JOHN DEERE 185 (02) PDF MANUAL

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JOHN DEERE 185 (02) PDF SUMMARY:

What are technical manuals divided into?

Technical manuals are divided into two parts: repair and diagnostics. Repair sections tell how to repair the components. Diagnostic sections help you identify the majority of routine failures quickly.

What do FOS manuals cover?

Fundamentals of Service (FOS) Manuals cover basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic types of failures and their causes. FOS Manuals are for training new personnel and for reference by experienced technicians.

What do technical manuals provide?

Technical Manuals are concise guides for specific machines and are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.

What should you do when you see the safety-alert symbol?

When you see this symbol on your machine or in the manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices.

What do signal words indicate?

A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards. Safety signs with signal word DANGER or WARNING are typically near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.

How should fuel be handled?

Handle fuel with care: it is highly flammable.

  • Do not refuel the machine while smoking or when near open flame or sparks.
  • Always stop the engine before refueling the machine.
  • Fill the fuel tank outdoors.
  • Prevent fires by keeping the machine clean of accumulated trash, grease, and debris.
  • Always clean up spilled fuel.

What type of clothing should be worn?

Wear close fitting clothing and safety equipment appropriate to the job.

How can you protect against noise?

Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

What are some safe maintenance practices?

  • Understand service procedure before doing work.
  • Keep area clean and dry.
  • Never lubricate or service machine while it is moving.
  • Keep hands, feet, and clothing from power-driven parts.
  • Disengage all power and operate controls to relieve pressure.
  • Lower equipment to the ground.
  • Stop the engine.
  • Remove the key.
  • Allow machine to cool.
  • Securely support any machine elements that must be raised for service work.
  • Keep all parts in good condition and properly installed.
  • Fix damage immediately.
  • Replace worn or broken parts.
  • Remove any buildup of grease, oil, or debris.
  • Disconnect the battery ground cable (-) before making adjustments on electrical systems or welding on the machine.

What should you do to avoid high-pressure fluids?

Escaping fluid under pressure 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.

What is the PTO Mounting Cap Screw Torque specification?

56 N·m (45 lb-ft)

What is the PTO Clutch Clearance specification?

  1. 41 mm (0.016 in.)

What are the Powered Wheels Wheel Hub-to-Axle Housing Clearance specifications?

  1. 25—1.02 mm (0.010—0.040 in.)

What are the Traction Drive Clutch Belt Clearance specifications?

94 mm (3.70 in.)

What are the Traction Drive Clutch Belt Guide Clearance specifications?

5 mm (0.20 in.)

What are the 5-Speed Transaxle Needle Bearings Output Pinion and Input Shaft Depth specifications?

  1. 43—3.81 mm (0.135—0.150 in.)

What is the 5-Speed Transaxle Cover Cap Screw Torque specification?

12 N·m (100 lb-in.)

What is the Hydrostatic Transmission Eaton Dump Valve Shaft Torque specification?

3 N·m (30 lb-in.)

What is the Hydrostatic Transmission Eaton Body-to-Cover Cap Screw Torque specification?

20 N·m (180 lb-in.)

What is the Hydrostatic Transmission Eaton Oil Reservoir Torque specification?

14 N·m (124 lb-in.)

What is the Hydrostatic Transmission Eaton Control Arm Clearance specification?

  1. 70—2.50 mm (0.028—0.098 in.)

What is the Hydrostatic Transmission Eaton Control Lever Spring Length specification?

42 mm (1.700 in.)

What is the Hydrostatic Transmission Sundstrand Center Section-to-Transmission Cap Screw Torque specification?

17 N·m (150 lb-in.)

What is the Hydrostatic Transmission Sundstrand Drain Plug Torque specification?

15 N·m (130 lb-in.)

What is the Hydrostatic Transmission Sundstrand Transmission Oil Capacity specification?

850 cc (28.7 fl oz)

What is the Hydrostatic Differential Peerless Ring Gear Cap Screw Torque specification?

10 N·m (88 lb-in.)

What is the Hydrostatic Differential Peerless Differential Cover Cap Screw Torque specification?

11 N·m (97 lb-in.)

What is the Hydrostatic Differential Peerless Differential Carrier-to-Case Thrust Surface Maximum Wear specification?

  1. 02 mm (0.040 in.)

What is the Hydrostatic Differential Kanzaki Idle Gear I.D. specification?

  1. 01—21.03 mm (0.827—0.828 in.)

What is the Hydrostatic Differential Kanzaki Idler Shaft O.D. specification?

  1. 99—17.00 mm (0.668—0.669 in.)

What is the Hydrostatic Differential Kanzaki Cam Lever Shaft O.D. specification?

  1. 97—20.03 mm (0.786—0.788 in.)

What is the Hydrostatic Differential Kanzaki Cam Lever Shaft Bore I.D. (Cover) specification?

  1. 10—20.20 mm (0.791—0.795 in.)

What is the Hydrostatic Differential Kanzaki Cam Lever Shaft Bore I.D. (Housing) specification?

  1. 05—20.08 mm (0.789—0.790 in.)

What is the Hydrostatic Differential Kanzaki Actuator Thickness (Includes Ball) specification?

  1. 10—9.30 mm (0.358—0.366 in.)

What is the Hydrostatic Differential Kanzaki Disc Thickness specification?

  1. 90—2.10 mm (0.075—0.083 in.)

What is the Hydrostatic Differential Kanzaki Plate Thickness specification?

  1. 40—2.60 mm (0.094—0.102 in.)

What is the Hydrostatic Differential Kanzaki Axle Housing (Needle Bearing) O.D. specification?

  1. 98—25.00 mm (0.983—0.984 in.)

What is the Hydrostatic Differential Kanzaki Counter Gear I.D. specification?

  1. 01—20.03 mm (0.788—0.789 in.)

What is the Hydrostatic Differential Kanzaki Pinion Drive O.D. specification?

  1. 00—20.02 mm (0.787—0.788 in.)

What is the Hydrostatic Differential Kanzaki Pinion Shaft O.D. specification?

  1. 97—13.98 mm (0.549—0.550 in.)

What is the Hydrostatic Differential Kanzaki Pinion Gear I.D. specification?

  1. 03—14.05 mm (0.552—0.553 in.)

What is the Hydrostatic Differential Kanzaki Differential Case (Axle End) I.D. specification?

  1. 08—20.10 mm (0.790—0.791 in.)

What is the Hydrostatic Differential Kanzaki Ring Gear Cap Screw Torque specification?

26 N·m (230 lb-in.)

What is the Hydrostatic Differential Kanzaki Bearing Retainer Tapping Bolts New Case Torque specification?

29 N·m (22 lb-ft)

What is the Hydrostatic Differential Kanzaki Bearing Retainer Tapping Bolts Used Case Torque specification?

25 N·m (221 lb-in.)

What is the Hydrostatic Differential Kanzaki Axle Tapping Bolts New Case Torque specification?

29 N·m (22 lb-ft)

What is the Hydrostatic Differential Kanzaki Axle Tapping Bolts Used Case Torque specification?

25 N·m (221 lb-in.)

What is the Hydrostatic Differential Kanzaki Ring Gear-to-Pinion Drive Gear Backlash specification?

  1. 15—0.30 mm (0.006—0.012 in.)

What is the Hydrostatic Differential Kanzaki Cam Lever Shaft Tapping Bolt New Case Torque specification?

29 N·m (22 lb-ft)

What is the Hydrostatic Differential Kanzaki Cam Lever Shaft Tapping Bolt Used Case Torque specification?

25 N·m (221 lb-in.)

What is the Hydrostatic Differential Kanzaki Case Cover Tapping Bolts New Case Torque specification?

29 N·m (22 lb-ft)

What is the Hydrostatic Differential Kanzaki Case Cover Tapping Bolts Used Case Torque specification?

25 N·m (221 lb-in.)

What is the Hydrostatic Differential Kanzaki Drain Plug Torque specification?

15 N·m (130 lb-in.)

What is the Brake Disk Gap Clearance specification?

  1. 50 mm (0.020 in.)

What is the Mower Spindle Maximum Mower Spindle Rolling Torque specification?

  1. 07 N·m (0.60 lb-in.)

What is the Mower Spindle Spindle Mounting Bolt Torque specification?

25 N·m (221 lb-in.)

What is the Mower Spindle Mower Blade Cap Screw Torque specification?

75 N·m (55 lb-ft)

What is the Mower Spindle Mower Drive Sheave Nut Torque specification?

125 N·m (92 lb-ft)

What are the engine specifications for the 130?

  • Manufacture: KAWASAKI
  • Engine Model Number: FC290V
  • Horsepower: 9
  • Cylinders: One
  • Cycle: Four
  • Speeds:
    • Full throttle, no load: 3350 ± 100 rpm
    • Slow idle, no load: 1400 ± 100 rpm
  • Spark Plug Type: Champion RN11YC
  • Spark Plug Gap: 0.70—0.80 mm (0.028—0.031 in.)

What are the engine specifications for the 160/165?

  • Manufacture: KAWASAKI
  • Engine Model Number: FB460V
  • Horsepower: 12.5
  • Cylinders: One
  • Cycle: Four
  • Speeds:
    • Full throttle, no load: 3350 ± 100 rpm
    • Slow idle, no load: 1400 ± 100 rpm
  • Spark Plug Type: Champion RCJ8, NGK-BMR4A
  • Spark Plug Gap: 0.60—0.70 mm (0.024—0.028 in.)

What are the engine specifications for the 175?

  • Manufacture: KAWASAKI
  • Engine Model Number: FC420V
  • Horsepower: 14
  • Cylinders: One
  • Cycle: Four
  • Speeds:
    • Full throttle, no load: 3350 ± 100 rpm
    • Slow idle, no load: 1400 ± 100 rpm
  • Spark Plug Type: Champion RN11YC
  • Spark Plug Gap: 0.70—0.80 mm (0.028—0.031 in.)

What are the engine specifications for the 180/185?

  • Manufacture: KAWASAKI
  • Engine Model Number: FC540V
  • Horsepower: 17
  • Cylinders: One
  • Cycle: Four
  • Speeds:
    • Full throttle, no load: 3350 ± 100 rpm
    • Slow idle, no load: 1400 ± 100 rpm
  • Spark Plug Type: Champion RN11YC
  • Spark Plug Gap: 0.70—0.80 mm (0.028—0.031 in.)

What are the electrical system specifications?

  • Battery, John Deere (TY6109): 12 Volt, 255 amp cold cranking capacity, capacity at 25 amp
  • Alternator Charging Capacity
    • 130: 13 Amp
    • 160/165: 13 Amp
    • 175: 13 Amp
    • 180/185: 15 Amp
  • Ignition: Solid State

What are the capacity specifications?

  • Fuel Tank: 8.3 L (2.2 gal)
  • Engine Oil, Without Filter
    • 130: 1.1 L (2.3 pt)
    • 160/165: 1.4 L (3 pt)
    • 175: 1.3 L (2.7 pt)
    • 180/185: 1.6 L (3.4 pt)
  • Engine Oil, With Filter
    • 160/165: 1.6 L (3.4 pt)
    • 175: 1.7 L (3.6 pt)
    • 180/185: 2.0 L (4.2 pt)
  • Transaxle
    • 130/160/180: 1.1 L (2.3 pt)
  • Hydrostatic Transmission
    • 165/175/185: 0.7 L (1.5 pt)
  • Differential
    • 165/175/185: 0.7 L (1.5 pt)

What are the travel speed specifications at 3300 RPM?

  • First Gear-Transaxle
    • 130/160/180: 2.2 km/h (1.4 mph)
    • 180 w/46 in. Mower: 2.4 km/h (1.5 mph)
  • Second Gear
    • 130/160/180: 3.5 km/h (2.2 mph)
    • 180 w/46 in. Mower: 3.8 km/h (2.4 mph)
  • Third Gear
    • 130/160/180: 5.3 km/h (3.3 mph)
    • 180 w/46 in. Mower: 5.6 km/h (3.5 mph)
  • Fourth Gear
    • 130/160/180: 6.7 km/h (4.2 mph)
    • 180 w/46 in. Mower: 7.2 km/h (4.5 mph)
  • Fifth Gear
    • 130/160/180: 7.8 km/h (4.9 mph)
    • 180 w/46 in. Mower: 8.5 km/h (5.3 mph)
  • Hydrostatic Transmission
    • Forward: 0-8 km/h (0-5 mph)
    • Reverse: 0-4 km/h (0-2.5 mph)

What are the approximate weight specifications?

  • 130: 184 kg (405 lb)
  • 160: 202 kg (445 lb)
  • 165 and 175: 213 kg (470 lb)
  • 180 with 30 in. Mower: 220 kg (485 lb)
  • 180 with 46 in. Mower: 236 kg (520 lb)
  • 180 with 38 in. Mower: 231 kg (510 lb)

What are the mower specifications for a 30-Inch mower?

  • Type: Rotary
  • Cutting Blades: One
  • Blade Length: 762 mm (30 in.)
  • Cutting Width: 762 mm (30 in.)
  • Cutting Height: 25.40—102 mm (1.00—4.00 in.)

What are the mower specifications for a 38-Inch mower?

  • Type: Rotary
  • Cutting Blades: Two
  • Blade Length: 496 mm (19.50 in.)
  • Cutting Width: 965 mm (38 in.)
  • Cutting Height: 25.40—102 mm (1.00—4.00 in.)

What are the mower specifications for a 46-Inch mower?

  • Type: Rotary
  • Cutting Blades: Three
  • Blade Length: 407 mm (16 in.)
  • Cutting Width: 1170 mm (46 in.)
  • Cutting Height: 38.10—102 mm (1.50—4.00 in.)

