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John Deere Sabre 14.542GS 1642HS 17.542HS Lawn Tractor TM1948 Service Repair Manual – PDF Download
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John Deere Sabre 14.542GS 1642HS 17.542HS Lawn Tractor TM1948 Service / Repair / Workshop Manual
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Description
John Deere Sabre 14.542GS 1642HS 17.542HS Lawn Tractor TM1948 Service / Repair / Workshop Manual
FILE DETAILS:
John Deere Sabre 14.542GS 1642HS 17.542HS Lawn Tractor TM1948 Service / Repair / Workshop Manual
LANGUAGE:ENGLISH
PAGES:260
DOWNLOADABLE:YES
FILE TYPE:PDF
JOHN DEERE SABRE 14.542GS 1642HS 17.542HS LAWN TRACTOR TM1948 SERVICE REPAIR MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
SAMPLE PAGE FROM THE MANUAL
John Deere Sabre 14.542GS 1642HS 17.542HS Lawn Tractor TM1948 Service / Repair / Workshop Manual
1. Lower lift arm shaft (G) onto tractor frame, and secure with screws (B).
2. Install lift arm lever bracket (E) onto stud on tractor frame and rod (D). Secure with washer and spring pin (F).
3. Install spring (C) onto lift arm shaft and frame.
4. With parking brake released, install tensioning spring (A) onto lift arm shaft (G).
5. Install fuel tank support rod and fuel tank. (See “Fuel Tank Removal and Installation” on page 250 in the Miscellaneous section.)
6. Install fender deck. (See “Fenderdeck Removal and Installation” on page 248 in the Miscellaneous section.)
7. Install steering wheel and pedestal assembly. (See “Steering Shaft and Pedestal Removal and Installation” on page 205 of the Steering section.)
8. Install mower deck.
TABLE OF CONTENTS:
John Deere Sabre 14.542GS 1642HS 17.542HS Lawn Tractor TM1948 Service / Repair / Workshop Manual
TM1948 - 14.542GS, 1642HS and 17.542HS Sabre Lawn Tractor........................................................... 1 Introduction.................................................................................................... 3 Manual Description.......................................................................................... 3 Safety.......................................................................................................... 5 Recognize Safety Information................................................................................ 5 Understand Signal Words..................................................................................... 5 Replace Safety Signs........................................................................................ 5 Be Prepared For Emergencies................................................................................. 5 Use Care In Handling And Servicing Batteries................................................................ 5 Prevent Battery Explosions.................................................................................. 5 Prevent Acid Burns.......................................................................................... 6 Wear Protective Clothing.................................................................................... 6 Service Machines Safely..................................................................................... 6 Use Proper Tools............................................................................................ 6 Park Machine Safely......................................................................................... 6 Support Machine Properly And Use Proper Lifting Equipment................................................... 7 Work In Clean Area.......................................................................................... 7 Using High Pressure Washers................................................................................. 7 Illuminate Work Area Safely................................................................................. 7 Work In Ventilated Area..................................................................................... 7 Warning: California Proposition 65 Warning.................................................................. 7 Remove Paint Before Welding Or Heating...................................................................... 7 Avoid Harmful Asbestos Dust................................................................................. 7 Service Tires Safely........................................................................................ 8 Avoid Injury From Rotating Blades, Augers And Pto Shafts.................................................... 8 Handle Chemical Products Safely............................................................................. 8 Dispose Of Waste Properly................................................................................... 8 Live With Safety............................................................................................ 8 Specifications & Information.................................................................................... 9 Table of Contents........................................................................................... 9 Specifications.............................................................................................. 11 Engine.................................................................................................. 11 Fuel System............................................................................................. 12 Electrical.............................................................................................. 12 Transaxle............................................................................................... 12 PTO Drive............................................................................................... 13 Steering................................................................................................ 13 Implement Lift.......................................................................................... 13 Tires................................................................................................... 13 Dimensions.............................................................................................. 13 Mower Decks............................................................................................. 14 Recommended Lubricants.................................................................................. 14 Fastener Torques............................................................................................ 15 Metric Fastener Torque Values........................................................................... 15 Metric Fastener Torque Value—grade 7.................................................................... 16 Inch Fastener Torque Values............................................................................. 16 General Information......................................................................................... 18 Gasoline................................................................................................ 18 Gasoline Storage........................................................................................ 18 Engine Oil.............................................................................................. 18 Engine Break–in Oil..................................................................................... 19 Alternative Lubricants.................................................................................. 19 Synthetic Lubricants.................................................................................... 20 Lubricant Storage....................................................................................... 20 Mixing Of Lubricants.................................................................................... 20 Chassis Grease.......................................................................................... 20 Hydrostatic Transmission Oil............................................................................ 20 Serial Number Locations..................................................................................... 21 Machine Product Identification Number................................................................... 21 Engine Serial Number.................................................................................... 21 Transaxle Serial Number................................................................................. 21 Engine - 14.5 & 16 hp Briggs & Stratton......................................................................... 23 Table of Contents........................................................................................... 23 Specifications.............................................................................................. 25 Gen..................................................................................................... 25 Tests and Adjustments Specifications.................................................................... 25 Repair Specifications................................................................................... 25 Torque Specifications (Alphabetical).................................................................... 