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;l

JOHN DEERE 2OO, 208, 210,212,214 AND


216 LAWN AND GARDEN TRAGTORS
Service Manual
SM-2105 (June'81)
TABLE OF CONTENTS
SECTION 1O - GENERAL SECTION 50 - POWER TRAIN
Group 5 - Tractor ldentification Group 5 - General lnformation
Group 10 - Specifications Group 10 - Clutch and Variable SPeed Drive
Group 15 ; Fuel and Lubricants Group 15 - Brakes
Group 20 - Tune-Up and. Adjustments Group 20 - 4-Speed Transaxle
Group 25 - PTO Clutch
(
SECTION 20 - ENGINE
Group 5 - General lnformation SECTION 60 - HYDRAULIC LIFT SYSTEM
Group 10 - Cylinder Head, Valves and Breather Group 5 - General lnformation
'-t Group 10
Group 15 - Minor Engine Recondttion - Control Valve I
,1

Group 20 - Maior Engine Recondition GrouP 15


i - Pump i
-t li

I Group 25 - Specifications Group 20 - Cylinder 1i


il

SECTION 30 - FUEL SYSTEM SECTION 70 - MISCELLANEOUS


Group 5 - General lnformation Group 5 - Steering Linkage
Group 10 - Carburetor Group 10 - Front Wheels and A.xles
Group 15 - Air Cleaner Group 15 - Lift Linkage
Group 20 - Fuel Strainer and Fuel Tank
Group 25 - Fuel PumP SECTION 80 - SPECIAL SERVICE TOOLS
Group 30 - SPecifications Group 5 - Engine Convenience Service Tools
Group 10 - Tractor Essential Service Tools
SECTION 40 ELECTRICAL SYSTEM Group 15 - Tractor Convenience Service Tools
Group 5 - General lnformation
Group 10 - Cranking System SECTION 90 - TRACTOR ATTACHMENTS
Group 15 - lgnition System Group 5 - 37A Snow Thrower
Group 20 - Charging System Group 10 - 39 and 47 Rolary Mowers
Group 25 - Lights Group 15 - 541A PTO
Group 30 - Electric Lift Group 20 - 31 Rotary Tiller
Group 35 - Electric PTO Clutch

(Alt information, illustrations, and specif ications Copyright @) 1980

?, contained in this service manual are based on the


tatest information available at the time of publication.
DEERE & COMPANY
Moline, lllinois
All rights reserved
The right is reserved to make changes at any time
without notice.)

'f Litho in U.S.A.

\
s
t-
7

Tractors, 200 Series


SM-2105 (Jun-Bt )

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 \

plicable, throughout this service manual.

Litho in U.S.A

_!

,i".
Tractors, 200 Series
General 10
Specifications 10-1
SM-2105 (Jun-81)

Group 10
SPECIFICATIONS
ENGINE SPECIFICATIONS
200 208 210
ftem

... K181S K241AQS


Engine Model No. .. K181QS
Kohler Kohler Kohler
Manu{aclurer
One One One
Cylinders
Four Four Four
Slroke/Cycle

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

Normal ComPression.. 1 10 to 120 psi 110 to 120 psi 1 10 to 120 psi


Valve Clearance
lntake (Cold)..... . 0.007 in. (0.178 mm) 0.007 in. (0.178 mm) 0.010 in. (0.254 mm)
0.016 in. (0.406 mm) 0.020 in. (0.508 mm)
Exhaust (Cold) ..... 0.016 in. (0.406 mm)
Battery BatterY Battery
lgnition .

Champion-J-8 or XJ8 Champion-RJ8 Champion-H-10


Spark Plug**.
AC-45-M or R-46 AC-451
Preslolite-14-7 Preslolite-14-L7B
o|l4-R8
0.025 in. (0.635 mm) 0,025 in. (0.635 mm) 0.035 in. (0.889 mm)
Spark Plug GaP . .
0.020 in. (0.508 mm) 0.020 in. (0,508 mm) 0.020 in. (0.508 mm)
Breaker Poinl GaP
Alternalor Alternalor' Alternalor
Charging System.
12-Volt 12-Volt 12-Volt
Starter. .
Dry-type Drytype Dry-type
Air Filter

K3OlAQS K321AQS K341AQS


Kohler Kohler Kohler
One One One
Four Four Fout

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 .

1700 to 1900 rpm 1700 to 1900 rpm 1700 to 1900 rpm


Speeds (ldle)
12 14 16
Horsepower*
110 to 120 psi 110 to 120 psi 110 to 120 psi
Normal Compression. . . . .

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. .

Dry-type Dry-tyPe Dry-type


Air Filter

*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

Litho in u.s.A.
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

Item 200,208 210,212, 214,216


CAPACITIES
Fuel Tank
Crankcase
lr-tr, ,.r. Garons (13.25 L) 3-1l2 U.S. Gallons (13.25
..(s.N.30001-95261)
L)
U.S. Pints (1.18 L)
3 U.S. Pts. (1.42 L)
l2-1/2 ***(S.N. 95262 and
up)
4 U.S. Pints (1.89 L) 'o
Transaxle. uu'l 3-1/2 U.S. Pints (1.65 L)
Hydraulic System (optional) . .
TRANSMISSION
l',,""':::'r 2 U.S. Pints (0.94 L)
Type . . lTransaxle Transaxle
Gear Selections....... ..... 14forward-lreverse 4forward - l reverse
TRAVEL SPEEDS - (r 3400 rpm I
I
1st Gear (Variable) to 0.9 mph (.6 to 1.6 kms/hr) 0.3 to 0.9 mph (.6 to I.6 kms/hr)
10.3
2nd Gear (Variable) .0 to 2.7 mph (2.1 to 4.6 kms/hr) 1.O to 2.7 mph (2.1 to 4.6 kms/hr)
11
3rd Gear (Variable) .8 to 4.7 mph (3.8 to 8.0 kms/hr) '1
.8 to 4.7 mph (3.8 to 8.0 kms/hr)
l1
4th Gear (Variable) to 7.0 mph (5.5 to 11.9 kms/hr) 2.6 to 7.0 mph (5.5 to I1.9 kms/hr)
12.6
Reverse (Variable) 1.4 to 3.7 mph (2.4 to 5.3 kms/hr) 1.4 Io 3.7 mph (2.4 to 5.3 kms/hr)
DIMENSIONS
Wheelbase 46 in. (1 .168 m) 46 in. (1.168 m)
Overall Length 67-1 /2 in. (1.715 m) 67-1/2 in. (1.715 m)
Overall Height 42 in. (1 .067 m) 42 in. (1.067 in)
Overall Width (maximum) ..... 4'l-1/2 in. (10.54 m) 41-1/2 in. (1.054 m)
WHEEL TREAD
Front. . . 31 in. (78 74 cm) 31 in. (78.74 cm)
Rear (GT-3 Tires) .. 27 in. or 33 in. (68.58 cm or 83.82 cm) 27 in. or 33 in. (68.58 cm or 83.82 cm)
(GT-5 Tires) 28-1/2 in. or 31 in. (72.39 cm or 78.74 cm) 28-1/2 in. or 31 in. (72.39 cm or 78.74 cm\
BRAKES
Type .. Band, pedal-operated Band, pedal-operated
Parking. Hand-lock foot brake Hand-lock foot brake
CLUTCH V-belt system V-belt system
PTO CLUTCH Manual Manual
STEERING Enclosed gear Enclosed gear
LIFT* . Manual, Electric Manual, Electric, Hydraulic
SHIPPING WEIGHT 200 Tractor - 691 lbs. (313 kg) 759 lbs. (344 ks)
2OB Tractor - 673 lbs. (305 kg)

*Electric and Hydraulic


Lifts are dealer installed options.
**Aluminum Pan
***Steel Pan

Litho in U.S.A.
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

performance and engine damage. Always use -2 -1 3'


clean gasoline storage cans and funnels. -30 -22" __L
I

-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.

a good quality single viscosity oil with a service


designation no higher than "SB" or "SC". DO NOT
use "SD" or "SE" service designation oits during Quality engine oils are blended, so additives are
break-in operation. lf "SB" or "SC" oils are not neither required nor recommended.
available, any single viscosity oil may be used.
After the first 5 hours of break-in operation, drain CAPACITIES
the engine crankcase and refill with fresh oil with a
service designation shown below. Fuel Tank 3-1l2 U.S. gallons (13.5 L)
Crankcase:
John Deere TORQ-GARD SUPREMETM engine oil is 200,208 2 U.S. pints (0.946 L)
recommended. lf other oils are used, they must be 210,212,214
premium quality engine oils meeting performance re- and 216 Aluminum Pan Engine
quirements of: 3 U.S. pints (1.42 L)
- API Service Classification Steel Pan Engine
CD/SD 4 U.S. pints (1.89 L)
- Military Specification
Transaxle 3-1l2 U.S. pints (1.65 L)
Hydraulic System
MtL-L-2104C
(optional equip.) 2 U.S. pints (0.94 L)
For low temperature operation, where oils meeting
the above requirements may not be available in ap-
propriate viscosity grade, oils meeting the performance
requirements of. API Service Classification CS/SC or
Military Specification MIL-L46152 may be used, but at
a shorter drain interval.

Litho in U.S.A.
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

- SAE Multipurpose Grease ac I

containing 3 to 5 percent ____I


He
molybdenum disulfide.
L

lf you operale your equipm€nt at temperalures b€low the


limits shown, mnsull your dealer for special lubricants

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)

LUBRICATING GREASE FITTINGS-Continued

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- )

e Fig. 4-Grease Fifting Locations


(Serial No. 109,001- )

Litho in U.S.A.
Tractors, 2O0 Series General 1O

SM-2105 (Jun-81) Tune-lJp and Adiustments 2O-5

7. Adjust Carburetor 1. Turn high-speed mixture needle (A), Figs. 10 or


11, clockwise until lightly seated. Close finger-tight
CAUTION: Prevent burns. Do not touch only. Then open 1-112 turns.
engine shrouds or muffler shield if engine
has been running. 2. Turn idle mixture needle (C) clockwise until
lightly seated. Close finger-tight only. Then open 2
ldle adjustment and high-speed adiustment must complete turns.
be made at the same time as each affects the other.
3. Start engine and raise throttle lever on dash
Adlust carburetor as follows: panel to "FAST" position. Allow engine to warm up'

4. Turn high-speed mixture needle (A) 1/8 turn


each time, clockwise or counterclockwise, until en-
gine runs smoothly at full throttle (3400 to 3500 rpm).

5. Move throttle lever to "SLOW" position and turn


idle mixture needle (C) 1/8 turn each time, clockwise
or counterclockwise, until engine runs smoothly
(1700 to 1900 rpm).
6. Advance throttle lever quickly to check for uni-
form acceleration. lf engine misses, fuel-air mixture
is too lean. Turn high-speed mixture needle (A)
counterclockwise until positive acceleration can be
obtained.

7. lf excessive exhaust smoke is noticed, mixture


A-High-Speed Mixture Needle is too rich. Readiust idle mixture needle (C), until en-
B-ldle Speed Screw gine idles smoothly at 1700 to 1900 rpm.
C-ldle Mixture Needle
Fig. 10-200 and 208 Tractor Carburetor 8. Check Engine Speed

Fig. 12-Checking Engine Speed With Vibration Tachometer

i9l dr*9S,Yl A vibration tachometer, Fig. 12, can be used lo


A-High-Speed Mixture Needle check engine for a slow idle speed of 1700 to 1900 rpm
B-ldle Speed Screw and a full throttle speed of 3400 to 3500 rpm.
C-ldle Mixture Needle
lf carburetor adlustments do not give correct en-
Fig. 11-210, 212,214 and 216 Tractot Carburetor
gine speed, adiust governor linkage' See Section 30'
Group 10.

Litho in U.S.A.
10 General Tractors, 200 Series
20-6 Tune-Up and Adjustments sM-2105 (Jun-81)

9. Change Engine Crankcase Oil 13. Check Tire Pressure


Refer to page 10-15-3. lnflate tires as shown in chart below.

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.

11. Lubricate Grease Fittings TIRE INFLATION PRESSURES

Refer to page 10-15-2. Tire Front Rear

12. Service Battery Regular 4.80 x 4.00-8 23 x 8.50-12


Equipment (2-ply)
Tires on 10 to 12 psi 5 to 10 psi
208 Tractor (4.13 to 5.65 ba| (2.34 to 4.75 bat)
4.20 to 5.74 kg/cma) (2.38 to 4.83 kg/cmz)

High-Flotation 16 x 6.50-8 23 x 8.50-12


Tires 6 to 16 psi 5 to 10 psi
(GT-3 Traclor) (2.82 to 7.58 bar) (2.34 to 4.75 bar)
(2.87 1o 7.70 kg/cmz) (2.38 to 4.83 kg/cmz)

Traction Tires 4.80 x 4.00-8 23 x 8.50-12


(GT-4 Tractor) 12 to 40 psi 5 to 10 psi
(5.65 to 19 bar) (2.34 to 4.75 bar)
(5.74 to 19 kg/cmz) (2.38 to 4.83 kg/cmz)

High-Flotation 16 x 6.50-8 23 x 10.50-'12


Tires 6 to 16 psi 5 to 10 psi
(GT-5 Tractor) (2.82 to 7.58 bar) (2.34 to 4.75 bat)
(2.87 to 7.70 kg/cmz) (2.38 to 4.83 kg/cmz)
Traction Tires 4.80 x 4.00-8 23 x 10.50-12
Fig. 1S-Battery Electrolyte Level
(a-Ply)
(GT-8 Tractor) 12 to 40 psi 5 to 10 psi
Check electrolyte every 25 hours of operation. (5.65 to 19 bar) (2.34 to 4.75 bar)
(5.74 to 19 kg/cma) (2.38 to 4.83 kg/cmz)
CAUTION: Battery electrolyte is poison-
ous and corrosive. lt can injure eyes, skin, 14. Check Operation and Condition of:
and clothing. Handle it carefully. lf electrolyte is
spilled, flush immediately with a solution of one A. Lights - Replace bulbs or wiring as necessary.
part baking soda to four parts water.
B. Lift System - Check manual, electric or hydraulic
lift for proper function. Once a week or every 50 hours
Keep shield on positive (+) terminal closed.
of operation check hydraulic fluid tevel. Hydraulic fluid
1. Remove caps. level should be within 1 inch (25.4 mm) from top of
reservoir. Use John Deere All Weather Hydrostatic
Fluid or an equivalent Type "F" Automatic Transmis-
2. lf necessary, add distilled water until tevel (A) is
1/4 lo 1/2 inch (6.4 to 12.7 mm) above ptares (B). sion Fluid.

