1990 Troy-Bilt Trail Blazer Sickle bar Mower
Contents
1. Aa Removing and installing the Engine 2 Komoving the NA IIIA lIbstaling tHe ENGO za Servicing the Engine Oil Drain Tube and siccsissscscessessasesssecesssagesacessoavecsausnesssbaxesnscosssecnesess SECTION 1 GENERAL INFORMATION This Manual provides service information for the TRAIL BLAZERO Sickle Bar Mower built by TROY BILT Manufacturing Company Troy New York Use this Manual for mow with serial number 0000100 and up All information illustrations and specifications contained in this Manual are based on the latest infor mation available at the time of publi cation The right is reserved to make changes at any time without notice If you have any questions concern ing the information contained in this Manual please contact Technical Service Department TROY BILT Manufacturing Company 102nd St amp 9th Ave Troy New York 12180 Call Toll Free 1 800 833 6990 This symbol is used to alert you to important safety messages in this Technical Manual in the Owner Operator Manual and on decals affixed to the mower When you see this symbol carefully read and follow its safety message Failure to do so could result in per sonal injury or property damage This Manual is divided into three sections as show2. AIM 13 Bearing Ecen 13 MAMA Ia 9 16 aa 13 14 Belt Cutler Bina 14 Wheel DIVA 11 7 zi P Cable Guard 1 5 1 Serre 5 SEA ua 8 Parts wema AS 3 Channel Drive Ar ia maid 9 Pre Service 400 8 Cutter lt 8 D Quick Reference Guide 6 8 Drive Assembly S 9 aaa 9 Safely iia 4 2 SPAK Saa 8 WI 9 Sprocket Jackshaft 11 Drive Socket 9 Storage removal of mower fom 4 OAE EENE 15 Tires Air 8 PROMOVA a 15 Engine Oil Drain Tube amp 8 W Wheel Shaft F ia 11 Flywheel 11 INSPECTION ia 13 11 INSTA AU ON ss 13 E i 13 Bl isao 14 ii aaa 14 G Grease Figs 8 Insp
3. APPAREL Don t wear loose clothing or jewelry that could get caught in moving parts of the mower or its engine AVOID MOVING PARTS Keep hands feet hair clothing and tools safely away from moving parts when the engine is running AVOID ACCIDENTAL STARTING Prevent unintentional starting by disconnecting the spark plug wire and keeping the wire away from the spark plug Place engine controls in the OFF position and make sure that both handlebar levers are not engaged make sure they are released WEAR EYE PROTECTION Safety goggles or a face shield should be worn whenever there is the possibility of danger to the eyes from flying parts or particles PREVENT FIRES AND EXPLO SIONS Gasoline is highly flammable and explosive It should be used and stored with extreme caution Keep gasoline away from open flames and sparks Do not smoke near gasoline cans or fuel tanks Do not add gaso line to a fuel tank when the engine is running or still hot wait until the engine has cooled before adding fuel Fill the fuel tank outdoors SECTION 1 GENERAL INFORMATION Safety First When working on the mower or its engine closely follow operating instructions and safety practices at all times Failure to do so could result in personal injury or property damage Here are some basic safety precautions you should keep in mind at all times when doing repair work well ventilated area Store gasoline in a cool well ventil
4. decal in front of the right hand grip A control panel operating instruc tions warning decal on the control panel between the handlebars A wheel drive lever decal in front of the left hand grip stabilization decal in front of the left hand grip A danger decal on the weed deflector A danger decal on the hood A single danger decal on the for ward portion of each side plate An oil drain location decal the left hand side of the engine deck plate A warning decal on the wheel drive belt cover An engine ignition switch identifica tion decal near the keyswitch for electric start models only A battery instruction warning decal on the rear hood electric start mod els only A TRAIL BLAZER Mower logo decal on the hood Tires Make sure that the tires are equal ly inflated to 10 20 PSI Make sure that both tires are in good condition Also make sure that the hair pin cot ter and the clevis pin are in place in both wheel hubs Cables Make sure that the blade drive cable and wheel drive cable are not crimped Make sure both levers move freely and that the cables are adjusted properly Make sure that the throttle cable is connected to the engine and that it operates properly Cutter Bar Make sure all rivets on the cutter bar are in place and securely attached Make sure all the blades are place Make sure the blades are tig
