Troy-Bilt E686N User Manual

Operator’s Manual

Rear-tine PTO Tiller Models

682J—Horse

E686N—Horse

E682L—Horse

Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-covered, brushcovered 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 by contacting the service department at Troy-Bilt LLC, P.O. Box 361131 Cleveland, Ohio 44136-0019.

IMPORTANT:READ SAFETY RULES AND INSTRUCTIONS CAREFULLY

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

PRINTED IN USA FORM NO. 770-10598C

(9/2003)

Model 682J Shown

TABLE OF CONTENTS

Content Page

Customer Support 2 Safety 3 Assembly 6 Features and Controls 11 Operation 14

Content Page

Maintenance 28 Troubleshooting 41 Attachments & Accessories 43

Parts List 44 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:

Copy the serial number here:

www.troybilt.com

TROY-BILT LLC P. O. BOX CLEVELAND, OH 44136

330-558-7220 1-800-520-5520

361131

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.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

WARNING

This machine meets voluntary safety standard B71.8 – 1996, which is sponsored by the Outdoor Power Equipment Institute, Inc., and is published by the American National Standards Institute.

Safety Alert Symbol

This is a safety alert symbol. It is used in this manual and on the unit to alert you to potential hazards. When you see this symbol,

read and obey the message that follows it. Failure to obey safety messages could result in personal injury or property damage.

Section

Safety

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. Put the Wheels/Tines/PTO Drive Lever into NEUTRAL 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. Be sure to take the following precautions:

a. Store fuel in containers specifically

designed for this purpose.

b. The gas cap shall never be removed

or fuel added while the engine is running. Allow the engine to cool for several minutes before adding fuel.

c. Keep matches, cigarettes, cigars,

pipes, open flames, and sparks away from the fuel tank and fuel container.

d. Fill fuel tank outdoors with extreme

care. Never fill fuel tank indoors. Use a funnel or spout to prevent spillage.

e. Replace all fuel tank and container

caps securely.

f. If fuel is spilled, do not attempt to

start the engine, but move the machine away from the area of spillage and avoid creating any source of ignition until fuel vapors have dissipated.

7. Never make adjustments when engine is running (unless recommended by manufacturer).

Operation

1. Do not put hands or feet near or under rotating parts. Do not allow hands or any other part of the body or clothing near the rotating tines or near any other moving part. The tines begin to rotate forward

once the engine starts, the Tines/PTO Clutch Lever is in the ENGAGE position, the Forward Interlock Levers are squeezed closed and the Wheels/Tines/PTO Drive Lever is shifted to FORWARD. The tines rotate in Reverse whether the Interlock Levers are closed or open.

2. Exercise extreme caution when on or crossing gravel drives, walks, or roads. Stay alert for hidden hazards or traffic. Do not carry passengers.

3. After striking a foreign object, stop the engine, remove the wire from the spark plug wire and prevent it from touching the spark plug. Thoroughly inspect the machine for any damage and repair the damage before restarting and operating the machine.

4. Exercise caution to avoid slipping or falling.

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 machine unattended. Stop engine. Disconnect spark plug wire and move it away from spark plug. Remove ignition key on electric start models

Section 1: Safety

8. Before cleaning, repairing, or inspect-

ing, 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. The flap on the tine hood must be down when operating the tiller, unless using the Hiller/Furrower attachment.

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 Speed Lever is in the FREEWHEEL position. In FREEWHEEL, the wheels will not hold the tiller back and the revolving tines could propel the tiller rapidly, possibly causing loss of control. Always engage the Wheel Speed Lever in either FAST or SLOW position before starting the engine or engaging the tines with the Wheels/Tines/PTO Drive Lever.

