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Sabre 1338 Gear Technical Manual

Sabre lawn tractor 38–inch and 46–inch (96 cm and 117 cm)
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Sabre Lawn Tractor
38–Inch and 46–Inch (96 cm and 117 cm)
Models: 1338 Gear
www.servicemanualall.com
www.servicemanualall.com
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1538 Gear
1538 Hydro
15538 Gear
15538 Hydro
Technical Manual
John Deere Consumer Products Group
1546 Gear
1638 Hydro
1646 Gear
1646 Hydro
TM–GX10131 (Mar–97)
LITHO IN U.S.A. (New)

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  • Page 1 Buy, Download, Print... Sabre Lawn Tractor 38–Inch and 46–Inch (96 cm and 117 cm) Models: 1338 Gear 1546 Gear 1638 Hydro 1538 Gear 1538 Hydro 1646 Gear 15538 Gear 1646 Hydro 15538 Hydro Technical Manual John Deere Consumer Products Group TM–GX10131 (Mar–97)

  • Page 2: Specifications And

    INTRODUCTION This technical manual is written for an experienced technician and contains sections that are specifically for Safety this product. It is a part of a total product support program. Specifications and Information The manual is organized so that all the information on a particular system is kept together.

  • Page 3: Handle Chemical Products Safely

    SAFETY HANDLE FLUIDS SAFELY-AVOID HANDLE CHEMICAL PRODUCTS FIRES SAFELY • BE PREPARED FOR EMERGENCIES TS1133 Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used include such items as lubricants, coolants, paints, and adhesives. A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.
  • Page 4 SAFETY USE CARE IN HANDLING AND USE SAFE SERVICE PROCEDURES SERVICING BATTERIES • WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.
  • Page 5 SAFETY • PARK MACHINE SAFELY • WORK IN CLEAN AREA 1. Depress brake pedal fully. • Before starting a job 2. Move park lever into lock position. 3. Check that shift lever has returned to neutral. 1. Clean work area and machine: 4.
  • Page 6 SAFETY • AVOID HARMFUL ASBESTOS DUST REPLACE DECALS Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer. Components in products that may contain asbestos fibers are brake pads and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way.
  • Page 7 SAFETY 1 - 6 3/5/97 www.servicemanualall.com...

  • Page 8: Table Of Contents

    CONTENTS SPECIFICATIONS & INFORMATION CONTENTS Page SPECIFICATIONS & INFORMATION SPECIFICATIONS......... . . 2 UNIFIED INCH TORQUE VALUES .

  • Page 9: Specifications

    SPECIFICATIONS SPECIFICATIONS & INFORMATION SPECIFICATIONS Engine: Make ..........Briggs and Stratton Style .
  • Page 10 SPECIFICATIONS SPECIFICATIONS & INFORMATION Power Train—K55 Transmission: Gear Transaxle— Make ............Dana Model.
  • Page 11 SPECIFICATIONS SPECIFICATIONS & INFORMATION Traction Drive Belt: Gear— New Belt Length ....... . 2660±8 mm (104.7±0.3 in.) Minimum Effective Length .
  • Page 12 SPECIFICATIONS SPECIFICATIONS & INFORMATION Average Overall Weight 46 inch (With Mower Deck, No Fuel) ..204.12 kg (450 lbs) Hitch Capacity— Export: Horizontal Pull Maximum........25 kg (56 lbs) Tongue Weight Maximum .

  • Page 13: Unified Inch Torque Values

    UNIFIED INCH TORQUE VALUES SPECIFICATIONS & INFORMATION UNIFIED INCH TORQUE VALUES 1 or 2 Grade No Marks and Head Markings Grade No Marks and Nut Markings Grade 1 Grade 5, 5.1 or 5.2 Grade 8 or 8.2 Grade 2 Lubricated Lubricated Lubricated Lubricated...

  • Page 14: Metric Torque Values

    METRIC TORQUE VALUES SPECIFICATIONS & INFORMATION METRIC TORQUE VALUES 10.9 12.9 Property Class 12.9 10.9 Head Markings 12.9 10.9 12.9 Property Class Markings Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9 Lubricated Lubricated Lubricated Lubricated Size lb-ft lb-ft lb-ft lb-ft lb-ft...

  • Page 15: Gasoline Specifications

    GASOLINE SPECIFICATIONS SPECIFICATIONS & INFORMATION GASOLINE SPECIFICATIONS LUBRICANT SPECIFICATIONS CAUTION ENGINE OIL Handle fuel with care, it is highly flammable. DO viscosity based expected NOT refuel machine: temperature range during the period between oil changes. • Indoors. Always fill fuel tank outdoors. The following oil is preferred: •...

  • Page 16: Grease

    LUBRICANT SPECIFICATIONS SPECIFICATIONS & INFORMATION GREASE SYNTHETIC LUBRICANTS Use grease based on the expected air temperature Synthetic lubricants may be used in John Deere range during the service interval. equipment if they meet the applicable performance requirements (industry classification and/or military The following greases are preferred: specification) as shown in this group.

  • Page 17: Serial Number Locations

    SERIAL NUMBER LOCATIONS SPECIFICATIONS & INFORMATION SERIAL NUMBER LOCATIONS GEAR TRANSAXLE SERIAL NUMBER When working on machines or components that are covered by warranty, it is IMPORTANT that you include the tractor identification number and the component serial numbers on the warranty claim form. The location of tractor identification number and component serial numbers are shown below.
  • Page 18 ENGINE INSTALLATION ..........5 The engines used on Sabre products are warranted by the manufacturer - Briggs &...
  • Page 19 CONTENTS CONTINUED ENGINE Page 3 - 2 2/11/97 www.servicemanualall.com...

  • Page 20: Specifications

    ENGINE SPECIFICATIONS SPECIFICATIONS NOTE: Engine service specifications and procedures are available from your local Briggs & Stratton dealer or by writing: BRIGGS & STRATTON CORPORATION Milwaukee, WI. 53201 For Parts Request: 13HP ..Illustrated Parts List Diamond Plus Model Series 28M700 to 28M799 15HP .

  • Page 21: Repair

    ENGINE REPAIR REPAIR CAUTION ENGINE REMOVAL 1. Turn all switches OFF and disconnect battery Gasoline is explosive. Do not expose to flame or negative ( - ) cable. spark. Serious injury can result. Store in a 2. Raise hood. Disconnect light harness on right side properly marked, safe container.

  • Page 22: Engine Installation

    ENGINE REPAIR Ground Wire Capscrews Nuts 12. Remove four cap screws. Remove engine. 3. Install lower engine ground connector on capscrew installed in step 2, and secure with washer and nut. ENGINE INSTALLATION 4. Install other three capscrews, washers, and nuts. Torque to 32 N•m (24 lb-ft).
  • Page 23 ENGINE REPAIR Capscrew 10. Connect and adjust throttle cable (C) to obtain full throttle and choke when lever is full forward, and 7. Install engine output shaft key and pulley assembly. idle when lever is rearward. Secure with washer, lock washer and capscrew. 11.
  • Page 24 CONTENTS ELECTRICAL CONTENTS Page ELECTRICAL SPECIFICATIONS......... . . 3 THEORY OF OPERATION .
  • Page 25 CONTENTS CONTINUED ELECTRICAL Page 4 - 2 2/11/97 www.servicemanualall.com...

  • Page 26: Specifications

    ELECTRICAL SPECIFICATIONS SPECIFICATIONS Battery: Voltage ............12 BCI group .

  • Page 27: Theory Of Operation

    ELECTRICAL THEORY OF OPERATION THEORY OF OPERATION WIRE COLOR ABBREVIATION CHART GENERAL INFORMATION Blk ........Black The theory of operation stories divide the electrical Blu .

  • Page 28: Electrical Schematic

    ELECTRICAL ELECTRICAL SCHEMATIC ELECTRICAL SCHEMATIC 4 - 5 3/5/97 www.servicemanualall.com...

  • Page 29: Wire Harness

    ELECTRICAL WIRE HARNESS WIRE HARNESS 4 - 6 3/5/97 www.servicemanualall.com...

