MTD LT-5 User manual

Service Manual
LT-5 Lawn Tractor
MTD Products Inc - Product Training and Education Department
FORM NUMBER - 769-01415
2/2005
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 inexperi-
enced 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 pub-
lication, although care has been taken to make it as complete and accurate as possible at the time of publication. How-
ever, 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 2005 MTD Products Inc. All Rights Reserved
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TABLE OF CONTENTS
General Information ....................................................................................................................1
Operator Controlled Reverse (OCR) ..........................................................................................1
Numbering System .....................................................................................................................2
Deck Removal ............................................................................................................................2
Blade Drive Belt Removal ..........................................................................................................3
Deck Idler Bracket Removal .......................................................................................................3
Spindle Removal ........................................................................................................................4
Fender Removal .........................................................................................................................5
Upper Drive Belt Removal ..........................................................................................................6
Lower Drive Belt Removal. .........................................................................................................8
Variable Speed Pulley Removal .................................................................................................8
Variable Speed Idler Bracket Removal ......................................................................................9
Transmission Removal – 618-04072 ........................................................................................10
Deck Lift Assembly ..................................................................................................................11
Removal of the Steering Shaft and Sector Gear ......................................................................12
Pedal Support Bracket Removal ..............................................................................................13
Speed Control Latch Removal .................................................................................................13
7-Speed Shift Lever Removal ..................................................................................................14
Parking Brake and Shift Control Adjustments ..........................................................................15
Toe-In Adjustment ....................................................................................................................15
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1
LT-5 LAWN TRACTOR (TROY-BILT MODEL
SHOWN)
GENERAL INFORMATION
Model used in the Service Manual - 13AN779G766
17.5 hp Briggs & Stratton engine - 42” cutting deck
• RMC - “Reverse Mowing Control” technology
• Greaseable Spindles.
• Square Shoulder Tires.
• Wider tires 15X6 and 20X8 .
• 18” Turning Radius
• Improved Independent Controls.
• Operational Controls on Fender and Dash.
• Cup Holder.
• Fully Welded Frame.
• 38” and 42” decks with Fast Attach.
• All decks are “Wash Kit” ready
• Enhanced Hour Meter Package
RMC - “REVERSE MOWING CONTROL”
The operator can choose to over-ride our “No Cut In
Reverse” safety system.
The revised ANSI Standard B71.1 taking effect Sep-
tember 1, 2004 states:
“A means shall be provided that prevents reverse drive
operation at a ground speed greater than 1 ft./sec.with
powered blade(s).
An override capability may be provided to permit
reverse drive with powered blades temporarily. If an
override capability is provided, it shall automatically
reset when one or more of the following actions occurs:
The blade(s) is (are) re-engaged or (2) the engine is
restarted or (3) the directional control is moved from
reverse.”
How It Works:
• Operator turns the key from the run position #3
to position #2. See Figure 1.
• Presses RMC button.
• Light indicator gives visual confirmation to the
operator.
Operator may mow in forward or reverse until:
• Leaves the tractor seat.
• Turns the key back to right (position #3).
• Turns the engine off (position #1).
Incorporated on 2005 LT-5 and RT99.
Figure 1
#1 #2 #3
#4
Servicing the LT-5 Lawn Tractor
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NUMBERING SYSTEM
The LT-5 will follow the same model number configura-
tion as the BFR which was the 600 series (frame size)
but now in the fifth position there will be a ( 7 ) to signify
transition to the new platform.
Example: 13AD789G790
1. DECK REMOVAL
1.1. Place the unit on a firm and level surface.
1.2. Remove the key from the ignition.
1.3. Lower the deck to its lowest cutting position.
1.4. Using needle nose pliers, remove the hairpin
clips securing the deck hanger brackets to the
deck. Release the hanger links from the deck.
See Figure 2.
1.5. Using a 1/2” socket, remove the hex head cap
screw securing the belt keeper to the frame.
Remove the belt keeper. See Figure 3.
NOTE: Note the location of the belt keeper dur-
ing removal. There are two holes in the side
frame. Use the forward hole during assembly.
1.6. Slide the deck forward and remove the deck belt
from around the engine pulley. See Figure 4.
1.7. Lift the front stabilizer from the front stabilizer
bracket.
