Professional Documents
Culture Documents
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s
t-
7
INTRODUCTION
This service manual contains service and mainte_
Specif ications and special tools are found in the
nance information for the John Deere 2OO,2Og, 21O, last
group of each section.
212, 214 and 216 Lawn and Garden Tractors and
attachments through 1gg2 model (SN 1g5,OO1_
Whenever new or revised pages are provided, insert
). them into your manual as soon as you receive them.
Your service manual will always be up_to_date and
The manual is divided into sections. Each section be
pertains to a certain component or operational
a valuable asset in your service department.
system
of the tractor or attachment. The information is
divided This safety alert symbol identifies impor_
into groups within each section.
tant safety messages in this manual. When
you see this symbol, be alert to the possibility
Emphasis is placed on diagnosing malfunctions, of
personal injury and carefully read the message
analysis and testing. Diagnosing malfunctions includes
possible troubles, their causes and how to that follows.
correct
them. Under specific components these troubles are
analyzed to help you understand what is causing
FOR YOUR CONVENIENCE
the
problem. ln this way, you can eliminate the Verlical lines appear in the margins of many of
cause the
rather than just replace the part. pages. These lines identify new malerial
and revised
information that affects specificalions, procedures,
and
Metric equivalents have been included,, where ap_ other imporlant instructions. .t \
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_!
,i".
Tractors, 200 Series
General 10
Specifications 10-1
SM-2105 (Jun-81)
Group 10
SPECIFICATIONS
ENGINE SPECIFICATIONS
200 208 210
ftem
tsore... 2.94 in. (74.6 mm) 2.94 in. (74.6 mm) 3.25 in. (82.5 mm)
2.75 in. (69.8 mm) 2.75 in. (69.8 mm) 2.88 in. (73.1 mm)
Stroke . .
18.6 cu. in. 18.6 cu. in. 23.9 cu. in.
Displacement........
3400 lo 3500 rpm 3400 to 3500 rpm 3400 to 3500 rpm
Speeds (Fast) No Load
1700 to 1900 rpm 1700 lo 1900 rpm 1700 to 1900 rpm
Speeds (ldle)
Horsepower* 8 I 10
Bore... 3.38 in. (85.8 mm) 3.50 in, (88.9 mm) 3.75 in. (95.2 mm)
3.25 in. (82.5 mm) 3.25 in. (82.5 mm) 3.25 in. (82.5 mm)
Stroke . .
29.1 cu. in. 31.3 cu. in. 35.9 cu. in.
Displacement
Load 3400 to 3500 rPm 3400 to 3500 rpm 3400 to 3500 rpm
Speeds (Fast) No .
Valve Clearance
0,010 in, (0.254 mm) 0.010 in. (0.254 mm) 0,010 in. (0.254 mm)
lntake (Cold) .
0,020 in, (o.5os mm) 0.020 in. (0.508 mm)
Exhaust (Cold) . .. .... 0.020 in. (0,508 mm)
Battery Battery BatterY
lgnition .
Champion-H-10 Champion-H-10 Champion-H-10
Spark Plug*..
AC-451 AC-451 AC-451
Prestol ite- 1 4-L7B Prestolite-1 4-L7B Prestol ite-1 4-L7B
0.035 in. (0.889 mm) 0.035 in. (0.889 mm) 0.035 in. (0.889 mm)
SparkPlugGaP........
GaP....... 0.020 in. (0.508 mm) 0.020 in, (0.508 mm) 0.020 in, (0.508 mm)
Breaker Poinl
Alternator Alternator Alternalor
ChargingSyslem...... '12-Volt
12-Volt 12-Voll
Slarter. .
*The horsepower rating shown is estabtished by the engine manufacturer in accordance with standard lnternal
in' Hg. Barometer and is developed from
combustion Engine Institute procedure. lt is corrected at 60'F. and 29.22
laboratory test engines equipped with standard air cleaner and muffler.
**ln canada, compliance'witi radio interference regulations certified. Reptace spark ptug with resistorlype spark
0, 212, 214 and 216 Tractors'
ptug onty. tJse Champion RJg for 200 and 208 Traitors. lJse Champion RH10 for 21
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10 General Tractors, 200 Series
1O-2 Specifications SM-2105 (Jun-81)
BATTERY SPECIFICATIONS
Tractor Battery
200,208 John Deere, 12 Volt, (AM30094), BCI Group U1, 135
cold cranking amps at 0"F (-17'C), 3O-minute
reserve capacity.
210. 212. 214.216 John Deere, 12 Volt, (AM31186), BCI Group Z2F,255
cold cranking amps at 0"F (-17"C), S5-minute
reserve capcaity.
TRACTOR SPECIFICATIONS
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Tractors, 200 Series General 10
SM-2105 (Jun-81) Fuel and Lubricants 15-1
Group 15
FUEL AND LUBRICANTS
FUEL
AIF T€UPENAIURE
Always use fresh, clean "regular grade or non- slt{cLE Ytscosrw
'C /a
fULTIYISCOSITY
leaded" gasoline having an octane rating of 87 or
higher. We recommend non-leaded gasoline because
it reduces cylinder head deposits.
The use of GASOHOL is not recommended.
Do not use gasohol, premium, ethyl or white gaso-
line. Never use special additives such as carburetor
cleaners, de-icers, or moisture-removing liquids in
your gasoline.
IMPORTANT: Do not mix oil with gasotine.
-1
Do
not permit dirt or other foreign matter to enter the
fuel system. This could cause hard starting, poor '
U
-31.
LUBRICANTS -ao'
-67'
Engine Crankcase
IMPORTANT: During the first 5 hours of break-in
IF YOU OPERATE YOUR EOUIPMENT AT TEMPERATUFES BELOW THE LIMITS
operation on a new engine or whenever the engine SHOWN, CONSULT YOUR DEALER FOR SPECIAL LUBRICANTS ANO STARTING
is overhauled or rebuilt with a new short block, use AIDS.
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10 General Tractors, 200 Series
15-2 Fuel and Lubricants SM-2105 (Jun-81)
Grease Fittings
John Deere High Temperature/Extreme Pressure
Grease is recommended for axle bearings and front -t--T
tl
axle pivots. lf other greases are used, use SAE Multi- tt
purpose High Temperature Grease with Extreme
Pressure (EP) performance capable of operating at fi3
o3
compartment temperatures above 1 50"C.
iH
rE
9i
John Deere Multipurpose Grease is recommended 4F
for all grease fittings. lf other greases are used, use: oi
32" Ti
IO
- SAE Multipurpose Grease J 14'- __
li
I
9;
l
Alternative Lubricants
Conditions in certain geographical areas outside the
United States and Canada may require different lubri-
cant recommendations than those printed in the oper-
ator's manual. Consult your John Deere dealer to
obtain alternative lubricant recommendations.
Litho in U.S.A.
General 10
Tractors, 200 Series
Fuel and Lubricants 15-5
SM-2105 (Jun-91)
A-Front Axle Spindles C-Primary Lift Shaft Fig. S-Hanger Spacer Fitting on 200 Series
B-Brake Pedal Shaft Tractors (Serial No. 190,001- )
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Tractors, 2O0 Series General 1O
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10 General Tractors, 200 Series
20-6 Tune-Up and Adjustments sM-2105 (Jun-81)
10. Check or Change Transaxle Lubricant Use high readings for heavy front loads such as
Refer to page 10-15-3. Lubricant level should be loaders; mid-range readings for blades and snow
level with the filler hole. throwers and low readings for normal lawn use.
NOTE: DO NOT fill to bottom ledge of fitter tube. C. Steering - Refer to Section 70lor steering gear
adjustment if required.
3. During freezing weather, run engine at least 1
hour to mix water and electrolyte thoroughly. D. Brakes - See Section 50 for brake adjustment.
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Tractors, 2OO Series Engine 20
SM-2105 (Jun-81) Cylinder Head, Valves, and Breather 10-1
Group 10
CYLINDER HEAD, VALVES AND BREATHER
GENERAL INFORMATION
M76999N
It is not necessary to remove the engine to lap or The exhaust valve insert, which is a press fit into
-grind valves, valve seats or service the breather. the block, can be replaced. The intake valve seat is
machined into the block.
The 210 and 212 Tractors have an exhaust valve Valve guides can be replaced when wear toler-
rotator. The 214 and 216 Tractors have valve rotators ances are exceeded.
on both intake and exhaust valves. Whenever the
valves are removed, be sure that the correct valve Exterior governor linkage can be adiusted for high-
spring is used with the rotator on the exhaust valve. speed setting and sensitivitY.
