Service Manual
Contents
1. Bolens SINCE 1850 Service Manual Bolens 683 Series Box Frame Tractor NOTE These materials are for use by trained technicians 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 de2. hanger link anti sway bar to the frame See Fig ure 18 uN 4 5 r5 I Deck Hanger Link Anti Sway Rad a Di Clip E EN Figure 18 NOTE There has been some issues with the deck belt rubbing on the Deck Hanger Link Anti Sway Rod on tractors with the 46 cutting deck This has been corrected on later production by moving the frame mounting bracket higher If you are experiencing belt damage contact MTD Customer Service for a Hanger Link with a bend in it See Figure 19 riginal Deck Hanger Link Anti Sway Rod Replacement rod with bend for 46 deck Figure 19 12 6 Remove the two hairpin clips securing the front hanger rods to the deck brackets and carefully lower the front of the deck to the ground See Figure 20 Figure 20 12 7 Remove the two hairpin clips that secure the two rear deck hangers to the deck stabilizer bracket and lower the deck to the ground See Figure 21 Rear Deck Hairpin Clips Figure 21 12 8 Raise the deck lift lever to its highest position to raise the lift links out of the way 12 9 Remove the deck from under the unit 13 DECK STABILIZER BRACKET REMOVAL NOTE For normal service and maintenance the deck stabilizer bracket does not need to be removed If mounting a snow thrower attach ment however the stabilizer will need to be removed 13 1 Remove the hairpin clip that secures the stabi lizer rod to the stabilizer bracket See Figure 22 BB
3. hub 718 0758A is being used on current production The new hub DOES NOT require the use of the washer Flange Nut E 18 15 Remove the lower drive belt from around the PAN lower portion of the variable speed pulley See Figure 34 Figure 32 18 14 Carefully lift the pulley off the transmission s input shaft and remove the upper drive belt from around it and the variable speed pulley NOTE Maintain the proper orientation of the Figure 34 pulley Tractors with a 46 cutting deck have spacers between the transmission and tractor frame to provide increased clearance for the cut ting deck The transmission pulley is manufac tured with a dish or concave shape The dish side should be facing DOWN on tractors with a 18 16 Remove the lower drive belt by lifting it through the cover panel opening 11 18 17 Install new belts following the previous instruc tions in the reverse order IMPORTANT When installing the engine pulley torque the hex bolt to between 38 and 50 foot pounds IMPORTANT When installing the transmission pulley make sure that the pulley is properly seated on the pulley hub and torque the flange nut to between 25 and 33 foot pounds NOTE Torquing the transmission pulley will be made easier by placing a 1 4 inch tapered punch through the hole in the pulley and holding it against the transmission See Figure 35 Figure 35 19 VARIABLE SPEED PULLEY REMOVAL 19 1 Remove the cutti
4. puller or recoil rope remove the spring from the belt idler bracket This will relieve tension on the belt 16 4 Remove the belt from around the idler pulleys and the three spindle pulleys 16 5 Install new belts and reassemble in the reverse order 17 DECK SPINDLE REPLACEMENT 17 1 Remove the deck from the tractor following the deck removal procedures in this manual 17 2 Using a 1 2 inch socket remove the belts guards located over each spindle by removing the self tapping screws securing them in place 17 3 Using a air impact wrench and 15 16 inch socket remove the spindle pulley hex flange nut NOTE Use a blade stop or a C clamp to hold the blade in place during nut removal See Fig ure 23 C Clamp Figure 23 17 4 Remove the pulley 17 5 Using a air impact wrench and 15 16 inch socket remove the cutting blade hex flange nut 17 6 Remove the cutting blade 17 7 Using a 1 2 inch socket remove the four self tap ping hex screws securing the spindle assembly to the cutting deck See Figure 24 Self Tapping Hex Screws Figure 24 17 8 Install the new spindle in the reverse order above NOTE During reassembly torque the self tap ping hex screws to between 90 and 110 inch pounds NOTE Torque the blade spindle hex flange nut to between 70 and 90 foot pounds 18 DRIVE BELT REMOVAL UPPER AND LOWER NOTE An air impact wrench will be required to remove the engi