What should you do if a different torque value or tightening procedure is listed for a specific application?

Do NOT use general torque values if a different torque value or tightening procedure is listed for a specific application. Check tightness of cap screws periodically.

What should you do when replacing shear bolts?

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.

What should you do with fasteners?

Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original.

What should you ensure when working with fasteners?

Make sure fastener threads are clean and you properly start thread engagement. This will prevent them from failing when tightening.

How should you tighten plastic insert or crimped steel-type lock nuts?

Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of amount shown in chart. Tighten toothed or serrated-type lock nuts to full torque value.

How should you tighten cap screws having lock nuts?

Tighten cap screws having lock nuts to approximately 50 percent of amount shown in chart.

What are the spark plug gap specifications?

  • 130, 175, 180/185: 0.70—0.80 mm (0.028—0.031 in.)
  • 160/165: 0.60—0.70 mm (0.024—0.028 in.)

What is the spark plug torque specification?

15 N·m (133 lb-in.)

What is the idle speed specification?

1400 rpm

What is the high speed specification?

3350 rpm

What is the order to perform tune-up adjustments?

Perform tune-up adjustments in the following order to improve the efficiency and operation of the tractor:

  1. Clean engine and cooling system.
  2. Clean air cleaner.
  3. Check or replace fuel filter.
  4. Check battery electrolyte level.
  5. Check spark.
  6. Check spark plug.
  7. Check compression.
  8. Adjust carburetor and engine speeds.
  9. Check crankcase breather.
  10. Check crankcase vacuum.
  11. Check and adjust governor.
  12. Check and adjust brakes.
  13. Check and adjust hydrostatic control lever linkage.
  14. Check hydrostatic control lever friction adjustment.
  15. Adjust steering axle.
  16. Check tire pressure.

How should you handle fuel?

Handle fuel carefully.

  • Always stop engine before refueling.
  • Fill fuel tank outdoors.
  • If the engine is hot, let the engine cool several minutes before you add fuel.
  • Do not smoke while you fill the fuel tank or service the fuel system.
  • Fill fuel tank only to the bottom of filler neck.

Is it okay to mix oil with gasoline?

Do NOT mix oil with gasoline.

What type of fuel is recommended?

Unleaded fuel is recommended. Regular leaded gasoline with an anti-knock index of 87 or higher may be used. Avoid switch from unleaded to regular gasoline to prevent engine damage.

Is the use of gasohol acceptable?

Use of gasohol is acceptable as long as the ethyl alcohol blend does not exceed 10 percent. Unleaded gasohol is preferred over leaded gasohol.

What is the fuel tank capacity?

Fuel tank capacity is 2-1/2 gal (9.5 L).

How should you fill the fuel tank?

Lift seat. Fill fuel tank at end of each day’s operation. This helps to keep condensation out of fuel tank.

What type of gasoline engine oil is recommended?

John Deere PLUS-4® engine oil is recommended. Other oils may be used if they meet API Service Classification SF or SE. Oils meeting Military Specification MIL-L-46167A may be used as arctic oils. Use oil viscosity based on the expected air temperature range during the period between oil changes.

What type of Peerless Differential Oil is recommended for all 165, 175 and 185 (S.N. —475000)?

SAE 90 oil is recommended in the differential. Other oils shown in the chart can also be used. Do NOT mix oils of different viscosities. Use oil viscosity as shown on the temperature chart for the expected air temperature range during the drain interval. Do NOT put SAE 90 oil in the hydrostatic transmission.

What type of Kanzaki Differential Oil is recommended for 185 (S.N. 475001— )?

SAE 10W30 engine oil with an API classification of SE, CC or CD is recommended in the differential. Do NOT mix oils of different viscosities. Do NOT put SAE 90 oil in the hydrostatic transmission or differential.

What type of Eaton Hydrostatic Transmission Oil is recommended for all 165, 175 and 185 (S.N. —475000)?

SAE 30 engine oil with an API classification of SE, CC or CD is recommended in the transmission. SAE 20 or 40 engine oil can also be used depending on temperature range during the service interval. Do NOT use type F automatic transmission fluid or any other type oil other than specified. Oil must be from a sealed plastic or all metal can to avoid any moisture.

What type of Sundstrand Hydrostatic Transmission Oil is recommended for 185 (S.N. 475001— )?

SAE 10W 30 engine oil with an API classification of SE, CC or CD is recommended in the transmission.

What type of General Purpose Grease is recommended?

Use grease as shown on the temperature chart for the expected air temperature range during the service interval. John Deere Multipurpose Grease is recommended. If other greases are used, use:

  • SAE Multipurpose Grease.
  • Multipurpose Grease containing 3 to 5 percent molybdenum disulfide.

At temperatures below -22˚F (-30˚C), use arctic greases such as those meeting Military Specification MIL-G-10924C.

Where can you find the product identification number?

The product identification number is listed in Section 10, Group 30.

Where can you find the engine serial number?

The engine serial number is listed in Section 10, Group 30.

What other manual should be used for Kawasaki engine repair?

For complete repair information the component technical manual (CTM) is also required. Use the component manual in conjunction with this machine manual.

How to Remove and Install Engine on the 130?

  1. Remove hood, muffler and pedestal shroud.
  2. Close fuel shut-off valve. Disconnect fuel line.
  3. Loosen cap screw and disconnect throttle cable.
  4. Disconnect two wires from ground terminal on right-hand side of engine.
  5. Disconnect wire from starter.
  6. Disconnect ignition wire (A) and remove wire from grommet (B).
  7. Remove electric PTO clutch. (See Section 40, Group 05).
  8. Depress clutch pedal and remove belt from idler wheel and drive sheave.
  9. Remove drive sheave (A) and key (B).
  10. Remove four engine mounting cap screws and belt guide (A).
  11. Rotate engine to clear oil drain from hole in frame and remove engine.
  12. When installing engine, apply NEVER-SEEZE lubricant to crankshaft before installing drive sheave.
  13. Tighten PTO clutch mounting cap screw to 56 N·m (45 lb-ft).
  14. Adjust throttle cable, choke, governor, fast idle and slow idle. (See Section 220).

How to Remove and Install Engine on the 160 and 165?

  1. Remove hood, muffler and pedestal shroud.
  2. Close fuel shut-off valve. Disconnect fuel line.
  3. Disconnect throttle cable (A).
  4. Disconnect two wires from ground terminal on right-hand side of engine.
  5. Disconnect wires (A and B). Remove wires from behind oil fill tube ©.
  6. Disconnect ignition wire (A) and remove wire from grommet (B).
  7. Remove electric PTO clutch. (See Section 40, Group 05).
  8. Relieve tension in traction belt for hydrostatic tractors. For gear driven tractors, depress clutch pedal. Remove belt from idler wheel and drive sheave.
  9. Remove drive sheave (A) and key (B).
  10. Remove four engine mounting cap screws. On gear driven tractors, remove belt guard (A).
  11. Rotate engine to clear oil drain from hole in frame and remove engine.
  12. When installing engine, apply NEVER-SEEZE lubricant to crankshaft before installing drive sheave.
  13. Tighten PTO clutch mounting cap screw to 56 N·m (45 lb-ft).
  14. Adjust throttle cable, choke, governor, fast idle and slow idle. (See Section 220).

How to Remove and Install Engine on the 175, 180 and 185?

  1. Remove hood, muffler and pedestal shroud.
  2. Close fuel shut-off valve. Disconnect fuel line.
  3. Loosen cap screw and disconnect throttle cable.
  4. Disconnect two wires from ground terminal on right-hand side of engine.
  5. Disconnect wires (A, B and C) from starter solenoid.
  6. Disconnect ignition wire (A) and remove wire from grommet (B).
  7. Remove electric PTO clutch. (See Section 40, Group 05).
  8. Relieve tension in traction belt for hydrostatic tractors. For gear driven tractors, depress clutch pedal. Remove belt from idler wheel and drive sheave.
  9. Remove drive sheave (A) and key (B).
  10. Remove four engine mounting cap screws. On gear driven units, remove belt guard (A).
  11. Rotate engine to clear oil drain from hole in frame and remove engine.
  12. When installing engine, apply NEVER-SEEZE lubricant to crankshaft before installing drive sheave.
  13. Tighten PTO clutch mounting cap screw to 56 N·m (45 lb-ft).
  14. Adjust throttle cable, choke, governor, fast idle and slow idle. (See Section 220).

What should I do if the electric PTO clutch needs repair?

Use CTM-5.

What other material is needed for the electric PTO clutch?

Use PT569 NEVER-SEEZ® Lubricant to lubricate the crankshaft.

How do you adjust the electric PTO clutch?

  1. Make sure the PTO switch is in the OFF position. Disconnect the spark plug wire and remove the key.
  2. Insert a 0.41 mm (0.016 in.) feeler gauge through the slot in the clutch plate. The gauge should be between the clutch rotor and armature.
  3. Tighten the lock nut until the feeler gauge begins to bind between the armature and rotor. Use a sweeping motion with the feeler gauge while making this adjustment. Do NOT overtighten.
  4. Repeat the procedure on the other two adjusting nuts.
  5. Connect the spark plug wire and start the engine. Move the PTO switch to the ON position. If the clutch does not engage, test the electrical connections for continuity or disassemble the PTO for inspection and repair.

How do you remove the electric PTO clutch?

  1. Disconnect the wiring harness (A).
  2. Remove the cap screw and washer.
  3. If the clutch is stuck on the crankshaft, use a plastic hammer to loosen the clutch from the crankshaft. Remove the clutch.

How do you disassemble the Ogura electric PTO clutch?

  1. Remove the three lock nuts.
  2. Support the PTO clutch assembly on the armature housing. Press on the rotor shaft only and remove the armature assembly.
  3. Remove the three springs (A).
  4. Remove the snap ring.
  5. Press the bearing and spacer form armature housing.
  6. Press the rotor from the electrical coil assembly using a 1-5/16 in. disk.
  7. Remove the snap ring.
  8. Press the bearing from the electrical coil assembly.

What should I inspect when inspecting the electric PTO clutch?

  • Inspect bearings (F) for wear or damage. Replace if necessary.
  • Inspect springs (B) for a broken condition. Replace springs if necessary.
  • Inspect contact surfaces of rotor © and armature (D) for scored or grooved condition. Check for weak or broken contact springs (I). Replace parts as needed.

Components:

  • A—Electric Coil Assembly
  • B—Spring (3 used)
  • C—Rotor
  • D—Armature Housing
  • E—Spacer (2 used)
  • F—Bearing (2 used)
  • G—Snap Ring
  • H—Lock Nut (3 used)
  • I—Contact Springs

How do you test the electrical coil of the electric PTO clutch?

NOTE: The battery must be fully charged and in good condition for a proper test.

  1. Connect a 12-volt battery to the PTO electrical leads.
  2. Put a tool across the coil. Electromagnetic action will hold the tool to the coil if the PTO coil is in good condition. If the tool is not attracted to the coil, replace the coil.

How do you assemble the electric PTO clutch?

  1. Press the bearing into the electrical coil assembly.
  2. Install the snap ring.
  3. Press the rotor into the electrical coil assembly.
  4. Put the spacer in the armature housing. Press the bearing against the spacer.
  5. Install the snap ring.
  6. Install the springs (A) and press the armature housing onto the rotor.
  7. Install the lock nuts.
  8. Adjust the PTO clutch after installing it on the tractor.

How do you disassemble the Warner electric PTO clutch?

  1. Remove the spacer.
  2. Remove the three nuts.
  3. Remove the armature assembly and the three springs (A).
  4. Remove the rotor.

What should I inspect when inspecting the Warner electric PTO clutch?

  1. Inspect bearings (A) for wear or damage. Replace bearings or housing assemblies as needed.
  2. Inspect springs © for broken condition. Replace springs if necessary.
  3. Inspect contact surfaces of rotor (D) and armature (E) for scored or grooved condition. Check for weak or broken contact springs (F). Replace parts as needed.

Components:

  • A—Bearing (2 used)
  • B—Electric Coil Housing Assembly
  • C—Spring (3 used)
  • D—Rotor
  • E—Armature Housing Assembly
  • F—Contact Spring

How do you assemble the Warner electric PTO clutch?

  1. Install the rotor on the electrical coil assembly.
  2. Install the three springs (A).
  3. Install the armature housing assembly.
  4. Install the three nuts.
  5. Install the spacer.
  6. Adjust the PTO clutch before installing it on the tractor.

How do you install the electric PTO clutch?

  1. Put NEVER-SEEZ lubricant on the crankshaft.
  2. Install the PTO clutch on the crankshaft with the pin on the tractor through the slot in the electric coil housing.
  3. Install the cap screw and washer. Hold the flywheel and tighten the cap screw to 56 N·m (45 lb-ft).
  4. Connect the wiring harness (A).

What other material is needed for the powered wheels?

Use PT569 NEVER-SEEZ® Lubricant to lubricate the rear axle.

How do you replace the rear wheels on a 130, 160, and 180?

  1. Lift the rear of the tractor so the rear wheels are off the ground. Put blocks or supports under the tractor frame.
  2. Remove the snap ring and washer. Remove the wheel.
  3. Inspect the shaft key and washer. Replace if necessary.
  4. Put NEVER-SEEZE lubricant on the axle.
  5. Install the washers and snap ring.
  6. Measure the clearance between the wheel hub and axle housing. Add washers behind the snap ring until the clearance is 0.25—1.02 mm (0.010—0.040 in.).
  7. Remove the blocking from the tractor.

How do you replace the rear wheels on a 165, 175, and 185?

