1200 Bunker and Field Rake TM1525
1200 Bunker and Field Rake TM1525
1200 Bunker and Field Rake TM1525
This manual is written for an experienced technician. Binders, binder labels, and tab sets can be ordered
Essential tools required in performing certain service by John Deere dealers direct from the John Deere
work are identified in this manual and are Distribution Service Center.
recommended for use.
This manual is part of a total product support
Live with safety: Read the safety messages in the program.
introduction of this manual and the cautions
presented throughout the text of the manual. FOS MANUALS—REFERENCE
Technical manuals are divided in two parts: repair Fundamentals of Service (FOS) Manuals cover basic
and diagnostics. Repair sections tell how to repair the theory of operation, fundamentals of troubleshooting,
components. Diagnostic sections help you identify the general maintenance, and basic type of failures and
majority of routine failures quickly. their causes. FOS Manuals are for training new
personnel and for reference by experienced
Information is organized in groups for the various technicians.
components requiring service instruction. At the
beginning of each group are summary listings of all Technical Manuals are concise guides for specific
applicable essential tools, other materials needed to machines. Technical manuals are on-the-job guides
do the job and service parts kits. containing only the vital information needed for
diagnosis, analysis, testing, and repair.
Section 10, Group 15—Repair Specifications, consist
of all applicable specifications, near tolerances and Component Technical Manuals are concise service
specific torque values for various components on guides for specific components. Component technical
each individual machine. manuals are written as stand-alone manuals covering
multiple machine applications.
MX,TMIFC,A -19-25MAR91
20
30
40
50
60
70
80
210
220
230
240
250
260
270
INDX
230
240
250
260
270
INDX
10
-UN-07DEC88
Follow recommended precautions and safe operating
practices.
T81389
DX,ALERT -19-04JUN90
-19-30SEP88
DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
TS187
DX,SIGNAL -19-04JUN90
-UN-23AUG88
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are
available from your John Deere dealer.
TS201
instruction.
DX,READ -19-04JUN90
-UN-23AUG88
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
TS227
spontaneously.
DX,FLAME -19-04JUN90
-UN-23AUG88
Never check battery charge by placing a metal object
across the posts. Use a volt-meter or hydrometer.
TS204
DX,SPARKS -19-04JUN90
DX,FIRE2 -19-04JUN90
If acid is swallowed:
-UN-23AUG88
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.
TS203
DX,POISON -19-04JUN90
-UN-23AUG88
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
X9811
hands and body from high pressure fluids.
DX,FLUID -19-09AUG91
-UN-24MAY89
• Disconnect the battery ground strap.
• Hang a “DO NOT OPERATE” tag in operator station.
TS230
DX,PARK -19-04JUN90
-UN-23AUG88
machine or attachment.
TS229
DX,LOWER -19-04JUN90
-UN-23AUG88
Prolonged exposure to loud noise can cause impairment
or loss of hearing.
TS206
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
DX,WEAR -19-10SEP90
DX,LOOSE -19-04JUN90
-UN-23AUG88
exhaust pipe extension.
TS220
DX,AIR -19-04JUN90
-UN-18OCT88
• Have the right parts on hand.
• Read all instructions thoroughly; do not attempt
shortcuts.
T6642EJ
DX,CLEAN -19-04JUN90
-UN-23AUG88
cage. The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
TS223
DX,LIGHT -19-04JUN90
-UN-23AUG88
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch.
TS220
Remove paint before welding or heating:
DX,PAINT -19-04JUN90
-UN-15MAY90
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can be
accidentally cut when heat goes beyond the immediate
flame area.
TS953
DX,TORCH -19-05OCT90
DX,SIGNS1 -19-04JUN90
-UN-23AUG88
Follow recommended procedure for removal and
installation of components in the manual.
TS226
DX,LIFT -19-04JUN90
-UN-12APR90
Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
TS952
an increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.
DX,TIRECP -19-24AUG90
-UN-23AUG88
Components in products that may contain asbestos fibers
are brake pads, brake band and lining assemblies, clutch
plates, and some gaskets. The asbestos used in these
components is usually found in a resin or sealed in
some way. Normal handling is not hazardous as long as
TS220
airborne dust containing asbestos is not generated.
DX,DUST -19-15MAR91
machine.
TS218
DX,SERV -19-04JUN90
-UN-08NOV89
Use power tools only to loosen threaded parts and
fasteners.
TS779
wrenches.
DX,REPAIR -19-04JUN90
-UN-26NOV90
fuel, coolant, brake fluid, filters, and batteries.
TS1133
Do not pour waste onto the ground, down a drain, or
into any water source.
DX,DRAIN -19-09AUG91
-19-07OCT88
TS231
DX,LIVE -19-04JUN90
10
05
12
MACHINE SPECIFICATIONS
ENGINE 10
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... John Deere “K” Series
10
1
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . . . OHV
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . FE290R
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . 7.5 kW (10 hp)
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ............... 1
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . 286 cm3 (17.5 cu. in.)
Bore and Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 x 60 mm (3.07 x 2.36 in.)
Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . 3800 rpm
Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . 1300—1550 rpm
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . . Electric
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . Pressurized
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . Forced Air
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . Dry Replaceable
Engine Shutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . Key Switch
FUEL SYSTEM
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor
Fuel Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump
ELECTRICAL SYSTEM
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt
Battery Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 Cold Cranking Amps at -18˚C (0˚F)
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Amp
POWER TRAIN
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt-Driven Torque Converter with Gear-Driven Transaxle
Number of Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forward-Neutral-Reverse
Clutch
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kawasaki, Wet 2.1 Reduction (Variable)
Engagement
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1600—1800 rpm
Travel Speeds
Forward/Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable, 0—18 km/h (0—11 mph)
STEERING/BRAKES
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical, Roller-Chain and Sprocket
6:1 Reduction Ratio
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanically Operated Disc with Park Brake
MX,1010HE,A1 -19-27SEP91
HYDRAULIC SYSTEM
Lift Pump (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oildyne Electro-Hydraulic Lift
10
10 CAPACITIES
2
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 L (2.5 U.S. gal)
Engine Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 L (3.0 U.S. pt)
Wet Reduction Clutch Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 L (1.3 U.S. pt)
Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 L (2.5 qt)
TIRES
Standard Equipment
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . One 22.5 x 10.00—8 2 PR High Floatation
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two 25 x 12.00—9 2 PR High Floatation
OVERALL DIMENSIONS:
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1054 mm (41.5 in.)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1676 mm (66 in.)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1473 mm (58 in.)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1041 mm (41 in.)
Ground Clearance at
Rake Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 mm (9.5 in.)
Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 mm (12 in.)
Approximate Shipping
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 kg (525 lb)
ATTACHMENT SPECIFICATIONS
RAKE (Standard)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Mount, Hand Lift Control
(Hydraulic Lift—Optional)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1981 mm (78 in.)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 kg (44 lb)
Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Five Section, Bunker or Field
Prong Rake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three Section, 24 Prongs
25—76 mm (1—3 in.) Adjustment
CULTIVATOR (Optional)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mid-Mount, 10 Blades, Hand Control
with 5-Position Depth Adjustment
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1626 mm (64 in.)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 kg (44 lb)
REPAIR SPECIFICATIONS
Item Measurement Specification 10
15
SECTION 20—ENGINE REPAIR 1
Finished ID 37.00—37.03 mm
(1.457—1.458 in.)
MX,1015HE,A1 -19-27SEP91
Roller Arm-to-Moveable
Sheave Half Cap Screw Torque 8 N·m (71 lb-in.)
Transaxle
Input Shaft
Washer Thickness 1.55—1.65 mm
(0.061—0.064 in.)
MX,1015HE,A2 -19-27SEP91
MX,1015HE,A2A -19-27SEP91
Retaining Plate-to-Case
Cap Screw Torque 25 N·m (221 lb-in.)
Transaxle Case-Half
Cap Screw Torque
(Same Case) 25 N·m (221 lb-in.)
(New Case) 29 N·m (257 lb-in.)
Drive Axles
Drive Axle-to-Frame Distance 30.15 mm (1.187 in.)
Locking Collar-to-Axle
Shaft Set Screw Torque 8 N·m (64 lb-in.)
MX,1015HE,A2B -19-27SEP91
Lower and Raise Relief Valve-to-Adapter Nut Torque 2 N·m (20 lb-in.)
TUNE-UP SPECIFICATIONS
MX,1015HE,A3 -19-27SEP91
TUNE-UP ADJUSTMENTS
10 Perform tune-up adjustments in the following order to
15 improve the efficiency and operation of the machine.
6
10. Adjust slow idle stop and idle mixture screw. 230 15
MX,1015HE,A4 -19-27SEP91
-UN-18OCT88
1. Inspect O-ring boss seat for dirt or defects.
T6243AE
3. Tighten fitting to torque value shown on chart.
ANGLE FITTING
-UN-18OCT88
2. Turn fitting into threaded boss until back-up washer
contacts face of boss.
T6520AB
4. Hold fitting head-end with a wrench and tighten
locknut and back-up washer to proper torque value.
TORQUE VALUE
3/8-24 UNF . . . . . . . . . . . . . . . . 8 . . . . . . . . . . . . . . 6
7/16-20 UNF . . . . . . . . . . . . . . . 12 . . . . . . . . . . . . . . 9
1/2-20 UNF . . . . . . . . . . . . . . . 16 . . . . . . . . . . . . . 12
9/16-18 UNF . . . . . . . . . . . . . . . 24 . . . . . . . . . . . . . 18
3/4-16 UNF . . . . . . . . . . . . . . . 46 . . . . . . . . . . . . . 34
7/8-14 UNF . . . . . . . . . . . . . . . 62 . . . . . . . . . . . . . 46
1-1/16-12 UN . . . . . . . . . . . . . . . 102 . . . . . . . . . . . . . 75
1-3/16-12 UN . . . . . . . . . . . . . . . 122 . . . . . . . . . . . . . 90
1-5/16-12 UN . . . . . . . . . . . . . . . 142 . . . . . . . . . . . . 105
1-5/8-12 UN . . . . . . . . . . . . . . . 190 . . . . . . . . . . . . 140
1-7/8-12 UN . . . . . . . . . . . . . . . 217 . . . . . . . . . . . . 160
04T,90,K66 -19-13AUG91
-19-04MAR91
TS1163
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft
M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410
M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580
M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800
M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000
M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500
M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000
M33 900 675 1150 850 1750 1300 220 1650 2500 1850 3150 2350 2900 2150 3700 2750
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500
DO NOT use these values if a different torque value Make sure fasteners threads are clean and that you
or tightening procedure is given for a specific properly start thread engagement. This will prevent
application. Torque values listed are for general use them from failing when tightening.
only. Check tightness of fasteners periodically.
Tighten plastic insert or crimped steel-type lock nuts
Shear bolts are designed to fail under predetermined to approximately 50 percent of the dry torque shown
loads. Always replace shear bolts with identical in the chart, applied to the nut, not to the bolt head.
property class. Tighten toothed or serrated-type lock nuts to the full
torque value.
Fasteners should be replaced with the same or
higher property class. If higher property class
fasteners are used, these should only be tightened to
the strength of the original.
a “Lubricated means coated with a lubricant such as engine oil, or
fasteners with phosphate and oil coatings. ”Dry means plain or zinc
plated without any lubrication. DX,TORQ2 -19-05JUN91
-19-04MAR91
TS1162
Grade 1 Grade 2b Grade 5, 5.1, or 5.2 Grade 8 or 8.2
N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft
1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5
5/16 7.7 5.5 10 7 12 9 15 11 20 15 25 18 28 21 35 26
3/8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46
7/16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75
1/2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115
9/16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160
5/8 67 50 85 62 105 78 135 100 170 125 215 160 215 160 300 225
3/4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400
7/8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650
1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975
1-1/8 470 300 510 375 470 300 510 375 900 675 1150 850 1450 1075 1850 1350
1-1/4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550
1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
DO NOT use these values if a different torque value Fasteners should be replaced with the same or
or tightening procedure is given for a specific higher grade. If higher grade fasteners are used,
application. Torque values listed are for general use these should only be tightened to the strength of the
only. Check tightness of fasteners periodically. original.
Shear bolts are designed to fail under predetermined Make sure fasteners threads are clean and that you
loads. Always replace shear bolts with identical grade. properly start thread engagement. This will prevent
them from failing when tightening.
b Grade 2 applies for hex cap screws (not hex bolts) up to 152 mm
(6-in.) long. Grade 1 applies for hex cap screws over 152 mm (6-in.)
long, and for all other types of bolts and screws of any length. DX,TORQ1 -19-15MAR91
10
15
10
FUEL
-UN-23AUG88
before filling fuel tank. Do not smoke while
filling the fuel tank or servicing the fuel
system. Fill fuel tank only to bottom of filler
neck.
TS185
oil with gasoline.
-UN-12SEP89
Use of gasohol is acceptable as long as the ethyl
alcohol blend does not exceed 10 percent. Unleaded
gasohol is preferred over leaded gasohol. Do not use
methanol blended fuels.
E33529
Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 gal (9.5 L)
MX,1020HE,A1 -19-27SEP91
STORING FUEL
DX,FUEL -19-04JUN90
-19-28NOV90
TS239
EX,1200RM,CA -19-27SEP91
TRANSAXLE OIL
MX,1020HE,A2 -19-27SEP91
-19-28NOV90
TS248
DX,GREA1 -19-15MAR91
LUBRICANT STORAGE
DX,LUBST -19-15MAR91
ALTERNATIVE LUBRICANTS
MX,ALTER,A -19-05FEB91
10
20
4
SERIAL NUMBERS
MX,1025FT,A4 -19-15JAN91
-UN-07AUG91
The machine’s 13 digit product identification number (A)
is located at the rear, left-hand side of the machine, on
the inside of the frame.
M80640
MX,1025HE,A1 -19-27SEP91
-UN-07AUG91
M80641
MX,1025HE,A2 -19-27SEP91
MX,1025HE,A3 -19-27SEP91
-UN-07AUG91
M80643
MX,1025HE,A4 -19-27SEP91
MX,1030HE,A1 -19-27SEP91
MACHINE FEATURES
-UN-07AUG91
•John Deere “K” Series FE290R single cylinder,
air cooled engine, with 7.5 kW (10 hp).
•Drive system consisting of a wet clutch/reduction
gearbox, a drive clutch, a driven clutch, a drive
belt and a transaxle.
M80644
•Wet clutch for smoother power transmission to the
torque converter.
•Kanzaki transaxle with differential lock. Slide M80644
•Gear shift pedals, forward and reverse in a single
range, variable speed drive system.
•Utility rack for carrying a variety of hand held
equipment.
•Hinged rear body cowling for ease of serviceability.
•Pedal operated disc brake.
-UN-07AUG91
•Accelerator pedal.
•Manual steering, roller chain and sprocket with 6:1
reduction ratio.
•Bunker/Field Rake
M80645
Slide M80645
MX,1030HE,A2 -19-27SEP91
-UN-28AUG91
•7.5 kW (10 hp)
•Bore and stroke of 78 x 60 mm (3.07 x 2.36 in.)
•Displacement of 286 cm3 (17.5 cu. in.)
•Overhead valve, 4-stroke cycle design.
M80646
•Solid state, transistorized, battery ignition
system.
•Die-cast aluminum block, head, and crankcase with Slide M80646
fins for cooling.
•Cast iron cylinder liner.
•Full pressure lubrication system with replaceable
oil filter.
•Crankcase oil capacity of 1.4L (3.0 U.S. pt).
•Automatic compression release.
•Electric start.
•Spark arresting muffler.
•Single-stage air filter with paper dry type
element. (A dual-stage heavy duty air cleaner is
available.)
•Kawasaki, wet clutch 2.1 reduction (variable)
gearbox.
MX,1030HE,A3 -19-27SEP91
The power train of the 1200 Bunker and Field Rake has 10
the following specifications and features:
30
3
-UN-28AUG91
•Drive clutch, drive belt and driven clutch.
•Kanzaki gear driven transaxle with foot pedal
operated differential lock.
•No shifting is required to increase speed, and
infinite speeds up to 18 km/h (11 mph) are the
M80647
result.
•The drive system automatically downshifts (changes
gear ratios) under load while maintaining engine rpm. Slide M80647
•Separate forward and reverse gear shift pedals in
a single range, variable speed drive system.
•Right foot operated brake system with a disc brake
mounted to the transaxle intermediate shaft.
-UN-10SEP91
M80659
Slide M80659
MX,1030HE,A4 -19-27SEP91
-UN-10SEP91
•13 Amp stator/alternator.
•12 Volt regulator/rectifier.
•Electronic ignition.
•Voltmeter.
•Hourmeter.
M80648
•Front light and switch (optional).
•Toggle switch for an electro-hydraulic lift
pump (optional). Slide M80648
-UN-10SEP91
M80649
Slide M80649
MX,1030HE,A5 -19-27SEP91
RAKE FEATURES
MX,1030HE,A6 -19-27SEP91
-UN-10SEP91
•Cultivator
•40-Inch Front Blade
•60-Inch Front Aluminum Blade
M80651
Slide M80651
-UN-10SEP91
M80652
Slide M80652
MX,1030HE,A7 -19-27SEP91
-UN-10SEP91
•Lawn Rollers
•Sweep Master
M80654
Slide M80654
-UN-10SEP91
M80655
Slide M80655
-UN-10SEP91
M80656
Slide M80656
MX,1030HE,A8 -19-27SEP91
-UN-10SEP91
M80657
Slide M80657
-UN-10SEP91
M80658
Slide M80658
MX,1030HE,A9 -19-27SEP91
10
30
8
Group 10—Muffler
Remove and Install . . . . . . . . . . . . . . . 20-10-1
20
-UN-17JAN89
20
05
1
TS225
MX,2005HE,A1 -19-27SEP91
-UN-23AUG88
machine or attachment, securely support the
machine or attachment. Failure to do so may
result in serious injury.
TS226
MX,LOW,AT -19-27SEP91
REMOVE ENGINE
-UN-07AUG91
8. Remove battery positive (+) cable from clamp (D).
M80662
CAUTION: Gasoline vapor is explosive. Do not
expose to spark or flame. Serious personal Right Side Shown
injury can result.
10. Disconnect hoses (B and E). Close all openings A—Choke Control Cable
using caps and plugs. B—Fuel Pump Vacuum Hose
C—Accelerator Cable
11. Disconnect spark plug wiring lead. D—Clamp
E—Fuel Supply Hose
MX,2005HE,A2 -19-27SEP91
-UN-07AUG91
A—Engine Wiring Harness Connector
B—Starter Solenoid Wiring Connector 20
C—Battery Positive Cable and Wiring Leads
D—Tie Strap
05
E—Ground Wiring Leads
3
M80663
Left Side Shown
MX,2005HE,A3 -19-27SEP91
-UN-07AUG91
M80664
MX,2005HE,A4 -19-27SEP91
MX,2005HE,A5 -19-27SEP91
INSTALL ENGINE
-UN-07AUG91
2. Install engine.
M80665
4. Install cultivator blade assembly, if equipped.
MX,2005HE,A6 -19-27SEP91
-UN-07AUG91
Group 15.)
M80664
MX,2005HE,A7 -19-27SEP91
-UN-07AUG91
A—Engine Wiring Harness Connector
B—Starter Solenoid Wiring Connector
C—Battery Positive Cable and Wiring Leads
D—Tie Strap
E—Ground Wiring Leads
M80663
Left Side Shown
MX,2005HE,A8 -19-27SEP91
-UN-07AUG91
20. Connect battery negative (—) cable and install
battery cover.
21. Fill engine with proper oil. (See Section 10, Group
20.)
M80662
22. Adjust choke. (See Section 220, Group 15.) Right Side Shown
20
05
6
-UN-23AUG88
machine or attachment, securely support the
machine or attachment. Failure to do so may
result in serious injury. 20
10
1
TS226
MX,LOW,AT -19-27SEP91
-UN-23AUG88
1. Remove nuts and lock washers (A).
TS271
4. Install new gasket and muffler.
-UN-07AUG91
M80661
MX,2010HE,A1 -19-27SEP91
20
10
2
30
-UN-17JAN89
machine manual.
TS225
MX,3005HE,A1 -19-27SEP91
30
05
SERVICE PARTS KITS 1
The following kits are available through your parts
catalog:
Complete Carburetor
MX,3005HE,A2 -19-27SEP91
-UN-23AUG88
machine or attachment, securely support the
machine or attachment. Failure to do so may
result in serious injury.
TS226
MX,LOW,AT -19-27SEP91
-UN-07AUG91
expose to spark or flame. Serious personal
injury can result.
M80666
3. Disconnect hoses (C and D). Close all openings using
caps and plugs.
30 4. Disconnect cable (L).
05
2
5. Remove hose from clamp (B).
-UN-25APR91
7. Separate carburetor from heat shield (H). Remove
carburetor.
