Professional Shop Manual
Troy-Bilt Pack Horse Powered WheelBarrow
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 2009 MTD Products Inc. All Rights Reserved
MTD Products Inc - Product Training and Education Department
FORM NUMBER - 769-05141
08/2009
Table of Contents
Chapter 1: Introduction ........................................................................................................ 1
About the text format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Understanding model and serial numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
The Troy-Bilt Pack Horse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Chapter 2: Drive belt and cables ............................................................................................ 5
Drive control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drive cable adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 3: brakes ....................................................................................................................9
Brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brake removal/replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 4: Transmission...................................................................................................... 13
Neutral control adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Transmission release cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Transmission removal/replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Chapter 5: Pivot bar and caster wheels .............................................................................. 19
Caster wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Caster wheel yoke and bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pivot Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Chapter 6: Maintenance ........................................................................................................23
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Changing the engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Clean the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Recommended service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
I
II
CHAPTER 1: INTRODUCTION
Professional Service Manual Intent: This manual is intended to provide service dealers with information that will
help them maintain and repair the Troy-Bilt Pack Horse.
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.
About the text format
Certain flags and key words are used to indicate the nature of the text that accompanies them. They are as follows:
! CAUTION
! WARNING
! DANGER
CAUTION: Indicates a potentially hazardous situation that, if not avoided, may result
in minor or moderate injury. It may also be used to alert against unsafe practices.
WARNING: Indicates a potentially hazardous situation that, if not avoided, could
result in death of serious injury.
DANGER: Indicates an imminently hazardous situation that, if not avoided, will result
in death or serious injury. This signal word is to be limited to the most extreme situations.
NOTE: “NOTE” is used to point-out helpful information that may not fit as a step in a procedure.
1.
Numbered steps indicate specific things that should be done, and the order in which they should be done.
1a. Sub steps will be lettered and nested within steps. Two or more sub steps may be combined to describe
the actions required to complete a step.
•
Bullet points: Indicate sub-steps or points of interest, without implying order or relative importance.
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.
1
Safety
This Service Manual is meant to be used along with the Operator’s Manual. Read the Operator’s Manual and
familiarize yourself with the safety and operational instructions for the equipment being worked on. Keep a copy of
the Operator’s Manual for quick reference. Operator’s manuals may be viewed for free at the brand support website.
It will be necessary to have the complete model and serial number for the equipment.
•
! CAUTION
Be prepared in case of emergency:
Keep a fire extinguisher nearby
Keep a first aid kit nearby
Keep emergency contact numbers handy
•
Replace any missing or damaged safety labels on shop equipment.
•
Replace any missing or damaged safety labels on equipment being serviced.
•
Grooming and attire:
! WARNING
Do not wear loose fitting clothing that may become entangled in equipment.
Long hair should be secured to prevent entanglement in equipment.
Jewelry is best removed.
•
Protective gear: includes, but is not limited to
Clear eye protection
while working around any machinery
Protective gloves
where necessary
Armored footwear
when working around any machinery
Hearing protection
in noisy environments
Chemically resistant gloves
when working with chemicals or solvents
Respirator
Appropriate tinted eye protection
Fame resistant headgear, jacket, chaps
2
when cutting or welding
when cutting or welding
•
Remember that some hazards have a cumulative effect. A single exposure may
cause little or no harm, but continual or repeated exposure may cause very serious
harm.
•
Clean spills and fix obviously dangerous conditions as soon as they are noticed.
•
Lift and support heavy objects safely and securely.
•
Be aware of your surroundings and potential hazards that are inherent to all power
equipment. All the labels in the world cannot protect a technician from an instant of
carelessness.
! CAUTION
! DANGER
when working with chemical or solvents
Exhaust fumes from running engines contain carbon monoxide (CO). Carbon monoxide is a colorless odorless gas that is fatal if inhaled in sufficient quantity. Only run engines
in well ventilated areas. If running engines indoors, use an exhaust evacuation system
with adequate make-up air ventilated into the shop.