1.8. Remove front stabilizer adjustment rod by sliding
rod forward untill the flat area is in line with stabi-
lizer bracket notch. Turn the rod 90 degrees and
remove it from the tractor.
1.9. Raise the deck lift lever to its highest cutting
position.
Figure 2
Deck Hanger Bracket
Hairpin Clip
Figure 3
Belt Keeper
Hex Cap Screw
Figure 4
Front Stabilizer Engine Pulley
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1.10. Using needle nose pliers, remove the hairpin clip
securing the deck engagement cable to the deck
flange. See Figure 5.
1.11. Slip the oval plastic retainer ring from the con-
nector. Pull the connector rearward, lining the
grooves in the connector with the deck flange
and slide it up and out of the flange. See Figure
6.
1.12. Remove the tension spring from the deck idler
bracket.
NOTE: Depending on which deck is installed on
the unit, it may be necessary to remove the spin-
dle brake connecting rod between the two spin-
dles in order to remove the deck engagement
spring.
1.13. Slide the deck out from under the unit.
Figure 5
Deck Engagement Cable
Deck Bracket
Figure 6
Deck Bracket
Oval Retainer
2. BLADE DRIVE BELT REMOVAL
NOTE: The 38” deck has a single pulley on the
idler. The 42” deck has two pulleys on the idler.
Disassembly procedures are similar.
2.1. Remove the cutting deck from the unit.
2.2. Using a ½” socket, remove the three screws
securing the belt cover to the deck. Repeat for
the other belt cover. See Figure 7.
NOTE: The belt covers are interchangeable.
2.3. Using a 9/16” socket and an open-end wrench,
loosen but do not remove the nuts securing both
idler pulleys to the idler bracket. See Figure 8.
2.4. Remove the belt from around the idler pulleys
and spindles.
Figure 7
Belt Covers
Figure 8
Idler Pulleys
Idler Bracket
Belt Guides
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3. DECK IDLER BRACKET REMOVAL
NOTE: The 38” deck has a single pulley on the
idler. The 42” deck has two pulleys on the idler.
Disassembly procedures are similar.
3.1. Remove the deck from the unit.
3.2. Remove the deck drive belt.
3.3. Remove the deck idler bracket spring. See Fig-
ure 9.
3.4. Remove the cotter pin holding the brake rod to
the idler bracket and remove the brake rod con-
nected to the idler bracket. See Figure 10.
3.5. Using a 9/16” socket and a 9/16” wrench,
remove the bolt and nut securing the idler
bracket to the frame. There is a shoulder spacer
under the idler bracket. Remove the idler
bracket. Inspect the idler bracket for wear or
damage. Inspect the brake puck at the end of
the idler bracket for wear or damage. The brake
puck is riveted to the idler bracket. See Figure
11.
NOTE: The 38” and 42” deck share the same
idler bracket. They each use unique mounting
holes. Correct holes are marked on the bracket.
This is also true for the tension springs. The hole
in the center of the bracket has a step washer in
it. See Figure 12.
3.6. Using two 9/16” wrenches remove the idler pul-
leys.
Figure 9
Deck Idler Bracket Spring
Figure 10
Brake Rod
Cotter Pin
Figure 11
Shoulder Spacer
Lower Spacer
Figure 12
Shoulder Spacer
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3.7. Inspect the pulleys and pulley bearings for dam-
age and wear. Replace as needed.
NOTE: When reassembling be sure to install the
spacer under the pulley and the thinner flat
washer on top.
NOTE: Lubricate the idler bracket with a small
amount of lithium grease during assembly. Per-
form this lubrication on a yearly basis.
4. RIGHT SPINDLE BRAKE
4.1. Remove the brake spring attached from the deck
frame to the brake assembly at the right spindle.
See Figure 13.
NOTE: Although similar, this spring is different
from the spring on the Idler arm. This spring may
be painted yellow.
Figure 13
Brake Assembly
Brake Spring
4.2. Using a ½ inch socket and a ½” wrench remove
the brake assembly bracket. Inspect the brake
puck for wear or damage. The brake puck is riv-
eted to the bracket and must be replaced as an
assembly. See Figure 14.