M80400
9. Remove heat shield (H) and gasket (I and G).
MX,3005HE,A3 -19-27SEP91
-UN-07AUG91
injury can result.
M80667
2. Remove fuel pump (D).
MX,3005HE,A4 -19-27SEP91
-UN-07AUG91
1. Disconnect fuel hoses (A and C). Close all openings
using caps and plugs.
M80668
NOTE: Arrow on filter housing must point in direction of
fuel flow.
MX,3005HE,A5 -19-27SEP91
-UN-07AUG91
7. Inspect tank for damage. Replace if necessary.
M80669
between cap screw (E) and support bracket.
MX,3005HE,A6 -19-27SEP91
30
05
5
-UN-07AUG91
M80670
A—Fuel Pump-to-Carburetor B—Fuel Pump-to-Crankcase C—Fuel Filter-to-Fuel Pump D—Fuel Tank-to-Fuel Filter
Hose Vacuum Hose Hose Hose
1. Remove air cleaner. (See Group 10.) 2. Inspect and replace fuel hoses (A—D) as
N
necessary.
CAUTION: Gasoline vapor is explosive. Do
not expose to spark or flame. Serious 3. Install air cleaner.
personal injury can result.
MX,3005HE,A7 -19-27SEP91
-UN-18SEP89
1. Loosen screw (A).
E33628
4. Remove nut (C).
30 5. Cut all tie straps.
05
6
6. Remove cable housing.
-UN-18SEP89
NOTE: Route new housing through loop under platform.
E33629
9. Install nut and tighten screw.
MX,3005HE,A8 -19-27SEP91
30
05
7
-UN-07AUG91
M80671
A—Clamp D—Cable F—Rod H—Pedal Pad
B—Screw E—Cotter Pin (2 used) G—Accelerator Pedal I—Accelerator Cable
C—Extension Spring
MX,3005HE,A9 -19-27SEP91
-UN-07AUG91
2. Remove nut and lock washer (C).
M80672
NOTE: When installing choke knob and cable, route
cable along right-hand side of machine.
30
05 5. Install choke knob and cable.
8
6. Install lock washer and nut.
-UN-07AUG91
7. Tighten screw (B).
M80673
MX,3005HE,A10 -19-27SEP91
-UN-23AUG88
machine or attachment, securely support the
machine or attachment. Failure to do so may
result in serious injury.
TS226
MX,LOW,AT -19-27SEP91
30
10
REMOVE AND INSTALL AIR CLEANER 1
1. Loosen hose clamp (A).
-UN-12OCT88
(B).
E32461
5. Install air cleaner.
Standard Air Cleaner
6. Heavy duty air cleaner: Install cap screws and nuts.
-UN-07AUG91
M80674
Heavy Duty Air Cleaner
MX,3010HE,A1 -19-27SEP91
-UN-07SEP88
2. Remove dust from air cleaner by tapping the element
with the palm of your hand, NOT ON A HARD
SURFACE.
M34527
3. If this does not remove dust, use compressed air
under 210 kPa (30 psi). Be careful not to damage the air
cleaner.
30
10 IMPORTANT: Do not wash air cleaner in fuel oil,
2
gasoline, or solvent. If you do, the air
cleaner must be replaced. Wash air
cleaner no more than 2 times as
directed below.
MX,3010HE,A2 -19-27SEP91
-UN-07AUG91
-UN-07AUG91
2. Remove wing nut, washer and primary element (A).
M80675
M80676
4. Remove wing nut washer and secondary element (C).
30
10
3
MX,3010HE,A3 -19-27SEP91
-UN-07AUG91
7. Direct air up and down the pleats, blowing from inside
to outside. Be careful not to make a break in the
elements.
M80677
8. After you clean the main element, put a lighted bulb
inside it. Inspect the element and gasket for damage.
Throw away an element that has the smallest break. If
30 the gasket is broken or missing, install a new element.
10
4
9. Be sure rubber gasket on end of elements are in
good condition. If gasket is damaged or missing, replace
element.
MX,3010HE,A4 -19-27SEP91
40
-UN-23AUG88
machine or attachment, securely support the
machine or attachment. Failure to do so may
result in serious injury.
TS226
MX,LOW,AT -19-27SEP91
-UN-07AUG91
3. Disconnect battery positive (+) cable. 1
M80678
5. If equipped with cultivator, remove blower screen (B).
6. Remove battery.
8. Install battery.
MX,4005HE,A1 -19-27SEP91
-UN-07AUG91
2
9. Install tie straps as necessary.
M80679
11. Apply petroleum jelly on battery terminals.
MX,4005HE,A2 -19-27SEP91
-UN-17JAN89
Use the component manual in conjunction with this
machine manual.
TS225
MX,4005FT,A1A -19-27SEP91
-UN-23AUG88
machine or attachment, securely support the
machine or attachment. Failure to do so may 1
result in serious injury.
TS226
MX,LOW,AT -19-27SEP91
-UN-07AUG91
2. Remove tie strap (E).
3. Remove cap screw and washer (D) and oil fill tube.
M80680
wiring leads (C).
MX,4010HE,A1 -19-27SEP91
-UN-07AUG91
2. Remove front wheel mud flap, if equipped.
M80681
regulator.
MX,4010HE,A2 -19-27SEP91
-UN-07AUG91
2. Remove front wheel mud flap, if equipped.
M80682
5. Install circuit breaker, lock nuts and screws.
MX,4010HE,A3 -19-27SEP91
-UN-07AUG91
2. Remove front wheel mud flap, if equipped.
M80683
5. Install circuit breaker, lock nuts and screws.
-UN-20AUG91
2. Remove front wheel mud flap, if equipped.
M80706
4. Remove screws, lock nuts and circuit breaker (B).
MX,4010HE,A4A -19-27SEP91
-UN-07AUG91
1. Remove battery cover and disconnect battery negative
(—) cable.
M80684
3. Disconnect wiring connector (B).
4. Remove lock nut and screw (A) and relay. “Down” Relay
-UN-07AUG91
10
8. Connect battery negative (—) cable and install cover. 5
M80685
“Up” Relay
MX,4010HE,A5 -19-27SEP91
-UN-07AUG91
NOTE: If not equipped with a front splash guard, go to
step 5.
M80690
3. Remove lock nuts and screws (A) from each side.
MX,4010HE,A6 -19-27SEP91
-UN-07AUG91
-UN-07AUG91
8. Connect wiring connectors.
M80686
M80687
10. Lower front hood.
-UN-07AUG91
NOTE: If not equipped with a front splash guard, go to
step 5.
M80690
3. Remove lock nuts and screws ( ) from each side.
MX,4010HE,A8 -19-27SEP91
-UN-07AUG91
-UN-07AUG91
8. Replace front light switch.
M80688
M80689
10. Install nut.
MX,4010HE,A9 -19-27SEP91
REPLACE VOLTMETER
-UN-07AUG91
NOTE: If not equipped with a front splash guard, go to
step 5.
M80690
3. Remove lock nuts and screws (A) from each side.
MX,4010HE,A10 -19-27SEP91
9. Replace voltmeter.
-UN-07AUG91
8 13. Lower front hood.
M80691
lb-ft).
MX,4010HE,A11 -19-27SEP91
REPLACE HOURMETER
-UN-07AUG91
NOTE: If not equipped with a front splash guard, go to
step 5.
MX,4010HE,A12 -19-27SEP91
8. Replace hourmeter.
-UN-07AUG91
14. Connect battery negative (—) cable and install cover. 9
A—Bracket
B—Hourmeter
C—Wiring Connector
M80692
D—Wiring Connector
-UN-07AUG91
M80693
Machine S.N. 906251—
MX,4010HE,A13 -19-27SEP91
-UN-07AUG91
NOTE: If not equipped with a front splash guard, go to
step 5.
M80690
3. Remove lock nuts and screws (A) from each side.
40
10 MX,4010HE,A14 -19-27SEP91
10
5. Remove ring and washer (A).
-UN-07AUG91
8. Connect wiring leads.
12. Install steering wheel. Tighten nut to 197 N·m (145 A—Retaining Ring and Washer
lb-ft). B—Wiring Lead (Blue with Black Stripe)
C—Wiring Lead (Yellow)
D—Wiring Lead (Green with Black Stripe)
13. Connect battery negative (—) cable and install cover.
MX,4010HE,A15 -19-27SEP91
-UN-07AUG91
2. Disconnect wiring connector (B).
M80696
4. Connect wiring connector.
40
MX,4010HE,A16 -19-27SEP91 10
11
REPLACE FRONT LIGHT
-UN-07AUG91
2. Loosen nut (B).
M80697
5. Replace front light.
MX,4010HE,A17 -19-27SEP91
-UN-07AUG91
2. Disconnect wiring connector (A).
M80698
4. Remove pump motor (C), O-ring (D) and coupler (E).
-UN-07AUG91
40 8. Connect wiring connector.
10
12 9. Connect battery negative (—) cable and install cover.
A—Wiring Connector
M80699
B—Cap Screw (2 used)
C—Hydraulic Pump Motor
D—O-Ring
E—Coupler
MX,4010HE,A18 -19-27SEP91
TS446 -UN-22JUN89
DX,JDG155 -19-05JUN90
-UN-23AUG88
machine or attachment, securely support the
machine or attachment. Failure to do so may 1
result in serious injury.
TS226
MX,LOW,AT -19-27SEP91
-UN-23AUG88
2. Be sure to bend locking tang back to its original
position (B) before installing connector body.
RW4218
MX,4025FH,A1 -19-15JAN91
-UN-23AUG88
TS0128
DX,ECONN,P -19-04JUN90
-UN-23AUG88
through extractor tool handle and push terminal
15 contact from connector.
2
TS0129
DX,ECONN,Q -19-04JUN90
-UN-23AUG88
mating. Be sure contacts are in proper alignment.
TS0130
5. Pull on wire slightly to be certain contact is locked in
place.
DX,ECONN,R -19-04JUN90
-UN-23AUG88
TS0131
DX,ECONN,S -19-04JUN90
40
-UN-23AUG88
15
3
TS0132
DX,ECONN,T -19-04JUN90
-UN-23AUG88
keyed A, B, C. “A” matches 1, “B”
matches 2 and “C” matches 3. See
component replacement stories for any
exceptions on connector codes.
TS0133
3. Install WEATHER PACK contact on wire. (See install
WEATHER PACK Contact in this section.)
DX,ECONN,U -19-04JUN90
-UN-23AUG88
6. Close connector body.
TS0130
DX,ECONN,V -19-04JUN90
-UN-23AUG88
15 b) Gray - 14 to 16 gauge wire
4 c) Blue - 10 to 12 gauge wire
TS0136
2. Strip insulation from wire to expose 6 mm (1/4 in.)
and align cable seal with edge of insulation.
DX,ECONN,AA -19-04JUN90
-UN-23AUG88
3. Place proper size contact on wire and use JDG144
Terminal Applicator to crimp contact in place with a “W”
type crimp.
TS0137
DX,ECONN,AB -19-04JUN90
-UN-23AUG88
TS0138
DX,ECONN,AC -19-04JUN90
40
15
-UN-02DEC88
5
TS0139
DX,ECONN,AD -19-04JUN90
40
15
6
-UN-07AUG91
M80700AE
A—Front Light E—Hourmeter H—Circuit Breaker J—Starter Solenoid
B—Voltmeter F—Voltage Regulator (Right-Hand Side) K—Engine Harness
C—Front Light Switch G—Circuit Breaker (Left-Hand I—Ground L—Neutral Start Switch
D—Key Switch Side)
MX,4015HE,A1 -19-27SEP91
40
15
7
-UN-07AUG91
M80701AE
A—Hydraulic Pump Switch C—Hydraulic Pump “Up” D—Hydraulic Pump “Down” E—Ground Wiring Leads
B—Circuit Breaker (Center) Relay Relay F—Hydraulic Pump Motor
2. Remove battery cover and disconnect battery 6. Connect wiring connectors and leads.
negative (—) cable.
7. Install tie straps as necessary.
3. Cut all tie straps.
8. Connect battery negative (—) cable and install
4. Disconnect wiring connector and leads (A—F). cover.
MX,4015HE,A2 -19-27SEP91
40
15
8
Group 20—Transaxle
Other Materials . . . . . . . . . . . ....... 50-20-1
Transaxle
Remove . . . . . . . . . . . . . . .. . . . . . 50-20-2
Remove External Components . . . . . . 50-20-4
Disassemble and Inspect . . . .. . . . . . 50-20-4
Assemble . . . . . . . . . . . . . .. . . . . . 50-20-13
Install External Components . .. . . . . . 50-20-20
Install . . . . . . . . . . . . . . . . .. . . . . . 50-20-21
50
-UN-23AUG88
machine or attachment, securely support the
machine or attachment. Failure to do so may
result in serious injury.
TS226
MX,LOW,AT -19-27SEP91
-UN-10SEP91
3. Remove muffler. (See Section 20, Group 10.)
M80707
05
4. Remove plug (B) to drain gear case. 1
5. Remove eight cap screws (A). Tap seam of case with
a plastic hammer and remove case cover and gasket.
MX,5005HE,A1 -19-27SEP91
-UN-10SEP91
A—Clutch Drum Assembly
B—Roller Chain
C—Output Shaft/Gear
D—Cap Screw and Washer
M80708
MX,5005HE,A2 -19-27SEP91
-UN-10SEP91
11. Make repairs as necessary. (See procedures in this
group.)
M80709
B—Cap Screw (4 used) E—Spacer
C—Gear Case Half
MX,5005HE,A3 -19-27SEP91
-UN-10SEP91
50
M80710
05
2
MX,5005HE,A4 -19-27SEP91
-UN-10SEP91
SPECIFICATIONS (MIN)
M80711
MX,5005HE,A5 -19-27SEP91
-UN-10SEP91
50
M80712
05
3
A—E-Clip C—Spring Washer E—Clutch Shoe (5 used) G—Drive Hub
B—Washer D—Washer/Retainer F—Spring (5 used) H—Clutch Drum
5. Push down on washer (B) and remove E-clips (A). 7. Inspect all parts for wear or damage. Replace as
necessary.
MX,5005HE,A6 -19-27SEP91
Drive Hub
MX,5005HE,A7 -19-27SEP91
-UN-10SEP91
grooves (B) of clutch drum flange. Install bushing below
clutch drum flange surface to specifications.
M80714
SPECIFICATIONS
-UN-10SEP91
M80715
50
05
4
MX,5005HE,A8 -19-27SEP91
-UN-10SEP91
M80716AE
MX,5005HE,A9 -19-27SEP91
-UN-10SEP91
E—Case Half Cover
F—Seal
50
M80717
05
5
Case Halves
MX,5005HE,A10 -19-27SEP91
50
05
6
-UN-10SEP91
M80660AE
MX,5005HE,A11 -19-27SEP91
1. Install clutch shoes (A) with tab (B) into slot (C) of
drive hub.
-UN-10SEP91
2. Install springs.
M80718
Drive Hub and Shoes
MX,5005HE,A12 -19-27SEP91
A—E-Clip (5 used)
B—Washer
C—Spring Washer
D—Washer/Retainer
E—Clutch Assembly
-UN-10SEP91
F—Clutch Drum
M80719
MX,5005HE,A13 -19-27SEP91
MX,5005HE,A14 -19-27SEP91
-UN-10SEP91
IMPORTANT: Install spacer (E) with chamfered ID
toward engine.
M80709
A—Baffle Cover
B—Cap Screw (4 used)
C—Gear Case Half
D—Key
E—Spacer
MX,5005HE,A15 -19-27SEP91
-UN-10SEP91
A—Clutch Drum Assembly
B—Roller Chain
C—Output Shaft/Gear
D—Cap Screw and Washer
M80708
MX,5005HE,A16 -19-27SEP91
-UN-10SEP91
8. Fill clutch assembly with proper oil. (See Section 10,
Group 20.)
MX,5005HE,A17 -19-27SEP91
RW12167 -UN-04MAY89
DX,JDM4A -19-27SEP91
OTHER MATERIAL
50
10
NEVER-SEEZ is a trademark of the Emhart Chemical Group.
1
MX,6005GC,A1 -19-15JAN91
-UN-23AUG88
machine or attachment, securely support the
machine or attachment. Failure to do so may
result in serious injury.
TS226
MX,LOW,AT -19-27SEP91
-UN-10SEP91
2. Put machine in gear and lock park brake.
M80760
3. Rotate inner sheave half toward front of machine and
outer sheave half toward rear.
MX,5010HE,A1 -19-27SEP91
-UN-04MAY89
RW12117
MX,5010HE,A2 -19-27SEP91
-UN-10SEP91
9. Remove drive belt.
M80761AE
MX,5010HE,A3 -19-27SEP91
-UN-10SEP91
1. Install belt on drive clutch (A).
M80762
MX,5010HE,A4 -19-27SEP91
-UN-10SEP91
unless force is applied at points half way around
the clutch.
M80763
counterclockwise. 10
3
4. Rotate sheave to complete installation.
MX,5010HE,A5 -19-27SEP91
-UN-10SEP91
cap screw and washers (A).
M80764
5. Make repairs as necessary. (See procedures in this
group.)
-UN-21NOV88
2. Remove lock ring (B) and washers (C).
RW12392
B—Lock Ring E—Ramp Plate
C—Washers (3 used)
MX,5010HE,A7 -19-27SEP91
-UN-21NOV88
6. Remove roller arm assemblies.
RW12164
(S.N. —840000)
-UN-10SEP91
50
M80765
10
(S.N. 840001— ) 5
MX,5010HE,A8 -19-27SEP91
-UN-21NOV88
used parts of the same kind.
RW12165
A—Roller Arm
B—Sleeves (2 used)
C—Shaft (S.N. —840000)
D—Spring (2 used) -UN-10SEP91
M80766
(S.N. 840001— )
MX,5010HE,A9 -19-27SEP91
-UN-21NOV88
5. Check movable sheave bushing for excessive wobble.
RW12394
Spider is an interference fit. Any movement
requires replacement.
(S.N. —840000)
6. Inspect springs (D) and retainers (E), if equipped, for
wear or damage. Replace if necessary.
A—Fixed Sheave
B—Movable Sheave
C—Spider
D—Spring (3 used)
E—Retainer (3 used)
50
-UN-10SEP91
10
6
M80767
(S.N. 840001— )
MX,5010HE,A10 -19-27SEP91
MX,5010HE,A11 -19-27SEP91
-UN-21NOV88
9. Assemble spider hot and dry, heat new spider to
80—123˚C (180—250˚F).
RW12395
10. Press spider onto hub using a bolt or 300 mm (12
in.) threaded stock, four washers, and two nuts.
MX,5010HE,A12 -19-27SEP91
-UN-21NOV88
RW12396
MX,5010HE,A12A -19-27SEP91
15. Install ramp plate (A), cup washer (B), washers and
nut.
-UN-21NOV88
16. Tighten spider until cup washer bottoms on hub.
MX,5010HE,A12B -19-27SEP91
18. Install snap ring (A) cup washer, washers, and nut.
-UN-21NOV88
ramp plate.
RW12398
WXA,050015,O -19-09MAY90
A—Roller Arm
-UN-21NOV88
B—Sleeves (2 used)
C—Shaft
D—Spring (2 used)
50
RW12165
10
8
(S.N. —840000)
-UN-10SEP91
M80766
(S.N. 840001— )
MX,5010HE,A13 -19-27SEP91
-UN-21NOV88
4. (S.N. —840000): Raise movable sheave against
spider and hook springs (B) behind tab of roller arm with
JDM4-A Clutch Spring Tool.
RW12399
(S.N. —840000)
-UN-10SEP91
50
M80768
10
(S.N. 840001— ) 9
MX,5010HE,A14 -19-27SEP91
-UN-21NOV88
7. Tighten cap screws to 12 N·m (107 lb-in.) and bend
tab to lock.
RW12400
MX,5010HE,A14A -19-27SEP91
-UN-10SEP91
4. Make repairs as necessary. (See procedures in this
group.)
M80769
driven shaft.
8. Install transaxle.
50
10
10
MX,5010HE,A15 -19-27SEP91
-UN-21NOV88
RW12404
MX,5010HE,A16 -19-27SEP91
WXA,050020,4 -19-09MAY90
-UN-21NOV88
A—Fixed Sheave Half
B—Movable Sheave Half
C—Cam
D—Spring
E—Key
F—Snap Ring
RW12406
MX,5010HE,A17 -19-27SEP91
-UN-21NOV88
tabs break off inside movable sheave ramp, remove tabs
using a drill bit.
RW12408
thread lock and sealer (medium strength) on tabs and 10
install ramp shoes. 11
4. Inspect movable sheave bushing (B) for excessive
wear.