  1. Lift the rear of the tractor so the rear wheels are off the ground. Put blocks or supports under the tractor frame.
  2. Remove the snap ring.
  3. Pull the wheel off the axle.
  4. Inspect the washer (B) and shaft key (A) on the right axle. Inspect the three washers © on the left axle only.
  5. Put NEVER-SEEZE lubricant on the shaft and install the wheel.
  6. Install the snap ring.
  7. Measure the clearance between the wheel hub and axle housing. Add washers © between the hub and axle housing until the clearance is 0.25—1.02 mm (0.010—0.040 in.).
  8. Remove the blocking from the tractor.

What other material is needed for the traction drive clutch?

Use PT569 NEVER-SEEZ® Lubricant to lubricate the bell crank, bushings, and sleeve ends.

How do you maintain the traction drive belt?

  1. The traction drive belt transmits power by friction and a wedging action against the sheaves. The belt is subject to normal wear through periodic heavy load and should be checked regularly. To check for normal wear, the belt and sides of sheaves should wear evenly.

  2. A slight raveling of the belt covering does not indicate premature failure. Cut off the raveling if the covering peels at the lap.

  3. Check for the causes of unusual belt wear as follows:

    • Examine sheaves for bent or chipped sidewalls (A). Check for excessive sidewall wear (B). Damaged sheaves cause rapid belt wear. A bent sidewall © reduces the gripping power of the belt. Replace sheaves having any of the above defects.
    • Check to be sure dirt has not lodged and packed in the sheave V-groove. Loosen dirt so it will fall out when the tractor is started.

How do you inspect the traction drive belt?

IMPORTANT: Never pry the belt over the edge of the sheave. Belt cords may be damaged. Put the belt in the sheave groove by hand.

  1. Lumpy traction drive belts can cause tractor vibration. Check the belt for swells and lumps. Install only factory-recommended drive belts of the proper length.
  2. Whenever unusual traction drive belt failure occurs, check immediately for the cause. After correcting the cause, replace the drive belt.

How do you clean the traction drive belt?

CAUTION: Do not clean the belt while the tractor is running.

  1. Clean the belt by wiping it with a clean cloth. Immediately wipe off any spilled oil or grease. Do not use solvents. They soften the belt and cause the clutch to grab.
  2. Do not use belt dressing. Dressings shorten belt life and often give only temporary gripping action while softening the belt and causing eventual deterioration.

How do you replace the traction drive belt on a 130, 160, 180, and 185 (S.N. 475001— )?

  1. Remove the mower from the tractor.
  2. Remove the electric PTO clutch.
  3. Loosen the adjusting idler nut. NOTE: Idler is not on 185 (S.N. 475001— ).
  4. Remove the two cap screws and nuts. Rotate the steering support so it is parallel to the drive belt.
  5. Disconnect the drag link (A).
  6. Loosen the two nuts and remove the belt guide (A).
  7. Remove the two cap screws and nuts (A) and rotate the clutch support parallel to the drive belt.
  8. Depress the clutch pedal and remove the drive belt from the sheaves.
  9. Replace the drive belt on the sheaves.
  10. Install and tighten the two cap screws and nuts (A) on the clutch support.
  11. Install the belt guide on the clutch assembly.
  12. Connect the drag link (A). Install and tighten the two cap screws and nuts on the steering support.
  13. Adjust the traction drive belt.
  14. Install the mower on the tractor.

How do you replace the traction drive belt on a 165, 175, and 185 (S.N. —475000)?

  1. Remove the mower from the tractor.
  2. Remove the electric PTO clutch.
  3. Remove the two cap screws and nuts. Rotate the steering support so it is parallel to the drive belt.
  4. Disconnect the drag link (A).
  5. Remove the pin (A) and disconnect the transmission linkage.
  6. Remove the traction drive belt.
  7. Install the drive belt (A) on the transmission sheave, idler assembly, engine sheave, and idler. Be sure the drive belt is routed from the right-hand side of the engine sheave to the TOP of the transmission sheave.
  8. Connect the linkage to the transmission.
  9. Fasten the steering support with two cap screws and nuts. Connect the drag link to the steering arm.
  10. Install the electric PTO clutch.
  11. Install the mower on the tractor.

How do you adjust the traction drive belt on models 130, 160, and 180?

  1. Remove the mower from the tractor.
  2. Put the transmission control lever in gear to hold the tractor. DO NOT engage the parking brake.
  3. Put the foot clutch in the engaged or in the up position.
  4. Loosen the nut on the adjusting idler.
  5. Slide the adjusting idler in the slot until a dimension (A) of 94 mm (3.7 in.) is obtained between the inner surface of the flat idler and the inside of the frame.
  6. Adjust the belt guide (B) to be parallel with the drive belt and maintain a clearance of 5 mm (0.20 in.) between the belt and the guide.
  7. Tighten the nut on the adjusting idler.
  8. Loosen the belt guide (A) and center the belt in the guide loop. Tighten the cap screw.
  9. Install the mower on the tractor.

How do you remove the traction drive clutch assembly on a 130, 160, 180, and 185 (S.N. 475001— )?

  1. Loosen the two nuts and remove the belt guide (A).
  2. Remove the clutch spring (A) and return spring (B).
  3. Remove the clutch support (A) and clutch assembly.
  4. Inspect the clutch assembly for wear or damage. Replace parts as needed.

How do you install the traction drive clutch assembly on a 130, 160, 180, and 185 (S.N. 475001— )?

  1. Put NEVER-SEEZE lubricant on the bushings © and ends of the sleeve (D). Put the bushings and sleeve in the bell crank (E).
  2. Install the traction clutch assembly and clutch support (A). Tighten the three nuts.
  3. Install the return spring and clutch spring.
  4. Install the belt guide.
  5. Adjust the traction drive belt.

How do you remove the belt tensioner on a 165, 175, and 185 (S.N. —475000)?

  1. Remove the traction drive belt.
  2. Disconnect the spring (A) from the frame.
  3. Remove the nut and belt tensioner assembly.
  4. Inspect the tensioner for wear or damage. Replace parts as necessary.

How do you install the belt tensioner on a 165, 175, and 185 (S.N. —475000)?

  1. Put NEVER-SEEZE lubricant on the bushings (A) and ends of the sleeve ©.
  2. Install the belt tensioner parts on the cap screw one part at a time. Connect the spring (A) to the bell crank.
  3. Install and tighten the nut.
  4. Connect the spring (A) to the shaft on the pedal assembly.
  5. Install the traction drive belt.

What other material is needed for the 5-speed transaxle?

Use John Deere HIGH TEMPERATURE Grease to lubricate the brake shaft keyways, needle bearings, and transaxle gears.

How do you remove the transaxle?

  1. Remove the mower.
  2. Put the transmission control lever in neutral.
  3. Remove the rear wheels.
  4. Depress the clutch pedal and remove the traction drive belt from the transaxle drive sheave.
  5. Disconnect the brake linkage.
  6. Disconnect the neutral start switch wire (A).
  7. Remove the two cap screws and nuts from the front support.
  8. Remove the cap screw and washer. Disconnect the shift arm.
  9. Remove the four nuts from the U-bolt and lower the transaxle from the tractor.

How do you remove the external transaxle parts?

  1. Remove the two self-tapping screws and remove the support.
  2. Remove the snap ring (A). Remove the transaxle drive sheave and key.
  3. Remove the neutral start switch.
  4. Remove the two cap screws and washers. Remove the brake assembly, disk, and brake puck.

How do you remove the internal components of the transaxle?

  1. Remove the Allen-head screw. Remove the spring and detent ball with a magnet.
  2. Remove the 17 cap screws. Tap the sides of the case with a plastic hammer and remove the top half of the case.
  3. Remove the shifter fan.
  4. Lift the gear assembly out of the case as one unit.
  5. Lift the differential assembly out.
  6. Remove the old grease from the case halves and parts. Wash the parts with solvent.

How do you disassemble the input shaft?

  1. Remove the snap ring and pinion gear (A).
  2. Remove the thrust washer and O-ring.
  3. Remove the input shaft, thrust washer (A), and snap ring (B).
  4. Inspect the input shaft, pinion gear, O-ring, and thrust washers for wear or damage. Replace parts if necessary.
  5. Inspect the input shaft bearings (A) for wear. Replace if necessary.

How do you disassemble the gear assembly?

  1. Remove the needle bearing (A), square-cut seal (B), thrust washer ©, output gear (D), and output pinion (E).
  2. Inspect the needle bearing (A) for wear. Replace if necessary.
  3. Remove the O-rings from each end of the output pinion. Inspect the needle bearings (A) for wear. Replace if necessary.
  4. Pull the ends of the shafts together and remove the drive chain.
  5. Remove the sprocket (A), bushing (B), thrust washer ©, spur gears (D), and bevel gear (E) from the countershaft.
  6. Remove the square-cut seal (A), bushing (B), and thrust washer © from the shifter and brake shaft.
  7. Remove the spur gears (A) and thrust washers (B) alternately.
  8. Remove the bushing (A), thrust washer (B), spur gear ©, spacer (D), and sprocket (E).
  9. Remove the shifter collar (A) and keys (B).
  10. Inspect the gears, bushings, washers, and shafts for wear or damage. Replace parts if necessary.
  11. Inspect the roller chain for damaged or broken links. Replace if necessary.

How do you disassemble the differential?

  1. Remove the ball bearings (A) and bushings (B).
  2. Remove the spring pin (A) using a punch.
  3. Remove the pinion shaft © and thrust washers (B).
  4. Rotate the axle to move the pinion gears out of position. Remove the pinion gears.
  5. Remove the snap ring. Remove the bevel gear (A), thrust washers (B), and axle ©.
  6. Inspect the bushings (A) for wear. Replace if necessary.
  7. Inspect the differential ball bearings, bushings, shafts, and gears for wear or damage. Replace parts if necessary.

How do you assemble the differential?

  1. Install the shorter axle (A) through the gear side of the ring gear housing.
  2. Install the thrust washers (B), bevel gear ©, and snap ring.
  3. Install the longer axle, thrust washers, bevel gear, and snap ring in the ring gear housing.
  4. Install the pinion gears on opposite sides of the ring gear housing. Rotate the axle to move the pinion gears into alignment with the pinion shaft holes.
  5. Insert the thrust washers (B) behind each pinion gear. Slide the pinion shaft © through the ring gear housing, thrust washers, and pinion gears.
  6. Install the spring pin (A).
  7. Install the bushings (B) and ball bearings (A).

How do you assemble the shifter and brake shaft?

  1. Put John Deere High-Temperature Grease or an equivalent in the keyways of the shaft.
  2. Position the keys (B) near the end of the shaft in the keyways. Put the shifter collar (A) over the keys with the thicker shoulder of the collar towards the shaft. Slide the collar and keys on the shaft.
  3. Install the sprocket (E) with the thicker shoulder towards the shifter collar.
  4. Install the spacer (D), spur gear ©, thrust washer (B), and bushing (A).
  5. Put the five thrust washers (B) and spur gears (A) on the shaft with the raised side of the thrust washers towards the shoulder © of the shaft. The flat side of the gears (A) MUST be towards the shoulder.
  6. Install the thrust washer ©, bushing (B), and square-cut seal (A).

How do you assemble the countershaft?

  1. Install the bevel gear (E) with the bevel towards the center of the shaft. Install the spur gears (D), smallest to largest, thrust washer ©, and bushing (B).
  2. Install the sprocket (A) with the thicker shoulder towards the bevel gear (E).
  3. Put the countershaft and shifter and brake shaft ends together. Install the drive chain.
  4. If the needle bearings (A) were removed from the output pinion, replace them with new bearings. Press the bearings to a depth of 3.43—3.81 mm (0.135—0.150 in.) below the top surface on each end.
  5. Put John Deere HIGH-TEMPERATURE Grease between the needle bearings. Put O-rings in each end of the output pinion.
  6. Install the output pinion (E), output gear (D), thrust washer ©, square-cut seal (B), and needle bearing (A).

How do you assemble the input shaft?

  1. If the needle bearings (A) were removed from the top cover, replace them with new bearings. Press the top bearing flush with the cover. Press the lower bearing from inside of the cover, to a depth of 3.43—3.81 mm (0.135—0.150 in.) below the surface. Put John Deere High-Temperature Grease between the needle bearings.
  2. Put the snap ring (B) and thrust washer (A) on the input shaft. Install the input shaft in the cover.
  3. Put the O-ring and thrust washer over the input shaft.
  4. Install the pinion gear (A) and snap ring.

How do you install the internal components of the transaxle?

  1. Install the differential assembly in the case.
  2. Install the gear assembly in the case.
  3. Make sure the tabs on the bushings (A) are rotated into the notch in the case.
  4. Install the shifter fan, putting the pins in the groove on the shifter collar.
  5. Put approximately 1.0 L (2.2 pt) of John Deere High-Temperature Grease around the gears in the transaxle case.
  6. Install the cover. Install and tighten the 17 cap screws to 12 N·m (100 lb-in).
  7. Install the detent ball, spring, and Allen-head screw. Tighten the screw one turn below flush with the case cover.

How do you install the external transaxle parts?

  1. Install the puck, disk, and brake assembly. Install and tighten the cap screws and washers.
  2. Install the neutral start switch.
  3. Install the key, transaxle drive sheave, and snap ring (A).
  4. Install the support and fasten with two self-tapping screws.

How do you install the transaxle?

  1. Position the transaxle under the tractor. Lift the transaxle and fasten with two U-bolts and nuts.
  2. Install the shift arm, washer, and cap screw.
  3. Install the two cap screws and nuts.
  4. Connect the brake linkage.
  5. Connect the wire (A) to the neutral start switch.
  6. Install the rear wheels.
  7. Adjust the traction drive belt.
  8. Adjust the brakes.
  9. Adjust the transmission control lever.