5. the ferrule attaching the shift rod to the shift lever assembly See Figure 45 Hair Pin and Washer S wey gt r A j R Shift Lever Assembly 7 Shift Rod Ferrule LATE gt Kf Rod Figure 45 NOTE To maintain adjustment wrap a piece of tape around the ferrule and shift rod to hold it in position 20 16 Using a 1 2 inch socket remove the two self tap ping screws securing the transmission to the torque bracket See Figure 46 0 y Self Tapping Screws _ Q Ris g Figure 46 NOTE There are four mounting holes machined into the transmission for mounting the transmis sion to the torque bracket The LOWER holes are used when installing the transmission into a tractor that has a 38 or 42 cutting deck The UPPER holes are used when installing the trans mission into a tractor with a 46 cutting deck 15 20 17 Using a 1 2 inch socket and 1 2 inch box wrench remove the four two on each side hex cap screws and flange lock nuts securing the transmission to the frame See Figure 47 Hex Cap Screws and Fle two on ez nge Lock Nuts side of frame Mounting Bracket Figure 47 NOTE There are two one on each side trans mission mounting brackets providing additional support for the frame and transaxle NOTE You will find two additional spacers one on each side used on tractors with a 46 cutting deck Make sure to install thes
6. Stabilizer Bracket pr ZB an y e A A 97 Py l l 8 gt i 7 Stabilizer Rod Y e j A i J N EAN ai 4 Figure 22 pe 4 yA 1 13 2 Slide the stabilizer rod out of the bracket and remove the bracket NOTE Make note of the orientation of the stabi lizer rod and stabilizer bracket prior to disassem bly The stabilizer bracket can be incorrectly installed upside down and or the stabilizer rod can be installed backwards during reassembly 14 DECK BELT REMOVAL 38 AND 42 DECKS 14 1 Remove the cutting deck from the tractor by fol lowing the procedures in the cutting deck removal section 14 2 Using a 1 2 inch socket remove the belts guards located over each spindle by removing the self tapping screws securing them in place 14 3 Remove and replace the belt 14 4 Reassemble in reverse order 15 UPPER DECK BELT REMOVAL 46 DECKS 15 1 Remove the cutting deck from the tractor by fol lowing the procedures in the cutting deck removal section NOTE On 46 decks you must also remove both the deck stabilizer bracket and stabilizer rod See deck stabilizer bracket removal section 15 2 The upper deck belt is removed by simply lifting it off the double pulley located at the rear of the cutting deck 16 LOWER DECK BELT REMOVAL 46 DECKS 16 1 Remove the upper deck belt See above 16 2 Using a 1 2 inch socket remove the belt guards 16 3 Using a spring
7. TF Figure 8 1 2 Unthread the shift knob and remove the two flange screws securing the shift cover panel in place See Figure 9 12 7 4 Figure 9 Remove the shift cover panel NOTE Remove the yellow wire that is attached to the spring switch on the underside of the shift cover panel Locate the deck disengagement rod and remove the hairpin clip securing the rod to the stabilizer shaft assembly See Figure 10 FROM BELOW Stabilizer Shaft 7 5 7 6 Hairpin Clip Deck Disengagement Rod i 4 Figure 10 Pull the rod toward the rear of the tractor to take up any slack in the rod then thread the rod in or out until the rod lines up with the hole in the sta bilizer shaft Insert the stabilizer shaft through the stabilizer shaft assembly and secure it with the hairpin clip T T 1 8 7 9 7 10 Check the adjustment by placing the deck lift lever in the BLADES STOP position The deck should move up and forward and the belt should become loose Attach the yellow wire removed earlier and reas semble the shift cover panel Start the unit and test the deck engagementilift lever to be certain that the blades fully disen gage when in the BLADES STOP position Repeat the adjustment if needed PARKING BRAKE ADJUSTMENT WARNING Never attempt to adjust the brakes while the engine is running If the tractor does not come to a complete stop when the clutch brake pedal is depre
8. e spacers during reassembly in order to provided enough clear ance for the cutting deck 20 18 Remove the transmission from the tractor See Figure 48 Figure 48 NOTE When removing the final two bolts one from each side use an assistant or support the transmission from below to ease removal from the tractor 16
9. e transmission pulley to the transmission See Figure 42 Transmission IAS gt Figure 42 NOTE Depending upon when the tractor was manufactured there may be a washer between the flange nut and the transmission pulley 20 10 Carefully lift the pulley off the transmission s input shaft and remove the upper drive belt from around it and the variable speed pulley See Fig ure 43 Figure 43 20 11 A pulley hub is located beneath the transmission pulley NOTE Maintain the proper orientation of the transmission pulley Tractors with a 46 cutting deck have spacers between the transmission 14 and tractor frame to provide increased clearance for the cutting deck The transmission pulley is manufactured with a dish or concave shape The dish side should be facing DOWN on trac tors with a 38 or 42 cutting deck and facing UP on tractors with a 46 cutting deck 20 12 Remove the cotter pin from the brake rod ferrule Use a new cotter pin during reassembly Part 714 0111 See Figure 44 Brake Extension Spring Brake Rod Ferrule Figure 44 20 13 Remove and washer and the brake extension spring from the ferrule at the base of the speed control arm See Figure 44 20 14 Remove the extension spring from the brake actuation arm NOTE During assembly insert the extension spring through hole of the brake arm from the transmission side of the arm 20 15 Remove the hair pin and washer from