14. Be aware that the tiller may unexpectedly bounce upward or jump forward 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 shallower depth regulator

settings, working gradually deeper with each pass.

c. Use slower wheel, tine and engine

speeds.

d. Clear the tilling area of all large

stones, roots and other debris.

e. Avoid using downward pressure on

handlebars. If need be, use slight upward pressure to keep the tines from digging too deeply.

f. Before contacting hard packed soil

at the end of a row, reduce engine speed and lift handlebars to raise tines out of the soil.

g. In an emergency, stop tines and

wheels by shifting the Wheels/Tines/PTO Drive Lever into NEUTRAL. If you can not reach the lever or have lost control of the tiller, let go of the handlebars and all controls. Do not attempt 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 hard or 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 the manufacturer of the tiller.

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 engine-governor 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 sufficiently.

25. POISON/DANGER—CAUSES SEVERE BURNS. The battery on electric

start models contains sulfuric acid. Avoid contact with skin, eyes or clothing. Keep out of reach of children.

Antidotes:

External– Flush immediately with lots of

water. Internal– Drink large quantities of water or milk. Follow with milk of magnesia, beaten eggs or vegetable oil. Call a doctor immediately. Eyes– Flush with water for 15 minutes. Get prompt medical attention.

26. DANGER– BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame

or smoking materials away. Ventilate when charging battery or using in an enclosed space. Always wear safety goggles when working near battery.

27. Please remember: You can always stop the tines and wheels by releasing all controls, or by moving the ignition switch and/or throttle control lever on the engine to OFF or STOP.

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

29. Use extreme caution when backing or pulling the machine towards you.

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

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

32. When loading or unloading the tiller, always disengage tines and use slower wheel and engine throttle speeds. Use sturdy ramps wide and strong enough to easily support the tiller (280-to-325 lbs., depending on model) and operator. Never go down ramps in FORWARD drive—the tiller could tip forward, exposing you to the tines (which should be disengaged). Always use REVERSE drive and back down ramps. To go up ramps, use FORWARD drive and follow the tiller.

33. The Forward Interlock Safety System should be tested for correct functioning every time the tiller or PTO power unit is used. See Section 4 in this Manual.

34. If using the optional Dozer Blade, either remove the tine attachment, or disengage the tines with the Tines/PTO Clutch Lever. Revolving tines are dangerous.

Section 1: Safety

Decals

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

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 for decal locations, descriptions and part numbers.

Figure 1: Location of Safety and Operating Decals.

(Briggs & Stratton engine shown)

Operating Symbols

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

FAST

SLOW

CHOKE

OFF

STOP

ROTATING

TINES

B) WARNING: Engine Ignition. Electric start models only.

C) WARNING: Operating and Safety Instructions

A) WARNING: Hot Surfaces. Top of the air cleaner housing.

D) Power Unit Operating Instructions

F) Engine Stabilization. Top of fuel tank.

E) Forward Interlock Lever (2)

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 flame-producing equipment. Store gasoline in an approved container, safely away from the reach of children.

6. Refer to the Maintenance sections 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.

TO AVOID SERIOUS INJURY:

• READ THE OWNER’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.

WARNING

STOP

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.

NOTE: Three different Horse model tillers are covered in this Manual. Use only the information applicable to your model. Tiller engines vary by model. Your engine may appear differently than those found in illustrations of this manual.

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.

STEP 1: Unpacking Instructions

NOTE: Do not severely bend any of the control cables on the unit.

1. The tiller is heavy. Do not attempt to remove it from the shipping platform until instructed to do so in these Assembly steps.

2. Remove all unassembled parts from the carton. The hardware bag is included in your literature packaging.

3. Check that you have the items listed below (contact your local dealer or the

Factory if any items are missing or damaged).

NOTE: Use the screw length template (Figure 2-1) to identify screws.

Loose Parts List

Qty. Description

1 Handlebar Assembly 1 Wheels/Tines PTO Drive Lever

The following items

are in the hardware bag:

2 20 oz. Bottles SAE 30W Oil 1 Clutch Pawl Spring 1 Belt Adjusting Tool 2 Plastic Cable Ties 1 Curved Head Screw, 1/4-20 x 2 1 Flanged Lock Nut, 1/4-20 1 Pan Head Screw, #10-32 x 1/2

The following parts (electric start models only), packaged separately.

