MTD 860 Series, Shop Handbook

Page 1: ...th 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 ...

Page 2: ...www mymowerparts com For Discount White Outdoor Parts Call 606 678 9623 or 606 561 4983 ...

Page 3: ... Drive belt and baffles 7 Chapter 5 Speed control system 10 How the speed control works 10 Speed control cable and lever 11 Clutch cable replacement 14 Chapter 6 Transmission and rear wheels 16 Transmission replacement 16 Low wheel mower 16 Large wheel mowers 21 www mymowerparts com For Discount White Outdoor Parts Call 606 678 9623 or 606 561 4983 ...

Page 4: ...ts Working on the cutting blade or drive system are two examples of situations that could place a technician at risk CAUTION Take measures to avoid the creation of a fire hazard when working around equipment that would normal contain fuel Drain and store fuel in safe containers Clean any fuel spills immediately Avoid exposing fuel to heat sources or open flame NOTE Replace any worn or damaged fast...

Page 5: ...nger on the 860 Series than they are on the 830 Series The single point height adjust lever is on the left hand side on the 830 Series but it is on the right hand sideonthe860Series The handlebar brackets are different between the two models The 860 Series has different final drive gears including an idler gear between the transmission axle and the ring gear in the rear wheel Figure 1 2 www mymowe...

Page 6: ...ure 2 1 nut Figure 2 2 Wheel removed Front axle To remove the front axle 1 Remove the front wheels 2 Set the height adjuster lever to the highest posi tion relieving the load on the lift assist torsion spring on the front axle See Figure 2 3 3 Remove the shoulder screw that holds the height adjuster connecting link to the front axle Use a 3 8 wrench See Figure 2 4 CAUTION The torsion spring on the...

Page 7: ...he tor sion spring from the deck shell See Figure 2 7 7 The torsion spring is captive on the front axle If either is damaged both must be replaced See Figure 2 8 8 Reinstall the front axle by reversing the steps used to remove it Replace the C clips if they have lost their ten sion Replace the flanged hex bushings if they are worn Do not trim the flanged hex bushings to ease installation They shou...

Page 8: ...5 8 wrench Figure 3 1 Blade Bolt Belville spring 6 Lift away the blade See Figure 3 2 7 Inspect the blade If it is bent or worn beyond proper sharpening replace it with a new blade 8 Sharpen and balance the blade if it is not badly worn NOTE The 830 and 860 Series mowers have a 3 in 1 blade The outer part of the leading edge cuts the grass A wing behind it lifts the grass for the next blade and pr...

Page 9: ...ve the wave washer See Figure 3 3 10 Install the blade with wave washer blade adap tor and bellville spring washer properly posi tioned Tighten the blade bolt to a torque of 38 50 ft lb 51 68 N m Figure 3 3 Crankshaft Wave washer Blade adaptor www mymowerparts com For Discount White Outdoor Parts Call 606 678 9623 or 606 561 4983 ...

Page 10: ...re located just in front of the handlebar brackets and can be removed using a 3 8 wrench There is one on the left and one on the right See Figure 4 3 4b Remove the two nuts and bolts that hold the right handlebar bracket to the mower deck using a pair of 1 2 wrenches They do not hold the baffle in place but they get in the way of its removal See Figure 4 4 Figure 4 3 Baffle screw Figure 4 4 Baffle...

Page 11: ...ley cover to the mower deck using a 3 8 wrench 7b Pull the crankshaft pulley cover and the lower sheave of the crankshaft pulley down freeing the belt from the crankshaft pulley See Figure 4 6 8 Remove the belt by 8a Pull the belt down off of the crankshaft See Figure 4 7 8b Slip the belt out of the transmission pulley and remove it See Figure 4 8 Figure 4 5 Figure 4 6 Belt Upper sheave Lower shea...

Page 12: ... engine See Figure 4 10 Figure 4 9 Upper sheave of crankshaft pulley Splines Figure 4 10 Crankshaft spacer varies with engine model 10 Replace the belt 10a Reverse the removal process 10b It will help to spread the sheaves on the transmission pulley and tug the belt deep into the sheaves of the transmission pul ley This will leave the maximum amount of slack in the belt so it is easier to slip aro...

Page 13: ... drive belt further out on the pulley The outer part of the pulley travels at a higher linear speed than the part closer to the crankshaft shifting the drive ratio in the direction of greater speed 5 The belt does not stretch any significant amount When the engine end pulley effectively grows the tension on the belt increases 6 The sheaves on the transmission pulley are spring loaded to react to t...

Page 14: ...ntrol cable and lever 1 Remove the crankshaft pulley cover as described in the DRIVE BELT section of this manual 2 Un hook the spring from the arm on the speed control cam See Figure 5 5 3 Release the barbed fitting on the end of the cable housing from the clutch housing A 9mm open end wrench or a Ford fuel line tool can be used to release the barbs See Figure 5 6 Figure 5 5 Crankshaft pulley cove...

