Troy-Bilt Horse E682L Operator's Manual

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TRnV BILT

Operator's Manual

Rear-tine PTO Tiller Models

E682L--Horse TM

682J--Horse TM

Model 682J Shown

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 by contacting the service department at Troy-Bilt LLC, P.O. Box 361131 Cleveland, Ohio 44136-0019.

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

PRINTED IN USA FORM NO. 770-10598A

(01/2002)

TABLE OF CONTENTS

Content Page

Calling Customer Support .................................................... 2

Safety ................................................................... 3

Assembly ................................................................. 6

Features and Controls ....................................................... 11

Operation ................................................................ 14

Maintenance .............................................................. 28

Troubleshooting ........................................................... 41

Attachments & Accessories .................................................. 43

Parts List ................................................................. 44

Warrany 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 read and understand what it says. Before you start assembling your new equipment, please locate the model plate on the equipment and copy the infor-

mation from it in the space provided below. This information is very important if you need help from our Customer Support Department or an authorized dealer.

You can locate the model number by looking at the rear surface of the tine shield. A sample model plate is explained below. For future reference, please copy the model number and the serial number of the equipment

in the space below

Copy Model Number Here

O BILT" TROY-BILT LL(

www.troybilt.com CL_E_ND, OH_136

• 866-840-648_

P. O. BOX 361131

330-558-7220

Copy Serial Number Here

ENGINEINFORMATION

The engine manufacturer is responsible for all engine-related issues with regards to performance, power-rating, speci-

fications, warranty and service. Please refer to the engine manufacturer's Owner's/Operator's Manual packed sepa- rately with your unit for more information.

CALLINGCUSTOMERSUPPORT

If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenance of this unit, please call the Customer Support Department.

your unit's model number and serial number ready when you call. See previous section to locate this

Call 1- (330) 558-7220 or 1- (866) 840-6483 to reach a Customer Support representative. Please have information. You will be asked to enter the serial number in order to process your call.

Safety

SafetyAlert Symbol

,_ This is a safetyalertsymbol. It is used inthis

Failureto obey safety messagescould result in personal injury or propertydamage.

Training

1. Carefullyreadthis Owner's Manual,the

separateEngineOwner's Manual,and any other literature you may receive.Bethor- oughly familiar with the controls and the proper useof the tiller and itsengine. Know howto stopthe unit and disengage the controls quickly.

2. Neverallow children to operatethe tiller. Neverallow adults to operatethe tiller without proper instruction.

3. Keepthe areaof operation clearof all persons, particularly children andpets.

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

andthemselves.

Preparation

1. Thoroughly inspect theareawherethe tiller isto beusedand remove all foreign objects.

2. Putthe Wheels/Tines/PTODrive Lever into NEUTRALbefore starting theengine.

3. Do not operatethe tiller without wearingadequate outergarments. Avoid loose garmentsor jewelry that could get caught in moving parts.

4. Do not operatethe tiller when barefoot or wearingsandals,sneakers,or light

footwear. Wear protectivefootwear that

will improve footing on slippery surfaces.

5. Do not till nearunderground electric cables,telephone lines,pipes or hoses. If in doubt, contact your telephoneor utility

company.

manualand on the unit to alertyou to potential hazards. Whenyou seethis symbol,

readand obey the messagethat follows it.

6. Warning:Handlefuel with care; it is highly flammable andits vapors are

explosive. Besureto takethe following precautions:

a. Store fuel in containersspecifically

designedfor this purpose.

b. The gascapshall neverbe removed

or fuel addedwhile the engineis running. Allow the engine to cool

for severalminutes beforeadding fuel.

c. Keepmatches,cigarettes, cigars,

pipes, openflames,andsparks awayfrom the fuel tank and fuel

container.

d. Fillfuel tankoutdoors with extreme

care. Neverfill fuel tank indoors. Usea funnel or spout to prevent

spillage.

e. Replaceall fuel tankand container

caps securely.

f. If fuel is spilled,do not attempt to

start the engine, but move the machine awayfrom the areaof

spillageand avoid creatingany source of ignition until fuel vapors

havedissipated.

7. Never makeadjustmentswhen engine is running (unlessrecommendedby

manufacturer).

Operation

1. Do not put hands or feet nearor under

rotating parts. Donot allow handsor any other part of the bodyor clothing nearthe rotating tines or nearanyother moving part. Thetines beginto rotate forward

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.

WARNING

Theengineexhaustfromthis productcontains chemicalsknowntotheStateofCaliforniatocause

cancer, birth defects or other reproductive harm.

oncethe enginestarts, the Tines/PTO ClutchLever is in the ENGAGEposition,

the Forward Interlock Leversaresqueezed

closedand the Wheels/Tines/PTODrive Leveris shiftedto FORWARD.Thetines rotate in Reversewhether the Interlock

Leversare closedor open.

2. Exerciseextreme caution when on or crossing graveldrives, walks, or roads.

Stayalert for hidden hazardsor traffic. Do not carry passengers.

3. After striking aforeign object, stop the engine,removethe wire from the spark

plug wire and preventit from touching the spark plug. Thoroughly inspectthe

machinefor anydamage and repairthe damagebefore restarting and operating

the machine.

4. Exercisecaution to avoid slipping or

falling.

5. If the unit should start to vibrate abnor- mally,stop the engine, disconnectthe

spark plugwire and preventit from

touching the spark plug, and check imme-

diatelyfor the cause.Vibration is generallya warning of trouble.

6. Stopthe engine,disconnect the spark plug wire and preventit from touching the

spark plugwheneveryou leavethe operatingposition, before unclogging the

tines, or when making any repairs,adjust-

ments or inspections.

7. Takeall possible precautionswhen leavingmachine unattended.Stopengine.

Disconnectspark plug wire and move it

away from spark plug. Removeignition

keyon electric start models

Section1: Safety

8. Beforecleaning, repairing, or inspect-

ing, stop the engine and make certain all moving parts havestopped. Disconnect the spark plug wire and prevent it from touching thespark plugto preventacci- dentalstarting.

9. Theflap onthe tine hood must be down when operatingthetiller, unless using the Hiller/Furrowerattachment.

10. Neverusethe tiller unlessproper guards, plates,or other safety protective devicesare in place.

11. Donot runenginein anenclosed area.Engineexhaustcontains carbon monoxide gas,adeadlypoison that is

odorless, colorless, and tasteless.

12. Keepchildren and pets away.

13. Neveroperatethe tiller underengine power if the WheelSpeedLeveris in the FREEWHEELposition. In FREEWHEEL,

thewheels will not hold the tiller backand the revolving tines could propel thetiller

rapidly, possibly causing lossof control. Alwaysengagethe Wheel SpeedLeverin either FASTor SLOWposition before starting the engineor engaging thetines

with theWheels/Tines/PTODrive Lever.