5. E MOWER L Page 10 3 Figure 2 Testing the Drive Arm Pivot Bearing B re h al r om SECTION 3 SERVICING THE MOWER Servicing the Wheel Shaft These instructions describe servicing the wheel shaft See Figure 3 as a reference for part locations in these instructions The numbers in parenthesis refer to item numbers in the figure Removing the Wheel Shaft See Section 5 of the Owner Operator Manual Removing the Wheel Drive Belt Steps 1 through 10 under removal for instructions on how to remove the wheel shaft Inspecting the Wheel Shaft These instructions describe the inspection of vital parts on the wheel shaft assembly In addition to inspect ing the parts you have removed you should also inspect any replacement parts you will use NOTE Thoroughly degrease and clean all parts except the belt before inspection Drive Belt The belt should not be frayed stretched or excessively worn Look at the belt near the idler pulley If the two sides of the belt are touching or are nearly touching replace the belt Figure 3 Wheel Shaft and Jackshaft See Figure 4 Engage the Wheel Drive Lever If the belt is properly adjusted the belt should be under tension If the belt is slack while you are pressing the Wheel Drive Lever readjust the wheel drive system If there is no fur ther adjustment in both adjusters replace the belt See the Owner Operator Manual Wheel Shaft Spr
6. L Page 8 3 90 released Engine Oil Drain Tube and Cap Fill the engine with oil to see if oil leaks from the engine oil drain tube cap If oil leaks from this area use a pair of pliers to tighten the tube Then tighten the cap Be careful not to over tighten the oil tube it is possi ble to strip the aluminum threads in the engine If oil still leaks after you tighten the tube and cap remove the cap and drain the oil See Servicing the Engine Oil Drain Tube and Cap in this manual for reinstallation instruc tions Wheel Assembly Push the mower forward and back ward The mower should roll easily If the wheels do not move easily make sure the wheel drive cable is not adjusted too tight See the Owner Operator Manual for instruc tions Also make sure that the wheels are not obstructed Spark Arrester Make sure the spark arrester is not damaged or rusted Cable Guard Make sure the cable guard below the engine deck is not bent and pinching the blade drive cable SECTION 2 PRE SERVICE INSPECTION WARNING When servicing the mower prevent unintentional starting of the engine by dis connecting the spark plug wire and keeping the wire away from the spark plug Place the engine throttle lever in its OFF position and make sure that the two handlebar levers are Decals Make sure all of the following decals are present and readable Replace any decals that are missing or unreadable A blade drive lever
7. OTROY BILT Technical Manual Trail Blazer Sicklebar Mower GARDEN WAY INC BrentChalmers com TRAIL BLAZER MOWER TECHNICAL MANUAL Page 2 3 90 TABLE OF CONTENTS SECTION 1 General Information SON 4 6 SECTION 3 Servicing the MOW GN sississississscsasnsscvennsencssonsneniesnansnasxaniasassessnsenasadacassanascnacnandensioneni ens 9 Servicing the DIVO Ai IA AI 9 Disassombino the DIVE 9 nr eee rene rs 9 29 9 Diva AM 9 the Removing mhe Wheel Sha aa Tre Wheel iia aaa Checking Shandon PAA th Wheel aa S rvicing tho Jackshaft iosian Removing Me 07775 7 07 aanp aanere EEEE Inspecting the Vackshaft Sprok ia COCCI ES TING Jackshan for installing Ui ii Servicing Removing the FIGA Removing the Flywheel ASI MDI NSENGA NS EWE eO aa BUS ii II UTE Bar Drvo seis ia aa ia UTI Monat
8. and then pressing the bolt bearing into the flywheel 6 Position the flywheel in place on the mower s chassis 7 Install a new flat washer 5 and thread the flywheel retaining nut 3 on the flywheel bolt 4 8 Tighten the flywheel bolt 4 to 180 to 200 ft lbs 9 Move the cutter bar drive belt back onto the flywheel Make sure the cut ter bar drive belt s tension is correct See Section 5 of the Owner Operator Manual Cutter Bar Drive Initial Setting 10 Install the left belt guide pin 11 Install the cutter bar drive belt cover 2 and tighten the bolts 1 that secure the cutter bar drive belt cover to the mower BrentChalmers com SECTION 3 SERVICING THE MOWER Removing and Installing the Engine These instructions describe how to remove and install the engine Use Figure 7 reference for part locations The numbers in parenthesis refer to item numbers in the figure Removing the Engine 1 Disconnect the throttle cable from the engine 2 Remove the head screws 1 that secure the wheel drive belt cover 2 to the mower Then remove the belt cover 3 Remove the hex head bolts 3 that secure the cutter bar drive belt cover 4 to the mower Then remove the belt cover 4 Remove the cutter bar belt guide 4A 5 Loosen and remove the screw 5 that secures the crankshaft pulley to the engine Also remove the disc washer 6 flat washer 7 and inter nal snap ring 8 6 Re