  • Page 30: Component Location

    ELECTRICAL COMPONENT LOCATION COMPONENT LOCATION Headlights Spark Plug Starter Motor Fuel Shut-Off Seat Switch Solenoid Ignition Switch Brake Switch Blade Drive Switch Starter Solenoid Battery 4 - 7 3/5/97 www.servicemanualall.com...

  • Page 31: Troubleshooting

    ELECTRICAL TROUBLESHOOTING TROUBLESHOOTING Problem or Symptom Check or Solution See Cranking Circuit Diagnosis See Ground Circuit Tests Test battery and connections. See Ignition Circuit Tests See Charging Circuit Tests See Starter Solenoid Test See Seat Switch Tests See headlight circuit test points.

  • Page 32: Diagnostics

    ELECTRICAL DIAGNOSTICS DIAGNOSTICS The 16 HP fuel shut-off solenoid is also energized by the ignition switch and allows fuel to flow to the carburetor. CRANKING & FUEL SHUTOFF The blade drive switch is located under the left side of the mower frame, at the end of the blade drive lever SOLENOID CIRCUIT OPERATION shaft.

  • Page 33: Cranking & Fuel Shutoff Solenoid Circuit Diagnosis

    ELECTRICAL DIAGNOSTICS CRANKING & FUEL SHUTOFF SOLENOID CIRCUIT DIAGNOSIS • Meter negative (—) lead on battery negative (—) terminal Test Conditions: • Ignition switch in OFF position • Meter positive (+) lead on numbered test point Test/Check Point Normal If Not Normal 1.
  • Page 34 ELECTRICAL DIAGNOSTICS BRAKE SWITCH 700 PUR 705 PUR/WHT BATTERY 941 WHT BLADE DRIVE 710 PUR SWITCH 401 YEL 705 PUR/WHT 100 Black 15A Fuse IGNITION 700 PUR SWITCH 200 RED 202 RED/WHT 201 RED FUEL SHUTOFF SOLENOID 401 YEL 710 PUR 105 BLK STARTER STARTER RELAY (SOLENOID)

  • Page 35: Ignition & Seat Switch Circuit Operation

    ELECTRICAL DIAGNOSTICS IGNITION & SEAT SWITCH CIRCUIT As the electric starter turns the flywheel, a magnet in the flywheel produces current in the primary coil of the OPERATION ignition module by electromagnetic induction. When the primary current builds to its highest level, the ignition module induces high voltage current into the Function: secondary coil.
  • Page 36 ELECTRICAL DIAGNOSTICS 942 WHITE 200 RED 941 WHITE KEY SWITCH 0=OFF 1=RUN 2=START STARTER 201 Orange SOLENOID 941 WHITE 401 YELLOW 942 WHITE BLADE 940 WHITE BLACK DRIVE SWITCH 0=OFF YELLOW 0=OFF 1=ON 1=ON ENGINE BRAKE CONNECTOR WHITE/ 0=OFF BLACK SWITCH 1=ON SEAT...

  • Page 37: Ignition Circuit Test Points

    ELECTRICAL DIAGNOSTICS IGNITION CIRCUIT TEST POINTS When diagnosing an ignition problem, isolate magneto circuit from ground circuit by separating engine connector. If engine will not start check magneto circuit first and then check ground circuit. If engine will not shut off, check ground circuit.
  • Page 38 ELECTRICAL DIAGNOSTICS Seat Switch Engine Connector White Black White/Black White/Black White White Brake Switch White/Black White White Blade Drive Switch White/Black Black White Key Switch White 4 - 15 3/5/97 www.servicemanualall.com...

  • Page 39: Charging & Headlight Circuit Operation

    ELECTRICAL DIAGNOSTICS CHARGING & HEADLIGHT CIRCUIT Theory of Operation: OPERATION The charging system is of the permanent magnet and stator design. Magnets imbedded into the crankshaft flywheel pass a multi-pole stator mounted under the flywheel, inducing alternating current into the stator Function: coils.

  • Page 40: Charging Circuit Diagnosis

    ELECTRICAL DIAGNOSTICS CHARGING CIRCUIT DIAGNOSIS Test Conditions: • Brake engaged, blade drive lever disengaged • Engine running at fast idle (3600 rpm) • Engine connector disconnected • Meter negative (–) lead on battery negative (–) terminal • Ignition switch in run position •...

  • Page 41: Headlights Circuit Diagnosis

    ELECTRICAL DIAGNOSTICS HEADLIGHTS CIRCUIT DIAGNOSIS Test Conditions: • Park brake engaged, blade drive disengaged • Engine running at fast idle • Meter negative (—) lead on battery negative (—) • Meter positive (+) lead on numbered test point terminal NOTE: But sure to set multi-meter to measure AC or DC voltage or amperage as required by test: Test/Check Point Normal If Not Normal...
  • Page 42 ELECTRICAL DIAGNOSTICS 120 Black Yel/Wht 451Yel/Wht Headlight Harness TO ENGINE Black Yellow/White TO CHASSIS Engine Connector Red/Black 451 YEL/WHT 120 Black Headlight Harness 4 - 19 3/5/97 www.servicemanualall.com...

  • Page 43: Tests And Adjustments

    ELECTRICAL TESTS AND ADJUSTMENTS TESTS AND ADJUSTMENTS • All cells more than 1.225 with less than 50 point variation, load test battery. • More than 50 point variation: replace battery. BATTERY TEST CHARGE BATTERY Reason: To check condition of battery and determine battery Reason: voltage.

  • Page 44: Battery Load Test

    ELECTRICAL TESTS AND ADJUSTMENTS IMPORTANT: Decrease charge rate if battery gases Procedure: or bubbles excessively or becomes too warm to 1. Turn load knob of tester clockwise until amperage touch. reading (A) is equal to: a.Cold cranking amperage rating (use blue scale). 5.

  • Page 45: Ac Voltage Output Test

    ELECTRICAL TESTS AND ADJUSTMENTS AC VOLTAGE OUTPUT TEST STARTER SOLENOID TEST Reason: Reason: To measure engine alternating current voltage output to To determine if starter solenoid or starter is defective. determine stator condition. Equipment: Equipment: • Jumper wire • Multimeter Black Wire Connections: 1.

  • Page 46: Starter Amp Draw Test

    ELECTRICAL TESTS AND ADJUSTMENTS STARTER AMP DRAW TEST SEAT SWITCH TEST Reason: Reason: To determine the amperage required to crank the To ensure proper operation of seat switch. engine and check starter motor operation under load. Equipment: Equipment: • Battery Tester •...

  • Page 47: Brake Switch / Blade Drive Switch Test

    ELECTRICAL TESTS AND ADJUSTMENTS BRAKE SWITCH / BLADE DRIVE BRAKE SWITCH ADJUSTMENT SWITCH TEST Reason: Reason: To ensure proper that engine starts only when brake fully applied. To make sure the brake pedal switch and blade drive switch operate properly. Procedure: Equipment: 1.

  • Page 48: Ignition Switch Test

    ELECTRICAL TESTS AND ADJUSTMENTS IGNITION SWITCH TEST Reason: To verify ignition switch functions are operating properly. Equipment: • Ohmmeter or Continuity Tester Procedure: 1. Park machine on level surface and turn ignition switch OFF. 2. Shift lever in NEUTRAL and park brake LOCKED. 3.

  • Page 49: Ground Circuit Tests

    ELECTRICAL TESTS AND ADJUSTMENTS GROUND CIRCUIT TESTS points. If a problem is indicated, disconnect the wiring harness connector to isolate the wire or component and check resistance again. Maximum allowable resistance in the circuit is 0.1 ohms. Reason: Check both sides of connectors closely as To check for opens, loose terminal wire crimps, poor disconnecting and connecting may temporarily connections, or corrosion in the ground circuit.

  • Page 50: Repair

    ELECTRICAL REPAIR REPAIR SEAT SWITCH REMOVAL & INSTALLATION IGNITION SWITCH REMOVAL & INSTALLATION NOTE: Seat switch connector has an internal spring which will short cavities of connector together when it is disconnected from seat switch. This prevents operator from defeating seat switch by leaving connector disconnected.