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.

4. lnstall caps. E. Belts and Equipment - Clean belts by wiping


them with a clean cloth. Do not use solvents. Solvents
will soften the material and cause belts to grab.

Litho in U.S.A.
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

A-Camshaft D-Breather AssemblY G-lntake Valve


B-Tappet E-Valve Spring H-Cylinder Head
C-Retainer F-Spring Retainer I Plug
-Drain
Fig. l-Schematic View of Cytinder Head, Valves and Breather

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.

Litho in u.s.A.
20 Engine Tractors, 200 Series
1O-2 Cylinder Head, Valves, and Breather sM-2105 (Jun-81)

DISASSEMBLY

t-g l-Cap
2-Washer
Screw

2+@ 3-Cylinder Head


4-Head Gasket
S-Hex. Nut
6-Stud
26 7-Exhaust Valve
25 8-lntake Valve
ri'[
l\ t\
2l
22
23
t\
1

k\ g-5
@+2
e
9-Upper Spring
10-lntake Valve Spring
Retainer

11-Lower Spring Retainer


1\ 20\ \s U-u 12-Tappet
18 13-Valve Keeper
t7\ *\ 14-Exhaust Valve Rotator

'*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.

On 200, 210, 212, 214 and 216 Tractors, remove the


hood, grille and side panels to provide access to the
engine.

On 208 Tractors, remove grille and hood support


with hood to provide access to the engine.

1. Disconnect battery cables, negative cable first,


Fig. 3.

2. On 200,21O,212,214 and216 Tractors, remove


shroud covering muffler.

3. Remove engine shrouding, coil, carburetor, gov-


ernor linkage and muffler.
tttl;747i}.y

Fig. 3-Disassembling Engine 4. Remove cylinder head, breather assembly and


(21 0 Tractor lllustrated) valves.

Litho in U.S.A.
Tractors, 200 Series Engine 20
sM-2105 (Jun-81) Cytinder Head, Valves and Breather 10-9

Checking Valve Lift INSTALLATION


lnstalling Valves

Fig. 22-Checking Valve Lift

lnstall a dial indicator as shown in Fig. 22. Be sure


valve being checked is fully closed when adlusting
indicator lo zero.

Rotate the crankshaft and observe the maximum A-Valve Spring Compressor C-Valve Keeper Tool
valve lift on the dial indicator. B-Tight Coils

Position the dial indicator on the other valve and


repeat rotation of the crankshaft observing the max-
Fig. 23-tnstalting Valve Springs, Retainers and Keepers
imum valve lift.
Place valve springs with upper and lower retainers in
Valve lift for each valve should be 0.250 inch (6.350
valve spring chamber. lnstall springs with tight coils (B)
mm) or more. lJ lift is less for either valve, the camshaft
up, Fig. 23.
lobe is worn and the camshaft must be replaced.
NOTE: On K241AQS and KSO|AQS engines, ex-
haust valve has a short spring for rotator' On K321AQS
and K341AQS engines, both intake and exhaust
valves have short springs for rotators. Install rotator in
valve spring.

Lubricate stems and install valves in guides. Using a


valve spring compressor (A, Fig. 23) compress the
springs and install keepers on valve stem with keeper
tool, (C). lf tool is not available, apply grease to
keepers to hold them on the valve stem and insert
them by hand.

Litho in U.S.A.
20 Engine Tractors, 200 Series
10-10 Cylinder Head, Valves and Breather SM-2105 (Jun-81)

Assembling Breather lnstalling Cylinder Head


The breather must be assembled in the correct order Always install a new head gasket when head has
as shown in Figs. 24 and 25. Use new gaskets if old been removed for service. This will assure a gastight
gaskets are damaged. lnstall breather plate so that fit.
small hole in bottom of plate is down.

v
IMPORTANT: Install head gasket dry. Do not
@ use Permatex or other sealant on gasket.

Clean and apply a light film of oit to head bott threads


to insure an accurate torque reading. lnstall washers
on head bolts with sharp edges down against cylinder
head.
@
-\
,,-. ( It is important to torque all cylinder head bolts evenly
and in correct sequence, Figs. 26 and 27, so that

E\Nrs
bo\J\
uneven stresses will not be set up in the cylinder wall.

NOTE: Cylinder head for 208 Tractor, Fig. 26, is


equipped with a lifting strap at position 1.
@ M17019N

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)

lnstalling Carburetor and


Governor Linkage
Refer to Section 30, Group 1O for carburetor and
Litho in U.S.A. governor linkage installation and adjustments.
Tractors, 200 Series Engine 20
SM-2105 (Jun-81) Minor Engine Recondition 15-9

lf any of the measurements in Fig. 23 exceed


"specifications," reboring is necessary. See Group
20, "Maior Engine Recondition" for reboring. lf, cylin-
der taper is more than 0.0015 inch (0.0381 mm), re-
boring is also necessary.

Deglazing Cylinder

Fig. 22-Measuring Crankshaft

Measure the outside diameter of the crankshaft


connecting rod journal, Fig. 22.
Compare the measurements between the connect-
ing rod LD. and the crankshaft iournal O.D. These
two measurements will give the proper clearance.
See "Specifications," page 20-25-1.
An undersize rod and cap, 0.010-inch (0.254 mm), t\.428639

is available lor service. A-Electric Drill B-Deglazing Hone Pattern

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.

IMPORTANT: Cover crankshaft with rags prior


to deglazing to keep small particles out of crank-
shaft bearings and other internal parts.

Operate the deglazing tool in and out vertically to


provide a cross-hatch pattern. Seb lnsert, Fig. 24.
Follow tool manufacturer's recommendations.

Carefully clean cylinder bore with soap and water


after deglazing. Dry thoroughly and apply a light coat
of oil to prevent rust.

A-Parallel Measurement B-Right'Angle Measurement

Fig. z3-Measuring Cylinder Bore

Usrng an inside telescoping gauge and microme-


ter, measure the cylinder bore, Fig. 23, parallel (A)
and at right angles (B) to the crankshaft. Measure at
both top and bottom of ring travel zone.

Litho in U.S.A.
20 Engine Tractors, 200 Series
15-10 Minor Engine Recondition SM-2105 (Jun-81)

ASSEMBLY Use a piston ring expander for ring installation to


avoid twisting or stretching rings which could perma-
lnstalling Piston Pin nently distort rings and reduce performance.

lnstall oil control ring first, starting with expander


(A, Fig. 26). Spiral lower chrome rail (D) into place,
install cast iron spacer (E), and then spiral upper
chrome rail (D) into place.

lnstall expander (A) behind lower compression ring


(C) and install compression rings as shown in Fig.
26. Stagger end gaps to prevent gaps from being in
alignment.

lnstalling Piston and Connecting Rod

Fig. 25-lnstalling Piston Pin

Clamp connecting rod in a soft-iawed vise. Liberal-


:\i i
ly coat piston, piston pin and connecting rod with oil. L,!i:

Push piston pin, Fig. 25, into place and install new
retainers. Be certain retainers are properly seated in
grooves.

lnstalling Piston Rings


tflZ04irrTI

Fig. 27-lnstalling Piston in Cylinder

Coat piston, rings, and crankshaft lournal with oil.


lnstall piston into cylinder with match mark on con-
necting rod facing flywheel side of engine.

Compress rings wrth a ring compressor (See


"Special Tools," Section 80) and gently push piston
down with hammer handle, Fig. 27, until connecting
rod is in position on crankshaft journal.
M17046N

A*Expanders
B-Chrome Ring (Bevel Up)
C-Cast lron Ring (Scraper Groove Down)
D-Chrome Steel Rails
E-Cast lron Spacer

Fig. 26-Piston Ring Assembly

Litho in U.S.A.
Engine 20
Tractors, 200 Series 20-9
Major Engine Recondition
SM-2105 (Jun-81)

NOTE: A short block is available for service'

Fig. 11-Measuring Crankshaft

Measure the outside diameter of the crankshaft


lafSl.tli$
connecting rod iournal, Fig. 18.
A-ParallelMeasurement B-RightAngle.Measurement
Compare the measurements between the connect-
ing rod l.D. and the crankshaft journal O'D' These Fig. 19-Measuring CYlinder Bore
two measurements will give the proper clearance'
See "specif ications," page 20-25-1' To measure cylinder bore, Fig. 19, use a cylinder
dial gauge, an inside micrometer or a telescoping
An undersize rod and cap, 0.010-inch (0'254 mm)' gauge and outside micrometer.
is available for service.
Measure cylinder bore as follows:
A competent machine shop can turn the iournal
down 0.01O-inch (0.254 mm). 1. Measure the bore parallel (A) to the crankshaft
at the top end of ring travel zone.
IMPORTANT: Always turn the crankshaft iour-
nal down when possible and install a new rod' 2. Measure the bore in the same position at the
This is the least expensive method of repair' bottom end of ring travel zone.

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.

Litho in U.S.A.
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

A-Deglazing Tool B-Deglazing Hone Pattern


Fig. 20-Deglazing Cylinder Bore

lf cylinder is within tolerance and not damaged,


lightly deglaze cylinder bore. Deglazing provides fast-
er more positive seating of new piston rings, and al_
so helps retain lubrication on cylinder walls during
break-in period.
Operate the deglazing tool vertically to provide a Fig. 2l-Honing the Cylinder
cross-hatch pattern. See insert, Fig. 20. Follow tool
manufacturer's recommendations. 6. Start the drill. Move the hone up and down in
the cylinder approximately 40 cycles per minute, Fig.
Boring Cylinder Btock 21. Follow the hone manufacturer,s recommenda_
tions.
Reboring of the cylinder block is necessary when
the bore is damaged or not within the specified IMPORTANT: Some hones require oil and
tolerance. some will not work with even a small amount of
oil on the cylinder wall.
NOTE: Cylinder shoutd be rebored for 0.010
(0.254 mm), 0.020 (0.508 mm) or 0.030 (0.762 mm)_ 7. Check the diameter of the cylinder regularly
inch oversize pistons. These are the oversizes during honing. (Stop the drill before measuring and
of_
fered for service. remove the hone from the cylinder).

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.

Litho in U.S.A.
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

23.9 cu. in. 29.07 cu. rn. 31.27 cu. in


Displa@ment
18.6 cu. in (528.44 cc)
(304.8 cc) (391.65 cc) (476.37 ccl

I (r 3600 rpm 10 (, 3600 rpm 12 (, 3600 rpm 14 @ 3600 rpm


Horsepower
.110 to 120 psl 110 to 120 PSI 110 to 120 psi 1'10 to 120 psi
Engine mmpression ( 1000 rpm)
0.035 in. 0.035 in. 0.035 in.
Spark plug gap 0.025 in. (0.889 mm)
(0.635 mt',) (0.889 mm) (0.889 mm)
3.375 in. 3.500 in. 0.003 in.
2.9375 in. 3.251 in. (0.0762 mm)
Cylinder bore (new) (82.57 mm) (85.73 mm) (88.9 mm)
(76.21 mm)
2-7/8 tn. 3-1/4 in 3-1l4 in.
Slroke 2-3/4 tn. (82.55 mm)
(69.85 mm) /73.03 mm)
0 o03 to 0.020 in. 0.003 to 0.02u rn. 0.003 to 0.020 in.
Crankshalt end PiaY 0.002 to 0.023 in (0.076 lo 0.508 mm)
(0.0508 to 0.5842 mm) (0.076 to 0.508 mm) (0.076 lo 0.508 mm)
0.007 to 0.016 in. 0.007 to 0.016 in. 0.007 to 0.0'16 in.
iournal-to-@nnecti ng rod
0.005 to 0.016 in (0.1778 to 0.4064 mm)
(O.1778la 0.4064 mm) (0.1778 to 0.4064 mm)
side clearance lO.127O to 0.4064 mm)
-cakshatt 1.1230 to 1.1265 in 1.179 to 1.181 in.
'1.1790 to'1.1825 in. '1.1790 to 1.1825 in.
Crankshatt journal Iength (@nnectrng (29.95 to 29.97 mm) {29.95 to 30.04 mm) (29.95 to 30.04 mm)
rod) (28.52 to 28.61 mm)
1.4995 to 1.5000 in. 1.4995 to 1.5000 in. 1.4995 to 1.5000 in. -0.0015 in.
Crankshaft journal diameter @nnecting 1.1855 to 1.1860 in. (38.09 to 38.10 mm) (-0.038 mm)
(30.11 to 30.12 mm) (38.09 to 38.10 mm) (38.09 to 38.10 mm)
rod bearing '1.5745
1.5743 to 1.5747 in. 1.5745 to 1.5749 in. to 1.5749 in.
Main bearinos (crankshaft journal) 1.181 1 to 1.1814 in.
(29.99 to 30.00 mm) (39.98 to 39.99 mm) (39.99 to 40.00 mm) (39.99 lo 40.00 mm)

1.5010 to 1.5025 in. 1.5010 to 1.5025 in. 1 5010 to 1.5025 in.