9. ated place safely away from any spark or flame produc ing equipment Store only in a U L approved con tainer Make sure this container is safely out of reach of children Wipe off any spilled gasoline and move the engine away from gasoline fumes before starting the engine Use cleaning solvents only accord ing to recognized safety practices never use gasoline as a cleaning sol vent Oily rags and waste should be packed in a U L approved covered metal safety container to prevent fire from spontaneous combustion HANDLE BATTERIES WITH CARE Do not charge the battery while the engine is running or hot Before charging the battery discon nect the spark plug wire and make sure it cannot accidentally touch the spark plug during charging Also remove the engine ignition key from the keyswitch electric start models only Use only the battery charger pro vided with the mower Do not allow the battery wires to touch each other Do not allow metal object that is in contact with a battery wire to touch another metal object that is in contact with the other battery wire Do not place the battery in an air tight container when charging the bat tery Remove all rings and metal jewelry when working on the battery or electri cal system AVOID ENGINE EXHAUST FUMES Do not run the engine in an enclosed area Exhaust gases con tain carbon monoxide an odorless and deadly poison Provide adequate ventilation at a
10. bearing feels tight or if the bearing wobbles as it spins replace the bearing Cutter Bar Drive Belt This inspection must be performed before you remove the flywheel Engage the Blade Drive Lever and observe the belt If the belt is not under tension and the blade drive cable is properly adjusted then the belt has stretched and you must replace it See Section 5 Cutter Bar Belt Drive Removal and Installation in the Owner Operator Manual for instructions Also check the belt for cracks and wear Flywheel Pin Make sure the pin on which the eccentric bearing sits has no rough edges or burrs Check the pin and the casting around the pin for cracks Use a piece of 200 grit emery cloth if necessary to smooth the pin Then apply a small amount of grease to the pin to hellp prevent rust Flywheel Bolt Make sure there are no flat spots on the bolt 4 that holds the flywheel If there are any flat spots replace the bolt Also make sure the threads on the bolt are not stripped Thoroughly check the flywheel bolt for any cracks or signs of deteriora tion Replace a damaged bolt SECTION 3 SERVICING THE MOWER Installing the Flywheel Assembly 1 Install a new flywheel pin shim 10 2 Press fit the eccentric bearing 9 3 Install the external snap ring 8 that retains the eccentric bearing 4 Install the flywheel shim 7 5 Install the flywheel bearing 6 by first pressing the bearing onto the bolt
11. ction Weed Deflector and Support Wheel Shaft Checking For Play Inspecting Shimming See the Owner Operator Manual for more information 1 Also see Engine Owner s Manudt rentC halme rs com TRAIL BLAZER MOWER TECHNICAL MANUAL Page 7 3 90 SECTION 1 GENERAL INFORMATION Taking the Mower Out of Storage The following instructions explain what you must do in order to ready a TRAIL BLAZER Mower for use after it has been stored according to the storage instructions in the Owner Operator Manual 1 Charge the battery See Section 5 Check the oil level adding oil should have a pressure of 10 to 20 PSI 5 of the Owner Operator Manual for inecessary Equally inflate or deflate the tires as instructions 6 Remove the spark plug necessary Don t over inflate the 2 Thoroughly inspect the mower for 7 Inspect the spark plug to see if any tires any loose broken or missing com oil is present the plug s electrode If NOTE After you start the engine ponents Repair them as necessary plug is fouled clean it or replace it you may see white smoke This is 3 Check all bolts to ensure that they Then reinstall the plug the oil in the cylinder burning off are tight 8 Make sure the spark plug wire is This white smoke will soon disap 4 Add fuel to the fuel tank securely connected to the spark plug pear 9 Check the tire pressure The tires BrentChalmers com TRAIL BLAZER MOWER TECHNICAL MANUA
