3URIHVVLRQDO 6KRS 0DQXDO LTX Series Riding Tractors NOTE: These materials are for use by trained technicians who are experienced in the service and repair of outdoor power equipment of the kind described in this publication, and are not intended for use by untrained or inexperienced individuals. These materials are intended to provide supplemental information to assist the trained technician. Untrained or inexperienced individuals should seek the assistance of an experienced and trained professional.
Table of Contents Chapter 1: Introduction Professional Shop Manual intent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description of the 900 series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Model and Serial Numbers . .
Chapter 5: Hydro. Drive and brake system About this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Externally repairable drive system problems . . . . . . . . . . . . . . . . . . . . . . . . 56 Indications that a transaxle is not warrantable . . . . . . . . . . . . . . . . . . . . . . . 61 Brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Neutral control adjustment . . . . . . . . . . . . . . .
Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Run Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Run Circuit / Reverse Caution mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine shutdown circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 8: Cutting Decks and lift shaft Cutting decks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deck removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . To clean the deck while it is removed:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blades . . . . . . . . . . . . . . . . . . . . . . . .
Introduction CHAPTER 1: INTRODUCTION Professional Shop Manual intent This Manual is intended to provide service dealers with an introduction to the mechanical aspects of the LTX series of tractors. • Detailed service information about the engine will be provided by the engine manufacturer, in most cases. Disclaimer: The information contained in this manual is correct at the time of writing. Both the product and the information about the product are subject to change without notice.
LTX Tractors • Be prepared in case of emergency: ! CAUTION Keep a fire extinguisher nearby Keep a first aid kit nearby Keep emergency contact numbers handy • Replace any missing or damaged safety labels on shop equipment. • Replace any missing or damaged safety labels on equipment being serviced. • Grooming and attire: ! WARNING Do not wear loose fitting clothing that may become entangled in equipment. Long hair should be secured to prevent entanglement in equipment. Jewelry is best removed.
Introduction Assembly Torque specifications may be noted in the part of the text that covers assembly, they may also be summarized in tables along with special instructions regarding locking or lubrication. Whichever method is more appropriate will be used. In many cases, both will be used so that the manual is handy as a quick-reference guide as well as a step-bystep procedure guide that does not require the user to hunt for information.
LTX Tractors Model and Serial Numbers The model and serial number tag can be found under the seat. See Figure 1.2. The serial number is located to the right of the model number as shown above. See Figure 1.2. Model number Serial number Figure 1.2 The model number is 13AX90AR010 The break down of what the character mean is as follows: 1 .............................................................................................. Cuts grass ....3 .........................................................
Engine Ralated Parts CHAPTER 2: ENGINE RELATED PARTS This manual will cover the engine accessories that are manufactured by Cub Cadet. IMPORTANT: Refer to the engine manufacturer’s manual for engine specific service information. Muffler Remove the muffler by following these steps: NOTE: The muffler and the exhaust pipes are welded together. They are replaced as one assembly. 1. Remove the hood and bumper by following the steps described in Chapter 4: Body/Chassis. 2.
LTX Tractors • Remove the screw that fastens the muffler support bracket to the cylinder head. See Figure 2.3. Screw Support bracket Figure 2.3 For twin cylinder engines: • Remove the two nuts that secure each exhaust pipe to the cylinder head. See Figure 2.4. Nuts Figure 2.
Engine Ralated Parts 4. Pull the muffler cover and muffler out together. 5. Rotate the muffler out of the muffler cover. See Figure 2.5. 6. With the muffler on a work bench, remove the four screws that hold the muffler deflector to the muffler. See Figure 2.6. 7. Install the muffler by following the above steps in reverse order. 8. Test run the tractor before returning to service. Figure 2.5 Screws Muffler deflector Figure 2.
LTX Tractors Fuel tank removal/replacement Remove/replace the fuel tank by following these steps: ! CAUTION Gasoline and its vapors are extremely flammable. Use common sense when working around the fuel system. • Work in a well-ventilated area. • Allow the engine to cool fully before starting work on the tractor. • Eliminate any sources of possible ignition from the work area, including but not limited to: heat sources, open flame, potential sparks.
Engine Ralated Parts Fuel Line NBR intermediate layer NBR inner liner The fuel line used by Cub Cadet is GREENbarTM. This is a multi-layer fuel line that meets the current EPA guidelines. NOTE: This fuel line has a thin inner liner. If a tear forms in this inner liner, fuel can get between the liner and the hose. This will cause the liner to collapse, cutting off the fuel flow. NOTE: Replace the fuel line only with GREENbarTM 700 series fuel line. CSM Cover Reinforcement THV barrier layer Figure 2.
LTX Tractors Evaporative (EVAP) emissions system The EPA has enacted rules that regulate the amount of vapors an engine’s fuel system is allowed to vent to the atmosphere. The rules are know as Tier III Emissions Standards. These rules apply to all engines built on or after 1/ 1/2012. Some of the requirements of tier III emissions include: • Tethered fuel caps. • Unvented fuel caps. • Low permeation (GREENbarTM) fuel line • Roll over valve vents The fuel tank has an unvented fuel cap.
Engine Ralated Parts Troubleshooting Symptom Engine starts, then dies Cause A blockage in the vent hose. The roll over valve is stuck closed. Engine runs rich Raw gasoline in the charcoal canister (if equipped). A blockage in the line between the charcoal canister (if equipped) and the intake manifold. Engine runs lean Wrong fuel cap installed. Leak in the vacuum lines. Gasoline vapor escaping from the engine The charcoal canister (if equipped) is saturated.
LTX Tractors Roll over valve vent To remove the roll over valve: 1. Open the hood. 2. Disconnect the vent hose. See Figure 2.11. Vent hose NOTE: The vent hose will have a red trace. Figure 2.11 3. Gently pry the roll over valve out of the fuel tank. See Figure 2.12. 4. Inspect the rubber grommet, replace if damaged. Roll over valve To install the roll over valve: 1. With the grommet on the roll over valve, install the roll over valve by pressing it into the opening in the tank. 2.
Engine Ralated Parts Testing the roll over valve The roll over valve vent has two functions. The first function is to vent the tank and the second function is to close off the vent if the tank is inverted. 15 in.Hg. Test the roll over valve by: 1. Remove the roll over valve by following the steps previously described in this section. 2. Connect a vacuum pump to the roll over valve. 3. Hold the roll over valve in an inverted position. 4. Apply a vacuum to the roll over valve. See Figure 2.13.
LTX Tractors 14
Steering CHAPTER 3A: STEERING Steering alignment Center the sector gear IMPORTANT: The front tires will have a “TOE-IN” between 1/16” and 1/4” to allow the unit to track properly. Figure 3A.1 1. Check the tire pressure in the front tires and make certain that they are at approximately 14 PSI. The rear tires should be at 10 PSI. 2. Place the unit on level ground. 3. Lower the deck lift lever to the lowest position. 4.
LTX Tractors 8. Loosen the jam nut at the rear of the right ball joint that secures the ball joint to the drag link, using a 1/ 2” wrench and an 11/16” wrench. See Figure 3A.3. 9. Remove the hex nut and lock washer, that secures the right ball joint to the right axle assembly, using a 1/2” wrench and a 9/16 wrench. 10. Remove the right hand ball joint from the right hand drag link. 11. Remove the left hand ball joint performing steps 8, 9 and 10 above. 12.
Steering Axles Identification mark NOTE: The left and right axle have a “L” or a “R” stamped on the end of the shaft for identification. See Figure 3A.4. 1. Jack up the front end of the tractor and securely place on jack stands. 2. Remove the front wheel by popping the hub cap off with a flat head screw driver. 3. Remove the cotter pin and the castellated washer. See Figure 3A.5. Figure 3A.
LTX Tractors 5. Support the axle and remove the steering block using two 1/2” wrenches. See Figure 3A.7. NOTE: The SLT models do not have a spacer. Steering block Spacer Figure 3A.7 6. Remove the spacer and lower the axle out of the pivot bar. NOTE: Starting in the 2010 season, some tractors will be equipped with a stamped pivot bar. These tractors will have plastic bushing where the axle rides inside the pivot bar. See Figure 3A.8.
Steering Sector gear and steering pinion gear If you are replacing the sector gear or steering pinion gear, check the condition of both gears for any wear or damage. It may be wise to replace both as a set. Steering Pinion Gear 1. Remove the cutting deck by following the steps described in Chapter 8: Cutting Decks and Lift Shaft 2. Jack up the front end of the tractor and securely place on jack stands. 3.
LTX Tractors 8. Remove the drag links from the sector gear. 9. Remove the six screws that secure the steering plate to the frame. See Figure 3A.12. Remove these screws on each side Figure 3A.12 10. Remove the steering plate. 11. Remove the hex cap screw, shoulder spacer and hex nut in the middle of the sector gear using two 9/ 16” wrenches. See Figure 3A.13. NOTE: Note the order the spacers and washer were removed so that they can be installed properly. See Figure 3A.14. sector gear Figure 3A.
Steering Steering shaft and hex bushing To remove the steering shaft or to replace the hex bushing: 1. Remove the cutting deck by following the steps described in Chapter 8: Cutting Decks and Lift Shaft 2. Jack up the front end of the tractor and securely place on jack stands. 3. Remove the steering wheel 3a. Remove the cover from the center of the steering wheel. See Figure 3A.15. Figure 3A.15 NOTE: The cover can be released by prying-in on the lock-tabs on the under-side of the steering wheel.
LTX Tractors 6. Lift up on the steering shaft and remove the washer. See Figure 3A.18. 7. Push the steering shaft up through the frame of the tractor. Remove the washer Lift up on the steering shaft Figure 3A.18 8. Remove the hex bushing. See Figure 3A.11. NOTE: Replace the hex bushing every time the steering shaft is removed. 9. Remove the hex bushing Remove the drag links from the sector gear. Figure 3A.19 10. Remove the six screws that secure the steering plate to the frame. See Figure 3A.
Steering Pivot bar To remove/replace the pivot bar: Remove this bolt 1. Jack up the front end of the tractor and securely place on jack stands. 2. Remove the axles by following the procedures described in the axle section of this chapter. 3. Slide the front deck link out of the frame. 4. Support the pivot bar. 5. Remove the pivot bar pivot bolt using two 3/4” wrenches. See Figure 3A.21. 6. Slide the pivot bar out of the frame. Figure 3A.
LTX Tractors 24
Electronic Power Steering CHAPTER 3B: ELECTRONIC POWER STEERING NOTE: The basic steering system, such as the tie rod ends, drag links axles, etc., is covered in Chapter 3A: Steering. In 2012, Cub Cadet introduced the Electronic Power Steering (EPS) system on the Cub select models of the LTX series of tractors. The EPS provides an electric assist to the steering wheel. The EPS is a system consisting of three sub-assemblies: the rubber torsion coupling, the EPS module and the EPS motor & gearbox.
LTX Tractors EPS motor & gearbox The steering input passes through the torsion coupling and module into the gearbox. The gearbox then passes the input force to the output shaft connected to the steering housing. The EPS motor assists in turning the input shaft by driving a set of planetary gears. The planetary gears drive a worm shaft. The worm shaft drives a worm gear on the output shaft. EPS module EPS motor Steering shaft coupler output shaft IMPORTANT: DO NOT open or service the steering gearbox.
Electronic Power Steering Troubleshooting the EPS (without the 725-05419 EPS tester) The first step in troubleshooting the EPS system is to understand how it works. See Figure 3B.4. • A constant 12 volts is supplied by the battery through a 40 amp fuse in the fuse box. ,JQLWLRQ PRGXOH • The EPS is grounded through the green wire. • The EPS senses the ignition pulses from the ignition module primary windings through the yellow wire with a white trace. *5281' 0$*1(72 %$77(5< Figure 3B.
LTX Tractors NOTE: Before troubleshooting any electrical circuit on a tractor, always make sure the battery is fully charged. NOTE: The EPS assembly has constant battery power and is not controlled by the ignition switch. To troubleshoot the EPS assembly: 5. Place the tractor on flat, level ground. 6. Remove any attachments that may be on the tractor. 7. Set the parking brake. 8. Turn the steering wheel so that the wheels are pointing straight forward. 9.
Electronic Power Steering 13. Check the current draw of the EPS assembly. 13a. Leave the DMM connected to the ground wire on the EPS and the battery. 13b. Place an amp clamp meter on the red wire with a black trace. See Figure 3B.9. NOTE: Cut the tape that seals the loom at the EPS connector end of the harness and slide the loom off of the wires to attach the amp clamp. Red wire with black trace 13c. Start the tractor. NOTE: The voltage reading on the DMM should now read over 13 volts.
LTX Tractors NOTE: A voltage spike over 18.5vdc +/- 1.2v @70°F will cause the voltage regulator to shut down. The regulator must be disconnected, then re-connected to reset it. NOTE: A sustained voltage over 25 volts will damage the EPS module. IMPORTANT: Loose battery cables or disconnecting jumper cables while the engine is running will create a high voltage spike that will damage the EPS system.
Electronic Power Steering EPS motor To remove/replace and test the EPS motor: NOTE: The EPS system has a 4 year warranty. DO NOT remove the EPS motor to test it within the warranty period. Outside of the warranty period, the EPS motor can be replaced separately from the EPS assembly. 1 Remove the EPS assembly by following the procedures described in the EPS removal section of this chapter. 2. Disconnect the EPS motor harness from the EPS module. Figure 3B.12 3.
LTX Tractors 8. Inspect the EPS motor gasket. If it is damaged, replace it. NOTE: Do not use a gasket sealant/adhesive on the EPS motor gasket. 9. Remove the sun gear from the EPS motor. 10. Install the sun gear into the planetary gear set. Sun gear Figure 3B.14 Harness EPS motor pigtail 11. Install the EPS motor. NOTE: While installing the EPS motor, align the motor pigtail with the EPS motor harness. 12.