26 Tests and Adjustments....................................................................................... 28 Throttle Cable Adjustment............................................................................... 28 Fuel Shutoff Solenoid Test.............................................................................. 28 Governor Adjustment - Static............................................................................ 28 Governor Adjustment - Dynamic........................................................................... 29 Governor Idle Adjustment................................................................................ 30 Slow Idle Carburetor Adjustment......................................................................... 30 Valve Clearance Adjustment.............................................................................. 31 Armature Air Gap Adjustment............................................................................. 32 Cylinder Leakdown Test.................................................................................. 32 Fuel and Air Repair......................................................................................... 34 Upper Blower Housing Removal and Installation........................................................... 34 Air Cleaner Service..................................................................................... 34 Carburetor Removal and Installation..................................................................... 34 Carburetor Disassembly.................................................................................. 35 Carburetor Inspection................................................................................... 37 Carburetor Assembly..................................................................................... 37 Breather Valve Service.................................................................................. 38 Engine Repair............................................................................................... 38 Engine Removal.......................................................................................... 38 Engine Installation..................................................................................... 39 Cylinder Head Removal and Installation.................................................................. 40 Cylinder Head Inspection and Repair..................................................................... 43 Valve Removal........................................................................................... 43 Valves Reface........................................................................................... 43 Valves Installation..................................................................................... 44 Governor Removal and Installation....................................................................... 45 Piston, Rings and Rod................................................................................... 45 Piston Inspection....................................................................................... 47 Connecting Rod Inspection............................................................................... 47 Cylinder Bore Inspection................................................................................ 49 Cylinder Bore Honing.................................................................................... 50 Cylinder Bore Cleaning.................................................................................. 50 Resizing Cylinder Bore.................................................................................. 50 Flywheel Removal and Installation....................................................................... 51 Crankshaft and Cam Gear Removal......................................................................... 52 Balance System Removal and Installation................................................................. 53 Crankshaft/Cam Gear Installation........................................................................ 54 Magneto Bearing Inspection.............................................................................. 55 Cam Gear Bearing Inspection............................................................................. 56 PTO Journal Inspection and Seal Replacement............................................................. 56 Starting Motor Removal and Installation................................................................. 57 Starting Motor Disassembly.............................................................................. 57 Starting Motor Assembly................................................................................. 59 Starting Motor Pinion Gear Replacement.................................................................. 61 ENGINE - 17.5 HP KOHLER......................................................................................... 63 Table of Contents........................................................................................... 63 Specifications.............................................................................................. 65 General Specifications.................................................................................. 65 Tests and Adjustments Specifications.................................................................... 65 Repair Specifications................................................................................... 65 Torque Specifications (Alphabetical).................................................................... 68 Special Or Required Tools............................................................................... 69 Tests and Adjustments....................................................................................... 70 Throttle Cable Adjustment............................................................................... 70 Choke Adjustment........................................................................................ 70 Governor Adjustment..................................................................................... 70 Fast Idle Speed Adjustment.............................................................................. 71 Slow Idle Speed Adjustment.............................................................................. 71 Cylinder Leakdown Test.................................................................................. 72 Automatic Compression Release (ACR) Check............................................................... 74 Crankcase Vacuum Test................................................................................... 75 Fuel Flow Test.......................................................................................... 77 Fuel Shutoff Solenoid Test.............................................................................. 77 Oil Pressure Test....................................................................................... 77 Ignition Armature Air Gap Adjustment.................................................................... 79 Fuel and Air Repair......................................................................................... 79 Blower Housing Removal and Installation................................................................. 79 Air Intake System Components............................................................................ 81 Carburetor Removal and Installation..................................................................... 81 Kohler Engine:Carburetor Disassembly & Inspection....................................................... 83 Engine Repair............................................................................................... 85 Fuel Pump Removal and Installation...................................................................... 85 Engine Removal and Installation......................................................................... 86 Rocker Arms Removal and Installation.................................................................... 89 Cylinder Head Removal and Installation.................................................................. 89 Valves And Springs Removal and Installation............................................................. 90 Cylinder Head Inspection................................................................................ 90 Valves Inspection....................................................................................... 91 Valve Guides Inspection................................................................................. 91 Valve Seats Recondition................................................................................. 92 Valves Lap.............................................................................................. 92 Breather Inspection..................................................................................... 93 Flywheel Removal and Installation....................................................................... 