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20 Engine Tractors, 200 Series
1O-2 Cylinder Head, Valves, and Breather sM-2105 (Jun-81)
DISASSEMBLY
t-g l-Cap
2-Washer
Screw
k\ g-5
@+2
e
9-Upper Spring
10-lntake Valve Spring
Retainer
'*2 2.7
^a7
1S-Exhaust Valve Spring
16-Hex. Nut
9*.@
A Yo- 17-Lock
18-Stud
Washer
'u€ 19-Cover
144 :,r#,U5:, 20-Outer Gasket
21-Seal
22-Filler
H,lr[l,g-'. 23-Baffle
f g-rl 24-Reed
2s-Breather Plate Assembly
12
26-lnner Gasket
M11559N 27-Yalve Guides
28-Exhaust Valve lnsert
Fig. 2-Exploded View of Cylinder Head, Valves, and Breather (210 and 212 Tractors illustrated)
Disassembling Engine
NOTE: lt is not necessary to remove the engine to
service the cylinder head, valves or breather.
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Tractors, 200 Series Engine 20
sM-2105 (Jun-81) Cytinder Head, Valves and Breather 10-9
Rotate the crankshaft and observe the maximum A-Valve Spring Compressor C-Valve Keeper Tool
valve lift on the dial indicator. B-Tight Coils
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20 Engine Tractors, 200 Series
10-10 Cylinder Head, Valves and Breather SM-2105 (Jun-81)
v
IMPORTANT: Install head gasket dry. Do not
@ use Permatex or other sealant on gasket.
E\Nrs
bo\J\
uneven stresses will not be set up in the cylinder wall.
A-Nut E-Stud After initial "run-in" period, let engine cool, then
B-Lock Washer F-Gaskels retorque head bolts.
C-Filter G-Seal
I!-Breather Plate H-Cover
Fig. 24-Breather Parts (200 and 2OB Tracto!
17 Ft-lbs.
(23 Nm)
qKf4Y) M17021N
yN
Fig. 26-Cylinder Head Bolt Tightening Sequence
(200 and 208 Tractor)
?[ @a @\
@
A-Nul G-Filter
MlzozoN
@tu
B-Lock Washer H-Baffle a 30 Ft-tbs.
(40 @
fStud l-Reed @ Nm)
D-Cover
E-Seal
J
-lnner Gasket
F-Outer Gasket
K-Breather Plate (Small
Hole Downward) @@@
Fig. 25-Breathet Pans M17022N
elo, 212,214 and 216 Tractors)
Fig. 27-Cylinder Head tult Tightening Sequence
(210, 212, 214 and 216 Tractors)
Deglazing Cylinder
NOTE: Connecting rod and crankshaft iournal Fig. 24-Deglazing Cylinder Bore
must be clean and meet specifications or engine fail'
ure will occur.
lf cylinder is within tolerance and not damaged,
lightly deglaze cylinder bore, Fig. 24. Deglazing pro-
lnspecting Cylinder vides faster, more positive seating of new piston
rings, and also helps retain lubrication on cylinder
walls during break-in period.
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20 Engine Tractors, 200 Series
15-10 Minor Engine Recondition SM-2105 (Jun-81)
Push piston pin, Fig. 25, into place and install new
retainers. Be certain retainers are properly seated in
grooves.
A*Expanders
B-Chrome Ring (Bevel Up)
C-Cast lron Ring (Scraper Groove Down)
D-Chrome Steel Rails
E-Cast lron Spacer
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Engine 20
Tractors, 200 Series 20-9
Major Engine Recondition
SM-2105 (Jun-81)
lnspecting and Repairing Cylinder Block 3. Measure the bore at right angles (B) to the
of ring travel zone'
crankshaft at the top end
Thoroughly clean the cylinder block and check for
cracks. at
4. Measure the bore in the same position the
bottom end of ring travel zone.
ln any area where cracks may be suspected, coat
the area with a mixture of 25 percent kerosene and
Compare the measurements taken in Steps 1 and
75 percent light engine oil.
3 above to find the out-of-round wear at the TOP
end of the bore.
Wipe the area dry and immediately apply a coating
of zinc oxide dissolved in wood alcohol. lf a crack is
Compare the measurements taken in Steps 2 and
present, the coating will become discolored at the
4 above to find the out-of-round wear at the BOT-
defective area.
TOM end of the bore.
Replace block if cracked.
Compare the results of measurements taken in
Steps 1 , 2, 3 and 4 to find out whether or not the
bore has worn taPered.
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20 Engine Tractors, 200 Series
2O-1O Major Engine Recondition
SM-2105 (Jun-81)
Deglazing Cylinder Bore 4. Rotate the adjusting nut on the hone until the
stones come in contact with the cylinder wall at the
narrowest point.
5. Turn the hone by hand. lf you cannot turn it, the
hone is too tight. Loosen hone until it can be turned
by hand.
M2a64A
Use a "hone" for reboring the cylinder. Use coarse 8. When the cylinder is approximately 0.002-inch
honing stones for removing most of the bore and (0.050 mm) within the desired bore specification,
medium honing stones for finishing. Use hones for change to medium stones and finish the bore. Finish
cast iron. BE SURE the correct hone is used and should not be perfectly smooth, but should have a 45
that stones are not worn. degree cross hatch pattern.
1. Anchor the cylinder block before reboring. 9. Clean the cylinder thoroughly. Use soap, warm
water and clean rag. Clean the cylinder wall for a
2. Set the drill press to operate from 450 to 700 "white glove" inspection. A clean white rag should
rpm. not show soil from the cylinder wall.
3. Lower the hone to the point where the lower IMPORTANT: DO NOT use sotvent or gasotine
end extends 1/2 to 3/4-inch (jZ.7O to 19.05 mm) because these fluids only wash all the oil from
past the end of the cylinder block. the cylinder wall. They do not remove metal parti-
cles produced during honing.
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Engine 20
Tractors, 200 Series
Specifications 25-1
SM-2105 (Jun-?1)
GrouP 25
SPECIFICATIONS
SPECIFICATIONS
20O Tractor- 214 Treclor Wgar
Kl81OS Engine 210 Traclor 212 Ftaclot
K301AOS Engine K321AOS Engine loleranco
Item 208 Tractor-K181S Engin( K241AOS Engine
oo l5 0.0015 in.
001 5 001 5
Cylinder taper (max.) oo25 (0.0381 mm)
*Measurcd iust below oil dng and at right angles to piston ptn
Litho in U.S.A.
20 Engine
Tractors, 200 Series
25-2 Specifications
SM-2105 (Jun-?1)
*Measurcd just
below oil ting and at (ight angtes to piston pin
Litho in U.S.A.
Tractors, 2A0 Series Engine 20
SM-2105 (Jun-81) Specifications 25-3
SPECIFICATIONS
2fi) Trector .traci.ot
Kl81OS Engins 210 Tractor 212 Tractor 214,216 Woar
2Og Tractor-Kl8 S Enginc K241AOS Engine K30|AOS Engine K321AOS, K341AOS Englno Tolerance
Item 1
0.0025 to 0.004 in. 0.0015 lo 0.003 in. 0.002 to 0.004 in. 0.002 to 0.004 in. +0.002 in.
Ring side clearance (middle rlng) (0.508 mm)
(0.0635 to 0.1016 mm) (0.0381 to 0.0762 mm) (0.0508 to 0.1016 mm) (0.0508 to 0.1016 mm)
0.001 lo 0.0025 in. 0.001 to 0.003 in. 0.001 to 0.003 in. 0.001 to 0.003 in. +0.002 in.
Fling side clearane (orl rrng) (0.0254 to 0.0762 mm) (0.508 mm)
(0.02il to 0.0635 mm) (0.0254 to 0.0762 mm) (0.0254 to 0.0762 mm)
0.007 lo 0.017 in. 0.010 to 0.020 in. 0.010 to 0.020 in. 0.010 lo 0.020 in. +0.010 in.
Ring end gaP (new bore maximum) (0.254 mm)
(O.1778 lo 0.0431 mm) (0.2540 lo 0.5080 mm) (0.2540 to 0.5080 mm) (0.2540 to 0.5080 mm)
005/.o03 0.001 to 0.0035 in. 0.001 to 0.0035 in. 0.001 to 0.0035 in.
