Transcript
Professional Shop Manual
400 Series Tiller 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. Read, understand, and follow all instructions and use common sense when working on power equipment. This includes the contents of the product’s Operators Manual, supplied with the equipment. No liability can be accepted for any inaccuracies or omission in this publication, although care has been taken to make it as complete and accurate as possible at the time of publication. However, due to the variety of outdoor power equipment and continuing product changes that occur over time, updates will be made to these instructions from time to time. Therefore, it may be necessary to obtain the latest materials before servicing or repairing a product. The company reserves the right to make changes at any time to this publication without prior notice and without incurring an obligation to make such changes to previously published versions. Instructions, photographs and illustrations used in this publication are for reference use only and may not depict actual model and component parts. © Copyright 2008 MTD Products Inc. All Rights Reserved
MTD Products Inc - Product Training and Education Department FORM NUMBER - 769-04441
10/2008
Table of Contents
Chapter 1: Introduction ........................................................................................ 1 Professional Shop Manual intent .................................................................... 1 Assembly ........................................................................................................ 1 Tiller description .............................................................................................. 2 Understanding model and serial numbers ...................................................... 2 Maintenance chart .......................................................................................... 3 Chapter 2: Belts ..................................................................................................... 5 Chapter 3: Cables .................................................................................................. 7 Forward drive cable ........................................................................................ 7 Reverse drive cable ........................................................................................ 9 Chapter 4: Engine Removal ............................................................................... 11 Engine removal ............................................................................................. 11 Engine installation......................................................................................... 12 Chapter 5: Transmission Removal .................................................................... 13 To remove/replace the transmission ............................................................. 13 Chapter 6: Drive shaft ......................................................................................... 17 Drive shaft removal ....................................................................................... 17 Drive shaft installation ................................................................................... 20 Chapter 7: Wheel/Tine Shaft and Worm Gear .................................................. 25 Wheel/Tine shaft and worm gear removal .................................................... 25 Wheel shaft and worm gear installation ........................................................ 26
Introduction
CHAPTER 1: INTRODUCTION Professional Shop Manual intent
Fasteners
This manual is intended to provide service dealers with repair and overhaul procedures for the 400 series tiller.
•
All of the fasteners used on this tiller are fractional inches.
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.
•
If a fastener has a locking feature that has worn, replace the fastener or apply a small amount of releasable thread locking compound such as Loctite® 242 (blue).
About the text format:
•
Some fasteners like cotter pins are single-use items that are not to be reused. Other fasteners such as lock washers, retaining rings, and internal cotter pins (hairpin clips) may be reused if they do not show signs of wear or damage. This manual leaves that decision to the judgement of the technician.
NOTE: is used to point-out information that is relevant to the procedure, but does not fit as a step in the procedure. CAUTION: is used to point-out potential danger to the technician, operator, bystanders, or surrounding property. •
Bullet points: indicate sub-steps or points.
Disclaimer: This manual is intended for use by trained, professional technicians. •
Common sense in operation and safety is assumed.
•
In no event shall MTD be liable for poor text interpretation, or poor execution of the procedures described in the text.
•
If the person using this manual is uncomfortable with any procedures they encounter, they should seek the help of a qualified technician.
Assembly 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. The level of assembly instructions provided will be determined by the complexity of reassembly, and by the potential for unsafe conditions to arise from mistakes made in assembly. Some instructions may refer to other parts of the manual for subsidiary procedures. This avoids repeating the same procedure two or three times in the manual.
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Introduction Tiller description
Understanding model and serial numbers
The 400 series tiller is a new tiller line that was introduced for the 2009 model year. This is a rear tine, counter rotating tiller. This tiller has a gear case transmission that features ball bearing on the wheel and tine shafts and bronze worm gears.See Figure 1.1.
The model number is 21AA40M1029. The break down of what the number mean is as follows: •
21A - - - - - - - - indicates that this is a tiller
•
- - - A - - - - - - - indicates the wheel size
•
- - - - 40 - - - - - indicates the transmission
•
- - - - - - M1 - - - indicates the engine
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- - - - - - - - 029 indicates the retailer that bought it.