MX,5010HE,A18 -19-27SEP91
MX,5010HE,A19 -19-27SEP91
5. Install key.
-UN-21NOV88
RW12410
WXA,050020,9 -19-09MAY90
-UN-21NOV88
50
RW12411
10
12
WXA,050020,10 -19-09MAY90
-UN-21NOV88
9. Press cam down enough to install snap ring.
RW12412
MX,5010HE,A20 -19-27SEP91
-UN-23AUG88
machine or attachment, securely support the
machine or attachment. Failure to do so may
result in serious injury.
TS226
MX,LOW,AT -19-27SEP91
-UN-18SEP89
1. Loosen screws (A).
E33623
15
4. Cut all tie straps. 1
5. Remove cable housing.
A—Screws
-UN-18SEP89
B—Nuts
C—Spring
D—Ball
E—Shift Lever
E33624
MX,5015HE,A1 -19-27SEP91
-UN-10SEP91
50
15
2
M80770
A—Forward Pedal D—Reverse Pedal F—Rod H—Forward Shift Cable
B—Pedal Pad E—Spring Pin (2 used) G—Spring (2 used) I—Reverse Shift Cable
C—Pedal Pad
MX,5015HE,A2 -19-27SEP91
-UN-10SEP91
50
15
3
M80771
A—Rod C—Link Rod E—Roll Pin F—Lever
B—Differential Lock Pedal D—Spring Pin (2 used)
MX,5015HE,A3 -19-27SEP91
50
15
4
OTHER MATERIAL
T43512 John Deere Thread Lock and Retain cap screws and fittings.
Sealer (medium strength)
TY6305 John Deere Clean and Cure Primer Cleans parts and speeds cure of
sealant.
-UN-23AUG88
machine or attachment, securely support the
machine or attachment. Failure to do so may
result in serious injury.
TS226
MX,LOW,AT -19-27SEP91
REMOVE TRANSAXLE
-UN-18SEP89
3. Remove rear wheels. (See Section 80, Group 10.)
E33563
5. Pull axle shaft out of coupler, both sides.
-UN-18SEP89
E33564
50
20
2
MX,5020HE,A2 -19-27SEP91
6. Drain transaxle.
-UN-10SEP91
14. Cut all tie straps.
M80772
20
3
17. Make repairs as necessary. (See procedures in this
group.)
A—Brake Caliper Lever
B—Nut
C—Clamps (4 used)
D—Tube
E—Lock Nut
F—Cap Screw, Washer and Nut (3 used)
G—Hydraulic Pump Wiring Connector
H—Neutral Start Switch Wiring Connector
I—Nuts
J—Differential Lock Rod
MX,5020HE,A3 -19-27SEP91
A—Brake Disc
B—Vent Tube
C—Mount Bracket
-UN-10SEP91
D—Gear Shift Lever
E—Neutral Start Switch
F—Differential Lock Lever
50
M80773
20
4
MX,5020HE,A4 -19-27SEP91
A—Input Shaft
B—Shift Block
C—Secondary Shaft
D—Differential
E—Differential Lock Shaft
-UN-10SEP91
M80774
MX,5020HE,A5 -19-27SEP91
-UN-10SEP91
M80775
MX,5020HE,A6 -19-27SEP91
50
20
5
SPECIFICATIONS
MX,5020HE,A7 -19-27SEP91
-UN-10SEP91
50
M80776
20
7
A—Sleeve E—Needle Bearing (2 used) H—Balls K—Forward Drive Gear
B—Ball Bearing F—Reverse Drive Sprocket I—Input Shaft L—Washer
C—Snap Ring G—Spring J—Shift Collar M—Ball Bearing
D—Washer
Input Shaft
MX,5020HE,A7A -19-27SEP91
-UN-10SEP91
M80777
A—Ball Bearing C—Snap Ring E—Washer F—Ball Bearing
B—Secondary Shaft D—Forward Driven Gear
50 Secondary Shaft
20
8 NOTE: Bearings (A and F) are press fit. 15. Remove parts (B—E).
14. Remove bearings (A and F) using a knife edged 16. Inspect parts for wear or damage. Replace as
puller and a press. necessary.
MX,5020HE,A8 -19-27SEP91
-UN-10SEP91
50
M80778
20
9
A—Long Output Shaft F—Washer (20 used) J—Snap Ring (2 used) N—Differential Housing Half
B—Ball Bearing G—Cap Screw (10 used) K—Bevel Pinion Shaft O—Nut (10 used)
C—Differential Lock Collar H—Washer (2 used) L—Pinion Gear (2 used) P—Ball Bearing
D—Differential Housing Half I—Bevel Gear (2 used) M—Washer (2 used) Q—Short Output Shaft
E—Final Drive Gear
Differential
17. Disassemble parts (A—Q). 21. Measure groove width of lock collar (C). Replace
collar if not within specifications.
NOTE: Bearings (B and P) are press fit.
22. Measure thickness of washers (H and M).
18. Remove bearings (B and P) using a knife-edged Replace washers if not within specifications.
puller and a press.
23. Measure ID of bevel pinions (L). Replace pinions
19. Remove collar (C). and shaft (K) if not within specifications.
20. Inspect parts for wear or damage. Replace as 24. Measure OD of shaft (K). Replace shaft and
necessary. pinions (L) if not within specifications.
SPECIFICATIONS
Groove Width of
Lock Collar (C) . . . . . . . . . . . . 7.10—7.30 mm (0.280—0.290 in.)
Washer (H) Thickness . . . . . . . . . 0.74—0.86 mm (0.029—0.033 in.)
Washer (M) Thickness . . . . . . . . . 0.96—1.04 mm (0.038—0.041 in.)
Pinion Gear (L) ID . . . . . . . . . . . 16.03—16.05 mm (0.631—0.632 in.)
Shaft (K) OD . . . . . . . . . . . . . . 15.95—15.97 mm (0.628—0.629 in.)
Shaft-to-Pinion Gear
Clearance (MAX) . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.010 in.)
MX,5020HE,A9 -19-27SEP91
-UN-10SEP91
M80779
A—O-Ring (2 used) D—Spring G—Snap Ring I—Large Roll Pin
B—Washer E—Washer H—Roll Pin (2 used) J—Small Roll Pin
C—Differential Lock Fork F—Differential Lock Shaft
50 25. Remove O-rings (A) and washer (B). 30. Measure thickness of lock fingers on fork (C).
20 Replace fork if not within specifications.
10 26. Place fingers of fork (C) in a vise. Compress
spring (D) using a valve spring compressor on ends 31. Measure ID of fork (C). Replace fork and shaft
of fork (C) and shaft (F). (F) if not within specifications.
27. Drive out roll pins (H, I and J). 32. Measure OD of shaft (F). Replace shaft and fork
(C) if not according to specifications.
28. Disassemble parts (C—G).
33. Measure free length and working load length of
29. Inspect parts for wear or damage. Replace as spring (D). Replace if not according to specifications.
necessary.
SPECIFICATIONS
MX,5020HE,A10 -19-27SEP91
SPECIFICATIONS
-UN-10SEP91
Case Bore ID . . . . . . . . . . . . . . 17.02—17.04 mm (0.670—0.671 in.)
Shaft-to-Case Bore
Clearance (MAX) . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.010 in.)
A—Cap Screw 50
M80780
B—Retaining Plate 20
C—Snap Ring 11
E—Shifter Arm Shifter Arm
F—Shifter Block
MX,5020HE,A11 -19-27SEP91
-UN-10SEP91
M80781
50
20 A—Seal C—Seal E—Transaxle Case Half G—Seal
12 B—Spacer D—Seal F—Spacers H—Transaxle Case Half
39. Inspect case halves (E an H) for cracks or 41. Replace seals (A, D and G) using a bushing,
damage. Replace halves if necessary. bearing and seal driver set. Install seals flush to case
bearing bores.
40. Remove spacers (B and F).
Remove seal (C) using a screwdriver. Install seal into
IMPORTANT: Replace all seals. Damaged seals case bore until it stops, using a bushing, bearing and
will leak. seal driver set.
MX,5020HE,A12 -19-27SEP91
ASSEMBLE TRANSAXLE
-UN-10SEP91
50
M80781
20
13
A—Seal C—Seal E—Transaxle Case Half G—Seal
B—Spacer D—Seal F—Spacers H—Transaxle Case Half
NOTE: Lubricate all internal parts with clean oil 2. Apply multipurpose grease to spacers (B and F) to
during assembly. hold in place.
IMPORTANT: Use new seals and O-rings during NOTE: Install spacers (F), as shown.
assembly. Damaged seals or O-ring
will leak. 3. Install spacers (B and F).
MX,5020HE,A13 -19-27SEP91
A—Cap Screw
B—Retaining Plate
C—Snap Ring
D—O-Ring
E—Shifter Arm
F—Shifter Block
-UN-10SEP91
50
M80780
20
14
Shifter Arm
MX,5020HE,A14 -19-27SEP91
10. Install double roll pin (G) with split facing away from
shaft fork.
12. Install spring pin (H) with split facing toward fork.
A—O-Ring (2 used)
-UN-10SEP91
B—Snap Ring
C—Washer
D—Spring
E—Differential Lock Fork
F—Roll Pin
G—Double Roll Pin
50
M80782
H—Roll Pin 20
I—Washer 15
Differential Lock Shaft
MX,5020HE,A15 -19-27SEP91
Differential
MX,5020HE,A16 -19-27SEP91
18. Install long output shaft (A) and notched bevel gear
(B) with snap ring (C) and washer (D) into housing half
with lock collar (E).
-UN-21NOV88
ring assembly into other housing half.
RW12092
MX,5020HE,A17 -19-27SEP91
20. Install bevel pinion shaft (A) with pinion gears (B)
and washers (C) into differential carrier half with lock
-UN-21NOV88
collar.
50
RW12136
20
16
MX,5020HE,A18 -19-27SEP91
-UN-21NOV88
RW12137
MX,5020HE,A19 -19-27SEP91
-UN-10SEP91
and seal driver set.
A—Ball Bearing
M80783
B—Washer
C—Forward Driven Gear
D—Snap Ring Secondary Shaft
E—Ball Bearing
MX,5020HE,A20 -19-27SEP91
-UN-21NOV88
29. Install shift collar to neutral position with shoulder (C)
toward short end of input shaft.
RW12128
Input Shaft
MX,5020HE,A21 -19-27SEP91
-UN-21NOV88
32. Press bearing tight against shoulder (C) of input
shaft.
RW12099
MX,5020HE,A22 -19-27SEP91
-UN-21NOV88
RW12100
MX,5020HE,A23 -19-27SEP91
35. Install bearing (A) onto shaft against snap ring (B)
using a piece of pipe and a press.
-UN-21NOV88
37. Install wear sleeve onto shaft against bearing using a
piece of pipe and a press.
50
RW12101
20
18
MX,5020HE,A24 -19-27SEP91
-UN-10SEP91
M80784
-UN-10SEP91
M80785
MX,5020HE,A25 -19-27SEP91
-UN-10SEP91
46. Apply multipurpose grease to shafts.
M80786
20
TORQUE SPECIFICATIONS
19
MX,5020HE,A26 -19-27SEP91
-UN-10SEP91
8. Install lever and roll pin (F).
M80773
20
20 Vent Tube (B) . . . . . . . . . . . . . . . . . . . . . . . . . 10 N·m (88 lb-in.)
Neutral Start Switch . . . . . . . . . . . . . . . . . . . . . . . 39 N·m (28 lb-ft)
A—Brake Disc
B—Vent Tube
C—Mount Bracket
D—Gear Shift Lever
E—Neutral Start Switch
F—Differential Lock Lever
MX,5020HE,A27 -19-27SEP91
INSTALL TRANSAXLE
-UN-10SEP91
7. Connect wiring connectors (G and H).
M80772
20
21
A—Brake Caliper Lever
B—Nut
C—Clamps (4 used)
D—Tube
E—Lock Nut
F—Cap Screw, Washer and Nut (3 used)
G—Hydraulic Pump Wiring Connector
H—Neutral Start Switch Wiring Connector
I—Nuts
J—Differential Lock Rod
MX,5020HE,A28 -19-27SEP91
-UN-18SEP89
flangette nuts to 25 N·m (216 lb-in.).
E33563
15. Install drive belt. (See Group 10.)
17. Fill transaxle with proper oil. (See Section 10, Group
20.)
50
20
22
MX,5020HE,A29 -19-27SEP91
-UN-10SEP91
6. Remove drive axle (A) using a jaw puller and a slide
hammer.
M80787
8. Inspect parts for wear or damage. Replace as
25
1
necessary.
MX,5025HE,A1 -19-27SEP91
-UN-10SEP91
13. Tighten bearing flangette lock nuts to specifications.
M80788
15. Tighten locking collar set screws to specifications.
SPECIFICATIONS
50
25
2
MX,5025HE,A2 -19-27SEP91
60
60
OTHER MATERIAL
-UN-23AUG88
machine or attachment, securely support the
machine or attachment. Failure to do so may
result in serious injury.
TS226
MX,LOW,AT -19-27SEP91
-UN-19SEP91
2. Remove lock nut (B) and disconnect chain (A).
M80863
MX,6005HE,A2 -19-27SEP91
-UN-19SEP91
NOTE: Install collar (E) with recessed side facing down.
M80864
10. Install eccentric collar (E) and tighten set screw to 8
N·m (64 lb-in.).
60
05 11. Install cap.
2 A—Steering Shaft
B—Spacer
C—Washer
D—Bushing (2 used)
E—Eccentric Collar
F—Set Screw
G—Cap
MX,6005HE,A3 -19-27SEP91
12. Connect chain (A) and install lock nut (B). Tighten
lock nut until snug. Rotate steering fork to check for
-UN-19SEP91
smooth operation.
MX,6005HE,A4 -19-27SEP91
-UN-19SEP91
2. Remove front wheel. (See Section 80, Group 10.)
M80863
MX,6005HE,A5 -19-27SEP91
A—Cap Screw
B—Lock Washer
C—Washer
D—Steering Disk
E—Washer (2 used)
F—Bearings (2 used)
G—Steering Fork
H—Chain
I—Stud -UN-19SEP91
M80865
MX,6005HE,A6 -19-27SEP91
A—Frame
B—Disk
C—Chain End
D—Steering Fork
-UN-19SEP91
M80866
MX,6005HE,A7 -19-27SEP91
-UN-19SEP91
14. Connect chain (A) and install lock nut (C). Tighten
lock nut until snug. Rotate steering fork to check for
smooth operation.
M80867
chain.
MX,6005HE,A8 -19-27SEP91
OTHER MATERIAL
AR85792 John Deere Multi-Purpose Adhesive Apply to brake lining half to hold in
place.
-UN-23AUG88
machine or attachment, securely support the
machine or attachment. Failure to do so may
result in serious injury.
60
10
1
TS226
MX,LOW,AT -19-27SEP91
-UN-23AUG88
containing asbestos fibers. Inhaled asbestos
fibers may cause lung cancer. Normal handling
is not hazardous as long as airborne dust
containing asbestos is not generated.
TS220
for cleaning. Avoid brushing or grinding
material containing asbestos. When servicing,
wear an approved respirator. A special vacuum
cleaner is recommended to clean asbestos. If
not available, apply a mist of oil or water on
the material containing asbestos.
-UN-19SEP91
Keep bystanders away from the area.
M80789
2. Remove cap screws and lock washers (B).
MX,6010HE,A2 -19-27SEP91
-UN-19SEP91
M80790
NOTE: Lining (G) is glued in housing half (H). Replace 60
only if necessary. 10
3
Remove pin (L) using a hammer and punch.
-UN-19SEP91
1. Disassemble parts (A—N).
M80791
3. Inspect linings (F and G) for excessive wear. Replace
if necessary.
-UN-19SEP91
2. Remove right-hand side rear wheel. (See Section 80,
Group 10.)
M80792
4. Remove four lock nuts and bolts (A).
-UN-19SEP91
M80793
MX,6010HE,A4 -19-27SEP91
-UN-19SEP91
necessary.
M80794
10. Install key and brake disk.
MX,6010HE,A5 -19-27SEP91
-UN-19SEP91
14. Install bolts and lock nuts (A). Tighten nuts to 25
N·m (216 lb-in.)
M80792
16. Install rear wheel. (See Section 80, Group 10.)
MX,6010HE,A6 -19-27SEP91
60
10
5
-UN-18SEP89
2. Loosen set screw (B) and remove adapter from cable.
E33626
4. Remove nuts (C) from both ends of housing.
-UN-18SEP89
E33627
MX,6010HE,A7 -19-27SEP91
-UN-19SEP91
M80795
A—Pedal Pad D—Extension Spring G—Cotter Pin (2 used) I—Brake Cable 60
B—Screw E—Cable H—Rod J—Park Brake Lock Lever 10
C—Clamp F—Brake Pedal 7
1. Remove brake cable (I). (See Replace Brake 4. Install all parts.
Cable and Housing in this group.)
5. Install brake cable.
2. Remove parts (A—H).
MX,6010HE,A8 -19-27SEP91
MX,6010HE,A9 -19-27SEP91
60
10
8
70
70
-UN-23AUG88
machine or attachment, securely support the
machine or attachment. Failure to do so may
result in serious injury.
TS226
MX,LOW,AT -19-27SEP91
-UN-07AUG91
2. Disconnect hoses (C). Close all openings using caps
and plugs.
M80702
4. Remove hydraulic pump.
8. Connect hoses.
MX,7005HE,A1 -19-27SEP91
-UN-07AUG91
7. Check shuttle valve (5) for free movement in bore and
70 O-ring for damage.
05
2
8. Inspect passages for plugged condition.
M80705
9. Clean components in solvent and dry with
compressed air. Be sure all passages are clear.
TORQUE SPECIFICATIONS
ITEM SPECIFICATION
-UN-07AUG91
6—Adapter 21—Screw
7—Ball 22—Fitting (2 used) 70
8—Eyelet 23—Suction Screen (2 05
9—Spring used) 3
10—Set Screw 24—Screw
11—Steel Ball (2 used) 25—Gear Pump
M80705
12—Eyelet (3 used) 26—O-Ring (2 used)
13—Spring (3 used) 27—Thermal Relief
14—Nut (2 used) Valve (2 used)
15—Lower Relief Valve 28—Plastic Ball (2 used)
MX,7005HE,A2A -19-27SEP91
7. Connect hoses.
-UN-07AUG91
A—Flange Nut
B—Hydraulic Hose-to-Cylinder Head End
C—Hydraulic Hose-to-Cylinder Rod End
D—Pin
M80703
MX,7005HE,A3 -19-27SEP91
70
05
4
-UN-07AUG91
70
05
5
M80704
A—Hydraulic Hose from C—Hydraulic Hose to Lift E—O-Ring (8 used) H—Quick Coupler—Male (2
Pump Cylinder F—Cap (2 used) used)
B—Hydraulic Hose from D—Hydraulic Hose to Lift G—Quick Coupler—Female (2 I—Cap (2 used)
Pump Cylinder used)
2. Disconnect hoses (A—D). Close openings using IMPORTANT: When installing tie straps, tie hoses
caps and plugs. to frame to keep away from driven
clutch and fuel tank spill tray. Hoses
3. Inspect parts for wear or damage. Replace as may split or spill tray will crack.
necessary.
6. Install tie straps as necessary.
4. Apply petroleum jelly to O-rings (E).
MX,7005HE,A4 -19-27SEP91
70
05
6
80
-UN-23AUG88
machine or attachment, securely support the
machine or attachment. Failure to do so may
result in serious injury.
TS226
MX,LOW,AT -19-27SEP91
-UN-20SEP91
Group 10.)
M80796
7. Install front hood.
MX,8005HE,A1 -19-27SEP91
-UN-20SEP91
5. Install screws and washers.
M80860
MX,8005HE,A2 -19-27SEP91
80
-UN-20SEP91
05
2
M80797
MX,8005HE,A3 -19-27SEP91
-UN-12OCT88
3. Inspect wheel bearings for wear or damage. Replace
if necessary. (See this group.)
E32487
MX,8010HE,A1 -19-27SEP91
-UN-20SEP91
NOTE: Remove bearings only if replacement is
necessary.
M80798
NOTE: Bearings are press fit in wheel and slip fit on
axle tube.
MX,8010HE,A2 -19-27SEP91
80
10
1
-UN-20SEP91
5. Install one bearing in wheel until seated using a
bearing, bushing and seal driver set.
M80799
bushing and seal driver set.
MX,8010HE,A3 -19-27SEP91
-UN-20SEP91
3. Remove cap screws and wheel.
M80861
NOTE: Valve stem must face outside of machine.