Electronic Power Steering EPS removal/replacement To remove/replace the EPS assembly: 1 Loosen Remove the hood, dash and fender by following the procedures described in Chapter 4: Body Panels. 2. Remove the fuel tank by following the procedures described in Chapter 2: Engine Related Parts. 3. Remove the steering pinion gear by following the procedures described in Chapter 3: Steering 4. Disconnect the EPS harness connector. Remove Steering coupler 5.
LTX Tractors 8. Remove the two screws securing the left dash support to the frame using a 3/8” wrench. See Figure 3B.18. 9. Slide the left dash support off of the EPS motor. Screws Figure 3B.18 10. Remove the two screws securing the EPS bracket to the frame. 11. Lift the EPS out of the tractor. NOTE: The EPS output shaft will pass through a spacer, and a bushing. See Figure 3B.19. 12. Install the EPS by following the previous steps in reverse order.
Body Panels CHAPTER 4: BODY PANELS What is covered by this chapter The intent of this chapter is to describe the removal and disassembly of the major body panels on the tractor. • Hood • Seat • Fenders • Dash panel “A” style hood NOTE: It is not absolutely necessary to remove the mowing deck for any procedures covered in this section. The technician may choose to remove the mowing deck so that it is easier to reach some parts of the tractor.
LTX Tractors Hood Hood removal: 1. The hood is front-hinged. See Figure 4.2. 2. Open the hood by lifting the rear edge to tilt it forward. Lift here Figure 4.2 3. Disconnect the headlight wires. See Figure 4.3. NOTE: The ground terminals and power terminals on the headlights are two different sizes. The green wires (ground) fit the larger terminals. The red wires (power) fit the smaller terminals. Inset: headlight detail Figure 4.3 4.
Body Panels Hood components: Headlight removal 1. With the spade terminals disconnected, rotate the lamp holder (socket) to release it from the grill assembly. See Figure 4.5. 2. Rotate the bulb to release it from the socket. See Figure 4.6. 3. Install the replacement lamp following the above steps in reverse order. Figure 4.5 Single-pin 1156-style lamp Socket Ground terminal Power terminal Figure 4.
LTX Tractors Hood components: side vent removal 2 lock tabs on top 1. Carefully pry the vent free of the lock tabs. See Figure 4.7. 2. Pull the vent out of the hood assembly. 3. Install the hood side vent by pressing it into the hood side opening until the lock tabs click into place, securing the vent. 2 lock tabs on bottom Figure 4.
Body Panels Hood components: grill removal Slotted mounting hole Grill Screw + washer 1. Remove the hood assembly from the tractor, and place it on a stable work surface. 2. Loosen, but do not remove the screws that hold the upper corners of the grill to the hood using a 3/8” wrench. See Figure 4.8. 3. Remove the two screws that hold the pivot bracket and grill to the hood assembly using a 1/2” wrench. See Figure 4.9. 4.
LTX Tractors Hood components: pivot bracket removal 1. Remove the four screws that hold the outer arms of the pivot bracket to the hood using a 3/8” wrench. See Figure 4.11. Small screws Small screws pivot bracket Figure 4.11 Pivot bracket 2. 3. Remove the two screws that hold the pivot bracket and grill to the hood assembly using a 1/2” wrench. See Figure 4.12. Large Screws Assemble and install the grill by reversing the steps used to remove it.
Body Panels Seat and Fenders ! CAUTION The battery will be removed in this procedure. Review the Operator’s Manual and the Chapter 7: Electrical Systems for important safety information about handling batteries before proceeding. IMPORTANT: Do not return an unsafe mower to service. There are four variants of fender used on the Cub Cadet Series 1000 for the model year 2009 and after: • Manual PTO models have two levers on the right fender: one for the deck height control and one for the PTO.
LTX Tractors Removal procedures for fenders are very similar on all variants. Where necessary, notes will be included to cover slight differences in procedures. 1. Seat removal: It is necessary to remove the seat before removing the fenders, primarily because of the seat safety switch connection. 1a. Tilt the seat up, and disconnect the negative battery cable. See Figure 4.14. Negative battery cable Figure 4.14 NOTE: The seat slides in three “T” slots in the seat bracket.
Body Panels Correct spring location 1f. The seat adjuster lever and spring will come easily off the bottom of the seat. See Figure 4.17. • The lever is located by a tab that fits into a slot on the bottom of the seat. • The spring fits into a toroidal (doughnut shaped) recess in the bottom of the seat. Seat adjuster lever Figure 4.17 1 Push in 2 slide forward 1g. To remove the seat safety switch: squeeze the tabs on the side of the switch, and push it into the seat base. See Figure 4.18. 1h.
LTX Tractors 2b. Remove the battery hold-down by prying the end of the hold-down out of the “U” shaped slot. 2c. Lift the battery out of the tractor. See Figure 4.20. 2d. Lift the battery tray out of the tractor. ! CAUTION Battery tray Battery hold-down Slot When reinstalling a battery in this tractor, use only the original type of battery. The negative terminal must go toward the rear of the tractor. Figure 4.20 NOTE: It is not necessary to remove the seat bracket when removing the fenders. 2e.
Body Panels Lift assist spring 3b. If the tractor has a deck lift assist spring, remove the deck or lift the mower deck to the highest position and support it with wood blocks. See Figure 4.23. NOTE: Tractors equipped with the 38” deck and 42” timedblade R-deck will not have lift assist springs. Figure 4.23 3c. Unhook and gently release the lift assist spring from the back of the tractor frame. See Figure 4.24. 3d.
LTX Tractors NOTE: A blow-gun with air pressure regulated to less than 25 PSI (1.72 Bars). may be inserted into the small hole at the end of a rubber grip to inflate it slightly, easing removal. See Figure 4.26. Air blow gun Figure 4.26 4. Remove the rubber foot pads. See Figure 4.27. Figure 4.27 5. Remove the drive pedals. 5a. Remove the reverse pad from the drive pedal (hydrostatic drive tractors only). See Figure 4.28. Reverse pedal pad Figure 4.
Body Panels Drive linkage 5b. Unbolt the drive pedal using a 1/2” wrench, and maneuver it out of the tractor. See Figure 4.29. 5c. Remove the brake pedal using a 1/2” wrench. Drive pedal Figure 4.29 Wax paper Bolts under label 6. Remove the fender panel. 6a. Carefully peel-up the large operating instructions label from the floor portion of the fender panel. See Figure 4.30. • Gentle application of heat will help loosen the adhesive.
LTX Tractors 6d. Remove the nuts and bolts that hold the front edge of each fender to the frame outriggers using a pair of 7/16” wrenches. See Figure 4.32. 6e. Carefully lift the fender assembly off of the tractor. Nut, bolt, and washer Figure 4.32 NOTE: On tractors equipped with a Kohler single cylinder engine, the front of the fender mounts to the outrigger using a rubber bushing and steel spacer. See Figure 4.33. Steel spacer Rubber bushing Figure 4.
Body Panels Steel reinforcement plate NOTE: The handle assemblies can be removed from the rear fenders using a 3/8” wrench, from beneath the fender. See Figure 4.34. Screws that hold the handle assembly Figure 4.34 NOTE: With the handle assembly removed, the steel reinforcement plate can be unbolted from the top side of the fender using a 3/8” wrench. See Figure 4.35. Reinforcement plate mounting screws Figure 4.
LTX Tractors Dash Panel The dash panel may be removed to provide easier access to the cruise-control and drive system linkages, or to replace the dash or dash support brackets. 1. Remove the fenders. 2. Remove the steering wheel: 2a. Remove the cover from the center of the steering wheel. See Figure 4.36. Figure 4.36 NOTE: The cover can be released by prying-in on the lock-tabs on the under-side of the steering wheel. See Figure 4.37. 2b.
Body Panels 3. Remove the fuel tank. 3a. Drain the fuel tank to a level that will not allow fuel to spill. NOTE: The tank may be drained by mechanical syphon or by disconnecting the fuel line from the fuel filter. 3b. Remove the two screws that hold the top of the wire form fuel tank bracket to the dash support brackets using a 3/8” wrench. See Figure 4.38. 3c. Support the fuel tank. 3d.
LTX Tractors 4. Disconnect the harness plugs from the following electrical devices under the dashboard: See Figure 4.41. Hour meter RMC Module • Hour meter Key switch • Key switch PTO switch • RMC module • PTO switch, if so equipped Figure 4.41 Throttle grip 5. 6. Use a phillips head screwdriver to remove the throttle control grip. See Figure 4.42. Carefully peel-off the throttle control label. • Gentle application of heat will help loosen the adhesive.
Body Panels 8. If the tractor has a separate choke cable, disconnect it from the engine. 9. Remove the locking clip that holds the cruise control / parking brake rod to the engagement lever assembly. See Figure 4.44. Figure 4.44 10. Disengage the rod from the lever assembly. Rod NOTE: The rod is kept in slight tension by a light spring that hooks between the frame and the step in the middle of the rod. See Figure 4.45. Spring Figure 4.45 11.
LTX Tractors 12. Remove the four screws that hold the base of the dash panel to the frame using a T-40 driver and a 1/ 2” wrench. See Figure 4.47. Torx head screw Hex-head cap screw Figure 4.47 NOTE: On tractors equipped with electronic power steering: See Figure 4.48. • Remove the screw that holds the EPS motor cover to the left side of the dash using a 3/8” wrench. • Pull the EPS motor cover off of the barbed fastener. EPS motor cover Figure 4.48 13. Lift the dash panel off of the tractor.
HYDRO. DRIVE AND BRAKE SYSTEM CHAPTER 5: HYDRO. DRIVE AND BRAKE SYSTEM About this chapter The drive and brake systems for the Cub Cadet Series 1000 tractor are combined. Two reasons for this: • The brake on the Series 1000 tractor is supplied with the transaxle. On hydrostatic-drive tractors, the brake comes from Hydro-Gear. • The brake pedal applies the brake and disengages the drive system. Both systems share common linkage.
LTX Tractors Externally repairable drive system problems Most of the problems listed in this section will result in a customer complaint of low power or low ground speed, sometimes accompanied by growling or similar noises from the transaxle. If the tractor is difficult to push, check the brakes and the hydraulic bypass. 1. 2. Engine performance: 1a. Find the specified engine RPM for the tractor ( 3,375-3,525 RPM for the Cub Cadet Series 1000). 1b.
HYDRO. DRIVE AND BRAKE SYSTEM 4. Check the brakes: See Figure 5.3. 4a. The brake linkage applies the brakes and disengages the drive belt. Confirm that both parts of the linkage are moving properly. • When the brake pedal is released, the transmission drive belt should be under tension. It should take about 3 lbs (1.36 Kg.) of force at the center of the longest span of the belt to move the belt 1/2” (1.3 cm) inward. Belt tension gauge • If the belt is not tensioning properly, the drive will slip.
LTX Tractors 4c. • Left foot on clutch /brake pedal Operator error: See Figure 5.5. If the customer complains of symptoms similar to a brake / clutch linkage problem, yet no mechanical problem is present, check the customer. Right foot on Reverse pedal Operator error Figure 5.5 5. Check the drive belt. See Figure 5.6. • In normal use, drive belts typically last for years without problems.
HYDRO. DRIVE AND BRAKE SYSTEM Drive pedal latch plate Travel limit pin Drive pedal bracket 6. Check the drive control linkage. See Figure 5.7. 6a. The travel limit pin fits into the curved slot in the drive pedal latch plate. The pedal bracket should have enough travel for the pin to hit both ends of the curved slot when the pedal is moved through the full range of its travel. 6b. Some lost motion is built into the linkage so that there is a “dead” range as the pedal moves from neutral to reverse.
LTX Tractors 6d. • • If the tractor makes drive noise or creeps while the pedal is in neutral, but seems to have lost speed in just one direction (forward or reverse): The rod connecting the pedal bracket to the arm on the transaxle may be bent, changing its effective length. See Figure 5.10. Drive control rod The transaxle neutral control may be out of adjustment. See the Neutral control adjustment section of this chapter. Figure 5.10 7.
HYDRO. DRIVE AND BRAKE SYSTEM Torque bracket mounting points 8. 9. Transaxle mounting: 8a. The primary symptoms of a transaxle that is loose in the frame are that it will lose drive or throw-off the drive belt in reverse. 8b. Check the torque bracket and the axle mounting points at the frame. See Figure 5.12. Eliminate heat factors • As hydrostatic transaxles wear, they will begin to lose drive power when they get hot. Torque bracket • Heat is the enemy of transaxle performance and longevity.
LTX Tractors Brake adjustment 1. 2. Test the operation of the brakes 1a. Disengage the transmission release rod by pulling it out and hooking it. 1b. Set the parking brake by depressing the brake/clutch pedal and pushing-down on the parking brake/cruise control lever. See Figure 5.13. 1c. Attempt to push the tractor. If it can be pushed by hand without skidding a rear wheel, check and adjust the brakes. 1d. Release the parking brake. 1e. Attempt to push the tractor again.
HYDRO. DRIVE AND BRAKE SYSTEM 2b. Check the gap between the brake rotor and the brake pads. • There is a fixed pad in the transaxle housing. • There is a moving pad in the brake caliper. • Wiggle the brake rotor slightly, and attempt to insert a 0.015” (0.38mm) feeler gauge between the rotor and either pad. 2c. Brake yoke Brake rotor Adjust the gap, if necessary, so that the feeler gauge slips between the pad and the rotor with light pressure. See Figure 5.16.
LTX Tractors Neutral control adjustment NOTE: Neutral control rarely goes out of adjustment on its own. If it needs adjustment, check for damaged linkage or signs of tampering. ! CAUTION The tractor engine and drive system must be operated to complete this procedure. Confirm that no hazards will be incurred by running the engine or operating the drive system: • Work in a well vented area to prevent carbon monoxide poisoning or asphyxiation. • Be careful to avoid contact with hot parts or moving parts.
