SUTECH 33” MOWER SERVICE MANUAL
Contents
1. Frayed or broken belts usually caused by sharp edges on Pulleys misalignment of Pulleys harsh engagements by the operator excessive heat due to slippages impact loadings and sticks Structure and weld failures Look over the Mower for any indication of structural cracks or any weld failures May be caused by inadequate welds excessive vibration or operator abuse Pivot enlargement Shaft and Bearing failures Inspect Bearings T for noisy operation and rough turning by spinning the component looking at the Bearing surface for excessive wear look for Seal P failure in Bearings and lack of lubrication Improper cutting Look for dull Blades drive Belt problems loose or improperly adjusted Belts and Pulleys broken Springs incorrect front to back Blade plane setting front of Blades should be set lower that the back of the Blades Cutting in grass and weeds that is too tall or wet Mulching Operation will give the best results if the grass is dry and you are not cutting more than 1 1 Keeping the underside of the deck clean will improve air flow and mulching results Additional mulching performance can be achieved by replacing the standard blades with optional P N 2107 10 Mulching Blades available from your dealer BASIC SERVICE INSTRUCTION 1 Try to determine the cause of the problem under investigat2. complete disassembly of all parts If possible leave the Brake parts together on the Hanger raise and securely block up rear Mower frame so tires clear the work surface Remove the 4 Wheel Lug Nuts 123 Removing Snap Ring 107 allows Remove 4 Bolts 118 and pull During reassembly be sure any Place the Mower on a stand and and Tire and Rim Assembly 101 Remove bolt 21 and FW 100 Bolt may have Loctite tap the wheel Hub 102 and slide off remove Square Key 121 In some cases the Wheel Hub may be difficult to remove Remove Snap Ring 240 Axle Hangers 110 or 131 can now be removed will need to tap off the Shaft because the Bearings will be lightly pressed on the Axle Shaft 122 also remove Hanger 113 Be sure to identify orientation of all the Hangers for proper reinstallation Bearings 108 and Spacer 109 to be removed and replaced apart 119 amp 129 Differential Axle Covers to gain access for inspecting and replacing Bevel Gears 124 and 127 Bearings Axle Shafts and other internal parts foreign materials and broken parts are removed that all i i i parts are thoroughly cleaned greased where required and that 6 Bearings are pressed in squarely and properly aligned Fad Differential Housing cavity with a high quality Lithium base grease Reassemble all parts in reverse order tighten bolts to torque specifications contained on page 1 Replacing parts on the LH side is similar to th
3. ON Care must be taken in the reassembly of the Transmission to insure that all Gears mesh properly and that the Shafts turn freely without being noisy 1 If the Input Pinion 340 has been removed then it must be reinstalled first Press in place and install all components with a new Seal Washer 345 Refer to measuring procedure in paragraph 4 below for selecting the proper Seal thickness 2 Install the Gear set Washers and Bearings on the Output Shaft assembly place the Shift Fork 312 around the Shift Collar 331 and lower the assembly into the Bottom Case align the Shift Fork 312 in its bottom pivot hole Center the Bearings in the Housing Be sure that the Shift Rollers 314 stay in place on the Shift Fork 3 Install all the Gears on the Countershaft press the Bearings tight against the shoulders and set the assembly in place be sure to mesh the Spur Gearing Lightly tap the Gear and Bearing set to move it left or right to obtain free movement of the Tapered Ring Gear At least 0 015 rotational clearance MUST be present for proper Input Pinion and Tapered Gear mesh 4 Use a micrometer to measure the distance between the outside of the case and the Bearing face approximately 0 250 to 0 275 on both ends of the Countershaft the Output Shaft and the Input Shaft assemblies Record this data for each location 5 Hold the Shafts in place and rotate the Input Shaft to verify proper Gear mes