5. SPINDLE REMOVAL
5.1. Remove the deck from the unit. See DECK
REMOVAL Section.
5.2. Remove the blade drive belt. See BLADE
DRIVE BELT REMOVAL Section.
5.3. Remove the deck Idler bracket and spindle
brake bracket. See DECK IDLER BRACKET
REMOVAL Section.
Figure 14
Riveted Brake Puck
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5.4. Using an impact wrench and a 15/16” socket
remove the pulley and blade from the spindle
assembly. See Figure 15.
NOTE: Use a blade stop to secure the blade and
prevent it from rotating during disassembly.
5.5. Using a ½” socket remove the spindle housing
for inspection or replacement. See Figure 16.
5.6. Assemble the spindle in reverse order of disas-
sembly. See Figure 17.
NOTE: During assembly, align the two bearing
spacers inside the spindle as you insert the spin-
dle shaft.
6. FENDER REMOVAL
6.1. Tip the seat forward.
6.2. Remove the battery and battery tray. See Figure
18.
Figure 15
Pulley
Spindle
Blade Stop
Figure 16
Figure 17
Figure 18
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6.3. Using a spring puller, carefully remove the seat
spring. See Figure 19.
CAUTION: The tension spring is wound very
tight.
6.4. Disconnect seat safety switch wires. See Figure
20.
NOTE: Remember to reconnect wires before
returning to service.
Figure 19
Spring Puller
Figure 20
Seat Safety Switch
6.5. Using a ½” socket remove the four bolts secur-
ing the seat bracket to the frame. See Figure 21.
6.6. Lift the seat off of the frame and set it aside.
6.7. Working from under the running boards and
using a ½” socket, remove the two nuts securing
the running boards to the frame. See Figure 22.
NOTE: The running board footpads cover the
bolts securing the fenders to the frame. It is not
necessary to remove the footpads. Hold down
on the top of the bolt during disassembly.
Figure 21
Seat Bolts
Figure 22
Running Board Nut
(One on each side)
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6.8. Using a heat gun, carefully heat the warning
label and peel it from the fender panel. Set it
aside to be re-installed during assembly. See
Figure 23.
6.9. Using 3/8” socket, remove the two screws secur-
ing the center section of the fender to the frame.
See Figure 24.
6.10. Remove the shifter knob, deck lift grip, and deck
engagement grip.
NOTE: You can use an air gun placed in the hole
at the top of each grip to ease disassembly.
6.11. Lift up on the rear of the fender to clear the seat
support springs, slide the fender towards the
rear and remove it from the tractor. See Figure
25.
NOTE: During removal, slip the seat safety
switch wires through the hole in the fender.
Remember to route these wires through the
same hole during assembly.
7. UPPER DRIVE BELT REMOVAL
NOTE: It is recommmended that both the upper
and lower drive belts be replaced as a set.
7.1. Tip the seat forward.
7.2. Disconnect the battery cables, remove the bat-
tery and the battery tray from the unit.
Figure 23
Heat Gun
Figure 24
Figure 25
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7.3. Using a spring puller or length of starter cord,
remove the large spring attached between the
variable speed idler arm and the rear of the trac-
tor frame. See Figure 26.
CAUTION: This is a very strong spring. Be care-
ful when removing and installing it.
7.4. Remove the small tension spring attached
between the long bolt extending up from the
frame and the transmission idler pulley. See Fig-
ure 27.
Figure 26
Figure 27
7.5. Using a 7/8” socket and extension, remove the
nut securing the transmission pulley to the trans-
mission. See Figure 28.
NOTE: Place a phillips screwdriver through the
hole in the pulley as a stop to ease removal of
the pulley nut.
7.6. Lift the pulley off the transmission and remove
the belt from around the pulley. See Figure 29.
7.7. Remove the drive belt up and over the variable
speed pulley. Replace in the reverse order of
disassembly.
NOTE: Replace both the upper and lower drive
belt as a set. See the LOWER DRIVE BELT
REMOVAL Section.
Figure 28
Transmission Pulley
Figure 29
Transmission Pulley
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8. LOWER DRIVE BELT REMOVAL.
NOTE: It is recommmended that both the upper
and lower drive belts be replaced as a set. The
following directions cover replacement of the
lower belt only. If both belts are being replaced,
refer to the upper drive belt removal section first
and then continue with the lower drive belt
removal instructions.
