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Simplicity
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1691996
Simplicity 1691996 User Manual
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5 - 5
5 Electrical T
roubleshooting
Low
er Wiring Har
ness
1
1
CLIP, Speed
2
1
WIRE ASSY., Headlight
3
2
SOCKET, Bulb
4
2
BULB, Headlight, 12.8V
5
1
TIE, Cable
6
2
BUSHING, Snap, Small
7
1
LENS, Headlight
8
1
BEZEL, Headlight
9
1
HEADLIGHT ASSY. (Incl. Ref. Nos. 3, 4, 7, 8 & 10)
10
2
HEAT SHIELD
11
1
WIRE ASSY., Seat Switch and Lift
12
1
WIRE ASSY., Engine Ground
13
1
HARNESS ASSY., Lower
14
1
SWITCH, Seat, Operator Present
REF.
NO.
QTY.
DESCRIPTION
LO
WER WIRING HARNESS
48
50
Table of Contents
1 General Information
3
Default Chapter
3
Table of Contents
3
Models Covered
4
Introduction
5
Manual Content
5
Safety Rules
6
General Repair Information
11
Bearings & Bushings
11
Belts & Pulleys
11
Electrical Parts
11
Fasteners & Hardware
12
Genuine Replacement Parts
12
Hydraulic Parts
12
Paint
12
Required Tools & Equipment
12
Systems Checks
12
Torque Specifications
13
Specifications
14
3 Maintenance
21
Storage
22
Temporary
22
Long Term
22
Preventative Maintenance Chart
23
Engine Maintenance Engine Oil Level
24
Engine Oil Filter
24
Engine Air Filter
24
Fuel Filter Service
25
Spark Plug Service
26
Mower Blade Service
27
Lubrication
28
Lubricating the Tractor
28
Lubricating the Mower
30
Tire Pressure
30
Check / Add Transmission Oil
31
Hydro-Gear K216 Models
31
Tuff Torq K215 Models
31
Tuff Torq K210 Models
31
Change Transmission Oil Hydro-Gear K216 Models
32
Tuff Torq K215 Models
33
Tuff Torq K210 Models
33
4 Adjustments
35
Idler Pulley
36
Steering Gear Adjustment
36
Neutral Adjustments
37
Tuff Torq K215A - Early Models
37
Hydro-Gear 216-3010L
39
Tuff Torq K210A (Gear Models)
39
Return to Neutral Adjustments
40
Tuff Torq K215A
41
Hydro-Gear 216-3010L
41
Clutch / Brake Adjustment - Hydros Tuff Torq K215A
41
Clutch Adjustment - Gear
42
Purging Air from Transaxle
42
Pto (Electric Clutch) Adjustment
43
Mower Adjustments
44
Side to Side Leveling
44
Front to Back Leveling
44
5 Electrical Troubleshooting
45
Principals of Operation
46
Checking out the System General
47
Basic Electrical Terms
47
Test Series
47
1 Checking the Power Supply
47
Wiring
47
Battery Tests
54
Battery Cables
55
2 Isolate Cranking and Safety Systems
56
Test Circuit Breaker
56
Test Power to Ignition Switch
57
Test Ignition Switch
57
Test Power to Solenoid
58
Test Solenoid
59
Solenoid Bench Test
59
Test Power to Starter
60
PTO Interlock Switch
61
Seat Switch (Mechanical)
61
Neutral Safety Switch (Mechanical)
63
Neutral Safety Switch (Electrical)
63
Interlock Module
64
Headlight Switch
64
Hour Meter
65
Inspect and Replace Dash Lights
66
Test Electric PTO Clutch
67
Electric Lift Tests
68
Table of Contents
71
6A Steering & Front Wheel Repair
72
General
72
Required Tools & Equipment
72
Elevating Front of Unit for Safe Service
72
Front Wheel Repair-Bearing Removal
74
Left Hand Spindle Repair
76
Right Hand Spindle / Steering Arm Repair
78
Tie Rod Repair
80
Steering Wheel Removal
82
Steering Shaft Removal
83
Steering Gear / Pitman Arm Service
84
Drag Link Removal
85
Hand Controls Repair General
88
Shift Rod Service
92
Front & Rear Shift Rod Service - Hydro-Gear 216
94
Attachment Lift Service
98
Engine Choke Control (Twin Cylinder Units)
105
Parking Brake Knob Removal
108
Parking Brake Rod Service
108
6C Foot Controls Repair
109
General
109
Foot Pedal Pad Replacement
109
Clutch Rod Service - Hydro-Gear 216
112
Brake Arm / Brake Rod Service - Hydro-Gear 216
113
Lockout Lever / Shift Pivot Assy Service
116
Clutch Rod Service - Tuff Torq K215A Models
119
Return-To Neutral Rod Service - Tuff Torq K215A
120
Brake Rod Service - Tuff Torq K215A
122
Hydrostatic Control Dampener Service
123
Front Clutch Rod Service - Tuff Torq K210A
129
Rear Clutch Rod Service - Tuff Torq K210A
129
Hood, Grille & Dash Repair General
131
Hood & Grille Removal
131
Dash Removal
133
Seat, Deck & Fuel Tank Repair Seat Removal
139
Seat Deck Removal
140
Fuel Tank Removal
140
Rear Wheel Repair General
142
Elevating Rear End for Safe Service
142
Rear Wheel Removal
142
Table of Contents
143
Tuff Torq K215A Transaxle General
144
Tear-Down and Reassembly
146
Sauer-Sundstrand BDU-21L-207 Hydrostatic Pump
157
General
157
Minor Repair - General
160
Plug / Fitting Torques
160
Shaft Seals
161
Charge Check Valves
162
Bypass Valve
163
Charge Pump
163
Major Repair
165
Disassembly Procedures
165
Hydro-Gear 216-3010L Transaxle General
169
Maintenance
172
Fluids/Greases
172
Oil & Filter Change
172
Inspection
173
Transaxle Repair
174
Removal
174
Hydro Pump Removal
178
Hydro Pump Installation
178
Axle Carrier Assemble
179
Transaxle Disassembly
180
Transaxle Assembly
183
Transaxle Installation
187
General
189
Minor Repair
191
Shaft Seals
192
Charge Check Valves
193
Bypass Valve
193
Charge Pump
194
Major Repairs
195
Disassembly Procedures
195
Assembly Procedures
197
Tuff Torq K210A Six Speed Transaxle General
199
Removal & Installation
202
Disassembly
203
Inspection
209
Assembly
212
8 Mower Deck Repair
221
Default Chapter
222
Deck & Arbors - Early Models
222
Deck & Arbors - Later Models
224
Clutch & Support -All Models
227
Height Adjustment & Rollers - 44
228
Height Adjustment & Rollers - 50
229
Mower Deck Repair
232
Mower Removal & Installation
232
PTO Belt Replacement
233
Arbor Drive Belt Replacement
233
Idler Pulley Service
234
Arbor Repair
235
Arbor Assembly Removal - All Models
235
Arbor Disassembly - Early Models
236
4
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Simplicity 1691996 Specifications
General
Brand
Simplicity
Model
1691996
Category
Tractor
Language
English
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