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Simplicity LEGACY Series User Manual
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13 - 17
13 Engine Removal & Installation
K
ohler - Engine Installation
Figure 15. Drive Shaft Guard/Shield Installation
A.
Guard Mounting Hardware
C.
Shield Mounting Hardware
B.
Drive Shaft Guard
D.
Drive Shaft Shield
D
A
C
B
Figure 16. PTO Component Installation
A.
PTO Belt Set
B.
Fan
C.
PTO Clutch Assembly
A
C
B
Not
for
Reproduction
186
188
Table of Contents
1 General Information
3
Table of Contents
3
Model Configuration
4
Models Covered
4
Model Identification
4
Mower Decks
5
About this Manual
6
Introduction
6
Manual Content
6
General Safety
7
Operation
7
Slope Operation
8
Dos and Don'ts
8
Do Not
8
Children
8
Transporting and Storage
8
Warnings and Labels
8
Fuel Handling
9
Personal Protective Equipment
9
Proper Tool Use
9
Service and Maintenance
9
Exhaust
10
Battery
10
Elevation of Unit
10
Electrical System
10
Work Area
11
Compressed Air
11
Lubricants
11
General Servicing
11
Cleaning
12
Electrical Parts
12
Inspection
12
Belts and Pulleys
12
Removal
12
General Repair Information
12
Bearings and Bushings
12
Lubrication
12
Introduction
12
Fasteners and Hardware
13
Genuine Replacement Parts
13
Paint
13
Required Tools and Equipment
13
Systems Checks
13
Torque Specifications
17
3 Maintenance
25
All Models
29
Changing Transmission Fluid and Filter
29
Check Tire Pressures
29
Check Transmission (Hydraulic System) Oil Level
29
Maintenance Procedures - All Models
29
Check Mower Deck Gear Box Oil
30
Servicing the Mower Blades
30
Blade Brake Check
31
Lubrication
32
Checking the Battery Fluid
34
Cleaning the Battery and Cables
34
Check Antifreeze Level (Liquid Cooled Engine Models)
35
Check/Change Air Filter
35
Maintenance - Gas Engine Models
35
Oil and Filter Change
35
Change Antifreeze (Liquid Cooled Engine Models)
36
Fuel Filter
36
Fuel Filter
37
Maintenance - Diesel Engine Models
37
Prime Fuel System
37
Change Antifreeze
38
Check Antifreeze Level
38
Check/Change Air Filter
38
Clean Radiator Screen
38
Oil and Filter Change
38
4 Adjustments
39
Brake Linkage Adjustment
40
Brake Switch Adjustment
40
Brake System
40
Cruise Control Lever Tension Adjustment
41
Differential Lock Cable Adjustment
41
Drive System
41
Neutral Adjustment
42
PTO Clutch Adjustment
43
Leveling
44
Mower Deck
44
Gauge Wheel Adjustment (54" Mower Only)
45
Pulley Stop Adjustment
45
Idler Pulley Adjustment (60" Mower Only)
46
Roller Bracket Adjustment (60" Mower Only)
46
6 Common Service Procedures
53
Mower Deck Removal and Installation
54
Removing the Mower Deck
54
Installing the Mower Deck
55
Mower Blade Removal and Installation
56
Elevating Rear End for Safe Service
57
Elevating the Tractor
57
Elevating Front End for Safe Service
58
Front Wheel Removal and Installation
59
Rear Wheel Removal and Installation
59
Wheel Bearing Replacement
59
Wheel Service
59
Battery
60
Battery Service
60
Charging System
67
Burnishing the Clutch
68
PTO Clutch Service
68
7 Electrical System Service
69
General Information
70
Section Contents
70
System Description
70
Principles of Operation
71
Safety Interlock System
71
Checking out the System
72
Linear Circuit Diagrams
83
Component Location and Replacement
86
Dashboard Components
86
Troubleshooting
93
Check/Clean Ground Cable
102
Check/Clean Wires and Connectors
102
Component Tests
102
Battery Tests
103
Charging Voltage Check
104
Isolated Battery Voltage Check
104
Preheat Timer Test
105
Glow Plug Relay Test
106
Ignition Switch Tests
106
PTO Switch Test
108
Accessory Power Connector Test
109
Cruise Control Switch Test
109
Brake Pedal Switch Tests
110
Height of Cut Switch Test
110
Seat Switch Safety Interlock Test
111
Seat Switch Test
111
Alternator
112
Circuit Breaker Test
112
Fuel Solenoid Test
112
Headlight Switch Test
112
PTO Clutch
112
Voltage Regulator
112
Fuel Level Sensor Test
113
Fuel Level Signal Test
113
8 Power Steering Service
115
Front Axle and Steering Group
117
Tilt Assembly
119
Checking Operation
120
Preliminary Checks
120
Remove and Replace
120
