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Sabre 1338 Gear Technical manual

Other manuals for 1338 Gear: Operator's Manual
Manual is about: Sabre Lawn Tractor 38–Inch and 46–Inch (96 cm and 117 cm)

Summary of 1338 Gear

  • Page 1

    Sabre lawn tractor 38–inch and 46–inch (96 cm and 117 cm) models: 1338 gear john deere consumer products group tm–gx10131 (mar–97) litho in u.S.A. (new) 1538 hydro 15538 gear 1646 hydro 1538 gear 1638 hydro 1646 gear technical manual 15538 hydro 1546 gear www.Servicemanualall.Com buy, download, prin...

  • Page 2

    Introduction 3/5/97 1 - 1 information specifications and 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 s...

  • Page 3

    Safety 1 - 2 3/5/97 handle fluids safely-avoid fires • be prepared for emergencies 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. Make sure machine is clean of tr...

  • Page 4

    Safety 3/5/97 1 - 3 use care in handling and servicing batteries • prevent battery explosions • keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode. • never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer....

  • Page 5

    Safety 1 - 4 3/5/97 • park machine safely 1. Depress brake pedal fully. 2. Move park lever into lock position. 3. Check that shift lever has returned to neutral. 4. Make sure blade drive lever is pulled back fully. 5. Move throttle lever to slow idle position and allow engine to idle for approximate...

  • Page 6

    Safety 3/5/97 1 - 5 • 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 and some gaskets. The asbestos used ...

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    Safety 1 - 6 3/5/97 www.Servicemanualall.Com.

  • Page 8: Contents

    Specifications & information contents page contents 3/5/97 2 - 1 specifications & information specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 unified inch torque values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 metric torque ...

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    2 - 2 3/5/97 specifications specifications & information specifications engine: make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs and stratton style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 10

    3/5/97 2 - 3 specifications & information specifications power train—k55 transmission: gear transaxle— make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dana model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 11

    2 - 4 3/5/97 specifications specifications & information traction drive belt: gear— new belt length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2660±8 mm (104.7±0.3 in.) minimum effective length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2631 mm (103.6 in.) maxim...

  • Page 12

    3/5/97 2 - 5 specifications & information specifications average overall weight 46 inch (with mower deck, no fuel) . . . . . 204.12 kg (450 lbs) hitch capacity— export: horizontal pull maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 kg (56 lbs) tongue weight maximum ...

  • Page 13

    2 - 6 3/5/97 unified inch torque values specifications & information unified inch torque values do not use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically. S...

  • Page 14

    3/5/97 2 - 7 specifications & information metric torque values metric torque values do not use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically. Shear bolts a...

  • Page 15: Caution

    2 - 8 3/5/97 gasoline specifications specifications & information gasoline specifications important: to avoid engine damage: • do not mix oil with gasoline • use only clean oil and fuel • use clean approved containers and funnels. • store oil and fuel in an area protected from dust, moisture and oth...

  • Page 16

    3/5/97 2 - 9 specifications & information lubricant specifications grease use grease based on the expected air temperature range during the service interval. The following greases are preferred: • moly high temperature ep grease • high temperature ep grease • multi-purpose grease other greases may b...

  • Page 17

    2 - 10 3/5/97 serial number locations specifications & information serial number locations when working on machines or components that are covered by warranty, it is important that you include the tractor identification number and the component serial numbers on the warranty claim form. The location...

  • Page 18: Contents

    Engine contents page contents 2/11/97 3 - 1 engine specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 service equipment and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 other materials . . . . . . . . . . . . . ...

  • Page 19

    Contents continued engine 3 - 2 2/11/97 page www.Servicemanualall.Com.

  • Page 20

    Specifications engine 2/12/97 3 - 3 specifications note: engine service specifications and procedures are available from your local briggs & stratton dealer or by writing: briggs & stratton corporation milwaukee, wi. 53201 for parts request: 13hp . . . . . . . . . .Illustrated parts list diamond plu...

  • Page 21: Caution

    Engine repair 3 - 4 2/12/97 repair engine removal 1. Turn all switches off and disconnect battery negative ( - ) cable. 2. Raise hood. Disconnect light harness on right side of hood. Lower hood to approximately 3/4 open and slide off bracket. 3. Remove two capscrews securing heat shield to frame. Re...

  • Page 22

    Repair engine 2/12/97 3 - 5 12. Remove four cap screws. Remove engine. Engine installation 1. Install engine in mower frame. 2. Put ground lead connector on top of front right hand engine mounting flange, and insert capscrew through connector, engine, and frame. Capscrews ground wire 3. Install lowe...

  • Page 23

    Engine repair 3 - 6 2/12/97 7. Install engine output shaft key and pulley assembly. Secure with washer, lock washer and capscrew. Torque to 75 n•m (55 lb-ft). 8. Connect wires to starter terminal (f). 9. Connect two (2) harness connectors (h). Capscrew f h 10. Connect and adjust throttle cable (c) t...

  • Page 24: Contents

    Electrical contents page contents 2/11/97 4 - 1 electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 theory of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 general information . . . . . . . . . . . . ...

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    Contents continued electrical 4 - 2 2/11/97 page www.Servicemanualall.Com.

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    Specifications electrical 3/5/97 4 - 3 specifications battery: voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 bci group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

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    Electrical theory of operation 4 - 4 3/5/97 theory of operation general 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 ...

  • Page 28

    Electrical schematic electrical 3/5/97 4 - 5 electrical schematic 2 01 re d 4 01 y e l red 71 0 p u r 100 blk 105 blk st a t or start e r motor start solenoid ig nition fuel solenoid shut -of f (16 hp only) 2 1 0 = of f 1 = run 0 2 = st art 0, 1 fra m e gr ou nd g battery 220 red/blk engine connect ...

  • Page 29

    Wire harness electrical 4 - 6 3/5/97 wire harness 1 2 3 946a wht/blk 941a wht 705pur/wht 7 00 pur 8mm (5/16") eyele t eng ine gr ou nd br ak e swi t c h 45 1yel/wht 12 0 blk a b h e ad lights 401yel 940 wht fuel solenoid 2 20red/blk engine 451 yel/wht 710 pur/wht 70 5 pur 945 wht 942 wht/blk bl ad e...

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    Component location electrical 3/5/97 4 - 7 component location headlights starter solenoid fuel shut-off solenoid starter motor spark plug blade battery seat switch brake drive switch ignition switch switch www.Servicemanualall.Com.

  • Page 31

    Troubleshooting electrical 4 - 8 3/5/97 troubleshooting engine will not crank. Engine cranks — will not start. Engine starts hard or w ill not stay r unnin g . Engine misses or runs rough. W eak or no spark. Engine will not shut off. Battery goes dead, discharges or overcharges. Headlights do not li...

  • Page 32

    Diagnostics electrical 3/5/97 4 - 9 diagnostics cranking & fuel shutoff solenoid circuit operation function: the cranking system is used to energize the starting motor. Operating conditions: in order to crank the engine; the blade drive lever must be disengaged (blade switch plunger depressed), the ...

