John Deere Sabre Lawn Tractor Technical Manual (TM-GX10238 )
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John Deere Sabre Lawn Tractor Technical Manual (TM-GX10238 )
LANGUAGE:ENGLISH
PAGES:161
DOWNLOADABLE:YES
FILE TYPE:PDF
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DESCRIPTION:
John Deere Sabre Lawn Tractor Technical Manual (TM-GX10238 )
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
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 Lawn Tractor Technical Manual (TM-GX10238 )
TM-GX10283 -- SABRE LAWN TRACTOR TECHNICAL MANUAL..................................... 1 Section 1 - INTRODUCTION.......................................................... 2 SAFETY........................................................................ 3 HANDLE FLUIDS SAFELY-AVOID FIRES.......................................... 3 HANDLE CHEMICAL PRODUCTS SAFELY........................................... 3 USE CARE IN HANDLING AND SERVICING BATTERIES.............................. 4 USE SAFE SERVICE PROCEDURES............................................... 4 REPLACE DECALS............................................................ 6 LIVE WITH SAFETY.......................................................... 6 Section 2 - SPECIFICATIONS & INFORMATION.......................................... 8 SPECIFICATIONS................................................................ 9 UNIFIED INCH TORQUE VALUES.................................................... 13 METRIC TORQUE VALUES.......................................................... 14 GASOLINE SPECIFICATIONS....................................................... 15 GASOLINE STORAGE.............................................................. 15 LUBRICANT SPECIFICATIONS...................................................... 15 ENGINE OIL.................................................................... 15 GREASE........................................................................ 16 ALTERNATIVE LUBRICANTS........................................................ 16 SYNTHETIC LUBRICANTS.......................................................... 16 OIL FILTERS................................................................... 16 LUBRICANT STORAGE............................................................. 16 SERIAL NUMBER LOCATIONS....................................................... 17 TRACTOR IDENTIFICATION NUMBER................................................. 17 ENGINE SERIAL NUMBER.......................................................... 17 GEAR TRANSAXLE SERIAL NUMBER.................................................. 17 HYDROSTATIC TRANSMISSION SERIAL NUMBER........................................ 17 Section 3 - ENGINE................................................................ 18 SPECIFICATIONS................................................................ 26 SERVICE EQUIPMENT AND TOOLS................................................... 20 OTHER MATERIALS............................................................... 20 REPAIR........................................................................ 21 ENGINE REMOVAL............................................................ 21 ENGINE INSTALLATION....................................................... 22 Section 4 - ELECTRICAL............................................................ 24 READING SCHEMATICS............................................................ 27 WIRE COLOR ABBREVIATION CHART................................................. 27 ELECTRICAL SCHEMATIC.......................................................... 28 WIRE HARNESS.................................................................. 29 COMPONENT LOCATION............................................................ 30 TROUBLESHOOTING............................................................... 31 DIAGNOSTICS................................................................... 32 CRANKING & FUEL SHUT-OFF SOLENOID CIRCUIT OPERATION....................... 32 CRANKING & FUEL SHUT-OFF SOLENOID CIRCUIT DIAGNOSIS....................... 33 IGNITION & SEAT SWITCH CIRCUIT OPERATION.................................. 35 IGNITION CIRCUIT TEST POINTS.............................................. 37 CHARGING & HEADLIGHT CIRCUIT OPERATION.................................... 39 CHARGING CIRCUIT DIAGNOSIS................................................ 40 HEADLIGHTS CIRCUIT DIAGNOSIS.............................................. 41 TESTS AND ADJUSTMENTS......................................................... 43 BATTERY TEST.............................................................. 43 CHARGE BATTERY............................................................ 43 STARTER SOLENOID TEST..................................................... 45 STARTER AMP DRAW 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 TRANSAXLE COMPONENT LOCATION.................................................. 58 TRACTION DRIVE SYSTEM COMPONENT LOCATION...................................... 59 THEORY OF OPERATION........................................................... 61 TRACTION DRIVE SYSTEM OPERATION............................................... 61 BRAKE SYSTEM OPERATION........................................................ 63 TRACTION BELT DRIVE TEST...................................................... 66 BRAKE TEST.................................................................... 66 BRAKE ADJUSTMENT.............................................................. 67 CLUTCH ACTUATING SPRING ADJUSTMENT............................................ 67 REPEAT TEST DRIVE............................................................. 68 TRACTION DRIVE BELT INSTALLATION.............................................. 71 TRACTION DRIVE SYSTEM REMOVAL................................................. 71 SHIFT LINKAGE REMOVAL & INSTALLATION.......................................... 73 TRANSAXLE REMOVAL & INSTALLATION.............................................. 74 TRANSAXLE DISASSEMBLY......................................................... 74 Input Shaft/Pinion Gear Disassembly:...................................... 76 Assemble Input Shaft/Pinion Gear Assembly:................................ 77 Shifter Disassembly:...................................................... 78 Idler Gear Disassembly:................................................... 79 INTERMEDIATE SHAFT & DRIVE SHAFT REPAIR....................................... 80 TRANSAXLE ASSEMBLY............................................................ 81 Differential/Axle Shaft Assembly:......................................... 81 Assemble Drive/Intermediate Shaft Assemblies:............................. 82 Assemble Idler Combination Gear Assembly:................................. 83 Assemble Transaxle Housing Case Halves:................................... 83 Intermediate & Drive Shaft Inspection:.................................... 80 Intermediate & Drive Shaft Disassembly:................................... 80 Differential/Axle Shaft Inspection:....................................... 81 Differential/Axle Shafts Disassembly:................................. 