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.
"
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