HYDRO. DRIVE AND BRAKE SYSTEM 6. Loosen the socket head cap screw that locks the adjusting puck using a 1/4” allen wrench. 7. Have a 1-1/8” wrench handy, or size an adjustable wrench to fit the adjusting puck. See Figure 5.19. 8. Start the engine and advance throttle to maximum RPM. 9. Set the adjusting puck so that neither wheel rotates. The brake rotor should also be stationary. 10. Lock the adjusting puck, then confirm that the wheels and brake rotor are still motionless. 11.
LTX Tractors Linkage: pedal shaft Description: The Clutch/brake pedal and the drive control pedal operate on two concentric shafts. • The clutch/brake shaft runs the full width of the tractor. • The drive control shaft is tubular, and pivots on the clutch/brake shaft. • Each shaft has a toothed latch plate. The latch plates are next to each other. • The cruise control/park brake lever operates a common pawl that engages the latch plate of whichever pedal is applied. See Figure 5.20.
HYDRO. DRIVE AND BRAKE SYSTEM Pedal shaft assembly removal Clutch/brake shaft Rod NOTE: Confirm that the parking brake is released before starting work. 1. Remove the mowing deck. 2. Remove the fenders, as described in the body panels chapter of this manual. 3. Disconnect the rod that joins the arm at the left side of the brake/clutch shaft to the drive belt tensioner pulley bracket. See Figure 5.22. • Remove and discard the cotter pin to disconnect the rod. Figure 5.22 Travel limit pin 4.
LTX Tractors 7. Remove and discard the push cap that holds the drive control pedal shaft onto the clutch/brake shaft. See Figure 5.25. Tie-rod separator Push cap Figure 5.25 8. Loosen the bolt that holds the left pedal shaft support strap using a 1/2” wrench. See Figure 5.26. 9. Remove the bolt that holds the right pedal shaft support strap using a 1/2” wrench. NOTE: This will allow the pedal shaft assembly to hang-down slightly on the right side of the tractor.
HYDRO. DRIVE AND BRAKE SYSTEM 11. Allow the drive pedal shaft to rotate down, then pull it off of the pedal shaft assembly. See Figure 5.28. Drive control pedal shaft Figure 5.28 12. Disconnect the brake rod from the clutch/brake latch plate. See Figure 5.29. Clutch/brake latch plate • Remove the cotter pin and flat washer to disconnect the brake rod. Discard the cotter pin. • Unhook the brake rod from the clutch/brake latch plate. Brake rod Flat washer Figure 5.29 13.
LTX Tractors Left side strap Right side strap NOTE: The pedal shaft support straps are two different sizes. The smaller strap holds-up the left (brake pedal) end of the pedal shaft assembly. The larger strap holds-up the right (drive control pedal) end of the pedal shaft assembly. See Figure 5.31. Figure 5.31 Clutch/brake pedal shaft 14. • The plastic bushings that fit between the two pedal shafts should be replaced any time they are removed.
HYDRO. DRIVE AND BRAKE SYSTEM NOTE: Leaving the drive control pedal shaft loose until after the brake rod is secured will make it easier. 15b. Position the drive control shaft and bushings, fasten the drive control rod to it, then drive the push cap on. See Figure 5.34. 15c. Tighten the pedal shaft support strap bolts to a torque of 12-15 ft-lbs. (16-20 N-m). 15d. Attach the belt tensioner pulley rod. 16. Test the drive system and all safety features before returning the tractor to service. Figure 5.
LTX Tractors Belt control; tensioner and idler pulleys V-sheave pulleys NOTE: The V-idler pulleys can be removed from below using a 1/2” wrench, with no disassembly beyond removing the cutting deck. See Figure 5.35. NOTE: Confirm that the parking brake is released before starting work. 1. Remove the mowing deck. 2. Remove the fenders by following the steps described in Chapter 4: Body Panels. Figure 5.35 3.
HYDRO. DRIVE AND BRAKE SYSTEM 5. Note the belt routing, then slip the drive belt off of the two pulleys on the tensioning bracket. 6. Remove the nut and bolt that hold the belt tensioner pulley bracket to the frame using a pair of 9/16” wrenches. See Figure 5.38. 7. Maneuver the belt tensioner bracket assembly to clear the belt, and remove it from the tractor. See Figure 5.39. Remove this bolt. Nut is above frame Figure 5.38 Figure 5.
LTX Tractors NOTE: When installed, the head of the bolt that holds the bracket assembly to the tractor rests against the shouldered side of the flat sheave idler pulley. See Figure 5.41. Shoulder height Figure 5.41 Flat sheave pulley • 9. Flat surface When installed, the spacers fit against the flat side of the flat sheave idler pulley. See Figure 5.42. Hex bushing Shoulder bushing The V-sheave tensioner pulley can be un-bolted from the bracket using a 1/2” wrench. Bolt Figure 5.42 10.
HYDRO. DRIVE AND BRAKE SYSTEM Drive belt replacement ! CAUTION The battery will be removed in this procedure. Review the Operator’s Manual and Chapter 7: Electrical System for important safety information about handling batteries before proceeding. 1. Remove the mowing deck. 2. Set the park brake to release belt tension. 3. Remove the battery and battery tray by following the procedures described in Chapter 4: Body Panels. See Figure 5.44. 4. Remove drive belt from the transaxle pulley.
LTX Tractors 4c. Remove the pulley. The belt will clear the belt keepers on top of the transaxle as the pulley comes up. See Figure 5.46. Figure 5.46 Top of hydro. pulley NOTE: Correct orientation of input pulley: See Figure 5.47. • Tall shoulder goes up. • Short shoulder with snap-ring stop goes down. Bottom of hydro. pulley Figure 5.47 5. Lift and safely support the tractor. See Figure 5.48. Figure 5.
HYDRO. DRIVE AND BRAKE SYSTEM 6. Work the belt out of the two pulleys on the belt tensioner bracket. See Figure 5.49. 7. Remove the single, fixed idler from the frame of the tractor using a 1/2” wrench. See Figure 5.50. 8. Remove the belt keeper near the engine pulley or electric PTO clutch, using a 1/2” wrench. Belt Belt route Figure 5.49 Fixed idler Belt keeper pin Figure 5.50 8a. With manual PTO, a single bolt holds the belt keeper to the frame, to the left side of the engine. See Figure 5.
LTX Tractors 8b. With electric PTO, there are two fasteners: See Figure 5.52. 8c. One bolt holds the belt keeper to the frame, to the left side of the engine. 8d. A nut holds the belt keeper to the right-side frame channel. Nut Belt keeper Bolt NOTE: The electric PTO belt keeper incorporates an anti-rotation bracket for the PTO clutch. Figure 5.52 9. Lower the engine pulley to remove the belt; manual PTO. 9a. Remove the bolt that holds the engine pulley to the crankshaft using a 5/8” wrench.
HYDRO. DRIVE AND BRAKE SYSTEM 10b. Remove the bolt that holds the PTO clutch to the engine crankshaft using a 5/8” wrench. See Figure 5.55. NOTE: An impact wrench and socket will be most effective. Otherwise it may be necessary to block the ring-gear to prevent the crankshaft from turning . ! CAUTION Crankshaft bolt The PTO clutch is heavy, and it may fall as the bolt is removed. PTO Clutch Figure 5.55 Washers (2) PTO clutch 10c. Carefully lower the PTO clutch and any associated hardware.
LTX Tractors Top of crankshaft pulley NOTE: The flat edge of the crankshaft pulley faces the electric PTO clutch. The end with the inside diameter chamfered goes against the fillet near the base of the crankshaft. See Figure 5.58. 11. If the drive belt failed prematurely, identify and correct the cause of the failure before installing a new belt. 12. Install the new belt by reversing the steps used to remove it. Bottom of crankshaft pulley Belt installation notes: • Install only a correct OEM belt.
HYDRO. DRIVE AND BRAKE SYSTEM Changing transaxle hydraulic fluid NOTE: The Hydro-Gear hydrostatic transaxle used in the Cub Cadet 1000 Series tractors typically lasts for many years of homeowner use without fluid maintenance. The primary reason to change the fluid would be contamination. NOTE: The ambient temperature should be above 60 deg. f. (15.5 deg. C.) to allow the fluid to drain and fill in a reasonable amount of time. ! CAUTION The battery will be removed in this procedure.
LTX Tractors 10. 11. Transmission release rod: operates bypass valve Fill the transaxle with 77 to 80 fluid ounces (2.3 to 2.4 L) of 20W-50 engine oil that has a minimum API classification of SL, and a minimum rating of 55 SUS @ 210 deg. F. (99 deg. C). (shown released) Purge the transaxle. See Figure 5.63. 11a. Open the bypass valve. 11b. Start the engine, and run it at low RPMs. 11c. Slowly cycle the drive pedal 6 times from full forward to full reverse, taking about 10 seconds to complete a stroke.
HYDRO. DRIVE AND BRAKE SYSTEM Brakes Brake arm Actuator spring hooks here NOTE: The brakes may be repaired in the tractor, using procedures shown on the bench. Return spring 1. The brake yoke is located on the right side of the transaxle. See Figure 5.65. • The heavy actuator spring connects to the top hole on the brake arm. Brake yoke • The light return spring draws the brake arm to the OFF position. • Remove the cotter pin and loosen or tighten the castle nut to adjust the brakes.
LTX Tractors 6. Brake arm Inside the brake yoke; • A steel backing plate fits between the friction pad and the actuator pins. • The pins fit into holes in the brake yoke housing. • The brake arm acts as a cam, pushing the pins when it rotates. • Spring Brake yoke Actuator pins (2) A small compression spring pushes the cam arm away from the pins, helping to release the brake. Backing plate Friction pad Figure 5.68 7. With the brake yoke removed, the brake rotor floats on a splined brake shaft.
HYDRO. DRIVE AND BRAKE SYSTEM Transaxle removal and replacement ! CAUTION The battery will be removed in this procedure. Review the Operator’s Manual and Chapter 7: Electrical System for important safety information about handling batteries before proceeding. 1. Remove the mowing deck by following the procedures described in Chapter 8: Cutting Decks and Lift Shaft. 2. Set the park brake to release belt tension. 3.
LTX Tractors 4c. 5. Remove the pulley. The belt will clear the belt keepers on top of the transaxle as the pulley comes up. See Figure 5.72. Loosen, but do not remove the wheel bolts (DoubleD axles) or lug nuts, using a 1/2” wrench or a 3/4” wrench, respectively. Figure 5.72 6. Unhook the large return-to-neutral spring from the back of the tractor frame. Leave the other end connected to the top of the return-to-neutral cam. See Figure 5.73.
HYDRO. DRIVE AND BRAKE SYSTEM Reverse safety switch (yellow wire) 10. Disconnect the wires from the reverse safety switch. See Figure 5.75. 10a. Unplug the yellow w/black trace wire. 10b. Remove the bolt that holds the green ground wire using a 3/8” wrench. Trunnion arm (green wire) Figure 5.75 Drive control rod Trunnion arm 11. Spring Disconnect the drive control rod from the trunnion arm of the hydro. See Figure 5.76. Cotter pin Figure 5.76 12.
LTX Tractors 14. Remove the torque bracket bolts using a 1/2” wrench. See Figure 5.78. Bolts Torque bracket Figure 5.78 15. Take the nuts off of the T-bolts that hold the transaxle to the frame using a 1/2” wrench. See Figure 5.79. NOTE: At this point, the brake actuator spring is still attached to the brake rod from the pedal shaft, and the brake arm on the transaxle. Figure 5.79 16. Carefully lower the transaxle out of the tractor. See Figure 5.80. Figure 5.
HYDRO. DRIVE AND BRAKE SYSTEM Large r-t-n spring 17. Move the transaxle forward to make some slack in the brake linkage. Use the slack to unhook the brake spring from the brake arm. 18. Carefully lift the transaxle onto a workbench for draining or disassembly as needed. Brake actuator spring Figure 5.81 Round hole Oblong hole 19. On the bench; 19a. The top of the reverse safety switch is held against the trunnion arm by the post on the drive control rod. See Figure 5.82.
LTX Tractors Large r-t-n spring 19c. The large return-to-neutral spring can be unhooked from the return-to-neutral cam. See Figure 5.84. r-t-n cam Small r-t-n spring Figure 5.84 19d. Remove the belt keeper from the top of the transaxle using a phillips head screwdriver. See Figure 5.85. 20. Belt keeper Installation notes: 20a. After repairs are done, and the transmission is re-filled with fluid, it may be “bench purged” if the technician has a way to drive the input shaft using a 1/2” drill motor.
HYDRO. DRIVE AND BRAKE SYSTEM Drive System Torque Specs. Fastener Torque in-lb. Torque N-m Seat bolt 150-180 17-20 Lug nut 350-500 41-57 Wheel bolt 160-190 18-22 Fan/pulley nut 360-520 41-59 Tq.
LTX Tractors 92
CVT DRIVE AND BRAKE SYSTEM CHAPTER 6: CVT DRIVE AND BRAKE SYSTEM About this chapter The drive and brake systems for the Cub Cadet Series 1000 tractor are combined. Two reasons for this: • The brake on the Series 1000 tractor is supplied with the transaxle. • The brake pedal applies the brake and disengages the drive system. Both systems share common linkage. The transaxle used in the Cub Cadet Series 1000 is a relatively simple gearbox containing forward, neutral, and reverse gears.
LTX Tractors Externally repairable drive system problems: Most of the problems listed in this section will result in a customer complaint of low power or low ground speed. If the tractor is difficult to push, check the brakes. 1. 2. Engine performance: • If the engine does not turn at the specified RPM, the tractor will not travel at its designed speed. See Figure 6.1. • If the engine does not produce the specified amount of power, the tractor will not have its designed amount of tractive force. 1a.
CVT DRIVE AND BRAKE SYSTEM 3b. Brake yoke If the linkage is working properly, but the brakes seem to be dragging, check the brake yoke. The linkage is not adjustable. See Figure 6.3. • When the brakes are released, it should be possible to wiggle the brake rotor within the yoke. • If the rotor is tight in the caliper, check the yoke adjustment. • If the rotor is tight in the yoke, check the operation of the yoke to confirm that it is not stuck.