The serial number is 1058K10005. The serial number reads as follows: 1...........................engineering level ..G.........................month of production (G = July) .....05....................day of the month .........8..................last digit of the year ...........K................plant it was built in Figure 1.1
..............1.............assembly line number .................0005.....number of unit built
Currently, the 400 series tiller will only be powered by the MTD engine. Information and repair procedures for it can be found in manual #769-04015.
Additional technical and service information may also be available to our company authorized service center personnel through our company corporate offices, regional parts distributors and regional service center field support personnel. Please contact the designated support office in your area or our corporate offices directly should further service information be needed. MTD Products LLC P.O. Box 368022 Cleveland, OH 44136 Telephone: (800) 800-7310 www.mtdproducts.com
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Introduction Maintenance chart
Maintenance item Check engine oil Check air filter
Each use *
Check trasmission oil
* *
Check for loose/broke tines
*
Check & gap spark plug Check cooling fins Check/clean spark arrestor Change oil Note on oil: Change air filter Note on air filter Drain or preserve fuel
Each 25 hrs. use Each 50 hrs. use
Replace if worn.
*
After prolonged storage * * Change oil after first 5 hrs. of use, and before prolonged storage. * Air filter and pre-filter life vary dramatically with operating conditions. Before prolonged storage
Fog or lube cylinder
Before prolonged storage
Rotate engine to TDC
Before prolonged storage
Remove wheels/lube wheel shaft
Once a year
Remove tines/lube tine shaft
Once a year
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Introduction
4
Belts
CHAPTER 2: BELTS The 400 series tiller has two belts; a forward drive belt and a reverse belt. Both belts have to come off together. It is recommended to replace both belts at the same time.
5.
Loosen the nut and bolt that secures the reverse idler pulley to the idler bracket using a pair of 7/ 16” wrenches. See Figure 2.2.
To remove/replace the belts: 1.
Disconnect and ground the spark plug wire.
2.
Remove the two screws that secure the belt cover. See Figure 2.1.
Remove these screws Washer
Figure 2.2
Figure 2.1
6.
Slide the reverse belt past the belt guards and off of the idler pulley.
7.
Push both belts down to the transmission pulley. See Figure 2.3.
Unhook spring
NOTE: The left screw has a washer to prevent the slot in the cover from opening up as the screw is tightened. 3.
Swing the belt cover up and off of the tiller.
4.
Slide the forward drive belt off of the engine pulley.
Belts pushed down Figure 2.3 8.
Unhook the reverse idler spring. See Figure 2.3.
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Belts 9.
Unhook the reverse cable Z-fitting from the reverse idler bracket.
12.
Remove the screw that secures the transmission pulley using a 1/2” socket and an impact wrench.
10.
Remove the reverse idler bracket using a 1/2” wrench. See Figure 2.4.
13.
Slide the transmission pulley and both belts off as one. NOTE: The transmission pulley is keyed to the drive shaft. Rotating the transmission pulley so that the key is on the top side of the drive shaft will help prevent it from falling out.
Shoulder spacer
Lock washer
14.
Place the new belts on the transmission pulley. See Figure 2.6. Reverse belt
Forword drive belt
Remove this screw
Fender washer Figure 2.4
11.
Remove the four screws that secure the transmission pulley shield.See Figure 2.5.
Figure 2.6 15.
Install the belts by following steps 1 through 13 in reverse order.
16.
Test run the tiller in a safe area before returning it to service. Belt routing
Remove these screws
Engine pulley
Figure 2.5
Transmission pulley Figure 2.7
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Cables
CHAPTER 3: CABLES The 400 series tiller has a forward drive cable and a reverse drive cable. The forward drive cable is actuated by a bail that the operator squeezes. The reverse drive cable is actuated by a lever. See Figure 3.1.
Reverse lever
Forward drive cable To remove/replace the forward drive cable: 1.
Disconnect and ground the spark plug wire.
2.
Disconnect the black cable fitting from the handle bar bracket. See Figure 3.3.