Camshalt pin-to-camshall clearance
(0.0254 to 0.0889 mm) (0.0254 to 0.0889 mm) 10.0254 to 0.0889 mm)
0.0005 to 0.002 in. 0.0005 to 0.002 in. 0.0005 to 0.002 in. 0.0005 to 0.002 in.
Camshaft pin-to-block (bearing plate end) (0.0127 to 0.0508 mm)
(O.O'127to 0.0508 mm) (O.O127 lo 0.0508 mm) (0.0127 lo 0.0508 mm)
0.0015 to 0.003 in. 0.0015 to 0.003 in. 0.0015 to 0.003 in. 0.0015 lo 0.003 in.
Camshall pin-lo-block (PTO end)
(0.0381 to 0.0762 mm) (0.0381 to 0.0762 mm) (0.0381 to 0.0762 mm) (0.0381 to 0.0762 mm)
0.001 to 0.0035 in. 0.001 to 0.0025 in. 0.00'1 to 0.0025 in. 0.001 to 0.0025 in.
Camshafl pin-to-breaker cam (0.0254 to 0.0635 mm)
(0.02il to0.0889 mm) (0.02S to 0.0635 mm) (0.0254 to 0.0635 mm)
oO05 to 0.010 in. 0.005 lo 0.010 in. 0.005 lo 0.010 in. 0.005 to 0.010 in.
Camshaft end play (0.127 to 0.254 mm)
(0.127 to 0.254 mm) (0.127 lo 0.254 mm) (0.127 to 0.254 mm)
0.001 to 0.0025 in. 0.001 to 0.0025 in. 0.001 to 0.0025 in. 0.001 to 0.0025 in. 0.0045 in.
Valve stem clearance in guide (intake) (0.025 to 0.063 mm) (0.1143 mm)
(0.025 to 0.063 mm) (0.025 to 0.063 mm) (0.025 to 0.063 mm)
0.0025 to 0.0040 in. 0.0025 to 0.0040 in. 0.0025 to 0.0040 in. 0.0025 to 0.0040 in. 0.0065 in.
Valve stem clearance in guide (exhaust) (0.0635 to 0.1016 mm) (1651 mm)
(0.0635 to 0.1016 mm) (0.0635 to 0.1016 mm) (0.0635 to 0.10'16 mm)
0.0005 to 0.0020 in. 0.0005 to 0.0020 in. 0.0005 to 0.0020 in. 0.0005 to 0.0020 in.
Valve guide in block (interference) (0.0127 to 0.0508 mm)
(O.0127 to 0.0508 mm) (0.0127 10 0.0508 mm) (0.0127 to 0.0508 mm
0.002 to 0.004 in. 0.003 to 0.005 in. 0.003 to 0.005 in. 0.003 to 0.005 in.
Valve seat in block (exhausl) (inlederene) (0.0762 to 0.1524 mm)
(0.0508 to 0.1016 mm) (0.0762 to 0.1524 mm) (0.0762 to 0.1524 mm
0.006 to 0.008 in. 0004 to 0.010 in. 0.008 lo 0.010 in. 0.008 io 0.010 in.
Valve clearance (intake) (@ld)
(0.1524 to 0.2032 mm) (0.2032 to 0.2540 mm) (0.2032 to 0.2540 mm (0.2032 to 0.2540 mm)
Valve cleerance (exhausl) {@ld) 0.015 lo 0.017 in. 0017 lo 0.020 in. 0.017 to 0.020 in. 0.017 1o 0.020 in.
(0.3810 to 0.4318 mm) (0.4318 to 0.5080 mm) {0.4318 to 0.5080 mm) (0.4318 1o 0.5080 mm)
1/32 in. 1/32 in. 1 /32 in. 1 /32 in. 1/16 in.
Valve seat width (0.794 mm) (1.588 mm)
(0.794 mm) (0.794 mm) (0.794 mm)
0.005 to 0.0020 in. 0.008 to 0.0023 in. 0.0008 to 0.0023 in. 0.0008 to 0.0023 in.
Valve lappel clearance rn block (0.0203 to 0.0584 mm)
(0.0127 lo 0.0508 mm) (0.0203 to 0.0584 mm) (0.0203 to 0.0584 mm)
o.2542 o.324 o.324 o 324
valve lift (zero lash)
0.312 to 0.313 in. 0.312 to 0.313 in. 0.312 to 0.313 in. 0.315 in.
Valve guide, LD. 0.312 to 0.313 in.
(7.924 to 7.950 mm) (7.924 to 7.950 mm) (7.924 to 7.950 mm) (8.001 mm)
(7.924 to 7.950 mm)
1 -5l1 6 1-15/32 in. 1-15/32 in. 1-15/32 in.
Valve guide, depth (37.31 mm) (37.31 mm)
(33.34 mm) (37.31 mm)
0.3105 lo 0.31 10 in. 0.3105 to 0.3110 in. 0.3105 to 0.3110 in. 0.3105 to 0.3110 in. 0.3090 in.
Valve stem, O.D. (intake) (7.8867 lo 7.8894 mm) (7.8486 mm)
(7.8867 to 7.8994 mm) (7.8867 lo 7.8894 mm) (7.8867 to 7.8894 mm)
0.3090 to 0.3095 in. 0.3090 lo 0.3095 in. 0.3090 to 0.3095 in. 0.3090 to 0.3095 in. 3.3080 in.
Valve stem, O.D. (exhaust) (7.8486 to 7.8613 mm) (7.8232 mm)
{7.8486 to 7.8613 mm) (7.8486 to 7.8613 mm) (7.8486 lo 7.8613 mm)
1/32 in. /32 in. 1 /32 in. 1/32 in. 'I
/16 in.
Valve lace wdth 1
(0.794 mm) (1.588 mm)
(0.794 mm) (0.794 mm) (0.794 mm)
1/16 /16 in. 'l/32 in.
Valve spflng squareness 1/ 16 in. I /16 in. in. 1
Litho in U.S.A.
I
20 Engine Tractors, 2A0 Series
25-4 Specifications sM-2105 (Jun-81)
Litho in u.s.A.
20 Engine Tractors, 200 Series
25-4 Specifications SM-2105 (Jun-91)
Litho in U.S.A.
Section 40
ELECTRICAL SYSTEM
Group 5
GENERAL INFORMATION
CONTENTS
Page Page
GROUP 5 - GENERALINFORMATION GROUP 20 . CHARGING SYSTEM
Wiring Diagrams 5-3 Principle of Operation 20-1
Description ........5-5 Alternator 20-1
Rectifier-Regulator ....20-2
GROUP 1O - CRANKING SYSTEM Diagnosing and Testing ......20-2
Principle of Operation 10-1 Charging System Tests. ....20-3
lgnition Switch 10-4 Repair ....20-4
Solenoid 10-4 Alternator-Stator .. ,....20-4
Starter 10-5
Diagnosing and Testing . 10-6 GROUP 25 - LIGHTS
Cranking System Tests 10-6 Description . . 25-1
Testing Battery 10-7 Diagnosing Malf unctions . . 25-1
Testing lgnition Switch 10-8 Testing . . . . 25-2
Testing Neutral-Start Safety Switches . 10-8 . Wiring Harness . 25-2
Testing Solenoid 10-10 Svritches . . 25-2
Testing Starter 10-'10
Testing Armature 10-10 GROUP 30 - ELECTRIC LIFT
Repair 10-11 Principle of Operation . . 30-1
Battery 10-1 1 Circuits. 30-2
Starter 10-13 Diagnosing and Testing 30-3
Adjustments 30-6
GROUP 15 . IGNITION SYSTEM Depth Control .... 30-6
Principle of Operation 1 5-1 Stop Spacer..... 30-6
lgnition Switch 15-2 Lift Lever Tension 30-7
Spark Plug 15-2 Cam and Control Switch Adiustment . . . . . 30-7
Breaker Points 15-2 Cam. . 30-7
Condenser 15-3 Control Switches 30-8
Coil .. 15-3 Disassembly and Repair 30-9
Diagnosis and Testing . 15-4 Disassembli ng 2-1 / 2-lnch (6.35 cm)
Make a Vrsual Test of Diameter Electric Motor and Actuator . . . . 30-9
Components and WirinS . . . . 15-4 Removing Actuator Assembly . . 30-9
Test Spark Plug . . . 15-4 Removing Electric Motor. . 30-9
Test Safety Switches . 15-5 RemovingGearBox ....30-10
PTO Safety Switch . t5-5 Removing Cover Tube and Actuator .. 30-10
Seat Safety Switch (70,001- ) . 15-5 Assembling 2-1/2-lnch (6.35 cm) Diameter
Test lgnition Switch . 15-6 Electric Motor and Actuator ...... 30-11
Adiusl Breaker Points . 15-6 Assembling Cover Tube and Actuator. 30-11
Replace Breaker Points. .15-7 Assembling Motor to Gear Box . 30-12
Time Engine . . .15-7 lnstalling Electric Lift Motor and
Test Condenser . . 15-9 Actuator 30-1 3
TestCoil .... . 15-9
Specifications . . 15-10
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40 Electrical System
5-2 General lnformation Tractors, 200 Series
SM-2105 (Jun-81)
Page
GROUP 30 - ELECTRTC LtFT-Continued
Disassembling 3-lnch (7.62 cm) Diameter
Electric Lift Motor and Actuator. . . .. . . . 30-14
.
