Professional Shop Manual 33” Wide Area Mower NOTE: These materials are for use by trained technicians who are experienced in the service and repair of outdoor power equipment of the kind described in this publication, and are not intended for use by untrained or inexperienced individuals. These materials are intended to provide supplemental information to assist the trained technician. Untrained or inexperienced individuals should seek the assistance of an experienced and trained professional.
Table of Contents Chapter 1: Introduction ........................................................................................... 1 Description of the Mower...................................................................................... 1 Fasteners .............................................................................................................. 1 Assembly ..............................................................................................................
33” Wide Area Mower CHAPTER 1: INTRODUCTION Description of the Mower Disclaimer: The information contained in this Manual is correct at the time of writing. Both the product and the information about the product are subject to change without notice. The Troy-Bilt 33” wide cut mower was discontinued in 2005. It has since been completely redesigned and released as a Cub Cadet for the 2007 season. See Figure 1.1. Disclaimer: This handbook is intended for use by trained, professional technicians.
Chapter 1: Introduction Assembly Model and Serial Numbers Torque specifications may be noted in the part of the text that covers assembly, they may also be summarized in tables along with special instructions regarding locking or lubrication. Whichever method is more appropriate will be used. In many cases, both will be used so that the manual is handy as a quick-reference guide as well as a step-by-step procedure guide that does not require the user to hunt for information.
MAINTENANCE CHAPTER 2: MAINTENANCE Cleaning Axle shafts Maintaining any piece of equipment begins with keeping it clean. Any spills such as fuel or oil should be wiped off promptly. Use a mild detergent and water to wash the mower. The rear axle shaft coming from the transmission is a double-D shaft. As required of all double-D axle shafts, the wheels should be removed once a year and the shafts coated with anti-seize. See Figure 2.1. NOTE: Do NOT use a pressure washer to clean the mower.
MAINTENANCE Front casters Spindles The front caster wheels of the mower are equipped with two grease fittings. Any grease injected into one side of the wheel will migrate to the other side. A high quality lithium grease is recommended. See Figure 2.2. Both blade spindles are equipped with grease fittings. The spindles should be greased every 50 hours or at the end of the mowing season which ever comes first. See Figure 2.4. Grease fitting Grease fitting Grease fittings Figure 2.2 Figure 2.
MAINTENANCE Fasteners Emissions Check all fasteners annually for any signs of loosening or damage. In order to meet the new EPA regulations, there has been some changes to the fuel system. The fuel tank is blow moulded and composed of a high density polymer. The fuel cap has a ratchet feature that will prevent the end user from over tightening it. Excessive vIbration is a primary cause of fatigue failures. Vibration can loosen fasteners and fatigue metal.
Drive system CHAPTER 3: DRIVE SYSTEM 3. A single belt is used to transfer power from the engine crankshaft to the input shaft of the transaxle. The left side control handle and cable operate a tensioner pulley that tightens the belt to engage the drive system and loosens the belt to de-clutch the drive system. Remove the belt guide that is near the idler pulley using a pair of 7/16” wrenches. See Figure 3.2.
Drive system 5. Drive Cable Slip the belt past the belt guide and work the belt off of the remaining pulleys. A cable is used to pull the idler pulley to engage the transmission driving the wheels. This puts tension on the drive belt allowing it to turn the transmission pulley. This cable is not adjustable. IMPORTANT: Before installing a new belt, it must be turned inside out to route the belt properly. 6. Install the belt following the above steps in reverse order. For belt routing See Figure 3.4.
Drive system 3. Remove the deck by following the steps described in Chapter 4: Deck and lift shaft. 4. Unhook the drive cable from the idler bracket. See Figure 3.7. Brakes The brake is released by squeezing either or both levers. The handle on the left hand side will release the brake when the drive control lever is engaged. See Figure 3.9. Drive cable Figure 3.7 5. Figure 3.9 Remove the cable from the frame by using two 1/2” wrenches to loosen the jam nuts. See Figure 3.8.