  • Page 33

    Diagnostics electrical 4 - 10 3/5/97 cranking & fuel shutoff solenoid circuit diagnosis test conditions: • meter negative (—) lead on battery negative (—) terminal • ignition switch in off position • meter positive (+) lead on numbered test point test/check point normal if not normal 1. Battery posi...

  • Page 34

    Diagnostics electrical 3/5/97 4 - 11 1 16 6 10 14 8 11 401 yel 700 pur red blk 710 pur 700 pur red 100 black 2 16 401 yel 4 200 red brake switch blade drive fuel shutoff solenoid starter relay (solenoid) ignition battery starter 705 pur/wht 12 13 9 705 pur/wht 7 switch 941 wht 710 pur 105 blk 202 re...

  • Page 35

    Electrical diagnostics 4 - 12 3/5/97 ignition & seat switch circuit operation function: to create a spark that ignites the fuel/air mixture in the engine. The ignition coil and module will produce a spark at the spark plug unless the ignition & seat switch circuit of the tractor chassis wiring acts ...

  • Page 36

    Diagnostics electrical 3/5/97 4 - 13 black red red 200 red black 401 yellow 100 frame ground battery key switch blade drive brake switch ground power control 1 0 1 0 1 0 0 1 2 ignition module e1 spark plug coil fuel solenoid shut-off (optional) 100 black 110 black 401 942 white yellow 941 white 941 ...

  • Page 37

    Diagnostics electrical 4 - 14 3/5/97 ignition circuit test points when diagnosing an ignition problem, isolate magneto circuit from ground circuit by separating engine connector. If engine will not start check magneto circuit first and then check ground circuit. If engine will not shut off, check gr...

  • Page 38

    Diagnostics electrical 3/5/97 4 - 15 110 black 945 white/black 946 white/black 945 white/black 940 white white 941 942 white 942 white 100 black 940 white s4 blade drive switch key switch 2 1 1 1 1 2 2 2 engine connector 1 3 3 3 3 2 3 3 945 white/black 942 white 940 white 1 1 2 3 3 2 seat switch bra...

  • Page 39

    Electrical diagnostics 4 - 16 3/5/97 charging & headlight circuit operation function: to maintain battery voltage between 11.8 and 13.2. Operating conditions: the engine must be running for the charging system to operate. Headlights are on only when the engine is running. Theory of operation: the ch...

  • Page 40

    Diagnostics electrical 3/5/97 4 - 17 charging circuit diagnosis note: be sure to set multimeter to read ac or dc voltage or amperage as test requires: test conditions: • brake engaged, blade drive lever disengaged • engine running at fast idle (3600 rpm) • engine connector disconnected • meter negat...

  • Page 41

    Diagnostics electrical 4 - 18 3/5/97 headlights circuit diagnosis note: but sure to set multi-meter to measure ac or dc voltage or amperage as required by test: test conditions: • park brake engaged, blade drive disengaged • engine running at fast idle • meter negative (—) lead on battery negative (...

  • Page 42

    Diagnostics electrical 3/5/97 4 - 19 engine connector 3 black 220 red/black 1 120 black yel/wht 2 headlight harness 5 7 120 black 451 yel/wht headlight harness 3 451yel/wht 2 red 451 yellow/white to engine to chassis 4 www.Servicemanualall.Com.

  • Page 43

    Electrical tests and adjustments 4 - 20 3/5/97 tests and adjustments battery test reason: to check condition of battery and determine battery voltage. Equipment: • hydrometer • voltmeter or battery tester procedure: 1. Clean battery terminals and top of battery. 2. Inspect battery terminals and case...

  • Page 44

    Tests and adjustments electrical 3/5/97 4 - 21 important: decrease charge rate if battery gases or bubbles excessively or becomes too warm to touch. 5. Check specific gravity after 30 minutes (60 minutes for maintenance-free battery). More than 50 point variation between cells: replace battery. Less...

  • Page 45

    Electrical tests and adjustments 4 - 22 3/5/97 ac voltage output test reason: to measure engine alternating current voltage output to determine stator condition. Equipment: • multimeter connections: 1. Disconnect engine connector (a). 2. Set multimeter to read ac voltage. 3. Connect red multimeter l...

  • Page 46

    Tests and adjustments electrical 3/5/97 4 - 23 starter amp draw test reason: to determine the amperage required to crank the engine and check starter motor operation under load. Equipment: • battery tester • photo tachometer connections: 1. Put transaxle in neutral. Engage park brake. 2. Test system...

  • Page 47

    Electrical tests and adjustments 4 - 24 3/5/97 brake switch / blade drive switch test reason: to make sure the brake pedal switch and blade drive switch operate properly. Equipment: • ohmmeter procedure: 1. Park machine on level surface and turn ignition switch off. 2. Shift lever in neutral and par...

  • Page 48

    Tests and adjustments electrical 3/5/97 4 - 25 ignition switch test reason: to verify ignition switch functions are operating properly. Equipment: • ohmmeter or continuity tester procedure: 1. Park machine on level surface and turn ignition switch off. 2. Shift lever in neutral and park brake locked...

  • Page 49

    Electrical tests and adjustments 4 - 26 3/5/97 ground circuit tests 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. Equipment: • ohmmeter or voltmeter chassis ground engine ground...

  • Page 50

    Repair electrical 3/5/97 4 - 27 repair ignition switch removal & installation 1. Remove rear retaining screws (a) and bracket (b). Note: front bracket (f) does not have to be removed. 2. Remove ignition switch connector (c). 3. Check and/or replace ignition switch as required. 4. Install new switch ...

  • Page 51

    Electrical repair 4 - 28 3/5/97 starter solenoid removal & installation procedure: 1. Park machine on level surface, park brake on, engine off. 2. Lift seat and remove negative battery cable from battery terminal. 3. Remove positive battery cable from battery terminal. 4. Remove battery hold-down (r...

  • Page 52: Contents

    Contents gear power train page 3/5/97 5 - 1 contents gear power train specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 other materials. ....

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    Gear power train contents continued 5 - 2 3/5/97 www.Servicemanualall.Com.

  • Page 54

    Specifications gear power train 2/12/97 5 - 3 specifications dimensions: overall axle width (end-to-end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735.4 mm (29 in.) overall case width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432.5 mm (17. In.) overa...

  • Page 55

    Gear power train specifications 5 - 4 2/12/97 gear ratios: 1st gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.67:1 2nd gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 56

    Troubleshooting gear power train 2/12/97 5 - 5 troubleshooting problem or symptom belt jumping off or slapping lack of drive in one o r bo th dir ection s loses power under load, belt slips, or erratic drive jerky or aggressive en gagemen t cann ot get all forward gears cannot get reverse gear jumps...

  • Page 57

    Gear power train component location 5 - 6 2/12/97 component location 1. Flange bearing 45. Spacer 2. Shim 46. Drive chain drive sprocket (9 teeth) 3. Spur gear (14 teeth) 47. Drive shaft bevel gear (42 teeth) 4. Shift collar 48. Shim 5. Shift key (4 used) 49. Drive shaft 6. Shifter fork 50. Drive sh...