14. Beaware thatthe tiller mayunex- pectedlybounceupwardor jump

forwardifthe tines shouldstrike extremelyhardpackedsoil, frozen

ground,or buried obstacleslike large stones,roots, orstumps. If in doubt aboutthe tilling conditions,alwaysuse thefollowingoperatingprecautionsto assistyouin maintainingcontrolofthe

tiller:

a. Walk behindandto oneside of the

tiller, usingonehandonthe han- dlebars.Relax yourarm, butusea securehandgrip.

b. Use shallowerdepthregulator

settings,workinggraduallydeeper with eachpass.

c. Use slowerwheel, tine and engine

speeds.

d. Clearthe tilling areaof all large

stones,rootsand otherdebris.

e. Avoidusingdownwardpressureon

handlebars.If needbe, useslight upwardpressureto keepthe tines fromdiggingtoo deeply.

f. Beforecontactinghardpackedsoil

at the endof arow, reduceengine speedand lift handlebarsto raise

tines outofthe soil.

g. In an emergency,stoptines and

wheels byshiftingthe Wheels/Tines/PTODriveLever

intoNEUTRAL.If youcan not

reachthe lever or havelostcontrol ofthe tiller, let go of thehandle-

barsand all controls. Do not attemptto restrainthetiller.

15. Do not overloadthe tiller's capacity by

attempting to till too deeply at too fast a rate.

16. Never operatethe tiller at high transport speedson hardorslippery

surfaces. Look behindand usecare when backing up.

17. Do not operatethe tiller on aslope that is too steep for safety. When on slopes, slow downand makesure you havegood footing. Never permit the tiller to freewheel down slopes.

18. Neverallow bystandersnear the unit.

19. Onlyuse attachments andaccessories that areapproved bythe manufacturerof

the tiller.

20. Usetiller attachments and acces- sories when recommended.

21. Never operatethe tiller without good visibility or light.

22. Never operatethe tiller if you are tired, or under the influenceof alcohol,

drugs or medication.

23. Operatorsshall nottamper with the engine-governorsettings on the machine; the governor controls the maximum safe operating speedto protect the engineand all moving parts from damagecaused by overspeed. Authorized serviceshall be sought if a problem exists.

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

25. POISON/DANGER--CAUSES SEVEREBURNS.The batteryon electric

start models contains sulfuric acid. Avoid contact with skin, eyesor clothing. Keep

out of reach of children.

Antidotes:

External- Flushimmediately with lots of

water.

Internal- Drink largequantities of water or milk. Followwith milk of magnesia, beateneggs orvegetableoil. Calla

doctor immediately.

Eyes- Flushwith water for 15 minutes. Getprompt medical attention.

26. DANGER-BATTERIESPRODUCE

EXPLOSIVEGASES. Keepsparks,flame

or smoking materialsaway. Ventilate when charging battery or using inan enclosed space. Alwayswear safety goggles when working near battery.

27. Pleaseremember:You canalways stop the tines andwheelsby releasingall controls, or by moving the ignition switch and/or throttle control leveronthe engine

to OFFor STOP.

28. To load or unloadthe tiller, seethe

instructions in Section 4 of this Manual.

29. Useextremecautionwhen backingor

pulling the machinetowards you.

30. Startthe enginecarefully accordingto

instructions and with feet well awayfrom the tines.

31. Neverpick upor carry a machine while the engineis running.

32. When loading or unloadingthe tiller, alwaysdisengage tinesand use slower wheel and enginethrottle speeds. Use sturdy ramps wide and strong enoughto easily support the tiller (280-to-325 Ibs., depending on model) andoperator.

Nevergo down ramps in FORWARD drive--the tiller could tip forward, exposing you to the tines (which should

be disengaged). Alwaysuse REVERSE drive and backdown ramps. Togo up

ramps, useFORWARDdrive and follow the tiller.

33. TheForward Interlock SafetySystem should betested for correct functioning every time thetiller or PTOpowerunit is

used. SeeSection 4 in this Manual.

34. If using the optional Dozer Blade, either removethe tine attachment,or disengagethe tineswith the Tines/PTO

ClutchLever. Revolvingtines are dangerous.

Section1: Safety

MaintenanceandStorage

1. Keepthe tiller, attachmentsandacces- sories insafe working condition.

2. Checkall nuts, bolts, andscrews at frequent intervalsfor proper tightness to

be surethe equipment is insafe working condition.

3. Neverstore the tiller with fuel in the fuel tank insidea building where ignition

sources are presentsuch ashot water and spaceheaters,furnaces, clothes dryers, stoves, electric motors, etc.). Allow engine to cool beforestoring in any

enclosure.

Decals

Foryour safetyand the safetyof others, various safetyand operational decalsare located onyour unit (Figure 1).

Keepthe decalscleanandlegibleat all times. Contactyour local servicedealer or the Factoryfor replacementsif any decalsare damagedor missing.

4. To reducethe chancesof afire hazard, keepthe enginefree of grass, leaves, or

excessivegrease.

5. Store gasolinein acool, well-ventilated

area,safely awayfrom any spark-or flame-producing equipment. Store

gasolinein an approvedcontainer, safely

away from the reachof children.

6. Referto the Maintenancesections of

this Manualand the separateEngine

Owner's Manualfor instructions if the

tiller is to be stored for an extended

period.

A) WARNING:HotSurfaces. Topoftheaircleanerhousing. SafetyInstructions

7. Neverperform maintenancewhile the engine is running orthe spark plugwire is connected, exceptwhen specifically

instructed to do so.

8. If thefuel tank hasto bedrained,do

this outdoors.

C) WARNING:Operatingand

D) PowerUnit

Referto the Parts List for decal locations,

descriptions andpart numbers.

OperatingSymbols

Varioussymbols (shown here,with word descriptions)areusedonthetillerandengine. Yourunitmaynothaveallofthesymbols.

• READTHEOWNER'SMANUAL.

• KNOWLOCATIONSANDFUNCTIONSOFALL CONTROLS.

• KEEPALL SAFETYDEVICESANDSHIELDSIN PLACEANDWORKING.

• NEVERALLOWCHILDRENORUNINSTRUCTEDADULTSTO OPERATETILLER.

• SHUTOFFENGINEANDDISCONNECTSPARKPLUGWIRE BEFOREMANUALLYUNCLOG-

GINGTINES ORMAKINGREPAIRS.

• KEEPBYSTANDERSAWAYFROM MACHINE.

• KEEPAWAYFROMROTATINGPARTS.

• USEEXTREMECAUTIONWHENREVERSINGORPULLINGTHE MACHINETOWARDSYOU.

F) EngineStabilization. Topof fueltank.

Figure1:LocationofSafetyand OperatingDecals.

(Briggs& Stratton engineshown)

B) WARNING:EngineIgnition. Electricstartmodelsonly.

I I I÷I

FAST SLOW CHOKE CHOKE

STOP ON OFF

TO AVOID SERIOUS INJURY:

ROTATING

TINES

Assembly

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 operatinginstructionsin this

manual.

Introduction

Carefullyfollow these assembly stepsto correctly prepareyour tiller for use. It is

recommendedthat you readthis Section in its entirety beforebeginning assembly.

NOTE:Varioustiller models are presented in this Manual. Useonly the information

appropriatefor your tiller model.