6. Lower machine.
1. Lower rake.
-UN-18SEP89
E33609
MX,8015HE,A1 -19-27SEP91
80
15
1
-UN-18SEP89
E33610
MX,8015HE,A2 -19-27SEP91
-UN-20SEP91
M80862
A—Pin E—Guide I—Center Angle L—L.H. Angle
B—Cap Screws F—Chain (2 used) J—Chain Link (10 used) M—Cap Screw (2 used)
C—Lock Nut (2 used) G—R.H. Angle K—Prong Rake Bolt (24 N—Frame
D—Compression Spring H—Rake Blade (5 used) used) O—Hitch
Inspect parts for wear or damage. Replace as Do not over tighten cap screws (B and M) or lock
necessary. nuts (C). Parts must be free to pivot.
80 MX,8015HE,A3 -19-27SEP91
15
2
INSPECT AND REPAIR MANUAL RAKE LIFT LEVER AND LINKAGE ASSEMBLY
-UN-20SEP91
M80868
A—Support D—Ball Joint G—Lock Nut J—Handle
B—Lock Nut E—Stud H—Compression Spring K—Grip
C—Lock Nut F—Latch I—Strap
Inspect all parts for wear or damage. Replace as Tighten lock nut (C) until tension of spring (H) allows 80
necessary. smooth engagement of handle (J) on latch (F). 15
3
Do not over tighten lock nuts (B and G). Parts must Adjust ball joints (D) as necessary.
be free to pivot.
MX,8015HE,A4 -19-27SEP91
-UN-20SEP91
M80869
A—Support C—Stud E—Lift Bracket G—Pin
B—Lock Nut D—Ball Joint F—Lock Nut H—Quick-Lock Pin
Inspect all parts for wear or damage. Replace as Adjust ball joints (D), as necessary.
necessary.
80
15 Do not over tighten lock nuts (B and F). Parts must
4 be free to pivot.
MX,8015HE,A5 -19-27SEP91
-UN-22SEP89
E33619
MX,8020HE,A1 -19-27SEP91
-UN-22SEP89
E33618
MX,8020HE,A2 -19-27SEP91
-UN-22SEP89
machine.
E33617
MX,8020HE,A3 -19-27SEP91
80
20
1
INSTALL FRONT BLADE
MX,8020HE,A4 -19-27SEP91
-UN-22SEP89
5. Slide cover (C) against locking collar (B).
E33618
MX,8020HE,A5 -19-27SEP91
-UN-22SEP89
7. Raise and lockout blade using quick-lock pin (B).
E33619
-UN-22SEP89
E33620
80 MX,8020HE,A6 -19-27SEP91
20
2
-UN-20SEP91
80
M80870
20
3
A—Quick-Lock Pin (3 used) D—Lock Nut (3 used) G—Stud J—Front Blade
B—Strap E—Cover H—Grip K—Pin (2 used)
C—Bracket F—Ball Joint (2 used) I—Bumper (2 used)
Inspect all parts for wear or damage. Replace as Adjust ball joints (F), as necessary.
necessary.
MX,8020HE,A7 -19-27SEP91
80
20
4
-UN-18SEP89
2. Remove quick-lock pin (D) and drilled pin from strap
(A). Repeat on opposite side.
E33615
4. Make repairs as necessary. (See procedure in this
group.)
-UN-18SEP89
NOTE: If hook bolt does not line up with pivot strap,
move left-hand collar (E) to adjust pivot shaft.
E33616
A—Strap
B—Quick-Lock Pin
C—Hook Bolt
D—Quick-Lock Pin
E—Locking Collar
MX,8025HE,A1 -19-27SEP91
80
25
1
-UN-20SEP91
M80871
A—Quick-Lock Pin (6 used) C—Compression Spring (2 D—Pin (2 used) E—Blade (5 used)
B—Hook Bolt (2 used) used)
-UN-20SEP91
M80872
80
A—Cap Screw (4 used) E—Spring (S.N. 840001— ) H—Lock Nut (S.N. J—Support (S.N. —840000) 25
B—Lock Nut F—Support (S.N. 840001— ) 840001— ) K—Spring (S.N. —840000) 3
C—Grip G—Adjustment Pin (S.N. I—Set Screw (2 used)
D—Handle 840001— )
Inspect all parts for wear or damage. Replace as Install R.H. rear cap screw (A) with head to inside of
necessary. frame.
Do not over tighten lock nut (B). Handle (D) must Machine (S.N. 840001— ): Adjust lock nut (H) until
pivot freely. length of spring (E) is 89 mm (3.500 in.).
MX,8025HE,A3 -19-27SEP91
80
25
4
210
210
ENGINE
Fast Idle Limiter Screw Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3800 rpm
Slow Idle Stop Screw Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm
Slow Idle Limiter Screw Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300—1500 rpm
Compression (Min.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 kPa (71 psi)
Intake and Exhaust Valve Clearance (Cold)
Range Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10—0.15 mm (0.004—0.006 in.)
Adjustment Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.125 ± 0.025 mm (0.005 ± 0.001 in.)
Compression Release Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Crankcase Vacuum (Min.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 mm (1.2 in.) water
Fuel Pump Pressure (Min.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12 kPa (0.9 psi)
Fuel Pump Flow (Min.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 mL/15 sec. (2.7 oz./15 sec.)
ELECTRICAL
Regulated Voltage Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 amps (Min.) at 12.2—13.8 V
Unregulated Voltage Output (Min.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... . . . . . . . . . . . 34 V
Stator Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... . . . . 0.24—0.4 ohms
Starter Amp Draw (Max.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... . 51 amps at 750 rpm
Starter No-Load Amperage (Max.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 50 amps at 6000 rpm
Starter No-Load rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... . . . . . . . . 6000 rpm
Ignition Coil Air Gap
Standard Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 mm (0.012 in.)
Misfire Condition Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Ignition Module Resistance
One Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1—5 K ohms
Opposite Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—6 K ohms
Ignition Coil Resistance
Primary Lead and Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.67—1.10 ohms
Spark Plug Lead and Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—10 K ohms
Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.64 mm (0.025 in.)
Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N·m (18 lb-ft)
POWER TRAIN
Drive Clutch Upshift (dimension from clutch edge to belt) . . . . . . . . . . . . . . . . . . . . . . . . . . 2 mm (1/16 in.)
Driven Clutch Spring Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27—80 N (6—18 lb)
HYDRAULIC
Pressure at Couplers (High Pressure Side) . . . . . . . . . . . . . . . . . . . . . . . 5171 ± 690 kPa (750 ± 100 psi)
Pressure at Couplers (Low Pressure Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2758 kPa (400 ± 50 psi)
Raise Relief Valve Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5171 kPa (750 psi)
Lower Relief Valve Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2758 kPa (400 psi)
Thermal Relief Valve Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17237—20684 kPa (2500—3000 psi)
Minimum Pump Flow at 750 psi (High Pressure Side) . . . . . . . . . . . . . . . . . . . . . . . . 2.8 L/min (.75 gpm) 210
Minimum Pump Flow at 400 psi (Low Pressure Side) . . . . . . . . . . . . . . . . . . . . . . . . 3.2 L/min (.85 gpm) 05
1
MX,21005HE,1A -19-27SEP91
210
05
2
MX,21010HE,1A -19-27SEP91
210
10
1
CONDITIONS:
•Machine parked on level surface.
-UN-12OCT88
•Key switch in off position.
•Park brake locked.
•Engine oil cold.
PROCEDURE:
E32466
•Clean dirt from area around dipstick.
•Remove engine oil dipstick and wipe off.
•Install dipstick in engine but do not thread dipstick onto Oil Level
dipstick tube.
•Remove dipstick and check level and condition of oil.
NORMAL:
•Level between full and add marks of dipstick.
•Oil not thick.
-UN-06AUG90
•Oil not diluted with fuel (should not be thin looking or
smell of fuel).
•No metal or dirt particles in oil.
IF NOT NORMAL:
M45603
•Add oil of proper weight to raise level to full mark on
dipstick.
Oil Condition
•Go to Section 220, Group 15 for engine
diagnosis, tests, and adjustments.
MX,21010HE,2A -19-19JUL91
210
10
2
CONDITIONS:
•Machine parked on level surface.
-UN-14NOV88
•Key switch in off position.
•Park brake locked.
•Wet clutch oil cold.
PROCEDURE:
E32613
•Clean dirt from area around dipstick (A).
•Remove wet clutch oil dipstick and wipe off.
•Install dipstick in clutch housing (B) but do not thread Oil Level
dipstick into dipstick tube.
•Remove dipstick and check level and condition of oil.
NORMAL:
•Level between full and add marks of dipstick.
•Oil not thick.
-UN-06AUG90
•No water, metal or dirt particles in oil.
IF NOT NORMAL:
•Add oil of proper weight to raise level to full mark on
dipstick.
M45603
•Go to Section 250, Group 15 for wet clutch diagnosis,
be sure this appears in 250-15.
Oil Condition
•Go to Section 50, Group 05 for wet clutch inspection.
MX,21010HE,3A -19-27SEP91
210
10
3
CONDITIONS:
•Park brake locked.
•Gear shift pedals in neutral position.
-UN-12OCT88
PROCEDURE:
•Turn key switch to run position.
•Pull front light knob out.
E32453
NORMAL:
•Front light lamp must be on.
IF NOT NORMAL:
•Go to Section 240, Group 15 for electrical diagnosis,
tests, and adjustments.
MX,21010HE,4A -19-27SEP91
210
10
4
NEUTRAL—START TEST
CONDITIONS:
•Park brake locked.
•Operator on seat.
-UN-12OCT88
PROCEDURE:
•Move forward shift pedal down.
•Turn key switch to start position.
E32445
NORMAL:
•Starting motor does NOT turn and engine does
NOT start. Transaxle Engaged
CONDITIONS:
•Park brake locked.
•Operator on seat.
PROCEDURE:
-UN-12OCT88
•Move reverse shift pedal down.
•Turn key switch to start position.
NORMAL:
•Starting motor does NOT turn and engine does
E32443
NOT start.
CONDITIONS:
•Park brake engaged.
•Operator on seat.
PROCEDURE:
•Move gear shift pedals to neutral position.
•Turn key switch to start position.
NORMAL:
•Starting motor turns.
IF NOT NORMAL:
•Go to Section 240, Group 15 for electrical
diagnosis, tests, and adjustments.
•Go to Section 250, Group 15 for power train
diagnosis, tests and adjustments.
210
10
MX,21010HE,5A -19-19JUL91 5
CONDITIONS:
•Machine parked on level surface.
•Park brake locked.
-UN-12OCT88
•Operator on seat.
•Gear shift pedals in neutral position.
•Pull choke knob out if engine is cold.
PROCEDURE:
E32442
•Turn key switch to start position.
NORMAL:
•Engine cranks and should start. With choke off,
engine runs smoothly in all throttle positions.
IF NOT NORMAL:
•Go to Section 220, Group 15 for engine and
-UN-12OCT88
fuel/air diagnosis, tests, and adjustments.
•Go to Section 240, Group 15 for ignition and
electrical diagnosis, tests, and adjustments.
E32443
MX,21010HE,6A -19-27SEP91
210
10
6
CONDITIONS:
•Machine parked on level surface.
•Park brake locked.
-UN-12OCT88
•Operator on seat.
PROCEDURE:
•Start engine and warm up for 2 minutes at fast idle.
•Move accelerator pedal from slow idle to fast idle
E32441
and back to slow idle slowly and rapidly.
NORMAL:
•Engine runs smoothly at all throttle settings.
•Engine accelerates and decelerates smoothly without
misfiring or stumbling.
IF NOT NORMAL:
•Go to Section 220, Group 15 for engine and
fuel/air diagnosis, tests, and adjustments.
•Go to Section 240, Group 15 for ignition
diagnosis, tests, and adjustments.
MX,21010HE,7A -19-19JUL91
210
10
7
CONDITIONS
•Operator on seat.
•Engine warmed up and operating at slow idle
-UN-12OCT88
-UN-12OCT88
•Park brake disengaged.
PROCEDURE:
•Push inner, (forward) pedal down and accelerate
engine slightly.
E32450
E32451
•Push outer, (reverse) pedal down and accelerate
engine slightly.
•Push both pedals until they are even (neutral) and Forward Reverse
accelerate engine slightly.
NORMAL:
•Machine should start to move smoothly (in forward
and reverse) with little or no shifter clash.
•Machine should not move in neutral position.
-UN-12OCT88
IF NOT NORMAL:
•Go to Section 250, Group 15 for power train diagnosis,
tests, and adjustments.
E32445
Neutral
MX,21010HE,8A -19-27SEP91
210
10
8
CONDITIONS:
•Operator on seat.
•Machine on large clear area for driving.
-UN-12OCT88
•Engine warmed up and operating at slow idle.
PROCEDURE:
•Push inner (forward) pedal down.
•Push accelerator pedal slowly.
E32441
NORMAL:
•Drive must engage smoothly.
PROCEDURE:
•Push inner, (forward) pedal down.
•Push accelerator pedal to wide open throttle.
NORMAL:
•Engine should accelerate to full rpm immediately.
•Vehicle should increase to full speed smoothly.
PROCEDURE:
•Push inner, (forward) pedal down.
•Drive vehicle onto hilly or soft ground to slow
vehicle travel.
NORMAL:
•Engine rpm must remain constant as vehicle speed
slows.
IF NOT NORMAL:
•Go to Section 250, Group 15 for power train
diagnosis, tests, and adjustments.
MX,21010HE,9A -19-27SEP91
210
10
9
CONDITIONS:
•Machine parked on a level surface.
•Engine operating at slow idle.
-UN-12OCT88
•Operator on seat.
PROCEDURE:
•Depress brake pedal.
•Engage park brake lever.
E32449
•Push inner, forward pedal down.
•Move throttle pedal to 1/4 throttle position.
NORMAL:
•Brake pedal remains engaged.
•Vehicle does not move.
PROCEDURE:
-UN-12OCT88
•Push outer, reverse pedal down.
•Move throttle pedal to 1/4 throttle position.
NORMAL:
•Brake pedal remains engaged.
E32447
•Vehicle does not move.
IF NOT NORMAL:
•Go to Section 260, Group 15 for brake diagnosis,
tests, and adjustments.
MX,21010HE,10A -19-19JUL91
210
10
10
CONDITIONS:
•Machine on level surface with large clear
area for driving.
-UN-12OCT88
•Operator on seat.
•Engine warmed up and running at slow idle.
•Inner, forward pedal pushed down.
PROCEDURE:
E32452
•Depress accelerator pedal to start machine moving
slowly.
•Turn steering wheel to make a tight turn (direction
not important).
•Depress differential lock pedal.
NORMAL:
•Differential lock engages.
•Vehicle will resist turning and try to push straight ahead.
IF NOT NORMAL:
•Go to Section 250, Group 15 for power train diagnosis,
tests, and adjustments.
MX,21010HE,11A -19-19JUL91
210
10
11
STEERING TEST
CONDITIONS:
•Machine on a hard level surface.
•Operator on seat.
-UN-03NOV88
•Engine stopped.
PROCEDURE:
•Turn steering wheel to stops, both left and right.
E32589
NORMAL:
•Steering wheel should move easily to stops in both
directions.
IF NOT NORMAL:
•Go to Section 260, Group 15 for steering diagnosis,
tests, and adjustments.
MX,21010HE,12A -19-27SEP91
210
10
12
220
MX,22005HE,1A -19-19JUL91
220
05
1
Slide M80540
MX,22005HE,2A -19-27SEP91
220
05
2
-19-29AUG91
220
05
M80540
3
MX,22005HE,3A -19-27SEP91
MX,22005HE,4A -19-27SEP91
220
05
4
-19-29AUG91
M80541
220
Slide M80541 05
5
MX,22005HE,5A -19-27SEP91
220
05
6
MX,22010HE,1A -19-27SEP91
220
10
1
MX,22010HE,2A -19-19JUL91
220
10
2
MX,22010HE,4A -19-27SEP91
220
10
4
-19-29AUG91
M80543
Slide M80543
MX,22010HE,5A -19-19JUL91
220
10
5
FUNCTION: and head cover (C) then direct the air flow (D) past
Remove heat from engine. the cooling fins (B) of the cylinder block and head.
The cooling fins are cast into the engine block and
MAJOR COMPONENTS: cylinder head to increase their surface area, allowing
•Intake Screen more of the heat generated by the engine to be
•Flywheel Fins transferred to the cooling air.
•Flywheel and Engine Covers
•Cooling Fins It is important that the intake screen remains free
from debris for proper air flow. The engine covers
THEORY OF OPERATION: should not be removed or altered, as cooling capacity
The engine is air cooled with air flow provided by a will be reduced. Cylinder block and head cooling fins
fan (F) that is a part of the flywheel (G). During must remain clean to properly dissipate heat. On this
operation, the fan draws air in through the intake engine, debris build-up on the intake screen or fins
screen (E). The fan housing (H), cylinder cover (A) will not affect the volume of air to the carburetor.
MX,22010HE,6A -19-27SEP91
220
10
6
-19-29AUG91
M80544
220
Slide M80544 10
7
MX,22010HE,7A -19-27SEP91
GOVERNOR OPERATION
MX,22010HE,10A -19-27SEP91
220
10
8
-19-29AUG91
M80545
220
Slide M80545 10
9
MX,22010HE,11A -19-27SEP91
-19-29AUG91
M80546AE
A—Weights C—Release Tab E—Camshaft G—Spring
B—Tappet D—Camshaft Gear F—Stop Pin
Slide M80546AE
MX,22010HE,8A -19-27SEP91
220
10
10
DIAGNOSTIC INFORMATION
220
15
1
MX,22015HE,1A -19-27SEP91
CONDITIONS:
•Key switch in off position. •Engine and fuel/air tests found in this group.
•Spark plug wire removed and grounded. •Ignition and electrical tests in Section 240
•Transaxle in neutral. Group 15.
•Park brake locked. •Power train tests in Sections 250 Group 15.
Consistent blue spark. (Key switch Check for faulty key switch.
in start position.) Check for faulty coil and/or module.
Check for shorted ignition wire or high
tension lead.
2. Head. Compression of 490 kPa (71 psi) Check condition of rings, piston and
minimum. cylinder walls.
Check for sticking or damaged compression
release components.
Check for sticking or damaged valve.
Check for misadjusted valves.
3. Crankcase. Crankcase vacuum of 30 mm (1.2 in.) Check for leaking crankcase seals and
of water. (Engine running at gaskets.
3800 rpm.) Check for sticking or damaged breather
components.
Check condition of rings, piston,
cylinder walls and valves.
4. Carburetor drain screw. Free flow of fuel when screw is Check for plugged tank vent.
removed from carburetor float bowl. Check for plugged filter.
Check for plugged or pinched hoses.
Check fuel pump pressure and flow.
5. Carburetor. Fuel not leaking from float bowl. Check for dirty or sticking inlet needle.
Choke linkage free and choke fully Check choke cable adjustment.
closed when choke knob is in
choke position.
6. Air filter elements. Not dirty or oil soaked. Clean or replace as needed.
7. Crankshaft. Wet reduction clutch not dragging. Check oil level and condition of wet
(Engine at slow idle.) reduction clutch.
8. Starter motor. Starter motor turning engine at a Check battery for minimum of 12.5 VDC.
220 minimum of 350 rpm. Check wiring, key switch, and solenoid
15 contacts.
2 Check for correct weight of engine oil.
Check compression release operation.
MX,22015HE,2A -19-27SEP91
-19-29AUG91
M80563
220
Slide M80563 15
3
MX,22015HE,3A -19-19JUL91
CONDITIONS:
•Key switch in off position. •Engine and fuel/air tests found in this group.
•Spark plug wire removed and grounded. •Ignition and electrical tests found in Section 240
•Transaxle in neutral. Group 15.
•Park brake locked. •Power train tests in Section 250 Group 15.
2. Head. Minimum compression of 490 kPa Check condition of rings, piston and
(71 psi). cylinder walls.
Check for sticking or damaged compression
release components.
Check for sticking or damaged valve.
Check for misadjusted valves.
3. Crankcase. Crankcase vacuum of 30 mm (1.2 in.) Check for leaking crankcase seals and
of water. (Engine running at gaskets.
3800 rpm) Check for sticking or damaged breather
components.
Check condition of rings, piston,
cylinder walls and valves.
4. Carburetor drain screw. Free flow of fuel when screw is Check for plugged tank vent.
removed from carburetor float bowl. Check for plugged filter.
Check for plugged or pinched hose.
Check fuel pump pressure and flow.
5. Carburetor. Fuel not leaking from float bowl. Check for dirty or sticking inlet needle.
Choke linkage free and choke fully Check for secure tube connection to
open when choke knob is not in carburetor vent port.
choke position. Check for correct adjustment of choke.
Adjust mixture and slow idle screw.
Check float for leakage and correct
position.
6. Air filter elements. Not dirty or oil soaked. Clean or replace as needed.
7. Crankshaft. Wet reduction clutch not dragging. Check oil level and condition of wet
(Engine at slow idle.) reduction clutch. Check wet reduction
220 clutch internal components.