Forward drive bail
Disconnect the cable fitting
Figure 3.1 The shape of the drive bail and reverse lever will help prevent the operator from engaging the reverse lever while in the forward mode. As the reverse lever is engaged, the bend on the bottom of it hits the drive bail making it necessary to release the drive bail. See Figure 3.2.
Figure 3.3 NOTE: A ford fuel line tool is useful to compress the ears on the cable fitting while removing it. See Figure 3.4.
Ford fuel line tool
Reverse lever hitting the drive bail
Figure 3.2
Figure 3.4
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Cables 3.
Unhook the Z-fitting from the forward drive bail.
7.
Slip the cable off of the pulley.
4.
Remove the two screws that secure the belt cover. See Figure 3.5.
8.
Disconnect the black cable fitting from the cable bracket. See Figure 3.6.
9.
Unhook the spring end of the cable from the forward idler bracket. See Figure 3.7.
Remove these screws Washer
Disconnect cable
Figure 3.5 NOTE: The left screw has a washer to prevent the slot in the cover from opening up as the screw is tightened. 5.
Swing the belt cover up and off of the tiller.
6.
Loosen, but do not remove the screw securing the cable pulley. See Figure 3.6.
Disconnect this cable
Loosen this screw Figure 3.6
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Figure 3.7 NOTE: The spring end of the cable is to help prevent over tensioning of the drive belt. 10.
Install the cable by following the previous steps in reverse order.
11.
Test run the tiller in a safe area before returning it to service.
Cables Reverse drive cable
5.
Swing the belt cover up and off of the tiller.
To remove the reverse drive cable:
6.
Slide the forward drive belt off of the engine pulley.
7.
Slide the reverse belt off of the idler pulley.
1.
Disconnect and ground the spark plug wire.
2.
Disconnect the red cable fitting from the handle bar bracket. See Figure 3.8.
7a. Loosen the nut and bolt that secures the idler pulley to the idler bracket. 7b. Slide the belt past the belt guides. 8.
Loosen, but do not remove the screw securing the cable pulley. See Figure 3.10.
Loosen this screw
Z-fitting
Disconnect the cable fitting Figure 3.8 3.
Unhook the Z-fitting from the forward drive bail.
4.
Remove the two screws that secure the belt cover. See Figure 3.9.
Figure 3.10 9.
Disconnect the red cable fitting from the cable bracket. See Figure 3.11.
Remove these screws Washer Disconnect this cable
Figure 3.9 NOTE: The left screw has a washer to prevent the slot in the cover from opening up as the screw is tightened.
Figure 3.11
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Cables 10.
Disconnect the cable Z-fitting.
11.
Install the reverse cable by following the previous steps in reverse order.
12.
Test run the tiller in a safe area before returning it to service.
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Engine Removal
CHAPTER 4: ENGINE REMOVAL At the time this manual was written, the MTD engine is the only available engine for the 400 series tiller. If a different brand of engine is used, the removal/replacement procedures will be the same.
5.
Loosen the nut and bolt that secures the reverse idler pulley to the idler bracket using a pair of 7/ 16” wrenches. See Figure 4.2.
Engine removal To remove/replace the engine: 1.
Disconnect and ground the spark plug wire.
2.
Remove the two screws that secure the belt cover. See Figure 4.1.
Remove these screws Washer Figure 4.2 6.
Slide the reverse belt past the belt guards and off of the idler pulley.
7.
Push both belts down to the transmission pulley. See Figure 4.3.
Unhook spring Figure 4.1 NOTE: The left screw has a washer to prevent the slot in the cover from opening up as the screw is tightened. 3.
Swing the belt cover up and off of the tiller.
4.
Slide the forward drive belt off of the engine pulley.
Belts pushed down Figure 4.3 8.
Unhook the reverse idler spring. See Figure 4.3.
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Engine Removal 9.
Unhook the reverse cable Z-fitting from the reverse idler bracket.
10.
Remove the four engine mounting screws using a 1/2” wrench.
11.
Lift the engine off of the tiller and place it in a safe work area.
Engine installation 1.
