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John Deere Sabre Yard & Graden Tractors Technical Manual TM1769 – PDF Download
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- John Deere Sabre Yard & Graden Tractors Technical Manual TM1769
- Models: 1438GS, 1438HS, 1438G, 1538HS, 1542HS, 1542G, 1542H, 15.538G, 15.538H, 15.542G, 15.542H, 1642G, 1642H, 1642HS, 1642HV, 1646H, 1646HS, 1646HV, 1742GS, 1742HS, 1846HV, 1846HMS, 2046HV
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Description
John Deere Sabre Yard & Graden Tractors Technical Manual TM1769
FILE DETAILS:
John Deere Sabre Yard & Graden Tractors Technical Manual TM1769
LANGUAGE:ENGLISH
PAGES:416
DOWNLOADABLE:YES
FILE TYPE:PDF
JOHN DEERE SABRE YARD & GRADEN TRACTORS TECHNICAL MANUAL TM1769 – PDF DOWNLOAD:
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DESCRIPTION:
John Deere Sabre Yard & Graden Tractors Technical Manual TM1769
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
• Component Location
• System Schematic
• Theory of Operation
• Troubleshooting Chart
• Diagnostics
• Tests & Adjustments
• Repair
Note: Depending on the particular section or system being covered, not all of the above groups may be used. Each section will be identified with a symbol rather than a number. The groups and pages within a section will be consecutively numbered. We appreciate your input on this manual. If you find any errors, or want to comment on the layout of the manual, please mail your comments back to us.
TABLE OF CONTENTS:
John Deere Sabre Yard & Graden Tractors Technical Manual TM1769
TM1841 - SABRE YARD & GARDEN TRACTORS.................................................... 1 Introduction......................................................................... 3 Section 1 - SAFETY................................................................... 4 Section 2 - SPECIFICATIONS AND INFORMATION........................................... 9 INCH TORQUE VALUES............................................................... 14 METRIC TORQUE VALUES............................................................. 15 GASOLINE SPECIFICATIONS.......................................................... 16 LUBRICANT SPECIFICATIONS......................................................... 16 SERIAL NUMBER LOCATIONS.......................................................... 18 Section 3 - KOHLER ENGINE............................................................ 19 SPECIFICATIONS................................................................... 21 GENERAL SPECIFICATIONS....................................................... 21 TEST & ADJUSTMENT SPECIFICATIONS............................................. 22 REPAIR SPECIFICATIONS........................................................ 22 TORQUE SPECIFICATIONS........................................................ 25 SPECIAL OR REQUIRED TOOLS.................................................... 26 THEORY OF OPERATION.............................................................. 27 GENERAL...................................................................... 27 COOLING SYSTEM............................................................... 27 CRANKCASE BREATHER SYSTEM.................................................... 27 LUBRICATION SYSTEM........................................................... 27 FUEL SYSTEM.................................................................. 27 CARBURETOR................................................................... 27 AIR INTAKE SYSTEM OPERATION.................................................. 27 GOVERNOR OPERATION........................................................... 27 IGNITION..................................................................... 28 ENGINE TROUBLESHOOTING CHART..................................................... 29 CARBURETOR TROUBLESHOOTING CHART............................................. 30 ENGINE TROUBLESHOOTING GUIDE..................................................... 31 ENGINE HARD TO START......................................................... 31 ENGINE MALFUNCTIONS AT LOW SPEED............................................. 32 ENGINE RUNS ERRATICALLY...................................................... 33 OIL CONSUMPTION IS EXCESSIVE................................................. 33 ENGINE HAS LOW POWER......................................................... 34 FUEL CONSUMPTION IS EXCESSIVE................................................ 34 IGNITION SYSTEM.............................................................. 34 TESTS AND ADJUSTMENTS............................................................ 35 GOVERNOR ADJUSTMENT.......................................................... 35 CHOKE ADJUSTMENT............................................................. 36 FAST IDLE SPEED ADJUSTMENT................................................... 37 SLOW IDLE SPEED ADJUSTMENT................................................... 38 CYLINDER COMPRESSION PRESSURE TEST........................................... 38 FUEL SHUTOFF SOLENOID TEST................................................... 40 CRANKCASE VACUUM TEST........................................................ 40 ENGINE OIL PRESSURE TEST..................................................... 42 FUEL PUMP TEST............................................................... 43 SPARK TEST................................................................... 43 SPARK PLUG GAP ADJUSTMENT.................................................... 44 IGNITION MODULE AIR GAP ADJUSTMENT........................................... 45 FLYWHEEL MAGNETS TESTS....................................................... 