Fasteners
•
The fasteners used on the equipment described in this manual, and the engine that powers it are a combination of metric and fractional inch. For this reason, wrench sizes are frequently identified in the text, and measurements are given in U.S. and metric scales.
•
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).
•
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.
Assembly instructions
•
Torque specifications may be noted in the part of the text that covers assembly. They may 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.
•
Lubricant quantity and specification may be noted in the part of the text that covers maintenance, and again
in the section that covers assembly. They may also be summarized in tables along with special instructions.
Whichever method is more appropriate will be used. In many cases, the information will be found in several
places in the manual 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 damage or 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.
3
The Troy-Bilt Pack Horse
The Troy-Bilt Pack Horse is a motorized wheelbarrow
designed to help home owners with demanding tasks
around the house. See Figure 1.1.
•
It is equipped with a HydroGear hydrostatic
transmission
•
The engine is a Briggs & Stratton 650 Series Engine
It has the capacity of:
•
500 lbs on level ground.
•
400 lbs on a slope.
•
Maximum safe slope angle of 10o.
Figure 1.1
Understanding model and serial numbers
The model number of a the Pack Horse described in this manual is 24A-7400066. The model and serial number
tag is located on the back of the frame. A break down of what the model number means is as follows:
•
24 - - - - - - - - - - - - - indicates that this is a chore performer
•
- - -A- - - - - - - - - - - - indicates the sales revision
•
- - - - “-”--- - - - - - - - - indicates the starter (recoil starter)
•
- - - - - - 7- - - - - - - - - indicates it is a wheelbarrow
•
- - - - - - - 4 - - - - - - - - indicates the transmission
•
- - - - - - - - -0- - - - -- - -indicates the handle panel style
•
- - - - - - - - - - 0- - - - - indicates the engine
•
- - - - - - - - - - - - 029 - indicates the customer
The serial number is 1J056G10005. The serial number reads as follows:
•
1...........................engineering level
•
..F.........................month of production (F = June)
•
.....05....................day of the month
•
.........9..................last digit of the year
•
...........G................plant it was built in
•
..............1.............assembly line number
•
.................0005.....number of unit built
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
4
Belts and Cables
CHAPTER 2: DRIVE BELT AND CABLES
Drive control cables
Anchor point
Reverse cable
Forward cable
Anchor point
The Troy-Bilt Pack Horse is equipped with a HydroGear
368-0510 transmission similar to the one used on lawn
tractors. The Pack Horse uses cables instead of linkages
to operate the transmission. The forward control cable
runs down the right side of the wheelbarrow and the
reverse cable runs down the left side of the wheelbarrow.
The forward control cable connects to the front side of
the control arm on the left side of the transmission and the
reverse cable connects to the rear. See Figure 2.1.
To replace a drive cable:
NOTE: The drive lever and cable are serviced as one
assembly.
1.
Figure 2.1
Release the barbed fitting on the end of the cable
housing from it’s anchor point.
NOTE: A 9mm open-end wrench or a Ford fuel line tool
can be used to release the barbs.
2.
Unhook the drive cable from the control arm.
3.
Remove the handle grip on the side to be replaced.
NOTE: Compressed air can be blown into the grip to assist
in sliding it off of the handlebar. See Figure 2.2.
Shoulder
bolt
4.
Remove the shoulder bolt that holds the drive lever
and cable to the handlebar using a 1/2” wrench and a
3/16” hex key. See Figure 2.2.
5.
Map out the route the cable follows on the wheelbarrow.
6.
Slide the drive cable and lever off of the wheelbarrow.
7.
Install the drive cable and lever by following the previous steps in reverse order.
Nut
Blow gun
Figure 2.2
NOTE: Route the cable in the same path as the old cable.
8.