15
4 8. Governor control panel. Engine operating at specified Adjust governor and idle speeds.
3800 rpm.
MX,22015HE,4A -19-27SEP91
-19-29AUG91
M80564
220
Slide M80564 15
5
MX,22015HE,5A -19-19JUL91
CONDITIONS:
•Key switch in off position. •Engine and fuel/air tests found in this group.
•Spark plug wire removed and grounded. •Ignition and electrical tests in Section 240
•Transaxle in neutral. Group 15.
•Park brake locked. •Power train tests in Section 250 Group 15.
2. Crankshaft. Wet reduction clutch not dragging. Check wet reduction clutch oil level
(Engine at slow idle.) and condition.
Check wet reduction clutch internal
components.
MX,22015HE,6A -19-19JUL91
220
15
6
-19-29AUG91
M80565
220
Slide M80565 15
7
MX,22015HE,7A -19-19JUL91
CONDITIONS:
•Key switch in off position.
•Spark plug wire removed and grounded.
•Transaxle in neutral.
•Park brake locked.
•Engine and fuel/air tests found in this group.
1. Air filter elements. Not dirty or oil soaked. Clean or replace filter elements.
2. Fuel tank. No pressure released from tank when Check tank vent, clean and replace faulty
cap removed. cap.
4. Fuel pump. Output pressure of 6 kPa (0.9 psi) Check crankcase vacuum.
at fast idle. Check vacuum hose and connections
for leaks.
Repair or replace fuel pump.
MX,22015HE,8A -19-19JUL91
220
15
8
-19-29AUG91
M80566
220
Slide M80566 15
9
MX,22015HE,9A -19-19JUL91
CONDITIONS:
•Key switch in off position.
•Spark plug wire removed and grounded.
•Transaxle in neutral.
•Park brake locked.
•Engine and fuel/air tests found in this group.
1. Air filter elements. Not dirty or oil soaked. Clean or replace filter elements.
5. Head. Valve stem to valve guide clearance Repair or replace components as needed.
within specifications.
MX,22015HE,10A -19-19JUL91
220
15
10
-19-29AUG91
M80567
220
Slide M80567 15
11
MX,22015HE,11A -19-19JUL91
CONDITIONS:
•Key switch in off position.
•Spark plug wire removed and grounded.
•Transaxle in neutral.
•Park brake locked.
•Engine and fuel/air tests found in this group.
1. Air filter elements. Not dirty or oil soaked. Clean or replace filter elements.
5. Head. Valve stem to valve guide clearance Repair or replace components as needed.
within specification.
220
15
12
MX,22015HE,12A -19-19JUL91
-19-29AUG91
M80568
220
Slide M80568 15
13
MX,22015HE,13A -19-19JUL91
ENGINE SURGES
CONDITIONS:
•Key switch in off position.
•Spark plug wire removed and grounded.
•Transaxle in neutral.
•Park brake locked.
•Engine and fuel/air tests found in this group.
2. Carburetor inlet hose. Free flow of fuel when hose removed Check for plugged filter.
from carburetor inlet fitting. Check for plugged or pinched hose.
(Engine at slow idle.) Check fuel pump pressure and flow.
Check crankcase vacuum.
3. Carburetor. Fuel in flow bowl. Check for dirty or sticking inlet needle.
Check float and correct position.
Check for secure tube connection to
carburetor vent port.
Choke cable free and choke fully Check for binding cable.
open when choke knob is pushed in. Check for correct adjustment of choke
cable.
Smooth idle at 1300—1500 rpm. Adjust mixture and slow idle screws.
4. Crankcase. Governor arm tight on governor shaft. Adjust governor and tighten clamp nut.
Governor arm and governor shaft both Adjust governor.
rotated as far counterclockwise as
possible.
MX,22015HE,14A -19-19JUL91
220
15
14
-19-29AUG91
M80569
220
Slide M80569 15
15
MX,22015HE,15A -19-19JUL91
CONDITIONS:
•Key switch in off position.
•Spark plug wire removed and grounded.
•Transaxle in neutral.
•Park brake locked.
•Engine and fuel/air tests found in this group.
1. Crankcase. Governor arm tight on governor shaft. Adjust governor and tighten clamp nut.
Governor arm and governor shaft both Adjust governor.
rotated as far counterclockwise as
possible.
Resistance to movement of governor Disassemble engine and check governor
arm. (Engine running at fast idle.) components.
2. Governor control panel. Linkage not binding or damaged. Repair or replace components as needed.
Governor spring installed and not Repair or replace spring as needed.
stretched.
3. Carburetor. Throttle valve and linkage not Repair or replace components as needed.
binding.
Slow idle screw adjusted Adjust slow idle.
correctly.
MX,22015HE,18A -19-19JUL91
220
15
16
-19-29AUG91
M80570
220
Slide M80570 15
17
MX,22015HE,19A -19-19JUL91
CONDITIONS:
•Key switch in off position. •Engine and fuel/air tests found in this group.
•Spark plug wire removed and grounded. •Ignition and electrical tests in Section 240, Group 15.
•Transaxle in neutral. •Power train tests in Section 250, Group 15.
•Park brake locked.
Test Location Normal If Not Normal
1. Air filter elements. Not dirty or oil soaked. Clean or replace elements as needed.
3. Fuel pump. 6 kPa (0.9 psi) at 3800 rpm Test crankcase vacuum.
Replace pump.
4. Carburetor inlet hose. Free flow of fuel when hose is Check for plugged filter.
removed from carburetor inlet Check for plugged or pinched hose.
fitting. (Engine at slow idle.)
No air bubbles. Insulate fuel line.
Try different fresh fuel.
Consistent blue spark. (Key switch Check for faulty key switch.
in start position.) Check for faulty coil and/or ignition
module.
Check for shorted ignition wire or high
tension lead.
6. Carburetor. Fuel not leaking from float bowl. Check for dirty or sticking inlet needle.
Check float for leaks and correct
position.
Choke cable free and choke fully Check for correct adjustment of choke
open when choke knob is pushed in. cable.
8. Head. Minimum compression of 490 kPa Check condition of rings, piston and
(71 psi). cylinder walls.
Check for sticking or damaged compression
release components.
Check for sticking or damaged valve.
Check for misadjusted valves.
220
15
18
MX,22015HE,20A -19-27SEP91
-19-29AUG91
M80571
220
Slide M80571 15
19
MX,22015HE,21A -19-19JUL91
9. Crankcase. Crankcase vacuum of 30 mm (1.2 in.) Check for leaking crankcase seals and
of water. (Engine running at gaskets.
3800 rpm.) Check for sticking or damaged breather
components.
Check condition of rings, piston,
cylinder walls and valves.
10. Crankshaft. Wet reduction clutch not dragging. Check wet reduction clutch oil level and
(Engine at slow idle.) condition.
Check wet reduction clutch internal
components.
MX,22015HE,21AA-19-19JUL91
220
15
20
-19-29AUG91
M80571
220
Slide M80571 15
21
MX,22015HE,21A -19-19JUL91
ENGINE FLOODING
CONDITIONS:
•Key switch in off position. •Engine and fuel/air tests found in this group.
•Spark plug wire removed and grounded. •Ignition and electrical tests in Section 240
•Transaxle in neutral. Group 15.
•Park brake locked.
Test Location Normal If Not Normal
3. Carburetor. Fuel not leaking from float bowl. Check for dirty or sticking inlet needle.
Check throttle cable adjustment.
Check float for leakage and correct
position.
Smooth idle at 1300 rpm. Adjust mixture and slow idle screw.
4. Fuel pump. Output pressure of 6 kPa (0.9 psi) Check crankcase vacuum.
at fast idle. Repair or replace fuel pump
MX,22015HE,22A -19-27SEP91
220
15
22
-19-29AUG91
M80572
220
Slide M80572 15
23
MX,22015HE,23A -19-19JUL91
CONDITIONS:
•Key switch in off position. •Engine and fuel/air tests found in this group.
•Spark plug wire removed and grounded. •Ignition and electrical tests in Section 240,
•Transaxle in neutral. Group 15.
•Park brake locked.
Test Location Normal If Not Normal
1. Spark plug. Consistent blue spark. (Key switch Check for faulty ignition coil or module.
in start position.) Check for shorted ignition wire or high
tension lead.
2. Carburetor. Free flow of fuel when float bowl Check for plugged tank vent.
drain screw is removed. Check for plugged filter.
Check for plugged or pinched hoses.
Check fuel pump flow and pressure.
Check for fuel contamination.
4. Flywheel. Crankshaft flywheel nut tight. Check for sheared flywheel key.
Tighten nut to 85 N·m (63 lb-ft).
MX,22015HE,24A -19-27SEP91
220
15
24
-19-29AUG91
M80573
220
Slide M80573 15
25
MX,22015HE,25A -19-19JUL91
CONDITIONS:
•Key switch in off position. •Engine and fuel/air tests found in this group.
•Spark plug wire removed and grounded. •Ignition and electrical tests in Section 240
•Transaxle in neutral. Group 15.
•Park brake locked.
Test Location Normal If Not Normal
1. Spark plug. Consistent blue spark. (Key switch Check for faulty ignition coil
in start position.) or module.
2. Carburetor. Choke cable free and choke fully Check for binding cable.
open when choke knob is pushed in. Check for correct choke cable adjustment.
Smooth slow idle. Adjust mixture and slow idle screws.
4. Flywheel. Crankshaft flywheel nut tight. Check for sheared flywheel key.
Tighten nut to 85 N·m (63 lb-ft).
MX,22015HE,26A -19-19JUL91
220
15
26
-19-29AUG91
M80574
220
Slide M80574 15
27
MX,22015HE,27A -19-19JUL91
3. Crankcase. Governor arm tight on governor shaft. Adjust governor and tighten clamp nut.
Governor arm and governor shaft both Adjust governor.
rotated as far counterclockwise as
possible.
4. Flywheel. Crankshaft flywheel nut tight. Check for sheared flywheel key.
Tighten nut to 85 N·m (63 lb-ft)
5. Ignition coil. Ignition coil air gap 0.3 mm Adjust coil air gap.
(0.012 in.).
Primary winding resistance Replace ignition coil.
0.67—1.10 ohms, secondary winding
resistance 6000—10000 ohms.
-19-29AUG91
M80575
220
Slide M80575 15
29
MX,22015HE,17A -19-19JUL91
REASON:
Make sure throttle valve of carburetor is adjusted
correctly in relation to the accelerator pedal.
-UN-28AUG91
PROCEDURE:
1. Loosen cable screw (A).
M80576
—contacts stop screw (C) when accelerator pedal
is NOT pressed.
—contacts stop screw (D) when accelerator pedal Slide M80576
is fully pressed.
MX,22015HE,28A -19-27SEP91
CHOKE ADJUSTMENT
REASON:
Make sure choke valve opens and closes completely
when knob is pushed and pulled.
-UN-28AUG91
PROCEDURE:
1. Loosen cable clamp (A).
M80577
—there is 2—3 mm (0.08—0.12 in.) clearance
between choke knob (B) and cable mount (C)
when choke open stop (D) contacts pin (E). Slide M80577
—choke close stop (F) contacts pin (E) when
choke knob is pulled out.
A—Cable Clamp
-UN-28AUG91
B—Choke Knob
C—Cable Mount
D—Choke Open Stop
E—Pin
220 F—Choke Close Stop
15
M80578
30
Slide M80578
MX,22015HE,29A -19-27SEP91
GOVERNOR ADJUSTMENT
-UN-28AUG91
REASON:
To make sure the governor is adjusted for full engine
rpm operating range.
PROCEDURE:
M80579
1. Move accelerator pedal to fast idle position.
MX,22015HE,30A -19-27SEP91
REASON:
Check and adjust engine fast idle rpm.
-UN-28AUG91
EQUIPMENT:
•JDM-71 Vibration Tachometer
PROCEDURE:
1. Move gear shift pedals to neutral position and lock
M80580
park brake.
SPECIFICATIONS:
•Fast idle .. 3800 rpm
220
15
31
MX,22015HE,31A -19-27SEP91
REASON:
Check and adjust engine slow idle rpm.
-UN-28AUG91
EQUIPMENT:
•JDM-71 Vibration Tachometer
PROCEDURE:
IMPORTANT: Forcing the idle mixture screw tight will
M80581
damage needle and seat. Tighten screw
lightly.
Slide M80581
1. Turn idle mixture screw (A) clockwise until lightly
seated, then turn counterclockwise 1-3/4 turns.
-UN-28AUG91
3. Operate engine at medium speed for 5 minutes.
M80582
until screw does not contact governor lever.
Slide M80582
6. Check engine speed using vibration tachometer.
220 SPECIFICATIONS:
15 •Slow idle (at carburetor) .. 1300 rpm
32 •Slow idle (governor control panel) .. 1300—1500 rpm
MX,22015HE,32A -19-27SEP91
REASON:
Determine the condition of the rings, piston, valves and
-UN-28AUG91
cylinder wall.
EQUIPMENT:
•JDM-59 Compression Gauge
M80583
CONNECTIONS:
1. Lock park brake. Put gear shift pedals in neutral
position. Slide M80583
PROCEDURE:
1. Use starter to turn engine for 5 seconds.
SPECIFICATIONS:
•Minimum compression .. 490 kPa (71 psi)
RESULTS:
•If compression is low, remove gauge and squirt a small
amount of engine oil into spark plug port. Repeat
compression test.
MX,22015HE,33A -19-27SEP91
220
15
33
REASON:
Check and adjust valve clearance for proper engine
operation. Proper valve clearance is critical for operation
-UN-28AUG91
of the compression release system.
EQUIPMENT:
•Feeler Gauge (blade type)
•Torque Wrench
M80584
•Crows Foot Wrench
1. Lock park brake. Put gear shift pedals in neutral A—High Tension Lead (grounded)
position. B—Intake Rocker Arm
C—Exhaust Rocker Arm
D—Lock Nut (2 used)
2. Remove high tension lead (A) and spark plug. E—Adjustment Screw (2 used)
Connect high tension lead to engine ground.
SPECIFICATIONS:
•Intake and exhaust valve
clearance (cold) .. 0.125 ± 0.025 mm
(0.005 ± 0.001 in.)
•Adjuster lock Nut .. 20 N·m (180 lb-in.)
•Rocker cover cap screw torque .. 6 N·m (53 lb-in.)
•Spark plug torque .. 20 N·m (180 lb-in.)
RESULTS:
•If valve clearance is not to specification, loosen lock nut
(D) and turn adjustment screw (E) as necessary. Tight
lock nut to specification.
220
15
34
MX,22015HE,34A -19-27SEP91
REASON:
To verify operation of the compression release system.
-UN-28AUG91
PROCEDURE:
1. Do valve clearance adjustment. (See procedure in this
group.)
M80585
position.
SPECIFICATIONS:
•Automatic compression
release lift .. 0.25 mm (0.010 in.)
RESULTS:
•If lift is less than specification, or not at all, compression
release is not operating. Disassemble engine and repair
or replace as needed.
MX,22015HE,35A -19-27SEP91
220
15
35
REASON:
To determine operation of breather, condition of seals,
gaskets, rings, piston and cylinder wall.
-UN-28AUG91
EQUIPMENT:
•JTO5698 U-Tube Manometer
•AHT8741-F66 Plug
•JTO5703 Barb Fitting
M80586
•JTO5699 Clear Fuel Line
PROCEDURE:
IMPORTANT: Do not make connections between
manometer and engine before engine is
operating. Water from the manometer
can be drawn into the engine
crankcase at start-up.
SPECIFICATIONS:
•Minimum crankcase vacuum at
fast idle (3800 rpm) .. 30 mm (1.2 in.)
water column
RESULTS:
•If crankcase vacuum is less than specification,
check for:
—Sticky of faulty breather assembly
—Leaking crankcase seals or gaskets
—Worn rings, piston or cylinder wall
220
15
36
MX,22015HE,36A -19-27SEP91
REASON:
To check for proper operation of fuel pump.
-UN-28AUG91
EQUIPMENT:
•JDG356 Pressure Gauge
•Graduated Container in milliliters (ounces)
•Watch or timer in seconds
M80588
PRESSURE TEST PROCEDURE:
1. Park brake locked. Gear shift pedals in neutral
position. Slide M80588
-UN-28AUG91
4. Connect gauge hose (B) to fuel pump outlet.
M80589
6. Stop engine. Connect outlet hose to outlet fitting.
Slide M80589
SPECIFICATIONS:
•Minimum fuel pump pressure .. 6.12 kPa (0.9 psi)
•Minimum fuel pump flow
in 15 seconds .. 90 mL (2.7 oz)
RESULTS:
•If pressure or flow is below specification, do the
following and test fuel pump again:
—Check crankcase vacuum (See procedure in this
group.)
—Inspect and clean fuel pump 220
15
•If pressure or flow is still below specification, replace 37
fuel pump.
MX,22015HE,38A -19-27SEP91
220
15
38
230
MX,23005HE,1A -19-19JUL91
MX,23005HE,2A -19-19JUL91
230
05
3
-19-29AUG91
M80547
Slide M80547
MX,23005HE,3A -19-19JUL91
A—Fuel Tank Cap D—Fuel Pump Inlet Hose G—Throttle Cable I—Fuel Filter Inlet Hose
B—Fuel Filter E—Fuel Pump H—Foot Throttle/Accelerator J—Fuel Tank
230 C—Fuel Pump Outlet Hose F—Fuel Pump Impulse Hose
05
4
MX,23005HE,4A -19-19JUL91
CARBURETOR COMPONENTS
MX,23005HE,6A -19-19JUL91
230
05
8
MX,23010HE,1A -19-27SEP91
A—Fuel Tank Vent D—Fuel Filter G—Fuel Pump Outlet Hose I—Fuel Pump Impulse Line
B—Fuel Tank Cap E—Fuel Pump Inlet Hose H—Fuel Pump J—Fuel Filter Inlet Hose
230 C—Fuel Tank F—Carburetor
10
2 FUNCTION: THEORY OF OPERATION:
Supply pressure fuel to the carburetor for engine Fuel is supplied to the carburetor (F) by a
operation. pressurized fuel system. The fuel tank vent (A) is
through the fuel tank cap (B). The fuel pump (H)
MAJOR COMPONENTS: draws fuel from the fuel tank (C) through the fuel
•Carburetor filter (D) to the fuel pump inlet. The fuel filter uses a
•Fuel Filter paper element to remove debris from the fuel and is
•Fuel Tank clear to facilitate service. Pressure fuel from the outlet
•Fuel Tank Cap of the fuel pump flows to the carburetor inlet. Fuel
•Fuel Pump pressure is maintained at the carburetor inlet needle
•Fuel Lines until the float allows more fuel in the bowl.
MX,23010HE,2A -19-27SEP91
MX,23010HE,4A -19-27SEP91
230
10
5
-19-
MXC80551AE
Slide MXC80551AE
MX,23010HE,5A -19-27SEP91
FUNCTION: (Q) through pilot jet (R). Air is also drawn through the
To supply fuel to operate the engine at low and high pilot air jet (E). At the pilot jet, the fuel and air mix
idle speeds with no load on the engine. and are drawn into the engine at low idle feed (D)
and transition feeds (F). The low idle feed supplies
MAJOR COMPONENTS: the fuel/air mixture to the engine at low idle and is
•Pilot Air Jet adjusted by the idle mixture screw (T). When the
•Pilot Jet engine is running at high idle, the fuel/air mixture is
•Idle Mixture Screw supplied by both the low idle feed and transition
•Throttle Valve feeds. The transition feeds also help during engine
•Main Jet acceleration.
THEORY OF OPERATION: The pilot jet and the pilot air jet are NOT adjustable.
When the engine operates at low or high idle, only a However, the idle mixture screw may be adjusted but
relatively small amount of fuel is required. When ONLY to control the VOLUME of mixture entering the
there is no load on the engine the position of the carburetor through the low idle feed. Turning the
throttle valve (low idle) (C) or throttle valve (high idle) screw clockwise decreases the flow, while turning it
(B) is almost closed. Air flow through the venturi (S) counterclockwise increases the flow. The pilot jet can
is not enough to draw fuel from the main nozzle (O), be removed for cleaning.
but is enough to draw fuel from the idle circuit.