  • Page 51: Starter Solenoid Removal & Installation

    ELECTRICAL REPAIR STARTER SOLENOID REMOVAL & INSTALLATION Procedure: 1. Park machine on level surface, park brake ON, engine OFF. 2. Lift seat and remove negative battery cable from battery terminal. 3. Remove positive battery cable from battery terminal. 4. Remove battery hold-down (rubber strap) from frame, and lift battery from tractor.
  • Page 52 GEAR POWER TRAIN CONTENTS CONTENTS Page GEAR POWER TRAIN SPECIFICATIONS......... . . 3 TORQUE SPECIFICATIONS .
  • Page 53 GEAR POWER TRAIN CONTENTS CONTINUED 5 - 2 3/5/97 www.servicemanualall.com...

  • Page 54: Specifications

    GEAR POWER TRAIN SPECIFICATIONS SPECIFICATIONS Dimensions: Overall Axle Width (End-To-End) ......735.4 mm (29 in.) Overall Case Width .

  • Page 55: Torque Specifications

    GEAR POWER TRAIN SPECIFICATIONS Gear Ratios: 1st Gear ............61.67:1 2nd Gear .

  • Page 56: Troubleshooting

    GEAR POWER TRAIN TROUBLESHOOTING TROUBLESHOOTING Problem or Symptom Check or Solution Belt sheaves, idlers, & guides loose, out of adjustment, worn, or damaged Belt worn, frayed, glazed, or stretched—replace belt Clutch/brake pedal linkage out of adjustment Clutch/brake components worn, bent, or broken— replace and adjust Shift lever and linkage bent, worn, out of...

  • Page 57: Component Location

    GEAR POWER TRAIN COMPONENT LOCATION COMPONENT LOCATION 1. Flange bearing 45. Spacer 2. Shim 46. Drive chain drive sprocket (9 teeth) 3. Spur gear (14 teeth) 47. Drive shaft bevel gear (42 teeth) 4. Shift collar 48. Shim 5. Shift key (4 used) 49.

  • Page 58: Transaxle Component Location

    GEAR POWER TRAIN COMPONENT LOCATION TRANSAXLE COMPONENT LOCATION Flush Only 10 N•m (88 lb-in.) 10 N•m (88 lb-in.) Shims (42 and 48) are critical when any gears or case halves are being replaced. 22 N•m (190 lb-in.) Use Form-In-Place Gasket Silicone Sealant to seal housing halves.

  • Page 59: Traction Drive System Component Location

    GEAR POWER TRAIN COMPONENT LOCATION TRACTION DRIVE SYSTEM COMPONENT LOCATION 1. Frame weldment—idler adjustment 34. Brake compression spring strap 2. Carriage bolt (M8x45) 35. Flange nut (M8) 3. Clutch bellcrank bracket 36. Adjustable idler 4. Bushing 37. Belt guide 5. Cap screw 38.
  • Page 60 GEAR POWER TRAIN COMPONENT LOCATION TRACTION DRIVE SYSTEM COMPONENT LOCATION SHIFT LINKAGE SYSTEM COMPONENT LOCATION 5 - 9 2/12/97 www.servicemanualall.com...

  • Page 61: Theory Of Operation

    GEAR POWER TRAIN THEORY OF OPERATION THEORY OF OPERATION TRACTION DRIVE SYSTEM OPERATION A. Clutch Pedal E. Tensioning Sheave B. Engine Drive Sheave F. Bellcrank Assembly C. Tensioning Spring G. Actuating Spring Assembly D. Clutch Shaft H. Transaxle Drive Sheave Function: The belt traction drive transfers power from the engine drive sheave to rotate without transferring any power...

  • Page 62: Transaxle Operation

    GEAR POWER TRAIN THEORY OF OPERATION TRANSAXLE OPERATION cross shaft and bevel gears (E) to both drive axles (K) out to the wheels and tires. The keyed drive wheels are retained by an E-Ring. Function: The transaxle transmits power from the engine to the drive axles and rear wheels, and provides gear selection of five forward speeds, one reverse, and neutral.

  • Page 63: Brake System Operation

    GEAR POWER TRAIN THEORY OF OPERATION BRAKE SYSTEM OPERATION A. Clutch/Brake Pedal E. Adjustable Idler Assembly B. Clutch Cross Shaft and Bellcrank F. Transaxle Drive (Input) Sheave C. Clutch Actuating Spring Assembly G. Brake Rod Assembly D. Clutch Bellcrank and Tensioning Idler Assembly H.

  • Page 64: Diagnosis

    GEAR POWER TRAIN DIAGNOSIS DIAGNOSIS Test Conditions: • Mower on level surface • Front wheels blocked • Mower deck removed • Rear wheels raised off ground with axle housings on jack stands. • Engine OFF • Park brake ON Test/Check Point Normal If Not Normal 1.
  • Page 65 GEAR POWER TRAIN 5 - 14 2/12/97 www.servicemanualall.com...

  • Page 66: Tests And Adjustments

    GEAR POWER TRAIN TESTS AND ADJUSTMENTS TESTS AND ADJUSTMENTS 2. Look for a steady pull in all three lower gears up the slope. 3. If traction test fails in any or all of the three lower CLUTCH/BRAKE LINKAGE gears, the belt tension must be adjusted. &TRACTION DRIVE ADJUSTMENT Reason: To ensure clutch/brake pedal linkage and traction drive...
  • Page 67 GEAR POWER TRAIN TESTS AND ADJUSTMENTS BRAKE SPRING ADJUSTMENT— 4. Measure distance between end of compression spring bracket (C) and front edge of brake rod stop tabs (D). • If distance is less than 2 mm (0.08 in.)— Contact Points 1.

  • Page 68: Shift Linkage Adjustment

    GEAR POWER TRAIN TESTS AND ADJUSTMENTS • shortening the clutch spring causes decreased drive traction and aggressiveness. SHIFT LINKAGE ADJUSTMENT Reason: To ensure shift lever obtains all shift positions and that neutral position does not allow transaxle to rotate. Conditions: •...

  • Page 69: Repair

    GEAR POWER TRAIN REPAIR 4. If transaxle rotates, move shift lever (D) slightly until Results: transaxle shift lever clicks firmly into it’s neutral • Test drive tractor to ensure all forward and reverse detent. (This may occur while shift lever (D) is in gears are obtained and that tractor does not move the reverse or first gear range of shift gate).

  • Page 70: Traction Drive Belt Inspection

    GEAR POWER TRAIN REPAIR 12. Remove belt from transaxle drive sheave, and pull through transaxle belt guide. 6. Depress and lock brake pedal (A) with park brake lever. 7. Remove front idler belt guide and sheave (B). 13. Pull belt from around engine drive sheave (G), and past front belt guide (H).

  • Page 71: Traction Drive Belt Installation

    GEAR POWER TRAIN REPAIR TRACTION DRIVE BELT INSTALLATION 5. Install drive belt through rear belt guide (A) and over transaxle drive sheave (B). 1. Install end of drive belt under belt guide (H), and 6. Install belt guides on clutch sheave and adjustable pull belt up between guide (H) and sheave (G).
  • Page 72 GEAR POWER TRAIN REPAIR 8. Remove clutch/brake pedal by removing mounting nut (G) and pulling pedal through frame. 9. Remove brake bracket from bellcrank by removing cotter key and washer (H). 10. Remove bellcrank from clutch shaft by removing CAUTION safety wire (I) securing roll pin, then driving out roll pin (J) and removing bellcrank.

  • Page 73: Shift Linkage Removal & Installation

    GEAR POWER TRAIN REPAIR SHIFT LINKAGE REMOVAL & INSTALLATION 6. Adjust mounting brackets (J and P) so shift rod (H) 1. Remove battery. can be removed from the left side of the frame. You 2. Block rear of tractor off ground. Remove left drive will have to “snake”...