1 1870 to 1.1885 in.
Conneclrng rod bore (large end) (38.'12 to 38.14 mm) (38.12 to 38.14 mm) (38.12 to 38.14 mm)
(30.14 to 30.16 mm)
0.6255 to 0.6259 in. 0.8596 to 0.85975 in 0.8757 to 0.87585 in. 0.8757 to 0.87585 in.
Connecting rod bore (small end) (22.24 to 22.25 mm) (22-24 to 22.25 mm)
(15.88 to '15.89 mm) (21.83 to 21 .84 mm)
0.001 to 0.002 in. 0.0035 in.
0.001 to 0.002 in. 0.001 to 0.002 in. 0.001 to 0.002 in.
Connecting rod-to-crankshall (0.0254 to 0.0508 mm) (0.0254 to 0.0508 mm) (0.0889 mm)
(0.0254 to 0.0508 mm) (0.0254 to 0.0508 mm)
iournal running clearance 0 O0O3 to 0.0008 in. 0.0015 in.
0.0006 to 0.0011 in. 0.0003 to 0.0008 ln. 0.0003 to 0.0008 in.
Connecling rod-to-piston p'n clearance (0.0076 to 0.0203 mm) (0.0076 to 0.0203 mm) (0.0381 mm)
{0.0152 to 0.0279 mm) 0.0076 to 0.0203 mm
0.003 in.
Cylinder head tlatness (max.) (0.0762 mm)

oo l5 0.0015 in.
001 5 001 5
Cylinder taper (max.) oo25 (0.0381 mm)

005 0.005 in.


oo5 005
Cylinder out-of-round (max.) .oo5 (b.127 mm)
'I
3.2470 to 3.2480 in. 3.3705 to 3.3715 in. 3.4971 to 3.4985 in.
Piston diameter (boltom skirl) 2.9332 to 2.9346 in (88.82 to 88.86 mm)
(74.50 to 74.53 mm) 1.82.47 b A2.49 mm) (85.61 to 85.63 mm)
0.000 to 0.0003 in. setect to ond.thiriib
lit..':r' i
0.000 to 0.0003 in. 0.000 to 0.0003 in 0.000 to 0.0003 in.
Piston pin-lo-Piston boss (0.000 to 0.0076 mm) (0.000 to 0.0076 mm) (0.000 to 0.0076 mm) PUsh
(0.000 to 0.0076 mm)
0.0075 to 0.0085 in 0.0065 to 0.0095 in. 0.007 to 0.010 in
*Piston-to-cyljnder bore (top ol skirt) 0.006 to 0.008 in. b
(O.1524 to 0.2032 mmi (0.1905 to 0.2159 mm) (0.1651 to 0.2413 mm) Ql77A 0.2540 mm)

0.8591 to 0.8593 in. o a752 lo 0.8754 in. 0.8752 to 0.8754 rn.


Pislon pin diameter 0.6247 lo 0.6249 in.
(22.23 to 22.24 mm\
(15.86 to 15.87 mm) (21.82 to 21.83 mm) (22.23 to 22.24 mm)
0.002 to 0.004 in 0.002 to 0.004 in +0.002 an.
0.0025 lo 0.004 in. 0.002 lo 0.004 in.
Ring side clearance (top ring) (0.0508 to 0.1016 mm) (0.0508 to 0.1016 mm) (O.O5O8 to 0.1016 mm) (0.508 mm)
(0.0635 to 0.1016 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)

SPECIFICATIONS-Co nti nued

216 Tractor Wear


llem K341AOS Engino Tolerance
Displacem€nt 35.89 cu in
(588.24 cc)
Horsepower 16 @ 3600 rpm
Engine compression (1000 rpm) 1 10 to 120 psr
Spark plug gap 0.035
(0.635 mm)
Cylinder bore (new) 3.750 in. 0.003 in.
(95.2 mm) (0.0762 mm)
3-1/4 in.
(82.55 mm)
Crankshaft end play 0.003 lo 0.020 in.
(0.076 to 0.508 mm)
Crankshall iournal-to-connecting rod 0.007 to 0.016 in.
side clearanc€ (01778 lo 0.4064 mm)
(.;rankshall lournal length (conn€cting 1.1790 to 1.1825 in.
rod) (29.95 to 30.04 mm)
Crankshaft journal diamel€r connecting 1.4995 to 1.5000 in.
rod bearing -0.0015 in.
(38.09 to 38.10 mm) ( 0.038 mm)
Main b€arings (crankshatt journal) 1.5745 to 1.5749 in.
(39.99 to 40.00 mm)
Connecting rod bore (targe end) 1.5O10 to 1.5025 in.
(38.12 to 38.14 mm)
Connecting rod bore (small end) 0.8757 to 0.87585 in.
(22.24 to 22.25 mm\'
Connecting rod-to-crankshaf I 0.001 lo 0.002 in. 0.0035 in.
journal running clearance (0.0254 lo 0.0508 mm) (0.0889 mm)
C;onnocltng rod-to-piston pin clearance 0.0003 lo 0.0008 in. 0.0015 tn.
(0.0076 lo 0.0203 mm) (0.0381 mm)
Cylinder head ltatness (max.) 0.003 in.
(0.0762 mm)
Cylinder laper (max.) 0015 0.0015 in.
(0.0381 mm)
Cylinder out-of -round (max.) .005 0.005 in.
(0.127 mm)
Piston diameler (bottom skirt) 3.4971 to 3.4985 in.
(88.82 td 88.86 mm)
Piston pin-to-pislon boss 0.000 to 0.0003 in. Sel€cl to one thumb
(0.000 to 0.0076 mm) push lit.
-Prston-lo-cylinder bore (top
ol skirt) 0.007 to 0.01 0 in.
(0.1778 1o 0.2540 mm)
Piston pin diameter 0.8752 lo 0.8754 in.
(22.23 to 22.24 mm)
Ring side clearance (top ring) 0.002 lo 0.004 in +0.002 in.
(0.0508 1o 0.1016 mm) (0.s08 mm)

*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)

45" 45' 45' 45'


Valve seat angle
45' 45' 45"
Valve laco angle 45',

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

(1.588 mm) (1.588 mm) ( .588 mm) (0.794 mm)


(1.588 mm) 1

18 to 20 lbs. at 43 to 49 lbs. at 43 to 49 lbs. al 43 to 49 lbs. at


Valve soring mmpressed (rntake) '1-5/16 in. lenglh
1-5l16 in. length 1-5/16 in. length 1-5,/16 in. length
(8.16 to 9.98 kg al (19.50 to 22.23 kg al (19.50 to 22.23 kq al {19.50 to 22.23 kg at
49.21 mm length) 49.21 mm length) 49.21 mm length) 49.21 mm length)

Litho in U.S.A.

I
20 Engine Tractors, 2A0 Series
25-4 Specifications sM-2105 (Jun-81)

S PECI FICATIONS-Conti nued


200 Tractor-
Kl8lOS Engine 210 Tractor 212 fraclot 214, 2rO Trector Wear
llem 2Og Trector-Kl8lS Engin( K241AOS Engine K301AQS Engine K32tAQS, K341AQS Enstno Tolerane

Valve spring mmpressed (exhaust) 18 lo 22 lbs. at 43 to 49 lbs. at 43 to 49 lbs. al 43 to 49 lbs. at


1-5l16 in. length 1-5l16 in. lengih 1-5l16 in. Iength '1-5l16 in. length
(8.16 to 9.98 kg at (19.50 to 22.23 kg at (19.50 to 22.23 kg at (19.50 to 22.23 kq ai
49.21 mm length) 49.21 mm length) 49.21 mm lenoth) 49.21 mm tenqth)
Valve spring free length (intake) 1-3/4 in. 1-13l16 in. 1-13/16 in. 1-13/16 in.
(44.45 mm) (46.04 mm) (46.04 mm) (46.04 mm)
Valve spring free length (exhaust) 1-3/4 in. 1-7/8 1-7/8 in.
tn. 1-7 /8 in.
(44.45 mm) (47.63 mm) (47.63 mm) (47.63 mm)
Governor bushing-to-governor cross 0.0005 to 0.0020 in. 0.001 to 0.0025 in. 0.001 lo 0.0025 in. 0.001 lo 0.0025 in.
shaft clearance (0.0127 to 0.0508 mm) (0.0254 to 0.0635 mm) (0.0254 to 0.0635 mm (0.0254 to 0.0635 mm)
Governor gear-to-governor shafl 0.0005 to 0.0020 ln. 0.0005 to 0.0020 in. 0.0005 to 0.0020 in. 0.OOO5 lo 0.0020 in.
(O.O127lo 0.0508 mm) (0.0127 lo 0.0508 mm) (0.0127 lo 0.0508 mm (0.0127 ro 0.0508 mm)
Ball bearing-to-cylinder btock (inlerference) 0.0014 to 0.0029 in. 0.0006 to 0.0022 in. 0.0006 to O.OO22 in. 0.0006 to 0.0022 in.
(0.0355 to 0.0736 mm) (0.0152 to 0.0558 mm) (0.0152 lo 0.0558 mm) (0.0152 to 0.0558 mm)
Eall bearing-to-bearing plate (interference) 0.0014 to 0.0029 in. 0.0012 to 0.0028 in. 0.0012 to 0.0028 in. 0.0012 to 0.0028 in.
(0.0355 to 0.0736 mm) (0.0304 to 0.0711 mm) (0.0304 to 0.0711 mm) (0.0304 to 0.07'11 mm)
Ball bearing-to-crankshaft 0.0002 to 0.0005 in 0.0004 to 0.0005 in. 0.0004 to 0.0005 in. 0.0004 to 0.0005 in.
(interlerence too loose) (0.0050 to O.O127 mm\ (0.0101 to 0.0127 mm) (0.0101 to 0.0127 mm (0.0101 to 0.0127 mm)

TORQUES FOR HARDWARE


Location Torque

200 and 208 Tractor 210, 212, 214, 216 Tractors


Cylinder head bolts 15-20 ft-lbs 25-30 ft-lbs
(20 to 27 N.m) (34 to 41 N.m)
Connecting rod cap screws 200 in-lbs 300 in-lbs
(22.6 N.m) (3a N.m)
Flywheel nut 45-55 ft-lbs 50-60 ft-lbs
(68 to 75 N.m) (68 to 81 N.m)
Spark plug (cold) 18-22 ft-lbs 18-22 ft-lbs
(24 to 30 N.m) (24 to 30 N.m)

Litho in u.s.A.
20 Engine Tractors, 200 Series
25-4 Specifications SM-2105 (Jun-91)

S PECI FICATIONS-Conti nued


2OO frcclot-
Kl8lOS Engine 210 Traclor 212 f?eclot 214,218 Ttac1,or Wear
Item 208 Tractor-Ki8l S Engin. K241AOS Engine K30lAQS Engire K321AOS, K341AOS Englne Tolerance

Valve spring mmpressed {exhaust) 18 io 22 lbs. at 43 to 49 lbs. at 43 to 49 lbs. at 43 to 49 lbs. at


1-5l16 in. length 1-5l16 in. length 1-5l16 in. length 1-5/16 in. length
(8.16 io 9.98 kg al (19.50 to 22.23 kg at (19.50 to 22.23 kg at (19.50 to 22.23 kg at
49.21 mm length) 49.21 mm length) 49.21 mm lenoth) 49.21 mm length)
Valve spring free length (intake) 1-3/4 in. 1-13/16 in. '1-13/16 in. 1-13,/16 in.
(44.45 mm) (46.04 mm) (46.04 mm) (46.04 mm)
Valve spring free length (exhaust) 1-3/4 in. 1-7 /8 in. 1-7/8 in. 1-7/8 ln.
(44.45 mm) (47.63 mm) (47.63 mm) (47.63 mm)
Governor bushing-lo-governor cross 0.0005 to 0 0O2O in 0.001 to 0.0025 in. 0.001 to 0.0025 in. 0.001 to 0.0025 in.
shaft clearance (0.0127 to 0.0508 mm) (0.0254 to 0.0635 mm) (0.0254 to 0.0635 mm) (0.0254 to 0.0635 mm)
Governor geatrto-governor shall 0.0005 to 0.0020 in. 0.0005 to 0.0020 in. 0.0005 to 0.0020 in. 0.0005 to 0.0020 in
(O.O127 Io 0.0508 mm) (0.0127 to 0.0508 mm) (0.0127 to 0.0508 mm) (O.O127lo 0.0508 mm)
Ball bearing-to-cylinder block (interference) 0.0014 to 0.0029 in. 0.0006 lo 0.0022 in. 0.0006 lo O.0O22 in. 0.0006 to 0.0022 in.
(0.0355 to 0.0736 mm) (0.0152 to 0.0558 mm) (0.0152 to 0.0558 mm (0.0152 to 0.0558 mm)
Ball bearing-to-bearing plate (interterence) 0.0014 to 0.0029 in. 0.0012 to 0.0028 in. 0.0012 to 0.0028 in. 0.0012 to 0.0028 in.
(0.0355 to 0.0736 mm) (0.0304 to 0.0711 mm) (0.0304 to 0.0711 mm (0.0304 to 0.0711 mm)
Ball bearing-to-crankshaft 0.0002 to 0.0005 in. 0.0004 to 0.0005 in 0.0004 to 0.0005 in. 0.0004 lo 0.0005 in.
(interlerence too loose) (0.0050 to 0.0127 mm) (0.0101 lo 0.0127 mm) (0.0101 to 0.0127 mm (0.0101 to 0.0127 mm)

TORQUES FOR HARDWARE


Location Torque

200 and 208 Tractor 2'lO, 212, 214, 216 Tractors

Cylinder head bolts 15-20 ft-lbs 25-30 ft-lbs


(20 to 27 N.m) (34 to 41 N.m)
Connecting rod cap screws 200 in-lbs 300 in-lbs
(22.6 N.m) (3a N.m)
Flywheel nut 45-55 ft-lbs 50-60 ft-lbs
(68 to 75 N.m) (68 to 81 N.m)
Spark plug (cold) 18-22 ft-lbs 18-22 ft-lbs
(24 to 30 N.m) (24 to 30 N.m)

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

Litho in U.S A
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
.