  • Page 58

    Component location gear power train 2/12/97 5 - 7 transaxle component location 9 10 11 12 13 14 15 16 30 31 32 33 34 35 36 6 37 29 25 26 27 28 46 47 48 49 50 51 52 53 54 55 56 57 71 70 69 68 67 66 65 75 76 77 79 78 80 81 83 82 84 87 86 85 73 72 74 64 63 62 61 59 38 40 41 39 42 43 44 45 24 23 22 21 2...

  • Page 59

    Gear power train component location 5 - 8 2/12/97 traction drive system component location 1. Frame weldment—idler adjustment 2. Carriage bolt (m8x45) 3. Clutch bellcrank bracket 4. Bushing 5. Cap screw 6. Clutch assist spring assembly 7. Carriage bolt (m8x45) 8. Clutch cross shaft 9. Park lever 10....

  • Page 60

    Component location gear power train 2/12/97 5 - 9 traction drive system component location shift linkage system component location 1 2 3 4 5 6 7 8 36 35 37 41 40 9 12 11 10 13 14 15 16 17 20 19 21 22 23 24 34 31 32 30 28 29 27 26 25 38 39 42 43 44 45 46 47 48 49 18 33 50 57 58 59 56 55 54 53 60 61 6...

  • Page 61

    Gear power train theory of operation 5 - 10 2/12/97 theory of operation traction drive system operation function: the belt traction drive transfers power from the engine to the 5-speed transaxle. The clutch pedal controls the belt traction drive, and allows the transaxle to be shifted through it’s f...

  • Page 62

    Theory of operation gear power train 2/12/97 5 - 11 transaxle operation function: the transaxle transmits power from the engine to the drive axles and rear wheels, and provides gear selection of five forward speeds, one reverse, and neutral. Forward gears: with engine running and clutch engaged, the...

  • Page 63

    Gear power train theory of operation 5 - 12 2/12/97 brake system operation function: the brake system allows the operator to slow down, stop, or lock the tractor into park position. Theory of operation: note: clutch/brake pedal has approximately 127 mm (5 in.) of travel, and operates as follows: the...

  • Page 64

    Diagnosis gear power train 2/12/97 5 - 13 diagnosis test conditions: • mower on level surface • mower deck removed • engine off • front wheels blocked • rear wheels raised off ground with axle housings on jack stands. • park brake on test/check point normal if not normal 1. Inspect traction drive be...

  • Page 65

    Gear power train 5 - 14 2/12/97 1 2 4 5 10 11 2 2 8 7 9 www.Servicemanualall.Com.

  • Page 66: Caution

    Tests and adjustments gear power train 2/12/97 5 - 15 tests and adjustments clutch/brake linkage &traction drive adjustment reason: to ensure clutch/brake pedal linkage and traction drive system maintains traction in all three lower gears up a 17° slope. Also, to ensure it disengages traction drive ...

  • Page 67

    Gear power train tests and adjustments 5 - 16 2/12/97 brake spring adjustment— 1. First check for brake disc contacting the case (1) and/or brake lever contacting its mounting bracket (2), top or bottom. If so, replace friction pucks and disc before making any adjustments. 2. Remove the mower deck. ...

  • Page 68

    Tests and adjustments gear power train 2/12/97 5 - 17 1. Unlock park brake and release pedal (a). 2. Measure clutch actuating spring length (b). Measurement should be 42—45 mm (1.65— 1.77in.). Clutch actuating spring length is adjusted by sliding rear idler sheave (c) on it’s slotted mounting bracke...

  • Page 69

    Gear power train repair 5 - 18 2/12/97 4. If transaxle rotates, move shift lever (d) slightly until transaxle shift lever clicks firmly into it’s neutral detent. (this may occur while shift lever (d) is in the reverse or first gear range of shift gate). 5. Stop engine. 6. Raise seat and loosen left ...

  • Page 70: Caution

    Repair gear power train 2/12/97 5 - 19 6. Depress and lock brake pedal (a) with park brake lever. 7. Remove front idler belt guide and sheave (b). 8. Remove clutch bellcrank belt guide (c). 9. Remove adjustable idler belt guide (d). 10. Remove park lever (e). 11. Remove mower drive lever return spri...

  • Page 71

    Gear power train repair 5 - 20 2/12/97 traction drive belt installation 1. Install end of drive belt under belt guide (h), and pull belt up between guide (h) and sheave (g). Pull belt over large sheave (g) and down into small sheave. 2. Route belt between mower drive lever (j) and switch (k), and ar...

  • Page 72: Caution

    Repair gear power train 2/12/97 5 - 21 6. Thread one end of a three foot long piece of starter rope under the front hook of clutch tension spring (c). Pull rope half way through spring until ends meet, and wrap ends around a bar several times to make a temporary handle. Pull handle until spring hook...

  • Page 73

    Gear power train repair 5 - 22 2/12/97 shift linkage removal & installation 1. Remove battery. 2. Block rear of tractor off ground. Remove left drive wheel. 3. Remove shift knob (g). 4. Remove lock nuts (m and o) to remove shift link (n). 5. Remove lock nuts (a and i) and cap screws (b and f). A–loc...

  • Page 74

    Repair gear power train 2/12/97 5 - 23 transaxle removal & installation 1. Raise mower off ground and support with jackstands under frame and not transaxle case. 2. Remove rear wheels. 3. Disconnect shift linkage (b) from shift arm (c). 4. Remove traction drive belt (a). Hint: lock park brake to loo...

  • Page 75

    Gear power train repair 5 - 24 2/12/97 4. Remove shift arm (a), and square-hole flat washer from transaxle shifter shaft remove shifter detent assembly: 1. Remove shifter shaft rubber boot (e). 2. Remove both set screws (h) and detent springs (g). Important: do not drop or lose detent balls. 3. Use ...

  • Page 76

    Repair gear power train 2/12/97 5 - 25 1. Remove brake assembly (a) (see previous procedure). Remove sixteen transaxle housing socket head screws (b). 2. Carefully separate transaxle housing case. Remove upper case from lower case assembly. 3. Inspect overall condition of transaxle without removing ...

  • Page 77

    Gear power train repair 5 - 26 2/12/97 2. Turn upper case half so input shaft is facing up. 3. Remove woodruff key (j), e-ring (i), shim washer (h), and input shaft (k). Important: do not scratch or deform upper case half bore when removing needle bearings. 4. Visually inspect condition of needle be...

  • Page 78

    Repair gear power train 2/12/97 5 - 27 5. Install input shaft (e) (with keyway on outside of case), large washer (i), small washer (j), bevel pinion gear (k), and snap ring (l). 6. Turn upper case half over. 7. Install a shim washer (c) (from shim kit) of the proper thickness that allows enough clea...

  • Page 79

    Gear power train repair 5 - 28 2/12/97 idler gear inspection: 1. Visually check overall condition of assembly, including shaft and bushings, gears for wear, pitting, broken teeth, etc. 2. Use a feeler gauge to measure clearance (a) between end surface of combination gear and side surface of case hal...

