John Deere Sabre 1338, 1538, 15538, 1546, 1638, 1646 Lawn Mower Service Repair Manual
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John Deere Sabre 1338, 1538, 15538, 1546, 1638, 1646 Lawn Mower Service Repair Manual
LANGUAGE:ENGLISH
PAGES:191
DOWNLOADABLE:YES
FILE TYPE:PDF
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DESCRIPTION:
John Deere Sabre 1338, 1538, 15538, 1546, 1638, 1646 Lawn Mower Service Repair Manual
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
TABLE OF CONTENTS:
John Deere Sabre 1338, 1538, 15538, 1546, 1638, 1646 Lawn Mower Service Repair Manual
TMGX10131 - Sabre Lawn Tractors.................................................................................... 1 INTRODUCTION................................................................................................... 2 Section 1 - SAFETY............................................................................................. 3 Section 2 - SPECIFICATIONS & INFORMATION....................................................................... 8 CONTENTS................................................................................................... 8 SPECIFICATIONS............................................................................................. 9 UNIFIED INCH TORQUE VALUES................................................................................. 13 METRIC TORQUE VALUES....................................................................................... 14 GASOLINE SPECIFICATIONS.................................................................................... 15 LUBRICANT SPECIFICATIONS................................................................................... 16 SERIAL NUMBER LOCATIONS.................................................................................... 17 Section 3 - ENGINE............................................................................................. 18 CONTENTS................................................................................................... 18 SPECIFICATIONS......................................................................................... 20 REPAIR................................................................................................. 21 ENGINE REMOVAL......................................................................................... 21 ENGINE INSTALLATION.................................................................................... 22 Section 4 - ELECTRICAL......................................................................................... 24 CONTENTS................................................................................................... 24 SPECIFICATIONS............................................................................................. 26 THEORY OF OPERATION........................................................................................ 27 ELECTRICAL SCHEMATIC....................................................................................... 28 WIRE HARNESS............................................................................................... 29 COMPONENT LOCATION......................................................................................... 30 TROUBLESHOOTING............................................................................................ 31 DIAGNOSTICS................................................................................................ 32 CRANKING & FUEL SHUTOFF SOLENOID CIRCUIT OPERATION..................................................... 32 IGNITION & SEAT SWITCH CIRCUIT OPERATION............................................................... 35 IGNITION CIRCUIT TEST POINTS........................................................................... 37 CHARGING & HEADLIGHT CIRCUIT OPERATION................................................................. 39 TESTS AND ADJUSTMENTS...................................................................................... 43 BATTERY TEST........................................................................................... 43 CHARGE BATTERY......................................................................................... 43 BATTERY LOAD TEST...................................................................................... 44 DC AMPERAGE OUTPUT TEST................................................................................ 44 AC VOLTAGE OUTPUT TEST................................................................................. 45 STARTER SOLENOID TEST.................................................................................. 45 STARTER AMP DRAW TEST.................................................................................. 46 SEAT SWITCH TEST....................................................................................... 46 BRAKE SWITCH / BLADE DRIVE SWITCH TEST................................................................. 47 BRAKE SWITCH ADJUSTMENT................................................................................ 47 IGNITION SWITCH TEST................................................................................... 48 GROUND CIRCUIT TESTS................................................................................... 49 REPAIR..................................................................................................... 50 IGNITION SWITCH REMOVAL & INSTALLATION................................................................. 50 SEAT SWITCH REMOVAL & INSTALLATION..................................................................... 50 STARTER SOLENOID REMOVAL & INSTALLATION................................................................ 51 Section 5 - GEAR POWER TRAIN................................................................................... 52 CONTENTS................................................................................................... 52 SPECIFICATIONS............................................................................................. 54 TROUBLESHOOTING............................................................................................ 56 COMPONENT LOCATION......................................................................................... 57 TRANSAXLE COMPONENT LOCATION............................................................................... 58 TRACTION DRIVE SYSTEM COMPONENT LOCATION................................................................... 