Litho in U.S.A.
Tractors, 200 Series Electrical System 40
SM-210s (Jun-81) Generallnformation 5-3
WIRING DIAGRAMS
IGNIT I ON
HEADL I GHTS
COIL SPARK PLUG
CON DENSER
STATOR
RECTIFIER
REGULATOR
BLAC K STARTER
SOL ENO I D
TRANSMI SS ION
NEUTRAL.START Sl/JITCH PTO NEUTRAL 12-VOLT BATTERY
M22349N START ShIITCH
Figure l-Wiring Diagram For 200, 210, 212 and 214 Tractors
(Serial No. 30,001 -70,000)
IGNITION
COI L SPARK PLUG
CONDENSER
STATOR
RECT I FI ER
REGULATOR
STARTER
TRANSMI SS I ON
NEUTRAT START Sl,lITCH PTO NEUTRAL 12-VOLT BATTERY
M2235AN START Stl]ITCH
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@ Electrical System Tractors, 200 Series
SM-2105 (Jun-81)
5-4 General lnformation
WIRING DIAGRAMS-ConIinued
]GNITION
HEADL I GHTS COIL SPARK PLUG
LT. GREEN
RECTI FI ER
RFGULATOR
AI4METEP, dTnculr
I-IIK BREAKER
BLACK STARTER
TRANSMi SS I ON
NEUTRAL START Sl^lITCII PTO NEUTRAL I2-VOLT BATTERY
M20963N START SI,IITCH
Fig. 3-Wiring Diagram For 210, 212, 214 and 216 Tractors
(Serial No. 70,001 -1 90,000)
sltrcxrzf\
FPW
xrv KEY SIIITCH
AEBD
DBIC
L IGHT
0!l GREEN
Arlr,rElER c-iil[-n
BREAKER
ELECTRIC CLUTCH
RECTIFIER
REGULATOR
. ELACX
ltt^""8
_JI
s0LEN0l0
=
SEAT SIIITCH PURPLT
PTO SI.IITCH
TRATS''II SS I OIl NEUTML
START SI.IITCH
Fig. 4-Wiring Diagram For 21O, 212, 214 and 216 Tractots
(Serial No. 190,001- )
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Tractors, 200 Series Electrical Sysfem 40
SM-2105 (Jun-81) General Information 5-5
DESCRIPTION
The 200 Series Tractors all have a 12-volt electrical All 200 Series Tractors are equipped with a battery-
system. The electrical system consists of the cranking, coil ignition system consisting of a battery, ignition
ignition and charging systems, plus the accessory cir- switch, safety neutral-start and interlock switches, ig-
cuit. nition coil, breaker points and condenser. See Group
15 for additional information.
The cranking system for 2OO, 210, 212 and 214
Tractors (Serial No. 30,001-70,000), Fig. 1, consists of The battery is charged with a 1S-amp alternator. A
a battery, solenoid, circuit breaker, key switch, two solid-state rectifier-regulator converts AC current from
neutral-start safety switches and a permanent magnet the alternator into DC current and also controls the rate
starter motor. See Group 10 for detailed information. of charging current to the battery. See Group 20 for
further information.
The cranking system tor 2O8,21O,212,214and 216
Tractors (Serial No. 70,001- ), Figs. 2,3 and 4 Electric lift is available for 200 Series Tractors. The
consists of a battery, solenoid, circuit breaker, key electric lift is position-responsive in that it reacts di-
switch, three neutral-start safety switches and a per- rectly to control lever movement. Detailed information
manent magnet starter motor. See Group 10 for de- can be found in Group 30.
tailed information.
NOTE: On 208 Tractors the yellow le4d wire for
200 Series Tractors (Serial No. 19O,OO1 and up are extra equipment headlights is removed from the igni-
equipped with an electric PTO clutch. The clutch draws tion switch accessory terminal and taped to the wiring
current from the battery and is activated by a switch on harness, Fig. 2. lf the lead is used, be careful to keep
the dash. lead away from heat or moving parts.
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Tractors, 200 Series
Electrical Srstem 40
Cranking Srstem 10-1
SM-2105 Uun-81)
Group 10
CRANKING SYSTEM
PRINCIPLE OF OPERATION
2OO, 21O, 212 And 214 Traclors (Serial No. 30,001-70'000)
r42235LN
The cranking system on 200, 210,212 and 214 The 12-volt battery has a hard rubber case with six
Tractors (Seriai No. 30,001 -7o,0oo), Fig. 1 , consists of individual cells. Each cell contains a specific number
a 12-volt battery (H), solenoid (D), circuit breaker (B)' of sets of negative and positive plates'
ammeter (A), key switch (G), two neutral-start safety
switches (E and F), and a permanent magnet starter All plates of like charge are interconnected so thal
motor (C). the accumulative charges are present at the positive
and negative batterY terminals.
The ignition switch (G) and neutral-start safety
As a battery discharges and the energy is not re'
switches (E and F) must be closed before the solenoid
plenished, the sulfuric acid is withdrawn from the
will activate the starting motor. For the engine to con-
electrolyte and the lead sulfate deposits build up or
tinue running, the PTO switch (E) must be closed to
activate the coil (l).
the plaies. This causes the specific gravity of the
electrolyte to diminish. Charging the battery reverser
the chemical reaction, restoring the electrolyte t<
The storage battery is of the lead-acid variety' original Potential.
Lead is used in the construction of the cell plates
and a sulfuric acid solution serves as the electrolyte' IMPORTANT: Avoid battery damage by charg
ing at the manufacturer's recommended ampere
Tractors are shipped from the factory with dry- hour charging rate.
charged batteries. This means the plates are
cfrargLO, but electrolyte must be added lust before
using.
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40 Electrical System Tractors, 200 Series
1O-2 Cranking System SM-2105 (Jun-81)
PRINCIPLE OF OPERATION-Continued
2O8, 21O, 212, 214 and 216 Tractors (Serial No. 70,001-190,000)
M22352N
A-Ammeler C-Starter Neulral- |
-Seat Safely-Slart Switch
F
(21O,212,214 and D-Solenoid -Transmission
Start Safety Swilch J Switch
216 Tractors only) E-PTO Neutral-Start G-lgnition Switch -Safety
K-Coil
B-Circuit Breaker Salety Switch H-Battery
The cranking system on 208, 21O,212,214 and216 The 12-volt battery has a hard rubber case with six
Tractors (Serial No. 70,001-190,000), Fig.2, consists individual cells. Each cell contains a specific number of
of a 12-volt battery (H), solenoid (D), circuit breaker sets of negative and positive plates.
(B), key switch (G), three neutral-start safety switches
(E, F, and l), and a permanent magnet starter motor All plates of like charge are interconnected so that
(c). the accumulative charges are present at the positive
The ignition switch (G) and neutral-start safety and negative battery terminals.
switches (E and F) must be closed before the solenoid
will activate the starting motor. For engine to continue As a battery discharges and the energy is not re-
running, the safety switch (J) or seat switch (l) must be plenished, the sulfuric acid is withdrawn from the elec-
closed to activate the coil (K). trolyte and the lead sulfate deposits build up on the
plates. This causes the specific gravity of the elec-
The storage battery is of the lead-acid variety. Lead trolyte to diminish. Charging the battery reverses the
is used in the constiuction of the cell plates and a chemical reaction, restoring the electrolyte to original
sulfuric acid solution serves as the electrolyte. potential.