Steering Wheel Replacement
120
Testing Steering Cylinder
120
Steering Tilt Assembly Installation
121
Steering Tilt Assembly Removal
121
Hydraulic Steering Unit Installation
122
Hydraulic Steering Unit Removal
122
Steering Cylinder Installation
123
Steering Cylinder Removal
123
Front Spindles - Installation
124
Front Spindles - Removal
124
Front Axle Removal and Installation
125
9 Drive Control Service
127
Two Speed Control Group
131
Basic Checks
134
Introduction
134
Remove and Replace
134
Cruise Control Disassembly/Assembly
135
General Drive Control Service
135
Cruise Control Switch Adjustment
136
Speed Pedal Disassembly/Assembly
137
Differential Lock Pedal Replacement
138
10 U-Type Hydrostatic Unit Service
139
Exploded View Diagrams
140
General
142
Hydraulic Fluid Recommendations
142
Safety Rules
142
Specific
142
Specifications
142
System Description
143
General
145
Test Procedure
145
Testing
145
Troubleshooting
146
Assembling Pump and Transaxle
147
Separating Pump and Transaxle
147
Disassembly, Repair, and Reassembly
148
Major Disassembly and Repair
149
Reassembly
151
12 Brake System Service
163
Brake Control and Parking Brake Group
165
Brake Caliper and Disc Replacement
166
Brake Linkage Service
168
Brake Pedal Assembly Replacement
169
Parking Brake Assembly Replacement
170
13 Engine Removal & Installation
171
13 Engine Removal & Installation
173
Engine Removal
182
General
182
13 Engine Removal & Installation
186
Engine Installation
186
Engine Removal
190
General
190
Engine Installation
202
Engine Removal
202
14 Hood, Dash, & Foot Rest Service
207
Heat Shield (Gas Engine Models)
211
Hood Installation
212
Hood Disassembly
213
Bumper Replacement
214
Dashboard Removal
214
Dashboard Replacement
215
15 Seat Deck & Fuel Tank Service
217
Seat Deck Group
219
Fuel Tank Group
221
Seat Deck Installation
222
Seat Deck Removal
222
Seat Pan Replacement
224
Seat Replacement
224
Seat Slide Rail Replacement
225
Tail Light Bezel Replacement
225
Seat Cover Replacement
226
Seat Switch Replacement
226
Fuel Tank Replacement
227
Fuel Level Sensor Replacement
228
16 Pto Clutch Service
229
PTO Clutch Removal
234
PTO Clutch Installation
236
Idler Pulley Replacement
238
PTO Belt Replacement
238
PTO Drive Replacement
239
PTO Clutch Electrical Tests
240
18 Mower Deck Service
245
48" Mower Deck - Housing, Covers & Gauge Wheel Group
246
48" Mower Drive, Belt, Arbor & Blade Group
248
48" Mower Roller Bar Group (SN 1 to 59999)
250
48" Mower Baffle & Inner Roller Group
254
48" Mower Height Adjust & Hitch Group
256
48" Mower Baffle Group (Export Models)
260
54" Mower Housing, Cover & Gauge Wheel Group
262
54" Mower Drive, Belt, Arbor & Blade Group
264
54" Mower Roller Bar Group
266
54" Mower Height Adjust & Hitch Group
268
60" Mower Housing, Cover & Gauge Wheel Group
270
60" Mower Drive, Belt, Arbor & Blade Group
272
60" Mower Roller Bar Group (SN 1 to 59999)
274
60" Mower Baffle & Inner Roller Group
278
60" Mower Height Adjust & Hitch Group
280
60" Mower Deflector & Stone Guard Group
282
60" Mower Baffles (Export Models)
284
Drive Shaft - SERVICE PARTS
286
Gearbox - SERVICE PARTS
288
Arbor Removal & Installation
290
Arbor Service
290
Idler Pulley Replacement
290
Mower Adjustments
290
Mower Belt Replacement
290
Mower Blade Service
290
Mower Deck Removal and Installation
290
Arbor Disassembly
291
Arbor Assembly
292
Drive Shaft and Gearbox Service
293
Drive Shaft Assembly
293
Drive Shaft Disassembly
293
Drive Shaft Removal & Installation
293
Gearbox Assembly
294
Gearbox Disassembly
294
Implement Lift Group (Gas Engine Models)
297
Implement Lift Group (Diesel Engine Models)
299
General
300
Lift Control Valve Replacement
300
Lift Pedal Assembly Replacement
301
Lift Cylinder Replacement
302
Lift Shaft Assembly Replacement
302
Components
307
Hose Connections
307
Flow
308
Disassembly
309
Reassembly
310
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Simplicity LEGACY Series Specifications
General
Brand
Simplicity
Model
LEGACY Series
Category
Lawn Mower
Language
English
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