JOHN DEERE
WORLDWIDE COMMERCIAL & CONSUMER
EQUIPMENT DIVISION
July 2009
Walk Greens Mower
220 E-Cut Hybrid
TM108519 JULY 2009
TECHNICAL MANUAL
North American Version
Litho In U.s.a.
INTRODUCTION
Manual Description
This technical manual is written for an experienced
technician and contains sections that are specifically for
this product. It is a part of a total product support program.
The manual is organized so that all the information on a
particular system is kept together. The order of grouping is
as follows:
•
Table of Contents
•
Specifications and Information
•
Identification Numbers
•
Tools and Materials
•
Component Location
•
Schematics and Harnesses
•
Theory of Operation
•
Operation and Diagnostics
•
Diagnostics
•
Tests and Adjustments
•
Repair
•
Other
Safety
Specifications and Information
Engine
Electrical
Power Train
Handlebar and Controls
Brakes
Note: Depending on the particular section or system
being covered, not all of the above groups may be
used.
The bleed tabs for the pages of each section will align with
the sections listed on this page. Page numbering is
consecutive from the beginning of the Safety section
through the last section.
We appreciate your input on this manual. If you find any
errors or want to comment on the layout of the manual
please contact us.
All information, illustrations and
specifications in this manual are based
on the latest information at the time of
publication. The right is reserved to
make changes at any time without
notice.
COPYRIGHT© 2009
Deere & Co.
John Deere Worldwide Commercial and
Consumer Equipment Division
All rights reserved
Previous Editions
COPYRIGHT©
Introduction
Attachments
Miscellaneous
SAFETY
Be Prepared for Emergencies
Safety
Recognize Safety Information
MIF
This is the safety-alert symbol. When you see this symbol
on your machine or in this manual, be alert to the potential
for personal injury.
Follow recommended precautions and safe servicing
practices.
MIF
When you work around fuel, do not smoke or work near
heaters or other fire hazards.
Understand Signal Words
A signal word - DANGER, WARNING, or CAUTION - is
used with the safety-alert symbol. DANGER identifies the
most serious hazards.
DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn
spontaneously.
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Replace Safety Signs
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.
Wear Protective Clothing
MIF
Replace missing or damaged safety signs. See the
machine operator’s manual for correct safety sign
placement.
MIF
Wear close fitting clothing and safety equipment
appropriate to the job.
Safety
-1
SAFETY
Prolonged exposure to loud noise can cause impairment or
loss of hearing. Wear a suitable hearing protective device
such as earmuffs or earplugs to protect against
objectionable or uncomfortable loud noises.
Support Machine Properly and Use Proper
Lifting Equipment
Operating equipment safely requires the full attention of the
operator. Do not wear radio or music headphones while
operating machine.
Service Machines Safely
MIF
If you must work on a lifted machine or attachment,
securely support the machine or attachment.
Do not support the machine on cinder blocks, hollow tiles,
or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
Follow recommended procedures in this manual.
MIF
Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
caught, severe injury could result.
Lifting heavy components incorrectly can cause severe
injury or machine damage. Follow recommended
procedure for removal and installation of components in the
manual.
Remove rings and other jewelry to prevent electrical shorts
and entanglement in moving parts.
Work in Clean Area
Use Proper Tools
6. Clean work area and machine.
Use tools appropriate to the work. Makeshift tools and
procedures can create safety hazards. Use power tools
only to loosen threaded parts and fasteners. For loosening
and tightening hardware, use the correct size tools. DO
NOT use U.S. measurement tools on metric fasteners.
Avoid bodily injury caused by slipping wrenches. Use only
service parts meeting John Deere specifications.
7. Make sure you have all necessary tools to do your job.
Before starting a job:
8. Have the right parts on hand.
9. Read all instructions thoroughly; do not attempt
shortcuts.
Illuminate Work Area Safely
Illuminate your work area adequately but safely. Use a
portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.
Park Machine Safely
1. Stop mower on a level surface, not on a slope.
2. Disengage mower blades and wheel drive.
3. Stop the engine.
4. Wait for the engine and all moving parts to stop.
5. Remove the spark plug wire before servicing the mower.
Safety
-2
SAFETY
Work in Ventilated Area
vacuum cleaner is recommended to clean asbestos. If not
available, apply a mist of oil or water on the material
containing asbestos. Keep bystanders away from the area.
Service Tires Safely
TS220
Engine exhaust fumes can cause sickness or death. If it is
necessary to run an engine in an enclosed area, remove
the exhaust fumes from the area with an exhaust pipe
extension.
MIF
Explosive separation of a tire and rim parts can cause
serious injury or death.
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.
WARNING: California Proposition 65 Warning
Gasoline engine exhaust from this product contains
chemicals known to the State of California to cause cancer,
birth defects, or other reproductive harm.
Remove Paint before Welding or Heating
Avoid potentially toxic fumes and dust. Hazardous fumes
can be generated when paint is heated by welding,
soldering, or using a torch. Do all work outside or in a well
ventilated area. Dispose of paint and solvent properly.
Remove paint before welding or heating: If you sand or
grind paint, avoid breathing the dust. Wear an approved
respirator. If you use solvent or paint stripper, remove
stripper with soap and water before welding. Remove
solvent or paint stripper containers and other flammable
material from area. Allow fumes to disperse at least 15
minutes before welding or heating.
Do not attempt to mount a tire unless you have the proper
equipment and experience to perform the job. Always
maintain the correct tire pressure. Do not inflate the tires
above the recommended pressure. Never weld or heat a
wheel and tire assembly. The heat can cause an increase
in air pressure resulting in a tire explosion. Welding can
structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension
hose long enough to allow you to stand to one side and
NOT in front of or over the tire assembly. Use a safety cage
if available.
Check wheels for low pressure, cuts, bubbles, damaged
rims or missing lug bolts and nuts.
Avoid Injury from Rotating Blades, Augers,
and PTO Shafts
Avoid Harmful Asbestos Dust
Avoid breathing dust that may be generated when handling
components containing asbestos fibers. Inhaled asbestos
fibers may cause lung cancer.
Components in products that may contain asbestos fibers
are brake pads, brake band and lining assemblies, clutch
plates, and some gaskets. The asbestos used in these
components is usually found in a resin or sealed in some
way. Normal handling is not hazardous as long as airborne
dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for cleaning.
Avoid brushing or grinding material containing asbestos.
When servicing, wear an approved respirator. A special
Safety
MIF
Keep hands and feet away while machine is running. Shut
off power to service, lubricate or remove mower blades,
augers or PTO shafts.
-3
SAFETY
Handle Chemical Products Safely
Live with Safety
MIF
Direct exposure to hazardous chemicals can cause serious
injury. Potentially hazardous chemicals used with John
Deere equipment include such items as lubricants,
coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
MIF
Before returning machine to customer, make sure machine
is functioning properly, especially the safety systems. Install
all guards and shields.
Dispose of Waste Properly
Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with John Deere equipment includes such items as oil, fuel,
coolant, brake fluid, filters, and batteries. Use leakproof
containers when draining fluids. Do not use food or
beverage containers that may mislead someone into
drinking from them. Do not pour waste onto the ground,
down a drain, or into any water source. Inquire on the
proper way to recycle or dispose of waste from your local
environmental or recycling center, or from your John Deere
dealer.
Safety
-4
SPECIFICATIONS AND INFORMATION TABLE OF CONTENTS
Specifications and Information
Table of Contents
General Specifications .....................................7
Metric Fastener Torque Values ......................7
Metric Fastener Torque Values—Grade 7 .....8
Inch Fastener Torque Values .........................9
Gasket Sealant Application ..........................10
O-Ring Seal Service Recommendations ......11
Face Seal Fittings - Inch Stud Ends Torque.11
Face Seal Fittings - Metric Stud Ends Torque..
12
O-Ring Face Seal Fittings ............................13
O-Ring Boss Fittings ....................................13
Fuels and Lubricants......................................14
Gasoline .......................................................14
Gasoline Storage..........................................14
Engine Oil.....................................................15
Engine Break–in Oil......................................15
Alternative Lubricants...................................15
Synthetic Lubricants .....................................15
Lubricant Storage .........................................16
Mixing Of Lubricants.....................................16
Grease..........................................................16
Transmission and Hydraulic Oil....................16
Serial Number Locations ...............................17
Record Identification Numbers .....................17
Machine Identification Number.....................17
Engine Serial Number ..................................17
Carburetor Identification Number .................17
Specifications and Information Table of Contents - 5
SPECIFICATIONS AND INFORMATION TABLE OF CONTENTS
Specifications and Information Table of Contents - 6
SPECIFICATIONS AND INFORMATION GENERAL SPECIFICATIONS
General Specifications
Metric Fastener Torque Values
4.8
9.8
10.9
4.8
8.8
9.8
10.9
12.9
4.8
8.8
9.8
10.9
12.9
10
5
10
10
10
12.9
12
10
10
5
5
Property
Class
and
Nut
Markings
12.9
8.8
12
Property
Class
and
Head
Markings
12
TS1163
TS1163
Class 4.8
Class 8.8 or 9.8
Class 10.9
Class 12.9
Lubricateda Drya
Lubricateda Drya
Lubricateda Drya
Lubricateda Drya
SIZE N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
M6
4.8
3.5
6
4.5
9
6.5
11
8.5
13
9.5
17
12
15
11.5
19
14.5
M8
12
8.5
15
11
22
16
28
20
32
24
40
30
37
28
47
35
M10
23
17
29
21
43
32
55
40
63
47
80
60
75
55
95
70
M12
40
29
50
37
75
55
95
70
110
80
140
105
130
95
165
120
M14
63
47
80
60
120
88
150
110
175
130
225
165
205
150
260
190
M16
100
73
125
92
190
140
240
175
275
200
350
225
320
240
400
300
M18
135
100
175
125
260
195
330
250
375
275
475
350
440
325
560
410
M20
190
140
240
180
375
275
475
350
530
400
675
500
625
460
800
580
M22
260
190
330
250
510
375
650
475
725
540
925
675
850
625
1075 800
M24
330
250
425
310
650
475
825
600
925
675
1150 850
1075 800
1350 1000
M27
490
360
625
450
950
700
1200 875
M30
675
490
850
625
1300 950
M33
900
675
1150 850
M36
1150 850
1350 1000 1700 1250 1600 1150 2000 1500
1650 1200 1850 1350 2300 1700 2150 1600 2700 2000
1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750
1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500
• DO NOT use these hand torque values if a different
torque value or tightening procedure is given for a specific
application. Torque values listed are for general use only
and include a ± 10% variance factor. Check tightness of
fasteners periodically. DO NOT use air powered wrenches.
• When bolt and nut combination fasteners are used,
torque values should be applied to the NUT instead of the
bolt head.
• Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
a
• Fasteners should be replaced with the same class.
Make sure fastener threads are clean and that you properly
start thread engagement. This will prevent them from failing
when tightening.
• Tighten toothed or serrated-type lock nuts to the full
torque value.
“Lubricated” means coated with a lubricant such as
engine oil, or fasteners with phosphate and oil
coatings. “Dry” means plain or zinc plated (yellow
dichromate—Specification JDS117) without any
lubrication.
Reference: JDS-200
Specifications and Information General Specifications - 7
SPECIFICATIONS AND INFORMATION GENERAL SPECIFICATIONS
Metric Fastener Torque Values—Grade 7
Size
Steel or Gray
Iron Torque
Aluminum
Torque
N•m (lb-ft)
N•m (lb-ft)
M6
11 (8)
8 (6)
M8
24 (18)
19 (14)
M10
52 (38)
41 (30)
M12
88 (65)
70 (52)
M14
138 (102)
111 (82)
M16
224 (165)
179 (132)
Specifications and Information General Specifications - 8
SPECIFICATIONS AND INFORMATION GENERAL SPECIFICATIONS
Inch Fastener Torque Values
8
5.2
5.1
5
1 or 2b
SAE
Grade
and Head
Markings
8.2
No Marks
5
2
SAE
Grade
and Nut
Markings
8
No Marks
TS1162
TS1162
Grade 1
Grade 2
a
Lubricated
a
Dry
b
Lubricated
Grade 5, 5.1 or 5.2
a
a
Dry
Lubricated
a
Grade 8 or 8.2
a
Lubricateda Drya
Dry
SIZE N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
1/4
3.7
2.8
4.7
3.5
6
4.5
7.5
5.5
9.5
7
12
9
13.5
10
17
12.5
5/16
7.7
5.5
10
7
12
9
15
11
20
15
25
18
28
21
35
26
3/8
14
10
17
13
22
16
27
20
35
26
44
33
50
36
63
46
7/16
22
16
28
20
35
26
44
32
55
41
70
52
80
58
100
75
1/2
33
25
42
31
53
39
67
50
85
63
110
80
120
90
150
115
9/16
48
36
60
45
75
56
95
70
125
90
155
115
175
130
225
160
5/8
67
50
85
62
105
78
135
100
170
125
215
160
215
160
300
225
3/4
120
87
150
110
190
140
240
175
300
225
375
280
425
310
550
400
7/8
190
140
240
175
190
140
240
175
490
360
625
450
700
500
875
650
1
290
210
360
270
290
210
360
270
725
540
925
675
1050 750
1-1/8 470
300
510
375
470
300
510
375
900
675
1150 850
1-1/4 570
425
725
530
570
425
725
530
1300 950
1-3/8 750
550
950
700
750
550
950
700
1700 1250 2150 1550 2700 2000 3400 2550
1250 925
990
725
1250 930
2250 1650 2850 2100 3600 2650 4550 3350
1-1/2 1000 725
• DO NOT use these hand torque values if a different
torque value or tightening procedure is given for a specific
application. Torque values listed are for general use only
and include a ± 10% variance factor. Check tightness of
fasteners periodically. DO NOT use air powered wrenches.
• Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
1300 975
1450 1075 1850 1350
1650 1200 2050 1500 2600 1950
• Tighten toothed or serrated-type lock nuts to the full
torque value.
a
“Lubricated” means coated with a lubricant such as
engine oil, or fasteners with phosphate and oil
coatings. “Dry” means plain or zinc plated (yellow
dichromate—Specification JDS117) without any
lubrication.
b
• Fasteners should be replaced with the same class.
Make sure fastener threads are clean and that you properly
start thread engagement. This will prevent them from failing
when tightening.
“Grade 2” applies for hex cap screws (not hex bolts)
up to 152 mm (6 in.) long “Grade 1” applies for hex cap
screws over 152 mm (6 in.) long, and for all other types
of bolts and screws of any length.
• When bolt and nut combination fasteners are used,
torque values should be applied to the NUT instead of the
bolt head.
Reference: JDS-G200
Specifications and Information General Specifications - 9
SPECIFICATIONS AND INFORMATION GENERAL SPECIFICATIONS
Gasket Sealant Application
Cleaning:
Clean both surfaces that will be joined using 100%
isopropyl alcohol. Wipe excess off with a clean cloth.
Cleaner/degreaser can be substituted for isopropyl alcohol.
How to Dispense/Apply/Assemble Gasket Sealants:
Dispense approximately 1 to 2 ounces of flexible form-inplace gasket on a clean sheet or table top. Avoid using
excess amounts that may be exposed for long periods of
time. This will help prevent contamination from surrounding
atmosphere such as dust with metal content.
Using an ink roller or similar devise, apply to one surface of
the joint by loading the roller from a plastic sheet and
transferring the material in a thin film to the joint. The
application should be the thinnest film possible, but
providing complete coverage. This can be judged by the
appearance of the joint once it is put together. Excessive
amounts of will cause incorrect bearing end play, extend
cure time, and will cause runoff of the material. A small
bead or buildup at the joint is permissible and indicates
good dispersion through the joint. Excess can be wiped
from the joint. Joining should take place within three
minutes after sealant application.
Apply proper cap screw torque and sequence as
applicable. Allow a minimum of 30 minutes before air test or
adding oil for test stand usage.
Disassembly:
Cured material can be removed with a wire brush or
scraper. Chemical cleaners are available for customer use,
should they be deemed necessary.
Specifications and Information General Specifications - 10
SPECIFICATIONS AND INFORMATION O-RING SEAL SERVICE
O-Ring Seal Service Recommendations
Face Seal Fittings - Inch Stud Ends Torque
Stud End
Tube Nut
Straight Stud and Tube Nut
Swivel Nut
Lock Nut
Tube Nut
Stud End
90° Swivel Elbow and Tube Nut
90° Adjustable Stud Elbow
Bulkhead Union and Bulkhead Lock Nut
MIF
Nominal Tube OD/Hose ID
Face Seal Tube/Hose End
Metric
Tube
OD
Inch Tube OD
Thread
Size
Tube Nut/
Swivel Nut
Torque
Bulkhead
Lock Nut
Torque
Thread
Size
Straight Fitting
or Lock Nut
Torque
mm
Dash
Size
in.
mm
in.
N•m
N•m lb-ft
in.
N•m
lb-ft
-3
0.188
4.76
3/8-24
8
6
6
-4
0.250
6.35
7/16-20
12
9
8
-5
0.312
7.94
1/2-20
16
12
10
-6
0.375
9.52
11/16-16
24
18
24
18
9/16-18
24
18
12
-8
0.500
12.70
13/16-16
50
37
46
34
3/4-16
46
34
16
-10
0.625
15.88
1-14
69
51
62
46
7/8-14
62
46
-12
0.750
19.05
1-3/16-12
102
75
102
75
1-1/16-12
102
75
22
-14
0.875
22.22
1-3/16-12
102
75
102
75
1-3/16-12
122
90
25
-16
1.000
25.40
1-7/16-12
142
105
142
105
1-5/16-12
142
105
32
-20
1.25
31.75
1-11/16-12 190
140
190
140
1-5/8-12
190
140
38
-24
1.50
38.10
2-12
160
217
160
1-7/8-12
217
160
9/16-18
16
217
lb-ft
12
O-Ring Stud Ends
12
9
Note: Torque tolerance is +15%, -20%
Specifications and Information O-Ring Seal Service Recommendations - 11
SPECIFICATIONS AND INFORMATION O-RING SEAL SERVICE
Face Seal Fittings - Metric Stud Ends Torque
Stud End
Tube Nut
Groove for Metric Identification
Straight Stud and Tube Nut
Swivel Nut
Lock Nut
Tube Nut
Groove for Metric
Identification
Stud End
90° Swivel Elbow and Tube Nut
90° Adjustable Stud Elbow
Bulkhead Union and Bulkhead Lock Nut
MIF
Nominal Tube OD/Hose ID
Face Seal Tube/Hose End
Metric Inch Tube OD
Tube
OD
Thread
Size
Hex Tube Nut/
Size Swivel
Nut
Torque
in.
mm
N•m lb-ft N•m lb-ft mm
9/16-18
17
16
mm
Dash in.
Size
mm
6
-4
0.250 6.35
8
-5
0.312 7.94
12
O-Ring Stud Ends, Straight Fitting or
Lock Nut
Bulkhead
Lock Nut
Torque
12
9
Thread
Size
Hex Steel or
Size Gray Iron
Torque
mm
Aluminum
Torque
N•m lb-ft N•m lb-ft
M12X1.5 17
21
15.5 9
6.6
M14X1.5 19
33
24
15
11
10
-6
0.375 9.52
11/16-16
22
24
18
24
18
M16X1.5 22
41
30
18
13
12
-8
0.500 12.70 13/16-16
24
50
37
46
34
M18X1.5 24
50
37
21
15
16
-10
0.625 15.88 1-14
30
69
51
62
46
M22X1.5 27
69
51
28
21
-12
0.750 19.05 1-3/16-12
36
102
75
102
75
M27X2
32
102
75
46
34
22
-14
0.875 22.22 1-3/16-12
36
102
75
102
75
M30X2
36
25
-16
1.000 25.40 1-7/16-12
41
142
105
142
105
M33X2
41
158
116
71
52
M38X2
46
176
130
79
58
28
32
-20
1.25
31.75 1-11/16-12 50
190
140
190
140
M42X2
50
190
140
85
63
38
-24
1.50
38.10 2-12
217
160
217
160
M48X2
55
217
160
98
72
60
Note: Torque tolerance is +15%, -20%
Specifications and Information O-Ring Seal Service Recommendations - 12
SPECIFICATIONS AND INFORMATION O-RING SEAL SERVICE
O-Ring Face Seal Fittings
A
A
A
C
B
B
MIF
1. Inspect the fitting sealing surfaces (A). They must be
free of dirt or defects.
2. Inspect the O-ring (B). It must be free of damage or
defects.
MIF
3. For angle fittings, loosen special nut (A) and push
special washer (B) against threads so O-ring can be
installed into the groove of fitting.
3. Lubricate O-rings and install into groove using
petroleum jelly to hold in place.
4. Turn fitting into the boss by hand until special washer or
washer face (straight fitting) contacts boss face and O-ring
is squeezed into its seat.
4. Push O-ring into the groove with plenty of petroleum
jelly so O-ring is not displaced during assembly.
5. To position angle fittings (C), turn the fitting counterclockwise a maximum of one turn.
5. Index angle fittings and tighten by hand-pressing joint
together to ensure O-ring remains in place.
6. Tighten straight fittings to torque value shown on chart.
For angle fittings, tighten the special nut to value shown in
the chart while holding body of fitting with a wrench.
Important: Avoid Damage! DO NOT allow hoses
to twist when tightening fittings. Use two
wrenches to tighten hose connections; one to
hold the hose, and the other to tighten the swivel
fitting.
Thread Size
Torquea
N•m
lb-ft
Number of
Flatsb
6. Tighten fitting or nut to torque value shown on the chart
per dash size stamped on the fitting.
3/8-24 UNF
8
6
2
7/16-20 UNF
12
9
2
O-Ring Boss Fittings
1/2-20 UNF
16
12
2
1. Inspect boss O-ring boss seat. It must be free of dirt and
defects. If repeated leaks occur, inspect for defects with a
magnifying glass. Some raised defects can be removed
with a slip stone.
9/16-18 UNF
24
18
2
3/4-16 UNF
46
34
2
7/8-14 UNF
62
46
1-1/2
1-1/16-12 UN
102
75
1
1-3/16-12 UN
122
90
1
1-5/16-12 UN
142
105
3/4
1-5/8-12 UN
190
140
3/4
1-7/8-12 UN
217
160
1/2
B
A
a
MIF
2. Put hydraulic oil or petroleum jelly on the O-ring (A).
Place electrical tape over the threads to protect
O-ring from nicks. Slide O-ring over the tape and into the
groove (B) of fitting. Remove tape.
Torque tolerance is ± 10 percent.
b
To be used if a torque wrench cannot be used. After
tightening fitting by hand, put a mark on nut or boss; then
tighten special nut or straight fitting the number of flats
shown.
Specifications and Information O-Ring Seal Service Recommendations - 13
SPECIFICATIONS AND INFORMATION FUELS AND LUBRICANTS
Fuels and Lubricants
Gasoline
c Caution:
Avoid Injury! Gasoline is HIGHLY
FLAMMABLE, handle it with care.DO NOT
refuel machine while:
indoors, always fill gas tank outdoors
machine is near an open flame or sparks
engine is running, STOP engine
engine is hot, allow it to cool sufficiently first
smoking
Help prevent fires:
fill gas tank to bottom of filler neck only
be sure fill cap is tight after fueling
clean up any gas spills IMMEDIATELY
keep machine clean and in good repair-free of
excess grease, oil, debris, and faulty or
damaged parts
any storage of machines with gas left in tank
should be in an area that is well ventilated to
prevent possible igniting of fumes by an open
flame or spark, this includes any appliance
with a pilot light
To prevent fire or explosion caused by STATIC
ELECTRIC DISCHARGE during fueling:
ONLY use a clean, approved POLYETHYLENE
PLASTIC fuel container and funnel WITHOUT
any metal screen or filter
To avoid engine damage:
•
DO NOT mix oil with gasoline
• ONLY use clean, fresh unleaded gasoline with an
octane rating (anti-knock index) of 87 or higher
• fill gas tank at the end of each day's operation to help
prevent condensation from forming inside a partially filled
tank
•
keep up with specified service intervals
MIF
• methyl tertiary butyl ether (MTBE) blends DO NOT
exceed 15% by volume
Important: Avoid Damage! DO NOT use METHANOL
gasoline because METHANOL is harmful to the
environment and to your health.
c Caution:
Avoid Injury! California Proposition 65
Warning: Gasoline engine exhaust from this
product contains chemicals known to the State
of California to cause cancer, birth defects, or
other reproductive harm.
Gasoline Storage
Important: Avoid Damage! Keep all dirt, scale, water
or other foreign material out of gasoline.
Keep gasoline stored in a safe, protected area. Storage of
gasoline in a clean, properly marked (“UNLEADED
GASOLINE”) POLYETHYLENE PLASTIC container
WITHOUT any metal screen or filter is recommended. DO
NOT use de-icers to attempt to remove water from gasoline
or depend on fuel filters to remove water from gasoline.
Use a water separator installed in the storage tank outlet.
BE SURE to properly discard unstable or contaminated
gasoline. When storing machine or gasoline, it is
recommended that you add John Deere Gasoline
Conditioner and Stabilizer (TY15977) or an equivalent to
the gasoline. BE SURE to follow directions on container
and to properly discard empty container.
Use of alternative oxygenated, gasohol blended, unleaded
gasoline is acceptable as long as:
• the ethyl or grain alcohol blends DO NOT exceed 10%
by volume or
Specifications and Information Fuels and Lubricants - 14
SPECIFICATIONS AND INFORMATION FUELS AND LUBRICANTS
Engine Oil
Use the appropriate oil viscosity based on the expected air
temperature range during the period between
recommended oil changes. Operating outside of these
recommended oil air temperature ranges may cause
premature engine failure.
The following John Deere oils are PREFERRED:
•
TURF-GARD™ - SAE 10W-30;
•
PLUS-4™ - SAE 10W-30;
•
TORQ–GARD SUPREME®—SAE 5W-30.
If the above recommended John Deere oils are not
available, use a break-in engine oil meeting the following
specification during the first 5 hours (maximum) of
operation:
•
The following John Deere oils are also recommended,
based on their specified temperature range:
•
The following John Deere oil is also recommended as a
break-in engine oil:
SAE 5W-30—API Service Classification SE or higher.
Important: Avoid Damage! After the break-in
period, use the John Deere oil that is
recommended for this engine.
TORQ-GARD SUPREME™ - SAE 30;
Other oils may be used if above John Deere oils are not
available, provided they meet one of the following
specifications:
•
SAE 30 - API Service Classification SJ or higher;
•
SAE 10W-30 - API Service Classification SJ or higher;
BREAK-IN OIL
-40
-22
-4
14
-40
-30
-20
-10
32 F
50
68
86
104
122
0C
10
20
30
40
50
SAE 5W-30
SAE 10W-30
-40
-22
-4
14
-40
-30
-20
-10
32 F
0 C
50
68
86
104
122
10
20
30
40
50
SAE 30
MIF
Engine Break–in Oil
Important: Avoid Damage! ONLY use a quality
break-in oil in rebuilt or remanufactured engines
for the first 5 hours (maximum) of operation. DO
NOT use oils with heavier viscosity weights than
SAE 5W-30 or oils meeting specifications API SG
or SH, these oils will not allow rebuilt or
remanufactured engines to break-in properly.
The following John Deere oil is PREFERRED:
•
BREAK–IN ENGINE OIL.
John Deere BREAK–IN ENGINE OIL is formulated with
special additives for aluminum and cast iron type engines
to allow the power cylinder components (pistons, rings, and
liners as well) to “wear-in” while protecting other engine
components, valve train and gears, from abnormal wear.
Engine rebuild instructions should be followed closely to
determine if special requirements are necessary.
John Deere BREAK–IN ENGINE OIL is also recommended
for non-John Deere engines, both aluminum and cast iron
types.
Alternative Lubricants
Conditions in certain geographical areas outside the United
States and Canada may require different lubricant
recommendations than the ones printed in this technical
manual or the operator's manual. Consult with your John
Deere Dealer, or Sales Branch, to obtain the alternative
lubricant recommendations.
Important: Avoid Damage! Use of alternative
lubricants could cause reduced life of the
component.
If alternative lubricants are to be used, it is recommended
that the factory fill be thoroughly removed before switching
to any alternative lubricant.
Synthetic Lubricants
Synthetic lubricants may be used in John Deere equipment
if they meet the applicable performance requirements
(industry classification and/or military specification) as
shown in this manual.
The recommended air temperature limits and service or
lubricant change intervals should be maintained as shown
in the operator’s manual.
Avoid mixing different brands, grades, or types of oil. Oil
manufacturers blend additives in their oils to meet certain
specifications and performance requirements. Mixing
different oils can interfere with the proper functioning of
Specifications and Information Fuels and Lubricants - 15
SPECIFICATIONS AND INFORMATION FUELS AND LUBRICANTS
these additives and degrade lubricant performance.
Transmission and Hydraulic Oil
Lubricant Storage
Important: Avoid Damage! Machine is filled with
John Deere HY-GARD™ (J20C) Transmission/
Hydraulic Oil at the factory. DO NOT mix oils. DO
NOT use type “F” automatic transmission fluid
All machines operate at top efficiency only when clean
lubricants are used. Use clean storage containers to
handle all lubricants. Store them in an area protected from
dust, moisture, and other contamination. Store drums on
their sides. Make sure all containers are properly marked
as to their contents. Dispose of all old, used containers and
their contents properly.
BIO HY-GARD
HY-GARD J20C
Mixing Of Lubricants
In general, avoid mixing different brands or types of
lubricants. Manufacturers blend additives in their lubricants
to meet certain specifications and performance
requirements. Mixing different lubricants can interfere with
the proper functioning of these additives and lubricant
properties which will downgrade their intended specified
performance.
Low Viscosity HY-GARD J20D
-40
-20
0
-40
-30
-20
20
-10
32 F
0 C
10
20
30
100
122
40
50
MIF
Use oil viscosity based on the expected air temperature
range during the period between oil changes.
Grease
Important: Avoid Damage! Use recommended
John Deere greases to avoid component failure
and premature wear.
The recommended John Deere greases are
effective within an average air temperature range
of -29 to 135 degrees C (-20 to 275 degrees F).
John Deere J20C HY-GARD Transmission/Hydraulic Oil is
recommended. John Deere J20D Low Viscosity HY-GARD
Transmission/Hydraulic Oil may also be used.
Use John Deere BIO HY-GARD™ oil when a biodegradable
fluid is required.
Other oils may be used if they meet John Deere standard
JDM J20C or J20D.
If operating outside that temperature range,
contact your Servicing dealer for a special-use
grease.
The following greases are preferred (this may change
for high speed applications such as cutting units):
•
80
60
40
John Deere Multi-Purpose SD Polyurea Grease
If not using any of the preferred greases, be sure to use a
general all-purpose grease with an NLGI grade No. 2
rating.
Wet or high speed conditions may require use of a specialuse grease. Contact your Servicing dealer for information.
Specifications and Information Fuels and Lubricants - 16
SPECIFICATIONS AND INFORMATION SERIAL NUMBER LOCATIONS
Serial Number Locations
Carburetor Identification Number
Record Identification Numbers
When ordering parts or submitting a warranty claim, it is
IMPORTANT that the machine product identification and
component serial numbers are included.
The location of the machine identification number and
component serial numbers are shown.
Machine Identification Number
M83820
A
C
B
MX42308
A- Machine Product Identification Number
B- Reel Product Identification Number
C- Engine Product Identification Number
Engine Serial Number
MX6042
Specifications and Information Serial Number Locations - 17
SPECIFICATIONS AND INFORMATION SERIAL NUMBER LOCATIONS
Specifications and Information Serial Number Locations - 18
ENGINE - GAS TABLE OF CONTENTS
Engine - Gas
Table of Contents
Specifications .................................................21
General Specifications .................................21
Test and Adjustment Specifications .............21
Repair Specifications....................................21
Tools and Materials ........................................25
Special or Essential Tools ............................25
Other Materials.............................................25
Component Location and Operation ............26
External Engine Components.......................26
Internal Engine Components........................28
Lubrication System Operation ......................29
Cooling System Operation ...........................31
Diagnostics .....................................................32
Engine Cranks But Will Not Start .................32
Engine Runs Poorly at Low RPM .................32
Engine Runs Poorly at High RPM ................33
Excessive Oil Consumption..........................34
Engine Overheats.........................................34
Excessive Fuel Consumption .......................34
Tests and Adjustments ..................................36
Check and Adjust Throttle Cable..................36
Adjust Slow Idle Speed ...............................36
Adjust Governor and Fast Idle Speed .........37
Test Cylinder Compression Pressure ..........37
Check and Adjust Valve Clearance..............38
Test Spark ...................................................39
Adjust Spark Plug Gap .................................40
Adjust Alternator Belt....................................40
Repair...............................................................42
Remove and Install Fuel Tank .....................42
Remove and Install Fuel Filter .....................43
Remove and Install Throttle Cable ..............43
Remove and Install Muffler ..........................43
Remove and Install Engine .........................44
Remove and Install Air Cleaner Assembly ..45
Service of Air Cleaner ..................................46
Remove and Install Throttle Plate
Assembly .....................................................47
Remove and Install Carburetor ...................47
Disassemble and Assemble Carburetor ......49
Clean and Inspect Carburetor .....................50
Replace Pilot Screw and Limiter Cap ..........50
Adjust Float Level ........................................51
Remove and Install Blower Housing
Assembly .................................................... 51
Remove and Install Recoil Starter .............. 52
Disassemble and Inspect Recoil Starter ..... 52
Assemble Recoil Starter ............................. 53
Remove and Install Ignition Coil ................. 54
Adjust Air Gap ............................................. 55
Test Ignition Coil ......................................... 55
Remove and Install Flywheel ...................... 56
Remove and Install Rocker Arm Cover ...... 56
Remove and Install Cylinder Head and
Valves ......................................................... 57
Disassemble and Assemble Cylinder Head
and Valves .................................................. 58
Inspect Cylinder Head and Valves .............. 58
Replace Valve Guide .................................. 60
Analyze Valves ............................................ 62
Recondition Valve Seats.............................. 63
Lap Valves ................................................... 63
Remove and Install Crankcase Cover ........ 64
Replace Bearing and Oil Seal ..................... 64
Remove and Install Camshaft and Tappets 65
Inspect Camshaft and Tappets ................... 65
Remove Piston and Connecting Rod .......... 66
Inspect Piston and Connecting Rod ........... 66
Disassemble Piston and Connecting Rod .. 67
Assemble Piston and Connecting Rod ....... 68
Inspect Piston and Connecting Rod ........... 69
Check Connecting Rod Side Play................ 71
Check Connecting Rod-to-Crankshaft
Clearance .................................................... 71
Check Piston Ring End Gap ........................ 72
Analyze Piston Ring Wear ........................... 72
Analyze Piston Wear ................................... 73
Remove and Install Crankshaft ................... 74
Inspect Crankshaft ...................................... 75
Replace Timing-Governor Gear .................. 75
Analyze Crankshaft and Connecting Rod
Wear ............................................................ 76
Inspect Cylinder Block ................................ 76
Crankshaft Bearing Inspection and
Replacement ............................................... 77
Replace Oil Seal ......................................... 77
Deglaze Cylinder Bore................................. 77
Rebore Cylinder Block ................................. 77
Remove and Install Governor ..................... 78
Engine - Gas Table of Contents - 19
ENGINE - GAS TABLE OF CONTENTS
Engine - Gas Table of Contents - 20
ENGINE - GAS SPECIFICATIONS
Specifications
General Specifications
Make. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Honda
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline, 25° inclined cylinder
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GX120
Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Natural
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 cm3 (7.2 cu in.)
Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 cycle
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mm (2.4 in.)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 mm (1.7 in.)
Compression Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5:1
Valve Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead valves
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Splash
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forced air
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dual-element (silent) type
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Float-type
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In-line
Engine Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 L (0.63 qt)
Type of Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recoil
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5 kg (34.2 lb)
Test and Adjustment Specifications
Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2950 ± 150 rpm
Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1700 ± 100 rpm
Cylinder Compression Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586-834 kPa (85-121 psi)
Intake Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 ± 0.02 mm (0.006 ± 0.001 in.)
Exhaust Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 ± 0.02 mm (0.008 ± 0.001 in.)
Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7-0.8 mm (0.028-0.031 in.)
Ignition Coil
Air Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 ± 0.2 mm (0.016 ± 0.008 in.)
Resistance (Primary Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8-1.0 ohm
Resistance (Secondary Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9-7.1 k-ohms
Repair Specifications
Engine
Engine Oil Capacity (Approx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 L (0.63 qt)
Oil Drain Plug Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 N•m (156 lb-in.)
Engine - Gas Specifications - 21
ENGINE - GAS SPECIFICATIONS
Fuel Tank
Capacity (Approx). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 L (0.66 gal)
Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Mounting Flange Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Fuel Filter Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (17 lb-in.)
Muffler
Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (204 lb-in.)
Air Cleaner Assembly
Air Cleaner Wing Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Air Cleaner Housing Flange Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 N•m (73 lb-in.)
Carburetor
Float Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.7 mm (0.54 in.)
Sediment Cup Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (36 lb-in.)
Flywheel
Flange Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 N•m (54 lb-ft)
Cylinder Head
Initial Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (102 lb-in.)
Final Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (204 lb-in.)
Maximum Cylinder Head Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)
Rocker Arm Pivot Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (204 lb-in.)
Rocker Arm Pivot Locknut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Standard Valve Guide ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50 mm (0.217 in.)
Valve Guide ID Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.572 mm (0.2194 in.)
Standard Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 mm (0.03 in.)
Valve Seat Width Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm (0.08 in.)
Valve Face Margin (Min). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 mm (0.024 in.)
Valve Spring
Standard Free Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.5 mm (1.20 in.)
Free Length Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.5 mm (1.16 in.)
Valve Guide
Intake Guide-to-Stem Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02-0.044 mm (0.0008-0.0017 in.)
Intake Guide-to-Stem Clearance Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)
Exhaust Guide-to-Stem Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06-0.087 mm (0.0024-0.0034 in.)
Exhaust Guide-to-Stem Clearance Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)
Valve Guide Installed Depth (Valve Guide Top-to-Cylinder Head Casting) . . . . . . . . . . . . . . . . . . . . . 3.0 mm (0.12 in.)
Intake Valve
Stem OD Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.48 mm (0.216 in.)
Stem OD Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.318 mm (0.2094 in.)
Maximum Valve Stem Out-of-Round. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.)
Head Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 mm (0.87 in.)
Engine - Gas Specifications - 22
ENGINE - GAS SPECIFICATIONS
Exhaust Valve
Standard Stem OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.44 mm (0.214 in.)
Stem OD Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.275 mm (0.2077 in.)
Maximum Valve Stem Out-of-Round. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.)
Head Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 mm (0.75 in.)
Crankcase Cover
Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (108 lb-in.)
Camshaft Holder ID Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.0 mm (0.55 in.)
Camshaft Holder ID Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.048 mm (0.5531 in.)
Piston
Connecting Rod Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (108 lb-in.)
Standard Piston Skirt Standard OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.985 mm (2.3616 in.)
Standard Piston Skirt OD Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.845 mm (2.3561 in.)
0.25 mm (0.010 in.) Oversize Piston Skirt Standard OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.235 mm (2.3716 in.)
0.25 mm (0.010 in.) Oversize Piston Skirt OD Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.095 mm (2.3661 in.)
0.50 mm (0.020 in.) Oversize Piston Skirt Standard OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.485 mm (2.38 in.)
0.50 mm (0.020 in.) Oversize Piston Skirt OD Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.345 mm (2.3761 in.)
Piston-to-Cylinder Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015-0.050 mm (0.0006-0.0020 in.)
Piston-to-Cylinder Clearance Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)
1st and 2nd Compression Piston Ring Standard Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 mm (0.06 in.)
1st and 2nd Compression Piston Ring Thickness Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.37 mm (0.054 in.)
Oil Control Piston Ring Standard Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 mm (0.10 in.)
Oil Control Piston Ring Thickness Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37 mm (0.093 in.)
Piston Ring Groove Standard Side Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015-0.045 mm (0.0006-0.0018 in.)
Piston Ring Groove Side Clearance Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Top and 2nd Piston Ring Standard End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2-0.4 mm (0.008-0.016 in.)
Top and 2nd Piston Ring End Gap Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.04 in.)
Oil Control Piston Ring Standard End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15-0.35 mm (0.006-0.014 in.)
Oil Control Piston Ring End Gap Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.04 in.)
Piston Pin Standard OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.0 mm (0.51 in.)
Piston Pin OD Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.954 mm (0.510 in.)
Piston Pin Bore Standard ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.002 mm (0.5119 in.)
Piston Pin Bore ID Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.048 mm (0.5137 in.)
Piston-to-Piston Pin Bore Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002-0.014 mm (0.0001-0.0006 in.)
Piston-to-Piston Pin Bore Clearance Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.)
Engine - Gas Specifications - 23
ENGINE - GAS SPECIFICATIONS
Connecting Rod
Connecting Rod Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (108 lb-in.)
Piston Pin Bushing Standard ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.005 mm (0.512 in.)
Piston Pin Bushing ID Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.07 mm (0.515 in.)
Standard Crankshaft Bearing Standard ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.02 mm (1.024 in.)
Standard Crankshaft Bearing ID Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.066 mm (1.0262 in.)
0.25 mm (0.010 in.) Undersize Crankshaft Bearing Standard ID . . . . . . . . . . . . 25.770-25.783 mm (1.0146-1.0151 in.)
0.25 mm (0.010 in.) Undersize Crankshaft Bearing ID Wear Limit . . . . . . . . . . . . . . . . . . . . . . . 25.816 mm (1.0164 in.)
Connecting Rod-to-Crankshaft Journal Standard Clearance. . . . . . . . . . . . . . . . . 0.040-0.063 mm (0.0016-0.0025 in.)
Connecting Rod-to-Crankshaft Journal Clearance Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)
Connecting Rod-to-Crankshaft Standard Side Clearance . . . . . . . . . . . . . . . . . . . . . . . . . 0.1-0.7 mm (0.004-0.028 in.)
Connecting Rod-to-Crankshaft Side Clearance Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 mm (0.043 in.)
Camshaft
Cam Lobe Standard Height (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.7 mm (1.09 in.)
Cam Lobe Height Wear Limit (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.45 mm (1.081 in.)
Cam Lobe Standard Height (Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.75 mm (1.093 in.)
Cam Lobe Height Wear Limit (Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.50 mm (1.083 in.)
Journal Standard OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.984 mm (0.5506 in.)
Journal OD Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.916 mm (0.5479 in.)
Crankshaft
Connecting Rod Journal Standard OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.98 mm (1.023 in.)
Connecting Rod Journal OD Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.92 mm (1.020 in.)
Cylinder Block
Standard Piston Cylinder Bore Standard ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.0 mm (2.36 in.)
Standard Piston Cylinder Bore ID Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.165 mm (2.3687 in.)
0.25 mm (0.010 in.) Oversize Piston Cylinder Bore Standard ID . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.25 mm (2.37 in.)
0.25 mm (0.010 in.) Oversize Piston Cylinder Bore ID Wear Limit . . . . . . . . . . . . . . . . . . . . . . . 60.415 mm (2.3787 in.)
0.50 mm (0.020 in.) Oversize Piston Cylinder Bore Standard ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.5 mm (2.38 in.)
0.50 mm (0.020 in.) Oversize Piston Cylinder Bore ID Wear Limit . . . . . . . . . . . . . . . . . . . . . . . 60.665 mm (2.3887 in.)
Engine - Gas Specifications - 24
ENGINE - GAS TOOLS AND MATERIALS
Tools and Materials
Other Material
Part No.
Special or Essential Tools
Note: Order tools according to information given in the
U.S. SERVICEGARD™ Catalog or in the European
Microfiche Tool Catalog (MTC).
Special or Required Tools
Tool Name
Tool No.
Tool Use
Digital Pulse
Tachometer
JT07270
Used to check/adjust
engine slow and fast
idle rpm.
Feeler Gauge
(Blade Type)
NA
Used to measure
intake and exhaust
valve clearance.
Compression
Gauge
JDM-59
Used to check engine
compression.
Spark Tester
D-05351ST
Used to check overall
condition of ignition
system.
5.5 mm Valve
Guide Driver
Tool
JDG504
Used to remove and
install valve guides.
5.5 mm Valve
Guide Reamer
JDG1023
Used to ream valve
guides.
PLASTIGAGE
™
NA
Used to check
connecting rod-tocrankshaft clearance.
PM38651 QUICK METAL™
(US)
660
(LOCTITE
™
PM38612
(Canada)
Other Materials
Other Material
Part No.
Part Name
Part Use
NA
Multi-Purpose
Grease
Prevents parts from
seizing. Apply to
engine crankshaft.
NA
Abrasive Sheet/Pad
Clean cylinder head.
NA
Stanisol (or
Kerosene)
Finish ream valve
guides.
NA
Prussian Blue
Compound
Check valve seat
contact.
NA
Lapping Compound
Lap valves into valve
seats.
NA
Lithium-Based
Grease
Pack oil seals.
NA
Zinc Oxide/Wood
Alcohol
Check block for
cracks.
Part Name
Engine - Gas Tools and Materials - 25
Part Use
Apply to inside of
limiter cap before
installation.
ENGINE - GAS COMPONENT LOCATION AND OPERATION
Component Location and Operation
External Engine Components
B
A
C
J
I
H
D
E
G
F
MX24123
A- Air Cleaner
B- Muffler
C- Fuel Tank
D- Oil Dipstick
E- Oil Drain Plug
F- Blower Housing
G- Recoil Starter
H- Fuel Shutoff Lever
I- Choke Lever
J- Carburetor
Engine - Gas Component Location and Operation - 26
ENGINE - GAS COMPONENT LOCATION AND OPERATION
A
B
C
D
K
E
F
G
J
H
I
MX24124
A- Fuel Tank
B- Muffler
C- Air Cleaner
D- Spark Plug Lead
E- Carburetor
F- Breather Hose
G- Rocker Arm Cover
H- Cylinder Head
I- Oil Drain Plug
J- PTO Output Shaft
K- Crankcase Cover
Engine - Gas Component Location and Operation - 27
ENGINE - GAS COMPONENT LOCATION AND OPERATION
Internal Engine Components
F
G
E
C
H
I
B
D
A
J
K
L
M
N
O
MIF (M83928)
A- Governor Gear
B- Governor Shaft
C- Governor Drive Gear
D- Connecting Rod
E- Piston
F- Piston Pin
G- Valve Spring
H- Valve Rotator (Exhaust Valve Only)
I- Rocker Arm
J- Push Rod Guide
K- Valve Guide
L- Push Rod
M- Tappet
N- Camshaft
O- Connecting Rod Oil Dipper
Engine - Gas Component Location and Operation - 28
ENGINE - GAS COMPONENT LOCATION AND OPERATION
Lubrication System Operation
A
B
C
D
I
H
E
B
C
F
G
H
MX6083
A- Connecting Rod Journal
B- Crankshaft
C- Well
D- Oil Supply Passage
E- Oil Supply Passage
F- Oil Return Passage
G- Camshaft
H- Oil Dipper
I- Oil Supply Passage
Engine - Gas Component Location and Operation - 29
ENGINE - GAS COMPONENT LOCATION AND OPERATION
Function
To provide oil to lubricate internal engine components.
Theory of Operation
The Honda GX120 uses a “splash” lubrication system
combined with a system of wells and passages to distribute
oil throughout the engine.
A dipper attached to the connecting rod cap is immersed
into the crankcase oil supply at each revolution of the
crankshaft. With the engine running, the dipper “splashes”
oil onto internal engine components, including camshaft
lobes, cylinder walls, tappets, piston pin and crankshaft ball
bearings.
Oil for the connecting rod journal is supplied by a small
passage on the underside of the connecting rod. Oil for the
camshaft and PTO shaft journals is collected in “wells”
located on the top of holders in the cylinder block and
crankcase covers and is routed to the journals by small
passages.
Oil is supplied to the rocker arms, valves and push rods by
a passage in the cylinder block and head. Oil returns to the
crankcase through a passage located between the tappets.
Engine - Gas Component Location and Operation - 30
ENGINE - GAS COMPONENT LOCATION AND OPERATION
Cooling System Operation
generated by the engine to the passing air. A high
proportion of the cooling air flows over the valve area in the
head, preventing valve sticking and seat wear due to
overheating.
Function
To remove heat from the engine.
Theory of Operation
The engine is air-cooled, with air flow provided by a fan
mounted to the flywheel. With the engine running, the fan
draws cooling air through openings in the recoil starter
housing. A blower housing and shrouds direct the cooling
air flow past fins cast into the cylinder head and block. The
increased surface area of the cooling fins transfers heat
It is important to maintain proper air flow by ensuring that
the air intake openings on the recoil starter housing and the
cooling fins on the cylinder block and head remain free of
debris. The engine cooling air shroud should not be
removed or altered, as cooling capacity will be reduced.
Cylinder block and head cooling fins must remain clean to
properly dissipate heat.
A
B
E
C
D
MX24125
A- Cooling Fins
B- Cylinder Head
C- Flywheel Fan
D- Fan Housing
E- Shroud
Engine - Gas Component Location and Operation - 31
ENGINE - GAS DIAGNOSTICS
Diagnostics
No: Adjust air gap.
Engine Cranks But Will Not Start
9. Check flywheel for damage. Test that flywheel
magnet has not become demagnetized. (See “Test
Flywheel Magnet” on page 158.) Is flywheel in good
condition?
Engine Cranks But Will Not Start
1. Does choke operate properly?
Yes: Go to next step.
Yes: Go to next step.
No: Replace flywheel. (See “Remove and Install
Flywheel” on page 56.)
No: Repair choke.
2. Is fuel in tank fresh, clean and of proper grade?
Yes: Go to next step.
No: Replace fuel in tank and lines with fresh, clean fuel
of proper grade.
3. Remove spark plug. Is the spark plug tip clear of any
drops of fuel?
Yes: Go to next step.
No: Possible incorrect use of choke. Clean spark plugs
and set choke properly.
10. Is cylinder compression within specification? (See
“Test Cylinder Compression Pressure” on page 37.)
Yes: Go to next step.
No: Repair or replace engine as necessary. (See
“Remove and Install Engine” on page 44. See
“Disassemble and Assemble Cylinder Head and
Valves” on page 58. See “Inspect Cylinder Head and
Valves” on page 58. See “Analyze Piston Ring Wear”
on page 72.)
11. Is fuel flow from tank adequate?
No: Check for plugged air cleaner.
Yes: Go to next step.
No: Check float level for proper adjustment. (See
“Adjust Float Level” on page 51.)
No: Replace fuel filter. (See “Remove and Install Fuel
Filter” on page 43.)
4. Is the correct spark plug installed and properly
adjusted?
12. Is carburetor clean and free of any build up in fuel
and air passages? (See “Remove and Install
Carburetor” on page 47.)
Yes: Go to next step.
No: Properly adjust and install the correct spark plug.
5. The ignition system should produce a steady, strong
blue spark. (See “Test Spark” on page 39.) Is the spark
weak or is there no spark at all?
Yes: Go to next step.
No: Ignition system operation is satisfactory. Go to step
10.
No: Check for error codes or electrical system problem.
(See “System: Ignition Circuit Diagnosis” on page 108.)
6. Disconnect yel/red wire connector leading to ignition
coil. Test for infinite resistance between yel/red wire
and engine ground with run/off switch in run position.
Does meter show infinite resistance?
No: Clean carburetor as necessary.
Engine Runs Poorly at Low RPM
Engine Runs Poorly at Low RPM
1. Is the correct spark plug installed and properly
adjusted?
Yes: Go to next step.
No: Install and properly adjust the correct spark plug.
2. Is slow idle speed adjusted properly? (See “Adjust
Slow Idle Speed” on page 36.)
Yes: Go to next step.
No: Adjust slow idle speed.
3. Is governor linkage operating properly? (See “Adjust
Governor and Fast Idle Speed” on page 37.)
Yes: Go to next step.
No: Repair short circuit as required.
7. Does ignition coil test OK? (See “Test Ignition Coil”
on page 55.)
Yes: Go to next step.
No: Adjust governor linkage.
Yes: Go to next step.
4. Is choke operating properly?
No: Replace ignition coil.
Yes: Go to next step.
8. Is air gap between ignition coil and flywheel adjusted
properly? (See “Adjust Air Gap” on page 55.)
No: Repair carburetor. (See “Clean and Inspect
Carburetor” on page 50.)
Yes: Go to next step.
Engine - Gas Diagnostics - 32
ENGINE - GAS DIAGNOSTICS
5. Does the ignition system produce a steady, strong
blue spark? (See “Test Spark” on page 39.)
Yes: Go to next step.
Carburetor” on page 50.)
3. Is governor spring in good condition?
Yes: Go to next step.
No: Follow “Results” of the spark test procedure.
No: Replace governor spring.
6. Is engine operating at normal temperature - engine
not overheating?
4. Is fast idle speed adjusted properly? (See “Adjust
Governor and Fast Idle Speed” on page 37.)
Yes: Go to next step.
Yes: Go to next step.
No: Engine load may be excessive. Reduce engine
load. Possible electrical load. (See “Symptom: Engine
Won’t Start or Feels Loaded While Starting” on
page 109.)
No: Adjust fast idle speed.
No: Clean cooling intake screen, engine shrouding,
and cooling fins.
Yes: Go to next step.
7. Is cylinder compression within specification? (See
“Test Cylinder Compression Pressure” on page 37.)
Yes: Go to next step.
5. Does the ignition system produce a steady, strong
blue spark? (See “Test Spark” on page 39.)
No: Follow “Results” of the spark test procedure. Go to
next step if problem continues.
6. Does ignition coil test OK? (See “Test Ignition Coil”
on page 55.)
No: Repair or replace engine as necessary. (See
“Remove and Install Engine” on page 44. See
“Disassemble and Assemble Cylinder Head and
Valves” on page 58. See “Inspect Cylinder Head and
Valves” on page 58. See “Analyze Piston Ring Wear”
on page 72.)
Yes: Go to next step.
8. Are valves properly adjusted? (See “Check and
Adjust Valve Clearance” on page 38.)
No: Engine load may be excessive. Reduce engine
load.
Yes: Go to next step.
No: Adjust valve clearance.
No: Clean cooling intake screen, engine shrouding,
and cooling fins.
9. Are carburetor and intake manifold flanges properly
sealed - no air leaks?
8. Is cylinder compression within specification? (See
“Test Cylinder Compression Pressure” on page 37.)
Yes: Go to next step.
Yes: Go to next step.
No: Seal flanged surfaces as required. (See “Remove
and Install Carburetor” on page 47.)
No: Repair or replace engine as necessary. (See
“Remove and Install Engine” on page 44. See
“Disassemble and Assemble Cylinder Head and
Valves” on page 58. See “Inspect Cylinder Head and
Valves” on page 58. See “Analyze Piston Ring Wear”
on page 72.)
10. Is carburetor clean and free of any build up in fuel
and air passages? (See “Clean and Inspect
Carburetor” on page 50.)
No: Clean carburetor as necessary.
No: Replace ignition coil(s).
7. Is engine operating at normal temperature - engine
not overheating?
Yes: Go to next step.
9. Are valves properly adjusted? (See “Check and
Adjust Valve Clearance” on page 38.)
Engine Runs Poorly at High RPM
Yes: Go to next step.
Engine Runs Poorly at High RPM
No: Adjust valve clearance.
1. Is the correct spark plug installed and properly
adjusted?
Yes: Go to next step.
No: Install and properly adjust the correct spark plug.
2. Is choke operating properly?
10. Is fuel flow from tank adequate?
Yes: Go to next step.
No: Replace fuel filter. (See “Remove and Install Fuel
Filter” on page 43.)
Yes: Go to next step.
11. Is float level in carburetor properly adjusted? (See
“Adjust Float Level” on page 51.)
No: Repair carburetor. (See “Clean and Inspect
Yes: Go to next step.
Engine - Gas Diagnostics - 33
ENGINE - GAS DIAGNOSTICS
No: Adjust float level.
Yes: Go to next step.
12. Are carburetor and intake manifold flanges properly
sealed - no air leaks?
No: Repair as necessary.
Yes: Go to next step.
No: Clean oil ring grooves. (See “Remove Piston and
Connecting Rod” on page 66.)
No: Seal flanged surfaces as required. (See “Remove
and Install Carburetor” on page 47.)
13. Is carburetor clean and free of any build-up in fuel
and air passages? (See “Clean and Inspect
Carburetor” on page 50.)
7. Are the oil ring grooves clear of obstructions?
Engine Overheats
Engine Overheats
1. Is engine being operated under normal operating
conditions?
Yes: Go to next step.
No: Clean carburetor as necessary.
Yes: Go to next step.
14. Is governor assembly in good condition with no
binding?
No: Repair as necessary. (See “Remove and Install
Governor” on page 78.)