Tractors are shipped from the factory with dry- IMPORTANT: Avoid battery damage by charg-
charged batteries. This means the plates are charged, ing at the manufacturer's recommended ampere-
but electrolyte must be added just before using. hour charging rate.
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Tractors, 200 Series Electrical System 40
SM-2105 (Jun-81) Cranking System 10-3
PRINCIPLE OF OPERATION-Continued
21O,212,214 and 216 Tractors (Serial No. 190,001-
The cranking system on 21O, 212, 214 and 216 The 12-volt battery has a hard rubber case with six
Tractors (Serial No. 190,0O1 and above), Fig.3, con- individual cells. Each cell contains a specific number of
sists of a 12-volI battery (H), solenoid (D), circuit sets of negative and positive plates."
breaker (B), key switch (G), three neutral-start safety All plates of like charge are interconnected so that
switches (E, F, and l), and a permanent magnet starter the accumulative charges are present at the positive
motor (C). and negative battery terminals.
The ignition switch (G) and neutral-start safety As a battery discharges and the energy is not re-
switches (E and F) must be closed before the solenoid plenished, the sulfuric acid is withdrawn from the elec-
will activate the starting motor. For engine to continue
trolyte and the lead sulfate deposits build up on the
running, the PTO Neutral-Start switch (E) or seat plates. This causes the specific gravity of the elec-
switch (l) must be closed to activate the coil (J). trolyte to diminish. Charging the battery reverses the
The storage battery is of the lead-acid variety. Lead chemical reaction, restoring the electrolyte to original
is used in the construction of the cell plates and a potential.
sulfuric acid solution serves as the electrolyte. IMPORTANT: Avoid battery damage by charg-
Tractors are shipped from the factory with dry- ing at the manufacturer's recommended ampere-
charged batteries. This means the plates are charged, hour charging rate.
but electrolyte must be added just before using.
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40 Electrical System Tractors, 200 Series
10-4 Cranking System sM-2105 (Jun-81)
:N16744]{
Ml6744N
A-Regulator C-Solenoid E-Accessories
B-Battery I)-lgnition
Fig. 4-lgnition Switch Terminals
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Tractors, 200 Series Electrical System 40
SM-2105 (Jun-81) Cranking System 1O-5
1-Lock Washer
1 2-Nut
I 3-Washer
6*J----' 4-lnsulating
5-Housing
Washer
t-
l 6-Thru Bolt
I
I
7-Armature
l 8-Stop Nul
l
9-Gear Stop Spacer
I 1o-Anti-Drift Spring
20 I
11-Drive Assembly
l
I
13-Thrust Washer
tzl l4-Dust Cover
1s-lnsulating Bushing
II
@r lG-Brush and Spring Kit
tu
@--i
' g re- 16
17-Machine Screw
18-Bolt
19-Brush Holder
2o-Commutator End Cap
21-Dust Cover Spacer.
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40 Electrical System Tractors, 200 Series
10-6 Cranking System SM-2105 (Jun-81)
1. Engine cranks but does not start. Problem in ignition System (See Group 15).
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Tractors, 200 Series
Electrical System 40
Cranking System 1O-7
SM-2105 (Jun-81)
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40 Electrical System Tractors, 200 Series
10-8 Canking System SM-2105 (Jun-81)
M14222N
Ml 4222N
Fig. 8-Test lgnition Switch
1-OFF A,B,C,D,E
2-RUN B,C,D,E A
3- START A,B,D,E c
Testing Neutral-Start Safety
Switches
The cranking system has two neutral-start safety
switches. Both of these switches must be closed to
allow current flow to the starter solenoid. One switch is Fig 1L-Test Transmission Neutral-Start S^f"ty S*it"h*'*uu"
located on a mounting plate under the lender-deck and (Fender-Deck Removed for Clarity)
is activated by the shift lever follower. The other switch
is mounted inside the pedestal under the dash and is To test the safety switches, connect a test light to the
operated by the PTO lever arm. switch leads as shown in Figs. 9 and 10. lf test light
does not glow, check adjustments. To adjust the PTO
neutral-start safety switch, Fig. 9, loosen the mounting
screws and adjust until switch closes with the PTO in
the disengaged position. lf test light fails to light, re-
place switch. To adjust the transmission neutral-start
safety switch, Fig. 10, loosen the mounting screws and
adjust until the switch closes with the shift lever in
neutral position. lf test light Jails to light, replace switch.
Testing PTO Switch Cranking Circuit On Testing PTO Switch Power Circuit On
200 Series Tractors (Serial No. 200 Selies Tractors (Serial No.
190,001- )
190,001- )
A[ []a A[
[a
Ic
M23233
'[e DIJ
I/123234
M23234
To test the PTO switch cranking circuit, remove the To test the PTO switch power circuit, remove the
two-terminal connector from the switch and attach a three{erminal connector, attach a test light to termi-
test light to the terminals shown in Fig' 11' The light nals shown in Fig. 12, and move toggle to "ON"
position. The test light should light. ll test light fails to
shoulJ light with the switch in the "OFF" position' lf the
light fails to light, replace the switch. light, replace the switch.
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40 Electrical System Tractors, 200 Series
10-10 Cranking System SM-2105 (Jun-91)
Testing Solenoid
Ml216-6N\
Testing Starter
lf the starter fails to crank properly when the engine
is known to be in good operating condition and the rest
of the cranking circuit is found to be satisfactory, re-
move the starter and check it further. (See page 40-
.10-13
for removal and repair of starter.) Fig. 1s-Testing for Grounds
With the starter removed from the engine, check the 2. GROUNDS - Grounds in the armature can be
armature for freedom of operation by turning the shaft. detected with a test lamp and probes, Fig. 15. lf the
Tight, dirty or worn bushings, or a bent or worn arma- lamp lights when one test probe is placed on the
ture shaft may cause the shaft to turn hard. Disas- commutator and the other probe on the armature core
semble the starter for further testing. or shaft, the armature is grounded.
3. OPENS - lnspect lor loosen connections at the
Testing Armature point where the armature windings are attached to the
commutator bars. Poor connections cause arcing and
lf inspection does not reveal the cause of failure, test burning of the commutator. Resolder any poor con-
the armature for opens, shorts, and grounds as follows: nections and turn armature commutator in a lathe to
provide a good surface for brushes.
lf tests reveal any of the above-listed conditions
other than a repairable open circuit, replace the arma-
Litho in U.S.A ture.
Tractors, 200 Series Electrical System 40
SM-2105 (Jun-91) Cranking System 10-11
REPAIR
Servicing BatterY
Good battery servicing should include the following
items:
1. Clean batterY.
Add electrolyte until plates are iust covered. Then 3. During freezing weather, run engine at least 1
charge at 30 to 40 amps lor 10 minutes or 15 amps hour to mix water and electrolyte thoroughly.
for 30 minutes.
4. lnstall caps.
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40 Electrical System Tractors, 2OO Series
10-12 Cranking System SM-2105 (Jun-81)
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Tractors, 200 Series Electrical System 40
sM-2105 (Jun-81) Cranking System 10-13
REPAIR-Continued
{@ d,r
-\z_p { \m1'
18-Bolt
1g-Brush Holder
20-Commutator End CaP
,s- A "a)ro 2l-Dust Cover Spacer
t***4
(
\l'.
-(o
M11627
Removing Starter
NOTE: On 200 Series Tractors below Serial No.
190,001 , engage PTO lever for access to cap screws
that secure starter to engine block.
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40 Electrical System Tractors, 200 Series
10-14 Cranking System SM-2105 (Jun-81)
REPAIR-Continued
M 16754N
Preparing the starter end cap (A), Fig. 22, is the first
step of starter asembly.
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Tractors, 200 Series Electrical System 40
sM-2105 (Jun-81) Cranking System 10-15
M16755N
away from end cap (C). lf this occurs, reload brushes A-Drive Gear D.-Dust Cover SPacer
into end cap and reassemblY. B-Gear Stop Spacer E-Stop Nut
C-Anti-Drift Spring F-Dust Cover
Align housing (A) with end cap (C) using the index
Fig. 21-Assembling Starter Drive
marks (B) on cap and housing as a guide, Fig. 23.
Place thrust washer (E) onto armature shaft, Fig. 23. Lubricate armature sha{t splines with a light coat of
Lubricate drive end cap bearing with light grease. oil. lnstall drive assembly components as shown, Fig.