The idle speed screw (V) controls the low idle engine
The intake stroke of the engine creates a vacuum on rpm. The screw keeps the throttle valve from closing
the back side of the throttle valve. This vacuum completely to provide a smooth low idle.
draws fuel from the bowl (K) through pilot passage
MX,23010HE,6A -19-27SEP91
MX,23010HE,8A -19-19JUL91
MX,23010HE,10A -19-27SEP91
230
10
12
DIAGNOSTIC INFORMATION
MX,23015HE,A1A -19-27SEP91
MX,23015HE,1A -19-19JUL91
230
15
2
240
Group 05—Component Location
Component Location Information . . . . . . . 240-05-1 Ignition Coil Air Gap Adjustment . . . . . . 240-15-25
Machine Electrical Components . . . . . . . 240-05-2 Ignition Coil Test . . . . . . . . . . . . . . . . 240-15-26
Engine Electrial Components . . . . . . . . . 240-05-4 Ignition Module Test . . . . . . . . . . . . . . 240-15-27
Hydraulic Lift and Front Light Spark Plug Gap Adjustment . . . . . . . . . 240-15-28
Components . . . . . . . . . . . . . . . . . . . 240-05-6 Key Switch Test . . . . . . . . . . . . . . . . 240-15-29
Flywheel Magnet Test . . . . . . . . . . . . . 240-15-30
Transaxle Neutral Switch Test . . . . . . . 240-15-31
Group 10—Theory of Operation
Hydraulic Lift/Lower Relays Test . . . . . . 240-15-32
Theory of Operation Information . . . . . . . 240-10-1 Front Light Switch Test . . . . . . . . . . . . 240-15-33
Wire Color Chart . . . . . . . . . . . . . . . . . 240-10-2 Ground Circuit Test . . . . . . . . . . . . . . 240-15-34
Cranking System Operation . . . . . . . . . . 240-10-4
Ignition System Operation
Group 20 —Wiring Schematics . . . . . . 240-20-1
Engine Running . . . . . . . . . . . . . . . . 240-10-6
Engine Shutting Off . . . . . . . . . . . . . . 240-10-8
Charging System Operation . . . . . . . . . 240-10-10
Front Light System Operation . . . . . . . . 240-10-12
Hourmeter/Voltmeter System Operation . 240-10-14
Electric-Hyraulic Lift System Operation
Lift . . . . . . . . . . . . . . . . . . . . . . . . 240-10-16
Lower . . . . . . . . . . . . . . . . . . . . . . 240-10-18
240
MX,24005HE,1 -19-27SEP91
Slide M44876
240
05 Optional Front Light and Optional Hydraulic Lift
2 located later in this group.
MX,24005HE,2 -19-27SEP91
Slide M44847
240
05
4 MX,24005HE,4 -19-27SEP91
240
05
5
-19-23JUL91
M44847
MX,24005HE,5 -19-27SEP91
A—Lift Switch C—Lift/Lower Relays E—Lift Relay Positive Cable G—Key Switch
B—Lift Relay Ground Cables D—Lift Motor F—Front Light H—Front Light Switch
Slide M44848
240
05
6 MX,24005HE,6 -19-27SEP91
240
05
8
•Cranking System
•Ignition System—Engine Running
•Ignition System—Engine Shutting Off
•Ignition System—Engine Shutting Off
•Charging System
•Optional Front Light System
•Hourmeter/Voltmeter System
•Optional Electric—Hydraulic Lift System—Lift
•Optional Electric—Hydraulic Lift System—Lower
MX,24010HE,1 -19-27SEP91
Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue
Blu/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue/Black
Blu/Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue/Red
Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black
Blk/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black/White
Blk/Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black/Yellow
Brn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown
Brn/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown/White
240 Brn/Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown/Yellow
10 Clr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clear
2 Dk Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Blue
Dk Brn/Lt Grn . . . . . . . . . . . . . . . . . . . Dark Brown/Light Green
Dk Brn/Red . . . . . . . . . . . . . . . . . . . . . . . . . Dark Brown/Red
Dk Brn/Yel . . . . . . . . . . . . . . . . . . . . . . . . . Dark Brown/Yellow
Dk Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Green
Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green
Grn/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green/White
Gry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gray
Lt Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Blue
Lt Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Green
Org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange
Org/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange/White
Pnk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink
Pur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple
Pur/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple/Black
Pur/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple/White
Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
Red/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Black
Red/Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Blue
Red/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/White
Red/Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Yellow
Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tan
Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White
Wht/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Black
Wht/Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Blue
Wht/Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Red
Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow
Yel/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Black
Yel/Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Red
Yel/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/White
MX,24010HE,2 -19-27SEP91
240
10
3
MX,24010HE,3 -19-27SEP91
MX,24010HE,5 -19-27SEP91
MX,24010HE,7 -19-27SEP91
MX,24010HE,9 -19-27SEP91
240 MAJOR COMPONENTS: The ground circuit provides a path to ground for the
10 •Battery front light through the key switch “G” terminal.
12 •20 Amp Circuit Breaker
•Key Switch
•Light Switch
•Front Light
MX,24010HE,11 -19-27SEP91
MX,24010HE,13 -19-27SEP91
MX,24010HE,15 -19-27SEP91
MX,24010HE,17 -19-27SEP91
240
10
20
DIAGNOSTIC INFORMATION
•Cranking
•Ignition
•Charging 240
•Front Light 15
•Hourmeter/Voltmeter 1
•Electric Hydraulic Lift System
MX,24015HE,1 -19-27SEP91
2. Key switch terminal ’B’. Battery voltage. Check battery cable connection, starter
battery terminal connection, 20 amp circuit
breaker, and red wires.
7. Starter solenoid terminal. Battery voltage. Test purple/white wire and connection
12 volts - test starter solenoid and starter.
MX,24015HE,2 -19-27SEP91
240
15
3
-19-29JAN90
M45424
Slide M45424
MX,24015HE,3 -19-27SEP91
1. Spark tester. Spark at tester. Test spark plug, test ignition coil, check
armature air gap, test ignition module, check
flywheel magnets.
TEST CONDITIONS:
•Key switch off.
•Engine connector (A) connected
2 to 3. Battery ground to Continuity. Check black wire.
engine ground.
TEST CONDITIONS:
•Key switch disconnected
5 to 6. Key switch terminal ’G’ Continuity. Replace key switch.
to key switch terminal ’M’.
TEST CONDITIONS:
•Key switch in on position
5 to 6. Key switch terminal No Continuity. Replace key switch.
’G’ to key switch terminal ’M’.
TEST CONDITIONS:
•Key switch in off position.
•Key switch connected
7 to 8. Key switch terminal Continuity. Check black wire.
’M’ to engine connector.
MX,24015HE,4 -19-27SEP91
240
15
5
-19-23JUL91
M44858
Slide M44858
MX,24015HE,5 -19-27SEP91
TEST CONDITIONS:
•Stator connector (A) connected.
4. Key switch terminal ’B’. Battery voltage. Test circuit breaker and red
wires.
MX,24015HE,6 -19-27SEP91
240
15
7
-19-29JAN90
M45427
Slide M45429
MX,24015HE,7 -19-27SEP91
7. Front light ground. Greater than 0 - Greater than 0.2 volts - test front light
less than 0.2 volts. ground circuit.
0 volts - test lamp.
MX,24015HE,8 -19-27SEP91
240
15
9
-19-23JUL91
M44857
Slide M44857
MX,24015HE,9 -19-27SEP91
6. Hourmeter ground. Greater than 0 - Greater than 0.2 volts - check hourmeter
less than 0.2 volts. ground circuit.
0 volts - replace hourmeter.
7. Voltmeter ground. Greater than 0 - Greater than 0.2 volts - check voltmeter
less than 0.2 volts. ground circuit.
0 volts - replace voltmeter.
MX,24015HE,10 -19-27SEP91
240
15
11
-19-23JUL91
M44859
Slide M44859
MX,24015HE,11 -19-27SEP91
5. Hourmeter orange & purple lead. Battery voltage. Test orange wire to voltmeter.
6. Hydraulic pump switch purple lead. Battery voltage. Test purple wires.
7. Hydraulic pump switch green lead. Battery voltage. Test hydraulic pump switch.
9. Hydraulic pump LIFT relay Greater than 0 - Greater than 0.2 volts - test hydraulic pump
ground terminal 86 (black lead) less than 0.2 volts. relay ground.
circuit.
0 volts - test hydraulic pump relay.
10. Hydraulic pump lift relay Battery voltage. Test red wire to relay.
terminal 30 (red lead).
11. Hydraulic pump relay Battery voltage. Test/replace hydraulic pump relay.
terminal 87 (larger green lead).
240
15
13
-19-23JUL91
M44860
MX,24015HE,13 -19-27SEP91
TEST CONDITIONS:
•Hydraulic pump switch in lower position
12. Hydraulic pump switch blue lead. Battery voltage. Test hydraulic pump switch.
240 13. Hydraulic pump lower relay Battery voltage. Test blue wire.
15 terminal 85 (blue lead).
14
14. Hydraulic pump lower relay Greater than 0 - Greater than 0.2 - test hydraulic pump
ground terminal 86 (black lead). less than 0.2 volts. relay ground circuit.
0 volts - test/replace hydraulic pump relay.
15. Hydraulic pump lower relay Battery voltage. Test red wire.
terminal 30 (red lead).
16. Hydraulic pump lower relay Battery voltage. Test/replace hydraulic pump relay.
terminal 87 (larger blue lead).
240
15
15
-19-23JUL91
M44861
MX,24015HE,15 -19-27SEP91
REASON:
To check voltage and determine condition of battery.
-UN-18SEP90
EQUIPMENT:
•Voltmeter or JTO5685 Battery Tester
•Hydrometer
240
M49595
PROCEDURE:
15 1. Clean battery terminals and top of battery.
16 Slide M49595
2. Inspect battery terminals and case for breakage or
cracks.
-UN-18SEP90
4. Remove surface charge by placing a small load on
the battery for 15 seconds.
M49596
Battery Tester.
Slide M49596
6. Check specific gravity of each cell with a hydrometer.
SPECIFICATIONS:
•Minimum battery voltage .. 12.4 volts.
•Minimum specific gravity .. 1.225 with less than 50 point
variation.
RESULTS:
•Battery voltage less than 12.4 VDC, charge battery. See
CHARGE BATTERY in this Group.
MX,24015HE,15A -19-27SEP91
CHARGE BATTERY
-UN-25SEP90
240
15
17
M49598
Slide M49598
3. Check if battery is accepting a 10 amp charge 7. Load test battery. See LOAD TEST BATTERY in
after 10 minutes at boost setting. this Group.
REASON:
To check condition of battery under load.
-UN-18SEP90
EQUIPMENT:
•JTO5685 Battery Tester
CONNECTIONS:
1. Turn load knob (A) of tester counter-clockwise to off.
240
M49597
15 2. Connect tester red cable (B) to battery positive post.
18 Slide M49597
3. Connect tester black cable (C) to battery negative
post.
A—Tester Load Knob
PROCEDURE: B—Tester Red Cable
C—Tester Black Cable
1. Turn load knob of tester clockwise until amperage
D—Amperage
reading (D) is equal to: E—Voltage
A. Cold cranking amperage rating (use blue scale).
—OR—
B. Three times ampere hour rating (use black scale).
RESULTS:
•If the battery does not pass the test and has not been
charged, charge battery and retest. See CHARGE
BATTERY in this Group.
•If the battery does not pass the test and has been
charged, replace battery.
MX,24015HE,15B -19-27SEP91
REASON:
To determine DC voltage output of charging system.
-UN-05SEP91
EQUIPMENT:
•Voltmeter
CONNECTIONS:
1. Park brake engaged. PTO disengaged.
240
M44864
2. Remove surface charge on battery by placing a small 15
load on it for about 15 seconds. Slide M44864 19
PROCEDURE:
1. Start engine and run at fast idle (3800 rpm).
SPECIFICATIONS:
•Regulated voltage .. 12.2—15.0 VDC at 3800 rpm.
RESULTS:
•If the DC voltage stays below the minimum
specification, run the Stator Unregulated Output Test.
(See procedure in this group.)
MX,24015HE,20 -19-27SEP91
REASON:
To determine the AC voltage output of stator.
-UN-05SEP91
EQUIPMENT:
•Voltmeter
CONNECTIONS:
1. Park brake engaged. PTO disengaged.
240
M44884
15 2. Separate stator wire connector.
20 Slide M44884
3. Connect meter leads (A) to terminals of engine side of
stator wire connector.
PROCEDURE:
1. Start engine and run at fast idle (3800 rpm).
2. Read meter.
SPECIFICATIONS:
•Stator unregulated voltage .. minimum 34 VAC at 3800
rpm.
RESULTS:
•If the unregulated voltage is below minimum
specification, replace stator and retest.
MX,24015HE,21 -19-27SEP91
REASON:
To determine amperage output of the charging system.
-UN-05SEP91
EQUIPMENT:
•JTO5712 Current Gun or equivalent
•JTO5685 Battery Tester
CONNECTIONS:
240
M44885
1. Park brake engaged. PTO disengaged.
15
2. Place current gun (A) over red wires (B) to starter. Slide M44885 21
-UN-05SEP91
5. Connect black battery tester clamp to frame.
PROCEDURE:
1. Start engine and run at fast idle (3800 rpm).
M44886
NOTE: Perform this test as quickly as possible to
Slide M44886
prevent damage to the electrical system
components. DO NOT apply a full load to the
battery for more than 10 seconds.
A—Current Gun
B—Red Wires
2. Turn load knob clockwise until voltage (F) reads 11 C—Load Knob
VDC. D—Battery Tester
E—Red Clamp
3. Read amperage (G) at current gun. F—Voltage
G—Amperage
SPECIFICATIONS:
•Amperage .. Minimum 13 amps at 3800 rpm.
RESULTS:
•If the amperage output is below minimum specification,
perform the Stator Unregulated Output Test. (See
procedure in this group.)
MX,24015HE,22 -19-27SEP91
REASON:
To determine if starter solenoid or starter motor is
defective.
-UN-23AUG91
EQUIPMENT:
•Jumper Wire
CONNECTIONS:
240
M44867
1. Put transaxle/transmission is neutral. Move key switch
15 to off position.
22 Slide M44867
2. Engage park brake.
PROCEDURE:
1. Connect jumper wire to positive battery terminal and
briefly jump to starter solenoid terminal (B).
—Starter runs: solenoid is good, check circuit wiring.
(See Cranking Circuit Test Points in this group.)
—Starter does not run: go to step 2.
MX,24015HE,23 -19-27SEP91
REASON:
To determine proper operation of starting motor.
-UN-23AUG91
EQUIPMENT:
•JTO5685 Battery Tester
•JTO5719 Photo Tachometer
240
M44868
CONNECTIONS:
1. Park brake engaged. PTO disengaged. 15
Slide M44868 23
2. Turn knob (A) of battery tester (B) off (fully
counter-clockwise).
-UN-05SEP91
4. Remove flywheel screen and install tachometer
reflective tape on flywheel.
M44883
PROCEDURE:
Slide M44883
1. Crank engine with starter and read engine rpm (D)
and DC voltage (E).
A—Knob
2. Turn key switch to OFF position.
B—Battery Tester
C—Tester Rod Clamp
NOTE: Conduct the following procedure as quickly as D—Engine RPM
possible to prevent damage to electrical E—DC Voltage
components. F—DC Amperage
SPECIFICATIONS:
•Engine speed .. minimum 350 rpm.
•Starter draw .. maximum 85 amps @ minimum 500 rpm.
RESULTS:
•If engine rpms and amperage draw are both below
specifications, check for excessive drag in engine or
drive train.
REASON:
To determine proper function of starting motor.
-UN-20NOV90
EQUIPMENT:
•JTO5712 Current Gun or equivalent
•12 Volt Battery
•Battery Jumper Cables
•Jumper Wire
240
M45867
15 CONNECTIONS:
24 1. Remove starter from engine. Slide M45867
PROCEDURE:
1. Touch free end of jumper wire to starter solenoid
engagement terminal (B) of starter.
SPECIFICATIONS:
•Starter no-load draw .. maximum 60 amps DC.
RESULTS:
•If the starter does not pass the test, disassemble and
repair as required. See Group 60 of CTM-5.
MX,24015HE,25 -19-27SEP91
REASON:
To adjust the air gap between the ignition coil and the
flywheel to a specific dimension needed for proper
-UN-29NOV90
ignition timing.
EQUIPMENT:
•0.3 mm (0.012 in.) feeler gauge
240
M45869
CONNECTIONS:
1. Put transaxle/transmission in neutral. 15
Slide M45869 25
2. Put key switch in off position.
PROCEDURE:
1. Turn flywheel magnet away from coil.
SPECIFICATIONS:
•Ignition coil air gap .. 0.3 mm (0.012 in.)
MX,24015HE,25A -19-27SEP91
REASON:
To determine condition of ignition coil windings.
-UN-21FEB90
EQUIPMENT:
•Ohmmeter
PROCEDURE:
1. Put transaxle/transmission in neutral. Put key switch in
240
M45483
OFF position.
15
26 2. Remove spark plug cap from spark plug wire. Slide M45483
SPECIFICATIONS:
•Primary lead and core resistance .. 0.67—1.10 ohms
•Spark plug lead and core resistance .. 6—10 K ohms
RESULTS:
•If resistance does not meet specifications, replace the
ignition coil.
MX,24015HE,28 -19-27SEP91
REASON:
To check if ignition module is good.
EQUIPMENT:
•No special equipment required.
PROCEDURE:
Due to variations in meters; that the ignition module is
very sensitive to the type of meter used; and that the 240
possible tests do not cover all malfunctions; the best way 15
to determine if the ignition module is good is to replace 27
the questionable ignition module with a known good
ignition module.
RESULTS:
•If the new ignition module does not solve the problem,
check the other ignition components for the cause of the
malfunction.
MX,24015HE,29 -19-27SEP91
REASON:
To maintain the correct gap between the center
electrode and the tab needed to produce a good spark.
-UN-25OCT89
EQUIPMENT:
•0.64 mm (0.025 in.) Feeler Gauge
PROCEDURE:
240
M48365
15 IMPORTANT: Do not clean spark plug with sand
28 paper or abrasives. Engine scoring can Slide M48365
result.
SPECIFICATIONS:
•Spark plug gap .. 0.6—0.7 mm (0.023—0.028 in.)
•Spark plug torque .. 25 N·m (18 lb-ft).
MX,24015HE,30 -19-27SEP91
REASON:
Determine proper operation of key switch.
-UN-27SEP90
EQUIPMENT:
•Ohmmeter.
CONNECTIONS:
1. Set ohmmeter to 1X ohms scale.
240
M49684
NOTE: On analog (swing needle) ohmmeters, set zero 15
point before every test. Slide M49684 29
PROCEDURE:
1. For ignition circuit, turn key switch from off to run
position.
SPECIFICATIONS:
•Key switch in off position .. continuity between posts A
and B.
•Key switch in off position .. no continuity between any
other pairs of posts.
•Key switch in run position .. no continuity between posts
A and B.
•Key switch in run position .. continuity between posts C
and F.
•Key switch in run position .. no continuity between posts
D and E.
•Key switch in start position .. no continuity between
posts A and B.
•Key switch in start position .. continuity between posts C
and F.
•Key switch in start position .. continuity between posts D
and E.
RESULTS:
•If the key switch does not pass all tests, replace switch.
MX,24015HE,31A -19-27SEP91
REASON:
To check strength of flywheel magnets.
-UN-29JAN90
NOTE: This is a rough test and should only be used to
determine flywheel magnet strength only if no
other cause for weakness or no spark is found.
EQUIPMENT:
240
M45476
•No special equipment needed
15
30 CONNECTIONS: Slide M45476
1. Park brake engaged. PTO disengaged. Key switch in
OFF position.
PROCEDURE:
1. Loosely hold handle of steel shaft screwdriver so that
shaft is about 25 mm (1 in.) away from magnet.
RESULTS:
•If screwdriver shank is not pulled into magnet, flywheel
will need to be replaced.
MX,24015HE,32 -19-27SEP91
REASON:
To make sure the transaxle neutral switch has continuity
when the transaxle is in neutral.
-UN-27AUG91
EQUIPMENT:
•Ohmmeter or continuity tester
CONNECTIONS:
240
M44871
1. Turn key switch off.
15
2. Put transaxle lever in neutral position. Slide M44871 31
PROCEDURE:
1. Check continuity across terminals (A).
SPECIFICATIONS:
•Switch should have continuity only when the transaxle
lever is in neutral.
RESULTS:
•If the continuity is not correct, replace switch.
•Also check transaxle shift linkage for wear at point of
switch contact.
MX,24015HE,33 -19-27SEP91
REASON:
To check relay terminal continuity in the energized and
-UN-25OCT89
de-energized condition.
EQUIPMENT:
•Ohmmeter or continuity tester
•Jumper wire
240
M48376
15 PROCEDURE:
32 1. Put transaxle in neutral. Slide M48376
RESULTS:
•If continuity is not correct, replace relay.
MX,24015HE,34 -19-27SEP91
REASON:
To make sure the front light switch terminals have
continuity when the front light switch is on.
-UN-29JAN90
EQUIPMENT:
•Ohmmeter or continuity tester
CONNECTIONS:
240
M45479
1. Put transaxle/transmission in neutral.
15
2. Put key switch in OFF position. Slide M45479 33
PROCEDURE:
1. Move front light switch to the ON position.
SPECIFICATIONS:
•Terminals should have continuity only when the switch
is ON.