InspectUnit

Inspectthe unitand carton for damage

immediately after delivery. Contactthe carrier (trucking company) if you find or suspect damage. Inform them of the damageand request instructions for filing a claim. To protectyour rights, put your claim inwriting and mail acopy to the carrier within 15 days after the unit has beendelivered. Contactusat the Factory if you needassistance inthis matter.

STEP1: UnpackingInstructions

NOTE:Do not severelybendany of the control cableson the unit.

1. Thetiller is heavy. Do not attemptto remove it from the shipping platform until instructed to do so in theseAssembly

steps.

2. Removeall unassembledpartsfrom the carton. Thehardwarebag is included in your literature packaging.

3. Checkthat you havethe items listed below (contact your local dealeror the

Factory if any items are missing or damaged).

NOTE: Usethe screw lengthtemplate (Figure2-1) to identify screws.

LoosePartsList

Qty. Description

1 HandlebarAssembly 1 Wheels/TinesPTODriveLever

Thefollowing items

are in the hardwarebag:

2 20 oz.Bottles SAE30W Oil 1 Clutch PawlSpring

1 BeltAdjusting Tool 2 PlasticCableTies

1 CurvedHeadScrew, 1/4-20 x 2 1 FlangedLock Nut, 1/4-20 1 PanHeadScrew,#10-32 x 1/2

Thefollowing parts (electric start models only), packagedseparately.

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:LEFTand RIGHTsides of the

tiller are as viewed from the

operator's position behind the han- dlebars(unless otherwise noted).

Tools]MaterialsNeeded

for Assembly

(1) 3/8" open-endwrench* (2) 7/16"open-end wrench* (2) 1/2" open-endwrench* (1) 9/16"open-end wrench* (1) 3/4"open-end wrench* (1) Flatblade screwdriver (1) Scissors (to trim plastic ties) (1) Tire pressuregauge (1) 4-1/2" highwood block to prop unit

* Adjustable wrenchesmay be used.

Figure2-1: Toidentifylengthofscrew,

placescrewontemplateasshownand

measuredistancebetweenbottomofscrew headandtipofscrew.

STEP 2: Attach Handlebar

IMPORTANT: When disassembling

handlebar assembly, keep left-side clamp

and ratchet separatedfrom the right-side clamp andratchet.

1. Disassemblethe handlebarassembly. To do this, remove the height adjustment

leverby turning the leverin a counter-

clockwise direction (Figure2-2).

2. Placethe handlebarendson either side ofthe base,with thewire harnesstoward

the rear ofthe base(Figure2-2).

3. Installthe heightadjustment lever

through the right-side clamp, handlebar end, ratchet, and base;then out through

the left-side ratchet, handlebarend,and clamp (Figure2-2). Securewith nut, but

don't fully tighten.

IMPORTANT:Do notforce the height

adjustment leverthrough the handlebars. The interlock wires may be blocking the

leverand could bedamaged.You may

gently movethe wiresaside if this condition occurs.

Section2: Assembly

4. Raisehandlebarsto oneof two height

settings andtighten the heightadjustment lever. Also, makesure all other mounting hardware issecurely tightened.

NOTE: Fully assembledhandlebar assembly should appearas shown in Figure2-3.

Figure 2-3. Fully assembled handle- bars.

STEP3: MoveTiller OffShipping Platform

1. Setthe DepthRegulatorLever (A, Figure2-4) to Travel position. Dothis

by lifting the tiller by the handlebars,then pulling straight backonthe leverand

sliding down to the highest notched setting.

2. Setthe WheelSpeedLever(B, Figure 2-4) to Freewheelposition. To do this,

move the leverapproximately halfway betweenthe Fastand Slow settings while

you rock the tiller forward andbackward until thewheels movefreely.

3. Lift Handlebarshighenoughto clear tiller tines and pull backfirmly to dislodge the tiller from the platform wheel wells.

STEP4: ConnectForward InterlockWire Harness

1. Removeany dirt fromthe Forward

Interlock wire harnessplug (C, Figure 2-5) andits receptacle(D).

2. Connect the Forward interlock wire harness plug (C,Figure2-5) to the recep- tacle (D).

STEP5: Attach WheelsiTines/PTODriveLever

1. Loosenthe bolt (Figure2-2) on the handlebar baseand swing the handlebars out to the right side.

Right Clam

Height

Adjustment

Lever

FRONT OFTILLER

Figure 2-2. Handlebar assembly.

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

Speed Lever (B).

2. Removeboth sets of nuts, star washers, screws, and one bushing

(A, B, C,D, E,F,G,Figure2-6) from the yoke plates(H). There is a bushing inside the short link (I). Becareful not to loseit when removing screw (G).

3. Slidethe platesat the endof the Wheels/Tines/PTOLeveroverthe yoke plates (Figure2-9). To aid in the next step, insert a screwtemporarily into the forward most holes (J, Figure2-7) of the yoke platesandthe lever.

Base

Handlebam

Base

Left Clamp

Nut

Wire Harness

Figure 2-5. Forward Interlock Wire Harness connection.

4. Align the rear most holes of theyoke platesand the Wheels/Tines/PTOLever. Uselong nose pliersto hold the bushing (L, Figure27) in placewhile insertingthe screw (K)through the leverand yoke plates.Install star washer (B, Figure2-6)

and nut (A),then handtighten.

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

Section2: Assembly

Removethe temporary screw (J, Figure 2-7) from the forward holes andmove the Wheels/Tines/PTOLeverfully forward.

Install the wider hook end of the clutch pawl spring (M, Figure2-8) down into the

small holeat the end of the handle. Use pliers to insert the other endinto the hole

in the long link bar (N). NOTE:Do not bend or over stretch the spring while installing.

6. Pull the Wheels/Tines/PTOLeverback to align the forward most holes (Q,Figure

2-9) inthe yoke platewith the holes in the lever plates. Also alignthe bushing that is insidethe short link bar (P). Install the screw, starwasher, and nut, then tighten securely.

Securelytighten allother hardware(Q,R, Figure2-9). Alsoensure that the spring (S) is properly seatedat both ends.

Completedassembly should appearas illustrated in Figure2-9.

7. Testthe operation of the Wheels/Tines/PTOLever. Pushthe lever

down until it engages in the Forward

position. The clutch roller (T, Figure2-

10) must rest beneaththe adjustment block (U). Next,move the lever upto the Neutral position. Theclutch roller (T,

Figure2-11) should rest on theface of the adjustment block (U). To test Reverse,lift and holdthe leverall the way up in

Reverseposition, then let it go. Thelever

should automatically return to the Neutral

position (Figure2-11). If not, do not use the tiller. Seeyour localauthorized dealer

or call the FactoryTechnicalService

Departmentfor instructions.

Figure 2-9: Fully assembled

Wheels/Tines/PTO Lever assembly.

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 2-8: Clutch pawl spring. Tilt

WheelsiTinesiPTO Lever fully

forward before installing spring.