12. e sound that there are no cracks in them WARNING When servicing the mower prevent unintentional starting of the engine by discon necting the spark plug wire and keeping the wire away from the spark plug Place the engine throttle lever in its OFF position and make sure that the two handlebar levers are released Drive Socket Holder Make sure the hole in the drive socket holder has not expanded Insert a new drive socket in the drive socket holder and move the socket back and forth If you find more than 020 play replace the drive arm Assembling the Drive Arm 1 Install the lower drive arm pivot bearing 3 You may be able to push the bearing in by hand or you may need to press it in Since this is a sealed bearing it does not need to be lubricated 2 Install the drive arm spacer 4 3 Install the upper drive arm pivot bearing 3 You may be able to push the bearing in by hand or you may need to press it in Since this is a sealed bearing it does not need to be lubricated 4 Install the upper internal snap ring 2 that retains the drive arm pivot bearings 5 Install the lower internal snap ring 1 that retains the drive arm pivot bearings Installing the Drive Arm See Section 5 of the Owner Operator Manual Cutter bar Drive Belt Removal and Installation Steps 6 through 9 for drive arm assembly installation instructions BrentChalmers com TRAIL BLAZER MOWER SECTION 3 SERVICING TH
13. e you back the mower up Before inspecting cleaning area Keep them under the watchful while you re backing it up be adjusting or repairing the mower or eye of an adult other than the per sure to look behind you for small cutter bar 1 stop the engine 2 dis son operating the mower Never children connect the spark plug wire and pre assume that children will remain vent it from touching the spark plug where you last saw them KEEP HANDS AND FEET AWAY 3 wait for all moving parts to stop FROM MOVING PARTS and 4 reinstall the plastic blade pro Do not put hands or feet near or tector on the blade On electric start under any moving parts Keep clear models also remove the Engine of the cutter bar at all times when the Ignition key from the keyswitch engine is running BrentChalmers com TRAIL BLAZER MOWER TECHNICAL MANUAL Page 6 3 90 SECTION 1 GENERAL INFORMATION Quick Reference Repair Index Information on the following topics can be found in the TRAIL BLAZER Owner Operator Manual Air Filter Air Pressure Tires Battery Removal Belts Cutter Bar Wheel Drive See this Technical Manual for additional information Blade Drive Lever Blade Guide Adjustment Carburetor Adjustment Cutter Bar Adjustment Assembly Removing Drive Arm Removal Installation See this Technical Manual for additional information Engine Ignition Switch See this Technical Manual for additional information Throttle Lev
14. ecting Drive arm asso eisrean 9 13 14 Wi 12 11 BrentChalmers com MN1390590 Printed in the USA 2 Brente taie Garden Way Inc mers com
15. er Fuel Grease Points Handlebar Height Adjustment Lubrication Points Motor Oil Oil Cutter Bar Drive Belt Guide Rubber Bushing and Drive Pin See the Owner Operator Manual for more information Drive Arm Assembly Disassembly Inspecting See the Owner Operator Manual for more information Engine Removal Drain Tube and Cap Replacement See the Owner Operator Manual for more information Information on the following topics can be found in this TRAIL BLAZER Technical Manual Operation Ordering Parts Pre Start Checklist Recoil Starter Spark Plug Specifications Starting Storage for Off Season Throttle Lever Engine Tire Pressure Troubleshooting Wheel Drive Lever Wheel Shaft Removal In Section 5 of the Owner Operator Manual Removing and Installing the Wheel Drive Belt removal Steps 1 through 10 Installation In Section 5 of the Owner Operator Manual Removing and Installing the Wheel Drive Belt installation Steps 4 through 12 See this Technical Service Manual for addition al information Jackshaft Removal In Section 5 of the Owner Operator Manual Removing and Installing the Wheel Drive Belt removal steps 1 through 10 Installation In Section 5 of the Owner Operator Manual Removing and Installing the Wheel Drive Belt installation Steps 4 through 12 See this Technical Manual for additional in for mation Flywheel Jackshaft Checking For Play Inspecting Shimming Pre Service Inspe