10. he frame here Spacer Figure 27 NOTE When re installing the extension springs after completing the repairs install the right hand ring first un Figure 29 18 7 Place the deck engagement lift lever in the BLADES STOP position 18 11 Disconnect the NEGATIVE black battery cable 18 8 Using a 1 4 inch socket remove both belt keep from the battery followed by the POSITIVE red ers on either side of the engine pulley See Fig cable See Figure 30 ure 28 NOTE There are four belt keeper mounting holes in the frame Mark the holes prior to removal to insure proper reassembly Figure 30 18 12 Detach the battery hold down rod and remove iil both the battery and battery tray from the tractor Figure 28 See Figure 30 10 18 13 Using an impact gun with a 7 8 inch socket 38 or 42 cutting deck and facing UP on tractors remove the flange nut securing the transmission with a 46 cutting deck pulley to the transmission See Figure 31 NOTE A pulley hub is located beneath the _ gt transmission pulley See Figure 33 Pulley Flange Nut WB i Vd Y Yow 9 Figure 31 A Washer Figure 33 Pulley Hub NOTE Depending upon when the tractor was Sul ey De e Wen PN LE Tange NOTE If you find wear or damage to the pulley nut and the transmission pulley If washer is lev h h A resent install during assembly See Figure 32 ana ee le Smponenn p redesigned pulley
11. in it Figure 6 NOTE Check the tractors tire pressure before performing any deck leveling adjustments 5 1 Perform deck leveling by removing the hairpin clip from the front left hanger bracket and adjust the ferrule up or down to set side to side level See Figure 7 Y wi 6 er Td pA FH roin ch N ACI WES 4 Y oo 6 2 SETTING THE DECK WHEEL HEIGHT ON MODELS SO EQUIPPED select the height position of the cutting deck by placing the Deck Engagement Lift Lever in any of the five different cutting height notches on the right side of the frame Adjust the deck wheels so that they are between 1 4 inch and 1 2 inch above the ground when the tractor is on a smooth flat surface such as a driveway and the height adjuster is in the lowest position WARNING Keep hands and feet away from the discharge opening of the cutting deck NOTE The deck wheels on models so equipped are an anti scalp feature of the deck and are not designed to support the weight of the cutting deck DECK ENGAGEMENT ADJUSTMENT NOTE The deck must disengage when the deck engagementilift lever is in the blade stop posi tion Adjust as follows 7 1 With the engine off place the deck engagement lift lever in the top cutting position not BLADES STOP position See Figure 8 Top Cutting Position LS Not BLADES STOP Positio24L EY a N oh e K lt P 4 gt 4 7 f gt u a gt ee gt 1 DE S OA E
12. n the high speed position or if the unit will not operate with the speed control in the low speed position proceed as follows 5 DECK LEVELING ADJUSTMENT 4 1 Place the shift lever in NEUTRAL NOTE The cutting deck is attached to the frame with steel rod hanger links The left front rod is threaded and has a ferrule which is used for 4 3 Place speed control lever in the high speed posi deck leveling See Figure 4 tion See Figure 3 4 2 Restart the engine Speed Control Lever Y Deck Hanger Links a g ya 7 See Dual AV Figure 4 Figure 3 NOTE There is also a Deck Hanger Link Anti 4 4 Release the clutch brake pedal fully Sway Rod that attaches from the front center of 4 5 Depress the clutch brake pedal the deck to the bracket on the right side of the frame See Figure 5 4 6 Place the speed control in the desired operating position 4 7 Place the shift lever in either FORWARD or REVERSE and follow normal operating proce dures Figure 5 NOTE There has been some issues with the deck belt rubbing on the Deck Hanger Link Anti Sway Rod on tractors with the 46 cutting deck 6 1 Model 13AQ683H163 This has been corrected on later production by moving the deck anti sway bracket higher If you are experiencing belt damage contact MTD Customer Service for a hanger link with a bend in it See Figure 6 Original Deck Hanger Link Anti Sway Rod eos 4 Hanger Link with bend