93 Camshaft Removal and Installation....................................................................... 94 Camshaft Inspection..................................................................................... 94 Camshaft End Play Measurement........................................................................... 95 Hydraulic Valve Lifters Removal and Installation........................................................ 95 Hydraulic Valve Lifters Inspection...................................................................... 96 Balancer Shaft Removal and Installation................................................................. 96 Balancer Shaft Inspection............................................................................... 97 Governor Removal and Installation....................................................................... 97 Governor Inspection..................................................................................... 98 Piston Assembly Removal................................................................................. 98 Piston Disassembly...................................................................................... 99 Piston Inspection....................................................................................... 99 Piston Ring End Gap Measurement......................................................................... 99 Piston Ring Side Clearance Measurement..................................................................100 Connecting Rod Measurement..............................................................................100 Kohler Engine:Piston Measurement........................................................................101 Piston Assembly.........................................................................................101 Piston Installation.....................................................................................102 Crankshaft Removal and Installation.....................................................................102 Crankshaft and Main Bearing Inspection..................................................................103 Crankshaft Alignment....................................................................................104 Oil Pan Removal and Installation........................................................................104 Oil Pan Seal Removal and Installation...................................................................105 Crankcase Oil Seal Removal and Installation.............................................................105 OIl Pickup Inspection...................................................................................106 Oil Pump Relief Valve Inspection........................................................................106 Oil Pump Installation...................................................................................106 Cylinder Block Removal and Installation.................................................................107 Cylinder Block Inspection...............................................................................107 Cylinder Bore Deglazing.................................................................................107 Stator and Ignition Module Removal and Installation.....................................................108 Voltage Regulator/Rectifier Removal and Installation....................................................109 Starting Motor Removal and Installation.................................................................109 Starting Motor Drive Replacement........................................................................109 Starting Motor Brush Replacement and Armature Test......................................................110 Electrical......................................................................................................113 Table of Contents...........................................................................................113 General Information.........................................................................................115 Reading Electrical Schematics...........................................................................115 Theory Of Operation Information.........................................................................116 Diagnostic Information..................................................................................116 Wire Color Abbreviation Chart...........................................................................116 Common Circuit Tests....................................................................................116 Conductors For 12 Volt Circuits.........................................................................117 Specifications..............................................................................................118 Electrical..............................................................................................118 System Schematics...........................................................................................119 Schematic and Wiring Harness Legend.....................................................................119 Component Location......................................................................................120 Main Electrical Schematic...............................................................................121 Main Electrical Schematic...............................................................................122 W1 Main Wiring Harness..................................................................................123 W1 Main Wiring Harness..................................................................................124 W1 Front Main Wire Harness Color Codes..................................................................125 W2 Rear Main Wire Harness Color Codes...................................................................125 W3 and W4 Jumper Wiring Harness.........................................................................125 W5 Headlight Wiring Harness.............................................................................126 W6 Engine Wiring Harness—14.542GS/1642HS................................................................126 W6 Engine Wiring Harness, Stator and N1 Voltage Regulator/Rectifier—17.542HS............................126 G2 Stator and N1 Voltage Regulator/Rectifier—14.542GS/1642HS............................................127 Y1 Fuel Shutoff Solenoid................................................................................127 N1 Voltage Regulator/Rectifier..........................................................................127 Diagnostics and.............................................................................................128 Power Circuit Operation.................................................................................128 Power Circuit Electrical Schematic......................................................................129 Power Circuit Diagnosis.................................................................................130 Cranking Circuit Operation..............................................................................132 Cranking Circuit Electrical Schematic...................................................................133 Cranking Circuit Diagnosis..............................................................................134 Ignition and Shutoff Circuit Operation..................................................................136 Ignition and Shutoff Circuit Electrical Schematic.......................................................137 Ignition and Shutoff Circuit Diagnosis..................................................................138 Charging Circuit Operation..............................................................................142 Charging Circuit Electrical Schematic...................................................................143 Charging Circuit Diagnosis..............................................................................144 PTO with RIO Circuit Operation..........................................................................146 PTO with RIO Circuit Schematic..........................................................................147 PTO with RIO Circuit Diagnosis..........................................................................148 Headlight Circuit Operation.............................................................................150 Headlight Circuit Electrical Schematic..................................................................151 Headlight Circuit Diagnosis.............................................................................152 Hour Meter/Service Light Circuit Operation..............................................................152 Hour Meter/Service Light Circuit Schematic..............................................................153 Hour Meter/Service Light Circuit Diagnosis..............................................................153 Tests and Adjustments.......................................................................................154 