16. g the Jackshaft These instructions describe inspecting vital parts of the jackshaft assembly In addition to inspecting the parts you have removed you should also inspect any replacement parts you will use NOTE Thoroughly degrease and clean all parts before inspection Jackshaft Sprocket Check for signs of sprocket wear If the sprocket must be replaced also replace the chain Checking the Jackshaft for Play After you install the jackshaft check it for play Check the jackshaft for end play There should be no more than 030 end play Also the jackshaft should spin freely Add shims 2 as neces sary to obtain this tolerance Grasp the jackshaft and try to move it forward and backward and up and down If the jackshaft moves more than 030 you should replace the bushing 3 If play is present after replacing the bushing inspect the jackshaft section that rests in the bushing it may be worn If the sec tion of the jackshaft that rests in the bushing is worn replace the jack shaft Installing the Jackshaft See Section 5 of the Owner Operator Manual Removing and Installing the Wheel Drive Belt Steps 4 through 12 for jackshaft installation instructions Jackshaft Pulley idler Pulley PTO Pulley Figure 4 Checking Wheel Drive Belt Wear BrentChalmers com SECTION 3 SERVICING THE MOWER Servicing the Flywheel These instructions describe how to service the flywheel Yo
17. he oper ation of the wheel drive and cutter bar drive levers Adjust the blade drive system and the wheel drive system if necessary See Section 5 Maintenance of the Owner Operator Manual BrentChalmers com TRAIL BLAZER MOWER TECHNICAL MANUAL Page 15 3 90 Servicing the Engine Oil Drain Tube and Cap If you see oil leaking from the oil drain tube oil drain cap you will have to make sure the tube and cap are properly tightened Tips for tightening the tube cap are Use loctite on the upper threads of the tube Install and tighten the tube first Then wrap teflon tape around the lower threads on the tube Install and tighten the cap Don t try to tight en the tube by tightening the cap that is attached to it If you do the next time you remove the cap to drain the oil you will also remove the tube and oil will spill on the belt Do not over tighten the tube Itis possible to strip the aluminum threads in the engine When removing the oil drain use a pair of pliers to hold the oil drain tube to make sure it doesn t move TRAIL BLAZER MOWER TECHNICAL MANUAL SECTION 3 SERVICING THE MOWER Page 16 3 90 Figure 6 Engine Removal Installation B ren h alm ers com TRAIL BLAZER MOWER TECHNICAL MANUAL a Page 17 3 90 A J Air Prossa 2 esses 8 Jackshaft AA SU isons 8 MUSA 12 REMOVA 12 S M Beanna
18. ht See the Owner Operator Manual for tightening instructions Make sure the bolts that hold the cutter bar mounts are tightly secured Make sure the nuts that secure the height adjuster to the back of the ledger bar are tight Make sure the drive pin is securely fastened to the cutter bar Grease Fittings Make sure the two grease fittings on the cutter bar support and the one on the drive arm assembly are in place and in good condition BrentChalmers com SECTION 3 SERVICING THE MOWER TRAIL BLAZER MOWER TECHNICAL MANUAL Page 9 3 90 This section SERVICING THE MOWER discusses repair procedures that not included the TRAIL BLAZER Mower Owner Operator Manual A Servicing the Drive Arm These instructions describe how to service the drive arm assembly See Figure 1 as a reference for part locations in these instructions See Section 5 of the Owner Operator Manual Cutter Bar Drive Belt Removal and Installation Steps 1 through 5 under removal for instructions on removal of the drive arm assembly Disassembling the Drive Arm You would disassemble the drive arm to replace the drive arm pivot bearings and drive arm spacer To find out if the bearings and spacer need to be replaced grab the drive arm near the pivot point and rock the drive arm side to side and check for play See Figure 2 for an illustration You must first remove the drive arm before proceeding with the