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

Figure 2-11: Neutral position; roller (7) rests against middle area of the adjustment block (U).

STEP6: CheckGearOilLevels

Your tiller hastwo separatetransmis-

sions: one for the PowerUnit (Figure 2-

12), the otherfor the Tine Attachment

(Figure2-13). Both transmissions were filled atthe factory with SAE#85W-140 weight gearoil (with anA.P.I rating of

GL-4). Checklevelin both transmis-

sions to verify that they are still correct.

SeeSection 5, TransmissionGearOil

Maintenancefor complete information

on howto check andfill the transmis-

sions.

Section2: Assembly

IMPORTANT: Checkgearoil level in both

transmissions after the first 2 hours of

new tiller operation, then every 30 operating hours thereafter. SeeSection 5

for instructions.

OilLevel Hole

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

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

STEP7: AddMotor0il to Engine

1. Beforeadding motor oil, park thetiller

on levelground. Levelthe engineby placinga sturdy block under thetines or

the tines depth regulator bar.

2. Referto the EngineOwner's Manual provided with your tiller for detailed infor-

mation onhow to add motor oil andfor motor oil specifications.

IMPORTANT:Two 20 oz. bottles of motor oil are included with your tiller. Checkthe

oil level as instructed in the Engine Owner's Manual provided with your tiller

BEFOREpouring the full amount of each bottle into the engine.

IMPORTANT:

• Change engine oil after first 2 hours of

newoperation.

• Check engine oil levelevery 5 hours of operation or eachuse.

STEP8: AttachEngineThrottle LeverandCable

Forshipping purposes, the throttle cable, together with the throttle lever, is wound

around the engine. Carefully unwindthe cable. If the throttle control label is

coveredwith a clear protectivecoating, peel it off.

To avoid electric shock from a short circuit (electric starttillers only), never

allow the throttle cable to touch the battery. Routecable belowthe battery,

onthe outsideof thebatteryholder.

To attachthe throttle leverandcable:

1. Runthethrottle cableup the inside edge of the right handlebarand position

the leverasshown in Figure2-14.

2. Fromthe outside of the handlebar, insert the curved headscrew (A, Figure 2-

14), through the handlebarand the center hole inthe throttle levermounting

bracket.

3. Looselyinstallthe flanged lock nut and movethe throttle leverbackto the

STOPposition.

4. Fromthe lever side of the bracket, threada pan headscrew (B, Figure2-14)

through the small hole in the throttle lever bracketand intothe handlebar. Tighten the screw securely.

5. Securelytighten boththe flanged lock nut and the curved headscrew.

6. Usetwo plastic tiesto securethe throttlecableto the right handlebarin two

places (Figure2-15). Loop eachtie around the handlebarand cable (serrated sidefaces in) and pull the ties tight. Trim

the ends.

Figure2-14: Engine ThrottleLever

position and installation.

Figure 2-15: Plastic Ties placement on handlebars.

STEP9: Adjust Air Pressure in

Tires

Forshipping purposes,the tires may be overinflated. Checkthe air pressurein eachtire andadjust them to between10

and 20 pounds persquare inch. You

must inflate eachtire to equalair pressuresto preventthe tiller from pulling

to one side.

Assembly is complete for recoilstart tillers. SeeAssembling TheElectric

Start Systemif you own anelectric start tiller; otherwise, refer to Section 3, Controlsfor information on tiller

controls.

Section2: Assembly

ASSEMBLINGTHEELECTRICSTARTSYSTEM

Thefollowing steps explain howto install and chargethe batteryon electric start tillers. For your safety,follow all steps and observe all accompanyingsafety messages. Section 5 contains othergeneralbattery maintenanceand recharginginstructions.

1. Usea 5/8" long screw (K,Figure2-18) and 1/4-20 hexnut (L) to connect the

Batteryproducesexplosivegases. *Keep away sparks, flames, and

cigarettes.

. Ventilate area whenchargingor using

batteryin anenclosedspace.

. Make surebatteryvent tube is always

openafter batteryis filled with acid.

Remove metal jewelry before working near the battery or near the electrical system. Failureto complymay cause a short circuit, resulting in electrical burns, a shock, or battery gas explosion.

positive (+) batterycable(B)to the positive (marked +) battery post (C).

Make surethat this is the cableonthe left side, with oneend attachedto the

solenoid (D).

2. Slidethe black rubber boot (E) com- pletely over the battery postandcable

connector.

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

4. Slidethe black rubber boot (J) com- pletely over the battery postandcable

connector.

To Avoid Personal Injury or Property

Damage:

* Do not touch positive batteryterminal

and any surrounding metal objects with tools, jewelry or other metal

items. Failure to complycould cause a short circuit leading to electrical burnsor explosionof batterygases.

* Neverbringa gascannearthe positive

(+) battery terminal. A short circuit could occurleading to an explosionof the gasoline or the battery gases. Always fill the engine fuel tank from thefront or sideof theengine.

NOTE:Ifthe battery is put into

serviceafter the dateshown onthe top of the battery, chargefor a

minimum of one hour at 6-10

amps. Referto the Maintenence section of this manualfor more

detailedinstructions regarding

proper batterycharging procedure

STEP1: Connectthe Wire HarnessReceptacle

1. Beforeinstalling the battery and its hold-down clamp, insert the plastic wire

harness receptacle(A, Figure2-18) into the prongs of the keyswitch (M)located

on the hold-down clamp.

2. Removethe ignition keysfrom the keyswitch andstore them safely away.

Do not insertthe key into the keyswitch until you complete this section andread

Section 3, Controls.

STEP 2: Install the

BatteryCables

NOTE:The cableterminals should be toward the rear (keyswitchside) of the

battery posts.

Assembly is complete for electric start tillers. SeeSection 3, Controlsfor information on tiller controls.

Never jump start the battery with a

vehicle battery or chargingsystem. This

may produce a battery explosion, causingacid orelectrical burns.

G(-)

Figure 2-18: Battery cable assembly.

FeaturesandControls

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 themachine.

Failure to follow these instructionscan resultin seriouspersonalinjury.

Introduction

This section describesthe location and function of the controls and features on

your tiller. Referto Section 4, Operation for detailedoperating instructions.

Practice usingthesecontrols, with the engine shut off, until you completely understand the operation of the controls

and feelconfident with eachof them. IMPORTANT:Referto the separateengine

manufacturer's Engine Owner's Manual for information about the controls on the

engine. NOTE:All referencesto left,right, front

and rearof themachineare basedon a position behindthe handlebarsandfacing

forward.

PTOAttachmentsFeature

In addition to powerfultilling capability, you canquickly convert your machine into a PTO(Power Take-Off)PowerUnit that iscapableof towing or powering

various TROY-BILTattachments. You canaccessthis capability by

removing the tines attachment (powered by the PTOPower Unit). The PTOPower

Unit isthen availablefor engine powered attachments,or for pulling ortowing non-

poweredattachments. SeeSection 4, PTOPower Unitfor detailedinformation

on installingand operating TROY-BILT PTOattachments.