Page 15: ...cable housing free of the control panel The stop at the end of the cable housing is usu ally placed in the notch that is second nearest the control lever assembly See Figure 5 10 NOTE Moving the cable to a notch that is closer to the control lever will shift the range of avail able ground speeds in a slower direction Moving the cable to a notch that is further from the control lever will shift the...

Page 16: ...Figure 5 12 Detent spring 10c Separate the control lever from the cable quadrant by removing the screw that con nects them Use a 5 16 wrench or driver See Figure 5 13 10d Pay attention to the orientation of the lever to the control panel and the quadrant dur ing reassembly See Figure 5 14 10e Reassemble the control panel by reversing the order of disassembly NOTE Some technicians find it easier to...

Page 17: ... barbed fitting and a spring connect the bottom end of the clutch cable to the transmission See Figure 5 16 3 Squeeze the barbs on the cable housing to release it from the bracket on the transmission A 9mm open end wrench or a Ford fuel line removal tool may be handy for this task See Figure 5 17 4 Once the cable housing is released from the bracket the spring on the end of the cable core can be u...

Page 18: ...ble bracket loose from the upper han dlebar See Figure 5 21 8 With the cable slack the Z fitting at the top end of the cable core can be un hooked from the clutch bale See Figure 5 22 NOTE Depending on parts availability the cable may have to be replaced in tandem with the engine stop cable 9 Install the replacement cable by reversing the removal process Figure 5 21 Cable bracket Figure 5 22 Engin...

Page 19: ...he baffle as described in Chapter 4 Drive belt and baffles See Figure 6 1 1b Set the cutting height to the highest position 1c Support the mower by the back of the deck in such a way that the rear wheels can be removed See Figure 6 2 2 Rear wheel and dust cover removal 2a Remove the rear wheels using a 1 2 wrench See Figure 6 3 Figure 6 1 Blade Baffle extension Baffle Removed Figure 6 2 Rear wheel...

Page 20: ...xle 2c Slip the spur gears off of the drive axle ends See Figure 6 5 NOTE The Torx screw that holds the spur gear to the drive axle should be installed with releas able thread locking compound such as LoctiteTM 242 blue Tighten it to a torque of 110 120 in lb 12 5 13 6 N m 2d Pull the drive pins out of the cross holes in the drive axle The pins should be lubri cated with a small amount of anti sei...

Page 21: ... axle bearings left and right sides See Figure 6 8 3c Pull the bearing keepers back inward to release the bearings from the height adjuster brackets See Figure 6 9 3d Drive the axle bearing assemblies outward to release the axle See Figure 6 10 Figure 6 7 Height adjustment connecting link Height adjustment handle Figure 6 8 Metal C clip Axle bearing keeper Figure 6 9 Handlebar bracket Axle bearing...

Page 22: ...discon nected as described in Chapter 5 Speed control system See Figure 6 13 5 Remove the transmission from the wheel carrier weldment See Figure 6 14 5a Slip the transmission in the direction of the longer drive axle shaft disengaging the shorter drive axle shaft from the wheel carrier assembly 5b Remove the axle bearing keepers from the axle 5c If the axle bearing keepers are in good con dition ...

Page 23: ... shaft remove the nut and the spring See Figure 6 16 6c With the nut and spring removed the vari able speed pulley can be lifted off of the input shaft See Figure 6 17 6d The two sheaves of the variable speed pul ley can be separated for cleaning or inspection See Figure 6 18 NOTE The splines should not need lubrication If any lubrication is applied use a dry PTFE TeflonTM or graphite based lubric...

Page 24: ...See Figure 6 19 Figure 6 19 2 The wheel cover is held to the rear wheel by a relatively small grip ring near the hub of the wheel See Figure 6 20 3 Remove the nut and flat washer from the axle using a 9 16 wrench 4 Pull the wheel off of the wheel axle See Figure 6 21 NOTE The 830 Series employs a spur gear that drives against the outside of the gear attached to the wheel In that arrangement the sp...

Page 25: ...with a T 20 Torx driver The axle must be clamped to prevent it from rotating See Figure 6 24 8 Beneath the spur gear is a drive pin Lubricate the drive pin with a small amount of anti seize compound on assembly See Figure 6 25 NOTE The Torx screw that holds the spur gear to the drive axle should be installed with releas able thread locking compound such as LoctiteTM 242 blue Figure 6 22 Idler gear...

Page 26: ...ight to the highest posi tion 10b Support the mower tipped back with the rear wheels elevated 10c Remove the baffle as described in Chapter 4 Drive belt and baffles 10d Remove the rear wheels spur gears drive pins idler gears and dust covers 10e Disconnect the height adjustment connec tor link from the left rear height adjuster 10f Remove the height adjustment handle from the right rear height adj...