Removing Actuator Assembly 30-1 4


Removing Electric Motor. 30-14
Removing Drive End Cap. . 30-14
Removing Spacer 30-14
Removing Gear Box 30-14
Removing Gear Tube Cover 30-1 5
Removing pivot. .
30-1 5
Removing Armature from Motor
Housing ....30_15
Removing Brushes 30_15
lnspecting 3-lnch (7.62 cm) Diameter
Electric Lift Motor and Actuator parts ... 30_16
Assembling 3-lnch (7.62 cm) Diameter
Electric Lift Motor and Actuator......... 30-17
lnstalling Brushes and Springs 30-'17
lnstalling Armature and End Cap . . . . 30-17
.

lnstalling Pivot. 30-17


lnstalling Gear Tube Cover 30-17
lnstalling Gear Box 30-18
lnstalling Drive End Cap. . 30-1 8
lnstalling Electric Motor. 30-1 8
lnstalling Electric Lift Motor and
Actuator 30-18

GROUP 35 - ELECTRIC PTO CLUTGIi


(200 TRACTORS SERTAL
NO. 19O,OO1 AND ABOVE)
Principle of Operation 35-1
Test Electric pTO Clutch 35-2
Adjusting Etectric pTO Ctutch 35-2
Removing Electric pTO Clutch 35-3
Disassembling Electric pTO Clutch 35-4
lnspection and Repair 35-5
Assembling Electric pTO Clutch 35-7
lnstalling Etectric pTO Clutch 35-8

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

Figure 2-Wiring Diagram For 208 Tractor

Litho in U.S.A.
@ 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

CON DEN SER


z
L IGHT d
SI.JITCH
STATOR

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

OFF RUN START

AEBD
DBIC

L IGHT
0!l GREEN

LI 6HT IgIITION COIL


sItTcH
KEY
EIlYtLLoll SIIITCH

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- )

Litho in U.S.A.
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.

Litho in u"s.A.
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

A-Ammeter C-Starter E-PTO Neutral'Start Salety Switch G-lgnition Switch


F-Transmission Neutral-Start H-Battery
B-Circuit Breaker D-Solenoid
SaletY Switch I
-Coil
Fig. 1-Cranking System Components

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.

Litho in U.S.A
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

Fig. Z-Cranking System Components

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.

Litho in U.S.A
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-

A-Ammeter D-Solenoid F-TransmissionNeutral- H-Battery


B-Circuit Breaker E-PTO Neutral-Start Start Salety Switch I Safety-Start
G-lgnition Switch
-Seat
Switch
C-Starter Salety Switch
J-Coil
Fig. 3-Cranking System Components

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.

Litho in U.S.A.
40 Electrical System Tractors, 200 Series
10-4 Cranking System sM-2105 (Jun-81)

lgnition Switch Once the key switch is permitted to return to the


"RUN" position, current is cut off from the solenoid
collapsing the electromagnetic field. The spring-loaded
plunger moves away from the contact point breaking
the circuit from the battery to the starter.

:N16744]{
Ml6744N
A-Regulator C-Solenoid E-Accessories
B-Battery I)-lgnition
Fig. 4-lgnition Switch Terminals

The ignition switch Fig. 4, directs the flow of elec-


tricity from the battery to the proper circuit.

When the switch is in the "START" position (key


turned all the way to the right) current is directed from
the battery to the key switch, through the neutral-start
safety switches to the starter solenoid.

When the switch returns to "RUN" position following


engine start, current is diverted from the solenoid and
routed to the accessory, charging and ignition circuits.
M20964N
Solenoid
The solenoid, Fig. 5, is an electric switch composed A-Eleclromagnet E-Starter Terminal
B-Plunger F-lngition Switch
of an electromagnet (A) and spring-loaded plunger (B). C-Contact Points Terminal
D-Positive Battery G-Base
On large terminal (D) is connected to the positive Terminal
terminal of the battery and the other terminal (E) is
connected to the starter. The solenoid base (G), is Fig. 5-Solenoid Assembly
grounded to the frame, as is the negative post of the
battery. When the ignition switch is turned to the
"START" position, current flows through the solenoid
windings forming a complete circuit with the grounded
base and setting up an electromagnetic field.

This draws the plunger into the center of the field,


overcoming a spring. A contact (C) at the end of the
plunger closes the circuit across the battery and starter
contact points permitting current flow from the battery
to the starter.

Litho in U.S.A.
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

12-Drive End Cap


ttw
I

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.

NOTE: Starters may vary as to design


of Drive End Cap and Mounting Bracket
for Housing. Refer to Parts Catalog for
differences in SMH|2A2 and SMH12A4
M11627 Starters. SMH| 2A4 shown.
Fig. i-Exploded View of Starter

Starter The permanent magnet starter needs current only


for the armature in order to set up opposing magnet-
The permanent magnet starter, Fig. 6, differs from
ic fields to start it turning.
wire-wound starter in construction, current requirement
and torque characteristics,
The starter drive consists of the starter drive gear
and spring which are mounted on the armature shaft.
On wire-wound starters, a relatively heavy current
When the armature turns, the drive gear moves later-
is directed through field coils and armature to build ally into mesh with the flywheel. As the engine starts
up a strong magnetic field necessary to start the ar- and speeds up, the armature is overrun, causing the
mature turning.
drive gear to disengage.

Litho in U.S.A.
40 Electrical System Tractors, 200 Series
10-6 Cranking System SM-2105 (Jun-81)

DIAGNOSING AND TESTING


PROBLEM TEST SEOUENCE

1. Engine cranks but does not start. Problem in ignition System (See Group 15).

2. Engine cranks a short time only. A. Test battery. Page 40-10-7


B. Check connections.
C. Test starter. Page 40-10-10

3. Engine cranks slowly. A. Test battery. Page 4O-1O-7


B. Check connections.
c. Test starter. Page 40-10-10

4. Engine does not crank. A. Test battery. Page 40-10-7


B. Check connections.
C. Test starter. Page 40-10-10
D. Test solenoid. Page 40-10-10
E. Test neutral-start safety switches. Page 4O-.10-8 and 40-10-9
F. Test ignition switch. Page 40-10-8

Cranking System Tests


A. Test Battery D. Test Solenoid
1. Check battery specific gravity, page 40-10-7. Connect battery directly to solenoid page 40-10-8.
lf battery is good, proceed to next test. lf solenoid energizes, test neutral-start salety
lf discharged, charge battery. switches. lf solenoid fails to energize, replace so-
lf battery is in poor condition, replace battery. lenoid.
2. Check battery voltage, page 40-10-7.
lf good, proceed to next test. E. Test Neutral-Start Safety Switches
lf poor, replace battery. Test Transmission Neutral-Start Safety Switch
Attach test light to the terminals, page 40-10-8 or
B. Check Connections 40-1 0-9.
Place the shift lever in neutral position.
1. Check all connections for looseness, corrosion,
lf test light lights, test neutral-start PTO safety
or breaks.
switch.
lf test light does not light on tractors below Serial
c. Test Starter
No. 190,0O1 , adjust switch as explained on page
1. Connect battery directly to starter. lf starter 40-10-8. lf test light does not light after adjust-
cranks engine, proceed to test solenoid, neu- ment, replace switch.
tral-start safety switches and ignition switch. lf
starter does not crank engine, remove starter Test PTO Neutral-Start Safety Switch
from iractor and test as instructed on page
Attach test light to terminals on switch page
40-10-10.
40-10-8 or 40-10-9. Place PTO lever or switch in
lf starter engages but does not crank engine:
disengaged position.
Check if PTO is engaged with load on PTO
lf test light lights, test ignition switch.
attachment.
lf test light does not light on tractors below Serial
Check for engine resistance such as seized
No. 190,001 , adjust switch as explained on page
piston, binding connecting rod, crankshaft
40-10-8. lf test light does not light after adjust-
bearings, or bushings. lf engine and PTO turn
ment, replace switch.
freely, remove starter and check it for:
Dirty or gummed armature.
F. Test lgnition Switch
Shorted or grounded armature, page
40-1 0-1 0. Check for continuity between terminals with the
Misaligned start motor. switch placed in each of three positions as ex-
plained on page 40-10-8.

Litho in U.S.A.
Tractors, 200 Series
Electrical System 40
Cranking System 1O-7
SM-2105 (Jun-81)

Testing Battery Checking BatterY Voltage


Checking Battery Specific Gravity With a battery in good condition, each cell contrib-
utes approximately 1.95 to 2.08 volts' lf battery
charge is low and less than 0.05 volt difference is
noted between the highest and lowest cells, the bat-
tery may be recharged.

lf this difference is more than 0.05 volts, this could


indicate a cracked plate or other damage which
could call for replacement of the battery.

There are two methods ol testing battery capacity'


Battery electrolyte temperature should be at or near
80'F (26.5'C) for these tests.

Before making either of the two following tests, first


check electrolyte level in battery. Add water if neces-
sary. lf water is added, be sure it is thoroughly mixed
with the underlying electrolyte by charging' Battery
voltage should be 11.5 to 12'6 volts before testing'
Refer to instructions supplied by test equipment
manufacturer, when using high-rate discharge equip-
M16866N ment.
Fig. 7-Checking SPecific GravitY
The first method of testing should be to crank the
To determine whether the battery is capable of engine for 15 seconds with the starting motor then
meeting the requirements of the starting motor, it is meisure the battery voltage. lf voltage is less than
necessary to duplicate operating conditions by sub- 9.6 volts at the end of 15 seconds cranking, replace
jecting the battery to a load test (check battery volt- battery.
age). To obtain a true test, the battery should be at
lelst 75 percent charged. This can be determined by As a second method, use high-rate discharge test
taking a hydrometer reading, Fig. 7' equipment. Discharge the battery by means ol a
heavy-duty carbon pile at a rate 3 times the ampere-
The following table illustrates typical ranges of hour capacity. Follow equipment manufacturer's rec-
specific gravity (amount of unused sulfuric acid re- ommendations for testing.
maining in the solution) for a cell in various states of
charge, with respect to its ability to crank the engine ll alter 15 seconds the battery voltage is less than
at 80'F (26.5'C) with initial full-charge specific gravity 9.0 volts, the battery fails to meet the load test' indi-
at 1.260 to 1 .280. cating loss of capacity or internal short circuits' Any
battery that passes the load test is a good battery
Specilic GravitY CaPacitY and can be relied upon to fulfill the requirements of
the starting motor under normal conditions'
1.260 to 1 .280 100%
1.230 to 1.250 75/"
1.200 lo 1.220 50"/"
1 .'170 to 1 .190 25"/"
1 .140 to 1 .160 Very little useful
capacitY
1 .1 10 to 1 .130 Discharged

Litho in U.S.A
40 Electrical System Tractors, 200 Series
10-8 Canking System SM-2105 (Jun-81)

Testing lgnition Switch Neutral-start safety switch failure usually requires


only adjustment to correct. lf the solenoid will not
activate when the PTO lever is in the disengaged
position and the shift lever is in neutral, check for
proper switch adjustment.

M14222N

Ml 4222N
Fig. 8-Test lgnition Switch

Remove battery to provide access. Remove coupler


from ignition switch to expose terminals. The ignition Fig. g-Test PTO Neutral-Start Safety Switch on 2O0
switch can be tested with a test light. Check lor conti- Series Tractors Below Serial No. lg0,00l
nuity between terminals with switch placed in each of
three positions. See Fig. 8, and chart below for current
llow diagram. lf switch is defective it must be replaced.

POSITION CLOSED OPEN

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.

IMPORTANT: To prevent premature failure or


damage to switch, be careful not to bottom plunger
under switch roller when adjusting switch.
Litho in U.S.A.
Tractors, 200 Series
Etectrical System 40
Cranking System 10-9
SM-210s (Jun-81)

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

Fig. l2-Testing PTo Switch Power Circuit on 200


Fig. ll-Testing PTO Switch Cranking Circuit on 200 190,001- . )
. 190,001- Series Tractors (Seriat No'
Series Tractors (Serial No. )

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.

Litho in U.S.A.
40 Electrical System Tractors, 200 Series
10-10 Cranking System SM-2105 (Jun-91)

Testing Solenoid

Ml216-6N\

i41€74&l{Y Fig. l4-Testing Armature for Shorts

1. SHORTS - A burned commutator bar indicates a


A-Positive Battery C-Test Light shorted armature. Short circuits are located by rotating
Terminal D-Solenoid Base the armature on a growler with a steel strip (hack-saw
B-lgnition Switch E-Negative Battery
Terminal blade) held on the armature, Fig. 14. The steel strip will
Terminal
vibrate on the area of the short circuit.
Fig. 3-Testing Solenoid
1

To test the solenoid, connect.lumper wires from the


negative battery post (E) to the solenoid base (D), and
from the positive battery post (A) to the ignition switch
terminal (B) at the solenoid. Connect a test light (C)
between the two large terminals on the solenoid, Fig.
13. The light should light when the solenoid is activat-
ed.

NOTE: On tractors equipped with either hydrautic or


electric lift, it may be necessary to remove the left-hand
side panel, loosen left-hand pedestal side, and lay it
back to gain access to the solenoid.

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

Battery CAUTION: After the battery is activated,


hydrogen and oxygen gases in the battery
Removing BatterY are very explosive. Therefore, it is necessary to
a ter- keep open flames and sparks away from battery.
Loosen bolts through terminal clamps. Use
minal puller to remove clamps. lf terminal puller is
not available, spread clamps before prying them off
battery posts.

To avoid iniury from a spark or short circuit, dis-


connect cable from the negative battery terminal tirst'
Then remove boot lrom positive terminal and discon-
nect cable from positive terminal.

Servicing BatterY
Good battery servicing should include the following
items:

1. Clean batterY.

2. lnspect cables including ground connections' A-Electrolyte Level B-Plates


Fig. 1}-Prcper Level of Electrolyte in Battery Cells
3. Clean terminals.
Checking Battery Electrolyte Level
4. lnspect hold-downs. Check electrolyte every 25 hours o{ operation.

5. lnspect case for leaks' CAUTION: Battery electrolyte is poison-


ous and corrosive. lt can iniure eyes, skin,
6. Make hydrometer test. and clothing. Handle it carefully. lf electrolyte is
spilled, flush immediately with a solution of one
7. Add water if necessary. Use caution to protect
part baking soda to four parts water.
tractor from electrolyte damage.
Keep shield on positive (+) terminal closed.
8. Recharge battery if less than 75 percent
charged. 1. Remove caps.
Activating New BatterY 2. lf necessary, add distilled water until level (A) is
When activating a new battery, remove battery 1/4lo 1/2 inch (6.4 to 12.7 mm) above plates (B).
from tractor before filling it with electrolyte. This will
prevent damage to tractor in case electrolyte spills. NOTE: DO NOT fill to bottom ledge of filler tube.

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.

Litho in U.S.A.
40 Electrical System Tractors, 2OO Series
10-12 Cranking System SM-2105 (Jun-81)

lnstalling Battery Cleaning Battery


Corrosion around the battery terminals is normal.
However, an accumulation of corrosion over a long
period can shorten the life of the battery. lt is therefore
important to keep battery terminals as clean as possi-
ble.

