PDF Technical Service Manual John Deere Sabre Yard Garden Tractors - 5 MB
This technical service manual covers the John Deere Sabre series of yard and garden tractors, including models 1948GV, 2148HV, 2354HV, and 2554HV.
It is designed for technicians and experienced owners who perform their own maintenance and repairs.
The manual contains in-depth information on diagnostics, engine service, transmission repair, and electrical systems.
Keep your Sabre tractor running perfectly for years to come with this detailed guide.
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--- Page 1 ---
SABRE YARD & GARDEN TRACTORS
1948GV/HV, 2148HV, 2354HV, 2554HV
TECHNICAL
MANUAL
John Deere
Worldwide Commercial and
Consumer Equipment Division
TM1841 (03Mar00)
Litho in U.S.A
--- Page 3 ---
SPECIFICATIONS & INFORMATION SPECIFICATIONS
SPECIFICATIONS
Engine (CV19 / CV21 / CV23)
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kohler
Model Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CV19 / CV21 / CV23
Horsepower
CV19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.17 kW (19 hp)
CV21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.66 kW (21 hp)
CV23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.15 kW (23 hp)
Displacement
CV19/CV21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624 cm3 (38.1 cu.in.)
CV23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677 cm3 (41.3 cu.in.)
Oil Capacity (w/ oil filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt.)
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fully Pressurized
Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Element, Full Flow, Spin-On Filter
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Stage
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal Discharge Below Frame
Engine (CV25)
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kohler
Model Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CV25
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.6 kW (25 hp)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725 cm3 (44.0 cu.in.)
Oil Capacity (w/ oil filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 L (2.1 qt.)
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fully Pressurized
Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Element, Full Flow, Spin-On Filter
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Stage
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal Discharge Below Frame
Fuel System
Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Natural
Fuel Tank Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear
Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 L (3 U.S. gal)
Fuel (minimum octane) . . . . . . . . . . . . . . . . . . . . . . . . . . Unleaded Gasoline, 87 Octane
Fuel Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Float-Type Side Draft Carburetor
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable In-Line
Electrical
Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . .Electronic Capacitor Discharge Ignition (CDI)
Type of Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Shift
Charging System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel Alternator
Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BCI Group, U1
Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V
Battery Reserve Capacity at 25 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 minutes
Battery Cold Cranking Amps at -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . .295 amps
3/3/00 2-3
--- Page 4 ---
KOHLER ENGINE GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Engine (19 hp)
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kohler
Model Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CV19
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.17 kW (19 hp)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624 cm3 (38.1 cu.in.)
Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 mm (3.03 in.)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 mm (2.64 in.)
Oil Capacity (w/ oil filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt.)
Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Element, Full Flow, Spin-On Filter
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fully Pressurized
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Stage
Engine (21 / 23 hp)
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kohler
Model Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CV22
Horsepower
CV21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.66 kW (21 hp)
CV23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.15 kW (23 hp)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674 cm3 (41.1 cu.in.)
Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 mm (3.15 in.)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 mm (2.64 in.)
Oil Capacity (w/ oil filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt.)
Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Element, Full Flow, Spin-On Filter
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fully Pressurized
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Stage
Engine (25 hp)
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kohler
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CV25
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18.4 kW (25 hp)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725 cm3 (44.0 cu.in.)
Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 mm (3.27 in.)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 mm (2.64 in.)
Oil Capacity (w/ oil filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 L (2.1 qt.)
Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Element, Full Flow, Spin-On Filter
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fully Pressurized
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Stage
3/7/00 3-3
--- Page 5 ---
KOHLER ENGINE ENGINE HARD TO START
ENGINE TROUBLESHOOTING GUIDE
ENGINE HARD TO START
Remove spark plug and NO Are sparks produced when spark plug YES • Faulty spark plug. Replace
check spark by cranking is replaced?
engine while having the NO
plug grounded against YES
engine block. Install
YES
spare plug to avoid fuel Are sparks produced between high • Faulty contact of plug
spitting from the hole. Correct
tension lead and engine block with cap terminal to lead.
(See “SPARK TEST” on plug cap removed? NO
page 25.)
• Faulty control unit. Replace
CAUTION:
To avoid electric YES
shock, do not hold Are sparks produced between high • Faulty ignition coil Replace
plug. Make sure to tension lead and engine block when with module.
hold plug cap. control unit is replaced? (See “SPARK NO • Faulty high tension
ADVANCE MODULE (SAM) TEST lead. Replace
(25 HP)” on page 28.) • Incorrect ignition coil
Correct
with module air gap.