19. itial Setting Steps 1 and 3 5 Put a wrench on the flywheel retaining nut 3 and hold the nut TRAIL BLAZER MOWER TECHNICAL MANUAL Page 13 3 90 while you put another wrench on the flywheel bolt 4 Then remove the nut and bolt 6 Discard the flat washer 5 7 Lift the flywheel off 8 Remove the flywheel bearing 6 and discard the flywheel shim 7 9 Remove the external snap ring 8 that retains the eccentric bearing 10 Remove the eccentric bearing 9 and discard the flywheel pin shim 10 Inspecting the Flywheel These instructions describe how to inspect vital parts on the flywheel assembly In addition to inspecting the parts you have removed you should also inspect any replacement parts you will use NOTE Thoroughly degrease and clean all parts except the bearings before inspection BrentChalmers com TRAIL BLAZER MOWER TECHNICAL MANUAL Page 14 3 90 Bearings bearing has a bluish color it indicates a lack of lubrication replace the bearing Both bearings are a press fit it is easier to check them on the flywheel before pressing them out Check the eccentric bearing by turning its outside race with your fin gers Check the flywheel bearings by rotating the flywheel by hand However if you have already removed the bearings check them as follows Pinch the bearing s inner race and spin it If you hear growl ing noise if the bearing doesn t spin if the
20. ll times After running the engine don t touch the muffler or other hot engine parts until they have cooled down HANDLE PARTS CAREFULLY With continued use the teeth on sprockets or other moving parts may wear to sharp knife like edges Therefore when handling these parts always use care to avoid cutting your self USE GENUINE TROY BILT REPLACEMENT PARTS Replacement parts manufactured by others could present safety haz ards even though they may fit on this ih mower KEEP UNAUTHORIZED PERSON NEL AWAY Keep the area of operation clear of all persons particularly small children and pets Stop both the cutter bar blade and the wheel drive when you are approached by any child inatten tive person or pet LEAVE GUARDS AND SAFETY DEVICES IN PLACE Never attempt to disconnect or remove guards or other safety devices or to defeat the purpose of them CHECK OPERATION OF HAND LEVERS BEFORE EACH USE Before each use check the opera tion of the handlebar levers See Section 4 Mower Operation in the Owner Operator Manual for specific instructions Do not use the mower if either handlebar lever is not function ing properly BrentChalmers com TRAIL BLAZER MOWER TECHNICAL MANUAL Page 5 3 90 SECTION 1 GENERAL INFORMATION KEEP CHILDREN AWAY WHEN LOOK BEHIND WHEN BACKING SHUT MOWER OFF WHEN PER OPERATING THE MOWER THE MOWER UP FORMING ANY MAINTENANCE Keep children out of the mowing Befor
21. move the crankshaft pulley 9 and cutter bar drive pulley key 10 7 Using a pair of pliers remove the cotter key 13 from the PTO pulley 14 8 Remove the PTO pulley and the PTO belt guide 15 9 Loosen and remove the three bolts 11 that secure the engine to the mower 10 Lift the engine off the mower s engine deck Installing the Engine 1 Place the engine back onto the mower deck 2 Place the engine mount spacers 12 and washers between the engine and the engine deck Install the three bolts 11 and the three belleville washers that secure the engine to the mower Tighten these bolts to 25 ft lbs 3 Make sure the belt washer is on the PTO shaft Install the PTO belt guide 15 and the PTO pulley 14 4 Install the cotter key 13 into the PTO pulley 14 5 Install the cutter bar drive pulley key 10 and the crankshaft pulley 9 Then install the internal snap ring 8 the flat washer 7 the disc wash er 6 and the screw 5 that secures the crankshaft pulley to the engine Reinstall the cutter bar belt guide 4A 6 install the cutter bar drive belt cover 4a with the bolts 3 7 Install the wheel drive belt cover 2 and the hex head screws 1 that secure it to the mower 8 Attach the throttle cable to the engine 9 To make sure the belts are proper ly connected remove the mower hood and inspect the belts 10 Add oil to the engine if needed start the engine and check t
22. n in the Table of Contents For best results read each section in its entirety before performing the procedure This Technical Manual is designed to be used in combination with the Owner Operator Manual The Owner Operator Manual contains additional service and maintenance information that is not covered in this TRAIL BLAZER MOWER TECHNICAL MANUAL Page 3 3 90 Technical Manual Refer to the Quick Reference Guide Page 6 for a listing of the service and main tenance topics that are covered in the Owner Operator Manual Service and maintenance information regarding engines is not covered in this Manual Such infor mation can be obtained by consulting the Service Repair Manuals available from the engine manufacturer You should however call our Technical Service Department with questions concerning engine replacement Throughout this Manual you will see references to the left and right side of the mower This refers to the left and right sides of the mower as you would see them when you are standing in the operator s position BrentChalmers com TRAIL BLAZER MOWER TECHNICAL MANUAL Page 4 3 90 KNOW THE MOWER AND ENGINE Read the Owner Operator Manual carefully Be sure you know what each mower and engine control does before you attempt to operate it Read and follow all safety rules Never allow inexperienced persons or children to operate the mower or its engine WEAR PROPER