Set the engine, with the motor cover plate installed, on the tiller. NOTE: The motor cover plate must sit between the cable pulley bracket and the screw securing the cable pulley bracket. See Figure 4.6.
NOTE: If replacing the engine, continue to step 12. 12.
Transfer the engine pulley, reverse idler bracket and the motor cover plate to the new engine. See Figure 4.4.
motor cover
Motor cover plate Bumper Cable pulley Engine pulley
Screw
Figure 4.6
Reverse idler bracket
2.
Tip the engine to the rear of the tiller and slide the bumper between the engine and the frame.
3.
Install the four engine mounting screws using a 1/2” wrench.
4.
Follow steps 1 through 9 in the previous section in reverse order.
5.
Test run the tiller in a safe area before the tiller is returned to service.
Figure 4.4 NOTE: If the idler pulley was removed from the idler bracket, it must be reassembled so that the spot welds face away from the idler bracket to ensure proper belt alignment. See Figure 4.5.
NOTE: The engine RPM should be set to 3500 RPMs for proper operation.
Spot welds must face away from the idler bracket Figure 4.5
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Transmission Removal
CHAPTER 5: TRANSMISSION REMOVAL To remove/replace the transmission: 1.
Remove the belts by following the procedures described in Chapter 2: Belts.
2.
Remove the engine by following the steps described in Chapter 4: Engine Removal.
3.
Loosen the forward drive cable pulley using a 3/ 8” wrench and slide the cable off of the pulley. See Figure 5.1.
5.
Unhook the idler bracket spring.See Figure 5.3.
Unhook the spring
Figure 5.3 6.
Remove the tires.
7.
Support the wheel shafts with wood blocks. See Figure 5.4.
Loosen screw and slide cable off of the pulley Figure 5.1 4.
Unhook the cable. See Figure 5.2.
Unhook the cable Support the wheel shafts with wood blocks
Figure 5.4 NOTE: Any time the wheels are removed or once a year, the wheel shafts should be coated with anti-seize or grease. Figure 5.2
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Transmission Removal 8.
Disconnect the front of the drag bar using a 5/8” and a 1/2” wrench. See Figure 5.5.
10.
Remove the two screws that secure the depth bar bracket to the rear of the transmission using a 1/2” wrench. See Figure 5.7.
Remove these screws
Remove nut and bolt Drag bar Figure 5.5 Figure 5.7 9.
Remove the four screws that secure the frame rails to the transmission using a 1/2” wrench. See Figure 5.6.
11.
Lift the frame, handle bar and tine shield off as one unit. See Figure 5.8.
Remove these screws
Figure 5.6
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Figure 5.8
Transmission Removal 12.
13.
Remove the tines. 12a. Remove the hair pin clip and clevis pin. See Figure 5.9.
Remove the idler bracket using a 1/2” wrench. See Figure 5.11.
Remove this screw Figure 5.11 Figure 5.9 14.
Install the transmission by following the previous steps in reverse order.
15.
Test run the tiller in a safe area before returning it to service.
12b. Slide the tines off of the shaft. NOTE: Any time the tines are removed or once a year, the tine shafts should be coated with antiseize or grease. NOTE: When installing the tines, make sure the curve of the tine is facing the direction of rotation. See Figure 5.10. Direction of rotation
Curve of the tine Front of tiller Figure 5.10
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Transmission Removal
16
Drive Shaft
CHAPTER 6: DRIVE SHAFT 2d. Turn the transmission over and drain the oil into a suitable drain pan..
Drive shaft removal 1.
2.
Remove the transmission from the tiller by following the steps described in Chapter 5: Transmission Removal.
NOTE: When refilling an empty transmission, use 24oz (.72 L) of a synthetic SAE 75W-140 EP (extreme pressure) oil.
Drain the transmission.
2e. Allow all of the gear oil to drain from the transmission.
2a. Remove the four hex flange screws securing the front transmission cover to the transmission housing using a 1/2” wrench. See Figure 6.1.
2f. Clean the gasket from the front transmission housing and cover using a scraper. 3.