LTX Tractors 5. Check the drive control linkage. See Figure 6.5. 5a. The travel limit pin fits into the curved slot in the drive pedal latch plate. The pedal bracket should have enough travel for the pin to hit both ends of the curved slot when the pedal is moved through the full range of its travel. 5b. Some relatively simple things that may go wrong with the pedal linkage: • Travel limit pin The drive pedal itself being loose on the bracket. Figure 6.5 • 5c.
CVT DRIVE AND BRAKE SYSTEM Indications that a transaxle is not warrantable Anything that would indicate misuse, abuse, neglect, accident, improper maintenance, alteration, vandalism, theft, fire, water or damage because of other peril or natural disaster will render the transaxle non-warrantable even though it is within the normal warranty period. Typical indicators of a void warranty would be: • The normal warranty is for 3 years or 120 hours, whichever comes first.
LTX Tractors • 2b. The rod that connects the clutch/brake latch plate to the heavy brake actuator spring should be just slack. See Figure 6.10. Brake spring Check the gap between the brake rotor and the brake pads. • There is a fixed pad in the transaxle housing. • There is a moving pad in the brake caliper. • Wiggle the brake rotor slightly, and attempt to insert a 0.010” (0.38mm) feeler gauge between the rotor and either pad. Brake rod Figure 6.10 2c. • Turn the nut to adjust the gap.
CVT DRIVE AND BRAKE SYSTEM Gear selector Gear selector Spring • The forward-neutral-reverse gear selector is on the left rear fender of the tractor. • A bracket and spring under the fender keep inward pressure on the selector to give it positive feel. See Figure 6.12. Figure 6.12 • The selector pivots on a frame-mounted bracket, transferring the motion to a push-pull rod connected to the transaxle. See Figure 6.13. • The linkage contacts the reverse safety switch tang when the tractor is in reverse.
LTX Tractors 4. Check that the gear selector handle is fully seated in the N notch on the fender. See Figure 6.15. 5. Tighten the adjustment bolt and re-check the position of the gear selector. Figure 6.15 Tensioner pulley control rod The tensioner pulley control rod is the link that ties the pedal shaft to the pulleys that tighten the front drive belt. See Figure 6.16.
CVT DRIVE AND BRAKE SYSTEM To check and adjust the link: 1. Jam nut Set the belts to their lowest speed position; 1a. Start the engine. 1b. Place the gear selector in Neutral and release the brake pedal. 1c. Depress the drive pedal to the end of its travel. 1d. Slowly release the drive pedal. 1e. When the drive pedal has reached the top of its travel, turn-off the engine. 2. Remove the mowing deck. 3. Loosen the link jam nut using a 9/16” wrench. See Figure 6.17. 4.
LTX Tractors Linkage: pedal shaft Description: The Clutch/brake pedal and the drive control pedal operate on two concentric shafts. • The clutch/brake shaft runs the full width of the tractor. • The drive control shaft is tubular, and pivots on the clutch/brake shaft. • Each shaft has a toothed latch plate. The latch plates are next to each other. • The cruise control/park brake lever operates a common pawl that engages the latch plate of whichever pedal is applied. See Figure 6.19.
CVT DRIVE AND BRAKE SYSTEM Travel limit pin 4. Remove the locking clip that holds the travel limit pin in place. 5. Withdraw the travel limit pin. See Figure 6.22. 6. Unhook and remove the clutch/brake pedal return spring. 7. Remove the cotter pin and flat washer that hold the brake rod into the latch plate. Discard the cotter pin. 8. Remove and discard the cotter pin that holds the tensioner pulley control rod to the “cobra head” arm on the drive control pedal. See Figure 6.23. 9.
LTX Tractors 10. Loosen the bolt that holds the left pedal shaft support strap using a 1/2” wrench. See Figure 6.25. 11. Remove the bolt that holds the right pedal shaft support strap using a 1/2” wrench. NOTE: This will allow the pedal shaft assembly to hang-down slightly on the right side of the tractor. Left pedal shaft support strap Figure 6.25 12. As the pedal shaft is lowered, and the drive control pedal shaft can be slipped to the right: See Figure 6.26.
CVT DRIVE AND BRAKE SYSTEM Cobra-head 14. Disconnect the cobra-head rod from the pedal shaft tie plate. See Figure 6.28. • Slip the tie plate off of the cobra head rod. Tie plate • Push the hex bushing out of the big end of the pedal shaft tie plate. Hex bushing • The hex bushing can be snapped-off of the brake pedal shaft. Figure 6.28 Drive control pedal shaft 15. Once the cobra-head rod is loose, the drive control pedal shaft can be rotated and slipped off of the brake pedal shaft. See Figure 6.
LTX Tractors 17a. Lubricate the points where the pedal shafts meet the frame with a good quality lithiumbased grease. See Figure 6.31. 17b. Position the two rods that connect to the brake pedal shaft as the pedal shaft assembly is being lifted into the tractor: • The rod that de-tensions the drive belts when the brake pedal is pressed. • The brake rod. • The rods fit into the holes in the brake shaft much more easily before the pedal shaft is fully in position. Figure 6.31 17c.
CVT DRIVE AND BRAKE SYSTEM Linkage: pedal tie strap NOTE: If there is reason to remove the pedal tie strap, it can be taken off without further disassembly of the pedal shaft. The most likely reason for this would be the discovery of damage to the plate or hex bushing while making an adjustment to the tensioner pulley control rod. Tensioner pulley control rod Cobra head 1. Remove the mowing deck. 2.
LTX Tractors NOTE: The hook on the tie strap goes over the trimmed section of the flange on the hex bushing. See Figure 6.36. 6. Install the tie strap by reversing the process used to remove it. Use a new cotter pin. 7. Test-drive the tractor to confirm that the drive system is working correctly before returning it to service. Figure 6.
CVT DRIVE AND BRAKE SYSTEM Belt control: tension make-up pulley ! CAUTION The battery will be removed in this procedure. Review the Operator’s Manual and Chapter 7: Electrical System for important safety information about handling batteries before proceeding. Bolt loosened 1. Remove the upper drive belt from the make-up tensioner pulley as described in the drive belts section of this chapter. See Figure 6.37. 2. Unbolt the arm from the torque bracket using a pair of 9/16” wrenches. See Figure 6.38.
LTX Tractors Tension make-up pulley 3. Shoulder bushing The arm pivots on a shouldered bushing. See Figure 6.39. • A shoulder bolt threads into the bottom of the arm, for the tension spring to hook onto. • The tension make-up pulley bolts to the top of the arm. Mounting bolt Shoulder bolt Figure 6.39 4. Install the arm by reversing the procedure used to remove it. • Lubricate the pivot point with grease or antiseize compound. • One end of the tensioner spring is offset.
CVT DRIVE AND BRAKE SYSTEM Belt control: variable speed pulley ! CAUTION The battery will be removed in this procedure. Review the Operator’s Manual and Chapter 7: Electrical System for important safety information about handling batteries before proceeding. Lateral spring 1. Remove the battery and battery tray by following the procedures described in Chapter 4: Body Panels. See Figure 6.41. 2. Disconnect the lateral spring from the frame, relieving tension from the make-up pulley. 3.
LTX Tractors Variable speed pulley 5. Roll the lower drive belt out of the lower sheave of the variable speed pulley. See Figure 6.43. 6. Unbolt variable speed pulley bracket from the transaxle using a 3/8” wrench. Bracket bolts Figure 6.43 7. Loosen, then remove the bolts that hold the variable speed pulley bracket to the frame using a 1/2” wrench. See Figure 6.44. 8. Lift the variable speed pulley and bracket out of the tractor. Variable speed pulley bracket bolts Figure 6.44 9.
CVT DRIVE AND BRAKE SYSTEM Bearing holder Bearings 9c. Lift the bracket, belt keeper, and bearing holder off of the pulley. 9d. Clamp the variable speed pulley bracket into a vise. Match-mark the bracket to the belt keeper. See Figure 6.46. 9e. Remove the three screws that fasten the bearing holder to the bracket, and lift away the bearing holder. See Figure 6.47. 9f. Inspect the bearings and variable speed pulley. Figure 6.
LTX Tractors Belt control: tensioner pulleys NOTE: The V-pulley can be removed from below using a 1/2” wrench, with no disassembly beyond removing the cutting deck. See Figure 6.48. V-pulley NOTE: Confirm that the parking brake is released before starting work. 1. Remove the mowing deck. 2. Remove the fenders, as described in the body panels chapter of this manual. Figure 6.48 3.
CVT DRIVE AND BRAKE SYSTEM 5. Remove the nut that holds the ball joint end of the tensioner pulley control rod to the tensioner pulley bracket using a 1/2” wrench. See Figure 6.51. 6. Note the belt routing, then slip the drive belt off of the two pulleys on the tensioning bracket. 7. Remove the nut and bolt that hold the belt tensioner pulley bracket to the frame using a pair of 9/16” wrenches. See Figure 6.52. 8.
LTX Tractors Bracket pivot point 9. On the bench, the flat-sheave idler pulley, and the spacers used to position it can be lifted off of the pulley bracket. See Figure 6.54. Figure 6.54 NOTE: When installed, the head of the bolt that holds the bracket assembly to the tractor rests against the shouldered side of the flatsheave idler pulley. See Figure 6.55. Shoulder height Figure 6.
CVT DRIVE AND BRAKE SYSTEM 10. The V-sheave tensioner pulley can be un-bolted from the bracket using a 1/2” wrench. 11. The rod that connects the bracket to the clutch/brake pedal shaft can be maneuvered to come out of its slot in the bracket. See Figure 6.57. 12. Assemble and install the belt tensioner pulley by reversing the steps used to remove and disassemble it. • Lubricate the pivot point with a good quality lithium-base grease. 13. Reinstall the fenders. Figure 6.57 14.
LTX Tractors Drive belt replacement ! CAUTION The battery will be removed in this procedure. Review the Operator’s Manual and Chapter 7: Electrical System for important safety information about handling batteries before proceeding. NOTE: The variable speed pulley system that drives this tractor counts on interplay between two belts: • If one belt fails, replace both belts. One new belt and one partially worn belt will not work the same as two new belts.
CVT DRIVE AND BRAKE SYSTEM NOTE: Use a rope to unhook the spring from the frame. See Figure 6.60. 4b. Loosen the tension idler pulley from its bracket using a 1/2” wrench. 4c. Lift the pulley far enough to allow the belt to clear the belt keepers. See Figure 6.61. 4d. The slack created will allow the upper belt to slip easily out of the top sheave of the variable speed pulley and off of the transmission input pulley. See Figure 6.62. 4e. Withdraw the belt through the battery opening under the seat.
LTX Tractors 5. Remove the lower (front) drive belt: 5a. Slip the belt off of the two tensioner pulleys. See Figure 6.63. Figure 6.63 Variable speed pulley 5b. Roll the belt off of the lower sheave of the variable speed pulley. See Figure 6.64. NOTE: The belt can be walked-up from the lower sheave to the upper sheave, then off. Rotate the variable speed pulley to help slip the belt past the belt keepers. 5c. Remove the belt from the engine pulley. Lower belt Figure 6.64 Manual PTO Upper belt A.
CVT DRIVE AND BRAKE SYSTEM C. Work the belt past the PTO pulley, and withdraw it from the front of the tractor. See Figure 6.66. Figure 6.66 Electric PTO A. Nut Remove the belt keeper near the crankshaft using a 1/2” wrench. • One bolt holds the belt keeper to the frame, to the left side of the engine. Belt keeper Bolt • A nut holds the belt keeper to the right side frame channel. Figure 6.
LTX Tractors C. Remove the bolt that holds the PTO clutch to the engine crankshaft using a 5/8” wrench. See Figure 6.69. NOTE: An impact wrench and socket will be most effective. Otherwise it may be necessary to block the ring-gear to prevent the crankshaft from turning . ! CAUTION The PTO clutch is heavy, and it may fall as the bolt is removed. Crankshaft bolt PTO Clutch Figure 6.69 Washers (2) PTO clutch D. Carefully lower the PTO clutch and any associated hardware. See Figure 6.70.
CVT DRIVE AND BRAKE SYSTEM Top of crankshaft pulley F. Withdraw the belt from the front of the tractor. NOTE: The flat edge of the crankshaft pulley faces the electric PTO clutch. The end with the inside diameter chamfered goes against the fillet near the base of the crankshaft. See Figure 6.72. NOTE: If the drive belt failed prematurely, identify and correct the cause of the failure before installing a new belt. Bottom of crankshaft pulley Figure 6.72 6.
LTX Tractors Transaxle removal and replacement ! CAUTION The battery will be removed in this procedure. Review the Operator’s Manual and Chapter 7: Electrical System for important safety information about handling batteries before proceeding. 1. Remove the upper drive belt as described in the drive belt replacement section of this chapter. 2. Remove the input pulley and input pulley adaptor from the transaxle using a 7/8” wrench. See Figure 6.74.
CVT DRIVE AND BRAKE SYSTEM V.S. pulley bracket bolts 3. Loosen, but do not remove the wheel bolts (Double-D axles) or lug nuts, using a 1/2” wrench or a 3/4” wrench, respectively. 4. Unbolt the variable speed pulley bracket from the transaxle using a 3/8” wrench. See Figure 6.76. 5. Lift, and safely support the tractor. The rear of the tractor should be high enough to allow the transaxle to pass under it. 6. Remove the rear wheels. If the tractor has Double-D axles, remove the wheel spacers too.
LTX Tractors 8. Disconnect the forward-neutral-reverse gear selector rod from the gear selector by rotating the rod 90 degrees. The coined ears on the rod will align with notches in the selector, and the rod can be pulledfree. See Figure 6.79. 9. Support the transaxle so that it can be lowered out of the tractor in a controlled fashion. Figure 6.79 10. Remove the torque bracket bolts using a 1/2” wrench. See Figure 6.80. Torque bracket bolts Figure 6.80 11.