WheelsiTines/PTODriveLever

Usethe Wheels/Tines/PTODriveLever(A, Figure3-1) to engageand disengage

powerto the transmission.

Figure 3-1:

A- Wheels/Tines/PTO Drive Lever

B- Forward Interlock Levers C- Wheel Speed Lever

D- Tines/PTO Clutch Lever

This leverhasthree operatingpositions: FORWARD,NEUTRALand REVERSE.

FORWARDisengagedwhen the leveris moved down until the clutch roller (G,

Figure3-2) engagesinto the detent position underthe adjustment block (H, Figure3-2). You will definitely feelthe leverengageinto this position.

Usethe FORWARDsetting to movethe wheels andtines forward, orto apply power to anoptional PTO(PowerTake Off) attachment. (Seealso Forward

Interlock Levers.)

To stop the wheels, tines orany PTO attachment,movetheleverto NEUTRAL

by tapping the leverupwards (Figure 3-3) and releasing.

• REVERSEis engagedwhen the lever is pushed(with an openpalm)all the way

up and heldin that position (Figure3-4). Usethis setting to movethe wheels in reverse. To stop moving inreverse, releasethe lever;it automatically returns

to the NEUTRALposition.

E- Depth Regulator Lever F- Handlebar Height Adjustment Lever

G- Engine Throttle Lever

IMPORTANT: Do not operatethe tines or

any PTOattachment in REVERSE.

• NEUTRALis this control's normal non- operating position. Thelever returns to

NEUTRALwhen it is tappedout of the FORWARDposition or releasedfrom the

REVERSEposition. NEUTRALposition

is betweenFORWARDand REVERSE (Figure3-3). Usethis setting to stop

the wheels,tinesor any PTOattach- ment.

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,

Figure3-1) are attachedundereach handlebargrip.

You must squeezeat least one of these

interlock levers up against the handlebar grip wheneverthe Wheels/Tines/PTO Drive Leveris engagedin FORWARD position.

Section3: FeaturesandControls

Figure 3-2: FORWARD posiUon;roller (G)rests under lhe adj_t block (H_

Figure 3-3: NEUTRAL position; roller (G) rests against middle area of the ad-

justment block (H).

Figure 3-4: REVERSE position; roller (G) rests against upper area ofthe ad-

justment block (H).

If both Forward Interlock Leversare

releasedbefore first returning the Wheels/Tines/PTODriveLever to

NEUTRAL,the enginewill 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

Usethe Wheel SpeedLever (C,Fig.3-1) to selectone of threeoperating positions: SLOW,FASTor FREEWHEEL.

- SLOW- Levermovedall the waydown. Most effectivefor normaltilling or for

low-speedtransport.

., FAST- Levermovedall theway up.

Most effectivefor cultivatingorfor fast- speedtransport.

- FREEWHEEL- Leverin betweenSLOW and FAST(wheelswill roll freely). Used

whentransporting the machineon level groundwithout enginepower,andwhen usingstationaryPTOattachments.

IMPORTANT: To avoid transmission damage, always move Wheels/Tines/PTO Drive Lever into NEUTRALbefore shifting

the WheelSpeedLever. 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/PT0 Drive Lever is engagedin FORWARDor REVERSE.

Tines/PTOClutchLever

Usethis lever(D, Figure3-1) to engageor disengagepower fromthe transmission

PTOclutchto the tinesor any PTOattach-

ment. Thiscontrol hastwo operating positions: ENGAGEand DISENGAGE.

- ENGAGE- Levermovedintodetentslot farthestfrom engine. Usethis positionto

operatetinesor otherPTOattachments. Aftershifting to ENGAGE,brieflyoperate machinein FORWARDto helpfully engagethe PTOclutch.

• DISENGAGE- Lever movedinto detent slot nearestengine. Usethis positionto

disengagepowertotines or otherPTO attachmentsbeforetransporting, loading,

turning, oroperatingin reverse.

IMPORTANT: To avoid transmission

damage, always move the Wheels/Tines/

PTO Drive Lever into NEUTRAL before

shifting the Tines/PTOClutch Lever.

DepthRegulatorLever

Usethis lever(E, Figure3-1) to regulate the tilling depth of the tines. This control also hasaTRAVELposition, which enablestransport with thetines off the ground.

To operatethe lever, lift up on the handle-

bars, pull the DepthRegulatorLever straight back,and then slide it up or down

to one of the eightdetent heightsettings. Theeight detent positions offer a range of

tine heightsettings. This enablesyou to select the heightthat is most effectivefor

a particularcondition. The top detent

position is theTRAVELsetting. Usethe second orthird detentfrom the top for

shallow tilling andcultivating. Usethe

otherdetents for deepertilling and for

powercomposting.

To avoid personal injury, always place the tines in the TRAVEL position before starting the engine. This preventsthe tines from touching the grounduntil youare ready to begin tilling.

HandlebarHeightAdjustment

Lever

Usethis lever(F, Figure3-1) to adjust the

handlebarsto oneof two heightsettings.

1. Tochangetheheight,hold the handle-

barswith one handand loosenthe leverin a counterclockwisedirection.

2. Movethe handlebarsto oneof the two

presetheightsettings.

3. Retightenthe lever.

NOTE:You can swapthe positions of the

inside handlebarratchetsto change the two presetsettings by approximately four

inches higheror lower. SeeSection 2,

Step2: Attach Handlebarfor detailed assembly information.

The tiller handlebarscan be swungout 30°to the rightside for use onlywith the PTOChipper/Shredderattachment. This

is doneby looseningthe mountingbolt on the handlebarbase. Never operate yourtiller orattachments,otherthanthe PTO Chipper/Shredder,with the handle- bars in the right side position. Doingso could result in unsafe handling and personalinjury.

EngineThrottleLever

Usethe throttle lever(G, Figure3-1) to adjust enginespeedaswell asto start and stopthe engine.

Move the leverawayfrom the STOP position before starting the engine. Enginespeedsare variableand range

betweenthe FASTand SLOW. Usethe STOPposition to turn the engineoff.

NOTE: A secondarythrottle leveris located onthe front of the 8HPandIOHP

engines. AseparateOn/Offsw_chmay alsobeavailableontheengine. (See EngineOwner'sManualfor information.)

KeyswitchStarter

Thekeyswitch starter on electricstart models (A, Figure3-5) hasthree positions: OFF,RUNand START.Turn the keyto STARTto start the engine. Releasethe keyand

it will returnto the RUNposition. Turn

the keyto OFFto stop the engine. (Anotherway to stop the engine is to move the engine

throttle leverto the Figure 3-5 STOPposition.)

Section3: FeaturesandControls

Engine Controls

Referto the engine manufacturer's Engine Owner's Manual (included inthe tiller lit- erature package)to identify the controls on your engine.

IMPORTANT:An engine On/Offswitch, 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.

To avoid serious personal injury or

damageto equipment, do not startyour engine at thistime. Complete starting

instructionsare describedin Section4,

Operation.

Before operating your machine, carefully read andunderstandall 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.