(See “IGNITION
MODULE AIR GAP
ADJUSTMENT” on
page 27.).
• Demagnetized Replace
flywheel.
Is compression YES Crank engine several times, then NO Add
•
No fuel in the tank.
sufficient? (See remove spark plug and observe Open
“CYLINDER electrodes. •
Closed shutoff valve.
COMPRESSION Are they wet? •
Clogged fuel filter. Clean
PRESSURE TEST” on •
Closed shutoff Check or
page 20.) YES solenoid. replace
• Plugged air hole in Clean
tank cap.
NO
• Plugged fuel line. Clean
• Excessive use of Open choke
choke.
• Clogged air cleaner. Clean
• Fuel level too high in Adjust
float bowl.
• Worn piston/piston Replace
rings.
• Stuck piston rings. Clean or replace
• Worn cylinder bore. Bore or replace
• Insufficient cylinder Retighten
head tightening.
• Faulty contact of valve Lap or grind
seat.
• Warped cylinder Repair or replace
head.
Check carburetor. • Check for plugged fuel passage. • Broken valve spring. Replace
• Check for plugged air passage. • Stuck valve. Clean or grind
• Check shutoff solenoid. • Leaking head gasket. Replace
• Check carburetor setting.
3/7/00 3 - 13
--- Page 6 ---
KOHLER ENGINE CRANKCASE VACUUM TEST
Test Equipment: JTO3503 Crankcase Vacuum Test Kit—
• JT05697 U-Tube Manometer Test Kit; or,
• JT03503 Crankcase Vacuum Test Kit
Procedure:
JT05697 U-Tube Manometer Test Kit—
1. Park machine on level surface.
2. Raise engine hood and remove dipstick.
IMPORTANT: Check oil fill cap and O-ring for
cracks or damage, replace as necessary. M85637
1. Repeat Steps 1 – 4 in JTO5697 test procedure.
IMPORTANT: DO NOT make connection between
test gauge and rubber plug BEFORE engine is
running at FAST idle or gauge damage may
result.
After test reading is made, DO disconnect test
gauge WHILE engine is running at FAST idle to
prevent damage to gauge.
M45642
2. Hold finger over rubber plug hole to keep oil from
spraying out. Start engine and run at FAST idle.
3. Install appropriate size rubber plug in dipstick tube. 3. Connect gauge, clear line, and barbed fitting to
4. Insert barbed fitting in rubber plug and connect rubber plug.
clear line to barbed fitting. 4. Record crankcase vacuum reading. Gauge should
show a minimum vacuum of 15 cm (6 in.) of
water movement.
IMPORTANT: DO NOT make connection between 5. Disconnect barbed fitting, clear line, and gauge
U-Tube Manometer and clear line BEFORE from rubber plug while engine is running at FAST
engine is running or fluid in manometer could idle. Hold finger over rubber plug hole to keep oil
be drawn into crankcase. from spraying out.
6. Move throttle to SLOW idle and turn engine OFF.
DO NOT turn engine OFF until clear line has
7. Remove rubber plug and install dipstick.
been disconnected from U-Tube Manometer.
5. Align ruler “zero” markings with top of water level in Results:
U-tube. If crankcase vacuum is BELOW specification, check
6. Start and run engine at FAST idle. the following:
7. Connect clear line to open U-Tube Manometer • Breather reed valve clearance and condition.
spigot. • Breather port is obstructed.
8. Record crankcase vacuum reading. Manometer • Rings, piston, and cylinder bore for wear or
should show a minimum vacuum of 15 cm (6 in.) damage.
of water movement.
9. Run engine at SLOW idle. DO NOT TURN ENGINE
OFF!
10. Disconnect clear line from open manometer spigot.
11. Turn engine OFF.
12. Remove plug from dipstick tube and install dipstick.
3/7/00 3 - 23
--- Page 7 ---
KOHLER ENGINE ROCKER ARMS REMOVAL AND INSTALLATION
2. Disconnect the electrical connections and fuel
supply hose from the carburetor.
3. Disconnect the governor and throttle linkage from
the carburetor. Remove the carburetor.
NOTE: The carburetor has no serviceable parts. If the
carburetor has any worn out or damaged parts,
the carburetor must replaced.
Installation:
NOTE: Installation is the reverse of removal.
B
1. Replace the gaskets, and install the carburetor to
the intake manifold.
2. Connect the electrical connections, and the fuel
supply hose.
M89867
3. Install the air cleaner base. See “AIR CLEANER
REMOVAL AND INSTALLATION” on page 31.
