Inspection; Installation - Troy-Bilt 7 HP Technical Manual

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 sureJhe
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.
"