Ground Circuit Tests....................................................................................154 Battery Voltage and Specific Gravity Tests..............................................................154 Battery – Charge........................................................................................155 Battery – Load Test.....................................................................................156 Starting Solenoid Test..................................................................................156 Starting Motor Amperage Draw—Loaded.....................................................................156 Starting Motor Amperage Draw—No-Load....................................................................157 Flywheel Magnet Test....................................................................................158 Regulated Voltage Test..................................................................................158 Alternator Output Test..................................................................................158 Voltage Regulator/Rectifier Test—17.542HS...............................................................159 Regulated Amperage Test.................................................................................159 Relay Test..............................................................................................160 Key Switch Test.........................................................................................160 PTO/Brake Switch Test...................................................................................161 RIO Switch Test.........................................................................................161 RIS Switch Test.........................................................................................162 Seat Switch Test........................................................................................162 Diode Test—Ignition Coil................................................................................163 Spark Test..............................................................................................163 Fuel Shutoff Solenoid Test..............................................................................164 Armature Air Gap Adjustment.............................................................................164 Power Train - Gear..............................................................................................167 Table of Contents...........................................................................................167 Specifications..............................................................................................169 General Specifications..................................................................................169 Torque Specifications...................................................................................169 Component...................................................................................................170 Drive Components........................................................................................170 Forward and Reverse Drive and Linkage...................................................................171 Theory of Operation.........................................................................................173 Clutch Pedal And Belt Traction Drive Operation..........................................................173 Transaxle Operation.....................................................................................174 Brake System Operation..................................................................................174 Troubleshooting.............................................................................................175 Troubleshooting Table...................................................................................175 Diagnostics.................................................................................................179 Gear Transmission.......................................................................................179 Gear Transmission (continued)...........................................................................180 Tests and Adjustments.......................................................................................181 Shift Linkage Adjustment................................................................................181 Repair......................................................................................................182 Traction Drive Belt Removal and Installation............................................................182 Shift Linkage Removal and Installation..................................................................183 Transaxle Removal and Installation......................................................................184 Transaxle:Gear:Disassembly..............................................................................185 Transaxle:Gear:Assembly.................................................................................186 Power Train - Hydrostatic.......................................................................................187 Table of Contents...........................................................................................187 Specifications..............................................................................................189 Repair Specifications...................................................................................189 Torque Specifications...................................................................................189 Component...................................................................................................190 Transaxle Components....................................................................................190 Drive Components........................................................................................191 Forward/Reverse Pedals and Linkage......................................................................192 Theory of Operation.........................................................................................193 Power Train Systems.....................................................................................193 Traction Drive Belt System..............................................................................193 Transaxle...............................................................................................193 Forward and Reverse Pedals..............................................................................193 Freewheel System........................................................................................193 Brake System............................................................................................193 Diagnostics.................................................................................................194 Hydrostatic Transmission................................................................................194 Tests and Adjustments.......................................................................................195 Traction Drive System Test..............................................................................195 Neutral Creep Adjustment................................................................................195 Transport (Freewheel) Test..............................................................................196 Repair......................................................................................................196 Traction Drive Belt Removal and Installation............................................................196 Traction Drive Belt Tensioner Removal and Installation..................................................198 Transaxle Removal and Installation......................................................................200 Control Pedal Removal and Installation..................................................................202 Steering........................................................................................................205 Table of Contents...........................................................................................205 Specifications..............................................................................................207 General Specifications..................................................................................207 Torque Specifications...................................................................................207 Component Location..........................................................................................208 Steering System Components..............................................................................208 Repair......................................................................................................209 Steering Shaft and Pedestal Removal and Installation....................................................209 Steering Sector Gear Removal and Installation...........................................................211 