  • Page 80

    Repair gear power train 2/12/97 5 - 29 intermediate shaft & drive shaft repair intermediate & drive shaft inspection: 1. Inspect overall condition of intermediate shaft and drive shaft assemblies, including gears for wear, pitting, broken teeth, etc. 2. For the drive shaft assembly (i), use a feeler...

  • Page 81

    Gear power train repair 5 - 30 2/12/97 differential/axle shaft inspection: 1. Visually check overall condition of assembly. 2. Use a feeler gauge to measure clearance (a) between side surface of shim washer and side surface of lower case: clearance . . . . . . 0.18—0.38 mm (0.007—0.015 in.), 3. If c...

  • Page 82

    Repair gear power train 2/12/97 5 - 31 5. Install axle shafts so beveled gears (e) mesh with differential internal shaft beveled gears. 6. Keep inward pressure on both axles as you install differential assembly in lower case housing. 7. Measure air gap between shim washers (f) and side of housing (h...

  • Page 83

    Gear power train repair 5 - 32 2/12/97 9. Measure air gaps (k and n)—(see inspect drive/ intermediate shaft assemblies). Make any changes in shim washer (m) thicknesses from shim kit and shim washer (j) thicknesses from shim kit to obtain proper air gaps. 10. When proper air gap is obtained, gears s...

  • Page 84

    Repair gear power train 2/12/97 5 - 33 1. Pack upper case beveled pinion gear and lower case housing assembly with 638 g (1.406 lbs) of multi-purpose ep grease. 2. Apply form-in-place gasket silicone sealant to lower case. 3. Be sure sealant does not contact any gear, shaft, or bearing surfaces. 4. ...

  • Page 85

    Gear power train repair 5 - 34 2/12/97 1. Install complete brake assembly to transaxle. 2. Tighten cap screws (k and m) to 20 n•m (160 lb-in.). 3. Tighten lock nut (l) to specification until there is a 10 mm (0.39 in.) clearance between thick friction puck and brake disc. Install drive sheave and sh...

  • Page 86

    2/11/97 6 - 1 contents continued hydrostatic power train page hydrostatic power train specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 repair specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ...

  • Page 87

    Hydrostatic power train contents continued 6 - 2 2/11/97 repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 traction drive belt removal—k55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 traction drive belt removal—k51. . . ...

  • Page 88

    Specifications hydrostatic power train 2/12/97 6 - 3 specifications gear teeth: k–55 k–51 spur gear (drive shaft) . . . . . . . . . . . . . . . . 6 teeth 12 teeth differential ring gear . . . . . . . . . . . . . . . . . 98 teeth 53 teeth differential bevel pinion gears cross shaft . . . . . . . . . ...

  • Page 89

    Hydrostatic power train specifications 6 - 4 2/12/97 repair specifications transaxle components wear tolerances: k–55 k–51 pump (input) shaft wear limit . . . . . . . . . . . . . . . . . . . . . . . Visual check n/a motor (drive) shaft wear limit . . . . . . . . . . . . . . . . . . . . . . . Visual ...

  • Page 90

    Specifications hydrostatic power train 2/12/97 6 - 5 other materials transaxle housing case half sealant: k–55 k–51 form-in-place silicone n/a gasket sealant pump connector pipe plug sealant: k–55 k–51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pipe sealant with teflon® n/a ...

  • Page 91

    Hydrostatic power train component location 6 - 6 2/12/97 component location component location—k55 1. Axle shaft/wheel key (2 used) 49. Spacer (m10x20x20) 2. Left axle shaft 50. Cap screw (m10x60) (3 used) 3. Left axle shaft seal 51. Pump filter 4. Left axle shaft bushing 52. Motor plate dowel pin (...

  • Page 92

    Component location hydrostatic power train 2/12/97 6 - 7 component location—k55 19 n•m 1 2 3 4 5 6 7 8 9 10 12 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 39 40 41 42 43 44 45 46 47 48 49 50 51 53 54 55 56 52 57 58 59 60 62 63 64 65 66 67 37 36 35 34 33 32 31 30 29 71 70 69 68 84 86 85 87 88 89 ...

  • Page 93

    Hydrostatic power train component location 6 - 8 2/12/97 component location—k51 1. Knob 2. 1/4x20 hex jam nut 3. Rod 4. E-ring 5. M6x30 bolt 6. Snap ring 7. Spacer 8. Sheave 9. Fan 10. Flnage lock nut 11. Lock nut 12. Screw 13. Screw 14. Strap 15. Push nut 16. Screw (r.H. Side) screw (l.H. Side not ...

  • Page 94

    Component location hydrostatic power train 2/12/97 6 - 9 component location—k51 1 4 new case: 27.4-31.4 n•m (20-23 lb-ft. ) used case: 22.5-27.4 n•m (16-20 lb-ft.) 11 11 2 3 6 5 8 9 7 10 11 14 11 11 17 12 15 14 16 13 www.Servicemanualall.Com.

  • Page 95

    Hydrostatic power train component location 6 - 10 2/12/97 traction drive system component location 1. Transaxle drive sheave (k55) 2. Transaxle drive sheave (k51) 3. Arm (k55) 4. Arm (k51) 5. Bolt m8 x 45 6. Spring 7. Bushing 8. Cap screw 9. Bolt (k51) 10. Spacer (k51) 11. Flange nut m8 12. Lock was...

  • Page 96

    Component location hydrostatic power train 2/12/97 6 - 11 pedal linkage assembly component location 1. Neutral switch 2. Lock nut, 9.525mm 3. Pivot 4. Nut, 3/8 in. 5. Rod 6. Washer 7. Cotter pin 8. Brake rod return spring 9. Brake spring strap 10. Brake compression spring 11. Washer 12. Park brake l...

  • Page 97

    Hydrostatic power train component location 6 - 12 2/12/97 shift linkage component location—k–55 transaxle 1. Cap screw (m6x20) 2. Shift arm 3. Lock nut (m6) 4. Lock nut (m10) 5. Flange nut (m8) 6. Return-to-neutral strap 7. Shift knob 8. Neutral return bushing 9. Rolled pin (m4x20) 10. Shift lever 1...

  • Page 98

    Component location hydrostatic power train 2/12/97 6 - 13 shift linkage component location—k–51 transaxle 1. Torsion spring 2. Spring pin (4 x 20 mm) 3. Gearshift lever 4. Knob 5. Lock nut 6. Strap 7. Roller 8. Bracket 9. Ball joint 10. Stud, adjusting 11. Nut, (5/16”) 12. Ball joint 13. Bushing 14....

  • Page 99

    Hydrostatic power train theory of operation 6 - 14 2/12/97 theory of operation in this group the sabre hydrostatic power train is separated into the following systems: • traction drive belt system • transaxle and shift linkage system • brake/neutral return pedal system • transport (free-wheeling) sy...