How do you adjust the transmission control lever on a 130, 160, and 180?

  1. Check the control lever adjustment. It must be centered in the neutral slot and 1 mm (0.040 in.) (A) from the edge of the slot.
  2. To adjust the lever, stop the engine and engage the park brake. Put the transmission control lever in the neutral position.
  3. Loosen the nuts (A). Use the nuts (A) to move the control lever forward or rearward to center the lever in the slot. Tighten the nuts (A).
  4. Loosen the nuts and turn the stop screw (B) until the control lever is 1 mm (0.040 in.) from the edge of the slot. Tighten the nuts.

What essential tools are needed for the hydrostatic transmission?

  • Seal Remover JDG213 – Used to remove the control shaft seal.
  • Seal Installer JDG214 – Used to install the control shaft seal.

What service equipment and tools are needed for the hydrostatic transmission?

  • 11/32-in. Drill Bit – Used to remove the dowel pin.
  • 5/16-18 NC Tap – Used to remove check valve bodies.

What other material is needed for the hydrostatic transmission?

  • SAE 30 Engine Oil – Used to fill the transmission.
  • SAE 90 Oil – Used to fill the differential.

What service parts kits are available for the hydrostatic transmission?

  • Motor Rotor Assembly Kit
  • Pump Rotor Assembly Kit

How do you remove the differential and hydrostatic transmission assembly on a 165, 175 and 185 (S.N. —475000)?

  1. Remove the mower.
  2. Put the transmission control lever in neutral.
  3. Drain the differential.
  4. Remove the rear wheels.
  5. Remove the fuel tank.
  6. Remove the heat shield.
  7. Remove the two nuts (A).
  8. Remove the transmission linkage and key (A) from the transmission.
  9. Loosen the three cap screws fastening the differential to the frame.
  10. Disconnect the brake linkage.
  11. Remove the four nuts fastening the differential to the frame.
  12. Remove the three cap screws and lower the differential and transmission assembly.
  13. Remove the traction drive belt from the transmission sheave. Remove the differential and transmission assembly.

How do you remove the transmission on an Eaton hydrostatic transmission?

  1. Remove the four cap screws and washers.
  2. Remove the transmission and gasket from the differential.

How do you replace the shaft seal on an Eaton hydrostatic transmission?

  1. Drain the transmission fluid.
  2. Remove the seal using the JDG213 Seal Remover.
  3. Lubricate the inner surface of the seal.
  4. Press the seal into position over the shaft with the JDG214 Seal Installer.

How do you remove and inspect the fan and sheave on an Eaton hydrostatic transmission?

  1. Remove and inspect the fan. Replace if damaged.
  2. Remove the two Allen-head screws and the transmission sheave.
  3. Inspect the sheave. Replace if damaged.

How do you disassemble the Eaton hydrostatic transmission?

  1. Drain the transmission at the reservoir. Remove the reservoir.
  2. Make a line across the cover and body to mark the correct positions for assembly.
  3. Remove the two Allen-head screws.
  4. Rotate the transmission so that the cover (A) is on top of the body (B). Loosen the cover. If the cover does not separate easily from the body, tap the cover and body with a plastic hammer.
  5. Lift the cover off the body.
  6. For proper ball positioning when assembling, put numbers on the rotor before removal.
  7. Use a wide rubber band to hold the pistons in place. Remove the rotor.
  8. Remove the retaining ring from the output shaft.
  9. Remove the gear (A).
  10. Remove the key (A) and spacer (B).
  11. Remove the output shaft ©.
  12. Remove the retaining ring.
  13. Remove the bearing (A) and oil seal (B).
  14. Remove the retaining ring from the input shaft.
  15. Remove the key (A) from the shaft.
  16. Remove the dump valve shaft.
  17. Remove the pivot pin assembly (A).
  18. For proper ball positioning when assembling, put numbers on the rotor before removal.
  19. Use a wide rubber band to hold the pistons in place. Remove the rotor.
  20. Remove the cam ring.
  21. Remove the button (A).
  22. Remove the input shaft and bearing assembly (B).
  23. Remove the oil seal ©.

How do you inspect the body and output shaft assembly of the Eaton hydrostatic transmission?

  1. Inspect the body (A). Replace if cracked or broken.
  2. Inspect the bearing (B) and output shaft ©. Replace if damaged.

How do I inspect the cover?

Inspect the cover, especially around the control shaft. Replace the cover if it is broken or cracked.

How do I inspect the input shaft assembly?

  • Inspect the retaining ring. Replace if damaged.
  • Inspect the input shaft and bearing.
  • If damage is found, remove the snap ring and remove the bearing from the shaft.
  • Install the bearing and a new snap ring on the shaft.

How do I inspect the control shaft assembly?

  • Remove and discard the oil seal from the control shaft assembly.
  • Inspect the dowel pin and control shaft. Replace if damaged.

How do I replace the control shaft assembly?

  1. Measure the distance between the center of the dowel pin and the end of the control shaft.
  2. Use this dimension to locate the dowel pin from the outside of the cover.
  3. Drill an 11/32-in. diameter hole in line with the center of the control shaft and dowel pin.
  4. Remove the dowel pin using a punch through the drilled hole.
  5. Remove the retaining ring and washer.
  6. Remove the control shaft.
  7. Install a 1/8-in. countersunk hex-head pipe plug in the drilled hole. The pipe plug must be even with the outside surface of the case.
  8. Lubricate the new control shaft and install it in the cover.
  9. Install the washer and retaining ring.
  10. Position the keyway as shown before installing the doweling pin.
  11. Install a new dowel pin through the shaft until 28.6 mm (1.13 in.) of the pin extends above the shaft.
  12. Install a new oil seal.

How do I inspect the rotor assemblies?

  1. Inspect for burrs or scoring in the bore.
  2. Inspect the ball pistons and springs.
  3. Check the rotor bushings for wear and scoring.
  4. Apply a thin film of oil on the ball pistons. Put the corresponding ball piston in the numbered hole of the rotor. Close the inner port of the rotor with a finger. Push on the ball with a thumb to ensure it feels spongy and does not stick.
  5. Repeat Step 4 for each ball piston. If one ball in the rotor set rolls or does not float in the rotor, replace the complete rotor assembly.
  6. If any irregularities are found, replace the rotor assembly.
  7. Install the springs and ball pistons in their original positions. Secure with a wide rubber band.

How do I inspect the pump race?

  1. Inspect the line where the ball pistons contact the pump race.
  2. If irregularities are found, replace the race and install it flush to 0.25 mm (0.010 in.) recessed from the edge of the cam.

How do I inspect the motor race?

Inspect the line where the ball pistons contact the motor race. Replace the race if it is not smooth or free of irregularities.

How do I inspect the pivot pin assembly?

  1. Remove and inspect the dump valve bracket and spring assembly. Replace if damaged.
  2. Inspect both pivot pin assembly journals. Replace the assembly if any irregularities are found.
  3. Inspect the dampening pistons. Replace if scored.
  4. Shake the pivot pin assembly to inspect the check balls. If the check balls do not rattle, the check valve assembly is faulty. Replace the valve assembly.

How do I replace the dampening pistons?

  1. Firmly tap the outside edge of the piston pin assembly on a work surface to dislodge the pistons.
  2. If the piston did not come out, see adhesive to fasten cap screw to it and pull the piston from the bore.
  3. Remove the back-up rings and O-rings from the pistons.
  4. Install new back-up rings and O-rings on the pistons.
  5. Lubricate the outer surface of the pistons and push the pistons into the bores with the smooth face up.

How do I replace the check valve assembly?

  1. Remove the coil pin.
  2. Tap holes in the check valve bodies using a 5/16-18 NC tap.
  3. Pull the check valve bodies out using a long cap screw or threaded puller.
  4. Remove and inspect the check balls and retaining rings. Replace any defective parts.
  5. Install the retaining rings and check balls.
  6. Install new check valve bodies, ensuring to allow for coil pin clearance.
  7. Install the coil pin.
  8. Install the dump valve bracket and springs.

How do I assemble the transmission?

  1. Lubricate the inner surface of the new seal using clean lubricant and install the seal.
  2. Install the input shaft and bearing assembly.
  3. Install the button.
  4. Install the cam ring.
  5. Check the cam ring movement to ensure it moves freely from stop to stop. If binding occurs at either stop, rotate the cam ring insert 180˚ and check movement again.
  6. Align the internal spline of the pump rotor with the external spline on the input shaft. Install the rotor and remove the rubber band.
  7. Install the pivot pin assembly.
  8. Install the dump valve shaft and tighten to 4 N·m (30 lb-in.).
  9. Install the retaining ring to the cover.
  10. Lubricate the inner surface of the new seal using clean lubricant. Install the seal with the rubber lip toward the counterbore in the body.
  11. Install the output shaft in the body so that the cross pin fits into the groove.
  12. Support the output shaft from below so that the cross pin of the shaft is tight against the body.
  13. Install the bearing and retaining ring.
  14. Check that the output shaft rotates freely by hand. If not, recheck the installation.
  15. Install the washer.
  16. Install the key in the shaft.
  17. Install the gear and retaining ring.
  18. Align the slot in the rotor assembly with the cross pin on the output shaft.
  19. Install the rotor assembly and remove the rubber band, if used.
  20. Install the cover to the body.
  21. Align the body and cover marks.
  22. Install two Allen-head screws and tighten to 20 N·m (177 lb-in.).
  23. Install a new seal ring to the oil reservoir recess in the cover.
  24. Install the oil reservoir and tighten to 14 N·m (124 lb-in.).

How do I install the fan and sheave?

  1. Install the sheave to the input shaft and fasten with two Allen-head screws.
  2. Install the fan on the input shaft.

How do I fill the transmission reservoir?

  1. Remove the plug and reservoir cap.
  2. Fill the reservoir with the recommended engine oil until fluid flows from the vent.
  3. Rotate both input and output shafts to release air trapped in the transmission. Add oil to the reservoir until oil re-appears at the vent, then install and tighten the plug.
  4. Refill the reservoir to the cold level FULL mark on units with a dipstick or until the oil is 140 mm (5.50 in.) below the top of the reservoir. Replace the reservoir cap.

How do I install the transmission?

  1. Install the gasket and transmission on the differential.
  2. Install four cap screws and washers.
  3. Fill the differential assembly with 0.7 L (1.5 pt) of SAE 90 oil.

How do I install the differential and hydrostatic transmission assembly?

  1. Position the differential and hydrostatic transmission assembly under the frame. Install the traction drive belt on the transmission sheave.
  2. Lift the right side of the rear axle and install the strap, nuts, and washers.
  3. Lift the left side of the rear axle and install the strap, nuts, and washers.
  4. Install three washers and cap screws. Tighten all differential and hydrostatic transmission mounting hardware.
  5. Connect the brake linkage.
  6. Install the key and transmission linkage.
  7. Tighten the nuts.
  8. Install the heat shield.
  9. Install the fuel tank.
  10. Install the rear wheels.
  11. Remove blocking from the tractor.
  12. Check the oil level in the differential. Oil should be a short distance below the plug hole.
  13. Adjust the transmission.
  14. Install the mower.

How do I separate the differential and transmission?

  1. Clean the transaxle assembly and drain the oil.
  2. Remove the fan, hose, drain plug, tow linkage, transmission and sheave.

How do I assemble the differential and transmission?

  1. Install the fan, hose, drain plug, tow linkage, transmission and sheave.
  2. Tighten the drain plug to 15 N·m (130 lb-in).
  3. After installing the complete transaxle into the machine, bleed the hydrostatic system.

How do I disassemble the transmission?

  1. Remove the center section from the transmission housing assembly.
  2. Remove the gasket.
  3. Remove the check valve (2 used), plug with packing (2 used), plug with packing, gasket, transmission housing assembly, bearing, dowel pin (2 used), needle bearing, by-pass valve assembly, cap screw (4 used), name plate, seal and center section from the center section.
  4. Remove the motor cylinder block and shaft assembly from the housing assembly.
  5. Remove the pump cylinder block and shaft assembly.
  6. Remove the plug with packing (3 used), filter assembly, fitting with packing, housing assembly, swashplate, cradle bearing (2 used), seal, bearing, trunion arm, and slot guide from the housing assembly.

How do I assemble the transmission?

  1. Install the plug with packing (3 used), filter assembly, fitting with packing, housing assembly, swashplate, cradle bearing (2 used), seal, bearing, trunion arm, and slot guide into housing assembly.
  2. Install the pump cylinder block and shaft assembly into the housing assembly.
  3. Install the motor cylinder block and shaft assembly.
  4. Install the check valve (2 used), plug with packing (2 used), plug with packing, gasket, transmission housing assembly, bearing, dowel pin (2 used), needle bearing, by-pass valve assembly, cap screw (4 used), name plate, seal and center section into the center section.
  5. Install new gasket.
  6. Install the center section onto the transmission housing assembly and tighten the cap screws to 17 N·m (150 lb-in).

How do I bleed the hydrostatic system?

  1. Fill the case and reservoir to the FULL line. The transmission oil capacity is approximately 850 cc (28.7 fl oz).
  2. Lift the rear wheels off the ground using a hoist. Put jackstands under the frame. Start the engine and idle it for two or three minutes.
  3. Apply full forward for 10 seconds.
  4. Bring to NEUTRAL for five seconds.
  5. Push the tow (bleed) valve for two seconds.
  6. Apply full forward for 15 seconds.
  7. Stop the engine and fill the reservoir to the FULL line.
  8. Start the engine and idle it. Put the transmission in NEUTRAL for 10 seconds.
  9. Apply full forward for 10 seconds and return to NEUTRAL.
  10. Stop the engine and fill the reservoir to the FULL line.
  11. Repeat Steps 1—10 if necessary.