Transmission Cover
Remove the rear transmission cover. 3a. Remove the four hex flange screws securing the rear transmission cover to the transmission housing assembly using a 1/2” wrench. See Figure 6.2. Rear Transmission Cover Hex Screws
Front Hex Screws Figure 6.1 2b. Wedge a sharp 5-in-1 painters tool or putty knife in between the cover and the transmission housing. 2c. Pry the cover off.
Figure 6.2 3b. Wedge a sharp 5-in-1 tool or putty knife in between the cover and the transmission housing. 3c. Pry the cover off.
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Drive Shaft 3d. Clean the gasket from the rear transmission housing and cover using a scraper. See Figure 6.3. Cover gasket
6.
Once the rear bearing cap is rotated enough to allow access to one of the corners, use the brass punch to drive the cover off.
7.
Clean the sealant from the rear of the transmission housing and the bearing cap. See Figure 6.5.
Remove sealant
Tine Worm
5-in-1 tool Figure 6.3 4.
Remove the remaining lower hex flange screw securing the rear bearing cap to the transmission housing assembly using a 1/2” wrench. See Figure 6.4. NOTE: The top two screws were removed with the depth bar bracket.
Transmission Housing Figure 6.5 8.
Remove the rear bearing cap shim(s). See Figure 6.6.
Place punch here
Rear Bearing Cap Shim
Rear Bearing Cap
Short Hex Flange Screw Figure 6.6 Figure 6.4
5.
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Using a brass punch and hammer, rotate the rear bearing cap to break the seal. See Figure 6.4.
Drive Shaft 9.
Measure the overall thickness of the rear bearing shims using a dial caliper. See Figure 6.7.
15.
Inspect the rear tapered roller bearing assembly for damage or wear. See Figure 6.9.
Dial Caliper Rear Tapered Roller Bearing Race
Drive Shaft Assembly Shims Figure 6.9 Figure 6 7 10.
Record the measurement for future reference.
11.
Thoroughly clean the exposed portion (front) of the drive shaft.
12.
Hold the front tapered roller bearing into the front race. See Figure 6.8.
16.
Remove the front drive shaft oil seal using a flat blade screwdriver. See Figure 6.10.
Race
Front tapered roller bearing
Internal Snap Ring Front Oil Seal
Support collar
Figure 6.8 13.
17.
Remove the front internal snap ring using retaining ring pliers.
18.
Remove the front tapered roller bearing race by lightly tapping on the perimeter with a drift punch and a hammer.
19.
The race should be gently pushed into the center of the transmission housing for ease of removal.
Slowly push the drive shaft assembly rearward and out of the transmission assembly. NOTE: If the front portion of the drive shaft will not pass through the roller bearing, a soft hammer or a hammer and a brass drift punch can be used for assistance. Do not use a hammer directly on the shaft.
14.
Figure 6.10
Remove the front tapered roller bearing. Inspect it for wear or damage.
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Drive Shaft Drive shaft installation 1.
Thoroughly clean the entire transmission housing.
2.
Clamp the transmission housing in a soft jawed vice. See Figure 6.11.
Transmission Housing
4.
Locate both hex flange screws that were securing the left and right hood brackets to the transmission assembly.
5.
Locate two sets of flat washers that would equal approximately .120” in thickness. See Figure 6.13.
Hex Flange Screws
Flat washers .120” in Thickness Per Side
Vice
Rear Bearing Cap
Protective Material Short Hex Screw and Lock Washer Figure 6.11
3.
Figure 6.13
Make certain all the drive shaft components are accounted for. See Figure 6.12.
NOTE: Measure the thickness of both washers using a dial caliper. See Figure 6.14. Dial Caliper
Snap Ring
Hex Flange Screws
Race Tapered Roller Bearing
Drive Shaft Assembly
Tapered Roller Bearing Race Shims Rear Bearing Cap Short Hex Flange Screw and Lock Washer Figure 6.12
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Washers
Figure 6.14
Drive Shaft 6.
Install the front snap ring using snap ring pliers. See Figure 6.15.
9.
Slide the front tapered roller bearing onto the drive shaft assembly.
10.
