Troy-Bilt 675B User Manual

Operator’s Manual

Rear-tine Tiller Model

Model 675B Shown (bumper syles vary)

675B—Pony

IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY

WARNING: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-covered, brush-covered or

grass-covered land unless the engine’s exhaust system is equipped with a spark arrester meeting applicable local or state laws (if any). If a spark arrester is used, it should be maintained in effective working order by the operator. In the State of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. A spark arrester for the muffler is available through your nearest engine authorized service dealer or contact the service department, P.O. Box 361131 Cleveland, Ohio 44136-0019.

TROY-BILT LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019

PRINTED IN U.S.A.

FORM NO.

769-00586A 9/22/03

TABLE OF CONTENTS

Content Page

Customer Support 2 Safety 3 Assembly 6 Features and Controls 9 Operation 11

Content Page

Maintenance 16 Off-season Storage 18 Troubleshooting 23 Parts List 24 Warranty Information Back Cover

FINDING MODEL NUMBER

This Operator’s Manual is an important part of your new rear-tine tiller. It will help you assemble, prepare and maintain the unit for best performance. Please r ead and understand wh at it says.

Before you start assembling your new equipment, please locate the model plate on th e equipment and copy the information from it in the space provided below. A sample model plate is also given below. You can locate the model plate by standing behind the unit and looking down at re ar surface of the tine shield. This information will be necessary to use the manufacturer’s web site and/or help from the Customer Support Department or an authorized service dealer.

Copy the model number here:

www.troybilt.com

TROY-BILT LLC P. O. BOX

361131 CLEVELAND, OH 44136 330-558-7220 1-800-520-5520

Copy the serial number here:

CUSTOMER SUPPORT

Please do NOT return the unit to the retailer from where it was purchased, without first contacting Customer Support.

If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenance of this unit, you can seek help from the experts. Choose from the op tions below:

Visit troy-bilt.com for many useful suggestions. Click on Customer Support button and you will get the four options reproduced here. Click on the appropriate button and help is immediately available.

The answer you are looking for could be just a mouse click away!

If you prefer to reach a Customer Support Representative, please call 1( 800) 520-5520.

The answer you are looking for could be just a mouse click away!

Engine Manual

The engine manufa cturer is responsible for all engin e-related issues with rega rds to performance, power-rating, specifications, warranty and service. Please refer to t he engine manufacturer’s Owner’s/Operator’s Ma nual, packed separately wi th your unit, for more information.

Training

1. Carefully read this Owner’s Manual, the separate

Engine Owner’s Manual, and any other literature you may receive. Be thoroughly familiar with the controls and the proper use of the tiller and its engine. Know how to stop the unit and disengage the controls quickly.

2. Never allow children to operate the tiller. Never allow adults to operate the tiller without proper instruction.

3. Keep the area of operation clear of all persons, particularly children and pets.

4. Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people, their property, and themselves.

Preparation

1. Thoroughly inspect the area where the tiller is to be used and remove all foreign objects.

2. Be sure all control levers are released and the Wheel Gear Lever is in ENGAGE position before starting the engine.

3. Do not operate the tiller without wearing adequate outer garments. Avoid loose garments or jewelry that could get caught in moving parts.

4. Do not operate the tiller when barefoot or wearing sandals, sneakers, or light footwear. Wear protective footwear that will improve footing on slippery surfaces.

5. Do not till near underground electric cables, telephone lines, pipes or hoses. If in doubt, contact your telephone or utility company.

6. Warning: Handle fuel with care; it is highly flammable and its vapors are explosive. Take the following precautions:

a. Store fuel in containers specifically

designed for this pure Wuaeratgasp sha[(Do-6.1b)5.6mwildspecifically d aeore sing thith carruner with-

5. If the unit should start to vibrate abnormally, stop the engine, disconnect the spark plug wire and prevent it from touching the spark plug, and check immediately for the cause. Vibration is generally a warning of trouble.

6. Stop the engine, disconnect the spark plug wire and prevent it from touching the spark plug whenever you leave the operating position, before unclogging the tines, or when making any repairs, adjustments or inspections.