  • Page 100

    Theory of operation hydrostatic power train 2/12/97 6 - 15 on the k-51 transaxle, the turnbuckle link (m) moves the transaxle shift lever (p). The shift lever turns the transaxle shifter shaft. K55 when in neutral, the shift linkage holds the shifter shaft (j) and the variable-angle pump swashplate ...

  • Page 101

    Hydrostatic power train theory of operation 6 - 16 2/12/97 forward: when the shift lever (a) is moved into forward position, the shift bracket (b) pivots, pulling the turnbuckle link (c) rearward. The transmission linkage turns the shifter shaft, and through it, the variable-angle pump swashplate in...

  • Page 102

    Theory of operation hydrostatic power train 2/12/97 6 - 17 o p q r j h i k l t u g s h i k r d b v when the brake pedal (a) is depressed, the bellcrank (b) and frame rod (f) rotate forward. This motion causes the brake rod (h) and neutral return strap (g), connected at the same point on the bellcran...

  • Page 103

    Hydrostatic power train theory of operation 6 - 18 2/12/97 theory of operation — k51 l.H. Side r.H. Side a e c d c b f g o p q d f g h i e j k l m n when the brake pedal (a) is depressed, the frame rod (b) and frame rod arms (c) rotate forward. This motion causes the brake rod (d) and neutral return...

  • Page 104

    Theory of operation hydrostatic power train 2/12/97 6 - 19 1. The first segment of travel (w) is taking-up freeplay in the brake and return-to-neutral linkages. 2. The next segment of travel (x) is returning the shift linkage to neutral and engaging the brake. Important: full brake engagement (drive...

  • Page 105

    Hydrostatic power train theory of operation 6 - 20 2/12/97 are unseated; allowing oil to flow freely. This allows the operator to push the tractor with the engine off and the brake released. Transport (free-wheel) system operation—k51 function: the transport (free-wheel) system allows the operator t...

  • Page 106

    Troubleshooting hydrostatic power train 2/12/97 6 - 21 troubleshooting problem or symptom belt jump ing of f or slapping lack of drive in one wheel or both loses power under load, belt slips, or erratic drive jerky or aggressive engagement cannot get full forward or reverse speed input shaft /pulley...

  • Page 107

    Hydrostatic power train troubleshooting 6 - 22 2/12/97 input sheave, input shaft, and axle keys or keyways loose, worn, or damaged—replace as necessary (k55 only) ● ● ● ● ● ● ● internal transaxle components worn, stripped, or broken— replace as necessary (k55 only) ● ● ● ● ● ● ● ● internal hydro pum...

  • Page 108

    Troubleshooting hydrostatic power train 2/12/97 6 - 23 bleed procedure overlooked or improperly done—repeat procedure correctly ● ● ● ● ● wheels and axle keys, key ways, or snap rings worn—replace as necessary ● ● ● ● motor drive shaft or axle seals worn or damaged— replace seals (k55 only) ● ● tran...

  • Page 109

    Hydrostatic power train diagnosis 6 - 24 2/12/97 diagnosis test conditions: • tractor on level surface. • front wheels blocked. • engine off. • rear wheels raised off surface with axle housings on jack stands. Test/check point normal if not normal 1. Fan fan in good condition and tight. Tighten fan....

  • Page 110

    Diagnosis hydrostatic power train 2/12/97 6 - 25 5 6 1 3 4 2 9 7 6 8 8 k55 shown used with k51 only www.Servicemanualall.Com.

  • Page 111

    Hydrostatic power train diagnosis 6 - 26 2/12/97 diagnosis—k55 test conditions: • tractor operated in test area. • tests run at engine slow idle and fast idle. • engine at operating temperature. • hydro run through full range of speeds in both directions. Test/check point normal if not normal 1. Shi...

  • Page 112

    Diagnosis hydrostatic power train 2/12/97 6 - 27 1 2 3 4 6 5 www.Servicemanualall.Com.

  • Page 113

    Hydrostatic power train diagnosis 6 - 28 2/12/97 diagnosis —k51 test conditions: • tractor operated in test area. • tests run at engine slow idle and fast idle. • engine at operating temperature. • hydro run through full range of speeds in both directions. Test/check point normal if not normal 1. Sh...

  • Page 114

    Diagnosis hydrostatic power train 2/12/97 6 - 29 1 2 3 4 5 6 www.Servicemanualall.Com.

  • Page 115: Caution

    Hydrostatic power train tests and adjustments 6 - 30 2/12/97 tests and adjustments traction drive system reason: to ensure shift, neutral return, and brake linkages and belt drive system maintain traction in lower 1/3 of forward speed range up a 17° slope. To ensure that transport (free-wheeling) va...

  • Page 116: Caution

    Tests and adjustments hydrostatic power train 2/12/97 6 - 31 drive belt adjustment k55 k55 1. Lock park brake. 2. Carefully pull larger tensioning idler (c) rearward until belt (a) can be removed from adjustable idler (e), then slowly release tensioning idler. 3. Loosen and move adjustable idler (e)...

  • Page 117

    Hydrostatic power train tests and adjustments 6 - 32 2/12/97 shift linkage adjustment k55 k51 1. Safely raise rear of tractor off the surface and block the front wheels. Remove rear wheels to gain access to transaxle shift linkage and to safely a b c e d c e d f check for creep in transaxle (axles t...

  • Page 118

    Tests and adjustments hydrostatic power train 2/12/97 6 - 33 k55 1. Make sure bellcrank assembly and transaxle right, front mounting bracket are oriented properly. Slot (c) should be aligned with transaxle housing rib (a) so that ear (d) of lower anchor washer is not wedged behind housing vertical r...

  • Page 119

    Hydrostatic power train tests and adjustments 6 - 34 2/12/97 (shown from r.H. Side) 2. Measure distance between centers of brake lever hole (g) and brake rod hole (i), distance should be 85 mm (3.35 in.). 3. If not, gradually adjust jam nuts (f and j) until specified measurement is obtained. 4. Depr...

  • Page 120: Caution

    Tests and adjustments hydrostatic power train 2/12/97 6 - 35 (l.H. Side of transaxle) if distance is less than or equal to 0.08 in. (2 mm): 1. Gradually adjust jam nuts until specified measurement is obtained. 2. Depress pedal and park brake. 3. Measure the distance from inside of brake rod stop tab...

  • Page 121: Caution

    Hydrostatic power train repair 6 - 36 2/12/97 repair traction drive belt removal—k55 1. Park tractor on level surface and remove battery. 2. Disconnect spark plug. 3. Remove mower deck. 4. Safely raise and block tractor to gain easy access to underside of frame. 5. Pull tensioning idler rearward unt...

  • Page 122: Caution

    Repair hydrostatic power train 2/12/97 6 - 37 8. Remove link arm from steering yoke by rotating link arm until parallel with steering yoke arm. 9. Remove belt from engine drive sheave and remove belt from tractor. Traction drive belt removal—k51 1. Park tractor on level surface and remove battery. 2...

  • Page 123

    Hydrostatic power train repair 6 - 38 2/12/97 traction drive belt installation – k55 1. Thread belt around belt guide on engine drive pulley assembly. Install on smaller drive pulley, nearest engine. 2. Place belt over pulley on input shaft of gear box. 3. Place belt over idler pulley. 4. Extend ten...