How do I disassemble the differential?

  1. Remove the brake assembly.
  2. Remove the cap screws and cover. Remove the case gasket.
  3. Remove the brake shaft and thrust washer.
  4. Remove the thrust washer and gear from the brake shaft.
  5. Inspect the surfaces of the thrust washers and brake shaft for wear. Inspect the gear teeth and splines for wear or damage. Replace parts if necessary.
  6. Remove the output shaft.
  7. Remove the thrust washer and spacer.
  8. Remove the output gear using a plastic hammer.
  9. Inspect the surfaces of the thrust washer and output shaft for wear. Inspect the gear teeth and splines for wear or damage. Replace parts if necessary.
  10. Remove the differential and axle assembly.

How do I disassemble the differential and axle?

  1. Remove the cap screws and separate the axles from the ring gear.
  2. Remove the pinion blocks, pinion gears, and shaft from the ring gear.
  3. Remove the snap ring.
  4. Remove the bevel gear, thrust washer, differential carrier, and two thrust washers from each axle.
  5. Inspect the thrust washers, differential carrier, and axle for wear. Inspect the bevel gear for wear or damage. Replace parts if necessary.

How do I inspect the differential case?

  1. Inspect the case and cover for cracks, stripped threads, and marred sealing surfaces. Replace if necessary.
  2. Inspect the needle bearings and seals for wear. If seals or bearings are removed, press them out from inside of case and replace with new parts.
  3. Inspect the bushings for wear. Replace parts if necessary.
  4. Inspect the differential carrier-to-case thrust surface for wear. If the case thrust surface is worn more than 1.02 mm (0.040 in.), replace the case.

How do I assemble the differential and axle?

  1. Install the washers, carrier, washer and gear on both axles and install the snap ring.
  2. Install the pinion gears and pinion blocks on the shaft. Install the pinion assembly into the ring gear.
  3. Install the assembled ring gear between the axles and tighten the cap screws to 9.5 N·m (84 lb-in).

How do I assemble the differential?

  1. Install the differential and axle assembly.
  2. Install the output gear on the ground shaft using a plastic hammer.
  3. Install the spacer and thrust washer on the output shaft.
  4. Install the output shaft assembly.
  5. Assemble the brake shaft and install the brake shaft assembly by putting the rear thrust washer into position first.
  6. Install the new gasket and cover and tighten the cap screws to 11 N·m (97 lb-in).
  7. Install the brake assembly.

How do I install the hydrostatic differential?

  1. Install the transmission on the hydrostatic differential.
  2. Remove the fill plug and add 0.7 L (1.5 pt) of SAE 90 oil to the differential. Check for leaks.
  3. Install the differential and transmission assembly on the tractor.

How do I disassemble the transmission?

  1. Remove the cover and idler gear assembly.
  2. Measure the idler gear and idler shaft.
  3. Remove the motor gear assembly and brake assembly.
  4. Measure the brake components.
  5. Remove the left and right axle assemblies.
  6. Measure the axle housings.
  7. Remove the pinion drive assembly.
  8. Measure the counter gear and pinion drive.
  9. Remove the differential assembly.
  10. Measure the pinion shaft, pinion gear and differential case.

How do I assemble the differential?

  1. Clean the screw threads using clean and cure primer and apply thread lock and sealer (medium strength) on the cap screw threads.
  2. Assemble the differential assembly.
  3. Tighten the cap screws to 26 N·m (230 lb-in).
  4. Assemble the pinion drive assembly (except items C, K and L).
  5. Tighten the tapping bolts to:
    • New Case: 29 N·m (260 lb-in)
    • Used Case: 25 N·m (221 lb-in)
  6. Assemble and install the left and right axle assemblies.
  7. Tighten the tapping bolts to:
    • New Case: 29 N·m (22 lb-ft)
    • Used Case: 25 N·m (221 lb-in)
  8. Measure the ring gear to pinion drive gear backlash at the key groove. The backlash specification is 0.15—0.30 mm (0.006—0.012 in).
  9. Adjust the backlash by adding or subtracting left axle shaft shims.
  10. Install the brake assembly and motor gear assembly.
  11. Tighten the tapping bolts to:
    • New Case: 29 N·m (22 lb-ft)
    • Used Case: 25 N·m (221 lb-in)
  12. Assemble the idler gear assembly. Oil grooves in the idler gear go toward the cover.
  13. Apply flexible sealant or an equivalent on the gasket surface of the differential cover and case.
  14. Install the cover and tapping bolts and tighten the tapping bolts to:
    • New Case: 29 N·m (22 lb-ft)
    • Used Case: 25 N·m (221 lb-in)

How do I assemble the differential and transmission?

  1. Install the fan, hose, drain plug, tow linkage, transmission and sheave.
  2. Tighten the drain plug to 15 N·m (130 lb-in).
  3. After installing the complete transaxle into the machine, bleed the hydrostatic system.

How do I remove the steering wheel and shaft?

  1. Remove the lock nut and washer.
  2. Drive out the pin and remove the steering wheel.
  3. Remove the pedestal shroud.
  4. Disconnect all wires and indicator lights from the dash.
  5. Loosen two nuts and remove two nuts.
  6. Lift the dash and remove the cotter pin and bearing.
  7. Remove the cotter pin.
  8. Drive the shaft up through the pinion gear and remove the gear and washer.
  9. Remove the bearing by aligning the sector gear teeth with the outside diameter of the bearing.
  10. Lift the shaft and remove the washers and spring.
  11. Remove the cotter pin and remove the shaft.

How do I remove the steering gear support?

  1. Disconnect the drag link.
  2. Remove two nuts from the support.
  3. Remove the sector gear support.

How do I disassemble and clean the sector gear support?

  1. Remove the cotter pin, washers, spring, and support.
  2. Mark the sector gear and sector shaft for alignment for ease of assembly.
  3. Remove the bearing, washer and sector gear.
  4. Remove the cotter pin to remove the steering sector support and bearing.
  5. Remove grease and clean the parts in solvent and dry the parts.

How do I inspect and repair the steering system?

  1. Inspect the steering shaft bushings for wear or cracks.
  2. Inspect the springs for damage.
  3. Inspect the steering shaft and sector shaft for wear or bent conditions. Inspect the splines for wear.
  4. Inspect the pinion gear and sector gear for worn, broken or damaged teeth and wear on inside diameters.
  5. Inspect the support for cracks.
  6. Inspect the sector shaft bearings for wear or cracks.

How do I assemble the sector gear support?

  1. Install the bearing and sector gear support on the sector shaft.
  2. Install the cotter pin, sector gear, washer, and bearing on the sector shaft, ensuring the mark on the gear aligns with the mark on the shaft.
  3. Install the sector gear support, washers, spring and cotter pin on the sector shaft.

How do I install the steering gear support?

  1. Install the steering gear support.
  2. Install and tighten two nuts.
  3. Connect the drag link.

How do I install the steering wheel and shaft?

  1. Install the shaft in the pedestal.
  2. Install the cotter pin, washers and spring on the steering shaft.
  3. Install the bushing and cotter pin.
  4. Install the steering wheel. Drive the pin through the wheel and shaft. Install and tighten the washer and nut.
  5. Install the steering shaft bushing.
  6. Put the logo on the steering wheel in a horizontal position and pull down on the steering wheel. Install the washer and pinion gear, making sure the dot on the pinion gear is in alignment with the dot on the sector gear.
  7. Install the cotter pin.
  8. Connect the drag link.
  9. Put the dash in position and install the nuts and tighten the nuts.
  10. Connect all dash wires and indicator lights.
  11. Install the pedestal shroud.
  12. Adjust the steering.

How do I adjust the steering?

  1. Make sure the dots on the pinion gear and sector gear are aligned. If the wheels are straight forward no further adjustment is required, otherwise continue with the following steps.
  2. Disconnect the drag link from the spindle.
  3. With dots still aligned, put the wheels straight forward.
  4. Loosen the nut and turn the ball joint until the drag link fits easily into the spindle without moving the wheels.
  5. Tighten the nut against the ball joint and connect the drag link to the spindle.

How do you inspect and repair front wheel and axle assemblies?

  1. Inspect wheel bearings for wear. If the wheel wobbles when rotated or bearings are visually worn, replace bearings.
    • a. Remove bearings from the wheel by driving them out with a punch.
    • b. Put multi-purpose grease on new bearings.
    • c. Drive new bearings into the wheel hub with driver.
  2. Inspect the tie rod and drag link for a bent condition. Inspect ball joints for wear and free movement. Replace any worn or bent parts.
  3. Put the spindle in the axle and check the spindle bore for wear or being out-of-round. Replace worn parts.
  4. Apply multi-purpose grease on spindles before installing in axle.
  5. Grease wheel bearings and pack cavity between bearings with multi-purpose grease and put a small amount on axle.

How do you install the front axle?

  1. Install the axle under the tractor. Match the boss on the pivot anchors with holes in the frame.
  2. Turn the pivot anchors against the frame and align the cap screw holes.
  3. Install and tighten two cap screws.
  4. Install the muffler guard with two cap screws.
  5. Install the muffler.
  6. Install the hood with two cap screws, spacers, washers, and nuts.
  7. If necessary, adjust the steering.

How do you remove the brake assembly on models 130, 160, and 180?

  1. Put blocks under the tractor frame and remove the right rear wheel.
  2. Disconnect the brake linkage.
  3. Remove two cap screws and remove the brake assembly.
  4. Slide the disk off the shaft. Remove the pad from behind the disk.

NOTE: The brake assembly consists of loose parts. Do not lose parts when removing the assembly.

How do you inspect and repair the brake assembly on models 130, 160 and 180?

  1. Inspect pads and plate for wear or damage.
  2. Inspect the disk for wear or cracks.
  3. Replace parts as necessary.

How do you install the brake assembly on models 130, 160, and 180?

  1. Put LUBRIPLATE on the brake shaft.
  2. Install the pad and disk with the hub out.
  3. Install the brake assembly. Install and tighten two cap screws.
  4. Connect the brake linkage.
  5. Install the right rear wheel.
  6. Adjust the brakes.

IMPORTANT: Brake pads and disk must be free of grease and oil.

How do you remove the brake assembly on all 165, 175 and 185 (S.N. —475000)?

  1. Put blocks under the tractor frame and remove the left rear wheels.
  2. Disconnect the brake linkage.
  3. Remove two cap screws and remove the brake assembly.
  4. Slide the disk against the frame and remove the rear pad.

NOTE: The brake assembly consists of loose parts. Do not lose parts. NOTE: To remove the brake disk, the transmission must be lowered. Brake pads can be removed without lowering the transmission. NOTE: For 185 (S.N. 475001— ), see Section 50, Group 26.

How do you inspect and repair the brake assembly on all 165, 175 and 185 (S.N. —475000)?

  1. Inspect pads and plate for wear or damage.
  2. Inspect disk for wear or cracks.
  3. Replace parts as necessary.

NOTE: For 185 (S.N. 475001— ), see Section 50, Group 26.

How do you install the brake assembly on all 165, 175 and 185 (S.N. —475000)?

  1. Put Lubriplate on the brake shaft.
  2. Install the pad and slide disk towards the differential.
  3. Install the brake assembly. Install and tighten two cap screws.
  4. Connect the brake linkage.
  5. Install the left rear wheel.
  6. Adjust the brakes.

NOTE: For 185 (S.N. 475001— ), see Section 50, Group 26. IMPORTANT: Brake pads and disk must be free of grease and oil.

How do you adjust the brakes on all 165, 175 and 185 (S.N. —475000)?

  1. Make sure the park brake is disengaged.
  2. With a feeler gauge, inspect the clearance between the pad and disk. Clearance should be 0.50 mm (0.020 in.).
  3. Turn the nut to obtain proper clearance.

NOTE: For 185 (S.N. 475001— ), see Section 250-10.

How do you remove a mower spindle?

  1. Remove the mower from the tractor.
  2. On 38 and 46-inch mowers, remove the mower drive belt.
  3. Remove the nut, mower drive sheave, and key. On 30-inch mower, remove two spacers.
  4. Remove the cap screw and washer to remove the blade.
  5. Remove nuts and bolts.
  6. Remove the spindle assembly.

NOTE: Mower spindles normally require no lubrication or service. If the spindle must be disassembled, be sure to lubricate and torque parts as instructed.

How do you service a 30-inch mower spindle?

  1. Press the spindle shaft down through the hub.
  2. Remove the lower snap ring. Press on the inner and outer rings of the upper bearing and remove the lower bearing and spacer.
  3. Turn the hub over and press the upper bearing out.
  4. Inspect bearings, shaft, spacer, and hub for wear or damage. Replace parts if necessary.
  5. Position the lower bearing in the hub. Make sure the land riding seal of bearing is away from the hub. Press the bearing against the upper snap ring.
  6. Put the spacer into position. Fill the area around the spacer 50 to 60 percent full of SAE multipurpose grease.
  7. Support the lower bearing and put the upper bearing into position. Make sure the land riding seal of the bearing is away from the hub. Press the upper bearing against the spacer, keeping the spacer in position.
  8. Install the lower snap ring. Fill the area around the snap ring 50 to 60 percent full of SAE multipurpose grease.
  9. Support the inner ring of the upper bearing and press the spindle shaft into the hub.
  10. Check the rolling torque of the spindle. The maximum allowable torque is 0.07 N·m (0.6 lb-in.).

How do you service a 38-inch mower spindle (S.N. —420000)?