2. Remove four valve cover cap screws (B) and
remove valve cover.
ROCKER ARMS REMOVAL AND
INSTALLATION
1. Remove air cleaner. It is not necessary to remove C
base.
A
D
M89843
M89857
IMPORTANT: Mark rocker arms, pivot ball spacers,
push rods, and lifters for assembly in original
locations.
NOTE: If removing the #1 valve cover it is necessary to
disconnect the breather hose from the breather
(A). 3. Remove cap screws (C) and pivot ball spacers (D).
4. Remove rocker arms.
5. Remove and inspect push rods. (See “PUSH ROD
INSPECTION” on page 41.)
3/7/00 3 - 33
--- Page 8 ---
KOHLER ENGINE CAMSHAFT REMOVAL AND INSTALLATION
CAMSHAFT REMOVAL AND
A INSTALLATION
1. Remove oil pan.
2. Remove hydraulic lifters. (See “ROCKER ARMS
REMOVAL AND INSTALLATION” on page 33.)
A
M89895
2. Remove cap screws (A) securing shields to engine M89842
block.
3. Remove camshaft (A).
B
4. Inspect camshaft closely, replace as necessary.
Installation:
1. Coat entire camshaft with engine oil.
M89896
3. Remove screws (B) securing stator to engine block.
Remove stator wire harness from groove in engine B
block. remove stator.
4. Inspect for damage.
Installation:
Installation is the reverse of removal.
Make sure that stator wire harness is in groove in M89894
engine block before installing shields.
Tighten stator cap screws to specification.
Adjust ignition module air gap per specifications. 2. Install camshaft with timing marks (B) on camshaft
(See “IGNITION MODULE AIR GAP ADJUSTMENT” gear and crankshaft gear aligned.
on page 27.) 3. Check camshaft end play. (See “CAMSHAFT END
PLAY” on page 44.)
Specifications:
Ignition Module Cap Screws IMPORTANT: If oil pan does not seat fully on block
. . . . . . . . . . . . . . . . . . 4.0 – 6.2 N•m (35 – 55 lb-in.) DO NOT force it down. STOP and find out why it
Stator Cap Screws . . . . . . . . . . . . . . 4 N•m (35 lb-in.) does not seat properly.
3/7/00 3 - 43
--- Page 9 ---
KOHLER ENGINE OIL PRESSURE SWITCH, REPLACE
OIL PRESSURE SWITCH, REPLACE OIL PUMP REMOVAL AND
1. Remove the carburetor air cleaner. INSTALLATION
1. Remove oil pan. (See “OIL PAN REMOVAL AND
INSTALLATION” on page 51.)
A
A
B
M89857
M89873
2. Disconnect the breather hose from the breather (A).
3. Remove nuts securing air cleaner base to 2. Remove cap screws (A) securing oil pump in oil
carburetor. Remove the air cleaner base. pan.
3. Remove and clean intake screen (B).
B
M87734
M89849
4. Remove oil pressure switch wire. 4. Inspect pump, surface of crankcase cover, and rotor
5. Remove oil pressure switch (B). for scoring, discoloration, and wear.
Installation: NOTE: The oil pump has no serviceable components.
Installation is the reverse of removal. If any pump components shows wear or
damage entire oil pump must be replaced.
• Tighten oil pressure switch to specification.
5. Replace oil pump as necessary.
Specification:
Switch Torque. . . . . . . . . . . . . . . . 4.5 N•m (40 lb-in.)
Installation:
Installation is the reverse of removal.
1. Tighten oil pump cap screws to specification.
Specification:
First Time Installation . . . . . . . . 10.7 N•m (95 lb-in.)
All Reinstallations . . . . . . . . . . . . 6.7 N•m (60 lb-in.)
3/7/00 3 - 53
--- Page 10 ---
ELECTRICAL ELECTRICAL SCHEMATIC
ELECTRICAL SCHEMATIC
Off
S1 Key On W2 Headlight
Switch Wiring Harness
400 Yel/Blk 400 Yel/Blk
450 Yel/Wht
211 Red 401 Yel
X3 E1 R.H. E2 L.H. W3 Engine Wiring
710 Pur/Blk 700 Pur S4 Light Harness (All Engines)
Switch Headlight Headlight
X4 To W3 W6 Engine
100
Engine Adaptor Wiring Harness
720 X3 Blk Wiring Harness
Pur X5
407 Yel 407 Yel Red Red
105 940 Wht 940 Wht Wht
Start Blk Y2 Fuel