13. ne pulley during this procedure It is recommended that both drive belts be changed at the same time 18 1 Place the deck engagement lift lever in the fully forward position 18 2 Set the parking brake on the unit 18 3 Unthread the shift knob and remove the two flange screws securing the shift cover panel in place See Figure 25 A y lt T Flange Scre N N s Figure 25 18 4 Remove the shift cover panel NOTE Remove the yellow wire that is attached to the spring switch on the underside of the shift cover panel 18 5 Using a spring puller or recoil rope disconnect the spring that is attached to the small hook found on the left rear portion of the transmission Rear Deck Stabilizer Spring See Figure 26 i er ibe il Rope Rear Deck Stabilizer oh 4 Figure 26 18 6 Using a spring puller MTD Part number 732 18 9 Using an air impact gun with a 5 8 inch socket 0571 disconnect the two springs which are remove the hex screw that secures the engine attached to the rear portion of the tractor pulley to the engine crankshaft frame Torque Bracket Extension Springs See 18 10 Carefully lower the pulley off the crankshaft and Figure 27 remove the belt from around it NOTE A spacer is located between the engine pulley and engine Be careful not to lose the spacer and be certain NOT to reinstall the Spacer upside down See Figure 29 springs attach to t
14. ng deck following the proce dures in the cutting deck removal section 19 2 Remove both upper and lower drive belts by fol lowing the procedures in the drive belt removal section 19 3 Using an impact wrench and a 1 2 inch socket remove the hex cap screw securing the variable speed pulley assembly to the variable speed bracket NOTE Use the transmission belt to place ten sion on the variable speed pulley in order to hold it in place while removing the hex cap screw See Figure 36 p ve PAY u E AY DA via Variable Speed Pulley amp 7 Bearing Cup Be i Figure 36 NOTE There is a flat washer under the hex cap screw 19 4 Slide the variable speed pulley assembly up and out of the bearing cup NOTE The variable speed pulley is a welded assembly and is not serviceable See Figure 37 Variable Speed Pulley HN Hex Cap Screw and Washer Figure 37 NOTE During reassembly Locktite the hex cap screw securing the variable speed pulley to the bearing cup with locktite 242 Torque to between 190 and 235 inch pounds 12 E Lub 20 20 1 20 2 N EN j Ci N NOTE There is a bearing cup attached to the variable speed bracket that holds the variable speed pulley The cup holds two bearings which are replaceable See Zn 38 Ss E LER 4 Variable Y gt Speed Brackets t A a 5 Figure 38 NOTE Lubricate
15. of the rod is exposed beyond the ferrule See Figure 13 q A o IE alo Be i HH m y E Ih m y Na Bo gt i 3 4 nego thr ads S exposed infront offerrule f r a u e _ o Oe gt nn F p i Faure 13 9 5 Reinsert the ferrule and secure it with a new cot ter pin 9 6 Reassemble the shift cover panel and test the unit for full range of speeds 10 STEERING ADJUSTMENT Some units have an adjustable tie rod others do not If an adjustable tie rod or ferrule is replaced the toe in of the front wheels must be checked See Figure 14 r DA NO gt N E DANS gt a ae Mi g id 2 AS e lt y a he se Figure 14 NOTE Make sure the steering wheel and front tires are in position for straight ahead travel 10 1 Measure the distance between the front tire rims in front of the pivot bar 10 2 Measure the distance between the front tire rims behind the pivot bar The measurement taken in front of the pivot bar should be between 1 16 and 5 16 less than the measurement taken behind the pivot bar If not loosen or tighten the ferrule on the right end of the tie rod until the cor rect toe in is achieved NOTE Lengthening the tie rod increases toe in shortening the tie rod decreases toe in IMPORTANT Do not reuse the original cotter pin Part Number 714 0470 11 BALL JOINT SERVICING NOTE If replacement of ball joint is required co
16. pict actual model and component parts Copyright 2005 MTD Products Inc All Rights Reserved MTD Products LLC Product Training and Education Department PRINTED IN USA FORM NO 769 00946 10 2003 Servicing the 2003 Bolens Box Frame Lawn Tractor BOLENS LAWN TRACTOR e Model 13AQ683G163 20 HP Briggs Stratton V Twin OHV I C Engine e Deck 42 Twin Blade Cutting Deck e Cast Aluminum Spindle Housings e 6 position Single Lever Blade Deck Engagement Transmission 8 Speed Transaxle Shift on the go Drive e Heavy Duty Box Frame e Positive Caster Wheel Design e Tires 15 x 6 Front and 20x 8 Rear Tires Other models Bolens models based on this frame style e Model 13AN683G163 17 hp Model 13A0683G163 18 hp e Model 13AQ683H163 22 hp 1 SEAT STYLES The seat styles vary by the tractor model These models use three different styles Standard Adjustment Quick Adjustment and Knob Adjust ment Refer to the owners manual for proper adjustment 2 BATTERY HOLD DOWN The battery is held in place by a flexible steel rod that loops around a tab on the rear frame and clips to a stamped opening at the front of the bat tery See Figure 1 Figure 1 3 STEERING WHEEL e This unit features a new three spoke steering wheel that mounts to the steering shaft with a 1 2 hex bolt bell washer and steering wheel cap See Figure 2 Figure 2 4 SPEED CONTROL If the unit stalls with the speed control i