  1. Press the spindle shaft down through the hub.
  2. Remove the lower snap ring. Press on the inner and outer rings of the upper bearing and remove the lower bearing and spacer.
  3. Turn the hub over and press the upper bearing out.
  4. Inspect bearings, shaft, spacer, and hub for wear or damage. Replace parts if necessary.
  5. Position the lower bearing in the hub. Make sure the land riding seal of bearing is away from the hub. Press the bearing against the upper snap ring.
  6. Put the spacer into position. Fill the area around the spacer 50—60 percent full of SAE multipurpose Grease.
  7. Support the lower bearing and put the upper bearing into position. Make sure the land riding seal of the bearing is away from the hub. Press the upper bearing against the spacer, keeping the spacer in position.
  8. Install the lower snap ring. Fill the area around the snap ring 50—60 percent full of SAE multipurpose grease.
  9. Support the inner ring of the upper bearing and press the spindle shaft into the hub.
  10. Check the rolling torque of the spindle. Maximum allowable torque is 0.07 N·m (0.60 lb-in.).

NOTE: There are two spindles on the 38-inch mower.

How do you disassemble the spindle on a 38-inch mower (S.N. 420001— )?

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How do you assemble the spindle on a 38-inch mower (S.N. 420001— )?

  1. Clean threads on the shaft and hub using clean and cure primer. Apply thread lock and sealer (medium strength) on threads. Install the hub on the shaft.
  2. Install the bearing to the bottom of the bore in the housing.
  3. Install the spacer.
  4. Install the bearing to the bottom of the bore in the housing.
  5. Align the internal spacer with the shaft. Press in the shaft until it bottoms.
  6. Press the housing onto the shaft using a deep-well socket or piece of pipe until the shaft assembly bottoms on the lower bearing.
  7. Install the key, sheave, and lock nut. Tighten the lock nut to 140 N·m (103 lb-ft).
  8. Fill the spindle housing completely with John Deere multipurpose grease or equivalent.

IMPORTANT: To prevent bearing damage, press only on the inner race.

How do you service a 46-inch mower spindle?

  1. Press the spindle shaft down through the housing.
  2. Remove the lower snap ring. Press on the inner and outer rings of the upper bearing and remove the lower bearing and spacer.
  3. Turn the hub over and press the upper bearing out.
  4. Inspect bearings, shaft, spacer, and hub for wear or damage. Replace parts if necessary.
  5. Position the lower bearing in the hub. Make sure the land riding seal of bearing is away from the hub. Press the bearing against the upper snap ring.
  6. Put the spacer into position. Fill the area around the spacer 50 to 60 percent full of SAE multipurpose grease.
  7. Support the lower bearing and put the upper bearing into position. Make sure the land riding seal of the bearing is away from the hub. Press the upper bearing against the spacer, keeping the spacer in position.
  8. Install the lower snap ring. Fill the area around the snap ring 50 to 60 percent full of SAE multipurpose grease.
  9. Support the inner ring of the upper bearing and press the spindle shaft into the hub.
  10. Check the rolling torque of the spindle. Maximum allowable torque is 0.07 N·m (0.6 lb-in.).

NOTE: There are three spindles on the 46-inch mower.

How do you install a mower spindle?

  1. Install the spindle assembly in the mower deck. Install and tighten nuts and bolts to 25 N·m (221 lb-in).
  2. Install the blade, washer, and cap screw. Tighten the cap screw to 75 N·m (55 lb-ft).
  3. On the 30-inch mower, install two spacers. Install the key, mower drive sheave, and nut. Tighten the nut to 125 N·m (92 lb-ft).
  4. Install the mower drive belt for 38 and 46-inch mowers.
  5. Install the mower on the tractor.

How do you remove the lift lever assembly?

  1. Remove the mower.
  2. Remove the pedestal shroud, control knobs, and platform.
  3. Relieve spring tension by rotating the bracket down.
  4. Remove the spring pin and washer.
  5. Remove the bracket and spring.
  6. Remove the snap rings from both ends of the lift shaft.
  7. Loosen all nuts on the left plate.
  8. Remove the front cap screw and nut from the latch.
  9. Raise the lift lever. Remove the rear nut to remove the cap screw and lift latch.
  10. Push the lift shaft to the right side of the tractor and pull the left plate away from the frame. Remove the lift lever assembly.

How do you disassemble the lift lever assembly?

  1. Pull or cut the grip off the handle.
  2. Turn the button counterclockwise to remove it.
  3. Remove the spring and washer.
  4. Remove the cap screw, spacer, and washer.
  5. Pull the latch hook and rod from the lift handle.
  6. Inspect parts. Replace damaged or worn parts.

How do you assemble the lift lever assembly?

  1. Install the rod and latch hook in the lift handle.
  2. Install the washer, spacer, and cap screw. Tighten the cap screw.
  3. Install the washer and spring.
  4. Install and tighten the push button.
  5. Moisten the inside of the handle with water. Push the grip on the handle.

How do you install the lift lever assembly?

  1. Install the lift shaft under the wiring harness and fuel line. Push the shaft to the right and put it in the mounting holes.
  2. Raise the lift lever and install the latch and rear cap screw. Install the nut on the cap screw.
  3. Install the front cap screw and nut.
  4. Tighten all nuts on the left plate.
  5. Install the right and left snap rings.
  6. Install the lift spring and bracket.
  7. Install the washer and spring pin. Rotate the bracket to the horizontal position.
  8. Install the platform, control knobs, and pedestal shroud.
  9. Install the mower.

What should you do before you start the machine operational checkout?

This operational diagnostics procedure is designed for you to perform a quick check of the machine in a step-by-step method.

It is recommended to perform these checks of the entire machine. These checks refer you to a specific system on the machine for a more detailed step-by-step method of resolving machine problems. These procedures also provide you with a method to evaluate trade-in equipment and perform an annual checkout.

A large majority of typical machine problems can be resolved using operational diagnostics with your sense of look, listen, and feel.

Perform these checks on a level surface. No special tools or equipment are required.

Begin with step one and read from left to right. Read the step completely before performing the check.

Do the entire procedure before continuing on to another section and correction of the indicated problem. Once the machine checkout is complete, turn to the appropriate sections in this manual.

How do you perform a machine operational checkout?

  • Dash Lamp Check:
    • Transmission in neutral.
    • Key switch ON.
    • LOOK: Oil pressure OK: Dash lamp and battery discharge lamp should NOT be on (if equipped).
      • OK: GO TO ‘TRANSMISSION NEUTRAL START CHECK.
      • NOT OK: PTO switch OFF. GO TO SECTION 240.
        • NOTE: For tractors not equipped with indicator lamps, GO TO ‘TRANSMISSION NEUTRAL START CHECK.
        • NOTE: Low fuel lamp will only come on if the fuel level is low.
  • TRANSMISSION NEUTRAL START CHECK:
    • Put the hydrostatic lever in neutral slow forward, or gear selector level in first gear forward.
    • Operator on seat.
    • Turn key switch to START.
    • LISTEN: Starter must NOT crank the engine.
      • OK: GO TO Æ‘PTO/SAFETY START CHECK.
      • NOT OK: CHECK defective, tractor will start and move forward. GO TO SECTION 240.
  • PTO/SAFETY START CHECK:
    • Turn PTO switch ON.
    • Operator on seat.
    • Fully depress the brake pedal.
    • Turn key switch to START.
    • LISTEN: Starter must NOT crank the engine.
      • OK: GO TO ÅÆSTARTING CIRCUIT CHECK FOR HYDROSTATIC TRACTORS.
      • NOT OK: defective, tractor will START. GO TO SECTION 240.
  • STARTING CIRCUIT CHECK FOR HYDROSTATIC TRACTORS:
    • Sit on seat.
    • Fully depress the brake pedal.
    • Turn key switch to START.
    • LISTEN: Starter must crank engine. The engine must start.
      • OK: GO TO Ö4aSTARTING CIRCUIT CHECK FOR GEAR TRACTORS.
      • NOT OK: GO TO SECTION 240.
  • STARTING CIRCUIT CHECK FOR GEAR TRACTORS:
    • Transmission in neutral.
    • Park brake set.
    • Turn key switch to START.
    • LISTEN: Starter must crank engine. The engine must start.
      • OK: GO TO ÒÖINDICATOR LAMP RUNNING CHECK.
      • NOT OK: GO TO SECTION 240.
  • INDICATOR LAMP RUNNING CHECK:
    • Start engine and run at full throttle.
    • LOOK: Battery discharge lamp must be OFF.
      • OK: GO TO ÕÒTHROTTLE AND CHOKE LEVER CHECK.
      • NOT OK: GO TO SECTION 240.
        • NOTE: If not equipped with indicator lamps, GO TO ÒTHROTTLE AND CHOKE LEVER CHECK.
        • Oil pressure lamp must be OFF.
  • THROTTLE AND CHOKE LEVER CHECK:
    • LISTEN: Engine must accelerate smoothly without hesitation.
    • Push throttle lever past detent to choke position, then return to fast idle.
      • OK: GO TO ÕBRAKE PEDAL LOCK CHECK.
      • NOT OK: CHECK GO TO SECTION 220.
        • Engine must falter, then resume speed.
  • BRAKE PEDAL LOCK CHECK:
    • Move lever (A) down toward lock position.
    • GEAR TRACTORS: Depress both brake and clutch pedals together.
    • HYDROSTATIC TRACTORS: Depress brake pedal fully.
    • LOOK: Pedals must stay engaged.
      • OK: GO TO ÚPTO CHECK OFF.
      • NOT OK: Depress pedals fully. Pull lever up to unlock position and release pedals. GO TO SECTION 250.
        • Pedals must return to normal position.
  • PTO CHECK OFF:
    • Sit on a seat.
    • Engine OFF.
    • Turn PTO switch ON.
    • Turn key switch ON.
    • LISTEN: PTO must NOT click ON.
      • OK: GO TO 1ÔÜSEAT SWITCH CHECK FOR PTO AND IGNITION.
      • NOT OK: GO TO SECTION 240.
  • SEAT SWITCH CHECK FOR PTO AND IGNITION:
    • Sit on seat.
    • Run engine at half throttle.
    • Turn PTO switch ON.
    • Raise up off seat.
    • LISTEN: Engine must stop.
      • OK: GO TO 1ÔTRANSMISSION FORWARD-REVERSE CHECK.
      • NOT OK: GO TO SECTION 240.
  • TRANSMISSION FORWARD-REVERSE CHECK:
    • HYDROSTATIC TRACTORS: Move lever to full forward and reverse.
    • GEAR TRACTORS: Shift through all forward gears and reverse.
      • FEEL: Tractor must accelerate smoothly in all speeds forward and reverse.
        • GEAR TRACTORS OK: Checkout procedure complete.
        • HYDROSTATIC TRACTORS OK: GO TO 1!TRANSMISSION NEUTRAL CHECK FOR HYDROSTATIC TRACTORS ONLY.
      • NOT OK: GO TO SECTION 250.
  • TRANSMISSION NEUTRAL CHECK FOR HYDROSTATIC TRACTORS ONLY:
    • Run engine about 3/4 throttle.
    • Brake OFF.
    • Leave transmission lever in neutral.
    • LOOK: Tractor must not creep forward or reverse.
      • OK: GO TO 1@1!BRAKE NEUTRAL RETURN CHECK FOR HYDROSTATIC TRACTORS ONLY.
      • NOT OK: GO TO SECTION 250.
  • BRAKE NEUTRAL RETURN CHECK FOR HYDROSTATIC TRACTORS ONLY:
    • Engine off.
    • Depress brake pedal firmly.
    • Transmission lever full forward.
    • LOOK: Transmission lever must return to neutral, tractor must stop.
      • OK: GO TO 1#HEADLIGHT CHECK (175, 180, and 185 Tractors).
      • NOT OK: GO TO SECTION 250.
  • HEADLIGHT CHECK:
    • Key switch ON.
    • Pull light switch out.
    • LOOK: Headlights must be ON.
      • OK: Checkout procedure complete. Machine OK.
      • NOT OK: GO TO SECTION 240.

What should you do before you start the engine system checkout?

Always begin with this group to identify a failure in the engine system. The step-by-step procedure will provide you with a quick check of the system. No tools are required to perform these checks.

Always start with the first step and follow the sequence from left to right. Read each step completely before performing the check.

This procedure is designed as a quick check of the system. While performing the check, concentrate only on the check you are performing and disregard signals from unrelated components.

How do you perform the engine system checkout?