23. ocket Check for signs of sprocket wear If the sprocket is worn the chain should also be replaced Checking the Wheel Shaft for Play After you install the wheel shaft check it for play Check the wheel shaft for end play There should be no more than 030 end play The wheel shaft should BrentChalmers com TRAIL BLAZER MOWER TECHNICAL MANUAL Page 11 3 90 spin freely Add shims 1 as neces sary to obtain this tolerance Grab the wheel shaft and try to move it forward and backward and up and down If the wheel shaft moves at all you should replace the axle bushing 1 If play is present after replacing the bushing inspect the wheel shaft section that rests in the bushing it may be worn If the wheel shaft is worn in this area replace the wheel shaft Installing the Wheel Shaft See Section 5 of the Owner Operator Manual Cutter Bar Drive Belt Removal and Installation Steps 5 through 11 under installation for instructions on drive arm assem bly installation TRAIL BLAZER MOWER TECHNICAL MANUAL Page 12 3 90 SECTION 3 SERVICING THE MOWER Servicing the Jackshaft These instructions describe how to service the jackshaft See Figure 3 as a reference for part locations in these instructions Removing the Jackshaft See Section 5 of the Owner Operator Manual Removing and Installing the Whee Drive Belt Steps 1 through 10 under removal for instructions on jackshaft removal Inspectin
24. se instructions 1 Remove the lower internal snap ring 1 that retains the drive arm pivot bearings 2 Remove the upper internal snap ring 2 that retains the drive arm pivot bearings 3 Remove the two drive arm pivot bearings 3 and the drive arm spacer 4 You may be able to remove these bearings by hand or you may have to carefully press them out Inspecting the Drive Arm These instructions describe how to inspect vital parts on the drive arm assembly addition to inspecting the parts you have removed you should also inspect any replacement parts you will use NOTE Thoroughly degrease and clean all parts except the bearings before inspection Channel Bolt Holes The four channel bolt holes should be just large enough to fit the bolt Replace the drive arm if the bolt holes have elongated Also there should be no cracks in the drive arm leading out from the channel bolt holes Replace the drive arm if there are any fatigue cracks Channel Check the entire channel for cracks If the channel has any cracks replace it Grease Fitting Make sure the grease fitting on the front of the drive arm is in place Grease the fitting to make sure it works correctly You should see grease coming out of the tube on the front of the drive arm after two pumps of the grease gun Welds Inspect the welds that hold the drive socket holder and the bearing retainer to the drive arm Make sure the welds ar
25. u would check the bearing on the flywheel if when engaging the Blade Drive Lever you hear a knocking noise which indicates that the bearings are bad See Figure 6 as a reference for part locations in these instructions The numbers in parenthesis refer to item numbers in the figure Removing the Flywheel Bearings There are two kinds of bearings on the flywheel Flywheel Bearing The flywheel has to be removed to remove this bearing You can remove this bearing by hand Then remove the flywheel shim 7 Eccentric Bearing You can remove the bearing while the flywheel is still in the mower To remove this bearing you must first take off the snap ring 9 Then Figure 5 The Flywheel installation remove the bearing by hand Then remove the flywheel pin shim 10 Removing the Flywheel Assembly 1 Remove the drive arm See Section 5 of the Owner Operator Manual Cutter Bar Drive Belt Removal and Installation Steps 1 through 5 under removal 2 Remove the bolts 1 that secure the cutter bar drive belt cover 2 to the mower Then remove the cutter bar drive belt cover 3 Remove the left side belt guide pin 4 Lift the cutter bar drive belt over the flywheel If the tension on the fly wheel belt is such that you cannot lift the belt over the flywheel relax the tension on the belt by loosening the upper or lower cutter bar drive cable adjusters See Section 5 of the Owner Operator Manual Cutter Bar Drive In
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