Front Axle Removal and Installation.....................................................................212 Brakes..........................................................................................................215 Table of Contents...........................................................................................215 Specifications..............................................................................................217 General Specifications..................................................................................217 Torque Specifications...................................................................................217 Component...................................................................................................218 Brake System – Gear Transaxle...........................................................................218 Brake System – Hydro Transaxle..........................................................................219 Tests and Adjustments.......................................................................................220 Park Brake Test.........................................................................................220 Test Drive..............................................................................................220 Brake Adjustment - Gear;Transaxle:Gear:Brake Adjustment;Tests and Adjustments:Brakes:Brake Adjustmen....220 Brake Adjustment - Hydro;Transaxle:Hydro:Brake Adjustment;Tests and Adjustments:Brakes:Brake Adjustm....221 Repair......................................................................................................222 Brake Linkage Removal and Installation – Gear...........................................................222 Brake Linkage Removal and Installation – Hydro..........................................................222 Brake Pedal Assembly Removal and Installation – Gear....................................................222 Brake Pedal Assembly Removal and Installation – Hydro...................................................224 Brake Removal and Installation – Gear...................................................................226 Park Brake Lever and Linkage............................................................................227 Attachments.....................................................................................................229 Table of Contents...........................................................................................229 Specifications..............................................................................................231 Repair Specifications...................................................................................231 Component Location..........................................................................................232 Deck Lift Assembly......................................................................................232 42-Inch Mower Deck......................................................................................233 Diagnostics.................................................................................................234 Blades Will Not Rotate..................................................................................234 Drive Belt Slips........................................................................................234 Drive Belt Will Not Stay On Pulleys.....................................................................235 Vibration...............................................................................................235 Uneven Cutting Or Striping..............................................................................236 Tests and Adjustments.......................................................................................237 Mower Deck Level:Checking;Tests and Adjustments:Checking Mower Deck Leveling............................237 Adjusting Mower Level...................................................................................238 Blade Brake.............................................................................................239 Mower Drive Belt Tension Adjustment.....................................................................240 Adjusting Mower Deck Wheels.............................................................................240 Repair......................................................................................................241 Mower Deck:Blade Brake Removal and Installation;Brakes:Mower Deck Blade Brake...........................241 Mower Blade Removal and.................................................................................241 Balancing Blades........................................................................................242 Sharpening Blades.......................................................................................242 Mower Deck Removal and Installation.....................................................................243 Primary Drive Belt Removal and Installation.............................................................244 Mower Deck:Spindle Removal and Installation;Spindle Removal and Installation............................245 Mower Deck Lift Linkage Removal and Installation........................................................246 Miscellaneous...................................................................................................247 Table of Contents...........................................................................................247 Specifications..............................................................................................249 Repair Specifications...................................................................................249 Tests and Adjustments.......................................................................................250 Tire Pressure Adjustment................................................................................250 Repair......................................................................................................250 Front Wheel Removal and Installation....................................................................250 Front Wheel Bushing Removal;Bushing, Front Wheel (Removal)..............................................251 Rear Wheel Removal and Installation.....................................................................251 Hood Removal and Installation...........................................................................251 Seat and Support Removal and Installation...............................................................252 Fenderdeck Removal and Installation.....................................................................252 Fuel Tank Removal and Installation......................................................................254 Index...........................................................................................................255 A...........................................................................................................255 B...........................................................................................................255 C...........................................................................................................255 D...........................................................................................................255 E...........................................................................................................255 F...........................................................................................................256 G...........................................................................................................256 H...........................................................................................................256 I...........................................................................................................257 K...........................................................................................................257 L...........................................................................................................257 M...........................................................................................................257 N...........................................................................................................258 P...........................................................................................................258 R...........................................................................................................258 S...........................................................................................................258 T...........................................................................................................258 U...........................................................................................................259 W...........................................................................................................259
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