To clean terminals, remove battery from tractor.


Remove all corrosion using a wire brush. Wash termi-
nals using a solution of one part ordinary baking soda
to four parts water. Do not permit cleaning solution to
enter battery cells.

Wash entire battery case, battery base and hold-


down strap with clean water.

Fig. 1 7-lnstalling Battery

1. Clean and dry battery and place in battery base.


Coat battery terminals with petroleum jelly.

2. lnstall hold-down and hook hold-down bolts in


slots. Tighten wing nuts.

3. Place shield on positve (+) terminal.

4. lnstall positive cable on positive (+)terminal, and


tighten bolt. Close shield.

IMPORTANT: Shield must be closed over posi-


tive (+) terminal.

5. lnstall ground cable on negative (-) terminal,


and tighten bolt.

Be sure vent holes in each cell cap are open.

NOTE: Damage to the alternator-stator or rectifier-


regulator can occur if battery polang is reversed, if the
baftery is fast charged, or if welding is done on the
tractor. Always connect positive cable to positive post,
negative cable to negative post. Disconnect the con-
nector from the regulator before charging, iumping or
welding.

Litho in U.S.A.
Tractors, 200 Series Electrical System 40
sM-2105 (Jun-81) Cranking System 10-13

REPAIR-Continued

Starter l-Lock Washer


2-Nut
3-Washer
4-lnsulating Washer
S-Housing
6-Thru Bolt
7-Armature
8-Stop Nut
9-Gear Stop Spacer
10-Anti-Drilt Spring
11-Drive Assembly
12-Drive End Cap
13-Thrust Washer
20
14-Dust Cover
1s-lnsulating Bushing
J- re
ttw
16-Brust and SPring Kit
17-Machine Screw

{@ 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

Fig. 19-Exploded View of Starter

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.

Remove left-hand side panel and left-hand pedes-


tal side to provtde access to starter.

Remove starter cable and two cap screws securing


starter to engine block.
,e
ryw
Disassembling Starter
Remove dust cover (F) from end of starter drive, Fig'
16. Hold drive gear (A) and remove 3/8-inch stop nut
(E). Remove drive parts from armature shaft. ,6i: $r,5JirJ o
A-Drive Gear D-Dust Cover
Cover Spacer
B-Gear Stop Spacer E-Stop Nut
C-Anti-Drilt Spring F-Dust Cover
Fig. 1 9-Disassembling Starter Drive

Litho in U.S.A.
40 Electrical System Tractors, 200 Series
10-14 Cranking System SM-2105 (Jun-81)

REPAIR-Continued

,l.ii d25xlll'. I'JI6?t3lt


Mr6752NY
A-Drive End Cap C-Thru Bolts A-lnput Brushes D-lnput Terminal
B-Commutator End Cap B-Ground Brushes E-Non-lnsulated Brush
C-lnsulated Brush Holders Holders
Fig. 2]-Disassembling Starter
Fig. 21 -Replacing Brushes
Remove the two thru bolts (C) which hold the end
Replace brushes whenever they show any amount
caps (A and B) to starter housing, Fig. 20. of wear. To replace input brush assembly (A), remove
nuts and washers from input terminal (D) and pull the
Remove commutator end cap (B) carefully, Fig.2O,
brushes out through the inside of cap. When assem-
to avoid losing brush springs which may pop out when
bling, place the input brushes (A) into the insulated
end cap is removed.
brush holders (C), Fig. 21.
Inspection The leads from the ground brushes (B) are attached
to the metal screws which secure the insulated brush
Clean and inspect starter drive components for ex-
holders (C) to the end cap, Fig. 21. Place the ground
cessive wear. Replace parts as necessary.
brushes (B) in the non-insulated brush holders (E).
See "Testing Starter" on page 40-10-10. Assembling Starter
lnspect bearing in mounting bracket and end cap.
Also inspect armature shaft. lf armature shaft has
excessive play in bearings, replace end caps. lt may be
necessary to replace armature if bearing surfaces are
worn badly. Excessive bearing play will allow armature
to rub against fields.

Clean and inspect commutator. lf surfaces are badly


grooved, true up on a lathe and undercut mica.
Brushes must make good contact with commuator.

M 16754N

B-Brushes C-Retaining Clips

Fig. 22-lnstalling Brushes

Preparing the starter end cap (A), Fig. 22, is the first
step of starter asembly.
Litho in U.S.A.
Tractors, 200 Series Electrical System 40
sM-2105 (Jun-81) Cranking System 10-15

Assem bling Starter-Continued


Place brush springs into brush holders. Then, in
succession, place each brush in its respective holder
with the beveled stde uP.
Compress brush spring and place a U-shaped re-
taining clip (C) made of banding steel onto each brush,
Fig.22.
Wipe commutator clean with a dry cloth and lubri-
cate armature shaft with a small amount of light
grease.
Place armature into end cap (A), Fig" 22' and re-
move U-shaped brush retaining clips.
,ul st5$tr-1:
Ml 6756NY

A-Drive End Cap B-Thru Bolts

Fig. 24-Assembling Drive End CaP

lnstall drive end cap (A), Fig. 24, onlo armature.


NOTE: The starter housing has a mark and an
indentation on the inside which must fit into the two
indentures on the drive end caP.
lnsert thru bolts (B), Fig. 24, and tighten lo 20 lo 25
in-lbs (0.2597 lo 0.3246 N'm) torque.
i:.1

M16755N

A-Starter Housing C!-Armature


E-Thrust Washer
B-lndex Marks
C-Commuator End CaP
P
Fig. 23-Aligning lndex Marks

Place starter housing (A) over armature (D) while


exerting down pressure on the armature, Fig. 23. This ItJStS:iiJ
ryw
vG1
prevents brush springs from pushing armature up and M16751NY

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.

lnstall starter on engine.

Litho in U.S.A
Tractors, 200 Series Electrical System 40
SM-2105 (Jun-81) lgnition System 15-3

Condenser Coil

:t;t7t?ft

A-Spring E-Construction Section A-Sealing Nipple E-Secondary Winding


B-Gasket F-Foil B-High-Tension Terminal F-Primary Winding
C-Hermetically Sealed G-lnsulation C-Coil Cap G-lron Core
D-Pressure Contact H-Foil D-Primarv rerminar l:ixli'?lll'lnsurato,
Fig. 4-Cutaway View of Condenser
Fig. S-CutawaY View of Coil
When the magnetic field in the coil collapses, volt-
age much higher than the original voltage is induced The ignition coil is a pulse transformer that steps
into the primary winding. As the breaker points open, up low voltage from the battery to the high-voltage
the current tends to continue flowing across the necessary to ignite the fuel-air mixture at the spark
points. The resulting arc would damage the points in plug gap.
a short time. The condenser, by absorbing the surge
of high-voltage, dampens the tendency of current to The coil contains three basic parts: A primary
arc across the points. The condenser also allows the winding consisting of a few hundred turns of relative-
magnetic field to collapse rapidly which contributes to ly heavy wire, a secondary winding consisting of
high-voltage induced into the secondary windings. many thousand turns of very fine wire, and laminated
soft iron which serves to concentrate the magnetic
field. These three units are placed in the coil case
and immersed in oil. The coil cap with its necessary
attachments to the windings completes the entire
coil.

When the primary circuit is energized (breaker


points closed), a magnetic field is built up around
both the primary and secondary coils. When the pri-
mary circuit is de-energized (breaker points open),
the magnetic field collapses about the coils inducing
a voltage within both of the coils. The voltage devel-
oped within the primary coil is absorbed and dissipat-
ed by the condenser. The voltage developed within
the secondary coil (possible 25,000 volts or more) is
distributed to the spark plug for igniting the fuel-air
mixture within the cylinder.

Litho in U.S.A.
40 Electrical System
Tractors, 200 Series
15-4 lgnition System SM-2105 (Jun-81)

DIAGNOSING AND TESTING

A. Make a Visual Check of Components B. Test Spark Plug


and Wiring
Remove ignition cable from spark plug and install
Make a visual check of the ignition circuit to find adaptor, Fig. 6, or an ordinary paper clip. Hold adaptor
broken leads, broken or loose connections, corroded approximately 1/8 inch (3.1g mm) away from spark
connections, possible cracks or broken components. plug terminal while cranking engine.
lf there is no spark at the plug terminal, hold the
high-tension lead at the steel base of the plug while
cranking engine. lf a spark jumps here, the plug is bad
and should be cleaned or replaced.

Litho in U.S.A.

-
Tractors, 200 Series Electrical System 40
SM-2105 (Jun-81) lgnition System 15-5

B. Test Spark Plug-Continued PTO Safety Switch

t/B NCH .!,.sli{,


';
nm .t! r= Fr' r
rLill+it5Liid
R $,{n{$*
;s

Fig. $-Checking Sqark at Plug Fig. 7-Testing PTO Safety Switches on 200 Series
Tractors (Serial No. 30,001 -1 90'000)

A weak spark or no spark indicates ignition system


difficulties. Test further to isolate problem. Attach test light leads to terminals of top PTO safety
switch. Engage and disengage PTO. Light should glow
A sharp, snapping spark indicates coil, breaker with PTO disengaged. Light should go out when PTO
points, and condenser are in good condition. is engaged. lf the test light does not glow with PTO
Every 100 hours, remove, inspect, and regap spark disengaged, check switch adiustment. To adiust, loos-
plugs to 0.025-inch (0.6350 mm). Bend only the outef en mounting screws and adiust until switch closes with
electrode when setting gap. the PTO disengaged. lf switch is adiusted correctly and
test light Jails to light, replace the switch.
Do not sandblast, wire brush, scrape, or otherwise
service a plug in poor condition. lnstall a new plug.
Use a spark plug wrench to remove and replace
plug. Tighten plug to 27 ft-lbs (26.6 Nm) torque. [a A

Good operating conditions are indicated if plug has a


light coating of gray or tan deposit' A dead white,
blistered coating could indicate overheating.
I c[+
A black (carbon) coating may indicate an over-rich
fuel mixture caused by a clogged air cleaner or im-
proper carburetor adiustment.
[E D[
M23237
C. Test Safety Switches
Test salety switches with a test light and check for Fig. 8-Testing PTO Switch lgnition Circuit on 200 Series
continuity between terminals. Tractors (Serial No. 190,001- )

IMPORTANT: Be sure test light leads do not


To test the PTO switch ignition circuit, remove the
touch each other to ensure proper testing.
three-terminal connector, attach a test light to termi-
nals shown Fig. 8, and move toggle to "OFF" position.
Test light should light. Move toggle to "ON" position
and test light should go out. lf not, replace the switch.

Litho in u.s.A.
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.

POSIT]oN CLOSED OPEN

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.

E. Adjust Breaker Points


Fig. 9-Testing Seat Safety Switch CAUTION: Disconnect spark plug cable to
prevent engine starting accidentally.
To test seat switch, disconnect coupler at seat
switch. Attach leads of test light to coupler terminals at
the switch. The test light should glow when pressure is
applied to seat cushion and go out when cushion is
released. lf switch does not operate correctly, replace
switch.

D. Test lgnition Switch

M16782NY
A-Feeler Gauge B-Locking Screw C-V-Slor
Fig. 11-Adjusting Breaker points

Remove ignition point cover and rotate engine fly-


wheel until points are at their wrdest opening.
Check point gap with a 0.020 inch feeler gauge (A).
lf adjustment is required, loosen locking screw (B) and
move screwdriver in V-slot (C) until points are properly
"n"*',)r*
set. After tightening locking screw (B), recheck point
Fig. l0-Testing lgnition Switch gap.
Engine operation is greatly affected by breaker point
Remove battery to provide access. Remove coupler
condition and adjustment. lf points are burned or badly
from ignition switch to expose terminals.
oxidized, little or no current will pass. As a result, the
engine may not operate at all or may miss particularly
at full throttle.

Litho in u.s.A.
Tracto:rs, 200 Series Electrical System 40
sM-2105 (Jun-81) lgnition System 15-7

Replace Breaker Points Static Timing Method

t'f167837;v
1,41 6783NY
N,416785NY

A-Breaker Point B-Push Rod


A-Flashlight Tester C-Ground
Attaching Screws B-Lead Screw t)-Lead
Fig. 12-Replacing Breaker Points and Condenser Fig. 14-Static Timing
To replace points, remove point cover; then remove
attaching screws (A), Fig. 12. Connect an ohmmeter or flashlight tester (A) to
Check condition of breaker point push rod (B). An breaker point lead screw (B) and to ground (C)' Fig. 14.
excessively tight push rod can hang-up and cause Breaker point lead (D) must be disconnected from
ignition failure, particularly with a hot engine. points.
lnstall new points. Replace cover, being certain
rubber grommet and cover gasket are in position and in Rotate engine normally until test light goes out,
good condition. indicating points are just starting to open. At this time,
the "S" mark on flywheel should be in alignment with
Time Engine the mark on the flywheel housing as shown in Fig. 13. lf
necessary, adiust gap slightly to obtain this condition.
The engine is equipped wrth a timing sight hole in
the blower housing.

M1 67 84N
M167gN

A-Spark Point B-Top Dead Center

Fig. 13-Timing Marks and Indicator

Two timing marks are stamped on the flywheel, Fig'


13. The "T" mark (B) indicates top dead center (TDC)'
while the "S" mark (A) indicates the spark point, which
is 20 degrees before TDC.
Two methods are used for timing - the static and
timing light methods.

Litho in U.S.A
40 Electrical System Tractors, 2OO Series
15-8 lgnition System
sM-2105 (Jun-81)

Time Engine-Continued

Timing Light Method


Several different types of timing lights are available.
Follow manufacturer's instructions for type used. The
following timing procedure can be used with most
timing lights.

Remove high-tension lead at spark plug. lnstall


adapter, Fig. 6, page 40-15-5, and reconnect spark
plug lead.

Connect one timing light lead to this adapter. Con-


nect second timing light lead to positive side of battery.
See timing light instructions for battery size, wiring, etc.
if I67Sdjr"y
Connect third timing light lead to ground.
A-Sight Hole B-Timing Light
Fig. 1S-Timing With Light

Rotate engine by hand until "S" mark is visible


through sight hole (A), Fig. 15. Chatk "S" line for easy
reading.