8.1. Remove the cutting deck. Refer to the section on
removing the cutting deck.
8.2. Using a spring puller or length of starter cord,
remove the large spring attached between the
variable speed idler arm and the rear of the trac-
tor frame. See Figure 30.
CAUTION: This is a very strong spring. Be care-
ful when removing and installing it.
8.3. Remove the small tension spring attached
between the long bolt extending up from the
frame and the transmission idler pulley. See Fig-
ure 31.
8.4. Remove the upper drive belt from around the
idler pulley. See Figure 32.
8.5. Remove the upper drive belt from around the
upper sheeve of the Variable Speed Pulley.
Figure 30
Spring Puller
Figure 31
Transmission Idler Tension Spring
Starter Cord Spring Puller
Figure 32
Upper Belt
Idler Pulley
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8.6. Raise the middle sheave of the variable speed
pulley to allow raising the lower drive belt around
the belt guard. See Figure 33.
8.7. Using a 5/8” socket on an impact gun, remove
the bolt securing the engine pulley to the engine
crankshaft.
Figure 33
Variable Speed Pulley
Lower Belt
8.8. Carefully lower the pulley from the crankshaft
and remove the belt from around the engine pul-
ley. See Figure 34.
NOTE: There is a spacer between the pulley
and the engine. The larger flange side should
face up during assembly. See Figure 35.
8.9. Replace the lower drive belt in the reverse order
of disassembly.
Figure 34
Engine Pulley
Spacer
Figure 35
Flange Spacer Engine Pulley
Hex Bolt and Washer
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9. VARIABLE SPEED PULLEY REMOVAL
9.1. Remove the cutting deck.
9.2. Using a spring puller or length of starter cord,
remove the large spring attached between the
variable speed idler arm and the rear of the trac-
tor frame. See Figure 36.
CAUTION: This is a very strong spring. Be care-
ful when removing and installing it.
9.3. Remove the small tension spring attached
between the long bolt extending up from the
frame and the transmission idler pulley. See Fig-
ure 37.
9.4. Remove the upper drive belt from around the
idler pulley.
9.5. Remove the upper drive belt from around the
upper sheeve of the Variable Speed Pulley.
9.6. Raise the middle sheave of the variable speed
pulley to allow raising the lower drive belt around
the belt guard. See Figure 38.
9.7. Using a ½” socket, remove the bolt securing the
variable speed pulley to the idler bracket.
9.8. Raise the variable speed pulley up and out of the
idler bracket. See Figure 39.
9.9. Replace the pulley in the reverse order of disas-
sembly.
10. VARIABLE SPEED IDLER BRACKET
REMOVAL
10.1. Follow steps 9.1 to 9.6 in the Variable Speed
Pulley Removal Section. Then continue with the
following steps.
Figure 36
Spring Puller
Figure 37
Transmission Idler Tension Spring
Starter Cord Spring Puller
Figure 38
Middle Sheave of Variable Speed Pulley
Lower Drive Belt
Hex Bolt
Figure 39
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10.2. Remove the cotter pin securing the variable
speed control rod to the variable speed idler
bracket. Remove the ferrule from the bracket
and let the rod hang down out of the way. See
Figure 40.
10.3. Using a ½” socket, remove the two screws
securing the torque bracket to the frame. See
Figure 41.
NOTE: If you are using air tools you can remove
the right rear tire to gain better access to the hex
screws.
Figure 40
Variable Speed Control Rod
Ferrule
Cotter Pin
Figure 41
Hex Screws
10.4. Using a ½” socket, remove the two screws
securing the torque bracket to the transmission.
See Figure 42.
NOTE: Pivot the idler bracket away from the
transmission to allow better access to the
mounting screws.
10.5. Remove the torque bracket and variable speed
idler assembly from the unit.
10.6. Inspect all components of the variable speed
assembly. See Figure 43.
10.7. Replace any warn or damaged parts.
10.8. Lubricate all moving parts before assembly.
Figure 42
Torque Bracket Mounting Screws
Figure 43
Deck Hanger Bracket
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11. TRANSMISSION REMOVAL – 618-04072
11.1. Remove the cutting deck.
11.2. Using a ½” socket, loosen the bolts securing the
wheels to the axles.