7. Take all possible precautions when leaving the machine unattended. Stop the engine. Disconnect spark plug wire and move it away from the spark plug. Move Wheel Gear Lever to ENGAGE.

8. Before cleaning, repairing, or inspecting, stop the engine and make certain all moving parts have stopped. Disconnect the spark plug wire and prevent it from touching the spark plug to prevent accidental starting.

9. Always keep the tiller tine hood flap down.

10. Never use the tiller unless proper guards, plates, or other safety protective devices are in place.

11. Do not run engine in an enclosed area. Engine exhaust contains carbon monoxide gas, a deadly poison that is odorless, colorless, and tasteless.

12. Keep children and pets away.

13. Never operate the tiller under engine power if the Wheel Gear Lever is in DISENGAGE (FREEWHEEL). In this position, the wheels will not hold the tiller back and the revolving tines could propel the tiller rapidly backward, possibly causing loss of control. Always move the Wheel

Gear Lever to ENGAGE before starting the engine or engaging the tines⁄wheels with the Forward Clutch or the Reverse Clutch.

14. Be aware that the tiller may unexpectedly bounce upward or jump backward if the tines should strike extremely hard packed soil, frozen ground, or buried obstacles like large stones, roots, or stumps. If in doubt about the tilling conditions, always use the following operating precautions to assist you in maintaining control of the tiller:

a. Walk behind and to one side of the

tiller, using one hand on the handlebars. Relax your arm, but use a

secure hand grip. b. Use slower engine speeds. c. Clear the tilling area of all large

stones, roots and other debris. d. Avoid using downward pressure on

handlebars. If need be, use slight

upward pressure to keep the tines

from digging too deeply. e. Before contacting hard packed soil

at the end of a row, reduce engine

speed and lift handlebars to raise

tines out of the soil.

f. In an emergency, stop tines and

wheels by releasing whichever

Clutch Lever is engaged. Do not at-

tempt to restrain the tiller.

15. Do not overload the tiller’s capacity by

attempting to till too deeply at too fast a rate.

16. Never operate the tiller at high transport speeds on slippery surfaces. Look behind and use care when backing up.

17. Do not operate the tiller on a slope that is too steep for safety. When on slopes, slow down and make sure you have good footing. Never permit the tiller to freewheel down slopes.

18. Never allow bystanders near the unit.

19. Only use attachments and accessories

that are approved by Garden Way Inc.

20. Use tiller attachments and accessories when recommended.

21. Never operate the tiller without good visibility or light.

22. Never operate the tiller if you are tired, or under the influence of alcohol, drugs or medication.

23. Operators shall not tamper with the enginegovernor settings on the machine; the governor controls the maximum safe operating speed to protect the engine and all moving parts from damage caused by overspeed. Authorized service shall be sought if a problem exists.

24. Do not touch engine parts which may be hot from operation. Let parts cool down

25. Please remember: You can always stop the tines and wheels by releasing the Forward Clutch Lever or the Reverse Clutch Control (whichever lever you have engaged) or by moving the Throttle Control Lever to STOP.

26. To load or unload the tiller, see the instructions in Section 4 of this Manual.

27. Use extreme caution when reversing or pulling the machine towards you.

28. Start the engine carefully according to instructions and with feet well away from the tines.

29. Never pick up or carry a machine while the engine is running.

Maintenance and Storage

1. Keep the tiller, attachments and accessories in safe working condition.

2. Check all nuts, bolts, and screws at frequent intervals for proper tightness to be sure the equipment is in safe working condition.

3. Never store the tiller with fuel in the fuel tank inside a building where ignition sources are present such as hot water and space heaters, furnaces, clothes dryers, stoves, electric motors, etc.). Allow engine to cool before storing in any enclosure.

4. To reduce the chances of a fire hazard, keep the engine free of grass, leaves, or excessive grease.

5. Store gasoline in a cool, well-ventilated area, safely away from any spark- or flameproducing equipment. Store gasoline in an approved container, safely away from the reach of children.