  • Page 124: Caution

    Repair hydrostatic power train 2/12/97 6 - 39 m l j n o k a d e f g h i b c 34 n•m (25 lb-ft.) 20 n•m (168 lb-in.) note: to remove transaxle drive sheave and fan assembly (a) transaxle must be lowered or completely removed from tractor. A. Transaxle drive sheave b. Washer c. Cap screw (m6x25) d. Adj...

  • Page 125: Caution

    Hydrostatic power train repair 6 - 40 2/12/97 power train linkage system removal/installation—k55 1. Remove mower deck. 2. Use procedure on previous page to remove bellcrank spring from frame. 3. Use this drawing for complete repair of system. 4. See tests and adjustments section to adjust drive bel...

  • Page 126

    Repair hydrostatic power train 2/12/97 6 - 41 transaxle removal and installation—k55 removal— 1. Safely raise and block rear of tractor off surface. 2. Safely support bottom of transaxle or have a helper hold transaxle in place when you remove final hardware (steps 13—14). 3. Remove drive wheels, in...

  • Page 127

    Hydrostatic power train repair 6 - 42 2/12/97 20. Install traction drive belt. Specification: flange nut to right-front mounting bracket . . . . . . . . . . . . 15 n•m (11 lb-ft.) cap screw and nut to left-front mounting bracket . . . . . . . . . . . . 15 n•m (11 lb-ft.) cap screws and nuts to frame...

  • Page 128

    Repair hydrostatic power train 2/12/97 6 - 43 1. Remove four cap screws (a) to remove reservoir cover. 2. Inspect cover for cracks or holes, replace as necessary. 3. If cover is in good condition and to be reused, clean off all gasket residue and wipe clean, then set cover and four cap screws aside ...

  • Page 129

    Hydrostatic power train repair 6 - 44 2/12/97 6. Measure brake components individually. 7. Replace components as necessary and as a set only. Set brake assembly components aside for final assembly. Specifications: brake components wear tolerances— (g) brake puck (minimum) . . . . . . . 8 mm (0.3 in....

  • Page 130

    Repair hydrostatic power train 2/12/97 6 - 45 1. If wear or leakage is detected, remove e-ring (c), actuating bracket (d), and pin (f). 2. Remove and discard o-ring (e). Replace it with new o-ring every time assembly is removed or leaking. 3. Inspect pin (f) and lower case bore (b) for pitting, scor...

  • Page 131

    Hydrostatic power train repair 6 - 46 2/12/97 inspect differential axle assembly— 1. Visually inspect assembly: • ring gear teeth (a) are all in good condition; • sides of ring gear (b) are not contacting walls of case half (c); • thrust plates (d) are holding assembly in proper alignment; • axle sh...

  • Page 132

    Repair hydrostatic power train 2/12/97 6 - 47 9. Inspect upper case half outer left and right axle bushings for scoring, pitting, wear, or discoloration. 10. Measure inside diameter of bushings (f) and k-55 inner left and right axle bushings (g). 11. If bushings exceed specification, replace upper c...

  • Page 133

    Hydrostatic power train repair 6 - 48 2/12/97 3. Hold downward on entire pump (f), motor (a), and center block (g) assembly with one hand as you gradually loosen three cap screws (c) with the other. 4. Keeping downward pressure steady, slowly remove three cap screws (c) and spacer (h). 5. Without lo...

  • Page 134

    Repair hydrostatic power train 2/12/97 6 - 49 2. Clean and inspect components individually once disassembled: • thrust bushings (a) should not be scored, pitted, or worn badly—measure thickness: thrust bushings thickness minimum . . . . . . . . . . . . . . . . . . 1.3 mm (0.050 in.); • swashplate (b...

  • Page 135

    Hydrostatic power train repair 6 - 50 2/12/97 block are damaged, they both must be replaced. If any component of motor cylinder block is damaged, a complete new motor cylinder block must be ordered. If upper or lower case halves show wear or damage, they need not be ordered as a set unless wear or d...

  • Page 136

    Repair hydrostatic power train 2/12/97 6 - 51 4. Install thin bearing thrust washer (g) first, ball bearing (h), and thick bearing thrust washer (i) on top (mates with pump pistons) into swashplate (j). Important: hold fingers tightly between all five pistons so pistons don’t drop out of cylinder bl...

  • Page 137

    Hydrostatic power train repair 6 - 52 2/12/97 1. Assemble motor cylinder block and drive shaft assembly (c) to center block. 2. Watch to see that end of pump shaft (j) is aligned with bronze plate center hole (i) as you execute step 3. 3. At a slight angle, align seal (a), ball bearings (b), and fix...

  • Page 138

    Repair hydrostatic power train 2/12/97 6 - 53 install filter, magnet, and transport (free- wheeling) assembly— 1. Carefully install new relief valve assemblies (b) to specification into center block bores (a). Specification: transport relief valve assemblies . . . . . . . . . . . . . . . Approximate...

  • Page 139

    Hydrostatic power train repair 6 - 54 2/12/97 important: when assembling case halves make sure that bypass push pins are fully seated in bore and that actuating bracket and rod are fully withdrawn. Failure to do so will result in broken push pins. 3. Align hole (c) with bleed port stack (a) and firm...

  • Page 140: Caution

    Repair hydrostatic power train 2/12/97 6 - 55 4. Install breather valve assembly (e) and fill cap (b). Tighten cap screws to 24 n•m (17 lb-ft.) install fan and drive sheave— 1. Assemble fan to transaxle drive sheave using two fan holes (c). Two washers and nuts (b) go under fan. Bottom fan lip (d) g...

  • Page 141: Caution

    Hydrostatic power train repair 6 - 56 2/12/97 traction drive belt tensioning system removal/ inspection/installation—k51 1. Remove mower deck. 2. Remove traction drive belt (see “traction drive belt removal—k51” on page 37) 3. Thread one end of a three foot long piece of starter rope under the front...

  • Page 142

    Repair hydrostatic power train 2/12/97 6 - 57 power train linkage system removal/installation—k51 1 2 3 4 5 6 7 8 9 10 11 12 13 14 11 15 16 13 17 11 18 19 20 21 22 23 24 25 26 27 27 27 26 26 28 29 30 31 27 26 32 35 34 33 36 37 38 39 39 40 41 42 43 44 45 46 47 48 49 50 51 52 1 m127365 knob 1 2 1/4” x...

  • Page 143: Caution

    Hydrostatic power train repair 6 - 58 2/12/97 transaxle removal and installation—k51 removal— 1. Safely raise and block rear of tractor off surface. 2. Safely support bottom of transaxle or have a helper hold transaxle in place while you remove final hardware. (see step 12.) 3. Remove mower deck. 4....

  • Page 144: Caution

    Repair hydrostatic power train 2/12/97 6 - 59 10. Remove cotter pin (h) and washers from brake linkage on l.H. Side of transaxle. Remove brake rod from brake lever. 11. Loosen, but do not remove, three flange nuts (i) and cap screws securing transaxle to l.H. Side of frame. 12. Being careful to not ...