Adjust the drive cable by following the procedures described in the drive cable adjustment section of this chapter.
9.
Test drive the wheelbarrow before returning it to service.
5
Belts and Cables
Drive cable adjustment
The drive control levers should have a 1/16” movement before pulling the cables.
NOTE: If excessive slack is present in the forward or reverse cables or if the wheelbarrow’s drive is disengaging intermittently during operation, the cables may need to be adjusted.
! CAUTION
If the forward or reverse cables are to tight, the wheelbarrow will drive as soon as the
brakes are released.
NOTE: If both of the drive levers are depressed at
the same time, the forward drive cable will out pull
the reverse cable and the wheelbarrow will drive forward.
To adjust the drive cables:
NOTE: If the wheelbarrow moves forward, one or
both of the cables are too tight. If the wheelbarrow
moves in reverse, the reverse cable is too tight.
1.
1/16”
Measure the movement of the tip of the drive control
levers before they pull on the cables.
See Figure 2.3.
Figure 2.3
2.
Hold the bottom of the in-line adjuster while twisting
it to tighten or loosen the drive cable.
See Figure 2.4.
3.
Test the cables to see if they are too tight.
3a. Move the wheelbarrow to a safe area.
In-line
adjuster
3b. Start the engine.
3c. Depress the brake levers without touching the
drive control levers.
Tighten
3d. If the wheelbarrow moves, one or both of the
drive cables are too tight.
4.
6
Test drive the wheelbarrow in a safe area before
returning it to service.
Loosen
Figure 2.4
Belts and Cables
Drive belt
To remove/replace the drive belt:
1.
Pull the idler pulley far enough to the left to slip the belt off of it. See Figure 2.5.
Idler pulley
Front of wheelbarrow
Figure 2.5
2.
Remove the belt cover using a 3/8” wrench. See Figure 2.6.
Belt cover
Figure 2.6
3.
Slide the belt off of the engine pulley.
4.
Slide the belt off of the transmission pulley.
NOTE: Avoid damaging the hydro cooling fan.
5.
Remove the belt from the wheelbarrow.
6.
Install the drive belt by following the previous steps in reverse order.
7.
Test drive the wheelbarrow in a safe area before returning it to service.
7
Belts and Cables
8
Brakes
CHAPTER 3: BRAKES
Brake adjustment
1.
Transmission release
lever
Figure 3.1
Feeler gauge
Test the operation of the brakes:
1a.
Move the transmission release lever to the ON
position. See Figure 3.1.
1b.
Attempt to push the wheelbarrow without
squeezing any of the control levers. If it can be
pushed by hand without skidding a front wheel,
check and adjust the brakes.
1c.
Squeeze the brake control lever.
1d.
Attempt to push the wheelbarrow again. If it
cannot be pushed with reasonable effort, check
the transmission release cable.
2.
Release the brakes by clamping the brake control
lever down.
3.
Visually inspect the brake to confirm that it functions
properly.
4.
Check the gap between the brake rotor and the brake
pads. See Figure 3.2.
•
There is a fixed pad in the transaxle housing.
•
There is a moving pad in the brake caliper.
•
Wiggle the brake rotor slightly, and attempt to
insert a .015” (.38mm) feeler gauge between the
rotor and either pad.
4a.
Rotor
Adjust the gap, if necessary, so that the feeler
gauge slips between the pad and the rotor with
light pressure.
•
If adjustment is necessary, remove and discard
the cotter pin that locks the adjusting nut.
•
Turn the nut to adjust the gap.
•
Release and apply the brake control lever, then
re-check the gap.
•
If the gap is consistent, install a new cotter pin to
secure the adjustment nut.
Figure 3.2
4b. If the brake seems to be sticking, or the rotor is discolored from dragging, remove the brake yoke for
repair or replacement.
4c. Re-test the operation of the brakes before returning the wheelbarrow to service.
