John-deere stx38 User Manual download pdf (Page 91)

3/21/97

4 - 7

ELECTRICAL

THEORY AND DIAGNOSTIC INFORMATION

NOTES

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TECHNICAL 1
STX30, STX38, and STX46 1
Lawn Tractors 1
STX38 Gear Drive 2
STX38 Hydrostatic Drive 2
STX38 Motorsport Edition 2
METRIC FASTENER TORQUE VALUES 14
METRIC FASTENER TORQUE 15
VALUE - GRADE 7 15
INCH FASTENER TORQUE VALUES 16
O-RING SEAL 17
SERVICE RECOMMENDATIONS 17
O-RING FACE SEAL FITTINGS 19
O-RING BOSS FITTINGS 19
GASOLINE SPECIFICATIONS 20
GASOLINE STORAGE 20
4–CYCLE ENGINES - EUROPE 21
4–CYCLE GASOLINE ENGINE OIL 22
NORTH AMERICA 22
BREAK–IN 4-CYCLE GASOLINE 24
ENGINE OIL - NORTH AMERICA 24
ENGINE OIL - EUROPE 25
HYDROSTATIC TRANSMISSION OIL 26
- NORTH AMERICA 26
- EUROPE 27
ALTERNATIVE LUBRICANTS 28
SYNTHETIC LUBRICANTS 28
LUBRICANT STORAGE 28
MIXING OF LUBRICANTS 28
OIL FILTERS 28
GEAR TRANSMISSION GREASE 29
ANTI-CORROSION GREASE 30
GREASE SPECIFICATIONS 31
GREASE - NORTH AMERICA 31
GREASE - EUROPE 31
SERIAL NUMBER LOCATIONS 32
TORQUE SPECIFICATIONS 40
(Alphabetical Order) 40
ESSENTIAL TOOLS 41
SERVICE PARTS KITS 41
MAIN COMPONENTS 46
ENGINE HARD TO START AND/OR 48
ENGINE STARTER KICKS OUT 48
THROTTLE CABLE ADJUSTMENT 50
CHOKE ADJUSTMENT 50
GOVERNOR ADJUSTMENT 51
FAST IDLE SPEED ADJUSTMENT 51
SLOW IDLE SPEED ADJUSTMENT 52
NON CARB/EPA (EARLY MODELS) 52
ATTENTION 53
CYLINDER COMPRESSION TEST 54
AUTOMATIC COMPRESSION 54
RELEASE (ACR) TEST 54
CRANKCASE VACUUM TEST 55
FUEL FLOW TEST 56
OIL PRESSURE TEST 56
FUEL AND AIR SYSTEM REPAIR 57
REMOVE AND INSTALL FUEL TANK 58
AND DASH PANEL ASSEMBLY 58
REPLACE FUEL FILTER 60
AIR INTAKE SYSTEM COMPONENTS 61
CARBURETOR 61
INSPECT CARBURETOR 62
REMOVE AND INSTALL ENGINE 63
REMOVE AND INSTALL ROCKER 64
INSPECT PUSH ROD 64
REMOVE AND INSTALL CYLINDER 64
REMOVE AND INSTALL VALVES 65
AND SPRINGS 65
INSPECT CYLINDER HEAD 65
INSPECT VALVES 65
ANALYZE VALVES 66
INSPECT VALVE GUIDES 67
RECONDITION VALVE SEATS 67
LAP VALVES 68
INSPECT BREATHER 68
REMOVE AND INSTALL FLYWHEEL 68
REMOVE AND INSTALL CAMSHAFT 69
INSPECT CAMSHAFT 69
MEASURE CAMSHAFT END PLAY 70
HYDRAULIC VALVE LIFTERS— 70
INSPECTION 70
BALANCER SHAFT REMOVAL & 71
BALANCER SHAFT INSPECTION 72
GOVERNOR REMOVAL & 72
GOVERNOR INSPECTION 73
REMOVE PISTON ASSEMBLY 73