25. Tighten stop nut (E) to 45 to 50 in-lbs (0.5843 to
0.6492 N.m) torque.
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Tractors, 200 Series Electrical System 40
SM-2105 (Jun-81) lgnition System 15-3
Condenser Coil
:t;t7t?ft
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40 Electrical System
Tractors, 200 Series
15-4 lgnition System SM-2105 (Jun-81)
Litho in U.S.A.
-
Tractors, 200 Series Electrical System 40
SM-2105 (Jun-81) lgnition System 15-5
Fig. $-Checking Sqark at Plug Fig. 7-Testing PTO Safety Switches on 200 Series
Tractors (Serial No. 30,001 -1 90'000)
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40 Electrical System Tractors, 200 Series
15-6 lgnition System SM-2105 (Jun-81)
Seat Safety Switch on 208, 21O,212,214 Tractors The ignition switch can be tested with a test light.
(Serial No. 70,001- ) and 216 Tractors Check for continuity between terminals with switch
placed in each of three positions. See Fig. 10 and chart
below for correct current flow diagram. lf switch is
defective, it must be replaced.
1-OFF A,B,C,D,E
2-RUN B,C,D,E A
3- START A,B,D,E c
NOTE: Prior to removing any switch, be sure cur-
rent is reaching the switch.
M16782NY
A-Feeler Gauge B-Locking Screw C-V-Slor
Fig. 11-Adjusting Breaker points
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Tracto:rs, 200 Series Electrical System 40
sM-2105 (Jun-81) lgnition System 15-7
t'f167837;v
1,41 6783NY
N,416785NY
M1 67 84N
M167gN
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40 Electrical System Tractors, 2OO Series
15-8 lgnition System
sM-2105 (Jun-81)
Time Engine-Continued
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Electrical System 40
Tractors, 200 Series
(Jun-81) lgnition SYstem 15-9
sM-2105
CONDENSER CONDENSER
CAPACITY CAPACITY
TOO HIGH T00 Low M16761N
t{10701ll
[,4 ] 6761 N
M16764N
M r 6764N
?4187 821'lI
A-Lamp Lights :Grounded Winding
B-Lamp Does Not Light = Open Winding
Fig. 1 7-Testing Condenser Capacity
Fig. 19-Testing Coit for Grounded or Open Windings
lf inspection or tests disclose a defective condenser,
replace condenser. lnstall a new condenser whenever To test the windings, use a test lamp and probes,
condition of points indicate need' Fig. 19.
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40 Electrical System Tractors, 2OO Series
15-10 lgnition System SM-2105 (Jun-81)
SPECIFICATIONS
Coil Resistance
PrimaryWindings :....2to3ohms
Windings
Secondary .8,OOO to 10,000 ohms
Condenser
Capacity-Microfarads . .. 0.1g to 0.23 mfds
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Tractors, 200 Series ElectricalSystem 40
SM-2105 (Jun-81) Electric PTO Clutch 35-1
Group 35
ELECTRIC PTO CLUTCH
200 SERIES TRACTORS (Serial No. 190'001-
PRINCIPLE OF OPRATION
Fig. 1-Electric PTO Clutch Circuitry on 200 Series Tractors (Serial No. 190'001-
The electric PTO clutch (A), Fig. 1, is activated with The seat safety-switch shuts off the engine when-
a PTO switch (B) located on the dash panel. The PTO ever the operator leaves the seat with the engine
switch also acts as a safety-start switch that directs running and the PTO engaged.
current from the solenoid terminal of the ignition switch
(C) to the solenoid (D) when the PTO switch is in the The electric PTO clutch requires approximately 4
"OFF" position. amps current to operate ProPerlY.
When the PTO switch is in the "ON" position, cur- A faulty clutch switch, loose wiring, short circuit or
rent is directed to the PTO clutch, activating the elec- defective battery can appear as clutch failure. Always
tromagnet, engaging the clutch. make a visual check of all connections, wires and
components as well as testing battery because these
problems can be a possible cause of clutch failure.
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40 Electrical System Tractors, 200 Series
35-2 Electric PTO Clutch SM-2105 (Jun-81)
Disconnect battery cables (D and G) from battery, Fig. 3-Remove ldler Hanger Assembly
Fig.2. Disconnect PTO clutch lead (A)from switch lead
(B). Connect a test light lead to PTO switch blue lead
Remove bolt and washer, Fig. 3. Slide idler hanger
terminal (C) and other test light lead to positive battery assembly off shaft.
cable (D). Turn key switch (F) to "RUN" position and
place PTO switch (E) in "ON" position. Test light
should light. lf test light does not light, lead wire, PTO
switch or key switch is defective.
wires where they enter field coil to see that the pulley
and rotor do not rub on wires. Also, check connector on
leads to be sure it is connected to leads securely and is
not defective. lf leads and connector to field coil is
good, check clutch adjustment. lf clutch is adjusted
properly and test light still does not light, remove and A-Slots B-Lock Nuts
repair clutch.
Fig. 4-Adjusting PTO Clutch
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Tractors, 200 Series Electrical System 40
SM-2105 (Jun-81) Electric PTO Clutch 35-3
;; ,.!{l
:jl
};;idrl [.1
:;;alioi'
^"
2
^:
Fig. S-Disconnect ctutch Lead wire 5. Hold flywheel in place with large screwdriver or
bar, Fig. 6, and remove clutch retaining bolt and
1. Cut and remove clutch lead tie strap, Fig. 5. Be washer, Fig. 7.
careful not to cut clutch lead wire.
6. Remove clutch assembly and key from crank-
2. Disconnect clutch lead from wiring harness. shaft.
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40 Electrical System Tractors, 200 Series
35-4 Electric PTO Clutch SM-2105 (Jun-81)
M2A554
Litho in U.S.A
Tractors, 200 Series Electrical System 40
SM-2105 (Jun-81) Electric PTO Clutch 35-5
Test field coil as instructed on page 40-35-6. lnspect for broken springs in pulley and armature
assembly (D), Fig. 12. Replace pulley and armature
lnspect field coil and rotor assembly (A), Fig. 12,lor assembly if springs are broken.
delective bearing. lf bearing is defective, the complete
field coil and rotor assembly must be replaced. lf rotor or armature is scored or grooved excessively,
consider replacing the complete clutch rather than
attempting to repair it.
Litho in U.S.A.
40 Electrical System Tractors, 200 Series
35-6 Electric PTO Clutch SM-2105 (Jun-91)
ffi
i,tz57E6f t,,l!.i7t7l
iM25786t M257a1
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Tractors, 200 Series Electrical System 40
SM-2105 (Jun-81) Electric PTO Clutch 35-7
M28559
1. Press two bearings onto collar, Fig. 15. 4. lnstall retaining ring in groove of pulley, Fig. 18.
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40 Electrical System Tractors, 200 Series
35-8 Electric PTO Clutch SM-2105 (Jun-81)
1. lnstall key in crankshaft keyway, Fig.20. 6. Tighten clutch retaining bolt 55 to 65 ft-lbs (74.5
to 88.1 N.m) torque
2. Align keyway in clutch with keyway in crankshaft
and slide clutch on crankshaft. Align clutch back plate NOTE: Hotd ftywheet firmty with screwdriver or bar,
slot with stud on engine plate. Slide clutch all the way Fig. 4, when torquing bolt.
on so it is in place over stud.
7. Remove cap screws from flywheel and screen
3. Connect clutch lead to wiring harness. after tightening clutch retaining bolt.
4. Secure clutch lead in place with a new tie strap. 8. Adjust clutch as explained on page 40-35-2.
IMPORTANT: Clutch lead wire must be posi- 9. Reinstall engine side panels and close hood.
tioned and routed so it does not contact any sharp
edges, primary belt, muffler wrapper, etc. Lead
wire must be slack enough to prevent breakage
from engine movement.
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Section 50
POWER TRAIN
Group 5
GENERAL INFORMATION
CONTENTS
Page Page
GROUP 5 - GENERAL INFORMATION GROUP 20 - 4-SPEED TRANSAXLE
Description .5-2 Principle of Operation .... 20-1
Gear Shift Pattern ......20-2
GROUP 10 - CLUTCH AND VARIABLE Diagnosing Malfunctions 20-3
SPEED DRIVE Disassembly 20-4
'10-1 Removing Transaxle. 20-5
Principle of Operation .
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50 Power Train Tractors, 200 Series
1O-2 Clutch and Variable Speed Drive SM-2105 (Jun-81)
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Tractors, 200 Series Power Train 50
SM-2105 (Jun-91) Clutch and Variable Speed Drive 10-5
Loose input sheave on transaxle hub. Variator arm binding in pivot (in pedestal).