Run engine at 1200 to 1800 rpm. Aim timing light


(B), Fig. 15, into sight hote (A). The tighr shoutd ftash
just as "S" mark is in alignment with mark on flywheel
housing inside sight hole as shown, Fig. 13, page
40,15-7.

lf timing is off, adjust breaker point gap slighfly to


correct.

Litho in U.S.A.
Electrical System 40
Tractors, 200 Series
(Jun-81) lgnition SYstem 15-9
sM-2105

F. Test Condenser G. Test Coil

CONDENSER CONDENSER
CAPACITY CAPACITY
TOO HIGH T00 Low M16761N
t{10701ll
[,4 ] 6761 N

B-Stationary Contact Fig. 1B-Testing Coil Power


A-Movable Contact
Fig. 1i-Breaker Point Build-UP
The ignition coil is either satisfactory or not' Coil
failure occurs all at once, much as an electric light bulb'
lf badly burned breaker points occur frequently, the It does not degenerate graduallY.
condenser should be suspected. lf condenser capacity
When coil failure is suspected, use an analyzer, Fig'
is too small, metal will transfer from the stationary
18 to test coil.
contact (B) to the movable contact (A) as illustrated in
the left-hand half of Fig. 16. lf capacity is too large, the Follow manu{acturer's recommendations to test the
metalwill build up on stationary contact (B), right-hand following:
half of Fig. 16.
1. Coil power test
Condensers can be tested off the tractor on test 2. Coil high-speed test
units such as the one shown in Fig. 17. Follow manu- 3. Coil surface insulation test
facturer's recommendations to make the following 4. Coil continuitY test
condenser tests: 5. Coil ground test
1. Capacity
2. Leakage Testing Coil for Grounded Windings
3. Short
4. Series resistance

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.

Litho in U.S.A.
40 Electrical System Tractors, 2OO Series
15-10 lgnition System SM-2105 (Jun-81)

SPECIFICATIONS

Spark Plug Gap


200 and 208 Tractor 0.025 in. (0.6350 mm)
210, 212,214 and
216 Tractor . . 0.035 in. (0.9g90 mm)

Breaker Point Gap .. 0.019 to 0.022 in.


(0.4572 to 0.5588 mm)

Coil Resistance
PrimaryWindings :....2to3ohms
Windings
Secondary .8,OOO to 10,000 ohms
Condenser
Capacity-Microfarads . .. 0.1g to 0.23 mfds

Litho in U.S.A.
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

A-Electric PTO Clutch C-lgnition Switch E-Battery


B-PTO Switch D-Solenoid F-Circuit Breaker

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.

Litho in U.S.A.
40 Electrical System Tractors, 200 Series
35-2 Electric PTO Clutch SM-2105 (Jun-81)

Tesling Electric PTO Clutch Adjusting Electric PTO Clutch


Disconnect engine spark plug wire and remove key
Testing PTO Switch Lead Wire
from ignition switch before adjusting clutch. Also, be
sure PTO switch is in the "OFF" down position.

A-Clutch Lead Connector E-PTO Swiich


B-Switch Lead Connector F-Key Switch
C-Blue Lead Terminal G-Negative Battery Cable
D-Positive Battery Cable H-Black Lead Terminal

Fig. 2-PTO Clutch Circuitry

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.

Testing PTO Clutch Leads and Field Coit


Connect test light leads to PTO clutch lead wire
terminals (l), Fig. 2. lf test light is on, lead wires and
f ield coil are good. lf test light does not light, check lead

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

Testing PTO Clutch Ground Circuit


lnsert a flat feeler gauge in each of three slots (A) in
Connect a test light lead to negative battery cable armature housing, Fig.4. Clearance between armature
(G), Fig. 2 and other test light lead to PTO switch btack plate and rotor should be 0.012 to 0.014 inches (0.30 to
lead terminal (H). Test light shoutd tighr. tf test tight 0.35 mm) when clutch is properly adjusted. Loosen or
does not light, ground lead is defective. tighten three lock nuts (B) to adlust clutch.

After checking PTO clutch adjustment, connect


spark plug wire to spark plug and start engine. Move
PTO switch to "ON" position. lf clutch still does not
engage, remove and disassemble clutch for inspection
and repair.

Litho in U.S.A
Tractors, 200 Series Electrical System 40
SM-2105 (Jun-81) Electric PTO Clutch 35-3

REMOVING ELECTRIC PTO CLUTCH

Remove both left and right-hand side panels.

;; ,.!{l
:jl
};;idrl [.1
:;;alioi'
^"
2
^:

Fig. 7-Remove Clutch Retaining Bolt


1v28548

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.

Fig. 6-Secure Flywheel

3. Place two 1/4 x 3-inch cap screws from stock


through flywheel screen into tapped holes of flywheel.

NOTE: Cap screws do not thread into holes of


flywheel.

4. Place a large screwdriver or small bar between


cap screws, Fig. 6.

Litho in U.S.A.
40 Electrical System Tractors, 200 Series
35-4 Electric PTO Clutch SM-2105 (Jun-81)

DISASSEMBLING ELECTRIC PTO CLUTCH

Fig. 10-Remove Bearings and Spacer

5. Support hub of pulley and press collar with bear-


Fig. B-Remove Lock Nuts, Pulley Assembly ings out of pulley assembly, Fig. 10.
and Springs

1. Remove three lock nuts, Fig. 8.

2. Remove pulley assembly.

3. Remove three springs

M2A554

Fig. 11-Remove Spacer and Bearing From Collar

6. Support bearings and press collar out of bear-


ings, Fig. 11.

Fig. 9-Remove Retaining Ring

4. Remove retaining ring, Fig. 9.

Litho in U.S.A
Tractors, 200 Series Electrical System 40
SM-2105 (Jun-81) Electric PTO Clutch 35-5

INSPECTION AND REPAIR

A-Field Coil and Rotor Assembly E-Spacer


B-Spring (3 used) F-Bearings (2 used)
C-Bearing Collar G-Retaining Ring
D-Pulley and Armature Assembly H-Elastic Lopk Nut (3 used)

Fig. |2-Exploded View of Electric PTO Clutch

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)

lnspecting Armature and Rotor Testing Field Coil

ffi
i,tz57E6f t,,l!.i7t7l
iM25786t M257a1

A-Contact Springs B-Rotor and Armature A-Test Lead Wires c-BatteryTerminals


B-Field Coil Leads D-Chisel
Fig. 13-lnspecting Armature and Rotor
Fig 14-Testing Field Coil
lnspect armature for weak or broken contact springs
(A), Fig. 13. Attach test lead wires (A), Fig.14, to field coil leads
(B) and battery terminals (C).
lnspect between rotor and armature contacts (B) for
paint. Be sure surfaces are clean. Place a chisel (D) across rotor. Electromagnetic
action will hold the chiselto rotor if PTO field is good. lf
chisel will not stick to rotor, field coil is defective and
the complete rotor and field coil assembly must be
replaced.

NOTE: Battery must be in good condition and fully


charged for test.

Litho in U.S.A.
Tractors, 200 Series Electrical System 40
SM-2105 (Jun-81) Electric PTO Clutch 35-7

ASSEMBLING ELECTRIC PTO CLUTCH

M28559

Fig. 1 S-Assemble Bearings Fig. 18-lnstall Retaining Ring

1. Press two bearings onto collar, Fig. 15. 4. lnstall retaining ring in groove of pulley, Fig. 18.

Fig. 1O-lnstall Spacer

2. Place spacer in pulley housing, Fig. 16


Fig 1e-tnsatt sp,i11i, Assembty
i:i:,
5. lnstall three springs, Fig. 19.

6. Put pulley assembly over stud bolts and springs.

7. lnstall three elastic lock nuts. Do not tighten nuts.

8. lnstall clutch on tractor as explained on page


40-35-8.

Fig. 17-lnstall Bearing Collar

3. Support armature and press bearings with collar


and spacer into pulley and armature assembly, Fig. 17.

IMPORTANT: Be sure to press on bearing O.D.


to prevent damaging bearing.

Litho in u.s.A
40 Electrical System Tractors, 200 Series
35-8 Electric PTO Clutch SM-2105 (Jun-81)

INSTALLING ELECTRIC PTO CLUTCH

Fig. 2)-lnstall Clutch Fig. 21-Tighten Clutch Retaining Bolt

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.

5. lnstall washer and clutch retaining bolt.

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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 .

Preliminary Diagnosis of Malfunctions . ... .. 10-3 Opening Transaxle... 20-6


Diagnosing Malfunctions 10-4 Removing lnternal Components ...... . .. 20-6
Repair . .. 10-6 Disassembling Shift Lever . 20-7
lnspecting V-Belts 10-6 lnspection and Repair 20-8
Cleaning V-Belts 10-6 Assembly 20-1 0
Replacing Primary V-Belt on 200 BevelGearDifJerential ..... 20-10
Series Tractors (Serial No. Bearings ....20-10
30,001-190,000) . 10-6 lnputShaltandGear ......20-11
Replacing Primary V-Belt on 200 ldler Gear and Pinion Shaft . ..... 20-11
Series Tractors (Serial No. Output Shaft and Gear. ...20-12
190,001- 10-7 Shifter Components.... ...20-12
Replacing Secondary V-Belt... 10-9 ldler Gear, Pinion and Thrust Washer . . 20-14
Removing Variator 10-10 Reverse ldler Shaft and Gear . . . 20'14
Disassembling Variator 10-1 1 Reverse ldler, ldler Gear Assembly and
lnspecting Variator 10-12 Spacer 20-14
Assembling Variator 10-1 3 Cluster Gear and Thrust Washer . 20-15
lnstalling Variator 10-14 lnstalling Differential 20-15
Adjustments 10-15 Placing Cover on Case 20-1 6
Variator Linkage Adjustment. 10-1 5 lnstalling Seals 20-1 6
Spring Adjustment. 10-1 5 lnstalling Axle Supports. . . . 20-17
Belt Guide Adjustment 10-15 Positioning Shifter Forks . 20-17
Variator Specifications ... . . 10-16 Assembling Shifter Lever . 20-17
lnstalling Transaxle. .. 20-17
GROUP 15 - BRAKES Torque for Hardware . . . 20-18
Principle of Operation. . 1 5-1
Diagnosing Malfunctions 1 5-1 GROUP 25 - PTO CLUTCH (200
Description 15-2 TRACTORS SERIAL NO.
Repair . . . 15-4 30,001-190,000)
Adjustment 15-6 Principle of Operation 25-'l
Diagnosing Malfunctions 25-1
Repair 25-2
Assembly. . . . ...... 25-6
Adjustments . . .. .. . 25-7

Litho in U.S.A.
50 Power Train Tractors, 200 Series
1O-2 Clutch and Variable Speed Drive SM-2105 (Jun-81)

PRI NC IPLE OF OPERATION-Continued


200, 2',1 O, 212,214 And 216 Tractors Only
Figs. 3, 4 and 5 show the different positions of the

? variable speed drive.

The slow speed position, Fig. 3, will provide for a


large primary and small secondary sheave circumfer-
d ence at the variator.

The high speed position, Fig. 4, provides a small


primary and large secondary sheave circumference
A-Variator D-Secondary Belt at the variator.
B-Secondary Belt ldler E-Engine Drive Sheave
C-Primary Belt F-Transaxle Elriven
Sheave When the clutch pedal is depressed, the variator
moves forward and releases the primary belt from
Fig. 3-SIow Speed Position the engine drive sheave, Fig. 5.

With this system, travel speeds can be changed


while the engine speed remains constant. All trans-
mission gear positions can be used in conjunction
with the variable speed control.

NOTE: The engine must be running to attow the


variator to change belt positions.

B-Secondary Belt ldler

Fig. 4-High Speed Position

A-Variator B-Secondary Belt ldler

Fig. s-Clutch Position

Litho in U.S.A
Tractors, 200 Series Power Train 50
SM-2105 (Jun-91) Clutch and Variable Speed Drive 10-5

Clutch Pedal Creeps Down Under Load Excessive Tractor Vibration


Load and torque sensing leature operating on 200, Dirt in sheave grooves.
210,212,214 and 216 Tractors. This is characteristic
of drive when encountering loads with variable speed Bent or damaged input sheaves.
control lever fully forward.
Loose input sheave cap screws (transaxle).
lf down-shifting too early, adlust variator spring for
greater lension on 200, 210, 212, 214 and 216 Trac- Primary or secondary V-belt worn or lumpy.
tors.
Tractor Will Not Move With Variable Speed Control
Variator linkage not properly adjusted on 200, 210, Lever Pulled Back on 200, 210,212,214 and 216
212,214 and 216 Tractors. Tractors
Variator not properly adiusted'
clutch will Not Disengage
Variator nol properly adjusted on 200, 210,212,214 Primary belt too long.
and 216 Tractors.
Dirty or greasy varialor sheave hub.
Primary or secondary belt too short.
Tractor Will Not Accelerate When Variable Speed
Clutch Pedal Jumps Control Lever is Moved Forward on 200, 210,212,
214 and 216 Tractors
primary or secondary V-belt worn or lumpy.
Variator not properly adjusted.
Dirl in sheave grooves.
Variator spring not adjusted properly.
Worn variator bearings on 200, 210, 212,214 and
2'16 Tractors. Dirty or gummy variator sheave hub.

Worn, bent, or nicked sheaves. Short secondary belt.

Loose input sheave on transaxle hub. Variator arm binding in pivot (in pedestal).

MisCellaneous Variator center sheave too tight on hub.

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.

Secondary bell idler arm pivot binding.

Litho in U.S.A
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.

A slight raveling of the belt does not indicate pre-


mature belt failure. Cut off the raveling when the cov-
ering begins to peel.

When evidence of extreme or abnormal belt wear


is noted, check first for faulty sheaves. A bent,
nicked or chipped sheave will cause rapid belt wear.
Replace sheaves found in this condition.
a:dt-it!:)

Belt wear, tractor vibration, and erratic operation


will result when dirt becomes packed and lodged in A-PTO Arm B-PTO Brake Shoe C-Clutch Shiave
V-grooves of the sheaves. Check especially the var-
iator sheave. Loosen and clean dirt from all sheaves. Fig. 7-Removing PTO Ctutch

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.