Excessive Oil Consumption
No: Adjust mower operation to comply with normal
operating conditions. (See owner’s manual for more
information.)
2. Is flywheel intake screen clear of debris?
Yes: Go to next step.
No: Clean screen of debris.
Excessive Oil Consumption
1. Is engine oil the correct viscosity for conditions?
3. Are engine cooling shrouds in place?
Yes: Go to next step.
Yes: Go to next step.
No: Drain oil from engine and replace with oil of proper
viscosity.
2. Is engine filled with oil to the proper level on the
dipstick (crankcase not excessively full)?
No: Repair or replace shrouds as needed.
4. Are flywheel fan and engine cooling fins free of
obstruction or debris and not damaged?
Yes: Go to next step.
No: Clean or repair as necessary.
Yes: Go to next step.
No: Drain excessive engine oil.
Excessive Fuel Consumption
3. Is cylinder compression within specification? (See
“Test Cylinder Compression Pressure” on page 37.)
Excessive Fuel Consumption
Yes: Go to next step.
1. Is choke operating properly?
No: Repair or replace engine as necessary. (See
“Remove and Install Engine” on page 44. See
“Disassemble and Assemble Cylinder Head and
Valves” on page 58. See “Inspect Cylinder Head and
Valves” on page 58. See “Analyze Piston Ring Wear”
on page 72.)
Yes: Go to next step.
4. Is the breather valve functioning properly?
Yes: Go to next step.
Yes: Go to next step.
No: Install and properly adjust the correct spark plug.
No: Clean or replace breather valve. (See “Remove
and Install Rocker Arm Cover” on page 56.)
3. Remove spark plugs. Are the spark plug tips clear of
any drops of fuel?
5. Is the drain in the breather chamber clear of
obstructions?
Yes: Go to next step.
Yes: Go to next step.
No: Clear obstructions from drain in breather chamber.
No: Possible incorrect use of choke. Clean spark plugs
and set choke properly.
6. Are the valve guides in good condition and not worn
excessively?
No: Check float level for proper adjustment. (See
“Adjust Float Level” on page 51.)
No: Repair carburetor. (See “Clean and Inspect
Carburetor” on page 50.)
2. Is the correct spark plug installed and properly
adjusted?
No: Check for plugged air cleaner.
Engine - Gas Diagnostics - 34
ENGINE - GAS DIAGNOSTICS
4. The ignition system should produce a steady, strong
blue spark. (See “Test Spark” on page 39.) Is the spark
weak or is there no spark at all?
Yes: Go to next step.
No: The ignition system is operating satisfactorily. Go
to step 6.
5. Do ignition coils test OK? (See “Test Ignition Coil” on
page 55.)
Yes: Go to next step.
No: Replace ignition coil(s).
6. Is cylinder compression within specification? (See
“Test Cylinder Compression Pressure” on page 37.)
Yes: Go to next step.
No: Repair or replace engine as necessary. (See
“Remove and Install Engine” on page 44. See
“Disassemble and Assemble Cylinder Head and
Valves” on page 58. See “Inspect Cylinder Head and
Valves” on page 58. See “Analyze Piston Ring Wear”
on page 72.)
7. Is slow idle speed adjusted properly? (See “Adjust
Slow Idle Speed” on page 36.)
Yes: Go to next step.
No: Adjust slow idle speed.
8. Is fast idle speed adjusted properly? (See “Adjust
Governor and Fast Idle Speed” on page 37.)
Yes: Go to next step.
No: Adjust fast idle speed.
9. Are cylinder head cap screws properly torqued - not
loose?
No: Torque cylinder head cap screws. (See “Remove
and Install Cylinder Head and Valves” on page 57.)
Engine - Gas Diagnostics - 35
ENGINE - GAS TESTS AND ADJUSTMENTS
Tests and Adjustments
Adjust Slow Idle Speed
Check and Adjust Throttle Cable
Important: Avoid Damage! DO NOT attempt to
adjust the carburetor unless you are a factory
trained technician with authorization to service
EPA/CARB Certified Emissions Carburetors.
Reason
To make sure the throttle control lever allows full range of
engine speeds.
Procedure
Reason
1. Park machine on a level surface.
To ensure that the engine is running at proper slow idle
rpm.
2. Move PTO switch to OFF position.
Special or Required Tools
Tool Name
3. Move run/off switch to OFF position.
Digital Pulse
Tachometer
4. Move travel clutch lever to released position.
5. Lock park brake.
6. Move handlebar engine speed control to slow idle
position.
Tool No.
JT07270
Tool Use
Used to check/adjust
engine slow and fast
idle rpm.
Procedure
1. Park machine on a level surface.
2. Move PTO switch to OFF position.
3. Move travel clutch lever to released position.
A
C
4. Lock park brake.
B
5. Start and run engine for five minutes to bring to
operating temperature.
D
6. Move throttle to slow idle position.
MX42916
7. Remove engine air cleaner assembly.
A
8. Loosen screw (A) securing throttle cable to engine
throttle lever swivel.
B
9. Move throttle to fast idle stop to ensure that throttle lever
(B) clears throttle cable housing end (C).
10.Check to see that throttle return spring pulls throttle
lever against low speed idle stop (D).
11.Tighten screw (A) with throttle lever against low speed
stop.
12.Start engine and move throttle lever from slow to fast to
slow positions to verify operation.
M83912
7. Hold a JT07270 Digital Pulse Tachometer at spark plug
lead (A).
8. Adjust slow idle adjustment screw (B) until the engine is
running at specified slow idle speed.
Specifications
Slow Idle Speed . . . . . . . . . . . . . . . . . . . . 1700 ± 100 rpm
Engine - Gas Tests and Adjustments - 36
ENGINE - GAS TESTS AND ADJUSTMENTS
Adjust Governor and Fast Idle Speed
Reason
To ensure that the engine is running at proper fast idle rpm.
Special or Required Tools
Tool Name
Digital Pulse
Tachometer
Tool No.
JT07270
Tool Use
D
Used to check/adjust
engine slow and fast
idle rpm.
Procedure
MX6001
1. Park machine on a level surface.
2. Move PTO switch to OFF position.
14.Adjust fast idle adjustment screw (D) until the engine is
running at specified fast idle speed.
3. Move run/off switch to OFF position.
Specifications
4. Move travel clutch lever to released position.
Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . 2950 ± 150 rpm
5. Lock park brake.
6. Remove fuel tank. (See “Remove and Install Fuel Tank”
on page 42.)
Test Cylinder Compression Pressure
Reason
To determine the condition of the piston, rings, cylinder
walls and valves.
Special or Required Tools
Tool Name
Compression
Gauge
C
B
Tool No.
JDM-59
Tool Use
Used to check engine
compression.
Procedure
A
c Caution:
Avoid Injury! Engine components,
especially the muffler, are HOT. Be careful
MX6000
7. Loosen M6 hex nut (A) securing governor arm to
governor shaft (B).
8. Move governor arm (C) to allow the throttle to open fully.
9. Rotate governor shaft as far as it will go in the same
direction. Tighten nut to secure arm on shaft.
10.Install fuel tank.
11.Start and run engine for five minutes to bring to
operating temperature.
not to touch while making adjustments.
Wear protective eye glasses and clothing.
Important: Avoid Damage! Ground the spark plug
high tension lead before turning the engine over to
check compression. Failure to ground the high
tension lead may result in ignition system damage.
1. Run engine for five minutes to bring to operating
temperature.
2. Park machine on a level surface.
12.Move throttle to fast idle position.
3. Move PTO switch to OFF position
13.Hold a JT07270 Digital Pulse Tachometer at spark plug
lead.
4. Move run/off switch to OFF position.
5. Move travel clutch lever to released position.
6. Lock park brake.
7. Remove spark plug.
Engine - Gas Tests and Adjustments - 37
ENGINE - GAS TESTS AND ADJUSTMENTS
Check and Adjust Valve Clearance
Reason
To ensure proper opening and closing of the intake and
exhaust valves.
A
Special or Required Tools
Tool Name
Feeler Gauge
(Blade Type)
Tool No.
NA
Tool Use
Used to measure
intake and exhaust
valve clearance.
Check Procedure
MX6002
Important: Avoid Damage! Perform adjustment
when engine is cold.
8. Install compression gauge (A) in spark plug hole.
1. Park machine on a level surface.
9. Ground high tension (spark plug) lead.
2. Move PTO switch to OFF position.
10.Move throttle control lever to fast idle position.
3. Move run/off switch to OFF position.
11.Pull recoil starter (full strokes) several times and record
highest gauge reading. Compare compression pressure
reading to specification.
4. Move travel clutch lever to released position.
5. Lock park brake.
6. Allow engine to cool.
Results
7. Remove spark plug.
Note: Specification listed is for an engine that has had
sufficient run time to allow rings to fully seat.
8. Ground high tension (spark plug) lead.
Compression that is lower than specifications on low
hour machines probably does not indicate a problem.
• If observed compression pressure is above
specification, adjust valves and check fuel and air intake
systems. Check exhaust for restriction.
• If pressure is below specification, squirt clean engine oil
into cylinder and repeat test (one squirt from oil can).
• If compression pressure DOES NOT increase after
retest, check for leaking intake or exhaust valves, valve
seats or cylinder head gasket. Replace parts as necessary.
• If compression pressure INCREASES after retest,
check rings, piston, and cylinder bore for broken rings,
scoring, wear, or damage. Replace parts as necessary.
9. Remove rocker arm cover. (See “Remove and Install
Rocker Arm Cover” on page 56.)
10.Slowly rotate engine crankshaft with recoil starter until
piston approaches top dead center (TDC) of compression
stroke (both intake and exhaust valves will be closed).
Note: Starter pulley indicator mark is visible at TDC of
both compression and exhaust strokes. Check and
adjust valve clearance with both valves closed at TDC
of compression stroke.
B
Specifications
Cylinder Compression
Pressure . . . . . . . . . . . . . . . . . 586-834 kPa (85-121 psi)
Spark Plug Torque
. . . . . . . . . . . . . . . . . . . . . . . . Hand Tight + 1/2 Turn With
New Plug
. . . . . . . . . . . . . . . . . . . . . . . Hand Tight + 1/8 to 1/4 Turn
for Used Plug
A
MX42926
11.Stop engine rotation with triangular mark (A) on engine
starter pulley aligned with top hole (B) of recoil starter
housing at TDC of compression stroke.
Engine - Gas Tests and Adjustments - 38
ENGINE - GAS TESTS AND ADJUSTMENTS
Test Spark
C
Reason
To test the overall condition of the ignition system.
Special or Required Tools
Tool Name
Tool No.
Tool Use
Spark Tester
D-05351ST
Used to check overall
condition of ignition
system.
Procedure
M83877
12.Use a blade-type feeler gauge (C) to measure valve
clearance.
1. Park machine on a level surface.
2. Move PTO switch to OFF position.
3. Move run/off switch to OFF position.
Check Procedure Results
If valve clearance does not meet specifications, perform
“Adjustment Procedure.”
4. Move travel clutch lever to neutral position.
5. Lock park brake.
6. Remove high tension lead from spark plug.
Adjustment Procedure
A
B
A
M83876
1. Hold rocker arm pivot and loosen rocker arm locknut (A).
2. Turn the rocker arm pivot to obtain specified clearance.
3. Tighten rocker arm pivot locknut to specification while
holding the rocker arm pivot.
4. Recheck clearance after tightening locknut.
5. Reinstall valve cover and secure with four M6x10 hex
head bolts. Tighten bolts to specification.
6. Reinstall spark plug and tighten to specification.
7. Install timing mark plug to fan housing.
Specifications
Intake Valve
Clearance . . . . . . . . 0.15 ± 0.02 mm (0.006 ± 0.001 in.)
Exhaust Valve
Clearance . . . . . . . . 0.20 ± 0.02 mm (0.008 ± 0.001 in.)
Rocker Arm Pivot Locknut Torque . . 10 N•m (84 lb-in.)
MX6003
7. Connect lead (A) of D-05351ST Spark Tester to spark
plug.
8. Connect high tension lead (B) to spark tester.
Important: Avoid Damage! DO NOT adjust spark
tester gap beyond 5.0 mm (0.200 in.) (5 turns), as
damage to ignition system could occur.
9. Adjust spark tester gap to 4.2 mm (0.166 in.) (4 turns)
with screw.
10.Pull recoil starter (full strokes) several times and watch
spark at spark tester. If engine will start, watch spark with
engine running. A steady, strong blue spark should be
observed.
Engine - Gas Tests and Adjustments - 39
ENGINE - GAS TESTS AND ADJUSTMENTS
Results
• If spark is weak, or no spark is present, install a new
spark plug and repeat test.
• If spark is still weak, or no spark is present, run tests on
individual components to find the cause of the malfunction.
A
Adjust Spark Plug Gap
Reason
To ensure correct spark plug gap for maximum
performance.
Special or Required Tools
Tool Name
Feeler Gauge
Tool No.
NA
Tool Use
Used to measure
spark plug gap.
MX42922
10.Check spark plug electrode gap (A) using a feeler
gauge. Set gap to specification.
11.Inspect spark plug sealing washer. Replace washer if
necessary.
12.Install plug finger-tight until washer is seated. Using a
spark plug wrench, tighten plug an additional 1/2 turn if a
new plug (or 1/8-1/4 turn for a used plug) to compress
washer.
Procedure
1. Park machine on a level surface.
2. Move PTO switch to OFF position.
Specifications
3. Move run/off switch to OFF position.
4. Move travel clutch lever to neutral position.
5. Lock park brake.
c Caution:
Avoid Injury! Engine components,
especially the muffler, are HOT. Be careful
not to touch while making adjustments.
Wear protective eye glasses and clothing.
Spark Plug Gap. . . . . . . . . . 0.7-0.8 mm (0.028-0.031 in.)
Spark Plug Torque
. . . . . . . . . . . . . . . . . . . . . . . . Hand Tight + 1/2 Turn With
New Plug
. . . . . . . . . . . . . . . . . . . . . . . Hand Tight + 1/8 to 1/4 Turn
for Used Plug
Adjust Alternator Belt
1. Remove belt cover and check belt tension. Belt should
deflect approximately 12 mm (1/2 in.) with 98 N (22 lb)
force (moderate thumb pressure) applied midway between
sheaves.
6. Allow engine to cool.
7. Remove spark plug.
Important: Avoid Damage! DO NOT clean spark
plug with sandpaper or abrasives. Engine
scoring can result from abrasives entering the
cylinder.
2. Adjust belt if deflection is not to specification.
A
8. Scrape or wire brush deposits from spark plug.
9. Inspect plug for cracked insulator or damaged
electrodes. Replace if any damage is apparent.
B
MX43197
Engine - Gas Tests and Adjustments - 40
ENGINE - GAS TESTS AND ADJUSTMENTS
C
MX42760
3. Loosen bolts (B and C).
4. Insert a 3/8 in. drive torque wrench to alternator bracket
square socket (A), and rotate alternator assembly forward
with a force of 27 N•m (239 lb-in.)
5. Tighten two M8 hex head bolts (B) securing alternator
mounting bracket while holding specified force on bracket.
6. Tighten M6 bolt (C) at alternator support bracket.
7. Check belt tension.
D
E
MX42759
8. Install cover (D) and secure with three M6 bolts (E).
Specifications
Alternator Belt Deflection
. . . . . . . . . . . . . . . . . . . . . 12mm @ 98 N (1/2 in. @ 22 lb)
Alternator Mounting Bracket Bolts (M8)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N•m (20 lb-ft)
Alternator Support Bracket Bolt (M6) 10 N•m (84 lb-in.)
Engine - Gas Tests and Adjustments - 41
ENGINE - GAS REPAIR
Repair
C
Remove and Install Fuel Tank
c Caution:
Avoid Injury! Gasoline is extremely
flammable. Gasoline vapor is explosive.
AVOID SMOKING. Always work in a
ventilated area away from open flame or
spark producing equipment, including
appliances with pilot flames.
1. Remove air cleaner assembly. (See “Remove and Install
Air Cleaner Assembly” on page 45.)
MX6006
4. Remove M6 hex head bolt (C).
D
E
MX42919
A
5. Remove two M6 flange nuts (E) and secured ground
wires (D).
MX6004
2. Remove drain plug (A) and drain fuel from carburetor
sediment cup to a properly marked container large enough
to hold fuel tank capacity.
6. Remove fuel tank.
7. Inspect fuel tank for signs of wear or damage. Replace if
necessary.
8. Inspect fuel filter. Clean and/or replace if necessary.
(See “Remove and Install Fuel Filter” on page 43.)
Installation
Installation is done in the reverse order of removal.
• Install ground wires to fuel tank studs as originally
installed.
B
•
Tighten cap screw and flange nuts to specification.
• Inspect for leaks. Repair leaks and wipe up spilled fuel
before starting engine.
MX6005
3. Disconnect fuel line (B) at carburetor.
Specifications
Fuel Tank Capacity (Approx). . . . . . . . . . 2.5 L (0.66 gal)
Fuel Tank Mounts . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Engine - Gas Repair - 42
ENGINE - GAS REPAIR
Remove and Install Fuel Filter
E
A
D
A
B
M83753
1. Remove fuel tank. (See “Remove and Install Fuel Tank”
on page 42.)
MX42927
4. Remove M6 hex nut (D) securing throttle cable clamp.
5. Disconnect cable end (E) at throttle lever.
2. Remove fuel line.
3. Remove fuel filter (B) with O-ring (A).
Installation
4. Clean and inspect fuel filter. Replace if necessary.
Installation is done in the reverse order of removal.
•
Installation
Installation is done in the reverse order of removal.
•
Install new throttle cable with dust cap at upper end.
• Adjust throttle cable. (See “Check and Adjust Throttle
Cable” on page 36.)
Tighten fuel filter to specification.
Remove and Install Muffler
Specifications
Fuel Filter Torque . . . . . . . . . . . . . . . . . 2 N•m (17 lb-in.)
Remove and Install Throttle Cable
c Caution:
Avoid Injury! To prevent possible
burns, allow engine to cool before removing
muffler.
1. Remove handlebar cover. (See “Remove and Install
Handlebar Cover” on page 198.)
2. Remove air cleaner cover and element. (See “Remove
and Install Air Cleaner Assembly” on page 45.)
A
C
MX42759
B
1. Remove three M6 socket pan head bolts securing
electronics/belt guard to electronics bracket.
A
MX6007
2. Remove guard.
3. Loosen clamp (A) and screw (B). Remove cable
assembly (C) from throttle plate.
Engine - Gas Repair - 43
ENGINE - GAS REPAIR
E
A
B
D
MX43198
3. Remove two M8 hex nuts (A) and bracket bolts (B)
securing muffler to cylinder head.
MX42759
3. Remove three M6 socket pan head bolts (D) securing
electronics/belt cover (E). Remove cover.
4. Remove muffler and gasket.
Installation
Installation is done in the reverse order of removal.
•
Use new gasket for installation.
•
Tighten mounting nuts to specification.
•
Reinstall electronics/belt cover
G
Specifications
F
H
Muffler Mounting Nut Torque . . . . . 24 N•m (204 lb-in.)
MX42760
Remove and Install Engine
1. Remove air cleaner cover and element. (See “Remove
and Install Air Cleaner Assembly” on page 45.)
4. Loosen M6 hex head alternator pivot bolt (F) and M8
hex head bolt (G) securing generator bracket to electronics
bracket.
5. Rotate alternator toward engine sheave, and release
drive belt (H) from alternator sheave.
B
A
J
I
C
MX6006
2. Loosen screw (A) securing cable clamp. Loosen screw
(B) securing cable to throttle lever. Remove throttle cable
assembly (C).
MX42846
6. Rotate alternator with mounting bracket (I) away from
engine sheave, and remove traction drive belt (J) from
engine sheave.
Engine - Gas Repair - 44
ENGINE - GAS REPAIR
14.Remove drain plug (L), and drain crankcase into
suitable container. Dispose of oil properly.
Installation
Note: If the engine has been rebuilt (cylinder rebored
or deglazed, etc.), the oil should be changed after the
first 20 hours (maximum) of operation.
M
Installation is done in the reverse order of removal.
K
• Fill engine to proper level with oil meeting specifications.
(See “Engine Oil” on page 15.)
L
• Adjust alternator belt tension. (See “Drive Belt Tension
Check and Adjustment” on page 170.)
MX42919
7. Cut wire tie (K) securing wire harness connectors (L).
• Adjust throttle cable. (See “Check and Adjust Throttle
Cable” on page 36.)
8. Mark connectors for identification at reassembly and
separate connectors.
Specifications
9. Remove two M6 hex nuts (M) securing wire harness
ground terminals to engine.
I
Engine Oil Capacity . . . . . . . . . . . . . . . . . . 0.6 L (0.63 qt)
M8 Alternator Bracket Bolts . . . . . . . . . 28 N•m (20 lb-ft)
M6 Alternator Support Bracket Bolt . . 10 N•m (84 lb-in.)
Electronics/Belt Cover. . . . . . . . . . . . . 10 N•m (84 lb-in.)
Engine Mounts . . . . . . . . . . . . . . . . . . . . 28 N•m (20 lb-ft)
Wiring Harness Ground. . . . . . . . . . . . 10 N•m (84 lb-in.)
Remove and Install Air Cleaner Assembly
J
A
B
MX42920
C
10.Cut wire tie (I) securing wire harness to engine
mounting plate.
D
11.Remove two M8 hex head bolts (J) securing front
engine mounting bracket to machine frame.
E
F
G
L
K
MX21103
1. Remove wing nut (A) and cover (B).
MX42921
12.Remove two M8 hex flanged nuts (K) securing rear
engine mounting bracket to vibration isolators.
2. Remove wing nut (C), air cleaner (D) with precleaner
(E), seal (F), and base (G).
13.Remove engine.
Engine - Gas Repair - 45
ENGINE - GAS REPAIR
E
A
F
M83775
3. Move fuel shutoff valve lever (F) to off position.
4. Move choke lever (E) to partial choke position.
I
MX42928
H
J
•
Install gasket (A) with cutouts matching carburetor ports.
•
Tighten housing flange nuts to specification.
• Tighten air cleaner element and cover wing nuts to
specification.
G
Specifications
MX42923
Air Cleaner Wing Nut Torque . . . . . . . . 9 N•m (78 lb-in.)
Air Cleaner Housing Flange
Nut Torque . . . . . . . . . . . . . . . . . . . . . 8.5 N•m (73 lb-in.)
5. Remove two M6 flanged hex nuts (G).
Service of Air Cleaner
6. Remove M6x20 hex head bolt (H).
7. Remove air duct (I) along with breather hose (J).
8. Inspect and clean air filter element. Replace if
necessary. (See “Service of Air Cleaner” on page 46.)
9. Inspect gasket for damage. Replace if necessary.
Installation
Installation is done in the reverse order of removal.
Important: Avoid Damage! Carefully remove air
cleaner cover and elements. Inspect inside
paper element and intake passage for signs of
dust. If present, replace elements and test
engine compression or inspect for damage.
Anytime the air cleaner is removed, check for
free choke plate operation during reassembly.
1. Remove air cleaner cover and element. (See “Remove
and Install Air Cleaner Assembly” on page 45.)
B
A
M83884
Engine - Gas Repair - 46
ENGINE - GAS REPAIR
2. Remove foam precleaner element (A) from paper
element (B).
MX6012
4. Disconnect governor spring (D).
3. Wash foam element in warm, soapy water; rinse and
allow to dry thoroughly.
5. Remove two M6 hex head bolts (E).
Important: Avoid Damage! DO NOT clean paper
element with solvent or compressed air.
Installation
6. Remove throttle plate assembly.
Installation is done in the reverse order of removal.
4. Gently tap paper element to remove dust.
• Adjust throttle cable. (See “Check and Adjust Throttle
Cable” on page 36.)
5. Inspect paper element:
• Element is still usable if you can see light through it
and element appears clean.
•
Replace element if oily, dirty, or damaged in any way.
6. Inspect cover and housing for damage. Replace parts
as necessary.
7. Assemble and install air cleaner assembly.
Remove and Install Throttle Plate Assembly
1. Remove air cleaner assembly. (See “Remove and Install
Air Cleaner Assembly” on page 45.)
Remove and Install Carburetor
c Caution:
Avoid Injury! Gasoline and its
fumes are extremely flammable. AVOID
SMOKING. Always work in a ventilated area
away from open flame or spark producing
equipment, including equipment or
appliances with pilot flames.
1. Remove air cleaner assembly. (See “Remove and Install
Air Cleaner Assembly” on page 45.)
A
B
C
C
A
B
MX6006
2. Loosen clamp (A) and screw (B) securing throttle cable
to throttle plate.
3. Remove throttle cable (C) from throttle plate assembly.
MX6013
2. Remove drain plug (A) and drain fuel into a properly
marked container large enough to hold the fuel tank
capacity.
3. Move choke lever (B) to partially closed position. Move
fuel shutoff lever (C) to OFF position.
E
D
Engine - Gas Repair - 47
ENGINE - GAS REPAIR
E
K
F
J
L
M
D
MX42923
4. Remove two M6 hex nuts (D) and M6x20 hex head bolt
(E) securing air duct assembly to carburetor
5. Remove air duct assembly (F) from mounting studs,
while withdrawing breather tube from valve cover.
M83777
Throttle plate assembly removed for photo clarity
only.
9. Remove spark plug lead (J) from insulator (K).
10.Remove carburetor gasket (L), insulator, and insulator
gasket (M).
G
Installation
Installation is done in the reverse order of removal.
MX6005
6. Disconnect fuel line (G) at carburetor.
•
Use new gaskets for installation.
•
Tighten air cleaner housing flange nuts to specification.
• Adjust engine slow idle speed. (See “Adjust Slow Idle
Speed” on page 36.)
• Adjust engine fast idle speed. (See “Adjust Governor
and Fast Idle Speed” on page 37.)
H
Specifications
Fuel Tank Capacity (Approx). . . . . . . . . . 2.5 L (0.66 gal)
Air Cleaner Wing Nut . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Carburetor Air Duct . . . . . . . . . . . . . . 8.5 N•m (73 lb-in.)
Carburetor Sediment Cup . . . . . . . . . . 4 N•m (36 lb-in.)
I
M83776
7. Slide carburetor away from engine until slot (H) aligns
with governor linkage. Disconnect linkage and spring (I).
8. Remove carburetor.
Engine - Gas Repair - 48
ENGINE - GAS REPAIR
Disassemble and Assemble Carburetor
c Caution:
Avoid Injury! Gasoline and its
fumes are extremely flammable. AVOID
SMOKING. Always work in a ventilated area
away from open flame or spark producing
equipment, including equipment or
appliances with pilot flames.
C
A
D
F
E
B
aa
Z
G
H
Y
X
I
W
J
V
K
U
L
T
S
R
Q
M
N
P
O
M83879
A- Pilot Jet
B- Fuel Valve
C- Screw (2 used)
D- Plate
E- Spring
F- Choke Lever
G- Pin
H- Packing
I- Choke Plate
J- Packing
K- Sediment Cup
L- Float Valve
M- Washer
N- Drain Screw
O- Screw
P- Washer
Q- Float Chamber
R- Gasket
S- Float Pin
T- Float
U- Main Jet
V- Main Nozzle
W- Carburetor Body
X- Spring
Y- Limiter Cap
Z- Pilot Screw
AA- Throttle Stop Screw
Engine - Gas Repair - 49
ENGINE - GAS REPAIR
Clean and Inspect Carburetor
Important: Avoid Damage! DO NOT clean holes
or passages with small drill bits or wire.
Note: If all rubber or plastic parts cannot be removed
for cleaning, use a cleaning solvent with a high flash
point that will not damage these parts when cleaning.
Leave pilot screw and limiter cap in place during
cleaning. Removal of limiter cap requires breaking the
pilot screw. Remove only if replacement of screw is
required. If replacement is required, See “Replace Pilot
Screw and Limiter Cap” on page 50.
1. Remove rubber and plastic parts from carburetor. Soak
all carburetor metal parts in a carburetor cleaning solution
for 1/2 hour maximum.
c Caution:
Avoid Injury! Reduce compressed
air to less than 210 kPa (2 bar) (30 psi) when
using for cleaning purposes. Clear area of
bystanders, guard against flying chips, and
wear personal protection equipment
including eye protection.
Important: Avoid Damage! Rinse carburetor
parts in warm water to neutralize corrosive
action of cleaner on aluminum.
• Inspect float valve (D) and valve seat (A) for wear or
damage. The tip should be smooth, without any
grooves, scratches or tears. If worn or damaged,
replace the float assembly and carburetor body as a set.
• Check float level height. (See “Adjust Float Level” on
page 51.)
Replace Pilot Screw and Limiter Cap
Other Material
Part No.
Part Name
PM38651 QUICK METAL®
(US)
660
(LOCTITE
®
PM38612
(Canada)
Part Use
Apply to inside of
limiter cap before
installation.
Procedure
Note: Removal of limiter cap requires breaking the
pilot screw. Remove only if replacement of screw is
required.
1. Remove broken pilot screw.
A
2. Rinse carburetor parts in warm water and dry with
compressed air. DO NOT use rag or paper to dry parts; lint
can plug holes and passages in carburetor.
B
3. Inspect all parts for wear or damage:
• Inspect the carburetor body for wear or damage.
Verify all sealing surfaces and flanges are smooth and
free of nicks and burrs. Replace as necessary.
MIF (M83882)
2. Place spring (A) on pilot screw (B) and install screw in
carburetor.
A
3. Turn pilot screw in (clockwise) until lightly seated, then
turn out (counterclockwise) 1-5/8 turns.
D
C
B
MIF (M83880)
A- Valve Seat
B- Float Valve (Worn)
C- Float Valve (Good)
D- Float Valve
Engine - Gas Repair - 50
ENGINE - GAS REPAIR
Important: Avoid Damage! DO NOT allow the
pilot screw to turn while installing limiter cap.
Remove and Install Blower Housing
Assembly
Remove the engine blower housing and cooling air shrouds
as required to service ignition or lighting (optional
equipment) coil or to clean engine cooling fins.
C
c Caution:
Avoid Injury! Gasoline and its
fumes are extremely flammable. AVOID
SMOKING. Always work in a ventilated area
away from open flame or spark producing
equipment, including equipment or
appliances with pilot flames.
M83883
4. Apply LOCTITE 660 QUICK METAL to inside of limiter
cap (C).
Note: The blower housing can be removed with the
engine installed to the machine and with (optional)
lighting kit installed if the recoil starter assembly is
removed first.
1. Remove air cleaner assembly. (See “Remove and Install
Air Cleaner Assembly” on page 45.)
5. Install limiter cap on pilot screw.
Adjust Float Level
B
1. Assemble carburetor (minus the float chamber).
2. Place carburetor with engine-side mounting flange down
on a flat, level surface.
A
B
M83766
M83910
3. Measure the distance from the bottom of the float to the
carburetor body with the float valve resting against the seat
as shown. DO NOT compress the spring. Compare float
height measurement to specification.
2. Remove three M6x10 hex head bolts (A) securing recoil
starter assembly to blower housing. Remove starter
assembly.
3. Remove four M6x12 hex head bolts (B) securing blower
housing to engine.
4. Replace the float and/or float valve if the measurement
is out of specification.
Specifications
Float Height. . . . . . . . . . . . . . . . . . . . . 13.7 mm (0.54 in.)
Engine - Gas Repair - 51
ENGINE - GAS REPAIR
Remove and Install Recoil Starter
C
A
MX42925
4. Remove fuel line from clip (C) on blower housing.
5. Remove blower housing.
M83768
1. Remove three M6x10 hex head bolts (A) securing recoil
starter assembly to blower housing.
E
2. Remove starter assembly.
Installation
Installation is done in the reverse order of removal.
F
•
Remove dirt and debris before installation.
•
Position recoil starter for best starter grip location.
Disassemble and Inspect Recoil Starter
M83767
6. Remove two M6x12 hex head bolts (E) securing cooling
air shroud (F) to cylinder head.
7. Remove shroud.
c Caution:
Avoid Injury! Recoil spring is
wound under tension. DO NOT let spring fly
loose. Hold spring firmly in place while
replacing. Wear safety glasses and gloves
to protect yourself from possible injury.
Installation
Installation is done in the reverse order of removal.
Specifications
A
Air Shroud . . . . . . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Blower Housing . . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Recoil Starter Housing . . . . . . . . . . . . 10 N•m (84 lb-in.)
C
B
M83942
1. Hold reel (A) and carefully feed starter rope out until
there is enough slack to untie knot (B).
2. Remove starter grip (C).
3. Hold reel and slowly allow the spring to relieve tension.
Engine - Gas Repair - 52
ENGINE - GAS REPAIR
D
E
F
A
C
E
G
H
B
M83843
M83943
4. Loosen reel cover screw (D) and remove reel cover (E).
5. Remove snap ring (F), two ratchets (G) and two springs
(H).
1. Insert hook (A) on outer side of spring (B) into groove
(C) on inside of reel (E).
Note: Leave approximately 30 cm (12 in.) of rope
outside starter reel.
I
E
F
J
M83842
M83841
6. Remove the starter reel (I) and spring from the starter
case (J).
7. Inspect all parts for wear or damage. Replace parts as
necessary.
2. Route starter rope (E) through starter reel and tie a knot
(F) as shown. Wind starter rope around reel in direction of
arrow. Leave approximately 30 cm (12 in.) of rope outside
starter reel.
G
Assemble Recoil Starter
I
c Caution:
Avoid Injury! Recoil spring is
wound under tension. DO NOT let spring fly
loose. Hold spring firmly in place while
replacing. Wear safety glasses and gloves
to protect yourself from possible injury.
H
J
M83841
3. Install starter reel (G) on starter case (H) with spring
inner hook (I) anchored to case tab (J).
Engine - Gas Repair - 53
ENGINE - GAS REPAIR
Remove and Install Ignition Coil
1. Remove fuel tank. (See “Remove and Install Fuel Tank”
on page 42.)
G
2. Remove blower housing. (See “Remove and Install
Blower Housing Assembly” on page 51.)
3. Remove throttle plate assembly. (See “Remove and
Install Throttle Plate Assembly” on page 47.)
H
A
M83840
4. Hold starter case (H) and rotate starter reel (G) two
revolutions in direction of arrow for preliminary winding.
B
K
L
M83769
4. Disconnect spark plug lead (A) from spark plug and
remove lead from retainer (B).
M83839
5. Hold position of starter reel while routing starter rope
through starter case rope guide (K)
E
D
6. Route starter rope through starter grip (L) and tie as
shown.
7. Allow recoil spring to wind starter rope on reel until grip
contacts rope guide.
C
Q
P
M83770
M
5. Disconnect ground wire (C).
N
6. Remove two M6x25 hex head bolts (D) securing ignition
coil to engine.
O
7. Remove coil.
M83838
8. Install ratchets (M), springs (N), snap ring (O) and reel
cover (P). Install and tighten reel cover screw (Q).
9. Check operation of the ratchet by pulling the starter rope
several times.
Engine - Gas Repair - 54
ENGINE - GAS REPAIR
Test Ignition Coil
Installation
Installation is done in the reverse order of removal.
Primary Side
A
A
B
M83885
M83905
• Secure ignition wire into ribs (A) on crankcase and
through grommet.
•
Adjust air gap. (See “Adjust Air Gap” on page 55.)
Measure resistance between ignition coil primary (black)
lead (A) and iron core (B). Replace ignition coil if resistance
is not within specification.
Secondary Side
Note: A false reading will be obtained if the spark plug
cap is not removed.
Adjust Air Gap
1. Rotate flywheel so that smooth flywheel surface is under
ignition coil.
A
A
A
B
M83886
1. Remove spark plug cap.
MX42924
2. Loosen two M6x25 hex head bolts (A) securing ignition
coil to engine.
3. Insert a 0.4 mm (0.016 in.) feeler gauge (B) between
flywheel and ignition coil.
4. Push ignition coil against feeler gauge and flywheel
while tightening mounting bolts.
2. Measure resistance between the end of the spark plug
lead (B) and iron core (A). Replace ignition coil if resistance
is not within specification.
Specifications
Primary Side
Ignition Coil Resistance . . . . . . . . . . . . . . . . 0.8-1.0 ohm
5. Turn flywheel to remove feeler gauge.
Secondary Side
Specifications
Ignition Coil Resistance . . . . . . . . . . . . . 5.9-7.1 k-ohms
Ignition Coil Air Gap. . . . . . 0.4 ± 0.2 mm (0.016 ± 0.008
in.)
Ignition Coil. . . . . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Engine - Gas Repair - 55
ENGINE - GAS REPAIR
Remove and Install Flywheel
1. Remove ignition coil. (See “Remove and Install Ignition
Coil” on page 54.)
B
A
C
B
A
E
D
M83904
M83903
2. Remove M6 hex head bolt (A) and shield (B).
•
Align lug (A) on starter pulley with hole (B) on flywheel.
•
Tighten flywheel nut to specification.
3. Remove flywheel nut (C).
Specifications
4. Remove starter pulley (D) and cooling fan (E).
Flywheel Nut Torque . . . . . . . . . . . . . . . 75 N•m (54 lb-ft)
Important: Avoid Damage! Use a puller to
remove flywheel. Avoid attaching puller to the
magnet sections. To avoid possible damage, DO
NOT hit the flywheel with a hammer to loosen.
Remove and Install Rocker Arm Cover
A
B
F
G
A
M83906
5. Install puller to flywheel (G), avoiding magnet (F).
6. Remove flywheel and shaft key.
M83758
1. Remove four M6x12 bolts (A) securing rocker arm cover
to cylinder head.
2. Remove breather tube (B) from rocker arm cover.
Installation
Installation is done in the reverse order of removal.
3. Remove rocker arm cover and gasket.
Installation
Installation is done in the reverse order of removal.
• Remove gasket material for mating surfaces of head
and rocker arm cover before installation.
•
Use new gasket for installation.
Engine - Gas Repair - 56
ENGINE - GAS REPAIR
Remove and Install Cylinder Head and Valves
1. Remove carburetor. (See “Remove and Install
Carburetor” on page 47.)
9. Loosen four M8x55 hex head bolts in the sequence
shown.
10.Remove head bolts, cylinder head, and gasket.
2. Remove throttle plate assembly. (See “Remove and
Install Throttle Plate Assembly” on page 47.)
11.Disassemble and inspect cylinder head and valves.
(See “Inspect Cylinder Head and Valves” on page 58.)
3. Remove muffler. (See “Remove and Install Muffler” on
page 43.)
Installation
4. Remove blower housing. (See “Remove and Install
Blower Housing Assembly” on page 51.)
5. Remove rocker arm cover. (See “Remove and Install
Rocker Arm Cover” on page 56.)
Installation is done in the reverse order of removal.
•
Use new gaskets for installation.
Important: Avoid Damage! Torque should be
applied in the sequence shown, in increments.
6. Disconnect spark plug lead.
A
1
4
M83778
3
2
7. Remove rocker arm pivot locknuts (A), and remove
rocker arm pivots and rocker arms.
M83780
8. Remove push rods.
Important: Avoid Damage! Loosen cylinder head
cap screws 1/4 turn at a time in the sequence
shown to avoid warping the cylinder head.
• Tighten cap screws in the sequence shown to initial
torque. Finish tightening cylinder head to final torque.
• Adjust valve clearance. (See “Check and Adjust Valve
Clearance” on page 38.)
Specifications
1
Cylinder Head Cap Screw
Initial Torque. . . . . . . . . . . . . . . . . . . . 12 N•m (102 lb-in.)
Cylinder Head Cap Screw
Final Torque . . . . . . . . . . . . . . . . . . . . 24 N•m (204 lb-in.)
3
4
2
M83780
Engine - Gas Repair - 57
ENGINE - GAS REPAIR
Disassemble and Assemble Cylinder Head
and Valves
E- Push Rod Guide Plate
F- Push Rod (2 used)
G- Valve Rotator (Exhaust Valve Only)
H- Retainer (Exhaust)
I- Valve Spring (2 used)
J- Valve Guide (Exhaust)
K- Exhaust Valve
L- Intake Valve
M- Valve Guide (Intake)
N- Seal (Intake)
O- Retainer (Intake)
A
B
C
D
C
D
• Inspect all parts for wear or damage. (See “Inspect
Cylinder Head and Valves” on page 58.)
E
F
Important: Avoid Damage! If valve rotator is not
installed, exhaust valve may drop into cylinder
when engine is started.
G
H
F
• Apply a light coat of clean engine oil to intake and
exhaust valve stems during assembly.
•
I
Tighten rocker arm pivot bolt to specification.
Specifications
O
J
Rocker Arm Pivot Bolt Torque . . . . . 24 N•m (204 lb-in.)
I
Inspect Cylinder Head and Valves
N
Other Material
M
Part No.
NA
Part Name
Part Use
Abrasive Sheet/Pad
Clean cylinder head.
Cylinder Head
1. Remove carbon deposits from combustion chamber
using abrasive pads or an equivalent.
c Caution:
Avoid Injury! Reduce compressed
air to less than 210 kPa (2 bar) (30 psi)
when using for cleaning purposes. Clear
area of bystanders, guard against flying
chips, and wear personal protection
equipment including eye protection.
K
2. Clean head with a suitable solvent and dry with
compressed air.
L
3. Inspect head for cracks or broken cooling fins.
MX42951
A- Rocker Arm Locknut (2 Used)
B- Rocker Arm Pivot (2 Used)
C- Rocker Arm (2 Used)
D- Rocker Arm Pivot Bolt (2 used)
4. Inspect gasket surface for burrs and nicks.
Engine - Gas Repair - 58
ENGINE - GAS REPAIR
Valve Seats
A
M83845
5. Use a straightedge and feeler gauge (A) to check head
for distortion at several points around head. Replace head
if distortion is greater than specification.
Valve Guides
1. Clean inside of valve guides with a valve guide cleaner.
M83847
Measure valve seat width. Recondition valve seat if
measurement is less than minimum specification or greater
than maximum specification.
Valve Springs
1. Inspect springs for pitting, rust and burrs. Replace if
necessary.
M83846
2. Measure inside diameter of valve guides. Compare
valve guide measurement to specification. Replace valve
guides if inside diameter is greater than wear limit. (See
“Replace Valve Guide” on page 60.)
3. Subtract the outside diameter of the valve stems from
inside diameter of valve guides to determine guide-to-stem
clearance.
4. If guide-to-stem clearance exceeds wear limit,
determine if new guides would bring clearance within
specifications. If so, replace guides. (See “Replace Valve
Guide” on page 60.) If guide-to-stem clearance would still
exceed wear limit, replace both guides and valves.
M50036
2. Measure spring free length. Replace spring if
measurement is less than specification.
Intake and Exhaust Valves
1. Remove carbon from valve head, face and stem with a
power-operated wire brush. Be sure carbon is removed, not
merely burnished.
2. Inspect valve head, face and stem for defects. Replace if
necessary.
Engine - Gas Repair - 59
ENGINE - GAS REPAIR
Specifications
Cylinder Head Distortion (Max). . . . 0.10 mm (0.004 in.)
Valve Guide ID . . . . . . . . . . . . . . . . . 5.50 mm (0.217 in.)
Valve Guide ID Wear Limit. . . . . . 5.572 mm (0.2194 in.)
Intake Guide-to-Stem Clearance
Standard . . . . . . . . . . . . . 0.02-0.044 mm (0.0008-0.0017
in.)
Wear Limit. . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)
M53961
3. Measure outside diameter of intake valve stem. Replace
if diameter is less than specification.
4. Measure outside diameter of exhaust valve stem.
Replace if diameter is less than specification.
A
B
M38087
5. Replace warped valves or valves with a valve face
margin (A) less than specification. Valve stem ends (B)
should be ground square before checking valve-to-tappet
clearance.
Exhaust Guide-to-Stem Clearance
Standard . . . . . . . . . . . . . 0.06-0.087 mm (0.0024-0.0034
in.)
Wear Limit. . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)
Valve Seat Width (Min) . . . . . . . . . . . . . 0.8 mm (0.03 in.)
Valve Seat Width (Max) . . . . . . . . . . . . 2.0 mm (0.08 in.)
Valve Spring Free Length (Standard) 30.5 mm (1.20 in.)
Valve Spring Free Length (Minimum) 29.5 mm (1.16 in.)
Valve Face Margin (Min) . . . . . . . . . 0.60 mm (0.024 in.)
Intake Valve
Stem Diameter (Standard) . . . . . . . . 5.48 mm (0.216 in.)
Stem Diameter (Minimum). . . . . . 5.318 mm (0.2094 in.)
Stem Out of Round (Maximum) . . . 0.03 mm (0.001 in.)
Exhaust Valve
Stem Diameter (Standard) . . . . . . . . 5.44 mm (0.214 in.)
Stem Diameter (Minimum). . . . . . 5.275 mm (0.2077 in.)
Stem Out of Round (Maximum) . . . 0.03 mm (0.001 in.)
Replace Valve Guide
Special or Required Tools
Tool Name
Tool No.
Tool Use
5.5 mm Valve
Guide Driver
JDG504
Used to remove and
install valve guides.
5.5 mm Valve
Guide Reamer
JDG1023
Used to ream valve
guides.
Other Material
Part No.
NA
M51753
6. Check valve stem for bends using V-blocks and a dial
indicator. Turn valve slowly and read variation on indicator.
Replace valve if out-of-round is greater than specification.
Part Name
Stanisol (or
Kerosene)
Part Use
Finish ream valve
guides.
Procedure
1. Disassemble and thoroughly clean the cylinder head.
(See “Disassemble and Assemble Cylinder Head and
Valves” on page 58.)
2. Chill the replacement valve guides in a freezer for about
Engine - Gas Repair - 60
ENGINE - GAS REPAIR
one hour prior to installation.
c Caution:
Avoid Injury! To prevent possible
burns, use heavy gloves when handling hot
Important: Avoid Damage! Allow the cylinder
head to cool to room temperature before
reaming valve guides.
cylinder head.
Important: Avoid Damage! DO NOT heat cylinder
head over 150°C (300°F). Excessive heat may
loosen valve seats.
D
3. Using an oven, heat cylinder head to 150°C (300°F).
4. Remove cylinder head from oven and place on wood
blocks with combustion chamber side up.
M83930
9. Coat JDG1023 Valve Guide Reamer (D) and valve
guides with Stanisol or kerosene lubricant.
10.Rotate reamer clockwise through the valve guide.
Continue rotating reamer while removing it from the valve
guide.
11.Thoroughly clean cylinder head to remove any cutting
residue.
A
M83931
5. Using a JDG504 Valve Guide Driver (A), drive valve
guides out from combustion chamber side.
6. Flip the cylinder head over (combustion chamber side
down) and place on a flat, firm surface.
7. Remove valve guides from freezer as needed.
A
M83914
B
12.Inspect valve guide bore; ensure that bore is straight,
round, and centered in valve guide. A valve guide with a
bore that is not centered should be replaced
13.Insert valve and check operation. Valve should move
smoothly in guide. If valve does not move smoothly, the
guide may have been damaged during installation. Replace
valve guide if necessary.
C
M83929
8. Install valve guides using a JDG504 Valve Guide Driver
(A):
• Exhaust guide is correctly installed when clip (B) is
fully seated against cylinder head casting.
14.Check valve-to-guide clearance. (See “Inspect Cylinder
Head and Valves” on page 58.)
Specifications
Valve Guide Installed Depth (Valve Guide Top-toCylinder Head Casting) . . . . . . . . . . . . 3.0 mm (0.12 in.)
• Install intake guide to specified depth (C) relative to
cylinder head casting.
Engine - Gas Repair - 61
ENGINE - GAS REPAIR
Analyze Valves
C
D
A
M30024
M29934
Deposits (A) on intake valve are caused by exhaust gas
leakage past the valve. This indicates that valve is not
seating properly.
Important: Avoid Damage! DO NOT grind the
exhaust valve or valve life will be shortened.
Lap the valves after resurfacing the seat to correct this
condition.
Note: Be sure to reset valve-to-tappet clearance after
grinding valve seats.
Exhaust valves are designed to function in temperatures
exceeding 2760°C (5000°F). However, when operating at
high temperatures for long periods of time, valve burning
may occur. Valves running too hot will show a dark
discoloration of the valve stem into the area protected by
the valve guide. Another indication is distortion of the valve
margin (C) and valve face (D). Valve seat inserts may also
begin to burn away.
Other causes for valves running hot are worn valve guides
or valve springs, incorrect valve clearance, lean fuel-air
mixture, and incorrect or overheated spark plug.
E
B
M29936
M5563
Valve stem corrosion (B) is caused by moisture in the
engine. Moisture in the fuel-air mixture can condense
inside the engine when the engine is stopped and cools
down.
Valve corrosion can also occur during storage. Fogging or
pouring oil in the combustion chamber before storing helps
prevent valve corrosion.
Using old or stale gasoline is a common cause for sticky
valves.
This gummy deposit (E) can be seen on the valve. When
this condition exists, the carburetor may also contain
gummy deposits and will require cleaning.
Always use fresh gasoline and drain fuel tank, lines and
carburetor before storing machine.
Corroded or pitted valves collect deposits and may cause
sticking valves. Replace badly corroded or pitted valves.
Engine - Gas Repair - 62
ENGINE - GAS REPAIR
Recondition Valve Seats
6. Use 30° or 60° cutters to narrow and adjust valve seats
so that valve makes contact with the middle of the valve
face.
Other Material
Part No.
NA
Part Name
Prussian Blue
Compound
Part Use
Check valve seat
contact.
1. Thoroughly clean the combustion chamber and valve
seats to remove carbon deposits.
2. Inspect valve seats for damage. If seats are loose,
warped or distorted beyond reconditioning, replace cylinder
head. Pitted or worn seats can be refaced using a seat
cutter.
• Use 30° cutter to remove material from top edge of
seat (contact too high).
• Use 60° cutter to remove material from bottom edge
of seat (contact too low).
7. Check valve seat width. If necessary, use a 45° cutter to
adjust seat width.
Lap Valves
Other Material
Part No.
NA
Part Name
Part Use
Lapping Compound
Lap valves into valve
seats.
If valve seat does not make proper contact, lap the valve
into the seat:
1. Apply a small amount of fine lapping compound to face
of valve.
M83849
3. Apply a light coat of Prussian Blue or erasable felttipped marker ink to valve face.
4. Insert valve and snap it closed against seat several
times. DO NOT rotate valve. Transferred marking
compound will show any area that is not concentric.
Important: Avoid Damage! Turn cutter
clockwise; DO NOT turn counterclockwise.
Continue to turn cutter as you lift it off the valve
seat.
5. To recondition seat, cut at a 45° angle to clean up seat.
M83848
2. Grip head of valve with a vacuum cup tool and turn valve
to lap valve to seat.
3. Lift valve from seat every 8 to 10 strokes. Lap until a
uniform ring appears around the surface of the valve face.
4. Wash all parts in solvent to remove lapping compound.
Dry parts.
A
5. Check position of lap mark on valve face. Lap mark must
be on or near the center of valve face.
B
M83916
A- Contact Too High
B- Contact Too Low
Engine - Gas Repair - 63
ENGINE - GAS REPAIR
Remove and Install Crankcase Cover
Replace Bearing and Oil Seal
1. Remove drain plug and drain oil from crankcase into
container of sufficient size to hold capacity.
Note: Remove bearing only if replacement is required.
A
B
A
M38073
A- Axial Free Play
B- Radial Free Play
1. Spin bearing by hand and check for axial and/or radial
free play. Replace bearing if it has excessive play or is
noisy.
B
MX6072
C
2. Remove seven M6x30 hex head bolts (A) securing
crankcase cover (B) to crankcase. Remove cover.
Installation
Installation is done in the reverse order of removal.
• Remove gasket material from mating surfaces before
installation.
•
Use new gasket for installation.
• Make sure two alignment pins are installed between
crankcase and crankcase cover.
•
Tighten bolts to specification.
Specifications
2. Remove oil seal (C).
Crankcase Capacity (Approx) . . . . . . . . . 0.6 L (0.63 qt)
Crankcase Cover Cap
Screw Torque . . . . . . . . . . . . . . . . . . 12 N•m (108 lb-in.)
D
MX6068
3. Drive bearing (D) out by using a driver set.
4. Apply a light coat of clean engine oil to bearing outer
Engine - Gas Repair - 64
ENGINE - GAS REPAIR
race.
Installation
5. Install bearing using driver set until fully seated against
housing.
Installation is done in the reverse order of removal.
6. Install new oil seal.
• Apply a light coat of clean engine oil to tappets and
bores and install tappets in original bores.
Remove and Install Camshaft and Tappets
• Apply a light coat of clean engine oil to camshaft lobes
and journals.
1. Remove cylinder head. (See “Remove and Install
Cylinder Head and Valves” on page 57.)
2. Remove crankcase cover. (See “Remove and Install
Crankcase Cover” on page 64.)
•
Align timing marks when installing camshaft.
Inspect Camshaft and Tappets
1. Inspect camshaft for wear or damage. Replace if
necessary.
A
MX6069
M83887
3. Rotate camshaft until timing marks (A) align.
4. Remove and inspect camshaft. (See “Inspect Camshaft
and Tappets” on page 65.)
Important: Avoid Damage! Tappets must be
installed in the same bores from which they were
removed.
2. Measure cam intake lobe height. Replace camshaft if
lobe height is less than specification.
3. Measure cam exhaust lobe height. Replace camshaft if
lobe height is less than specification.
B
M83888
C
MX6070
5. Mark intake (B) and exhaust (C) tappets to aid in
reinstallation to correct bore.
4. Measure flywheel side journal and PTO side journal
diameter. Replace camshaft if either journal diameter is
less than specification.
6. Remove and inspect tappets for wear or damage.
Replace if necessary.
Engine - Gas Repair - 65
ENGINE - GAS REPAIR
Remove Piston and Connecting Rod
1. Remove camshaft and tappets. (See “Remove and
Install Camshaft and Tappets” on page 65.)
2. Check cylinder bore for carbon and varnish ridges.
These ridges can cause piston damage if not removed.
3. If necessary, remove ridge from top of cylinder bore
using a ridge reamer.
A
M83889
5. Measure inside diameter of camshaft holder in
crankcase cover. Replace crankcase cover if diameter is
greater than specification.
B
MX6065
4. Turn crankshaft to expose connecting rod end cap (A).
5. Remove connecting rod hex head bolts (B) and
connecting rod cap.
6. Push piston and connecting rod assembly from cylinder
bore.
A
MX6066
6. Measure inside diameter of camshaft bearing bore (A) in
block. Replace block if diameter is greater maximum
specification.
Specifications
Cam Lobe Height
Wear Limit (Intake) . . . . . . . . . . . . . 27.45 mm (1.081 in.)
Cam Lobe Height
Wear Limit (Exhaust) . . . . . . . . . . . 27.75 mm (1.083 in.)
Flywheel Side Journal
Diameter Wear Limit. . . . . . . . . . 13.916 mm (0.5479 in.)
PTO Side Journal
Diameter Wear Limit. . . . . . . . . . 13.916 mm (0.5479 in.)
Camshaft Bearing Bore (Max.) . 14.048 mm (0.5531 in.)
7. Disassemble and inspect all parts for wear or damage.
(See “Disassemble Piston and Connecting Rod” on
page 67. See “Inspect Piston and Connecting Rod” on
page 69.)
Inspect Piston and Connecting Rod
1. Deglaze cylinder bore. (See “Deglaze Cylinder Bore” on
page 77.)
2. Stagger piston ring end gaps 180° apart, but do not
align with oil ring side rail end gaps.
3. Apply a light coat of clean engine oil to piston and rings.
Compress rings with a ring compressor.
4. Apply a light coat of clean engine oil to cylinder bore,
connecting rod bearing surface and ring compressor.
Engine - Gas Repair - 66
ENGINE - GAS REPAIR
Disassemble Piston and Connecting Rod
A
B
C
A
G
F
B
M83824
5. Install piston and connecting rod assembly in cylinder
bore with triangle mark (A) on piston facing the push rod
opening (B).
E
D
C
D
M83890
A- 1st Compression Ring
B- 2nd Compression Ring
C- Oil Control Ring
D- Connecting Rod
E- Retaining Ring (2 used)
F- Piston Pin
G- Piston
Cap Screws
12 N•m (9 lb-ft)
MX6065
6. Install connecting rod cap (C) with dipper toward
camshaft and ribs on cap and connecting rod aligned.
Tighten cap screws (D) to specification.
7. Install camshaft and tappets, crankcase cover and
cylinder head.
Specifications
Connecting Rod Bolt Torque . . . . . . 12 N•m (108 lb-in.)
• Analyze piston and piston ring wear. (See “Analyze
Piston Ring Wear” on page 72. See “Analyze Piston Wear”
on page 73.)
•
Remove piston rings using a piston ring expander.