  • Page 74: Transaxle Removal & Installation

    GEAR POWER TRAIN REPAIR TRANSAXLE REMOVAL & 7. Support transaxle with jack stands or have a helper hold transaxle in place while you remove INSTALLATION hardware. 1. Raise mower off ground and support with 8. Remove front cap screws (F) and rear hardware jackstands under frame and not transaxle case.
  • Page 75 GEAR POWER TRAIN REPAIR 4. Remove shift arm (A), and square-hole flat washer from transaxle shifter shaft Remove Shifter Detent Assembly: 1. Remove shifter shaft rubber boot (E). 2. Remove both set screws (H) and detent springs (G). IMPORTANT: DO NOT drop or lose detent balls. 3.
  • Page 76 GEAR POWER TRAIN REPAIR Input Shaft & Pinion Gear Inspection: 1. Remove brake assembly (A) (see previous procedure). Remove sixteen transaxle housing socket head screws (B). 1. Visually check overall condition of assembly, including the key and keyway, and the drive sheave hub keyway.
  • Page 77 GEAR POWER TRAIN REPAIR Bearing Inside Diameter ..15.89–15.92 mm (0.625–0.627 in.) 6. Replace both bearings by carefully pressing them from case bore without damaging bore. 7. Pack area between bearing with Multi-Purpose EP Grease. 8. Clean and inspect bore. If scratched or deformed, replace upper case half.
  • Page 78 GEAR POWER TRAIN REPAIR Shifter Disassembly: 5. Install input shaft (E) (with keyway on outside of case), large washer (I), small washer (J), bevel pinion gear (K), and snap ring (L). 1. Lift shifter shaft (B) from lower case half mounting hole (C) and groove of shift collar (D).
  • Page 79 GEAR POWER TRAIN REPAIR Idler Gear Inspection: 3. Separate and inspect idler components: • Washers (B and D) should be 0.632 x 1.00 x 0.026 in., not scored nor discolored (burnt). • Spacer (C) should be 0.630 x 1.00 x 0.169 in., not scored nor discolored (burnt).

  • Page 80: Intermediate Shaft & Drive Shaft Repair

    GEAR POWER TRAIN REPAIR INTERMEDIATE SHAFT & DRIVE SHAFT REPAIR Exploded View Intermediate & Drive Shaft Inspection: Intermediate & Drive Shaft Disassembly: 1. Lift both drive (I) and intermediate (E) shaft 1. Inspect overall condition of intermediate shaft and assemblies from transaxle case together. drive shaft assemblies, including gears for wear, 2.

  • Page 81: Transaxle Assembly

    GEAR POWER TRAIN REPAIR Differential/Axle Shaft Inspection: 2. Carefully remove axle shaft assembly components from ring gear (G). Be sure to remember each components orientation to its neighbor and to the ring gear (G). Mark the same side of each component to aid reassembly.
  • Page 82 GEAR POWER TRAIN REPAIR 5. Install axle shafts so beveled gears (E) mesh with differential internal shaft beveled gears. 6. Keep inward pressure on both axles as you install 4. Install remaining intermediate shaft components in differential assembly in lower case housing. their proper order and orientation (reference top 7.
  • Page 83 GEAR POWER TRAIN REPAIR • Washers (A and C) should be 0.632 x 1.00 x 0.026 in., • Spacer (B) should be 0.630 x 1.00 x 0.169 in., • Narrow combination gear (D) should have 35 good teeth and wide combination gear (E) should have 12 good teeth, •...
  • Page 84 GEAR POWER TRAIN REPAIR 1. Pack upper case beveled pinion gear and lower Install Brake Assembly: case housing assembly with 638 g (1.406 lbs) of Multi-Purpose EP grease. 2. Apply Form-In-Place Gasket Silicone Sealant to lower case. 3. BE SURE sealant DOES NOT contact any gear, shaft, or bearing surfaces.
  • Page 85 GEAR POWER TRAIN REPAIR 1. Install complete brake assembly to transaxle. 2. Tighten cap screws (K and M) to 20 N•m (160 lb-in.). 3. Tighten lock nut (L) to specification until there is a 10 mm (0.39 in.) clearance between thick friction puck and brake disc.
  • Page 86 John Deere will replace the transaxle assembly. NOTE: If internal hydro component parts are suspected (after performing all external checks and adjustments) CALL SABRE SERVICE DEPARTMENT FOR AUTHORIZATION TO REPLACE TRANSAXLE ASSEMBLY. 6 - 1 2/11/97 www.servicemanualall.com...
  • Page 87 HYDROSTATIC POWER TRAIN CONTENTS CONTINUED REPAIR ..........36 TRACTION DRIVE BELT REMOVAL—K55.

  • Page 88: Effective Length

    HYDROSTATIC POWER TRAIN SPECIFICATIONS SPECIFICATIONS Gear Teeth: K–55 K–51 Spur Gear (drive shaft) ....6 teeth 12 teeth Differential Ring Gear ....98 teeth 53 teeth Differential Bevel Pinion Gears Cross shaft .

  • Page 89: Repair Specifications

    HYDROSTATIC POWER TRAIN SPECIFICATIONS REPAIR SPECIFICATIONS Transaxle Components Wear Tolerances: K–55 K–51 Pump (Input) Shaft Wear Limit ..... . . Visual Check Motor (Drive) Shaft Wear Limit .

  • Page 90: Other Materials

    HYDROSTATIC POWER TRAIN SPECIFICATIONS OTHER MATERIALS Transaxle Housing Case Half Sealant: K–55 K–51 Form-In-Place Silicone Gasket Sealant Pump Connector Pipe Plug Sealant: K–55 K–51 ........Pipe Sealant With Teflon® .

  • Page 91: Component Location

    HYDROSTATIC POWER TRAIN COMPONENT LOCATION COMPONENT LOCATION COMPONENT LOCATION—K55 1. Axle Shaft/Wheel Key (2 used) 49. Spacer (M10x20x20) 2. Left Axle Shaft 50. Cap Screw (M10x60) (3 used) 3. Left Axle Shaft Seal 51. Pump Filter 4. Left Axle Shaft Bushing 52.
  • Page 92 HYDROSTATIC POWER TRAIN COMPONENT LOCATION COMPONENT LOCATION—K55 27 N•m (20 lb-ft.) 57 N•m (42 lb-ft.) 40 N•m (30 lb-ft.) New Case: 31 N•m (278 lb-in. Used Case: 27 N•m (243 lb-in.) 19 N•m (168 lb-in.) 24 N•m (217 lb-in.) 24 N•m (217 lb-in.) 8 N•m (72 lb-in.) 90 91 6 - 7...

  • Page 93: Component Location-K51

    HYDROSTATIC POWER TRAIN COMPONENT LOCATION COMPONENT LOCATION—K51 1. Knob 2. 1/4X20 Hex Jam Nut 3. Rod 4. E-Ring 5. M6X30 Bolt 6. Snap Ring 7. Spacer 8. Sheave 9. Fan 10. Flnage Lock Nut 11. Lock Nut 12. Screw 13. Screw 14.
  • Page 94 HYDROSTATIC POWER TRAIN COMPONENT LOCATION COMPONENT LOCATION—K51 New Case: 27.4-31.4 N•m (20-23 lb-ft. Used Case: 22.5-27.4 N•m (16-20 lb-ft.) 6 - 9 2/12/97 www.servicemanualall.com...

  • Page 95: Traction Drive System Component Location

    HYDROSTATIC POWER TRAIN COMPONENT LOCATION TRACTION DRIVE SYSTEM COMPONENT LOCATION K–55 TRANSAXLE K–51 TRANSAXLE 1. Transaxle Drive Sheave (K55) 8. Cap Screw 15. Bolt M8 x 45 2. Transaxle Drive Sheave (K51) 9. Bolt (K51) 16. Idler 3. Arm (K55) 10.

  • Page 96: Pedal Linkage Assembly Component Location

    HYDROSTATIC POWER TRAIN COMPONENT LOCATION PEDAL LINKAGE ASSEMBLY COMPONENT LOCATION K–55 TRANSAXLE K–51 TRANSAXLE 1. Neutral Switch 9. Brake Spring Strap 17. Lock Nut M8 (K55) 2. Lock Nut, 9.525mm 10. Brake Compression Spring 18. Brake Pedal (K55) 3. Pivot 11.