17. ssed or the unit rolls when the parking brake is applied the brake needs to be adjusted The brake is located on the right side of the transmis sion 8 1 8 2 Locate the hex nut on the right side of the brake assembly See Figure 11 Figure 11 Using a 1 2 wrench and a feeler gauge set the gap between the brake disk and brake puck at 011 See Figure 11 SPEED CONTROL ADJUSTMENT NOTE When operating the unit initially or after replacing the belts there will be little difference between the highest two speeds until after the belts have gone through a break in period and have seated themselves in the pulleys If the full range of speeds cannot be reached on the tractor adjust the speed control as follows 9 1 Unthread the shift knob and remove the two flange screws securing the shift cover panel in place 9 2 Remove the shift cover panel NOTE Remove the yellow wire that is attached to the spring switch on the underside of the shift cover panel 9 3 Remove the cotter pin that secures the speed control rod ferrule to the speed bracket During reassembly use a new cotter pin Part 714 0111 See Figure 12 A I 4 j CottepPin u 3 D Coptrol Rod Fafrujo ED Figure 12 NOTE At the factory the speed control rod is adjusted so that 5 8 of the rod is exposed beyond the ferrule 9 4 Adjust the speed control by threading the ferrule inward so that no more than 3 4
18. the pivot points of the variable speed bracket with Never Seize See Figure 38 TRANSMISSION REMOVAL NOTE The transmission can be removed with out removing the cutting deck We have removed the deck for clarity of pictures Place the deck engagement lever in the engaged position lowest cutting position Disconnect the NEGATIVE black battery cable from the battery followed by the POSITIVE red cable See Figure 39 Figure 39 20 3 20 4 20 5 20 6 20 7 gt Kom r 2 e gt ia j a e r rr rt _ hi f rs Detach the battery hold down rod and remove both the battery and battery tray from the tractor See Figure 39 Raise the rear of the tractor off the ground and support it in a way to allow removal of the rear wheels See Figure 40 Support Straps u Mi Im Figure 40 6 N Remove both rear wheels See Figure 40 Release the parking brake Using a spring puller MTD Part number 732 0571 disconnect the two springs which are attached to the rear portion of the tractor frame Torque Bracket Extension Springs See Figure 41 Figure 41 20 8 Using a spring puller or recoil rope disconnect the spring that is attached to the small hook found on the left rear portion of the transmission Note the location of the hook during disassem bly 20 9 Using an impact gun with a 7 8 inch socket remove the flange nut securing th
19. unt the number of threads showing behind the jam nut in order to maintain the correct steering alignment See Figure 15 ED 6 gra e Ball Joint Drag Link N Steering Arm T ES Steering Arm Jam Nut Y _ 3 Figure 15 11 1 Using a 11 16 inch combination wrench loosen the drag link jam nut but do not back it away from the ball joint _ 1 2 Use a 1 2 inch open end wrench to hold the ball joint while using a 9 16 inch open end wrench to loosen the steering arm jam nut securing the ball joint to the steering arm 11 3 Remove the ball joint from the steering drag link 11 4 Replace the ball joint in the reverse order 12 CUTTING DECK REMOVAL 12 1 Place the deck engagement lever in the engaged position lowest cutting position 12 2 Using a spring puller or recoil rope disconnect the spring that is attached to the small hook found on the left rear portion of the transmission Note the location of the hook where it attaches to the transmission before removal See Figure 16 Deck Tension Spring gf Q gt AN Sr AMA N gt o i hr _ Recoil Rope 4 Figure 16 12 3 Using a 1 4 inch wrench remove the two belt keepers on each side of the engine pulley See Figure 17 a _r Deck Belt x a ee E Belt Keepers ar Fi vd y n f 1 A Figure 17 12 4 Remove the deck belt from the engine pulley 12 5 Remove the hairpin clip securing the deck
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