  • ENGINE OIL LEAK check:
    • Inspect for external engine oil leakage from oil pressure sensor, oil filter, oil filter adapter, engine base gasket, dipstick tube, and drain plug.
      • OK: GO TO ‘FUEL LEAK CHECK.
      • NOT OK: Repair or replace, then Check engine oil level, condition, and optional viscosity, and GO TO ‘FUEL LEAK CHECK.
        • NOTE: Oil filter is not used on the 130 Tractor and optional on 160 and 165 Tractors and early model 175.
  • FUEL LEAK check:
    • Inspect for external fuel leakage from fuel tank, fuel pump, fuel filter, carburetor, fuel lines, and fittings.
      • OK: GO TO Æ‘AIR CLEANER AND AIR INTAKE SCREEN check.
      • NOT OK: Repair or replace, then GO TO: Æ‘AIR CLEANER AND AIR INTAKE SCREEN check.
  • AIR CLEANER AND AIR INTAKE SCREEN check:
    • Inspect precleaner, filter element, and air intake screen for debris or a plugged condition.
      • OK: GO TO ÅÆTHROTTLE LEVER check.
      • NOT OK: Clean or replace, then GO TO ÅÆTHROTTLE LEVER check.
        • Remove air cleaner cover.
  • THROTTLE LEVER check:
    • Move throttle lever from low idle position to high idle position.
      • FEEL: Throttle lever must move smoothly from low to high idle position with slight friction.
        • OK: GO TO ÖÅENGINE START check.
        • NOT OK: GO TO ‘, GROUP 10.
      • LOOK: Throttle lever must contact stop in the dash at high idle position.
  • ENGINE START check:
    • Put PTO switch in OFF position.
    • Move throttle lever to choke position.
    • Put transmission lever in neutral position.
    • Depress brake pedal.
    • Turn key switch to START position.
    • Starter must crank engine. The engine must start.
      • OK: GO TO ÒÖCHOKE LINKAGE check.
      • NOT OK: GO TO ;, GROUP 10.
  • CHOKE LINKAGE check:
    • Run engine at half throttle.
    • Quickly move throttle lever to choke position, then to run position.
      • LISTEN: Engine must falter, then resume speed.
        • OK: GO TO ÕÒENGINE OIL PRESSURE check.
        • NOT OK: GO TO Æ, GROUP 10.
  • ENGINE OIL PRESSURE check:
    • Run engine at full throttle.
    • LOOK: Engine oil must not leak from oil filter or adapter gaskets. Exhaust smoke must not be blue.
      • OK: GO TO ÜÚENGINE PERFORMANCE check.
      • NOT OK: GO TO Ü, GROUP 10.
        • Oil pressure lamp must go OFF.
        • NOTE: This check is only for late model 175’s and all 180 and 185 Tractors.
  • ENGINE PERFORMANCE check:
    • Move throttle lever from slow idle to fast idle position.
    • LISTEN: Engine must accelerate smoothly, without hesitation.
      • OK: GO TO ÜENGINE LOAD PERFORMANCE check.
      • NOT OK: GO TO ;, GROUP 10.
        • Engine must not make any abnormal sounds or backfire.
        • Exhaust gas must be clear.
      • LISTEN: Governor must hold the engine at a constant rpm and not surge.
  • ENGINE LOAD PERFORMANCE check:
    • Engage PTO lever.
    • Move throttle lever to fast idle position.
    • Mow tall grass, if possible, to load engine.
      • LOOK: Exhaust gas must be clear.
      • LISTEN: Governor must increase and decrease engine rpm smoothly to match load conditions.
        • OK: System normal.
        • NOT OK: GO TO ;, GROUP 10.
        • Engine must not make any abnormal sounds or backfire.

What should you do if you completed the checkout procedure and did not isolate a malfunction?

If you completed the checkout procedure and did not isolate a malfunction, the problem may be intermittent.

Try to duplicate the conditions of the malfunction identified by the operator.

REPEAT THE ENGINE SYSTEM CHECKOUT PROCEDURE IN THIS GROUP.

IF MALFUNCTION IS NOT IDENTIFIED AFTER REPEATING ENGINE SYSTEM CHECKOUT PROCEDURE: FACTORY ASSISTANCE IS AVAILABLE THROUGH THE DEALER TECHNICAL ASSISTANCE CENTER (DTAC).

What should you do before you start the engine system diagnosis?

Always perform the system checkout procedure in Group 05 BEFORE making any tests or adjustments in this group. The step-by-step procedures in this group provide you with the detailed diagnostic information you will need to isolate a malfunction. Basic diagnostic equipment is used.

It is assumed that you are familiar with the machine and its engine and fuel system components.

Engine rpm and temperature are critical in most engine tests. Be sure to follow test specifications carefully.

Always start with the first step and follow the sequence from left to right. Read each step completely before performing the check.

Upon completing a test or adjustment, check to see whether the problem is corrected by performing the checkout procedure in Group 05.

How do you identify the engine problem?

If the engine does not operate properly, select the appropriate symptom/problem from the list.

After selecting the appropriate symptom or problem, go to that step and perform the checks, tests, or adjustments in the order shown to isolate and repair the malfunction.

If engine does not crank, see Section 240.

  • ENGINE WILL NOT START: GO TO A
  • ENGINE STARTS HARD WHEN COLD, HOT, SITTING OR ENGINE KILLS WHEN HOT (HAS SPARK): GO TO B
  • ENGINE SURGES OR SURGES AT FAST IDLE WITH NO LOAD: GO TO C
  • ENGINE SURGES (NEW UNIT): GO TO D
  • ENGINE BACKFIRES WHEN STARTING OR BACKFIRES THROUGH CARBURETOR: GO TO E
  • ENGINE BACKFIRES THROUGH MUFFLER WHEN SHUT OFF: GO TO F
  • ENGINE MISSES: GO TO G
  • ENGINE LOSES POWER OR RUNS ROUGH WHEN HOT: GO TO H
  • ENGINE KNOCKS AT SLOW IDLE: GO TO I
  • ENGINE KNOCKS OR VIBRATES AT FAST IDLE: GO TO J
  • ENGINE OIL LEVEL INCREASES OR GAS IN OIL: GO TO K
  • ENGINE CONTINUES TO RUN (DIESELS) AFTER KEY IS SHUT OFF: GO TO L
  • ENGINE KILLS WHEN PTO IS ENGAGED: See Section 240.
  • ENGINE KILLS WHEN TRANSMISSION LEVER IS MOVED OUT OF NEUTRAL: See Section 240.
  • ENGINE OVERHEATS: GO TO M
  • ENGINE HAS BLACK EXHAUST SMOKE: GO TO N
  • ENGINE HAS BLUE EXHAUST SMOKE OR OIL IN AIR CLEANER: GO TO O
  • ENGINE USES TOO MUCH OIL: GO TO P
  • ENGINE USES TOO MUCH FUEL: GO TO Q

What are the troubleshooting steps if the engine will not start?

  1. Drain fuel and replace with fresh fuel.
  2. Test ignition spark.
  3. Test fuel transfer pump output.
  4. Inspect and adjust the throttle cable.
  5. Inspect and adjust the choke.
  6. Adjust the carburetor idle mixture screw.
  7. Check and adjust the governor linkage.
  8. Check the carburetor float adjustment.
  9. Check starter cranking RPM.
  10. Test compression.
  11. Test crankcase vacuum.
  12. Check and adjust valve clearance.

What are the troubleshooting steps if the engine starts hard when cold, hot, sitting, or the engine kills when hot (has spark)?

  1. Test ignition spark for hot “blue” spark.
  2. Drain fuel and replace with fresh fuel.
  3. Test fuel transfer pump output.
  4. Inspect and adjust the throttle cable.
  5. Inspect and adjust the choke.
  6. Check the carburetor float adjustment.
  7. Check starter cranking RPM.
  8. Test compression.
  9. Check and adjust valve clearance.
  10. Test ignition system.
  11. Check the flywheel key for a partially sheared condition.
  12. Check PTO clutch for dragging.

What are the troubleshooting steps if the engine surges or surges at fast idle with no load?

  1. Drain fuel and replace with fresh fuel.
  2. With the engine running, remove the air cleaner cover. If surging stops, the Kawasaki engine surge engine cooling fins or air filter is plugged. Remove engine shrouding and clean cooling fins. Check engine cooling screen to blower housing clearance.
  3. Inspect and adjust the throttle cable.
  4. Inspect and adjust the choke.
  5. Inspect and adjust the governor.
  6. Adjust carbruetor idle mixture screw and slow idle.
  7. Adjust fast idle.
  8. Inspect carburetor for a plugged condition from varnish deposits.
  9. Check the carburetor float adjustment.
  10. Check for an air intake leak. Verify by spraying aerosol lubricant (such as WD-40) around carburetor mating surfaces and intake manifold.
  11. Check the fuel tank vent for a plugged condition.
  12. Test fuel pump output.
  13. Check and adjust valve clearance.
  14. Test crankcase vacuum.
  15. If the engine was disassembled, check static timing.

How do you align the throttle control lever and control plate for fast idle speed adjustment?

Align the hole in the throttle control lever with the hole in the control plate and install a 15/64 in. drill bit through the holes.

What is the procedure for fast idle speed adjustment?

  1. Start and run the engine for 10 minutes.
  2. Move the throttle lever on the dash to the fast idle position.
  3. Move the transmission control lever to the neutral position.
  4. Lock the park brake.
  5. Check the engine speed using a JDM-71 Vibration Tachometer.
  6. Put the tachometer on the forward or rearward air cleaner.
  7. Set the tachometer to read 3350 rpm.
  8. Loosen the cap screws.
  9. Move the control plate until the tachometer reads 3350 ± 100 rpm.
  10. Tighten the cap screws.
  11. After adjustment, go to choke.

How do you perform a slow idle speed adjustment?

  1. Start and run the engine for 10 minutes.
  2. Move the transmission control lever to the neutral position.
  3. Move the throttle lever on the dash to the slow idle position.
  4. Lock the park brake.
  5. Turn the idle mixture screw clockwise until lightly seated, then counterclockwise 1-1/8 turns.
  6. Check the engine speed using a JDM-71 Vibration Tachometer.
  7. Turn the idle mixture screw in until the engine speed drops, then out until the engine speed increases and begins to drop again.
  8. Adjust the idle mixture screw until the highest engine speed is reached.
  9. Turn the slow idle stop screw for highest engine speed between 1350 to 1450 rpm.
  10. Turn screw out an additional 1/4 turn.
  11. Turn the slow idle stop screw to get an idle speed of 1400 ± 100 rpm.

How do you perform a cylinder compression test?

  1. Disconnect and ground the spark plug wire. An ignition test plug can be used.
  2. Remove the spark plug and install a JDM-59 Compression Gauge.
  3. Move the throttle lever to the fast idle position.
  4. Lock the park brake.
  5. Turn the key switch to the START position.
  6. Record the pressure reading.
    • Compression at or near 150 psi: Check valve lash, then check the automatic compression release spring and weights.
    • Minimum compression 160 and 165…380 kPa (55 psi).
    • Minimum compression 130, 175, 180, 185…483 kPa (71 psi).
  7. If compression pressure increases, put clean engine oil on piston rings through the spark plug hole. Check rings, piston, and cylinder bore for broken rings, scoring, wear, or damage, and replace if necessary. Then repeat the test.
  8. If compression pressure is still low, check for leaking intake or exhaust valves, valve seal, or cylinder head gasket and replace if necessary.
  9. Remove the compression gauge.

What are the steps for a crankcase vacuum test?

  1. Remove dipstick.
  2. Make test connections from JTO5697 U-Tube Manometer Kit.
    • A-8741-F66 Plug
    • B-JTO5703 Barb Fitting
    • C-JTO5699 Line
    • D-JTO5698 U-Tube Manometer
  3. Run engine at fast idle.
  4. Record crankcase vacuum reading.
    • Minimum vacuum for 130…7 cm (2.8 In. water)
    • Minimum vacuum for 160, 165, 175, 180, and 185…25 cm (9.8 in. water)
  5. If crankcase vacuum is low, inspect for:
    • Damaged breather
    • Excessive breather air gap
    • Leaking fuel pump vacuum line
    • Damaged dipstick or engine seals
  6. Close manometer valve before shutting off engine.

How do you conduct an oil pressure test?

  1. Check the engine oil level and viscosity.
  2. For units with an oil filter, disconnect the oil pressure sensor wiring lead and remove the oil pressure sensor. For units without an oil filter, remove the pipe plug. Note: This test is not used for 130 Tractor.
  3. Make test connections with one of these fittings, hose, and gauge:
    • A-JTO3338 90˚ Elbow Fitting
    • B-JTO3349 Fitting
    • C-JTO3017 Hose
    • D-JTO3344 Gauge, 2000 kPa (300 psi)
  4. Run the engine at fast idle.
    • Oil pressure should be at least 240 kPa (35 psi).
  5. If the oil pressure is low, inspect for:
    • Damaged or worn oil pressure relief valve
    • Plugged oil pump suction screen
    • Loose oil pump cover cap screws
    • Damaged or worn oil pump

What are the steps for a fuel pump test?

  1. Start and run the engine for 5 minutes to heat the engine oil to normal operating temperature.
  2. Disconnect and plug the fuel pump outlet hose.
  3. Start and run the engine at slow idle for 1 minute to fill the carburetor with fuel.
  4. Connect the JDG356 Pressure Gauge to the fuel pump outlet.
  5. Start and run the engine at fast idle for 15 seconds, then record the pressure reading and stop the engine.
    • Minimum pressure for 160 and 165…3.68 kPa (0.5 psi)
    • Minimum pressure for 130, 175, 180, and 185…6.12 kPa (0.9 psi)
  6. Remove the fuel pump outlet pressure gauge and connect the hose.
  7. Disconnect the fuel pump outlet hose from the carburetor and put it in a graduated container.
  8. Start and run the engine at fast idle for 15 seconds, then stop the engine and record the container measurement.
    • Minimum flow for 130 and 175…80 mL/15 seconds (2.7 oz/15 seconds)
    • Minimum flow for 160, 165, 180, and 185…90 mL/15 seconds (3 oz/15 seconds)
  9. If the fuel pump pressure or flow is low, inspect for:
    • Plugged fuel tank vent, fuel lines, or fuel filter
    • Low crankcase vacuum
    • Damaged or worn fuel pump

How do you test for the ignition spark?

  1. Engage the park brake and put the transmission lever in neutral.
  2. Disconnect the spark plug wire.
  3. Install a spark tester on the spark plug wire.
  4. Crank the engine and check for spark.
    • Hot “blue” spark: GO TO 1:a
    • No spark or “yellow” weak spark: GO TO SECTION 240

How to inspect a spark plug?