Do not use belt dressings. Dressings often give


only temporary gripping action while softening the
belt and causing eventual deterioration, and shorten-
ing of the belt life.

Litho in U.S.A.
Tractors, 2OO Series
Power Train 50
sM-2105 (Jun-81) Ctutch and Variable Speed Drive 1O-7

Replacing Primary V-Belt on 200 Series


Tractors (Serial No. 190,001- )

Fig. 9-Disconnect Clutch Lead Wire

M16728N 1. Cut and remove clutch lead tie strap, Fig. 9. Be


A-Secondary Belt ldler D-Primary Belt Guide careful not to cut clutch lead wire.
B-Secondary Belt E-Primary Belt
C-Brake Pedal Shaft 2. Disconnect clutch lead from wiring harness.
Fig. 8-Removing Primary Belt

On 200, 210, 212, 214 and 216 fractors, move the


variable speed control lever forward. Push up on sec-
ondary belt idler (A) and remove the secondary belt (B)
from variator or secondary sheave.

Depress clutch pedal so secondary belt (B) may be


pulled past brake Pedal shaft (C)'

Loosen the primary belt guide (D) at the variator or


secondary sheave and remove the primary belt (E).

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.

4. Place a large screwdriver or small bar between


cap screws, Fig. 10.

Litho in U.S.A
50 Power Train Tractors, 200 Series
10-8 Clutch and Variable Speed Drive SM-2105 (Jun-81)

Replacing Primary V-Belt on 200 Series


Tractors (Serial No.
190,001- FContinued

Fig. 11-Remove Clutch Retaining Bolt


A-Secondary Belt ldler D-Primary Belt Guide
5. Hold flywheel in place with large screwdriver or B-Secondary Belt E-Primary Belt
bar, Fig. 10, and remove clutch retaining bolt and C-Brake Pedal Shalt
washer, Fig. 1 1.
Fig. 13-Replacing Primary Belt
6. Remove clutch assembly and key from crank-
shaft. 9. Push up on secondary belt idler (A) and remove
the secondary belt (B) from variator or secondary
sheave, Fig. 13.

10. Loosen primary belt guide (D) and remove pri-


mary belt (E).

11. lnstall new belt and adjust belt guide.


'12. Reinstall secondary belt.

13. Depress brake pedal and set park brake.

14. lnstall primary belt with sheave on crankshaft,


Fig. 12.
Fig. 12-Remove Sheave and Belt

7. Rernove sheave with belt from crankshaft, Fig.


12.

8. Depress brake pedal and release park brake.

Litho in U.S.A.
Tractors, 200 Series Power Train 50
SM-2105 Uun-81) Clutch and Variable Speed Drive 10-9

Replacing Secondary V-Belt

,|4

Fig. 14-lnstall clutch

1. lnstall key in crankshaft keyway, Fig. 14.


2. Align keyway in clutch with keyway in crankshaft
and slide clutch on crankshaft. Align clutch back plate M16729N

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

3. Connect clutch lead to wiring hbrness. Fig. 16-Re7lacing 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.

Litho in U.S.A
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)

A-Secondary Belt B-*Primary Belt Guide Fig. 21-Removing Variator Spring


C-Primary Belt
Fig. 1B-Removing Variator Move the variable speed control lever forward.
Remove secondary belt (A) from the variator Disconnect variator spring by removing nut from
sheave. See page 50-10-9. eyebolt.
Loosen 5/16-inch (7.938 mni) cap screw securing CAUTION: Variator spring is under slight
primary belt guide (B) to variator arm. Pivot guide away tension"
to allow room for primary belt (C) to be removed.

Fig. 22-Removing Pivot Shoulder Bolt


Fig. 9-Removing Variator
1

Remove plug from pedestal and remove variator


Depress clutch pedal to pivot variator forward. Re- pivot shoulder bolt.
move primary belt from variator sheave.

Fig. 2)-Disconnecting Speed Control Link


Fig. 23-Removing Variator
Remove battery and battery base to provide access.
Disconnect speed control shaft link from speed control Guide variator assembly out through bottom of trac-
shaft. tor.

Litho in U.S.A.
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

A-Hub Assembly B-Press

Fig. 26-Pressing Hub Bearing

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

Place variator hall sheave (A), Fig' 24' in a vise (B),


with soft jaws. lnsert ends of two large punches in
holes of sheave. Place a bar between punches. Then
turn counterclockwise to remove half sheave. Lift
center sheave (C) {rom variator hub.

Fig. 29-Press Variator Shaft

Place hub in a vise with soft laws and remove other


half sheave as described at the left, using punches or
the special tool. Press bearing out of variator arm as
Fis. 2,-Removins sheaves with shown in Fig. 27.
:#,i::
Using the same procedure as described above, a
special tool, Fig. 25, can be used. This tool is not
available f rom a supplier, but can be made by drilling a
bar of steel and inserting 3/8-inch (9.525 mm) round
slock,2-3/4 inches (69.850 mm) apart at the centers
and 1-inch (25.40O mm) long. After tool has been tried
and checked, weld round stock in place.

Litho in U.S.A.
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

A-Bearing B-Hub C-Shaft


Fig. 29-Measuring Hub and Bearing

Measure press fit between bearing (A) and hub (B),


Fig. 29. Refer to wear tolerances, page 50-10-16.
Check press fit of bearing shaft (C) in variator arm.
Replace parts necessary to obtain proper fit.
IMPORTANT: The center sheave bearing is lu-
bricated with a special grease at the factory that
will last for the lifetime of the sheave. Do not
attempt to lubricate this bearing.

Litho in U.S.A
Tractors, 2aO Series Power Train 50
SM-2105 (Jun-91) Clutch and Variable Speed Drive 10-15

ADJUSTMENTS

Variator Linkage Adiustment on 20O,21A, Spring Adjustment on 2O0,210,212,


212,214 and 216 Tractors 214 and 216 Tractors

Fig. 41-Adjusting Variator Spring

To obtain desired torque and load sensing charac-


teristics, adiust the variator spring as follows:
A-Variable Speed Control C-lgnition Key
For greater load sensitivity (variator increases
Lever D--CaP Screw
B-Socket Wrench torque earlier under load) loosen the spring tension
by lengthening the eyebolt. For less load sensitivity,
Fig. S9-Adiusting Variator tighten the spring tension by shortening the eyebolt.

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.

2. Pry button plug from adjusting hole in right side


of the tractor pedestal and loosen cap screw (D) one
to two turns with a 314-inch (19.050 mm) socket
wrench (B).

3. Disconnect spark plug cable and ground. Turn


ignition key (C) to crank engine several revolutions
with starter until the clutch pedal raises as high as it
will go.

4. Take up slack in linkage by pushing down on


cap screw (D). Tighten cap screw (D) and replace
button plug in adlusting hole.

NOTE: lf, after adiusting variator linkage, tractor rUJdSfilif


witt not move when the variable speed control lever
Fig. 41-Adiusting Belt Guide
is in first notch on the quadrant (slow speed position)
and the clutch pedal is released, install a new prima- lf the primary belt lumps the variator sheave when
ry belt. the clutch pedal is depressed, the distance between
the variator and primary belt guide should be
checked. Distance between guide and sheave should
not exceed 1/8 inch (3.175 mm).

Litho in U.S.A.
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 o.D. ... 1.999 to 2.001 in. (50.7746 mm to 50.8254 mm)

Hub l.D.

Bearing O.D... .. 1.1806 to 1.1811 in. (29.9822 mm to 29.9999 mm)


Bearing Shaft O.D. .... 0.6262 to 0,6267 in. (15.9055 mm to 15.9182 mm)

Bearing Support 1.D.... 0.6240 to 0.6255 in. (15.8496 mm to 15.8877 mm)

Primary Belt Guide


(Distance Between Variator and Guide) .....1/16 to 1/g in. (1.588 mm to 3.175 mm)

Litho in U.S.A
Tractors, 200 Series Power Train 50
SM-2105 (Jun-81) Ctutch and Variable Speed Drive 10-13

0.6a6?" Tfi A.6t.67"


(15.9055 mm T0 15.9182 nm)

.l
.999" T0 2.001"
l*fl.7746 mm T0 50"&?54'mm]

a.0r15' T0 ?,00?5' a .624*', t0 8"6?55"


( 50. B3B1 mm T0 50.8635 mm )
t15,fr498 nn TQ 15.S877 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

Fig. 31 -Variator Component Dimensions

{3.175 mrn

Fig. s2-Press Bearing on Hub

Fig. 37-Press Arm on Shaft


Assembling Variator
(2OO, 21O, 212, 214 and 216 Tractors)
Wipe a light film of oil on bearrng shaft' Place
Thread one sheave onto hub. Coat bearing case variator arm on bearrng shaft with weld down. Press
with a light film of oil. Place hub with sheave on press variator arm on bearing shaft untilend of bearing shaft
bed. Press bearing into hub shaft first until bearing end is flush with outside of variator arm, Fig. 33.
is 1/8 inch (3.175 mm) below hub face, Fig. 32.
Clamp assembly in vise having soft iaws. Place
center sheave on hub and thread half sheave on hub.
IMPORTANT: Press on outer race of bearing Using two large punches and bar, or special tool,
only.
tighten sheaves firmly by turning sheave in clockwise
direction.

Litho in U.S.A
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":::

Fig. 37-Connecting Speed Control Link


Fig. 34-Spiking Threads

Spike threads three or four places on both sides of


Connect speed control link with spring locking pin,
variator, Fig. 34. Fig. 37.

lnstalling Variator
(2OO,210,212,214 and 216 Tractor)

Fig. 38-lnstalling Variator Spring


t"r:S$-rCtf \
Attach variator spring to variator and eyebolt and
Fig. 35-lnstalling Variator tighten eyebolt for desired tension, Fig. 38.
lnstall variator assembly from under tractor. Guide
pivot through notch in tractor frame, Fig. 35. Reinstall battery base and battery.

Reinstall belts on variator.

After installation is completed, make final adjust-


ments to variator.

Fig. 3i-lnstailing Shoulder Bolt

Litho in U.S.A.
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
oI IP-$ffi
\-
e
t
Ql

ffiU) wN
rdl sSgcni

A-Seal E-Small Snap Ring


B-Roller Bearings F-Ball Bearing
C-PTO Drive Sheave G-Outer Snap Ring
flnner Snap Ring H-PTO Clutch Pivot

Fig. l-PTO Ctutch Drive Sheave Assembly on 200 Series Tractors


(Serial No. 30,001 -1 90,000)

PRINCIPLE OF OPERATION DIAGNOSING MALFUNCTIONS


The manual PTO clutch on 200 Series Tractors Clutch Will Not Engage
(Serial No. 30,001-190,000), is the cup and cone-type. Clutch linkage bent or broken.
The cone, which has the clutch lining bonded to it, is
attached directly to the engine crankshaft. The cup (C), Clutch linkage out of adjustment.
Fig. 1, slides on the crankshaft, and is controlled by the Clutch lining on fulcrum bolt worn excessively.
PTO clutch linkage.
Clutch Will Not Disengage
Engaging the PTO clutch, slides the cup into contact
with the cone, starting rotation. Disengaging the PTO Clutch linkage bent or broken.
clutch slides the cup out of engagement with the cone Clutch linkage out of adlustment.
and into engagement with the brake shoe, stopping
rotation. Clutch Will Not Stop Rapidly When Disengaged
Clutch brake shoe out of adjustment.
Clutch brake shoe linrng worn excessively.

PTO Drive Sheave Noisy


Drive sheave bearing drY.
Bearing worn excessively.
PTO clutch pivot bearing worn excessively.

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
.Gb
UlM M166B1N

A-PTO Clutch Pivot J Snap Ring


B-Outer Snap Ring -lnner Bearing (2
K-Needle used)
R
S
-Clutch Cone With Lining
C-Ball Bearing L Seal T
-Key Brake
D-Small Snap Ring -Oil
M-PTO Clutch Cup With Bearings -Clutch Shoe
U-5116"x1-114" Cap Screw and
E-Sheave Bolt N-7116"x1-114" UNF Lock Washer
F-Lock Washer Cap Screw V Nut
G-Nut O-Lock Washer -Lock
W-Fulcrum Bolt
H-Sheave P-Retaining Washer X Arm
I-PTO Clutch Cup Q-Bearing lnner Race Y
-Clutch Spring
-Return
Fig. 2-Exploded View of PTO Clutch Assemly
Disassembly lnspection
Remove clutch arm (X) from PTO clutch pivot (A) lnspect clutch linings and mating surfaces for ex-
and fulcrum bolt (W). Loosen clutch brake shoe (T) cessive wear. lnspect bearings, bearing inner race
to allow PTO clutch cup (M) to be removed. Remove and seal. lnspect PTO brake shoe for excessive
cap screw (N) and washers (O and P) from end of wear. Replace parts as necessary.
crankshaft and remove bearing inner race (e). Re-
move clutch cone (R) and key (S).

Remove outer snap ring (B). Press PTO clutch piv-


ot (A) out of PTO clutch cup (l). Remove inner snap
ring (J). Press two needle bearings (K) and oil seal
(L) out of PTO drive sheave. Remove small snap
ring (D) from PTO clutch pivot (A) and press bearing
(C) off clutch pivot (A).

Litho in U.S.A.
Section 70
MISCELLANEOUS
Group 5
STEERING LINKAGE
CONTENTS

Page Page

GROUP 5 - STEERING LINKAGE GROUP 10 - FRONT WHEELS AND AXLES


General lnformation ......5-2 lntroduction 10-1
Steering Analysis .. .5-3 Repair .. .. 10-1
Seal and Retainer . .5-3 Removing and lnstalling Front Wheels .. . 10-3
Housing .. .5-3 Removing and lnstalling Spindle ... 1O-4
Spindle 5-4 Removing and lnstalling Front Axle .. .. .. 10-4
Ball joint s.... ...5-4
Diagnosing Malfunctions ........5-5 GROUP 15 - LIFT LINKAGE
Repair 5-6 General lnformation .. . . 15-1
Removing Steering Wheel and Steering Manual Lift .. . 15-1
Gear.. ..... ..5-6 ConnectingLink.. ..'.15-1
Disassembling Steering Gear ..... .....5-7 Helper Spring Kit.... 15-1
lnspecting Steering Gear Parts. . .
. . .. . .5-7 Depth Control .. 15-1
Assembly ....5-7 Diagnosing Malfunctions -. . . 15-2
AssemblingsteeringGear. ...5-7
lnstalling Steering Gear.. .....5-8
Adlustments ........5-9
Steering Gear. ........5-9
Adlusting Toe-ln . .. 5-10
Adlusting Steering Linkage .. 5-10
Torque for Hardware

Litho in U.S.A.
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.