RESULTS:
•If continuity is not correct, replace front light switch.
MX,24015HE,35 -19-27SEP91
REASON:
To check for opens or poor connections in the ground
circuit.
-UN-29JAN90
EQUIPMENT:
•Ohmmeter or continuity tester
PROCEDURE:
240
M45480
1. Turn key switch to OFF position.
15
34 2. Put transaxle/transmission in neutral.
3. Connect ohmmeter or continuity tester to negative A—Battery Negative Terminal To Engine Ground
terminal of battery and ground terminal of circuit or B—Wiring Harness To Engine Ground
component to be tested.
RESULTS:
•If continuity is not indicated, check for open wiring or
poor connections.
MX,24015HE,36 -19-27SEP91
SCHEMATICS INFORMATION
240
20
MX,24020HE,1 -19-27SEP91 1
240
20
5
-19-23JUL91
M44872
Slide M44872
MX,24020HE,5 -19-27SEP91
240
20
6
-19-05SEP91
M44873
Slide M44873
MX,24020HE,6 -19-27SEP91
240
20
7
-19-23JUL91
M44874
Slide M44874
MX,24020HE,7 -19-27SEP91
240
20
8
250
250
05
1
MX,25005HE,1A -19-19JUL91
MX,25005HE,2A -19-27SEP91
250
05
2
A—Spring (5 used) C—Drive Hub E—Roller Chain F—Output Shaft and Gear
B—Clutch Shoe (5 used) D—Clutch Drum
MX,25005HE,4A -19-27SEP91
250
05
4
250
05
5
-19-29AUG91
M80555
Slide M80555
MX,25005HE,5A -19-19JUL91
TRANSAXLE COMPONENTS
A—Forward Drive Gear E—Reverse Drive Chain I—Final Drive Gear, L—Pinion Gear
B—Forward Driven Gear F—Input Shaft Differential Housing M—Output Shaft
C—Reverse Drive Sprocket G—Shift Collar J—Differential Lock Collar N—Differential Lock Shaft
D—Reverse Driven Sprocket H—Secondary Shaft K—Bevel Gear
MX,25005HE,6A -19-19JUL91
250
05
6
250
05
7
-19-29AUG91
M80556
Slide M80556
MX,25005HE,7A -19-19JUL91
250
05
8
-19-29AUG91
M80624
Slide M80624
MX,25005HE,8A -19-27SEP91
250
05
9
-19-29JAN90
M48601
Slide M48601
MX,25005HE,9A -19-27SEP91
250
05
10
A—Drive Hub C—Shoe Spring E—Roller Chain F—Output Shaft and Gear
B—Clutch Shoe D—Clutch Drum
FUNCTION: Connects and disconnects power around a bushing on the engine crankshaft. A roller
between the engine and the drive clutch. The gears chain connects gear of drum to gear on output shaft.
of the wet clutch provide a 2:1 reduction.
The wet clutch operates using centrifugal force. As
MAJOR COMPONENTS: the engine rpm increases, the spring-loaded shoes
•Drive Hub pivot out due to the centrifugal force. The shoes
•Clutch Shoe contact the drum. When the centrifugal force is great
•Shoe Spring enough, friction between the drum and shoes causes
•Clutch Drum the drum to turn with the shoes. The drum turns the
•Roller Chain roller chain which turns the output shaft. Due to the
250 •Output Shaft and Gear different size gears in the wet clutch the output shaft
10 turns half as fast as the engine crankshaft. This
2 THEORY OF OPERATION: reduction in speed allows for increase in pulling
The drive is keyed to the engine crankshaft. Five power of vehicle.
laminated metal shoes are mounted on the drive hub
and are connected to one another by springs. A Oil in the clutch case provides lubrication and cooling
clutch drum surrounds the shoes and is free to rotate for bearings and clutch.
MX,25010HE,2A -19-27SEP91
250
10
3
-19-29AUG91
M80557
Slide M80557
MX,25010HE,3A -19-19JUL91
FUNCTION: arms are forced out they contact the ramp plate. The
To engage the drive belt at a specified rpm and vary roller arms follow the contour of the ramp plate and
the pully diameter depending on engine rpm. force the moveable sheave toward the fixed sheave.
This action causes the belt (A) to ride up between
MAJOR COMPONENTS: the two sheave surfaces in effect changing the
•Fixed Sheave Face working diameter of the drive clutch.
•Ramp Plate
•Moveable Sheave Idle rpm: The clutch sheaves are farthest apart and
•Roller Arms the drive belt is located at the bottom of the sheave
•Rollers halves. The sheave halves make contact with the
250 drive belt but there is no movement since wet clutch
10 THEORY OF OPERATION: has not allowed drive clutch to turn due to low rpm.
4 The fixed sheave face (B) is keyed to the output
shaft of the wet clutch. Attached to the fixed sheave Midrange rpm: The roller arm assemblies have moved
at the other end of the clutch hub is the ramp plate further down the ramp plate causing the moveable
(F). The moveable sheave (E) and the roller arm sheave to move closer to the fixed sheave. This
assembly ride on the clutch hub between the fixed forces the belt further toward the top of the clutch
sheave and the ramp plate. assembly.
The drive clutch is rpm sensitive and operates using High rpm: The roller arms have moved against the
the principal of centrifugal force. Increasing engine ramp plate the full extent of their travel forcing the
rpm causes the roller arms (C) and rollers (D) to sheave halves together. This results in the drive belt
swing out due to centrifugal force. The roller arms are being moved to the largest diameter of the drive
attached to the moveable sheave. As these roller clutch.
MX,25010HE,4A -19-27SEP91
250
10
5
-19-29AUG91
M80558AE
Slide M80558AE
MX,25010HE,5A -19-19JUL91
250
10
7
-19-29AUG91
M80559AE
Slide M80559AE
MX,25010HE,7A -19-19JUL91
250
10
8
-19-31JAN90
M45433
Slide M45433
Whenever the drive belt (A) is engaged, torque from from the resistance of the wheels is felt on the
the belt is felt on the movable sheave (B), and torque stationary sheave (C).
MX,25010HE,16A -19-27SEP91
250
10
9
-19-31JAN90
M45434
A—Stationary Sheave B—Key C—Transaxle Input Shaft D—Ramp
Slide M45434
MX,25010HE,17A -19-27SEP91
250
10
10
-19-31JAN90
M45435
Slide M45435
MX,25010HE,18A -19-27SEP91
250
10
11
-19-31JAN90
M45436
A—Stationary Sheave C—Spring Retainer E—Ramp F—Wear Button
B—Movable Sheave D—Clutch Spring
Slide M45436
There are two components that control belt tension The movable sheave rides along the ramp as it
and shift pattern. These are the clutch spring (D) and opens and closes. Attached to the movable sheave
the ramp (E). are wear buttons (F) that allow these two components
to move smoothly. The ramp is attached to the
One end of the clutch spring is attached to the ramp stationary sheave. It assists in controlling the shift
which is keyed to the stationary sheave (A) and the pattern depending on load.
other end of the spring is attached to the movable
sheave (B) half. The spring is causing a resistance
when the driven clutch is opening and is assisting
when the clutch is closing.
MX,25010HE,19A -19-27SEP91
MX,25010HE,8A -19-27SEP91
250
10
13
-19-29AUG91
M45437
Slide M45437
MX,25010HE,9A -19-19JUL91
MX,25010HE,10A -19-19JUL91
250
10
15
-19-29AUG91
M80560
Slide M80560
MX,25010HE,11A -19-19JUL91
MX,25010HE,12A -19-19JUL91
250
10
17
-19-29AUG91
M80561
Slide M80561
MX,25010HE,13A -19-19JUL91
MX,25010HE,14A -19-19JUL91
250
10
19
-19-29AUG91
M80562
Slide M80562
MX,25010HE,15A -19-19JUL91
250
10
20
DIAGNOSTIC INFORMATION
MX,25015HE,1A -19-27SEP91
CONDITIONS:
•Vehicle on level surface.
•Park brake locked.
•Engine operating at slow idle.
•Power train tests and adjustments in this section and
group.
1. Shift cables. Cables installed correctly, ends not Inspect and adjust shift cables.
broken, and all hardware tight.
Cable does not bind and has full Repair or replace shift cables.
travel.
250 2. Transmission shift Moves into three distinct positions Inspect lever to transaxle shift shaft
15
2 lever (cables —forward roll pin.
disconnected). —neutral Disassemble and inspect transaxle
—reverse shifter components.
MX,25015HE,2A -19-19JUL91
250
15
3
-19-29AUG91
M80596
Slide M80596
MX,25015HE,3A -19-27SEP91
CONDITIONS:
•Vehicle on level surface.
•Park brake locked.
•Engine operating at slow idle.
•Power train tests and adjustments in this section and
group.
1. Shift cables. Cables installed correctly, ends Inspect and adjust shift cables.
not broken and all hardware tight.
Cable does not bind and has full Repair or replace shift cables.
travel.
250 2. Drive belt. Belt in good condition and within Replace drive belt.
15
4 specifications.
3. Drive clutch. Turns drive belt upon wet clutch Clean drive clutch using compressed air.
engagement. Disassemble and inspect drive clutch
components.
4. Wet reduction clutch. Correct quantity and type of oil in Fill with specified oil to proper
clutch. level.
Wet clutch engages drive clutch at Disassemble and inspect wet clutch
1600—1800 rpm. components.
5. Transaxle. Correct quantity and type of oil Fill with specified oil to correct
in transaxle. level.
Transmits power from input shaft Disassemble, inspect and repair
to output shaft. transaxle components.
MX,25015HE,4A -19-27SEP91
250
15
5
-19-29AUG91
M80597
Slide M80597
MX,25015HE,5A -19-19JUL91
CONDITIONS:
•Vehicle on level surface.
•Gear shift pedals in neutral position.
•Park brake locked.
•Engine operating at slow idle.
•Power train tests and adjustments in this
section and group.
3. Driven clutch. Belt engages driven clutch. Driven Disassemble and inspect driven clutch.
clutch completes upshift and Adjust driven clutch torsion spring.
backshifts smoothly as engine is Replace worn components.
accelerated and decelerated.
4. Wet reduction clutch. Smooth clutch engagement between Disassemble and inspect wet clutch.
engine and drive clutch.
Little or no slippage under load. Replace worn components.
6. Engine. With drive belt and drive clutch Inspect internal components of
removed, engine accelerates engine.
and decelerates smoothly, without
abnormal noise.
MX,25015HE,6A -19-27SEP91
250
15
7
-19-29AUG91
M80598
Slide M80598
MX,25015HE,7A -19-19JUL91
CONDITIONS:
•Vehicle on level surface.
•Engine operating at slow idle.
•Attachments raised.
•Gear shift pedals in forward or reverse position.
•Power train tests and adjustments in this
section and group.
1. Drive belt. Belt in good condition and New belt can cause slight creeping.
within specifications.
2. Engine. Engine slow idle below wet clutch Adjust engine rpm to specification.
250 engagement rpm.
15
8
3. Drive clutch. Upshifts and backshifts smoothly Disassemble and inspect drive clutch
with change in engine rpm. components.
4. Wet reduction clutch. Correct quantity and type of oil. Fill with specified oil to proper
level.
Wet clutch engages drive clutch Disassemble and inspect wet
at 1600—1800 rpm. clutch components.
MX,25015HE,8A -19-27SEP91
250
15
9
-19-29AUG91
M80599
Slide M80599
MX,25015HE,9A -19-19JUL91
CONDITIONS:
•Vehicle on level surface.
•Engine operating at slow idle.
•Gear shift pedal in forward position.
•Accelerate engine to engage wet clutch.
MX,25015HE,10A -19-27SEP91
250
15
11
-19-29AUG91
M80620
Slide M80620
MX,25015HE,11A -19-19JUL91
CONDITIONS:
•Vehicle on level surface.
•Engine operating.
•Gear shift pedal in forward position.
•Push throttle pedal to accelerate engine.
•Power train tests and adjustments in this
section and group.
•Engine tests and adjustments in Section 220,
Group 15.
1. Vehicle performance Smooth upshift with operator and Vehicle pulling/pushing power exceeded.
pulling load added to vehicle. Reduce load to vehicle.
250
15
12
2. Drive belt. Belt in good condition and Check belt alignment.
within specification. Replace drive belt.
3. Drive clutch. Upshifts and backshifts smoothly. Clean drive clutch using compressed air.
Disassemble and inspect drive clutch
components.
4. Wet reduction clutch. Correct quantity and type of oil. Fill wet clutch with specified oil to
proper level.
Wet clutch engages drive clutch at Disassemble and inspect wet clutch
1600—1800 rpm. components.
Little or no slippage under load. Replace worn components.
5. Driven clutch. Belt engages driven clutch. Driven Disassemble and inspect driven clutch.
clutch completes upshift Replace worn components.
and backshift smoothly as engine
is accelerated and decelerated.
7. Transaxle. Correct quantity and type of oil Fill with specified oil to correct
in transaxle. level.
Transmits power from input shaft Disassemble, inspect and repair
to output shaft. transaxle.
MX,25015HE,12A -19-27SEP91
250
15
13
-19-29AUG91
M80621
Slide M80621
MX,25015HE,13A -19-19JUL91
CONDITIONS:
•Park brake locked.
•Engine stopped.
•Power train tests and adjustments in this
section and group.
1. Vehicle performance. Smooth upshift with operator and Vehicle pulling/pushing power causing
pulling load added to vehicle. belt to slip excessively. Reduce load.
Replace belt as necessary.
2. Drive and driven Clutches in alignment. Check and correct clutch alignment.
clutches.
250
15
14 3. Drive clutch. Engages at specified wet clutch rpm. Clean drive clutch using compressed air.
Upshifts and backshifts smoothly Disassemble, inspect and repair worn
with change in engine rpm. drive clutch components.
4. Driven clutch. Upshifts and backshifts smoothly Clean and inspect driven clutch
with change in engine rpm. components.
Adjust spring tension as necessary.
MX,25015HE,14A -19-27SEP91
250
15
15
-19-29AUG91
M80622
Slide M80622
MX,25015HE,15A -19-19JUL91
CONDITIONS:
•Vehicle on level surface.
•Engine operating at slow idle.
•Power train tests and adjustments in this
section and group.
1. Control linkage. Linkage installed correctly and Repair or replace linkage as necessary.
hardware secure.
250
15
17
-19-29AUG91
M80623
Slide M80623
MX,25015HE,17A -19-19JUL91
REASON:
Make sure drive belt is within specifications for proper
machine operation.
-UN-28AUG91
PROCEDURE:
1. Measure drive belt across the top width.
M80590
3. Check belt for slipping.
Slide M80590
SPECIFICATIONS:
•Minimum belt width .. 27 mm (1-1/16 in.)
250
15 RESULTS:
18 •If belt is not within specifications, replace drive belt.
•If belt is excessively loose to the point where it’s
slipping, replace drive belt.
MX,25015HE,17AA-19-10SEP91
REASON:
Make sure shift pedals are adjusted correctly in relation
to transaxle shift shaft.
-UN-28AUG91
PROCEDURE:
1. Shift transaxle into forward using forward shift pedal.
M80592
moving transaxle control arm from forward detent to
neutral and back to forward detent.
Slide M80592
3. Check forward pedal position. The stop on the pedal
must be a distance (C) of 3 mm (1/8 in.) above the floor
plate. 250
15
4. If pedal position is not within specification: 19
•Loosen cable clamps (A).
-UN-28AUG91
•Adjust cable length until pedal stop is to
Specification.
•Keep cable tight and slide cable clamps tight
against control arm.
•Tighten cable clamps.
M80595
5. Shift transaxle into reverse using reverse shift pedal.
Slide M80595
MX,25015HE,18A -19-19JUL91
REASON:
Verify the full upshift of the clutching system.
-UN-28AUG91
PROCEDURE:
1. Draw a line (A) on face of drive sheave (B), extending
from the center to the outer edge. Use an all purpose
marker or equivalent.
M80593
2. With the transmission in neutral and the park brake
locked, accelerate the engine to wide open throttle for a
couple of seconds, then release accelerator pedal. Slide M80593
-UN-28AUG91
RESULTS:
•If full upshift is not achieved, check the
following possible problems:
—Low engine RPM
—Slipping wet clutch
M80594
—Sticking or binding drive or driven clutch due
to worn parts
Slide M80594
—Worn belt
MX,25015HE,19A -19-27SEP91
REASON:
To determine the condition of the driven clutch spring.
-UN-29JAN90
EQUIPMENT:
•Spring Scale
•Vise Grip Pliers
PROCEDURE:
M45459
1. Put transaxle in forward or reverse position and lock
the park brake.
Slide M45459
2. Remove drive belt.
SPECIFICATIONS:
•Driven clutch spring
torsional force .. 27—80 N (6—18 lb)
RESULTS:
•If spring force is less than specification, engine RPM is
reduced and the upshift occurs faster.
MX,25015HE,20A -19-27SEP91
REASON:
To increase or decrease torsional force of the driven
-UN-29JAN90
clutch spring.
PROCEDURE:
1. Remove and disassemble driven clutch. (See
procedure in Section 50, Group 05.)
M45460
2. Put spring between cam and moveable sheave with
ends of spring against retaining tabs (A). Slide M45460
MX,25015HE,21A -19-27SEP91
260
MX,26005HE,1 -19-27SEP91
260
05
1
STEERING COMPONENTS
MX,26005HE,2 -19-29AUG91
260
05
2
260
05
3
-19-06SEP91
M44875
Slide M44875
MX,26005HE,2A -19-29AUG91
BRAKE COMPONENTS
MX,26005HE,3 -19-29AUG91
260
05
4
260
05
5
-19-06SEP91
M44845
Slide M44845
MX,26005HE,4 -19-27SEP91
MX,26005HE,6 -19-29AUG91
260
05
6
260
05
7
-19-06SEP91
M44836
Slide M44836
MX,26005HE,6A -19-29AUG91
260
05
8
-19-06SEP91
M44844
Slide M44844
MX,26005HE,5 -19-29AUG91
MX,26010HE,1 -19-27SEP91
260
STEERING SYSTEM OPERATION 10
1
FUNCTION:
To direct movement of machine in forward or reverse.
MAJOR COMPONENTS:
•Steering Wheel
•Steering Shaft
•Disk and Chain
•Steering Fork and Bearings
THEORY OF OPERATION:
Steering of the 1200 Bunker Rake is controlled by a
gear on the steering shaft which is connected to a large
disk by a chain. The disk is splined to the steering fork,
which turns the front wheel.
MX,26010HE,1A -19-27SEP91
BRAKE OPERATION
MX,26010HE,2 -19-27SEP91
260
10
3
-19-06SEP91
M44843
Slide M44843
MX,26010HE,3 -19-27SEP91
260
10
4
DIAGNOSTIC INFORMATION
MX,26015HE,1 -19-27SEP91
CONDITIONS:
•Park brake engaged.
•Front wheel raised off ground.
MX,26015HE,2 -19-27SEP91
260
15
3
-19-06SEP91
M44842
Slide M44842
MX,26015HE,3 -19-29AUG91
CONDITIONS:
•Rear wheels raised off ground
MX,26015HE,4 -19-27SEP91
260
15
5
-19-06SEP91
M44877
Slide M44877
MX,26015HE,5 -19-27SEP91
REASON:
Adjust brakes to ensure proper operation.
-UN-18SEP89
PROCEDURE:
1. Loosen screw (B).
E33626
3. Loosen adjusting nuts (C) to remove slack from cable
but not extending cable to the point of brake Slide E33626
engagement.
MX,26015HE,6 -19-27SEP91
260
15
6
270
MX,27005HE,A1 -19-11SEP91
270
05
1
MX,27005HE,A2 -19-11SEP91
270
05
2
270
05
3
-19-19SEP91
M80625
Slide M80625
MX,27005HE,A3 -19-27SEP91
MX,27005HE,A4 -19-11SEP91
270
05
4
270
05
5
-19-19SEP91
M80626AE
Slide M80626AE
MX,27005HE,A5 -19-11SEP91
270
05
6
MX,27010HE,A2 -19-11SEP91
Neutral Operation (C) force the check valve (G) pushes the shuttle
towards the center and closes the check valve.