Important: Avoid Damage! DO NOT reuse piston
pin retaining rings. Always use new retaining
rings for assembly.
• Inspect all parts for wear or damage. (See “Inspect
Piston and Connecting Rod” on page 69.)
Engine - Gas Repair - 67
ENGINE - GAS REPAIR
Assemble Piston and Connecting Rod
Important: Avoid Damage! DO NOT reuse piston
pin retaining rings.
C
B
D
M83892
5. Before installing rings on piston, check ring end gap in
cylinder bore. (See “Check Piston Ring End Gap” on
page 72.)
Important: Avoid Damage! Install all rings with
marking facing up.
A
Be sure that top and second compression rings are
not interchanged.
DO NOT align any piston ring end gaps with piston
pin bore.
H
M83830
G
1. Install connecting rod (A) to piston (B) with long end of
connecting rod toward triangle mark (C) on piston.
2. Apply a light coat of clean engine oil to piston pin (D)
and connecting rod bearing.
F
3. Install piston pin.
Important: Avoid Damage! DO NOT align
retaining ring gap with cutout in piston pin bore.
E
M83850
M83891
4. Install retaining ring (E) on each side by inserting one
end in groove, and holding other end with a needle-nosed
pliers, rotate the ring into place.
6. Install oil control and compression rings:
• Install oil control ring (F) in bottom groove with mark
facing up. Position end gap approximately 45° away
from triangle mark.
Engine - Gas Repair - 68
ENGINE - GAS REPAIR
• Install 2nd compression ring (G) in middle grove with
mark facing up. Position end gap approximately 120°
away from end gap of oil control ring.
• Install 1st compression ring (chrome plated) (H) in
top grove with mark facing up. Position end gap
approximately 120° away from end gap of 2nd
compression ring.
Inspect Piston and Connecting Rod
Piston
Important: Avoid Damage! DO NOT use a caustic
cleaning solution or a wire brush to clean piston.
1. Remove all deposits from piston.
M83894
7. Using new rings, check piston ring-to-groove clearance
at several points around piston. Replace piston if any
clearance is greater than specification.
A
M29946
2. Clean carbon deposits from piston ring grooves with a
ring groove cleaner (A). If cleaning tool is not available,
break an old ring and use it to carefully clean groove.
M83895
3. Check that all oil return passages in grooves are open.
8. Measure piston outside diameter at a point 10 mm (0.4
in.) from the bottom of the skirt and 90° to the piston pin
bore. Replace piston if outside diameter measures less
than specifications.
4. Inspect piston for scoring or fractures. Replace piston if
damaged.
9. Measure cylinder bore diameter. (See “Inspect Cylinder
Block” on page 76.)
10.Subtract piston outside diameter measurement from
cylinder bore measurement to determine piston-to-cylinder
bore clearance.
11.Replace piston and/or rebore cylinder block if clearance
is greater than specification. (See “Rebore Cylinder Block”
on page 77.)
M83893
5. Measure 1st and 2nd compression ring thicknesses.
Replace ring if measurement is less than specification.
6. Measure oil control ring thickness. Replace ring if
measurement is less than specification.
Engine - Gas Repair - 69
ENGINE - GAS REPAIR
M80427
12.Measure piston pin bore diameter in piston. Replace
piston if measurement is greater than specification.
M83896
3. Measure connecting rod piston pin bore. Replace
connecting rod if measurement is greater than
specification.
Note: If the engine has had a previous major overhaul,
an undersized connecting rod may have been installed.
A 0.25 mm (0.010 in.) undersize connecting rod is
available.
Measuring Positions
M83897
4. Install connecting rod cap. Tighten cap screws to
specification.
M82050A
13.Measure piston pin diameter at six places. Replace pin
if any measurement is less than specification.
14.Subtract piston pin outside diameter measurement from
piston pin bore measurement to determine piston pin-tobore clearance. Replace piston pin and/or piston if
clearance is greater than specification.
Connecting Rod
1. Analyze crankshaft and connecting rod wear. (See
“Analyze Crankshaft and Connecting Rod Wear” on
page 76.)
2. Clean and inspect connecting rod. Replace if scored or
damaged.
5. Measure connecting rod crankshaft bearing. Replace
connecting rod if measurement is greater than
specifications.
Specifications
Note: If the engine has had a previous major overhaul,
an oversized piston may have been installed. Pistons
and rings are available in 0.25 mm (0.010 in.) and 0.50
mm (0.020 in.) oversize.
1st Compression Ring
Thickness (Min) . . . . . . . . . . . . . . . . 1.37 mm (0.054 in.)
2nd Compression Ring
Thickness (Min) . . . . . . . . . . . . . . . .1.37 mm (0.054 in.)
Oil Control Ring
Thickness (Min) . . . . . . . . . . . . . . . .2.37 mm (0.093 in.)
Engine - Gas Repair - 70
ENGINE - GAS REPAIR
Piston Ring-to-Groove
Clearance (Max) . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Piston-to-Cylinder Bore
Clearance (Max) . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)
Piston Pin Bore
Diameter (Max) . . . . . . . . . . . . . 13.048 mm (0.5137 in.)
Piston Pin
Diameter (Min). . . . . . . . . . . . . . 12.954 mm (0.5100 in.)
Piston Pin-to-Bore
Clearance (Max) . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.)
Connecting Rod Piston
Pin Bore Diameter (Max) . . . . . . . . 13.07 mm (0.515 in.)
Connecting Rod Cap
Cap Screw Torque . . . . . . . . . . . . . . 12 N•m (108 lb-in.)
Specifications
Piston OD Specifications (Wear Limit)
1. Remove crankshaft from cylinder block. (See “Remove
and Install Crankshaft” on page 74.)
Standard Piston . . . . . . . . . . . . 59.845 mm (2.3561 in.)
0.25 mm (0.010 in.)
Oversize Piston. . . . . . . . . . . . . 60.095 mm (2.3661 in.)
0.50 mm (0.020 in.)
Oversize Piston. . . . . . . . . . . . . . 60.345 mm (2.3761 in.)
Connecting Rod Cap Screw Torque . 12 N•m (108 lb-in.)
Connecting Rod Side
Clearance (Max) . . . . . . . . . . . . . . . . . 1.1 mm (0.043 in.)
Check Connecting Rod-to-Crankshaft
Clearance
Special or Required Tools
Tool Name
PLASTIGAGE
™
Tool No.
NA
Tool Use
Used to check
connecting rod-tocrankshaft clearance.
2. Clean all oil from crankshaft journal and connecting rod
bearing surfaces.
Note: DO NOT rotate crankshaft while PLASTIGAGE is
in place.
Crankshaft Bearing Diameter (Wear Limit)
A
Standard Crankshaft . . . . . . . . . 26.066 mm (1.0262 in.)
0.25 mm (0.010 in.) Undersize
Crankshaft . . . . . . . . . . . . . . . . . . 25.816 mm (1.0164 in.)
Check Connecting Rod Side Play
1. Remove crankshaft from cylinder block. (See “Remove
and Install Crankshaft” on page 74.)
M83899
3. Place a piece of PLASTIGAGE on the crankshaft
journal, and install connecting rod and cap. Tighten
connecting rod bolts (A) to specification.
Note: If the engine has had a previous major overhaul,
an undersized connecting rod may have been installed.
A 0.25 mm (0.010 in.) undersize connecting rod is
available.
M83898
2. Install connecting rod on crankshaft. Tighten connecting
rod cap screws to specification.
3. Measure connecting rod side clearance. Replace
connecting rod and/or crankshaft if clearance is greater
than specification.
Engine - Gas Repair - 71
ENGINE - GAS REPAIR
Analyze Piston Ring Wear
Rings of the wrong size or rings having improper end gaps
will not conform to the shape of the cylinder. This results in
high oil consumption and excessive blow-by.
B
Ring end gaps should be staggered on the piston during
installation. (See “Assemble Piston and Connecting Rod”
on page 68.) Aligned ring end gaps can also cause
excessive oil consumption and blow-by.
A
M83900
4. Remove cap and measure width of PLASTIGAGE strip
(B). If clearance is greater than specification, replace
connecting rod and recheck clearance.
5. If, after replacing connecting rod, clearance is still
beyond specification, replace crankshaft.
Specifications
Connecting Rod Bolt Torque . . . . . . 12 N•m (108 lb-in.)
Connecting Rod-toCrankshaft Clearance (Max) . . . . . . 0.12 mm (0.005 in.)
Check Piston Ring End Gap
M29943
Light scuffing or scoring (A) of both rings and piston occurs
when unusually high friction and combustion temperatures
approach the melting point of the piston.
When this condition exists, it is due to one or more of the
following probable causes:
•
Dirty cooling shroud and cylinder head
•
Lack of cylinder lubrication
•
Improper combustion
•
Wrong bearing or piston clearance
•
Too much oil in crankcase causing fluid friction
B
M83892
1. Install each ring squarely in bore approximately 25.4
mm (1.00 in.) down from top of cylinder.
2. Measure end gap. Replace rings if end gap is greater
than specification.
Specifications
Piston Ring End Gap (Max) . . . . . . . . . 1.0 mm (0.04 in.)
M29944
The engine operating at abnormally high temperature may
cause varnish, lacquer or carbon deposits (B) to form in the
piston ring grooves making the piston rings stick. When this
happens, excessive oil consumption and blow-by will occur.
Engine overheating and ring sticking is usually caused by
one or more of the following:
Engine - Gas Repair - 72
ENGINE - GAS REPAIR
•
Overloading.
•
High oil consumption
•
Incorrect ignition timing
•
Increased deposits in combustion chamber
•
Lean fuel mixture
•
Sticking compression rings
•
Dirty cooling fins
Increased oil consumption may be caused by:
•
Incorrect oil
•
Worn side rails with low tension
•
Low oil supply
•
Worn or distorted inner spacer
•
Stale fuel
Analyze Piston Wear
C
Detonation is abnormal combustion causing excessive
temperature and pressure in the combustion chamber.
Commonly called knock, spark knock or timing knock,
detonation occurs as the compressed fuel-air mixture
ignites spontaneously to interrupt the normal ignition.
M29945
Vertical scratches (C) across the piston rings are due to an
abrasive in the engine. Abrasives may be airborne, may
have been left in the engine during overhaul, or may be
loose lead or carbon deposits.
When this condition exists, check for one or more of the
following:
•
Damaged, collapsed or improperly installed air filter
• Loose connection or damaged basket between air
cleaner and carburetor
M29947
The following is a list of possible causes for detonation:
•
Pre-ignition
•
Lean fuel mixture
•
Low octane fuel
•
Air leak around carburetor-to-cylinder head gasket
•
Advanced ignition timing
•
Air leak around throttle shaft
•
Engine lugging
• Buildup of carbon deposits on piston or cylinder head,
causing excessive compression
• Failure to properly clean cylinder bore after
reconditioning engine
• Wrong cylinder head or milling of head increasing
compression ratio
A
E
D
M38101
Abrasive particles in engine oil cause scratches on side
rails (D) of oil control ring. Inner spacer (E) wear or
distortion may cause:
Engine - Gas Repair - 73
M30039
ENGINE - GAS REPAIR
Pre-ignition is the igniting of the fuel-air mixture prior to
regular ignition spark. Pre-ignition causes shock, resulting
in pings, vibration, detonation and power loss. Severe
damage to piston top (A), rings, or valves may result from
pre-ignition.
Check the following for causes of pre-ignition:
•
Internal carbon deposits
•
Incorrect spark plug (high heat range)
•
Broken ceramic in spark plug
•
Sharp edges on valves
•
Sharp edges in combustion chamber
C
M29949
A broken retaining ring caused the damage (C) shown.
Retaining rings loosen or break due to:
B
•
Rod misalignment
•
Excessive crankshaft end play
•
Crankshaft journal taper
•
Weak retaining rings
•
Incorrectly installed retaining rings
Inertia can cause a broken retaining ring to beat out the
piston and cylinder, causing extensive damage.
Remove and Install Crankshaft
Other Material
M29948
Check rod and piston alignment when piston shows a
diagonal wear pattern (B) extending across the skirt of the
piston. Contact with the cylinder wall shows on the bottom
of the skirt at left and at the ring lands at the right.
Part No.
NA
Part Name
Multi-Purpose
Grease
Part Use
Prevents parts from
seizing. Apply to
engine crankshaft.
A cylinder bored at an angle to the crankshaft can also
cause improper ring contact with the cylinder.
1. Remove flywheel. (See “Remove and Install Flywheel”
on page 56.)
This condition causes:
2. Remove camshaft. (See “Remove and Install Camshaft
and Tappets” on page 65.)
•
Rapid piston wear
•
Uneven piston wear
•
Excess oil consumption
3. Remove piston and connecting rod. (See “Remove
Piston and Connecting Rod” on page 66.)
Engine - Gas Repair - 74
ENGINE - GAS REPAIR
Specifications
Connecting Rod
Journal Diameter (Min) . . . . . . . . . 25.92 mm (1.020 in.)
Replace Timing-Governor Gear
Note: The removal/installation procedure is identical
for both the timing and governor gears.
A
1. Mark a reference line on the timing/governor gear and
crankshaft.
MX6066
4. Remove crankshaft (A).
5. Inspect ball bearing in cylinder block. (See “Crankshaft
Bearing Inspection and Replacement” on page 77.)
6. Inspect crankshaft for wear or damage. (See “Inspect
Crankshaft” on page 75.)
A
Inspect Crankshaft
M83921
1. Analyze crankshaft and connecting rod wear. (See
“Analyze Crankshaft and Connecting Rod Wear” on
page 76.)
2. Using a knife-edged puller (A), separate and remove
gear from crankshaft.
3. Using the old gear as a reference, mark the new gear in
the same position as the old gear.
C
B
M83920
2. Measure connecting rod journal. Replace crankshaft if
journal diameter is less than minimum specification.
3. Check connecting rod-to-crankshaft clearance. (See
“Check Connecting Rod-to-Crankshaft Clearance” on
page 71.)
4. Check connecting rod side play. (See “Check
Connecting Rod Side Play” on page 71.)
M83922
4. Support the crankshaft (B) as shown.
5. Place the gear (C) on the crankshaft and align the
marks on the gear and crankshaft.
6. Using driver, press gear on crankshaft until fully seated.
5. Inspect timing and governor drive gears for wear or
damage. Replace if necessary. (See “Replace TimingGovernor Gear” on page 75.)
Engine - Gas Repair - 75
ENGINE - GAS REPAIR
Analyze Crankshaft and Connecting Rod
Wear
A
Check connecting rod and cap for damage or unusual wear
patterns.
Lack of lubrication or improper lubrication can cause the
connecting rod and cap to seize the crankshaft; the
connecting rod and piston may both break, causing other
internal damage. Inspect block carefully before rebuilding
engine.
B
C
Crankshaft and connecting rod damage can also result
from:
•
Engine run low on oil or without oil
•
Oil not changed regularly
•
Bearing cap installed incorrectly
D
Inspect Cylinder Block
Other Material
Part No.
NA
E
Part Name
Part Use
Zinc Oxide/Wood
Alcohol
Check block for
cracks.
1. Clean block and check for cracks.
Note: Cracks not visible to the eye may be detected by
coating the suspected area with a mixture of 25%
kerosene and 75% light engine oil. Wipe area dry and
immediately apply coating of zinc oxide dissolved in
wood alcohol. If crack is present, coating becomes
discolored at the defective area. Replace block if any
cracks are found.
A bare block is available for service.
M82411A
2. Measure cylinder bore diameter at three positions; top
(A), middle (B) and bottom (C). At these three positions,
measure in both directions; parallel to the crankshaft
centerline (D) and aligned with crankshaft rotation (E).
Specifications
Note: If the engine has had a previous major overhaul,
oversize pistons and rings may have been installed.
Pistons are available in 0.25 mm (0.010 in.) and 0.50
mm (0.020 in.) oversize.
Cylinder Bore ID, Standard Piston
Standard . . . . . . . . . . . . . . . . . . . . . . . 60.0 mm (2.36 in.)
Wear Limit. . . . . . . . . . . . . . . . . . 60.165 mm (2.3687 in.)
Cylinder Bore ID, 0.25 mm (0.010 in.) Oversize Piston
Standard . . . . . . . . . . . . . . . . . . . . . . 60.25 mm (2.37 in.)
Wear Limit. . . . . . . . . . . . . . . . . . 60.415 mm (2.3787 in.)
Cylinder Bore ID, 0.50 mm (0.020 in.) Oversize Piston
Standard . . . . . . . . . . . . . . . . . . . . . . . 60.5 mm (2.38 in.)
Wear Limit. . . . . . . . . . . . . . . . . . 60.665 mm (2.3887 in.)
Engine - Gas Repair - 76
ENGINE - GAS REPAIR
Crankshaft Bearing Inspection and
Replacement
Note: Remove bearing only if replacement is required.
A
A
M83864
M83865
1. Remove worn or damaged oil seal (A) from crankcase
bore.
2. Pack lithium-based grease inside lips of replacement
seal.
B
3. Install replacement seal with lip toward inside of
crankcase using a seal driver set.
C
Deglaze Cylinder Bore
1. Deglaze cylinder bore using a rigid hone with a 220 to
300 grit stone.
2. Use hone as instructed by manufacturer to obtain a 45°
crosshatch pattern.
M38073
1. Spin bearing (A) by hand and check for axial (B) and/or
radial (C) free play. Replace bearing if it has excessive play
or is noisy.
2. Remove oil seal.
3. Remove bearing using a driver set.
4. Apply a light coat of clean engine oil to bearing outer
race.
5. Install bearing using driver set until fully seated against
crankcase casting.
Important: Avoid Damage! DO NOT use gasoline,
kerosene, or commercial solvents to clean
cylinder bore. Solvents will not remove all
abrasives from cylinder walls.
3. Clean cylinder walls using clean white rags and warm,
soapy water. Continue to clean cylinder until white rags
show no discoloration.
4. Dry cylinder and apply a light coat of clean engine oil.
Rebore Cylinder Block
6. Install new oil seal.
Important: Avoid Damage! Check stone for wear
or damage. Use correct stone for the job.
Replace Oil Seal
Other Material
Part No.
NA
Part Name
Lithium-Based
Grease
Part Use
Pack oil seals.
Note: The cylinder can be rebored to use 0.25 mm
(0.010 in.) and 0.50 mm (0.020 in.) oversize piston and
rings. Have a reliable repair shop rebore the block, or
use a drill press and honing tool.
Rebore cylinder with a honing tool to initial and final
bore specifications.
1. Align center of bore to drill press center.
2. Lower and raise hone until end extends 20-25 mm
Engine - Gas Repair - 77
ENGINE - GAS REPAIR
(0.75-1.0 in.) past end of cylinder.
Remove and Install Governor
3. Adjust hone stones until they contact the narrowest
point of the cylinder walls.
1. Remove crankshaft. (See “Remove and Install
Crankshaft” on page 74.)
4. Coat the inside of cylinder with honing oil. Turn hone by
hand. Adjust if too tight.
5. Run drill press between 200-250 rpm. Move hone up
and down in cylinder approximately 20 times per minute.
A
Note: Measure bore when cylinder is cool.
6. Stop press and check cylinder diameter.
Note: Finish should not be smooth. It should have a
40°-60° crosshatch pattern.
B
C
7. Check bore for size, taper and out-of-round.
M83902
2. Remove governor return spring (A) from governor arm.
3. Remove governor linkage rod (B) from governor arm.
4. Remove governor spring (C) from governor arm.
E
F
D
M82412A
8. If cylinder bore exceeds wear limit, rebore cylinder or
replace block.
9. Hone the cylinder an additional 0.007-0.009 mm
(0.0003-0.0004 in.) for final bore specifications. This allows
for 0.020 mm (0.0008 in.) shrinkage when cylinder cools.
Important: Avoid Damage! DO NOT use gasoline,
kerosene, or commercial solvents to clean
cylinder bore. Solvents will not remove all
abrasives from cylinder walls.
G
M83826
5. Remove nut (D) and bolt (E) securing governor arm
from shaft.
6. Remove governor arm (F) and washer (G).
10.Clean cylinder walls using clean white rags and warm,
soapy water. Continue to clean cylinder until white rags
show no discoloration.
11.Dry cylinder and apply a light coat of clean engine oil.
Engine - Gas Repair - 78
ENGINE - GAS REPAIR
Installation
I
Installation is done in the reverse order of removal.
H
•
Check to make sure governor weights move freely.
•
Insert clip firmly into shaft groove.
•
Check to ensure that slider moves freely.
J
A
M83829
7. Remove clip (H), governor arm shaft (I), and washer (J).
O
Q
P
K
M83827
M
• Position shaft over governor slider, and install clip (A)
with straight side of clip against groove in shaft.
N
L
D
C
B
M83828
8. Spread governor weights (K) and remove slider (L).
M83902
9. Remove washer (M).
10.Remove clip (N) and governor weight holder (O).
11.Remove washer (P).
• Reinstall governor spring (B) to governor arm hole
marked “1”.
12.Remove both pins (Q) and weights (K) if necessary.
• Reinstall linkage rod (C) and spring hook (D) to end hole
in governor arm
13.Inspect all parts for wear or damage. Replace parts as
needed.
• Adjust governor. (See “Adjust Governor and Fast Idle
Speed” on page 37.)
Engine - Gas Repair - 79
ENGINE - GAS REPAIR
Engine - Gas Repair - 80
ELECTRICAL TABLE OF CONTENTS
Electrical
Table of Contents
Information .....................................................83
Reading Electrical Schematics.....................83
Theory Of Operation Information..................84
Diagnostic Information..................................84
Wire Color Abbreviation Chart......................84
Common Circuit Tests..................................85
Conductors For 12 Volt Circuits ...................85
Specifications .................................................86
General Specifications .................................86
Tools and Materials ........................................87
Tools.............................................................87
Materials.......................................................87
Component Location......................................88
Engine Components.....................................88
Reel Motor Controller ...................................89
Reel Motor....................................................90
Alternator......................................................91
Schematics and Harnesses ...........................92
Schematic and Harness Legend ..................92
Main Electrical Schematic ............................93
W1 Upper Wiring Harness............................97
W2 Lower Wiring Harness............................98
W1 Upper Wire Color Codes......................100
W2 Lower Wire Color Codes......................100
W3 Rectifier Wiring Harness ......................101
W3 Wire Color Codes.................................102
W4 Auxiliary Light Wiring Harness
[Optional] ....................................................102
W4 Wire Color Codes.................................102
Operation and Diagnostics ..........................103
Power Circuit Operation .............................103
Power Circuit Schematic ............................104
System: Power Supply Diagnostic Check ..106
Ignition Circuit Operation - Engine
Shutting Off ................................................106
Ignition Circuit Schematic...........................107
System: Ignition Circuit Diagnosis..............108
Symptom: Engine Won’t Start or
Feels Loaded While Starting ......................109
Electronic Controllers ..................................110
Data Bus Systems......................................110
CAN Bus Theory of Operation....................110
CAN Network Voltage Checks ...................110
Troubleshooting Electronic Controllers ......112
Accessing Addresses and Diagnostic
Trouble Codes ........................................... 112
Approved Software for Control Unit ........... 113
Controller and Motor Diagnostics .............. 113
Electronic Controller Theory of Operation . 113
Diagnostic LED Blink Codes (Fault Codes)114
Reel Motor Theory of Operation ................ 115
Reel Motor Controller Signals.................... 115
Alternator Signals ...................................... 116
Operating Conditions ................................. 116
Diagnostic LED Fault Codes...................... 116
Symptom: Diagnostic LED Fault Codes .... 117
DTC Error Codes Table ............................. 120
System: DTC Readings ............................. 126
WBG_000628.12 Stuck in Boot Block
(Blink Code SOLID ON)............................. 126
WBG_002513.03 (Blink Code 7-3) Orange Phase (A) is Shorted to Supply..... 127
WBG_002513.04 (Blink Code 7-2) Orange Phase (A) is Shorted to Ground.... 127
WBG_002513.05 (Blink Code 7-4) Orange Phase (A) is Open ........................ 128
WBG_002514.03 (Blink Code 7-3) Black Phase (B) is Shorted to Supply........ 129
WBG_002514.04 (Blink Code 7-2) Black Phase (B) is Shorted to Ground....... 129
WBG_002514.05 (Blink Code 7-4) Black Phase (B) is Open............................ 130
WBG_002515.03 (Blink Code 7-3) Green Phase (C) is Shorted to Supply ...... 131
WBG_002515.04 (Blink Code 7-2) Green Phase (C) is Shorted to Ground ..... 131
WBG_002514.05 (Blink Code 7-4) Green Phase (C) is Open .......................... 132
WBG_003353.00 (Blink Code 8-1) Alternator Over Temp Threshold ............... 133
WBG_003353.01 (Blink Code 8-3) Alternator Hall Loss ................................... 134
WBG_003509.00 (Blink Code 7-5) Pot Signal Voltage High............................. 134
WBG_003509.01 (Blink Code 7-5) Pot Signal Voltage Low.............................. 135
WBG_003510.00 (Blink Code 9-7) Pot Supply Voltage High............................ 136
WBG_003510.01 (Blink Code 9-7) Pot Supply Voltage Low............................. 137
WBG_003511.00 (Blink Code 9-5) Hall Voltage High ....................................... 137
Electrical Table of Contents - 81
ELECTRICAL TABLE OF CONTENTS
WBG_003511.01 (Blink Code 9-5) Hall Voltage Low ........................................138
WBG_003597.00 (Blink Code 9-3) Controller 14V High ....................................139
WBG_003597.01 (Blink Code 9-3) Controller 14V Low.....................................139
WBG_521153.00 (Blink Code NONE) Manufacturer Service Code........................140
WBG_521153.15 (Blink Code 2-9) Controller Shutdown Over Temp................140
WBG_522327.00 (Blink Code 2-10) Motor Over Temp .......................................141
WBG_522917.00 (Blink Code 2-5) Controller Current Threshold 3 Shutdown..142
WBG_522917.06 (Blink Code 2-8) Controller Hardware Current Shutdown .....143
WBG_522917.15 (Blink Code 2-5) Controller Current Threshold 1 Shutdown..144
WBG_522917.16 (Blink Code 2-5) Controller Current Threshold 2 Shutdown..145
WBG_522918.00 (Blink Code 1-5) Motor Start Failed 3x Fault .........................146
WBG_522918.02 (Blink Code 1-10) Motor Spin Direction Shutdown..................147
WBG_522918.15 (Blink Code 1-6) Motor Stalled While Running......................148
WBG_522919.02 (Blink Code NONE) Manufacturer Service Code........................149
WBG_522919.03 (Blink Code 6-6) Hall Resync Shutdown ...............................149
WBG_522919.04 (Blink Code NONE) Manufacturer Service Code........................150
WBG_522919.08 (Blink Code NONE) Manufacturer Service Code........................150
WBG_522919.09 (Blink Code NONE) Manufacturer Service Code........................150
WBG_522919.12 (Blink Code 6-4) Invalid Hall State Detected at Start-Up.......150
WBG_522937.02 (Blink Code 8-2) Frequency of Clip Shutdown ......................151
WBG_522976.12 (Blink Code 8-4) Incorrect Application Software....................152
WBG_523666.00 (Blink Code 9-2) Bus Voltage High........................................152
WBG_523666.01 (Blink Code 1-7) Bus Voltage Low ........................................153
WBG_523666.02 (Blink Code 1-7) Low VBUS on Start ....................................154
WBG_523666.15 (Blink Code NONE) Manufacturer Service Code ...................... 154
Tests and Adjustments ............................... 155
Backlap Switch Test .................................. 155
Run/Off Switch Test................................... 155
Park Brake Switch Test ............................. 156
Clutch Switch Test ..................................... 157
Test Flywheel Magnet ............................... 158
Reel Motor Test ......................................... 158
Reel Motor Wiring/Phase Test................... 159
Frequency of Cut (FOC)
Potentiometer Test .................................... 159
Bridge Rectifier Test .................................. 160
Electrical Table of Contents - 82
ELECTRICAL INFORMATION
Information
Reading Electrical Schematics
S1 Key
Switch
B
Wht
Wht
Red
Red
X1
F2
15 Amp
Fuse
S1
800
Pink
6 X3
A
D
K2
Ignition
Relay
D
C
Start
210
Red
X2
X3
M
On Off
SeatSeat
S2
Seat
Switch
414
Yel/
Blk
Run
3
Off
L
F1
Fusible
Link
721
Pur
G
M1
Starting
Motor
Blk
W1
Shielded
Ground
E
2
J
4
1
5
2
E
W2
Engine
Wiring
Harness
T1
Ignition
X5
Yel/Wht
Coil
I
X3
710
Pur
H
S
M
5
X3
Red
G1
Battery
1
3
X2
B
4
K1
Start
Relay
1
215
Org
F3
15 Amp
Fuse
K
H
B
E1
Spark
Plug
F
X3
X4
Yel/
Wht
Yel/Wht
Yel/
Wht
Wht
F
805 Pnk
Blk/Yel
T2
Ignition
Coil
N
E2
Spark
Plug
O
C
105 Blk
mif
The schematic is made up of individual circuits laid out in a
sequence of related functions. It is formatted with all power
wires (A) across the top and all ground wires (B) across the
bottom. Current flow is generally from top to bottom
through each circuit and component. All components are
shown in the off position. The diagram does not list
connector (C) information unless needed to avoid
confusion. If the connector is shown, the number next to it
is the terminal pin location (D) in the connector.
Each component is shown by a symbol (E), its name (F),
and an identification code (G). The identification code
contains a device identifying letter (H) and number (I).
The identifying letter is always the same for a specific
component, but the identifying numbers are numbered
consecutively from upper left to lower right. The terminal
designation (J) is placed directly inside or outside the
symbol next to the connecting wire path. Switch positions
(K) are also placed directly inside or outside the symbol.
The solid line (L) shows the position the switch is currently
in and dash lines (M) represent other switch positions.
The circuit number (N) and wire color (O) of the wires are
shown directly next to the wire path.
The same component name and identification code are
used consistently on all diagrams in this section.
Components can be easily cross-referenced.
Electrical Information - 83
ELECTRICAL INFORMATION
Theory Of Operation Information
Wire Color Abbreviation Chart
The theory of operation stories divide the electrical system
into individual circuits by function. Each circuit is isolated
from the main wiring schematic and only shows the
components that are used in it. The story contains
information on function, operating conditions, and theory of
operation. The circuit schematics are drawn with the
components in the operating position, with the power, or
battery positive, into them across the top and the ground, or
battery negative, across the bottom.
Diagnostic Information
The diagnostic procedures is used to test the complete
circuit regardless of the problem or complaint. Select a
symptom or system from the quick check or
troubleshooting chart and follow the test procedures under
that heading.
The diagnostic procedure lists:
•
Test conditions
•
Test sequence
•
Test location
•
Normal reading
•
Check or test to perform if reading is not normal
When performing the test or check, be sure to set your
machine up to the TEST POINT/PROCEDURES listed in
the first column and follow the sequence carefully. The
middle RESULTS column gives the reading or condition
that should be obtained in BOLD print. If the results of the
test or check are not normal, perform the test, check, or
adjustment listed below the BOLD print. The system
diagram that accompanies each test procedure is drawn to
resemble machine components. The leader line points to
the exact point the test is to be made.
Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black
Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue
Brn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown
Grn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green
Gry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gray
Org. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange
Pnk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink
Pur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple
Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tan
Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White
Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow
Blk/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black/White
Blu/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue/White
Brn/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brown/White
Brn/Yel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown/Yellow
Dk Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Blue
Dk Brn/Lt Grn . . . . . . . . . . . . . Dark Brown/Light Green
Dk Brn/Red . . . . . . . . . . . . . . . . . . . . . . Dark Brown/Red
Dk Brn/Yel . . . . . . . . . . . . . . . . . . . . . Dark Brown/Yellow
Dk Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Green
Lt Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Blue
Lt Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Green
Org/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange/White
Pnk/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink/Black
Pur/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Purple/White
Red/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Black
Red/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/White
Wht/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Black
Wht/Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Red
Yel/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Black
Yel/Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Red
Yel/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yellow/White
Electrical Information - 84
ELECTRICAL INFORMATION
Common Circuit Tests
High Resistance or Open Circuit:
Shorted Circuit:
M85601 MIF
M85600 MIF
A shorted circuit may result in the wrong component
operating (i.e. improper wire-to-wire contact). To test for a
shorted or improperly wired circuit:
High resistance or open circuits usually result in slow, dim
or no component operation (i.e. poor, corroded, or
disconnected connections). Voltage at the component will
be low when the component is in operation. To test for high
resistance and open circuits:
1. Check all terminals and grounds of the circuit for
corrosion.
2. If terminals are not corroded or loose, the problem
1. Turn component switch ON.
3. is in the component or wiring.
2. Start at the controlling switch of the component that
should not be operating.
Grounded Circuit:
3. Follow the circuit and disconnect wires at connectors
until component stops operating.
4. Shorted or improper connections will be the last two
wires disconnected.
M85602 MIF
Grounded circuits usually result in no component operation
or a blown fuse.
Conductors For 12 Volt Circuits
Stranded Conductors For 12 Volt Circuits
SAE Wire Size (Gauge)
20
18
16
14
12
10
Metric Wire Size (MM)
0.8
0.8
1.0
2.0
3.0
5.0
Typical Stranding
7 X 28
16 X 30
19 X 29
19 X 27
19 X 25
19 X 23
Minimum Conductor Area In Circular
Mils
1072
1537
2336
3702
5833
9343
Electrical Information - 85
ELECTRICAL SPECIFICATIONS
Specifications
General Specifications
Specifications
Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 phase full wave
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 phase 48 volts
Electrical Specifications - 86
ELECTRICAL TOOLS AND MATERIALS
Tools and Materials
Tools
Special or Required Tools
Tool Name
Tool No.
Tool Use
Digital Multimeter
JT05791A
Used to test alternator amperage and voltage.
Used to test diodes, switches, relays,
solenoids, and fuses for continuity.
Current Clamp-On Probe
JT02153
Used to measure starting motor current.
Hand Held Digital Tachometer
JT05719
Used to measure rpm.
Weatherpack, Narrow
JDG777
Used to remove terminal from connector body.
Weatherpack, Extractor
JDG364
Used to remove terminal from connector body.
Weatherpack, Extractor Wide
JDG776
Used to remove terminal from connector body
Electrician’s Pliers
JDG145
Used to strip insulation from wire.
Crimper
JDG360
Used to crimp terminals on wire.
Thermometer
N/A
Used to measure water temperature.
12-Volt wall outlet power supply
JDG11015
Used to power Service ADVISOR™ EDL
(Electronic Data Link)
Electric Reel Motor Tester
JDG10429
Used to test reel motor and alternator.
Materials
Other Material
Part No.
Part Name
Part Use
N/A
Dielectric Grease
Seal connections.
N/A
Dow 739 RTV
Sealant
Waterproof
connections.
Electrical Tools and Materials - 87
ELECTRICAL COMPONENT LOCATION
Component Location
Engine Components
B
A
C
MIF (M83948)
A- Engine Ground
B- E1 Spark Plug
C- A1 Ignition Coil
Electrical Component Location - 88
ELECTRICAL COMPONENT LOCATION
Reel Motor Controller
aa
J4 Machine
Connector
P2 Phase
Connector
Z
J6 CAN
Connector
C
E
F
D
G
H
B
A
Y
V
W
X
S
U
M
T
L K
R
P1 Motor
Sensor Connector
48Vdc Power
Connector
MX41907
A- Org, pin A - Hour Meter, Alternator Hall Supply
B- Pur, pin B - Clutch Switch Digital Input (Gnd)
C- Wht, pin C - PTO Switch Digital Input (Gnd)
D- Brn, pin D - Alternator Thermal Switch (Analog
In)
E- Red, pin E- Not Used
F- Pnk, pin F - Not Used
G- Yel, pin G - CAN Hi
H- Grn, Pin H - CAN Lo
I- Blk, Pin J - Not Used
J- Blu, pin K - Alternator Hall Effect (Engine Speed)
(Frequency Digital Input)
K- Grn, pin A - Park Brake Switch (0Vdc to enable)
Input
L- Blk, pin B - Sensor Return (Not Ground)
M- Wht, pin C - FOC potentiometer in, 4.3Vdc to
0Vdc
N- Red, pin D - FOC potentiometer supply, 4.3Vdc
O- Brn, pin E - Reel direction (0Vdc= FWD,
4.3Vdc= REV) Input
P- Blu, Pin F - Fault Out to Diagnostic LED
Q- Red, pin A - 48 Vdc Power In
R- Blk, pin B - 48 Vdc Gnd
S- Blk, pin A - Sensor Return Input
T- Red, pin B - 12 Vdc Sensor Power Output
U- Blu, pin C - Thermal Shutdown Input
V- Brn, pin D - Hall C-A
W- Wht, pin E - Hall B-C
X- Grn, pin F - Hall A-B
Y- Lt Grn, pin C - Phase C
Z- Blk, pin B - Phase B
AA- Org, pin A - Phase A
Electrical Component Location - 89
Q
I
J
N
O
P
ELECTRICAL COMPONENT LOCATION
Reel Motor
A
B
G
H
F
E
D
C
K
I
J
MX41988
A- P1-M1 - Sensor Connector
B- P2-M1 - Phase Connector (Input)
C- Blk, pin A - Sensor Return
D- Red, pin B - 12Vdc Hall Sensor Power
E- Blu, pin C - Thermal Shutdown
F- Org, pin D - Hall C-A Output
G- Wht, pin E - Hall B-C Output
H- Grn, pin F - Hall A-B Output
I- Org, pin A - Phase A Input
J- Blk, pin B - Phase B Input
K- Lt Grn, pin C - Phase C Input
Electrical Component Location - 90
ELECTRICAL COMPONENT LOCATION
Alternator
A
B
G
H
F
E
D
C
K
I
J
MX41988
A- J1-X12 - Sensor Connector
B- J2-X13 - Phase Connector (Output)
C- Blk, pin A - Gnd
D- Red, pin B - 12Vdc Hall Sensor Power Input
E- Blu, pin C - Thermal Switch (Analog Output)
F- Org, pin D - Hall Output (Engine Speed
Frequency)
G- Wht, pin E - Not Used
H- Grn, pin F - Not Used
I- Org, pin A - Phase A Output
J- Blk, pin B - Phase B Output
K- Lt Grn, pin C - Phase C Output
Electrical Component Location - 91
ELECTRICAL SCHEMATICS AND HARNESSES
Schematics and Harnesses
Connectors
Schematic and Harness Legend
J1
RMC8 Reel Motor Controller (SE1)
J4
RMC8 Reel Motor Controller (SE1)
J6
RMC8 Reel Motor Controller (SE1)
P1
RMC8 Reel Motor Controller Connector (SE1)
P2
RMC8 Reel Motor Controller Connector (SE1)
X01
CAN Bus Service Connector (SE1)(W2)
X02
RMC8 Reel Motor Controller P2 to M1 (SE1)
X03
RMC8 Reel Motor Controller P1 to M1 (SE1)
X04
12 Vdc Input Connector (SE1)(W2)
X05
W2 Lower Wiring Harness to RMC8 Controller
J6 Connector (SE1)(W2)
Component
A1
Voltage Controlled Rev Limiter (SE4)(W3)
E1
Auxiliary Light [optional] (SE3)(W4)
G1
48V Alternator (SE2)(W3)
G2
12V Auxiliary Alternator [optional] (SE2)(W4)
H1
Diagnostic LED (SE5)(W1)
M1
Reel Motor (SE1)
P1
Hour Meter (SE5)(W1)
R1
CAN Terminating Resistor (SE1)(W2)
R2
CAN Terminating Resistor (SE1)(W2)
X06
R3
Frequency of Cut (FOC) Potentiometer
(SE5)(W1)
W2 Lower Wiring Harness to RMC8 Controller
J4 Connector (SE1)(W2)
X07
W3 Rectifier Wiring Harness to RMC8
Controller J1 Connector (SE1)(W3)
X08A
W2 to W3 Org Wire Connector (SE2)(W2)
X08B
W3 to W2 Org Wire Connector (SE2)(W3)
X09
Engine Ground Connector (SE2)(W3)
X10
Engine Ground Connector (SE2)(W2)
X11
Engine Magneto Connector (SE2)(W3)
X12
W2 to G1 Alternator Connector (SE2)(W2)
X13
W3 to G1 Alternator Connector (SE4)(W3)
X14A
W2 to W1 Connector (SE5)(W2)
X14B
W1 to W2 Connector (SE5)(W1)
RMC8
Reel Motor Controller (SE1)(W2)(W3)
S1
Backlap Forward/Reverse Switch (SE3)(W2)
S2
Park Brake Switch (SE5)(W1)
S3
PTO Switch (SE5)(W1)
S4
Clutch Switch (SE5)(W1)
S5
Run/Off Switch (SE5)(W1)
S6
Light Switch [optional] (SE3)(W4)
V1
3 Phase Full Wave Bridge Rectifier (SE4)(W3)
Wiring Harnesses
W1
Upper Wiring Harness
W2
Lower Wiring Harness
W3
Rectifier Wiring Harness
W4
Auxiliary Light Wiring Harness [optional]
Electrical Schematics and Harnesses - 92
ELECTRICAL SCHEMATICS AND HARNESSES
Main Electrical Schematic
(Page 1 of 4)
X07
J1
RMC8
Reel
Motor
Controller
48V
Blk
Red
B
A
Phase C Lt Grn
Phase B Blk
Phase A Org
P1
X03
Grn
Wht
Brn
Blu
Red
Blk
F
E
D
C
B
A
Reel Direction Input
PB Switch Input
Sensor Return
Diag. LED Output
FOC Pot Output
FOC Pot Input
J4
E
A
B
F
D
C
Brn
Grn
Blk
Blu
Red
Wht
E
A
B
F
D
C
J6
E
D
C
B
A
K
J
H
G
F
Red
Blu
Wht
Pur
Org
Brn
Blk
Grn
Yel
Pnk
E
D
C
B
A
K
J
H
G
F
CAN Lo
CAN Hi
C
B
A
C
B
A
Hall A-B Input
Hall B-C Input
Hall C-A Input
Temp Shutdown Input
12 V Sensor Output
Sensor Return Input
Alt Temp
PTO
Clutch
Supply Output
Engine Speed
147B Blk
201B Red
X02
P2
C
B
A
B
A
B
A
F
E
D
C
B
A
Lt Grn
Blk
Org
F
E
D
C
B
A
Grn
Wht
Brn
Blu
Red
Blk
E
A
B
F
D
C
619D Brn
620A Grn
112A Blk
451A Blu
258A Red
318A Wht
X06
F
E
D
C
B
A
M1 Reel
Motor
X05
E
D
C
B
A
K
J
H
G
F
300 Blu
701A Lt Grn
636A Lt Blu
601 Red
623 Brn
500A Grn
501A Yel
SP03
SP04
109 Blk
221 Red
A
B
C
D
E
F
G
H
J
A
B
C
A
B
X04
12 Vdc
Input
Connector
109 Blk
221 Red
501E Yel
500E Grn
501E Yel
R2
120
A 501D Yel
B 500D Grn
500E Grn
SP05
501C Yel
SP06 500C Grn
X01 CAN
Diagnostic
Connector
SE1 - Controller and Reel Motor
mif
Electrical Schematics and Harnesses - 93
501B Yel
500B Grn
A
B
R1
120
ELECTRICAL SCHEMATICS AND HARNESSES
Main Electrical Schematic (Page 2 of 4)
147B Blk
201B Red
S1 Backlap
Forward/Reverse
Switch
134 Blk
619D Brn
112B Blk
134 Blk
112A Blk
601 Red
601A Red
P1
SP01
254A Pnk
SP02
600 Blk
302A Org
X08A
X08B
303B Org
303B Org
303A Org
303C Org
SP07
147D Blk
100 Blk
220 Red
X09
X10
126A Blk
G2 Auxiliary
Alternator
Engine
E1 Light
12 Vdc
303A
Org
Engine
X11
100 Blk
B
200 Red
A
220 Red
200 Red
Magneto
623 Brn
300 Blu
601A Red
600 Blk
Belt Drive
1.21 : 1
X12
A
E
F
B
C
D
Blk
Wht
Grn
Red
Blu
Brn
A
E
F
B
C
D
Org
Blk
Lt Grn
A
B
C
G1 Alternator
SE3 - Light
SE2 - Engine / Alternator
mif
Electrical Schematics and Harnesses - 94
C
A
N.O.
ON-OFF
S6 Light
Switch
Optional Light Kit
A
E
F
B
C
D
A
B
ELECTRICAL SCHEMATICS AND HARNESSES
Main Electrical Schematic (Page 3 of 4)
147B Blk
201B Red
620A Grn
112B Blk
451A Blu
258A Red
318A Wht
701A Lt Grn
636A Lt Blu
254A Pnk
302A Org
126A Blk
147D Blk
A1 Voltage
Controlled
Rev Limiter
48V Sense
Run/Off Switch
Gnd
201C Red
147B Blk
SP08
147A Blk
303C Org
147C Blk
147C Blk
201B Red
201C Red
SP09
201A Red
V1 3 Phase Full Wave
Bridge Rectifier
X13
A
B
C
A
A
B
C
257A Org
257B Wht
257C Lt Grn
DC POS
201A Red
DC NEG
147A Blk
B
C
SE4 - Rectifier
mif
Electrical Schematics and Harnesses - 95
X14A
X14B
A
B
C
D
E
F
G
H
J
K
A
B
C
D
E
F
G
H
J
K
620B Grn
112C Blk
451B Red
258B Red
318B Wht
701B Lt Grn
636B Lt Blu
254B Pnk
302B Org
126B Blk
ELECTRICAL SCHEMATICS AND HARNESSES
Main Electrical Schematic (Page 4 of 4)
620B Grn
149 Blk
112C Blk
SP10
NO
A2
A1
B2
B1
S2 Park Brake
Switch
NC
149 Blk
128 Blk
148 Blk
135A Blk
140 Blk
145 Blk
H1 Diagnostic
LED
128 Blk
451B Red
C Pot C Blk
Pot B Blk
B
Pot A Blk
A
10
8
6
5
4
3
2
1
7
9
135A Blk
701B Lt Grn
C
B
A
5.8k
140 Blk
636B Lt Blu
4
3
2
302B Org
126B Blk
SE5 - Controls
mif
Electrical Schematics and Harnesses - 96
S3 PTO
Switch
1
S4 Clutch
Switch
A
B
145 Blk
254B Pnk
R3 Frequency of
Cut (FOC)
Potentiometer
6
5
B
A
A B
620B Grn
112C Blk
451B Red
258B Red
318B Wht
701B Lt Grn
636B Lt Blu
254B Pnk
302B Org
126B Blk
C
B
A
J1-S3
148 Blk
318B Wht
258B Red
P1
Hourmeter
S5 Run/Off
Switch
ELECTRICAL SCHEMATICS AND HARNESSES
W1 Upper Wiring Harness
(Page 1 of 1)
S3 PTO
Switch
701B Lt Grn
135A Blk
A 254B Pnk
B 145 Blk
P1
Hourmeter
S5 Run/Off
Switch
126B Blk
302B Org
128
140
X14B to W2
Lower Wiring
Harness
145
128
Blk
148
149
112C
135A
H1 Diagnostic
LED
SP10
451B
Red
A 258B Red
B 318B Wht
C 148 Blk
R3 Frequency of
Cut Potentiometer
620B Grn
149 Blk
S2 Park Brake
Switch
S4 Clutch
Switch
140 Blk
636B Lt Blu
mif
Electrical Schematics and Harnesses - 97
A 620B Grn
B 112C Blk
C 451B Red
D 258B Red
E 318B Wht
F 701B Lt Grn
G 636B Lt Blu
H 254B Pnk
J 302B Org
K 126B Blk
ELECTRICAL SCHEMATICS AND HARNESSES
W2 Lower Wiring Harness
(Page 1 of 2)
X01 CAN
Diagnostic
Connector
R2
120
A 109 Blk
B 221 Red
C 501E Yel
D 500E Grn
A 501D Yel
B 500D Grn
X14A to W1
Upper Wiring
Harness
A 620A Grn
B112B Blk
C 451A Blu
D 258A Red
E 318A Wht
F 701A Lt Grn
G 636A Lt Blu
H 254A Pnk
J 302A Org
K 126A Blk
500D
500E
SP06
500C
X04
A 109 Blk
B 221 Red
12 Vdc
Input
Connector
Cap
mif
Electrical Schematics and Harnesses - 98
501D
501E
SP05
501C
ELECTRICAL SCHEMATICS AND HARNESSES
W2 Lower Wiring Harness (Page 2 of 2)
126A Blk
302A Org
X08A
To W3
Wiring
Harness
S1 Backlap
Switch
X10
Engine
Ground
619D Brn
134 Blk
X12 TO G1 Alternator
A 600 Blk
B 601A Red
C 300 Blu
D 623 Brn
X06
A 620A Grn
B 112A Blk
C 318A Wht
D 258A Red
E 619D Brn
F 451A Blu
500B
500C
501A
SP01
SP04
500A
600
134
112B
112A
RMC8
Reel
Motor
Controller
501B
SP03 501C
A 501B Yel
B 500B Grn
R1
120
mif
Electrical Schematics and Harnesses - 99
X05
A 601 Red
B 636A Lt Blu
C 701A Lt Grn
D 300 Blu
G 501A Yel
H 500A Grn
K 623 Brn
ELECTRICAL SCHEMATICS AND HARNESSES
W1 Upper Wire Color Codes
W2 Lower Wire Color Codes
Size/No./Color
Wire Connection Points
Size/No./Color
Wire Connection Points
1.0 112C Blk
X14B (B), Spice SP10
0.8 109 Blk
X01 (A), X04 (A)
0.8 126B Blk
X14B (K), S5
1.0 112A Blk
X06 (B), Splice SP01
0.8 128 Blk
Splice SP10, H1
1.0 112B Blk
Splice SP01, X14A (B)
0.8 135A Blk
Splice SP10, S3 (2)
0.8 126A Blk
X10, X14A (K)
0.8 140 Blk
Splice SP10, S4 (A)
0.8 134 Blk
Splice SP01, S1
0.8 145 Blk
Splice SP10, P1 (B)
0.8 221 Red
X01 (B), X04 (B)
0.8 148 Blk
Splice SP10, R3 (C)
0.8 254A Pnk
Splice SP02, X14A (H)
0.8 149 Blk
Splice SP10, S2 (A1)
0.8 258A Red
X06 (D), X14A (D)
0.8 254B Pnk
X14B (H), P1 (A)
0.8 300 Blu
X05 (D), X12 (C)
0.8 258B Red
X14B (D), R3 (A)
0.8 302A Org
X08A, X14A (J)
0.8 302B Org
X14B (J), S5
0.8 318A Wht
X06 (C), X14A (E)
0.8 318B Wht
X14B (E), R3 (B)
0.8 451A Blu
X06 (F), X14A (C)
0.8 451B Red
X14B (C), H1
1.0 500A Grn
X05 (H), Splice SP04
0.8 620B Grn
X14B (A), S2 (A2)
1.0 500B Grn
Splice SP04, R1 (B)
0.8 636B Lt Blu
X14B (G), S4 (B)
1.0 500C Grn
Splice SP04, Splice SP06
0.8 701B Lt Grn
X14B (F), S3 (1)
1.0 500D Grn
Splice SP06, R2 (B)
1.0 500E Grn
Splice SP06, X01 (D)
1.0 501A Yel
X05 (G), Splice SP03
1.0 501B Yel
Splice SP03, R1 (A)
1.0 501C Yel
Splice SP03, Splice SP05
1.0 501D Yel
Splice SP05, R2 (A)
1.0 501E Yel
Splice SP05, X01 (C)
0.8 600 Blk
Splice SP01, X12 (A)
0.8 601 Red
X05 (A), Splice SP02
0.8 601A Red
Splice SP02, X12 (B)
0.8 619D Brn
X06 (E), S1
0.8 620A Grn
X06 (A), X14A (A)
0.8 623 Brn
X05 (K), X12 (D)
0.8 636A Lt Blu
X05 (B), X14A (G)
0.8 701A Lt Grn
X05 (C), X14A (F)
Electrical Schematics and Harnesses - 100
ELECTRICAL SCHEMATICS AND HARNESSES
W3 Rectifier Wiring Harness
V1 3 Phase Full Wave
Bridge Rectifier
147D Blk
303A Org
X09
Engine
Ground
147A (-)
257A
257B
X11 Engine
Magneto
257C
303B Org
201A (+)
X08B to W2
Wiring Harness
201A
Red
257C
Lt Grn
257B
Wht
257A
Org
147A
Blk
303B
303A SP07
303C
A1 Voltage
Controlled
Rev Limiter
201C Red
303C Org
147C Blk
147A SP08
147B
147C
147D
201A
SP09
201B
X07
RMC8 Reel
Motor
Controller
48V
201C
A 201B Red
B 147A Blk
X13 to G1
Alternator
A 257A Org
B 257B Wht
C 257C Lt Grn
mif
Electrical Schematics and Harnesses - 101
ELECTRICAL SCHEMATICS AND HARNESSES
W3 Wire Color Codes
Size/No./Color
Wire Connection Points
Size/No./Color
Wire Connection Points
1.0 201C Red
Splice SP09, A1
5.0 147A Blk
V1 (-), Splice SP08
5.0 257A Org
X13 (A), V1 (A)
5.0 147B Blk
Splice SP08, X07 (B)
5.0 257B Wht
X13 (B), V1 (B)
1.0 147C Blk
Splice SP08, A1
5.0 257C Lt Grn
X13 (C), V1 (C)
1.0 147D Blk
Splice SP08, X09
0.8 303A Org
Splice SP07, X11
5.0 201A Red
V1 (+), Splice SP09
0.8 303B Org
Splice SP07, X08B
5.0 201B Red
Splice SP09, X07 (A)
1.0 303C Org
Splice SP07, A1
W4 Auxiliary Light Wiring Harness [Optional]
220 Red
200 Red
E
C
A
D
B
S6
Light Switch
200 Red
G2
Auxiliary
Alternator
220 Red
100 Blk
B
A
100 Blk
E1 Light
mif
W4 Wire Color Codes
Size/No./Color
Wire Connection Points
1.0 100 Blk
E1 (A), G2
1.0 220 Red
E1 (B), S6 (C)
1.0 200 Red
S6 (A), G2
Electrical Schematics and Harnesses - 102
ELECTRICAL OPERATION AND DIAGNOSTICS
Operation and Diagnostics
Power Circuit Operation
The machine does not have a battery and therefore no
power is provided to the electrical circuits unless the engine
is running. The engine drives the alternator.
A separate 12 volt wall outlet supply is needed to power the
Service ADVISOR™ EDL (electronic data link). The EDL is
required to connect a computer to the machine.
Alternator
The alternator is driven by the engine and a connecting
belt. The alternator produces a 3 phase 48 volt output that
goes to the bridge rectifier.
There is a 12 volt sensor power input to the alternator from
the reel motor controller.
Bridge Rectifier
The bridge rectifier is a three phase full wave bridge
rectifier that converts the alternating current power from the
alternator output to 48 volts direct current. The 48 volts DC
powers the reel motor controller and subsequently the rest
of the power circuits.
Reel Motor Controller
The reel motor controller has several different voltage
outputs.
The controller contains a voltage inverter to supply power
to the reel motor. The output is a 20 kHz pulse width
modulation (PWM) signal which is variable to change the
speed of the reel motor.
The controller produces a 4.3 volt DC output. The output is
provided to the frequency of cut (FOC) potentiometer. The
4.3 to 0 volt return signal from the FOC potentiometer
controls the output signal that controls the reel speed.
A ground input signal from the backlap switch will change
the output power to the reel motor causing it to rotate in the
opposite direction.
The controller has two 12 volt DC outputs. The 12 volt
output to the reel motor provides power to the reels internal
Hall sensor. The 12 volt DC supply output provides power
to the hourmeter and to the alternator internal Hall sensor.