The steering gear has a 14:1 steering ratio. lt is a


cam and lever type steering gear, utilizing the cam
(D), lever arm (H), pivot botr (t) and tapered srud (J)
shown in Fig. 1.

The lever arm (H) is actuated whenever the cam is


rotated. This in turn, pulls or pushes the drag link
connected to the left steering spindle, turning the
wheels left or right.

The left and right-hand steering spindles are con-


nected by a tie rod (C, Fig. 2) to give equal move-
ment on both spindles.

,'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

B-Spring Washer | -Pivot Bolt F-@


C-Cup
D-Cam
J
-Tapered Stud
K-Lock Nut fi
E-Jam Nuts
F-Adiusting
G-Grease Fitting
Plug
L-Seal
M-Seal Retainer
N-Cotter Pin
q*
9-D
g-F
O-Bearing Balls
M17223N
Fig. l-Ross Steering Gear

A-Ball Joint D-Lock Washer


B-Nut (L.H. Threads) E-Nut (R.H. Threads)
C-Tie Rod F-Jam Nuts
Fig. 2-Tie Rod

Litho in U.S.A.
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'/
%
eq
E-g B
-@ -/
@''

\ Yv'
LJ

,\ \I Nbdw
q-R
JNb M17 240N

A-Ball Joint Assembly | -Grease Fitting P-R.H. Front Wheel SPindle


B-Jam Nut with R.H. Threads J Front Wheel SPindle CFSnap Ring
-L.H. Pin Bushing
K-King R-Valve Stem
C-Tie Rod
D-Cap Screw L-Axle with Bushing S-Bearing
E-Lock Washer M-King Pin Bolt T-Front Wheel Disk
F-Drag Link N-Cotter Pin U-Spring Washer
G-Jam Nut with L.H. Threads O-Slotted Nut V-Spindle Cap
H-Ball Joint Assembly
Fig. l-Exploded View of Front Wheels and Axles on 200 Series Tractors
(Serial No. 30,001 -1 90,000)

Litho in U.S.A.
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-

Litho in U.S.A.
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

I Fitting B-lnner Bearing F-Retaining Ring


D-Valve Stem -Grease G-Wheel
C-Valve Stem
E-Outer Bearing J
-Wheel D.-Outer Bearing
Fig. 3-Removing Front Wheel Components
Fig. 4-Removing Front Wheel Components
from Spindle
from Spindle

Jack up tractor until wheel clears the ground. Re-


Jack up tractor until wheel clears the ground.
move cap screw (H), Fig. 3. Remove spindle cap (G),
outer bearinS (E), wheel (J), inner bearing (B) and
Remove hub cap (E) and retaining ring (F), Fig. 4.
spring washer (C).
Remove outer bearinS (D), wheel (G), and inner
Pack wheel bearings with John Deere Multipurpose
bearing (B).
Lubricant or an equivalent SAE multipurpose-type
grease.
NOTE: Bearings normally do not require repacking.
However, if there is lack of grease in the bearings or
lnstall wheel in reverse order of removal.
wheel hub cavity, repack the cavity and hand pack the
bearings before reassembly. IJse John Deere Multi-
NOTE: There is no adiustment necessary on front
purpose Lubricant or an equivalent SAE multipur'
wheel bearings. pose-type grease.

lnstall wheel in reverse order of removal.

Litho in U.S.A.
70 Miscellaneous Tractors, 200 Series
10-4 Front Wheels and Axles SM-2105 (Jun-81)

Removing and lnstalling Spindle Removing and lnstalling Front Axle

NI.7 245tlZ
t\t1 7243NY

A-Axle C-Slotted Nut


B-King Pin Bolt D-Cotter Pin
M,i/ g4awy
Fig. 6-lnstalling Axle on Tractor
A-Tie Rod End C-Snap Ring
B-Snap Ring Pliers I)--Spindle
Remove cotter pin (D), Fig. 6, slotted nut (C) and
Fig. S-Removing Snap Ring king pin (B). Remove axle (A).

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).

Litho in U.S.A
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.

lf parts become worn or damaged, they must be


replaced.
Connecting Link on 200 Tractors (Serial
No. 30,001-190,000)
lf correct lifting or lowering travel cannot be
achreved with attachment linkage, adjust the length
of the connecting link (E). This will change the travel
up or down on the manual lift.

The proper link length is 11.9 inches (302.3 mm)


from the center of each yoke.

Helper Spring Kit


The helper spring (H) is available for mounted
equipment such as the snow thrower, front blade, ro-
tary tiller, and integral hitch.
A-Thumb Release F-Mower Litt Link
B-Lilt Lever G-Secondary Lift Shalt
C-Primary Lift Shaft H-Helper Spring When installed, the helper spring decreases the et
D-Offset Pin | Control fort required to raise heavy equipment with the man-
E-Connecting Link
-Depth
J
-Quadrant ual lift lever.
Fig 1-Manual Lift Linkage
Depth Control
Proper adjustment of the depth control (l) allows
the mower or center blade to return to the same pre-
set height each time it is raised and lowered.

The depth control allows the operator to lock the


mower or center blade in the raised position while
using the manual lift lever to operate front- or rear-
mounted equipment.

NOTE: Front- or rear-mounted equipment cannot


be locked in the raised position with the depth control
knob.

Litho in U.S.A.
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.

Lift lever not properly seated in lever hub.

Very Little Lift.


Lift rod not properly adjusted (rod from secondary
lift shaft arm to front-mounted equipment).
Turn yoke onto lift rod.
Connecting link not properly adjusted on 200 Series
Tractors Serial No. 30,001-190,O00 (rod between
primary and secondary lift shaft).
Turn yoke onto link.

No Lift When Lift Lever is in Fully Raised Position.


Connecting link not properly adjusted on 200 Series
Tractors Serial No. 30,001-190,000 (rod between
primary and secondary lift shaft)for mower, integral
hitch and tiller.

Lift rod not properly adlusted for front-mounted


equipment.

Broken weld on primary lift shaft (in pedestal).

Lift Lever Will Not Stay in Raised position.


Weak or broken release rod spring.

Thumb release not properly seated on release rod.

Very Little Down Travel.


Depth control screw turned all the way down.
Turn depth control counterclockwise.

Lift rod not properly adjusted for front-mounted


equipment.

Connecting link not properly adjusted on 200 Series


Tractors Serial No. 30,001-190,000 (rod between
primary and secondary lift shaft).

Litho in U.S.A.
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

GROUP 5 - 37A SNOW THROWER GROUP 15 - 541A PTO ATTACHMENT


Tractor Adjustments ....-..5-2 Servicing PTO Attachment . ... 15-1
Disassembly 1 5-1
Adlusting Lift Connecting Link
on Tractors (Serial No. lnspecting PTO Attachment Parts 15-4
3O,OO1-190,000). ....5-2 Assembly 15-5
Checking Electric Lift (Extra Equipment) . - . .5-2 Lubrication . 15-7
Adjusting Snow Thrower Lift. .. -. -...5-3
Rotor Drive Chain. .......5-4 GROUP 20 - 31 ROTARY TILLER
Tightening Drive Chain .......5-4 Replacing Tiller Drive Belt. 20-1
Replacing Drive Chain ........5-4 Adiusting Tiller Drive Belt and Guide 20-1
Replacing Drive Belt ......5-5 Replacing Primary Drive Belt 20-2
Replacing Rotor and Bearings .. .5-6 Adjusting Encased Drive Chain 20-3
Replacing Wear Plate .....5-6 Adjusting External Drive Chain 20-3
ReplacingscraperBlade. .......5-7 Leveling Tiller. .. . 2O-4
Replacing Shear Bolt.. ...5-7 Replacing External Drive Chain . . .. . . 2O-4
Lubrication .. .5-8 Replacing Upper Enclosed Drive Chain
Bearings 20-5
GROUP 10 - 39 AND 47 ROTARY MOWERS Replacing Lower Enclosed Drive Chain
Tractor Adjustments . .. . 10-1 Bearings 20-6
Adlusting Lift Connecting Link Chain Case 20-7
on Tractors (Serial No. Removing Chain Case 20-7
30,001-190,000) 10-1 Disassembling Chain Case. 20-9
Checking Electric Lift (Extra Equipment) . . 10-'1 lnspecting Chain Case Parts . 20-10
Replacing Drive Belt 10-2 Assembling Chain Case 20-10
Replacing Deck Belt 10-3 Replacing Tiller Tines 20-11
Servicing Mower Blades 10-3 Determining Right or Left-Hand Tines . . . 2O-11
Removing and lnstalling Blades 10-3 Determining Right or Left-Hand' Tine
Sharpening Blades 10-3 Assemblies . 2o-1'l
Balancing Blades with a Balancer 10-4 Extension Tine Assemblies.. ..... 20-11
Balancing Blades without a Balancer. . . . . 10-4 Lubrication 20-12
Servicing Mower Spindles 10-5 Daily or Every 8 Hours of Operation . .. . 20:12
Two Weeks or Every 50 Hours of
Operation .. 20-12
Tractor Adiustments . .. 20-13
Adlusting Lift Connecting Link
on Tractors (Serial No.
3O,OO1-190,000) .. 20-13
Adiusting Tiller Lift Height . . 20-13
Checking Electric Litt (Extra Equipment) . 20-13

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. 2-Adjusting Stop Spacer

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:

1. Loosen the stop spacer bolt, Fig. 2.

2. Pull lift lever all the way to the rear.

3. Move the lift lever forward untilthe key switch can


be turned on and off without activating the lift sole-
noids.

4. Move the spacer lorward until it touches the


control switch arm and tighten.

Litho in U.S.A.
90 Tractor Attachments Tractors, 200 Series
5-4 37A Snow Thrower sM-2105 (Jun-81)

ROTOR DRIVE CHAIN


Tightening Drive Chain

A-Jam Nut C-Bolts


Fig. S-Removing Chain Guard B-Stop Screw D-Countershaft
Fig. 7-Adjusting Drive Chain Tension
Remove chain guard, Fig. 5.
lf adjustment is necessary, loosen jam nut (A), Fig.
7, on stop screw (B). Loosen the four bolts (C) which
position the countershaft (D), leaving a slight tension
on the outer two bolts. Move the countershaft either
forward or backward to obtain correction chain tension
shown in Fig. 6, and align countershaft parallel to the
snow thrower shell. Adjust stop screw (B) to hold
countershaft (D) in position. Tighten jam nut (A).

Replacing Drive Chain


M2648?

Fig. 6-Checking Drive Chain Tension

Check rotor drive chain tension by turning top idler


sprocket counterclockwise to tighten lower strand of
chain, Fig. 6.

Place a straight-edge across the top two sprockets


and measure chain sag midway between the two
sprockets. Chain sag should be between 1/8 x 1/4 M2g90s
inch (3.18 to 6.35 mm).
Fig. B-Beplacing Drive Chain
'1. Remove chain guard, Fig. 5.

2. Remove spring clip and coupler link, Fig. 8.


3. Remove chain and install new chain and coupler
link.
4. Adlust chain tension as explained under Fig. 7.
5. Reinstall chain guard, Fig. 5.

Litho in U.S.A.
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)

Fig. 2-Adjusting Stop Spacer


Fig. 1-Adiusting Lift Connecting Link
lf tractor is equipped with an electric lift, check
1. Remove lift connecting link, Fig. 1. adjustment of the stop spacer.

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:

1. Loosen the stop spacer bolt, Fig. 2.

2. Pull lift lever all the way to the rear.


3. Move the lift lever forward until the key switch can
be turned on and off without activating the lift sole-
noids.

4. Move the spacer forward until it touches the


control switch arm and tighten.

Litho in U.S.A.
90 Tractor Attachments Tractors, 20O Series
10-2 39 and 47 Rotary Mowers SM-2105 (Jun-81)

REPLACING DRIVE BELT


CAUTION: To prevent personal injury, dis-
engage power, shut ofl engine and make
sure blades have stopped revolving before servic-
ing.

Fig. S-Replacing Drive Belt


Fig. S-Releasing ldler Tension and
Removing Side Panel
3. Pull idler assembly toward rear and remove belt
from mower sheave, Fig. 5. Slip belt off PTO sheave
1. Turn handle on bumper plate counterclockwise to and out of tractor.
release idler spring tension, Fig. 3. Turn handle until
there is approximately 3/4-inch (19 mm) clearance 4. lnstall new belt exactly as shown above. Do not
between the handle and bumper plate when the handle install belt with a reverse twist which causes mower
is pulled out. blades to operate backwards.
5. Pull idler assembly toward rear and position belt
Remove right-hand engine side panel. over mower sheave.
6. Turn handle on bumper plate clockwise until
spring is tight against backside of bumper plate. Then
turn handle one or two turns counterclockwise to back
off spring.

Fig. 4-Disconnecting Clutch Arm

2. Pivot clip upward and slide clutch arm to the rear.

Fig. i-Adjusting Belt Guide

7. Loosen idler sheave bolt and adjust belt guide to


within 1/B inch (3.18 mm) of belt when mower is
lowered to operating position, Fig. 6.
8. Replace clutch arm and tractor side panel.

Litho in U.S.A.
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.

Checking Electric Lift (Extra Equipment)

FiS. 1-Adiusting Lift Connecting Link

1. Remove lift connecting link, Fig. 1. Fig. 3-Adiusting Stop Spacer

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.

2. Pull lift lever all the way to the rear.


3. Move the lift lever forward untilthe key switch can
be turned on and off without activating the lift sole-
noids.

LIFT RON 4. Move the spacer forward until it touches the


control switch arm and tighten.

Fig. 2-Adiusting Tiller Lift Height

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.