Slide the drive shaft assembly into the front tapered roller bearing race.
11.
Position the rear bearing race over the rear tapered roller bearing.
12.
Set the rear bearing cap in position. See Figure 6.17.
Race
Hex Flange Screws
Front Snap Ring
Figure 6.15 7.
Lubricate and install the front tapered roller bearing race into the front of the transmission housing. It should seat up against the front retaining ring.
Short Hex Flange Screw and Lock Washers
NOTE: The front race is installed from inside the transmission housing. 8.
Carefully insert the drive shaft assembly into the transmission housing until the front of it reaches the front transmission cavity. See Figure 6.16.
Slide Drive Shaft Assembly Into Position
Tapered Roller Bearing
Rear Bearing Cap
Figure 6.17 NOTE: Do not put sealant on the bearing cap. 13.
Fasten the rear bearing cap to the transmission housing with the hex flange screws and flat washers using a 1/2” wrench.
14.
Tighten the hex screws to a torque of 100 in lbs (11 Nm). NOTE: The drive shaft rides in a pair of tapered roller bearings. Tapered roller bearings have low friction, a lot of surface area and they bear thrust loads very well. The worm drive system used in this tiller is very sturdy, but it generates high thrust loads on the drive shaft. If the end-play is too tight, the bearings will over-heat as they are jammed into their races. If the end play is too loose, The bearings will move around in their races, damaging the rollers, cages and will put dimples in the race.
Figure 6.16
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Drive Shaft 15.
15d. From the total shaft end play measurement, subtract .005” (.130mm). See Figure 6.20.
Shim the rear drive shaft bearing to set the drive shaft end play to .005”-.015” (.130-.380mm). 15a. Pull the drive shaft assembly forward all the way, and set up a dial indicator at the front of it. See Figure 6.18.
Dial Caliper
Magnetic Base Drive Shaft
Rear Bearing Cap Shims
Pull Forward
Figure 6.20
Zero Dial Indicator Figure 6.18
•
15b. Zero the dial indicator out. 15c. Push the drive shaft assembly rearward all the way, and record the amount of drive shaft assembly end play. See Figure 6.19.
This is the maximum thickness of the stack of shims that should be used between the rear bearing cap and the bearing race. 15e. From the total shaft end play measurement, subtract .015” (.380mm).
•
This is the minimum thickness of the stack of shims that should be used between the rear bearing cap and the bearing race. 15f. Remove the rear bearing cap and install the stack of shims that falls within the thickness range described in steps 15d and 15e.
Example:
Push Drive Shaft Rearward
End Play Measurement Figure 6.19
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Drive shaft assembly end play
.062”
Rear bearing cap shims
.051”
Total
=.011”
Drive Shaft 16.
Apply a 3/16” (4.75mm) bead of Threebond® 1217H, Permatex® Ultra Black #82180 or equivalent sealant on the rear bearing cap.
17.
Secure the rear bearing cap to the transmission assembly with the hex flange screws and washers removed earlier using a 1/2” wrench. NOTE: Tighten the hex screws to a torque of 100 in lbs (11 Nm). NOTE: Leave the two top screws in place until the sealant has cured. Then they may be removed until the tiller is reassembled.
18.
Verify the end play is between .005”-.015” by repeating steps 15-17.
19.
Fill the transmission with 24oz (.72 L) of a synthetic SAE 75W-140 EP (extreme pressure) oil.
20.
Install the transmission covers using new gaskets.
21.
Install the transmission in the tiller.
22.
Test run the tiller in a safe area before returning it to service.
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Drive Shaft
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Wheel/Tine Shaft and Worm Gear
CHAPTER 7: WHEEL/TINE SHAFT AND WORM GEAR Wheel/Tine shaft and worm gear removal NOTE: The procedure for removing a wheel shaft and a tine shaft are exactly the same. The procedure will be described for the tine shaft and can be repeated for the wheel shaft. 1.
Remove the transmission from the tiller by following the steps described in Chapter 5: Transmission Removal.
2.
Drain the transmission by following the steps described in Chapter 6: Drive Shaft.