6. Refer to the storage instructions in the Maintenance section of this Manual and the separate Engine Owner’s Manual for instructions if the tiller is to be stored for an extended period.

7. Never perform maintenance while the engine is running or the spark plug wire is connected, except when specifically instructed to do so.

8. If the fuel tank has to be drained, do this outdoors.

Safety Decals

For your safety and the safety of others, various safety and operational decals are located on your unit (see Figure 1-2 below).

Keep the decals clean and legible at all times. Contact your local service dealer or the factory for replacements if any decals are damaged or missing.

Refer to the Parts List in this manual for decal locations, part numbers and ordering instructions.

Control Description

(on Control Panel)

Tine Warning

Starting Stabilization

Message (on engine)

Warning Messages

(on tine hood)

Hot Surfaces⁄Moving Belts

Warning (on belt cover)

Figure 1-2: Location of Safety and Operating Decals

Operating Symbols

Various symbols (shown here, with word descriptions) may be used on the tiller and engine. NOTE: Your unit may not have all of the symbols.

FAST SLOW STOP TILLER DIRECTION LEVER DIRECTION

CHOKE

OFF

REVERSE

WARNING

TO AVOID SERIOUS INJURY:

• READ THE OPERATOR’S MANUAL.

• KNOW LOCATIONS AND FUNCTIONS OF ALL CONTROLS.

• KEEP ALL SAFETY DEVICES AND SHIELDS IN PLACE AND WORKING.

• NEVER ALLOW CHILDREN OR UNINSTRUCTED ADULTS TO OPERATE TILLER.

• SHUT OFF ENGINE AND DISCONNECT SPARK PLUG WIRE BEFORE MANUALLY UNCLOGGING TINES OR MAKING REPAIRS.

• KEEP BYSTANDERS AWAY FROM MACHINE.

• KEEP AWAY FROM ROTATING PARTS.

• USE EXTREME CAUTION WHEN REVERSING OR PULLING THE MACHINE TOWARDS YOU.

ROTATING TINES

SECTION 2: ASSEMBLY

WARNING: To prevent

personal injury or property damage, do not start the engine until all assembly steps are complete and you have read and understand the safety and operating instructions in this Manual.

Introduction

Carefully follow these assembly steps to correctly prepare your tiller for use. It is recommended that you read this Section in its entirety before beginning assembly.

Inspect unit

Inspect the unit and carton for damage immediately after delivery. Contact the carrier (trucking company) if you find or suspect damage. Inform them of the damage and request instructions for filing a claim. To protect your rights, put your claim in writing and mail a copy to the carrier within 15 days after the unit has been delivered. Contact us at the factory if you need assistance in this matter.

Unpacking and Assembly Instrutions

STEP1: UNPACKING INSTRUCTIONS

1. Remove any card-board inserts and

packaging material from the carton. Remove any staples from the bottom of the carton and remove the carton.

2. Cut the large, plastic tie strap that secures the transmission tube to the shipping pallet. Leave the handlebars on top of the tiller to avoid damaging any cables.

3. A bag with loose hardware is inside the literature envelope. Check the contents against the following list and Figure 2-1. Contact your local dealer or the factory if any items are missing or damaged.

NOTE: For electric start units, a second hardware bag is located near the battery.

4. The tiller is heavy. You should not attempt to remove it from the shipping platform until instructed to do so in these “Assembly” steps.

Hardware Bag Parts List

Ref. Qty. Description

1 2 3/8-16 x 1" Hex Hd. Screw 2 1 Keyed Washer 3 1 Wheel Gear Lever Knob 4 1 Height Adjustment Flange

(See Figure 2-2)

5 2 3/8" Flat Washer 6 2 #10 Lockwasher 7 23⁄8"-16 Nylock Lock Nut 8 2 #10-32 x 1/2" Rnd Hd Screw 9 2 #10-32 Nut 10 1 Cotter Pin (not used) 11 4 Plastic Tie Strap (2 not used)

Tools / Materials Needed

for Assembly

(1) 3/8" open-end wrench* (2) 9/16" open-end wrench* (1) 7/8" open-end wrench" (1) Scissors (to trim plastic ties) (1) Ruler (1) Small board (to tap plastic knob on

lever) (1) Tire pressure gauge (1) Clean oil funnel (1) Clean, high-quality motor oil. Refer to

the separate Engine Owner’s Manual

for motor oil specifications and quan-

tity required.