4. SUTECH 33 MOWER SERVICE MANUAL It is our objective to provide basic instructions for Service personnel to better diagnose and repair the 33 Mower and to ensure that the Mower is properly set up for mowing as delivered to the customer Part numbers referred to in the Service Manual are identified as those pictured in the Parts Book Many of the adjustments have been presented in the Owners Manual and the Service Personnel are directed to those sections CONTENTS PAL OPM AGT OM eias eaa aeai Dia aE te 1 Diagnostic Information 2 Service Instructions 3 Lubrication Requirements 4 Drive Assembly 5 SPUN Ss ice fe e ea Soi co bute tole 6 EV ANSMLSS LOM sses Sees eee a Gee 7 Transmission Reassembly 8 9 Special Equipment Required Small and large internal snap ring pliers SUTECH 33 MOWER SERVICE MANUAL DIAGNOSTIC INFORMATION We advise Service and Sales personnel to be looking for unusual operation when observing a Mower during operation either with the customer or trying to diagnose a problem with a Mower that has been returned by the customer for service Most importantly look beyond the obvious broken parts to investigate what caused the problem this will prevent future service calls Vibration could be caused by bent Mower Blades bent Spindle Shafts bent Engine Crankshaft broken Pulleys or loose parts
5. and safe operation Grease points should be lubricated every 25 30 hours and oil points every 35 40 hours or yearly under normal operating conditions Commercial use or extreme conditions will require shorter lubrication intervals Grease Any good quality Lithium based grease e Differential 2 grease fittings e Blades Spindles 3 grease fittings e Blade Break 1 grease fitting e Front wheels amp yokes 4 grease fittings Oil Any good quality SAE 30 oil e Belt Guide Rollers 2 under belt cover e Pivot Point on all operational controls breaks shift lever blade driver lever and presence controls e Transmission oil check level in sight glass add if required e Caster Yoke Height Adjustment Spacers Mower Storage For extended storage we recommend the use of a good quality fuel stabilizer to prevent starting problems DRIVE ASSEMBLY REPAIR Differential and Drive Assembly follow the instructions on page 6 of the Wheel Drive Belt items 1 8 Fig 9 amp and brake assemblies from both sides of the Mower identified in the Parts Book on pages 7 amp 8 DRIVE To access or remove the the Owners Manual for replacing 10 and remove the hangers Part numbers referred to are It is possible to replace many of the Differential Gearing Bearings and other drive parts without fully removing the apies drive If possible try to minimize
6. e Blade Spindle is not bent or damaged 7 Thoroughly clean and replace any damaged parts and reassemble Fill grease cavity with a high quality lithium base grease Reinstall all parts see Fig 5 for proper mounting order of the Blade and associated parts Follow instructions outlined in the Owners Manual for proper V Belt installation and Controls adjustments TRANSMISSION REPAIR The Transmission is serviceable and can be repaired by following proper procedures In some cases where inspections need to be performed to diagnose a problem they can be done without completely removing the Transmission from the Mower It is recommended to pressure wash the Transmission to remove accumulated dirt and oil Refer to pages 9 amp 10 of the Parts Book TRANSMISSION 1 For the Manual start Mowers remove the Transmission cover to gain access to the Transmission 2 For the Electric start Mowers disconnect the cables and remove the Battery and its Supports to gain access 3 Remove the two Wheel Drive Belts 202 from the Pulley 4 Remove the Oil Sight plug 348 and drain the oil use care not to damage the plug Remove the Shift Lever 301 amp 302 5 Remove the RH amp LH Bearing Covers 317 328 amp 339 USE a thin putty knife or thin Bladed screwdriver to loosen the cover and work the covers outward The Seal Rings 318 and 329 will probably be damaged upon disassembly and should not be reused Measure the thickness of
7. e RH side except Snap Ring 114 must be removed to replace the Differential Pulley 115 Use a brass bar to remove pressed on parts Hammering with steel will raise burrs and make reassembly difficult or impossible SPINDLE REPAIR The Belt Cover must be removed to access the Spindles Follow instructions on pages 4 amp 5 of the Owners Manual for loosening all Belts Spindle Housings and Spindles become damaged when the Mower Blades hit large objects Bearings fail due to lack of periodic greasing and from dirt entering the Bearing Following a good greasing schedule will tend to flush the Bearings of dirt and keep them clean Part numbers referred to are identified in the Parts Book on pages 5 amp 6 MOWER DECK 1 Remove Nut 15 and the Bolt 48 for the outer Spindles and Bolt 49 for the Center Spindle to remove the respective Mower Blade parts These three Bolts are Grade 8 CAUTION Always replace these Bolts with the Approved SUTECH replacement parts 2 For LH Spindle Service carefully disengage the Blade Brake Spring and move the Brake mechanism out of the way Remove the Blade Drive Pulley 17 3 Remove the 4 bolts nuts 21 amp 31 attaching the Spindle Housing to the Mower Deck Degrease and clean the debris from the Spindle Assembly 5 Remove Snap Ring 35 and Press Bearings 36 out top of Spindle Housing 40 peg 6 Remove Sq Keys 37 39 or 42 to press off Spindle Bearings 36 Check to see that th