Drive system Brake adjustment The two cable design allows the operator to mow without engaging the traction (wheel) drive. This is a handy feature for mowing in tight areas where maneuverability is needed. The traction drive can also be engaged independently of the deck. This is a handy feature for transport. The shift rod can be easily moved with a side to side push from the users hand. To shift from one gear to another the mower needs to be completely stopped.
Drive system 7. If the brake needs to be adjusted, tighten or loosen the adjustment nut with a 1/2” wrench, See Figure 3.13. Brake caliper NOTE: If the brake is set too tight the mower will drag and not drive smoothly. NOTE: If the mower doesn’t stop immediately after both control levers are released the adjustment may be to loose. 1. Raise the rear of the mower at least 18” off the ground. 2. Safely support mower with jack stands. 3. Remove the spring that maintains tension on the brake.
Drive system 5. Remove the two See Figure 3.16. caliper mounting 8. bolts. Inspect the brake yoke for signs of corrosion that may prevent proper movement of pins through the yoke. See Figure 3.18. Actuator Pins Adjustment Screw Brake Yoke Front Brake Pad Brake Pad Plate Figure 3.16 Figure 3.18 6. Remove the caliper and outboard brake puck. 7. Slide the brake disc off the splined shaft to expose the inboard brake pad for inspection. See Figure 3.17.
Drive system Brake cables 3. To replace the cables: NOTE: These cables are not adjustable. 1. The cable will now be loose enough to slip the zfitting from the handle. See Figure 3.21. Deck engagement cable Loosen the lock nuts located on the cable brackets and slide it up the cable. The bracket is located on the handle bar beneath the dash panel on both sides of the handle bars. See Figure 3.19. Brake Cable Figure 3.21 4.
Drive system 5. Loosen the connecting nut of the loop link coupler with a 3/8” wrench to free the eyelets on the brake cable. See Figure 3.23. 7. Pull each cable out and down to free the cable from the frame. The cables can be pulled 1 at a time through the lowest hole in the punch out. See Figure 3.25. 3/8” wrench Figure 3.23 Figure 3.25 6. Loosen the two lock nuts at the lower frame to free the cable from the frame. Use a pair of ½” wrenches. See Figure 3.24.
Drive system Transmission Removal and replacement 1. Loosen wheel bolts using a 1/2” wrench. 2. LIft and safely support mower so that the wheels are at least 18” off the ground. 3. Remove both rear wheels . See Figure 3.26. 6. Detach the lower shift rod from the upper shift rod using a pair of 1/2” wrenches. See Figure 3.28. 1/2” Wrenches 1/2” hex bolt Figure 3.28 7. Figure 3.26 4. Remove the traction drive belt as described on the tractor drive belt section. 5.
Drive system 8. Remove the hairpin clip that fastens the spring tension rod to the transmission. See Figure 3.30. 11. Lower the transmission and tilt it forward to guide it out from under the frame. 12. When the transmission is out of the mower remove the lower shift rod, spring retention rod, and extension spring. Install them on the new Transmission. Hairpin clip NOTE: Bench test the transmission prior to replacing or shipping to the manufacturer for warranty.
CUTTING DECK AND LIFT SHAFT CHAPTER 4: CUTTING DECK AND LIFT SHAFT Deck removal 1. 5. Take the deck cover off by removing the three self tapping screws with a 3/8” wrench. See Figure 4.1. Remove the four hairpin clips in the deck lift links and slide the deck to the left to clear the hanging pins on the lift links. See Figure 4.3. Self Tapping Screws 4 hairpin locations Figure 4.3 Figure 4.1 6. NOTE: Early 2007 production used nuts and bolts to fasten the belt cover on. 2.
CUTTING DECK AND LIFT SHAFT Cleaning the deck Blades Clean debris off of the deck every time the deck cover is removed. It is routine maintenance that will make the deck easier to work on and prolong the life of the deck and spindles. The condition of the blades will greatly effect the quality of the cut. The blades should be sharpened and balanced after every five acres, depending on local conditions. A dull blade tears the grass instead of cutting it.