NOTE: The hydrostatic transaxle creates it’s own braking force from the hydraulic pressure in the hydraulic
motor. The brakes are more of a parking brake than a service brake. They generally show little wear over the
life of the wheelbarrow.
9
Brakes
Brake removal/replacement
NOTE: There are two main reasons to remove the
caliper: to replace the pads, or to free stuck parts.
1.
The brake yoke is located on the left side of the
transaxle. See Figure 3.3.
•
The brake cable connects to the top hole on the
brake arm.
•
The Heavy brake spring draws the brake arm to the
ON position.
2.
Disconnect the brake cable from the brake arm.
3.
Loosen both brake yoke bolts using a 3/8” wrench.
4.
Slip the return-to-neutral spring off of the spacer on
the front bolt.
5.
The yoke and outer pad will separate from the transaxle.
6.
Inside the brake yoke: See Figure 3.4.
•
A steel backing plate fits between the friction pad
and the actuator pins.
•
The pins fit into holes in the brake yoke housing.
•
The brake arm acts as a cam, pushing the pins
when it rotates.
•
A small compression spring pushes the cam arm
away from the pins, helping to release the brake.
7.
With the brake yoke removed, the brake rotor floats
on a splined brake shaft. See Figure 3.5.
•
The by-pass arm must be removed to take the rotor
off.
•
The flat side goes in, the collar faces out.
•
A second brake pad fits into a recess behind the
rotor.
8.
Assembly notes:
•
If any lubricant is used on the pins or between the
brake shaft and the rotor, apply it VERY sparingly.
•
Apply a small amount of thread locking compound
such as Loctite 242TM (blue) to the threads of the
brake yoke bolts.
•
Tighten the brake yoke bolts to a torque of 80 to 120
in-lbs. (9 to 14 N-m).
Brake arm
Brake cable
Castle nut
Cotter pin
Brake yoke
Figure 3.3
Brake arm
Spring
Brake yoke
Actuator pins (2)
Backing plate
Friction pad
Figure 3.4
Brake pad
Brake rotor
By-pass
arm
NOTE: Adjust and test the brakes after any work on
brake system.
Figure 3.5
10
Brakes
Brake cable
Brake arm
Brake cable
Barbed fitting
NOTE: If the wheelbarrow does not come to a complete
stop when the brake lever is released, or if the
wheelbarrow can roll with the brake lever released,
the brake needs to be adjusted.
To remove/replace the brake cable:
1.
Release the barbed fitting on the end of the cable
housing from the transmission torque bracket.
NOTE: A 9mm open-end wrench or a Ford fuel line tool
can be used to release the barbs.
Figure 3.6
2.
Push the cable into the hole in the transmission
torque bracket enough to make the spring on the end
of the cable go slack.
3.
Unhook the brake cable from the brake arm.
4.
Slide the inner cable and the spring end through the
hole in the transmission torque bracket.
See Figure 3.7.
5.
Unhook the brake cable from the brake arm.
6.
Release the barbed fitting on the end of the cable
housing from the cable bracket on the handle bar.
See Figure 3.8.
7.
Slide the inner cable through the slot in the bracket.
8.
Unhook the Z-fitting from the brake lever.
9.
Slide the cable out of the wheelbarrow.
Hole in torque bracket
Figure 3.7
10. Install the brake cable by following the previous steps
in reverse order.
11.
Test drive the wheelbarrow in a safe area before
returning it to service.
Cable bracket
Belt Routing
Figure 3.8
Figure 3.8
11
Brakes
12
Transmission
CHAPTER 4: TRANSMISSION
The Troy-Bilt Pack Horse is equipped with a HydroGear 368-0510 transmission similar to the one used on lawn
tractors. The HydroGear Service and Repair manual for the transmission on this wheel barrow is form number BLN51260. The training video BLN-51763 covers this transmission and is available from HydroGear.