Failureto follow these instructionscan

resultin seriouspersonalinjury.

ration

INTRODUCTION

Readthis Section ofthe manual thoroughly before you start the engine. Then,take the time to familiarizeyourself

with the basic operation of the tiller

beforeusing it inyour garden. Find an open, levelareaandpractice usingthe

tiller controls without the tines engaging the soil (put tines inTravelsetting--

Section 3, DepthRegulator Lever). Only after you've becomecompletelyfamiliar

with the tiller should you beginusing it in the garden.

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

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.

Break-InOperation

Perform the following maintenanceduring thefirst hours of new operation (see MaintenanceSection in this Manualand

maintenanceinformation inthe Engine Owner's Manual).

1. Changeengine oil afterfirst 2 hours of newengine operation.

Figure: 4-1

2. After the first 2 hours of new operation, checkthe gearoil levels inthe

PTOPower Unitandthe tine attachment

transmissions.

3. Checkfor loose or missing hardware on unit. Tighten or replaceas needed.

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

StartingandStoppingthe Engine

Thefollowing stepsdescribehow to start and stopthe engine.

IMPORTANT: Do not attempt to engage the tines, wheels, or any PTOattachment

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 Section3, Featuresand Controls.

Pre-StartChecklist

Make thefollowing checks and perform the following services before starting the

engine.

1. Readthe Safetyand ControlsSections in this Manual. Readthe separate Engine

Owner's Manual provided by the engine manufacturer.

2. Checkunit for looseor missing hardware. Serviceas required.

3. Checkengine oil level. SeeEngine Owner's Manual.

4. Shift the Wheels/Tines/PTODrivelever (Figure4-2) into NEUTRALposition. See

Section3, Controlsfor more information on this lever.

5. CheckSafety Guards. All guards and

covers must besecurely in place.

6. Checkair cleaner. SeeEngineOwner's Manual.

7. Attach spark plug wire to spark plug.

8. CheckEngineCooling System. Clear

cooling fins andair intake screen of debris.

9. Select High/Low Belt Speedrange.

10. Adjust HandlebarHeight.

11. Fillthe fueltank with gasolinein

accordancewith the directions in the separate EngineOwner's Manual. Follow

all instructions andsafetyrules carefully.

GASOLINEIS HIGHLYFLAMMABLEAND ITS VAPORSAREEXPLOSIVE.

Follow gasoline safety rules in this Manual (Section 1) and in the separate

EngineOwner'sManual. Failureto followgasolinesafety instruc-

tions can result in serious personal injuryandpropertydamage.

RecoilStartRope (atfrontofengine)

Wheels/Tines/PTO

DriveLever

Tines/PTO

Figure 4-2." Tiller and engine controls.

Section4: Operation

EngineThrottle

Lever

_ Forward

Depth

InterlockLevers

Regulator Lever

Startingthe Engine:

To help prevent serious personalinjury or damagetoequipment:

• Always place Wheels/Tines/PTODrive

Lever into NEUTRAL before starting engine, and before engaging wheels,

tinesor otherPTO-drivenattachments.

• Never run engine indoors or in

enclosed, poorly ventilated areas. Engine exhaust contains carbon monoxide, an odorless and deadly gas.

• Avoid engine muffler and nearby

areas. Temperatures in these areas mayexceed150OF.

1. With the engineoff, placethe

Wheels/Tines/PTODriveLever (Figure 4-2) in the NEUTRALposition. If inthe FORWARDposition, tap the lever sharply upward, it should automatically moveinto NEUTRALposition.

2. Putthe DepthRegulator Leverinthe Travel position (leverall the way down) so that the tines are off the ground. To do this, lift uponthe handlebars,pull the lever (Figure4-2) back,andpush it down all the way to the top detent (notched) position.

3. Move theWheel SpeedLever(Figure 4-2) to eitherthe SLOWor FASTposition. Besureto roll the wheelswhile shifting the leveruntil thewheelsengage.

NOTE:If usingaPTOstationary attach- ment, movetheWheelSpeedLeverinto

FREEWHEELand block thewheelsto preventthe equipmentfrom moving(Figure

4-29 onpage29).

4. MovetheTines/PTOClutchLeverinto DISENGAGEposition(Figure4-2).

NOTE:Usethe ENGAGEpositionifyouwant thetinesto revolveor toapplypowertoa

PTO-drivenstationaryattachment.

5. If engineis equippedwith afuel valve, turn valveto OPENposition as instructed in theseparate EngineOwner's Manual.

6. If engineis equippedwith an ON/OFF switch, move theswitch to ON.

7. Move engine throttle lever(Figure 4-2) awayfrom STOP.

8. Chokeor prime engine asinstructed in the separateEngineOwner's Manual.

9. If not equipped with anelectric start system, placeone handon thefuel tank to stabilizethe unit when you pull the recoil starter rope. Usethe recoil starter rope to start the engineas instructedin the separateEngineOwner's Manual.

10. If equipped with anelectric start system,turn keyto STARTpositionto crank enginethen releasewhenenginestarts. If

theenginedoesnotstart rightaway,donot

holdkeyatSTARTfor morethan afew seconds.Releasethentry againaftera short pause.Damageto startermotorcanoccurif itis crankedmorethan15secondsper

minute.

11. Iftheenginedoesnotstart aftera numberoftries,refertothe EngineOwner's

Manualforspecificinstructions.

12. Whenenginestarts, move theThrottle Leverto the SLOWposition andthen graduallymovechoke lever(on enginesso

equipped)to OFFor RUNposition.

13. Movethe throttle speed control to FASTsettingwhen tilling.

Starting Electric Start Engines

with the Recoil Starter Rope

You may,at some point, haveto start an

electricstart enginewith the recoil starter rope. Beforeattempting to do so,

perform the following applicablesteps:

• If you suspectthe battery chargeis weak,and there is novisible damage.

Disconnectcables from batteryand cleanboth cableterminals, andthe battery posts inaccordance with the instructions providedin Section 5,

BatteryCareand Maintenance.

Section4: Operation

Reconnectthe cables andsecurely tighten to batteryposts. Theenginewill rechargethe battery if the battery is still good.

• If you suspectthe batter is "dead", or if the batteryis damaged,disconnect, and

remove it. Haveit checkedby a qualifiedtechnician.

• If battery has beenremoved,wrap cable terminals atend of positive cablewith

electricaltape andsecurethecableto

the batterybracket. This will prevent

electricaldischarge.

• Before pulling the recoil starter rope, turn the keyswitch to the RUNposition.

Move theThrottle Lever awayfrom STOPposition and set the chokeas

applicable. SeeEngineOwner's Manual.

Stopping the Engine and Tiller

1. Tostop the wheelsand tines, movethe

Wheels/Tines/PTODriveLever into

NEUTRALposition andthen releaseboth ForwardInterlock Levers.

2. Move the engineThrottle Leverto the STOPposition. Thenonelectric start models, turn the keyto OFF. Removethe key for safekeeping.

NOTE: Theenginemayhavea separate Throttle Control Leverand ON/OFFswitch

on the engine. Thesecontrols can also be usedto stop the engine. Seethe Engine Owner's manualfor information specific to your engine.