CVT DRIVE AND BRAKE SYSTEM NOTE: At this point, the brake actuator spring is still attached to the brake rod from the pedal shaft, and the brake arm on the transaxle. 12. Carefully lower the transaxle out of the tractor. Figure 6.82. See Figure 6.82 13. Move the transaxle forward to make some slack in the brake linkage. Use the slack to unhook the brake spring from the brake rod. See Figure 6.83. Unhook here Brake rod Figure 6.
LTX Tractors Rod end NOTE: The brake spring has a tighter hook on the brake arm end than on the brake rod end. It is much easier to disconnect the spring from the rod. See Figure 6.84. 14. Carefully lift the transaxle onto a workbench for disassembly as needed. 15. Installation notes: 15a. Check adjustment of the brake before installing the transaxle. Arm end 15b. Connect both ends of the brake actuator spring before lifting the transaxle back into the tractor. 15c.
CVT DRIVE AND BRAKE SYSTEM Transaxle repair 1. Assess the damage from the outside: See Figure 6.85. 1a. If the tractor is within the warranty period, is the damage consistent with a warrantable failure? 1b. If the tractor is beyond the warranty period, is the transaxle feasible to repair? 1c. Are the axles bent? 1d. Is the housing broken from the outside-in? 1e. Is the housing broken from the inside-out? 1f. Spin-test: • Will the input shaft turn in neutral? Figure 6.
LTX Tractors 6. Disassemble the brake: 6a. Unhook and remove the brake spring. See Figure 6.88. Figure 6.88 6b. Unbolt the brake yoke from the transaxle using a 3/8” wrench. See Figure 6.89. Brake yoke Figure 6.89 6c. Slip the brake rotor off of the brake shaft (splined end of bevel gear shaft). See Figure 6.90. Brake shaft Brake pad (fixed) Brake rotor Figure 6.
CVT DRIVE AND BRAKE SYSTEM 6d. Brake arm Inspect the brake shaft and inner brake pad. NOTE: The inner pad is epoxied in-place, but may be pried-out for replacement. 6e. Brake yoke Disassemble and inspect the brake yoke. See Figure 6.91. Brake pins Backing plate Brake pad Figure 6.91 Lower housing 7. Remove the 13 remaining perimeter screws that hold the upper transaxle housing to the lower transaxle housing using a 3/8” wrench. 8. Separate the two housings. See Figure 6.92.
LTX Tractors 11. Slip the seals, bearings, and washers off of the differential and axle assembly. See Figure 6.94. Differential and axle assembly NOTE: When correctly installed, the seals fit on the axle shaft with the lips facing out. Their primary purpose is to exclude dirt and moisture. Grease does not tend to migrate past the axle seals. NOTE: If the transaxle is to be re-built, replace the bearings and seals with new ones. 12. Inspect the differential and axle assembly. 12a.
CVT DRIVE AND BRAKE SYSTEM Shift fork 13f. Check the shift collar and fork for wear. 13g. Check shift collar teeth and splines for wear or damage. See Figure 6.96. 14. Check the interior of the transaxle housings. 14a. If there is heavy gear-tooth damage on the ring gear of bevel gears, there is likely to be large debris in the grease. Dispose of the grease if the transaxle is to be rebuilt. Teeth splines 14b.
LTX Tractors 16. If there is a reason to take-apart the input pinion, use the following steps: 16a. Remove the hog-ring pulley stop by pryingopen the end gap and slipping it up the shaft. See Figure 6.99. Hog ring Figure 6.99 Input shaft 16b. Use a screwdriver to pry-off the E-ring. See Figure 6.100. E-ring Figure 6.100 16c. Remove the shim washers. See Figure 6.101. Shims set end-play Figure 6.
CVT DRIVE AND BRAKE SYSTEM 16d. Pull the pinion shaft out of the housing. See Figure 6.102. Needle bearings Figure 6.102 Pinion gear Thrust washer 16e. Inspect the shaft and bearings. See Figure 6.103. Figure 6.
LTX Tractors 17. Final evaluation: It may not be necessary to fully disassemble the transaxle to identify the damage or find the root cause of a warrantable failure. At this point of disassembly, or some point earlier in the process, the technician should be able to make an assessment of whether it is feasible to repair the transaxle. It should also be possible to positively identify what went wrong in a warrantable transaxle replacement. If the transaxle is to be warranted, reassemble it for shipping.
CVT DRIVE AND BRAKE SYSTEM Shims Reduction-gear side bearing (long) Shims 19c. Re-install the shims in their original locations on the bevel gear shaft. 19d. Smear some DurinaTM grease on the surfaces of the shaft that will ride in the flange bearings. 19e. Install new bevel gear shaft bearings, with their flanges facing the shims. See Figure 6.105. NOTE: The bevel gear shaft bearings are of different lengths. Seal The longer bearing goes on the reduction gear end of the shaft.
LTX Tractors 21. Press the differential and the reverse gears as close together as they will go while remaining properly seated in the housing. 22. Confirm that there is at least 0.030” (0.762mm) between the rivet heads on the differential and the back side of the reverse gear. See Figure 6.108. 23. Collective axle end play (the amount one axle shaft moves when the opposite axle is pushed) should be between 0.010”-0.080” (0.25-2.0mm). 24.
CVT DRIVE AND BRAKE SYSTEM 35c. Install the brake rotor, with the flat side facing the transaxle housing. See Figure 6.110. 35d. Install the brake yoke to the transaxle, being careful not to let the friction pad or backing plate fall out of place. 35e. Tighten the brake yoke screws to a torque of 90-135 in-lbs. (10-15 N-m). Brake rotor Figure 6.110 35f. Set the clearance between the pads and rotor to 0.010-0.015” (0.25-0.38mm) using the adjusting nut on the brake yoke. See Figure 6.111. 35g.
LTX Tractors Transmission Specifcations Specification U.S. Metric Pinion end play 0.010”-0.015” 0.25-0.38mm Pinion run-out 0.002”-0.010” 0.05-0.25mm Pinion backlash 0.006”-0.014” 0.15-0.36mm Differential rivet.-to-gear clearance 0.030” minimum 0.762mm Axle end-play 0.010”-0.08” 0.25-2.0 Amount of Durina grease, 2 10 oz. tubes (P/N: 737-0148) 20 fl.oz 0.59 liters Brake clearance 0.010”-0.015” 0.25-0.38mm Drive System Torque Specs. Fastener 140 Torque in-lb.
Electrical System CHAPTER 7: ELECTRICAL SYSTEM Introduction This chapter is divided into four sections: • Section 1: About this chapter and precautions • Section 2: Components • This section will describe the location and operation of the electrical components on the mower. Where appropriate, some disassembly or component removal instructions will be included.
LTX Tractors Key switch The Key Switch is similar to those used in a variety of MTD applications since 1999. The difference, in this case, is that it is incorporated in the same housing as the RMC module. The two items are not available separately. See Figure 7.1. 1. RMC Module Front In the “OFF” position, continuity can be found between the M, G, and A1 terminals. See Figure 7.2.
Electrical System 3. 4. • Symptom: Crank, spark, but no fuel: First check the fuel tank to verify that there is fuel in it. If there is fuel in the fuel tank, test for power at the afterfire solenoid. If there is no power there, then check for continuity from B to A1 in the START position. If power is reaching the red wire that connects to the A1 terminal in the start position, the problem lies down stream of the key switch.
LTX Tractors RMC Module RMC Module The RMC Module is in the same housing as the key switch and is not available separately. For the purpose of diagnosis, it is treated separately. Diagnosis of the module with the key switch introduces too many overlapping variables. See Figure 7.3. • Principle: To diagnose the module, the simplest approach is to check all of the inputs (safety circuits) that are connected to it.
Electrical System RMC module plug test (electric PTO) Red 1. Disconnect the molded 8-pin plug from the RMC module. See Figure 7.5. 2. Looking at the plug head-on, it will be configured as shown in the diagram: There will be 8 female pin terminals. When probed they should yield the results described in the following sections. See Figure 7.6. 3. 5. Purple Top left middle square-shape: Yellow wire with Black trace: • Behavior: Should show DC power with the key on.
LTX Tractors • Loss of ground to the reverse switch. 6. 7. 8. 9. 146 Top right rounded-shape: is a green wire. • Behavior: The green wire should always have continuity to ground. • Circuitry: The green wire leads to ground. • Interpretation: If this ground path is not good, there will probably be other ground-related issues with the tractor: slow starter motor, slow battery charge, dim lights. All ground connections should be mechanically secure and corrosion free.
Electrical System RMC module plug test (manual PTO) 1. 2. 3. Disconnect the molded 8-pin plug from the RMC module. See Figure 7.7. Looking at the plug head-on, it will be configured as shown in the diagram: There will be 8 female pin terminals. When probed they should yield the results described in the following sections. See Figure 7.8.
LTX Tractors • 6. 7. Interpretation: If this ground path is not good, there will probably be other ground-related issues with the tractor: slow starter motor, slow battery charge, dim lights. All ground connections should be mechanically secure and corrosion free. Bottom left square-shape: The red wire on the OCR plug carries battery voltage. • Behavior: With key switch in any of the run positions, D.C.
Electrical System Electric PTO switch Understanding the electric PTO switch • • • In A-Com, power is supplied to the PTO switch from the A1 terminal of the ignition switch through a red wire. When the PTO switch is turned on this completes the circuit to allow power to go to the PTO clutch. It is a normally opened (N.O.) set of contacts. See Figure 7.9. B-COM is in the safety shut-down circuit. It is a normally opened (N.O.) set of contacts. A circuit is completed from the (N.O.
LTX Tractors PTO relay The PTO relay is located on the main harness, underneath the electric PTO switch. See Figure 7.10. The PTO relay disengages the PTO clutch when it is energized and latches on until the PTO switch is turnedoff. The list below details the function of the PTO relay. 3 Green wire Electric PTO switch COM (Common) terminal Ground for PTO clutch (not energized) or relay latch (energized). Hard-wired to ground 5 White/black trace Normally Open (N.O.
Electrical System PTO switch (manual PTO) • The manual PTO switch is mounted on the right side of the seat box section of the frame. See Figure 7.11. • The PTO switch plunger is depressed when the PTO lever is moved to the “off” position. • The switch has two pair of contacts: one (N.O.) and one (N.C.). • The Orange wire with black trace connects to one of the (N.O.) terminals of the PTO switch. When the PTO is turned “off” the (N.O.
LTX Tractors Brake switch (manual PTO) • The brake switch is mounted on the top side of the frame, on the left side behind the dash. • The brake switch used on manual PTO tractors is a triple pole single throw switch. It has one set of contacts that are normally closed (N.C.) and the other two sets are normally open (N.O.). See Figure 7.12. • The plunger on the switch is depressed when the clutch / brake pedal is depressed, declutching the drive belt and applying the brakes.
Electrical System Brake switch (electric PTO) The brake switch is mounted on the top side of the frame, on the left side behind the dash. See Figure 7.13. • The plunger on the switch is depressed when the clutch / brake pedal is depressed, declutching the drive belt and applying the brakes. The switch contains two sets of contacts. • The brake switch is accessed by removing the fender and dash. The fender and dash can be removed by following the steps described in Chapter 4: Body/Chassis.
LTX Tractors Reverse Safety Switch The Reverse Safety Switch is a simple metal contact tang switch. CVT transmissions Tractors that have the CVT transmissions have the reverse switch mounted on the left side of the frame, by the rear wheel. When the tractor is placed in reverse, the shift linkage will contact the switch providing a ground, See Figure 7.15. This switch has a red wire with black trace that goes directly to the RMC module. See Figure 7.15. Reverse Safety Switch Figure 7.
Electrical System Seat Safety Switch The Seat Safety Switch is mounted inside the seat. It contains two sets of (N.O.) contacts See Figure 7.18. • The yellow wire goes to the RMC module. When the seat is vacant, the contacts close, providing a ground path to the RMC module. If the seat is empty, the circuit is completed, de-activating the RMC module. • The yellow wire with white trace goes to the brake switch.
LTX Tractors Starter solenoid The starter solenoid is mounted inside the seat box section of the frame. See Figure 7.19. Starter solenoid Figure 7.19 The starter solenoid can be accessed by removing the battery box and reaching through the opening. See Figure 6.20.
Electrical System Start Circuit Turning the key to the START position: • spins the starter motor • enables the ignition • energizes the afterfire solenoid . # , 3 - 4. &USE 04/ 3WITCH h/FFv ! Power goes from the key switch S terminal to the brake switch (N.O.) contacts. (orange wire) If the brake is off, the switch plunger will be up and the (N.O.) contacts will be open. The system monitor will measure open circuit voltage, illuminating the brake symbol. 2b.
LTX Tractors Once the starter motor spins, we still need spark and fuel to make the engine run. 1. The ignition sparks are generated by an ignition module. The ignition module will work as long as the primary windings are not grounded. With the key switch in any position other than off, there is no connection between the M (Module) terminal and the G (Ground) terminal. See Figure 7.22. NOTE: In ignition systems that have breakers to cause the magnetic field to collapse, the coil is called a magneto.
Electrical System +EY 3WITCH h2EVERSE #AUTION -ODEv , 3 3YSTEM -ONITOR ! ' !FTERFIRE 3OLENOID ! " - 3. 04/ 3WITCH 'ROUND 'ROUND ! 04/ 2ELAY !T 2EST " &USE # *URXQG 6ROHQRLG 6WDUWHU 0RWRU . # . / #/- 0/3 .%' "ATTERY 'RND the afterfire solenoid • the windings of the PTO relay (electric PTO) • the PTO switch C-COM terminal (electric PTO) • the RMC module “A1 pwr” terminal • the system monitor (EADLIGHTS 237 • • the headlights See Figure 7.24.