2 Nuts, 1/4-20

(for battery terminals)

2 Screws, 1/4-20 x 5/8

(for battery terminals)

2 Keys

(in ignition switch)

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

Tools/Materials Needed for Assembly

(1) 3/8" open-end wrench* (2) 7/16" open-end wrench* (2) 1/2" open-end wrench* (1) 9/16" open-end wrench* (1) 3/4" open-end wrench* (1) Flat blade screwdriver (1) Scissors (to trim plastic ties) (1) Tire pressure gauge (1) 4-1/2" high wood block to prop unit *

Adjustable wrenches may be used.

STEP 2: Attach Handlebar

IMPORTANT: When disassembling handlebar assembly, keep left-side clamp and ratchet separated from the right-side clamp and ratchet.

1. Disassemble the handlebar assembly. To do this, remove the height adjustment lever by turning the lever in a counterclockwise direction (Figure 2-2).

2. Place the handlebar ends on either side of the base, with the wire harness toward the rear of the base (Figure 2-2).

3. Install the height adjustment lever through the right-side clamp, handlebar end, ratchet, and base; then out through the left-side ratchet, handlebar end, and clamp (Figure 2-2). Secure with nut, but don't fully tighten.

IMPORTANT: Do not force the height adjustment lever through the handlebars. The interlock wires may be blocking the

Section

Assembly

Figure 2-1: To identify length of screw, place screw on template as shown and measure distance between bottom of screw head and tip of screw.

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.

WARNING

Section 2: Assembly

lever and could be damaged. You may gently move the wires aside if this condition occurs.

4. Raise handlebars to one of two height settings and tighten the height adjustment lever. Also, make sure all other mounting hardware is securely tightened.

NOTE: Fully assembled handlebar assembly should appear as shown in Figure 2-3.

STEP 3: Move Tiller Off Shipping Platform

1. Set the Depth Regulator Lever (A, Figure 2-4) to Travel position. Do this by lifting the tiller by the handlebars, then pulling straight back on the lever and sliding down to the highest notched setting.

2. Set the Wheel Speed Lever (B, Figure 2-4) to Freewheel position. To do this, move the lever approximately halfway between the Fast and Slow settings while you rock the tiller forward and backward until the wheels move freely.

3. Lift Handlebars high enough to clear tiller tines and pull back firmly to dislodge the tiller from the platform wheel wells.

STEP 4: Connect Forward Interlock Wire Harness

1. Remove any dirt from the Forward Interlock wire harness plug (C, Figure 2-5) and its receptacle (D).

2. Connect the Forward Interlock wire harness plug (C, Figure 2-5) to the receptacle (D).

STEP 5: Attach Wheels/Tines/PTO Drive Lever

1. Loosen the bolt (Figure 2-2) on the

handlebar base and swing the handlebars out to the right side.

2. Remove both sets of nuts, star washers, screws, and one bushing (A, B, C, D, E, F, G, Figure 2-6) from the yoke plates (H). There is a bushing inside the short link (I). Be careful not to lose it when removing screw (G).

3. Slide the plates at the end of the Wheels/Tines/PTO Lever over the yoke plates (Figure 2-9). To aid in the next step, insert a screw temporarily into the forward most holes (J, Figure 2-7) of the

yoke plates and the lever.

4. Align the rear most holes of the yoke plates and the Wheels/Tines/PTO Lever. Use long nose pliers to hold the bushing (L, Figure 27) in place while inserting the screw (K) through the lever and yoke plates. Install star washer (B, Figure 2-6) and nut (A), then hand tighten.

5. Retrieve the clutch pawl spring (Figure 2-8) from hardware bag.

Figure 2-2. Handlebar assembly.