45 SPARK ADVANCE MODULE (SAM) TEST (25 HP)...................................... 46 REPAIR........................................................................... 47 ENGINE REMOVAL............................................................... 47 ENGINE INSTALLATION.......................................................... 48 AIR CLEANER REMOVAL AND INSTALLATION......................................... 49 FUEL PUMP, REMOVAL AND INSTALLATION.......................................... 50 CARBURETOR REMOVAL AND INSTALLATION.......................................... 50 ROCKER ARMS REMOVAL AND INSTALLATION......................................... 51 HYDRAULIC VALVE LIFTERS INSPECTION........................................... 52 STARTING MOTOR REMOVAL AND INSTALLATION (19/21/23 HP)........................ 53 STARTING MOTOR REMOVAL AND INSTALLATION (25 HP).............................. 53 CYLINDER HEAD REMOVAL AND INSTALLATION....................................... 54 VALVES AND SPRINGS REMOVAL AND INSTALLATION.................................. 56 VALVE SPRING INSPECTION...................................................... 57 VALVE INSPECTION............................................................. 57 VALVE GUIDES INSPECTION...................................................... 58 CYLINDER HEAD INSPECTION..................................................... 58 RECONDITION VALVE SEATS...................................................... 58 LAP VALVES................................................................... 59 PUSH ROD INSPECTION.......................................................... 59 CRANKCASE REED VALVE INSPECTION.............................................. 59 FLYWHEEL REMOVAL AND INSTALLATION............................................ 60 STATOR REMOVAL AND INSTALLATION.............................................. 60 CAMSHAFT REMOVAL AND INSTALLATION............................................ 61 CAMSHAFT INSPECTION.......................................................... 62 CAMSHAFT END PLAY............................................................ 62 GOVERNOR REMOVAL AND INSTALLATION............................................ 63 GOVERNOR CONTROL SHAFT REMOVAL AND INSTALLATION.............................. 63 PISTON REMOVAL............................................................... 64 PISTON DISASSEMBLE........................................................... 64 PISTON PIN INSPECTION........................................................ 65 PISTON INSPECTION............................................................ 65 PISTON RING END GAP.......................................................... 65 PISTON RING SIDE CLEARANCE................................................... 65 PISTON TO BORE MEASUREMENT................................................... 66 CRANKSHAFT MEASUREMENT....................................................... 67 PISTON ASSEMBLY.............................................................. 68 PISTON INSTALLATION.......................................................... 69 OIL PAN REMOVAL AND INSTALLATION............................................. 69 OIL PAN CRANKSHAFT SEAL REMOVAL AND INSTALLATION............................. 70 CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION................................. 70 OIL PRESSURE SWITCH, REPLACE................................................. 71 OIL PUMP REMOVAL AND INSTALLATION............................................ 71 BLOCK INSPECTION............................................................. 72 CYLINDER BORE DEGLAZE........................................................ 72 CONDUCTORS FOR 12 VOLT CIRCUITS.............................................. 77 Section 4 - ELECTRICAL............................................................... 73 THEORY OF OPERATION INFORMATION.................................................. 75 DIAGNOSTIC INFORMATION....................................................... 75 WIRE COLOR ABBREVIATION CHART................................................ 75 READING ELECTRICAL SCHEMATICS................................................ 76 COMMON CIRCUIT TESTS......................................................... 77 SPECIFICATIONS................................................................... 78 COMPONENT LOCATION............................................................... 79 ELECTRICAL SCHEMATIC AND WIRING HARNESS LEGEND............................... 80 ELECTRICAL SECTION WIRING HARNESS LEGEND..................................... 80 STANDARD ELECTRICAL SCHEMATIC................................................ 81 W1 MAIN WIRING HARNESS....................................................... 84 W2 HEADLIGHT WIRING HARNESS.................................................. 87 W3 ENGINE WIRING HARNESS..................................................... 87 W4 ENGINE WIRING HARNESS..................................................... 87 W5 (CV19/CV21/CV23) ENGINE WIRING HARNESS.................................... 87 W6 ENGINE WIRING HARNESS..................................................... 87 W7 (CV25) ENGINE WIRING HARNESS.............................................. 88 W8 (CV25) ENGINE WIRING HARNESS.............................................. 88 TROUBLESHOOTING.................................................................. 89 THEORY AND DIAGNOSIS............................................................. 90 POWER CIRCUIT OPERATION...................................................... 90 POWER CIRCUIT SCHEMATIC...................................................... 91 POWER CIRCUIT DIAGNOSIS...................................................... 