Electrical Operation and Diagnostics - 103
ELECTRICAL OPERATION AND DIAGNOSTICS
Power Circuit Schematic
X07
J1
48V
RMC8
Reel
Motor
Controller
Blk
Red
B
A
X02
P2
Phase C Lt Grn
Phase B Blk
Phase A Org
C
B
A
12 V Sensor Output
FOC Pot Output
FOC Pot Input
J6
E
D
C
B
A
K
J
H
G
F
Supply Output
X03
F
E
D
C
B
A
F
E
D
C
B
A
Red
Blk
J4
E
A
B
F
D
C
Lt Grn
Blk
Org
C
B
A
C
B
A
P1
F
E
D
C
B
A
147B Blk
201B Red
B
A
B
A
F
E
D
C
B
A
Red
Blk
X06
E
A
B
F
D
C
E
A
B
F
D
C
Blk
Red
Wht
112A Blk
A
B
C
M1 Reel
Motor
SP01
258A Red
318A Wht
X05
E
D
C
B
A
K
J
H
G
F
Org
E
D
C
B
A
K
J
H
G
F
SP02
601 Red
254A Pnk
600 Blk
601A Red
147D Blk
X09
Engine
Belt Drive
1.21 : 1
X12
600 Blk
601A Red
A
E
F
B
C
D
A
E
F
B
C
D
Blk
Red
X13
A
E
F
B
C
D
A
B
C
Org
Blk
Lt Grn
A
B
C
G1 Alternator
SE1 - Controller and Reel Motor
SE2 - Engine / Alternator
mif
Electrical Operation and Diagnostics - 104
A
B
C
257A Org
257B Wht
257C Lt Grn
48 Volt AC
48 Volt DC
12 Volt DC
4.3 Volt DC
4.3 to 0 Volt DC
ELECTRICAL OPERATION AND DIAGNOSTICS
Power Circuit Schematic (2 of 2)
147B Blk
201B Red
X14A
X14B
A
B
C
D
E
F
G
H
J
K
A
B
C
D
E
F
G
H
J
K
258A Red
318A Wht
254A Pnk
R3 Frequency of
Cut (FOC)
Potentiometer
318B Wht
258B Red
258B Red
318B Wht
C
B
A
C Pot C Blk
Pot B Blk
B
Pot A Blk
A
C
B
A
5.8k
254B Pnk
147D Blk
48V Sense
201C Red
147B Blk
147C Blk
147C Blk
P1
Hourmeter
147A Blk
Run/Off Switch
Gnd
254B Pnk
201B Red
201C Red
B
A
A B
A1 Voltage
Controlled
Rev Limiter
SP08
SP09 201A Red
V1 3 Phase Full Wave
Bridge Rectifier
A
257A Org
257B Wht
257C Lt Grn
DC POS
201A Red
DC NEG
147A Blk
B
C
SE5 - Controls
SE4 - Rectifier
mif
Electrical Operation and Diagnostics - 105
ELECTRICAL OPERATION AND DIAGNOSTICS
System: Power Supply Diagnostic Check
Power Supply Check
Ignition Circuit Operation - Engine Shutting
Off
Operating Conditions
Function
•
Machine parked safely on stand
•
Remove reel motor from reel
To shut the engine off by grounding the ignition coil through
the run/off switch.
• Connect Service ADVISOR computer with separate 12
VDC power supply to electronic data link (EDL).
Do not make any effort to measure high voltages anyplace
except at the bridge rectifier for the 48V. Service ADVISOR
will tell you what the voltage is at the input to the controller
48 Volt Power Supply Diagnostics
1. Start engine and run at specified idle. Engage reel
motor and read current on motor. Is the current reading
1 - 3 amps? [RLK WBG Motor Current]
Operating Conditions
•
Run/Off switch in off position.
Theory of Operation
When the run/off switch is moved to the off position, a path
to ground is provided through the switch. This prevents
voltage from building up in the coil primary windings,
preventing a spark from being generated.
Yes: Go to next step.
No: Check for belt slippage. (See “Drive Belt Tension
Check and Adjustment” on page 170.)
2. Check the ECU power supply voltage. Is the ECU
power supply 42 VDC or higher? [RLK WBG ECU
Power Supply Voltage #1, Switched]
Yes: Power supply tests good.
No: Go to next step.
3. Test rectifier. (See “Bridge Rectifier Test” on
page 160.) Does the rectifier test okay?
Yes: Swap the alternator with known good alternator.
Submit DTAC case with Readings data of before and
after alternator change.
No: Replace bridge rectifier.
Specification
Engine RPM Speed. . . . . . . . . . . . . . . . . . .2645 ± 10 rpm
Electrical Operation and Diagnostics - 106
ELECTRICAL OPERATION AND DIAGNOSTICS
Ignition Circuit Schematic
X14A
X14B
A
B
C
D
E
F
G
H
J
K
A
B
C
D
E
F
G
H
J
K
302A Org
126A Blk
302B Org
126B Blk
S5 Run/Off
Switch
A1 Voltage
Controlled
Rev Limiter
302A Org
X08A
X08B
48V Sense
Run/Off Switch
303C Org
Gnd
147C Blk
SP07
303B Org
147C Blk
303C Org
303A Org
V1 3 Phase Full Wave
Bridge Rectifier
A
X11
DC POS
B
Coil
DC NEG
C
SP08
Spark
Plug
147D Blk
MIF
Electrical Operation and Diagnostics - 107
147A Blk
ELECTRICAL OPERATION AND DIAGNOSTICS
System: Ignition Circuit Diagnosis
Test Conditions
•
Run/Off switch in off position.
•
Travel clutch in neutral position.
• Check connection(s) for corrosion and looseness
when checking/testing.
200 Yel/Red
MIF
When diagnosing an ignition problem, isolate the magneto
circuit from the ground circuit by disconnecting the run/off
switch connectors. If the engine will not start, check the
magneto circuit first and then the ground circuit. If the
engine will not shut off, check the ground circuit first.
Remember, the engine is stopped by grounding the ignition
coil through the run/off switch.
3. Run/Off switch in run position. Ignition coil
connected to 303A Org wire. Measure resistance at
run/off switch, terminal 2 (302B Org wire). Is resistance
0.8-1.0 ohm?
Test Procedure
No: Test 302 Org wires and connections.
1. Perform spark test. (See “Test Spark” on page 39.)
Does test produce a strong blue spark?
Yes: Go to next step.
Yes: Go to next step.
4. Run/Off switch in the off position. Measure
resistance at run/off switch, terminal 2 (302B Org wire).
Is resistance more than 0.1 ohm?
Yes: Go to next step.
No: No spark present. Test ignition coil. (See “Test
Ignition Coil” on page 55.)
No: No spark present. Check armature air gap. (See
“Adjust Air Gap” on page 55.)
No: No spark present. Check flywheel magnet. (See
“Test Flywheel Magnet” on page 158.)
No: No spark present. Possible rev limiter failed, will
ground out solenoid. Replace rev limiter if all other
components test okay.
No: Test ignition coil. (See “Test Ignition Coil” on
page 55.)
5. Measure resistance at run/off switch, terminal 3
(126B Blk wire). Is resistance more than 0.1 ohm?
Yes: Go to next step.
No: Replace run/off switch.
No: Weak spark. Check spark plug condition and gap.
(See “Adjust Spark Plug Gap” on page 40.) If plug is
good, continue checking ignition circuit.
B
M83752
A
6. Measure resistance from ground screw to engine
block (B). Is resistance less than 0.1 ohm?
No: Clean connections between ground wire and
engine block.
MX6279
2. Ignition coil disconnected (A). Connect positive lead
of ohmmeter to ignition coil. Is resistance 0.8-1.0 ohm?
Yes: Go to next step.
No: Check ignition coil. (See “Test Ignition Coil” on
page 55.)
Electrical Operation and Diagnostics - 108
ELECTRICAL OPERATION AND DIAGNOSTICS
Symptom: Engine Won’t Start or Feels
Loaded While Starting
Starting Problems
Procedure:
1. Check that the engine has good spark. (See “Test
Spark” on page 39.) Is there a good spark?
Yes: Go to next step.
No: Check ignition circuit (See “System: Ignition Circuit
Diagnosis” on page 108.)
2. Disconnect the motor controller from the 48V bus via
the 2-pin 48V connector. Attempt to start engine. Does
the engine start?
Yes: Shut off engine and reconnect the motor
controller. Check suspect connector or controller short.
Inspect connector and controller harness. Before
replacing controller re-connect and attempt to start
again.
No: Go to next step.
3. Test the bridge rectifier. (See “Bridge Rectifier Test”
on page 160.) Does the rectifier test okay?
Yes: Go to next step.
No: Replace the bridge rectifier.
4. Disconnect the alternator belt. Does the engine
start?
Yes: Test for phase shorts in the alternator. If phases
are shorted, swap with a known good alternator.
No: Engine problem. (See “Engine Cranks But Will Not
Start” on page 32, or “Engine Runs Poorly at Low
RPM” on page 32.)
Electrical Operation and Diagnostics - 109
ELECTRICAL ELECTRONIC CONTROLLERS
Electronic Controllers
CAN Network Voltage Checks
Data Bus Systems
Note: These procedures should be followed in
sequence until the problem is resolved.
The reel motor controller electronic control unit is connected via the W2 lower wiring harness and a data bus system (CAN BUS [CAN = CONTROLLER AREA
NETWORK]).
The data BUS system forms a communication network for
data-sharing and diagnostics.
Reason:
To check the CAN Hi(+) and CAN Lo(-) signals for proper
voltage.
Equipment:
•
Multimeter
The lines that link up the elements of a data BUS system
are known as communication lines.
• A separate 12 volt wall outlet supply is needed to power
the Service ADVISOR™ EDL (electronic data link). The
EDL is required to connect a computer to the machine.
CAN Bus Theory of Operation
Check for proper voltage:
The Controller Area Network (CAN-BUS) is used to allow
communication to the control unit.
The CAN bus has terminating resistors in the bus. The
terminating resistors are required to reduce faults in the
communication lines
1. Park machine safely.
2. Connect a ground lead to the engine ground (located on
the front of the engine) and route it close to the CAN
diagnostic connector.
3. Start the engine.
The control unit can send and receive digital messages via
the CAN-BUS.
In order to regulate the information being transmitted, the
electronic control unit has an interface controller built in.
While the electronic control unit is fully occupied performing
its own tasks, the interface controller manages the
information on the CAN-BUS and passes required
information onto the bus.
A
Diagnostic Trouble Codes (DTCs) are based on the CAN
ISO and J1939 SAE Standards. These are worldwide
standards for automotive and off-highway machines and
are controlled by an ISO industry committee.
B
MX40887
4. Use a multimeter to measure CAN Hi (A) and CAN Lo
(B) voltages at the Service ADVISOR diagnostic connector.
5. Correct readings (desired):
•
CAN Hi (A to ground): 2.50 - 3.50 V
•
CAN Lo (B to ground): 1.50 - 2.49 V
6. Incorrect readings:
•
One or both voltages above 5 V.
•
One or both voltages below 1 V.
•
CAN Hi and CAN Lo voltages are equal.
•
Voltages out of specification but between 1 - 5 V.
Electrical Electronic Controllers - 110
ELECTRICAL ELECTRONIC CONTROLLERS
Check for Short Circuits to CAN Hi and CAN Lo:
1. This check should only be performed if the previous
checks of CAN Hi and CAN Lo indicated:
CAN Hi Result
(A)
CAN Lo Result
(B)
0.1V
0.06 - 0.14
•
Voltage at or near battery voltage.
•
Voltage above 5 volts.
0.2V
0.13 - 0.27
•
Voltage below 1 volt.
0.3V
0.21 - 0.4
0.4V
0.26 - 0.54
0.5V
0.33 - 0.67
0.6V
0.39 - 0.81
0.7V
0.46 - 0.94
0.8V
0.52 - 1.0
0.9V
0.59 - 1.0
1.0V
0.65 - 1.0
• Voltages of CAN Hi and CAN Lo were stable and
equal.
2. Verify all connectors and terminators are connected.
3. Start the engine.
3. If results are within acceptable limits according to table:
A
•
B
CAN differential voltage is OK.
4. If results are not within acceptable limits according to
table:
MX40887
4. Use a multimeter to measure CAN Hi (A) and CAN Lo
(B) voltages at the Service ADVISOR diagnostic connector,
from machine engine ground to CAN Hi and CAN Lo.
Record values.
• CAN Hi result approximately 2X CAN Lo result. Loss
of CAN Lo between controller and passive terminator.
• CAN Lo result approximately 2X CAN Hi result. Loss
of CAN Hi between controller and passive terminator.
5. Remove one of the two CAN passive terminators.
Voltages Within Range but Out of Specification:
6. Check for a change in voltage on CAN Hi and CAN Lo
from value recorded. If voltage changed, terminator is bad,
replace passive terminator.
Perform the following until voltages are within specification:
7. Repeat procedure for the other terminator.
Note: Voltage higher than 5 V on either CAN Hi or CAN
Lo indicates a short to high voltage. Voltage lower than
1 V indicates a short to ground. If CAN Hi and CAN Lo
are equal, they could be shorted together.
1. Replace or test passive terminators.
2. With engine off and terminators removed, perform
continuity checks on all CAN bus circuits. See CAN Bus
Topology diagrams for machine’s configuration.
Compare CAN Hi and CAN Lo Voltages:
Note: The CAN bias voltage is 2.5 V on the CAN Hi and
Lo. To evaluate the CAN Hi and CAN Lo circuits, the
voltage recorded for each must be calculated in
reference to this bias.
1. To calculate CAN voltage bias differential where A=CAN
Hi voltage and where B=CAN Lo voltage and:
•
CAN Hi: Recorded voltage minus 2.5V=A
•
CAN Lo: 2.5V minus Recorded voltage=B
2. Compare results from CAN Hi and CAN Lo calculations.
Values must be within 35% of each other. Use the following
table to evaluate:
Electrical Electronic Controllers - 111
ELECTRICAL ELECTRONIC CONTROLLERS
Troubleshooting Electronic Controllers
Note: This reference is a guideline for troubleshooting
problems that still exist after standard diagnostics have
been performed. These problems are typically due to
specific operating conditions, intermittent failures or, in rare
cases, control unit failures. Depending on the situation,
some or all of the following may be important.
Problems Due to Specific Operating Conditions:
Review all recorded codes and consult with operator to
determine operating and machine conditions when the
problem occurs. Record details.
• Does code/problem occur at the same time as other
problems?
• Does code/problem occur when machine is warm or
cold?
• Does code/problem occur during field or transport
operation?
• Does code/problem occur while performing a specific
action?
• When did code/problem first appear? Was there any
maintenance performed recently? (If yes, inspect areas of
maintenance for inadvertent damage or improper
installations.)
Attempt to recreate code/problem based on conditions. If
possible, repeat operational, system, electrical or
mechanical checks under these conditions.
Problems Due to Intermittent Electrical Failures:
Note: Electrical intermittent failures are usually caused
by harness, terminal or connector problems.
•
Inspect all connectors and terminals of related circuits.
• Inspect mechanical linkages for interference with
harnesses or connectors.
• Inspect harnesses for missing or improperly installed
clamps or bands. Loose harnesses that are allowed to
move too freely or harnesses that are banded too tightly
may result in worn or damaged wires.
• Inspect mechanical linkages for proper operating
condition.
Problems Due to Control Unit Failures:
Note: Before replacing control unit, review all tests.
Control units are the least likely cause of failure!
• If all checks have been made with no problems
identified, check power and ground circuits.
Accessing Addresses and Diagnostic Trouble
Codes
The control unit monitors electrical circuits. The unit then
stores the relevant diagnostic trouble code if there is a malfunction (error). However, not all of the diagnostic trouble
codes indicate a current problem, since most of the circuits
are monitored only at the actual moment of activation or
when they are actually activated (switched on). To make
sure that the diagnostic trouble code you are troubleshooting is ”active”, you should proceed as follows:
1. General procedure for dealing with diagnostic
trouble codes:
• Start the machine and check for diagnostic LED blink
codes (fault codes)
• Carry out an operational test (activate the circuit
affected) or test operation of the machine
• If it is not possible to (re-)produce a relevant
diagnostic fault code by means of a functional check and
the problem is still present in the circuit, deal with the
codes you noted earlier.
2. Procedure for dealing with diagnostic trouble codes
using Service ADVISOR:
• Access diagnostic trouble codes via the ”Diagnostic”
tab
•
”Active” diagnostic trouble codes take priority
•
If no "ACTIVE" diagnostic trouble codes are present:
❏ Delete diagnostic trouble code(s)
❏ Carry out an operational test (activate the circuit
affected) or test operation of the machine
❏ Shut off engine and turn restart it after five seconds
(re-initiate the control units)
❏ If no active diagnostic trouble codes are present,
deal with the ”SAVED” codes
❏ If it is not possible to (re-)produce a relevant
diagnostic trouble code by means of a functional check
or operational test, and the circuit problem persists, the
cleared diagnostic trouble codes must be checked; if the
codes are associated with the problem on the machine,
they must be processed.
Note: Cleared diagnostic trouble codes should only be
dealt with if it is not possible to (re-)produce the
problem on the machine (no active or saved codes are
present after a functional test has been carried out)
and when the description of diagnostic trouble code
can be associated with the machine problem.
• Inspect all connectors and terminals of associated
control units.
Electrical Electronic Controllers - 112
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
3. Processing cleared diagnostic trouble codes using
Service ADVISOR:
• Every time a diagnostic trouble code is accessed, it
is saved in Service ADVISOR in the ”Readings Logs” of
the job that is being processed. Before it is cleared, the
diagnostic trouble code status of the machine can be
accessed via the ”Sessions” menu or ”Logs”.
4. Status of diagnostic trouble codes in Service
ADVISOR:
•
Status: ”ACTIVE” (priority I):
❏ Diagnostic trouble code cannot be cleared.
❏ Current problem with the machine.
•
Status: ”SAVED” (priority 2):
❏ Diagnostic trouble code can be cleared
❏ At present the problem is not recognized by the
control unit (example: faulty switch or circuit not
activated at the moment).
Approved Software for Control Unit
Important: Avoid Damage! When reprogramming
electronic control units, always comply with the
relevant instructions (e.g. installation instructions,
DTAC or PIP).
Do NOT reprogram the control unit if the version
numbers of the new and current software are
identical, or if the control unit is already
programmed with a newer software version.
Note: New software always includes the properties that
were newly introduced with the previous software.
However, not all software versions can be used on every
machine.
Note: The software for reprogramming is either supplied
with the Service ADVISOR data DVD, or else it must be
downloaded from John Deere's Intranet (John Deere
Custom Performance (Software Delivery System)).
For the current summary of software, see PATHWAYS or
DTAC.
All identical controllers on the machine should be running
the same software version.
Controller and Motor Diagnostics
Electronic Controller Theory of Operation
Controllers Onboard Machine:
Reel Motor Controller - Controls the reel motor functions,
monitors for faults, and drives trouble and fault codes.
The reel motor controller has several different voltage
outputs. (See “Power Circuit Operation” on page 103.)
The controller supplies power to the reel motor. The output
is a 20 kHz pulse width modulation (PWM) signal which is
variable to change the speed of the reel motor.
The controller also supplies a 4.3 volt DC output to the
frequency of cut (FOC) potentiometer. The 4.3 to 0 volt
return signal from the FOC potentiometer controls the
output signal that controls the reel speed.
A ground input signal from the backlap switch will change
the output power to the reel motor causing it to rotate in the
opposite direction and at a slower speed.
The controller has two 12 volt DC outputs. The 12 volt
output to the reel motor provides power to the reels internal
Hall sensor. The 12 volt DC supply output provides power
to the hourmeter and to the alternator internal Hall sensor.
The reel motor controller uses the CAN bus system to
supply Service ADVISOR with readings and diagnostic
trouble codes (DTCs). The CAN bus is not connected to
anything else. A separate 12 volt wall outlet supply is
needed to power the Service ADVISOR™ EDL (electronic
data link). The EDL is required to connect a computer to
the machine.
If the controller has an active DTC, it may shut down the
reel motor, or the engine.
Diagnostic codes are a function of the CAN bus system,
and fault codes are a separate logic output to the
diagnostic LED on the control panel.
Diagnostic Trouble Codes (DTCs)
DTCs are CAN bus system codes that are created by the
controller and stored in the controller memory. They are
non-volatile codes that can be recalled and displayed using
Service ADVISOR software. The Service ADVISOR
software can used used to clear DTCs from the controller
memory.
Fault Codes (LED Display Blink Codes)
Fault codes are created by the controller and sent as an
output to the LED to be a visual representation of faults
present at that time. (See “Diagnostic LED Fault Codes” on
page 116 for reading procedure.)
Fault code driven blink codes Fault codes are also meant to
be used as an aid in diagnosing some machine problems.
Electrical Controller and Motor Diagnostics - 113
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
Diagnostic LED Blink Codes (Fault Codes)
temperature resulted in shutting down motor.
Electronic Control Module Diagnostic Codes
• Code 8-2 (Eight pulses followed by a short pause
followed by two pulses.) Indicates failure to hold frequency
of clip (FOC) due to excessive load or jammed reel.
Note: The code will cycle continuously with a 2-second
pause between display cycles.
Only one code can be displayed at a time. Repeat
check procedure after repairs have been completed.
It is important to remember that the LED displayed fault
codes are not stored in the controllers memory. If the
machine is shut down the fault codes can not be recalled
later.
• Code 1-5 (One pulse followed by a short pause followed
by five pulses.) Indicates that the motor failed to start.
• Code 1-6 (One pulse followed by a short pause followed
by six pulses.) Indicates that the reel stalled.
• Code 1-7 (One pulses followed by a short pause
followed by seven pulses.) Indicates low alternator voltage.
• Code 1-10 (One pulses followed by a short pause
followed by ten pulses.) Indicates reel direction reversed for
1/4 turn of motor.
• Code 2-5 (Two pulses followed by a short pause
followed by two pulses.) Indicates that motor current over
the limit, due to excessive loads or jammed reel.
• Code 8-3 (Eight pulses followed by a short pause
followed by three pulses.) Indicates alternator speed
sensor error resulted in shutting down motor.
• Code 8-4 (Eight pulses followed by a short pause
followed by four pulses.) Indicates incorrect controller for
this machine.
• Code 9-2 (Nine pulses followed by a short pause
followed by two pulses.) Indicates alternator output too
high.
• Code 9-3 (Nine pulses followed by a short pause
followed by three pulses.) Indicates internal controller
failure.
• Code 9-5 (Nine pulses followed by a short pause
followed by five pulses.) Motor position sensor supply is
shorted to external power line or ground.
• Code 9-7 (Nine pulses followed by a short pause
followed by seven pulses.) Indicates supply voltage from
controller to speed potentiometer is low/high.
• Code 2-9 (Two pulses followed by a short pause
followed by nine pulses.) Indicates internal controller
temperature resulted in controller shutting down motor.
• Code 2-10 (Two pulses followed by a short pause
followed by ten pulses.) Indicates internal motor
temperature resulted in controller shutting down motor.
• Code 6-4 (Six pulses followed by a short pause followed
by four pulses.) Indicates motor position sensor error at
start.
• Code 6-6 (Six pulses followed by a short pause followed
by six pulses.) Indicates motor position sensor error while
running.
• Code 7-2 (Seven pulses followed by a short pause
followed by two pulses.) Indicates phase short to ground.
• Code 7-3 (Seven pulses followed by a short pause
followed by three pulses.) Phase wire shorted to supply
line.
• Code 7-4 (Seven pulses followed by a short pause
followed by four pulses. Phase wire open between motor
and controller.
• Code 7-5 (Seven pulses followed by a short pause
followed by five pulses.) Indicates potentiometer speed
control voltage is too low.
• Code 8-1 (Eight pulses followed by a short pause
followed by one pulse.) Indicates internal alternator
Electrical Controller and Motor Diagnostics - 114
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
Reel Motor Theory of Operation
Reel Motor Controller Signals
Overview:
CAN:
The machine has an electric reel motor controlled by the
reel motor controller. The motor has various sensors to
provide feedback to the controller for command, safety, and
diagnostic functions.
• J6-X05 Org, pin A - Hour Meter, Alternator Hall Supply
(output)
Theory of Operation:
The motor is a brushless DC, three phase, bidirectional
type. All aspects of the motor’s functionality is controlled by
the controller.
When conditions are correct for motor operation, three
phase, pulse width modulated, current at 48Vdc will be
supplied to the motor. The motor will then spin at a nominal
2800 rpm (±10%). The motor’s normal ambient operating
temperature is -20°C to +40°C (-4°F to 104°F).
As the motor spins, internal Hall effect sensors provide the
controller with speed, stalling, and direction of spin
information.
The motor also has a thermal protection circuit. This is a
normally closed switch when operating conditions are met.
If the motor experiences an internal overtemp condition
(140±5°C [284±11°F}), the switch will open and the
controller will stop the motor until it cools.
As the motor sends sensor information back to the
controller, the controller broadcasts this information on the
CAN bus. This will consist of either motor operational
parameters or as diagnostic trouble codes. This information
can be read using Service ADVISOR. An abbreviated
version is sent to the diagnostic LED as blink codes.
•
J6-X05 Pur, pin B - Clutch Switch Digital Input (Gnd)
•
J6-X05 Wht, pin C - PTO Switch Digital Input (Gnd)
• J6-X05 Blu, pin D - Alternator Thermal Switch (Analog
In)
•
J6-X05 Red, pin E - Not Used
•
J6-X05 Pnk, pin F - Not Used
•
J6-X05 Yel, pin G- CAN Hi
•
J6-X05 Grn, pin H - CAN Lo
•
J6-X05 Blk, pin J - Not Used
• CJ6-X05 Brn, pin K - Alternator Hall Effect (Engine
Speed) (Frequency Digital Input)
Motor Control:
• J4-X06 Grn, pin A - Park Brake Switch (0Vdc to enable)
(input)
•
J4-X06 Blk, pin B - Gnd
• J4-X06 Wht, pin C - FOC potentiometer in, 4.3Vdc to
0Vdc
•
J4-X06 Red, pin D - FOC potentiometer supply, 4.3Vdc
• J4-X06 Brn, pin E - Reel direction (0Vdc= FWD,
4.3Vdc= REV) (input)
• J4-X06 Blu, pin F - Fault out to Diagnostic LED (reel
blink code)
Motor Sensors:
•
P1 Blk, pin A - Sensor Return Input
•
P1 Red, pin B - 12Vdc Sensor Power Output
•
P1 Blu, pin C - Thermal Shutdown Input
•
P1 Brn, pin D - Hall C-A Input
•
P1 Wht, pin E - Hall B-C Input
•
P1 Grn, pin F - Hall A-B Input
Reel Motor Power:
•
P2 Org, pin A - Phase A Output
•
P2 Blk, pin B - Phase B Output
•
P2 Grn, pin C - Phase C Output
Controller Power:
•
X07 or P1-X07, Red, pin A - 48Vdc Input
•
X07 or P1-X07, Blk, pin B - 48Vdc Gnd
Electrical Controller and Motor Diagnostics - 115
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
Alternator Signals
Sensors:
•
the backlap/mow switch is in BACKLAP position.
•
the parking brake is engaged.
• the travel lever is released to the (rearward) disengaged
position.
•
P1-M1 Blk, pin A - Sensor Return Output
•
P1-M1 Red, pin B - 12Vdc Sensor Power Input
•
P1-M1 Blu, pin C - Thermal Shutdown Output
•
P1-M1 Brn, pin D - Hall C-A Output (engine speed)
Using Mow/Backlap Switch
•
P1-M1 Wht, pin E - Not Used
•
P1-M1 Grn, pin F - Not Used
The Mow/Backlap switch should be in the mow position for
all mowing and transport operation. The switch backlap
position is only used during machine service. (See
Backlapping Cutting Units in SERVICE section.)
Reel Motor Power:
•
P2 Org, pin A - Phase A Output
•
P2 Blk, pin B - Phase B Output
•
P2 Grn, pin C - Phase C Output
Diagnostic LED Fault Codes
If there is an active diagnostic trouble code (DTC), the
diagnostic LED will flash. This will be a series of blinks
followed by a pause and another series of blinks. These
blink codes are a concise version of the full Walk Behind
Greens mower (WBG) diagnostic trouble codes (DTCs).
Operating Conditions
Using Run Switch
•
Pushing the PTO switch to the disengaged position will
stop mowing and backlapping reel rotation.
Push run/stop toggle switch forward to run engine.
• Pull run/stop toggle switch back (toward operator) to
stop engine.
Using Operator Presence Bail
c Caution:
Avoid Injury! This machine is
equipped with an operator presence system to
protect the operator and bystanders. Do not
attempt to alter the function of the operator
presence system.
• The display panel (Blink Codes) display a code to inform
the operator of a problem. This code will corollate to the
WBG error, but will not reveal the specific type of failure (i.e.
it will reveal what component is having trouble, but not
necessarily what the specific problem is).
The WBG DTC codes will only be seen when using Service
ADVISOR.
Service ADVISOR Live Readings
GTMower(J1939)
WBG - Walk Behind Greens Mower
•
WBG Clutch Switch
•
WBG Direction Switch
The operator presence bail when squeezed with handlebar
permits engagement of the travel lever and cutting unit.
•
WBG Drive Motor Speed
•
WBG Drive Motor Speed Command
Using PTO Switch
• WBG Drive Motor Torque Limit Command - Driving
Torque
The operator presence bail stops the machine forward
travel and cutting unit when released.
Pushing the PTO switch to the ON position will engage the
cutting unit for mowing operation only if all the following
conditions are met:
• the operator presence bail is pushed forward and held
with the handlebar.
•
the parking brake is released.
• the travel lever is pushed forward into the engaged
position.
•
•
WBG ECU Power Supply Voltage #1, Switched
•
WBG Motor Current
•
WBG Motor Driver Heat Sink Temperature
•
WBG Operating Modes
•
WBG PTO State
•
WBG Parking Brake Switch
the backlap/mow switch is in MOW position.
Pushing the PTO switch to the ON position will engage the
cutting unit for backlapping service only if all following
conditions are met:
Electrical Controller and Motor Diagnostics - 116
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
Symptom: Diagnostic LED Fault Codes
There are some controller errors that may cause the
controller or reel to shut down, or cause the reel to slow
down, that do not have blink codes. If the engine will run but
the reel does not operate there may be a DTC code
produced that does not have a corresponding blink code.
Service ADVISOR must be used to check for those DTC
codes. (See “DTC Error Codes Table” on page 120.)
LED Blink Code
Check
Possible DTC Codes
Code 1-5 Indicates that the motor
failed to start.
Jammed reel.
WBG_522918.00
Tight reel to bed knife clearance.
Failed bearings.
Code 1-6 Indicates that the reel
stalled.
Jammed reel.
WBG_522918.15
Tight reel to bed knife clearance.
Failed bearings.
Code 1-7 Indicates low alternator
voltage.
Engine RPM too low.
WBG_523666.01
Low or no voltage output from alternator.
WBG_523666.02
Poor connections on alternator or alternator harness.
Alternator belt slippage.
Alternator malfunction.
Excessive reel load from items in Code 1-6.
Code 1-10 Indicates reel direction
reversed for 1/4 turn of motor.
Jammed reel.
WBG_522918.02
Jammed or failed attachment.
Damaged bed knife or reel.
Code 2-5 (2-8) Indicates that
motor current over the limit, due to
excessive loads or jammed reel.
(high current draw)
Jammed reel.
WBG_522917.00
Tight reel to bed knife clearance.
WBG_522917.06
Failed bearings.
WBG_522917.15
WBG_522917.16
Code 2-9 Indicates internal
controller temperature resulted in
controller shutting down motor.
(high current draw)
Tight reel to bed knife clearance.
WBG_521153.15
Cutting unit not turning freely.
Overheated controller.
Controller cooling fins plugged with debris.
Heavy load on motor.
Code 2-10 Indicates high internal
motor temperature resulted in
controller shutting down motor.
Disconnected wiring harness connectors.
WBG_522327.00
Reel motor wires are damaged.
Cutting unit not turning freely.
Dull reel or bed knife.
Heavy load on motor.
Code 6-4 Indicates motor position
sensor error at start.
Disconnected wiring harness connectors.
Damaged or broken wires.
Electrical Controller and Motor Diagnostics - 117
WBG_522919.12
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
LED Blink Code
Check
Possible DTC Codes
Code 6-6 Indicates motor position
sensor error while running.
Tight reel to bed knife clearance.
WBG_522919.03
Cutting unit jammed by debris.
Overheated reel motor.
Disconnected wiring harness connectors.
Damaged or broken wires.
Jammed or failed attachment.
Code 7-2 Indicates phase short to
ground.
Debris in connectors.
WBG_2513.04
Wires from controller to motors shorted to ground.
WBG_2514.04
Internal short in motor.
WBG_2514.04
Internal short in controller.
Code 7-3 Indicates high current to
motor, or phase short to supply.
Broken or damaged wires between motor and controller.
WBG_2513.03
Contaminated connections between motor and controller.
WBG_2514.03
WBG_2515.03
Code 7-4 Indicates open highamperage wire between motor
and controller.
Broken or damaged wires between motor and controller.
WBG_2513.05
Contaminated connections between motor and controller.
WBG_2514.05
WBG_2515.05
Code 7-5 Indicates potentiometer
speed control voltage is too high
or too low.
Poor connection between controller and frequency of cut
potentiometer.
WBG_3509.00
WBG_3509.01
Damaged wires between controller and frequency of cut
potentiometer.
Potentiometer malfunction.
Code 8-1 Indicates internal
alternator temperature resulted in
shutting down motor.
Tight reel to bed knife clearance.
WBG_3353.00
Dull reel or bed knife.
Heavy load on motor.
Cutting unit not turning freely.
Disconnected wiring harness connectors.
Code 8-2 Indicates failure to hold
frequency of clip (FOC) due to
excessive load or jammed reel.
Cutting unit jammed by debris.
WBG_522937.02
Tight reel to bed knife clearance.
Dull reel or bed knife.
Cutting unit not turning freely.
Jammed or failed attachment.
Code 8-3 Indicates alternator
speed sensor error resulted in
shutting down motor.
Disconnected wiring harness connectors.
Code 8-4 Indicates incorrect
controller for this machine.
Wrong controller on machine. Need to replace with proper
controller for model of machine.
WBG_522976.12
Code 9-2 Indicates alternator
output too high.
Alternator malfunction.
WBG_523666.00
WBG_3353.01
Damaged or broken alternator wires.
Alternator over speed.
Electrical Controller and Motor Diagnostics - 118
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
LED Blink Code
Check
Possible DTC Codes
Code 9-3 Indicates internal
controller voltage regulator failure.
(14 volt output high or low)
Check Diagnostic Troubleshooting Codes - Service
ADVISOR only.
WBG_3597.00
Code 9-5 Indicates signal wires
shorted to external power line or
ground. The signal voltage from
the controller is high or the return
signal voltage is low.
Broken or damaged wires between motor and controller.
WBG_3511.00
Signal wires shorted to ground.
WBG_3511.01
Code 9-7 Indicates supply voltage
from controller to speed
potentiometer is too high or too
low.
Poor connection between controller and frequency of cut
potentiometer.
WBG_3597.01
Contaminated connector.
Damaged wires between controller and frequency of cut
potentiometer.
Shorted ground on frequency of cut potentiometer.
Potentiometer malfunction.
Electrical Controller and Motor Diagnostics - 119
WBG_3510.00
WBG_3510.01
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
DTC Error Codes Table
A separate 12 volt wall outlet supply is needed to power the
Service ADVISOR™ EDL (electronic data link). The EDL is
required to connect a computer to the machine.
A computer with current Service ADVISOR™ software is
required to read the DTC Error Codes.
Diagnostic Trouble Code (DTC)
Blink
Code
PTO
Cycle
Clear
Engine
Fault
Shutdown Description
Clear
Possible Cause/Solution
WBG_00628.12 See
“WBG_000628.12 Stuck in Boot
Block (Blink Code SOLID ON)” on
page 126
SOLID
ON
false
false
STUCK IN
BOOT BLOCK
Programming failure. Install
latest payload into controller
{7 - 3}
WBG_2513.03
See “WBG_002513.03 (Blink Code
7-3) - Orange Phase (A) is Shorted
to Supply” on page 127
false
true
PHASE A
SHORT TO
SUPPLY
(PHASE HIGH)
Inspect high current wires to
motor.
{7 - 2}
WBG_2513.04
See “WBG_002513.04 (Blink Code
7-2) - Orange Phase (A) is Shorted
to Ground” on page 127
false
true
PHASE A
SHORT TO
GND (PHASE
LOW)
Most likely short in highamperage phase wire. Inspect
for damage.
{7 - 4}
WBG_2513.05
See “WBG_002513.05 (Blink Code
7-4) - Orange Phase (A) is Open”
on page 128
false
true
PHASE A
OPEN
Open high-amperage wire.
Check harness and connector.
{7 - 3}
WBG_2514.03
See “WBG_002514.03 (Blink Code
7-3) - Black Phase (B) is Shorted
to Supply” on page 129
false
true
PHASE B
SHORT TO
SUPPLY
(PHASE HIGH)
Inspect high current wires to
motor.
{7 - 2}
WBG_2514.04
See “WBG_002514.04 (Blink Code
7-2) - Black Phase (B) is Shorted
to Ground” on page 129
false
true
PHASE B
SHORT TO
GND (PHASE
LOW)
Most likely short in highamperage phase wire. Inspect
for damage.
{7 - 4}
WBG_2514.05
See “WBG_002514.05 (Blink Code
7-4) - Black Phase (B) is Open” on
page 130
false
true
PHASE B
OPEN
Open high-amperage wire.
Check harness and connector.
{7 - 3}
WBG_2515.03
See “WBG_002515.03 (Blink Code
7-3) - Green Phase (C) is Shorted
to Supply” on page 131
false
true
PHASE C
SHORT TO
SUPPLY
(PHASE HIGH)
Inspect high current wires to
motor.
{7 - 2}
WBG_2515.04
See “WBG_002515.04 (Blink Code
7-2) - Green Phase (C) is Shorted
to Ground” on page 131
false
true
PHASE C
SHORT TO
GND (PHASE
LOW)
Most likely short in highamperage phase wire. Inspect
for damage.
{7 - 4}
WBG_2515.05
See “WBG_002514.05 (Blink Code
7-4) - Green Phase (C) is Open”
on page 132
false
true
PHASE C
OPEN
Open high-amperage wire.
Check harness and connector.
Electrical Controller and Motor Diagnostics - 120
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
Diagnostic Trouble Code (DTC)
Blink
Code
PTO
Cycle
Clear
Engine
Fault
Shutdown Description
Clear
Possible Cause/Solution
{8 - 1}
WBG_3353.00 See
“WBG_003353.00 (Blink Code 8-1)
- Alternator Over Temp Threshold”
on page 133
true
true
Alternator is over temp
threshold. Likely cause is
excessive load. Check belt
tension; Check for failed
bearings.
WBG_3353.01 See
{8 - 3}
“WBG_003353.01 (Blink Code 8-3)
- Alternator Hall Loss” on page 134
false
false
Alternator missed Hall state,
open connection to Hall sensor.
{7 - 5}
WBG_3509.00
See “WBG_003509.00 (Blink Code
7-5) - Pot Signal Voltage High” on
page 134
true
true
HIGH FAULT
POT
Bad connection between
controller and frequency of cut
potentiometer; sensor return
wire is open.
{7 - 5}
WBG_3509.01
See “WBG_003509.01 (Blink Code
7-5) - Pot Signal Voltage Low” on
page 135
true
true
LOW FAULT
POT
Indicates speed potentiometer
wire is shorted to ground or
sensor return or pot supply is
open.
{9 - 7}
WBG_3510.00
See “WBG_003510.00 (Blink Code
9-7) - Pot Supply Voltage High” on
page 136
true
true
HIGH FAULT
POT SUPPLY
Poor connection or bad
connection between controller
and frequency of cut
potentiometer, or potentiometer
malfunction.
{9 - 7}
WBG_3510.01
See “WBG_003510.01 (Blink Code
9-7) - Pot Supply Voltage Low” on
page 137
true
true
LOW FAULT
POT SUPPLY
Poor connection or bad
connection between controller
and frequency of cut
potentiometer, or potentiometer
malfunction.
{9 - 5}
true
true
HIGH FAULT
HALL PWR
9-5 Blink Code: Motor control
sensor wire voltage is High.
Signal wires shorted to external
power line. Inspect connector
and wires. Possible internal
controller regulator failure.
Disconnect motor and inspect
sense wire output from control.
{9 - 5}
WBG_3511.01
See “WBG_003511.01 (Blink Code
9-5) - Hall Voltage Low” on
page 138
true
true
LOW FAULT
HALL PWR
9-5 Blink Code: Motor control
sensor wire voltage is Low.
Signal wires shorted to Ground.
Inspect connector and wires.
Possible internal controller
regulator failure. Disconnect
motor and inspect sense wire
output from control.
{9 - 3}
WBG_3597.00
See “WBG_003597.00 (Blink Code
9-3) - Controller 14V High” on
page 139
true
true
HIGH FAULT
14V
Connections/Controller
WBG_3511.00
“See “WBG_003511.00 (Blink
Code 9-5) - Hall Voltage High” on
page 137
Electrical Controller and Motor Diagnostics - 121
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
Diagnostic Trouble Code (DTC)
Blink
Code
PTO
Cycle
Clear
{9 - 3}
WBG_3597.01
See “WBG_003597.01 (Blink Code
9-3) - Controller 14V Low” on
page 139
true
true
LOW FAULT
14V
Connections/Controller
NONE
false
false
System
reaction
monitor, not a
fault. Used for
internal data
collection.
Manufacturer Service Code
{2 - 9}
WBG_521153.15 See
“WBG_521153.15 (Blink Code 2-9)
- Controller Shutdown Over Temp”
on page 140
true
true
CONTROLLER
OVER TEMP
2-9 Blink Code: Internal
controller temperature resulted
in controller shutting down
motor. Likely heavy load on
motor/controller combined with
high ambient temperature. If
controller is cool to touch and
fault does not clear then suspect
controller.
{2 - 10}
true
true
MOTOR OVER
TEMP
2-10 Blink Code: Internal motor
temperature resulted in
controller shutting down motor.
Likely heavy load on motor/
controller. If happens with 6-1
invalid start position then
connector is off. Let motor cool
and if signal does not clear then
check motor wires for damage.
Do continuity check of internal
motor temperature switch.
{2 - 5}
WBG_522917.00 See
“WBG_522917.00 (Blink Code 2-5)
- Controller Current Threshold 3
Shutdown” on page 142
true
true
OVER
CURRENT3
2-5 Blink Code: Motor current
over the limit. Likely cause is
excessive load. Check for
jammed reel; Check reel to bed
knife clearance; Monitor current
into controller. Check for jammed
reel or failed bearings.
{2 - 8}
WBG_522917.06 See
“WBG_522917.06 (Blink Code 2-8)
- Controller Hardware Current
Shutdown” on page 143
true
true
HARDWARE
OVER
CURRENT
2-5 Blink Code: Motor current
over the limit. Likely cause is
excessive load. Check for
jammed reel; Check reel to bed
knife clearance; Monitor current
into controller. Check for jammed
reel or failed bearings.
WBG_521153.00 See
“WBG_521153.00 (Blink Code
NONE) - Manufacturer Service
Code” on page 140
WBG_522327.00 See
“WBG_522327.00 (Blink Code 210) - Motor Over Temp” on
page 141
Engine
Fault
Shutdown Description
Clear
Electrical Controller and Motor Diagnostics - 122
Possible Cause/Solution
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
Diagnostic Trouble Code (DTC)
Blink
Code
PTO
Cycle
Clear
{2 - 5}
WBG_522917.15 See
“WBG_522917.15 (Blink Code 2-5)
- Controller Current Threshold 1
Shutdown” on page 144
true
true
OVER
CURRENT1
2-5 Blink Code: Motor current
over the limit. Likely cause is
excessive load. Check for
jammed reel; Check reel to bed
knife clearance; Monitor current
into controller. Check for jammed
reel or failed bearings.
{2 - 5}
WBG_522917.16 See
“WBG_522917.16 (Blink Code 2-5)
- Controller Current Threshold 2
Shutdown” on page 145
true
true
OVER
CURRENT2
2-5 Blink Code: Motor current
over the limit. Likely cause is
excessive load. Check for
jammed reel; Check reel to bed
knife clearance; Monitor current
into controller. Check for jammed
reel or failed bearings.
{1 - 5}
WBG_522918.00 See
“WBG_522918.00 (Blink Code 1-5)
- Motor Start Failed 3x Fault” on
page 146
true
false
START FAILED
1-5 Blink Code: Motor failed to
start. Likely mechanical
obstruction in reel. Likely cause
is excessive load. Check for
jammed reel; Check reel to bed
knife clearance; Monitor current
into controller. Check for jammed
reel or failed bearings;
{1 - 10}
true
false
DIR ERROR3
1-10 Blink Code: Reel direction
reversed for 1/4 turn of motor.
Hit obstacle or attachment issue.
Check reel, bed knife,
attachment for damage.
{1 - 6}
WBG_522918.15 See
“WBG_522918.15 (Blink Code 1-6)
- Motor Stalled While Running” on
page 148
true
false
MOTOR
STALLED
1-6 Blink Code: Motor stalled
while running. Reel obstructed
while turning. Likely cause is
excessive load. Check for
jammed reel; Check reel to bed
knife clearance; Monitor current
into controller. Check for jammed
reel or failed bearings.
NONE
false
false
System
reaction
monitor, not a
fault. Used for
internal data
collection.
Manufacturer Service Code
WBG_522918.02 See
“WBG_522918.02 (Blink Code 110) - Motor Spin Direction
Shutdown” on page 147
WBG_522919.02 See
“WBG_522919.02 (Blink Code
NONE) - Manufacturer Service
Code” on page 149
Engine
Fault
Shutdown Description
Clear
Electrical Controller and Motor Diagnostics - 123
Possible Cause/Solution
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
Diagnostic Trouble Code (DTC)
Blink
Code
PTO
Cycle
Clear
Engine
Fault
Shutdown Description
Clear
Possible Cause/Solution
{6 - 6}
WBG_522919.03 See
“WBG_522919.03 (Blink Code 6-6)
- Hall Resync Shutdown” on
page 149
true
false
HALL RESYNC 6-3 Blink Code: Motor position
ERROR
sensor error while running; If
accompanied multiple stalls or
motor hot likely due to heavy
load. Check for contamination in
connectors; bent pin; broken
wiring, failed internal motor
sensor.
WBG_522919.04 See
“WBG_522919.04 (Blink Code
NONE) - Manufacturer Service
Code” on page 150
NONE
false
false
System
reaction
monitor, not a
fault. Used for
internal data
collection.
Manufacturer Service Code
WBG_522919.08 See
“WBG_522919.08 (Blink Code
NONE) - Manufacturer Service
Code” on page 150
NONE
false
false
System
reaction
monitor, not a
fault. Used for
internal data
collection.
Manufacturer Service Code
WBG_522919.09 See
“WBG_522919.09 (Blink Code
NONE) - Manufacturer Service
Code” on page 150
NONE
false
false
System
reaction
monitor, not a
fault. Used for
internal data
collection.
Manufacturer Service Code
{6 - 4}
WBG_522919.12 See
“WBG_522919.12 (Blink Code 6-4)
- Invalid Hall State Detected at
Start-Up” on page 150
false
true
START
POSITION
INVALID
When motor not running there is
an invalid hall pattern. If it occurs
with 2-10 motor temperature
fault, most likely is that connector
is disconnected. Check for
connector off; contamination in
connectors; bent pin; broken
wiring, failed internal motor
sensor.
{8 - 2}
WBG_522937.02 See
“WBG_522937.02 (Blink Code 8-2)
- Frequency of Clip Shutdown” on
page 151
true
false
8-2 Blink Code: Frequency of
clip shutdown. Broadcast motor
speed command not within set
parameter. Alternator rpm too
low.
{8 - 4}
WBG_522976.12 See
“WBG_522976.12 (Blink Code 8-4)
- Incorrect Application Software”
on page 152
false
true
Incorrect Application Software.
Electrical Controller and Motor Diagnostics - 124
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
Diagnostic Trouble Code (DTC)
PTO
Cycle
Clear
Engine
Fault
Shutdown Description
Clear
Possible Cause/Solution
WBG_523666.00 See
{9 - 2}
“WBG_523666.00 (Blink Code 9-2)
- Bus Voltage High” on page 152
true
false
HIGH FAULT
VBUS
9-2 Blink Code: Alternator output
exceeding 48v. Check alternator
speed and connections.
WBG_523666.01 See
{1 - 7}
“WBG_523666.01 (Blink Code 1-7)
- Bus Voltage Low” on page 153
true
false
LOW FAULT
VBUS
1-7 Blink Code: 48V DC Low Alternator voltage Below 20 Volts
when running. Overloaded reel
or insufficient engine rpms.
Possible alternator malfunction.
WBG_523666.02 See
{1 - 7}
“WBG_523666.02 (Blink Code 1-7)
- Low VBUS on Start” on page 154
false
false
LOW VBUS ON
START
1-7 Blink Code: 48V DC Low Alternator voltage Below 20 Volts
when running. Overloaded reel
or insufficient engine rpms.
Possible alternator malfunction.
NONE
false
false
System
reaction
monitor, not a
fault. Used for
internal data
collection.
Manufacturer Service Code
WBG_523666.15 See
“WBG_523666.15 (Blink Code
NONE) - Manufacturer Service
Code” on page 154
Blink
Code
Electrical Controller and Motor Diagnostics - 125
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
System: DTC Readings
Service ADVISOR Live Readings Available
GTMower(J1939)
Reel operates at a reduced speed or does not function.
Code Caused By:
WBG - Walk Behind Greens Mower
• WBG Clutch Switch (Value is clutch switch digital
ground input (yes/no))
•
WBG_000628.12 Stuck in Boot Block (Blink
Code SOLID ON)
Symptom: Reel Operation Degraded
WBG Direction Switch (Values are fwd and backlap)
• WBG Drive Motor Speed (Value is actual speed (digital
frequency))
• WBG Drive Motor Speed (Value is commanded speed
to use with direction switch and potentiometer check)
Software error.
Alarm Level:
Stop
To Clear Display:
N/A
Control Unit Response:
• WBG Drive Motor Torque Limit Command - Driving
Torque (Value is 0 to 13 N•m (min/max))
Function degraded
• WBG ECU Power Supply Voltage #1, Switched (Value is
48V power to controller from alternator)
Snapshot Recorded:
•
WBG Motor Current (Value is average of three phases)
• WBG Motor Driver Heat Sink Temperature (Value is -30
to 95° C (at 96 ± C controller will shut down))
• WBG Operating Modes (OFF, CHARGE_PUMP,
FWD_START, FWD_RUN, REV_START, REV_RUN,
PLUG_BRAKE. (FWD or REV is a function of which side
the reel motor is on and the direction switch. A motor on the
left side of the reel with the Direction Switch in forward will
actually say "REV_START".))
• WBG PTO State (Value is PTO switch digital ground
input (yes/no))
• WBG Parking Brake Switch (Value is park brake switch
digital ground input (yes/no))
Obtaining Live Readings
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
"Diagnostics" tab to view the controller fault.
N/A
Required Tools:
Service ADVISOR
Preliminary Checks:
None
Check for presence of these codes to assist diagnosis:
• WBG_522976.12 (Blink Code 8-4) Incorrect Application
Software
Diagnosis
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
Recall, record (SnapShot Test under Interactive test), and
clear codes.
•
Recall codes again and check for return of this code.
•
End of tests if code does not return.
Clear codes using Diagnostic tab.
Procedure:
1. Connect Service ADVISOR and install available
payload for controller. Does this clear error code?
Yes: End of procedure.
No: Open DTAC case.
Electrical Controller and Motor Diagnostics - 126
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
WBG_002513.03 (Blink Code 7-3) - Orange
Phase (A) is Shorted to Supply
Symptom: (Blink Code 7-3) Reel Stops
Note: Common conditions to cause code.
Reel Stops or Does Not Operate
•
Code Caused By:
Procedure:
• Phase wire shorted to 48V supply or another phase
wire.
Faulty controller.
Alarm Level:
1. Visually verify that the phase leads to the motor are
not frayed or shorted together. Inspect connector for
damage. Are phase wires and connector to motor
okay?
Stop
Yes: Replace reel controller.
To Clear Display:
No: Repair wire or connector.
High voltage to phase A in orange wire or motor (phase
high).
Stop and start engine.
WBG_002513.04 (Blink Code 7-2) - Orange
Phase (A) is Shorted to Ground
Symptom: (Blink Code 7-2) Reel Stops
Alarm Frequency:
Only when active.
Reel Stops or Does Not Operate
Control Unit Response:
Reel stops.
Code Caused By:
Snapshot Recorded:
Low current to phase A in orange wire or motor (phase
low).
No
Alarm Level:
Required Tools:
Stop
None
To Clear Display:
Preliminary Checks:
Stop and start engine.
Inspect high current wires to motor.
Check for presence of these codes to assist diagnosis:
•
Any other 48V phase errors on reel controller
Alarm Frequency:
Only when active.
Control Unit Response:
Diagnosis
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
•
Recall codes again and check for return of this code.
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
Reel stops.
Snapshot Recorded:
No
Required Tools:
None
Preliminary Checks:
Inspect high current wires to motor.
Check for presence of these codes to assist diagnosis:
•
Any other 48V phase or current errors on reel controller
Diagnosis
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
SERVICE ADVISOR™: This procedure can be performed
Electrical Controller and Motor Diagnostics - 127
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
Snapshot Recorded:
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
None
•
Recall codes again and check for return of this code.
Preliminary Checks:
•
Recreate operating conditions that caused code.
Inspect high current wires to motor.
•
End of tests if code does not return.
Check for presence of these codes to assist diagnosis:
No
Required Tools:
Note: Common conditions to cause code
•
•
Phase wire shorted to ground.
Diagnosis
•
Faulty motor or controller.
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
Procedure:
1. Visually verify that the phase leads to the motor are
not frayed or shorted together. Inspect connector for
damage. Are phase wires or connector to motor
damaged?
Yes: Repair wire or connector.
No: Go to next step.
2. Disconnect motor from controller and observe
Service ADVISOR diagnostics. [RLK WBG Motor
Current] Is the currently active fault for the controller
now showing OPEN phase?
Yes: Replace reel motor.
Any other 48V phase errors on reel controller
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
•
Recall codes again and check for return of this code.
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
Note: Common conditions to cause code
No: Replace controller.
WBG_002513.05 (Blink Code 7-4) - Orange
Phase (A) is Open
Symptom: (Blink Code 7-4) Reel Stops
Reel Stops or Does Not Operate
•
Phase wire open.
•
Faulty motor or controller.
Procedure:
1. Are heavy current wires and connectors damaged?
Yes: Repair wire or connector.
Code Caused By:
No: Go to next step
No current to phase A in orange wire or motor (phase low).
Alarm Level:
Stop
2. Connect to Service ADVISOR and check current
reading. [RLK WBG Motor Current] Clear code and
check for return of problem. Does problem return?
Yes: Go to next step.
To Clear Display:
No: Go to next step.
Stop and start engine.
3. Swap motor with a known good motor. Is problem
resolved?
Alarm Frequency:
Only when active.
Control Unit Response:
Reel stops.
Yes: Replace motor.
No: Go to next step.
4. Swap controller with a known good controller.
Connect to Service ADVISOR and check current
reading. [RLK WBG Motor Current]
Yes: Clear code and check for return of problem.
Electrical Controller and Motor Diagnostics - 128
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
5. Does problem return?
•
Recreate operating conditions that caused code.
Yes: Open DTAC case.
•
End of tests if code does not return.
No: Intermittent problem. Duplicate conditions to cause
code and repeat procedure.
Note: Common conditions to cause code
WBG_002514.03 (Blink Code 7-3) - Black
Phase (B) is Shorted to Supply
Symptom: (Blink Code 7-3) Reel Stops
• Phase wire shorted to 48V supply or another phase
wire.
•
Faulty controller.
Procedure:
1. Visually verify that the phase leads to the motor are
not frayed or shorted together. Inspect connector for
damage. Are phase wires and connector to motor
okay?
Reel Stops or Does Not Operate
Code Caused By:
High voltage to phase B in black wire or motor (phase
high).
Yes: Replace reel controller.
No: Repair wire or connector.
Alarm Level:
Stop
WBG_002514.04 (Blink Code 7-2) - Black
Phase (B) is Shorted to Ground
Symptom: (Blink Code 7-2) Reel Stops
To Clear Display:
Stop and start engine.
Reel Stops or Does Not Operate
Alarm Frequency:
Code Caused By:
Only when active.
Low current to phase B in black wire or motor (phase low).
Control Unit Response:
Alarm Level:
Reel stops.
Stop
Snapshot Recorded:
To Clear Display:
No
Stop and start engine.
Required Tools:
Alarm Frequency:
None
Only when active.
Preliminary Checks:
Inspect high current wires to motor.
Control Unit Response:
Check for presence of these codes to assist diagnosis:
Reel stops.
•
Snapshot Recorded:
Any other 48V phase errors on reel controller
Diagnosis
No
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
Required Tools:
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
Preliminary Checks:
None
Inspect high current wires to motor.
Check for presence of these codes to assist diagnosis:
•
Any other 48V phase or current errors on reel controller
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
Diagnosis
•
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
Recall codes again and check for return of this code.
Electrical Controller and Motor Diagnostics - 129
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
page 116 for the on-board display procedure.