  1. Remove the spark plug.
  2. Inspect the spark plug for cracked or broken porcelain, worn or eroded electrodes, and excessive carbon or oily deposits.
    • A normal spark plug will have brown to grayish-tan deposits and slight wear on the electrodes.
    • Replace the plug if worn or damaged.
  3. Adjust the electrode gap to:
    • 130, 175, 180, 185 . . . . . . . . . . . . . . . . . . . . . . 0.7-0.8 mm (0.028-0.031 in.)
    • 160, 165 . . . . . . . . . . . . . . . . . . . . . . . 0.6-0.7 mm (0.024-0.028 in.)

What is the carburetor cleaning procedure?

  1. Remove, disassemble, and clean the carburetor.
  2. Soak the carburetor in a good carburetor cleaning solvent for 1/2 hour maximum.
  3. Spray all passages with aerosol carburetor cleaning solvent.
  4. Rinse the carburetor with warm water and dry with compressed air.
  5. Make all carburetor adjustments.

What electrical system checkouts are included in Section 240?

  • Dash Lamp Circuit Check
  • Starting Circuit Check (Hydrostatic)
  • Starting Circuit check (Gear)
  • Ignition Spark Check
  • Transmission Neutral Check
  • PTO Neutral Start Check
  • Indicator Lamp Running Check
  • PTO Check
  • Seat Switch Check for PTO and Ignition
  • Headlight Check

What electrical system diagnoses are included in Group 10?

  • Verify System Grounds
  • Battery Tests
  • Dash Lamp Circuit Tests
  • Starting Circuit Tests
  • Transmission Neutral Start Switch Test for Gear Tractors
  • PTO/Safety Switch Test
  • PTO Circuit Test
  • Seat Switch Test for PTO Circuit
  • Seat Switch and Connector Test
  • Headlight Tests

What electrical system component tests are included in Group 15?

  • Starter Amp Draw Test
  • Starter No-Load RPM Test
  • Starter No-Load Amp Test
  • Battery Voltage Test
  • Regulated Output Test
  • Unregulated Voltage Test

How to perform an electrical system checkout?

  1. Begin with Group 05 to identify a failure in the electrical system.
  2. Follow the step-by-step procedures for a quick check of the system.
  3. No tools are required to perform these checks.
  4. If a failure is indicated, a more detailed check, adjustment, or test will be required.
  5. Always start with the first step and follow the sequence from left to right.
  6. Read each step completely before performing the check.
  7. This procedure is designed as a quick check of the system.
  8. Concentrate only on the check being performed and disregard signals from unrelated components.
  9. Transmission in neutral, PTO OFF: Key switch ON.
    • OK: GO TO Æ; discharge lamp and oil pressure lamp should NOT be ON (if equipped).
    • NOT OK: GO TO ; GROUP 10.
    • NOTE: Low fuel lamp will only come on if the fuel level is low.
  10. Sit on seat and fully depress brake pedal: Turn key to START.
    • LISTEN: Starter must crank engine, engine must start (use choke position as needed).
    • OK: GO TO Æ‘.
    • NOT OK: GO TO 2b.
  11. Transmission in neutral, brake locked ON: Turn key switch to START.
    • LISTEN: Starter must crank engine, engine must start (use choke position as needed).
    • OK: GO TO Æ2a.
    • NOT OK: GO TO 2b.
  12. Brake pedal locked ON: Use a spark tester to determine if the engine is firing. Open hood, disconnect spark plug wire.
    • LOOK: Tester must indicate spark.
    • OK: GO TO SECTION 220.
    • NOT OK: GO TO 2n, GROUP 10.
  13. Operator on seat: Put hydrostatic lever in neutral slow forward or gear selector lever in first gear forward.
    • Turn key switch to START.
    • LISTEN: Starter must NOT crank engine.
    • N CAUTION: Be aware that if neutral start circuit is defective, tractor will start and move forward.
    • OK: GO TO ÅÆ.
    • NOT OK: GO TO Æ, GROUP 10.
  14. Turn PTO switch ON. Turn key switch to START.
    • LISTEN: Starter must NOT crank engine.
    • N CAUTION: Be aware that if PTO neutral start circuit is defective, tractor will start and PTO will engage.
    • OK: GO TO ÖÅ.
    • NOT OK: GO TO Å, GROUP 10.
  15. Start engine and run at full throttle: LOOK: Battery discharge lamp must be OFF.
    • Oil pressure lamp must be OFF.
    • NOTE: If not equipped with indicator lamps, GO TO Ò.
    • OK: GO TO ÒÖ.
    • NOT OK: GO TO ;, GROUP 10.
  16. Engine OFF: Turn key switch ON.
    • Turn PTO switch ON.
    • LISTEN: PTO must click ON.
    • OK: GO TO ÕÒ.
    • NOT OK: GO TO Ö, GROUP 10.
  17. Sit on seat: Run engine at half throttle.
    • Turn PTO switch ON.
    • Raise up off seat.
    • LISTEN: Engine must stop.
    • OK: GO TO ÚÕ.
    • NOT OK: GO TO Ò, GROUP 10.
  18. Key switch ON: Pull light switch out.
    • LOOK: Headlights must be ON.
    • OK: GO TO ÜÚ.
    • NOT OK: GO TO Õ, GROUP 10.
  19. Completing all checks in this procedure indicates that all functions of the electrical system are operating satisfactorily:
    • If the operator complaint was not identified, the problem may be intermittent.
    • Try to duplicate the conditions of the malfunction as identified by the operator.
    • Verify the system ground connections and test the battery as instructed in Group 10, then repeat checkout procedure.
    • Factory assistance is available through the Dealer Technical Assistance Center (DTAC).

What should be done before performing tests in Group 10?

  • Always perform the system checkout in Group 05 before making any tests in this group.
  • It is very important that all ground connections are clean and tight and that the battery is fully charged.
  • Verify the system ground circuits and test the battery.
  • Always start with the first step and follow the sequence from left to right.
  • Read each step completely before performing the test.
  • Upon completing a test or adjustment, check to see whether the problem is corrected by performing the checkout procedure for that step in Group 05.
  • Clean and tighten ground connections as needed before testing the battery or performing diagnosis.

How to perform battery tests?

  1. Check electrolyte level in each cell or battery.
    • If low add the proper amount of clean soft water.
  2. Check specific gravity of each cell with a hydrometer.
    • All cells less than 1.175: GO TO C
    • All cells more than 1.225 with less than 50 points variation: GO TO D
    • All cells less than 1.225 with less than 50 points variation: GO TO B
    • Variation more than 50 points: REPLACE BATTERY
  3. Test Battery Voltage: Check battery voltage with voltmeter or JTO5685 Battery Tester.
    • NOTE: Battery need not be disconnected from tractor.
    • 12.4 V OR MORE: GO TO F
    • LESS THAN 12.4 V: GO TO C
  4. Charge Battery: Connect variable rate charge to battery. Start charger at a slow rate. Increase charge rate one setting at a time.
    • Check ammeter (on charger) after one minute at each setting.
    • Try to maintain a 10-amp charge rate. Use boost setting as necessary.
    • The maximum charging time at boost setting is 10 minutes.
    • Allow an additional 5 minutes for each 10˚F below 70˚F.
    • If battery did not need water at Step A and is accepting 10-amp charge…GO TO E
    • If battery required water at Step A or if all cells were below 1.175 but battery is accepting a 10-amp charge… GO TO D
    • If battery does not accept a 10-amp charge after 10 minutes at boost setting, REPLACE BATTERY.
  5. Increase Charge Rate: Set charger at 15-25 amps. Decrease charge rate after 30 minutes.
    • (60 if battery gases or minutes for bubbles excessively maintenance free or becomes too warm battery).
    • IMPORTANT: Check specific gravity between cells.
    • IF VARIATION BETWEEN CELLS IS MORE THAN 50 POINTS, REPLACE BATTERY.
    • IF VARIATION BETWEEN CELLS IS LESS THAN 50 POINTS, GO TO Æ
  6. Continue Charging Battery: Continue charging battery until specific gravity is 1.230-1.265 points.
    • IF BATTERY WAS DISCHARGED AT A FAST RATE: Charge battery at 20-25 amps. Battery may require 2-4 hours charging time. Decrease charge rate if battery gases or bubbles too much or if battery gets too warm to hold. THEN…GO TO F
    • IMPORTANT: IF BATTERY WAS DISCHARGED AT A SLOW RATE (OR DISCHARGE RATE IS UNKNOWN): Charge battery at 10-15 amps for 6-12 hours. (Maintenance-free battery may need 4-8 hours.) THEN…GO TO F (Maintenance-free battery may require 12-24 hours).
  7. Load Test Battery: Connect JTO5685 Tester to battery. Follow instruction on back of meter for testing battery. REPLACE BATTERY AS NEEDED.

How to perform dash lamp circuit tests?

  1. If any lamp does not operate properly, select the appropriate test as listed at right.
    • NO LAMPS WORK: GO TO 1a
    • APPROPRIATE TEST: GO TO ;
    • OIL PRESSURE LAMP TESTS: GO TO 1f
    • BATTERY DISCHARGE LAMP TESTS: GO TO 1j
    • LOW FUEL LAMP TESTS: GO TO 1Ô
  2. No Lamps Work: Open hood. Turn key switch ON.
    • Voltage Test: Check for voltage at yellow wire (A) on the key switch.
      • VOLTAGE: Yellow wire to voltage regulator and dash lamps is open. Run new wires or replace harness.
      • NO VOLTAGE: GO TO 1b
  3. Main voltage Test at Key Switch: Key switch OFF. Check for voltage at a single red/blue wire (A) on key switch.
    • VOLTAGE: Replace key switch.
    • NO VOLTAGE: GO TO 1c
  4. Voltage Test at Circuit Breaker: Key switch OFF. Remove lower pedestal panel. Check for voltage at both terminals of circuit breaker (A).
    • VOLTAGE ONE TERMINAL: Replace breaker.
    • VOLTAGE BOTH TERMINALS: Repair or replace red/blue wire to key switch.
    • NO VOLTAGE: GO TO 1d
  5. Voltage Test at Solenoid For 160, 165, 175, 180 and 185 Tractors: Key switch OFF. Check for voltage at terminal (A) with two red wires.
    • NOTE: For 130 Tractors, GO TO 1e
    • VOLTAGE: Repair or replace red wire to circuit breaker.
    • NO VOLTAGE: Check battery cables and system ground connection at frame.
  6. Voltage Test at Solenoid for 130 Tractors: Key switch OFF. Check for voltage at terminal with three red wires (A).
    • VOLTAGE: Repair or replace red wire to circuit breaker.
    • NO VOLTAGE: Check battery cables and system ground connection at frame.
  7. Oil Pressure Lamp Circuit Test: Disconnect wire (A) from oil pressure switch. Ground wire lead to engine block.
    • Turn key switch ON.
    • LOOK: Lamp must be ON.
      • LAMP ON: Replace oil pressure switch.
      • LAMP NOT ON: GO TO 1g
      • NOTE: If lamp does not go out, GO TO 1!
  8. Oil Pressure Lamp Voltage Test: Open hood. Remove oil pressure lamp socket from the dash panel. Check bulb.
    • Turn key switch ON.
    • Check for voltage at terminal (A) with a single yellow lead.
      • VOLTAGE: GO TO 1h
      • NO VOLTAGE: Yellow wire to key switch is open. Repair or run new wire to key switch.
  9. Oil Pressure Lamp Ground Circuit Test: Disconnect wire from oil pressure switch.
    • Check continuity of tan wire between lead at switch (A) and lead at bulb socket (B).
      • NO CONTINUITY: Repair or replace tan wire from bulb socket to oil pressure switch.
  10. Oil Pressure Lamp Short Circuit Test: Key switch OFF. Check for continuity between tan wire at switch (A) and ground.
    • CONTINUITY: Tan wire is shorted to ground. Repair or replace.
    • NO CONTINUITY: Check engine oil pressure as instructed in Section 220.
  11. Battery Discharge Lamp Circuit Test: Key switch oFF. Remove indicator lamp socket from back of dash panel.
    • Check for continuity between terminal with black wire (A) and ground.
      • NOTE: If the lamp does not go off, GO TO 1n Remove and check bulb.
      • CONTINUITY: GO TO 1k.
      • NO CONTINUITY: Black ground wire is open. Repair or run new wire to ground.
  12. Battery Discharge Lamp Voltage Test: Remove indicator lamp socket from dash panel.
    • Turn key switch ON.
    • Check for voltage at socket terminal with orange wire (A).
      • VOLTAGE: Circuit OK, be sure bulb contacts are aligned for good contact with socket.
      • NO VOLTAGE: GO TO 1l
  13. Battery Discharge Lamp Voltage Test at Voltage Regulator connector: Remove lower pedestal shroud.
    • Turn key switch ON.
    • Check for voltage at orange lead (A) at Voltage Regulator connector.
      • VOLTAGE: Repair or replace engine wire to bulb socket.
      • NO VOLTAGE: GO TO 1m
  14. Battery Discharge Lamp Voltage Test at Voltage Regulator: Turn key switch ON.
    • Check for voltage at yellow lead (A) at regulator connector.
      • VOLTAGE: Verify yellow connector is making good contact, then, replace voltage regulator.
      • NO VOLTAGE: GO TO 1a
  15. Battery Discharge Lamp Operational Test: Check battery voltage using JTO5685 Battery Tester or lead.
    • Check battery voltage ground spark plug with a voltohmmeter to be sure it is less than 12.
    • Crank engine for 5-10 seconds.
      • Crank engine again if needed.
      • For this test, battery voltage must be 12 or less.
      • If voltage is higher than 12.2, use the following procedure to discharge battery.
      • Leave key switch ON.
      • Listen: Starter must run.

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