92 CRANKING CIRCUIT OPERATION................................................... 96 CRANKING CIRCUIT SCHEMATIC................................................... 97 CRANKING CIRCUIT DIAGNOSIS................................................... 98 IGNITION CIRCUIT OPERATION...................................................100 IGNITION CIRCUIT SCHEMATIC...................................................101 IGNITION CIRCUIT DIAGNOSIS...................................................102 ENGINE SHUTOFF CIRCUIT OPERATION.............................................104 ENGINE SHUTOFF CIRCUIT SCHEMATIC.............................................105 ENGINE SHUTOFF CIRCUIT DIAGNOSIS.............................................106 CHARGING CIRCUIT OPERATION...................................................108 CHARGING CIRCUIT SCHEMATIC...................................................109 CHARGING CIRCUIT DIAGNOSIS...................................................110 PTO CIRCUIT OPERATION........................................................112 PTO CIRCUIT SCHEMATIC........................................................113 PTO CIRCUIT DIAGNOSIS........................................................114 REVERSE IMPLEMENT OPTION (RIO) CIRCUIT OPERATION.............................116 REVERSE IMPLEMENT OPTION (RIO) CIRCUIT SCHEMATIC.............................117 REVERSE IMPLEMENT OPTION (RIO) CIRCUIT DIAGNOSIS.............................118 REVERSE IMPLEMENT OPTION (RIO) CIRCUIT DIAGNOSIS.............................120 HEADLIGHT CIRCUIT OPERATION..................................................122 HEADLIGHT CIRCUIT SCHEMATIC..................................................123 W2 HEADLIGHT WIRING HARNESS..................................................123 HEADLIGHT CIRCUIT DIAGNOSIS..................................................124 TESTS AND ADJUSTMENTS............................................................126 GROUND CIRCUIT TESTS.........................................................126 BATTERY TEST.................................................................127 CHARGE BATTERY...............................................................127 BATTERY LOAD TEST............................................................128 STARTING SOLENOID TEST (CV19/ CV21/CV23).....................................129 STARTING MOTOR SOLENOID TEST (CV25)..........................................129 STARTING MOTOR LOADED AMPERAGE DRAW TEST.....................................130 STARTING MOTOR NO-LOAD AMPERAGE & RPM TESTS (CV19/ CV21/CV23 ENGINES)........131 STARTING MOTOR NO-LOAD AMPERAGE & RPM TESTS (CV25 ENGINE)....................132 SPARK TEST...................................................................134 LIGHT SWITCH TEST............................................................134 KEY SWITCH TEST..............................................................135 PTO/RIP SWITCH TEST..........................................................135 RELAY TEST...................................................................136 BRAKE or REVERSE IMPLEMENT OPTION SWITCH TEST................................136 OIL PRESSURE SWITCH TEST (CV23/CV25).........................................137 SEAT SWITCH TEST.............................................................138 FLYWHEEL MAGNET TEST.........................................................138 STATOR OUTPUT TEST...........................................................139 VOLTAGE REGULATOR/RECTIFIER TEST.............................................139 ARMATURE WITH COIL (CV19/CV21/ CV23).........................................140 AIR GAP ADJUSTMENT (CV19/ CV212/CV23)........................................140 ARMATURE TEST (CV19/CV21/ CV23)..............................................140 ARMATURE WITH COIL (CV25)....................................................141 AIR GAP ADJUSTMENT (CV25)....................................................141 ARMATURE TEST (CV25).........................................................141 REPAIR...........................................................................142 STARTING MOTOR REMOVAL & INSTALLATION (CV19/CV21/CV23).......................142 STARTING MOTOR DRIVE REPLACEMENT (CV19/CV21/CV23)............................143 BRUSH REPLACEMENT & ARMATURE TEST (CV19/CV21/ CV23)..........................143 STARTING MOTOR REMOVAL & INSTALLATION (CV25).................................145 STARTING MOTOR DISASSEMBLY & ASSEMBLY (CV25).................................146 Section 5 - POWER TRAIN—GEAR.........................................................149 SPECIFICATIONS...................................................................151 ADJUSTMENT SPECIFICATIONS....................................................151 REPAIR SPECIFICATIONS........................................................151 TORQUE SPECIFICATIONS........................................................151 OTHER MATERIALS..............................................................151 THEORY OF OPERATION..............................................................152 BELT DRIVE SYSTEM OPERATION..................................................152 TRANSAXLE OPERATION..........................................................153 MANUAL SHIFT LINKAGE COMPONENT LOCATION......................................155 CLUTCH PEDAL LINKAGE COMPONENT LOCATION......................................156 TROUBLESHOOTING CHART............................................................157 DIAGNOSIS........................................................................158 MACHINE WILL NOT MOVE IN FORWARD OR REVERSE..................................158 