Snapshot Recorded:
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
No
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
Required Tools:
None
Preliminary Checks:
Inspect high current wires to motor.
•
Recall codes again and check for return of this code.
Check for presence of these codes to assist diagnosis:
•
Recreate operating conditions that caused code.
•
•
End of tests if code does not return.
Diagnosis
Note: Common conditions to cause code
•
Phase wire shorted to ground.
•
Faulty motor or controller.
Procedure:
1. Visually verify that the phase leads to the motor are
not frayed or shorted together. Inspect connector for
damage. Are phase wires or connector to motor
damaged?
Any other 48V phase errors on reel controller
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
Yes: Repair wire or connector.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
No: Go to next step.
•
Recall codes again and check for return of this code.
2. Disconnect motor from controller and observe
Service ADVISOR diagnostics. [RLK WBG Motor
Current] Is the currently active fault for the controller
now showing OPEN phase?
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
Yes: Replace reel motor.
•
Phase wire open.
No: Replace controller.
•
Faulty motor or controller.
WBG_002514.05 (Blink Code 7-4) - Black
Phase (B) is Open
Symptom: (Blink Code 7-4) Reel Stops
Code Caused By:
No current to phase A in black wire or motor (phase low).
Stop
Procedure:
1. Are heavy current wires and connectors damaged?
Yes: Repair wire or connector.
No: Go to next step
Reel Stops or Does Not Operate
Alarm Level:
Note: Common conditions to cause code
2. Connect to Service ADVISOR and check current
reading. [RLK WBG Motor Current] Clear code and
check for return of problem. Does problem return?
Yes: Go to next step.
No: Go to next step.
To Clear Display:
3. Swap motor with a known good motor. Is problem
resolved?
Stop and start engine.
Yes: Replace motor.
Alarm Frequency:
No: Go to next step.
Only when active.
Control Unit Response:
4. Swap controller with a known good controller.
Connect to Service ADVISOR and check current
reading. [RLK WBG Motor Current]
Reel stops.
Yes: Clear code and check for return of problem.
Electrical Controller and Motor Diagnostics - 130
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
5. Does problem return?
•
Recreate operating conditions that caused code.
Yes: Open DTAC case.
•
End of tests if code does not return.
No: Intermittent problem. Duplicate conditions to cause
code and repeat procedure.
Note: Common conditions to cause code
WBG_002515.03 (Blink Code 7-3) - Green
Phase (C) is Shorted to Supply
Symptom: (Blink Code 7-3) Reel Stops
• Phase wire shorted to 48V supply or another phase
wire.
•
Faulty controller.
Procedure:
1. Visually verify that the phase leads to the motor are
not frayed or shorted together. Inspect connector for
damage. Are phase wires and connector to motor
okay?
Reel Stops or Does Not Operate
Code Caused By:
High voltage to phase C in green wire or motor (phase
high).
Yes: Replace reel controller.
No: Repair wire or connector.
Alarm Level:
To Clear Display:
WBG_002515.04 (Blink Code 7-2) - Green
Phase (C) is Shorted to Ground
Symptom: (Blink Code 7-2) Reel Stops
Stop and start engine.
Reel Stops or Does Not Operate
Alarm Frequency:
Code Caused By:
Only when active.
Low current to phase C in green wire or motor (phase low).
Control Unit Response:
Alarm Level:
Reel stops.
Stop
Snapshot Recorded:
To Clear Display:
No
Stop and start engine.
Required Tools:
Alarm Frequency:
None
Only when active.
Preliminary Checks:
Control Unit Response:
Inspect high current wires to motor.
Reel stops.
Check for presence of these codes to assist diagnosis:
Snapshot Recorded:
Stop
•
Any other 48V phase errors on reel controller
Diagnosis
Required Tools:
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
•
No
Recall codes again and check for return of this code.
None
Preliminary Checks:
Inspect high current wires to motor.
Check for presence of these codes to assist diagnosis:
•
Any other 48V phase or current errors on reel controller
Diagnosis
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
Electrical Controller and Motor Diagnostics - 131
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
Snapshot Recorded:
No
Required Tools:
None
Preliminary Checks:
•
Recall codes again and check for return of this code.
Inspect high current wires to motor.
•
Recreate operating conditions that caused code.
Check for presence of these codes to assist diagnosis:
•
End of tests if code does not return.
•
Any other 48V phase errors on reel controller
Note: Common conditions to cause code
Diagnosis
•
Phase wire shorted to ground.
•
Faulty motor or controller.
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
Procedure:
1. Visually verify that the phase leads to the motor are
not frayed or shorted together. Inspect connector for
damage. Are phase wires or connector to motor
damaged?
Yes: Repair wire or connector.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
No: Go to next step.
2. Disconnect motor from controller and observe
Service ADVISOR diagnostics. [RLK WBG Motor
Current] Is the currently active fault for the controller
now showing OPEN phase?
•
Recall codes again and check for return of this code.
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
Yes: Replace reel motor.
Note: Common conditions to cause code
No: Replace controller.
•
Phase wire open.
•
Faulty motor or controller.
WBG_002514.05 (Blink Code 7-4) - Green
Phase (C) is Open
Symptom: (Blink Code 7-4) Reel Stops
No: Go to next step
Code Caused By:
No current to phase C in green wire or motor (phase low).
Stop
To Clear Display:
1. Are heavy current wires and connectors damaged?
Yes: Repair wire or connector.
Reel Stops or Does Not Operate
Alarm Level:
Procedure:
2. Connect to Service ADVISOR and check current
reading. [RLK WBG Motor Current] Clear code and
check for return of problem. Does problem return?
Yes: Go to next step.
No: Go to next step.
Stop and start engine.
3. Swap motor with a known good motor. Is problem
resolved?
Alarm Frequency:
Yes: Replace motor.
Only when active.
No: Go to next step.
Control Unit Response:
4. Swap controller with a known good controller.
Connect to Service ADVISOR and check current
reading. [RLK WBG Motor Current]
Reel stops.
Yes: Clear code and check for return of problem.
Electrical Controller and Motor Diagnostics - 132
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
5. Does problem return?
•
Recall codes again and check for return of this code.
Yes: Open DTAC case.
•
Recreate operating conditions that caused code.
No: Intermittent problem. Duplicate conditions to cause
code and repeat procedure.
•
End of tests if code does not return.
WBG_003353.00 (Blink Code 8-1) - Alternator
Over Temp Threshold
Symptom: (Blink Code 8-1) Reel Stops
•
Heavy load of reel motor.
•
Dull reel or bed knife
•
Bed knife not adjusted properly.
Reel Stops or Does Not Operate
•
Controller cooling fins blocked
Code Caused By:
•
Disconnected or damaged alternator wires.
Alternator temperature too high.
Procedure:
Note: Common conditions to cause code
1. Allow machine components to cool. Check reel and
alternator cooling fins for debris. Is problem resolved?
Alarm Level:
Stop
Yes: End of tests.
To Clear Display:
No: Go to next step.
Stop and start engine
2. Check reel to bed knife adjustment and adjust bed
knife as necessary. Is problem resolved?
Alarm Frequency:
Yes: End of tests.
Only when active.
No: Go to next step.
Control Unit Response:
3. Test bridge rectifier. See “Bridge Rectifier Test” on
page 160. Does rectifier test okay?
Reel stops.
Yes: Go to next step.
Snapshot Recorded:
No: Replace rectifier.
Yes
4. Check alternator/drive belt. See “Drive Belt Tension
Check and Adjustment” on page 170. Is belt too tight?
Required Tools:
None
Preliminary Checks:
Check alternator temperature.
Check for presence of these codes to assist diagnosis:
• WBG_003353.00 Alternator Over Temp Threshold
(Blink Code 8-1)
• WBG_522917.xx Motor current over limit (Blink Codes
2-5 or 2-8)
Yes: Adjust belt. During adjustment check alternator for
ease of alternator rotation (note that alternator has
cogged feeling during rotation as magnets are passed).
If alternator is hard to turn or has grinding feeling,
suspect alternator bearing problem.
No: Go to next step.
5. Inspect alternator wires, wire connections. Repair or
replace alternator as necessary. Is problem resolved?
Yes: Return machine to service.
No: Go to next step.
Diagnosis
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
6. Connect to Service ADVISOR and check alternator
current reading. [RLK WBG Motor Current] Clear
code(s) and check for return of problem. Does problem
return?
Yes: Swap alternator with known good alternator. Is
problem resolved?
Yes: Replace alternator.
No: Go to next step.
7. Does problem return?
Electrical Controller and Motor Diagnostics - 133
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
Yes: Open DTAC case. DTAC case should be
submitted showing this fault with the serial number of
the controller.
No: Intermittent problem. Duplicate conditions to cause
code and repeat procedure.
WBG_003353.01 (Blink Code 8-3) - Alternator
Hall Loss
Symptom: (Blink Code 8-3) Reel Stops
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
Note: Common conditions to cause code
•
Disconnected wiring harness connectors.
•
Damaged or broken alternator wires to controller.
Procedure:
1. Is WBG_003353.00 Alternator Over Temp Threshold
code present?
Reel Stops or Does Not Operate
Code Caused By:
Alternator speed sensor error.
Yes: Most likely cause is disconnected or damaged
wiring harness between alternator and controller.
Inspect and repair as necessary.
Alarm Level:
No: Go to next step.
Stop
2. Clear code and check for return of problem. Does
problem return?
To Clear Display:
Yes: Check supply voltage. See “System: Power
Supply Diagnostic Check” on page 106.
Stop and start engine
Alarm Frequency:
No: Intermittent problem. Duplicate conditions to cause
code and repeat procedure.
Only when active.
3. Swap controller with known good controller. Is
problem resolved?
Control Unit Response:
Reel stops.
Yes: Replace controller. DTAC case should be
submitted showing this fault with the serial number of
the controller.
Snapshot Recorded:
Yes
None
WBG_003509.00 (Blink Code 7-5) - Pot Signal
Voltage High
Symptom: Blink Code 7-5
Preliminary Checks:
Blink Code only.
Check for presence of these codes to assist diagnosis:
Code Caused By:
• WBG_003353.00 Alternator Over Temp Threshold
(Blink Code 8-1)
Indicates FOC (frequency of cut) potentiometer voltage is
high.
• WBG_522937.02 Frequency of Clip Shutdown (Blink
Code 8-2)
Alarm Level:
Required Tools:
Service Alert
Diagnosis
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
•
Recall codes again and check for return of this code.
To Clear Display:
Cycle PTO switch; or, Stop and start engine
Alarm Frequency:
Only when active.
Control Unit Response:
None
Snapshot Recorded:
No
Electrical Controller and Motor Diagnostics - 134
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
Multimeter
WBG_003509.01 (Blink Code 7-5) - Pot Signal
Voltage Low
Symptom: Blink Code 7-5
Preliminary Checks:
Blink Code only.
Required Tools:
Check for presence of these codes to assist diagnosis:
• WBG_003510.00 Pot Signal Voltage High (Blink Code
9-7)
•
WBG_003597.00 14V Voltage High (Blink Code 9-3)
Code Caused By:
Indicates FOC (frequency of cut) potentiometer voltage is
low.
Alarm Level:
Diagnosis
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
Service Alert
To Clear Display:
Cycle PTO switch; or, Stop and start engine
Alarm Frequency:
Only when active.
Control Unit Response:
None
•
Recall codes again and check for return of this code.
Snapshot Recorded:
•
Recreate operating conditions that caused code.
No
•
End of tests if code does not return.
Required Tools:
Note: Common conditions to cause code
Multimeter
•
Faulty potentiometer sensor return wire
Preliminary Checks:
•
Faulty controller power supply
Check for presence of these codes to assist diagnosis:
Procedure:
1. Check the connector for water, corrosion or bent
pins. Is 4.3Vdc present at FOC (frequency of cut)
potentiometer, Red wire?
Yes: Go to next step.
No: If no 003597.00 (Blink Code 9-3) code present, go
to next step. Otherwise, troubleshoot high 14Vdc code.
2. Is there continuity to ground at speed control
potentiometer, Blk wire?
Yes: Test potentiometer.
Yes: Check for Wht wire, short to voltage.
No: Test ground circuit.
3. Replace controller with known good controller. Does
problem resolve?
Yes: Replace controller.
No: Open DTAC case.
• WBG_003510.01 Pot Supply Voltage low (Blink Code 97)
•
WBG_003597.01 14V Voltage low (Blink Code 9-3)
Diagnosis
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
•
Recall codes again and check for return of this code.
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
Electrical Controller and Motor Diagnostics - 135
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
Note: Common conditions to cause code
Preliminary Checks:
•
Poor wire connections
Check for presence of these codes to assist diagnosis:
•
Faulty potentiometer
•
Potentiometer signal wire shorted to ground.
• WBG_003509.00 Pot Signal Voltage High (Blink Code
7-5)
• WBG_003597.00 14V Voltage High (Blink Code 9-3) Indicates failed controller voltage regulator
Procedure:
1. Is 4.3Vdc present at FOC potentiometer, Red wire?
Yes: Go to next step.
• WBG_522937.02 Frequency of Clip Shutdown (Blink
Code 8-2)
No: If no 003597.01 (Blink Code 9-3) code present, go
to next step. Otherwise, troubleshoot low 14Vdc code.
Diagnosis
2. Is there continuity to ground at FOC potentiometer,
Blk wire?
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
Yes: Test potentiometer.
Yes: Check for Wht wire short to ground.
No: Test ground circuit.
3. Replace controller with known good controller. Does
problem resolve?
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
Yes: Replace controller.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
No: Open DTAC case.
•
Recall codes again and check for return of this code.
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
WBG_003510.00 (Blink Code 9-7) - Pot Supply
Voltage High
Symptom: Blink Code 9-7
Note: Common conditions to cause code
Blink Code only.
•
Faulty potentiometer
Code Caused By:
•
Faulty potentiometer external wiring
Indicates supply voltage from controller to FOC (frequency
of cut) potentiometer is high.
•
Faulty controller power supply
Procedure:
Service Alert
1. Check the connector for water, corrosion or bent
pins. Is 4.3Vdc present at FOC (frequency of cut)
potentiometer Red wire?
To Clear Display:
Yes: Go to next step.
Cycle PTO switch; or, Stop and start engine
No: If no 003597.00 (Blink Code 9-3) code present, go
to next step. Otherwise, troubleshoot high 14Vdc code.
Alarm Level:
Alarm Frequency:
Only when active.
2. Is 4.3Vdc present at controller?
Yes: Check Red wire for short to power.
Control Unit Response:
Yes: Check for Wht wire short to ground.
None
No: Replace controller.
Snapshot Recorded:
3. Replace controller with known good controller. Does
problem resolve?
No
Required Tools:
Yes: Replace controller.
No: Open DTAC case.
Multimeter
Electrical Controller and Motor Diagnostics - 136
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
WBG_003510.01 (Blink Code 9-7) - Pot Supply
Voltage Low
Symptom: Blink Code 9-7
Note: Common conditions to cause code
•
Faulty potentiometer
Blink Code only.
• Potentiometer supply wire shorted to ground
voltage.
Code Caused By:
•
Indicates supply voltage from controller to FOC (frequency
of cut) potentiometer is low.
Procedure:
Faulty controller power supply
1. Check wires and connectors for damage. Is 4.3Vdc
present at FOC (frequency of cut) potentiometer Red
wire?
Alarm Level:
Service Alert
Yes: Go to next step.
To Clear Display:
No: If no 003597.01 (Blink Code 9-3) code present, go
to next step. Otherwise, troubleshoot low 14Vdc code.
Cycle PTO switch; or, Stop and start engine
2. Is 4.3Vdc present at controller?
Alarm Frequency:
Yes: Check Red wire for short to ground
Only when active.
Yes: Check for Wht wire short to ground.
Snapshot Recorded:
No: Replace controller.
No
3. Replace controller with known good controller. Does
problem resolve?
Control Unit Response:
Yes: Replace controller.
None
No: Open DTAC case.
Required Tools:
Multimeter
Preliminary Checks:
Check for presence of these codes to assist diagnosis:
• WBG_003509.01 Pot Signal Voltage Low (Blink Code 75)
• WBG_003597.01 14V Voltage Low (Blink Code 9-3) Indicates failed controller voltage regulator or low input
voltage.
WBG_003511.00 (Blink Code 9-5) - Hall
Voltage High
Symptom: Blink Code 9-5
Blink Code only.
Code Caused By:
Indicates voltage from controller to Hall sensors is high.
Alarm Level:
Service Alert
Diagnosis
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
To Clear Display:
Cycle PTO switch; or, Stop and start engine
Alarm Frequency:
Only when active.
Control Unit Response:
None
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
Snapshot Recorded:
•
Recall codes again and check for return of this code.
No
•
Recreate operating conditions that caused code.
Required Tools:
•
End of tests if code does not return.
Multimeter
Electrical Controller and Motor Diagnostics - 137
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
Preliminary Checks:
To Clear Display:
Check for presence of these codes to assist diagnosis:
Cycle PTO switch; or, Stop and start engine
• WBG_003510.00 Pot Signal Voltage High (Blink Code
7-5)
Alarm Frequency:
• WBG_003597.00 14V Voltage High (Blink Code 9-3) Indicated failed controller voltage regulator.
Only when active.
Control Unit Response:
Diagnosis
None
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
Snapshot Recorded:
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
Required Tools:
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
•
Recall codes again and check for return of this code.
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
Note: Common conditions to cause code
•
Faulty controller
Procedure:
1. Is Hall voltage over 15 V?
Yes: Replace controller.
No: Go to next step.
2. Swap controller with a known good controller. Is
problem resolved?
Yes: Replace controller. DTAC case should be
submitted showing this fault with the serial number of
the controller.
No: Open DTAC case.
WBG_003511.01 (Blink Code 9-5) - Hall
Voltage Low
Symptom: Blink Code 9-5
Blink Code only.
Indicates signal voltage from Hall sensor to controller is
low.
Service Alert
Multimeter
Preliminary Checks:
Check for presence of these codes to assist diagnosis:
• WBG_003510.01 Pot Signal Voltage Low (Blink Code 75)
• WBG_003597.01 14V Voltage Low (Blink Code 9-3) Indicated failed controller voltage regulator.
Diagnosis
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
•
Recall codes again and check for return of this code.
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
Note: Common conditions to cause code
•
Hall supply wire shorted to ground.
•
Faulty controller power supply
Procedure:
Code Caused By:
Alarm Level:
No
1. Unplug the motor for test. Is at least 11.3Vdc present
at Hall power output.
Yes: Plug motor back in. If voltage is low with motor
plugged back in, but not when unplugged then swap
motor to see if problem moves with the motor or stays
with the controller. Go to next step.
No: If no 003597.01 (Blink Code 9-3) code present, go
to next step. Otherwise, troubleshoot low 14Vdc code.
Electrical Controller and Motor Diagnostics - 138
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
2. Is 14Vdc present at controller, Red wire?
page 116 for the on-board display procedure.
Yes: Check Red wire for short to ground.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
Yes: Check Wht wire short to ground.
No: Replace controller.
3. Swap controller with a known good controller. Is
problem resolved?
Yes: Replace controller. DTAC case should be
submitted showing this fault with the serial number of
the controller.
No: Open DTAC case.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
•
Recall codes again and check for return of this code.
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
WBG_003597.00 (Blink Code 9-3) - Controller
14V High
Symptom: Blink Code 9-3
Note: Common conditions to cause code
Blink Code only.
•
Faulty 48V alternator
Code Caused By:
•
Faulty controller ground connection
Indicates an internal 14V voltage regulator failure in reel
motor controller.
•
Faulty controller power supply
• If code happened once, cleared, and did not
reoccur, suspect possible transient voltage spike
Procedure:
1. If none of the above symptoms or causes can be
found, swap controller with a known good controller. Is
problem resolved?
Alarm Level:
Service Alert
To Clear Display:
Cycle PTO switch; or, Stop and start engine
Alarm Frequency:
Yes: Replace controller. DTAC case should be
submitted showing this fault with the serial number of
the controller.
No: Open DTAC case.
Only when active.
WBG_003597.01 (Blink Code 9-3) - Controller
14V Low
Symptom: Blink Code 9-3
Control Unit Response:
None
Snapshot Recorded:
Blink Code only.
No
Code Caused By:
Required Tools:
Indicates an internal 14V voltage regulator failure in reel
motor controller.
None
Alarm Level:
Preliminary Checks:
Service Alert
Check for presence of these codes to assist diagnosis:
• WBG_523666.00 (Blink Code 9-2) 48V Alternator High.
If code appears, troubleshoot first.
• WBG_003510.00 (Blink Code 9-7) - Pot Supply Voltage
High
•
WBG_003511.00 (Blink Code 9-5) - Hall Voltage High
To Clear Display:
Cycle PTO switch; or, Stop and start engine
Alarm Frequency:
Only when active.
Control Unit Response:
Diagnosis
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
None
Electrical Controller and Motor Diagnostics - 139
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
No
WBG_521153.00 (Blink Code NONE) Manufacturer Service Code
Symptom: None
Required Tools:
No blink code or operational changes.
Snapshot Recorded:
None
Control Unit Response:
Preliminary Checks:
None - will record DTC in Service ADVISOR
Check for presence of these codes to assist diagnosis:
• WBG_523666.01 (Blink Code 9-2) - 48V Alternator Low.
If code appears, troubleshoot first.
• WBG_003510.01 (Blink Code 9-7) - Pot Supply Voltage
Low
•
WBG_003511.01 (Blink Code 9-5) - Hall Voltage Low
Diagnosis
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
Procedure
No diagnostic procedure is used. This is a system reaction
monitor, not a fault. Used for internal data collection.
WBG_521153.15 (Blink Code 2-9) - Controller
Shutdown Over Temp
Symptom: Reel Stops Possible Blink Code 2-9
Reel Stops or Does Not Operate
Code Caused By:
Indicates internal controller temp high from controller/motor
drawing too much current and/or high ambient temperature;
and controller is shut down.
Alarm Level:
Stop
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
To Clear Display:
•
Recall codes again and check for return of this code.
Cycle PTO switch; or, Stop and start engine
•
Recreate operating conditions that caused code.
Alarm Frequency:
•
End of tests if code does not return.
Note: Common conditions to cause code
•
Faulty 48V alternator
•
Faulty controller ground connection
•
Faulty controller power supply
Only when active.
Control Unit Response:
Controller/Motor shutdown
Snapshot Recorded:
Yes
Procedure:
1. If none of the above symptoms or causes can be
found, swap controller with a known good controller. Is
problem resolved?
Required Tools:
Yes: Replace controller. DTAC case should be
submitted showing this fault with the serial number of
the controller.
Preliminary Checks:
No: Open DTAC case.
JDG10429 Electric Reel Motor Tester
Check for presence of these codes to assist diagnosis:
• WBG_522917.00 Controller Current Threshold 3
Shutdown (Blink Code 2-5)
• WBG_522917.06 Controller Hardware Current
Shutdown (Blink Code 2-5)
• WBG_522918.15 Motor Stall While Running (Blink
Code 1-6)
• WBG_522919.12 (Blink Code 6-1) This code likely
indicates that the reel motor connector is disconnected.
Electrical Controller and Motor Diagnostics - 140
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
Diagnosis
controller temperature. Is temperature high while
controller feels cool to touch? [RLK WBG Motor Driver
Heat Sink Temperature]
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
•
Recall codes again and check for return of this code.
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
Yes: Replace controller. DTAC case should be
submitted showing this fault with the serial number of
the controller.
WBG_522327.00 (Blink Code 2-10) - Motor
Over Temp
Symptom: (Blink Code 2-10) Reel Stops
Reel Stops or Does Not Operate
Code Caused By:
Indicates high internal motor temperature resulted in
controller shutting down motor.
Note: Common conditions to cause code
Alarm Level:
•
Heavy load on reel
Stop
•
Excessive debris in reel
•
Controller cooling fins blocked
•
Jammed reel
•
Incorrect bed knife clearance
•
Failing bearings on reel
Only when active.
•
High ambient temperature
Control Unit Response:
To Clear Display:
Cycle PTO switch; or, Stop and start engine
Alarm Frequency:
Procedure:
Motor shutdown
1. Check controller cooling fins for debris. Is debris
present?
Yes: Allow components to cool, clean debris.
Snapshot Recorded:
Yes
No: Go to next step.
Required Tools:
2. Check controller internal temperature using
“Readings” in Service ADVISOR. Is the temperature
reading above 90 degrees C (194 degrees F)? [RLK
WBG Motor Driver Heat Sink Temperature]
JDG10429 Electric Reel Motor Tester
Yes: Allow machine components to cool for an hour.
Does temperature drop and is problem resolved? Go to
next step.
• WBG_522917.00 Controller Current Threshold 3
Shutdown (Blink Code 2-5)
No: If after a minimum of hour hour cooling the
temperature does not drop below 90 degrees C (194
degrees F), swap controller and test machine.
3. Investigate current draw using “Readings” in Service
ADVISOR. Remove reel motor from reel to look for a
high load. Is problem resolved? [RLK WBG Motor
Current]
Yes: Suspect reel problems, see common conditions.
Preliminary Checks:
Check for presence of these codes to assist diagnosis:
• WBG_522917.06 Controller Hardware Current
Shutdown (Blink Code 2-5)
• WBG_522918.15 Motor Stall While Running (Blink
Code 1-6)
• WBG_522919.12 (Blink Code 6-1) This code likely
indicates that the reel motor connector is disconnected.
Diagnosis
No: Suspect reel motor. See “Reel Motor Test” on
page 158.
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
4. Install reel motor to reel. Check and monitor
SERVICE ADVISOR™: This procedure can be performed
Electrical Controller and Motor Diagnostics - 141
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
Note: Use the JDG10429 Electric Reel Motor Tester.
5. Test motor. See “Reel Motor Test” on page 158.
Does motor pass test?
Yes: Go to next step.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
•
Recall codes again and check for return of this code.
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
No: Check for broken or damaged wires. Replace reel
motor if necessary.
WBG_522917.00 (Blink Code 2-5) - Controller
Current Threshold 3 Shutdown
Symptom: (Blink Code 2-5) Reel Stops
Note: Common conditions to cause code
Reel Stops or Does Not Operate
•
Heavy load on reel
Code Caused By:
•
Excessive debris in reel
Indicates high controller current draw (most severe level)
•
Jammed reel
•
Incorrect bed knife clearance
•
Failing bearings on reel
•
High ambient temperature
Alarm Level:
Stop
To Clear Display:
Procedure:
Cycle PTO switch; or, Stop and start engine
Note: It is normal in some high ambient temperatures
and high load conditions for the motor to get hot and
protect itself via the internal temperature switch.
Alarm Frequency:
1. Allow motor to cool and see if active fault clears.
Does the fault clear?
Only when active.
Control Unit Response:
Controller/Motor shutdown
Yes: Check reel motor cooling fins for debris. Check for
other common conditions to cause code. Is problem
resolved?
Snapshot Recorded:
Yes: Go to next step.
Required Tools:
No: Go to step 3.
JDG10429 Electric Reel Motor Tester
2. Investigate current draw using “Readings” in Service
ADVISOR. Remove reel motor from reel to look for a
high load. Is problem resolved? [RLK WBG Motor
Current]
Yes
Preliminary Checks:
Check for presence of these codes to assist diagnosis:
No: Go to next step.
Note: The presence of any stored 522917.xx codes for
the controller likely indicates ongoing problems with
controller/reel combination.
3. Check the 6 pin connector for bent or pushed back
pins. Is connector problem found?
• WBG_522917.15 Controller Current Threshold 1
Shutdown (Blink Code 2-5) (least severe level)
Yes: Repair pins and connector.
• WBG_522917.16 Controller Current Threshold 2
Shutdown (Blink Code 2-5) (moderately severe level)
Yes: Suspect reel problems, see common conditions.
No: Go to next step.
4. Temperature sensor check - Unplug motor from
controller. Check continuity between P1-M1 pin C and
P1-M1 pin A on motor harness end. Is there continuity?
Yes: Go to next step.
No: Check for broken or damaged wires. Replace reel
motor if necessary.
• WBG_522917.06 Controller Hardware Current
Shutdown (Blink Code 2-5)
• WBG_522918.15 Motor Stall While Running (Blink
Code 1-6)
Diagnosis
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
Electrical Controller and Motor Diagnostics - 142
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
No: Check for broken or damaged wires. Replace reel
motor if necessary.
page 116 for the on-board display procedure.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
5. Swap controller with a known good controller. Is
problem resolved?
Yes: Replace controller. DTAC case should be
submitted showing this fault with the serial number of
the controller.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
•
Recall codes again and check for return of this code.
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
Note: Common conditions to cause code
WBG_522917.06 (Blink Code 2-8) - Controller
Hardware Current Shutdown
Symptom: (Blink Code 2-8) Reel Stops
Reel Stops or Does Not Operate
Code Caused By:
•
Heavy load on reel
•
Excessive debris in reel
•
Controller cooling fins blocked
Alarm Level:
•
Jammed reel
Stop
•
Incorrect bed knife clearance
To Clear Display:
•
Failing bearings on reel
Cycle PTO switch; or, Stop and start engine
•
High ambient temperature
Indicates high controller current draw
Alarm Frequency:
Procedure:
Only when active.
1. Check controller cooling fins for debris. Is debris
present?
Control Unit Response:
Yes: Allow components to cool, clean debris.
Controller/Motor shutdown
No: Go to next step.
Snapshot Recorded:
2. Check controller internal temperature using
“Readings” in Service ADVISOR. Is the temperature
reading above 90 degrees C (194 degrees F)? [RLK
WBG Motor Driver Heat Sink Temperature]
Yes: Allow machine components to cool for an hour.
Does temperature drop and is problem resolved? Go to
next step.
No: If after a minimum of hour hour cooling the
temperature does not drop below 90 degrees C (194
degrees F), swap controller and test machine.
3. Investigate current draw using “Readings” in Service
ADVISOR. Remove reel motor from reel to look for a
high load. Is problem resolved? [RLK WBG Motor
Current]
Yes: Suspect reel problems, see common conditions.
No: Go to next step.
Note: Use the JDG10429 Electric Reel Motor Tester.
4. Test motor. See “Reel Motor Test” on page 158.
Does motor pass test?
Yes
Required Tools:
JDG10429 Electric Reel Motor Tester
Preliminary Checks:
Check for presence of these codes to assist diagnosis:
Note: The presence of any stored 522917.xx codes for
the controller is indicate ongoing problems with
controller/reel combination.
• WBG_522917.15 Controller Current Threshold 1
Shutdown (Blink Code 2-5) (least severe level)
• WBG_522917.16 Controller Current Threshold 2
Shutdown (Blink Code 2-5) (moderately severe level)
• WBG_522917.00 Controller Current Threshold 3
Shutdown (Blink Code 2-5)
• WBG_522918.15 Motor Stall While Running (Blink
Code 1-6)
Yes: Go to next step.
Electrical Controller and Motor Diagnostics - 143
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
Note: Use the JDG10429 Electric Reel Motor Tester.
Diagnosis
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
4. Test motor. See “Reel Motor Test” on page 158.
Does motor pass test?
Yes: Go to next step.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
No: Check for broken or damaged wires. Replace reel
motor if necessary.
5. Swap controller with a known good controller. Is
problem resolved?
Yes: Replace controller. DTAC case should be
submitted showing this fault with the serial number of
the controller.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
•
Recall codes again and check for return of this code.
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
WBG_522917.15 (Blink Code 2-5) - Controller
Current Threshold 1 Shutdown
Symptom: (Blink Code 2-5) Reel Stops
Note: Common conditions to cause code
Reel Stops or Does Not Operate
•
Heavy load on reel
Code Caused By:
•
Excessive debris in reel
Indicates high controller current draw (least severe level)
•
Controller cooling fins blocked
•
Jammed reel
•
Incorrect bed knife clearance
•
Failing bearings on reel
To Clear Display:
•
High ambient temperature
Cycle PTO switch; or, Stop and start engine
•
Controller 3-phase output shorted to ground
Alarm Frequency:
•
Low current due to faulty bridge rectifier
Only when active.
Alarm Level:
Stop
Procedure:
Control Unit Response:
1. Check controller cooling fins for debris. Is debris
present?
Controller/Motor shutdown
Yes: Allow components to cool, clean debris.
Snapshot Recorded:
No: Go to next step.
Yes
2. Check controller internal temperature using
“Readings” in Service ADVISOR. Is the temperature
reading above 90 degrees C (194 degrees F)? [RLK
WBG Motor Driver Heat Sink Temperature]
Required Tools:
Yes: Allow machine components to cool for an hour.
Does temperature drop and is problem resolved? Go to
next step.
No: If after a minimum of hour hour cooling the
temperature does not drop below 90 degrees C (194
degrees F), swap controller and test machine.
3. Investigate current draw using “Readings” in Service
ADVISOR. Remove reel motor from reel to look for a
high load. Is problem resolved? [RLK WBG Motor
Current]
Yes: Suspect reel problems, see common conditions.
JDG10429 Electric Reel Motor Tester
Preliminary Checks:
Check for presence of these codes to assist diagnosis:
Note: The presence of any stored 522917.xx codes for
the controller likely indicates ongoing problems with
controller/reel combination.
• WBG_522917.15 Controller Current Threshold 1
Shutdown (Blink Code 2-5) (least severe level)
• WBG_522917.06 Controller Hardware Current
Shutdown (Blink Code 2-5) (moderately severe level)
• WBG_522917.00 Controller Current Threshold 3
Shutdown (Blink Code 2-5)
No: Go to next step.
Electrical Controller and Motor Diagnostics - 144
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
• WBG_522918.15 Motor Stall While Running (Blink
Code 1-6)
No: Go to next step.
Note: Use the JDG10429 Electric Reel Motor Tester.
Diagnosis
4. Test motor. See “Reel Motor Test” on page 158.
Does motor pass test?
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
Yes: Go to next step.
No: Check for broken or damaged wires. Replace reel
motor if necessary.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
5. Swap controller with a known good controller. Is
problem resolved?
Yes: Replace controller. DTAC case should be
submitted showing this fault with the serial number of
the controller.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
•
Recall codes again and check for return of this code.
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
WBG_522917.16 (Blink Code 2-5) - Controller
Current Threshold 2 Shutdown
Symptom: (Blink Code 2-5) Reel Stops
Note: Common conditions to cause code
Reel Stops or Does Not Operate
•
Heavy load on reel
Code Caused By:
•
Excessive debris in reel
•
Controller cooling fins blocked
Indicates high controller current draw (moderately severe
level)
•
Jammed reel
Alarm Level:
•
Incorrect bed knife clearance
Stop
•
Failing bearings on reel
•
High ambient temperature
•
Low current due to faulty bridge rectifier
To Clear Display:
Procedure:
1. Check controller cooling fins for debris. Is debris
present?
Yes: Allow components to cool, clean debris.
No: Go to next step.
2. Check controller internal temperature using
“Readings” in Service ADVISOR. Is the temperature
reading above 90 degrees C (194 degrees F)? [RLK
WBG Motor Driver Heat Sink Temperature]
Yes: Allow machine components to cool for an hour.
Does temperature drop and is problem resolved? Go to
next step.
No: If after a minimum of hour hour cooling the
temperature does not drop below 90 degrees C (194
degrees F), swap controller and test machine.
3. Investigate current draw using “Readings” in Service
ADVISOR. Remove reel motor from reel to look for a
high load. Is problem resolved? [RLK WBG Motor
Current]
Yes: Suspect reel problems, see common conditions.
Cycle PTO switch; or, Stop and start engine
Alarm Frequency:
Only when active.
Control Unit Response:
Controller/Motor shutdown
Snapshot Recorded:
Yes
Required Tools:
JDG10429 Electric Reel Motor Tester
Preliminary Checks:
Check for presence of these codes to assist diagnosis:
Note: The presence of any stored 522917.xx codes for
the controller likely indicates ongoing problems with
controller/reel combination.
• WBG_522917.15 Controller Current Threshold 1
Shutdown (Blink Code 2-5) (least severe level)
• WBG_522917.06 Controller Hardware Current
Shutdown (Blink Code 2-5) (moderately severe level)
Electrical Controller and Motor Diagnostics - 145
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
Current]
• WBG_522917.00 Controller Current Threshold 3
Shutdown (Blink Code 2-5)
Yes: Suspect reel problems, see common conditions.
• WBG_522918.15 Motor Stall While Running (Blink
Code 1-6)
No: Go to next step.
Note: Use the JDG10429 Electric Reel Motor Tester.
Diagnosis
4. Test motor. See “Reel Motor Test” on page 158.
Does motor pass test?
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
Yes: Go to next step.
No: Check for broken or damaged wires. Replace reel
motor if necessary.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
5. Swap controller with a known good controller. Is
problem resolved?
Yes: Replace controller. DTAC case should be
submitted showing this fault with the serial number of
the controller.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
•
Recall codes again and check for return of this code.
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
Note: Common conditions to cause code
WBG_522918.00 (Blink Code 1-5) - Motor Start
Failed 3x Fault
Symptom: (Blink Code 1-5) Reel Stops
Reel Stops or Does Not Operate
Code Caused By:
•
Heavy load on reel
•
Excessive debris in reel
•
Controller cooling fins blocked
•
Jammed reel
•
Incorrect bed knife clearance
Stop
•
Failing bearings on reel
To Clear Display:
•
High ambient temperature
Cycle PTO switch
•
Low current due to faulty bridge rectifier
Alarm Frequency:
Procedure:
Motor failed to start after 3 tries. No Hall effect state
changes reported to controller.
Alarm Level:
Only when active.
1. Check controller cooling fins for debris. Is debris
present?
Control Unit Response:
Yes: Allow components to cool, clean debris.
Controller/Motor shutdown
No: Go to next step.
Snapshot Recorded:
2. Check controller internal temperature using
“Readings” in Service ADVISOR. Is the temperature
reading above 90 degrees C (194 degrees F)? [RLK
WBG Motor Driver Heat Sink Temperature]
Yes
Required Tools:
JDG10429 Electric Reel Motor Tester
Yes: Allow machine components to cool for an hour.
Does temperature drop and is problem resolved? Go to
next step.
Preliminary Checks:
No: If after a minimum of hour hour cooling the
temperature does not drop below 90 degrees C (194
degrees F), swap controller and test machine.
• WBG_522918.15 Motor Stalled While Running (Blink
Code 1-6)
3. Investigate current draw using “Readings” in Service
ADVISOR. Remove reel motor from reel to look for a
high load. Is problem resolved? [RLK WBG Motor
Check for presence of these codes to assist diagnosis:
• WBG_522919.02 Manufacturer Service Code
[Unexpected Hall Received] (Blink Code NONE)
•
WBG_522919.04 Manufacturer Service Code [Incorrect
Electrical Controller and Motor Diagnostics - 146
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
Hall signal during run] (Blink Code NONE)
Diagnosis
WBG_522918.02 (Blink Code 1-10) - Motor
Spin Direction Shutdown
Symptom: (Blink Code 1-10) Reel Stops
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
Reel Stops or Does Not Operate
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
Reel direction reversed for 1/4 turn of motor.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
To Clear Display:
•
Recall codes again and check for return of this code.
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
Note: Common conditions to cause code
Code Caused By:
Alarm Level:
Stop
Cycle PTO switch
Alarm Frequency:
Only when active.
Control Unit Response:
Reel shutdown
•
Obstruction in reel
•
Excessive debris in reel
Snapshot Recorded:
•
Jammed reel
Yes
•
Incorrect bed knife clearance
Required Tools:
•
Failing bearings on reel
JDG10429 Electric Reel Motor Tester
Procedure:
Preliminary Checks:
1. Check for common conditions to cause problem. Are
any common problems found?
Check for presence of these codes to assist diagnosis:
Yes: Correct problem.
• WBG_522918.15 Motor Stalled While Running (Blink
Code 1-6)
No: Go to next step.
2. Investigate current draw using “Readings” in Service
ADVISOR. Remove reel motor from reel to look for a
high load. Is problem resolved? [RLK WBG Motor
Current]
Yes: Suspect reel problems.
No: Go to next step.
• WBG_522919.02 Manufacturer Service Code
[Unexpected Hall Received] (Blink Code NONE)
Diagnosis
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
Yes: Go to next step.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
No: Check for broken or damaged wires. Replace reel
motor if necessary.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
4. Swap controller with a known good controller. Is
problem resolved?
•
Recall codes again and check for return of this code.
Yes: Replace controller. DTAC case should be
submitted showing this fault with the serial number of
the controller.
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
Note: Use the JDG10429 Electric Reel Motor Tester.
3. Test motor sensors. Do sensors pass test?
Electrical Controller and Motor Diagnostics - 147
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
Note: Common conditions to cause code
Required Tools:
• Reel obstructed while running or attachment issue Check reel, bed knife, and attachment for damage
JDG10429 Electric Reel Motor tester or multimeter
Procedure:
1. Check for common conditions to cause problem. Are
any common problems found?
Preliminary Checks:
Check for presence of these codes to assist diagnosis:
None
Yes: Correct problem.
Diagnosis
No: Go to next step.
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
2. Investigate current draw using “Readings” in Service
ADVISOR. Remove reel motor from reel to look for a
high load. Is problem resolved? [RLK WBG Motor
Current]
Yes: Suspect reel problems.
No: Go to next step.
Note: Use the JDG10429 Electric Reel Motor Tester.
3. Test motor sensors. Do sensors pass test?
Yes: Go to next step.
No: Check for broken or damaged wires. Replace reel
motor if necessary.
4. Swap controller with a known good controller. Is
problem resolved?
Yes: Replace controller. DTAC case should be
submitted showing this fault with the serial number of
the controller.
WBG_522918.15 (Blink Code 1-6) - Motor
Stalled While Running
Symptom: (Blink Code 1-6) Reel Stops
Reel Stops or Does Not Operate
Code Caused By:
Reel stopped while running
Alarm Level:
Stop
To Clear Display:
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
•
Recall codes again and check for return of this code.
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
Note: Common conditions to cause code
• Reel obstructed while running or attachment issue Check reel, bed knife, and attachment for damage
•
Excessive load
•
Obstruction in reel
•
Jammed reel
•
Incorrect bed knife clearance
•
Failing bearings on reel
•
Excessive debris in reel
Procedure:
1. Check for common conditions to cause problem. Are
any common problems found?
Yes: Correct problem.
No: Go to next step.
Alarm Frequency:
2. Investigate current draw using “Readings” in Service
ADVISOR. Remove reel motor from reel to look for a
high load. Is problem resolved? [RLK WBG Motor
Current]
Only when active.
Yes: Suspect reel problems.
Control Unit Response:
No: Go to next step.
Cycle PTO switch
Reel shut down
Note: Use the JDG10429 Electric Reel Motor Tester.
Snapshot Recorded:
3. Test motor sensors. Do sensors pass test?
Yes
Yes: Go to next step.
Electrical Controller and Motor Diagnostics - 148
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
No: Check for broken or damaged wires. Replace reel
motor if necessary.
4. Swap controller with a known good controller. Is
problem resolved?
Yes: Replace controller. DTAC case should be
submitted showing this fault with the serial number of
the controller.
WBG_522919.02 (Blink Code NONE) Manufacturer Service Code
Symptom: None
Diagnosis
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
No blink code or operational changes.
•
Recall codes again and check for return of this code.
Control Unit Response:
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
None - will record DTC in Service ADVISOR
Note: Common conditions to cause code
Procedure
No diagnostic procedure is used. This is a system reaction
monitor, not a fault. Used for internal data collection.
WBG_522919.03 (Blink Code 6-6) - Hall
Resync Shutdown
Symptom: Blink Code 6-6
Blink Code only.
Code Caused By:
•
Heavy load on reel
•
Excessive debris in reel
•
Controller cooling fins blocked
•
Jammed reel
•
Incorrect bed knife clearance
•
Failing bearings on reel
•
Water in motor
Procedure:
Motor position sensor error while running
Alarm Level:
1. Check for common conditions to cause problem. Are
any common problems found?
Yes: Correct problem.
Stop
No: Go to next step.
To Clear Display:
Alarm Frequency:
2. Investigate current draw using “Readings” in Service
ADVISOR. Remove reel motor from reel to look for a
high load. Is problem resolved? [RLK WBG Motor
Current]
Only when active.
Yes: Suspect reel problems.
Control Unit Response:
No: Go to next step.
Cycle PTO switch
Note: Use the JDG10429 Electric Reel Motor Tester.
None
3. Test motor sensors. Do sensors pass test?
Snapshot Recorded:
Yes: Go to next step.
Yes
No: Check for broken or damaged wires. Replace reel
motor if necessary.
Required Tools:
JDG10429 Electric Reel Motor Tester
Preliminary Checks:
Check for presence of these codes to assist diagnosis:
None
4. Swap controller with a known good controller. Is
problem resolved?
Yes: Replace controller. DTAC case should be
submitted showing this fault with the serial number of
the controller.
Electrical Controller and Motor Diagnostics - 149
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
WBG_522919.04 (Blink Code NONE) Manufacturer Service Code
Symptom: None
Alarm Frequency:
No blink code or operational changes.
Control Unit Response:
Only when active.
None
Control Unit Response:
None - will record DTC in Service ADVISOR
Snapshot Recorded:
No
Procedure
No diagnostic procedure is used. This is a system reaction
monitor, not a fault. Used for internal data collection.
WBG_522919.08 (Blink Code NONE) Manufacturer Service Code
Symptom: None
No blink code or operational changes.
Control Unit Response:
Required Tools:
JDG10429 Electric Reel Motor Tester
Preliminary Checks:
Check for presence of these codes to assist diagnosis:
• WBG_522327.00 (Blink Code 2-10) Motor Over Temp Most likely motor connector is disconnected, contaminated
terminals, bent pins, etc.
None - will record DTC in Service ADVISOR
Diagnosis
Procedure
No diagnostic procedure is used. This is a system reaction
monitor, not a fault. Used for internal data collection.
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
WBG_522919.09 (Blink Code NONE) Manufacturer Service Code
Symptom: None
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
No blink code or operational changes.
Control Unit Response:
None - will record DTC in Service ADVISOR
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
•
Recall codes again and check for return of this code.
•
Recreate operating conditions that caused code.
Procedure
•
End of tests if code does not return.
No diagnostic procedure is used. This is a system reaction
monitor, not a fault. Used for internal data collection.
Note: Common conditions to cause code
WBG_522919.12 (Blink Code 6-4) - Invalid Hall
State Detected at Start-Up
Symptom: Blink Code 6-4
Blink Code only.
• Bad connections or wiring between controller and
reel motor.
•
Water in motor
Procedure:
Note: Use the JDG10429 Electric Reel Motor Tester.
Code Caused By:
1. Do sensors pass test?
Motor position error at start.
Yes: Go to next step.
Alarm Level:
No: Check for broken or damaged wires, contaminated
connector terminals, bent pins, etc.
Stop
To Clear Display:
Stop and start engine
No: Replace reel motor.
2. Swap controller with known good controller. Does
problem resolve?
Yes: Replace controller
Electrical Controller and Motor Diagnostics - 150
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
No: If controller replaced and problem does not clear,
suspect motor problems.
WBG_522937.02 (Blink Code 8-2) - Frequency
of Clip Shutdown
Symptom: (Blink Code 8-2) Reel Stops
Reel Stops or Does Not Operate
Code Caused By:
Failure to hold frequency of clip (FOC).
Alarm Level:
Diagnosis
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
•
Recall codes again and check for return of this code.
•
Recreate operating conditions that caused code.
To Clear Display:
•
End of tests if code does not return.
Cycle PTO switch
Note: Common conditions to cause code
Alarm Frequency:
•
Engine rpm too low.
Only when active.
•
Bed knife not adjusted properly.
Control Unit Response:
•
Jammed reel.
Reel stops.
•
Low current due to faulty bridge rectifier
Stop
Procedure:
Snapshot Recorded:
Yes
1. Check for common conditions to cause problem. Are
any common problems found?
Required Tools:
Yes: Correct problem.
None
No: Go to next step.
Preliminary Checks:
2. Investigate current draw using “Readings” in Service
ADVISOR. Remove reel motor from reel to look for a
high load. Is problem resolved? [RLK WBG Motor
Current]
Check that engine is run at high enough rpm and ground
speed
Check for jammed reel.
Check for ease of reel rotation, proper bed knife to reel
clearance.
Check for presence of these codes to assist diagnosis:
Note: The presence of any stored 522917.xx codes for
the controller likely indicates ongoing problems with
controller/reel combination.
• WBG_522917.15 Controller Current Threshold 1
Shutdown (Blink Code 2-5) (least severe level)
• WBG_522917.06 Controller Hardware Current
Shutdown (Blink Code 2-5) (moderately severe level)
• WBG_522917.00 Controller Current Threshold 3
Shutdown (Blink Code 2-5)
• WBG_522918.15 Motor Stall While Running (Blink
Code 1-6)
Yes: Suspect reel problems. Check reel for adjustment
or damage.
No: Go to next step.
3. Investigate frequency of clip (FOC) potentiometer
using “Readings” in Service ADVISOR. Does the drive
motor speed command change with engine rpm
changes? [RLK WBG WBG Drive Motor Speed] AND
[RLK WBG WBG Drive Motor Speed Command]
Yes: Go to step 5.
No: Suspect reel sensor, go to next step.
Note: Use the JDG10429 Electric Reel Motor Tester.
4. Test motor sensors. Do sensors pass test?
Yes: Go to next step.
No: Check for broken or damaged wires. Replace reel
motor if necessary.
5. Does the drive motor speed command change when
Electrical Controller and Motor Diagnostics - 151
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
the FOC potentiometer is rotated? [RLK WBG WBG
Drive Motor Speed Command]
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
Yes: Go to next step.
•
Recall codes again and check for return of this code.
No: Test FOC potentiometer. See “Frequency of Cut
(FOC) Potentiometer Test” on page 159.
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
6. Test bridge rectifier. See “Bridge Rectifier Test” on
page 160. Replace rectifier if necessary. Does rectifier
test okay?
Yes: Intermittent problem. Duplicate conditions to
cause code and repeat procedure if symptom reoccurs.
Note: Common conditions to cause code
•
Corrupt software.
•
Incorrect controller used on machine.
Procedure:
WBG_522976.12 (Blink Code 8-4) - Incorrect
Application Software
Symptom: (Blink Code 8-4) Reel Stops
1. Connect Service ADVISOR and install available
payload for controller. Does this clear error code?
Reel Stops or Does Not Operate
No: Open DTAC case.
Code Caused By:
Incorrect controller or incorrect controller software.
Alarm Level:
Yes: End of procedure.
WBG_523666.00 (Blink Code 9-2) - Bus
Voltage High
Symptom: Blink Code 9-2
Blink Code only.
Stop
Code Caused By:
To Clear Display:
48V alternator over voltage.
Stop and start engine
Alarm Level:
Alarm Frequency:
Stop
Only when active.
To Clear Display:
Control Unit Response:
Cycle PTO switch
Reel stops.
Alarm Frequency:
Snapshot Recorded:
Only when active.
No
Control Unit Response:
Required Tools:
None
None
Snapshot Recorded:
Preliminary Checks:
Yes
Check DTAC solutions.
Required Tools:
Check for software payload update.
Multimeter
Diagnosis
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
Preliminary Checks:
Check for presence of these codes to assist diagnosis:
• Check for WBG_523666.00 codes from other
controllers. If additional controllers report a problem,
suspect 48V alternator. If only one controller reports
problem, check controller connections and ground.
Electrical Controller and Motor Diagnostics - 152
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
Diagnosis
Control Unit Response:
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
None
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
Yes
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
•
Recall codes again and check for return of this code.
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
Note: Common conditions to cause code
•
Alternator malfunction
Procedure:
Snapshot Recorded:
Required Tools:
Multimeter
Preliminary Checks:
Check for presence of these codes to assist diagnosis:
• Check for WBG_523666.02 code. Check controller
wiring and connections.
Diagnosis
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
Yes: Go to next step.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
No: Check for broken or damaged wires, shorts to
ground from alternator to controller on negative wire.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
2. Swap controller with known good controller. Does
problem resolve?
•
Recall codes again and check for return of this code.
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
1. Test output of 48V alternator. Is output okay? [RLK
WBG ECU Power Supply Voltage #1, Switched]
Yes: Replace controller.
No: If controller replaced and problem does not clear,
return to alternator troubleshooting.
WBG_523666.01 (Blink Code 1-7) - Bus
Voltage Low
Symptom: Blink Code 1-7
Blink Code only.
Code Caused By:
Note: Common conditions to cause code
•
Engine under-speed
•
Excessive load on reel.
•
Dirty or corroded alternator harness connections
•
Alternator malfunction
Procedure:
48V alternator voltage low.
1. Test output of 48V alternator. Is output okay? [RLK
WBG ECU Power Supply Voltage #1, Switched]
Alarm Level:
Yes: Go to next step.
Stop
No: Check for broken or damaged wires, shorts to
ground from alternator to controller on positive wire.
To Clear Display:
Cycle PTO switch
2. Swap motor with known good motor. Does problem
resolve?
Alarm Frequency:
Yes: Replace motor.
Only when active.
No: Go to next step
3. Inspect for bent pins on controller connections. Are
connector pins okay?
Yes: Go to next step.
Electrical Controller and Motor Diagnostics - 153
ELECTRICAL CONTROLLER AND MOTOR DIAGNOSTICS
No: Repair if necessary or replace controller. If
controller replaced and problem does not clear, return
to alternator troubleshooting.
WBG_523666.02 (Blink Code 1-7) - Low VBUS
on Start
Symptom: Blink Code 1-7
Note: Common conditions to cause code
•
Engine under-speed
•
Failed 48V alternator
•
Excessive load on reel at start up.
Procedure:
Blink Code only.
1. Test output of 48V alternator. Is output okay? [RLK
WBG ECU Power Supply Voltage #1, Switched]
Code Caused By:
Yes: Go to next step.
48V alternator below 20V at start
No: Check for broken or damaged wires, shorts to
ground from alternator to controller on positive wire.
Alarm Level:
Stop
2. Inspect for bent pins on controller connections. Are
connector pins okay?
To Clear Display:
Yes: Go to next step.
Stop and start engine
No: Repair connector.
3. Replace controller. Does problem resolve?
Alarm Frequency:
No: If controller replaced and problem does not clear,
return to alternator troubleshooting.
Only when active.
Control Unit Response:
Snapshot Recorded:
WBG_523666.15 (Blink Code NONE) Manufacturer Service Code
Symptom: None
Yes
No blink code or operational changes.
Required Tools:
Control Unit Response:
Multimeter
None - will record DTC in Service ADVISOR
Preliminary Checks:
Procedure
Check for presence of these codes to assist diagnosis:
No diagnostic procedure is used. This is a system reaction
monitor, not a fault. Used for internal data collection.
None
• Check for WBG_523666.01 code. Check wiring or
controller problems; check alternator.
Diagnosis
If not using SERVICE ADVISOR™ or if unable to make a
connection: See “Diagnostic LED Fault Codes” on
page 116 for the on-board display procedure.
SERVICE ADVISOR™: This procedure can be performed
by making a connection to the machine and using the
”Diagnostics” tab to view and clear codes. Use Snapshot
Test under Interactive Test tab for specific controller to
record fault.
• Recall, record (Snapshot test under Interactive Tests)
and clear codes.
•
Recall codes again and check for return of this code.
•
Recreate operating conditions that caused code.
•
End of tests if code does not return.
Electrical Controller and Motor Diagnostics - 154
ELECTRICAL TESTS AND ADJUSTMENTS
Tests and Adjustments
the switch in the MOW and BACKLAP positions.
Backlap Switch Test
Backlap Switch Continuity
Reason
Switch
Position
Terminal
Continuity
Mow
No Continuity
Backlap
Continuity
To verify proper backlap switch operation.
Special or Required Tools
Tool Name
Digital
Multimeter
Tool No.
JT05791
Tool Use
Used to measure
switch continuity.
Procedure 1
Results
•
If continuity is not correct, replace switch.
Run/Off Switch Test
1. Park machine safely on a level surface.
2. Connect Service ADVISOR EDL and 12Vdc power
supply.
Reason
To make sure the run/off switch is operating properly.
Special or Required Tools
3. Start and run machine.
4. Place switch in both positions and check switch position
reading. [RLK WBG Direction Switch]
Results
• If switch position reading changes when switch is
changed, switch tests good.
• If switch position reading does not change when switch
is changed, go to procedure.
Tool Name
Ohmmeter (or
Continuity
Tester)
Tool No.
NA
Tool Use
Used to test switch
terminals for
continuity.
Procedure
1. Park machine on a level surface.
2. Move run/off switch to off position.
Procedure 2
3. Lock park brake.
1. Park machine safely on a level surface.
4. Disconnect wires from switch.
2. Move run/off switch to off position.
3. Lock park brake.
4. Disconnect backlap switch connector and remove
switch.
