First off, I apologize for the long post. I know this thread is old, but I have to chime in hear. Last year I experienced this problem twice throughout the summer. I chaulked it up to the lawn being too think and probably a little wetter than I normally like to cut...but sometimes you have no control over the weather.
Anyway, the other night I cut my 30,000 sf lawn. Height of the mower was at 3", and the lawn was at a sporadic 4"-4 1/4". Lawn was not wet, but a little moist in spots, as moist turf is in New England this time of year. After only 2 passes, I new that I had already snapped my shear pin on the "PTO" gear box side of the transfer shaft. So, having a number of spares, pulled into the garage, replaced, and 15 minutes later, back to mowing. About 20 minutes later...same thing, except it was the shear bolt I had just replaced. Back to the garage, repair, back to mowing....about 20 minutes later...guess what??? Replaced with my last remaining spare, but noticed the "PTO" side gear box was really hot, while the "fan" side gear box was only slightly warm.
I managed to finish mowing my lawn, but decided to perfrom an oil changed on both gearboxes. On the "PTO" gear box, oil level was at about 3/4 and was very black and somewhat thin. On the "Fan" gearbox, oil was full and still had quite a bit of color to it. Not sure why this was such, as I had not yet performed an oil service on either gearbox, so this is how it came from the "factory". Topped off both gearboxes with fresh SAE 90 (that exceeds GL 5) and ran the grass catcher at full throttle for nearly 20 minutes (while tractor was parked). I know I didn't have much of a load on the grass catcher, but neither gear box got beyond slightly warm.
I am thinking that the deficient gear oil cause the gear box to heat up substantially, causeing the shear bolt to heat up and weaken. I guess I will find out the next time I mow the lawn. Has anyone else experience anything like this?
Also, I disagree with mowing at 1/2 throttle...manual says to mow at full throttle in low range (for BX series). I would think there would be less of a "load" on the bagger drive chain at full throttle...just my 2 cents.