Tractor Does Not Move (Engine Running) Tractor Will Not Attain Specilied Travel Speed
Variator binding belts on 200,210,212,214 and 216 Variator not properly adlusted on 200, 210,212,214
Tractors. and 216 Tractors.
Move variable speed control lever forward.
Clutch shaft binding.
Parking brake set'
Dirty or gummy variator sheave hub on zoo, z1o,
Variator not properly adlusted on 200, 210,212,214 212, 214 and 216 Tractors.
and 216 Tractors.
Variator spring nol adjusted properly on 200, 210,
Primary belt too long. 212,214 and 216 Tractors.
Variator arm binding in pivot (in pedeslal) on 200, Weak secondary idler spring.
210, 212,214 and 216 Tractors.
Variator arm binding in pivot (in pedestal) on 200,
Secondary belt idler spring broken. 210,212,214 and 216 Tractors.
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50 Power Train Tractors, 200 Series
10-6 Clutch and Variable Speed Drive SM-2105 (Jun-81)
REPAIR
lnspecting V-Belts Replacing Primary V-Belt on 200 Series
The V-belts transmit power by lriction and a wedg- Tractors (Serial No. 30,001-190,000)
ing action against the sheaves. All belts and sheaves
wear with use. Normal wear can be recognized as
even wear, both on the belt and sides of sheaves.
See page 50-10-4 of "Diagnosing Malfunctions" Remove right-hand side panel. Unclip PTO arm (A)
for other possible causes of belt wear. and push it to the rear away from the machine.
Cleaning V-Belts Loosen cap screw securing PTO brake shoe (B)
enough so PTO clutch sheave (C) can be pulled off the
Clean belts by wiping them with a clean cloth. engine crankshaft.
Avoid use of solvents since this will soften the belt
materials and cause the clutch to grab. Replace belts
found to be oily or greasy.
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Tractors, 2OO Series
Power Train 50
sM-2105 (Jun-81) Ctutch and Variable Speed Drive 1O-7
lnstall new belt and PTO clutch in opposite order' Fig. 1 }-secure FlYwheel
IMPORTANT: After replacing primary belt, 3. Place two 1/4 x 3-inch cap screws from stock
readjust variator on 200, 21O, 212,214 and 216 through flywheel screen into tapped holes of flywheel'
Tractors. Refer to "Adiustments" page 50-10-15.
NOTE: Cap screws do not thread into holes of
flywheel.
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50 Power Train Tractors, 200 Series
10-8 Clutch and Variable Speed Drive SM-2105 (Jun-81)
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Tractors, 200 Series Power Train 50
SM-2105 Uun-81) Clutch and Variable Speed Drive 10-9
,|4
slot with stud on engine plate. Slide clutch all the way A-Secondary Belt ldler C-Brake Pedal Shaft
on so it is in place over stud. B-Secondary Belt
4. Secure clutch lead in place with new tie strap. Move variable speed control lever forward on trac-
IMPORTANT: Clutch lead wire must be posi- tors so equipped. Raise secondary belt idler (A) and
tioned and routed so it does not contact any sharp slip belt (B)off variator sheave. Depress clutch pedalto
edges, primary belt, muffler wrapper, etc. Lead allow secondary belt (B) to be pulled past brake pedal
wire must be slack enough to prevent breakage shaft (C).
from engine movement.
5. lnstall clutch retaining bolt and washer.
M r6654NY
Fig. 1S-lnstall Clutch Retaining Bolt C-Cap Screws
A-Transaxle Driven
Sheave D-Secondary Belt ldler
6. Tighten clutch retaining bolt 55 to 65 ft-lbs (74.5
B-Secondary Belt
to 88.1 N.m) torque, Fig. 15. Hold flywheel firmly with
screwdriver or bar, Fig. 10, when torquing bolt. Fig. 17-lnstalling Secondary Belt
7. Remove cap screws from flywheel and screen
alter tightening bolt. Loosen cap screws (C) on sheave (A). Remove
secondary belt and install new belt. Raise idler (D) and
8. Adjust clutch as explained on page 40-35-2. install belt on sheave (A). Tighten cap screws (C).
9. Reinstall both engine side panels and close Check variator and brake adlustments after belt re-
placement.
hood.
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50 Power Train Tractors, 20O Series
10-10 Clutch and Variable Speed Drive SM-2105 (Jun-81)
Removing Variator (200, 21O,212,274 and
216 Tractors)
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Tractors, 200 Series Power Train 50
sM-2105 (Jun-81) Ctutch and Variable Speed Drive 10-11
Disassembling Variator w
(200, 21O,212,214 and 216 Tractors)
f,r
ru
IT
It
,r
t, 2
u J, a
t
i
1
")
I
M 1 6663N
I/r 6662N Place variator bearing and hub assembly (A) under
A-Half Sheave B-Vise C-Center Sheave press (B) with sheave down Fig. 26. Press bearing
from hub. Be sure to press against outer'race only.
Fig. 24-Removing Variator Sheaves
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50 Power Train Tractors, 200 Series
10-12 Clutch and Variable Speed Drive SM-2105 (Jun-81)
lnspecting Variator
(2OO, 21O, 212, 214 and 216 Tractors)
t41&665tt ],11*696N"
A-l.D. of Center Sheave Bearinq B-o.D. or v"ri"tol l"l,'i t\, I 6666N
A-Bushing B-Shoulder Bolt
Fig. 29-Measuring Center Sheave and Hub
Fis 3O-lnspecting Shoulder Bolt and Bushing
Alter cleaning parts thoroughly, measure l.D. of
center sheave bearing (A) and O.D. of variator hub (B),
Fig. 28. Refer to wear tolerances, page 50-10-16. lnspect brass bushings (A) and shoulder bolt (B) for
Replace center sheave or hub if wear limits are ex- wear or damage, Fig. 30. The variator arm must pivot
freely.
ceeded. Do not attempt to service center sheave
bearing. Bearing and center sheave are available as
an assembly only.
Check center sheave and half sheaves for wear on
the sheave faces or for evidence of damage or nicks.
Replace parts that may cause excessive belt wear or
would upset the balance of the variator assembly.
s*R
I'Cl 5 r.t0ll-l'
lvl 1 6730NY
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Tractors, 2aO Series Power Train 50
SM-2105 (Jun-91) Clutch and Variable Speed Drive 10-15
ADJUSTMENTS
1. To adlust the variator linkage, place the variable Belt Guide Adiustment on 2OO,210, 212,
speed control lever (A) in notch 5 on the quadrant; 214 and 216 Tractors
which is the third notch from the front of the tractor.
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50 Power Train Tractors, 200 Series
10-16 Clutch and Variable Speed Drive SM-2105 (Jun-81)
VARIATOR SPECIFICATIONS
Component Dimension
Center Sheave l.D. with Bearing ... 2.0015 to 2.0025 in. (50.8381 mm to 50.8635 mm)
Hub l.D.
Litho in U.S.A
Tractors, 200 Series Power Train 50
SM-2105 (Jun-81) Ctutch and Variable Speed Drive 10-13
.l
.999" T0 2.001"
l*fl.7746 mm T0 50"&?54'mm]
Lt88{}" 7q \.leLL^
t2*.*872 *u TO 29 "9499 mm)
t.L7rn" T0 i.:.s0ff"
t29.946A nm 10 29,9700 nm)
Mls68?31
{3.175 mrn
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50 Power Train Tractors, 200 Series
10-14 Clutch and Variable Speed Drive sM-2105 (Jun-81)
Assem bl ing Variator-Continued lnstall shoulder bolt and tighten securely, Fig. 29.
::) >\
: .r::
i iiil
l!(!-'l
i;ir .d
:=.S":::
lnstalling Variator
(2OO,210,212,214 and 216 Tractor)
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Tractors, 200 Series
Power Train 50
sM-2105 (Jun-91) PTO Clutch 25'1
Group 25
PTO CLUTCH
2OO SERIES TRACTORS SERIAL NO. 30,001.190'OOO
aq
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t
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ffiU) wN
rdl sSgcni
Litho in U.S.A.
50 Power Train Tractors, 200 Series
25-2 PTO Clutch SM-2105 (Jun-81)
REPAIR
G L
t\:
r-o sbeb
i-d"b
i-:
i,\l!