The transmission used on the Pack Horse wheelbarrow is equipped with a dampener. The dampener smooths
the acceleration and deceleration of the transmission. See Figure 4.1.
Dampener
Figure 4.1
Neutral control adjustment
NOTE: Neutral control rarely goes out of adjustment on its own. If it needs adjustment, check for damaged
cables or signs of tampering.
! CAUTION
! CAUTION
The wheelbarrow engine and drive system must be operated to complete this procedure.
Confirm that no hazards will be incurred by running the engine or operating the drive system:
Work in a well vented area to prevent carbon monoxide poisoning or asphyxiation.
•
Be careful to avoid contact with hot parts or moving parts.
1.
Loosen the wheel bolt on the left front wheel of the wheelbarrow using a 1/2” wrench.
2.
Lift and safely support the front of the wheelbarrow.
3.
Remove the left front wheel.
4.
Release the brakes by clamping the brake control lever down.
13
Transmission
5.
Confirm that the drive control cables are not pulling on the control arm. The roller on the control arm must be
centered in the “elbow” of the control cam. See Figure 4.1.
•
If the roller is not centered in the elbow of the control cam, identify and correct the problem before proceeding.
6.
Loosen the socket head cap screw that locks the adjusting puck using a 1/4” allen wrench.
7.
Have a 1-1/8” wrench handy, or size an adjustable wrench to fit the adjusting puck. See Figure 4.3.
Roller
Control cam
Adjusting puck
Figure 4.2
Figure 4.3
8.
Start the engine and advance throttle to maximum RPM.
9.
Set the adjusting puck so that neither wheel rotates. The brake rotor should also be stationary.
10.
Lock the adjusting puck, then confirm that the wheels and brake rotor are still motionless.
11.
Turn-off the engine.
12.
Reinstall the front wheel:
12a. Lubricate the axle with anti-seize compound before positioning the wheel on the wheelbarrow.
12b. Apply thread locking compound such as Loctite 242TM (blue) to the threads of the wheel bolt.
12c. Slide the wheel assembly onto the axle shaft.
12d. Install the bolt and belleville washer so that the inside diameter contact area of the washer is against the
bolt head and the outside diameter contact area is against the wheel.
13.
Lower the tractor to the ground.
14.
Tighten the bolt to a torque of 12-15 ft-lbs. (16-20 N-m).
15.
Test the drive system and all safety features before returning the unit to service.
14
Transmission
Transmission release cable
To remove/replace the transmission release cable:
1.
Release the barbed fitting on the end of the cable housing from the transmission torque bracket.
NOTE: A 9mm open-end wrench or a Ford fuel line tool can be used to release the barbs.
2.
Slide the inner cable through the slot in the torque bracket.
3.
Unhook the transmission release cable from the by-pass arm on the transmission. See Figure 4.5.
By-pass
arm
Release
cable
Figure 4.4
4.
Release the barbed fitting on the end of the cable housing from the pivot bar mounting bracket.
5.
Slide the inner cable through the slot in the pivot bar mounting bracket. See Figure 4.4.
Slot
pivot bar
mounting bracket
Z-fitting
Figure 4.5
NOTE: The belt cover was removed for a clearer picture.
6.
Unhook the Z-fitting from the transmission release lever.
7.
Install the transmission release cable by following the previous steps in reverse order.
8.
Test drive the wheelbarrow before returning it to service.
15
Transmission
Transmission removal/replacement
1.
Loosen the wheel bolt on the left front wheel of the wheelbarrow using a 1/2” wrench.
2.
Lift and safely support the front of the wheelbarrow.
3.
Remove the front wheels.
4.
Pull the idler pulley far enough to the left to slip the belt off of it. See Figure 4.6.
Idler pulley
Front of wheelbarrow
Transmission
torque bracket
Figure 4.6
5.
Slide the belt off of the transmission pulley.
6.
Release the barbed fitting on the end of the brake cable housing from the transmission torque bracket.