Left Ratchet

Right Ratchet

Handlebars

Right Clamp

Left Clamp

Height Adjustment Lever

Wire Harness

Base Bolt

Base

FRONT OF TILLER

Nut

Figure 2-3. Fully assembled handlebars.

Left-Side Clamp and Nut

Figure 2-4: Photo shows the Depth Regulator Lever (A) and the Wheel Speed Lever (B).

Figure 2-5. Forward Interlock Wire Harness connection.

Figure 2-6: Illustration shows the yoke plates (H), nuts, washers, and screws (A, E, B, F, D, G), bushing (C), and long and short links (I, J).

Figure 2-7: Drive Lever assembly.

Figure 2-11: Neutral position; roller (T) rests against middle area of the adjustment block (U).

Figure 2-10 Forward position; roller (T) rests under the adjustment block (U).

T U

Figure 2-8: Clutch pawl spring. Tilt Wheels\Tines\PTO Lever fully forward before installing spring.

Section 2: Assembly

Figure 2-9: Fully assembled Wheels/Tines/PTO Lever assembly.

STEP 6: Check Gear Oil Levels

Your tiller has two separate transmissions: one for the Power Unit (Figure 2-

12), the other for the Tine Attachment (Figure 2-13). Both transmissions were filled at the factory with SAE #85W–140 weight gear oil (with an A.P.I rating of GL-4). Check level in both transmissions to verify that they are still correct. See Section 5,

Transmission Gear Oil

Maintenance for complete information

on how to check and fill the transmissions.

Remove the temporary screw (J, Figure 2-7) from the forward holes and move the Wheels/Tines/PTO Lever fully forward. Install the wider hook end of the clutch pawl spring (M, Figure 2-8) down into the small hole at the end of the handle. Use pliers to insert the other end into the hole in the long link bar (N).

NOTE: Do not bend or over stretch the spring while installing.

6. Pull the Wheels/Tines/PTO Lever back to align the forward most holes (Q, Figure 2-9) in the yoke plate with the holes in the lever plates. Also align the bushing that is inside the short link bar (P). Install the screw, star washer, and nut, then tighten securely.

Securely tighten all other hardware (Q, R, Figure 2-9). Also ensure that the spring (S) is properly seated at both ends.

Completed assembly should appear as illustrated in Figure 2-9.

7. Test the operation of the Wheels/Tines/PTO Lever. Push the lever down until it engages in the Forward position. The clutch roller (T, Figure 2-

10) must rest beneath the adjustment block (U). Next, move the lever up to the Neutral position. The clutch roller (T, Figure 2-11) should rest on the face of the adjustment block (U). To test Reverse, lift and hold the lever all the way up in Reverse position, then let it go. The lever should automatically return to the Neutral position (Figure 2-11). If not, do not use the tiller. See your local authorized dealer or call the Factory Technical Service Department for instructions.

Section 2: Assembly

IMPORTANT: Check gear oil level in both transmissions after the first 2 hours of new tiller operation, then every 30 operating hours thereafter. See Section 5 for instructions.

STEP 7: Add Motor Oil to Engine

1. Before adding motor oil, park the tiller on level ground. Level the engine by placing a sturdy block under the tines or the tines depth regulator bar.

2. Refer to the Engine Owner’s Manual provided with your tiller for detailed information on how to add motor oil and for motor oil specifications.

IMPORTANT: Two 20 oz. bottles of motor oil are included with your tiller. Check the oil level as instructed in the Engine Owner’s Manual provided with your tiller BEFORE pouring the full amount of each bottle into the engine.

IMPORTANT:

• Change engine oil after first 2 hours of new operation.

• Check engine oil level every 5 hours of operation or each use.

STEP 8: Attach Engine Throttle Lever and Cable

For shipping purposes, the throttle cable, together with the throttle lever, is wound around the engine. Carefully unwind the cable. If the throttle control label is covered with a clear protective coating, peel it off.

To attach the throttle lever and cable:

1. Run the throttle cable up the inside edge of the right handlebar and position the lever as shown in Figure 2-14.

2. From the outside of the handlebar, insert the curved head screw (A, Figure 2-

14), through the handlebar and the center hole in the throttle lever mounting bracket.