11.3. Support the unit at the rear with the wheels off
the ground. Leave room to lower the transmis-
sion from the unit. See Figure 44.
11.4. Remove the axle bolts from both rear wheels.
Remove the rear wheels.
11.5. Using a spring puller or length of starter cord,
remove the large spring attached between the
variable speed idler arm and the rear of the trac-
tor frame. See Figure 45.
11.6. Remove the small tension spring attached
between the long bolt extending up from the
frame and the transmission idler pulley. See Fig-
ure 46.
11.7. Remove the hairpin clip securing the shift rod to
the transmission. Move the shift rod out of the
way. See Figure 47.
11.8. Using a ½” socket, remove the two screws
securing the torque bracket to the transmission.
Figure 44
Figure 45
Metal Spring Puller
Figure 46
Starter cord used as spring puller
Figure 47
Hairpin Clip Shift Rod
Torque Bracket Hex Bolts
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11.9. Using a ½” socket, remove the four bolts, lock
washers and nuts securing the transmission to
the frame. See Figure 48.
NOTE: Support the transmission during this pro-
cedure to keep it from falling from the unit.
11.10. As you remove the transmission, slip the upper
drive belt from around the transmission pulley.
See Figure 49.
11.11. Disconnect the brake rod spring from the brake
arm. See Figure 49.
11.12. Service the transmission and install in the
reverse order of disassembly.
NOTE: During assembly, route the upper drive
belt around the transmission pulley as you install
the transmission into the tractor.
Figure 48
Support Straps
Transmission Mounting Bolts
Figure 49
Brake Rod and Spring
Upper Drive Belt
12. DECK LIFT ASSEMBLY
NOTE: You might be inclined to try to remove
the deck lift assembly without removing the
fender assembly. While it can be done, it is much
easier to take the few minutes to remove the
fender.
12.1. Remove the fender assembly as described in
section 5.
12.2. Remove E-clips from both ends of deck lift shaft.
See Figure 50.
12.3. Remove plastic hex bushings. Inspect for wear
and damage replace as needed. See Figure 51.
Figure 50
Right “E” Clip Plastic Bushing
Left “E” Clip
Plastic Bushing
Figure 51
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12.4. Slide deck lift shaft to left to allow right side to
come out of the frame. See Figure 52.
12.5. Slide deck lift shaft to right to allow the left side
to come out of the frame.
12.6. Carefully lift out the assembly. See Figure 53.
12.7. Inspect the deck lift shaft for wear, cracks and
bends. See Figure 54.
13. DECK LIFT INSPECTION
13.1. Access is gained by removing the battery and
battery box. Inspect the lever for proper opera-
tion and engagement of the deck safety switch.
See Figure 55.
Figure 52
Deck Lift Shaft
Figure 53
Figure 54
Figure 55
Deck Engagement Lever Deck Safety Switch
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14. SERVICING THE SOLENOID.
14.1. The solenoid can be inspected and serviced by
removing the battery and battery box. See Fig-
ure 56.
15. REMOVAL OF THE STEERING SHAFT AND
SECTOR GEAR
15.1. Engage the parking brake on the tractor. This
will ease disassembly later.
15.2. Remove the cutting deck.
15.3. Raise the hood or remove the hood.
15.4. Remove the right side panel. See Figure 57.
Figure 56
Solenoid
Figure 57
Panel Mounting Fasteners
15.5. Working from under the tractor, use a #4 phillips
bit on a socket to remove the screw securing the
steering shaft through the frame. See Figure 58.
15.6. Using a 9/16” socket on the bottom and a 9/16”
wrench on the top, remove the center bolt on the
sector gear bracket. See Figure 59.
15.7. Order of parts is: bolt, bell washer, top plate,
spacer through sector gear, frame and flange
lock nut.
15.8. Using a 9/16” socket on the bottom and a 7/16”
wrench on the top, remove the flange lock nut
and shoulder bolt passing through the groove of
the sector gear.
Figure 58
Plillips Head Screw
Center Bolt
Shoulder Bolt
Steering Shaft
Center Bolt
Shoulder Bolt
Figure 59
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