Operating the Tiller

Whenfirst practicing,keeptheTines/PTO ClutchLeverin DISENGAGEpositionand theWheelSpeedLeverinSLOWposition.

To avoid serious personal injury or

damageto equipment:

• Alwaysplace Wheels/Tines/PTODrive Lever in NEUTRAL before starting engine, and before engagingwheels,

tinesor otherPTOattachments.

• Be sure thereare no obstaclesbehind youbeforemovingin reverse.

• Wheels/Tines/PTODriveLever should automatically return to NEUTRAL

when released from REVERSE position. If it doesnot, movelever to

NEUTRALmanually and discontinue use until you adjust the lever. See

Section 5, Checking and Adjusting

ReverseDrive System.

• No reverse motion should occur if Wheels/Tines/PTODrive Lever is not held up in REVERSE. SeeSection 5,

Checking and Adjusting Reverse Drive System for adjustment steps.

Do not use tiller unless properly adjusted.

• Alwaysreturn to NEUTRALand let all motion stop before shifting to

FORWARDor REVERSE.

Thefollowing pagesprovide guidelines for using your tiller effectivelyandsafely in variousgardening applications. Be sure to read Tilling Tips& Techniques,in this Section, beforeyou actually putthe

tines into the soil. This isa traditional standard-rotating-tine

(SRT) tiller with forward rotating tines. It operates inacompletelydifferent manner than counter-rotating-tine (CRT)tillers, or

from front-tine tillers.

Movingthe Tiller ForwardandTilling

1. Start the engine and gradually increase engine speedto FAST(see Startingthe

Engine,this Section).

The ForwardInterlock Safety System is designedfor the operator'ssafety. Do not disconnector attempt to defeat the purpose of the system. If the system malfunctions,immediately contactyour

local authorized dealer or the TROY-BILT Technical Service Depart-

ment for assistance. Do not use the tiller or the PTO power unit until the

Forward Interlock Safety System is functioning properly. Always test the system before using the tiller or PTO powerunit.

2. Testthe ForwardInterlock Safety

System. See TestingForward Interlock System,this Section.

Keepaway fromrotatingtines. Rotating

tineswill causeinjury.

3. When practicing, setthe Depth

Regulator Leverto Travel position. Otherwise,set the Depth Regulator Lever

to a desireddepth.

4. Move Tines/PTOClutch Leverto ENGAGEposition if you want the tines to

turn. If practicing, leavein DISENGAGE.

IMPORTANT: Do not move Tines/PTO Clutch Lever to ENGAGE unless

Wheels/Tines/PTO Drive Lever is in

NEUTRAL.Tiller damagemay occur!

5. To movethe tiller forward andengage

the tines,squeezeandholdeither Forward

Interlock Lever(Figure4-3)againstthe handlebargrip, thenmove the

Wheels/Tines/PTODriveLeverdownto

FORWARDposition.

Figure 4-3: Moving tiller forward: squeeze one Forward Interlock Lever

and then move Wheels/Tines/PTO Drive Lever down to FORWARD.

6. Whenthe tiller movesforward, relax and let thewheels power thetiller along

while thetines dig. Walk behindand to one sideof the tiller. Walk on the side

that is not yet tilled (Figure4-4). Usea

firm grip on the handlebarsbut keepyour

arm relaxed. IMPORTANT: Letthe tiller move aheadat

its own pace. Do not push it ahead--this reduces operator control and tilling effi- ciency. Do not push handlebars down in an attempt to dig deeper-- this takes weight off the wheels, reduces traction, and causes the tines to try to propel the

tiller.

StoppingForwardMotionandTines

1. Tostop forward motion, tap

Wheels/Tines/PTODriveLever upward into NEUTRAL.Then releasethe Forward

Interlock Levers. Thewheels and tines will stop and the engine will continue

running.

2. In an emergency,releaseall of the control levers. Thisstops forward motion and shuts-off the engine.

To Help Avoid Personal Injury or Damageto Equipment:

• Be sure no obstaclesare behindyou beforeoperatingthe tiller in REVERSE.

• Disengagethe tines, reduce engine speed, and move the Wheel Speed Lever to SLOW position before operating in REVERSE. Avoid using FAST wheel speed until you are familiar withbackingthe tiller.

Figure 4-4: Guide tiller with one hand.

Moving the Tiller in Reverse IMPORTANT: Do not till while in

REVERSE.

1. Shift theTines/Wheels/PTODriveLever (Figure4-2) into NEUTRALand movethe

WheelSpeedLever to the SLOW position.

2. Move Tines/PTOClutch Lever(Figure 4-2) into DISENGAGEposition.

3. Verify that the area behindyou is clear.

4. Lift upthe handlebarsuntil the tines

are off theground, thenshift the Wheels/Tines/PTODriveLever allthe way up and hold. You do not needto squeeze

the Forward Interlock Leversto use mve_e.

5. Theunit immediatelyengagesin reverse. Periodicallycheck behindyou while holding the handlebarsupandthe Wheels/Tines/PTOLeverin its upper-most position.

Stopping Reverse Motion

Releasethe Wheels/Tines/PTODrive Lever- the lever automatically returns to the NEUTRALposition. This stops the

wheels immediately.(TheForward

Interlock Leverswill notstop REVERSE motion.)

ToStopthe Engine

Move the engineThrottle Leverto the STOPposition. Then, on electric start

models, turn keyto OFF. Removethe key for safekeeping.

Section4: Operation

MakingTurns

Turningthe tiller is easyand just requires

practice. First find the balance point betweenthe engine and thetines by lifting upthe handlebars(Figure4-5). Onceyou

find the balancepoint, then letthe

poweredwheelsdo theturning as you pushsidewayson the handlebarsin the

direction of theturn. Practice theturning

maneuverdescribed herein alarge open area. Oncecomfortableturning the tiller, you canthen take it to the gardenarea.

1. Atthe endof a row, movethe Wheels/ Tines/PTODrive Lever(Figure4-2)to

NEUTRALpositionand reducethe engine speed.

2. Move the Tines/PTOClutch Lever

(Figure4-2) into the DISENGAGE

position.

3. Resumeforward operation, and lift

handlebarsuntil tines are off theground

(Figure4-5). Findthe balancepoint

betweenthe engine and thetines. Then

pushthe handlebarsin the direction of the turn. Be very careful to keepfeetandlegs

away fromthe tines (which should bedis-

engaged). Letthe poweredwheels do the

hardwork. The insidewheelwill pivotin

placewhile the outsidewheel drives the

tiller around inthe direction ofthe turn.

Figure 4-5: Turning the tiller.

NOTE:Use REVERSEif necessaryto turn

in alimited space.

Section4: Operation

4. Whenthe turn is complete,shift to

NEUTRALand lowerthe handlebars. Move Tines/PTOClutch Leverbackto ENGAGEposition and resumeforward

operation.