LTX Tractors Run Circuit +EY 3WITCH h2EVERSE #AUTION -ODEv With the key switch in the RUN position, the A1 terminal sends power to: • the afterfire solenoid • the windings of the PTO relay (electric PTO) , !FTERFIRE 3OLENOID ! " - 04/ 3WITCH 'ROUND the PTO switch C-COM terminal (electric PTO) • the headlights • the system monitor " &USE # This is identical to what happens with the key in the START position, except that the circuit that actually spins the starter motor is not energized.
Electrical System Run Circuit / Reverse Caution mode +EY 3WITCH h2EVERSE #AUTION -ODEv ' , 3 3YSTEM -ONITOR ! With the key in Reverse Caution mode, A1 gets power from the B terminal, just like the normal run position. 2. In addition, A2 is internally connected to the L terminal. L is normally used for the lighting circuit. !FTERFIRE 3OLENOID ! " - 1. 04/ 3WITCH 'ROUND 'ROUND ! 04/ 2ELAY !T 2EST " &USE 2a. In this case, a separate lighting circuit draws power from A1 2b.
LTX Tractors Engine shutdown circuits Engine shutdown circuits stop the engine by disabling the ignition and removes power from the afterfire solenoid. .H\ 6ZLWFK * Key switch shut-down: See Figure 7.27. $IWHUILUH 6ROHQRLG % *URXQG )XVH 0DJQHWR The A1 terminal is de-energized. 6ROHQRLG NOTE: On older electrical systems, prior to 2008, the afterfire solenoid was powered by the alternator. In order to turn off the afterfire solenoid, the A1 terminal was shorted to ground inside the key switch.
Electrical System Charging circuit How it works 1. When the engine is running, magnets attached to the underside of the flywheel induce A.C. (Alternating Current) in the stator that is mounted beneath the flywheel. See Figure 7.29. 2. The A.C. travels from the stator to and from the regulator/rectifier through the two white wires. Stator NOTE: The magnets inside the flywheel act as a rotor for the charging system. Rotor (magnets in recess) Figure 7.29 3. Regulator/ Rectifier D.C.
LTX Tractors 5. From the harness connector: See Figure 7.31. 5a. The red/white trace wire leads to the 20A fuse. 5b. From the fuse, the wire connects to the starter solenoid, sharing the “hot” post with the battery cable. 5c. .H\ 6ZLWFK 2. 3. / 6 0 $ % *URXQG $OWHUQDWRU 6WDWRU The shared post on the starter solenoid provides the final connection for the alternator output to reach the battery. )XVH 6WDUWHU 6ROHQRLG Testing Sequence: 1.
Electrical System 5. Figure 7.33 Stator check: See Figure 7.33. 5a. With the key switch OFF, unplug the stator from the regulate/rectifier. 5b. Check resistance through the stator using a digital multimeter set to read Ohms. • It should be between 0.1Ω and 0.14Ω. • A high reading indicates a fault in the windings. • A low reading indicates a short in the windings. • There should be a reading of O.L. (Open Line) between either lead and the engine block.
LTX Tractors 6. Regulator/rectifier check: See Figure 7.35. 6a. Check the ground. • With the engine running and the stator leads reconnected to the regulator/rectifier, perform a ground-side voltage-drop test from the regulator/ rectifier to the engine block. • If the voltage reading is greater than 0.1 Volts D.C., replace or properly fasten the ground wire that connects the regulator/rectifier to the engine block. Retest to confirm good connection. Figure 7.35 6b. 166 Bench Test: See Figure 7.
Electrical System 7. If the regulator/rectifier fails any one of these tests, replace it with a new one. Test # Pos. Probe COM. Probe Results 1 Housing B+ O.L. (infinite resistance) 2 Housing A.C. 1 O.L. (infinite resistance) 3 Housing A.C.2 > 1.0 Ω (5 second delay) 4 B+ A.C.1 0 Ω (Perfect continuity) 5 B+ A.C.2 > 1.0 Ω 6 B+ Housing > 1.0 Ω 7 A.C.1 B+ 0 Ω (Perfect continuity) 8 A.C.1 A.C.2 > 1.0 Ω 9 A.C.1 Housing > 1.0 Ω 10 A.C.2 B+ O.L.
LTX Tractors PTO Circuit (electric PTO) Basic Operation: See Figure 7.38. .H\ 6ZLWFK ³5XQ´ 1. 3. The PTO clutch gets power from the A1 terminal of the key switch through the C-(N.O.) terminal of the PTO switch when it is turned ON. The PTO clutch gets ground through the PTO relay COM terminal via the PTO relay (N.C.) terminal when the relay is not energized. $ * / 6 $ 372 &OXWFK $ % % 0 & *URXQG 1 & 1 2 &20 2.
Electrical System .H\ 6ZLWFK ³5XQ´ 2. $ * / 6 $ 372 &OXWFK $ % % 0 & 1 & 1 2 &20 *URXQG The seat switch contains two sets of contacts. The set with the yellow wire leads to ground when the contacts of the seat switch are closed. See Figure 7.39. 2a. When the operator leaves the seat, the seat switch connects the yellow wire to a ground path. 2b. That ground path passes through the RMC module to ground the PTO relay windings when the mower is put in reverse.
LTX Tractors Reverse Mower Control (RMC) circuit operation Historically, Cub Cadet residential mowers have not been able to mow in reverse. This has not been required by any laws or safety regulations, it was just safer for our customers and those around them. Then in 2005, ANSI regulations for residential mowers were changed, requiring that the mowing blades turn off when the mower is put in reverse. The new standard did allow for a user controlled over ride system.
Electrical System When the RMC module is armed and activated, it effectively disconnects the reverse switch from the circuit. See Figure 7.43. .H\ 6ZLWFK ³5XQ´ $ * / 6 $ The RMC module is disarmed and deactivated when the seat is vacated. It gets a ground signal through the second set of contacts in the seat switch.
LTX Tractors Electrical diagnosis NOTE: Electrical diagnostic procedures and tools are the same for all Cub Cadet and MTD mowers. This section is written in a way to provide basic trouble shooting skills that can be used on any mower. With a basic understanding of the behavior of electricity and the tools used to measure that behavior, a technician can be about 80% effective at finding electrical problems.
Electrical System • Low Voltage: Many electronic devices simply stop working if system voltage falls below a given threshold. If a 12 volt system is run at 11 volts with a failing alternator, electronic controls may stop working. • Bad Grounds: Bad grounds can reduce the effective system voltage, create resistance and heat, and send false signals. This is the single most common source of electronic gremlins. • Heat and Vibration: Heat and vibration are hard on most mechanical devices.
LTX Tractors Ohm’s Law Ohm’s Law relates voltage, amperage, and resistance. It states that voltage is the product of current times resistance. • It is written as V = I x R. • In simplest terms, it goes like this: • It takes 1 volt to push 1 amp through a resistance of 1 ohm (1 = 1 x 1). • This equation can be rearranged using algebra to solve for any one variable. • Those who were traumatized by algebra can represent Ohm’s law as a triangle.
Electrical System Kirchhoff’s voltage law Kirchhoff’s voltage law deals with voltage drops. A voltage drop is the amount of voltage used up or “dropped” by resistance in a circuit. Ohm’s law states that V = I x R, every component in a circuit has resistance, even the wires. To push current through resistance, it takes voltage. Kirchhoff’s voltage law states that the sum of all the voltage drops equals the source voltage.
LTX Tractors Types of circuits There are three ways a circuit can be wired: • Series • Parallel • Series/parallel Series Series circuits are wired so that the current has only one path to follow. If one component in the system fails, the circuit will be broken and whole system will not work. See Figure 7.48. Switch Lamp Battery Figure 7.48 Parallel Parallel circuits are wired so that current has multiple paths to follow.
Electrical System Series/parallel Series/parallel circuits have some sections wired in series and some in parallel. See Figure 7.50. Lamp Battery Lamp Lamp Lamp Switch Figure 7.50 What can go wrong? There are three types of failures that can occur in an electrical circuit: 1. Shorts 2. Opens 3. Increased resistance Shorts A short is when electricity takes a path that it was not designed to take bypassing a component in the circuit.
LTX Tractors The Tools Equipment needed to diagnose an electrical system: • DMM (Digital multimeter) • Wiring schematic or diagram Equipment that may be useful: 178 • Fused jumper wires. • Test light • Self-powered continuity light • Ammeter • Battery charger • Battery tester • Battery jumper cables • Hand tools to gain access to components. • Flashlight.
Electrical System Digital multimeter A DMM is the most useful tool to troubleshoot any electrical system. There is an amazing variety of DMMs on the market. Some are very basic, others are tailored to specific industries, and some high-end graphing meters function like oscilloscopes. Even the most basic ones are quite versatile. See Figure 7.51. Uses Voltage Set DMM to read “Volts DC (_ _ _)” if using an autoranging meter or to an appropriate scale (typically 20 Volts DC) if using a more basic model.
LTX Tractors Wiring diagram or schematic A wiring or a schematic diagram and the ability to read it are very important in troubleshooting a circuit. The diagram shows how the circuit was designed and what paths the electricity is suppose to flow. Fused jumper wires Fused jumper wires are handy to help find bad grounds or to jump across switches for testing purposes. ! CAUTION Only use fused jumper wires. If there is a short in the circuit, using an un-fused jump could damage components in the circuit.
Electrical System Ammeters and specialized charging system testers Inductive ammeters or “amp clamps” are available in many forms. Some are as simple as a gauge to be held against the circuit in question when it is energized. The operating principle is based on magnetic field induced by the current flow. See Figure 7.53. DMM with inductive ammeter feature Inductive ammeter There are two primary reasons to measure amperage. The first is to check the output of a charging system or battery.
LTX Tractors Batteries Batteries produce flammable and explosive gases, particularly during charging. ! CAUTION • Do not smoke or allow an open flame or heat source near the battery. • Charge batteries in an open area • Wear eye protection and acid resistant gloves when handling batteries. • Do not allow direct metal contact across the posts. This will produce extreme heat that may cause direct burns or ignite flammable gas.
Electrical System Checking battery condition There are three things to do when testing a battery: 1. • Visual inspection • Electrolyte test • Operational test Visual inspection • Inspect the battery and battery connections for corrosion. Clean if necessary. Neutralize acid with baking soda, and protect the terminals once they are cleaned. NOTE: Battery cable corrosion is the most common type of increased resistance circuit failures.
LTX Tractors Battery Testers There are four major ways to check a battery: • Electrolyte test using a specific gravity tester (hydrometer) to compare the density of the electrolyte in a fully charged battery to the density of water (water = 1.0 s.g.). • Electrolyte test using a refractometer to check the density of the electrolyte by measuring the degree to which light waves bend when passing through the electrolyte.
Electrical System Fixed load testers Fixed load testers (sometimes called toasters) are inexpensive load testers found at any auto parts store. See Figure 7.56. NOTE: Because they have a fixed load value, they do not give most batteries a reliable and safe load test. Most fixed load testers have a load that is more than 50% of the rated CCA of riding mower batteries. This makes them inappropriate to use on smaller pieces of outdoor power equipment.
LTX Tractors Battery discharge test Occasionally a battery will discharge while sitting unused. To test for a battery that is “leaking” voltage: 1. Confirm that operator technique is not creating a situation that cases a draw. As an example, if a homeowner habitually turns their equipment off using a safety switch (perhaps vacating the seat with the key switch still ON), that may leave a relay or fuel shut-off solenoid energized. 2. Disconnect and charge the battery fully. 3.
Electrical System Electrical Troubleshooting 1. The first step in troubleshooting is to always verify the complaint. Defining and verifying the problem reduces the possibility of misunderstanding and helps clarify the diagnostic approach. 2. The next step is to check the simple stuff first: • Check the fuse or fuses: NOTE: Failure of any fuse is an indication that there is a problem of some sort in the circuit that the fuse protects. • Look for obvious physical damage.
LTX Tractors 6. Starting with a fully charged battery and battery cable connections that are clean and tight, measure the battery voltage. See Figure 7.59. 7. With the circuit energized, start at either end of the circuit and check for voltage. • If starting at the battery end of a powered circuit, trace it through until power vanishes. • If starting at the ground end of a powered circuit, trace it through to the point that power appears.
Electrical System Voltage Drop Test To review: • Ohm’s law states that it takes voltage to push current through a resistance. • Kirchhoff’s voltage law states that the sum of all the voltage drops equals the source voltage. • Combining those two laws, we see that any restriction in a circuit (e.g.: loose connector damaged wire, or corroded terminal) will use up some voltage as the current is pushed through. • A voltage drop test is a way of looking for that voltage.
LTX Tractors A similar ground-side test on a mower with a slowcranking starter motor can be conducted between the engine block and the negative battery post. See Figure 7.62. 1. With the starter engaged, this machine exhibited a voltage drop reading of 0.312 volts, indicating a poor ground connection. 2. Individually, these readings should lead a technician to inspect the connection between the solenoid and the ground path on the first mower (e.g.
Electrical System 6. Voltage drop on a good circuit should be less than 0.1 volts. A voltage drop reading on the meter of greater than 0.2 volts indicates a fairly substantial problem that demands attention. • As an example, if the mower had a slow-turning starter, the ground-side voltage drop measured below 0.1 volts, and there was not a parasitic load on the engine (e.g. PTO clutch that is not fully disengaged), it would be logical for the technician to check voltage drop to the starter. See Figure 7.
LTX Tractors Testing switches • Refer to the “COMPONENTS” section of this chapter that describes the function of the individual switches to be tested. • Switches can be tested “hot” by looking for voltage at the appropriate posts. This is not definitive, since the source of the voltage is not always confirmed. Checking for voltage does not work on switches that work by providing a ground path to the magneto primary windings or a solid state control device.
Electrical System Diodes • What is a diode? A diode acts like a one way valve, allowing current to flow in only one direction. See Figure 7.66. Silver band (-) • Which way does this electrical check-valve work? There will be a band on one end of the diode. The band indicates the negative side of the diode (+) • Most DMMs have the ability to test a diode. electrons flow from the negative to the positive. Figure 7.66 Testing a diode: 1. Isolate the diode in the circuit. 2.