3. Loosely install the flanged lock nut and move the throttle lever back to the STOP position.

4. From the lever side of the bracket, thread a pan head screw (B, Figure 2-14) through the small hole in the throttle lever bracket and into the handlebar. Tighten the screw securely.

5. Securely tighten both the flanged lock nut and the curved head screw.

6. Use two plastic ties to secure the throttle cable to the right handlebar in two places (Figure 2-15). Loop each tie around the handlebar and cable (serrated side faces in) and pull the ties tight. Trim the ends.

Figure 2-12: Checking oil level on Power Unit Transmission.

Figure 2-13: Checking oil level on Tine Attachment Transmission.

To avoid electric shock from a short circuit (electric start tillers only), never allow the throttle cable to touch the battery. Route cable below the battery, on the outside of the battery holder.

Figure 2-14: Engine Throttle Lever position and installation.

Figure 2-15: Plastic Ties placement on handlebars.

Oil Level Hole

Tie

Assembly is complete for recoil start tillers. See Assembling The Electric Start System if you own an electric start tiller; otherwise, refer to Section 3,

Controls for information on tiller

controls.

STEP 9: Adjust Air Pressure in Tires

For shipping purposes, the tires may be overinflated. Check the air pressure in each tire and adjust them to between 10 and 20 pounds per square inch. You must inflate each tire to equal air pressures to prevent the tiller from pulling to one side.

WARNING

Section 2: Assembly

NOTE: If the battery is put into service after the date shown on the top of the battery, charge for a minimum of one hour at 6-10 amps. Refer to the Maintenence section of this manual for more detailed instructions regarding proper battery charging procedure

STEP 1: Connect the Wire Harness Receptacle

1. Before installing the battery and its hold-down clamp, insert the plastic wire harness receptacle (A, Figure 2-18) into the prongs of the keyswitch (M) located on the hold-down clamp.

2. Remove the ignition keys from the keyswitch and store them safely away. Do not insert the key into the keyswitch until you complete this section and read Section 3,

Controls.

STEP 2: Install the Battery Cables

NOTE: The cable terminals should be toward the rear (keyswitch side) of the battery posts.

1. Use a 5/8" long screw (K, Figure 2-18) and 1/4-20 hex nut (L) to connect the positive (+) battery cable (B) to the positive (marked +) battery post (C). Make sure that this is the cable on the left side, with one end attached to the solenoid (D).

2. Slide the black rubber boot (E) completely over the battery post and cable connector.

3. Use a 5/8" long screw and 1/4-20 hex nut to connect the negative (-) battery cable (F) to the negative (marked -) battery post (G) and secure with screw (H) and nut (I).

4. Slide the black rubber boot (J) completely over the battery post and cable connector.

Assembly is complete for electric start tillers. See Section 3,

Controls for

information on tiller controls.

ASSEMBLING THE ELECTRIC START SYSTEM

The following steps explain how to install and charge the battery on electric start tillers. For your safety, follow all steps and observe all accompanying safety messages. Section 5 contains other general battery maintenance and recharging instructions.

Battery produces explosive gases.

• Keep away sparks, flames, and cigarettes.

• Ventilate area when charging or using battery in an enclosed space.

• Make sure battery vent tube is always open after battery is filled with acid.

Remove metal jewelry before working near the battery or near the electrical system. Failure to comply may cause a short circuit, resulting in electrical burns, a shock, or battery gas explosion.

To Avoid Personal Injury or Property Damage:

• Do not touch positive battery terminal and any surrounding metal objects with tools, jewelry or other metal items. Failure to comply could cause a short circuit leading to electrical burns or explosion of battery gases.

• Never bring a gas can near the positive (+) battery terminal. A short circuit could occur leading to an explosion of the gasoline or the battery gases. Always fill the engine fuel tank from the front or side of the engine.