81 Section 6 - HYDROSTATIC POWER TRAIN............................................... 86 SPECIFICATIONS................................................................ 88 REPAIR SPECIFICATIONS......................................................... 89 TORQUE SPECIFICATIONS......................................................... 89 OTHER MATERIALS............................................................... 90 COMPONENT LOCATION............................................................130 COMPONENT LOCATION—EXTERNAL............................................... 91 COMPONENT LOCATION—EXTERNAL............................................... 92 TRACTION DRIVE SYSTEM COMPONENT LOCATION.................................. 93 SHIFT LINKAGE COMPONENT LOCATION.......................................... 94 THEORY OF OPERATION........................................................... 95 TRACTION DRIVE BELT SYSTEM OPERATION...................................... 95 TRANSAXLE AND SHIFT LINKAGE SYSTEM OPERATION.............................. 95 BRAKE/NEUTRAL RETURN PEDAL COMPONENT LOCATION & OPERATION................. 97 TRANSPORT (FREE-WHEEL) SYSTEM OPERATION................................... 98 TROUBLESHOOTING...............................................................100 DIAGNOSIS.....................................................................103 TESTS AND ADJUSTMENTS.........................................................107 TRACTION DRIVE SYSTEM.....................................................107 DRIVE BELT ADJUSTMENT.....................................................107 SHIFT LINKAGE ADJUSTMENT..................................................108 BELLCRANK SPRING TENSION ADJUSTMENT.......................................109 BRAKE SPRING ADJUSTMENT...................................................109 REPAIR........................................................................111 TRACTION DRIVE BELT REMOVAL...............................................111 TRACTION DRIVE BELT INSPECTION............................................111 TRACTION DRIVE BELT INSTALLATION..........................................111 TRACTION DRIVE BELT TENSIONING SYSTEM REMOVAL/ INSPECTION/INSTALLATION....112 POWER TRAIN LINKAGE SYSTEM REMOVAL/INSTALLATION...........................113 TRANSAXLE REMOVAL AND INSTALLATION........................................115 TRANSAXLE EXTERNAL COMPONENTS REMOVAL.....................................116 TRANSAXLE INSTALLATION....................................................117 TRANSAXLE DISASSEMBLY.....................................................118 TRANSAXLE ASSEMBLY........................................................125 Section 7 - STEERING..............................................................128 COMPONENT LOCATION............................................................130 STEERING..................................................................130 SERVICE EQUIPMENT AND TOOLS...................................................131 REPAIR........................................................................131 STEERING GEAR REMOVAL.........................................................131 REPLACE PEDESTAL BUSHINGS.....................................................132 ADJUST STEERING BACKLASH......................................................132 Section 8 - ATTACHMENTS...........................................................134 COMPONENT LOCATION -- ATTACHMENTS.............................................136 LIFT LINKAGE..............................................................136 38 INCH DECK..............................................................137 42 INCH DECK..............................................................138 46 INCH DECK..............................................................139 TESTS AND ADJUSTMENTS.........................................................140 REPAIR........................................................................150 DECK LEVELING (SIDE-TO-SIDE)..............................................141 DECK LEVELING (FRONT-TO-REAR).............................................142 SPINDLE BRAKE ADJUSTMENT..................................................140 MOWER BELT TENSION ADJUSTMENT.............................................140 READJUSTING SUSPENSION TO OBTAIN 1 1/4– 4 INCH CUT HEIGHT.................143 MOWER DECK REMOVAL........................................................143 REPLACING MOWER DECK BELT.................................................144 MOWER DECK INSTALLATION...................................................145 MOWER SPINDLE ASSEMBLY....................................................147 GAGE WHEEL ADJUSTMENT.....................................................148 Section 9 - MISCELLANEOUS.........................................................134 COMPONENT LOCATION............................................................152 FUEL TANK AND DASH PANEL..................................................152 REPAIR........................................................................153 FRONT WHEELS REMOVAL & INSTALLATION.......................................153 REAR WHEELS REMOVAL & INSTALLATION........................................153 FRONT WHEEL BEARING REPAIR................................................153 FRONT AXLE REMOVAL........................................................154 FRONT AXLE INSTALLATION...................................................154 FRONT AXLE REPAIR.........................................................154 FUEL TANK AND DASH PANEL REMOVE AND INSTALL...............................154 INDEX.............................................................................158 A.............................................................................158 B.............................................................................158 C.............................................................................158 D.............................................................................158 E.............................................................................158 F.............................................................................158 G.............................................................................159 H.............................................................................159 I.............................................................................160 L.............................................................................160 M.............................................................................160 O.............................................................................160 R.............................................................................160 S.............................................................................160 T.............................................................................161 W.............................................................................161
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⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
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