59 THEORY OF OPERATION........................................................................................ 61 TRACTION DRIVE SYSTEM OPERATION........................................................................ 61 TRANSAXLE OPERATION.................................................................................... 62 BRAKE SYSTEM OPERATION................................................................................. 63 DIAGNOSIS.................................................................................................. 64 TESTS AND ADJUSTMENTS...................................................................................... 66 CLUTCH/BRAKE LINKAGE & TRACTION DRIVE ADJUSTMENT....................................................... 66 SHIFT LINKAGE ADJUSTMENT............................................................................... 68 REPAIR..................................................................................................... 69 TRACTION DRIVE BELT REMOVAL............................................................................ 69 TRACTION DRIVE BELT INSPECTION......................................................................... 70 TRACTION DRIVE BELT INSTALLATION....................................................................... 71 B TRACTION DRIVE SYSTEM REMOVAL........................................................................ 71 SHIFT LINKAGE REMOVAL & INSTALLATION................................................................... 73 TRANSAXLE REMOVAL & INSTALLATION 7. Support transaxle with jack stands or have a helper................ 74 TRANSAXLE DISASSEMBLY.................................................................................. 74 INTERMEDIATE SHAFT & DRIVE SHAFT REPAIR................................................................ 80 TRANSAXLE ASSEMBLY..................................................................................... 81 Section 6 - HYDROSTATIC POWER TRAIN............................................................................ 86 CONTENTS................................................................................................... 86 SPECIFICATIONS............................................................................................. 88 COMPONENT LOCATION......................................................................................... 91 TRACTION DRIVE SYSTEM COMPONENT LOCATION................................................................... 95 PEDAL LINKAGE ASSEMBLY COMPONENT LOCATION.................................................................. 96 SHIFT LINKAGE COMPONENT LOCATION—K–55 TRANSAXLE............................................................ 97 SHIFT LINKAGE COMPONENT LOCATION—K–51 TRANSAXLE............................................................ 98 THEORY OF OPERATION........................................................................................ 99 TRACTION DRIVE BELT SYSTEM OPERATION................................................................... 99 TRANSAXLE AND SHIFT LINKAGE SYSTEM OPERATION .......................................................... 99 B BRAKE/NEUTRAL RETURN PEDAL COMPONENT LOCATION & OPERATION............................................101 TRANSPORT (FREE-WHEEL) SYSTEM OPERATION—K55............................................................104 TRANSPORT (FREE-WHEEL) SYSTEM OPERATION—K51............................................................105 TROUBLESHOOTING............................................................................................106 DIAGNOSIS..................................................................................................109 DIAGNOSIS—K55..............................................................................................111 DIAGNOSIS —K51.............................................................................................113 TESTS AND ADJUSTMENTS......................................................................................115 TRACTION DRIVE SYSTEM..................................................................................115 DRIVE BELT ADJUSTMENT..................................................................................116 TRANSPORT (FREE-WHEEL) VALVE ADJUSTMENT—K55............................................................116 SHIFT LINKAGE ADJUSTMENT check for creep in transaxle (axles turning while.............................117 E D BELLCRANK SPRING TENSION ADJUSTMENT................................................................117 BRAKE SPRING ADJUSTMENT— K55...........................................................................118 BRAKE SPRING ADJUSTMENT— K51...........................................................................119 REPAIR.....................................................................................................121 TRACTION DRIVE BELT REMOVAL—K55 Link Arm...............................................................121 TRACTION DRIVE BELT REMOVAL—K51........................................................................122 TRACTION DRIVE BELT INSPECTION.........................................................................122 TRACTION DRIVE BELT INSTALLATION – K55.................................................................123 TRACTION DRIVE BELT INSTALLATION—K51 ..................................................................123 TRACTION DRIVE BELT TENSIONING SYSTEM REMOVAL/ INSPECTION/INSTALLATION—K55 REMOVAL/INSTALLATION—K55....124 POWER TRAIN LINKAGE SYSTEM REMOVAL/INSTALLATION—K55....................................................125 TRANSAXLE REMOVAL AND INSTALLATION—K55.................................................................126 TRANSAXLE DISASSEMBLY—K55..............................................................................127 TRANSAXLE ASSEMBLY—K55.................................................................................135 TRANSAXLE INSTALLATION—K55.............................................................................140 TRANSAXLE BLEED PROCEDURE—K55..........................................................................140 TRACTION DRIVE BELT TENSIONING SYSTEM REMOVAL/INSPECTION/INSTALLATION—K51..............................141 POWER TRAIN LINKAGE SYSTEM REMOVAL/INSTALLATION—K51....................................................142 TRANSAXLE REMOVAL AND INSTALLATION—K51.................................................................143 TRANSAXLE EXTERNAL COMPONENTS REMOVAL—K51..............................................................144 