ANALYZE PISTON RING WEAR 74
ANALYZE PISTON WEAR 74
PISTON ASSEMBLY 77
MEASUREMENT 77
INSTALL PISTON ASSEMBLY 78
INSTALL CONNECTING ROD 79
CRANKSHAFT REMOVAL & 79
CRANKSHAFT ALIGNMENT 80
REMOVE AND INSTALL OIL PAN 80
CRANKCASE OIL SEAL 81
INSPECT OIL PICKUP 82
OIL PUMP RELIEF VALVE 82
INSPECT ION 82
OIL PUMP INSTALLATION 82
CYLINDER BLOCK REMOVE & 83
INSTALL 83
CYLINDER BLOCK INSPECT 83
CYLINDER BORE DEGLAZING 83
REBORE CYLINDER BLOCK 84
READING ELECTRICAL 89
SCHEMATICS 89
COMMON CIRCUIT TESTS 90
STX38 (SN 210001— ) 100
STX46 (SN 240001— ) 100
WIRING HARNESS DIAGRAMS 101
WIRING SCHEMATICS 102
STX30 (SN 135160—160000) 104
STX38 (SN 139616—160000) 104
STX38 (SN 160001—210000) 106
CIRCUIT OPERATION AND 110
DIAGNOSIS 110
CRANKING CIRCUIT OPERATION 110
ELECTRICAL 111
CRANKING CIRCUIT DIAGNOSIS 112
IGNITION CIRCUIT OPERATION 118
CHARGING CIRCUIT OPERATION 128
PTO CIRCUIT OPERATION 136
PTO CIRCUIT DIAGNOSIS POINTS 138
PTO AND HEADLIGHTS CIRCUITS 140
OPERATION 140
TESTS AND ADJUSTMENTS 146
GROUND CIRCUIT TESTS 146
BATTERY TEST 147
CHARGE BATTERY 147
BATTERY LOAD TEST 148
REGULATED VOLTAGE OUTPUT 149
UNREGULATED VOLTAGE OUTPUT 149
STARTER SOLENOID TEST 150
STARTER AMP DRAW TEST 150
IGNITION SPARK TEST 151
IGNITION MODULE AIR GAP 151
ADJUSTMENT 151
IGNITION MODULE TEST 152
SEAT SWITCH TEST 152
BRAKE PEDAL/PARK BRAKE 153
SWITCH TESTS 153
BRAKE SWITCH ADJUSTMENT 153
HEADLIGHT SWITCH TEST 154
(OPTIONAL) 154
KEY SWITCH TESTS 154
PTO SWITCH TESTS 155
PTO CLUTCH TEST 155
PTO CLUTCH AIR GAP 156
FLYWHEEL MAGNETS 156
TRANSMISSION NEUTRAL SWITCH 157
REMOVE AND INSTALL KEY 158
SWITCH AND PTO SWITCH 158
REMOVE AND INSTALL SEAT 158
REMOVE AND INSTALL STARTER 159
SOLENOID 159
REMOVE AND INSTALL STATOR 159
AND IGNITION MODULE 159
REPAIR PTO CLUTCH 160
REPLACE BENDIX DRIVE 161
REPAIR STARTER AND REPLACE 161
REPAIR STARTER ARMATURE 162
REMOVE AND INSTALL 163
CONTENTS 165
SPECIFICATIONS 167
GENERAL SPECIFICATIONS 167
REPAIR SPECIFICATIONS 169
OTHER MATERIALS 171
COMPONENT LOCATION 173
STX30 (SN 135159—160758) 175
STX38 (SN 139615—185586) 175
TRANSAXLE—DANA 5-SPEED 176
STX38 (SN 210001—301382) 176
STX38 (SN 301383— ) 178
TRACTION DRIVE SYSTEM 182
THEORY OF OPERATION 184
CLUTCH PEDAL AND BELT 184
OPERATION STX30 & STX38 184
(SN —210000) 184
TRANSAXLE OPERATION 187