  • Page 97: Shift Linkage Component Location-K-55 Transaxle

    HYDROSTATIC POWER TRAIN COMPONENT LOCATION SHIFT LINKAGE COMPONENT LOCATION—K–55 TRANSAXLE 1. Cap Screw (M6x20) 13. Support Strap 23. Shift/Return-To-Neutral Bracket 2. Shift Arm 14. Shoulder Bolt 24. Flange Nut (M8) 3. Lock Nut (M6) 15. Cap Screw (M10x25) 25. Lock Nut (5/16-24 UNF 3B) 4.

  • Page 98: Shift Linkage Component Location-K-51 Transaxle

    HYDROSTATIC POWER TRAIN COMPONENT LOCATION SHIFT LINKAGE COMPONENT LOCATION—K–51 TRANSAXLE 1. Torsion Spring 8. Bracket 15. Screw M10 x x25 2. Spring Pin (4 x 20 mm) 9. Ball Joint 16. Screw M8 x 25 3. Gearshift Lever 10. Stud, Adjusting 17.

  • Page 99: Theory Of Operation

    HYDROSTATIC POWER TRAIN THEORY OF OPERATION THEORY OF OPERATION TRANSAXLE AND SHIFT LINKAGE SYSTEM OPERATION In this group the Sabre hydrostatic power train is separated into the following systems: • Traction Drive Belt System Function: • Transaxle and Shift Linkage System The function of the transaxle is to transfer power from •...
  • Page 100 HYDROSTATIC POWER TRAIN THEORY OF OPERATION Shaft R.H. Frame Rail Removed For Clarity On the K-51 transaxle, the turnbuckle link (M) moves the transaxle shift lever (P). The shift lever turns the transaxle shifter shaft. When the hydrostatic drive lever (I), is in the neutral position (J), the shift bracket (K) is centered in it’s mounting bracket (L), and the turnbuckle link (M) is centered in the slot on the right side frame.

  • Page 101: Brake/Neutral Return Pedal Component Location & Operation

    HYDROSTATIC POWER TRAIN THEORY OF OPERATION Forward: cylinder (G), motor (output) shaft (H), differential assembly, and drive axles to turn in the reverse direction. BRAKE/NEUTRAL RETURN PEDAL COMPONENT LOCATION & OPERATION Function: The brake system allows the operator to slow down or stop the tractor, return the shift linkage to neutral, and lock the brake into park.
  • Page 102 HYDROSTATIC POWER TRAIN THEORY OF OPERATION When the brake pedal (A) is depressed, the bellcrank (B) and frame rod (F) rotate forward. This motion causes the brake rod (H) and neutral return strap (G), connected at the same point on the bellcrank, to move forward at the same time.
  • Page 103 HYDROSTATIC POWER TRAIN THEORY OF OPERATION Theory of Operation — K51 When the brake pedal (A) is depressed, the frame rod (B) and frame rod arms (C) rotate forward. This motion causes the brake rod (D) and neutral return strap (E), to move forward at the same time.

  • Page 104: Transport (Free-Wheel) System Operation-K55

    HYDROSTATIC POWER TRAIN THEORY OF OPERATION 1. The first segment of travel (W) is taking-up freeplay in the brake and return-to-neutral linkages. 2. The next segment of travel (X) is returning the shift linkage to neutral and engaging the brake. IMPORTANT: Full brake engagement (drive wheels stop turning) must not occur until shift linkage has returned to neutral completely.

  • Page 105: Transport (Free-Wheel) System Operation-K51

    HYDROSTATIC POWER TRAIN THEORY OF OPERATION are unseated; allowing oil to flow freely. This allows the When the actuating rod (A) is pulled out to its locked operator to push the tractor with the engine off and the position, the linkage assembly (B) rotates the actuating brake released.

  • Page 106: Troubleshooting

    HYDROSTATIC POWER TRAIN TROUBLESHOOTING TROUBLESHOOTING Problem or Symptom Check or Solution Belt sheaves and idlers loose, out of adjustment, worn, or damaged— tighten, replace, or adjust properly Belt worn, frayed, glazed, or stretched—replace belt Tensioning spring weak or broken—replace as necessary Accumulation of grass and other debris in...

  • Page 107: Hydrostatic Power Train Troubleshooting

    HYDROSTATIC POWER TRAIN TROUBLESHOOTING Problem or Symptom Check or Solution Input sheave, input shaft, and axle keys or keyways loose, worn, or damaged—replace as necessary (K55 Only) Internal transaxle components worn, stripped, or broken— replace as necessary (K55 Only) Internal hydro pump and/ or motor cylinder block and valve plate mating surfaces worn or scored—...
  • Page 108 HYDROSTATIC POWER TRAIN TROUBLESHOOTING Problem or Symptom Check or Solution Bleed procedure overlooked or improperly done—repeat procedure correctly Wheels and axle keys, key ways, or snap rings worn—replace as necessary Motor drive shaft or axle seals worn or damaged— replace seals (K55 Only) Transaxle case halves cap screws loose or stripped—tighten to 27...

  • Page 109: Diagnosis

    HYDROSTATIC POWER TRAIN DIAGNOSIS DIAGNOSIS Test Conditions: • Tractor on level surface. • Front wheels blocked. • Engine OFF. • Rear wheels raised off surface with axle housings on jack stands. Test/Check Point Normal If Not Normal 1. Fan Fan in good condition and tight. Tighten fan.
  • Page 110 HYDROSTATIC POWER TRAIN DIAGNOSIS Used with K51 Only K55 Shown 6 - 25 2/12/97 www.servicemanualall.com...

  • Page 111: Diagnosis-K55

    HYDROSTATIC POWER TRAIN DIAGNOSIS DIAGNOSIS—K55 Test Conditions: • Tractor operated in test area. • Tests run at engine slow idle and fast idle. • Engine at operating temperature. • Hydro run through full range of speeds in both directions. Test/Check Point Normal If Not Normal 1.
  • Page 112 HYDROSTATIC POWER TRAIN DIAGNOSIS 6 - 27 2/12/97 www.servicemanualall.com...

  • Page 113: Diagnosis -K51

    6. Internal hydro components NOTE: If internal hydro component parts are suspected (after performing all external checks and adjustments) CALL SABRE SERVICE DEPARTMENT FOR AUTHORIZATION TO REPLACE TRANSAXLE ASSEMBLY. 6 - 28 2/12/97 www.servicemanualall.com...
  • Page 114 HYDROSTATIC POWER TRAIN DIAGNOSIS 6 - 29 2/12/97 www.servicemanualall.com...

  • Page 115: Tests And Adjustments

    HYDROSTATIC POWER TRAIN TESTS AND ADJUSTMENTS TESTS AND ADJUSTMENTS 1. Test drive tractor to see if traction drive system pulls tractor up a 17° slope in lower 1/3 of forward range. 2. Look for a steady pull up the slope. TRACTION DRIVE SYSTEM 3.

  • Page 116: Drive Belt Adjustment

    HYDROSTATIC POWER TRAIN TESTS AND ADJUSTMENTS DRIVE BELT ADJUSTMENT TRANSPORT (FREE-WHEEL) VALVE ADJUSTMENT—K55 1. Replace lever assembly (A) components as needed. 2. Slowly engage lever (A) into over-center position (B). 3. Watch closely that actuating pin (E) moves inward 1. Lock park brake. all-the-way and, as lever snaps into over-center position, does not move outward at all.

  • Page 117: Shift Linkage Adjustment

    HYDROSTATIC POWER TRAIN TESTS AND ADJUSTMENTS SHIFT LINKAGE ADJUSTMENT check for creep in transaxle (axles turning while shift linkage is in neutral position without brake engaged). 2. Check that all shift linkage hardware is in good condition and tight. Replace components as necessary.

  • Page 118: Brake Spring Adjustment-K55

    HYDROSTATIC POWER TRAIN TESTS AND ADJUSTMENTS 2. Check shift linkage bellcrank spring tension by measuring spring length distance (E) between flanged nut and top anchor washer and adjust to specification. This will ensure shift lever will remain stationary wherever operator lets go of lever anywhere in shift quadrant.

