C) for damage. G A B H D F MIF 2. Inspect tie rod (A), front axle (B), and steering cylinder (C) for damage. I MIF Picture Note: I. Side View Steering Tests and Adjustments - 373 STEERING TESTS AND ADJUSTMENTS D I I M MIF Picture Note: I. Side View J 3. Mark the center (D) on the front of the tires. K L 4. Measure distance between marks (E) from front (F) of right front tire to front of left front tire. Record distance. MIF 5. Rotate the tires 180 degrees so the marks on the front of the tires are now on the rear of the tires. Measure distance between marks (G) from back of right front tire to back of left front tire. Record distance. 3. Measure from the center “bead” of left rear tire - from front of tire to machine frame (J) and then from back of tire to machine frame (K). Record measurements. 6. Distance (E) should be 1 - 6 mm (0.04 - 0.24 in.) less than distance (G). 4. Front measurement (J) should be 0 - 10 mm (0 - 0.4 in.) less then rear measurement (K). 7. Loosen tie rod nuts (H) and adjust tie rods equally to achieve the specified toe-in. 5. If necessary, adjust linkage. Rear Wheel Procedure: • Loosen jam nuts (L). • Rotate adjustment nut (M) until measurement difference meets specification. 1. Set toe-in on front wheels. Note: The 10 mm cap screw must be perpendicular to rear pivot plate and mounting plate when installed. • Tighten jam nuts to 68 N•m (50 lb-ft). 6. Repeat exact procedure for right rear tire. Specifications: Front Toe-In . . . . . . . . . . . . . . . 1 - 6 mm (0.04 - 0.24 in.) Rear Toe-In (each tire parallel to frame) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 10 mm (0 - 0.4 in.) M I L Front MX14233 2. Turn steering wheel until a 10mm cap screw can be installed through pivot plate and frame holes (I). Steering Tests and Adjustments - 374 STEERING REPAIR Repair Steering Column Removal and Installation 1. Remove the instrument panel and shroud to access steering assembly. See “Instrument Panel Removal and Installation” on page 463 in the Miscellaneous section. Removing: M A B B A A C B M C L D E N E MX35550 2. Remove snap ring (A), washer (B), and busing (C). L 3. Remove springs (E and L). K J F 4. Remove lever (M). I H G F D C H G G O F MIF A- Snap Ring (2 used) B- Washer (2 used) C- Bushing (2 used) D- Tilt Steering Housing E- Tilt Return Spring F- Flange Nut (2 used) G- Pivot Bolt (2 used) H- Nut I- Pawl J- Bolt K- Sector L- Spring M- Lever N- Steering Column Shaft O- Foam Spacer MX35551 5. Remove nut (F) on each side of column. 6. Push pivot bolt (G) into tilt steering housing. It may be necessary to shift steering shaft to get pivot bolt through bracket and housing. Remove pivot bolt. 7. Repeat pivot bolt removal on other side. 8. Slide tilt steering housing (D) up and off of steering column shaft. 9. Lift and remove steering column shaft. 10.If required, remove nut (H), bolt (J) and pawl (I). Installing: 1. Apply multipurpose grease to slotted end of steering column shaft. Steering Repair - 375 STEERING REPAIR 2. If removed, install lower bushing (C) into tilt steering housing. 3. Place steering shaft into steering control unit and if removed, install lower snap ring (A) and washer (B). 4. Lower tilt steering housing over column. 5. Install pivot bolts and nuts. 6. Install top bushing (C), washer and snap ring. Install lever (M). E 7. Install springs (E and L). 8. Install instrument panel and shroud (A). 9. Install steering wheel and nut. Tighten nut to specification. Install steering wheel cover. MX35898 Specifications: Steering Wheel Nut. . . . . . . . . 34 - 41 N•m (25 - 30 lb-ft) Steering Valve Removal and Installation 7. Remove three push pins (E) and slide closeout cover up on the steering shaft to access the steering valve mounting cap screws. Removing: 1. Remove the instrument panel and shroud to access steering assembly. See “Instrument Panel Removal and Installation” on page 463 in the Miscellaneous section. 2. Clean the area around the steering valve to prevent dirt and debris from getting into the hydraulic system. B F MX35899 D 8. Remove two cap screws (F) holding steering valve to machine frame. C 9. Remove steering valve from machine frame, and make repairs to valve as necessary. D Installing: A MX35897 3. Remove the two cap screws (A) and tube clamps. 4. Label the hydraulic hoses (B) for their location to the retainer plate (C). The hydraulic lines will only align to their proper locations. 5. Remove two cap screws (D). 6. Move retainer plate (C) just enough to remove hydraulic hoses and lines. Note: When installing steering valve, install cap screws finger-tight until all hydraulic lines are in place. 1. Raise steering valve into position and finger-tighten cap screws holding valve to machine frame. Important: Avoid Damage! Always use new O-rings. Damaged or used O-rings will leak. 2. Install hydraulic hoses and lines into the steering valve. 3. Install retainer plate into position and install and tighten two cap screws to 30 N•m (22 lb-ft). Steering Repair - 376 STEERING REPAIR 4. Install and tighten the tube clamp and cap screws holding line in position to machine frame. Panel Removal and Installation” on page 463 in the Miscellaneous section. 5. Tighten two cap screws, holding steering valve to machine frame. Specifications: 6. Slide the closeout cover down into position and secure with three push pins. Retainer Plate Cap Screws . . . . . . . . . . 30 N•m (22 lb-ft) Steering Valve Mounting Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (150 lb-in.) 7. Install the instrument panel and shroud. See “Instrument Steering Valve Disassembly and Assembly G E F H D C A B I J K L N M O M81128 A- Steering Valve Housing B- O-Ring C- Wear Plate D- Drive Shaft E- Gerotor Set F- Seal Ring G- End Cover H- Cap Screw I- O-Ring J- O-Ring K- Spacer L- O-Ring M- Plug N- O-Ring O- Check Ball 1. Remove cap screws to remove components from housing. 2. Remove manual steering check components. 3. Check ball, O-ring, and plug. Steering Repair - 377 STEERING REPAIR R Q A S P T M81129 4. Pull spool and sleeve assembly (S) from steering valve housing (A). 5. Remove quad seal (Q), thrust bearing race (R), and thrust bearing (T) components. Q R A W Important: Avoid Damage! Use care not to damage seal bore during removal. 6. Pry dust seal (P) from housing. M81131ae W 11.Install one bearing race (R) and sleeve (W) into valve housing (A). 12.While holding sleeve and bearing race tightly into housing, install quad seal (Q) into groove between bearing race and housing. Make sure the seal is not twisted. V U 13.Remove sleeve and bearing race. X Y W Z M81130 7. Remove pin (X) to separate sleeve (W) from spool (Y). V U 8. Remove retaining collar (U). c Caution: Avoid Injury! Use care when removing springs because springs (V) are under tension. X Y Z 9. Remove retaining ring (Z). M81130 10.Inspect all machined mating surfaces for scratches or burrs. Clean all parts in clean solvent and air dry. 14.Install retaining ring (Z). 15.Install two flat leafs of springs (V) in slot of spool (Y). Then install curved leafs between flat leafs, three at a time. Install retaining collar (U) over springs. Steering Repair - 378 STEERING REPAIR 16.Apply clean hydraulic oil to spool and install spool in sleeve (W). Springs must fit into notches of sleeve. 17.Install pin (X). R Q A S P T M81129 18.Install dust seal (P) with open side of seal away from housing (A). Use a disk driver to push seal to bottom of bore. Apply petroleum jelly to seal lips and quad seal (Q). Q A R AA A T R P M81134 S 21.Put housing (A) in a vise (AA) with the gerotor end up. 22.Install parts in housing. 23.Align holes of wear plate with housing holes. M81133ae 19.Install thrust bearing race (R), thrust bearing (T), and second thrust bearing race (R) components. 20.Apply clean hydraulic oil to spool and sleeve assembly (S). Carefully install assembly into housing (A) so not to damage seals. Important: Avoid Damage! Tighten vise only enough to hold housing or damage may occur to housing and sleeve. 24.Make sure drive shaft slot fits on pin and holes of wear plate align with holes of housing. 25.Align holes of gerotor with holes of wear plate. 26.Install cap screws and tighten in a criss-cross pattern to 17 N•m (150 lb-in.). 27.Remove steering valve from vise. Install ball, O-ring and plug. Tighten plug to 17 N•m (150 lb-in.). Steering Repair - 379 STEERING REPAIR Steering Cylinder Removal and Installation Front Axle Removal and Installation 1. Engage park brake. 2. Remove hood. See “Hood Removal and Installation” on page 458 in the Miscellaneous section. A 3. Remove battery. A B C MX11934 1. Disconnect hydraulic hose (C) and loosen hose (A) from steering cylinder (B). B A MX11936 B 4. Lift front of machine until front wheels (B) are off the ground. Install jack stands. 5. Remove two front wheels. 6. Remove steering cylinder (A) without disconnecting hydraulic lines. See “Steering Cylinder Removal and Installation” on page 380. E D D MX11935 C 2. Remove cotter pin (E) and nut (D) from each end of steering cylinder. Note: Cylinder ball joint ends are tapered. Use a forked tool or soft-faced hammer to loosen stud ends. 3. Remove steering cylinder and disconnect cylinder (B) from hose (A). 4. Replace steering cylinder if necessary. 5. Connect steering cylinder (B) to hose (A) and tighten hose to 16 N•m (144 lb-in.). 6. Install steering cylinder (B) to spindle arm and through axle housing. 7. Install nuts (D) and tighten to 33 N•m (24 lb-ft). Tighten nut to insert cotter pins (E). 8. Connect hydraulic hose (C) and tighten to 16 N•m (144 lb-in.). 9. Bleed the steering system. MX11937 Picture Note: 2-Wheel steer Shown; All wheel steer similar 7. Install a lift or hoist on axle. Remove lock nut (D) and bolt to remove front axle assembly (C). 8. Repair or replace axle assembly. 9. Apply multi-purpose grease to pivot bushings in axle assembly. 10.Lift axle assembly into position, while making sure machine frame fits between head of guide bolts and axle. Steering Repair - 380 STEERING REPAIR 11.Install bolt and lock nut (D). Tighten cap screw and lock nut to 203 N•m (150 lb-ft). A 12.Install steering cylinder. See “Steering Cylinder Removal and Installation” on page 380. B D C 13.Install front wheels and lower machine to the ground. F 14.Check and adjust axle toe-in. A G Front Axle Disassembly and Assembly D Note: All axle repair can be done while on the machine except for the axle pivot bushings (C). C E H K G C J I C B J G H I MIF Picture Note: 2-Wheel Steering Shown MX11938 Picture Note: 2-Wheel Steer Axle Shown 1. Remove nut (G) from both sides of axle and remove tie rod (J). 2. Remove snap ring (B) to remove spindle. 3. Repeat steps for other spindle. A- Bushing B- Snap Ring C- Bushing D- Grease Fitting E- Front Axle F- Front Spindle, Right G- Nut H- Ball Joint I- Nut J- Tie Rod K- Front Spindle, Left Note: Remove components from axle and replace as necessary. Steering Repair - 381 STEERING REPAIR 7. Install spindles (F and P), snap rings (B). B 8. Attach tie rod to ends of spindles and tighten nuts (G) to 61 N•m (45 lb-ft). C A D B 9. Check length of tie rod from center of stud to center of stud. Adjust rod length to approximately 292 mm (11-1/2 in.). F 10.Check and adjust axle toe-in after axle is installed. A Q R C E D G S T H I J P G K H L K O N G J G M MIF Picture Note: All Wheel Steering Shown A- Bushing B- Snap Ring C- Bushing D- Grease Fitting E- Front Axle F- Front Spindle, Right G- Nut H- Ball Joint I- Tie Rod J- Nut K- Ball Joint L- Steering Rod M- Shaft N- Cotter Pin O- Nut P- Front Spindle, Left Q- Cotter Pin R- Washer S- Nut T- Steering Cylinder 4. Install four flanged bushings (A) into axle until flange is tight to 1 mm (0.04 in.) maximum gap to casting. 5. Install two bushings (C) into axle bore until end of bushing is even with casting surface. 6. If removed, install three grease fittings (D). Steering Repair - 382 STEERING REPAIR Rear Steering Linkage - All Wheel Steering Components: B A D C E F G S H R I J K L P B Q O MX14246 A- Cotter Pin (4 used) B- Castle Nut (4 used) C- Pivot Plate D- Pivot Bracket E- Seal F- Tapered Roller Bearing G- Spacer H- Snap Ring I- Roller Bearing Q A M J- Washer K- Castle Nut L- Cap M- Tie Rod End N- Nut, LH Thread O- Nut, Adjuster P- Nut Q- Tie Rod R- Lock Nut S- Link Rod, Rear Steering Repair - 383 O N M STEERING REPAIR Removal: C G- Cotter Pin H- Cap Seal I- Grease Fitting J- Snap Ring K- Spacer B 1. Pry cap seal (H) from pivot plate. 2. Remove cotter pin (G), castle nut (F), washer (E) and pivot plate assembly parts. Note: Outer race of two tapered bearings (D) is slip fit. D 3. Remove pivot plate components. A MX14386 1. Remove lock nut (A) to disconnect rear link rod (B) from pivot plate assembly (C). 2. Remove left and right tie rod assemblies by removing hardware parts (C) from knuckle arm end and parts from pivot plate end of tie rods. 3. Remove cap screws and washers to remove pivot assembly (D). Disassembly: 4. Inspect bearings and ball joints for wear. Replace as necessary. Assembly: 1. Apply extreme pressure grease to rollers of bearings. 2. Install snap ring, upper bearing and seal into pivot plate. Install seal with closed side into bore first and even with top of pivot plate. 3. Install pivot plate, spacer, lower bearing, washer and nut. Tighten nut while making sure slot of nut aligns with hole in pivot shaft. 4. Install cotter pin. Fill cavity with extreme pressure grease and install cap seal. B A C Installation: 1. Install pivot assembly using cap screws and washers. Tighten cap screws to 91 N•m (67 lb-ft). K 2. Install right and left tie rods with castle nuts (A) and cotter pins. D 3. Check and adjust rear axle toe-in. See “Toe-In Adjustment All Wheel Steering” on page 373. J A E I G H F B MX14254 A- Seal B- Pivot Bracket C- Pivot Plate D- Tapered Roller Bearing (2 used) E- Washer F- Castle Nut C MX14386 4. Connect rear rod (A) to pivot plate (B) using lock nut (C). Tighten lock nut to 170 N•m (125 lb-ft). Steering Repair - 384 STEERING REPAIR Steering Intermediate Linkage - AWS I F K J F E H G E C D B A MX35905 A- Lock Nut - 170 N•m (125 lb-ft) B- Rear Intermediate Link Rod C- Lock Nut - 170 N•m (125 lb-ft) D- Rear Pivot E- Lock Nut - 68 N•m (50 lb-ft) F- Cap Screw - 84 N•m (62 lb-ft) G- Middle Link Rod H- Front Pivot I- Lock Nut - 170 N•m (125 lb-ft) J- Front Intermediate Link Rod K- Lock Nut - 170 N•m (125 lb-ft) 2. Remove front pivot (H) or rear pivot (D) by removing cap screws (F) and nuts. Installation: 1. Install pivot. 2. Install link rods. Make sure front and rear steering assemblies are centered. Tighten lock nut to 170 N•m (125 lb-ft). 3. Connect front end of middle link rod (F) to front pivot using lock nut. Tighten lock nut to 68 N•m (50 lb-ft). Note: Rear (B) intermediate link is not adjustable. Ball joint ends are peened to rod. Complete link must be replaced if any part is worn or damaged. Removal: 1. Remove lock nut (A and C) from each end of link. Steering Repair - 385 STEERING REPAIR Front and Rear Pivots D C A B W E A F V M G J I U L E K L G H T O S R Q O N G MIF A- Ball Bearing B- Spacer C- Snap Ring D- Pivot Lock Nut E- Flange Nut F- Screw (4 used) G- Lock Nut H- Pivot Lock Nut I- Screw J- Housing, Rear Pivot K- Spacer L- Ball Bearing (2 used) M- Pivot Arm N- Link Rod, Rear O- Snap Ring P- Tie Rod End Q- Jam Nut R- Adjustment Nut S- Jam Nut T- Link Rod, Middle U- Tie Rod End V- Shaft, Pivot Arm W- Housing, Front Pivot Steering Repair - 386 STEERING REPAIR Removing: 1. Remove nut and snap ring. Replace parts as necessary. Installing: 1. Install one bearing at a time in a press, making sure to include spacer between bearings. Seat snap ring after removing assembly from press. 2. Install pivot arm shaft and lock nut. Tighten lock nut to specification. Specifications: 2WD Pivot Lock Nut . . . . . 200 ± 40 N•m (148 ± 30 lb-ft) 4WD Pivot Lock Nut . . . . . 367 ± 73 N•m (271 ± 54 lb-ft) Jam Nuts . . . . . . . . . . . . . . . . . . . . . . . . 68 N•m (50 lb-ft) Flange Nuts . . . . . . . . . . . . . . . . . . . . . . 80 N•m (59 lb-ft) Lock Nuts . . . . . . . . . . . . . . . . . . . . . 170 N•m (125 lb-ft) Steering Repair - 387 STEERING REPAIR Steering Repair - 388 BRAKES TABLE OF CONTENTS Brakes Table of Contents Specifications ...............................................391 General Specifications ...............................391 Test and Adjustment Specifications ...........391 Repair Specifications..................................391 Special or Essential Tools ..........................391 Other Materials...........................................391 Component Location....................................392 Brake System Component Location...........392 Brake/Differential Linkage (Exploded)........393 Theory of Operation .....................................394 Brake System Operation ............................394 Diagnostics ...................................................395 Brakes ........................................................395 Tests and Adjustments ................................397 Brake/Differential Linkage Adjustment .......397 Repair.............................................................399 Brake/Differential Linkage Removal and Installation ..................................................399 Brakes Removal and Installation................401 Brakes Table of Contents - 389 BRAKES TABLE OF CONTENTS Brakes Table of Contents - 390 BRAKES SPECIFICATIONS Specifications General Specifications Brakes: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal wet disk Test and Adjustment Specifications Brake/Differential Linkage Adjustment: With 45 N (10 lb force) applied to brake and differential lock arm just contacting differential lock shaft, adjust differential lock link outward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 turns Repair Specifications Transaxle Brake Cover Cap Screws Torque - Used Transaxle Case . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (221 lb-in.) Transaxle Brake Cover Cap Screws Torque - New Transaxle Case. . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Brake Switch Striker Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (108 lb-in.) Brake Adjustment Gap (Pin and Brake Rod Spring Retainer) . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9 mm (0.12 - 0.35 in.) Special or Essential Tools Note: Order tools according to information given in the U.S. SERVICE-GARD™ Catalog or in the European Microfiche Tool Catalog (MTC). Special or Required Tools Tool Name Gauge Tool No. F67-10-61505 Tool Use For measuring gap between roll pin and brake rod spring retainer (brake adjustment). Other Materials Other Material Part No. Part Name Part Use TY15130 John Deere Form-in-Place Gasket Seal mating surfaces of transaxle TY6305/TY9485/#764 Cure primer Clean thread of sealing suraces TY9370/TY9477/#242 Thread Lock and Sealer (Medium Strength) Retain brake mounting cap screws Brakes Specifications - 391 BRAKES COMPONENT LOCATION Component Location Brake System Component Location A B C O N D E M L K J I H MX14415 A- Pad, Brake Pedal B- Handle, Park Brake Rod C- Park Brake Rod D- Latch E- Mid-Lift Shaft F- Differential Lock Shaft G- Differential Lock Arm G F H- Differential Lock Link I- Brake Arm and Cam J- Rod, Brake Arm K- Brake Rod L- Brake Return Spring M- Brake Shaft N- Brake Spring Retainer O- Brake Pedal Brakes Component Location - 392 BRAKES COMPONENT LOCATION Brake/Differential Linkage (Exploded) D B C E H F A G I J AO K AN AL AM L M P O AK N AJ Q AI R S T U V O W AH AG X AE AD AF Z AC Y AB AA Brakes Component Location - 393 Y BRAKES THEORY OF OPERATION MIF A- Rod, Parking Brake B- Washer C- Coupling D- Cotter Pin E- Screw F- Handle G- Brake Pedal H- Pad, Brake Pedal I- Strip J- Screw K- Bushing L- Latch M- Washer N- Rod, Cruise Control Disconnect O- Bearing P- Washer Q- Screw R- Spring Pin S- Bolt T- Guide U- Compression Spring V- Washer W- Cotter Pin X- Yoke Y- Spring Locking Pin Z- Pin AA- Brake Arm and Cam AB- Rod, Rear Brake AC- Mid-Lift Shaft AD- Retainer, Brake Spring AE- Pin AF- Extension Spring AG- Cap Screw AH- Striker AI- Brake Shaft AJ- Spring Locking Pin AK- Lock Nut AL- Washer AM- Spring AN- Foam Pad AO- Bushing Theory of Operation Brake System Operation Note: See “Component Location” on page 392. Function: Provide a means of stopping the machine and also prevent movement when not in use. System Operation: When the brake pedal is depressed, the brake spring retainer is pulled forward. The brake spring is compressed and spring tension pulls the brake rods and the brake arm and cam forward. As the brake arm and cam rotates, the cam plate rotates, rolling three balls up a ramp. When the balls move up the ramp, the cam plate pushes against the brake plates, forcing the brake plates and brake discs together. The brake plates are attached to the transaxle housing through external tangs on the plates. The brake plates cannot rotate. Brake discs that are splined to the reduction shaft are located between the brake plates. The brake discs rotate whenever the reduction shaft rotates. The pressure of the brake plates against the brake discs stops the reduction shaft rotation. At the same time the brake arm and cam is engaged, the differential lock is also engaged to provide braking to both rear wheels. The brake arm and cam pushes the differential lock link and arm rearward. The differential lock shaft and fork move into the transaxle and engage the differential lock pins to lock both axles together. When the brake pedal is released, the brake return spring pulls the brake pedal and linkage to the disengaged position. The linkage pulls the cam plate away, releasing the pressure against the plates and disk. The brake pedal can be locked in the engaged position to be used as a parking brake. When the park brake rod is engaged, the park brake pawl contacts a tab on the brake pedal to hold the pedal in the engaged position. Brakes Theory of Operation - 394 BRAKES DIAGNOSTICS Diagnostics Symptom: Brake Problems Problem Cause - Solution Brakes 3. Brakes will not release? a. No: Go to next step. 4. Brakes noisy or chatter? a. No: Go to next step. Symptom: Brake Problems Problem Cause - Solution 1. Poor or no brakes? a. No: Go to next step. b. Yes: Brake pedal or linkage bent, binding or worn. Brake spring broken or collapsed. Brake linkage freeplay adjustment incorrect. Brake arm and cam bent, binding, or worn. Differential lock arm bent, binding, or worn. Brake plates and disks warped, grooved, or worn. Transaxle internal differential lock components binding or worn. Transaxle internal brake components binding or worn. 2. Brakes binding or a. No: Go to next step. brake effort excessive? b. Yes: Brake pedal or linkage bent, binding or worn. Brake spring broken or collapsed. Brake linkage freeplay adjustment incorrect. Park brake rod and pawl bent or binding. Brake arm and cam bent, binding, or worn. Differential lock arm bent, binding, or worn. Brake plates and disks warped, grooved, or worn. Transaxle internal brake components binding or worn. Transaxle internal differential lock components binding or worn. Brakes Diagnostics - 395 b. Yes: Brake pedal or linkage bent, binding or worn. Brake spring broken or collapsed. Brake return spring broken or stretched. Brake linkage freeplay adjustment incorrect. Park brake rod and pawl bent or binding. Differential lock arm bent, binding, or worn. Brake arm and cam bent, binding, or worn. Brake plates and disks warped, grooved, or worn. Transaxle internal brake components binding or worn. Transaxle internal differential lock components binding or worn. b. Yes: Brake pedal or linkage bent, binding or worn. Brake spring broken or collapsed. Park brake rod and pawl bent or binding. Brake arm and cam bent, binding, or worn. Differential lock arm bent, binding, or worn. Brake plates and disks warped, grooved, or worn. Transaxle internal brake components binding or worn. Transaxle internal differential lock components binding or worn. BRAKES DIAGNOSTICS Symptom: Brake Problems Problem Cause - Solution Symptom: Parking Brake Problems Problem Cause - Solution 5. Excessive brake wear? 2. Park brake will not release? a. No: Go to next step. 3. Parking brake will not engage? a. No: Go through diagnostic procedures or go back to step 1. a. No: Go through diagnostic procedures or go back to step 1. b. Yes: Brake pedal or linkage bent, binding or worn. Brake return spring broken or stretched. Brake linkage freeplay adjustment incorrect. Brake arm and cam bent, binding, or worn. Differential lock arm bent, binding, or worn. Brake plates and disks warped, grooved, or worn. Transaxle internal brake components binding or worn. Transaxle internal differential lock components binding or worn. Symptom: Parking Brake Problems Problem Cause - Solution 1. Parking brake will not engage? a. No: Go to next step. b. Yes: Brake pedal or linkage bent, binding or worn. Brake spring broken or collapsed. Brake return spring broken or stretched. Brake linkage freeplay adjustment incorrect. Park brake rod and pawl bent or binding. Brake arm and cam bent, binding, or worn. Differential lock arm bent, binding, or worn. Brake plates and disks warped, grooved, or worn. Transaxle internal brake components binding or worn. Transaxle internal differential lock components binding or worn. Brakes Diagnostics - 396 b. Yes: Brake pedal or linkage bent, binding or worn. Brake return spring broken or stretched. Brake linkage freeplay adjustment incorrect. Park brake rod and pawl bent or binding. Brake arm and cam bent, binding, or worn. Differential lock arm bent, binding, or worn. Brake plates and disks warped, grooved, or worn. Transaxle internal brake components binding or worn. Transaxle internal differential lock components binding or worn. b. Yes: Brake pedal or linkage bent, binding or worn. Brake spring broken or collapsed. Brake linkage freeplay adjustment incorrect. Park brake rod and pawl bent or binding. Brake arm and cam bent, binding, or worn. Differential lock arm bent, binding, or worn. Brake plates and disks warped, grooved, or worn. Transaxle internal brake components binding or worn. Transaxle internal differential lock components binding or worn. BRAKES TESTS AND ADJUSTMENTS Tests and Adjustments Brake/Differential Linkage Adjustment Reason: To adjust brake linkage for proper braking and differential lock engagement when the brake pedal is applied. Machine creeps when on a slope with park brake engaged. Brakes may not stop machine completely when operating on an incline. 2. Disconnect brake arm rod (F) from brake arm (H). This is easiest if done from left underside of machine by pulling the cotter pin from the brake arm rod end. Test Equipment: • B- Striker C- Brake Rod Yoke D- Retainer, Brake Spring E- Roll Pin F- Brake Arm Rod G- Link Rod H- Brake Arm I- Differential Lock Arm J- Differential Lock Shaft Spring Scale 3. Disconnect the forward end of link rod (G) from brake arm (H). Procedure: 1. Release brake pedal. c asCaution: Avoid Injury! Do not pre-load brakes excessive wear of brake components will result. 4. Connect spring scale to bottom of brake arm (H) and pull forward with 45 N (10 lb. force). 5. Push link rod (G) rearward until differential lock arm (I) contacts the differential lock shaft (J). 6. Check alignment of link rod (G) and brake arm (H) as shown below. D E F K C A B G F L G H H I MX14384 A- Cap Screw MX14281 J 7. Front of link rod (G) should be flush or up to 2 mm (0.08 in.) behind front edge of brake arm (H) hole (K). Brakes Tests and Adjustments - 397 BRAKES TESTS AND ADJUSTMENTS Note: It may be necessary to move link rod (G) into rear hole (as shown above), if linkage cannot be adjusted enough for proper function of brake arm. 8. Adjust rod by turning inward or outward (link has left hand threads), one full turn at a time, up to 6 turns. 9. Remove spring scale slowly to relieve tension. D 10.Reinstall link rod, brake arm rod and cotter pins. 11.Adjust brake rod yoke (C) until there is no freeplay in the brake linkage with the brake pedal released. Check linkage for binding after adjustment. If rear wheels are rotated and brakes drag, linkage is too tight. Rotate rear wheels to be sure differential lock is not engaged and brakes do not drag. E C B MX14384 A MIF Picture Note: NOTE: Side view shown • With the park brake locked, and using a F67-10-61505 Gauge, the brake rod roll pin (E) must be 3 - 9 mm (0.12 0.35 in.) away from brake rod spring retainer (D). If not, shorten brake rod by rotating brake rod yoke (C) in either direction. 12.Loosen cap screw (A). • 13.Depress brake pedal and engage park brake lock. • If brakes don’t hold, this indicates that linkage is “bottoming out” on differential lock, preventing “full” brake engagement, OR brake service is required. Note: The actuator must not contact the switch body. Engage brake. See if it holds on slope in question. 14.Rotate actuator (B) until the switch plunger is depressed, but not bottomed out. 15.Hold actuator in position and tighten cap screw (A) to 12 N•m (108 lb-in.). 16.Retest machine on slope with park brake engaged. 17.If machine will not hold on slope without tires creeping, repeat above steps until machine will hold. Results: If the brake/differential linkage adjustment is correct: • The brake linkage should not have any freeplay with the brake pedal released and the differential lock should not be engaged. • The differential lock will be engaged when the brakes are engaged. Note: Brake arm rod (F) may have to be relocated to rear hole (L) if yoke (C) cannot be adjusted to pivot. Brakes Tests and Adjustments - 398 BRAKES REPAIR Repair Brake/Differential Linkage Removal and Installation Removing: 1. Disconnect negative battery terminal and remove fender deck. See “Fender Deck Removal and Installation” on page 459 in the Miscellaneous section. 2. Remove footrest. L- Brake Arm Rod M- Pin N- Brake Rod Yoke O- Spring, Brake Return P- Striker Q- Cap Screw 3. Making sure the parking brake is released, and using a suitable spring tool, disconnect brake return spring (O) from mid-Lift shaft (H) and brake shaft (A) arm. 4. Remove spring pin and pin (B) holding brake spring retainer (C) to arm on brake shaft (A). R S D E E C F B D Z H A Y G G X V M G O Q P N U W T L F P A K J G Q MIF I 5. Loosen nut (Q) and remove striker (P) from end of brake shaft. MX14384 A- Brake Shaft B- PIn C- Retainer, Brake Spring D- Brake Pedal E- Parking Brake Rod F- Bolts (2) G- Bearing H- Mid-lift shaft I- Differential Lock Arm J- Brake Arm K- Link Rod 6. Remove two bolts (F), washer (T), and brake pedal (D) from brake shaft. 7. Remove bushings (G) on both sides of machine and inspect for wear. Replace, as necessary. 8. Slide brake shaft to left of machine, while carefully removing cruise control disconnect rod (U) from bottom of brake shaft (A). 9. Remove brake shaft and inspect for wear or damage. Replace, as necessary. 10.To remove parking brake rod (E) and latch (Y): • Remove screw (S) and parking brake handle (R). Brakes Repair - 399 BRAKES REPAIR • Remove spring pin (W) and washer (V) from under latch (Y). Raise parking brake rod out of hole in latch (Y), and lower rod from beneath machine. • Remove latch (Y), by removing nut (X), bolt (Z), and associated hardware. Installing: C R S B H E A D Z Y O G X V U W MX14384 T P F 6. Install brake spring retainer (C) to arm on brake shaft (A), and secure with pin (B) and spring pin. 7. Making sure the parking brake is released, and using a suitable spring tool, disconnect brake return spring (O) from mid-Lift shaft (H) and brake shaft (A) arm. A G 8. Install footrest. Q MIF 1. To install parking brake rod (E) and latch (Y): 9. Install fender deck and connect negative battery terminal. See “Fender Deck Removal and Installation” on page 459 in the Miscellaneous section. • Install latch (Y), by installing hardware, bolt (Z) and nut (X). • Raise parking brake rod from under machine, and install bottom of rod into latch (Y). Install washer (V) and spring pin (W) under latch (Y). • Install parking brake handle (R) and screw (S). 2. Install bushings (G) on both sides of machine. 3. Raise brake shaft (A) right side end into machine frame. Install cruise control disconnect rod (U) to bottom of brake shaft (A). 4. Install brake pedal (D) and washer (T). Secure with two bolts (F). 5. Install striker (P) onto end of brake shaft and secure with nut (Q). When entire brake assembly is installed, adjust brake switch. See “Brake Switch Test and Adjustment” on page 220 in the Electrical section. Brakes Repair - 400 BRAKES REPAIR Brakes Removal and Installation C B D A E F G S L K R Q I P H O N J M L K MX14424 A- Snap Ring B- Brake Actuator Plate C- Friction Plate D- Steel Plate E- Steel Ball F- Clevis Pin G- Washer H- Spring Lock Pin I- O-Ring J- Interlock Plate K- Cotter Pin L- Washer M- Rod N- Adjusting Nut O- Nut P- Rod Q- Cam Lever R- Brake Cover S- Cap Screw 1. Remove transaxle. See See “Transaxle Removal and Installation” on page 297 in the Hydrostatic Power Train section. Important: Avoid Damage! Use care not to lose steel balls (E). 2. Inspect components on brake cover (R). Replace as necessary. Apply petroleum jelly to O-ring. Brakes Repair - 401 BRAKES REPAIR 3. Inspect plates for wear or spline damage. If groove pattern in friction plates is no longer visible, replace plates. 4. Apply petroleum jelly to balls (E) and install balls in cover. 5. Install steel plates (D) and friction plates (C) alternately beginning with a steel plate. 6. Apply a bead of John Deere Form-in-Place Gasket to brake cover mating surface of transaxle case. 7. Install brake actuator plate (B) and brake cover assembly (R). Brake Cover Cap Screw Torque Specifications: Used Transaxle Case . . . . . . . . . . . . . . 25 N•m (18 lb-ft) New Transaxle Case . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) 8. Check brake/differential linkage adjustment. See “Brake/ Differential Linkage Adjustment” on page 397. Brakes Repair - 402 ATTACHMENTS TABLE OF CONTENTS Attachments Table of Contents Specifications ...............................................405 General Specifications ...............................405 Torque and Repair Specifications ..............407 Diagnostics ...................................................409 48, 54 and 62-Inch Mower Deck Diagnosis409 45 Loader Diagnosis ..................................412 Tests and Adjustments ................................414 Adjusting Cutting Height (48C, 54C, and 62C Mower Deck).......................................414 Adjusting Mower Deck Wheels...................414 Mower Deck Level Check and Adjustment.414 Adjusting Mower Level Side-to-Side ..........415 Adjusting Mower Level Front-to-Rear.........416 Adjusting Latch Rod ...................................416 Cylinder Leakage Test ...............................417 45 Loader Lubrication.................................417 Repair.............................................................418 Cleaning Grass and Debris From Machine 418 Mower Deck Belt and Shield Removal and Installation ..................................................418 Mower Deck Blade Removal and Installation ..................................................420 Mower Deck Blade - Sharpen ....................420 Mower Deck Blade - Balance .....................421 48C Mower Deck Spindle Removal and Installation ..................................................421 Idlers...........................................................423 Jacksheave ................................................424 54C Mower Deck Spindle Removal and Installation ..................................................424 Jacksheave ................................................426 Idlers...........................................................427 62C Mower Deck Spindle Removal and Installation ..................................................427 Mower Deck Drive Shaft Removal and Installation ..................................................429 Mower Deck Drive Shaft Repair .................430 Mower Deck Gearbox Removal and Installation ..................................................431 Mower Deck Gearbox Repair .....................433 General Information..................................... 434 Reading Electrical Schematics .................. 434 Operation and Diagnostics ........................ 435 Diagnostic Information ............................... 435 Wire Color Abbreviation Chart ................... 435 Common Circuit Tests ............................... 436 Conductors For 12 Volt Circuits................. 436 Identification Numbers ................................ 437 Generator................................................... 437 Alternator ................................................... 437 Component Location ................................... 438 Generator................................................... 438 Alternator Components.............................. 439 Control Panel ............................................. 440 Generator Gear Box Components ............. 441 Schematics and Harnesses ........................ 442 Wiring Harness Legend ............................. 442 Connectors ................................................ 442 Standard Electrical Schematic................... 443 Operation and Diagnostics ......................... 445 Generator Circuit Operation....................... 445 Generator Circuit Diagnosis....................... 445 Tests and Adjustments ............................... 447 Generator Stator Test ................................ 447 Generator Rotor Test................................. 448 Ground Fault Circuit Interrupter (GFCI) Checks....................................................... 448 Generator Ground Test.............................. 449 Repair............................................................ 449 Stator Excitation Field Restoration ............ 449 PTO Shield Removal and Installation ........ 450 Generator Removal and Disassembly ....... 450 Gear Case Removal and Disassembly...... 450 Rotor Bearing Removal and Installation .... 452 Rotor Fan Removal and Installation .......... 452 Generator Assembly and Installation......... 453 Control Panel Removal and Installation..... 454 Attachments Table of Contents - 403 ATTACHMENTS TABLE OF CONTENTS Attachments Table of Contents - 404 ATTACHMENTS SPECIFICATIONS Specifications General Specifications 48-Inch Mower Deck: Discharge Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mulch, Bag or Side Cutting Height Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - 127 mm (1 - 5 in.) Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 kg (117 lb) Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 cm (48 in.) PTO Gearbox Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 L (13.5 oz) Belt Tension Spring Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.8 cm (5-7/16 in.) Blade Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.25 in.) Higher in Rear Anti-Scalp Wheel Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.25 in.) 54-Inch Mower Deck: Discharge Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mulch, Bag or Side Cutting Height Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - 127 mm (1 - 5 in.) Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 kg (170 lb) Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137.2 cm (54 in.) PTO Gearbox Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 L (13.5 oz) Belt Tension Spring Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.8 cm (5-7/16 in.) Blade Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.25 in.) Higher in Rear Anti-Scalp Wheel Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.25 in.) 62-Inch Mower Deck: Discharge Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mulch, Bag or Side Cutting Height Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - 127 mm (1 - 5 in.) Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 kg (200 lb) Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157.5 cm (62 in.) PTO Gearbox Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 L (13.5 oz) Belt Tension Spring Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.8 cm (5-7/16 in.) Blade Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.25 in.) Higher in Rear Anti-Scalp Roller Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Adjustable Loader Specifications: Maximum Lift Height To Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1854.2 mm (73 in.) Maximum Lift Height Under Level Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1752.6 mm (69 in.) Maximum Clearance Under Fully Dumped Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1447.8 mm (57 in.) Reach With Bucket Dumped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584.2 mm (23 in.) Maximum Bucket Dump Angel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 degrees 2WD: Reach with Bucket On Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1128.6 mm (44.43 in.) 4WD: Reach With Bucket On Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1098.6 mm (43.25 in.) Bucket Roll-Back Angle On Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 degrees Digging Depth Below Ground Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.6 mm (4 in.) Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 kg (515 lb) Attachments Specifications - 405 ATTACHMENTS SPECIFICATIONS Loader Hydraulic System: Rated Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6895 kPa (1000 psi) Lift Cylinder Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 mm (1.75 in.) Bucket Cylinder Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 mm (1.75 in.) Break out Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 kg (770 lb) Bucket Rollback Force at Ground Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 kg (740 lb) Lift Capacity at 914 mm (36 in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 kg (640 lb) Lift Capacity at Full Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 kg (365 lb) Bucket: Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1219 mm (48 in.) Capacity (Struck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 cu. m (5.0 cu. ft) Recommended Lubricants: Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GL-5 (90W) Greases - High-Speed: Blade Spindles (3 places) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere Multi-Purpose SD Polyurea Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . or John Deere Multi-Purpose Lithium Complex Grease PTO Shaft Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere Multi-Purpose SD Polyurea Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . or John Deere Multi-Purpose HD Lithium Complex Grease Greases - Other Applications: Caster Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere Multi-Purpose HD Lithium Complex Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . or John Deere Moly High Temperature EP Grease Caster Wheel Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere Multi-Purpose HD Lithium Complex Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . or John Deere Moly High Temperature EP Grease PTO Shaft Splines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere Multi-Purpose HD Lithium Complex Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . or John Deere Moly High Temperature EP Grease Note: If not using any of the preferred greases, be sure to use a general purpose grease with an NLGI Grade No. 2 rating. Avoid use of John Deere Moly High Temperature EP Grease on high speed applications such as mower spindles and rear axles. PTO Generator Specifications: 120 VAC (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Amp, NEMA 5-20R, GFCI Protected Duplex Receptacles 240 VAC (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Amp, NEMA 6-50 Receptacle Maximum Output (Intermittent) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10560 watts Rated Voltage (AC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120/240 Continuous Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9600 watts Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Hz Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Weight (Shipping). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 kg (247 lb) Weight (Operating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kg (194 lb) Height (approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.1 cm (30.75 in.) Width (approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.9 cm (27.13 in.) Length (approximate). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.4 cm (31.25 in.) PTO Input Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Spline, 1 - 3/8 in. Diameter Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80W90 GL5 Gear Lube Gear Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.63 L (23 oz) Attachments Specifications - 406 ATTACHMENTS SPECIFICATIONS Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discrete Output Thermal Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Over/Under Voltage Meter Stator Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self Exciting, Dual Output Brushless Rotor Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self Regulating Brushless Torque and Repair Specifications 48-Inch Mulch, Bag or Side Discharge Mower Decks: Blade Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.) Blade Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 N•m (50 lb-ft) Spindle Mounting Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ± 4 N•m (230 ± 4 lb-in.) Spindle Sheave Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 N•m (106 lb-ft) Lower Seal Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 mm (0.31 in.) below hub flange Gauge Wheel Roller Shaft Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Jack Sheave Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 N•m (100 lb-ft) Tensioning Idler Sheave Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) 54-Inch Mulch, Bag or Side Discharge Mower Decks: Blade Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.) Blade Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 N•m (50 lb-ft) Spindle Mounting Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ± 4 N•m (230 ± 4 lb-in.) Spindle Sheave Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 N•m (106 lb-ft) Lower Seal Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 mm (0.31 in.) below hub flange Gauge Wheel Roller Shaft Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Jack Sheave Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 N•m (100 lb-ft) Tensioning Idler Sheave Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) 62-Inch Mulch, Bag or Side Discharge Mower Decks: Blade Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.) Blade Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 N•m (50 lb-ft) Spindle Mounting Lock Nut (6 used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 N•m (18 ± 4 lb-ft) Spindle Flanged Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 N•m (188 lb-ft) Support Arm Pivot Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 ± 20 N•m (99 ± 20 lb-ft) Front Caster Wheel Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 N•m (60 lb-ft) PTO Gear Box to Frame Cap Screw (4 used). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 N•m (73 lb-ft) Loader Specifications: Hydraulic System Rated Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6895 kPa (1000 psi) Lift Cylinder Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 mm (1.75 in.) Bucket Cylinder Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 mm (1.75 in.) Breakout Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 kg (770 lb) Bucket Rollback Force at Ground Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 kg (740 lb) Lift Capacity at 914 mm (36 in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 kg (640 lb) Lift Capacity at Full Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 kg (365 lb) Attachments Specifications - 407 ATTACHMENTS SPECIFICATIONS PTO Generator Electrical Specifications: Watts (AC) Rated (Continuous) at power factor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9600 Watts (AC) Rated (Peak). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10560 Rated Voltage (AC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120/240 Rated Amperage (120 VAC) at each outlet at 40° C (104° F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Rated Amperage (240 VAC) at outlet at 40° C (104° F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Hz Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Attachments Specifications - 408 ATTACHMENTS DIAGNOSTICS Diagnostics 48, 54 and 62-Inch Mower Deck Diagnosis Special or Required Tools Tool Name Leveling Gauge Tool No. AM130907 Tool Use To check blade level. Test Procedure A B Test Conditions: • Machine parked safely. • PTO disengaged. MX11040a 2. Is mower deck level front-to-back? Yes: Go to next step. Mower Deck Linkage No: Adjust linkage (B) as needed. See “Mower Deck Level Check and Adjustment” on page 414. Mower Deck Drive Belt A A B C MX11041 B 1. Is the mounting hardware (A) in place and secure? B C Yes: Go to the next step. MX11043a No: Tighten or replace hardware. 1. Are the drive belt (A), sheaves (B), and pulleys (C) free of debris? Mower Deck Level Yes: Go to next step. A No: Remove belt shields and remove debris. 2. Is the drive belt slipping? Yes: Check for worn belt or debris around sheaves or mower plugged. No: Go to the next step. 3. Is the correct belt installed? Yes: Go to the next step. MX11041 1. Is mower deck level side-to-side? No: Replace belt. 4. Is the drive belt damaged, worn, stretched or broken? Yes: Go to step. No: Adjust clevis (A) as needed. See “Mower Deck Level Check and Adjustment” on page 414. Yes: Replace belt if necessary. No: Go to the next step. Attachments Diagnostics - 409 ATTACHMENTS DIAGNOSTICS D A MX11043a A A 5. Is the discharge chute (D) plugged? MX11047 Yes: Check to see if belt is installed correctly. 4. Is the spindle (A) properly lubricated? No: Go to the next step. Yes: Go to the next step. Mower Drive Belt Tension Spring No: Apply specific grease to lube fittings at top of spindle. 5. Are bearing free of ware or damage and rotate smoothly? Yes: End test. No: Repair or replace spindles as needed. Mower Blades A 1. Are blades tight on spindle? MX11047 1. Is the tension spring (A) damaged, worn or weak? Yes: Replace spring. Yes: Go to the next step. No: Tighten blade cap screw. See “Mower Deck Blade Removal and Installation” on page 420. 2. Are the blades bent, worn or damaged? No: Go to the next step. Yes: Replace blades. Spindle and Housing 1. Is the spindle sheave running straight and true, not damaged or bent? No: Go to the next step. Yes: Go to the next step. No: Repair or replace as needed. 2. Is the belt off sheave? Yes: Install or replace belt. No: Go to the next step. 3. Is there material wrapped around spindle or blade? M61524 Yes: Remove material. No: Go to the next step. 3. Are the blades properly sharpened and balanced? Yes: Go to the next step. No: Sharpen and balance blades. 4. Is the cut even? Yes: Go to the next step. No: Sharpen and balance blades. Attachments Diagnostics - 410 ATTACHMENTS DIAGNOSTICS Test Procedure B 5. Is there too much vibration? Yes: Balance blades. Test Conditions: No: Go to the next step. • Machine parked on a clean, level surface, away from people and objects. 6. Does the mower load down tractor? Yes: Check for bent blades. No: Go to the next step. 7. Are the blades scalping the grass? Yes: Check for bent blades. No: End test. • Engine running at fast idle. • Engine at operating temperature. • Mower deck lowered to the ground. • PTO engaged. Engine Gauge Wheel Assemblies 1. Is the engine running at the correct RPM? Yes: End test. No: Check engine operation. See Engine Section. Mower Deck Drive Shaft A MX11044 1. Are the gauge wheel assemblies properly lubricated? Yes: End test. A No: Apply specified grease to pivot lubrication fittings (A) on each gauge wheel. MX11043 1. Is the drive shaft (A) operating smoothly, without any unusual noises, or vibrations? Yes: Go to the next step. No: Slowly reduce engine rpm and listen for problem area. Disengage PTO and stop engine. Repair or replace faulty or damaged components. Attachments Diagnostics - 411 ATTACHMENTS DIAGNOSTICS 45 Loader Diagnosis Test Procedure A Test Conditions: • Machine parked safely. Hydraulic System C A MX8268 4. Is the loader operation slow or jerky? Yes: Check to ensure that lift cylinder shut-off valve (C) is completely closed. No: Go to the next step. MX12364 1. Is the loader operation slow or jerky? Yes: Check transaxle oil level at filler (A). No: Go to the next step. 2. Is the loader operation slow or jerky? Yes: Replace transaxle filter. No: Go to the next step. D MX13535 5. Does the bucket or lift arms drift down from raised position? Yes: Check control valve (D) for damaged O-rings, wiper seals, or internal leakage. No: Go to the next step. B MX13537 3. Is the loader operation slow or jerky? Yes: Check hydraulic circuit (B) for oil leaks. No: Go to the next step. Attachments Diagnostics - 412 ATTACHMENTS DIAGNOSTICS E MX12362 6. Are there oil leaks or insufficient lift capacity? Yes: Check cylinders (E) for damaged O-rings, wiper seals, or internal leakage. No: Go to the next step. F MX13537 7. Are the cylinders inoperative? Yes: Check the connection (F) between control valve and cylinder hoses. No: Test complete. Attachments Diagnostics - 413 ATTACHMENTS TESTS AND ADJUSTMENTS Tests and Adjustments Mower Deck Level Check and Adjustment Adjusting Cutting Height (48C, 54C, and 62C Mower Deck) Adjusting Cutting Height: Mower cutting height can be adjusted from approximately 25 - 127 mm (1-5 in.), depending on the machine. When lift lever is in highest (transport) position, cutting height is approximately 127 mm (5 in.), 114.3 mm (4.5 in.) for AWS. c Caution: Avoid Injury! Mower blades may be sharp. Wear heavy gloves or wrap the blade edges with a rag to prevent injury during handling. Special or Required Tools 1. Stop machine on a hard, level surface. 2. Pull back top hydraulic lever to raise mower deck to highest (transport) position. 3. Turn cutting height knob to desired cutting height. Mower will be at that cutting height when it is lowered. 4. Push forward top hydraulic lever to lower mower deck. 5. Park machine safely. See Parking Safely in the Safety section. 6. Check that the actual height-of-cut matches, within 6.35 mm (1/4 in.), the reading on the cutting height knob. If they do not match, adjust mower deck side-to-side and/or frontto-rear. Adjusting Mower Deck Wheels 1. Inflate vehicle tires to correct pressure. 2. Raise mower deck to highest (transport) position and adjust cutting height. 3. Lower deck to mowing position. 4. Park machine safely. See Parking Safely in Safely section. Tool Name Leveling Gauge Tool No. AM130907 Tool Use To check blade level. 1. Park machine safely. See Parking Safely in Safely section. 2. Lower mower deck to the ground. 3. Inflate vehicle tires to correct pressure. 4. Set mower deck to desired cutting height. 5. Make sure that mower deck wheels and rear hangers are set to the same height. 6. Adjust anti-scalp wheel to proper height specification on left and right side of mower deck. c Caution: Avoid Injury! Mower blades may be sharp. Wear heavy gloves or wrap the blade edges with a rag to prevent injury during handling. 7. Turn the blade until parallel to front axle. B A A M40137 MX11075 5. Pull gauge wheel release rod (A) and position wheel in correct hole (B). See decal located on deck. 8. Measure distance (A) from tip of outside blade to the ground using AM130907 Leveling Gauge. Repeat steps 7 and 8 for outer blade tip on opposite side of deck. 9. Turn outer mower blades to face front-to-rear, perpendicular to front axle. 10.Measure distance from front left and right blade tips to ground. Repeat step for left and right blade tips. Attachments Tests and Adjustments - 414 ATTACHMENTS TESTS AND ADJUSTMENTS Results: • The blade cutting heights should be equal side-to-side. • The blade height front-to-rear should be to the specified difference. Mower Blade and Mower Deck Wheel Heights Mower Deck Wheel . . . . . . . . . . . . . . . . . . . . . 6-13 mm (1/4-1/2 in.) from the ground Rear Blade Tip Higher Than Front Blade Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm ( 0.25 in.) • Remove spring locking pin (C) and drilled pin (D) from each lift arm. • Turn each yoke (B) clockwise to raise lift arm. • Turn each yoke counterclockwise to lower the lift arm. • Attach each yoke to lift arm with drilled pin (D) and spring locking pin (C). 5. Lower mower deck to level surface. 6. Turn left blade parallel to axle and complete measurement. Hold drive belt and turn right blade parallel to axle and complete measurements. Adjusting Mower Level Side-to-Side c Caution: Avoid Injury! Rotating blades are dangerous. Before adjusting or servicing mower: • Disconnect spark plug wire(s) to prevent engine from starting accidently. E • Always wear gloves when handling mower blades or working near blades. Important: Avoid Damage! Mower deck lift system can be damaged if lift arms are not adjusted correctly. Check adjustment each time mower is installed to allow gap between lift arms and frame stop at full lift height. 1. Park machine safely. See Parking Safely in Safely section. MIF 7. Measure from each outside blade tip (E) to the level surface. 8. Adjust deck side to side until measurement is equal. 2. Inflate vehicle tires to correct pressure. 3. Pull back top hydraulic lift lever to raise mower deck to highest (transport) position. B B D A D C MX11041 A 9. Remove spring locking pin (C) and drilled pin (D) from each lift arm (A). C 10.Adjust yoke until deck is level side to side. MX11041 4. Check that the lift arm (A) does not contact frame stop. If needed, adjust yokes (B) on both sides of mower until there is a slight gap of 1.6 mm (1/16 in.) on both sides. • Turn yoke (B) counterclockwise to lower mower deck. • Attach yoke to lift arm with drilled pin and spring locking pin. Attachments Tests and Adjustments - 415 ATTACHMENTS TESTS AND ADJUSTMENTS Adjusting Mower Level Front-to-Rear 4. Loosen two rear nuts (B) on front deck hanger. 5. Adjust two front nuts: Checking Procedure: 1. Lower mower deck to level surface. • Turn two front nuts (C) clockwise to raise front of mower deck. 2. Park machine safely. See Parking Safely in Safely section. • Attach yoke to lift arm with drilled pin and spring locking pin. 3. Inflate vehicle tires to correct pressure. 4. Turn right blade so tip points straight forward. 5. Hold drive belt and turn left blade until blade tip also points straight forward. 6. Measure distance (A) from end of nut to end of bolt. This measurement should be the same on each side of the front hanger. 7. Tighten rear nuts after making adjustment. 8. Measure blade tip again and adjust front deck hanger if necessary. A Adjusting Latch Rod B A M40137a 6. Measure from front (A) and rear of each blade tip to the level surface. 7. The front of blade should be 6mm (0.25 in.) lower than the rear of blade. C Adjusting Procedure: MX12365 1. Lower mower deck to level surface. 2. Park machine safely. See Parking Safely in Safely section. 1. Loosen jam nut (A) on end of latch rod (B). 2. Turn latch rod (B) in or out to obtain require length. 3. Make sure there is at least 13 mm (0.50 in.) (C) of thread engagement on end of latch rod (B). 4. Tighten jam nut. A C B C B MX11040a 3. Measure distance (A) from end of nut to end of bolt. This measurement should be the same on each side of the front deck hanger. Attachments Tests and Adjustments - 416 ATTACHMENTS TESTS AND ADJUSTMENTS Cylinder Leakage Test 45 Loader Lubrication Reason To make sure cylinder leakage is within allowable limits, allowing proper hydraulic circuit operation. A Procedure 1. Start engine and drive machine for 5 - 10 minutes to warm hydraulic oil. A A A 2. Lock park brake. 3. Start engine and fully extend cylinder rod. 4. Stop engine and activate a hydraulic function to relieve pressure in the system. A A MX12362 Lubricate six pivot points (A) on each side of loader by pumping grease into grease fittings. T6222AL 5. Disconnect rod end hose and install a plug in hose end. 6. After oil stops dripping from cylinder port, put a measuring beaker under the cylinder port to catch oil. 7. Start engine and operate at slow idle. Actuate the cylinder extend function for one minute. 8. Stop engine. Measure oil collected and connect hose. 9. Repeat procedure to test each cylinder. Results If measured oil is not within specifications, repair cylinder as necessary. Specification: Cylinder Leakage . . . . . . . . . . . . . 5 mL/min (1/6 oz/min) Attachments Tests and Adjustments - 417 ATTACHMENTS REPAIR Repair A B Cleaning Grass and Debris From Machine A Important: Avoid Damage! Clean under deck shields and in the engine compartment before each use to help prevent heavy grass and thatch build-up on the machine. A A MX11055 Picture Note: 62C-Inch Mower Deck 3. Loosen six hex nuts (A) securing belt guard cover to mower deck. On 62C mower deck, left belt guard has only one hex nut to remove. Do not remove step (B). C C MX8825 1. Remove belt shields (A) from mower deck. 2. Lift belt shields up off of the attaching bolts. 3. Inspect belt shields for cracks, wear or damage. Replace if necessary. 4. Installation is done in the reverse order of removal. Mower Deck Belt and Shield Removal and Installation Procedure: c Caution: Avoid Injury! To avoid personal injury, make sure engine is off and mower deck PTO and drive belt have stopped before removing belt shields. 1. Park machine on level surface. MX19469 4. Clean top of mower deck and area around all of the sheaves (C) of debris. 5. Lift belt shield up off of the attaching bolts. 6. Inspect belt shield for cracks, wear or damage. Replace if necessary. Important: Avoid Damage! To prevent damage to mower belt: • Do not clean belt using parts cleaning solvent or belt dressing. They soften belt and shorten belt life. 2. Remove mower deck from machine. 7. Clean and inspect belt for damage. A • If belt does not need to be replaced, stop here. Install belt shields. A • If belt needs to be replaced, continue with next step. c Caution: Avoid Injury! To prevent injury when removing idler spring: • Wear eye protection. MX11043 • Use a locking pliers. Picture Note: 54-Inch Mower Deck Attachments Repair - 418 ATTACHMENTS REPAIR I D MX11047 8. Remove idler tension spring (D) to relieve tension on belt. MX11050 12.Tilt gearbox (I) forward and remove deck drive belt. 13.Remove belt from all spindle sheaves. Discard belt. 14.Installation is in reverse order. E Specification: Gearbox-to-Deck Frame Cap Screws . . 73 N•m (54 lb-ft) F MX19468 9. Remove clip (E) and washer (F). Lift idler arm up to remove belt. G H MX11051 10.Loosen two nuts (G) on rear gearbox. 11.Remove two front nuts and carriage bolts (H). Attachments Repair - 419 ATTACHMENTS REPAIR Mower Deck Blade Removal and Installation Removal: D c Caution: Avoid Injury! Service mower blades safely. C B • Disconnect spark plug wires or negative (-) battery cable to prevent accidental startup. A • Mower blades are sharp. Always wear gloves when handling or working near blades. 