LTX Tractors No continuity 6. Switch the leads and repeat the test. 7. The meter should indicate no continuity. See Figure 7.69. 8. If the results do not match the above, replace the diode. Silver band (-) Figure 7.
Electrical System Relay Most of the relays used by MTD or Cub Cadet have five pins. See Figure 7.70. • • • Spade 3 Common Windings: Terminals 1 & 2 are the outer-most of the row of three small spade terminals. When one has power and the other is connected to ground, the relay is energized. Spade 5 N.O. Spade 1 Windings Normally, a resistance reading between terminals 1&2 will produce a measurement of about 100Ω.
LTX Tractors Schematics -ANUAL 04/ 196
%LECTRIC 04/ Electrical System 197
LTX Tractors 3,48 WITH %03 AND +OHLER $3! )GNITION 198
,48 WITH %03 Electrical System 199
LTX Tractors 200
Cutting Decks And Lift Shaft CHAPTER 8: CUTTING DECKS AND LIFT SHAFT Cutting decks The 900 series comes with a variety of deck options. The procedure to remove the deck is the same for all. The eighth digit of the model number will identify which deck is on the tractor.
LTX Tractors B. Remove the nut that secures the belt guard to the right side of the frame using a 1/2” wrench. See Figure 8.2. Remove this nut Figure 8.2 Remove this clip C. Pull in on the belt guard and slide it towards the rear of the tractor. D. Slide the PTO belt off of the engine pulley. E. Remove the hair pin clip that secures the PTO cable to the deck. See Figure 8.3. Figure 8.3 F. Unhook the spring end of the PTO cable from the idler pulley bracket. See Figure 8.4.
Cutting Decks And Lift Shaft 4. Pull the deck pins on both sides and rotate them to keep them out. See Figure 8.5. Pull and rotate the deck pin Figure 8.5 NOTE: The 50” and 54” decks will have an addition stabilizer link on the back of the deck. Disconnect it by removing the bow tie clip. See Figure 8.6. Rear stabilizer link Figure 8.6 Remove this click pin Figure 8.7 5. Remove the click pin and washer that secures the front lift rod to the deck and slide the rod away from the deck. See Figure 8.7.
LTX Tractors Cleaning the deck Clean the debris off of the mower deck every time the mower is used. It is routine maintenance that will make the deck easier to work on and prolong the life of the deck and spindles. ! CAUTION Debris build up on the mower deck is an unsafe condition. The debris traps heat in the spindles causing damage to the spindle bearings. Debris around the belt can overheat. To clean the deck while it is removed: 1. Blow all the debris off of the top of the deck using compressed air.
Cutting Decks And Lift Shaft Blades The condition of the blades will greatly affect the quality of the cut. The blades should be sharpened and balanced after every five acres, depending on local conditions. A dull blade tears the grass instead of cutting it. Torn grass blades leaves a rough look and makes the grass vulnerable to diseases. Blades need to be examined for damage before sharpening. Blades must be balanced after sharpening to minimize vibrations. Bent blades are a sign of a blade impact.
LTX Tractors 4. Remove the blade. 5. Install the blade by following the above steps in reverse order. Tighten the blade nut to a torque of 70 - 90 ft-lbs (95 - 122 Nm). NOTE: There are words stamped onto the blade. They must be facing the ground while cutting grass. See Figure 8.10. NOTE: The spindle has a star on the shaft. The blade must be seated over the star before tightening the nut. NOTE: A 15/16” wrench can be used to hold the top of the spindle shaft. 6.
Cutting Decks And Lift Shaft Spindles The spindles are a complete unit. The only replaceable part is the pulley. The spindles are equipped with a grease fitting that should get one squirt of grease after every use of the deck wash system or every 10 hours of use. NOTE: The bearings are sealed. Grease fills the void around the bearings. Over-greasing the spindles may push the bearing out of the spindle housing, ruining the spindle. Pulley nut To replace a pulley: 1.
LTX Tractors NOTE: Some belt covers have belt guides built into them. See Figure 8.13. 5. Remove the pulley nut using an impact wrench with a 15/16” socket. 6. Install the spindle pulleys by following the above steps in reverse order. 7. Test run the tractor before returning to service. Belt guides Figure 8.13 To replace a spindle: 1. Remove the deck as described at the beginning of this chapter. 2. Remove the blade following the steps described in the previous section of this chapter. 3.
Cutting Decks And Lift Shaft PTO belt The function of the PTO belt is to transfer the mechanical force from the engine to the blades. The PTO belt encounters many different forces: • The friction of the belt grabbing the different pulleys creates heat. This heat softens the belt which weakens it. • Every time the electric PTO is engaged, the PTO belt is subjected to an impact load. When the electric PTO is engaged, it goes from 0 to 3,600 RPM instantly. This can actual remove sections of the belt.
LTX Tractors Loosen this belt keeper NOTE: On the 50” and the 54” deck, The belt keeper on the brake side of the idler bracket must be removed and the other belt keeper needs to be loosened. See Figure 8.16. Remove this belt keeper Figure 8.16 4. Route the new belt around the pulleys. • For a 38” “F” deck, See Figure 8.17. Figure 8.17 • For a 42” “G” deck and a 46” “T” deck, See Figure 8.18. Figure 8.
Cutting Decks And Lift Shaft PTO belt Timing belt • For a 42” timed “R” deck, See Figure 8.19. Figure 8.19 • For a 42” staggered “S” deck. See Figure 8.20. Figure 8.20 • For a 46” “H” deck, See Figure 8.21. Figure 8.
LTX Tractors • For 50” “P” and 54” “K” decks, See Figure 8.22. 5. Reinstall and/or tighten all belt guards and keepers that were loosened to remove the PTO belt. 6. Install the deck as described at the beginning of this chapter. 7. Test drive the tractor before returning to service. Figure 8.
Cutting Decks And Lift Shaft Timing belt To service the timing belt: 1. Remove the deck as described at the beginning of this chapter. 2. Remove the PTO belt by following the steps described in the previous section of this manual. 3. Remove the PTO belt idler spring. See Figure 8.23. 4. Remove the timing belt idler stop using a pair of 9/16” wrenches. See Figure 8.24. Remove this spring Figure 8.23 NOTE: The idler spring pulley applies the tension to the timing belt.
LTX Tractors 6. Work the belt off of the pulleys. PTO idler pulley NOTE: The PTO idler pulley and the timing belt idler pulley can be moved apart, making clearance to remove the timing belt. See Figure 8.26. Timing belt idler pulley Figure 8.26 7. To install the timing belt turn the blades 90o apart. See Figure 8.27. NOTE: Failure to time the blades will result in the blades hitting each other. ¡ Figure 8.27 NOTE: The timing marks will line up with the blades and would need to be 90o apart.
Cutting Decks And Lift Shaft Leveling the deck For the best quality cut, the deck must be level side to side and the front of the deck should be 1/4” - 3/8” lower than the rear of the deck. To level the deck: NOTE: Check the tractor’s tire pressure before performing any deck leveling adjustments. The recommended operating tire pressure are: • Approximately 10 psi for the rear tires • Approximately 14 psi for the front tires Side to Side Leveling 1.
LTX Tractors Front To Rear Leveling The front of the cutting deck is supported by an adjustable front deck hanger rod. This rod can be adjusted to set the front to rear pitch of the deck. The front of the deck should be between 1/4-inch and 3/8-inch lower than the rear of the deck. Adjust if necessary as follows: 1. 2. With the tractor parked on a firm, level surface, move the deck to the mid height position (third or fourth notch) using the deck lift lever.
Cutting Decks And Lift Shaft Deck Wheel Adjustment The cutting decks are of a “floating” design. This means that they are suspended above the ground. The gauge wheels occasionally touch the ground. They are designed to bump the deck up and over irregularities. This helps prevents scalping damage to the turf and damage to the deck. Adjust the wheels as follows: Ball wheel 1. Place the tractor on a smooth, flat surface and move the deck to the desired mowing height using the deck lift lever. 2.
LTX Tractors Deck lift shaft assembly removal/replacement 1. Remove the deck by following the steps described at the beginning of this chapter. 2. Remove the fender by following the steps described in Chapter 4: Body/Chassis. 3. Remove the hairpin clips that hold the top of the deck lift cables and slide the cables out of the deck lift shaft assembly. See Figure 8.34. Remove hair pin clip Deck lift handle Figure 8.34 4. Unhook the lift assist spring (if equipped). See Figure 8.35. Figure 8.
Cutting Decks And Lift Shaft 5. Remove the E-clips that retain the bushings. See Figure 8.36. 6. Remove the bushings. See Figure 8.37. 7. Work shaft out of the seat box assembly. 8. Work the lift shaft handle and spring off of the deck lift shaft. 9. Install the deck lift shaft by following the above steps in reverse order. Remove the E-ring Figure 8.36 Remove bushings Figure 8.
LTX Tractors Deck lift links and cables The deck lift links have two functions. The first function is to support the rear of the deck. The second function is to raise or lower the deck in response to movement of the deck lift lever. To accomplish the second function, the deck lift cables run from the deck lift shaft assembly and over a pulley to the lift links. There are two sets of lift links used on the 900 series tractors. The links used on the 38” and 42” decks have a left and a right lift link.
Cutting Decks And Lift Shaft 3. Remove the two screws that secure the deck lift arm indexing plate using a 1/2” wrench. See Figure 8.40. 4. Push the deck lift arm as far forward as it will go. 5. Remove the hair pin clip that secures the lift cable to the lift shaft then slide the clevis pin out of the cable. See Figure 8.41. Remove these screws Figure 8.40 Remove this pin NOTE: With the indexing bracket loose, there should be enough clearance to slide the clevis pin out past the frame. Figure 8.
LTX Tractors 222
Maintenance Intervals CHAPTER 9: MAINTENANCE INTERVALS Lubrication To help keep the 900 series in proper running order it is recommended the following lubrication intervals be used (adjustable to local conditions). Use a high quality petroleum grease to lubricate the tractor.
LTX Tractors The spark plug(s) The spark plug(s) should be checked, cleaned and re-gapped on a monthly basis or every 100 hours of use. The plugs should be replaced every six months or 300 hours of use. When checking the spark plug(s), a dry, light colored residue on the plugs is a sign of running lean. If there is a thick, wet, black residue on the plug the engine is running rich. If either of these conditions are present, it would indicate a problem with the carburetor.
Maintenance Intervals Air filter and foam pre-cleaner A dirty air filter and/or foam pre-cleaner can reduce engine power, increase fuel consumption and make starting more difficult. The foam pre-cleaner should be checked before each use and cleaned every 25 hours. The air filter should be cleaned before each use and replaced every two months or 50 hours of use. Refer the engine manufacturer’s service manual for the proper procedure access the air filter. To clean a pre-cleaner: 1.
LTX Tractors Oil change The oil change interval is every 100 hrs. NOTE: The first oil change should be preformed at 5 hours. To change the oil: 1. Remove the cap from the oil drain. See Figure 9.3. 2. Slide a piece of 1/2” i.d. rubber hose onto the drain. 3. Push in on the oil drain and rotate 90 degrees to open the drain. 4. After all of the oil has been drained, close the oil drain. 5. Remove the drain hose. 6. Place the cap back on the oil drain. 7. Fill engine with new oil.
Maintenance Intervals Fuel system What you should know about fuel. Most of the fuel presently available in North America is oxygenated to some extent. This is commonly done through the addition of ethanol. Most engines offered for sale on outdoor power equipment in the North American markets are designed to tolerate no more than 10% ethanol by volume Ethanol is hygroscopic, meaning it absorbs water. If left exposed to air, it will draw water out of the air.
LTX Tractors Clean the engine Air cooled engines cool better when they are clean. Check for signs of animal or insect infestation, especially after off-season storage. Clean or replace any infested parts as needed. Figure 9.6 Lubricate the pedal shaft NOTE: The deck does not need to be removed to perform this procedure. 1. Remove the screw that secures the pedal shaft support strap using a 1/2” wrench. See Figure 9.7. 2. Gently pull down on the pedal shaft. 3.
APPENDIX HYDRO-GEAR APPENDIX This Hydro-Gear manual is reprinted, in its entirety with permission from Hydro-Gear.
APPENDIX 230
We set the wheels in motion.
Table of Contents Section Page Foreword........................................................................................................................................ 1 Section 1 Description and Operation .......................................................................................... 2 Introduction ...............................................................................................................................................................2 General Description .........
FOREWORD Headquartered in Sullivan, Illinois, Hydro-Gear® is a world leader in the design, manufacture, and service of quality hydrostatic transaxles for the lawn and garden industry. The mission of our company is to be recognized by our customers and the industry as a world-class supplier and the quality leader in everything we do. This Service and Repair Manual is designed to provide information useful in servicing and troubleshooting the Hydro-Gear 310-0510 Integrated Hydrostatic Transaxle (IHT).
SECTION 1. DESCRIPTION AND OPERATION INTRODUCTION The purpose of this manual is to provide information useful in servicing the Hydro-Gear® Integrated Hydrostatic Transaxle (IHT). This manual includes the IHT’s general description, hydraulic schematic, technical specifications, servicing and troubleshooting procedures. The transaxle normally will not require servicing during the life of the vehicle in which it is installed.
INPUT SHAFT VARIABLE SWASH PLATE CYLINDER BLOCK ASSEMBLY CYLINDER BLOCK ASSEMBLY 10 CC VARIABLE 10 CC FIXED DISPLACEMENT PUMP FIXED DISPLACEMENT ANGLE DISPLACEMENT MOTOR CHECK VALVE BYPASS ACTUATOR CHECK VALVE FILTER ASSEMBLY RESERVOIR DIFFERENTIAL ASSEMBLY TRANSAXLE HOUSING Figure 2. 310-0510 Hydraulic Flow Illustration HYDRAULIC SCHEMATIC Figure 2 provides an illustration of the hydraulic oil circuit.