5. Use an ohmmeter to test switch continuity.
B
A
A
B
M83946
5. Move switch to run position.
6. Check continuity across terminals 2 (A) and 3 (B). There
should be no continuity.
7. Move switch to off position.
8. Check continuity across terminals 2 (A) and 3 (B). There
should be continuity.
Results
MX20453
If continuity is not correct, replace switch.
6. Test continuity between switch terminals (A and B) with
Electrical Tests and Adjustments - 155
ELECTRICAL TESTS AND ADJUSTMENTS
Park Brake Switch Test
Procedure 2
Reason
In addition to switch function, the brake switch should be
checked for proper adjustment to the park brake lever.
To verify proper park brake switch operation.
1. Run/off switch in off position.
Special or Required Tools
Tool Name
Digital
Multimeter
2. Brake switch harness connector disconnected.
Tool No.
JT05791
Tool Use
Used to measure
switch continuity.
Procedure 1
3. Use an ohmmeter to test switch continuity.
Note: The park brake switch has both normally open
(NO) and normally closed (NC) switches. Only the NO
switch is used. Refer to the wire harness connector
terminals for switch terminals to be tested.
1. Park machine safely on a level surface.
2. Move run/off switch to off position.
3. Release park brake.
4. Disconnect brake switch harness connector.
C
5. Use an ohmmeter to test switch continuity.
Note: The park brake switch has both normally open
(NO) and normally closed (NC) switches. Only the NO
switch is used. Refer to the wire harness connector
terminals for switch terminals to be tested.
D
A
B
MX43341
4. Test continuity between switch terminals (A and B) with
park brake control lever (C) in brake applied and released
positions. Refer to terminal locations in removed wire
harness connector (D) for switch terminals to be tested.
C
D
Park Brake Switch Continuity
A
B
Brake Control Position
Terminal Continuity
Released
No Continuity
Applied
Continuity
MX43341
6. Test continuity between switch terminals (A and B) with
switch plunger (C) in depressed and released positions.
Refer to terminal locations in removed wire harness
connector (D) for switch terminals used.
Park Brake Switch Continuity
Switch Plunger Position
Terminal Continuity
Released
No Continuity
Depressed
Continuity
Park Brake Switch Adjustment
A reel motor circuit switch is actuated by the park brake
control, The switch position must be properly adjusted so
that the switch contacts close when the brake control lever
is in the brake position.
Results
•
If continuity is not correct, replace switch.
Electrical Tests and Adjustments - 156
ELECTRICAL TESTS AND ADJUSTMENTS
C
A
C
B
MX43340
A
1. Check to see that contacts in brake switch (A) close
when park brake control lever is moved to brake position.
B
• Listen for click when control lever is moved to brake
position.
• Remove wire harness connector (B) and check for
continuity through switch when control lever is moved to
brake position.
MX43342
5. Test continuity between switch terminals (A and B) with
switch plunger (C) in depressed and released positions.
Clutch Switch Continuity
2. Loosen fasteners securing brake switch body to
handlebar bracket, and adjust switch position as required.
Tighten fasteners to secure switch location.
Switch Plunger Position
Terminal Continuity
Released
No Continuity
Clutch Switch Test
Depressed
Continuity
Reason
Results
To verify proper clutch switch operation.
•
Special or Required Tools
Tool Name
Digital
Multimeter
Procedure 2
Tool No.
JT05791
If continuity is not correct, replace switch.
Tool Use
Used to measure
switch continuity.
6. Run/off switch in off position.
7. Clutch switch harness connector disconnected.
8. Use an ohmmeter to test switch continuity.
Procedure 1
1. Park machine safely on a level surface.
2. Move run/off switch to off position.
3. Disconnect clutch switch connector.
4. Use an ohmmeter to test switch continuity.
C
A
B
MX43343
9. Test continuity between switch terminals (A and B) with
clutch control lever (C) in applied and released positions.
Electrical Tests and Adjustments - 157
ELECTRICAL TESTS AND ADJUSTMENTS
Blower Housing Assembly” on page 51.)
Clutch Switch Continuity
Clutch Control Position
Terminal Continuity
Released
No Continuity
Applied
Continuity
A
Results
•
If continuity is not correct, adjust switch position.
Clutch Switch Adjustment
A reel motor circuit switch is actuated by the clutch control,
The switch position must be properly adjusted so that the
switch contacts close when the clutch control lever is in the
drive position.
M83945
5. Hold a steel tool about 25 mm (1.0 in.) from flywheel
magnet (A). The tool should be attracted by the magnet.
Results
Replace the flywheel if the magnet does not attract the tool.
Reel Motor Test
Special or Required Tools
A
B
C
MX43339
1. Check to see that contacts in clutch switch (A) close
when clutch control lever is moved to drive position.
• Listen for click when control lever is moved to drive
position.
• Remove wire harness connector (B) and check for
continuity through switch when control lever is moved to
drive position.
2. Loosen fasteners securing clutch switch body to
handlebar bracket, and adjust switch position as required.
Tighten fasteners to secure switch location.
Tool Name
Tool No.
Diagnostic Tool
JDG10429
Tool Use
Used to test electric
reel motor.
Reason
To determine if reel motor is operating properly.
Procedure
1. Machine parked on a level surface.
2. STOP engine and disconnect spark plug.
3. Connect reel motor 6-pin connector (A) to the diagnostic
tool.
B
Test Flywheel Magnet
Reason
To make sure the flywheel magnet has enough force to
induce current in the ignition coil.
Procedure
1. Park machine on a level surface.
2. Move run/off switch to off position.
MX23605
3. Lock park brake.
4. Remove blower housing. (See “Remove and Install
4. When the gear on the motor is rotated, the diagnostic
tool will light the LEDs in the order as indicated on pattern
(B). Depending on the direction the gear is rotated, the
Electrical Tests and Adjustments - 158
ELECTRICAL TESTS AND ADJUSTMENTS
pattern may be indicated in the reverse order. Amber LED
must be ON at all times.
5. While rotating the gear, move the wires near the
connector terminals. Observe the light pattern. An erratic
light pattern indicates a broken wire. Use the following
chart to pinpoint which wire is broken:
Reel Motor Wiring/Phase Test
Reason:
To test the motor internal phase to phase resistance in
order to troubleshoot erratic motor performance.
Required Tools:
Symptom
Probable Cause
•
No lights.
Broken black wire or
contamination of the black
wire terminal.
Procedure:
No red lights.
Broken red wire or
contamination of the red
wire terminal.
Important: Avoid Damage! Perform this procedure
only if all other diagnostics (Service ADVISOR or
Blink Codes) have been performed. Repeated
disconnection of connectors will cause damage to
the connector.
No amber light.
Broken blue wire or
contamination of the blue
wire terminal.
1. Park machine safely with park brake locked.
One red light not
functioning.
Broken green, white, or
orange wire or
contamination of one of
these terminals.
2. With engine off and spark plug disconnected,
disconnect reel motor phase connector from controller.
3. Measure for continuity between all pin combinations.
Important: Avoid Damage! Do not cut or remove
conduit from phase wires. If wiring is damaged
within conduit, motor must be replaced.
6. Repair broken wires and clean terminals as needed.
7. While rotating the gear, move the wire harness at the
area where the harness enters the body of the motor.
Observe the light pattern. If any of the lights flickers or goes
out while moving the wire harness, replace the motor.
Results
•
Repair broken wires and clean terminals as needed.
• If a broken wire is determined to be near or inside the
motor body, the motor must be replaced.
Digital Multimeter
4. If continuity is not present, check for damaged wiring or
connectors (exposed from conduit).
5. While connected to multimeter, move wiring to different
positions and note if continuity changes sporadically. If so,
this is indicative of faulty wiring or connector.
6. If continuity is not present or does not change, replace
reel motor if repair not possible.
Specification:
Continuity between all phase combinations . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . Motor external wiring OK
Frequency of Cut (FOC) Potentiometer Test
Reason:
To test the frequency of cut potentiometer for proper
resistance and operation.
Required Tools:
•
Digital Multimeter
Procedure:
1. Park machine safely with park brake locked.
2. With engine off and spark plug disconnected,
disconnect FOC potentiometer from wiring harness.
3. Measure for continuity between all pin combinations
Electrical Tests and Adjustments - 159
ELECTRICAL TESTS AND ADJUSTMENTS
while rotating potentiometer knob.
Results:
If potentiometer resistance does not meet specification
replace potentiometer. (See “FOC Potentiometer
Replacement” on page 198.)
C
C
B
B
A
A
mif
Specifications:
A to C Resistance (approx.). . . . . . . . . . . . . . 5600 ohms
A to B Resistance (approx.). . . . . . . .1100 to 4500 ohms
C to B Resistance (approx.). . . . . . . .1100 to 4500 ohms
Bridge Rectifier Test
Reason:
To test the bridge rectifier proper operation.
Required Tools:
•
Digital Multimeter with Diode Test
147A (-)
257A
257B
257C
201A (+)
A (257A Org)
B (257B Wht)
C (257C Lt Grn)
POS (201A Red)
NEG (147A Blk)
mif
Test Procedure:
There should be test conduction in one direction only
between the following connections, and no shorts.
•
A to POS; and NEG to A
•
B to POS; and NEG to B
•
C to POS; and NEG to C
Results:
Replace rectifier if test measurements do not match given
measurements.
Electrical Tests and Adjustments - 160
POWER TRAIN TABLE OF CONTENTS
Power Train
Table of Contents
Specifications ...............................................163
Adjustment Specifications ..........................163
Repair Specifications..................................163
Tools...........................................................163
Component Location and Operation ..........164
Drive Belt and Differential System..............164
Gear Case Components.............................165
Traction Roller Components ......................166
Diagnostics ...................................................167
Machine Will Not Drive ...............................167
Noisy Operation..........................................167
Machine Does Not Reach Full Ground
Speed .........................................................168
Machine Speed is Erratic ...........................168
Traction Drive Pulls to One Side ................168
Park Brake Does Not Hold Machine...........169
Tests and Adjustments ................................170
Drive Belt Tension Check and Adjustment.170
Traction Roller Drive Chain Slack
Adjustment .................................................171
Checking and Filling Gear Case.................171
Repair.............................................................172
Clutch Control Cable Replacement ............172
Traction Drive Belt Replacement ...............173
Alternator Drive Belt Replacement ............174
Alternator Sheave Removal and
Replacement ..............................................175
Differential Gear Case Removal and
Installation .................................................176
Differential Gear Case Disassembly and
Inspection ...................................................180
Differential Gear Case Assembly ...............182
Traction Roller Assembly Removal and
Installation ..................................................184
Power Train Table of Contents - 161
POWER TRAIN TABLE OF CONTENTS
Power Train Table of Contents - 162
POWER TRAIN SPECIFICATIONS
Specifications
Adjustment Specifications
Traction Roller Drive Chain Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.25 in.)
Repair Specifications
Torque Specifications
Alternator Belt Tensioner Bracket (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N•m (20 lb-ft)
Alternator Mounting Bolts (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Alternator Sheave Nut (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft)
Axle Bearing Spindle to Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N•m (20 lb-ft)
Axle Sprocket Retainer to Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 N•m (80 lb-ft)
Belt Guard to Electronics Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Differential Gear Case Mount to Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N•m (20 lb-ft)
Control Cable Jam Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Drive Clutch Tensioner Bracket to Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N•m (20 lb-ft)
Drive Chain Slack Adjuster to Side Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N•m (20 lb-ft)
Electronics Bracket to Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N•m (20 lb-ft)
Gear Case Drain Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Gear Case Fill Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Gear Case Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Park Brake Bracket to Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Rectifier Block to Electronics Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Side Drive Cover to Side Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Side Drive Input Shaft Bearing Housing to Side Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Side Drive Input Sprocket Retainer to Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 N•m (40 lb-ft)
Traction Roller Center Bearing Housing to Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N•m (20 lb-ft)
Traction Roller Side Bearing Housing to Side Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Lubrication
Differential Gear Case Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 L (0.3 pt) (4.8 oz)
Differential Gear Case Oil . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere HY-GARD (J20C) Transmission/Hydraulic Oil
Side Drive Bearing Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere Multi-Purpose SD Polyurea Grease
Side Drive Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere Multi-Purpose SD Polyurea Grease
Traction Roller Center Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere Multi-Purpose SD Polyurea Grease
Tools
Special or Required Tools
Tool Name
Puller
Tool No.
JDG10945
Tool Use
Remove sheave from
alternator shaft
Power Train Specifications - 163
POWER TRAIN COMPONENT LOCATION AND OPERATION
Component Location and Operation
Drive Belt and Differential System
Function
The machine drive system transfers engine power through
a gear case to the traction roller or transport wheel
assemblies. A differential incorporated in the gear case
allows independent drive to left and right sides for reduced
turning effort and machine impact on turf surfaces.
Theory of Operation
The differential gear case input shaft is loosely connected
to the engine by a V-belt. As the travel clutch control lever is
moved to the engaged position, a connecting cable acts
through linkage to press an idler pulley against the drive
belt.
With pressure applied to the drive belt, the belt grips the
engine and gear case input sheaves. The gear case input
shaft transfers power through an internal drive chain and
differential assembly to left and right output shafts.
The output shafts are connected to final reduction chain
drives on each side of the machine frame. The driven
sprockets at each side are connected to the traction roller
assembly axle shafts.
The gear case differential allows left and right halves of the
roller to turn at different speeds, resulting in smoother turns
with reduced effort and impact on turf surfaces.
Wheel assemblies can be installed to the roller axle shafts
for machine transport without roller ground contact. The
wheel assemblies incorporate quick-lock mechanisms for
ease of installation or removal.
Power Train Component Location and Operation - 164
POWER TRAIN COMPONENT LOCATION AND OPERATION
Gear Case Components
I
J
K
H
G
L
F
M
E
D
A
C
B
E
N
A
O
W
E
R
A
T
G
S
T
U
R
P
Q
MX42947
A- Seal (3 used)
B- Screw (8 used)
C- Cover
D- Chain, Roller
E- Ball Bearing (3 used)
F- Shaft, Input 12T
G- Bearing (2 used)
H- Pin (2 used)
I- Case
J- Washer, Nylon
K- Plug 1/2-20
L- Screw, M8
M- Washer
N- Shaft, Output LH
O- Shaft, Output RH
P- Lock Nut (2 used)
Q- Sprocket 39T
R- Gear, Side (2 used)
S- Differential Housing
T- Pin (2 used)
U- Gear, Planet (2 used)
V- Cap, Differential
W- Screw, Shoulder (2 used)
Power Train Component Location and Operation - 165
V
POWER TRAIN COMPONENT LOCATION AND OPERATION
Traction Roller Components
A
B
C
D
E
C
B
F
G
H
I
M
T
J
S
J
K
L
R
Q
P
O
M
N
L
K
J
J
N
O
P
Q
R
S
MX42948
A- Spindle
B- Seal (2 used)
C- Bearing (2 used)
D- Hub
E- Cap Screw (8 used)
F- Spacer
G- Castle Nut
H- Cotter Pin
I- Roller (2 used)
J- Cap Screw (14 used)
K- Axle (2 used)
L- Key (2 used)
M- Grease Fitting (2 used)
N- Housing (2 used)
O- Seal (2 used)
P- Bearing (2 used)
Q- Snap Ring (2 used)
R- Cover (2 used)
S- Sprocket (2 used)
T- Nut (2 used)
Power Train Component Location and Operation - 166
T
POWER TRAIN DIAGNOSTICS
Diagnostics
Case Disassembly and Inspection” on page 180.)
Symptom: Machine Will Not Drive
8. Are traction drive chains in good condition and not
damaged?
Yes: Go to next step.
Test Conditions
No: Replace drive chain(s).
•
Machine parked on a level surface.
•
Run/off switch in off position.
9. Are traction drive roller sprockets in good condition
and not damaged? Are keys in place and not
damaged?
•
Travel clutch disengaged.
•
Park brake released.
Yes: Go to next step.
No: Sprockets are damaged. Replace sprockets. (See
“Traction Roller Components” on page 166.)
1. Is park brake band tight on brake drum? (See “Park
Brake Adjustment” on page 208.)
No: Keys are missing and/or damaged. Replace keys.
(See “Traction Roller Components” on page 166.)
Yes: Adjust or repair park brake.
10. Is differential gear case input shaft sprocket in good
condition and not damaged?
No: Go to next step.
Yes: Go to next step.
2. Are drive sheave, drive sheave key, and keyway in
good operating condition?
No: Replace sprocket. (See “Differential Gear Case
Disassembly and Inspection” on page 180.)
Yes: Go to next step.
11. Is differential gear case chain in good condition and
not damaged?
No: Replace sheave and/or key.
3. Are drive belts free from damage (broken, worn,
frayed, glazed, or stretched)? Are drive belts loose
without proper tension?
Yes: Go to next step.
No: Replace chain. (See “Differential Gear Case
Disassembly and Inspection” on page 180.)
Yes: Go to next step.
12. Are differential gears in good condition and not
damaged?
No: Replace drive belts. (See “Traction Drive Belt
Replacement” on page 173.)
No: Replace differential gears. (See “Differential Gear
Case Disassembly and Inspection” on page 180.)
4. Do drive belts appear to be correctly tensioned?
Yes: Go to next step.
Symptom: Noisy Operation
No: Adjust drive belt(s) tension. (See “Drive Belt
Tension Check and Adjustment” on page 170.)
5. Is differential gear case input shaft key in good
condition and not damaged?
Yes: Go to next step.
No: Key is missing or damaged. Replace key. (See
“Differential Gear Case Disassembly and Inspection”
on page 180.)
6. Is differential gear case input shaft in good condition
and not damaged?
Yes: Go to next step.
No: Replace input shaft. (See “Differential Gear Case
Disassembly and Inspection” on page 180.)
7. Are differential gear case output shafts in good
condition and not damaged?
Test Conditions
•
Machine parked on a level surface.
•
Run/off switch in off position.
•
Travel clutch disengaged.
•
Park brake unlocked.
•
Engine cold.
1. Is traction drive chain slack adjustment correct? Are
chains properly lubricated?
Yes: Go to next step.
Yes: Go to next step.
No: Chains are loose. Tighten drive chains. (See
“Traction Roller Drive Chain Slack Adjustment” on
page 171.)
No: Replace output shaft(s). (See “Differential Gear
No: Chains need lubrication. Apply grease to chains.
Power Train Diagnostics - 167
POWER TRAIN DIAGNOSTICS
(See “Grease” on page 16.)
3. Does drive belt appear to be correctly tensioned?
2. Are traction roller assembly bearings in good
operating condition?
No: Adjust drive belt tension. (See “Drive Belt Tension
Check and Adjustment” on page 170.)
Symptom: Machine Speed is Erratic
Yes: Go to next step.
No: Replace bearings. (See “Traction Roller
Components” on page 166.)
3. Is oil up to the bottom of the oil fill port?
Test Conditions
Yes: Go to next step.
•
Machine parked on a level surface.
No: Oil is low. Fill to correct level with oil meeting
specifications. (See “Transmission and Hydraulic Oil”
on page 16.)
•
Run/off switch in off position.
•
Travel clutch disengaged.
•
Park brake unlocked.
4. Are differential gear case shaft (frame) bearings in
good operating condition?
1. Is drive belt damaged (broken, worn, frayed, or
stretched)? Is drive belt glazed, or contaminated with
oil?
Yes: Go to next step.
No: Replace bearings. (See “Frame and Drive Covers”
on page 256.)
Yes: Replace drive belt. (See “Traction Drive Belt
Replacement” on page 173.)
5. Are differential gears in good condition and not
damaged or badly worn?
No: Go to next step
Yes: Go to next step.
2. Is traction drive belt tension adjustment correct?
No: Replace differential gears. (See “Differential Gear
Case Disassembly and Inspection” on page 180.)
Yes: Go to next step.
6. Are differential gear case assembly bearings (input
and output shafts) in good operating condition?
No: Adjust drive belt tension. (See “Drive Belt Tension
Check and Adjustment” on page 170.)
No: Replace bearings. (See “Differential Gear Case
Disassembly and Inspection” on page 180.)
3. Is traction drive chain slack adjustment correct? Are
chains properly lubricated?
Symptom: Machine Does Not Reach Full
Ground Speed
No: Chains are loose. Tighten drive chains. (See
“Traction Roller Drive Chain Slack Adjustment” on
page 171.)
Symptom: Traction Drive Pulls to One Side
Test Conditions
•
Machine parked on a level surface.
•
Run/off switch in off position.
•
Travel clutch disengaged.
•
Park brake unlocked.
Test Conditions
•
Machine parked on a level surface.
•
Run/off switch in off position.
•
Travel clutch disengaged.
•
Park brake unlocked.
1. Is park brake unlocked?
Yes: Go to next step.
1. Is traction drive chain slack adjustment correct? Are
chains in good operating condition?
No: Unlock park brake.
2. Is drive belt free from damage (broken, worn, frayed,
glazed, or stretched)? Is drive belt loose without proper
tension?
Yes: Go to next step.
No: Replace drive belt. (See “Traction Drive Belt
Replacement” on page 173.)
Yes: Go to next step.
No: Chains are loose. Adjust drive chain slack. (See
“Traction Roller Drive Chain Slack Adjustment” on
page 171.)
No: Replace drive chain(s).
Power Train Diagnostics - 168
POWER TRAIN DIAGNOSTICS
2. Are traction drive roller sprockets in good condition
and not damaged? Are keys in place and not
damaged?
Yes: Go to next step.
No: Sprockets are damaged. Replace sprockets. (See
“Traction Roller Components” on page 166.)
No: Keys are missing and/or damaged. Replace keys.
(See “Traction Roller Components” on page 166.)
3. Are differential gear case shaft (frame) bearings in
good operating condition?
Yes: Go to next step.
No: Replace bearings. (See “Frame and Drive Covers”
on page 256.)
4. Are differential gear case assembly bearings (output
shafts) in good operating condition?
Yes: Go to next step.
No: Replace bearings. (See “Differential Gear Case
Disassembly and Inspection” on page 180.)
5. Are differential gears in good condition and not
damaged?
Yes: Go to next step.
No: Replace differential gears. (See “Differential Gear
Case Disassembly and Inspection” on page 180.)
6. Are differential gear case output shaft sprocket(s)
and/or key(s) in good operating condition?
No: Replace sprockets and/or keys.
Symptom: Park Brake Does Not Hold Machine
Test Conditions
•
Machine parked on a level surface.
•
Run/off switch in off position.
•
Travel clutch disengaged.
•
Park brake unlocked.
1. Is park brake properly adjusted?
Yes: Go to next step.
1. Adjust park brake. (See “Park Brake Adjustment” on
page 208.)
2. Is brake band in good operating condition and not
glazed or damaged?
No: Replace brake band. (See “Park Brake Band
Replacement” on page 210.)
Power Train Diagnostics - 169
POWER TRAIN TESTS AND ADJUSTMENTS
Tests and Adjustments
Traction Drive Belt Tension Adjustment Procedure
1. Park machine on a level surface.
Drive Belt Tension Check and Adjustment
• When properly adjusted, with engine stopped and travel
clutch lever disengaged, the machine should move freely.
With travel clutch lever applied, the traction roller should not
move.
• When properly adjusted, with engine running and set at
low idle, park brake released and travel clutch lever
disengaged, machine should not move.
2. Move run/stop switch to stop position.
3. Move travel clutch lever to released position.
Note: If the travel clutch releases itself while engaged,
drive belt tension may be excessive. Reduce belt
tension by turning inner and outer jam nuts toward the
control cable housing.
• With engine running and set at low idle, park brake
released, travel clutch lever applied and holding machine
by handlebars, transport wheels should spin on gravel or
concrete surface.
• With engine running, park brake released, travel clutch
lever applied, unit should propel itself up an incline.
A
Check Procedure
1. Park machine on a level surface.
B
2. Move run/stop switch to stop position.
3. Move travel clutch lever to released position.
4. Pull the machine backward: transport wheels and roller
should turn freely.
• If transport wheels and roller turn freely, proceed to
next step.
• If transport wheels or roller do not turn, adjust belt
tension.
MX42345
4. Adjust inner and outer jam nuts (A) at upper end of
travel clutch control cable to adjust drive belt tension.
• If drive belt tension is too loose, turn jam nuts away
from cable housing (B).
• If drive belt tension is too tight, turn jam nuts toward
cable housing.
5. Move travel clutch lever to applied position.
6. Pull the machine backward: transport wheels and roller
should not turn.
• If transport wheels or roller turn, or excessive force is
required to engage clutch, adjust belt tension.
D
• If transport wheels and roller do not turn, proceed to
next step.
C
7. Move travel clutch lever to released position.
8. Start engine and run at low idle. The machine should not
move forward. If it does, adjust belt tension.
9. With engine running at low idle, hold machine by the
handlebars to prevent it from moving. Release the brake
and engage the clutch.
MX42344
• If transport wheels spin on gravel or concrete, clutch
control is properly adjusted.
5. Adjust jam nuts just until deflection is seen at bracket
(C) when control level is moved to travel position. Tighten
jam nuts to specification.
• If transport wheels will not spin on gravel or concrete,
clutch control adjustment for greater tension is required.
6. Repeat check procedure.
• If clutch disengages, belt control adjustment for
reduced tension is required.
7. If there is insufficient adjustment available at upper
cable end for proper belt tension adjustment, make further
adjustment at cable lower end jam nuts (D).
Power Train Tests and Adjustments - 170
POWER TRAIN TESTS AND ADJUSTMENTS
Specification
5. Tighten nut (B).
Control Cable Jam Nuts . . . . . . . . . . . 10 N•m (84 lb-in.)
6. Lubricate drive chain using John Deere Multi-Purpose
SD Polyurea Grease or equivalent SAE multipurpose
grease.
Traction Roller Drive Chain Slack Adjustment
7. Install cover and secure with original hardware.
Reason
8. Install transport wheel.
To maintain proper drive chain slack adjustment.
9. Repeat steps on opposite side.
Procedure
10.Lower machine from kick stand.
1. Raise machine on kick stand and remove transport
wheel.
Specifications
Traction Roller Drive Chain Deflection. . 6 mm (0.25 in.)
Drive Chain Slack Adjuster Nut . . . . . . 28 N•m (20 lb-ft)
Side Drive Cover Retaining Nut . . . . . 10 N•m (84 lb-in.)
A
Checking and Filling Gear Case
C
A
MX42349
2. Remove three M6 nuts (A) at side drive cover and
remove cover from machine.
B
MX42357
B
1. Support cutting unit so that machine is level, with rear
surface of gear case (A) vertical.
D
2. Remove drain plug (B).
3. Check level of lubricant. Oil should be at the bottom of
drain opening.
C
4. If oil is required, remove fill plug (C) and add specified
oil until the oil begins to flow from drain opening.
•
Oil Capacity: 140 mL (4.8 oz.)
5. Reinstall fill and drain plugs with sealing washers and
tighten securely.
MX42515
3. Loosen M8 nut (B) on drive chain slack adjuster.
6. Remove block used to level unit.
4. Move adjuster (C) as required to provide 6 mm (0.25 in.)
deflection at mid point (D) of drive chain, or 11 mm (0.43
in.) total deflection (combined deflection for both
directions).
Power Train Tests and Adjustments - 171
POWER TRAIN REPAIR
Repair
Clutch Control Cable Replacement
If the clutch control cable is damaged or does not slide
freely in the housing, the cable should be replaced.
A
Clutch Control Cable Removal
MX42849
1. Install cable assembly through slotted hole in lower
handlebar bracket (A).
B
A
C
B
D
C
MX42847
1. Remove cotter pin (A) and drilled pin (B) securing clutch
cable yoke to control lever arm.
D
E
2. Remove dust cap (C) and outer jam nut (D).
F
3. Withdraw cable housing ferrule and slide cable through
slot in handlebar bracket.
MX42850
I
2. Remove outer jam nut (B), and slide cable through slot
in gear case bracket (C).
H
3. Insert cable housing ferrule into bracket, and install
outer jam nut. Adjust inner and outer jam nuts so that
threaded portion of ferrule is approximately centered in
bracket.
F
G
4. Install flat washer (D) and return spring (E) to cable.
5. Compress spring and insert cable end (G) into tensioner
bracket slot.
MX42850
K
4. Compress spring (F), and disconnect clutch cable end
(G) from tensioner bracket.
L
5. Remove spring and flat washer (H) from cable.
6. Remove outer jam nut (I) and slide cable end from
bracket.
H
I
7. Remove cable assembly from handlebar brace.
Clutch Control Cable Installation
J
Fit a replacement clutch control cable to the handlebar with
the cable dust cover at the upper end. Take care to avoid
kinking the inner cable during installation.
MX42847
6. Remove dust cap (H) and outer jam nut (I) from cable
housing ferrule and fit cable end through slot in upper
Power Train Repair - 172
POWER TRAIN REPAIR
handlebar bracket (J).
7. Install outer jam nut to ferrule, and adjust inner and
outer jam nuts to approximately center threaded portion of
ferrule in bracket.
8. Install dust cap to ferrule end.
F
9. Install drilled pin (K) securing clevis to clutch control
arm. Secure pin with cotter pin (L).
E
10.Adjust drive belt tension. (See “Drive Belt Tension
Check and Adjustment” on page 170.)
Traction Drive Belt Replacement
MX42846
4. Rotate alternator with mounting bracket (E) away from
engine sheave, and remove traction drive belt (F) from
engine sheave.
A
F
I
MX42759
H
G
1. Remove three M6x20 socket pan head bolts (A)
securing cover to electronics bracket. Remove cover.(
MX42757
5. Remove M10 flanged shoulder bolt (G) and spacer
washer (H) securing drive tensioner bracket (I) to gear
case. Move bracket aside.
6. Remove drive belt (F) from gear case input sheave.
C
7. Replace traction drive belt and reverse steps for
reassembly, or go on to replace alternator drive belt.
Specifications
D
B
MX42760
2. Loosen M6 hex head alternator support bolt (B) and two
M8 hex head bolts (C) securing alternator mounting bracket
to electronics bracket.
Alternator Mounting Bracket Bolts (M8)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N•m (20 lb-ft)
Alternator Support Bracket Bolt (M6). 10 N•m (84 lb-in.)
Belt Guard Bolts . . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Drive Chain Slack Adjuster Nut . . . . . . 28 N•m (20 lb-ft)
Drive Clutch Tensioner Bracket Bolt . . 55 N•m (40 lb-ft)
3. Rotate alternator toward engine sheave, and release
drive belt (D) from alternator sheave.
Power Train Repair - 173
POWER TRAIN REPAIR
Alternator Drive Belt Replacement
5. Remove alternator drive belt from engine sheave.
Remove Drive Belt
6. Install replacement alternator and traction drive belts in
reverse order of steps for removal.
7. Adjust belt tension (see below).
Adjust Belt Tension
1. Check belt tension. Belt should deflect approximately 12
mm (1/2 in.) with 98 N (22 lb) force (moderate thumb
pressure) applied midway between sheaves.
A
A
MX42759
1. Remove three M6x20 socket pan head bolts (A)
securing cover to electronics bracket. Remove cover.
B
MX43197
2. Insert a 3/8 in. drive torque wrench to alternator bracket
square socket (A), and rotate alternator assembly forward
with a force of 27 N•m (239 lb-in.)
C
3. Tighten two M8 hex head bolts (B) securing alternator
mounting bracket while holding specified force on bracket.
B
D
MX42760
2. Loosen M6 hex head alternator support bolt (B) and M8
hex head bolt (C) securing generator bracket to electronics
bracket.
C
3. Rotate alternator toward engine sheave, and release
drive belt (D) from alternator sheave.
MX42760
F
4. Tighten M6 bolt (C) at alternator support bracket.
5. Check belt tension, adjust if necessary.
E
MX42846
4. Rotate alternator with mounting bracket (E) away from
engine sheave, and remove traction drive belt (F) from
engine sheave.
Power Train Repair - 174
POWER TRAIN REPAIR
(B).
D
3. Remove alternator from mounting brackets.
C
D
E
E
MX42759
MX43118
6. Install cover (D) and secure with three M6 bolts (E).
4. Support alternator so that there is no strain on wiring
harness (C).
Specifications
Alternator Belt Deflection
. . . . . . . . . . . . . . . . . . . . . 12mm @ 98 N (1/2 in. @ 22 lb)
Alternator Mounting Bracket Bolts (M8)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N•m (20 lb-ft)
Alternator Support Bracket Bolt (M6) 10 N•m (84 lb-in.)
Belt Guard Bolts . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Drive Chain Slack Adjuster Nut. . . . . . 28 N•m (20 lb-ft)
Drive Clutch Tensioner Bracket Bolt . 55 N•m (40 lb-ft)
Alternator Sheave Removal and Replacement
Special or Required Tools
Tool Name
Puller
Tool No.
JDG10945
Note: Use of an air or electric impact wrench will ease
removal of the alternator belt sheave retaining nut.
5. Remove M10 hex nut (D) securing belt sheave (E) to
alternator shaft.
Important: Avoid Damage! Do not pry against the
alternator case or use improvised tools to remove
the alternator belt sheave. Use John Deere tool
JDG10945 to remove the sheave from the alternator.
Use of other tools may result in damage to the
alternator.
Tool Use
Remove sheave from
alternator shaft
Alternator Sheave Removal
1. Remove alternator drive belt. (See “Alternator Drive Belt
Replacement” on page 174.)
B
MX43119
6. Remove belt sheave from alternator shaft using John
Deere tool JDG10945.
A
MX43117
2. Remove three M6x105 hex head bolts (A) and hex nuts
securing alternator to mounting brackets. Retain spacer
Power Train Repair - 175
POWER TRAIN REPAIR
Alternator Sheave Installation
D
A
A
F
E
MX43117
MX43120
1. Ensure that alternator shaft key (A) is installed to shaft.
4. Secure alternator to inner mounting bracket with two
M6x105 hex head bolts (D) and M6 hex nuts. Tighten to
specification.
5. Install third M6x105 hex head bolt (D) with flat washer
(E) through outer mounting bracket and spacer (F).
6. Install drive belt to alternator sheave.
B
7. Adjust alternator drive belt tension and tighten third
mounting bolt to specification. (See “Alternator Drive Belt
Replacement” on page 174.)
C
Specifications
Alternator to Mounting Bracket (M6) . 10 N•m (84 lb-in.)
Alternator Sheave Nut (M10) . . . . . . . . . 49 N•m (36 lb-ft)
MX43118
2. Install sheave (B) and M10 hex nut (C) to alternator
shaft. Tighten nut to specification.
Differential Gear Case Removal and
Installation
Differential Gear Case Removal
1. Place machine on a stable, level work surface of a
convenient height.
A
B
C
MX43121
B
3. Install alternator between inner (A) and outer (B)
mounting brackets, with wire harness (C) located next to
heat sink.
A
MX42758
2. Support machine with blocks (A) under ends of traction
roller.
3. Rotate locking levers (B) and remove left and right
transport wheels.
Power Train Repair - 176
POWER TRAIN REPAIR
10.Rotate alternator to release drive belt (K). Remove drive
belt from generator sheave.
C
D
F
E
G
L
MX42757
4. Compress spring (C), and remove drive clutch cable end
(D) from drive tensioner linkage. (See “Clutch Control
Cable Replacement” on page 172.)
5. Remove M10 flanged shoulder bolt (E) and spacer
washer (F) securing drive tensioner bracket to gear case.
Remove bracket.
6. Remove drive belt from gear case input sheave.
7. Disconnect park brake cable Z-hook (G) from actuating
lever. (See “Replace Park Brake Cable” on page 209.)
MX42761
11.Remove two M8x20 hex head bolts (L) securing foot of
electronics bracket to machine frame.
Note: Remove attaching hardware to temporarily move
the rectifier block and mow/backlap switch for
electronics bracket bolt removal. Do not remove wire
terminals from the rectifier block or switch.
M
H
N
MX42762
MX42759
8. Remove three M6x20 socket pan head bolts (H)
securing cover (I) to electronics bracket. Remove cover.
12.Remove M6 locknut (M) securing rectifier block to
electronics bracket. Do not disconnect wires. Reinstall bolt
and locknut to rectifier block.
13.Remove nut, lock washer, and locating washer securing
mow/backlap switch (N) to electronics bracket. Do not
disconnect wires. Reinstall attaching hardware to switch in
order removed.
J
14.Move mow/backlap switch and rectifier block with
attached wires aside.
K
I
MX42760
9. Loosen M6 alternator pivot bolt (I) and M8 hex head bolt
(J) securing generator bracket to electronics bracket.
Power Train Repair - 177
POWER TRAIN REPAIR
Important: Avoid Damage! Drive axles may be
damaged if not properly supported when removing
or installing drive sprocket retaining nuts. Use a
deep-well socket fully inserted on the hexagonal
portion of drive axle ends to hold the axle when
removing or installing drive chain sprocket retaining
nuts. Holding the axle tip only may result in twisting
or breakage of the axle tip.
O
S
MX42763
15.Remove M8 hex nut and M8x90 carriage bolt (O)
securing electronics bracket to gear case.
16.Rotate electronics assembly with generator away from
gear case.
R
17.Remove drive belt from gear case and engine sheaves.
MX42767
20.Hold axle shaft with deep well socket (R) fully inserted
on hexagonal portion of axle shaft.
P
21.Loosen M10 hex nut (S) retaining side drive input shaft
sprocket while holding axle shaft. Remove nut.
Note: If the differential gear case only is to be removed,
separate the drive chain at the master link and remove
only the side drive input shaft sprockets.
MX42764
18.Remove three M6 flange nuts (P) securing left and right
side drive covers to side plates. Remove side covers.
a. Separate side drive chain master links.
b. Remove side drive input sprockets.
Note: If the gear case is to be removed as a part of
more comprehensive service to include traction roller
bearings, proceed to the following steps to remove the
side drive chain together with both input and axle drive
sprockets.
Q
T
MX42765
19.Loosen M8 hex nut (Q) securing traction drive chain
slack adjuster.
MX42768
22.Loosen retaining nut (T) securing axle drive sprocket
Power Train Repair - 178
POWER TRAIN REPAIR
mount to machine frame.
while holding axle shaft. Remove nut.
a. Remove sprockets and side drive chain as an
assembly.
29.Remove gear case from machine.
30.Remove left side bearing housing from shaft.
Differential Gear Case Installation
Note: If traction roller inspection or service is to be
carried out, remove roller before reassembly of side
drive.
U
Gear Case installation is done in the reverse order of
removal.
• Fill differential gear case assembly with oil meeting
specifications. Ensure that gear case lubricating oil level is
correct. (See “Transmission and Hydraulic Oil” on page 16.)
MX42769
23.Remove shaft key (U) from side drive input shaft.
24.Repeat side drive disassembly steps for opposite side.
• Adjust drive chain slack. (See “Traction Roller Drive
Chain Slack Adjustment” on page 171.)
• Adjust alternator drive belt tension. (See “Alternator
Drive Belt Replacement” on page 174.)
• Adjust drive belt tension. (See “Drive Belt Tension
Check and Adjustment” on page 170.)
• Adjust park brake. (See “Park Brake Adjustment” on
page 208.)
W
X
Specifications
V
MX42766
25.Remove three M6x10 socket head bolts (V) securing
right shaft bearing housing to side plate.
26.Rotate bearing housing to pass lubrication fitting (W)
through side plate cutout (X). Remove bearing housing
from shaft.
Axle Side Bearing Housing . . . . . . . . . . 28 N•m (20 lb-ft)
Axle Sprocket Retainer . . . . . . . . . . . . 108 N•m (80 lb-ft)
Differential Gear Case Mount . . . . . . . . 28 N•m (20 lb-ft)
Drive Chain Slack Adjuster . . . . . . . . . . 28 N•m (20 lb-ft)
Electronics Bracket . . . . . . . . . . . . . . . . 28 N•m (20 lb-ft)
Rectifier Block . . . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Side Drive Cover . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Side Drive Input Bearing Housing . . . 10 N•m (84 lb-in.)
Side Drive Input Sprocket Retainer . . . 55 N•m (40 lb-ft)
Y
Z
MX42770
27.Remove three M6x10 socket head bolts (Y) securing left
side drive shaft bearing housing to side plate.
28.Remove two M8x20 hex bolts (Z) securing gear case
Power Train Repair - 179
POWER TRAIN REPAIR
Differential Gear Case Disassembly and
Inspection
D
B
A
MX42833
1. Remove drain plug (A) and drain oil into properly
marked container.
MX42835
4. Remove eight M6 x 25 socket head bolts (D) securing
gear case halves.
2. Remove flanged hex nut (B) securing drive sheave with
park brake drum to gear case input shaft. Remove drive
sheave and shaft key.
E
C
MX42836
MX42834
5. Separate gear case halves at external lugs (E). Do not
pry on gear case sealing surfaces. Remove right gear case
half.
3. Remove three M6x25 hex head bolts (C) securing park
brake bracket to gear case. Remove park brake assembly.
H
Important: Avoid Damage! Gear case sealing
surfaces may be damaged by prying cases apart.
Separate case halves only at provided external lugs.
Damage to sealing surfaces may result in lubricating
oil leakage.
G
F
MX42837
6. Remove differential unit (F), together with drive chain
(G) and input shaft (H) with sprocket and bearing from right
gear case half.
7. Clean and inspect differential assembly for wear or
damage. Replace unit if necessary.
Power Train Repair - 180
POWER TRAIN REPAIR
I
O
MX6063
8. Inspect bearing (I) on input shaft assembly. Replace
bearing if worn or damaged.
MX42840
14.Remove shaft seal (O) from left gear case half.
P
J
K
MX42841
MX42838
9. Remove right output shaft (J) with bearing (K).
10.Clean and inspect bearing. Replace bearing if worn or
damaged.
15.Remove shaft seals (P) from right gear case half.
16.Remove sealing material from gear case mating
surfaces.
17.Clean and dry all metal parts.
N
M
L
MX42839
11.Remove left output shaft (L) with bearing (M).
12.Clean and inspect output shaft bearing. Replace
bearing if worn or damaged.
13.Inspect input shaft sleeve bearing (N). Replace if worn
or damaged.
Power Train Repair - 181
POWER TRAIN REPAIR
Differential Gear Case Assembly
Important: Avoid Damage! Always use new seals
when reassembling gear case components.
Damaged or used parts will leak.
Note: Lubricate all seals with multi-purpose grease for
assembly.
B
Apply clean oil to all internal parts during assembly.
(See “Transmission and Hydraulic Oil” on page 16.)
C
MX42838
3. Apply tape to threaded end of right output shaft (B).
4. Install output shaft to right gear case half, ensuring that
shaft bearing (C) is fully seated in case bore.
A
D
MX42840
E
MX42837
A
5. Apply tape to threaded end of gear case input shaft (E).
6. Install differential unit (E) with input shaft, bearing,
sprockets, and drive chain to right gear case.
7. Ensure that input shaft bearing is fully seated in gear
case and differential is fitted to output shaft splines.
MX42841
1. Lubricate new seals (A) with assembly grease and
install with seal lips facing inward to left and right gear case
halves.
8. Rotate input shaft assembly and make sure that entire
assembly rotates freely.
2. Ensure that gear case bearing bores are clean.
Important: Avoid Damage! Shaft seals may be
damaged by threads or other shaft edges during
assembly. Apply multi-purpose grease to seal lips
and apply tape to threaded shaft ends before
installation. Damaged seals may leak.
G
F
H
Note: Ensure that shaft bearings are fully seated in
housing bores upon assembly.
MX42839
9. Apply tape to threaded end of left output shaft (F).
10.Install output shaft to left gear case half, ensuring that
Power Train Repair - 182
POWER TRAIN REPAIR
shaft bearing (G) is fully seated in case bore.
Note: Ensure that bolt holes are completely
surrounded when applying gasket sealant.
11.Apply a continuous bead of sealant to sealing surface
(H) of left gear case.
12.Align shafts and case dowel pins and install left gear
case half to right half.
N
13.Turn right drive axle if needed to match splines to
differential splines for case reassembly.
MX42843
17.Rotate gear case input shaft so that shaft keyway is at
top, and install shaft key (N).
J
K
I
O
L
P
MX42834
14.Install eight M6 x 25 socket head bolts (I) to secure gear
case halves. Tighten bolts to specification.
15.Install park brake bracket (J) to gear case. Secure
bracket to case with three M6 hex head bolts (K), with two
flat washers (L) under lower bolt. Tighten bolts to
specification.
MX42833
18.Install drive sheave with park brake drum (O) to gear
case input shaft, and secure with M10 hex nut (P). Tighten
nut to specification.
Important: Avoid Damage! Machine is filled with
John Deere HY-GARDTM (J20C) Transmission/
Hydraulic Oil at the factory. DO NOT mix oils. DO
NOT use type “F” automatic transmission fluid.
Note: Differential lubricating oil level is correct when
oil is visible at bottom of drain opening with gear case
standing upright on mounting foot.
L
M
MX42842
16.Position park brake return spring leg (M) on output shaft
side of washers (L).
Q
MX42844
Power Train Repair - 183
POWER TRAIN REPAIR
19.Stand gear case upright, and add oil through fill opening
(Q) to proper level with oil meeting specifications. (See
“Transmission and Hydraulic Oil” on page 16.)
B
20.Install differential gear case drain and fill plugs with new
seal washers, and tighten to specification.
21.Proceed to Traction Roller Removal if traction roller
bearings are to be inspected or serviced, or see Install
Differential Gear Case for machine reassembly.
Specifications
Drive Sheave Retainer . . . . . . . . . . . . . 55 N•m (40 lb-ft)
Gear Case Drain Plug. . . . . . . . . . . . . 10 N•m (84 lb-in.)
Gear Case Fill Plug. . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Gear Case Housing . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Park Brake Bracket. . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Traction Roller Assembly Removal and
Installation
Traction Roller Removal
The traction roller assembly may be removed from the
machine for inspection or service of bearings or other
components. Removal of the roller assembly may be done
separately or as a part of comprehensive service. When
done with other service, preliminary steps for roller removal
may already be done as a part of differential gear case
service.
MX42765
4. Loosen M8 hex nut (B) securing drive chain slack
adjusters.
Important: Avoid Damage! Drive axles may be
damaged if not properly supported when removing
or installing drive sprocket retaining nuts. Use a
deep-well socket fully inserted on hexagonal portion
of axle to hold axle when removing or installing
drive chain sprocket retaining nuts. Holding axle tip
only may result in twisting or breakage of axle tip.
Note: Input and axle shaft sprocket retaining nuts on
both left and right sides of machine have right hand
threads.
D
1. Safely support machine under front of frame with
mowing unit attached. Bottom of side plates must be
elevated sufficiently to clear drive roller axle bearing
housings when roller is removed.
2. Remove transport wheels.
C
MX42767
A
5. Hold axle shaft with deep well socket (C) fully inserted
on hexagonal portion of axle shaft.
6. Loosen M10 hex nut (D) retaining side drive input shaft
sprocket while holding axle shaft. Remove nut.
MX42764
3. Remove three M6 flange nuts (A) securing left and right
side drive covers. Remove covers.
Power Train Repair - 184
POWER TRAIN REPAIR
B
E
MX42768
MX42827
7. Loosen retaining nut (E) securing axle drive sprocket
while holding axle shaft. Remove nut.
8. Remove sprockets and drive chain as an assembly.
B
C
D
MX42829
F
a. Remove snap ring (B) from axle bearing housing.
b. Remove bearing (C) from housing.
c. Remove seal (D) from housing.
d. Install new seal to bearing housing with outer surface
flush to housing and with seal lip facing bearing.
MX42825
9. Remove three M8x20 hex head bolts (F) securing left
and right roller shaft bearing housings to side plates.
10.Lower traction roller assembly evenly to clear machine
side plates and remove.
e. Install new bearing to housing with sealed side of
bearing facing away from housing seal.
f. Install snap ring to housing snap ring groove.
Traction Roller Bearing Inspection and Repair
E
A
MX42828
MX42826
1. Remove bearing assemblies (A) from left and right
traction roller axle shafts.
3. Remove four M8x40 hex head bolts (E) securing right
traction roller half to internal hub. (Traction roller axle
removed for clarity.)
4. Remove right roller half from hub.
2. Check condition of traction roller axle shaft bearings.
Replace bearings if needed.
Power Train Repair - 185
POWER TRAIN REPAIR
12.Secure right roller half to internal hub with four M8x40
hex head bolts. Tight to specification.
Note: Roller axle bearing housing lubrication fittings
should face rearward for ease of access when
installed.
13.Install bearing housing assemblies to right and left roller
axles.
H
G
Traction Roller Installation
F
MX42830
5. Remove cotter pin (F) securing castle nut on internal
hub spindle.
6. Remove M16 hex castle nut (G) securing internal hub
(H) to spindle.
Important: Avoid Damage! Drive axles may be
damaged if not properly supported when removing
or installing drive sprocket retaining nuts. Use a
deep-well socket fully inserted on hexagonal portion
of axle to hold axle when removing or installing
drive chain sprocket retaining nuts. Holding axle tip
only may result in twisting or breakage of axle tip.
Note: Left side internal hub bearing arrangement is
similar to right, but without spacer.
A
K
J
B
C
I
MX42826
1. Center traction roller assembly (A) between machine
side plates (B).
MX42831
7. Remove hub assembly and check condition of left and
right internal bearings. Replace bearings if needed.
2. Raise roller assembly evenly with axle bearing housings
(C) between side plates, Support roller assembly near
installed position.
a. Remove spacer (I).
b. Remove seal (J).
c. Remove bearing (K).
d. Pack hub center with specified grease.
e. Install bearing, with open side of bearing toward
center of hub.
f. Install new seal, with seal lip facing bearing and outer
edge of seal flush with hub end.
E
g. Reinstall spacer (right side only).
8. Reinstall internal hub assembly to roller internal spindle.
D
MX42825
9. Install hex castle nut to spindle until snug, then loosen
one nut flat or until cotter pin can be installed.
3. Install side drive bottom covers (D) over right and left
roller axles.
10.Install cotter pin to secure spindle castle nut.
4. Align bolt holes in cover, side plate, and axle bearing
housing, and install three M8x20 hex head bolts (E).
11.Align bolt holes in right roller half and internal hub
flange.
Power Train Repair - 186
POWER TRAIN REPAIR
5. Align bolt holes and install bolts to secure opposite side
bearing.
I
6. Lift axles to bring securing bolts (E) to top of mounting
holes, and tighten all bolts to specification.
J
F
MX42767
G
11.Install hex nut (I) securing side drive sprocket to input
shaft.
MX42845
7. Turn axle and input shafts so that keyways are at top of
shafts. Install input shaft key (F) and axle shaft key (G).
12.Hold axle shaft with deep well socket fully inserted on
hexagonal portion of axle shaft while tightening retaining
nut to specification.
13.Adjust side drive chain slack to specification, and secure
slack adjuster hex nut (J).
14.Repeat side drive installation steps for opposite side.
Specifications
Axle Bearing Spindle to Roller . . . . . . . 28 N•m (20 lb-ft)
Axle Side Bearing Housing . . . . . . . . . . 40 N•m (30 lb-ft)
Axle Sprocket Retainer . . . . . . . . . . . . 108 N•m (80 lb-ft)
Center Bearing Housing to Roller . . . . 28 N•m (20 lb-ft)
Drive Chain Slack Adjuster . . . . . . . . . . 28 N•m (20 lb-ft)
Input Sprocket Retainer. . . . . . . . . . . . . 55 N•m (40 lb-ft)
Side Drive Cover . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
MX42765
8. Install drive chain and sprockets as an assembly to side
drive input and axle shafts.
H
MX42768
9. Install retaining nut (H) securing axle drive sprocket to
axle.
10. Hold axle shaft with a deep socket fully inserted on
hexagonal portion of axle shaft while tightening retaining
nut to specification.
Power Train Repair - 187
POWER TRAIN REPAIR
Power Train Repair - 188
HANDLEBAR AND CONTROLS TABLE OF CONTENTS
Handlebar and Controls
Table of Contents
Component Location....................................191
Controls ......................................................191
Clutch Control and Operator Presence
Bail .............................................................192
Brake Control and Throttle Lever ...............193
Diagnostics ...................................................194
Symptom: Clutch Control Does Not Fully
Disengage ..................................................194
Symptom: Brake Control Does Not Fully
Disengage ..................................................194
Symptom: Operator Presence Bail Does
Not Return Fully .........................................194
Handlebar Control Adjustments..................195
Throttle Lever Tension Adjustment ............195
Throttle Lever Travel Adjustment ...............195
Operator Presence Bail Adjustment ...........195
Park Brake Switch Adjustment ...................196
Clutch Switch Adjustment...........................196
Handlebar Height Adjustment ....................197
Repair.............................................................198
Remove and Install Handlebar Cover ........198
FOC Potentiometer Replacement ..............198
Handlebar Assembly Removal and
Installation .................................................200
Handlebar and Controls Table of Contents - 189
HANDLEBAR AND CONTROLS TABLE OF CONTENTS
Handlebar and Controls Table of Contents - 190
HANDLEBAR AND CONTROLS COMPONENT LOCATION
Component Location
Controls
B
C
A
D
N
M
L
E
K
J
I
F
G
H
MX42949
A- Clutch Control Lever
B- Throttle Lever
C- Diagnostic Indicator LED
D- Operator Presence Bail
E- Park Brake Lever
F- Travel Clutch Cable
G- Park Brake Cable
H- Backlap Forward/Reverse Switch
I- Throttle Cable
J- Service ADVISOR CAN Connection
K- Hourmeter
L- Frequency of Cut (FOC) Potentiometer
M- Cutting PTO Switch
N- Engine Run/Off Switch
Handlebar and Controls Component Location - 191
HANDLEBAR AND CONTROLS COMPONENT LOCATION
Clutch Control and Operator Presence Bail
H
F
A
G
E
C
I
D
B
J
F
G
K
M
L
N
K
P
O
R
Q
MX6026
A- Knob
B- Bolt
C- Lever
D- Torsion Spring
E- Pawl
F- Lubrication Fitting (2 used)
G- Flange Nut (2 used)
H- Bail
I- Arm
J- Bolt (2 used)
K- Nut (2 used)
L- Stud
M- Cap Screw
N- Nut
O- Arm
P- Cotter Pin
Q- Pin
R- Cable Assembly
Handlebar and Controls Component Location - 192
HANDLEBAR AND CONTROLS COMPONENT LOCATION
Brake Control and Throttle Lever
F
B
E
G
C
A
D
B
X
H
W
I
V
K
J
U
L
T
M
L
B
N
R
Q
S
P
MX6025
A- Nut
B- Flange Nut (3 used)
C- Cap Screw
D- Clamp
E- Throttle Cable Assembly
F- Knob
G- Fiber Washer
H- Throttle Lever
I- Spring Washer (2 used)
J- Locknut
K- Plate
L- Bolt (3 used)
O
M- Bolt
N- Lever
O- Knob
P- Arm
Q- Nut
R- Cap Screw
S- Brake Cable Assembly
T- Wiring Harness
U- Run/off Switch
V- Washer (2 used)
W- Lock Washer
X- Lock Plate
Handlebar and Controls Component Location - 193
HANDLEBAR AND CONTROLS DIAGNOSTICS
Diagnostics
clutch control cable.
Symptom: Clutch Control Does Not Fully
Disengage
No: Check switch position adjustment and correct as
needed.
Clutch Control Checks
1. Does the traction drive belt tensioner disengage
when the Operator Presence Control (OPC) is
released?
Symptom: Operator Presence Bail Does Not
Return Fully
Operator Presence Bail Control
Yes: Go to next step.
1. Does the operator presence bail return fully and
deactivate switch when released?
No: Check for sticking, dirt, or corrosion at the clutch
control pivot.
No: Check for sticking, dirt, or corrosion at the clutch
control pivot.
No: Check for sticking, dirt, or corrosion at the drive belt
tension arm pivot.
No: Check for bends, broken wires, or corrosion in the
clutch control cable.
No: Check for bends, broken wires, or corrosion in the
clutch control cable.
No: Check for sticking, dirt, or corrosion at the drive belt
tension arm pivot.
2. Does the clutch control lever tab open the handlebar
switch when the OPC is released?
No: Check switch position adjustment and correct as
needed.
No: Check for sticking, dirt, or corrosion at the clutch
control pivot and clean or repair as needed.
No: Check for sticking, dirt, or corrosion at the drive belt
tension arm pivot and clean or repair as needed.
No: Check for bends, broken wires, or corrosion in the
clutch control cable and clean or repair as needed.
No: Check switch position adjustment and correct as
needed.
Symptom: Brake Control Does Not Fully
Disengage
Brake Control
1. Does the park brake disengage when the park brake
control lever is released?
Yes: Go to next step.