  • Page 145

    Hydrostatic power train repair 6 - 60 2/12/97 2. Remove c-clip (a) and upper fan retainer (b). 3. Remove drive sheave and fan assembly. 4. Remove fan lower retainer (c) and e-ring (d). Install drive sheave and fan— 1. Install e-ring (a) in groove on input shaft, and fan lower retainer (b) with flat ...

  • Page 146: Contents

    Contents steering page 2/11/97 7 - 1 contents steering component location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 service equipment and tools...

  • Page 147

    Notes steering 7 - 2 2/11/97 www.Servicemanualall.Com.

  • Page 148

    Component location steering 2/12/97 7 - 3 component location steering cotter pin washer washer tie rod steering link bushing washer sector arm pinion shaft “c”-clip washers bushing bushing washer cotter pin washer bushing steering wheel retainer bolt washers nylock nut washer bushing www.Servicemanu...

  • Page 149

    Steering repair 7 - 4 2/12/97 service equipment and tools note: order tools from your service-gard catalog. Some tools may be available from a local supplier. Repair steering gear removal 1. Remove battery and safely raise front of tractor. 2. Remove fuel tank and dash panel. See “fuel tank and dash...

  • Page 150

    Repair steering 2/12/97 7 - 5 note: write down location and number of washers on pinion and sector gear shafts. If a new shaft is installed, number and placement of washers may need adjustment. 5. Remove cotter pin and washer(s) (e) from steering pinion shaft (f). 6. Remove pinion gear shaft from bo...

  • Page 151

    Steering repair 7 - 6 2/12/97 4. Align marks on sector gear and pinion gear as steering pinion shaft (d) is installed from the bottom of the tractor. 5. Install washers (e) and cotter pin (c). 6. Install and fasten tie rods (long leg of tie rod is installed in axle spindle). 7. Install steering whee...

  • Page 152: Contents

    Attachments contents page contents 2/14/97 8 - 1 attachments component location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 lift linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 38 inch deck (– 1996)...

  • Page 153

    Notes attachments 8 - 2 2/14/97 www.Servicemanualall.Com.

  • Page 154

    Component location attachments 3/5/97 8 - 3 component location lift linkage 1. Remove battery and mower deck. 2. Check for worn or damaged components. 3. Adjust latch quadrant using slotted holes, if necessary, for smooth engagement with latch. 4. Install and adjust mower deck. 5. Install battery. L...

  • Page 155

    Attachments component location 8 - 4 3/5/97 38 inch deck (– 1996) 1. Pin 2. Bolt 3. Bushing 4. Eyebolt 5. Rod, adjusting 6. Flange bushing 7. Draft arm pin 8. Bracket, rh draft 9. Lock nut, m6 10. Bracket, lh draft 11. Tension arm, pto 12. Cotter pin 13. Washer 14. Washer 15. Sheave, flat idler 16. ...

  • Page 156

    Component location attachments 3/5/97 8 - 5 38 inch deck (1997 –) 1. Strap, pto spring 2. Cotter pin 3. Washer 4. Compression spring 5. Spring locking pin 6. Shield 7. Screw, m6 x 12 8. End, pto rod 9. Nut 10. Rod, lh brake 11. Arm, idler 12. Belt 13. Spindle assembly 14. Bolt, m8x16 15. Flange nut,...

  • Page 157

    Attachments component location 8 - 6 3/5/97 46 inch deck (– 1996) 1. Pin 2. Pad, brake (w/spring) 3. Eyebolt 4. Nut, push on 5. Rod, adjusting 6. Bushing 7. Pin 8. Bracket, rh draft 9. Lock nut, m6 10. Bracket, lh draft 11. Tension arm 12. Cotter pin 13. Washer 14. Washer 15. Pulley 16. Arm, idler 1...

  • Page 158

    Component location attachments 3/5/97 8 - 7 www.Servicemanualall.Com.

  • Page 159

    Attachments component location 8 - 8 3/5/97 46 inch deck (1997 –) 1. Shield, rh belt 2. Bracket, rh rear draft 3. Bracket, lh rear draft 4. Bushing 5. Rod, adjusting 6. Flange nut, m10 7. Eyebolt 8. Bushing, idler pivot 9. Bolt, carriage m8 x 35 10. Rod 11. Arm, idler 12. Washer, 6.4x12x1.6 13. Cott...

  • Page 160: Caution

    Tests and adjustments attachments 3/5/97 8 - 9 tests and adjustments before performing any service or adjustments: 1. Depress clutch/brake pedal fully and set parking brake. 2. Place gearshift lever in neutral (n) position. 3. Place pto lever in “disengaged” position. 4. Turn ignition key “off” and ...

  • Page 161: Caution

    Attachments tests and adjustments 8 - 10 3/5/97 important: do not attempt to loosen jam nut on tension rod without using a suitable wrench to support fitting. • loosen jam nut. • turn fitting on tension rod in proper direction to lengthen or shorten effective rod length. • tighten jam nut to 27 n•m ...

  • Page 162

    Tests and adjustments attachments 3/5/97 8 - 11 note: adjusting “j” bolts are on both left and right hand sides of rear draft arms. For minor side- to-side adjustments, do not alter factory preset of right hand side adjusting “j” bolt. Reset left hand side adjusting “j” bolt to obtain proper side-to...

  • Page 163: Caution

    Attachments repair 8 - 12 3/5/97 readjusting suspension to obtain 1– 4 inch cut height note: normal settling of the deck suspension after years of use may cause cut height range to shift downward. This may be readjusted by resetting the right hand adjusting “j” bolt adjuster. Adjustments are easier ...

  • Page 164: Caution

    Repair attachments 3/5/97 8 - 13 7. Remove two spring pin clips from two rear draft pins holding rear draft arms to mower frame. 8. Remove rear draft pins from draft arms. 9. Raise mower deck lift lever to highest position. Remove blocks from under deck. 10. Pull deck out from under side of mower, b...

  • Page 165: Caution

    Attachments repair 8 - 14 3/5/97 mower deck installation 1. Raise the mower deck lift lever to its highest point by pressing the lift lever lock and raising the lever up. 2. Slide deck under mower from side, being careful not to catch rear draft brackets on frame. 3. Place deck on 2 in. (5cm) blocks...

  • Page 166: Caution

    Repair attachments 3/5/97 8 - 15 mower spindle assembly removal note: spindles are not serviceable. The spindle, complete with pulley, must be replaced as an assembly if any parts are needed. 1. Remove deck unit from machine. See “mower deck removal” on page 11 38-inch mower: 46-inch mower: 2. Remov...

  • Page 167

    Attachments repair 8 - 16 3/5/97 important: do not add grease to spindle grease fitting. Grease fittings are for manufacturers use only. Adding grease may damage spindle seals. Important: blade bolt is grade 8 heat treated 1. Install each spindle assembly in reverse order. Tighten mounting hardware ...