  • Page 119: Brake Spring Adjustment-K51

    HYDROSTATIC POWER TRAIN TESTS AND ADJUSTMENTS (Shown from R.H. Side) Specifications: Brake Components Wear Tolerances— (K) brake puck (minimum) ..8 mm (0.3 in.) (L) brake lever (minimum) ..25 mm (1.0 in.) (M) brake disc (minimum) .
  • Page 120 HYDROSTATIC POWER TRAIN TESTS AND ADJUSTMENTS (L.H. side of transaxle) 30° Max. 17° 2. Carefully test drive tractor to see if traction drive system pulls tractor steadily up a 17° slope in lower 1/3 of forward range. If distance is less than or equal to 0.08 in. (2 mm): 3.

  • Page 121: Repair

    HYDROSTATIC POWER TRAIN REPAIR REPAIR TRACTION DRIVE BELT Link Arm Cotter Pin REMOVAL—K55 1. Park tractor on level surface and remove battery. 2. Disconnect spark plug. 3. Remove mower deck. 4. Safely raise and block tractor to gain easy access to underside of frame.

  • Page 122: Traction Drive Belt Removal-K51

    HYDROSTATIC POWER TRAIN REPAIR Tension Idler Belt Adjust. Idler Yoke Arm 5. Pull tensioning idler rearward until belt can be removed from adjustable idler. Release tensioning idler and remove belt from tensioning idler, and 8. Remove link arm from steering yoke by rotating link transaxle drive sheave.

  • Page 123: Traction Drive Belt Installation - K55

    HYDROSTATIC POWER TRAIN REPAIR TRACTION DRIVE BELT TRACTION DRIVE BELT INSTALLATION – K55 INSTALLATION—K51 Tension Idler Tension Idler Belt Engine Pulley Yoke Arm Link Arm Adjust. Idler Belt Adjust. Idler 1. Thread belt around belt guide on engine drive pulley 1.

  • Page 124: Traction Drive Belt Tensioning System Removal/ Inspection/Installation-K55

    HYDROSTATIC POWER TRAIN REPAIR TRACTION DRIVE BELT TENSIONING SYSTEM REMOVAL/ INSPECTION/INSTALLATION—K55 A. Transaxle drive sheave 1. Remove mower deck. B. Washer C. Cap screw (M6x25) D. Adjustable idler weldment bracket CAUTION E. Carriage bolt (M8x35) F. Cap screw (M8x20) Bellcrank tensioning spring is under high tension. G.

  • Page 125: Power Train Linkage System Removal/Installation-K55

    HYDROSTATIC POWER TRAIN REPAIR POWER TRAIN LINKAGE SYSTEM 1-Cap Screw (M6x20) 33-Cotter Pin (M3.2x20) 2-Shift aRm 34-Compression Spring REMOVAL/INSTALLATION—K55 3-Lock Nut (M6) 35-Washer 4-Lock Nut (M10) 36-Cotter Pin (M3.2x20) 1. Remove mower deck. 5-Shift Link 37-Washer 6-Snap Ring 38-Brake Pedal Pad 7-Anchor waSher 39-Brake Pedal CAUTION...

  • Page 126: Transaxle Removal And Installation-K55

    HYDROSTATIC POWER TRAIN REPAIR TRANSAXLE REMOVAL AND 11. Pull transport lever (N) into over-center position to remove two left-hand mounting cap screws and INSTALLATION—K55 flange nuts (M). 12. Remove transaxle to workbench. 13. Remove snap ring (E) to remove shift link (D). Removal—...

  • Page 127: Transaxle Disassembly-K55

    Should an internal defect result in a transaxle failure within the warranty period, the transaxle will be replaced as a complete assembly. NOTE: If internal hydro component parts are suspected (after performing all external checks and adjustments) CALL SABRE SERVICE DEPARTMENT AUTHORIZATION REPLACE TRANSAXLE ASSEMBLY.
  • Page 128 HYDROSTATIC POWER TRAIN REPAIR Remove Brake Assembly— 1. Remove four cap screws (A) to remove reservoir cover. 2. Inspect cover for cracks or holes, replace as 1. First, inspect brake assembly for wear or damage: necessary. • check for brake disc contact points at case points (1 3.
  • Page 129 HYDROSTATIC POWER TRAIN REPAIR Upper Case Half 6. Measure brake components individually. 7. Replace components as necessary and as a set only. Set brake assembly components aside for final assembly. Lower Case Half Specifications: Brake Components Wear Tolerances— 2. Carefully separate transaxle housing into upper and (G) brake puck (minimum) .
  • Page 130 HYDROSTATIC POWER TRAIN REPAIR Disassemble Shifter Shaft Assembly— Maximum Air Gap 0.15 mm (0.0059 in.) 1. If wear or leakage is detected, remove e-ring (C), actuating bracket (D), and pin (F). (Pump, motor, and center block removed for clarity) 2. Remove and discard o-ring (E). Replace it with new o-ring every time assembly is removed or leaking.
  • Page 131 HYDROSTATIC POWER TRAIN REPAIR Inspect Differential Axle Assembly— Short Axle Side 2. Turn c-ring (D) in its groove so gap (C) faces down to keep c-ring from falling down inside case. 3. Carefully slide short axle outward slightly while holding axle bevel gear (B) stationary, just enough to expose c-ring (D).
  • Page 132 HYDROSTATIC POWER TRAIN REPAIR IMPORTANT: Axle shaft seals (O) must be replaced every time axles are remove. Protect new seals by wrapping tape over splines and c-ring grooves of axle shafts before assembly. 18. Inspect upper case journals (K) and bushings seat grooves (R) for excessive wear, scoring, pitting, or discoloration.
  • Page 133 HYDROSTATIC POWER TRAIN REPAIR 3. Hold downward on entire pump (F), motor (A), and IMPORTANT: Carefully remove components so center block (G) assembly with one hand as you case bore is not damaged. gradually loosen three cap screws (C) with the other.
  • Page 134 HYDROSTATIC POWER TRAIN REPAIR 2. Clean and inspect components individually once 1. Carefully separate motor and drive shaft disassembled: components. • thrust bushings (A) should not be scored, pitted, or 2. Clean and inspect components individually once worn badly—measure thickness: disassembled: Thrust bushings thickness •...

  • Page 135: Transaxle Assembly-K55

    HYDROSTATIC POWER TRAIN REPAIR block are damaged, they both must be replaced. If any component of motor cylinder block is damaged, a complete new motor cylinder block must be ordered. If upper or lower case halves show wear or damage, they need not be ordered as a set unless wear or damage is severe enough.
  • Page 136 HYDROSTATIC POWER TRAIN REPAIR 4. Install thin bearing thrust washer (G) first, ball bearing (H), and thick bearing thrust washer (I) on top (mates with pump pistons) into swashplate (J). IMPORTANT: Hold fingers tightly between all five pistons so pistons don’t drop out of cylinder block during assembly and spline alignment.
  • Page 137 HYDROSTATIC POWER TRAIN REPAIR 1. Assemble motor cylinder block and drive shaft 2. Assemble and hold differential cross-shaft, bevel assembly (C) to center block. gears, and ring gear assembly (F) together as you align it with motor drive shaft spur gears (C) and 2.
  • Page 138 HYDROSTATIC POWER TRAIN REPAIR Install Filter, Magnet, Transport (Free- 4. Install new o-ring (J) on actuating pin and install in Wheeling) Assembly— lower case half bore (G). 1. Carefully install new relief valve assemblies (B) to specification into center block bores (A). 5.
  • Page 139 HYDROSTATIC POWER TRAIN REPAIR IMPORTANT: When assembling case halves make sure that bypass push pins are fully seated in bore and that actuating bracket and rod are fully withdrawn. Failure to do so will result in broken push pins. 3. Align hole (C) with bleed port stack (A) and firmly push lower case half onto upper case half.

  • Page 140: Transaxle Installation-K55

    HYDROSTATIC POWER TRAIN REPAIR 4. Install breather valve assembly (E) and fill cap (B). motor shaft and bleed internal pump, motor, and Tighten cap screws to 24 N•m (17 lb-ft.) center block assembly. 4. Stop pouring oil when oil reaches bottom of hole. Install Fan and Drive Sheave—...