I
I
I
e
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UlM M166B1N
Litho in U.S.A.
Section 70
MISCELLANEOUS
Group 5
STEERING LINKAGE
CONTENTS
Page Page
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70 Miscellaneous Tractors, 20O Series
5-2 Steering Linkage SM-2105 (Jun-81)
GENERAL INFORMATION
The steering linkage consists of the steering gear
assembly, drag link, spindles and tie rod.
,'tJl 7f 3?.iil 6
Ayqrr
-e -- A
s-rl
4
B I
\
@
t.t
A-Housing H-Lever Arm
f a
D*9
I
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Tractors, 200 Series Miscellaneous 70
SM-210s (Jun-81) Front Wheels and Axles 10-1
Group 10
FRONT WHEELS AND AXLES
INTRODUCTION
Reler to Group 5, "steering Linkage" for service drag link, tie rod, toe-in adiustment, etc. This group
and adlustment of all linkage related to the front covers only front wheel spindles, bearings and axle.
wheels. Group 5 includes service of ball ioints,
REPAIR
B-.-r6t
r6.
@aS' @-a
I o\-
A
A'/
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eq
E-g B
-@ -/
@''
\ Yv'
LJ
,\ \I Nbdw
q-R
JNb M17 240N
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70 Miscellaneous Tractors, 200 Series
10-2 Front Wheel and Axles SM-210s (Jun-91)
REPAIR-Continued
e4*e
GJ--C
@o
*h W{r
rthv
d{
q-@
A-Ball Joint Assembly | Ring P-R.H. Front Wheel Spindle
B-Jam Nut with R.H. Threads J
-SnapFront Wheel
C-Tie Rod -L.H. Pin Bushing Spindle
K-King
O-Snap Ring
R-Valve Stem
D-Wheel Cap
-Axle with Bushing S-Bearing
L
E-Lock Washer M-King Pin Bolt T-Front Wheel Disk
F-Drag Link N-Cotter Pin
G-Jam Nut with L.H. Threads O-Slotted Nut
H-Ball Joint Assembly
Fig" 2-Exploded View of Front Wheels and Axles on 200 Series Tractors (Serial No. tgO,OOl-
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Tractors, 200 Series Miscellaneous 70
SM-2105 (Jun-81) Front Wheels and Axles 10-3
Removing and lnstalling Front Wheels on 200 Removing and lnstalling Front Wheels on 200
Series Tractors (Serial No. 30,001-190,000) Series Tractors (Serial No. 190,001 and Above)
-N{
..t B
.N @qq T\
,$&
A-Spindle
B-lnner Bearing
C-Spring Washer
F-Washer
G-Spindle
H-Cap
M17247N
CaP
Screw
M17241N \\r
A-Spindle E-Hub
E--o
Cap
ir285m
Litho in U.S.A.
70 Miscellaneous Tractors, 200 Series
10-4 Front Wheels and Axles SM-2105 (Jun-81)
NI.7 245tlZ
t\t1 7243NY
To remove spindle (D), disconnect tie rod end (A), Grease king pin assembly and install axle (A), Fig. 6.
and using a snap ring pliers (B), remove snap ring (C) Tighten king pin bolt (B) until it takes 25 to 75 lbs.
from spindle (D), Fig. 5. Slip spindle (D) out of axle. (1 1.34 lo 34.02 kg) force at the end of the axle to rotate
it up or down. Secure slotted nut (C) with cotter pin (D).
Apply a light coat of grease on upper spindle shaft.
lnstall spindle (D) into axle, Fig. 5. Secure with snap
ring (C).
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Tractors, 200 Series Miscellaneous 70
SM-2105 (Jun-91) Lift Linkage 15-1
Group 15
LIFT LINKAGE
GENERAL INFORMATION
Manual Lift
The manual lift linkage, for the 200 Series Trac-
tors, normally doesn't require adiustment or service
other than lubrication.
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70 Miscellaneous Tractors, 2OO Series
15-2 Lift Linkage SM-2105 (Jun-81)
DIAGNOSING MALFUNCTIONS
Hard Lifting. Lift Lever Hard to Move Forward.
No helper spring (extra equipment) or improper Helper spring too tight.
to
spring tension. lnstall spring or increase tension Loosen spring tension (release all tension when
reduce lift effort. using mower).
Lift shaft and/or lift shaft hub needs lubrication. Lift shaft and/or lift shaft hub needs lubrication.
Lift Lever Breakage. Lift lever not properly seated in lift lever hub.
No helper spring (extra equipment) or improper
spring tension. lnstall spring or increase tension to
reduce lift effort.
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Tractors, 200 Series Tractor Aftachments 90
SM-2105 (Jun-81) 37A Snow Thrower 5-1
Section 90
TRACTOR ATTACHMENTS
Group 5
37A SNOW THROWER
TABLE OF CONTENTS
Page Page
Litho in U.S.A.
90 Tractor Attachments Tractors, 200 Series
5-2 37A Snow Thrower SM-2105 (Jun-81)
TRACTOR ADJUSTMENTS
Adjusting Lift Connecting Link On Checking Electric Lift (Extra Equipment)
Tractors (Serial No. 30,001-190,000)
Fig. 1-Adjusting Lift Connecting Link lf tractor is equipped with an electric lift, check
adjustment of the stop spacer.
1. Remove lift connecting link, Fig. 1.
To check, turn the tractor ignition key switch to
2. Turn clevis on link until the proper length of 1 1 .9 "RUN" position and pullthe lift lever all the way to the
inches (302.26 mm) between the centers of the clevis rear.
pin holes is obtained. Reinstall link.
After the lift has traveled to its fully raised position,
IMPORTANT: When reinstalling link, be sure the turn the key switch off. lf the lift solenoid clicks, ad-
stop on the secondary lift shaft is toward the front justment is necessary.
so the lift arms must be raised slightly to connect
the link. Adjust as follows:
Litho in U.S.A.
90 Tractor Attachments Tractors, 200 Series
5-4 37A Snow Thrower sM-2105 (Jun-81)
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Tractors, 200 Series Tractor Attachments 90
SM-2105 (Jun-?1) 39 and 47 Rotary Mowers 10-1
Group 10
39 AND 47 ROTARY MOWERS
TRACTOR ADJUSTMENTS
Adjusting Lift Connecting Link On Checking Electric Lift (Extra Equipment)
Tractors (Serial No. 30,001-190,000)
2. Turn clevis on link until the proper length of 11.9 To check, turn the tractor ignition key switch to
inches (302.26 mm) between the centers of the clevis "RUN" position and pull the lift lever all the way to the
pin holes is obtained. Reinstall link. rea(.
IMPORTANT: When reinstalling link, be sure the After the lift has traveled to its fully raised position,
stop on the secondary lift shaft is toward the front turn the key switch off. lf the lift solenoid clicks, ad-
so the lift arms must be raised stightly to connect lustment is necessary.
the link.
Adjust as follows:
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90 Tractor Attachments Tractors, 20O Series
10-2 39 and 47 Rotary Mowers SM-2105 (Jun-81)
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I- Tractors, 200 Series Tractor Attachments 90
SM-2105 (Jun-81) 31 Rotary Tiller 20-13
TRACTOR ADJUSTMENTS
Adjusting Lift Connecting Link On NOTE: lf tiller is equipped with two holes in the pivot
Tractors (Serial No. 30,001-190,000) arm, the lift link should be attached to the upper hole.
Later modeltillers have only one hole in the pivot arm.
2. Turn clevis on link until the proper length of 11.9 lf tractor is equipped with an electric lift, check
inches (302.26 mm) between the centers of the clevis
adiustment of the stop spacer.
pin holes is obtained. Reinstall link.
IMPORTANT: When reinstalling link, be sure the To check, turn the tractor ignition key switch to
stop on the secondary lift shaft is toward the front "RUN" position and pull the lift lever all the way to the
so the lift arms must be raised slightly to connect rear.
the link.
After the lift has traveled to its fully raised position,
Adjusting Tiller Lift Height turn the key switch off. lf the lift solenoid clicks, ad-
justment is necessary.
Raise tiller to a transport height of 14 inches (356
mm) from the ground to the top of the tine shaft. Block Adjust as follows:
the tiller in this position.
1. Loosen the stop spacer bolt, Fig. 3.
Disconnect lift rod from rear lift pivot. Loosen lam nut
and turn yoke on or off rod until lift height is 14 inches
(356 mm).
Litho in U.S.A.