8. hing Use a wrench to move the Shift Collar to verify that shifting is free as the Input Shaft is rotated 10 i et Install the Detent Spring 310 Install the Shift Lever and 9 Clean the mating faces of the Case halves and apply Loctite sealant No 587 to the Bottom Case Do not put any sealant on the Bearing bores in the Ball Socket 311 and place some grease on top of the Detent Spring 310 Put the Detent Ball 309 on the Spring in the grease and lower the Top Case 308 onto the Bottom Case Align the Shift Fork with its opening in the Top Case lower and align the Roll Pins carefully push the Case halves together without disturbing the Detent Ball while holding the halves together turn the Input Shaft and select each shift position Rotate the Input Shaft to recheck that 0 015 rotational clearance is present with the Tapered Ring Gear Install the 6 screws 304 amp 307 and tighten Do not over tighten two center Bolts that screw into the aluminum case doing so will strip the threads Select thickness of the Seal washer Using the depth measured in par 3 above subtract that value from 0 290 Example depth is 0 270 then washer thickness is 290 270 0 020 Do this for each end of both Shafts SUTECH offers three Seal Washers 006 012 and 020 thickness Install the 4 screws 316 for each Bearing Cover install the appropriate Seal and tighten Rotate the in
9. ion and develop a plan of action to repair the problem in the most efficient way and in the least amount of shop or field servic time 2 It is possible to replace many of the parts or repair the major assemblies without fully removing them from the Mower If possible try to minimize complete disassembly of all parts thus reducing the amount of repair time 3 When servicing the Mower always try to select a work area that is free of debris and that that any oil or grease has been removed from the floor 4 If possible place the Mower on a stand and raise and securely block the tires to prevent the Mower from falling or rolling off the work surface Try placing the Mower at a height that minimizes bending over wher repairs can be made in a more comfortable position 5 Use safety glasses when repairing the Mower and be careful as sharp edges may be present 6 Use the following guidelines for tightening bolts and screws Over tightening hardware may cause subsequent failure to a Mower component when the customer or another person is operating the Mower Bolt size Torque ft lbs 12 24 2 3 20 J LEt 5 16 18 15 22 3 8 16 30 40 7 16 20 50 60 LUBRICATION REQUIREMENTS All parts that require lubrication have been lubricated during assembly These parts will however require additional periodic lubrication for maximum mower life
10. put Shaft to be sure if rotates freely and that no binding exists Reinstall all parts removed during the service work in reverse order Operate the Mower to see that proper running is obtained
11. the Seal Rings used on all four Bearing Covers This will give a guide as to the correct seal thickness to select upon reassembly 6 Remove all six Bolts 304 amp 307 holding the Transmission covers together Be careful where and how you tap the cover to lift it up off the roll pins The Aluminum sealing and bearing surfaces are easily damaged The Detent Steel Ball 309 may fall into the Bottom Transmission Case use a magnet to retrieve the Ball Remove Pulley 204 on the Output Shaft 332 LH side of the Transmission 7 Most all of the internal components are serviceable at this point Further inspection will determine what parts need replacing Thoroughly inspect all Bearings for rough running and damaged sides Inspect all Gearing for damaged faces especially if some teeth have broken Replace all damaged parts 8 8 If the Input Pinion Shaft Gear 340 is damaged then it must be removed out the bottom of the Case Access can be gained by removing the Transmission Drive Belt 207 and Transmission Input pulley 209 Refer to the Owners Manual Fig 8 page 6 Remove the 4 Phillips head Screws 316 and Bearing Cover 346 as outlined above From inside the Bottom Case tap the Input Pinion Shaft 340 Bearing and Seal set out 9 Clean all parts and remove any foreign material from the bottom Case Clean the mating faces of the Case halves Sutech will have applied a liquid sealing compound REASSEMBLY OF THE TRANSMISSI
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