  • Page 168: Contents

    Miscellaneous contents page contents 3/5/97 9 - 1 miscellaneous component location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 fuel tank and dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 repair . . . . . . . . . . . . . ....

  • Page 169

    Notes miscellaneous 9 - 2 3/5/97 www.Servicemanualall.Com.

  • Page 170

    Component location miscellaneous 3/5/97 9 - 3 component location fuel tank and dash panel 1. Fuel tank 2. Filler cap 3. Dash panel 4. Clip nut (2 used) 5. Screw (6 used) 6. Fastener grommet (4 used) 7. Hose clamps (6 used) 8. Screw 9. Fuel delivery hose (typical) 10. Fuel shut-off valve 11. Fuel fil...

  • Page 171

    Miscellaneous repair 9 - 4 3/5/97 repair front wheels removal & installation 1. Safely lift and support tractor. 2. Remove plastic cap. 3. Remove snap ring (a) and wheel. 4. Clean axle, washers, and bearings of old grease. 5. Inspect bearings for excessive wear. Replace if necessary. Note: front whe...

  • Page 172

    Repair miscellaneous 3/5/97 9 - 5 front axle removal 1. Safely support front of tractor. 2. Remove front wheels. See “front wheels removal & installation” on page 4. 3. Disconnect draft arms (d) from axle. 4. Remove tie rods (c) at spindle arms. 5. Remove muffler shield(s) and muffler (b). 6. Remove...

  • Page 173: Caution

    Miscellaneous repair 9 - 6 3/5/97 2. Turn fuel shut-off valve (d) (early models only), to closed position, or clamp fuel line closed between filter and tank. 3. Disconnect fuel line at filter (b) side of fuel shut-off valve. 4. Remove fill cap and drain any fuel into an approved container. 5. Discon...

  • Page 174

    Repair miscellaneous 3/5/97 9 - 7 18. Install overflow tube and fuel line to fuel tank spigots. 19. Install fuel tank lip (k) in console notches (l) while aligning six mounting holes. Cable assembly overflow hose fuel tank l k screws cable assembly 20. Fasten fuel tank to dash panel with six screws....

  • Page 175

    Miscellaneous repair 9 - 8 3/5/97 26. Place blade drive lever into hole in dash and frame. 27. Insert plastic grommet note: apply anti-seize lubricant to steering shaft before installing steering wheel. 28. Install washer(s) exactly as removed earlier onto steering shaft. 29. Install steering wheel ...

  • Page 176: Contents

    Service information bulletins contents page contents 3/5/97 10 - 1 s service information bulletins service information bulletin (no. 96-001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 service information bulletin (no. 96-002) . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 177

    Contents continued service information bulletins 9 - 2 3/5/97 page s www.Servicemanualall.Com.

  • Page 178: Service Information Bulletin

    Service information bulletins 3/5/97 10 - 3 s service information bulletin no. 96-001 may 1, 1996 subject: engine surging when cold affects: sabre lawn tractors engines on sabre lawn tractors are environmentally friendly! All briggs & stratton engines used on the sabre lawn tractors are california a...

  • Page 179: Service Information Bulletin

    Service information bulletins 10 - 4 3/5/97 s service information bulletin no. 96-002 may 13, 1996 subject: mulching blades contacting each other affects: sabre lawn tractors with bm 18617 (38”) and bm 18618 (46”) mulch kits installed. There have been a few reports of the mulching blades contacting ...

  • Page 180: Service Information Bulletin

    Service information bulletins 3/5/97 10 - 5 s service information bulletin no. 96-003 may 14, 1996 subject: chattering noise from under the frame affects: sabre lawn tractors the mower drive lever (key # 58 below) uses a loose fitting, long spacer (key # 150) that fits around the lever shaft between...

  • Page 181: Service Information Bulletin

    Service information bulletins 10 - 6 3/5/97 s service information bulletin no. 96-008 october 15, 1996 subject: mower drive belt smoking when pto (blade drive) lever is disengaged - may be accompanied by a “squeling” noise (addendum to sib 96-004, may 14, 1996) affects: sabre lawn tractors complaint...

  • Page 182: 38" Mower Deck

    Service information bulletins 3/5/97 10 - 7 s service information bulletin 96-008 (continued) page 2 the preset tension rod measurements for the 38-inch deck should be 17-20 mm (0.75 [3/4] in.). Measurement should be taken from face of tension rod adjuster to end of threaded tension rod (see figure ...

  • Page 183

    Service information bulletins 10 - 8 3/5/97 s service information bulletin 96-008 (continued) page 3 46 inch deck only - if the proper clearances shown below cannot be obtained without deforming the upper ground drive keeper (part of frame weldment), remove and re-install the jacksheave belt keeper ...

  • Page 184

    Service information bulletins 3/5/97 10 - 9 s service information bulletin 96-008 (continued) page 4 the following illustrations show the correct belt routing and belt keeper (guide) orientation for the 38 and 46 inch mower decks. Improperly oriented belt keepers can result in thrown belts, prematur...

  • Page 185: Service Information Bulletin

    Service information bulletins 10 - 10 3/5/97 s service information bulletin no. 96-009 october 15, 1996 subject: mower belt smoking comes off affects: models1338 gear & 1538 hydro sabre lawn tractors with 38-inch (96 cm) mower deck complaint or symptom: mower deck belt comes off during mowing or whe...

  • Page 186: Service Information Bulletin

    Service information bulletins 3/5/97 10 - 11 s service information bulletin no. 96-010 october 31, 1996 subject: engine surging affects: 1538 hydro, 1546 gear, 1646 hydro sabre lawn tractors complaint or symptom: engine runs lean and surges (or hunts) after warm-up during first few hours of running....

  • Page 187

    Service information bulletins 10 - 12 3/5/97 s www.Servicemanualall.Com.

  • Page 188

    Index 3/5/97 index - 1 a alternative lubricants . . . . . . . . . . . . . . . . . . . . . . 2-9 b battery charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 load test . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 specifications . . . . . . . . . . . . . . . . . . . . ...

  • Page 189

    Index index - 2 3/5/97 gear power train brake component location . . . . . . . . . . . . . . . 5-12 spring adjustment . . . . . . . . . . . . . . . . . 5-16 test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 clutch actuating spring . . . . . . . . . . . . . . . . 5-16 component locati...

  • Page 190

    Index 3/5/97 index - 3 hydrostatic power train (continued) traction drive belt installation k51 . . . . 6-38 traction drive belt installation k55 . . . . 6-38 traction drive belt removal k51 . . . . . . 6-37 traction drive belt removal k55 . . . . . . 6-36 traction drive belt tensioning system k55 r...

  • Page 191

    Index index - 4 3/5/97 m mower deck 38 inch (— 1996) . . . . . . . . . . . . . . . . . . . . . . 8-4 38 inch (1997 —) . . . . . . . . . . . . . . . . . . . . . . 8-5 46 inch (— 1996) . . . . . . . . . . . . . . . . . . . . . . 8-6 46 inch (1997 —) . . . . . . . . . . . . . . . . . . . . . . 8-7 gage...