MACHINE WILL NOT MOVE IN FORWARD OR REVERSE..................................160 MACHINE MOVES IN ONE DIRECTION ONLY, OR DOESN’T MOVE IN ONE OR MORE GEARS....162 LOSES POWER UNDER LOAD, BELT SLIPS, ERRATIC DRIVE............................164 LOSES POWER UNDER LOAD, BELT SLIPS, ERRATIC DRIVE............................166 JERKY AND AGGRESSIVE ENGAGEMENT..............................................168 SHIFTS HARD..................................................................170 NOISY OPERATION..............................................................172 NOISY OPERATION, continued...................................................174 ADJUSTMENTS......................................................................176 GEARSHIFT LEVER NEUTRAL ADJUSTMENT...........................................176 TRACTION DRIVE BELT TENSION ADJUSTMENT.......................................176 REPAIR...........................................................................177 TRANSAXLE REMOVAL AND INSTALLATION...........................................177 TRANSAXLE DISASSEMBLY AND INSPECTION.........................................178 TRANSAXLE ASSEMBLY...........................................................183 DIFFERENTIAL REMOVAL, DISASSEMBLY AND INSTALLATION...........................187 TRACTION DRIVE CLUTCH ASSEMBLY REMOVAL AND INSTALLATION......................189 TRACTION DRIVE BELT REMOVAL AND INSTALLATION.................................190 Section 6 - POWER TRAIN—HYDROSTATIC..................................................191 SPECIFICATIONS...................................................................193 TRANSAXLES...................................................................193 ADJUSTMENT SPECIFICATIONS....................................................193 REPAIR SPECIFICATIONS........................................................193 TORQUE SPECIFICATIONS........................................................193 OTHER MATERIALS..............................................................194 COMPONENT LOCATION...............................................................195 THEORY OF OPERATION..............................................................202 DRIVE SYSTEM OPERATION.......................................................202 HYDROSTATIC SYSTEM OPERATION.................................................204 GEAR POWER FLOW..............................................................206 TRANSAXLE BRAKE..............................................................207 TROUBLESHOOTING..................................................................208 DIAGNOSIS........................................................................210 TRACTOR WILL NOT MOVE FORWARD OR REVERSE.....................................210 NOISY OPERATION..............................................................214 TRACTOR CREEPS...............................................................216 TRACTOR MOVES IN ONE DIRECTION ONLY..........................................218 ERRATIC SPEED................................................................220 TRACTOR DOES NOT ACHIEVE FULL GROUND SPEED...................................222 PARK BRAKE DOES NOT HOLD TRACTOR ON HILL.....................................226 TRACTOR IS TOO AGGRESSIVE IN FORWARD OR REVERSE..............................228 FREEWHEEL VALVE WILL NOT WORK................................................229 ADJUSTMENTS......................................................................230 HYDROSTATIC TRANSAXLE BLEEDING PROCEDURE.....................................230 NEUTRAL CREEP ADJUSTMENT.....................................................230 PEDAL HEIGHT ADJUSTMENT......................................................231 BRAKE LINKAGE ADJUSTMENT.....................................................232 TRACTION DRIVE BELT TENSION ADJUSTMENT.......................................232 REPAIR...........................................................................234 TRANSAXLE REMOVAL AND INSTALLATION...........................................234 TRANSAXLE DISASSEMBLY........................................................240 TRANSAXLE ASSEMBLY...........................................................249 TRACTION DRIVE BELT REMOVAL AND INSTALLATION.................................258 DRIVE BELT TENSIONER ASSEMBLY................................................259 Section 7 - STEERING.................................................................261 SPECIFICATIONS...................................................................263 THEORY OF OPERATION..............................................................264 STEERING SYSTEM..............................................................264 TROUBLESHOOTING..................................................................265 STEERING SYSTEM TROUBLESHOOTING CHART........................................265 STEERING SYSTEM DIAGNOSIS....................................................266 DRAG LINK ADJUSTMENT.........................................................267 REPAIR...........................................................................267 STEERING WHEEL REMOVAL AND INSTALLATION......................................267 STEERING SHAFT...............................................................267 STEERING SECTOR REMOVAL & INSTALLATION.......................................269 LEFT TURN STOP MODIFICATION..................................................270 Section 8 - BRAKES...................................................................271 SPECIFICATIONS...................................................................273 ADJUSTMENT