NOTE: Use of the Thexton seal removal tool kit TWX-4006 is the preferred method of removing the seals. For information on purchasing kits contact: Thexton Toolworx 1157 Valley Park Drive. Suite 150 Shakopee, MN 55379 800-328-6277 Instructions on how to use this tool kit can be found in manual number 769-02093 available from MTD Publications.
NOTE: If removing the worm gear(s) , remove the drive shaft by following the steps described in Chapter 6: Drive Shaft. 3.
Secure the transmission in a soft jawed vise.
4.
Remove the left and right tine shaft oil seals from the transmission housing . See Figure 7.1.
NOTE: Make certain the transmission oil seal bores are not damaged during removal. 5.
Remove the left and right retaining rings securing the tine shaft using retaining ring pliers. See Figure 7.2.
Retaining Ring Oil Seal
Tine Shaft
Figure 7.1 Figure 7.2
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Wheel/Tine Shaft and Worm Gear 6.
Push the tine shaft to the right, forcing the right tine shaft bearing out of the transmission housing. NOTE: The bearing is a slip fit. If it is stuck, use a block of wood and a large hammer. NOTE: The washer will be damaged by the HiPro key.
7.
Remove the bearing and washer from the right side of the tine shaft. See Figure 7.3.
Wheel shaft and worm gear installation 1.
Install the worm gear
2.
Drive the Hi-Pro key into the tine shaft using a soft mallet.
3.
Install the tine shaft through the bearing bore, through the tine shaft worm gear and out the other side of the transmission.
4.
Slide the Hi-Pro key into the tine shaft worm gear.
5.
On each side, slide the washer over the tine shaft.
6.
On each side, slide the tine shaft bearing over the drive shaft until it passes the snap ring groove..
Hi-pro key
NOTE: If the bearing sticks, a 1” I.D. PVC pipe by 7” long works well as a bearing installation tool. See Figure 7.4..
Washer
1” ID PVC Pipe
Bearing
Figure 7.3 NOTE: Starting in the 2009 season, the spacers will be removed and the bearings will be recessed into the housing.
7” Long
NOTE: Remove the worm gear through the top of the transmission housing. 8.
Slide the wheel shaft back into the housing until the Hi-Pro key contacts the tine shaft worm gear.
9.
Rotate the tine shaft until the Hi-Pro key slides into the worm gear key way.
10.
Drive the tine shaft to the left, forcing the left tine shaft bearing out of the transmission housing.
11.
If the bearing is stuck, use a block of wood and a large hammer. NOTE: The washer will be damaged by the HiPro key.
12.
Remove the Hi-Pro key from the tine shaft using a punch and a hammer.
13.
Inspect the tine shaft assembly components for wear or damage.
26
Figure 7.4 7.
Install the outer retaining rings onto the tine shaft using retaining ring pliers.
Wheel/Tine Shaft and Worm Gear 8.
Lubricate the insides of the tine shaft oil seals with grease. See Figure 7.5.
15.
Repeat steps 11-14 on the opposite side. NOTE: The tine and wheel shafts are not shimmed for end play.
Apply Sealant to the Outside of the Wheel Shaft Seal 16.
Install the drive shaft.
17.
Fill the transmission with 24oz (.72 L) of a synthetic SAE 75W-140 EP (extreme pressure) oil.
18.
Install the transmission in the tiller.
19.
Test run the tiller in a safe area before returning to service.
Lubricate the Inside of the Wheel Shaft Seal Figure 7.5 9.
Apply sealant to the outer perimeter of the tine shaft oil seals.
10.
Lubricate the right and left sides of the tine shaft
11.
Position one of the tine shaft oil seals over a seal protector. See Figure 7.6.
Oil Seal Transmission Housing
Seal Protector Figure 7.6 12.
Slide the seal protector over one end of the tine shaft and up to the outer retaining ring.
13.
Push the tine shaft seal into the transmission housing as far as it will go, and remove the tine shaft seal protector.
14.
Drive the tine shaft seal into the transmission housing using a seal installation tool.
27
Wheel/Tine Shaft and Worm Gear
28