See Figure 4.7.
NOTE: A 9mm open-end wrench or a Ford fuel line tool can be used to release the barbs.
Brake arm
Brake cable
Barbed fitting
Figure 4.7
7.
Push the cable into the hole in the transmission torque bracket far enough to make the spring on the end of the
cable go slack.
8.
Unhook the brake cable from the brake arm.
9.
Slide the inner cable and the spring end through the hole in the transmission torque bracket.
10.
Unhook the brake cable from the brake arm.
16
Transmission
11.
Release the barbed fitting on the end of the transmission release cable housing from the transmission
torque bracket.
12.
Slide the inner cable through the slot in the torque
bracket.
13.
Unhook the transmission release cable from the bypass lever on the transmission. See Figure 4.8.
14.
Release the barbed fitting on the end of the reverse
drive cable housing from transmission torque
bracket.
15.
Unhook the reverse drive cable from the control arm.
16.
Remove the two screws that secure the transmission
to the torque bracket using a 1/2” wrench.
17.
Support the transmission to prevent it from falling off
of the wheelbarrow.
18.
Remove the four nuts and bolt that fasten the transmission and the support brackets to the frame using a
1/2” wrench. See Figure 4.9.
19.
Carefully lower the transmission out of the wheelbarrow enough to get at the forward drive cable..
20.
Release the barbed fitting on the end of the forward
drive cable housing from bracket on the transmission.
21.
Unhook the reverse drive cable from the control arm.
22.
Carefully lower the transmission all the way out of the
wheelbarrow.
23.
Install the transmission by following the previous
steps in reverse order.
24.
Test drive the wheelbarrow in a safe area before
returning it to service.
By-pass
lever
Release
cable
Figure 4.8
Bolts
Nuts
Figure 4.9
17
Transmission
18
Pivot bar and caster wheels
CHAPTER 5: PIVOT BAR AND CASTER WHEELS
Caster wheels
The Pack Horse is equipped wit two caster wheels. These wheels have ball bearing in the rims and tubed tires.
There are no service parts for these wheel and tire assemblies. They must be replaced as whole assemblies.
To remove/replace a caster wheel:
1.
Lift and safely support the rear of the wheelbarrow.
2.
Remove the axle bolt and nut using a pair of 9/16”
wrenches. See Figure 5.1.
3.
Slide the caster wheel out of the yoke.
4.
Slide the spacer out of the wheel hub.
5.
Install the caster wheel by following the previous
steps in reverse order.
6.
Test drive the wheelbarrow in a safe area before
returning it to service.
Yoke
Caster wheel
Figure 5.1
Spacer
Figure 5.2
19
Pivot bar and caster wheels
Caster wheel yoke and bushings
To remove/replace the caster wheel yoke:
Screw
Fender washer
1.
Lift and safely support the rear of the wheelbarrow.
2.
Remove the caster wheel by following the procedures described in the previous section of this chapter.
3.
Remove the screw and fender washer that secures
the yoke to the pivot bar using a 9/16” wrench
4.
Slide the yoke out of the pivot bar. See Figure 5.3.
NOTE: There are two thrust washers and a needle
thrust bearing between the bottom of the
pivot bar and the yoke.
5.
Install the yoke by following the previous steps in
reverse order.
6.
Test drive the wheelbarrow in a safe area before
returning it to service.
Needle
bearing
Figure 5.3
To remove/replace the yoke bushings:
1.
Lift and safely support the rear of the wheelbarrow.
2.
Remove both yokes by following the procedures
described in the previous section of this chapter.
3.
Pry the bushings out of the pivot bar.
See Figure 5.4.
NOTE: When replacing the bushing, replace all four
at the same time.
4.
Drive in the new bushings with a rubber mallet or a
soft faced hammer.
5.
Install the yokes and wheels by following the procedures described in the previous section of this chapter.
6.
Test drive the wheelbarrow in a safe area before
returning it to service.