1. Park machine safely. See Parking Safely in the Safety section. 2. Remove mower from machine. 3. Turn mower over and place a block of wood between blade and mower deck to prevent blade from turning when removing bolt. M74256 • Check that deflector cup (D) is properly seated between mower spindle and blade (C). • Install blade with bent tip up. • Install and hand-tighten bolt (A) with washer (B) until mower blade is in full contact with spindle. • Make sure to install blade washer with concave side toward blade. D • C Tighten blade cap screw to specification. Specification: B Blade Cap Screw Torque . . . . . . . . . . . . 68 N•m (50 lb-ft) Mower Deck Blade - Sharpen A Procedure: M74256 4. Remove bolt (A) with washer (B), blade (C) and deflector (D). 5. Inspect blade for cracks, wear or damage, sharpen balance or replace blades as necessary. c Caution: Avoid Injury! Wear goggles and gloves when sharpening mower blades. 1. Sharpen blade using grinder, file or power sharpener. 6. Tighten bolt to 68 N•m (50 lb-ft). A B Installation: c Caution: Avoid Injury! The blade is sharp. To help prevent personal injury, wear heavy gloves or wrap the end of the blade with a rag. • Installation is done in the reverse order of removal. Important: Avoid Damage! Improperly installed blades can loosen during operation. Do not lubricate or use power tools when installing the blade bolt or the bolt will be ineffective. M61830 2. Do not alter original bevel (A) of 30°. Maintain blade cutting edge (B) to specification, rather than a razor-type edge. 3. Balance blade. Specification: Blade Cutting Edge . . . . . . . . . . . . . 0.40 mm (0.016 in.) Use a hand torque wrench and tighten bolts to blade bolt torque of: 68 N•m (50 lb-ft). Attachments Repair - 420 ATTACHMENTS REPAIR Mower Deck Blade - Balance Procedure: A c Caution: Avoid Injury! Wear gloves or wrap blade with rag to prevent personal injury. B Important: Avoid Damage! Balance blades after sharpening or mower deck may vibrate excessively. 1. Clean and inspect blade. 2. Sharpen blade. See “Mower Deck Blade - Sharpen” on page 420. A MX9609 3. Remove four nuts and washers (A) and spindle (B). 4. Make repairs as necessary. See “Spindle Disassembly/ Inspection” on page 421. A Installation is done in the reverse order of removal: • Tighten spindle mounting lock nuts to 26 N•m (230 lbin.). M61524 3. Put blade on a nail in a vise or wall stud. 4. Turn blade to the horizontal position (A). If the blade is not balanced, the heavy end will drop. 5. Grind blade edge of heavy end. Do not alter original blade bevel angle of 30°. 48C Mower Deck Spindle Removal and Installation Removal 48C: c Caution: Avoid Injury! To help prevent personal injury, wear heavy gloves or wrap the end of the blade with a rag. 1. Remove drive belt. See “Mower Deck Belt and Shield Removal and Installation” on page 418. 2. Remove mower blade. Important: Avoid Damage! Install blade with bent tips up. Install blade washer with concave side to blade. • Install blade and tighten blade cap screw to 68 N•m (50 lb-ft). Specification: Blade Cap Screw Torque . . . . . . . . . . . . 68 N•m (50 lb-ft) Spindle Mounting Lock Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . 26 ± 4 N•m (230 ± 4 lb-in.) Spindle Disassembly/Inspection c Caution: Avoid Injury! To help prevent personal injury, wear heavy gloves or wrap the end of the blade with a rag. Important: Avoid Damage! Do not install hexagon end of spindle shaft in a vise to remove spindle sheave nut. The hexagon end of the spindle shaft will be damaged resulting in improper blade operation. Note: Remove bearings only if replacement is necessary. Attachments Repair - 421 ATTACHMENTS REPAIR B H D E F A E H C I C E D J G K M E H L MX9610 1. Install blade (K), washer (L), and cap screw (M) on spindle shaft. If only the nut (A) or spindle sheave (B) need to be replaced, and the spindle is still in the deck, use a block of wood to prevent the blade from turning. If spindle is not in the deck, put blade in a soft-jaw vise. Tighten cap screw (M) to 68 N•m (50 lb-ft). 2. Hold the blade with a vise or a block of wood. Remove nut (A), spindle sheave (B), and lubrication fitting (I). MIF 8. Inspect all parts for wear or damage. Replace parts as necessary. Assembly 48C: B A C 3. Remove cap screw, washer and blade. 4. Pull spindle shaft (J) out of spindle hub (F). 5. Remove seal rings (C) noting location of notched side. 6. Remove seals (D) and bearings (E) using a punch. Bearings (E) are seated against hub shoulder (H) and cannot be removed with a press. D MX9611 G 1. Install upper bearing (A) tight against spindle hub shoulder (B) using a 1-13/16 disk and press. 2. Install upper seal (C) with lip toward bearing, tight against bearing using a 1-13/16 disk and press. MX9612 7. Remove spacer (G). E D M44950 3. Install upper seal ring (D), with grease notch (E) toward bearing, inside seal lip. Attachments Repair - 422 ATTACHMENTS REPAIR H I G F B A H D L J G MX9612 4. Install spacer (G). Important: Avoid Damage! Do not press lower bearing (H) tight against hub shoulder (F). The bearing and seal must be installed to a specific dimension for proper sealing of spindle. 5. Install lower bearing (H) in hub using a 1-13/16 in. disk and press, just enough so the lower seal can be installed. I K F E MX9610 8. Install spindle shaft (D). Important: Avoid Damage! Do not install hexagon end of spindle shaft in a vice to install spindle sheave nut. The hexagon end of the spindle shaft will be damaged resulting in improper blade operation. 9. Install blade (G), washer (E), cap screw (F) and deflector (L) on spindle shaft. Tighten cap screw to 68 N•m (50 lb-ft). Important: Avoid Damage! Make sure the hexagon shaped hole in spindle sheave is aligned with the hexagon portion of the spindle shaft. MX9613 6. Install lower seal (I) with lip toward bearing using a 1-13/ 16 in. disk and a press, until seal is 7.8 mm (0.31 in.) below hub flange (K). 7. Install lower seal ring (J), with grease notch away from bearing, inside seal lip. 10. Hold the blade with a soft-jaw vise or if spindle is in the mower deck, with a block of wood. Install spindle sheave (B), nut (A), and lubrication fitting (H). Tighten nut to 145 N•m (106 lb-ft). 11. Remove cap screw, washer and blade. 12. Lubricate spindle with multipurpose grease at lubrication fitting. Idlers Note: Idler sheaves are welded and contain a nonserviceable bearing. If bearing replacement is needed, replace entire idler sheave. Attachments Repair - 423 ATTACHMENTS REPAIR Jacksheave 54C Mower Deck Spindle Removal and Installation Disassembly 48C: Note: Bearings are seated against shoulder in jack sheave, and must be removed one at a time, from either side. Remove bearings only if replacement is necessary. Removal 54C: c Caution: Avoid Injury! To help prevent personal injury, wear heavy gloves or wrap the end of the blade with a rag. 1. Remove drive belt. See “Mower Deck Belt and Shield Removal and Installation” on page 418. A B 2. Remove mower blade. A B C A B MIF A A- Shoulder B- Upper Bearing C- Spacer MX9609 3. Remove four nuts and washers (A) and spindle (B). 1. Remove one bearing using a suitable puller, or a pin punch and hammer. 2. Remove spacer. 4. Make repairs as necessary. See “Spindle Disassembly/ Inspection” on page 425. Installation is done in the reverse order of removal: 3. Remove second bearing using a press, or suitable driver and mallet. • Tighten spindle mounting lock nuts to 26 N•m (230 lbin.). 4. Inspect all parts for wear or damage, replace as needed. Assembly: • Install bearings tight against shoulder in jack sheave using a press, or suitable driver and mallet. Be sure to install spacer between bearings. Important: Avoid Damage! Install blade with bent tips up. Install blade washer with concave side to blade. • Install blade and tighten blade cap screw to 68 N•m (50 lb-ft). Specification: Blade Cap Screw Torque . . . . . . . . . . . . 68 N•m (50 lb-ft) Spindle Mounting Lock Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . 26 ± 4 N•m (230 ± 4 lb-in.) Attachments Repair - 424 ATTACHMENTS REPAIR Spindle Disassembly/Inspection G c Caution: Avoid Injury! To help prevent personal injury, wear heavy gloves or wrap the end of the blade with a rag. Important: Avoid Damage! Do not install hexagon end of spindle shaft in a vise to remove spindle sheave nut. The hexagon end of the spindle shaft will be damaged resulting in improper blade operation. Note: Remove bearings only if replacement is necessary. MX9612 7. Remove spacer (G). 8. Inspect all parts for wear or damage. Replace parts as necessary. Assembly 54C: B B A E C D F A C D E I N C D MX9611 J 1. Install upper bearing (A) tight against spindle hub shoulder (B) using a 1-13/16 disk and press. 2. Install upper seal (C) with lip toward bearing, tight against bearing using a 1-13/16 disk and press. K M L MX9610 1. Install blade (K), washer (L), cap screw (M) and deflector (N) on spindle shaft. If only the nut (A) or spindle sheave (B) need to be replaced, and the spindle is still in the deck, use a block of wood to prevent the blade from turning. If spindle is not in the deck, put blade in a soft-jaw vise. Tighten cap screw (M) to 68 N•m (50 lb-ft). 2. Hold the blade with a vise or a block of wood. Remove nut (A), spindle sheave (B), and lubrication fitting (I). 3. Remove cap screw, washer and blade. D E M44950 3. Install upper seal ring (D), with grease notch (E) toward bearing, inside seal lip. 4. Pull spindle shaft (J) out of spindle hub (F). F 5. Remove seal rings (C) noting location of notched side. 6. Remove seals (D) and bearings (E) using a punch. Bearings (E) are seated against hub shoulder (H) and cannot be removed with a press. J I H G MX9612 4. Install spacer (G). Attachments Repair - 425 ATTACHMENTS REPAIR Important: Avoid Damage! Do not press lower bearing (H) tight against hub shoulder (F). The bearing and seal must be installed to a specific dimension for proper sealing of spindle. 5. Install lower bearing (H) in hub using a 1-13/16 in. disk and press, just enough so the lower seal (I) can be installed. K Important: Avoid Damage! Make sure the hexagon shaped hole in spindle sheave is aligned with the hexagon portion of the spindle shaft. 10.Hold the blade with a soft-jaw vise or if spindle is in the mower deck, with a block of wood. Install spindle sheave (Q), nut (R), and lubrication fitting (P). Tighten nut to 145 N•m (106 lb-ft). 11.Remove cap screw, washer and blade. I J 9. Install blade (M), washer (N), cap screw (O) and deflector (S) on spindle shaft. Tighten cap screw to 68 N•m (50 lb-ft). 12.Lubricate spindle with multipurpose grease at lubrication fitting. Jacksheave Disassembly 54C: 1. Inspect all parts for wear or damage. Replace parts if necessary. MX9613 6. Install lower seal (I) with lip toward bearing using a 1-13/ 16 in. disk and a press, until seal is 7.8 mm (0.31 in.) below hub flange (K). A C B A 7. Install lower seal ring (J), with grease notch away from bearing, inside seal lip. Q E R D P M45998AE L S 2. Inspect bearing (A) for wear or damage. Replace if necessary. M O N MX9610 8. Install spindle shaft (L). Important: Avoid Damage! Do not install hexagon end of spindle shaft in a vice to install spindle sheave nut. The hexagon end of the spindle shaft will be damaged resulting in improper blade operation. Note: Bearings (A) are seated against shoulder in jack sheave (B), and must be removed one at a time, from either side. Remove bearings (A) only if replacement is necessary. 3. Remove one bearing (A) using a suitable puller, or a pin punch and hammer. 4. Remove spacer (C). 5. Remove second bearing (A) using a press, or suitable driver and mallet. 6. Inspect all parts for wear or damage, replace as needed. Attachments Repair - 426 ATTACHMENTS REPAIR Assembly: MP29544A • Install bearings (A) tight against shoulder in jack sheave (B) using a press, or suitable driver and mallet. Be sure to install spacer between bearings. • Tighten jack sheave nut (D) to 136 N•m (100 lb-ft). • Tighten tensioning idler sheave nut (E) to 27 N•m (20 lbft). Idlers Note: Idler sheaves are welded and contain a nonserviceable bearing. If bearing replacement is needed, replace entire idler sheave. 62C Mower Deck Spindle Removal and Installation Removal 62C: Important: Avoid Damage! Always install new bearings and seals when servicing spindles. A- Lubrication Fitting (apply grease) B- Flanged Nut C- Sheave D- Upper Seal E- Bushing F- Upper Bearing G- Flanged Lock Nut H- Housing I- Spacer J- Lower Bearing K- Lower Seal Ring L- Lower Seal M- Spindle Shaft N- Deflector O- Blade P- Blade Washer Q- Cap Screw 1. Place blade (O) in a soft-jawed vise. 2. Remove flanged nut (B). 3. Remove lubrication fitting (A), sheave (C) and bushing (I). A B 4. Remove cap screw (Q), washer (P), deflector (N) and blade (O). C 5. Remove spindle shaft from housing (J). 6. Remove lower seal ring (K) and lower seal (L). D G E F H I Note: Remove upper bearing (F) and lower bearing (J) only if replacement is necessary. 7. Upper and lower bearings are seated against spindle hub shoulder and cannot be removed with a press. Remove upper seal (D) and bearings using a punch. 8. Remove spacer (I). 9. Inspect all parts for wear or damage. Replace parts as needed. J K L M N O R P Q Attachments Repair - 427 ATTACHMENTS REPAIR Assembly 62C: U O D M B H L I C K A N MP29644b 1. Using a press and disk driver large enough to contact the bearing outer race, install lower bearing (A) until it is seated against the shoulder in the housing (B). J P 2. Turn the housing over. 3. Install spacer (C). Center the spacer over the lower bearing. Important: Avoid Damage! Using disk drivers, support both the inner and outer races of the upper and lower bearings when installing the upper bearing. Do not support the housing by allowing it to rest on its end. 4. Using a press and disk driver, install upper bearing (D) until it rests against the bottom of the housing shoulder. Note: The inner diameter chamfer of the seal ring is away from the bearing. S Q T MP29644C 7. Install bushing (L). 8. Using a press and disk, install upper seal (H) and lower seal (N) with open side toward bearing until the face of the seal is flush with the end of the housing (I). 9. Install spindle shaft (J) into housing. 10.Install bushing (K) and sheave (M). 11.Install flanged nut (O). Important: Avoid Damage! Blade (Q) must be properly seated on the spindle, and concave side of blade washer (R) MUST face toward blade. 12.Install lower deflector (P), blade (Q), and washer (S) and cap screw (T). G E F 13.Tighten blade cap screw to 320 N•m (236 lb-ft). MX2537 5. Using a press and disk, install lower seal (E) with open side toward bearing until the face of the seal is at the specified height (F) from the lower end of the housing. 6. Install lower seal ring (G) with the outer diameter chamfered edge toward bearing. 14.Place blade in a soft-jawed vise. 15.Tighten flange nut to specification. 16.Loosen blade cap screw and retighten to specification. 17.Apply specified grease to lubrication fitting (U). Specifications: Seal Face Distance from Lower End of Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.57 mm (0.10 in.) Blade Cap Screw Torque . . . . . . . . . . . . 68 N•m (50 lb-ft) Attachments Repair - 428 ATTACHMENTS REPAIR Flanged Nut Torque . . . . . . . . . . . . . 255 N•m (188 lb-ft) Recommended Grease . . . . . . . . . . . . . . . . . . . . . John Deere Multi-Purpose SD Polyurea Grease or John Deere Multi-Purpose Lithium Complex Grease D Mower Deck Drive Shaft Removal and Installation E Removal: Important: Avoid Damage! Use of incorrect greases can result in premature wear of parts and component failures. 1. Lift up PTO drive shaft cover to gain access to the front PTO drive shaft universal joint. MX8823 4. Inspect the universal joint (D) and lubrication fitting (E) for wear or damage. Replace as necessary. Installation: B • A Installation is done in the reverse order of removal. • Remove tape from PTO gearbox input shaft, using care not to misplace shaft key. • Apply a light coat of MPG-2 Multi-Purpose Grease to splines of drive shaft. • Install drive shaft onto PTO gearbox input shaft. Tighten flange head cap screw to specification. • Apply specified grease to lubrication fitting on universal joint. See Mower Spindle Grease in Specifications and General Information section. MX7111 2. Remove flanged head cap screw (A) to remove drive shaft from PTO gearbox input shaft (B). Specification: Drive Shaft Flanged Head Cap Screw . 81 N•m (60 lb-ft) C MX7109 3. Using care not to misplace shaft key (C), wrap a piece of tape around shaft key and PTO gearbox input shaft. Attachments Repair - 429 ATTACHMENTS REPAIR Mower Deck Drive Shaft Repair A B V T U S C R M Q L P O N K J I H G D E F MX5733 A- Lubrication Fitting B- Yoke, with Tube C- Yoke D- Snap Ring E- Bearing F- Guard G- Spring Pin H- Shaft I- Snap Ring J- Universal Joint Yoke K- Universal Joint L- Lubrication Fitting M- Snap Ring N- Snap Ring O- Locking Collar P- Compression Spring Q- Ball R- Snap Ring S- Universal Joint Yoke T- Lubrication Fitting U- Universal Joint V- Snap Ring • Inspect all parts for wear or damage. Replace parts as needed. • Apply a light coat of MPG-2 Multi-Purpose Grease to splines of drive shaft. (See Anti-Corrosion Grease in Specifications and General Information section.) Attachments Repair - 430 ATTACHMENTS REPAIR Mower Deck Gearbox Removal and Installation 4. Adjust mower height control knob to 38.1 mm (1.5 in.). 5. Push top hydraulic lever forward to lower deck to the ground. Removal: D A MX11077 6. Reach under machine from left side and pull coupler (D) to release deck PTO driveshaft. MX11076 1. Pull back top hydraulic lift lever (A) to raise mower deck to highest (transport) position. 7. Put PTO driveshaft on top of deck. 2. Park machine safely. See Parking Safely in the Safety section of the operator’s manual. c Caution: Avoid Injury! Rotating blades are dangerous. Before adjusting or servicing E F mower: • Disconnect spark plug wire(s) to prevent engine from starting accidently. • Always wear gloves when handling mower blades or working near blades. C B MX11078 8. Pull out pin and pull down release latch (E) on front deck hanger bracket (F) to release deck. Rear of deck will slide off draft arms at this step. F MX11075 3. Turn all gauge wheels to the deck removal position: • Pull back on gauge wheel release rod (B). • Turn gauge wheel sideways. MX11052a 9. Remove front deck hanger bracket (F) from mower deck. • Move gauge wheel up until release rod engages in deck removal holes (C) on side of rod. 10.Start engine. Attachments Repair - 431 ATTACHMENTS REPAIR 11.Pull back top hydraulic lever to raise draft arms to highest position. 12.Turn off engine. K G K L MX11051 MX11055 13.Remove each belt guard cover (G). 16.Remove two nuts (K) on rear of gearbox. 17.Remove four bolts (L) from front of gearbox and remove belt. H MX11047 N 14.Remove idler tension spring (H) to relieve tension on belt. M I J MX5735 18.Remove cap screw (M) to remove drive sheave (N) from gearbox. 19.Inspect drive sheave for wear or damage. Replace if necessary. Installation: MX11048 15.Remove clip (I) and washer (J). Lift idler arm up to remove belt. • Installation is done in the reverse order of removal. • Install drive sheave to gearbox and tighten cap screw to specification. • Wrap belt around drive sheave and install gearbox onto mower deck frame. Tighten cap screws to specification. • Install tension spring, and adjust belt tension to specification. Attachments Repair - 432 ATTACHMENTS REPAIR • Install belt shield. • Remove tape from gearbox input shaft, using care not to misplace shaft key. • Apply a light coat of MPG-2 Multi-Purpose Grease to gearbox input shaft. • Install drive shaft onto gearbox input shaft and tighten cap screw to specification. • Install drive shaft onto PTO output shaft. Specifications: Drive Sheave Cap Screw . 129 ± 9.5 N•m (95 ± 9.5 lb-ft) Gearbox-to-Frame Cap Screw . . . . . . . 99 N•m (73 lb-ft) Drive Shaft Cap Screw . . . . . . . . . . . . . 