  • Page 141: Traction Drive Belt Tensioning System Removal/ Inspection/Installation-K51

    HYDROSTATIC POWER TRAIN REPAIR TRACTION DRIVE BELT A. Transaxle Drive Sheave B. Spacer TENSIONING SYSTEM REMOVAL/ C. Cap Screw INSPECTION/INSTALLATION—K51 D. Cap Screw (M8x20) 1. Remove mower deck. E. Bushing F. Bellcrank G. Bolt (M8x45) CAUTION H. Bolt (M8x45) I. Tensioning Spring Bellcrank tensioning spring is under high tension.

  • Page 142: Power Train Linkage System Removal/Installation-K51

    HYDROSTATIC POWER TRAIN REPAIR POWER TRAIN LINKAGE SYSTEM REMOVAL/INSTALLATION—K51 19 20 M127365 Knob 11H278 Cotter Pin 1/4” x 20 Hex Jam Nut M125566 Knob M127363 M125565 Gearshift Lever F2863R E- Ring 34M7130 Spring Pin, 4 x 20 MM 19M7874 Bolt, M6 x 30 M118187 Torsion Spring, R.H.

  • Page 143: Transaxle Removal And Installation-K51

    HYDROSTATIC POWER TRAIN REPAIR TRANSAXLE REMOVAL AND INSTALLATION—K51 Removal— 1. Safely raise and block rear of tractor off surface. 2. Safely support bottom of transaxle or have a helper hold transaxle in place while you remove final hardware. (See step 12.) 3.

  • Page 144: Transaxle External Components Removal-K51

    (after performing all external 2. Insert six cap screws through transaxle and frame checks and adjustments) CALL SABRE holes, and loosely place flange nuts on cap SERVICE DEPARTMENT FOR screws. Tighten cap screws to specification.

  • Page 145: Transaxle Installation-K51

    HYDROSTATIC POWER TRAIN REPAIR 2. Install drive sheave and fan, fan retainer (C) with 2. Remove c-clip (A) and upper fan retainer (B). flat side towards fan, and c-clip (D). 3. Remove drive sheave and fan assembly. TRANSAXLE INSTALLATION—K51 1. Install transaxle. See “TRANSAXLE REMOVAL AND INSTALLATION—K51”...
  • Page 146 STEERING CONTENTS CONTENTS Page STEERING COMPONENT LOCATION ........3 STEERING .
  • Page 147 NOTES STEERING 7 - 2 2/11/97 www.servicemanualall.com...

  • Page 148: Component Location

    STEERING COMPONENT LOCATION COMPONENT LOCATION STEERING Steering Wheel Nylock Nut Washer Retainer Bolt Washers “C”-Clip Washers Bushing Cotter Pin Washer Bushing Bushing Washer Bushing Washer Sector Arm Pinion Shaft Tie Rod Steering Link Washer Bushing Washer Cotter Pin 7 - 3 2/12/97 www.servicemanualall.com...

  • Page 149: Service Equipment And Tools

    STEERING REPAIR SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from your SERVICE-GARD Catalog. Some tools may be available from a local supplier. Name Inside Puller and Slide Hammer Remove steering bushings. REPAIR STEERING GEAR REMOVAL 1. Remove battery and safely raise front of tractor. 2.

  • Page 150: Replace Pedestal Bushings

    STEERING REPAIR 13. Install assembly in reverse order, making sure pinion gear and sector gear alignment marks are aligned as steering pinion shaft (F) is installed. REPLACE PEDESTAL BUSHINGS Bushings M51991 NOTE: Write down location and number of washers on pinion and sector gear shafts.
  • Page 151 STEERING REPAIR Sector Gear Marks Pinion Gear 4. Align marks on sector gear and pinion gear as steering pinion shaft (D) is installed from the bottom of the tractor. 5. Install washers (E) and cotter pin (C). 6. Install and fasten tie rods (Long leg of tie rod is installed in axle spindle).
  • Page 152 CONTENTS ATTACHMENTS CONTENTS Page ATTACHMENTS COMPONENT LOCATION ........3 LIFT LINKAGE .
  • Page 153 NOTES ATTACHMENTS 8 - 2 2/14/97 www.servicemanualall.com...

  • Page 154: Component Location

    ATTACHMENTS COMPONENT LOCATION COMPONENT LOCATION LIFT LINKAGE Lift Lever Lift Assist Spring Screw Lift Lever Lock Lift Arm (RH) Lift Arm (LH) Flange Nut Screw Latch Springs Retaining Screw Bracket Push Bushing Spacer Flange Nut Roller Washer Latch Bar Flange Nut Latch Quadrant Plate Screw...

  • Page 155: Inch Deck (- 1996)

    ATTACHMENTS COMPONENT LOCATION 38 INCH DECK (– 1996) 1. Pin 16. Arm, Idler 31. Carriage Bolt, M8X35 46. Spacer 2. Bolt 17. Washer 32. Rod, RH Brake 47. Wheel 3. Bushing 18. Bushing 33. Belt Guide 48. Screw, M10X70 4. Eyebolt 19.

  • Page 156: Inch Deck (1997 -)

    ATTACHMENTS COMPONENT LOCATION 38 INCH DECK (1997 –) 15 2 18 19 24 25 1. Strap, PTO Spring 18. Spacer 35. Screw, M10x70 49. Rod, Adjusting 2. Cotter Pin 19. Guide, Belt 36. Label, Danger 50. Bushing 3. Washer 20. Mower Deck 37.

  • Page 157: Inch Deck (- 1996)

    ATTACHMENTS COMPONENT LOCATION 46 INCH DECK (– 1996) 1. Pin 19. End, PTO Rod 36. Spring Locking Pin 53. Chute 20. Nut, M10 37. Rod, Front Draft 54. Mower Deck 2. Pad, Brake (W/Spring) 21. Brake Rod 38. Ball, Leveling 55.
  • Page 158 ATTACHMENTS COMPONENT LOCATION 8 - 7 3/5/97 www.servicemanualall.com...

  • Page 159: Inch Deck (1997 -)

    ATTACHMENTS COMPONENT LOCATION 46 INCH DECK (1997 –) 1. Shield, RH Belt 19. Compression Spring 36. Bolt, Carriage M8x40 52. Guide, Belt 2. Bracket, RH Rear Draft 20. Rod, PTO Spring 37. Guide, Belt 53. Lock Nut, M8 3. Bracket, LH Rear Draft 21.

  • Page 160: Tests And Adjustments

    ATTACHMENTS TESTS AND ADJUSTMENTS TESTS AND ADJUSTMENTS 5. Measure distance from brake surface to pulley braking surface. Specifications: BEFORE PERFORMING SERVICE Brake to Pulley ADJUSTMENTS: Distance ......2–3 mm (0.08–0.12 in.) 1. Depress clutch/brake pedal fully and set parking brake. 6.

  • Page 161: Deck Leveling (Side-To-Side)

    ATTACHMENTS TESTS AND ADJUSTMENTS DECK LEVELING (SIDE-TO-SIDE) IMPORTANT: Do not attempt to loosen jam nut on tension rod without using a suitable wrench to 1. Park tractor on a hard, level surface. support fitting. 2. Stop engine and remove key. Disengage blade drive.

  • Page 162: Deck Leveling (Front-To-Rear)

    The installed rods should (P/N TY15272) may be obtained through your exhibit identical amounts of movement between local Sabre Service Center at nominal cost to left and right rods. If one rod moves more freely aid in deck adjustment.

  • Page 163: Readjusting Suspension To Obtain 1- 4 Inch Cut Height

    ATTACHMENTS REPAIR READJUSTING SUSPENSION TO OBTAIN 1– 4 INCH CUT HEIGHT NOTE: Normal settling of the deck suspension after years of use may cause cut height range to shift downward. This may be readjusted by resetting the right hand adjusting “J” bolt adjuster.

  • Page 164: Replacing Mower Deck Belt

    ATTACHMENTS REPAIR 6. Reinstall belt guard and tighten cap screws securely. Guide Rod 7. Install mower deck on tractor. See “MOWER DECK INSTALLATION” on page 13. 8. Adjust mower deck belt tension. See “MOWER BELT TENSION ADJUSTMENT” on page 8. 9.