Never jump start the battery with a vehicle battery or charging system. This may produce a battery explosion, causing acid or electrical burns.

Figure 2-18: Battery cable assembly.

C (+)

G (-)

DANGER

WARNING

DANGER

OIL

Section

Features and Controls

Introduction

This section describes the location and function of the controls and features on your tiller. Refer to Section 4,

Operation

for detailed operating instructions.

Practice using these controls, with the engine shut off, until you completely understand the operation of the controls and feel confident with each of them.

IMPORTANT: Refer to the separate engine manufacturer’s Engine Owner’s Manual for information about the controls on the engine.

NOTE: All references to left, right, front and rear of the machine are based on a position behind the handlebars and facing forward.

PTO Attachments Feature

In addition to powerful tilling capability, you can quickly convert your machine into a PTO (Power Take-Off) Power Unit that is capable of towing or powering various TROY-BILT attachments.

You can access this capability by removing the tines attachment (powered by the PTO Power Unit). The PTO Power Unit is then available for engine powered attachments, or for pulling or towing nonpowered attachments. See Section 4, PTO Power Unit for detailed information on installing and operating TROY-BILT PTO attachments.

Wheels/Tines/PTO Drive Lever

Use the Wheels/Tines/PTO Drive Lever (A, Figure 3-1) to engage and disengage power to the transmission.

This lever has three operating positions: FORWARD, NEUTRAL and REVERSE.

• FORWARD is engaged when the lever is

moved down until the clutch roller (G, Figure 3-2) engages into the detent position under the adjustment block (H, Figure 3-2). You will definitely feel the lever engage into this position.

Use the FORWARD setting to move the wheels and tines forward, or to apply power to an optional PTO (Power Take Off) attachment. (See also

Forward

Interlock Levers.)

To stop the wheels, tines or any PTO attachment, move the lever to NEUTRAL by tapping the lever upwards (Figure 3-3) and releasing.

• REVERSE is engaged when the lever is

pushed (with an open palm) all the way up and held in that position (Figure 3-4). Use this setting to move the wheels in reverse. To stop moving in reverse, release the lever; it automatically returns to the NEUTRAL position.

IMPORTANT: Do not operate the tines or any PTO attachment in REVERSE.

• NEUTRAL is this control’s normal non-

operating position. The lever returns to NEUTRAL when it is tapped out of the FORWARD position or released from the REVERSE position. NEUTRAL position is between FORWARD and REVERSE (Figure 3-3). Use this setting to stop the wheels, tines or any PTO attachment.

IMPORTANT: Always shift to NEUTRAL before starting the engine or before engaging the wheels, tines or any PTO attachment.

Forward Interlock Levers

The Forward Interlock Levers (B, Figure 3-1) are attached under each handlebar grip.

You must squeeze at least one of these interlock levers up against the handlebar grip whenever the Wheels/Tines/PTO Drive Lever is engaged in FORWARD position.

Figure 3-1: A– Wheels/Tines/PTO Drive Lever E– Depth Regulator Lever B– Forward Interlock Levers F– Handlebar Height Adjustment Lever C– Wheel Speed Lever G– Engine Throttle Lever D– Tines/PTO Clutch Lever

Before operating your machine, carefully read and understand all safety, controls, operating instructions in this Manual, the separate Engine Owner’s Manual and on the decals on the machine.

Failure to follow these instructions can result in serious personal injury.

WARNING

Section 3: Features and Controls

Figure 3-2: FORWARD position; roller (G) rests under the adjustment block (H).

Figure 3-3: NEUTRAL position; roller (G) rests against middle area of the adjustment block (H).

Figure 3-4: REVERSE position; roller (G) rests against upper area of the adjustment block (H).

Verify Position of Clutch Roller

When you shift between FORWARD, NEUTRAL and REVERSE, the clutch roller at the base of the Wheels/Tines/PTO Drive Lever should be positioned as shown in Figures 3-2, 3-3 and 3-4. Verify the position of the clutch roller as you shift the lever. If it is not positioned correctly, contact the Factory or see your local authorized dealer.