81 N•m (60 lb-ft) Mower Deck Gearbox Repair L- Snap Ring M- Bearing Cup N- Bearing O- Shim P- Snap Ring Q- Shaft Seal R- Shaft Seal S- Snap Ring T- Shim U- Bearing Cup V- Bearing W- Input Shaft X- Keyway Y- Gear Z- Housing • Inspect all parts for wear or damage. Replace seals or plugs as needed. If gears are worn or damaged, replace gearbox assembly. A B C F D Note: Gearbox oil capacity is approximately 0.4 L (13.5 oz). E Z X G Y H J W Important: Avoid Damage! Do not overfill the gearbox with oil. Damage to internal gearbox seal will result. I • Fill gearbox to proper level with approved gear oil. See Oils and Lubricants in the Specifications and General Information section. K V L U M N P T R S O Q MX5738 A- Plug B- Output Shaft with Gear C- Shim D- Bearing E- Bearing Cup F- Plug G- Snap Ring H- Shim I- Bearing Cup J- Bearing K- Pipe Plug (2 used) Attachments Repair - 433 ATTACHMENTS GENERAL INFORMATION General Information Reading Electrical Schematics S1 Key Switch B Wht Wht Red Red X1 F2 15 Amp Fuse S1 X2 X3 M X3 800 Pink D D 6 C Start On Off Seat Seat S2 A Seat Switch 414 Yel/ Blk 30 K2 Ignition Relay 87 86 85 Run 210 Red Off L K F3 15 Amp Fuse K1 Start Relay F1 Fusible Link J X3 H 1 215 Org X2 721 Pur/ Wht F 805 Pnk/Blk W3 X3 Engine X4 Wiring Yel/ Harness T2 T1 Wht Ignition Ignition X5 Yel/Wht Coil Yel/Wht Coil Red S B G1 Battery W1 Shielded Ground G M1 Starting Motor M Blk 710 Pur E E I X3 H E1 Spark Plug B F O SE1-Power and Starting Circuit Blk/Yel C N SE2-Ignition and Interlock Circuit MIF The schematic is made up of individual circuits laid out in a sequence of related functions. It is formatted with all power wires (A) across the top and all ground wires (B) across the bottom. Current flow is generally from top to bottom through each circuit and component. All components are shown in the off position. The diagram does not list connector (C) information unless needed to avoid confusion. If the connector is shown, the number next to it is the terminal pin location (D) in the connector. Each component is shown by a symbol (E), its name (F), and an identification code (G). The identification code contains a device identifying letter (H) and number (I). The identifying letter is always the same for a specific E2 Spark Plug Yel/ Wht Wht P Q 105 Blk SE3-PTO and Interlock component, but the identifying numbers are numbered consecutively from upper left to lower right. The terminal designation (J) is placed directly outside the symbol next to the connecting wire path. Switch positions (K) are also placed directly outside the symbol. The solid line (L) shows the position the switch is currently in and dash lines (M) represent other switch positions. Each circuit is identified at the bottom of the drawing by a section number (N) and section name (O). The circuit number (P) and wire color (Q) of the wires are shown directly next to the wire path. The same component name and identification code are used consistently on all diagrams in this section. Components can be easily cross-referenced. Attachments General Information - 434 ATTACHMENTS GENERAL INFORMATION Operation and Diagnostics Wire Color Abbreviation Chart The operation and diagnostics stories divide the electrical system into individual circuits by function. Each circuit is isolated from the main wiring schematic and only shows the components that are used in it. The story contains information on function, operating conditions, and theory of operation. The circuit schematics are drawn with the components in the operating position, with the power, or battery positive, into them across the top and the ground, or battery negative, across the bottom. Diagnostic Information The diagnostic procedure is used to test the complete circuit regardless of the problem or complaint. Select a symptom or system from the quick check or troubleshooting chart and follow the test procedures under that heading. The diagnostic procedure lists: • Test conditions. • Test sequence. • Test location. • Normal reading. • Check or test to perform if reading is not normal. When performing the test or check, be sure to set your machine up to the test conditions listed and follow the sequence carefully. Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue Brn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown Grn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green Gry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gray Org. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange Pnk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink Pur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tan Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow Blk/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black/White Blu/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue/White Brn/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brown/White Brn/Yel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown/Yellow Dk Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Blue Dk Brn/Lt Grn . . . . . . . . . . . . . Dark Brown/Light Green Dk Brn/Red . . . . . . . . . . . . . . . . . . . . . . Dark Brown/Red Dk Brn/Yel . . . . . . . . . . . . . . . . . . . . . Dark Brown/Yellow Dk Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Green Lt Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Blue Lt Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Green Org/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange/White Pnk/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink/Black Pur/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Purple/White Red/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Black Red/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/White Wht/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Black Wht/Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Red Yel/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Black Yel/Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Red Yel/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yellow/White Attachments General Information - 435 ATTACHMENTS GENERAL INFORMATION Common Circuit Tests High Resistance or Open Circuit: Shorted Circuit: MIF MIF A shorted circuit may result in the wrong component operating (i.e. improper wire-to-wire contact). To test for a shorted or improperly wired circuit: 1. High resistance or open circuits usually result in slow, dim or no component operation (i.e. poor, corroded, or disconnected connections). Voltage at the component will be low when the component is in operation. To test for high resistance and open circuits: 2. Check all terminals and grounds of the circuit for corrosion. 1. Turn component switch ON. 3. If terminals are not corroded or loose, the problem is in the component or wiring. 2. Start at the controlling switch of the component that should not be operating. Grounded Circuit: 3. Follow the circuit and disconnect wires at connectors until component stops operating. 4. Shorted or improper connections will be the last two wires disconnected. MIF Grounded circuits usually result in no component operation or a blown fuse. Conductors For 12 Volt Circuits Standard Conductors For 12 Volt Circuits SAE Wire Size (Gauge) 20 18 16 14 12 10 Metric Wire Size (mm) 0.5 0.8 1.0 2.0 3.0 5.0 Typical Stranding 7 X 28 16 X 30 19 X 29 19 X 27 19 X 25 19 X 23 Minimum Conductor Area In Circular Mils 1072 1537 2336 3702 5833 9343 Attachments General Information - 436 ATTACHMENTS IDENTIFICATION NUMBERS Identification Numbers Generator A MX19672A A- Generator Identification Alternator A MX19203 A- Alternator Identification Attachments Identification Numbers - 437 ATTACHMENTS COMPONENT LOCATION Component Location Generator A B E C D I F H MX19672 I- Alternator A- Control Panel B- Voltage Meter C- Fan Housing D- Transmission E- Transmission Oil Fill Plug F- PTO Shield G- Mounting Pin H- Base Attachments Component Location - 438 G ATTACHMENTS COMPONENT LOCATION Alternator Components F G H D E C K B A I C K J L M N MX19887 A- Fan Housing B- Rotor C- Varistor (R1 and R2) D- Control Case E- Bolt F- Exciter Capacitors (C1 and C2) G- Terminal Board H- Air Intake Vent I- Cap J- Bearing K- Diode (V1 and V2) L- Fan Friction Collar M- Fan N- Air Vent Attachments Component Location - 439 ATTACHMENTS COMPONENT LOCATION Control Panel B A B A E D C C MX19674 B A C B A D C F E MIF A- 20 Amp Circuit Breaker (F1 and F4) B- 40 Amp Circuit Breaker (F2 and F3) C- 120 Volt/20 Amp GFCI Protected Duplex Receptacle (X1 and X3) D- 240 Volt/40 Amp Receptacle (X2) E- O-Ring Attachments Component Location - 440 ATTACHMENTS COMPONENT LOCATION Generator Gear Box Components D E C F B B A H B M I K J L MX19882 A- Seal B- Bearing C- Plug D- Nut E- Cap F- Seal G- Plug H- Bearing I- Plug (BPT) J- Bolt K- Cap L- Bolt M- Bolt Attachments Component Location - 441 G ATTACHMENTS SCHEMATICS AND HARNESSES Schematics and Harnesses Wiring Harness Legend C1 - Capacitor (SE2) C2 - Capacitor (SE2) F1 - Circuit Breaker - 20 Amp (SE1) F2 - Circuit Breaker - 40 Amp (SE1) F3 - Circuit Breaker - 40 Amp (SE1) F4 - Circuit Breaker - 20 Amp (SE1) G1 - Generator L1 - Stator Coil (SE2) L2 - Excitation Coil (SE2) L3 - Excitation Coil (SE2) L4 - Stator Coil (SE2) L5 - Rotor Coil (SE2) L6 - Rotor Coil (SE2) P1 - Voltmeter (SE1) R1 - Varistor (SE2) R2 - Varistor (SE2) V1 - Diode (SE2) V2 - Diode (SE2) W1 - Control Panel Internal Ground Connectors X1 - 120 Volt, 20 Amp, GFCI Receptacle (SE1) X2 - 240 Volt, 40 Amp Receptacle (SE1) X3 - 120 Volt, 20 Amp, GFCI Receptacle (SE1) Attachments Schematics and Harnesses - 442 ATTACHMENTS SCHEMATICS AND HARNESSES Standard Electrical Schematic Wht Wht/Yel Blk/Yel Blk Wht/Yel Wht 135 Wht 120 Wht W2 U2 V2 U1 V1 W1 P1 Voltmeter Blk/Yel Blk 530 Red 515 Blk F1 F3 F2 F4 140 Wht 525 Red X1 (GFCI) 535 Blk 520 Red 125 Wht X3 (GFCI) 130 Wht 540 Red 505 Blk X2 540 Red 510 Blk 110 Grn 115 Grn 120 Wht W1 SE1 - Output Section MIF Attachments Schematics and Harnesses - 443 ATTACHMENTS SCHEMATICS AND HARNESSES G1 Generator L1 Stator Coil L4 Stator Coil Wht Wht/Yel L2 Blk/Yel Rotor L5 L3 L6 Exciter Circuits Blk Red C1 Capacitor Grn C2 Capacitor V1 Diode Blk V2 Diode Blk/Yel Wht/Yel Wht R1 Varistor Wht Wht/Yel Blk/Yel Blk SE2 - Alternator MIF Attachments Schematics and Harnesses - 444 R2 Varistor ATTACHMENTS OPERATION AND DIAGNOSTICS Operation and Diagnostics Generator Circuit Diagnosis Generator Circuit Operation Test Procedure A Function: Test Conditions: To provide circuit breaker protected 120 and 240 volt AC outputs. • Machine warmed up and running with a minimum 50 watt load applied to generator. Operating Conditions: Generator AC Output The PTO must be ON and rotating at 540 rpm for the generator transmission to provide a 3600 rpm output in order to provide 60 Hz alternating current to the generator outputs. The 20 amp, 120 volt duplex outlets are GFCI protected and the unit must be connected to a suitable earth ground for these circuits to function properly. 1. Is the PTO running at 540 rpm to provide correct 60 Hz output from all of the AC receptacles? Yes: Test complete. No: Check to make sure that the PTO is running at 540 rpm. Go to test procedure B. Test Procedure B Theory of Operation: c Caution: Avoid Injury! The field capacitors have the capability to store very high voltages. NEVER touch both capacitor terminals with bare hands as this could cause rapid discharge and result in an electrical shock. Discharge capacitors by bridging the terminals with a screwdriver shaft that has an insulated handle before servicing. The generator is a brushless design with stator self excitation capability to provide a magnetic field within which the rotor will induce voltage. Self excitation is provided by two angle shifted, in relation to the power windings, capacitors (one per 120 VAC output). These capacitors set up the magnetic field within which the rotor turns to inductively generate AC power. Proper operation of these capacitors are essential for correct generator output. As the rotor turns, power is generated in two independent 120 volt sets of windings in the stator. These outputs are directed to the generator control panel wiring. To obtain a 240 volt AC output, the two 120 volt outputs are combined at receptacle X2. Unit grounding is provided by several ground straps connecting the base, generator, roll guard, and ultimately, a user installed earth ground connection. The generator circuit is equipped with an over/under voltage warning meter. Test Conditions: • Key switch in the OFF position. • Generator excitation capacitors accessible. • All terminal block leads disconnected. Generator Internal Components 1. Did generator provide proper output in test procedure A? No: The excitation field capacitors may need to be energized. See “Stator Excitation Field Restoration” on page 449. Low engine speed/PTO speed, faulty windings, or defective capacitors can cause excitation field failure. No: Check for continuity between one Red and one Grn capacitor lead. If there is continuity, the stator is shorted. Replace stator. No: Disconnect the excitation capacitor leads and measure the resistance between the Red wires. Repeat for the Grn pair. If the resistance is not approximately 1.2 ohms, replace the stator. No: After discharging each capacitor, measure the resistance across each of the capacitor’s terminals. If the resistance increases (increasing as capacitor charges), the capacitor is OK. If not, replace the capacitor. No: Check for continuity between each capacitor lead and each black stator power lead. If there is continuity, the stator is shorted and must be replaced. No: Measure the resistance across each of the rotor’s diode ends. See “Generator Rotor Test” on page 448. No: Check continuity between each of the rotor’s diode ends and ground. If there is continuity, the rotor is Attachments Operation and Diagnostics - 445 ATTACHMENTS OPERATION AND DIAGNOSTICS Test Procedure D shorted and must be replaced. No: Check for continuity between the rotor body and the stator body. If there is continuity, isolate the source of the short and repair or replace components as necessary. No: If generator voltage no load output is too high, excitation capacitors may be holding too high a charge. Short each capacitor and recharge. See “Stator Excitation Field Restoration” on page 449. No: Check for low no-load or low loaded voltage. Possible faulty rotor diodes. See “Generator Rotor Test” on page 448. Yes: Go to test procedure C. • Key switch in the OFF position. Generator Circuit Breakers 1. Are the individual circuit breakers tripping? Yes: Ensure that the load on the circuit does not exceed its respective amperage rating. Yes: The device connected to the receptacle may be short circuiting and causing excessive current draw on the generator. Yes: Distribute the 120 volt loads evenly across the duplex receptacles. Test Procedure C Yes: Ensure that the frequency of the device connected to the receptacle matches that of the generator’s output. Test Conditions: • Test Conditions: Key switch in the OFF position. Yes: Remove top panel and inspect internal wiring for problems. Generator GFCI Circuit 1. Did the GFCI circuit trip during test procedure A? No: Test complete. Yes: Check to ensure the generator earth ground is connected properly. Yes: Check the generator to base grounds. See “Generator Ground Test” on page 449. Yes: Test the GFCI circuits. See “Ground Fault Circuit Interrupter (GFCI) Checks” on page 448. Yes: Ensure that the frequency of device connected to the receptacle matches that of the generator’s output. Yes: Ensure that the load of the device connected to the generator does not exceed the rated output of the generator or receptacle. No: Go to test procedure D. Attachments Operation and Diagnostics - 446 ATTACHMENTS TESTS AND ADJUSTMENTS Tests and Adjustments L1 Stator Coil Generator Stator Test L4 Stator Coil L3 L2 Exciter Circuits Reason: To verify that the stator coils have proper continuity (not open or shorted). Grn Red Test Equipment: • Ohmmeter C1 Capacitor Procedure: C2 Capacitor 1. Remove the four screws securing the control panel cover. Wht U2 V2 Wht/Yel E C Blk A B Blk/Yel V1 W1 D MIF 4. With the terminal wires disconnected, check the resistance between the Blk wire (B) and Wht wire (C). There should be continuity. B 5. With the terminal wires disconnected, check the resistance between the Blk wire (D) and Wht wire (E). There should be continuity. MX19886 2. Disconnect white and green wires (A) and ground shunt (B) from the terminal block, noting their positions. 3. Disconnect the harness ground on stator housing. 6. Check for continuity between the two White wires (C and E). There should be no continuity. If there is, the stator is shorted. 7. Check for continuity between the stator housing and all wires. There should be no continuity. If there is, the stator is shorted. Specifications: Blk to Wht wire resistance (approximately). . . 1.0 ohms White wire to White wire . . . . . . . . . . . . . . Infinity ohms • If specifications are not met, replace stator. Attachments Tests and Adjustments - 447 ATTACHMENTS TESTS AND ADJUSTMENTS Generator Rotor Test 4. Repeat for second diode. The readings should meet specifications. Test Equipment: • 5. Place lead on end of diode and one end on stator housing. Repeat test with a one lead placed on the end of each diode. There should be no continuity. If there is, the rotor is shorted. Ohmmeter Reason: To verify that the rotor coils and components have proper continuity and resistance (not open or shorted). This test verifies circuit integrity ONLY. If specifications are not met, rotor discrete components (diodes and varistors) can not be tested individually. Procedure: Specifications: Resistance at each diode (approximately) . . . 1.5 ohms Diode to stator housing . . . . . . . . . . . . . . . Infinity ohms Diode to diode . . . . . . . . . . . . . . . . . . . . . . Infinity ohms • If specifications are not met, replace rotor. Ground Fault Circuit Interrupter (GFCI) Checks c Caution: Avoid Injury! The GFCI circuits may not function unless the generator is properly A MX19883 1. Remove the four screws securing the side cover of generator housing. grounded. Situations exist where a GFCI will not afford any protection against the hazards of electrical shock. EXAMPLE: If a person touches two or more conductors from a damaged cord set and is not in direct contact with the ground, he or she may receive a shock. Since there is no path to ground for a ground fault current to flow through, the GFCI will not operate and serious injury may result. Reason: The 20 amp, 120 VAC outlets are protected by ground fault circuit interrupters (GFCI). The GFCI has to meet the following operational checks. • When the test button is pressed, the reset button must pop out and the voltage to the GFCI and the 5-20R duplex receptacle must be zero. B • When the reset button is pressed back in, power must return to the GFCI duplex receptacle. • When a 5mA “ground fault” is applied from either receptacle’s Hot Line to Frame Ground, the reset button must pop out and the receptacle power must be zero. Use tester available from electrical or building stores. MX17383 2. Locate the diode for each of the rotor coils (B). Note: The diodes are in a parallel circuit with the varistors and the rotor windings. Do not unsolder the diodes for testing. 3. Place an ohmmeter lead on the each end of diode. Measure resistance. Attachments Tests and Adjustments - 448 ATTACHMENTS REPAIR Generator Ground Test Repair Reason: Stator Excitation Field Restoration To ensure that the generator, base, and control panel share a common ground. To restore the stator self excitation capacitor charge in the event of no generator output. Equipment: • Reason: Ohmmeter Procedure: 1. Visually inspect all ground points to ensure that wires and cables are attached securely and are in good condition. If the generator has no AC output, it is possible that the excitation field has dissipated and the field capacitors will have to be recharged. Procedure: 2. Set VOM to RX1 setting. A B A MX19672a 1. Remove the four control panel cover screws (A) and remove cover. 3. Connect one VOM lead to the ground terminal (A). 4. Connect second lead to ground test points (B). Results: • Resistance should not exceed 0.2 ohms. • If resistance exceeds 0.2 ohms, check condition of affected wires and connections. Repair or replace as necessary. c Caution: Avoid Injury! The field capacitors have the capability to store very high voltages. NEVER touch both capacitor terminals with bare hands. as this could cause rapid discharge and result in an electrical shock. Discharge capacitors by bridging the terminals with a screwdriver shaft that has an insulated handle before servicing. 2. Discharge the capacitors. Attachments Repair - 449 ATTACHMENTS REPAIR Generator Removal and Disassembly c Caution: Avoid Injury! Generator weighs approximately 49 Kg (108 lbs). Use an assistant or proper equipment to aid in generator removal. Procedure: B MX19885 3. Using jumper wires, apply a DC power source (such as the 12 volt starting battery) across the terminals of either of the field capacitors (B) for approximately 1 second. A 4. Replace terminal block cover and secure with four mounting screws. B PTO Shield Removal and Installation MX19191 1. Remove fan cover (A) from each side of generator. 2. Remove locknuts from two bolts (B) securing generator to base bracket. 3. Remove locknut securing rear of generator to base bracket. 4. Remove generator from base bracket. A Gear Case Removal and Disassembly Procedure: MX17182 Removal: 1. Remove the four bolts securing the protective shield to the transmission. A 2. Remove shield. Installation: • Installation is in the reverse of removal. MX19191 1. Remove fan cover (A) from each side of generator. Attachments Repair - 450 ATTACHMENTS REPAIR F B H H B F E MX19884 2. Remove four bolts (B) securing gear case to generator housing. G MX19882a 5. Remove four bolts (E) securing plate to housing. 6. Remove top and bottom plugs (F) and drain gear oil into a suitable container. 