  • Page 165: Mower Deck Installation

    ATTACHMENTS REPAIR MOWER DECK INSTALLATION 5. Raise front of draft arms to align holes in end of draft arms with holes in mower frame. Install draft pins through rear draft arms and mower frame. Secure with spring pin clips. CAUTION Mower lift lever is under high tension.

  • Page 166: Mower Spindle Assembly

    ATTACHMENTS REPAIR MOWER SPINDLE ASSEMBLY CAUTION REMOVAL Blades are sharp and could cause personal injury. Wear gloves or wrap blades with shop NOTE: Spindles are not serviceable. The spindle, cloths to remove and install blades. DO NOT complete with pulley, must be replaced as an hold blade with bare hand.

  • Page 167: Gage Wheel Adjustment

    ATTACHMENTS REPAIR GAGE WHEEL ADJUSTMENT IMPORTANT: DO NOT add grease to spindle grease fitting. Grease fittings This unit has been equipped with gage wheels to manufacturers use only. Adding grease may minimize scalping by the mower deck when mowing damage spindle seals. uneven terrain.
  • Page 168 CONTENTS MISCELLANEOUS CONTENTS Page MISCELLANEOUS COMPONENT LOCATION ........3 FUEL TANK AND DASH PANEL .
  • Page 169 NOTES MISCELLANEOUS 9 - 2 3/5/97 www.servicemanualall.com...

  • Page 170: Component Location

    MISCELLANEOUS COMPONENT LOCATION COMPONENT LOCATION FUEL TANK AND DASH PANEL Fuel Shut-Off Valve Used On Early Models Only 1. Fuel Tank 6. Fastener Grommet (4 used) 11. Fuel Filter 2. Filler Cap 7. Hose Clamps (6 used) 12. Flange Screw 3.

  • Page 171: Repair

    MISCELLANEOUS REPAIR REPAIR REAR WHEELS REMOVAL & INSTALLATION FRONT WHEELS REMOVAL & 1. Safely lift and support tractor. INSTALLATION 1. Safely lift and support tractor. 2. Remove plastic cap. M55832 2. Remove plastic cap (C), E-ring (D) (gear) or snap ring (F) (hydro), and outer washer (E).

  • Page 172: Front Axle Removal

    MISCELLANEOUS REPAIR FRONT AXLE REMOVAL FRONT AXLE REPAIR 1. Safely support front of tractor. 1. Remove axle. See “FRONT AXLE REMOVAL” on page 5. 2. Remove front wheels. See “FRONT WHEELS REMOVAL & INSTALLATION” on page 4. 2. Remove bushing (I), you may need to use a driver and hammer or an hydraulic press.
  • Page 173 MISCELLANEOUS REPAIR 11. Remove mower deck blade drive lever through dash, retain plastic grommet. CAUTION 12. Remove fuel tank/dash panel assembly to workbench. Gasoline is explosive. Do not expose to flame or spark. Serious injury can result. Catch or wipe Cable Assembly up any spilled fuel immediately.
  • Page 174 MISCELLANEOUS REPAIR 20. Fasten fuel tank to dash panel with six screws. 21. Install lever on end of throttle cable assembly. Fuel Tank Cable Assembly Overflow Hose 18. Install overflow tube and fuel line to fuel tank 22. Align fuel hose with slot (M), overflow tube with spigots.
  • Page 175 MISCELLANEOUS REPAIR Blade Drive Lever Plastic Grommet Steering Column Washers 26. Place blade drive lever into hole in dash and frame. 27. Insert plastic grommet NOTE: Apply anti-seize lubricant to steering shaft before installing steering wheel. 28. Install washer(s) exactly as removed earlier onto steering shaft.
  • Page 176 CONTENTS Service Information Bulletins CONTENTS Page Service Information Bulletins Service Information Bulletin (No. 96-001) ........3 Service Information Bulletin (No.
  • Page 177 CONTENTS CONTINUED Service Information Bulletins Page 9 - 2 3/5/97 www.servicemanualall.com...

  • Page 178: Service Information Bulletins

    SABRE Lawn Tractors ENGINES ON SABRE LAWN TRACTORS ARE ENVIRONMENTALLY FRIENDLY! All Briggs & Stratton engines used on the SABRE lawn tractors are California Air Resources Board (C.A.R.B.) approved. In order to meet the established emissions standards, the carburetors on these C.A.R.B. approved engines, are calibrated leaner than those engines which do not pass the C.A.R.B.

  • Page 179: Service Information Bulletin (No. 96-002)

    SUBJECT: MULCHING BLADES CONTACTING EACH OTHER AFFECTS: SABRE Lawn Tractors with BM 18617 (38”) and BM 18618 (46”) Mulch Kits installed. There have been a few reports of the mulching blades contacting each other following installation of the mulch kit.

  • Page 180: Service Information Bulletin (No. 96-003)

    CHATTERING NOISE FROM UNDER THE FRAME AFFECTS: SABRE Lawn Tractors The mower drive lever (key # 58 below) uses a loose fitting, long spacer (key # 150) that fits around the lever shaft between the frame and the pivot arm (key # 103) under the frame, Due to the proximity of the transaxle drive belt to the bushing, the vibration of the drive belt, can cause the belt to contact the bushing resulting in a chattering noise.

  • Page 181: Service Information Bulletin (No. 96-008)

    DISENGAGED - MAY BE ACCOMPANIED BY A “SQUELING” NOISE (ADDENDUM TO SIB 96-004, MAY 14, 1996) AFFECTS: SABRE Lawn Tractors Complaint or Symptom: 1) Mower drive belt smokes when PTO (blade drive) lever is dis-engaged. 2) May be accompanied by a “squealing” noise at higher engine speeds.
  • Page 182 PTO (BLADE DRIVE) LEVER IS MOVED TO THE DISENGAGED POSITION The brake pad clearance with PTO (blade drive) lever engaged should be 2-3 mm (0.078 - 0.118.). Refer to SABRE Technical Manual (M126434) for adjustment procedures. Turn Page Page 2 of 4...
  • Page 183 SERVICE INFORMATION BULLETINS Service Information Bulletin 96-008 (continued) Page 3 46 INCH DECK ONLY - If the proper clearances shown below cannot be obtained without deforming the upper ground drive keeper (part of frame weldment), remove and re-install the jacksheave belt keeper on the front side of the bracket mounting flats (See Figure 3 below). Figure 3 FRONT Engine Jacksheave...
  • Page 184 SERVICE INFORMATION BULLETINS Service Information Bulletin 96-008 (continued) Page 4 The following illustrations show the correct belt routing and belt keeper (guide) orientation for the 38 and 46 inch mower decks. Improperly oriented belt keepers can result in thrown belts, premature belt wear or breakage.

  • Page 185: Service Information Bulletin (No. 96-009)

    SUBJECT: MOWER BELT SMOKING COMES OFF AFFECTS: MODELS1338 GEAR & 1538 HYDRO SABRE Lawn Tractors with 38-inch (96 cm) Mower Deck Complaint or Symptom: Mower deck belt comes off during mowing or when PTO (blade drive) lever is engaged. Situation: - Too much clearance between idler arm pulley and belt guide (part of idler arm) results in belt coming off of idler arm pulley.

  • Page 186: Service Information Bulletin (No. 96-010)

    Paper element may not show evidence of oil wicking if examined only from the outside. Solution: - Replace paper air filter element and file warranty through SABRE only if this condition is found in the first few hours of operation*. Additional Information: - Part numbers for the paper air filter elements are listed below: Briggs &...
  • Page 187 SERVICE INFORMATION BULLETINS 10 - 12 3/5/97 www.servicemanualall.com...
  • Page 188 INDEX Alternative Lubricants ..... . 2-9 Electrical AC Voltage Output Test ....4-22 Battery Charging .
  • Page 189 INDEX Idler Gear Inspection ....5-28 Gear Power Train Intermediate/Drive Shaft Brake Inspection ....5-29 Component Location .
  • Page 190 INDEX Drive Sheave And Fan Hydrostatic Power Train (continued) Installation K51 ....6-60 Traction Drive Belt Installation K51 ..6-38 Removal K51 .
  • Page 191 INDEX Starter Amp Draw Test ..... . . 4-23 Mower Deck Solenoid Test ......4-22 38 Inch (—...

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