If both Forward Interlock Levers are released before first returning the Wheels/Tines/PTO Drive Lever to NEUTRAL, the engine will stop.

IMPORTANT: The Forward Interlock Levers are a safety control that stops the engine should you lose control while going forward and cannot shift into NEUTRAL.

Wheel Speed Lever

Use the Wheel Speed Lever (C, Fig. 3-1) to select one of three operating positions: SLOW, FAST or FREEWHEEL.

• SLOW – Lever moved all the way down.

Most effective for normal tilling or for low-speed transport.

• FAST – Lever moved all the way up.

Most effective for cultivating or for fastspeed transport.

• FREEWHEEL – Lever in between SLOW

and FAST (wheels will roll freely). Used when transporting the machine on level ground without engine power, and when using stationary PTO attachments.

IMPORTANT: To avoid transmission damage, always move Wheels/Tines/PTO Drive Lever into NEUTRAL before shifting the Wheel Speed Lever.

IMPORTANT: When shifting into SLOW or FAST, gently roll the machine forward or backward to help fully engage the wheel gears. When engaged, the wheels will not turn unless the engine is running and the Wheels/Tines/PTO Drive Lever is engaged in FORWARD or REVERSE.

Tines/PTO Clutch Lever

Use this lever (D, Figure 3-1) to engage or disengage power from the transmission PTO clutch to the tines or any PTO attachment. This control has two operating positions: ENGAGE and DISENGAGE.

• ENGAGE – Lever moved into detent slot

farthest from engine. Use this position to operate tines or other PTO attachments. After shifting to ENGAGE, briefly operate machine in FORWARD to help fully engage the PTO clutch.

• DISENGAGE – Lever moved into detent

slot nearest engine. Use this position to disengage power to tines or other PTO attachments before transporting, loading, turning, or operating in reverse.

IMPORTANT: To avoid transmission damage, always move the Wheels/Tines/ PTO Drive Lever into NEUTRAL before shifting the Tines/PTO Clutch Lever.

Depth Regulator Lever

Use this lever (E, Figure 3-1) to regulate the tilling depth of the tines. This control also has a TRAVEL position, which enables transport with the tines off the ground.

To operate the lever, lift up on the handlebars, pull the Depth Regulator Lever straight back, and then slide it up or down to one of the eight detent height settings.

The eight detent positions offer a range of tine height settings. This enables you to select the height that is most effective for a particular condition. The top detent position is the TRAVEL setting. Use the second or third detent from the top for shallow tilling and cultivating. Use the other detents for deeper tilling and for power composting.

Handlebar Height Adjustment Lever

Use this lever (F, Figure 3-1) to adjust the handlebars to one of two height settings.

1. To change the height, hold the handle-

bars with one hand and loosen the lever in a counterclockwise direction.

2. Move the handlebars to one of the two

preset height settings.

3. Retighten the lever.

NOTE: You can swap the positions of the inside handlebar ratchets to change the two preset settings by approximately four inches higher or lower. See Section 2, Step 2: Attach Handlebar for detailed assembly information.

To avoid personal injury, always place the tines in the TRAVEL position before starting the engine. This prevents the tines from touching the ground until you are ready to begin tilling.

WARNING

Engine Throttle Lever

Use the throttle lever (G, Figure 3-1) to adjust engine speed as well as to start and stop the engine.

Move the lever away from the STOP position before starting the engine. Engine speeds are variable and range between the FAST and SLOW. Use the STOP position to turn the engine off.

NOTE: A secondary throttle lever is located on the front of the 8HP and 10HP engines. A separate On/Off switch may also be available on the engine. (See Engine Owner’s Manual for information.)

Engine Controls

Refer to the engine manufacturer’s Engine Owner’s Manual (included in the tiller literature package) to identify the controls on your engine.