7. Remove bolts (G) securing case halves and separate case. Note: If gears are damaged, replace entire gear case assembly. C 8. Remove gear shaft assemblies and inspect for damage. Replace bearings as necessary. 9. Remove and replace seals (H) before assembly. Assembly: Assembly is performed in the reverse order of disassembly. MX19883 3. Remove the four screws (C) securing the side cover of generator housing. • Replace gear shaft seals. • Clean case halves and seal with gasket compound. • Install plugs. Gear Case Oil Fill: 1. Install gear case to generator or place gear case on flat work surface. D Note: If gear case is overfilled, oil may come out of top vent plug during operation. If oil leaks occur during operation, check for proper oil level. MX17383 4. Loosen bolt (D) approximately five full turns and tap on bolt with a soft mallet to loosen the gear case tapered shaft from the rotor. Remove bolt and gear case. Attachments Repair - 451 ATTACHMENTS REPAIR A B MX17351 B MX17188 2. Remove top (A) and side (B) case plugs. 3. Fill case with 80W90 GL5 Gear Lube (approximately 16 oz) until gear oil comes out of side plug opening (B). 4. Install and tighten plugs. Rotor Bearing Removal and Installation Removal: 1. Remove gear case from generator. See “Gear Case Removal and Disassembly” on page 450. 2. Using a press, install bearing on shaft until it stops on bearing seat (B). 3. Ensure that bearing rotates freely and does not bind. Rotor Fan Removal and Installation Removal: 1. Clean rotor shaft and ensure that it is free of all dirt and grease. 2. Stand rotor on a level surface with the bearing end down. 2. Remove rotor assembly from generator. A A MX17345 3. Using a suitable puller (A), slowly remove fan from rotor shaft. MX17352 3. Stand rotor assembly upright on a level surface and attach a suitable bearing puller (A) to rotor bearing. 4. Slowly remove bearing from rotor shaft. Installation: 1. Place bearing evenly on rotor shaft. Attachments Repair - 452 ATTACHMENTS REPAIR Generator Assembly and Installation Assembly and Installation: 1. Assemble generator by applying medium strength thread lock to bolts securing generator end support bracket to transmission (if removed for transmission replacement). B A MX17347 4. Inspect the fan friction collar (B) for deformation. Replace as necessary. MX19708 Installation: 2. Set end support bracket against gear case and insert bolts (A). Tighten bolts to specification. 1. If removed, replace fan friction collar. 2. Place rotor and fan on press. 3. Wipe gear case shaft taper clean of grease and debris. B C MX17348 C 3. Place a block of wood (C) on fan to allow for even pressure distribution. 4. Slowly apply pressure until fan seats on rotor shaft flange. MX19709 4. Slide rotor and fan assembly (B) onto crankshaft. 5. Insert rotor to gear case retaining bolt (C) through lock washer and rotor into crankshaft. Tighten finger tight. 6. Gently slide stator and end housing over rotor. Attachments Repair - 453 ATTACHMENTS REPAIR Control Panel Removal and Installation Removal: E 1. Remove the control panel cover. A D F MX19884 B 7. Slide two bolts and nuts (D) at bottom of stator housing and tighten finger tight. Install two bolts (E) into holes at top of stator housing, install nuts, and tighten. Tighten bolts to specification. 8. Tighten rotor retaining bolt slowly and ensure rotor turns smoothly inside of stator. MX19885 2. Disconnect wires from the terminal block (A). 3. Disconnect ground wires (B). 9. Ensure that rotor bearing is seated completely in stator housing. 4. Remove control panel. 10. Tighten rotor bolt to specification. Installation: 11. Install three generator support bolts (F). • Installation is in the reverse of removal. F MX19191 12. Install generator end cover and vent covers (F). 13. Connect all wiring in the reverse of disassembly. Specifications: Generator support bracket to gear case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.) Generator to support bracket . . . . . 21 N•m (186 lb-in.) Rotor to rotor retaining bolt . . . . . . 21 N•m (186 lb-in.) Attachments Repair - 454 MISCELLANEOUS TABLE OF CONTENTS Miscellaneous Table of Contents Specifications ...............................................457 Repair Specifications..................................457 Other Materials...........................................457 Repair.............................................................458 Headlights Adjustment ...............................458 Hood Removal and Installation ..................458 Fender Deck Removal and Installation ......459 Foot Deck Removal and Installation...........460 Fuel Tank Removal and Installation ...........460 Fuel Pump/Fuel Gauge Sensor Removal and Installation ...........................................461 Rear Wheel Removal and Installation ........462 Front Wheel Removal and Installation .......462 Instrument Panel Removal and Installation 463 Lift Linkage Removal and Installation.........464 Lift Linkage Adjustment: .............................465 Deck Height Stop Removal and Installation ..................................................465 Miscellaneous Table of Contents - 455 MISCELLANEOUS TABLE OF CONTENTS Miscellaneous Table of Contents - 456 MISCELLANEOUS SPECIFICATIONS Specifications Repair Specifications Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.6 L (6.5 gal) Fuel Pump/Sensor Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 N•m (12 lb-in.) Steering Wheel Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N•m (28 lb-ft) Front Wheel Cap Screw (2-Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 N•m (54 lb-ft) Front Wheel Lugs (5 used) (4-Wheel Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 N•m (65 lb-ft) Rear Wheel Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 N•m (65 lb-ft) Other Materials Other Material Part No. LOCTITE® PRODUCTS Loctite#/U.S. #/Canadian TY9370/TY9477/#242 Part Name Thread Lock and Sealer (Medium Strength) Part Use To seal threads on control valve screws, spool detent, and small plugs Miscellaneous Specifications - 457 MISCELLANEOUS REPAIR Repair • Turn bulb assembly 1/4 turn counterclockwise to remove. Headlights Adjustment • Insert new bulb assembly into housing and turn 1/4 turn clockwise to install. 1. Park machine safely. See Parking Safely in the Safety Section. • Connect wire harness. 7. Lower hood. 2. Raise hood. Hood Removal and Installation Removing: A 1. Raise hood. A Important: Avoid Damage! Disconnect headlight harness before removing hood. B C A MX14303 3. Loosen both cap screws (A) holding headlight fixture (B) securely to hood. 4. To adjust headlights, loosen cap screw (C), and rotate headlight fixture (B) up or down. Tighten cap screw (C). 5. Tighten cap screws (A) holding fixture to hood. 6. To replace headlights: MX13552 2. Disconnect headlight harness (A) on left side of machine. c contains Caution: Avoid Injury! Halogen light bulb gas under pressure. The bulb may shatter if the glass is scratched or dropped. Wear eye protection and handle bulb with care when removing or replacing. D E MX13551 3. Pull hood forward and roll hood up and out of rail. MX13624 • Disconnect wire harness (D) from defective bulb assembly (E). Miscellaneous Repair - 458 MISCELLANEOUS REPAIR Fender Deck Removal and Installation Installing: A Removal: 1. Park machine safely. See Parking Safely in the Safety Section. 2. Raise hood and disconnect negative battery terminal. A B C MX13551 D 1. Position hood (A) upright. F E B MX14169 3. Slide seat fully forward and tip up. 4. Disconnecting seat switch wiring connector (A), remove wire and sheath from notched area (B) in seat platform. 5. Remove spring pin (C) and pivot rod. Remove seat. 6. Remove two rear cap screws (D). 7. Slide seat fully rearward and remove two front cap screws and seat platform. MX13629 2. Install first set of rollers (B) on hood into rail. 3. Connect headlight harness on left side of machine. 4. Tilt rear of hood toward steering wheel and lift hood up and drop second set of rollers into rail. 5. Allow hood to roll downward on rail. 6. Lower hood. 8. MFWD machines only: Remove shift lever knob on right side of fender deck before fender deck removal. See “Shift Lever Linkage (MFWD) Removal and Installation” on page 278 in the Power Train section. 9. Disconnect tail light wiring harness connector (E). 10.Remove fuel tank support bracket (F), under left rear tire and fuel cap. c EFI Caution: Avoid Injury! Machines with (FD711D) engines: Release of fluids from pressurized fuel system can cause serious injuries. Relieve fuel system pressure before servicing. Miscellaneous Repair - 459 MISCELLANEOUS REPAIR Foot Deck Removal and Installation G Removal: 1. Park machine safely. See Parking Safely in the Safety Section. 2. Raise hood and disconnect negative battery terminal. 3. Remove fender deck. See “Fender Deck Removal and Installation” on page 459. 4. Remove the rubber foot mats from each side. MX15401/MX15402 11.(FD711D) EFI Engines Only: Loosen the fuel pressure relief screw (G) to relieve the high pressure in the return fuel hose; then tighten it. 5. Remove the two carriage bolts from each side, securing the foot deck to the frame. 6. Remove the foot deck from the frame. Installation: Note: Route wires and hoses to prevent pinching. 1. Installation is the reverse of removal. I Fuel Tank Removal and Installation Removal: 1. Park machine safely. See Parking Safely in the Safety Section. 2. Raise hood and disconnect negative battery terminal. c EFI Caution: Avoid Injury! Machines with (FD711D) engines: Release of fluids from pressurized H MX14172 fuel system can cause serious injuries. Relieve fuel system pressure before servicing. 12.Remove cap screws (H). 13.Remove fender deck (I), being careful to guide seat switch wiring through hole in bottom of platform. A 14.Immediately install fuel cap, being sure to not allow dirt or other debris to enter fuel tank. Installation: Note: Route wires and hoses in fuel tank slots to prevent pinching. 1. Installation is the reverse of removal. MX15401/MX15402 3. (FD711D) EFI Engines Only: Loosen the fuel pressure relief screw (A) to relieve the high pressure in the return fuel hose; then tighten it. 4. Remove fender deck. See “Fender Deck Removal and Installation” on page 459. Miscellaneous Repair - 460 MISCELLANEOUS REPAIR B F H Fuel Pump/Fuel Gauge Sensor Removal and Installation Removal: C 1. Park machine safely. See Parking Safely in the Safety Section. 2. Raise hood and disconnect negative battery terminal. D G c EFI Caution: Avoid Injury! Machines with (FD711D) engines: Release of fluids from pressurized E B I fuel system can cause serious injuries. Relieve fuel system pressure before servicing. D MX14173 A 5. Remove two cap screws (B) and bracket (C). 6. Remove three clips (D) holding wiring harnesses in place. 7. Disconnect sending unit wiring harness connector (E). c explosive Caution: Avoid Injury! Fuel Vapors are and flammable. • Do not smoke while handling fuel. • Keep fuel away from flames or sparks. • Fill fuel tank outdoors or in a well ventilated area. • Clean up spilled fuel immediately. • Use clean approved non-metal container to prevent static electric charge. MX15401/MX15402 3. (FD711D) EFI Engines Only: Loosen the fuel pressure relief screw (A) to relieve the high pressure in the return fuel hose; then tighten it. 4. Remove fender deck. See “Fender Deck Removal and Installation” on page 459. • Use clean approved plastic funnel without screen or filter, to prevent static electric discharge. D B C 8. Loosen hose clamp and remove drain-back hose (F). Cap hose to keep fuel from draining. 9. Squeeze tabs on end of fuel supply hose and disconnect hose (G) from stationary line on sending unit. Cap hose to keep fuel from draining. 10.Remove fuel tank, taking care to move all fuel lines and wiring harnesses, including seat switch (H) and tail light (I) harnesses, out of the way to avoid damaging them. D D D E A MX14174 Installation: Note: Route wires and hoses in fuel tank slots to prevent pinching. Picture Note: (FD711D) EFI supply hose (C) shown; (FD671D) engines have standard clamped hose. 5. Disconnect sending unit wiring connector (A). 1. Installation is the reverse of removal. 6. Loosen clamp and disconnect drain-back hose (B). 7. (FD711D) EFI Engines Only: Squeeze tabs on end of supply hose (C) and disconnect hose. Miscellaneous Repair - 461 MISCELLANEOUS REPAIR 8. Remove five cap screws (D) and fuel pump/sensor (E). Front Wheel Removal and Installation 9. Inspect parts for wear or damage. Replace if necessary. 1. Lift machine high enough to remove weight from wheels. Place jack stands under machine frame. Installation: Note: Route wires and hoses in fuel tank slots to prevent pinching. D C 1. Installation is the reverse of removal. 2. Tighten five cap screws (D) in a star pattern to specification. Do not overtighten. B Specifications: Mounting Cap Screws . . . . . . . . . . . . 1.4 N•m (12 lb-in.) A Rear Wheel Removal and Installation 1. Lift machine high enough to remove weight from wheels. Place jack stands under machine frame. MX11939 Picture Note: 2-wheel drive shown; 4-wheel drive has five lugs securing wheel to hub similar to rear wheels. A B 2. Remove cap screw (A) and plate (B). Note: Remove bearings only if replacement is necessary. 3. Inspect bearings (C) for wear or damage. Replace if necessary. • Remove either bearing (C) using a slide hammer and inside puller. MX11940 • Remove bearing on opposite end using a driver set and a press. 2. Remove five lug bolts (A) and rear wheel assembly • Installation is done in the reverse order of removal. • Pack inside areas of wheel hub bearings with multipurpose grease. • Install wheels with valve stems (B) facing away from machine and tighten lug bolts to specification. Installation is done in the reverse order of removal. Specifications: • Install wheels with valve stems (D) facing away from machine and tighten fastener(s) to specification. Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 N•m (65 lb-ft) Install bearings flush to wheel hub. Specifications: Two-Wheel Drive Cap Screw . . . . . . . . . 73 N•m (54 lb-ft) Four-Wheel Drive Lugs . . . . . . . . . . . . . 88 N•m (65 lb-ft) Miscellaneous Repair - 462 MISCELLANEOUS REPAIR Instrument Panel Removal and Installation 9. Remove screw (D) holding instrument panel onto pedestal. Removing: 1. Park machine safely. See Parking Safely in the Safety Section. I 2. Raise hood and disconnect negative battery terminal. J H A MX35888 C B D 10.The steering column shields snap onto the steering column. a. Grasp the front shield (H) and firmly pull the top of the shield out and then lift the shield off of the steering column. C MX35886 3. Remove steering wheel cover and steering wheel (A). See “Steering Column Removal and Installation” on page 375 in Steering section. 4. Remove throttle handle (B). b. Lift the top shield (I) up to unsnap it from the steering column. c. Pivot the steering column down (toward the seat) and firmly flex the top shield (I) and the instrument panel (J) to remove the shield. 5. Pull top of left and right side panels (C) out to remove pins from holes in machine frame. 6. Remove screw (D) holding instrument panel onto pedestal. L K G D F MX35889 11.Remove the latch spring (K). E 12.Unsnap the latch (L) from the steering column. MX35887 7. Remove screw securing cruise control latch (E) and parking brake latch (F). 8. Remove SCV lever boot (G). Miscellaneous Repair - 463 MISCELLANEOUS REPAIR 5. Remove the spring pins and drilled pins securing the draft arms to the lift link (A) and the frame (B). 6. Turn lift link 45°, and remove from end of lift arm. 7. Remove cap screw, washer (C) and lift arm from end of mid-lift shaft. I E G D MX35890 13.Slowly raise instrument panel, being careful to remove all electrical connections beneath panel and guiding panel past SCV levers (M). F Installation: MX35892 Note: Route wires to prevent pinching. 8. Disconnect the return spring (D) from the intermediate brake bellcrank. 1. Installation is the reverse of removal. Specifications: Steering Wheel Nut. . . . . . . . . . . . . . . . 38 N•m (28 lb-ft) 9. Remove the spring pin and drilled pin (E) and disconnect the brake actuator link from the intermediate brake bellcrank. Lift Linkage Removal and Installation 10.Remove the spring pin (F) and differential lock bellcrank from the differential lock pedal rod. Removal: 11.Rotate the differential lock bellcrank 90° and remove bellcrank from differential link (G). 1. Park machine safely. See Parking Safely in the Safety Section. 2. Raise hood and disconnect negative battery terminal. 12.At the transaxle, remove the spring pin and washer and remove the differential link from the machine. 3. Remove fender deck. See “Fender Deck Removal and Installation” on page 459. I 4. Remove foot deck. See “Foot Deck Removal and Installation” on page 460. C L J K H MX35893 B 13.Remove spring pin (H) from end of brake rod at transaxle arm and cam, and remove brake rod from intermediate brake bellcrank (I). A MX35891 14.Disconnect the front (J) and rear (K) hydraulic lines from the cylinder. Miscellaneous Repair - 464 MISCELLANEOUS REPAIR 15.Remove the two nuts and u-bolt (L) allowing the cylinder to be free of the frame. 16.Remove bearings from each end of the mid-lift shaft. 17.Remove the mid-lift shaft and cylinder from the machine as an assembly. Installation: 1. Installation is the reverse of removal. 2. Perform “Lift Linkage Adjustment:” procedure below. Important: Avoid Damage! Mower deck lift system can be damaged if lift arms are not adjusted correctly. Check adjustment each time mower is installed to allow gap between lift arms and frame stop (C) at full lift height. 7. Check that the lift arm (D) does not contact the frame stop (C). If needed, adjust yokes (E) on both sides of mower until there is a slight gap of 1.6 mm (1/16 in.) on both sides. Specifications: • Remove spring locking pin (F) and drilled pin (G) from each lift arm. Lift Arm Cap Screws . . . . . . . . . . . . . . 38 N•m (28 lb-ft) • Turn each yoke (E) clockwise to raise the lift arm. Lift Linkage Adjustment: • Turn each yoke (E) counterclockwise to lower the lift arm. Reason: • Attach each yoke to lift arm with drilled pin (G) and spring locking pin (F). To make sure that lift system linkage is adjusted properly. Procedure: 1. Inspect for bent or broken mid-shaft, height indicator, etc. Replace components if necessary. Note: On AWS machines there is an additional bracket (H) mounted to the machine frame that limits lift arm rise. 2. Remove fender deck and footrest. Deck Height Stop Removal and Installation 3. Extend rockshaft cylinder completely (pull back on top SCV lever). Removal: 4. Rotate the height indicator to make sure it rotates freely at full transport height. 5. Locate strap underneath machine (this strap is the link that connects the rockshaft cylinder to the mid-lift welded shaft). This strap has a slot in it pointing towards the front of the machine. The welded pin in the mid-lift shaft travels within this slot. 1. Park machine safely. See Parking Safely in the Safety Section. 2. Raise hood and disconnect negative battery terminal. 3. Remove fender deck. See “Fender Deck Removal and Installation” on page 459. 4. Remove foot deck. See “Foot Deck Removal and Installation” on page 460. A C B E B G H F A D MX35894 MX14280 6. The lift arms have headed pins (A) welded to them that support the lift links. Check to make sure the P-hooks on lift links (B) move freely about the pins. 5. Remove the three nuts and carriage bolts (A). 6. Rotate the height stop assembly up and disconnect the detent spring (B) from the frame slot. Miscellaneous Repair - 465 MISCELLANEOUS REPAIR Installation: Disassembly: 1. Installation is the reverse of removal. E I B MX35895 A 1. Rotate the stop cam (E) to expose the detent spring (I). 2. Disconnect the detent spring (I) from the mounting bracket. Pivot the detent spring downward and rotate the stop cam (E) to expose the opposite end of the spring. Disconnect the spring from the mounting bracket (D). A MX35894 2. Insert the detent spring (B) through the frame slot and secure height stop assembly with the three carriage bolts and nuts (A). C B D F G H E MX35896 A- Pivot Pin B- Spacer C- Bushing D- Mounting Bracket E- Stop Cam F- Bushing G- Spacer H- Bowtie Spring Pin 3. Remove the bowtie spring pin (H). 4. Remove the pivot pin (A), spacers (B and G), bushings (C and F), and stop cam (E) from the mounting bracket (D). 5. Inspect all parts for wear and damage. Replace as needed. Miscellaneous Repair - 466 INDEX Numerics 48C Mower Deck Spindle Removal and Installation . . 421 54C Mower Deck Spindle Removal and Installation . . 424 62C Mower Deck Spindle Removal and Installation . . 427 A Alternative lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Attachments Component Location PTO Generator . . . . . . . . . . . . . . . . . . . . . . . . 438 Conductors for 12 Volt Circuits . . . . . . . . . . . . . . . 436 Diagnosis Loader Diagnosis . . . . . . . . . . . . . . . . . . . . . . 412 Mower Deck Diagnosis . . . . . . . . . . . . . . . . . . 