No: Check for sticking, dirt, or corrosion at the brake
control pivot.
No: Check for sticking, dirt, or corrosion at the brake
band pivot.
No: Check for bends, broken wires, or corrosion in the
brake control cable.
2. Does the brake control lever tab open the handlebar
switch when the brake is released?
No: Check for sticking, dirt, or corrosion at the clutch
control pivot.
No: Check for sticking, dirt, or corrosion at the drive belt
tension arm pivot.
No: Check for bends, broken wires, or corrosion in the
Handlebar and Controls Diagnostics - 194
HANDLEBAR AND CONTROLS HANDLEBAR CONTROL
Handlebar Control Adjustments
6. Move handlebar engine speed control to slow idle
position.
Throttle Lever Tension Adjustment
Reason
To apply enough tension to hold throttle position, yet allow
easy throttle movement.
C
Procedure
A
1. Park machine on a level surface.
D
B
2. Move run/off switch to off position.
3. Move travel clutch lever to neutral position.
4. Lock park brake.
MX42916
5. Remove handlebar cover. (See “Remove and Install
Handlebar Cover” on page 198.)
Note: Proper throttle pivot adjustment allows easy
movement of throttle control while holding desired
throttle position during operation.
7. Remove engine air cleaner assembly.
8. Loosen screw (A) securing throttle cable to engine
throttle lever swivel.
9. Move throttle to fast idle stop to ensure that throttle lever
(B) clears throttle cable housing end (C).
10.Check to see that throttle return spring pulls throttle
lever against low speed idle stop (D).
A
11.Tighten screw (A) with throttle lever against low speed
stop.
12.Move throttle lever from slow to fast to slow positions to
verify operation.
13.Reinstall air cleaner assembly.
Operator Presence Bail Adjustment
Reason
M83759
6. Adjust tightness at throttle pivot bolt (A) for desired
throttle lever tension.
7. Install handlebar cover.
To ensure that travel clutch is disengaged when bail is
released.
Procedure
1. Park machine on a level surface.
Throttle Lever Travel Adjustment
2. Move run/off switch to off position.
3. Move travel clutch lever to neutral position.
Reason
To make sure the throttle control lever allows full range of
engine speeds.
4. Lock park brake.
Procedure
1. Park machine on a level surface.
2. Move PTO switch to OFF position.
3. Move run/off switch to OFF position.
4. Move travel clutch lever to released position.
5. Lock park brake.
Handlebar and Controls Handlebar Control Adjustments - 195
HANDLEBAR AND CONTROLS HANDLEBAR CONTROL
Park Brake Switch Adjustment
A reel motor circuit switch is actuated by the park brake
control, The switch position must be properly adjusted so
that the switch contacts close when the brake control lever
is in the brake position.
A
A
M83855
C
5. Loosen two nuts (A).
B
B
MX43340
C
1. Check to see that contacts in brake switch (A) close
when park brake control lever is moved to brake position.
• Listen for click when control lever is moved to brake
position.
• Remove wire harness connector (B) and check for
continuity through switch when control lever is moved to
brake position.
M83856
6. Secure operator presence bail (B) against handlebar
(C).
2. Loosen fasteners securing brake switch body to
handlebar bracket, and adjust switch position as required.
Tighten fasteners to secure switch location.
Clutch Switch Adjustment
A reel motor circuit switch is actuated by the clutch control,
The switch position must be properly adjusted so that the
switch contacts close when the clutch control lever is in the
drive position.
D
E
M83857
A
7. Rotate engagement arm (E) upward as far as possible.
8. Tighten nuts (D).
B
C
9. Release operator presence bail.
MX43339
1. Check to see that contacts in clutch switch (A) close
when clutch control lever is moved to drive position.
•
Listen for click when control lever is moved to drive
Handlebar and Controls Handlebar Control Adjustments - 196
HANDLEBAR AND CONTROLS HANDLEBAR CONTROL
position.
• Remove wire harness connector (B) and check for
continuity through switch when control lever is moved to
drive position.
2. Loosen fasteners securing clutch switch body to
handlebar bracket, and adjust switch position as required.
Tighten fasteners to secure switch location.
C
Handlebar Height Adjustment
Reason
To allow the operator to choose a comfortable handlebar
height.
Procedure
1. Park machine on a level surface.
MX42909
6. Adjust handlebar bracket height so that frame tabs (C)
are located in same slot on both left and right height
adjuster brackets.
2. Move run/off switch to off position.
7. Tighten locknuts (A) securing height adjuster brackets to
specification.
3. Move travel clutch lever to neutral position.
Specification
4. Lock park brake.
Handlebar Height Adjuster Bracket . . . 55 N•m (40 lb-ft)
B
A
B
A
MX6037
5. Loosen M10 locknuts (A) securing height adjuster
brackets (B) on each side of mower frame sufficiently to
allow vertical movement of brackets.
Note: Handlebar height adjusting brackets must
engage the frame tab in the same bracket slot at both
the left and right sides. Make sure bracket (B) is
straight up and down before tightening fasteners.
Handlebar and Controls Handlebar Control Adjustments - 197
HANDLEBAR AND CONTROLS REPAIR
Repair
Note: Make a reference mark, or note the FOC
potentiometer position relative to a mounting bracket
alignment slot, in order to install a replacement
potentiometer in the correct position.
Remove and Install Handlebar Cover
A
E
D
B
F
MX43345
MX42910
5. Make a reference mark (D) in alignment with
potentiometer on mounting bracket, or note potentiometer
position relative to bracket reference slot (E) (if present).
1. Remove two hex head bolts (A).
2. Remove handlebar cover (B).
6. Separate potentiometer wire harness at connector (F).
FOC Potentiometer Replacement
Important: Avoid Damage! Wire harness for the
handlebar cover mounted PTO switch or diagnostic
indicator can be damaged when the handlebar cover
is removed. Handle the cover carefully and support
the cover so as to avoid strain on the wire harness
while the cover is removed for service procedures.
H
G
1. Remove handlebar cover. (See “Remove and Install
Handlebar Cover” on page 198.)
2. Lift cover, and lay cover aside on park brake control
lever. Avoid strain on PTO switch or diagnostic indicator
wiring harness or connectors.
MX43346
7. Carefully pry potentiometer control knob (G) from
potentiometer shaft. Retain and set aside knob and seal
ring (H).
A
B
I
C
MX43344
3. Remove clutch switch wire harness connector (A) from
switch and move aside.
4. Remove M6 bolt (B) securing FOC control cover (C) to
handlebar bracket. Remove cover and set aside with bolt.
MX43347
8. Remove potentiometer shaft outer nut (I) along with
toothed lock washer. Remove potentiometer.
Handlebar and Controls Repair - 198
HANDLEBAR AND CONTROLS REPAIR
K
E
J
D
MX43349
9. Install wiring connector (J) for new potentiometer to
handlebar harness connector.
10.Install potentiometer to handlebar bracket with shaft
inner nut (K) installed.
Note: Adjust the position of the replacement
potentiometer inner shaft nut so that no more than two
threads extend beyond the outer shaft nut when
tightened.
MX43345
a. Align potentiometer body to reference mark (D)
made prior to disassembly, or to reference slot (E) (if
present) on mounting bracket.
Note: If the FOC potentiometer was loose, or if no
alignment marks are available, index the potentiometer
control shaft to the mounting plate reference points by
checking control shaft range of movement.
L
L
P
O
N
M
MX43348
MX43347
b. Rotate potentiometer shaft fully counterclockwise.
Shaft flat (N) should face FOC reference point 5 (O).
11. Install toothed lock washer and outer shaft nut (L) and
tighten until snug.
c. Rotate shaft fully clockwise. Shaft flat should face
FOC reference point 1 (P).
12.Adjust position of inner and outer shaft nuts so that no
more than two threads (M) extend past outer nut.
d. Adjust potentiometer position if required to balance
range of travel between minimum and maximum FOC
reference points 1 and 5.
13.Align potentiometer body to properly index control knob
to mounting plate FOC references.
14.Tighten outer shaft nut (L), securing potentiometer
position in mounting bracket.
Note: Hold the potentiometer shaft seal in place
around the shaft outer nut when installing the control
knob to the shaft. Ensure that the seal lies flat against
the mounting bracket surface with the knob installed.
Handlebar and Controls Repair - 199
HANDLEBAR AND CONTROLS REPAIR
G
Handlebar Assembly Removal and
Installation
H
Handlebar Assembly Removal
The handlebar assembly can be removed if required.
Removal of the handlebar assembly involves disconnection
of throttle, clutch, and park brake control cables. These
control cables may require readjustment for proper function
upon reassembly.
MX43346
15.Install and hold seal ring (H) around potentiometer shaft
outer nut. Align control knob (G) to control shaft flat, and
install knob to shaft. Ensure that control knob is fully
installed and that seal ring lies flat against bracket.
16.Rotate FOC control knob fully clockwise and
counterclockwise to check pointer position against
mounting bracket marks for FOC reference points 1 and 5.
B
C
A
D
17.Adjust FOC potentiometer position if required.
MX42911
1. Remove dust cap (A) from diagnostic connector.
2. Depress locking tabs (B) securing diagnostic connector
to handlebar bracket, and remove connector from bracket.
A
3. Dislocate locking tab and separate handlebar wiring
harness connectors (C).
B
4. Cut cable ties (D) securing handlebar harness to left
handlebar.
C
MX43344
18.Install FOC control cover (C). Secure cover with M6 bolt
(B).
19.Install wiring harness connector (A) to clutch switch.
20.Install handlebar cover and secure with two M6x12
bolts.
G
F
H
MX42848
1. Remove park brake cable outer jam nut (F) from
threaded ferrule at gear case bracket (G).
2. Withdraw ferrule and pass cable through slot in park
brake bracket.
3. Remove Z-hook (H) from park brake linkage arm.
Handlebar and Controls Repair - 200
HANDLEBAR AND CONTROLS REPAIR
L
R
K
I
J
Q
S
MX42850
MX42916
4. Compress spring (I), and disconnect clutch cable end
(J) from tensioner bracket.
9. Mark throttle cable housing (Q) at clamp as an aid for
reassembly.
5. Remove spring and flat washer (K) from cable.
10.Loosen bolt (R) securing clamp to throttle cable
housing.
6. Remove outer jam nut (L) and slide cable end from
bracket.
11.Hold throttle lever nut and loosen screw (S) securing
throttle cable to nut.
12. Remove cable from throttle lever nut and clamp.
M
T
MX42914
7. Remove wing nut (M) securing air cleaner cover.
Remove cover.
MX42764
13.Remove three M6 flanged hex nuts (T) securing left and
right side drive covers to side plates.
N
O
P
U
MX42915
8. Remove wing nut (N) securing air cleaner. Remove air
cleaner element (O) and air cleaner base (P).
MX42917
14.Hold handlebar pivot bolt (U).
Handlebar and Controls Repair - 201
HANDLEBAR AND CONTROLS REPAIR
Important: Avoid Damage! Hooked end of brake
cable end MUST swing freely.
X
V
B
W
MX42912
15.Remove M10 stop nuts (V) securing left and right
handlebars ends to pivot bolts.
16.Remove M10 stop nuts (W) securing left and right
handlebar height adjuster brackets to machine frame.
Remove brackets.
17.Loosen M10 hex nuts (X) securing left and right
handlebar pivot bolts to side plates sufficiently to remove
handlebars.
18.Remove handlebar assembly.
MX42847
3. Apply multipurpose grease to hook (B) on end of brake
cable.
4. Adjust park brake. (See “Park Brake Adjustment” on
page 208.)
• Adjust throttle cable. (See “Check and Adjust Throttle
Cable” on page 36.)
• Adjust clutch control cable. (See “Drive Belt Tension
Check and Adjustment” on page 170.)
Handlebar Assembly Installation
Handlebar installation is done in the reverse order of
removal. Reinstall and adjust control cables as described in
appropriate controls section.
Note: When installing handlebar height adjusting
brackets, bracket slots must engage frame tabs. Frame
tabs should be located in the same bracket slot at both
the left and right sides. Make sure bracket is straight
up and down before tightening fasteners.
B
A
MX42909
1. Adjust handlebar bracket position for comfortable
operating height with frame tabs (A) located in same slot on
both left and right height adjuster brackets (B).
2. Ensure that brackets are vertical, with frame tabs
engaged in bracket slots, and tighten adjuster hardware.
Handlebar and Controls Repair - 202
BRAKES TABLE OF CONTENTS
Brakes
Table of Contents
Specifications ...............................................205
Specifications .............................................205
Component Location and Operation ..........206
Brake System Operation ............................206
Diagnostics ...................................................206
Machine Cannot Be Moved ........................206
Brake Does Not Engage With Control
Lever in Brake Position ..............................206
Brake Does Not Hold Machine ...................207
Excessive Brake Wear ...............................207
Checks and Adjustments.............................208
Park Brake Adjustment ..............................208
Repair.............................................................209
Replace Park Brake Cable ........................209
Park Brake Band Replacement ..................210
Brakes Table of Contents - 203
BRAKES TABLE OF CONTENTS
Brakes Table of Contents - 204
BRAKES SPECIFICATIONS
Specifications
Specifications
Torque Specifications
Electronics/Belt Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Gear Case Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 N•m (40 lb-ft)
Park Brake Band. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Park Brake Cable Jam Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Traction Drive Tensioner Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 N•m (40 lb-ft)
Brakes Specifications - 205
BRAKES COMPONENT LOCATION AND OPERATION
Component Location and Operation
Diagnostics
Symptom: Machine Cannot Be Moved
Brake System Operation
Function
To provide a means of preventing the machine from moving
when not in operation.
Theory of Operation
The band type park brake acts on a drum which is a part of
the differential gear case input sheave.
Test Conditions
•
Machine parked on a level surface.
•
Run/off switch in OFF position.
•
Travel clutch disengaged.
•
Reel PTO switch in OFF position.
•
Park brake control in released position.
C
1. Is park brake lever unlocked?
D
Yes: Go to next step.
No: Unlock park brake.
2. Is brake cable properly adjusted?
Yes: Go to next step.
B
No: Adjust cable. (See “Park Brake Adjustment” on
page 208.)
A
3. Is brake cable return spring in good working order
and not missing?
MX42850
Yes: Go to next step.
When the park brake control is moved to the brake position,
an attached cable (A) acts through linkage to contract the
brake band (B) around the brake drum (C). With the brake
band tightened around the drum, the power train input shaft
(D) is prevented from turning.
No: Replace return spring.
4. Are gear case drive chain or differential unit
damaged?
Yes: Replace drive chain or differential unit as required.
Symptom: Brake Does Not Engage With
Control Lever in Brake Position
Test Conditions
•
Machine parked on a level surface.
•
Run/off switch in OFF position.
•
Travel clutch disengaged.
•
Reel PTO switch in OFF position.
•
Park brake control in brake position.
1. Is brake cable properly adjusted and not broken or
binding?
Yes: Go to next step.
No: Brake cable is not properly adjusted. Adjust brake
cable. (See “Park Brake Adjustment” on page 208.)
Brakes Component Location and Operation - 206
BRAKES DIAGNOSTICS
Yes: Go to next step.
No: Brake cable is broken or binding. Replace brake
cable. (See “Replace Park Brake Cable” on page 209.)
No: Keys are damaged or missing. Replace key(s).
(See “Traction Roller Assembly Removal and
Installation” on page 184.)
2. Is brake band/lining clean and in good operating
condition?
6. Is the differential gear case assembly in good
operating condition without internal damage?
Yes: Go to next step.
No: Brake band/lining is worn. Adjust brake cable. (See
“Park Brake Adjustment” on page 208.) If brake will still
not engage after adjustment, replace brake band. (See
“Park Brake Band Replacement” on page 210.)
Yes: Go to next step.
No: Repair differential gear case assembly as
necessary. (See “Differential Gear Case Disassembly
and Inspection” on page 180.)
No: Brake band lining is contaminated. Clean brake
drum and replace brake band.
7. Are differential gear case output shaft sprocket keys
in good operating condition and not missing?
No: Brake band mounting hardware is loose or missing.
Tighten and/or replace mounting hardware.
No: Replace keys.
Symptom: Brake Does Not Hold Machine
8. Is gear case input shaft key in good condition and in
place?
No: Replace key.
Test Conditions
Symptom: Excessive Brake Wear
•
Machine parked on a level surface.
•
Run/off switch in OFF position.
•
Travel clutch disengaged.
Test Conditions
•
Reel PTO switch in OFF position.
•
Machine parked on a level surface.
•
Park brake control in brake position.
•
Run/off switch in OFF position.
•
Travel clutch disengaged.
1. Is brake cable properly adjusted?
•
Reel PTO switch in OFF position.
Yes: Go to next step.
•
Park brake control in released position.
No: Adjust brake cable. (See “Park Brake Adjustment”
on page 208.)
2. Is brake band/lining clean and in good operating
condition?
Yes: Go to next step.
1. Is park brake assembly free of dirt or other abrasive
material?
Yes: Go to next step.
No: Clean brake assembly.
No: Brake band/lining is worn. Adjust brake cable. If
brake will still not engage after adjustment, replace
brake band. (See “Park Brake Band Replacement” on
page 210.)
2. Is brake cable properly adjusted?
No: Adjust brake cable. (See “Park Brake Adjustment”
on page 208.)
3. Are traction drive chains in good operating condition
and not broken or damaged?
3. Is park brake linkage return spring in good
condition?
Yes: Go to next step.
Yes: Go to next step.
No: Replace drive chain(s).
No: Replace return spring.
4. Are traction roller assembly sprockets in good
operating condition and not damaged?
4. Is park brake band damaged or distorted?
Yes: Replace park brake band.
Yes: Go to next step.
No: Replace sprocket(s). (See “Traction Roller
Assembly Removal and Installation” on page 184.)
5. Are traction roller sprocket keys in good operating
condition and not damaged?
Brakes Diagnostics - 207
BRAKES CHECKS AND ADJUSTMENTS
Checks and Adjustments
Park Brake Adjustment
Reason
To ensure that the park brake holds the machine when
locked.
A
Check Procedure
1. Lock park brake.
B
2. Run engine at slow idle.
3. Engage operator presence bail.
MX42847
4. Slowly engage travel clutch lever.
Result: Engine should stall with no movement of the
mower.
5. Loosen park brake cable outer jam nut (A) at handlebar
bracket.
6. Tighten cable inner jam nut (B).
Adjustment Procedure
7. Repeat check procedure. Make further adjustment as
necessary for satisfactory brake hold.
If the park brake does not satisfactorily hold the machine
from movement when following the check procedure, adjust
the park brake cable length for increased hold.
8. If proper adjustment cannot be obtained, replace the
park brake band.
Specification
Park Brake Cable Jam Nut . . . . . . . . . 10 N•m (84 lb-in.)
A
C
B
MX42352
1. Loosen lower park brake cable outer jam nut (A) at park
brake bracket (B).
2. Tighten inner jam nut (C).
3. Repeat check procedure. Make further adjustment as
necessary for satisfactory brake hold.
4. If no further adjustment can be made at lower adjuster,
make necessary control cable length adjustment at
handlebar bracket end.
Brakes Checks and Adjustments - 208
BRAKES REPAIR
Repair
Install Park Brake Cable
Replace Park Brake Cable
Fit a replacement park brake cable to the machine with the
ferrule end dust cap at the handlebar control end. Take
care to avoid kinking the inner cable during installation.
If the park brake control cable is damaged or does not slide
freely in its housing, the cable assembly should be
replaced.
Note: Apply a small amount of multi-purpose grease to
the Z-hook cable ends before installation to prevent
wear of the control cable pivot points.
Remove Park Brake Cable
B
A
B
A
C
MX42848
1. Remove park brake cable outer jam nut (A) from
threaded ferrule at gear case bracket (B).
2. Withdraw ferrule and pass cable through slot in park
brake bracket.
MX42849
1. Pass new park brake cable assembly with dust cap at
upper end through lower handlebar brace (A) and behind
upper bracket (B).
3. Remove Z-hook (C) from park brake linkage arm.
C
B
G
C
F
D
D
E
MX42847
MX42847
4. Remove dust cap (D) and outer jam nut (E) from ferrule
threads at cable upper end.
2. Remove dust cap (C) and outer jam nut (D) from ferrule
threads at upper end of control cable.
5. Pass cable through slot in handlebar bracket (G).
3. Apply a small amount of grease to cable end Z-hook (C),
and install to control arm.
6. Remove Z-hook (F) from park brake control lever.
Remove cable from handlebar.
4. Pass cable through slot and insert threaded ferrule
through handlebar bracket (B).
5. Install outer jam nut to ferrule threads.
6. Adjust inner and outer jam nuts so that ferrule threads
are centered on bracket.
7. Fit dust cap to end of ferrule threads.
Brakes Repair - 209
BRAKES REPAIR
Park Brake Band Disassembly
F
E
A
G
I
H
MX42352
8. Apply a small amount of grease to lower cable end Zhook (E), and install to park brake actuating lever. Ensure
that cable is located between lever locating tabs (F).
MX42908
1. Safely secure park stand (A) in a partially lowered
position for access to park brake components.
9. Remove outer jam nut (G) from lower ferrule.
10.Pass cable through slot (H) and insert threaded ferrule
through park brake bracket (I).
C
11.Reinstall jam nut to lower ferrule, and adjust inner and
outer jam nuts to center threaded portion of ferrule in the
bracket.
B
12.Check operation of park brake. (See “Park Brake
Adjustment” on page 208.)
13.Tighten jam nuts at upper and lower ferrules to
specification.
MX42759
Specification
Control Cable Jam Nuts . . . . . . . . . . . 10 N•m (84 lb-in.)
2. Remove three M6 socket pan head bolts (B) securing
electronics/belt cover (C) to electronics bracket. Remove
cover.
Park Brake Band Replacement
If the park brake does not hold satisfactorily and there is no
further adjustment available at the control cable threaded
ends, or if the brake band is damaged or contaminated with
lubricant, the brake band must be replaced.
I
G
H
Note: If the park brake does not hold satisfactorily
because of lubricant contamination, the source of the
leakage should be corrected before installing new
parts.
F
E
D
MX42850
3. Remove flanged shoulder bolt (D) and spacer washer
(E) securing traction drive belt tensioner bracket (F) to gear
case.
4. Compress return spring (G) and disconnect control
cable end (H) from tensioner bracket.
5. Remove spring and washer (I) from control cable end.
Brakes Repair - 210
BRAKES REPAIR
L
K
J
O
P
R
Q
MX42851
6. Remove traction drive belt (J) from gear case input
sheave. Move belt forward to clear gear case.
7. Move handlebar park brake control to engage park
brake.
8. Remove M10 hex nut (K) securing sheave/brake drum
(L) to gear case input shaft.
9. Release park brake control.
MX42907
12.Remove short hex head shoulder bolt (O) securing end
of park brake band to linkage arm (P).
13.Remove long shoulder bolt (Q) and flat washer (R)
securing end of park brake band to park brake bracket.
14.Remove brake band.
Park Brake Band Reassembly
Note: Gear case input shaft key may fall from input
shaft when sheave/drum is removed.
M
E
N
D
B
C
A
MX42907
MX42906
10.Slide sheave away from gear case. Move sheave as
required for access to park brake band (M) and attaching
hardware.
11. Secure and set aside input shaft key (N).
1. Insert long hex head shoulder bolt (A) to one end of new
park brake band (B). Install flat washer (C) to bolt.
2. Install brake band to brake bracket, securing band with
shoulder bolt.
3. Secure free end of brake band to brake linkage arm (D)
with short hex head shoulder bolt (E).
4. Tighten bolts to specification.
Brakes Repair - 211
BRAKES REPAIR
10.Compress return spring and insert cable end (L) into
belt tensioner bracket.
11.Position tensioner bracket for installation to gear case
with drive belt on top of idler.
F
G
12. Insert shoulder bolt (M) through tensioner bracket and
flat washer (N) and install to gear case. Tighten to
specification.
O
MX42906
5. Move machine forward or backward as required to bring
gear case input shaft keyway to top of shaft. Install shaft
key (F) to keyway.
P
6. Align keyway and install sheave (G) to gear case input
shaft.
MX42759
H
13.Reinstall electronics/belt cover (O) and secure with
three M6 socket pan head bolts (P).
14.Adjust park brake cable. (See “Park Brake Adjustment”
on page 208.)
I
15.Release park stand to retracted position.
Specifications
MX42851
7. Install M10 hex head nut (H) to secure sheave to input
shaft. Hold sheave with park brake, and tighten nut to
specification.
Electronics/Belt Cover. . . . . . . . . . . . . 10 N•m (84 lb-in.)
Gear Case Sheave . . . . . . . . . . . . . . . . . 55 N•m (40 lb-ft)
Park Brake Band . . . . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Traction Drive Tensioner Pivot . . . . . . . 55 N•m (40 lb-ft)
8. Install traction drive belt (I) to engine and gear case
sheaves.
J
K
L
M
N
MX42850
9. Install flat washer (J) and return spring (K) to traction
control cable.
Brakes Repair - 212
ATTACHMENTS TABLE OF CONTENTS
Attachments
Table of Contents
Specifications ...............................................215
General Specifications ...............................215
Adjustment Specifications ..........................215
Repair Specifications..................................215
Tools and Materials ......................................216
Special or Essential Tools ..........................216
Dealer Fabricated Tools .............................216
Other Materials...........................................216
Component Location....................................217
Cutting Unit - QA-5 .....................................217
Greens Tender Conditioner (GTC).............218
Theory of Operation .....................................219
Reel and Bed Knife Grinding......................219
Rollers ........................................................221
Performance Variables...............................221
Diagnostics ...................................................222
Marcelling ...................................................222
Streaking ....................................................222
Height-of-Cut (HOC) Changes ...................222
Poor Quality of Cut .....................................222
Reel Does Not Rotate ................................223
Unit Not Cutting ..........................................223
Tests and Adjustments ................................224
Adjusting Frequency of Clip (FOC) ............224
Adjust Bed Knife-to-Reel ............................224
Adjusting Bed Knife and Bed Knife Shoe
Position for Worn Reel (QA-5 Reel) ...........225
Backlapping Cutting Unit ............................226
Grinding Reel and Bed Knife......................228
Adjust Height-of-Cut Range (QA-5 Reel) ...230
Adjust Height-of-Cut (HOC) (QA-5 Reel) ...230
Adjust Cutting Shield ..................................231
Adjust Front Roller (QA-5 Reel) .................232
Adjusting Greens Tender Conditioner
(GTC) .........................................................233
Repair.............................................................234
Inspect Reel and Bed Knife........................234
Remove and Install Electric Reel Motor .....235
Removing and Installing Cutting Units .......236
Adjusting Cutting Unit Limit Chains ............237
Reel Motor Drive Belt Removal and
Installation ..................................................238
Reel Removal and Installation
(QA-5 Reel) ................................................239
Remove and Install Bed Knife - QA-5 Reel 241
Remove and Install Front Roller - QA-5
Reel ........................................................... 243
Repair Front Roller .................................... 243
Remove and Install Rear Roller - QA-5
Reel ........................................................... 244
Remove and Install Greens Tender
Conditioner ................................................ 244
Disassemble and Inspect Greens Tender
Conditioner ................................................ 247
Attachments Table of Contents - 213
ATTACHMENTS TABLE OF CONTENTS
Attachments Table of Contents - 214
ATTACHMENTS SPECIFICATIONS
Specifications
General Specifications
Cutting Units:
Cutting Unit Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48V electric motor with controller
Reel Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7 cm (5 in.)
Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559 mm (22 in.)
Number of Blades (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Number of Blades (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Front Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional - smooth or grooved
Bed Knife Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bed Knife-to-Reel
Frequency of Clip
11 Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1-12.2 mm (0.16-0.48 in.)
7 Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4-0.25 mm (0.25-0.75 in.)
Cutting Height (Minimum)
Standard Bed Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 mm (1/8 in.)
Optional Tournament Bed Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 mm (7/64 in.)
Optional Low-Cut Bed Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm (5/64 in.)
Greens Tender Conditioner (Optional)
22 inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mm (2-3/8 in.) diameter, 75 blades
Rotary Brush (Optional) . . . . . . . . . . . . . . . . . . . . Interlocked with reel, rotation in reverse direction 60 mm (2-3/8 in.)
diameter
GTC Cutter Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 mm (1/32 in.)
Material of GTC Cutter Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special hardened carbon steel, star shaped
Adjustable Brush or Cutter Height . . . . . . . . . . . . . . . . . . . . . 10 mm (13/32 in.) below to 5.5 mm (7/32 in.) above cut
Gear Drive (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear driven from reel shaft
Gear Drive Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . opposite direction of reel rotation
Adjustment Specifications
Specifications:
Bed Knife-to-Reel Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 mm (0.001 in.)
Front Roller Out-of-Parallel (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 mm (0.002 in.)
Cutting Unit Shield Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.04 in.)
Vertical Cutting Unit Flap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 mm (0.5 in.)
Brush-to-Roller Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-1 mm (0-0.031 in.)
Repair Specifications
Specifications:
Bed Knife Shoulder Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 N•m (40 lb-ft)
Bed Knife Mounting Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N•m (62 lb-in.)
Front Roller Eccentric Lock Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 N•m (60 lb-ft)
GTC Shaft Retaining Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 N•m (35 lb-ft)
Vertical Cutting Unit Shaft Runout (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.)
Attachments Specifications - 215
ATTACHMENTS TOOLS AND MATERIALS
Tools and Materials
Other Material
Special or Essential Tools
Note: Order tools according to information given in the
U.S. SERVICEGARD™ Catalog or in the European
Microfiche Tool Catalog (MTC).
Part No.
Part Name
Part Use
TY24425
John Deere Special
Purpose HD Water
Resistant Grease
Used to lubricate
roller shaft bearing.
Special or Required Tools
Tool Name
Tool No.
Tool Use
Bearing Installer JDG243
Used to install
bearings.
Bearing Installer JDG506
Used to install
bearings.
Roller Bearing
Puller
JDG795
Used to remove
bearings from rollers.
Height-of-Cut
Gauge Bar
AMT2978
Used to adjust front
roller, cutting height.
Bench Plate
NA
Used to adjust front
roller.
Dealer Fabricated Tools
A
B
C
E32285
Attach a piece of rubber hose (B) and additional handle (C)
to a paint brush (A) to extend its length. This is used to
apply lapping compound.
Other Materials
Other Material
Part No.
Part Name
Part Use
NA
Lapping Compound
Used to backlap bed
knife/cutting reels.
TY25083
John Deere Golf and
Turf Cutting Unit
Grease
Used to lubricate
mower bearings and
seals.
AN10256
2
John Deere Corn
Head Grease
Used to lubricate reel
drive gearcase.
Attachments Tools and Materials - 216
ATTACHMENTS COMPONENT LOCATION
Component Location
Cutting Unit - QA-5
A
H
B
A
G
F
E
C
D
MX41240
A- Rear Roller Height Adjuster
B- Bed Knife Adjusters
C- Bed Knife Cam Plate
D- Bearing Housing / Motor Mount
E- Front Roller
F- Reel
G- Lubrication Fittings
H- Bearing Housing
Attachments Component Location - 217
ATTACHMENTS COMPONENT LOCATION
Greens Tender Conditioner (GTC)
A
G
B
A
I
H
C
G
D
E
F
MX42950
A- Rear Roller Height Adjuster
B- Bed Knife Adjuster
C- Counterweight for Reel Motor
D- Greens Tender Conditioner Drive Housing
E- Greens Tender Conditioner Height and Tension
Mechanism
F- Front Roller Height Adjustment
G- Greens Tender Conditioner Engage/Disengage
Wing Nut
H- Front Roller
I- Greens Tender Conditioner
Attachments Component Location - 218
ATTACHMENTS THEORY OF OPERATION
Theory of Operation
Reel and Bed Knife Grinding
Reel and Bed Knife Relationship
Reel mowers are precision machines requiring daily
maintenance to maintain the well-groomed appearance of
turfgrass. The scissor-like shearing action, which only a
reel mower is capable of achieving, is only possible if the
reel and bed knife are sharp and the bed knife-to-reel
clearance is maintained.
Close examination of the bed knife-to-reel relationship
reveals two square edges passing one another with
approximately 0.050 mm (0.002 in.) clearance. There are
several reasons why this clearance is necessary.
• When the reel is allowed to contact the bed knife, the
square (sharp) edges of the reel and bed knife will roll over,
becoming dull.
In order for the grass to be cut at the proper height, it must
contact the bed knife at the cutting edge. This is
accomplished by grinding a 15° relief angle on the front
face of the bed knife. Without a relief angle, the blade of
grass will contact the lower edge of the bed knife and be
bent over at too much of an angle prior to being cut. In the
case of mowing greens, where very small cuts are being
taken, the reel may not capture the grass at all, and no
grass will be cut.
Although some spin grinding machine manufacturers say
backlapping is not necessary, John Deere recommends
backlapping after spin grinding to remove burrs and rough
edges left from the spin grinding procedure. Backlapping
produces a honed edge that will cut the grass evenly and
leave the tops of the grass with clean, straight edges.
It is important to note that dull cutting edges will tear rather
than shear the grass drawn into the bed knife. This will
shock the grass plant and retard its growth.
• Contact between the reel and bed knife generates heat.
Heat generated through this contact will distort the shape
of the bed knife. Distortion causes the bed knife to draw
closer to the reel, resulting in more rollover of the cutting
surfaces and more heat generated in the bed knife.
• Drag produced by an improperly adjusted cutting unit
may result in an unacceptable clip ratio, undue strain on
drive mechanisms and premature wear of the cutting unit.
Reasons for Grinding
• To restore the cylindrical shape of a reel that has
become cone-shaped due to improper adjustment of the
bed knife-to-reel clearance or worn reel bearings.
• To restore the edge when the grass is not being cut
across the entire length of the bed knife, evidenced by
streaks of grass left after the mower has passed, usually
the result of nicked blades caused by hitting foreign objects
in the grass.
• To restore the edge when the lack of frequent
backlapping allowed the edge to be rounded beyond the
capability of the backlapping procedure to restore the edge.
• To restore the edge when the bed knife-to-reel
clearance has been improperly adjusted (reel contacting
bed knife).
Cutting action begins as the bed knife positions the grass to
be cut at the cutting edge. The reel then pulls the grass
toward the bed knife, where it is sheared by the cutting
edges as they pass one another.
Attachments Theory of Operation - 219
ATTACHMENTS THEORY OF OPERATION
Relief Grinding
CORRECT
Single
Relief Grind
INCORRECT
Excessive
Relief
Grind
Double
Relief Grind
No Relief
Flat
Ground
Secondary Relief
20°
20°
Cutting Edge
Cutting Edge
Reel Blades
Cutting Edge
6.5° Relief
15 Relief
Bed Knife
MIF
John Deere recommends relief grinding the reels before
spin grinding for the following reasons:
• Reduces blade contact area, results in less friction,
requiring less horsepower to drive the reels.
•
Ensures longer wear life.
•
Less time is required to backlap.
Backlapping
Backlapping is used to sharpen the cutting edges when
grinding is not necessary. See “Reel and Bed Knife
Grinding” on page 219 to determine if grinding is
necessary.
When compared to grinding, backlapping removes a very
small amount of metal, requires less time and will effect a
smooth, clean cut.
• Reduces pulling and tearing of the grass as the unit gets
dull by use.
• Provides an area for backlapping compound to be
trapped to more effectively backlap reels.
• Relief grinding removes metal from the trailing edge of
the blade, forming an angle (relief angle) to reduce the
contact area of the cutting edges.
• Because of the relief grind it is possible, with
backlapping, to true a reel (make it round) if a blade is
0.025-0.050 mm (0.001-0.002 in.) out of round.
The backlapping procedure is accomplished by spinning
the reel backwards while applying special abrasive
compounds to the reel. Usually, coarse compounds are
used initially, followed by a finer abrasive for final honing.
Recommended grits for fairways and roughs are 60-, 80and 120-grit. Reel sharpening compounds should not be
toxic, oily, or greasy.
The cutting unit should be inspected, backlapped, adjusted
and checked daily for a uniform cut along the complete
length of the bed knife. It is important that the adjustment
allows the reel to turn freely without dragging against the
bed knife. Metal-to-metal contact will generate heat,
causing the reel to expand and intensifying the dragging
that produces more heat. This vicious cycle will quickly
“shut down” the mower.
Attachments Theory of Operation - 220
ATTACHMENTS THEORY OF OPERATION
Rollers
Smooth Roller
The roller is used as a ground-sensing device to follow
changes in the contour of the turf as the mower moves
forward. A smooth roller is also generally used on the rear
of a cutting unit to establish the cutting height range.
(Under certain circumstances, grooved rollers are used on
the rear.) A front roller used in conjunction with a rear roller
is needed to achieve more exact cutting heights under 25
mm (1 in.).
Grooved Roller
A grooved roller follows changes in the contour of the turf in
a similar fashion as a smooth roller. The main advantage in
using a grooved roller rather than a smooth one comes
when cutting long grass that is very wet. Grass that is wet
will tend to stay down rather than spring up after the roller
passes. Grooved rollers will not bend the grass over,
allowing it to be cut rather than passed over.
Along with advantages come disadvantages. Because of
the reduced contact area inherent with a grooved roller, the
roller may penetrate deeper into the soil (especially in wet
conditions), lowering the effective cutting height and
possibly scalping the turf. Serious consideration should be
given to mowing fairways or greens with a grooved roller
attached, especially when the turf is very wet.
Performance Variables
Three performance variables that affect the quality of cut
are:
•
Number of reel blades
•
Reel rpm
•
Ground speed of machine
equals the Cutting Height (CH). If CR is 20% greater than
CH, marcelling (a wavy, rib-like appearance) can occur. CR
should be within 20% of CH. Therefore, a CH of 13 mm
(0.50 in.) requires a CR of 10-15 mm (0.40-0.60 in.). If CH
is 20% greater than CR, the rotating blades create a
fanning effect that blows the grass down without cutting it.
CR is controlled by the performance variables (the number
of blades on the reel, ground speed and reel speed). In
most cases, only two of these performance variables (the
number of blades on the reel and/or the vehicle ground
speed) are changeable for a given cutting height.
Since the number of blades on the reel, the reel speed, the
cutting height and the clip ratio (since CR must equal CH)
are known, the formula to calculate optimum vehicle ground
speed (mph) is:
mph = (reel rpm) x (CR) x (No. of blades) ÷ 1056
Example:
Using:
•
At a tested reel speed of 2100 rpm
•
9-blade reel on a 22-in. cutting unit
•
CH = 0.14 (therefore, CR = 0.14)
Optimum vehicle ground speed (mph) is:
(2100) x (0.14) x (9) ÷ 1056 = 2.5 mph
Note: To measure vehicle ground speed (mph):
• Measure an 88-ft distance and record the length of
time (in seconds) it takes to travel that distance.
• Vehicle ground speed equals 60 divided by that time.
Note: When discussing performance variables, we
must assume that other factors such as rate of growth,
mowing frequency, soil fertility and equipment
condition have been considered and are not affecting
the quality of cut.
To apply performance variables to a formula, we need to
understand three terms:
Shear Point - A single point of cutting contact between the
cutting unit and the turf. Due to the reel mower design,
there are an infinite number of shear points across the bed
knife.
Clip Ratio (CR) - The forward distance traveled between
successive cutting contacts at any one shear point.
Cutting Height (CH) - The distance above the soil line that
grasses are clipped.
The most uniform cut occurs when the Clip Ratio (CR)
Attachments Theory of Operation - 221
ATTACHMENTS DIAGNOSTICS
Diagnostics
3. Is the condition of the soil good (not rough or
changing)?
Marcelling
Yes: Go to next step.
No: Use a smooth roller.
Procedure
4. Is the cutting unit floating properly?
1. Is the ground speed correct?
Yes: Go to next step.
Yes: Go to next step.
No: Increase or decrease ground speed as necessary.
(See “Performance Variables” on page 221.)
No: See operator’s manual.
5. Are the roller clamp bolts tight?
2. Is engine rpm correct (not too low)?
Yes: Go to next step.
Yes: Go to next step.
No: Perform height-of-cut (HOC) Adjustment. (See
“Adjust Height-of-Cut Range (QA-5 Reel)” on
page 230.)
No: Increase engine speed to specification. (See
operator’s manual.)
6. Are the rollers concentric (not out-of-round)?
3. Are the reel and bed knife sharp?
Yes: Go to next step.
Yes: Go to next step.
No: Perform backlapping and bed knife-to-reel
adjustment. (See “Backlapping Cutting Unit” on
page 226 and “Adjust Bed Knife-to-Reel” on page 224.)
4. Is the correct number of reel blades being used for
desired clip ratio (CR)?
No: Install reel with correct number of blades. (See
“Performance Variables” on page 221.)
No: Replace roller. (See “Remove and Install Front
Roller - QA-5 Reel” on page 243, or “Remove and
Install Rear Roller - QA-5 Reel” on page 244.)
7. Are the roller bearings in good condition (not worn)?
No: Replace roller bearings. (See “Remove and Install
Front Roller - QA-5 Reel” on page 243.)
Poor Quality of Cut
Streaking
Procedure
Procedure
1. Is the grass at an acceptable height (not too high)?
1. Is the bed knife-to-reel clearance within specification
and consistent along the bed knife?
Yes: Go to next step.
Yes: Go to next step.
2. Are the reel and bed knife sharp?
No: Perform bed knife-to-reel adjustment. (See “Adjust
Bed Knife-to-Reel” on page 224.)
Yes: Go to next step.
2. Are the reel and bed knife in good condition (no
nicks, uneven wear, or distortions)
No: Perform backlapping and bed knife-to-reel
adjustment. (See “Backlapping Cutting Unit” on
page 226 and “Adjust Bed Knife-to-Reel” on page 224.)
No: Grind reel and bed knife. (See “Reel and Bed Knife
Grinding” on page 219.)
3. Is the bed knife-to-reel clearance within specification
and consistent along the bed knife?
No: Mow grass more frequently.
Height-of-Cut (HOC) Changes
Yes: Go to next step.
Procedure
No: Perform bed knife-to-reel adjustment. (See “Adjust
Bed Knife-to-Reel” on page 224.)
1. Is the grass dry enough for proper cutting (not too
wet)?
4. Are the roller bearings in good condition (not worn or
seized)?
Yes: Go to next step.
No: Replace roller bearings.
No: Allow sufficient time for grass to dry before cutting.
2. Is the roller clean (no grass or dirt collecting on the
roller)?
Yes: Go to next step.
No: Install scraper or power brush on roller.
Attachments Diagnostics - 222
ATTACHMENTS DIAGNOSTICS
Reel Does Not Rotate
6. Is the bed knife-to-reel clearance within specification
and consistent along the bed knife?
Procedure
No: Perform bed knife-to-reel adjustment. (See “Adjust
Bed Knife-to-Reel” on page 224.)
1. Is the machine operating properly?
Yes: Go to next step.
No: See machine operator’s manual.
2. Are the reel and bed knife free of debris?
Yes: Go to next step.
No: Remove material jammed between reel and bed
knife.
3. Is coupler (or couplers) installed?
Yes: Go to next step.
No: Install coupler (or couplers). (See “Remove and
Install Electric Reel Motor” on page 235.)
4. Are mower electrical control circuits operating
correctly?
No: See appropriate diagnostics in Electrical section.
Unit Not Cutting
Procedure
1. Is the grass dry and height of cut not excessive?
Yes: Go to next step.
No: Allow sufficient time for grass to dry and mow more
frequently.
2. Are the engine and ground speeds correct?
Yes: Go to next step.
No: Adjust engine speed to specification. (See
operator’s manual.) Adjust ground speed to conditions.
(See “Performance Variables” on page 221.)
3. Is the correct number of blades used for conditions?
Yes: Go to next step.
No: Install reel with correct number of blades. (See
“Performance Variables” on page 221.)
4. Is the frequency of clip correct?
Yes: Go to next step. It may be necessary to change to
a more aggressive bed knife.
No: Adjust frequency of clip. (See “Adjusting Frequency
of Clip (FOC)” on page 224.)
5. Are the reel and bed knife sharp?
Yes: Go to next step.
No: Perform backlapping and bed knife-to-reel
adjustment. (See “Backlapping Cutting Unit” on
page 226 and “Adjust Bed Knife-to-Reel” on page 224.)
Attachments Diagnostics - 223
ATTACHMENTS TESTS AND ADJUSTMENTS
Tests and Adjustments
The frequency of clip is infinitely variable between
positions 1 and 5 on the control label (C). FOC
specifications for each control position are listed on
the control label and in the table that follows.
Adjusting Frequency of Clip (FOC)
Important: Avoid Damage! Operating the reels at a
high speed can cause excessive bed knife and reel
wear. Operate the reels at the appropriate frequency
of clip.
1. Park machine safely. (See Park Safely in the Safety
section.)
Control 11 Blade Reel FOC
Position
7 Blade Reel FOC
1
4.1 mm (0.16 in.)
6.4 mm (0.25 in.)
2
4.6 mm (0.18 in.)
7.1 mm (0.28 in.)
3
5.6 mm (0.22 in.)
8.9 mm (0.35 in.)
4
9.7 mm (0.38 in.)
15.2 mm (0.60 in.)
5
12.2 mm (0.48 in.)
19.1 mm (0.75 in.)
4. Adjust FOC speed control (D) to desired speed for reel
type, greens and conditions. (Turning the control counterclockwise from position 1 will reduce the frequency of clip.
Turning the control clockwise from position 5 will increase
the frequency of clip.)
A
B
• For mowing greens, set the control (D) to the
desired FOC (Greens typically use 4.1-4.6 mm (0.160.18 in.) with an 11 blade reel).
MX42457
2. Remove 6 mm screw (A) and cover (B) from rear of
handle bar.
• For mowing approaches and tee boxes, frequency
of clip may be reduced by turning the speed control
knob counterclockwise.
Note: FOC is variable and calculated from FOC
potentiometer and alternator (engine rpm) speed.
5. Install FOC cover (B) and secure with 6 mm screw (A).
D
C
Adjust Bed Knife-to-Reel
Reason
To maintain bed knife-to-reel clearance for clean,
consistent cutting.
Procedure
MX42458
3. Locate Frequency of Clip (FOC)[reel speed] control (C).
Note: Reel speed can be adjusted depending on the
type of application for the greens mower, which type of
cutting units are used, and grass height and
conditions.
It may be appropriate to reduce frequency of clip when
cutting taller grass to prevent grass from being blown
over and not being cut. Faster reel speeds with dry
grass may cause grass clippings to be thrown over the
grass catcher.
c Caution:
Avoid Injury! Always wear protective
gloves when working on or near the cutting
reel or bed knife. Severe personal injury can
result from contact with the sharp cutting
edges.
1. Remove cutting units from mower. (See “Removing
Cutting Unit” on page 236.)
2. Position cutting unit upright on workbench as shown.
Attachments Tests and Adjustments - 224
ATTACHMENTS TESTS AND ADJUSTMENTS
condition of the reel.
• If there is contact at the center of the bed knife:
Grind the reel and/or bed knife to eliminate the “frown” in
the bed knife or the out-of-round condition of the reel.
A
Specifications
Bed Knife-to-Reel Clearance. . . . 0.025 mm (0.001 in.)
Adjusting Bed Knife and Bed Knife Shoe
Position for Worn Reel (QA-5 Reel)
MX42930
3. Turn bed knife adjuster (A) on both sides of cutting unit
counterclockwise until bed knife (B) is tight against cutting
reel (C)
4. Slowly tighten tower adjuster (A) clockwise, alternating
from side to side until bed knife begins to pull away from the
cutting reel. Cutting reel should rotate freely.
After grinding has reduced the reel diameter to about
122 mm (4.8 in.), the eccentric housings for the bed
knife shoe pivot bolts can be inverted to increase the
useful life of the reel.
1. Remove the cutting unit from machine.
A
Note: Make sure that when making the final
adjustment, the bed knife is moving away from cutting
reel.
B
C
MX41169
D
B
E35559
2. Increase bed knife clearance by turning hex adjuster
bolt (A) clockwise until spring (B) is completely
compressed. Repeat for opposite side.
5. Alternately turn adjusters (A) no more than one flat at a
time until bed knife (B) to reel (C) clearance (D) measures
0.025 mm to 0.050 mm (0.001 in. to 0.002 in.).
Important: Avoid Damage! Always rotate the
cutting wheel backwards to prevent damaging or
dulling the cutting edges of the reel and/or bed
knife.
6. Slowly rotate the cutting reel backwards and check the
gap at several points along the entire length of the bed
knife using a 0.050 mm (0.002 in.) feeler gauge. The feeler
gauge should not pass between the bed knife and cutting
reel at any point.
Results
• If the gap is 0.050 mm (0.002 in.) or greater at the
center of the bed knife: Grind the reel and/or bed knife to
eliminate the “smile” in the bed knife or the out-of-round
E
D
C
MX42931
3. Remove bed knife pivot shoulder bolt (C) and spring
washers (D).
4. Remove M8 hex stopnut (E) securing eccentric.
Attachments Tests and Adjustments - 225
ATTACHMENTS TESTS AND ADJUSTMENTS
Backlapping Cutting Unit
Reason
To provide a consistent cutting action and prolong reel life.
Dealer Fabricated Tools
F
C
A
MX42932
5. Remove eccentric (F).
B
6. Invert eccentric and reinstall to side frame.
7. Reinstall M8 stopnut securing eccentric to side frame.
E32285
Note: Install spring washers to shoulder bolt with
concave sides facing (washer edges touching) each
other.
Attach a piece of rubber hose (A) and additional handle (B)
to a paint brush (C) to extend its length. This is used to
apply lapping compound.
8. Install shoulder bolt through spring washers and
eccentric to bed knife shoe.
Procedure
9. Tighten fasteners to specification.
c Caution:
Avoid Injury! Rotating blades are
dangerous and can cut fingers and toes. Keep
10.Repeat process to invert eccentric on opposite side.
11.Adjust bed knife-to-reel clearance.
12.Adjust front roller parallel to bed knife.
hands and feet away while greensmower is
running.
Disengage greens and turf conditioner (GTC)
before backlapping.
13.Set height of cut.
14.Backlap reel.
15.Check height of cut and adjust as necessary.
Specifications
Reel to Bed Knife Clearance . . . . . 0.025 mm (0.001 in.)
Bed Knife Eccentric Retainer . . . . . . . 28 N•m (20 lb-ft)
Bed Knife Shoulder Bolt . . . . . . . . . . . 55 N•m (40 lb-ft)
Important: Avoid Damage! Backlapping cutting units
should be done by trained personnel as needed.
Backlap intervals will vary depending on conditions.
Backlapping is done to prolong reel life, prevent
downtime and provide a consistently sharp cutting
action.
1. Park machine safely. (See Park Safely in the Safety
section.)
Note: To help maintain sharp edges required on cutting
reels, bed knife-to-reel clearance should be checked
before the backlapping function begins. The bed knife
must be adjusted properly to ensure light, even
contact over the length of the cutting blades.
2. Check bed knife-to-reel clearance on cutting reel. Adjust
if necessary.
3. Start engine and adjust throttle to a low or middle
position.
4. Lock park brake.
Attachments Tests and Adjustments - 226
ATTACHMENTS TESTS AND ADJUSTMENTS
A
C
M79054
MX42459
5. Place mow/backlap switch in the BACKLAP (A) position
7. Using a long-handled brush (C), carefully apply an initial
course grit reel sharpening compound, uniformly from one
end of the cutting reel to the other. Repeat application in
opposite direction. Allow cutting reel to continue running
backwards until reel is quiet.
c Caution:
Avoid Injury! Rotating blades are
dangerous and can cut fingers and toes. Keep
hands and feet away while greensmower is
operating.
Do not attempt to disengage the cutting units
using the frequency of clip control knob. Reels
can continue to rotate if engine is running.
B
MX42460
6. Press PTO switch to engaged (B) position to start reel
rotation.
c Caution:
Avoid Injury! Rotating blades are
dangerous. Keep hands and feet away while
greensmower is operating.
Use a brush with a long handle when
performing backlapping procedure to keep
fingers and hands from rotating blades.
Note: To stop reel rotation at any time during the
backlap operation, place engine run/stop switch in
STOP position, place PTO switch in disengaged
position, place mow/backlap switch in MOW position,
or lock the park brake.
If reel rotation is stopped by any action other than the
PTO switch, it may be necessary to turn the PTO switch
off, then on to resume reel rotation,
8. Periodically disengage cutting units by pressing the PTO
switch to the disengaged position and turning the run/stop
switch to the STOP position to shut down the machine.
Visually check the blade appearance.
9. Check for uniform clearance across entire bed knife. If
clearance is not uniform, repeat backlapping procedure
until clearance is uniform across entire bed knife.
10.Repeat lapping process using progressively finer
lapping compounds as required until the bed knife and reel
are returned to a sharp condition.
Important: Avoid Damage! Do not operate cutting
reels in the forward direction until reel sharpening
compound is washed from the unit. Unless properly
washed, the reels can be dulled by the compound.
11.Use water to thoroughly wash off all reel sharpening
compound while cutting reels are turning in reverse.
12.Stop reel and shut down engine. Adjust bed knife-to-reel
clearance.
Attachments Tests and Adjustments - 227
ATTACHMENTS TESTS AND ADJUSTMENTS
streaks of grass left after the mower has passed, usually
the result of nicked blades caused by hitting foreign objects
in the grass.
• To restore the edge when the lack of frequent
backlapping allowed the edge to be rounded beyond the
capability of the backlapping procedure to restore the edge.
• To restore the edge when the bed knife-to-reel
clearance has been improperly adjusted (reel contacting
bed knife).
D
Cutting action begins as the bed knife positions the grass to
be cut at the cutting edge. The reel then pulls the grass
toward the bed knife, where it is sheared by the cutting
edges as they pass one another.
MX42459
13.Place mow-backlap switch in the MOW (D) position.
Results
Reel and bed knife should be sharp and free from minor
nicks and scratches.
Grinding Reel and Bed Knife
Reel and Bed Knife Relationship
Reel mowers are precision machines requiring daily
maintenance to maintain the well-groomed appearance of
turfgrass. The scissor-like shearing action, which only a
reel mower is capable of achieving, is only possible if the
reel and bed knife are sharp and the bed knife-to-reel
clearance is maintained.
Close examination of the bed knife-to-reel relationship
reveals two square edges passing one another with
approximately 0.050 mm (0.002 in.) clearance. There are
several reasons why this clearance is necessary.
• When the reel is allowed to contact the bed knife, the
square (sharp) edges of the reel and bed knife will roll over,
becoming dull.
In order for the grass to be cut at the proper height, it must
contact the bed knife at the cutting edge. This is
accomplished by grinding a 15° relief angle on the front
face of the bed knife. Without a relief angle, the blade of
grass will contact the lower edge of the bed knife and be
bent over at too much of an angle prior to being cut. In the
case of mowing greens, where very small cuts are being
taken, the reel may not capture the grass at all, and no
grass will be cut.
Although some spin grinding machine manufacturers say
backlapping is not necessary, John Deere recommends
backlapping after spin grinding to remove burrs and rough
edges left from the spin grinding procedure. Backlapping
produces a honed edge that will cut the grass evenly and
leave the tops of the grass with clean, straight edges.
It is important to note, dull cutting edges will tear rather
than shear the grass drawn into the bed knife. This will
shock the grass plant and retard its growth.
Grinding the Bed Knife
Note: Bed knife and support assembly must be ground
as a complete unit.
A
• Contact between the reel and bed knife generates heat.
Heat generated through this contact will distort the shape
of the bed knife. Distortion causes the bed knife to draw
closer to the reel, resulting in more rollover of the cutting
surfaces and more heat generated in the bed knife.
• Drag produced by an improperly adjusted cutting unit
may result in an unacceptable clip ratio, undue strain on
drive mechanisms and premature wear of the cutting unit.
B
Reasons for Grinding
• To restore the cylindrical shape of a reel that has
become cone-shaped due to improper adjustment of the
bed knife-to-reel clearance or worn reel bearings.
• To restore the edge when the grass is not being cut
across the entire length of the bed knife, evidenced by
M47199
1. When grinding the bed knife, it is important to have a
6.5° relief angle on the top surface (A) and a 15° relief
angle on the front surface (B).
Attachments Tests and Adjustments - 228
ATTACHMENTS TESTS AND ADJUSTMENTS
2. Put entire bed knife support and bed knife in a suitable
grinder and grind just until material is consistently removed
from the entire length of the top and front surfaces of the
bed knife.
Grinding the Reel
INCORRECT
CORRECT
Excessive
Relief Grind
Double
Relief Grind
Relief
Grind
No
Relief Grind
Flat Ground
Secondary Relief
20°
20°
No Relief
Reel Cutting Edge
Reel Cutting Edge
6.5° Relief
Bed Knife
15 Relief
MIF
John Deere recommends relief grinding the reels before
spin grinding for these reasons:
• Reduced blade contact area results in less friction,
requiring less horsepower to drive the reel and increases
fuel efficiency.