* Adjustable wrenches may be used.

IMPORTANT:

the engine crankcase before the engine is started. Follow the instructions in this “Assembly” Section and in the separate Engine Owner’s Manual.

NOTE: LEFT and RIGHT sides of the tiller are as viewed from the operator’s position behind the handlebars.

STEP 2: ATTACH HANDLEBARS

1. Cut the large, plastic cable ties that se-

cure the handlebar ends to the handlebar mounting tabs on the transmission top cover.

2. Gently lift handlebar (do not overstretch attached cable) and place handlebar crossbrace (B, Figure 2-3) in front of curved height adjustment bracket (C).

Motor oil must be added to

Figure 2-1: Loose hardware (shown in reduced size).

Figure 2-2: Handlebar height adjustment uses the flange head screw.

Flange

Figure 2-3: Forward clutch control cable not shown for clarity.

3. With the forward clutch cable (N, Figure 2-4) on the inside of handlebar, posi-

tion the handlebar ends on the outside of the two mounting tabs (M, Figure 2-3) on the transmission top cover.

NOTE: The curved handlebar height adjustment bracket appears as shown in C, Figure 2-3 for non-electric start units. For electric start units, the bracket is loosened and moved to one side.

4. Loosely attach the handlebars to the mounting tabs with two 3/8-16 x 1" screws (heads of screws go to inside of tabs), 3/8" flat washers and 3/8"-16 lock nuts (O, Figure 2-4).

Figure 2-4: Attach handlebars.

5. Move the handlebars up or down to align the threaded hole in the cross-brace with one of the four slots in the curved height adjustment bracket. Place the keyed washer (E, Figure 2-3) on the flange head height adjustment screw (F) with the raised keys (edges) of the washer facing down.

6. Thread the height adjustment screw (F, Figure 2-3) into the hole in the handlebar cross-brace, making sure that the raised keys on the washer fit into the slot on the height adjustment bracket. Tighten the height adjustment screw securely. Next, securely tighten the two screws and nuts in the ends of the handlebar (M, Figure 2-

3).

7. To remove the tiller from its shipping platform, first carefully unwrap the wheel gear cable (with attached lever - see Figure 2-5) from around the chassis. Move the Wheel Gear Lever (G) to the DISENGAGE position--this allows the wheels to rotate freely. Use the handlebars to roll the tiller off the platform.

Figure 2-5: Carefully unwrap Wheel Gear Lever and move lever to DISENGAGE.

NOTE: The Wheel Gear Lever will be installed later in this procedure.

IMPORTANT:

Use the DISENGAGE position only when the engine is not running. Before starting the engine, the Wheel Gear Lever must be placed in the ENGAGE position (see Section 3 for details).

STEP 3: ATTACH REVERSE CLUTCH CONTROL CABLE

1. Carefully unwrap the reverse clutch

control cable (H, Figure 2-6) from its shipping position and route it up along the inside edge of the left side handlebar. A knob and large hex nut (I) is installed on the cable.

Left Side

Handlebar

Figure 2-6: Attach reverse clutch control assembly to slotted hole in handlebar panel.

Reverse Clutch

Control Knob

Slot in Control Panel

2. Insert the cable into the slot in the con-

trol panel and fit the threaded assembly into the hole in the slot (see Figure 2-6). Be sure that the flat side of the threaded assembly is aligned with the flat side of the hole. Slide the hex nut (I) up the cable and tighten it securely.

3. Test the function of the reverse clutch control cable by pulling the knob out and releasing it. The knob should return to its neutral position against the tapered bushing. If it doesn’t, contact your local dealer or the factory for technical.