409 Electrical Common Circuit Tests . . . . . . . . . . . . . . . . . . 436 Conductors for 12 Volt Circuits . . . . . . . . . . . . 436 Diagnostic Information . . . . . . . . . . . . . . . . . . 435 Reading Electrical Schematics . . . . . . . . . . . . 434 Theory of Operation Information . . . . . . . . . . 435 Wire Color Abbreviation Chart . . . . . . . . . . . . 435 General Specifications . . . . . . . . . . . . . . . . . . . . . 405 Generator Circuit Diagnosis . . . . . . . . . . . . . . . . . 445 Identification Numbers PTO Generator . . . . . . . . . . . . . . . . . . . . . . . . 437 Mower Deck Blade Balance . . . . . . . . . . . . . . . . . 421 PTO Generator Electrical Control Panel Removal and Installation . . . . . 454 Generator Assembly and Installation . . . . . . . 453 Generator Circuit Diagnosis . . . . . . . . . . . . . . 445 Generator Circuit Operation . . . . . . . . . . . . . . 445 Generator Ground Test . . . . . . . . . . . . . . . . . 449 Generator Removal and Disassembly . . . . . . 450 Generator Rotor Test . . . . . . . . . . . . . . . . . . . 448 Generator Stator Test . . . . . . . . . . . . . . . . . . . 447 Ground Fault Circuit Interrupter Checks . . . . . 448 PTO Shield Removal and Installation . . . . . . . 450 Rotor Bearing Removal and Installation . . . . . 452 Rotor Fan Removal and Installation . . . . . . . . 452 Standard Electrical Schematic . . . . . . . . . . . . 443 Stator Excitation Field Restoration . . . . . . . . . 449 Wiring Harness Legend . . . . . . . . . . . . . . . . . 442 PTO Generator Gear Case Removal . . . . . . . . . . 450 Repair 48C Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423 48C Jacksheave . . . . . . . . . . . . . . . . . . . . . . . 424 48C Mower Deck Spindle Remove/Install . . . 421 54C Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427 54C Jacksheave . . . . . . . . . . . . . . . . . . . . . . . 426 54C Mower Deck Spindle Remove and Install 424 62C Mower Deck Spindle Remove and Install 427 Cleaning Grass and Debris from Machine . . . 418 Mower Deck Belt Shield Remove and Install . 418 Mower Deck Blade Removal and Installation . 420 Mower Deck Blade Sharpen . . . . . . . . . . . . . . 420 Mower Deck Drive Shaft Remove and Install . 429 Mower Deck Drive Shaft Repair . . . . . . . . . . . .430 Mower Deck Gearbox Remove/Install . . . . . . .431 Mower Deck Gearbox Repair . . . . . . . . . . . . . .433 Repair Specifications . . . . . . . . . . . . . . . . . . . . . . .407 Tests and Adjustments Adjusting Cutting Height . . . . . . . . . . . . . . . . .414 Adjusting Loader Latch Rod . . . . . . . . . . . . . . .416 Adjusting Mower Deck Wheels . . . . . . . . . . . .414 Adjusting Mower Level Front to Rear . . . . . . . .416 Adjusting Mower Level Side to Side . . . . . . . .415 Cylinder Leakage Test . . . . . . . . . . . . . . . . . . .417 Loader Lubrication . . . . . . . . . . . . . . . . . . . . . .417 Mower Deck Level Check and Adjustment . . .414 Wire Abbreviation Chart . . . . . . . . . . . . . . . . . . . . .435 Avoid Harmful Asbestos Dust . . . . . . . . . . . . . . . . . . . . . .4 Avoid Injury Rotating Blades, Augers And PTO Shafts . . . . . . . . .5 Axle, front Disassembly/assembly . . . . . . . . . . . . . . . . . . . . . .381 Removal/installation . . . . . . . . . . . . . . . . . . . . . . . .380 B Brake PTO, disassembly/inspection/assembly . . . . . . . . .289 PTO, removal/installation . . . . . . . . . . . . . . . . . . . .288 Brake test, Mid-PTO . . . . . . . . . . . . . . . . . . . . . . . . . . .270 Brake/differential linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .397 Brakes Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .395 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .394 Removal/installation . . . . . . . . . . . . . . . . . . . . . . . .401 Break-in engine oil 4-cycle gasoline . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 C California Proposition 65 Warning . . . . . . . . . . . . . . . . . .4 Center valve block, hydrostatic power train . . . . . . . . .310 Charge pressure test . . . . . . . . . . . . . . . . . . . . . . . . . .352 Charge pump Disassembly/assembly . . . . . . . . . . . . . . . . . . . . . .283 Flow quick test, at charge pump . . . . . . . . . . . . . . .268 Flow quick test, at couplers . . . . . . . . . . . . . . . . . .351 Pressure quick test, at charge pump . . . . . . . . . . .268 Pressure quick test, at couplers . . . . . . . . . . . . . . .351 Removal/installation . . . . . . . . . . . . . . . . . . . . . . . .282 Charge pump pressure test . . . . . . . . . . . . . . . . . . . . .267 Component Location Attachments PTO Generator . . . . . . . . . . . . . . . . . . . . . . . .438 Brake/Differential Linkage (Exploded) . . . . . . . . . .393 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .392 Electrical, Engine Components (FD671D) . . . . . . .113 Electrical, Engine Components (FD750D EFI) . . . .114 Electrical, Instrument Panel . . . . . . . . . . . . . . . . . .115 Electrical, Machine Left Side . . . . . . . . . . . . . . . . .112 Index - 1 INDEX Electrical, Machine Right Side . . . . . . . . . . . . . . . 111 Engine - Liquid-Cooled FD671D Engine Only . . . . . . . . . . . . . . . . . . . . 27 FD711D Engine Only . . . . . . . . . . . . . . . . . . . . 28 Final Drive (MFWD) . . . . . . . . . . . . . . . . . . . . . . . 239 Front Axle Assembly (MFWD) . . . . . . . . . . . . . . . 242 Front Axle Gear Case (MFWD) . . . . . . . . . . . . . . 240 Hydrostatic Power Train . . . . . . . . . . . . . . . . . . . . 237 Rear PTO (optional) . . . . . . . . . . . . . . . . . . . . . . . 258 Rear PTO Gear Case Assembly . . . . . . . . . . . . . . 243 Steering System 2 - Wheel Steer . . . . . . . . . . . . . . . . . . . . . . . 362 All Wheel Steer . . . . . . . . . . . . . . . . . . . . . . . . 363 All Wheel Steer Rear Axle . . . . . . . . . . . . . . . 364 Control arm damper Removal/installation . . . . . . . . . . . . . . . . . . . . . . . 280 Control linkage adjustment, transaxle . . . . . . . . . . . . . 272 Coolant specifications Gasoline engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Cruise control linkage, check and adjustment . . . . . . . 273 Cylinder, Steering Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372 Removal/installation . . . . . . . . . . . . . . . . . . . . . . . 380 D Deck Height Stop Removal/Installation . . . . . . . . . . . . 465 Diagnosis Attachments Loader Diagnosis . . . . . . . . . . . . . . . . . . . . . . 412 Mower Deck Diagnosis . . . . . . . . . . . . . . . . . . 409 Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395 Engine - Liquid-Cooled . . . . . . . . . . . . . . . . . . . . . . 34 Engine Tests . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 Preliminary Hydraulic System Inspection . . . . 349 System Tests . . . . . . . . . . . . . . . . . . . . . . . . . 350 Hydrostatic transmission . . . . . . . . . . . . . . . . . . . . 260 Hydrostatic transmission Tests . . . . . . . . . . . . . . . 264 Mid-PTO System . . . . . . . . . . . . . . . . . . . . . . . . . 262 Mid-PTO System Tests . . . . . . . . . . . . . . . . . . . . . 265 PTO Generator Circuits . . . . . . . . . . . . . . . . . . . . 445 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369 Steering Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370 Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 Transaxle Tests . . . . . . . . . . . . . . . . . . . . . . . . . . 266 Differential 2-Wheel Drive Disassembly/Assembly . . . . . . . . . . . . . . . . . 300 Final pinion shaft, inspection . . . . . . . . . . . . . 300 MFWD Disassembly/Assembly . . . . . . . . . . . . . . . . . 301 Final pinion shaft, inspection . . . . . . . . . . . . . 301 Differential Input Housing (MFWD) Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . 331 Differential lock Linkage, inspection . . . . . . . . . . . . . . 281 Differential lock Shaft, disassembly/assembly . . . . . . 298 Directional control valves Removal/installation . . . . . . .284 Dispose of Waste Properly . . . . . . . . . . . . . . . . . . . . . . . .5 Drain interval, gasoline engine coolant . . . . . . . . . . . . . .19 Drive Shaft (MFWD) Removal/Installation . . . . . . . . . .329 Drive shaft Disassembly/inspection/assembly . . . . . . . . . . . . .285 Removal/installation . . . . . . . . . . . . . . . . . . . . . . . .285 Drive train Mid and Rear PTO, removal and installation . . . . .291 Mid-PTO, removal/installation . . . . . . . . . . . . . . . .290 E Electrical Charging Circuit Diagnosis . . . . . . . . . . . . . . . . . . .167 Charging Circuit Electrical Schematic . . . . . . . . . .165 Charging Circuit Operation - All Models . . . . . . . . .164 Component Location Engine Components (FD671D) . . . . . . . . . . . .113 Engine Components (FD750D EFI) . . . . . . . . .114 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . .115 Machine Left Side . . . . . . . . . . . . . . . . . . . . . .112 Machine Right Side . . . . . . . . . . . . . . . . . . . . .111 Cranking Circuit Electrical Schematic - All Models .162 Cranking Circuit Operation - All Models . . . . . . . . .161 Display Panel Pin, Wire, and Signal Location . . . .187 Electrical Schematic - X700 (1 of 2) . . . . . . . . . . . .119 Fuel Injection Sensor and Diagnostic Circuit Electrical Schematic - X720/X724/X728 . .206 Fuel Injection Sensor and Diagnostic Circuit Operation - X720/X724/X728 . . . . . . . . . .203 Fuel Pump and Fuel Injector Circuit Electrical Schematic - X485 and X585 . . . . . . . . . . .198 Fuel Pump and Fuel Injector Circuit Operation X720/X724/X728 . . . . . . . . . . . . . . . . . . . .197 Fuel Pump and Fuel Shutoff Circuit Electrical Schematic - X700 . . . . . . . . . . . . . . . . . . .195 Fuel Pump and Fuel Shutoff Circuit Operation X700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194 Ignition Circuit Electrical Schematic - X700 . . . . . .169 Ignition Circuit Electrical Schematic - X720/ X724/X728 . . . . . . . . . . . . . . . . . . . . . . . . .174 Ignition Circuit Operation - X700 . . . . . . . . . . . . . .168 Ignition Circuit Operation - X720/X724/X728 . . . . .173 Instrument Panel Circuit Operation - All Models . .185 Lights Circuit Electrical Schematic - All Models . . .189 Lights Circuit Operation - All Models . . . . . . . . . . .188 PTO Circuit Electrical Schematic . . . . . . . . . . . . . .179 PTO Generator Schematics . . . . . . . . . . . . . . . . . .443 PTO/RIP Circuit Operation . . . . . . . . . . . . . . . . . . .177 Power Circuit Electrical Schematic - X700 . . . . . . .141 Power Circuit Electrical Schematic - X720/ X724/X728 . . . . . . . . . . . . . . . . . . . . 151, 154 Power Circuit Operation - X700 . . . . . . . . . . . . . . .140 Power Circuit Operation - X720/X724/X728 . . . . . .149 Reading Electrical Schematics . . . . . . . . . . . . . . . .103 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 Index - 2 INDEX Alternator Removal, Inspection, and Installation (Optional) . . . . . . . . . . . . Ignition Coil Replacement . . . . . . . . . . . . . . . Stator Replacement . . . . . . . . . . . . . . . . . . . . Schematic And Wiring Harness Legend - X700 . . Schematic And Wiring Harness Legend - X720/ X724/X728 . . . . . . . . . . . . . . . . . . . . . . . . Specifications General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test and Adjustment . . . . . . . . . . . . . . . . . . . Tests and Adjustments Air Temperature Test - X720/X724/X728 . . . . Battery - Charge . . . . . . . . . . . . . . . . . . . . . . . Battery - Load Test . . . . . . . . . . . . . . . . . . . . . Battery Voltage and Specific Gravity Test . . . Brake Switch Test and Adjustment . . . . . . . . Common Circuit Tests . . . . . . . . . . . . . . . . . . Coolant Temperature Sensor Test X720/X724/X728 . . . . . . . . . . . . . . . . Diode Test . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Coolant Temperature Sensor Test . . . Engine Oil Pressure Switch Test . . . . . . . . . . Fuel Injection Module Test - X720/X724/X728 Fuel Injector Test - X720/X724/X728 . . . . . . . Fuel Shutoff Solenoid Test - X700 . . . . . . . . . Fuel Tank Sensor Test . . . . . . . . . . . . . . . . . . Fuse Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ground Circuit Tests . . . . . . . . . . . . . . . . . . . Ignition Coil Test . . . . . . . . . . . . . . . . . . . . . . . Key Switch Test . . . . . . . . . . . . . . . . . . . . . . . Lights Switch Test . . . . . . . . . . . . . . . . . . . . . PTO Solenoid Test . . . . . . . . . . . . . . . . . . . . . PTO Switch Test (optional) . . . . . . . . . . . . . . PTO/RIP Switch Test . . . . . . . . . . . . . . . . . . . Power Port Switch Test . . . . . . . . . . . . . . . . . RIO Switch Adjustment . . . . . . . . . . . . . . . . . RIO Switch Test . . . . . . . . . . . . . . . . . . . . . . . Regulated Amperage and Voltage Test . . . . . Regulated Voltage Test . . . . . . . . . . . . . . . . . Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Switch Test . . . . . . . . . . . . . . . . . . . . . . Spark Plug Gap Adjustment . . . . . . . . . . . . . . Spark Plug Gap Test . . . . . . . . . . . . . . . . . . . Spark Test . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Armature Test . . . . . . . . . . . . . . . . . . . Starter Field Windings Test . . . . . . . . . . . . . . Starter Solenoid Test . . . . . . . . . . . . . . . . . . . Starting Motor Amp Draw Test . . . . . . . . . . . . Starting Motor Condition . . . . . . . . . . . . . . . . . Starting Motor No-load Amperage and RPM Test . . . . . . . . . . . . . . . . . . . . . Stator Resistance Test (Optional Auxiliary Alternator) . . . . . . Stator Resistance Test (Standard Configuration) . . . . . . . . . . 231 230 230 116 117 107 108 107 227 209 210 208 220 208 227 224 216 217 225 225 224 224 222 208 229 219 217 222 223 218 219 222 221 211 211 218 220 228 228 229 216 216 214 215 214 215 213 213 Unregulated Voltage Test (Optional Auxiliary Alternator) . . . . . . .212 Unregulated Voltage Test (Standard Configuration) . . . . . . . . . . .212 Vacuum Pressure Test - X720/X724/X728 . . .226 W1 Main Wiring Harness - X700 (1 of 2) . . . . . . . .125 W1 Main Wiring Harness - X700 (2 of 2) . . . . . . . .126 W1 Main Wiring Harness - X720/X724/X728 (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .127 W1 Main Wiring Harness - X720/X724/X728 (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .128 W1 Main Wiring Harness Color Codes - X700 . . . .136 W1 Main Wiring Harness Color Codes - X720/ X724/X728 . . . . . . . . . . . . . . . . . . . . . . . . .137 W2 Engine Wiring Harness - X700 . . . . . . . . . . . . .129 W2 Engine Wiring Harness - X720/X724/X728 . . .130 W2 Engine Wiring Harness Circuit Schematic X720/X724/X728 . . . . . . . . . . . . . . . . . . . .131 W2 Engine Wiring Harness Color Codes - X700 . .138 W2 Engine Wiring Harness Color Codes - X720/ X724/X728 . . . . . . . . . . . . . . . . . . . . . . . . .138 W3 Headlight Wiring Harness . . . . . . . . . . . . . . . .132 W3 Headlight Wiring Harness Color Codes . . . . . .138 W3 Rear Wiring Harness . . . . . . . . . . . . . . . . . . . .132 W4 PTO Option Wiring Harness . . . . . . . . . . . . . .132 W4 Rear Wiring Harness Color Codes . . . . . . . . . .138 W5 PTO Option Wiring Harness Color Codes . . . .139 Engagement pressure and brake test, Mid-PTO . . . . .270 Engine - Liquid-Cooled Air Cleaner Removal/Installation . . . . . . . . . . . . . . .58 Breather Valve Removal and Installation . . . . . . . . . . . . . . . . . .95 Camshaft Disassembly/Inspection . . . . . . . . . . . . . . . . . . .91 Removal and Installation . . . . . . . . . . . . . . . . . .90 Repair Specifications . . . . . . . . . . . . . . . . . . . . .24 Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Coolant Pump Removal/Installation . . . . . . . . . . . . .54 Cooling Fan and Bracket Removal/Installation . . . .53 Crankcase Cover Inspection . . . . . . . . . . . . . . . . . .82 Crankcase Cover Removal and Installation . . . . . . .80 Crankshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Removal/Replacement . . . . . . . . . . . . . . . . . . . .92 Repair Specifications . . . . . . . . . . . . . . . . . . . . .24 Cylinder Bore Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89 Cylinder Bore, Pistons and Rings Repair Specifications . . . . . . . . . . . . . . . . . . . . .25 Cylinder Head Assembly Repair Specifications . . . . . . . . . . . . . . . . . . . . .24 Cylinder Head Removal/Installation . . . . . . . . . . . . .65 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Engine Removal and Installation . . . . . . . . . . . . . . .73 Engine Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Index - 3 INDEX FD671D Engine Only Component Location . . . . . . . . . . . . . . . . . . . . Repair Carburetor Removal and Installation . . . . . Intake Manifold Removal/Installation . . . . . Tests & Adjustments Choke Adjustment . . . . . . . . . . . . . . . . . . . Fuel Pump Flow Test for Carburetor . . . . . Fuel Pump Pressure Test for Carburetor . . FD711D Engine Only Component Location . . . . . . . . . . . . . . . . . . . . Repair Fuel Injector Removal/Installation . . . . . . . Fuel Pressure Regulator Remove/Install . . Intake Manifold Removal/Installation . . . . . Throttle Body Removal/Installation . . . . . . Tests & Adjustments Bleed Fuel System . . . . . . . . . . . . . . . . . . . Fuel Pump Pressure Test for Fuel Injection Fan belt, removal/installation . . . . . . . . . . . . . . . . . Flywheel Removal and Installation . . . . . . . . . . . . . Fuel/Air System Tests & Adjustments . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . . . Governor Assembly Removal and Installation . . . . Muffler Removal and Installation . . . . . . . . . . . . . . Oil Pump Repair Specifications . . . . . . . . . . . . . . . . . . . . Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump Removal and Installation . . . . . . . . . . . . . Oil Screen Removal and Installation . . . . . . . . . . . . Piston Removal and Installation . . . . . . . . . . . . . . . Piston and Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator Removal/Installation . . . . . . . . . . . . . . . . . Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Specifications . . . . . . . . . . . . . . . . . . . . . . . Rocker Arms Removal and Installation . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting Motor Disassembly/Assembly . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . Tests & Adjustments Compression Test . . . . . . . . . . . . . . . . . . . . . . Cooling System Test . . . . . . . . . . . . . . . . . . . . Crankcase Vacuum Test . . . . . . . . . . . . . . . . . Engine Oil Pressure Test . . . . . . . . . . . . . . . . . Fan Belt Tension Adjustment . . . . . . . . . . . . . . Fast Idle Speed Adjustment . . . . . . . . . . . . . . . Governor Adjustment . . . . . . . . . . . . . . . . . . . . Low Idle Speed Adjustment . . . . . . . . . . . . . . . Radiator Bubble Test . . . . . . . . . . . . . . . . . . . . Radiator Cap Pressure Test . . . . . . . . . . . . . . . Thermostat Test . . . . . . . . . . . . . . . . . . . . . . . . Throttle Cable Adjustment . . . . . . . . . . . . . . . . Throttle Lever Adjustment . . . . . . . . . . . . . . . . 27 60 66 41 47 47 Valve Clearance Adjustment . . . . . . . . . . . . . . .43 Tests & Adjustments Specifications . . . . . . . . . . . . .23 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . .29 Thermostat Removal and Installation . . . . . . . . . . . .52 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . .25 Valve Train Removal and Installation . . . . . . . . . . . .79 Valves & Valve Lifter Repair Specifications . . . . . . . . . . . . . . . . . . . . .24 Engine oil specifications 4-cycle, gasoline . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 28 F 63 64 67 62 Face seal fittings torque With inch stud ends . . . . . . . . . . . . . . . . . . . . . . . . .11 With metric stud ends . . . . . . . . . . . . . . . . . . . . . . . .12 Fender Deck Removal and Installation . . . . . . . . . . . . .459 Final Drive Cover Removal/Installation (MFWD) . . . . .324 Final Drive Housing Removal/Installation (MFWD) . . . .326 Final pinion shaft 2-Wheel Drive Differential, inspection . . . . . . . . . .300 MFWD Differential, inspection . . . . . . . . . . . . . . . .301 Foot Control Linkage, Removal/Installation . . . . . . . . .275 Front Axle Housing (MFWD) Disassembly/Assembly . .332 Front Wheel Removal and Installation . . . . . . . . . . . . .462 Front axle Disassembly/assembly . . . . . . . . . . . . . . . . . . . . . .381 Removal/installation . . . . . . . . . . . . . . . . . . . . . . . .380 Front pivot, disassembly/assembly . . . . . . . . . . . . . . . .386 Fuel gauge sensor, removal/installation . . . . . . . . . . . .461 Fuel pump, removal/installation . . . . . . . . . . . . . . . . . .461 Fuel tank, removal/installation . . . . . . . . . . . . . . . . . . .460 49 48 53 77 24 23 82 58 24 96 95 98 84 87 56 52 24 77 26 69 71 69 43 50 44 46 49 42 41 42 51 51 50 40 40 G Gasoline engine coolant Drain interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Gasoline specifications 4-cycle engines . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Gasoline storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Gear case oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Gear transmission grease . . . . . . . . . . . . . . . . . . . . . . . .17 Grease, Anti-Corrosion, Specifications . . . . . . . . . . . . . .17 Grease, Mower Spindle, Specifications . . . . . . . . . . . . .17 Ground Circuit Tests . . . . . . . . . . . . . . . . . . . . . . . . . . .208 H Handle Chemical Products Safely . . . . . . . . . . . . . . . . . .5 Handling And Servicing Batteries . . . . . . . . . . . . . . . . . . .1 Headlights, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .458 Height Stop Removal/Installation . . . . . . . . . . . . . . . . .465 Hood Removal and Installation . . . . . . . . . . . . . . . . . . .458 Hydraulic control levers and linkage inspection . . . . . .358 Hydraulic control valve Disassembly/inspection/assembly . . . . . . . . . . . . .355 Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .354 Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . .355 Index - 4 INDEX Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Hydraulic oil warm-up procedure . . . . . . . . . 267, 351, 372 Hydraulics Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 Hydraulic System Tests . . . . . . . . . . . . . . . . . 350 Preliminary Hydraulic System Inspection . . . . 349 Theory of operation . . . . . . . . . . . . . . . . . . . . . . . . 341 Hydrostatic power train Center section system operation . . . . . . . . . . . . . 247 Center valve block . . . . . . . . . . . . . . . . . . . . . . . . 310 Directional control valves system operation . . . . . 247 Transaxle oil flow . . . . . . . . . . . . . . . . . . . . . . . . . 250 Hydrostatic pressure relief valve (45 loader) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284 Hydrostatic pump, inspection . . . . . . . . . . . . . . . . . . . 313 Hydrostatic transmission Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 Hydrostatic transmission Installation . . . . . . . . . . . . . . 312 Hydrostatic transmission motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 Hydrostatic transmission motor (2-Wheel Drive) Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . 306 Hydrostatic transmission motor (MFWD) Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . 308 Hydrostatic transmission motor Installation . . . . . . . . . 311 Hydrostatic transmission oil . . . . . . . . . . . . . . . . . . . . . . 16 I Identification Numbers Attachments PTO Generator . . . . . . . . . . . . . . . . . . . . . . . . 437 Ignition Coil Replacement and Adjustment . . . . . . . . . 230 Illuminate Work Area Safely . . . . . . . . . . . . . . . . . . . . . . 3 Inch Fastener Torque Values . . . . . . . . . . . . . . . . . . . . 10 Instrument Panel Removal and Installation . . . . . . . . . 463 K Knuckle assembly All wheel steer, removal/installation . . . . . . . . . . . 323 Knuckle housing, disassembly/assembly . . . . . . . . . . 323 L Leakage test Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering valve and cylinder . . . . . . . . . . . . . . . . . . Levers, Hydraulic control, inspection . . . . . . . . . . . . . . Lift Linkage Removal/Installation . . . . . . . . . . . . . . . . . Lift cylinder Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal/installation . . . . . . . . . . . . . . . . . . . . . . . Linkage Brake/differential Adjustment . . . . . . . . . . . . . . . . Cruise control linkage, check and adjustment . . . Differential lock, inspection . . . . . . . . . . . . . . . . . . .281 Foot Control, Removal/Installation . . . . . . . . . . . . .275 Hydraulic control levers, Inspection . . . . . . . . . . . .358 Intermediate, all wheel steer, installation . . . . . . . .385 Lift, Removal/Installation . . . . . . . . . . . . . . . . . . . .464 Rear steering All wheel steer . . . . . . . . . . . . . . . . . . . . . . . . .383 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .384 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .384 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .384 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .383 Transaxle control, adjustment . . . . . . . . . . . . . . . .272 Transaxle, full forward adjustment . . . . . . . . . . . . .273 Live With Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Loader Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . .417 Lubricant Alternative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Synthetic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 M MFWD Removal/Installation . . . . . . . . . . . . . . . . . . . . .329 Machine serial number locations . . . . . . . . . . . . . . . . . .19 Metric fastener torque values Grade 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Mid-PTO Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265 Drive train, removal/installation . . . . . . . . . . . . . . .290 Engagement pressure and brake test . . . . . . . . . .270 Mixing of lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Mower Deck Belt Shield Removal and Installation . . . .418 Mower Deck Blade Balance . . . . . . . . . . . . . . . . . . . . .421 Mower Deck Blade Removal and Installation . . . . . . . .420 Mower Deck Blade Sharpen . . . . . . . . . . . . . . . . . . . . .420 Mower Deck Drive Shaft Removal and Installation . . . .429 Mower Deck Drive Shaft Repair . . . . . . . . . . . . . . . . . .430 Mower Deck Gearbox Removal and Installation . . . . . .431 Mower Deck Gearbox Repair . . . . . . . . . . . . . . . . . . . .433 Muffler Removal and Installation Engine - Liquid-Cooled . . . . . . . . . . . . . . . . . . . . . . .58 O 354 353 372 358 464 O-Ring Boss Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 O-ring face seal fittings . . . . . . . . . . . . . . . . . . . . . . . . . .13 Output Shaft (MFWD) Removal/Installation) . . . . . . . . . . . . . . . . . . . . . . .304 353 355 397 273 Index - 5 INDEX P PTO Mid and Rear Drive train, removal and installation . . . . . . . . 291 Rear Drive train, removal and installation . . . . . . . . 291 Removal and Installation . . . . . . . . . . . . . . . . 294 Relief Valve Disassembly/inspection/Assembly . . . . . . . . . 287 Removal/installation . . . . . . . . . . . . . . . . . . . . 287 Solenoid Valve Disassembly/assembly . . . . . . . . . . . . . . . . . . 286 Removal/installation . . . . . . . . . . . . . . . . . . . . 286 PTO Brake Disassembly/inspection/assembly . . . . . . . . . . . . 289 Removal/installation . . . . . . . . . . . . . . . . . . . . . . . 288 PTO Generator Alternator Components . . . . . . . . . . . . . . . . . . . . . 439 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438 Control Panel Removal and Installation . . . . . . . . 454 Electrical Generator Ground Test . . . . . . . . . . . . . . . . . 449 Ground Fault Circuit Interrupter Checks . . . . . 448 Rotor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448 Stator Excitation Field Restoration . . . . . . . . . 449 Stator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 447 Electrical Attachments PTO Electrical Schematic . . . . . . . . . . . . . . . . 443 PTO Generator Wiring Harness Legend . . . . 442 Electrical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 445 Electrical Operation Attachments Generator Circuit Operation . . . . . . . . . . . 445 Gear Box Components . . . . . . . . . . . . . . . . . . . . . 441 Gear Case Removal . . . . . . . . . . . . . . . . . . . . . . . 450 Generator Assembly and Installation . . . . . . . . . . 453 Generator Removal and Disassembly . . . . . . . . . 450 PTO Shield Removal and Installation . . . . . . . . . . 450 Rotor Bearing Removal and Installation . . . . . . . . 452 Rotor Fan Removal and Installation . . . . . . . . . . . 452 PTO clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302 Park Machine Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Power train, hydraulic schematic . . . . . . . . . . . . . . . . . 339 Power train, system operation, external . . . . . . . . . . . 253 Pressure relief valve, hydrostatic (45 loader) . . . . . . . 284 Pressure test, charge . . . . . . . . . . . . . . . . . . . . . . . . . 352 Pressure test, charge pump . . . . . . . . . . . . . . . . . . . . 267 Prevent Acid Burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Prevent Battery Explosions . . . . . . . . . . . . . . . . . . . . . . . 2 R Reading Electrical Schematics . . . . . . . . . . . . . . . . . . Rear PTO 540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive train, removal and installation . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 259 291 258 Removal and Installation . . . . . . . . . . . . . . . . . . . .294 Rear Wheel Removal and Installation . . . . . . . . . . . . . .462 Rear axle assembly All wheel steer, disassembly/assembly . . . . . . . . .322 Two wheel steer, disassembly, assembly . . . . . . .319 Rear axle assembly (All Wheel Steer) Removal/installation . . . . . . . . . . . . . . . . . . . . . . . .321 Rear axle assembly (Two Wheel Steer) Removal/installation . . . . . . . . . . . . . . . . . . . . . . . .319 Rear pivot, disassembly/assembly . . . . . . . . . . . . . . . .386 Rear steering Linkage All wheel steer . . . . . . . . . . . . . . . . . . . . . . . . .383 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .384 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .384 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .384 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .383 Recognize Safety Information . . . . . . . . . . . . . . . . . . . . . .1 Remove Paint Before Welding Or Heating . . . . . . . . . . . .4 Repair Attachments 48C Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .423 48C Jacksheave . . . . . . . . . . . . . . . . . . . . . . .424 48C Mower Deck Spindle Remove/Install . . . .421 54C Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .427 54C Jacksheave . . . . . . . . . . . . . . . . . . . . . . .426 54C Mower Deck Spindle Remove and Install .424 62C Mower Deck Spindle Remove and Install .427 Cleaning Grass and Debris from Machine . . . .418 Mower Deck Belt Shield Remove and Install . .418 Mower Deck Blade Balance . . . . . . . . . . . . . . .421 Mower Deck Blade Removal and Installation .420 Mower Deck Blade Sharpen . . . . . . . . . . . . . .420 Mower Deck Drive Shaft Remove and Install .429 Mower Deck Drive Shaft Repair . . . . . . . . . . . .430 Mower Deck Gearbox Remove and Install . . .431 Mower Deck Gearbox Repair . . . . . . . . . . . . . .433 Repair Specifications . . . . . . . . . . . . . . . . . . . .407 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 Alternator Removal, Inspection, and Installation (Optional) . . . . . . . . . . . . .231 Ignition Coil Replacement and Adjustment . . .230 Stator Replacement . . . . . . . . . . . . . . . . . . . . .230 Engine - Liquid-Cooled . . . . . . . . . . . . . . . . . . . . . . .52 PTO Generator Field Restoration . . . . . . . . . . . . . .449 Replace Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 S Schematic Hydraulic, power train . . . . . . . . . . . . . . . . . . . . . . .339 Service Machines Safely . . . . . . . . . . . . . . . . . . . . . . . . . .3 Service Tires Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Service recommendations O-ring face seal fittings . . . . . . . . . . . . . . . . . . . . . . .13 Index - 6 INDEX Shaft Drive, disassembly/inspection/assembly . . . . . . . 285 Drive, removal/installation . . . . . . . . . . . . . . . . . . . 285 Shaft, differential lock, disassembly/assembly . . . . . . 298 Specifications Anti-Corrosion Grease . . . . . . . . . . . . . . . . . . . . . . 17 Brakes General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391 Test and Adjustment . . . . . . . . . . . . . . . . . . . 391 Electrical General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Test and adjustment . . . . . . . . . . . . . . . . . . . . 107 General Specifications Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . 405 Hydraulic General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338 Test and adjustment . . . . . . . . . . . . . . . . . . . . 337 Miscellaneous Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457 Mower Spindle Grease . . . . . . . . . . . . . . . . . . . . . . 17 Power train General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 Test and adjustment . . . . . . . . . . . . . . . . . . . . 235 Repair Specifications Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . 407 Steering General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361 Test and adjustment . . . . . . . . . . . . . . . . . . . . 361 Spindle Housing (MFWD) Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . 328 Stator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Steering Column, removal/installation . . . . . . . . . . . . . . . . . 375 Cylinder, leakage test . . . . . . . . . . . . . . . . . . . . . . 372 Cylinder, removal/installation . . . . . . . . . . . . . . . . 380 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370 Front and rear pivots, disassembly/assembly . . . . 386 Intermediate linkage all wheel steer, installation . 385 Operation, all wheel steer . . . . . . . . . . . . . . . . . . . 365 Rear, linkage All wheel steer . . . . . . . . . . . . . . . . . . . . . . . . 383 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 384 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 384 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383 Steering valve Disassembly/assembly . . . . . . . . . . . . . . . . . . . . . 377 Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372 Operation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368 Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .366 Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .367 Removal/installation . . . . . . . . . . . . . . . . . . . . . . . .376 Support Machine Properly . . . . . . . . . . . . . . . . . . . . . . . .3 Synthetic lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 T Tests and Adjustments Attachments Adjusting Cutting Height . . . . . . . . . . . . . . . . .414 Adjusting Loader Latch Rod . . . . . . . . . . . . . . .416 Adjusting Mower Deck Wheels . . . . . . . . . . . .414 Adjusting Mower Level Front to Rear . . . . . . . .416 Adjusting Mower Level Side to Side . . . . . . . .415 Cylinder Leakage Test . . . . . . . . . . . . . . . . . . .417 Loader Lubrication . . . . . . . . . . . . . . . . . . . . . .417 Mower Deck Level Check and Adjustment . . .414 Electrical Air Temperature Test - X720/X724/X728 . . . . .227 Battery - Charge . . . . . . . . . . . . . . . . . . . . . . . .209 Battery - Load Test . . . . . . . . . . . . . . . . . . . . .210 Battery Voltage and Specific Gravity Test . . . .208 Brake Switch Test and Adjustment . . . . . . . . .220 Common Circuit Tests . . . . . . . . . . . . . . . . . . .208 Coolant Temperature Sensor Test X720/X724/X728 . . . . . . . . . . . . . . . . .227 Diode Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .224 Engine Coolant Temperature Sensor Test . . .216 Engine Oil Pressure Switch Test . . . . . . . . . . .217 Fuel Injection Module Test - X720/X724/X728 225 Fuel Injector Test - X720/X724/X728 . . . . . . . .225 Fuel Shutoff Solenoid Test - X700 . . . . . . . . . .224 Fuel Tank Sensor Test . . . . . . . . . . . . . . . . . . .224 Fuse Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222 Ground Circuit Tests . . . . . . . . . . . . . . . . . . . .208 Ignition Coil Test . . . . . . . . . . . . . . . . . . . . . . .229 Key Switch Test . . . . . . . . . . . . . . . . . . . . . . . .219 Lights Switch Test . . . . . . . . . . . . . . . . . . . . . .217 PTO Solenoid Test . . . . . . . . . . . . . . . . . . . . . .222 PTO Switch Test (optional) . . . . . . . . . . . . . . .223 PTO/RIP Switch Test . . . . . . . . . . . . . . . . . . . .218 Power Port Switch Test . . . . . . . . . . . . . . . . . .219 RIO Switch Adjustment . . . . . . . . . . . . . . . . . .222 RIO Switch Test . . . . . . . . . . . . . . . . . . . . . . . .221 Regulated Amperage and Voltage Test . . . . . .211 Regulated Voltage Test . . . . . . . . . . . . . . . . . .211 Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .218 Seat Switch Test . . . . . . . . . . . . . . . . . . . . . . .220 Spark Plug Gap Adjustment . . . . . . . . . . . . . . .228 Spark Plug Gap Test . . . . . . . . . . . . . . . . . . . .228 Spark Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .229 Starter Armature Test . . . . . . . . . . . . . . . . . . .216 Starter Field Windings Test . . . . . . . . . . . . . . .216 Starter Solenoid Test . . . . . . . . . . . . . . . . . . . .214 Starting Motor Amp Draw Test . . . . . . . . . . . . .215 Starting Motor Condition . . . . . . . . . . . . . . . . .214 Index - 7 INDEX Starting Motor No-load Amperage and RPM Test . . . . . . . . . . . . . . . . . . . . . 215 Stator Resistance Test (Optional Auxiliary Alternator) . . . . . . 213 Stator Resistance Test (Standard Configuration) . . . . . . . . . . 213 Unregulated Voltage Test (Optional Auxiliary Alternator) . . . . . . 212 Unregulated Voltage Test (Standard Configuration) . . . . . . . . . . 212 Vacuum Pressure Test - X720/X724/X728 . . 226 Engine Water Pump/Alternator Drive Belt Adjustment . 51 Engine - Liquid-Cooled . . . . . . . . . . . . . . . . . . . . . . 40 Theory of Operation Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Engine - Liquid-Cooled . . . . . . . . . . . . . . . . . . . . . . 29 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365 Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247 Toe-in adjustment All wheel steer . . . . . . . . . . . . . . . . . . . . . . . . . . . 373 Two wheel steer . . . . . . . . . . . . . . . . . . . . . . . . . . 373 Torque values Face seal fittings With inch stud ends . . . . . . . . . . . . . . . . . . . . . 11 With metric stud ends . . . . . . . . . . . . . . . . . . . . 12 Inch Fastener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Metric fastener, grade 7 . . . . . . . . . . . . . . . . . . . . . 14 Metric fasteners, standard . . . . . . . . . . . . . . . . . . . . 9 Straight fitting or special nut . . . . . . . . . . . . . . . . . . 14 Transaxle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 Case, inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 317 Control linkage adjustment . . . . . . . . . . . . . . . . . . 272 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 Internal system operation . . . . . . . . . . . . . . . . . . . 254 Linkage full forward adjustment . . . . . . . . . . . . . . 273 Neutral adjustment . . . . . . . . . . . . . . . . . . . . . . . . 271 Oil flow system operation . . . . . . . . . . . . . . . . . . . 250 Removal/installation . . . . . . . . . . . . . . . . . . . . . . . 297 Right cover, disassembly/assembly . . . . . . . . . . . 316 Transmission oil, hydrostatic . . . . . . . . . . . . . . . . . . . . . 16 V Valve Hydraulic control Disassembly/inspection/assembly . . . . . . . . . .355 Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . .354 Removal/Installation . . . . . . . . . . . . . . . . . . . . .355 PTO Relief Disassembly/inspection/assembly . . . . . . . . . .287 Removal/installation . . . . . . . . . . . . . . . . . . . . .287 PTO Solenoid Disassembly/assembly . . . . . . . . . . . . . . . . . .286 Removal/installation . . . . . . . . . . . . . . . . . . . . .286 Steering Disassembly/assembly . . . . . . . . . . . . . . . . . .377 Operation, manual . . . . . . . . . . . . . . . . . . . . . .368 Operation, neutral . . . . . . . . . . . . . . . . . . . . . .366 Operation, turning . . . . . . . . . . . . . . . . . . . . . .367 Removal/installation . . . . . . . . . . . . . . . . . . . . .376 W Warm-up procedure Hydraulic oil . . . . . . . . . . . . . . . . . . . . . 267, 351, 372 Water Pump/Alternator Drive Belt Adjustment . . . . . . . .51 Wear Protective Clothing . . . . . . . . . . . . . . . . . . . . . . . . .2 Work In Clean Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Work In Ventilated Area . . . . . . . . . . . . . . . . . . . . . . . . . .4 U Understand Signal Words . . . . . . . . . . . . . . . . . . . . . . . . Use Proper Lifting Equipment . . . . . . . . . . . . . . . . . . . . . Use Proper Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using High Pressure Washers . . . . . . . . . . . . . . . . . . . . 1 3 3 3 Index - 8
Source Exif Data:
File Type : PDF File Type Extension : pdf MIME Type : application/pdf PDF Version : 1.4 Linearized : No Subject : X700, X720, X724 and X728 Select Series Tractors Modify Date : 2005:09:30 15:45:53-03:00 Keywords : 2349 Create Date : 2005:09:27 11:41:15Z Page Count : 478 Creation Date : 2005:09:27 11:41:15Z Mod Date : 2005:09:30 15:45:53-03:00 Producer : Acrobat Distiller 5.0.5 (Windows) Author : John Deere WCCE Metadata Date : 2005:09:30 15:45:53-03:00 Creator : John Deere WCCE Title : TM2349 Description : X700, X720, X724 and X728 Select Series Tractors Page Mode : UseOutlinesEXIF Metadata provided by EXIF.tools