EXTERNAL FEATURES 310-0510 FAN FRICTION PACK BELT KEEPER CONTROL ARM BRAKE ARM BRAKE DISC ADJUSTING PUCK BYPASS ARM Return to Neutral Option Friction Pack Option AXLE CLIP FILL PORT AXLE CLIP EXPANSION TANK AXLE SHAFT INPUT SHAFT AXLE CLIP AXLE CLIP 4 310-0510 IHT
MODEL RECOGNITION 618-0319 173839 310-0510 IHT 166768 104-1760 036932 618-0389A 5
TECHNICAL SPECIFICATIONS Technical specifications for the 310-0510 IHT are listed in Table 1. Table 1. 310-0510 Technical Specifications Overall Transaxle Reduction 22.15:1 Axle Shaft Options Type: Keyed / Double “D” Diameter: 0.75 inch; 19.05 mm Input Speeds Maximum: 3000 RPM Minimum: 1800 RPM Brake Type Disc Maximum Tire Diameter 20 inch; 508 mm Weight of Unit 30 lb; 14 kg PRODUCT IDENTIFICATION The model and configuration of the 310-0510 IHT can be determined from the label shown in Figure 3.
SECTION 2. SAFETY This symbol points out important safety instructions which, if not followed, could endanger the personal safety and/or property of yourself and others. Read and follow all instructions in this manual before attempting maintenance on your transaxle. When you see this symbol - HEED ITS WARNING. Wear appropriate clothing. Loose or hanging clothing or jewelry can be hazardous. Use the appropriate safety equipment, such as eye and hearing protection, and safety-toe and slipproof shoes.
SECTION 3. TROUBLESHOOTING WARNING Do not attempt any servicing or adjustments with the engine running. Use extreme caution while inspecting the drive belt assembly, and all vehicle linkage! Follow all safety procedures outlined in the vehicle owner’s manual! In many cases problems with the 310-0510 are not related to a defective transaxle, but are caused by slipping drive belts, partially engaged bypass valves, and loose or damaged control linkages.
SECTION 4. SERVICE AND MAINTENANCE NOTE: Any servicing dealer attempting a warranty repair must have prior approval before conducting maintenance of a Hydro-Gear® product unless the servicing dealer is a current Authorized Hydro-Gear Service Center. EXTERNAL MAINTENANCE Regular external maintenance of the 310-0510 IHT should include the following: 1. Check the vehicle operator’s manual for the recommended load ratings. Insure the current application does not exceed load rating.
FLUID CHANGE FLUID CHANGE PROCEDURE This transaxle is factory filled, sealed and does not require oil maintenance. However, in the event of oil contamination or degradation, oil addition or change may alleviate certain performance problems. 8. Install the tank support bracket and self tapping bolt making sure not to cross thread the bolt. Torque the bolt to the lower value of the torque specification listed in Table 5. 9. Fill the transaxle at the oil fill port according to Figure 4. 1.
PURGING PROCEDURES Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that it be purged from the system. These purge procedures should be implemented any time a hydrostatic system has been opened to facilitate maintenance or any additional oil has been added to the system. Air creates inefficiency because its compression and expansion rate is higher than that of the oil approved for use in hydrostatic drive systems.
RETURN TO NEUTRAL SETTING (FOOT CONTROL) WARNING WARNING POTENTIAL FOR SERIOUS INJURY Certain procedures require the vehicle engine to be operated and the vehicle to be raised off the ground. To prevent possible injury to the servicing technician and/or bystanders, insure the vehicle is properly secured. The return to neutral mechanism on the transmission is designed to set the directional control into a neutral position when the operator removes their foot from the foot control.
BRAKE MAINTENANCE BRAKE SETTING FRICTION PACK ADJUSTMENT 1. Remove the brake arm bias spring, and then the cotter pin securing the brake castle nut. The friction pack dampens or holds the operator control lever in its desired position. 2. Insert a 0.015" feeler gage between the brake disc and top brake puck, and then set the brake by finger tightening or loosening the castle nut. 3. Install a new cotter pin to secure the castle nut, and then install the brake arm bias spring.
SECTION 5. REPAIR HOW TO USE THIS SECTION Each subassembly illustrated in this section is illustrated by an exploded view showing the parts involved. The item reference numbers in each illustration are for assembly instructions only. See pages 31 and 33 for part names and descriptions. A complete exploded view and item list of the transaxle is provided at the end of this section. Many of the parts and subassemblies of this transaxle can be removed and serviced independently of other components.
TOOLS AND TORQUES Table 4. Required Tools Miscellaneous 310-0510 Service & Repair Manual Flat Blade Screw Driver (2) Torque Wrench Air Impact Wrench Rubber Mallet Breaker Bar Side Cutters/Snips Pliers Needle Nose Large External Snap Ring Sockets 1/2"- 3/8" Adapter 1/2" Deep 7/16" Deep 9/16" Deep 3/4" Deep 7/8" 10 mm T-25 Torx Head Table 5.
BRAKE ASSEMBLY AND BYPASS ARM Refer to Figure 8. INSPECTION DISASSEMBLY 1. Inspect the brake arm bias spring (66), castle nut (69), washer (73), brake arm (68), actuating pins (62), spring (71), brake yoke screws (63/64), brake yoke (58), pucks (60), puck plate (61), bypass arm (49), spacer (65) and brake rotor (59) for wear or damage. 1. Remove the brake arm bias spring (66). Note the orientation of the spring for proper reassembly. 2.
CONTROL ARM AND FRICTION PACK Refer to Figure 9. 3. Inspect the inner wedge puck (90). DISASSEMBLY 4. Inspect the friction pack stud (76) for wear or damage. 1. Remove the brake assembly. See page 16. 2. Loosen and remove the friction pack lock nut (80), flat washer (73), spring (78), spacer (79), washer clip (82) and puck (77). Discard the lock nut (80). 3. Remove the hex head screw (16) from the directional control. ASSEMBLY 1. Install the friction pack stud (76), if removed.
SEAL KIT REPLACEMENT Before disassembly, wipe the unit free of any debris to avoid contamination. Refer to Figure 10. input shaft. 2. The seal (13) can be replaced by following steps 2-6 of the procedure used to replace the axle seals. Axle Seal Trunnion Seal 1. Remove the axle clips (93) from the axle horns (for units with keyed axle shafts). 2. Remove the seal retaining rings (12). 3. Carefully pull the axle seals (34) out of the housing bore with a “hook” type tool.
SIDE HOUSING Refer to Figure 11. ASSEMBLY DISASSEMBLY 1. Apply a bead of sealant around the perimeter of the side housing face. See sealant pattern on page 28. 1. Remove the brake assembly and bypass arm. See page 16. 2. Remove the control arm and friction pack. See page 17. 3. Remove the oil from the transaxle. See page 10. 4. After all of the oil has been removed from the transaxle, remove the housing screws (7) and torque strap screw (8). 5.
AXLE SHAFT, DIFFERENTIAL & REDUCTION GEARS Refer to Figure 12. 3. Inspect the bull gear for wear or damage. DISASSEMBLY 4. Inspect the reduction gears, shaft and washers. 1. Remove the brake assembly and bypass arm. See page 16. 5. Inspect the housing bores. ASSEMBLY 2. Remove the control arm and friction pack. See page 17. 1. Reassemble and install the reduction gears (28 & 29), jack shaft pin (41) and washers (72). 3. Remove the oil from the transaxle. See page 10. 2. Install the bull gear (30).
MOTOR SHAFT AND BYPASS ROD 2. Inspect the bypass rod (48) for wear or damage. Refer to Figure 13. DISASSEMBLY 1. Remove the brake assembly and bypass arm. See page 16. 2. Remove the control arm and friction pack. See page 17. 3. Drain the oil from the transaxle. See page 10. 4. Remove the side housing. See page 19. 5. Remove the axle shaft, differential and reduction gears. See page 20. 6. Remove the flat washer (52), motor shaft and pinnion gear (24 & 27), and the flat washer (108). ASSEMBLY 1.
INPUT SHAFT Refer to Figure 14. ASSEMBLY DISASSEMBLY 1. Install the block thrust washer (56) and spring (55) onto the input shaft (9). 2. Ensure that the pump block is aligned concentrically with the center section running face. 3. Insert the input shaft (9), with bearing (14) and retaining ring (10), into the pump block assembly. NOTE: Do not force the shaft and bearing as damage may occur. If alignment is correct the shaft assembly will fit into place. 4.
HYDRAULIC COMPONENTS Refer to Figures 15-24. DISASSEMBLY 12. Reassemble the pistons, springs and seats into the cylinder block and set aside. (Pump Block) 13. (See Fig. 18) Remove the thrust bearing assembly (19) from the swashplate (4). 1. Remove the brake assembly and bypass arm. See page 16. (Center Section/Filter) 2. Remove the control arm and friction pack. See page 17. 3. Drain the oil from the transaxle. See page 10. 4. Remove the side housing. See page 19. 5.
HYDRAULIC COMPONENTS seats for excessive wear or damage. NOTE: Piston seats may be held in place in the piston by residual oil. 22. Reassemble the pistons, springs and seats into the cylinder block and set aside. 23. Remove the thrust bearing assembly (19) from the housing (1). Inspect the thrust bearing and thrust bearing cavity in the housing. INSPECTION 1. Inspect the pump cylinder block running surface for wear or damage. 2. Inspect the swashplate and thrust bearing assemblies for wear or damage. 3.
HYDRAULIC COMPONENTS 13. Tighten the center section mounting screws (44) to the proper torque. Refer to Table 5. (Swashplate/Pump Block) 14. (See Fig. 18) Install the pump thrust bearing (19) in the trunnion machined swashplate (4). NOTE: Place the thin race of the bearing towards the swashplate. The thick race must face the pistons. 4 15. (See Fig. 16) Place the pump block assembly (5), pistons down, on top of the thrust bearing in the swashplate (4). 5 16.
HYDRAULIC COMPONENTS Axle Horn 44 1 19 44 5 Figure 19 Figure 22 124 5 3 Figure 20 24 Figure 23 Short Shaft 3 46 Post Figure 24.
TRANSAXLE INSTALLATION Use the following procedure to complete the installation of the transaxle on the vehicle. 1. Install and secure the transaxle on the vehicle according to the instructions in the vehicle owner’s manual. 2. With the vehicle raised, install the wheels on the axles, and snug the wheel hardware. 3. Lower the vehicle wheels to the ground and torque the wheel hardware per the vehicle owner’s manual.
SEALANT APPLICATION NOTE: Prior to applying the new sealant, the old sealant must be removed from all surfaces. A small consistent bead of the sealant around the housing face will be sufficient. Use sparingly. The illustration below indicates the correct areas.
310-0710 INTEGRATED HYDROSTATIC TRANSAXLE DESCRIPTION TRANSAXLE REMOVAL The 310-0710 transaxle is an upgraded 310-0510 unit with different axle shafts, pump cylinder block assembly, center section and seal kit. The 310-0710 will have, as standard, black axle shafts. Flanged hubs will be an available option. It is necessary to remove the 310-0710 from the vehicle before performing the repair procedures presented in the repair section.
310-0710 EXPLODED VIEW 30 310-0510 IHT
310-0710 ITEMS LIST No. DESCRIPTION No. DESCRIPTION 1 Main Housing, Assembly, Black Main Housing, Black Bushing .865 x .985 x .790 Side Housing, Assembly, Black Side Housing, Black Bushing .865 x .985 x .790 Bushing .624 x .719 x .562 Center Section Assembly Center Section Machined Bushing .707 x .788 x .591 Swashplate, Trunnion Machined Block - Assembly Block - Cylinder Piston Spring Compression Thrust - Washer Sealant Hex Flange Screw 1/4-20 x 1.25 Shaft, Input Ring - Retaining Washer, Flat 1.23 x 1.
310-0610 EXPLODED VIEW 32 310-0510 IHT
310-0610 ITEMS LIST No. DESCRIPTION No. DESCRIPTION 1 Main Housing, Assembly Main Housing Bushing .865 x .985 x .790 Pin, Headless Standard Side Housing, Assembly Side Housing Bushing .865 x .985 x .790 Bushing .624 x .719 x .562 Center Section Assembly Center Section Machined (5 piston) Bushing .707 x .788 x .591 Swashplate, Trunnion Machined Block - Assembly Block - Cylinder Piston Spring Compression Thrust - Washer Sealant Screw, Hex Washer 1/4-20 x 1.
6—SEALANT 57—20W-50 OIL 127—SEAL & O-RING KIT 310-0510 EXPLODED VIEW 34 310-0510 IHT
310-0510 ITEMS LIST No. DESCRIPTION No. DESCRIPTION 1 Main Housing, Assembly Main Housing, Machined Bushing .865 x .985 x .790 Pin, Standard Headless Side Housing, Assembly Side Housing, Machined Bushing .865 x .985 x .790 Bushing .624 x .719 x .562 Center Section Assembly Center Section Machined (5 piston) Bushing .707 x .788 x .591 Swashplate, Trunnion Machined Block - Assembly Block - Cylinder Pistons Springs, Compression Thrust - Washer Sealant (10.1 oz.) Hex Flange Screw 1/4-20 x 1.
GLOSSARY OF TERMS Axial Piston: Type of design for hydraulic motors and pumps in which the pistons are arranged parallel with the spindle (input or output shaft). Bantam Duty: A descriptive term relating to the product capacity (meaning: light duty). Bypass Valve: A valve whose primary function is to open a path for the fluid to bypass the motor or pump. Also referred to occasionally as the freewheel valve or dump valve.
GLOSSARY OF TERMS Hydrostatic Transaxle: A multi-component assembly including a gear case and a hydrostatic transmission. Hydrostatic Transmission: The combination of a hydraulic pump and motor in one housing to form a device for the control and transference of power. Inlet Line: A supply line to the pump. Integrated Hydrostatic Transaxle (IHT): The combination of a hydrostatic transmission and gear case in one housing to form a complete transaxle.
© 2008 HYDRO-GEAR Printed in U.S.A. Rev.
MTD Products Inc - Product Training and Education Department FORM NUMBER - 769-04590B /00 6/2012