STEP 4: ATTACH FORWARD CLUTCH CONTROL CABLE

1. Remove any fasteners (rubber bands,

tape, etc.) that may secure the Forward Clutch Control levers (J, Figure 2-7) to the handlebar.

Figure 2-7: Forward Clutch Control levers (J). Forward clutch control linkage (K).

2. The forward clutch control cable (with attached spring) is hanging loosely near the right-side wheel. Being careful not to kink or stretch the cable, insert the z-connector (L, Figure 2-8 – end of the spring) into the hole at the end of the forward clutch control linkage (K, Figure 2-7).

Figure 2-8

3. Attach the cable adjuster (A, Figure 2-9) to the bracket on the right-side handlebar. Use two 1⁄2" wrenches to loosen the two jam nuts (B) just enough to slide the cable adjuster onto the bracket. Then hand tighten the jam nuts.

Figure 2-9

CAUTION: Incorrect cable

adjustment could cause the wheels and tines to rotate unexpectedly. Follow adjustment procedures carefully. Failure to do so could result in personal injury or property damage.

4. Check for correct spring⁄cable tension as instructed in Section 5, Checking and Adjusting Forward Clutch Belt Tension.

5. When tension is correct, tighten the two jam nuts (B) securely.

STEP 5: CHECK TRANSMISSION GEAR OIL LEVEL

The transmission was filled with gear oil at the factory. However, be sure to check the oil level at this time to make certain it is correct.

IMPORTANT:

the gear oil level is low. Doing so will result in severe damage to the transmission components.

1. With the tiller on level ground, pull the Depth Regulator Lever (R, Figure 2-13) back and then slide it to the second notch from the top. NOTE: If the lever does not move, lift the tine hood flap and look for a plastic tie securing the lever in place. Cut and remove the tie.

2. Remove the oil level check plug (M, Figure 2-10) on the left-side of the transmission. (Due to dried paint on the plug threads, it may require some force to remove the plug the first time.) The gear oil level is correct if oil starts to flow out of the hole as the plug is removed. If so, securely reinstall the plug.

Figure 2-10: Gear oil level check plug.

3. If oil does not flow from the check hole, add oil as follows:

Do not operate the tiller if

Figure 2-11: Adding gear oil.

NOTE: Do not use automatic transmission fluid or motor oil in the transmission.

(a) Clean area around the fill hole (N, Figure 2-11) and unscrew gear oil fill plug.

(b) If adding only a few ounces of gear oil, use API rated GL-4 or GL-5 gear oil having a viscosity of SAE 140, SAE 85W-140 or SAE 80W-90. If refilling an empty transmission, use only GL-4 gear oil having a viscosity of SAE 85W-140 or SAE 140.

(d) Reinstall and tighten securely the gear oil fill plug (M, Figure 2-10).

STEP 6: ATTACH WHEEL GEAR LEVER

1. Insert the Wheel Gear Lever (P, Figure

2-12) up through the slot in the control panel that is labeled “WHEEL GEAR.”

2. Insert two #10-32 x 1⁄2" round head screws down through the “+” marks on the control panel decal and securely attach the wheel gear mounting bracket using two #10 lockwashers and #10-32 nuts.

3. Use a small board or rubber mallet to tap the Wheel Gear Lever knob securely onto the lever (R, Figure 2-13).

4. Secure the wheel gear cable and the reverse clutch control cable to the left-side handlebar with two plastic ties (S, Figure 2-13) located about two feet apart. Snip off any excess tie length with ors.

STEP 7: CHECK AIR

Use a tire pressure gauge to check the air pressure in both tires. Deflate or inflate both tires equally to between 15 PSI and 20 PSI. Be sure that both tires are inflated equally or the unit will pull to one side.

Figure 2-12: Attach Wheel Gear Lever.

Figure 2-13: Attach wheel gear cable and reverse clutch cable with cable ties (S).

STEP 8: CHECK HARDWARE

Inspect the hardware on the unit and tighten any loose screws, bolts and nuts.

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