TRANSAXLE INSTALLATION—K51.............................................................................145 Section 7 - STEERING...........................................................................................146 CONTENTS...................................................................................................146 COMPONENT LOCATION.........................................................................................148 SERVICE EQUIPMENT AND TOOLS................................................................................149 REPAIR.....................................................................................................149 STEERING GEAR REMOVAL..................................................................................149 REPLACE PEDESTAL BUSHINGS..............................................................................150 ADJUST STEERING BACKLASH...............................................................................150 Section 9 - ATTACHMENTS........................................................................................152 MISCELLANEOUS..............................................................................................168 CONTENTS...................................................................................................168 COMPONENT LOCATION.........................................................................................170 REPAIR.....................................................................................................171 FRONT WHEELS REMOVAL & INSTALLATION....................................................................171 REAR WHEELS REMOVAL & INSTALLATION.....................................................................171 FRONT WHEEL BEARING REPAIR.............................................................................171 FRONT AXLE REMOVAL.....................................................................................172 FRONT AXLE INSTALLATION................................................................................172 FRONT AXLE REPAIR......................................................................................172 FUEL TANK AND DASH PANEL REMOVE AND INSTALL............................................................172 CONTENTS...................................................................................................152 COMPONENT LOCATION.........................................................................................154 38 INCH DECK (– 1996)..................................................................................155 38 INCH DECK (1997 –)..................................................................................156 46 INCH DECK (– 1996)..................................................................................157 46 INCH DECK (1997 –)..................................................................................159 TESTS AND ADJUSTMENTS......................................................................................160 SPINDLE BRAKE ADJUSTMENT...............................................................................160 MOWER BELT TENSION ADJUSTMENT..........................................................................160 DECK LEVELING (SIDE-TO-SIDE)...........................................................................161 DECK LEVELING (FRONT-TO-REAR)..........................................................................162 READJUSTING SUSPENSION TO OBTAIN 1– 4 INCH CUT HEIGHT..................................................163 REPAIR.....................................................................................................163 MOWER DECK REMOVAL.....................................................................................163 REPLACING MOWER DECK BELT..............................................................................164 MOWER DECK INSTALLATION................................................................................165 MOWER SPINDLE ASSEMBLY.................................................................................166 GAGE WHEEL ADJUSTMENT..................................................................................167 Section 10 - Service Information Bulletins.....................................................................176 CONTENTS...................................................................................................176 INDEX..........................................................................................................188 A..........................................................................................................188 B..........................................................................................................188 C..........................................................................................................188 D..........................................................................................................188 E..........................................................................................................188 F..........................................................................................................188 G..........................................................................................................188 H..........................................................................................................189 I..........................................................................................................190 L..........................................................................................................190 M..........................................................................................................191 O..........................................................................................................191 Q..........................................................................................................191 R..........................................................................................................191 S..........................................................................................................191 T..........................................................................................................191 W..........................................................................................................191
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