Troy-Bilt Horse Tiller Technical Manual - Page 18

PTO

HORSE

MODEL

TECHNICAL

MANUAL

Page

5-2

4/90

SECTION

5:

PTO

Power

Unit

Transmission

Inspection

These

instructions

describe

how

to

inspect

vital

parts

on

the

PTO

power

unit

housing

cover.

In

addi-

tion

to

inspecting

the

parts

you

have

removed,

you

should

also

inspect

any

replacement

parts.

Note:

Thoroughly

degrease

and

clean

all

parts

before

inspection.

Plunger

Bolt

—

You

must

replace

the

neutral

plunger

assembly

if

it

is

frozen

(penetrating

oil

will

sometimes

free

a

frozen

bolt)

or

if

the

plunger

bolt

(13)

has

snapped

off.

To

determine

if

the

plunger

bolt

is

frozen,

perform

the

follow-

ing

test:

1.

Loosen

the

hex

jam

nut

(14).

2.

Gently

tighten

the

plunger

locking

bolt

(15)

until

it

stops,

then

add

a

1/4

turn

to

lock

it.

3.

Loosen

the

flange

locknut

(16).

4.

Loosen

the

plunger

bolt

(13).

If

you

cannot

loosen

the

bolt

or

if

the

bolt

snaps

off,

replace

the

neu-

tral

plunger

assembly

with

a

new

one.

If

the

plunger

bolt

is

not

frozen

on

the

plunger,

restore

the

plunger

assembly

to

its

previous

settings

by

reversing

steps

1,

2

and

3.

Cover

—

Inspect

the

cover

for

cracks. Also,

make

sure

the

threads

in

the

handlebar

mounting

base

are

not

damaged.

Installation

1.

Affix

the

gasket

(12)

to

the

cover.

2.

Start

the

four

bolts

(3)

and

the

lockwashers

(if

present)

in

the

cover.

3.

Tighten

the

two

forward

bolts

but

leave

the

two

rear

bolts

loose.

4.

Reattach

the

tiller

attachment

to

the

PTO

power

unit

and

then

reinstall

the

transmission

assem-

bly

on

the

tiller.

See

Section

4

for

instrucitions.

5.

Refill

the

transmission

with

gear

oil

if

it

was

previously

drained.

See

the

Owner/Operator

Manual

for

instructions

on

how

to

refill

the

transmission

with

oil.

Neutral

Plunger

Assembly

You

would

disassemble

the

PTO

power

unit

housing

cover

if

you

found

the

neutral

plunger

assem-

bly

to

be

frozen

or

if

the

bolt

snapped

off.

Disassembly

1.

Place

the

housing

cover

on

an

arbor

press

and

press

down

on

the

neutral

plunger

bolt

(13).

2.

Loosen

the

hex

jam

nut

(14)

then

loosen

the

plunger

locking

bolt

(15)

until

it

clears

the

groove

in

the

neutral

plunger

(17).

3.

Let

the

arbor

press

up.

4.

Remove

the

spring

(18).

Note:

If

you

are

servicing

an

8

HP

Kohler

engine

you

may

want

to

discard

the

spring

and

install

a

new

one

if

the

same

spring

has

been

in

use

for

several

years.

5.

If

you

are

installing

a

new

plunger

assembly,

discard

the

old

plunger,

clip

ring

(19),

flange

nut

(16),

and

neutral

plunger

bolt

(13).

Assembly

1.

Use

a

hammer

to

seat

the

clip

ring

(19)

in

the

groove

of

the

neu-

tral

plunger

(17).

2.

Thread

the

flange

nut

(16)

onto

the

plunger

bolt

(13)

about

three

quarters

of

the

way.

3.

Apply

a

coating

of

nickel

-

based

anti

-locking

compound

to

the

threads

of

the

plunger

bolt.

4.

Lubricate

the

inside

threads

of

the

neutral

plunger

(17).

5.

Thread

the

plunger

bolt

(13)

and

the

attached

flanged

nut

into

the

neutral

plunger.

6.

Slip

the

spring

(18)

on

the

neutral

plunger.

7.

Apply

a

coating

of

nickel

-

based

anti

-locking

compound

on

the

bottom

of

the

neutral

plunger

and

insert

the

neutral

plunger

into

the

housing

cover.

8.

Place

the

housing

cover

on

an

arbor

press.

9.

Turn

the

plunger

locking

bolt

(15)

until

it

is

finger

tight

and

you

feel

it

strike

the

neutral

plunger.

Then

maintain

very

light

pressure

on

the

bolt

with

a

wrench.

10.

Slowly

press

the

plunger

assembly

down.

When

the

groove

in

the

neutral

plunger

reaches

the

plunger

locking

bolt,

the

pressure

on

the

bolt

will

be

relieved.

11.

Tighten

the

plunger

locking

bolt

until

it

is

seated

and

then

back

it

off

1/2

turn.

12.

Release

the

arbor

press

pres-

sure

from

the

plunger

assembly.

13.

Hold

the

plunger

locking

bolt

in

place

and

tighten

the

hex

jam

nut

(14).

14.

Adjust

the

plunger

assembly

for

proper

reverse

action

by

refer-

ring

to

the

adjustment

instructions

in

the

Owner/Operator

Manual.

1

Troy-Bilt Horse Tiller Technical Manual - Page 18

Inspection, Installation, Neutral, Plunger, Assembly

Page 18 highlights