When the hydraulic lift spring in the switch is
released, the motor (D) and gear pump (E) stop Oil in the lift cylinder is now trapped, keeping the
operating. The oil pressure at the outlet side of the rake in its desired position. Both inlet checks (A)
gear pump decreases. Pressure oil from the lift close also.
cylinder (F) and the spring in the DN port check valve
MX,27010HE,A4 -19-11SEP91
270
10
4
10
6
A—Gear Pump E—Lift Cylinder G—Raise Relief Valve Spring J—DN Port Check Valve
B—UP Port Check Valve F—Thermal Relief Valve H—Lower Relief Valve Spring K—Pressure Oil
C—Thermal Relief Valve Spring I—Lower Relief Valve L—Return Oil
D—Raise Relief Valve
Relief Valves Operation becomes blocked, oil pressure will increase on the
DN side of the gear pump. When oil pressure
NOTE: Lift circuit of pump is shown in diagram. Relief overcomes the lower relief valve spring (H) the relief
valves in the lower circuit operate the same valve (I) opens, allowing high pressure oil to relieve
as the relief valves in lift circuit. to the reservoir. The lower relief valve is set at about
2758 kPa (400 psi). The lower relief valve is also
If the lift cylinder (E) is raising and the load is too adjustable.
heavy or an oil passage becomes blocked, oil
pressure will increase at the outlet side of the gear With the lift system in the neutral position, the checks
pump (A). When oil pressure overcomes the raise (B and J) are closed. If the lift cylinder encounters a
relief valve spring (G), the relief valve (D) opens shock load, oil pressure in the cylinder will increase
allowing the high pressure oil to relieve to the because it is blocked by the lift check. When oil
reservoir. This protects the gear pump from damage. pressure overcomes the thermal relief valve spring
The raise relief valve is set at about 5171 kPa (750 (F), the relief valve (C) opens allowing the high
psi). The raise relief valve is adjustable by turning the pressure oil to relieve to the reservoir. This protects
relief valve body. the lift cylinder from damage. The thermal relief valve
is set at about 17237—20684 kPa (2500—3000 psi).
When the lift cylinder is lowering and rake contacts The thermal relief valve is not adjustable.
the ground, cylinder bottoms or an oil passage
270
10
8
MX,27010HE,A8 -19-11SEP91
270
10
10
DIAGNOSTIC INFORMATION
MX,27015HE,A1 -19-11SEP91
CONDITIONS:
•Park brake locked
•Transaxle in neutral
•Key switch in ON position
2. Reservoir oil level. Minimum oil level above suction Add oil.
screens.
Oil not foamy or milky. Replace oil.
4. Lift cylinder pivot and rod. Lift cylinder moves freely, rod Repair or replace lift cylinder.
not bent or damaged.
5. Hydraulic pump UP port. Raise relief valve pressure about Check raise relief valve (A) spring, ball,
5171 kPa (750 psi). and seat for debris, damage or leakage.
Adjust or replace raise relief valve
and check relief pressure again. If
pressure is still low, continue testing.
270
15
2 6. Inlet checks. Ball and seat free from debris Replace pump.
and not damaged.
9. Thermal relief valve. Spring not broken or cracked. Replace thermal relief valve.
Ball and seat free from debris
and not damaged.
MX,27015HE,A2 -19-11SEP91
270
15
3
-19-19SEP91
M80632AE
Slide M80632AE
MX,27015HE,A3 -19-27SEP91
CONDITIONS:
•Park brake engaged
•Transaxle in neutral
•Key switch in ON position
1. Rake pivot Rake must move freely and pivot Repair or replace pivot hardware.
hardware not bent or damaged.
2. Reservoir oil level. Minimum oil level above suction Add oil.
screens.
4. Lift cylinder pivot and rod. Lift cylinder moves freely, rod Repair or replace lift cylinder.
not bent or damaged.
5. Hydraulic pump DN port. Lower relief valve pressure about Check lower relief valve (A) spring, ball
2758 kPa (400 psi). and seat for debris, damage or leakage.
Adjust or replace lower relief valve
and check relief pressure again. If
pressure is still low, continue testing.
270
15
4 6. Inlet checks. Ball and seat free from debris Replace pump.
and not damaged.
MX,27015HE,A4 -19-11SEP91
270
15
5
-19-19SEP91
M80633AE
Slide M80633AE
MX,27015HE,A5 -19-11SEP91
REASON:
To check raise relief valve pressure setting.
-UN-19SEP91
EQUIPMENT:
•JTO5471 0—6900 kPa (0—1000 psi) gauge
PROCEDURE:
1. Move transaxle shift lever to neutral and engage park
M80634
brake.
-UN-19SEP91
5. Turn key switch to ON position. Move hydraulic pump
switch to raise position. Record raise relief valve
pressure. Release switch.
SPECIFICATIONS:
M80635
•Oil temperature .. 22˚C (72˚F)
•Raise relief valve pressure .. 4826—5516 kPa
Slide M80635
270 (700—800 psi)
15
6 RESULTS:
•If pressure is not within specification, adjust raise relief
valve:
—Remove reservoir.
—Install reservoir.
MX,27015HE,A6 -19-11SEP91
REASON:
To check lower relief valve pressure setting.
-UN-19SEP91
EQUIPMENT:
•JTO5471 0—6900 kPa (0—1000 psi) gauge
PROCEDURE:
1. Move transaxle shift lever to neutral and engage park
M80636
brake.
-UN-19SEP91
5. Turn key switch to ON position. Move hydraulic pump
switch to lower position. Record lower relief valve
pressure. Release switch.
SPECIFICATIONS:
M80637
•Oil temperature .. 22˚C (72˚F)
•Lower relief valve pressure .. 2413—3103 kPa
Slide M80637
(350—450 psi) 270
15
RESULTS: 7
•If pressure is not within specification, adjust lower relief
valve:
—Remove reservoir.
—Install reservoir.
MX,27015HE,A7 -19-11SEP91
270
15
8
270
20
1
-19-19SEP91
M80627AE
Slide M80627
MX,27020HE,A1 -19-11SEP91
270
20
2
A C
Accelerator cable Carburetor
Adjustment . . . . . . . . . . . . . . . . . . . 220-15-30 Remove and install . . . . . . . . . . . . . . 30-05-2
Replace . . . . . . . . . . . . . . . . . . . . . . 30-05-6 Repair . . . . . . . . . . . . . . . . . . . . . . . 30-05-1
Accelerator cable housing, replace . . . . . 30-05-6 Carburetor choke circuit operation . . . . . . 230-10-8
Accelerator pedal assembly, inspect and Carburetor components location . . . . . . . 230-05-6
repair . . . . . . . . . . . . . . . . . . . . . . . 30-05-7 Carburetor float/main circuit operation . . . 230-10-4
Air cleaner elements Charge system test points . . . . . . . . . . . 240-15-6
Replace—Heavy duty . . . . . . . . . . . . 30-10-3 Charging system operation . . . . . . . . . 240-10-10
Replace—Standard . . . . . . . . . . . . . . 30-10-2 Choke adjustment . . . . . . . . . . . . . . . 220-15-30
Air cleaner—Heavy duty Choke knob and cable, remove and
Remove and install . . . . . . . . . . . . . . 30-10-1 install . . . . . . . . . . . . . . . . . . . . . . . 30-05-8
Remove, inspect & install elements . . . 30-10-3 Clutch system operation . . . . . . . . . . . 250-10-12
Air cleaner—Standard Component location
Remove and install . . . . . . . . . . . . . . 30-10-1 Brake . . . . . . . . . . . . . . . . . . . . . . . 260-05-4
Remove, inspect & install element . . . . 30-10-2 Brake caliper . . . . . . . . . . . . . . . . . . 260-05-6
Amperage output test . . . . . . . . . . . . . 240-15-21 Brake pedal . . . . . . . . . . . . . . . . . . . 260-05-8
Attachment specifications . . . . . . . . . . . 10-10-2 Carburetor . . . . . . . . . . . . . . . . . . . . 230-05-6
Driven clutch . . . . . . . . . . . . . . . . . . 250-05-9
Attachments and kits . . . . . . . . . . . . . . 10-30-5
Engine electrical . . . . . . . . . . . . . . . . 240-05-4
Automatic compression release operation 220-10-10
Engine internal . . . . . . . . . . . . . . . . . 220-05-2
Engine lubrication system . . . . . . . . . . 220-05-4
Front light . . . . . . . . . . . . . . . . . . . . 240-05-6
B Fuel and air . . . . . . . . . . . . . . . . . . . 230-05-2
Battery cables, replace . . . . . . . . . . . . . 40-05-2 Fuel system . . . . . . . . . . . . . . . . . . . 230-05-4
Battery charging . . . . . . . . . . . . . . . . 240-15-17 Hydraulic lift . . . . . . . . . . . . . . . . . . . 240-05-6
Battery voltage test . . . . . . . . . . . . . . 240-15-16 Hydraulic lift pump . . . . . . . . . . . . . . 270-05-4
Battery, remove and install . . . . . . . . . . 40-05-1 Hydraulic lift system . . . . . . . . . . . . . 270-05-2 INDX
Body cowling, remove and install . . . . . . 80-05-2 Machine electrical components . . . . . . 240-05-2 1
Brake cable Power train . . . . . . . . . . . . . . . . . . . 250-05-2
Adjustment . . . . . . . . . . . . . . . . . . . . 260-15-6 Steering . . . . . . . . . . . . . . . . . . . . . 260-05-2
Replace . . . . . . . . . . . . . . . . . . . . . . 60-10-6 Transaxle . . . . . . . . . . . . . . . . . . . . 250-05-6
Brake cable housing, replace . . . . . . . . . 60-10-6 Wet reduction clutch . . . . . . . . . . . . . 250-05-4
Brake caliper Compression and cylinder leakage test . 220-15-33
Disassemble, inspect and assemble . . . 60-10-3 Compression release check . . . . . . . . . 220-15-35
Remove and install . . . . . . . . . . . . . . 60-10-2 Cooling system operation . . . . . . . . . . . 220-10-6
Brake caliper components . . . . . . . . . . . 260-05-6 Crankcase vacuum test . . . . . . . . . . . . 220-15-36
Brake components . . . . . . . . . . . . . . . . 260-05-4 Cranking circuit test points . . . . . . . . . . . 240-15-2
Brake disk, remove, inspect and install . . 60-10-4 Cranking system operation . . . . . . . . . . 240-10-4
Brake pad contact adjustment . . . . . . . . 60-10-7 Cultivator
Brake pedal assembly, inspect and repair . 60-10-7 Inspect and repair . . . . . . . . . . . . . .. 80-25-2
Brake pedal components . . . . . . . . . . . . 260-05-8 Remove and install . . . . . . . . . . . . .. 80-25-1
Brake system operation . . . . . . . . . . . . . 260-10-2 Cultivator linkage
Brake/park brake test . . . . . . . . . . . . . 210-10-10 Inspect and repair . . . . . . . . . . . . . .. 80-25-3
Breather system operation . . . . . . . . . . . 220-10-4
Bunker rake
Electrical component location . . . . . . . 240-05-2 D
Index-1 171095
Index
Page Page
Index-2 171095
Index
Page Page
G INDX
K 3
Gasoline engine oil . . . . . . . . . . . . . . . 10-20-2
Key switch
Gear shift pedals, inspect and repair . . . . 50-15-2
Replace . . . . . . . . . . . . . . . . . . . . . . 40-10-5
Governor adjustment . . . . . . . . . . . . . 220-15-31
Test . . . . . . . . . . . . . . . . . . . . . . . 240-15-29
Governor operation . . . . . . . . . . . . . . . 220-10-8
Key switch circuit breaker, replace . . . . . 40-10-4
Grease
Key switch test . . . . . . . . . . . . . . . . . 240-15-29
Extreme pressure and multipurpose . . . 10-20-3
Kits and attachments . . . . . . . . . . . . . . 10-30-5
Ground circuit test . . . . . . . . . . . . . . . 240-15-34
L
H
Lift cylinder, remove and install . . . . . . . 70-05-4
Hood, remove and install . . . . . . . . . . . . 80-05-1
Load test battery . . . . . . . . . . . . . . . . 240-15-18
Hourmeter/voltmeter circuit test points . . 240-15-10
Lower relief valve pressure test . . . . . . . 270-15-7
Hourmeter/voltmeter system operation . . 240-10-14
Lubricants
Hourmeter, replace . . . . . . . . . . . . . . . . 40-10-8
Storage . . . . . . . . . . . . . . . ....... 10-20-3
Hydraulic diagnosis
Lift cylinder will not lower . . . . . . . . . . 270-15-4
Lift cylinder will not raise . . . . . . . . . . 270-15-2
Hydraulic hoses, inspect and replace . . . . 70-05-5 M
Hydraulic lift component location . . . . . . . 240-05-6 Machine Specifications . . . . . . . . . . . . . 10-10-1
Index-3 171095
Index
Page Page
O
Oil, wet clutch . . . . . . . . . . . . . . ..... 10-20-2
S
Operational checks and tests
Brake/park brake . . . . . . . . . . . . . . 210-10-10 Schematics
Differential lock . . . . . . . . . . . . . . . . 210-10-11 Hydraulic lift system . . . . . . . . . . . . . 270-20-1
Drive engagement and shift . . . . . . . . 210-10-9 Serial numbers
Engine fast and slow idle . . . . . . . . . . 210-10-7 Engine . . . . . . . . . . . . . . . . . . . . . . 10-25-1
Engine oil level and condition . . . . . . . 210-10-2 Hydraulic pump . . . . . . . . . . . . . . . . 10-25-2
Engine start test . . . . . . . . . . . . . . . . 210-10-6 Product . . . . . . . . . . . . . . . . . . . . . . 10-25-1
Optional front light . . . . . . . . . . . . . . . 210-10-4 Transaxle . . . . . . . . . . . . . . . . . . . . 10-25-1
Start test . . . . . . . . . . . . . . . . . . . . . 210-10-5 Shift cables
Steering . . . . . . . . . . . . . . . . . . . . 210-10-12 Adjustment . . . . . . . . . . . . . . . . . . . 250-15-19
Transaxle forward/reverse . . . . . . . . . . 210-10-8 Slow and fast idle circuits operation . . . . 230-10-6
Wet clutch oil level and condition . . . . . 210-10-3 Slow idle adjustment . . . . . . . . . . . . . . 220-15-32
Spark plug gap adjustment . . . . . . . . . 240-15-28
Specific gravity test . . . . . . . . . . . . . . 240-15-16
Specifications . . . . . . . . . . . . . . . . . . . 210-05-1
P Specifications
Power train adjustments Attachment . . . . . . . . . . . . . . . . . . . 10-10-2
INDX Transaxle shift cables . . . . . . . . . . . 250-15-19 Machine . . . . . . . . . . . . . . . . . . . . . 10-10-1
4 Power train components location . . . . . . 250-05-2 Repair . . . . . . . . . . . . . . . . . . . . . . . 10-15-1
Power train diagnostics Splash guard, remove and install . . . . . . 80-05-2
Differential lock will not operate . . . . . 250-15-16 Starter
Jerky or aggressive engagement . . . . 250-15-10 Remove and install . . . . . . . . . . . . . . 40-10-2
Lack of drive—Both directions . . . . . . . 250-15-4 Repair . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Lack of drive—One direction . . . . . . . . 250-15-2 Starter loaded amp test . . . . . . . . . . . . 240-15-23
Noisy operation—Both directions . . . . . 250-15-6 Starter loaded RPM test . . . . . . . . . . . 240-15-23
Premature belt wear . . . . . . . . . . . . 250-15-14 Starter no-load amperage test . . . . . . . 240-15-24
Slow erratic acceleration . . . . . . . . . 250-15-12 Starter solenoid test . . . . . . . . . . . . . . 240-15-22
Vehicle creeps—In gear at idle . . . . . . 250-15-8
Steering and brake diagnostics
Power train tests
Brake effort, noise, wear, etc. . . . . . . . 260-15-4
Drive belt inspection . . . . . . . . . . . . 250-15-18
Steering components . . . . . . . . . . . . . . 260-05-2
Driven clutch spring adjustment . . . . . 250-15-22
Steering fork assembly
Driven clutch spring check . . . . . . . . 250-15-21
Remove, inspect and install . . . . .... 60-05-3
Full upshift check . . . . . . . . . . . . . . 250-15-20
Steering shaft
Remove, inspect and install . . . . . . . . 60-05-1
Steering system theory of operation . . . . 260-10-1
R Steering test . . . . . . . . . . . . . . . . . . . 210-10-12
Raise relief valve pressure test . . . . . . . 270-15-6 Steering vibration or noise . . . . . . . . . . . 260-15-2
Index-4 171095
Index
Page Page
Tune-up
Adjustments . . . . . . . . . . . . . . . . . . . 10-15-6
T Specifications . . . . . . . . . . . . . . . . . . 10-15-5
Test and adjustment specifications . . . . . 210-05-1
Theory of operation
V
Automatic compression release . . . . . 220-10-10
Valve clearance adjustment . . . . . . . . . 220-15-34
Brake system . . . . . . . . . . . . . . . . . . 260-10-2
Voltage regulator, replace . . . . . . . . . . . 40-10-3
Carburetor choke circuit . . . . . . . . . . . 230-10-8
Voltage test
Carburetor float/main circuits . . . . . . . . 230-10-4 Regulated . . . . . . . . . . . . . . . . . . . 240-15-19
Charging system . . . . . . . . . . . . . . . 240-10-10 Unregulated . . . . . . . . . . . . . . . . . . 240-15-20
Clutch system . . . . . . . . . . . . . . . . 250-10-12 Voltmeter, replace . . . . . . . . . . . . . . . . 40-10-7
Cooling system . . . . . . . . . . . . . . . . . 220-10-6
Cranking system . . . . . . . . . . . . . . . . 240-10-4
Differential lock . . . . . . . . . . . . . . . . 250-10-18
W
Drive clutch . . . . . . . . . . . . . . . . . . . 250-10-4
Wet clutch oil . . . . . . . . . . . . . . . .... 10-20-2
Driven clutch . . . . . . . . . . . . . . . . . . 250-10-6
Wet reduction clutch
Electric-hydraulic lift . . . . . . . . . . . . . 240-10-16
Assemble . . . . . . . . . . . . . . . . . . . . 50-05-7
Engine lubrication system . . . . . . . . . . 220-10-2 Components location . . . . . . . . . . . . . 250-05-4
Front light system . . . . . . . . . . . . . . 240-10-12 Cross section . . . . . . . . . . . . . . . . . . 50-05-6
Governor . . . . . . . . . . . . . . . . . . . . . 220-10-8 Disassemble and inspect . . . . . . . . . . 50-05-2
Hourmeter/voltmeter system . . . . . . . 240-10-14 Install . . . . . . . . . . . . . . . . . . . . . . . 50-05-8
Hydraulic lift system . . . . . . . . . . . . . 270-10-2 Oil level and condition check . . . . . . . 210-10-3
Ignition system off . . . . . . . . . . . . . . . 240-10-8 Operation . . . . . . . . . . . . . . . . . . . . 250-10-2
Ignition system running . . . . . . . . . . . 240-10-6 Remove . . . . . . . . . . . . . . . . . . . . . 50-05-1
Slow and fast idle circuits . . . . . . . . . . 230-10-6 Wheel bearings, inspect and replace . . . . 80-10-1
Steering system . . . . . . . . . . . . . . . . 260-10-1 Wheels, remove and install
Transaxle forward . . . . . . . . . . . . . . 250-10-14 Front . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
Transaxle reverse . . . . . . . . . . . . . . 250-10-16 Rear . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
Wet reduction clutch . . . . . . . . . . . . . 250-10-2 Wire color chart, electrical . . . . . . . . . . . 240-10-2
Torque value Wiring harness, replace
O-Ring boss fitting . . . . . . . . . . . . .. 10-15-7 Hydraulic pump . . . . . . . . . . . . . . . . 40-15-7 INDX
Torque values
Machine . . . . . . . . . . . . . . . . . . . . . 40-15-6 5
Wiring schematics . . . . . . . . . . . . . . . . 240-20-1
Inch . . . . . . . . . . . . . . . . . . . . . . .. 10-15-9
Metric . . . . . . . . . . . . . . . . . . . . . .. 10-15-8
Transaxle
Assemble . . . . . . . . . . . . . . . . . . . . 50-20-13
Disassemble and inspect . . . . . . . . . . 50-20-4
Install . . . . . . . . . . . . . . . . . . . . . . . 50-20-21
Install external components . . . . . . . . . 50-20-20
Remove . . . . . . . . . . . . . . . . . . . . . 50-20-2
Remove external components . . . . . . . 50-20-4
Transaxle components location . . . . . . . . 250-05-6
Transaxle forward operation . . . . . . . . . 250-10-14
Transaxle forward/reverse test . . . . . . . . 210-10-8
Transaxle neutral switch test . . . . . . . . 240-15-31
Transaxle oil . . . . . . . . . . . . . . . . . . . . 10-20-2
Transaxle reverse operation . . . . . . . . . 250-10-16
Transaxle shift cable housings, replace . . 50-15-1
Transaxle shift cables
Replace . . . . . . . . . . . . . . . . . . . . .. 50-15-1
Index-5 171095
Index
INDX
6
Index-6 171095