CUTTING DECK AND LIFT SHAFT Blade removal 1. 2. 5. Remove the deck as described in the previous section of this chapter or lift the tractor using a professional grade lift. Install the blade by following the above steps in reverse order. Tighten the blade nut to a torque of 70 - 90 ft-lbs ( 95 - 122 Nm). NOTE: The blades have a star center. The star must seat on the raised star on the bottom of the spindle shaft with the fins of the blade pointing to the deck.
CUTTING DECK AND LIFT SHAFT Spindles To replace a spindle: The spindles are a complete unit. The only replaceable parts are the pulleys. The spindles are equipped with a grease fitting that should get one squirt of grease after every use of the deck wash system or every 10 hours of use. 1. Remove the deck as described at the beginning of this chapter. 2. Remove the blade following the steps described in the previous section of this chapter. 3.
CUTTING DECK AND LIFT SHAFT PTO belt 2. Slide the cover off of the mower. The function of the PTO belt is to transfer the mechanical force from the engine to the blades. The belt faces a lot of different forces. 3. Release the tension on the engagement pulley. Disconnect the spring end of the deck engagement cable from the Idler bracket. See Figure 4.11. • Clutching and de-clutching • Heat from bending or deformation. • The friction of the belt against the pulleys creates heat.
CUTTING DECK AND LIFT SHAFT 5. Deck Timing Belt Remove the belt guide by the engine pulley with a pair of 3/8 wrenches. See Figure 4.13. To service the deck timing belt: 1. Take the deck cover off by removing the three self tapping screws. See Figure 4.14. Remove this nut three self tapping screws Figure 4.13 6. Slide the belt off of the pulleys. 7. Discard the old belt. 8. Install a new deck belt by following the steps above in reverse order. 9. Test run the mower before returning to service.
CUTTING DECK AND LIFT SHAFT 4. Slide the belt off of the left side spindle. 7. 5. Back the jam nut on the idler stop bolt to the head of the bolt. See Figure 4.16. With the tension relieved slip the timing belt off of the pulleys. 8. To install the timing belt turn the blades 90o apart. See Figure 4.18. Idler Stop Bolt 90o Figure 4.16 6. Figure 4.18 Insert a 3/8” ratchet or breaker bar into the square hole in the idler bracket.
CUTTING DECK AND LIFT SHAFT 10. Slide the timing belt over the spindles. Test run the mower before returning to service. 11. Swing the idler pulley away from the belt using a 3/8” ratchet for leverage. Deck engagement (PTO) cable 12. Slip the timing belt behind the idler pulley. See Figure 4.20. To service the PTO cable: 1. Unhook the top Z-fitting from the blade engagement lever. See Figure 4.22. PTO cable Idler Stop Bolt Figure 4.20 Figure 4.
CUTTING DECK AND LIFT SHAFT 3. Take the deck cover off by removing the three nuts and bolts. See Figure 4.24. 6. NOTE: depending on production date the nuts and bolts may have been replaced by self tapping screws. Remove the cable from the frame using two 1/2” wrenches. See Figure 4.26. Blade cable Remove these bolts or screws Figure 4.26 7. Install the PTO cable by following the above steps in reverse order. 8. Test run the mower before returning to service. Figure 4.24 4.
CUTTING DECK AND LIFT SHAFT Leveling the deck Deck lift shaft and lever For the best quality cut, the deck must be level side to side and the front of the deck should be 1/4” - 3/8” lower than the rear of the deck. To remove the deck lift shaft: Side to Side Leveling 1. With the mower parked on a firm, level surface, move the deck to the mid height position using the deck lift lever. Rotate one blade so that it is perpendicular with the mower frame. 2.
CUTTING DECK AND LIFT SHAFT NOTE: The deck adjustment lever is divided into three (3) parts, the adjustment handle and two (2) lever pivot brackets. See Figure 4.30. Adjustment handle Lever Pivot Brackets Figure 4.30 4. Remove the split bushing from the rear lift shaft. See Figure 4.31. Split bushing Lift shaft Figure 4.31 5. Work the shaft out of the frame. 6. Repeat steps 4 and 5 on the front lift shaft. 7. Reinstall the lift shaft and lift lever by following the above steps in reverse order.