•
Ensures longer wear life.
•
Less time is required to backlap.
• Reduces pulling and tearing of the grass as the unit gets
dull by use.
• Provides an area for backlapping compound to be
trapped to more effectively backlap reels.
• Relief grinding removes metal from the trailing edge of
the blade, forming an angle (relief angle) to reduce the
contact area of the cutting edges.
• The reduced cutting edge contact area resulting from
relief grinding makes it possible to true a reel (make it
round) through backlapping if a blade is 0.025-0.050 mm
(0.001-0.002 in.) out of round.
Attachments Tests and Adjustments - 229
ATTACHMENTS TESTS AND ADJUSTMENTS
Adjust Height-of-Cut Range (QA-5 Reel)
Adjust Height-of-Cut (HOC) (QA-5 Reel)
Reason
1. Park machine safely.
To set front roller range for proper height-of-cut position.
B
Procedure
1. Remove cutting units from mower. (See “Removing
Cutting Unit” on page 236.)
2. Place cutting unit upright on a stable working surface
with the front roller at the top.
Note: The effective height-of-cut may differ from the
bench setting due to the weight of options used, type
of roller (grooved or smooth), soil conditions, grass
condition and the use of competitive machines in
conjunction with one another.
A
MX41000
C
2. Locate the height of cut adjuster (A) on top rear of reel
side casting (either side).
B
A
3. Turn the height of cut adjustment counterclockwise to
shorten height of cut or clockwise to lengthen height of cut.
NOTE: Adjusters are connected with cross shaft (B) so
turning one side simultaneously turns the other.
MX43199
E
3. Loosen nut (A) on each roller bracket.
4. Align cutting unit frame marks (B) with desired mark on
roller bracket (C) and on each side of the cutting unit to
determine the HOC adjustment range. Each mark
represents approximately 5mm (0.2 in.) change in height.
Make sure brackets on each side are on the same mark.
5. Tighten nuts.
D
6. Adjust parallelism of front roller. (See “Adjust Front
Roller (QA-5 Reel)” on page 232.)
C
Results
Front roller range positioned for proper height-of-cut
adjustment.
M97423, M97422
4. On the height-of-cut (HOC) gauge bar, set center
adjustment bolt head (C) at the desired height of cut (D).
Lock wing nut (E).
Attachments Tests and Adjustments - 230
ATTACHMENTS TESTS AND ADJUSTMENTS
11.Turn adjuster (L) until side to side HOC is equal, and
then reinstall cross shaft.
H
Adjust Cutting Shield
Reason
Correct adjustment of the cutting shield improves the
performance of the grass catcher.
Procedure
F
1. Remove cutting units from mower. (See “Removing
Cutting Unit” on page 236.)
G
2. Place cutting unit on a stable working surface.
B
J
I
A
MX43097
5. Place cutting unit upright on a stable working surface
with front roller at top.
6. Install HOC gauge bar with inside of bolt head (F)
against edge of bed knife approximately 51 mm (2 in.) from
end of bed knife.
7. Turn in adjuster (G) against bottom of bed knife until
gauge bar contacts front roller (H). Tighten wing nut on
adjuster to secure position.
8. Turn adjuster (I) until the rear roller (J) contacts the HOC
gauge bar.
MX43200
3. Loosen left and right locknuts (A) and on each side of
cutting unit.
4. Raise or lower shield (B) to desired position.
C
9. Check HOC adjustment setting from side to side and
adjust if necessary.
J
K
L
MX41171
• Maintain an approximate 1.5 mm (0.06 in.) clearance
(C) between the bottom of the shield and the top of the
cutting blades.
5. Tighten bolts.
MX41001
10.If side to side HOC adjustment is necessary, pull against
spring tension on cross shaft (J) to disconnect it from hex
coupling (K). Remove the cross shaft.
Results
Proper clearance between shield and cutting blades will
result in greater grass catching performance.
Attachments Tests and Adjustments - 231
ATTACHMENTS TESTS AND ADJUSTMENTS
Specifications
Cutting Shield Clearance . . . . . . . . . . . 1.5 mm (0.06 in.)
Adjust Front Roller (QA-5 Reel)
F
NOTE: Use of a bench plate or a two or three bolt
height-of-cut gauge bar is recommended when
adjusting front roller parallel with the bed knife.
E
H
Always adjust bed knife-to-reel before adjusting front
roller for parallelism.
Always make parallelism adjustment after adjusting
front roller height of cut range.
MX43201
5. Rotate eccentric adjuster (F) until front roller (G) sits flat
and parallel with the bench plate. Gap (H) should not
exceed 0.050 mm (0.002 in.) maximum.
Parallelism Adjustment with Bench Plate
1. Position cutting unit upright on flat surface or
workbench.
6. Hold roller eccentric adjuster (F) and tighten hex head
bolt (E) to specification.
Specification
D
Eccentric Adjuster Hex Head Bolt . . . . 81 N•m (60 lb-ft)
Parallelism Adjustment with HOC Gauge Bar
A
B
C
A
B
M97254
2. Set bench plate (A) on a level surface.
3. Set cutting unit on top of bench plate. The bed knife (B)
must rest firmly against the plate stop (C), with the cutting
reel blade (D) on top of plate stop.
C
F
MX43096
1. Place cutting unit upright on a stable work surface with
the front roller (A) at top.
E
MX43199
4. Loosen hex head bolt (E) securing eccentric adjuster on
one of the roller brackets.
2. Install HOC gauge bar (B) to rollers approximately 51
mm (2 in.) from the end of the bed knife.
3. Adjust length of gauge bolt (C) so that underside of bolt
head just slips over edge of bed knife with gauge bar
resting on front and rear rollers.
Attachments Tests and Adjustments - 232
ATTACHMENTS TESTS AND ADJUSTMENTS
4. Remove gauge bar, and turn out gauge bolt by 1/4 turn
(moving bolt head away from gauge bar). Secure gauge
bolt position with wing nut.
F
Adjusting Greens Tender Conditioner (GTC)
Note: Height Of Cut must be adjusted prior to adjusting
the Greens Tender Conditioner. (See “Adjust Height-ofCut (HOC) (QA-5 Reel)” on page 230.)
The Greens Tender Conditioner should be adjusted for
a depth of engagement no greater than 0.79 mm (0.031
in.) below the height of cut.
G
H
A
F
E
G
H
E
D
C
D
B
MX43097
5. Reinstall gauge bar to cutting unit, with gauge bolt head
under bed knife edge. Ensure that underside of gauge bolt
head contacts bed knife.
6. Press bottom of gauge bar toward rear roller (D), and
turn in second gauge bolt (E) until bolt end contacts bottom
of bed knife. Secure gauge bolt position with wing nut.
MX43095
7. Press gauge bar against rear roller, and measure
distance (F) between front roller and gauge bar at both
ends of reel.
1. Position cutting unit upright on a stable working surface
with front roller (A) at top.
8. Adjust front roller height if measured distance between
gauge bar and roller exceeds 0.050 mm (0.002 in.) from left
to right ends.
2. Adjust height of cut gauge bolt (B) so that underside of
bolt head contacts top of bed knife with ends of gauge bar
contacting front and rear rollers. Tighten gauge bolt
locknut.
a. Loosen M10 hex head bolt (G) securing eccentric
adjuster (H) at roller end with greatest gap between
roller and gauge bar.
b. Rotate eccentric adjuster to bring roller closer to
gauge bar.
c. Tighten eccentric adjuster locking bolt to
specification.
9. Recheck distance between roller and gauge bar at each
end.
Specifications
Roller to Bed Knife Out of Parallel (Max) . . . . 0.050 mm
(0.002 in.)
Eccentric Adjuster Hex Head Bolt . . . 81 N•m (60 lb-ft)
3. Measure bed knife gauge bolt height (C).
Note: GTC depth of engagement gauge bolt height is
determined by the height of cut gauge bolt length
minus the desired GTC depth of engagement . GTC
depth should be no greater than 0.79 mm (0.031 in.)
below cutting height.
4. Subtract desired GTC engagement (D) from height of
cut (C) to obtain length (E) for GTC gauge bolt (F), Secure
gauge bolt position with wing nut.
5. Place preset gauge bar on cutting unit with height of cut
(HOC) bolt (B) on bed knife. Gauge bar ends should rest on
the front and rear rollers with underside of HOC bolt head
on bed knife.
Attachments Tests and Adjustments - 233
ATTACHMENTS REPAIR
6. Rotate wing nuts (G) at left and right sides of cutting unit
to lower GTC to operating position. If GTC tips contact
gauge bolt before GTC is fully lowered, turn in M10 hex
locknuts (H).
Repair
7. Adjust height of GTC by turning left or right locknuts as
required to bring tips of GTC in contact with end of gauge
bolt.
c Caution:
Avoid Injury! Avoid injury from
rotating blades. Keep hands and feet away
8. Remove gauge bar.
Inspect Reel and Bed Knife
from blades while machine is running.
Always wear protective gloves when working
on or near the reel or bed knife. Severe
personal injury can result from contact with the
sharp cutting edges.
Never allow more than one person at a time to
work on a cutting unit. Serious personal injury
could result.
1. Visually inspect cutting unit for damage. Chipped paint,
dents or gouges may indicate the need for a closer look at
the frame for distortion, broken weldments or other damage
that could prevent proper adjustment. Repair or replace
parts as necessary.
2. Inspect for vertical or lateral movement in the reel or
bearings supporting the reel. Repair or replace as
necessary.
A
M84825
3. While rotating the reel in the reverse direction by hand,
inspect each blade cutting edge (A) for nicks, gouges or
distortion. Ensure the cutting edge land does not exceed
more than 3/4 of the blade thickness. Restore the relief
angle and cutting edge before continuing with this
procedure. (See “Reel and Bed Knife Grinding” on
page 219.)
Attachments Repair - 234
ATTACHMENTS REPAIR
Important: Avoid Damage! NEVER lift or carry reel
motor by wire harness. Damage to harness
conductors or reel motor harness connectors may
result.
B
4. Remove reel motor.
Reel Motor Wiring Harness Disconnect
M84823
Disconnect reel motor harness connectors only if the motor
needs replacement or workbench service. Take care to
avoid contamination or damage to connectors.
4. Inspect the bed knife cutting edge (B) for nicks, gouges
or distortion.
5. Inspect the bed knife for uneven wear (indicated by
uneven land width across the length of the bed knife).
Ensure the cutting edge land does not exceed 3/4 of the
cutting edge. Replace the bed knife if the cutting edge
extends below 1.45 mm (0.057 in.) from the mounting
surface.
C
B
Remove and Install Electric Reel Motor
A
Reel Motor Removal
When removing the cutting unit for service it is
recommended to remove the reel motor from the reel
with the wiring harness connected. Disconnect reel
motor harness connectors only if the motor needs
replacement or workbench service. Take care to avoid
contamination or damage to connectors.
1. Park the machine safely. (See “Park Machine Safely” on
page 2.)
A
MX43177
1. Remove M8 hex nut (A) and washer securing harness
clamp to side plate.
2. Cut wire tie (B) securing harness connectors to frame.
3. Separate two reel motor harness connectors (C).
Reel Motor Wire Harness Connection
Reconnect and secure reel motor wire harness as originally
installed. Ensure that connectors are clean and free of
damage before joining connectors.
Reel Motor Installation
Installation is done in the reverse order of removal.
D
B
A
C
MX41804
A
2. Loosen two M10 hex head bolts (A) sufficiently to
remove reel motor from end frame.
3. Rotate reel motor assembly until slots (B) clear bolt
heads.
B
MX43098
1. Fill reel drive socket (A) with John Deere Cutting Unit
Grease or NLGI Grade 0 Grease.
2. Insert reel motor drive spindle (B) into reel drive socket.
Attachments Repair - 235
ATTACHMENTS REPAIR
Rotate reel motor until mounting lugs (C) engage M10 hex
head mounting bolts (D).
3. Tighten mounting bolts to specification.
attachment link.
I
Specification
Reel Motor Mount . . . . . . . . . . . . . . . . . 55 N•m (40 lb-ft)
Removing and Installing Cutting Units
Removing Cutting Unit
1. Park the vehicle safely. (See Park Safely in the Safety
section.)
Important: Avoid Damage! Removal of cutting unit
will make drive unit unstable without support.
Failure to support drive unit may result in damage.
When cutting unit is removed, rotate drive unit
forward to rest on cutting unit attachment link.
I
J
MX42454
6. Loosen two M10 hex flange head bolts (I), and rotate
and remove reel motor (J) from cutting unit housing.
Installing Cutting Units
A
C
B
MX42456
A
B
2. Remove spring locking pin (A) flat washer (B) and limit
chain (C) from anchor pin on each side of cutting unit.
MX43098
1. Ensure that cutting unit drive socket (A) is filled with
grease. Use John Deere Special Purpose HD Cornhead
Grease if additional lubrication is needed.
2. Align reel motor drive spindle (B) with reel drive socket,
and install reel motor to cutting unit.
H
E
D
F
MX42505
3. Remove spring locking pin (E) and clevis pin (F)
securing cutting unit to cutting unit attachment link (H).
E
4. Roll cutting unit away from machine.
5. Rotate drive unit forward to rest on cutting unit
MX42454
Attachments Repair - 236
ATTACHMENTS REPAIR
3. Rotate motor to engage mounting lugs (D) with M10
bolts (E).
C
4. Tighten mounting bolts to specification.
A
5. Roll cutting unit under machine.
B
H
G
MX42456
F
1. Initial working length for limit chain (A) should be 7 links,
with upper chain anchor studs (B) centered in slots (C).
This will provide maximum float and maximum rear roller
drop when lifted. The majority of greens will not require
maximum float. Turning and maneuvering will be easiest if
float is limited to the requirements of the greens surface.
I
J
MX42505
6. Align holes in cutting unit yoke (F), catcher bracket (G),
and cutting unit attachment link (H).
7. Insert clevis pin (I) fully and secure with spring locking
pin (J).
M
Note: Use care not to exceed maximum float setting. If
excessive chain slack is permitted, rear roller
adjustment towers may contact front frame cross bar
causing damage. Minimum clearance on flat ground,
with cutting unit rotated to limit is 6.5 mm (0.25 in.)
between rear roller tower and frame.
K
L
B
D
MX42456
8. Install left and right limit chains (K) on cutting unit
housing pins. Make sure chains are not twisted.
MX43099
Adjusting Cutting Unit Limit Chains
2. With machine on level surface and with transport wheels
removed, adjust position of left and right limit chain anchor
studs. Anchor stud position should be adjusted to maintain
minimum clearance (D) between cutting unit and machine
frame.
Limit chains on each side of the cutting unit control the
amount of cutting unit float while mowing and the amount of
rear roller drop when the unit is lifted for turns.
3. If full floating is not required (relatively flat or nonundulating green), adjust upper chain anchor studs (B) to
further limit float and reduce rear roller drop.
9. Install flat washers (L) and spring locking pins (M) on
each cutting unit housing pin.
Specifications
Cutting Unit to Frame Clearance (Min.) 6.5 mm (.25 in.)
Limit Chain Anchor Stud . . . . . . . . . . . 28 N•m (20 lb-in.)
Attachments Repair - 237
ATTACHMENTS REPAIR
Reel Motor Drive Belt Removal and
Installation
G
Drive Belt Removal
1. Remove reel motor assembly. (See “Remove and Install
Electric Reel Motor” on page 235.)
F
2. Thoroughly clean and dry outside of reel motor
assembly.
Important: Avoid Damage! Do not use excessive
force to remove drive cover.
A
MX41009
7. Remove shaft assembly (F) and belt (G).
8. Clean and inspect drive belt. Replace belt, if necessary.
B
9. Inspect drive pulleys and bearings. Replace parts as
needed.
Special or Required Tools
Tool Name
Puller
Tool No.
JDG10945
MX43178
3. Remove three M6 hex nuts (A) and two M6x25 hex head
bolts (B).
Tool Use
Remove belt sheave
from motor shaft
Drive Belt Pulley Removal
Remove the drive belt pulley if the pulley is damaged or if
the reel motor is to be replaced.
D
E
B
C
B
C
A
MX43179
MX41808
4. Install two bolts (B) (removed in previous step) into jack
holes (C).
1. Remove M10 locknut (A) securing belt pulley to reel
motor.
5. Slowly and alternately tighten bolts to separate drive
cover (D) from reel motor housing (E).
2. Remove three M6x105 hex head bolts (B) securing
inner belt housing to reel motor.
6. Remove cover (D).
3. Remove belt housing (C) from reel motor.
Attachments Repair - 238
ATTACHMENTS REPAIR
Important: Avoid Damage! Do not pry against reel
motor to remove belt pulley. Use JDG10945 puller to
remove pulley. Use of improvised tools to remove
belt pulley may result in damage to reel motor or belt
pulley.
D
4. Using JDG10945 Puller, remove belt pulley from reel
motor.
Drive Belt Pulley Installation
Reinstall the drive belt housing to the reel motor with the
housing extension facing away from the motor wiring
harness for proper harness routing when the reel motor is
installed to the machine.
MX41008
4. Install drive cover (E) to reel motor.
Drive Belt Installation
5. Remove tape from output shaft.
A
C
A
B
B
MX43178
MX41009
1. Install drive belt (A) to belt pulleys while inserting shaft
assembly (B) into reel motor housing bearing bore (C).
6. Install three M6 hex nuts (A) and two M6x25 hex head
bolts (B). Tighten in an alternating pattern to specification.
Specification
Reel Motor Belt Cover . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Reel Removal and Installation (QA-5 Reel)
D
Removal
1. Remove cutting unit from power unit. (See “Removing
Cutting Unit” on page 236.)
2. Remove greens tender conditioner (if equipped).
MX41010
3. Remove front and rear rollers. (See “Remove and Install
Front Roller - QA-5 Reel” on page 243 and “Remove and
Install Rear Roller - QA-5 Reel” on page 244.)
2. Rotate shaft and belt while seating shaft to bearing to
keep belt aligned in center of sprockets.
4. Remove bed knife. (See “Remove and Install Bed Knife QA-5 Reel” on page 241.)
3. Cover output shaft splines (D) with tape to protect drive
cover seal.
5. Place cutting unit on a stable work surface.
Attachments Repair - 239
ATTACHMENTS REPAIR
11.Remove snap ring (E) from left and right side frame
bearing housings.
A
Note: Wave washer is installed to left side reel frame
bearing housing.
B
F
C
MX43100
6. Remove M10 hex flange nuts (A) and M8x25 socket flat
head bolt (B) securing left side frame to cross braces.
7. Remove M8 hex flanged nut (C) securing grass shield to
left side frame assembly.
8. Remove left side reel frame assembly
MX41384
12.Remove wave washer (F) from left side bearing
housing.
G
H
D
MX41385
MX41382
13.Remove bearing race (G) and bearing (H) from left and
right side bearing housings.
9. Remove reel (D) from right side reel frame.
10.Remove bearing cap from right side reel frame?
Note: Always replace bearing seals when servicing
mowing unit bearings.
E
MX41383
Attachments Repair - 240
ATTACHMENTS REPAIR
A
I
B
C
MX41386
E
14.Remove seal (I) from left and right side housings.
15.Clean and inspect all parts. Replace parts as needed.
Installation
MX41169
• Turn hex adjuster (A) counterclockwise until spring
(B) is completely compressed. Repeat on opposite side.
Assembly is done in the reverse order of disassembly.
4. RemoveM10x30 hex head bolt (C) on each side
connecting adjuster link to bed knife shoe.
Remove and Install Bed Knife - QA-5 Reel
5. Rotate cutting unit forward 90 degrees with bed knife up
off of the bench.
Removal
6. Remove rear roller assembly. (See “Remove and Install
Rear Roller - QA-5 Reel” on page 244.)
c Caution:
Avoid Injury! Blades are sharp and
rotate quickly:
• Keeps hands and feet away from cutting
reels while machine is running.
c Caution: Avoid Injury! Mower parts are sharp!
Wear gloves when handling bed knife and reel.
• Always wear gloves while working on
cutting reels.
• Watch for rotation of cutting reels. Rotating
one cutting reel can cause another blade or
cutting reel to rotate.
F
1. Remove the cutting unit from machine. (See “Removing
Cutting Unit” on page 236.)
E
D
2. Position cutting unit with the bottom side down on a flat
surface or workbench.
3. Relieve tension from bed knife tension springs on both
sides of cutting unit.
MX41012
7. Remove shoulder bolt (D) and two spring washers from
each end of bed knife shoe.
8. Slide bed knife/shoe assembly (E) down out of shield (F)
and out of the cutting unit.
9. If original bed knife is to be used again, grind the bed
knife. (See “Grinding the Bed Knife” on page 228.)
Attachments Repair - 241
ATTACHMENTS REPAIR
Installation
1. Remove and discard screws attaching bed knife to bed
knife shoe.
A
Note: Remove any dirt, debris, or corrosion from bed
knife and bed knife shoe.
2. Ensure that bed knife and bed knife mounting area of
shoe are free from any dirt, debris, or corrosion before
reinstalling bed knife to shoe.
3. Install bed knife using new screws. Alternate tightening
by starting with center screws and working out to the ends.
Tighten screws to specification.
C
4. If installing a used bed knife, grind the bed knife. (See
“Grinding the Bed Knife” on page 228.)
MX41160
8. Install M10x30 hex head bolts (C) through adjuster links
into bed knife shoe. Tighten hardware to specification.
9. Restore bed knife spring tension by turning hex adjuster
(A) clockwise.
10.Install rear roller. (See “Remove and Install Rear Roller QA-5 Reel” on page 244.)
A
11.Adjust bed knife-to-reel. (See “Adjust Bed Knife-to-Reel”
on page 224.)
12.Set height-of-cut. (See “Adjust Height-of-Cut (HOC)
(QA-5 Reel)” on page 230.)
MX41003
5. Slide bed knife and support assembly into position and
secure with shoulder bolt (A) on each side.
13.Backlap reel. (See “Backlapping Cutting Unit” on
page 226.)
14.Check height-of-cut and adjust as necessary.
Specifications
Bed Knife Height Adjuster Link . . . . . . 55 N•m (40 lb-ft)
Bed Knife Mounting Screw . . . . . . . . . . 7 N•m (62 lb-in.)
Bed Knife Shoulder Bolt . . . . . . . . . . . . 55 N•m (40 lb-ft)
MX41013
• Install shoulder bolt (D) with two spring washers on
each side of unit. Make sure outer edges of spring
washers touch and inner holes have space between
them.
•
Tighten hardware to specification.
6. Position cutting unit with bottom side down on flat
surface or workbench.
7. Install each adjustment assembly inside housing
mounting bracket.
Attachments Repair - 242
ATTACHMENTS REPAIR
Remove and Install Front Roller - QA-5 Reel
Repair Front Roller
1. Remove cutting units from mower. (See “Removing
Cutting Unit” on page 236.)
Disassembly
2. Place cutting unit on a stable working surface with the
front roller suspended.
1. Remove front roller assembly from reel housing. (See
“Remove and Install Front Roller - QA-5 Reel” on
page 243.)
G
F
C E
A
D
A
B
B
C
MX43199
3. Place marks (A) on each eccentric and roller bracket for
reassembly purposes.
4. Remove M10x25 hex head bolt (B) and eccentric
adjuster (C) on each end of roller.
5. Remove roller and end bracket assembly.
MX20405
2. Remove locknut (A) from both ends of shaft.
3. Remove grease fitting (B) from both ends of shaft.
4. Push shaft through roller to remove.
Installation
5. If spacer (C) and O-ring (D) do not come out with shaft,
pull out to remove.
Installation is done in the reverse order of removal.
6. Remove outer seals (E).
Note: Roller brackets are offset. For standard use, the
roller should be installed offset toward the cutting unit.
7. Remove bearing and race (F).
If a Greens Tender Conditioner (GTC) is installed, the
roller should be installed offset away from the cutting
unit.
9. Repeat for opposite end of roller if needed.
•
Install roller with eccentric adjusters and bolts.
8. Remove inner seal (G).
10.Inspect all components and replace as necessary.
Assembly
• Align marks made during disassembly on eccentrics
and brackets.
•
G
F
D
E
Tighten bolts to specification.
C
A
• Check roller height of cut and parallelism adjustments.
(See “Adjust Height-of-Cut (HOC) (QA-5 Reel)” on
page 230.)
Specification
Eccentric Adjuster Hex Head Bolt . . . 81 N•m (60 lb-ft)
MX41948
1. Install inner seal (G) with lip facing out.
2. Pack bearing (F) with TY25083 Golf and Turf Cutting
Attachments Repair - 243
ATTACHMENTS REPAIR
2. Center rear roller between brackets.
Unit Grease. Install bearing.
Important: Avoid Damage! Install outer seals with
lips facing in.
3. Apply TY25083 Golf and Turf Cutting Unit Grease
between lips of outer seals. Press outer seals (E) into
place.
4. Install shaft in roller and approximately center it
lengthwise.
Important: Avoid Damage! Use care not to catch seal
lips when installing spacer.
5. Install new O-ring (D) in spacer (C). Apply a light coat of
grease to bore of spacer and install with O-ring next to
bearing.
3. Install caps (B) and cap screws (A) on both sides of
cutting unit.
4. Tighten cap screws to specification.
Specification
Roller Retaining Cap . . . . . . . . . . . . . . 10 N•m (84 lb-in.)
Remove and Install Greens Tender
Conditioner
Remove Greens Tender Conditioner (GTC)
c can
Caution: Avoid Injury! Blades are sharp and
cut. Use caution and wear gloves when
handling blades or working near blades.
6. Repeat for opposite end of roller.
7. Install both locknuts (A) and tighten until end play is
gone, yet roller rotates freely.
C
8. Install front roller assembly onto reel housing. (See
“Remove and Install Front Roller - QA-5 Reel” on
page 243.)
D
A
B
Remove and Install Rear Roller - QA-5 Reel
Removal
1. Remove cutting unit from mower. (See “Removing
Cutting Unit” on page 236.)
2. Remove roller brush (if equipped).
3. Place cutting unit upside down on a stable working
surface (rollers facing up).
MX43101
1. Remove cutting unit from mower. (See “Removing and
Installing Cutting Units” on page 236.)
2. Position cutting unit upright on a stable work surface
with front roller at top.
3. Remove locknut (A) and height adjuster (B) from left and
right conditioner height adjustment links (C).
A
4. Rotate conditioner assembly downward to free height
adjustment links from height adjuster guides.
B
MX43202
5. Remove height adjuster links with springs (D) from GTC
attachment points.
4. Remove two M6x20 socket head bolts (A) and caps (B)
on both sides of cutting unit.
5. Remove roller.
Installation
1. Install roller bearing spindle shaft into cutting unit.
Attachments Repair - 244
ATTACHMENTS REPAIR
M
L
I
G
E
F
H
MX43102
6. Hold compression hex nut (E) and remove M10 lock nut
(F) from conditioner shaft.
7. Support conditioner roller (G) and remove GTC shaft
trailing arm (H) from reel housing and conditioner shaft.
8. Remove conditioner roller from drive housing (I).
MX43104
10. Rotate GTC transmission (L) to limit of rotation.
11.Remove retainer (M) securing transmission to reel
frame.
12.Remove transmission from reel frame.
Install Greens Tender Conditioner (GTC)
c can
Caution: Avoid Injury! Blades are sharp and
cut. Use caution and wear gloves when
handling blades or working near blades.
K
J
A
MX43103
9. Remove M10x90 hex head bolt (J) securing
counterweight (K) to reel frame. Remove counterweight.
MX43105
1. Fill attachment drive socket (A) with John Deere Cutting
Unit Grease or NLGI Grade 0 Grease.
Attachments Repair - 245
ATTACHMENTS REPAIR
C
H
B
I
MX43108
7. Align captive pin (H) in GTC roller end socket with slot (I)
in drive shaft and install roller to shaft.
MX43106
2. Install attachment drive assembly (B) to right side reel
bearing retainer boss.
3. Insert drive assembly retainer (C) to secure drive
assembly to reel side frame.
J
K
G
D
E
MX43102
F
8. Fit GTC trailing arm to left side reel bearing retainer
boss (J) while assembling GTC to drive shaft.
9. Install M10 hex locknut (K) securing GTC roller to trailing
arm. Tighten to specification.
MX43107
4. Align internal and external bushings (D) in hub of GTC
trailing arm (E).
5. Hold GTC roller (F) upright and install trailing arm to
roller shaft.
6. Ensure that GTC roller shaft is fully inserted in trailing
arm, with shaft end threads (G) fully exposed.
M
L
MX43109
10.Hold nut (L) and tighten compression nut (M) securely.
Attachments Repair - 246
ATTACHMENTS REPAIR
N
O
P
I
H
Q
R
F
G
J
MX43111
5. Remove hex locknut (F), gear (G) and shoulder bolt
from inner housing.
MX43101
11.Install GTC height adjuster link (N) with spring (O) to left
and right trailing arms.
12.Rotate GTC assembly toward mowing unit while
inserting left and right height adjuster links into side frame
brackets (P).
Note: The GTC shift collar may remain in the outer gear
case housing when the case is separated. Remove the
shift collar for inspection and proper order of
reassembly.
6. Remove shift collar (H) and gear (I) from output shaft
(J).
13.Secure height adjuster links with height adjusters (Q)
and M10 hex locknuts (R).
K
14.Adjust GTC height. (See “Adjusting Greens Tender
Conditioner (GTC)” on page 233).
Disassemble and Inspect Greens Tender
Conditioner
Disassembly - Drive
1. Remove GTC drive and shaft assembly from reel
housing. (See “Remove and Install Greens Tender
Conditioner” on page 244.)
A
MX43113
7. Remove snap ring (K) and remove output shaft
assembly from inner housing.
D
M
N
L
E
B
C
MX43109
2. Remove M8x30 hex head bolts (A) with selector retainer
(B) from outer drive housing.
3. Remove control knob (C) from housing.
4. Separate GTC inner drive housing (D) from outer
housing (E).
Attachments Repair - 247
MX43112
ATTACHMENTS REPAIR
8. Remove lock nut (L), gear (M), and shoulder bolt from
outer housing.
9. Remove input shaft assembly (N) from housing.
S
P
O
R
MX41620
12.Remove seal (R) and O-ring (S) from inner housing.
MX41817
10.Remove snap ring (O) and bearing (P) from gears.
13.Clean and inspect all components and replace as
necessary. Clean all old gasket material from mating
surfaces.
Assembly - Drive
1. Replace all shaft seals with new ones.
Q
B
MX41616
11.Remove bearings (Q) from output shaft.
A
MX41818
2. Install bearings (A) on input shaft (B) and install shaft
assembly into housing.
Attachments Repair - 248
ATTACHMENTS REPAIR
bearing will be visible. The outer housing idler gear is
offset toward the outside of the gear case (snap ring
hidden from view with the gear properly installed).
C
L
K
I
MX41616
3. Install bearings (C) on output shaft.
J
D
E
M
MX41816
6. Install gear (I) and shift collar (J) to output shaft.
MX41615
4. Install output shaft assembly (D) in housing and secure
with snap ring (E).
F
7. Install idler gears to inner and outer housings. Snap ring
(K) in inner housing idler gear should be visible with gear
installed. Insert shoulder bolts (L) through housing and idler
gear bearing, and secure with M8 hex locknuts (M). Tighten
fasteners to specification.
G
H
N
O
MX41819
MX41817
8. Place some grease in outer housing bore (N) to hold
spring washer (O) in place and install spring washer?
5. Install bearings (F) into idler gears (G) and secure with
snap rings (H).
Note: GTC idler gears are offset from the bearing
centerlines. The idler gear installed to the inner gear
case housing is offset toward the inside of the gear
case. When installed, the snap ring securing gear and
Attachments Repair - 249
ATTACHMENTS REPAIR
R
S
O
P
MX43114
14.Position shift collar within housing bore so that shift
collar groove (R) is positioned to receive shift selector pin
(S).
MX41620
9. Install new seal (O) with lip and spring facing out.
10.Apply a light coat of grease to housing and install O-ring
(P) in housing.
T
Note: Grease has been omitted from gearcase for
image clarity.
Q
MX41820
15.Inspect selector O-ring (T). Replace if necessary.
16.Install selector, ensuring that the selector pin is fully
inserted and engages slot in shift collar.
V
MX41816
11.Install new gasket (Q).
U
12.Pack gear case housing cavities with grease.
13.Assemble gear case inner and outer housing
assemblies.
MX41815
17.Install selector retainer (U) and two M8x30 hex head
bolts (V).
Attachments Repair - 250
ATTACHMENTS REPAIR
D
C
X
A
E
B
F
MX43338
1. Loosely install compression nut (A) with inner ferrule (B)
on shaft.
2. Insert pin (C) in shaft. Install and index blade stack
retainer (D) over exposed ends of pin.
MX42105
18.Fill attachment drive socket (X) with John Deere Cutting
Unit Grease or NLGI Grade 0 Grease.
3. Alternately install spacers (E) and blade segments (F)
on shaft.
G
19.Install GTC drive on reel housing. (See “Remove and
Install Greens Tender Conditioner” on page 244.)
Disassembly - Shaft Assembly
1. Remove GTC assembly from reel housing. (See
“Remove and Install Greens Tender Conditioner” on
page 244.)
A
D
MX43115
4. Install hex nut (G) to secure blade segments and
spacers. Tighten securely.
F
5. Install GTC shaft to mowing unit. (See “Install Greens
Tender Conditioner (GTC)” on page 245.)
Disassembly - Shaft Support Bracket
1. Remove GTC shaft support bracket from reel housing.
(See “Remove and Install Greens Tender Conditioner” on
page 244.)
B
E
C
MX41552
2. Remove nut (A) on end of shaft. Remove spacers (B)
and blade segments (C) as required.
Note: As nut (A) is loosened, retainer (D) on the
opposite shaft end can be moved to remove its
retaining pin.
D
C
B
A
3. Remove compression nut (F) and inner ferrule.
4. Inspect all components and replace as necessary.
Assembly - Shaft Assembly
MX41555
Note: Ensure that the retainer pin remains within the
retainer recess during GTC assembly.
2. Remove seal (A), bearing (B), spacer (C) and bearing
(D) from bracket.
Attachments Repair - 251
ATTACHMENTS REPAIR
Install the support bracket to the assembled shaft with
the shaft upright.
I
F
E
H
MX41554
3. Remove seal (E).
G
4. Inspect all components and replace as necessary.
Assembly - Shaft Assembly
MX43116
4. Install spacer bushing (F) to support arm outer seal.
5. Hold GTC shaft (G) upright, and install support arm to
shaft. Shaft threads (H) should extend past spacer bushing
when assembled.
6. Install M10 locknut (I) to secure support arm to shaft.
Tighten to specification.
A
MX41554
1. Install seal (A) with lip and spring facing out. Install seal
flush to housing surface.
7. Install GTC shaft support bracket to reel housing. (See
“Remove and Install Greens Tender Conditioner” on
page 244.)
Specification
GTC Roller Support Bracket Retainer . 55 N•m (40 lb-ft)
B
C
D
E
MX41555
2. Install bearing (B), spacer (C), bearing (D) in bracket.
3. Install seal (E) with lip and spring facing out. Install seal
flush to housing surface.
Note: Install the spacer bushing to the GTC support
bracket outer seal before installing the bracket.
Attachments Repair - 252
MISCELLANEOUS TABLE OF CONTENTS
Miscellaneous
Table of Contents
Tools and Materials ......................................255
Other Materials...........................................255
Repair.............................................................255
Remove and Install Transport Wheel ........255
Frame and Drive Covers ............................256
Miscellaneous Table of Contents - 253
MISCELLANEOUS TABLE OF CONTENTS
Miscellaneous Table of Contents - 254
MISCELLANEOUS TOOLS AND MATERIALS
Tools and Materials
Repair
Other Materials
Remove and Install Transport Wheel
Other Material
Part No.
TY6341
Part Name
Part Use
Applied to frame and
John Deere MultiPurpose SD Polyurea drive cover grease
Grease
fittings.
A
MX6037
1. Place machine on stand (A).
B
MX43176
2. Rotate latch (B) and slide wheel from shaft. Repeat
procedure for other side.
Installation
Installation is done in the reverse order of removal.
Miscellaneous Tools and Materials - 255
MISCELLANEOUS REPAIR
Frame and Drive Covers
A
Y
H
B C
Z
I
J
D
K
L
M
AF
AE
E
F
V
R
AA
N
O
P
Z
G
Q
U
AA
AB
X
R
Y
W
R
T
P
S
L
O
X
M
K
W
N
I
J
Q
H
R
U
S
W
AC
D
T
AD
C
B
AJ
AI
G
F
AE
E
U
W
AF
AH AG
V
AE
MX42952
A- Right Cover
B- Nut (2 used)
C- Idler (2 used)
D- Snap Ring (2 used)
E- Bearing (2 used)
F- Spacer (2 used)
G- Plate (2 used)
H- Flange Nut (2 used)
I- Key (2 used)
J- Sprocket (2 used)
K- Bearing Housing 2 used)
L- Lubrication Fitting (2 used)
M- Right Panel
N- Screw (6 used)
O- Bearing (2 used)
P- Seal (2 used)
Q- Carriage Bolt (2 used)
R- Flange Nut (4 used)
S- Shoulder Bolt (6 used)
T- Washer (6 used
U- Flange Nut (10 used)
V- Spacer (6 used)
W- Carriage Bolt (8 used)
X- Carriage Bolt (2 used)
Y- Stops (4 used)
Z- Bracket, Right
AA- Washer (2 used)
AB- Rear Crossbar
AC- Drive Chain (2 used)
AD- Left Cover
AE- Bolt (6 used)
Miscellaneous Repair - 256
MISCELLANEOUS REPAIR
AF- Screw (6 used)
AG- Seal (2 used)
AH- Seal Housing (2 used)
AI- Bolt (2 used)
AJ- Front Crossbar
• Inspect all parts for wear or damage. Replace parts as
necessary.
• Apply John Deere Multi-Purpose SD Polyurea Grease to
grease fittings.
Miscellaneous Repair - 257
MISCELLANEOUS REPAIR
Miscellaneous Repair - 258
INDEX
A
Air Cleaner
Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . 45
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
B
Backlap Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Backlapping
Tests and Adjustments . . . . . . . . . . . . . . . . . . . . . 226
Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Bed Knife
Remove and Install
QA-5 Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Bed Knife Shoe, Adjusting . . . . . . . . . . . . . . . . . . . . . . 225
Bed Knife, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Belts, Adjusting Drive . . . . . . . . . . . . . . . . . . . . . . . . . 170
Belts, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Blower Housing, Remove and Install . . . . . . . . . . . . . . 51
Brake Control/Throttle Lever . . . . . . . . . . . . . . . . . . . . 193
Brake, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Brakes
Band Replacement . . . . . . . . . . . . . . . . . . . . . . . . 210
Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . 209
Diagnosis
Brake Does Not Engage
When Lever Engaged . . . . . . . . . . . . . . . 206
Brake Does Not Hold Machine . . . . . . . . . . . . 207
Excessive Brake Wear . . . . . . . . . . . . . . . . . . 207
Machine will not move . . . . . . . . . . . . . . . . . . 206
Diagnosis, Brake Does Not Engage
When Lever Engaged . . . . . . . . . . . . . . . . . . . 206
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
C
Camshaft and Tappets
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . 65
Carburetor
Clean/Inspect/Rebuild . . . . . . . . . . . . . . . . . . . . . . . 50
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . 49
Float Level Adjustment . . . . . . . . . . . . . . . . . . . . . . 51
Identification Number . . . . . . . . . . . . . . . . . . . . . . . 17
Pilot Screw and Limiter Cap Replacement . . . . . . . 50
Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . 47
Chains, Adjusting Drive Roller . . . . . . . . . . . . . . . . . . . 171
Clutch Control Cable Remove and Install . . . . . . . . . . 172
Clutch Control/Operator Presence Bail . . . . . . . . . . . . 192
Component Location
Cutting Unit
QA-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Greens Tender Conditioner (GTC) . . . . . . . . . . . . 218
Controls Component Location . . . . . . . . . . . . . . . . . . . 191
Cooling System Operation . . . . . . . . . . . . . . . . . . . . . . 31
Crankcase Cover
Bearing/Oil Seal Replacement . . . . . . . . . . . . . . . . 64
Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . 64
Crankshaft
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . .74
Timing/Governor Gear Replacement . . . . . . . . . . . .75
Crankshaft and Connecting Rod, Analyze Wear . . . . . .76
Cutting Unit
Adjustment Specifications . . . . . . . . . . . . . . . . . . .215
General Specifications . . . . . . . . . . . . . . . . . . . . . .215
QA-5
Components . . . . . . . . . . . . . . . . . . . . . . . . . . .217
Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .236
Repair Specifications . . . . . . . . . . . . . . . . . . . . . . .215
Shield Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .231
Cutting Unit Limit Chains, Adjust . . . . . . . . . . . . . . . . .237
Cylinder Block
Bearing Inspect and Replace . . . . . . . . . . . . . . . . . .77
Deglaze Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . .77
Rebore Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Cylinder Compression Pressure Test . . . . . . . . . . . . . . .37
Cylinder Head and Valves
Analyze Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . .58
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Lap Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Recondition Valve Seats . . . . . . . . . . . . . . . . . . . . .63
Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . .57
Valve Guide Replacement . . . . . . . . . . . . . . . . . . . .60
D
Dealer Fabricated Tools
Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . .216
Diagnosis
Ignition Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Power Train, Erratic Speed . . . . . . . . . . . . . . . . . .168
Power Train, Machine Does Not Reach Full Ground
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Power Train, Machine Will Not Drive . . . . . . . . . . .167
Power Train, Noisy Operation . . . . . . . . . . . . . . . .167
Power Train, Park Brake Does Not Hold Machine .169
Power Train, Traction Drive Pulls to One Side . . . .168
Reel Attachments . . . . . . . . . . . . . . . . . . . . . . . . . .222
Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Input Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Differential Gear Case
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
Disassemble and Inspection . . . . . . . . . . . . . . . . .180
Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .176
Disassemble and Inspect
Greens Tender Conditioner . . . . . . . . . . . . . . . . . .247
Drive Belt
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
Drive Belt/Differential System Operation . . . . . . . . . . .164
Drive Belts, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . .170
Drive Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256
Index - 1
INDEX
E
Electrical
Common Circuit Tests . . . . . . . . . . . . . . . . . . . . . . 85
Conductors for 12 Volt Circuits . . . . . . . . . . . . . . . . 85
Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . 84
Flywheel Magnet Test . . . . . . . . . . . . . . . . . . . . . . 158
Ignition Circuit Diagnosis . . . . . . . . . . . . . . . . . . . 108
Ignition Circuit Operation, Engine Shutting Off . . . 106
Reading Electrical Schematics . . . . . . . . . . . . . . . . 83
Run-Off Switch Test . . . . . . . . . . . . . . . . . . . . . . . 155
Theory of Operation Electrical Information . . . . . . . 84
W3 Rectifier Wiring Harness . . . . . . . . . . . . . . . . . 101
Electronic Control Module
Input Circuits Diagnostic Codes . . . . . . . . . . . . . . 114
Electronic Controllers
Accessing Addresses and
Diagnostic Trouble Codes . . . . . . . . . . . . . . . 112
Approved Software for Control Units . . . . . . . . . . 113
CAN Bus Theory of Operation . . . . . . . . . . . . . . . 110
CAN Network Voltage Checks . . . . . . . . . . . . . . . 110
Data Bus Systems . . . . . . . . . . . . . . . . . . . . . . . . 110
Trouble Shooting Electronic Controllers . . . . . . . . 112
Electronic Controllers Theory of Operation . . . . . . . . . 113
Engine
Diagnostics
Engine Cranks but Will Not Start . . . . . . . . . . . 32
Engine Malfunctions at High RPM . . . . . . . . . . 33
Engine Malfunctions at Low RPM . . . . . . . . . . 32
Engine Overheats . . . . . . . . . . . . . . . . . . . . . . . 34
Excessive Fuel Consumption . . . . . . . . . . . . . . 34
Excessive Oil Consumption . . . . . . . . . . . . . . . 34
External Component Location . . . . . . . . . . . . . . . . 26
Internal Component Location . . . . . . . . . . . . . . . . . 28
Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . 44
Repair Specifications . . . . . . . . . . . . . . . . . . . . . . . 21
Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Test and Adjustment Specifications . . . . . . . . . . . . 21
Error Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Error Codes
WBG_000628.12 (Blink Code NONE)
Stuck in Boot Block . . . . . . . . . . . . . . . . . . . . 126
WBG_002513.03 (Blink Code 7-3)
Orange Phase (A) is Shorted to Supply . . . . . 127
WBG_002513.04 (Blink Code 7-2)
Orange Phase (A) is Shorted to Ground . . . . 127
WBG_002513.05 (Blink Code 7-4)
Orange Phase (A) is Open . . . . . . . . . . . . . . . 128
WBG_002514.04 (Blink Code 7-2)
Black Phase (B) is Shorted to Ground . . . . . . 129
WBG_002514.05 (Blink Code 7-4)
Black Phase (B) is Open . . . . . . . . . . . . . . . . 130
Green Phase (C) is Open . . . . . . . . . . . . . . . . 132
WBG_002515.03 (Blink Code 7-3)
Green Phase (C) is Shorted to Supply . . . . . . 131
Index - 2
WBG_002515.04 (Blink Code 7-2)
Green Phase (C) is Shorted to Ground . . . . . .131
WBG_003353.00 (Blink Code 8-1)
Alternator Over Temp Threshold . . . . . . . . . . .133
WBG_003353.01 (Blink Code 8-3)
Alternator Missed Hall State . . . . . . . . . . . . . .134
WBG_003509.00 (Blink Code 7-5)
Pot Signal Voltage High . . . . . . . . . . . . . . . . . .134
WBG_003509.01 (Blink Code 7-5)
Pot Signal Voltage Low . . . . . . . . . . . . . . . . . .135
WBG_003510.00 (Blink Code 9-7)
Pot Supply Voltage High . . . . . . . . . . . . . . . . .136
WBG_003510.01 (Blink Code 9-7)
Pot Supply Voltage Low . . . . . . . . . . . . . . . . . .137
WBG_003511.00 (Blink Code 9-5)
Hall Voltage High . . . . . . . . . . . . . . . . . . . . . . .137
WBG_003511.01 (Blink Code 9-5)
Hall Voltage Low . . . . . . . . . . . . . . . . . . . . . . .138
WBG_003597.00 (Blink Code 9-3)
Controller 14V High . . . . . . . . . . . . . . . . . . . . .139
WBG_003597.01 (Blink Code 9-3)
Controller 14V Low . . . . . . . . . . . . . . . . . . . . .139
WBG_521153.00 (Blink Code NONE)
Manufacturer Service Code . . . . . . . . . . . . . . .140
WBG_521153.15 (Blink Code 2-9)
Controller Shutdown Over Temp . . . . . . . . . . .140
WBG_522327.00 (Blink Code 2-10)
Motor Over Temp . . . . . . . . . . . . . . . . . . . . . . .141
WBG_522917.00 (Blink Code 2-5)
Controller Current Threshold 3 Shutdown . . . .142
WBG_522917.06 (Blink Code 2-8)
Controller Hardware Current Shutdown . . . . . .143
WBG_522917.15 (Blink Code 2-5)
Controller Current Threshold 1 Shutdown . . . .144
WBG_522917.16 (Blink Code 2-5)
Controller Current Threshold 2 Shutdown . . . .145
WBG_522918.00 (Blink Code 1-5)
Motor Start Failed 3x Fault . . . . . . . . . . . . . . . .146
WBG_522918.02 (Blink Code 1-10)
Motor Spin Direction Shutdown . . . . . . . . . . . .147
WBG_522918.15 (Blink Code 1-6)
Motor Stalled While Running . . . . . . . . . . . . . .148
WBG_522919.02 (Blink Code NONE)
Manufacturer Service Code . . . . . . . . . . . . . . .149
WBG_522919.03 (Blink Code 6-6)
Hall Resync Shutdown . . . . . . . . . . . . . . . . . . .149
WBG_522919.04 (Blink Code NONE)
Manufacturer Service Code . . . . . . . . . . . . . . .150
WBG_522919.08 (Blink Code NONE)
Manufacturer Service Code . . . . . . . . . . . . . . .150
WBG_522919.09 (Blink Code NONE)
Manufacturer Service Code . . . . . . . . . . . . . . .150
WBG_522919.12 (Blink Code 6-4)
Invalid Hall State Detected at Start-Up . . . . . .150
WBG_522937.02 (Blink Code 8-2)
Frequency of Clip Shutdown . . . . . . . . . . . . . .151
INDEX
WBG_522976.12 (Blink Code 8-4)
Incorrect Application Software . . . . . . . . . . . . 152
WBG_523666.00 Bus Voltage High
(Blink Code 9-2) . . . . . . . . . . . . . . . . . . . . . . . 152
WBG_523666.01 Bus Voltage Low
(Blink Code 1-7) . . . . . . . . . . . . . . . . . . . . . . . 153
WBG_523666.02 Low VBUS on Start
(Blink Code 1-7) . . . . . . . . . . . . . . . . . . . . . . . 154
WBG_523666.15 Manufacturer Service Code
(Blink Code NONE) . . . . . . . . . . . . . . . . . . . . 154
I
Flywheel Magnet Test . . . . . . . . . . . . . . . . . . . . . . . . . 158
Flywheel, Remove and Install . . . . . . . . . . . . . . . . . . . . 56
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Frequency of Clip (FOC), Adjust . . . . . . . . . . . . . . . . . 224
Front Roller
Remove and Install
QA-5 Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Tests and Adjustments
QA-5 Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Fuel Filter Remove and Install . . . . . . . . . . . . . . . . . . . . 43
Fuel Tank Remove and Install . . . . . . . . . . . . . . . . . . . . 42
L
F
G
Idle Speed Adjustment
Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Ignition Circuit
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Operation, Engine Shutting Off . . . . . . . . . . . . . . .106
Ignition Coil
Air Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .55
Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . .54
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Level 1 Codes (Display Panel) . . . . . . . . . . . . . . . . . . .116
Limit Chains, Adjust Cutting Unit . . . . . . . . . . . . . . . . .237
Lubrication
Alternative Lubricants . . . . . . . . . . . . . . . . . . . . . . . .15
Engine Break-In Oil . . . . . . . . . . . . . . . . . . . . . . . . .15
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Mixing of Lubricants . . . . . . . . . . . . . . . . . . . . . . . . .16
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Synthetic Lubricants . . . . . . . . . . . . . . . . . . . . . . . . .15
Lubrication System Operation . . . . . . . . . . . . . . . . . . . . .29
M
Gasoline Specifications
4-Cycle Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Gasoline Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Gear Case, Lubricating . . . . . . . . . . . . . . . . . . . . . . . . 171
Governor
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . 78
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Greens Tender Conditioner
Depth-of-Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Disassemble and Inspect . . . . . . . . . . . . . . . . . . . 247
Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . 244
Greens Tender Conditioner (GTC) . . . . . . . . . . . . . . . 218
Grinding
Reel and Bed Knife . . . . . . . . . . . . . . . . . . . . 219, 228
Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
H
Handlebar
Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 197
Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . 200
Height-of-Cut
Adjustment
QA-5 Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Range Adjustment
QA-5 Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Machine Identification Number . . . . . . . . . . . . . . . . . . . .17
Muffler, Remove and Install . . . . . . . . . . . . . . . . . . . . . .43
O
O-Ring Boss Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
O-Ring Face Seal Fittings . . . . . . . . . . . . . . . . . . . . . . . .13
Oil, Transmission and Hydraulic . . . . . . . . . . . . . . . . . . .16
Operation
Ignition Circuit, Engine Shutting Off . . . . . . . . . . . .106
Operator Presence Bail
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
P
Piston Rings
Analyze Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Check End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Piston and Connecting Rod
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Connecting Rod Side Play . . . . . . . . . . . . . . . . . . . .71
Connecting Rod-to-Crankshaft Clearance . . . . . . . .71
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Piston, Analyze Wear . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Index - 3
INDEX
Power Train
Adjustment Specifications . . . . . . . . . . . . . . . . . . . 163
Component Location and Operation . . . . . . . . . . . 164
Diagnosis
Erratic Speed . . . . . . . . . . . . . . . . . . . . . . . . . 168
Machine Does Not Reach Full Ground Speed 168
Machine Will Not Drive . . . . . . . . . . . . . . . . . . 167
Park Brake Does Not Hold Machine . . . . . . . . 169
Traction Drive Pulls to One Side . . . . . . . . . . 168
Diagnosis, Noisy Operation . . . . . . . . . . . . . . . . . 167
Repair Specifications . . . . . . . . . . . . . . . . . . . . . . 163
R
Reading Electrical Schematics . . . . . . . . . . . . . . . . . . . 83
Rear Roller
Remove and Install
QA-5 Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Recoil Starter
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Disassemble and Inspect . . . . . . . . . . . . . . . . . . . . 52
Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . 52
Reel
Remove and Install
QA-5 Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Reel Attachments
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Reel Drive Belt
Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . 238
Reel Motor
Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . 235
Reel Motor - 2500E Test . . . . . . . . . . . . . . . . . . . . . . . 158
Reel Motor Controller Signals . . . . . . . . . . . . . . . . . . . 115
Reel Motor Safety Interlock Operating Conditions . . . 116
Reel Motor Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Reel Motor Theory of Operation . . . . . . . . . . . . . . . . . 115
Reel and Bed Knife
Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219, 228
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Reel-to-Bed Knife
Tests and Adjustments . . . . . . . . . . . . . . . . . . . . . 224
Relief Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Remove and Install
Bed Knife
QA-5 Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Cutting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Front Roller
QA-5 Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Greens Tender Conditioner . . . . . . . . . . . . . . . . . 244
Rear Roller
QA-5 Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Reel
QA-5 Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Reel Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Reel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Repair
Front Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
Reel and Bed Knife
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234
Rocker Arm Cover, Remove and Install . . . . . . . . . . . . .56
Roller Drive Chains, Adjusting . . . . . . . . . . . . . . . . . . .171
Rollers Theory of Operation . . . . . . . . . . . . . . . . . . . . .221
Run-Off Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . .155
S
Spark Plug Gap Adjustment . . . . . . . . . . . . . . . . . . . . . .40
Spark Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Special or Essential Tools
Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . .216
Specifications
Cutting Unit
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
Speed, Adjust Frequency of Clip (FOC) . . . . . . . . . . . .224
T
Tests and Adjustments
Backlapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
Cutting Shield Adjustment . . . . . . . . . . . . . . . . . . .231
Front Roller
QA-5 Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . .232
Greens Tender Conditioner
Depth-of-Cut . . . . . . . . . . . . . . . . . . . . . . . . . .233
Grinding
Reel and Bed Knife . . . . . . . . . . . . . . . . . . . . .228
Height-of-Cut
Adjustment
QA-5 Reel . . . . . . . . . . . . . . . . . . . . . . . . .230
Range Adjustment
QA-5 Reel . . . . . . . . . . . . . . . . . . . . . . . . .230
Reel-to-Bed Knife . . . . . . . . . . . . . . . . . . . . . . . . . .224
Throttle Cable
Check and Adjustment . . . . . . . . . . . . . . . . . . . . . . .36
Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . .43
Throttle Lever
Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . .195
Throttle Plate, Remove and Install . . . . . . . . . . . . . . . . .47
Tools and Materials
Dealer Fabricated Tools . . . . . . . . . . . . . . . . . . . . .216
Other Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
Special or Essential Tools . . . . . . . . . . . . . . . . . . .216
Torques
Face Seal Fittings
Inch Stud Ends . . . . . . . . . . . . . . . . . . . . . . . . . .11
Metric Stud Ends . . . . . . . . . . . . . . . . . . . . . . . .12
Inch Fastener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Metric Fastener . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Metric Fastener-Grade 7 . . . . . . . . . . . . . . . . . . . . . .8
Index - 4
INDEX
Traction Roller
Disassemble and Assemble . . . . . . . . . . . . . . . . . 166
Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . 184
Traction Roller Drive Chain Tension Adjustment . . . . 171
Transport Wheels, Remove and Install . . . . . . . . . . . . 255
V
Valve Clearance Check and Adjustment . . . . . . . . . . . . 38
Valves
Analyze Condition . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Lap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
W
W1 Upper Wiring Harness Color Codes . . . . . . . . . . . 100
W2 Lower Wiring Harness Color Codes . . . . . . . . . . . 100
W3 Rectifier Wiring Harness . . . . . . . . . . . . . . . . . . . . 101
W3 Rectifier Wiring Harness Color Codes . . . . . . . . . 102
W4 Light Wiring Harness Color Codes . . . . . . . . . . . . 102
Index - 5
INDEX
Index - 6