20
Bushings
Figure 5.4
Pivot bar and caster wheels
Pivot Bar
To remove/replace the pivot bar:
1.
Lift and safely support the rear of the wheelbarrow.
2.
Remove both yokes by following the procedures
described in the previous section of this chapter.
3.
Remove the belt cover by removing the four screws
that secure it using a 3/8” wrench. See Figure 5.5.
4.
Release the barbed fitting on the end of the cable
housing from the pivot bar mounting bracket.
5.
Slide the inner cable through the slot in the pivot bar
mounting bracket. See Figure 5.6.
6.
Unhook the Z-fitting from the transmission release
lever.
7.
Remove the two screws that fasten each of the frame
support brackets to the frame using a 1/2” wrench.
See Figure 5.7.
Belt cover
Figure 5.5
Slot
pivot bar
mounting bracket
Z-fitting
Figure 5.6
Pivot bar
frame
support bracket
Figure 5.7
21
Pivot bar and caster wheels
8.
Remove the nuts and bolts that fasten the spacer
tubes to the pivot bar mounting bracket using a pair
of 9/16” wrenches. See Figure 5.8.
9.
Remove the pivot bar shoulder bolt using a 3/4” and
9/16” wrench.
10.
Slide the pivot bar out of the wheelbarrow.
Pivot bar shoulder bolt
Spacers
Figure 5.8
11.
Remove both of the center bushings from the pivot
bar. See Figure 5.9.
12.
Install the pivot bar by following the previous steps
in reverse order.
13.
Test drive the wheelbarrow in a safe area before
returning it to service.
Bushing
Figure 5.9
22
Maintanence
CHAPTER 6: MAINTENANCE
Lubrication
To help keep the Pack Horse wheelbarrow in proper running order it is recommended the following lubrication intervals be used (adjustable to local conditions). Use a high quality petroleum grease to lubricate the tractor.
Lube Point
Number of
fittings
Interval
Rear axles
2
25 hours
Front axles
Coat the
shafts
yearly
NOTE: Lubricate all of the pivot points with a light coating of oil once a season.
Engine maintenance
The recommended maintenance intervals listed in this manual are a guideline. They are adjustable for local conditions.
NOTE: For engine repair and maintenance procedures refer to the engine manufacturer.
Changing the engine oil
1.
Pull the idler pulley far enough to the left to slip the belt off of it. See Figure 5.1.
Idler pulley
Front of wheelbarrow
Figure 5.1
23
Maintanence
2.
Remove the belt cover using a 3/8” wrench. See Figure 5.2.
Belt cover
Figure 5.2
3.
Slide the belt off of the engine pulley.
4.
Remove the oil dip stick.
5.
Place a suitable oil receptacle under the engine.
6.
Remove the drain plug using a 3/8” drive ratchet and an extension.
Drain plug
Figure 5.3
7.
Install the drain plug when all of the oil has drained out.
8.
Dispose of the used oil in a safe and legal manner.
9.
Fill the engine with 20 oz. of oil that meets the engine manufacturers specifications.
10.
Test drive the wheelbarrow in a safe area before returning it to service.
24
Maintanence
Clean the engine
Air cooled engines cool better if they are clean. Check for nesting or signs of nesting especially after dormant season
storage.
Plugged
air filter
Mouse nest
Figure 5.4
Recommended service intervals
Before
Each Use
Every
10 hours
Check Engine Oil Level
X
X
Check Air Filter
X
Clean and Re-oil Air
Filter’s Foam
Pre-cleaner
Every
25 hours
Every
50 hours
Every
100
hours
Prior
to storing
X
Replace the Air Filter
X
Change the Engine Oil
X
Lube the Rear Axles
X
Clean the Engine
Cooling Fins
X
Check the Spark Plug
Gap & Condition
X
Replace the Fuel FIlter
X
X
25
Maintanence
26