SPECIFICATIONS....................................................273 REPAIR SPECIFICATIONS........................................................273 OTHER MATERIALS..............................................................273 COMPONENT LOCATION AND OPERATION.................................................274 BRAKE SYSTEM OPERATION—GEAR TRANSAXLE........................................274 BRAKE SYSTEM OPERATION—HYDROSTATIC TRANSAXLE.................................275 HYDROSTATIC INTERNAL BRAKE LINKAGE OPERATION.................................276 TROUBLESHOOTING..................................................................277 DIAGNOSIS........................................................................278 BRAKES DO NOT ENGAGE WHEN PEDAL DEPRESSED....................................278 PARK BRAKE DOES NOT HOLD MACHINE ON HILL.....................................278 NOISY OPERATION..............................................................279 MACHINE WILL NOT MOVE, OR IS SLOW IN FORWARD.................................279 MACHINE WILL NOT MOVE, OR IS SLOW REVERSE....................................280 BRAKE SWITCH DOES NOT ENGAGE WHEN BRAKE PEDAL IS DEPRESSED...................280 ADJUSTMENTS......................................................................281 BRAKE ADJUSTMENT— HYDROSTATIC TRANSAXLE......................................281 BRAKE ADJUSTMENT—GEAR TRANSAXLE..............................................281 REPAIR...........................................................................282 BRAKE LINKAGE................................................................282 BRAKE PEDAL ASSEMBLY.........................................................282 BRAKE REMOVAL AND INSTALLATION—HYDROSTATIC...................................283 BRAKE REMOVAL AND INSTALLATION—GEAR TRANSAXLE................................284 PARK BRAKE LEVER AND LINKAGE...............................................285 IDLERS AND SHEAVES 48/54 INCH................................................293 GAUGE WHEELS COMPONENT LOCATION..............................................292 Section 9 - ATTACHMENTS..............................................................287 SPECIFICATIONS...................................................................289 ADJUSTMENT SPECIFICATIONS....................................................289 REPAIR SPECIFICATIONS........................................................289 SPECIAL OR ESSENTIAL TOOLS...................................................289 SERVICE PARTS KITS...........................................................289 COMPONENT LOCATION...............................................................290 MOWER DECK COMPONENTS 48/54 INCH.............................................290 DRAFT ARMS COMPONENT LOCATION................................................291 TROUBLESHOOTING..................................................................294 MOWER DECK TROUBLESHOOTING CHART.............................................294 DIAGNOSIS........................................................................295 MOWER DRIVE CHECKS...........................................................295 MOWER DECK WILL NOT RUN......................................................297 MOWER DECK VIBRATES..........................................................298 CUTS UNEVENLY................................................................299 ADJUSTMENTS......................................................................300 MOWER LEVEL SIDE-TO-SIDE.....................................................300 MOWER LEVEL FRONT-TO-REAR....................................................301 MOWER GAGE WHEELS ADJUST.....................................................302 REPAIR...........................................................................302 MOWER BLADES REMOVAL AND INSTALLATION........................................302 SHARPEN MOWER BLADES.........................................................303 BALANCING MOWER BLADES.......................................................303 MOWER DECK REMOVAL AND INSTALLATION..........................................304 SPINDLES 48/54 INCH REMOVAL AND INSTALLATION.................................305 SPINDLES 48/54 INCH DISASSEMBLY AND INSPECTION...............................305 Section 10 - MISCELLANEOUS...........................................................309 SPECIFICATIONS...................................................................311 OTHER MATERIALS..............................................................311 COMPONENT LOCATION...............................................................312 FRONT AXLE AND TIRES COMPONENT LOCATION......................................312 REPAIR...........................................................................314 FRONT AXLE REMOVAL AND INSTALLATION..........................................314 FRONT WHEEL REMOVAL AND INSTALLATION.........................................316 FRONT WHEEL BUSHING REMOVAL..................................................316 HOOD REMOVAL AND INSTALLATION................................................317 SEAT AND SUPPORT REMOVAL AND INSTALLATION....................................317 FENDER DECK REMOVAL AND INSTALLATION.........................................317 MOWER DECK LIFT LINKAGE......................................................318 HEIGHT ADJUSTER..............................................................318 LIFT ASSIST AND DEPTH STOP OPERATION.........................................313 INDEX................................................................................319
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