IMPORTANT: An engine On/Off switch, a secondary throttle control, a choke lever and a fuel line shut-off control may be located on the engine. Refer to your Engine Owner’s Manual for detailed information.

Section 3: Features and Controls

The tiller handlebars can be swung out 30oto the right side for use only with the PTO Chipper/Shredder attachment. This is done by loosening the mounting bolt on the handlebar base. Never operate your tiller or attachments, other than the PTO Chipper/Shredder, with the handlebars in the right side position. Doing so could result in unsafe handling and personal injury.

To avoid serious personal injury or damage to equipment, do not start your engine at this time. Complete starting instructions are described in Section 4, Operation.

Keyswitch Starter

The keyswitch starter on electric start models (A, Figure 3-5) has three positions: OFF, RUN and START. Turn the key to START to start the engine. Release the key and it will return to the RUN position. Turn the key to OFF to stop the engine. (Another way to stop the engine is to move the engine throttle lever to the STOP position.)

Figure 3-5

WARNING

Section

Operation

INTRODUCTION

Read this Section of the manual thoroughly before you start the engine. Then, take the time to familiarize yourself with the basic operation of the tiller before using it in your garden. Find an open, level area and practice using the tiller controls without the tines engaging the soil (put tines in Travel setting— Section 3,

Depth Regulator Lever). Only after you’ve become completely familiar with the tiller should you begin using it in the garden.

Break-In Operation

Perform the following maintenance during the first hours of new operation (see Maintenance Section in this Manual and maintenance information in the Engine Owner’s Manual).

1. Change engine oil after first 2 hours of new engine operation.

2. After the first 2 hours of new operation, check the gear oil levels in the PTO Power Unit and the tine attachment transmissions.

3. Check for loose or missing hardware on unit. Tighten or replace as needed.

4. Check tension on forward drive belt after first 2 hours of operation.

Starting and Stopping the Engine

The following steps describe how to start and stop the engine.

IMPORTANT: Do not attempt to engage the tines, wheels, or any PTO attachment until you have read all of the operating instructions in this Section. Also review the safety rules in Section 1,

Safety and the tiller and engine controls information in Section 3, Features and Controls.

Pre-Start Checklist

Make the following checks and perform the following services before starting the engine.

1. Read the Safety and Controls Sections in this Manual. Read the separate Engine Owner’s Manual provided by the engine manufacturer.

2. Check unit for loose or missing hardware. Service as required.

3. Check engine oil level. See Engine Owner’s Manual.

4. Shift the Wheels/Tines/PTO Drive lever (Figure 4-2) into NEUTRAL position. See Section 3, Controls for more information on this lever.

5. Check Safety Guards. All guards and covers must be securely in place.

6. Check air cleaner. See Engine Owner’s Manual.

7. Attach spark plug wire to spark plug.

8. Check Engine Cooling System. Clear

cooling fins and air intake screen of debris.

9. Select High/Low Belt Speed range.

10. Adjust Handlebar Height.

11. Fill the fuel tank with gasoline in

accordance with the directions in the separate Engine Owner’s Manual. Follow all instructions and safety rules carefully.

Your tiller and its optional PTO Power Unit attachments are capable of causing serious injury to untrained or careless operators.

To avoid serious personal injury or property damage, read the Owner’s Manual that is provided with any optional accessories or attachments before using the tiller or PTO Power Unit.

Figure: 4-1

Before operating your machine, carefully read and understand all safety (Section 1), controls (Section 3) and operating instructions (Section 4) in this Manual, in the separate Engine Owner’s Manual, and on the decals on the machine.

Failure to follow these instructions can result in serious personal injury.

GASOLINE IS HIGHLY FLAMMABLE AND ITS VAPORS ARE EXPLOSIVE.

Follow gasoline safety rules in this Manual (Section 1) and in the separate Engine Owner’s Manual.

Failure to follow gasoline safety instructions can result in serious personal injury and property damage.

WARNING

DANGER

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