PEERLESS MODELS 187
915-012A/915-012B 187
BRAKE SYSTEM COMPONENT 190
LOCATION AND OPERATION 190
TROUBLESHOOTING 192
CLUTCH/BRAKE PEDAL LINKAGE 198
AND TRACTION DRIVE SYSTEM 198
BRAKE SPRING ADJUSTMENT 198
BRAKE PAD ADJUSTMENT 199
CLUTCH SPRING ADJUSTMENT 200
SHIFT LINKAGE ADJUSTMENT 201
BRAKES STX30 & STX38 202
(SN —210000) REMOVAL/ 202
INSTALLATION 202
TRACTION DRIVE BELT REMOVAL/ 203
INSPECTION/INSTALLATION— 203
TRANSAXLE CASE—DISASSEMBLY 213
TRANSAXLE CASE—ASSEMBLY 216
STX38 & STX46 LATE MODEL 217
REMOVAL/INSPECTION/ 219
INSTALLATION— 219
TRANSAXLE—REMOVAL/ 221
TRANSAXLE—DISASSEMBLY 221
TRANSAXLE ASSEMBLY— 228
BRAKES—ASSEMBLY 232
HYDROSTATIC POWER TRAIN 234
HYDROSTATIC TRANSAXLE 239
BELT TRACTION DRIVE SYSTEM 242
TRANSAXLE AND SHIFT LINKAGE 242
SYSTEM OPERATION 242
BRAKE/NEUTRAL RETURN 244
SYSTEM COMPONENT LOCATION 244
AND OPERATION 244
TRANSPORT (FREE-WHEEL) 247
DIAGNOSIS CONTINUED 252
DRIVE BELT ADJUSTMENT 255
TRANSPORT (FREE-WHEEL) VALVE 255
BELLCRANK SPRING TENSION 256
REPEAT TEST DRIVE 258
INSPECTION/INSTALLATION 259
TRACTION DRIVE BELT 260
TENSIONING SYSTEM REMOVAL/ 260
POWER TRAIN LINKAGE SYSTEM 261
TRANSAXLE REMOVAL AND 262
TRANSAXLE DISASSEMBLY 263
DIFFERENTIAL AXLE— 268
DISASSEMBLY 268
PUMP, MOTOR, AND CENTER 270
BLOCK—DISASSEMBLY 270
TRANSAXLE ASSEMBLY 273
TRANSAXLE CASE HALVES— 278
ASSEMBLY 278
BRAKE ASSEMBLY— 278
RESERVOIR COVER AND 279
BREATHER VALVE—ASSEMBLY 279
FAN AND DRIVE SHEAVE— 279
TRANSAXLE BLEED PROCEDURE 280
STEERING 282
SERVICE EQUIPMENT AND TOOLS 283
STEERING BACKLASH 284
STEERING GEAR ASSEMBLY— 285
REMOVAL 285
PEDESTAL BUSHINGS— 286
REPLACEMENT 286
SERVICE EQUIPMENT & TOOLS 289
OTHER MATERIAL 289
FRONT WHEELS— 291
TOE-IN & CAMBER 291
FRONT AXLE 292
REMOVAL & INSTALLATION 292
MOWER DECKS 293
LIFT SYSTEM 293
STX38 (M00STXB595001—750000) 293
STX38 (M00STXB010001—139615) 293
STX38 (M00STXB139616—210000) 294
LIFT LINKAGE REPAIR— 295
STX30 & 295
STX38 (SN —210000) 295
STX38 (SN 210001— ) & 296
30-INCH MOWER DECK 297
SPINDLES— 303
STX38 (SN 210001— ) & 303
STX46 (SN 240001— ) 303
MOWER BLADE ADJUSTMENT 305
MOWER DECK BLOWOUT—STX46 307
MOUNTING PLATE 308
MOWER FRAME 308
INDEX - 6 314

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John-deere stx38 User Manual Page 91

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