Transporting The Tiller Around Your Property

When the engineis running, thetiller's

poweredwheels make moving the tiller to

and from the gardeneasy. If the engine is

not running set the WheelSpeedLever to FREEWHEELposition to roll the tiller to

another location.

To help avoid personal injury from revolving tines, always put the

Tines/PTOClutch Lever in DISENGAGE positionbeforetransporting,loading,or unloadingUiler.

1. Placethe Tines/PTOClutch Leverin DISENGAGEposition.

2. MoveDepthRegulatorLeverdownall the

way intotheTravelsetting.

3. If using enginepower, moveWheel SpeedLeverto either SLOWor FAST,and

usethe Wheels/Tines/PTODrive Leverto drivethe wheels.

4. If theengine is stopped, moveWheel SpeedLeverto FREEWHEEL,and manually push tiller.

Testing the Forward Interlock SafetySystem

The Forward Interlock SafetySystem is

designedto shut thetiller engine off immediately if you losecontrol and cannot stop moving FORWARDby

shifting theWheels/Tines/PTODrive Lever into NEUTRAL. Whenyou releaseboth

Forward Interlock Levers,they send ground to the ignition system thereby stopping theengine. Squeezingoneor both levers up against the handlebars enablesthe ignition system;therefore,

you must squeezeat leastone lever whenever the Wheels/Tines/PTODrive

Leveris engagedin FORWARD. IMPORTANT: The interlock system also

prevents the engine from starting if the

Wheels/Tines/PTODrive Lever is engaged

in FORWARD.

The ForwardInterlockSafetySystem is designedfor the operator's safety. Do not disconnector attempt to defeat the purpose of the system, if the system malfunctions, immediately contactyour

local authorized dealer or the TROY-BILT Technical Service Depart-

ment for assistance. Do not use the tiller or the PTO power unit until the

Forward Interlock Safety System is functioning properly. Always test the system before using the tiller or PTO powerunit.

HowtoCheckthe Interlock System

The Forward Interlock System hasan electro-mechanicaldesign, and so is subject to normal wearand possiblemal- function. Checkthe system for proper

operationeach time prior to using the

tiller or PTOpower unit.

Figure 4-6: Plug and receptacle of Forward Interlock Safety System must be securely connected.

To test the ForwardInterlockSystem:

1. Movetiller outside to levelground. Removeany obstacles.

2. Checkthat the ForwardInterlockwire harnessplug, at the bottom ofthe handle-

bars (Figure4-6), is securelyconnected

to the receptacleon the top, right sideof the transmission.

3. MoveWheel SpeedLever(Figure4-2)

to SLOWposition and moveTines/PTO

ClutchLever to DISENGAGE.

4. Start engine asdescribed under Starting andStopping the Engine,in this

section. Setengine throttle lever to SLOW,and let enginewarm up.

5. Squeezeand hold just one of the

Forward Interlock Leversagainst the handlebargrip while movingthe Wheels/

Tines/PTO DriveLever down to FORWARD(Figure4-3). As the tiller

movesforward, releasethe ForwardInter- lock Leverbriefly. The engineshould

start to stall out if the interlock system is working properly. If it does start tostall, quickly squeezethe lever up againstthe handlebargrip, andthen return the

Wheels/Tines/PTO Drive Leverto NEUTRAL. Repeatthis test to checkthat

the engine beginsto stall out when the other ForwardInterlock Leveris released.

6. If the enginedoes not beginto shut off

when either ForwardInterlock leveris released,shut theengine off, removethe

key (if electric start), and donotoperate the tiller or PTOpowerunituntil the

systemhasbeenrepaired and isfunc- tioningproperly.

IMPORTANT:To avoid possible damage

to the ForwardInterlock Safetysystem, do not use high-pressure sprays nearthe wire harnessreceptacleor neutralplunger assembly.

Loading and Unloading the Tiller

Thefollowing provides information on tiller loading, unloading, andrequirements before loading and unloading the tiller.

Readthe following instructions carefully

beforeattempting to load or unloadyour tiller.

BeforeLoadingorUnloadingthe Tiller

• Ramps must be strong enoughto

support the combined weight of thetiller and handlers.Theyshould providegood

traction to prevent slipping; they should

haveside railsto guide thetiller along

the ramps;and they should havea

locking deviceto securethemto the vehicle.

• Handlersshould wear sturdy footwear

that will helpto preventslipping.

Section4: Operation

• Turnthe vehicle's engineoff and apply its parkingbrake.

• Positionthe loading vehicleso that the

ramp angle isas flat aspossible (the less incline to the ramp,the better).

Loadingthe Tiller

1. Use loading rampsthat arestrong and

wide enough to safely holdthe weight of the tiller andthe operator combined-- your tiller weighs between280 and 325

Ibs.

2. Move the Tines/PTOClutch Lever

(Figure4-2) into DISENGAGEposition.

3. Setthe DepthRegulatorlever (Figure

4-2) to the Travel position.

4. Move WheelSpeedLever (Figure4-2)

into SLOWposition and reducethe enginethrottle speed.

5. Shift the Wheels/Tines/PTOLever

(Figure4-2) into FORWARDposition and follow the tiller up the ramps (Figure4-7). Checkthe wheelsas you move the tiller forward. Ensurethat they moveupthe center of eachramp.

6. Preventtiller from rolling in vehicle.

LeaveWheel SpeedLeverin FASTor SLOWposition, chock wheels with blocks

and tie down the tiller.

Figure 4-7: To go up ramps, use FORWARD drive.

Unloading the Tiller IMPORTANT:Neverunload thetiller in

FORWARDdrive. Thetiller could tip forward andexposeyou to the tines

(which should bedisengagedas instructed).

1. Use loading rampsthat arestrong and

wide enough to safely holdthe weight of the tiller andthe operator combined--

your tiller weighs between280 and 325 Ibs.

2. Move the Tines/PTOClutch Lever (Figure 4-2) to DISENGAGEposition.

3. Setthe DepthRegulatorLever (Figure 4-2) to the Travel position.

4. Move WheelSpeedLever (Figure4-2) to SLOWposition and reducethe engine throttle speed.

IMPORTANT: Look behind you before you backdown the ramp to ensurethat all is clear. While descending, keepchecking for obstacles behindyou.

5. Move and holdthe Wheels/Tines/PT0 Lever into REVERSEdrive and backdown the ramps (Figure4-8). Checkthewheels

asyou move the tiller backward. Ensure that they movedown the center of each ramp.

Figure 4-8: TOgo down ramps, use REVERSE drive.

Changing Speed Belts

Your tiller hastwo belt-driven speed ranges- HIGH RANGEand LOWRANGE

- you pick one or the other by deciding which setof pulleygrooves to movethe forward belt into. Bymoving the belt from onespeed rangeinto the other, in

combination with the FASTand SLOW wheel speeds,you obtain a choice of four

different forward wheel speedsandtwo different tine speeds.

To help avoid serious personal injury, stop the engine, remove the ignition

key, disconnect spark plug wire and move the wire away from the spark plug, and let engine and muffler cool downbeforechangingbelt speeds.

Changingthe beltfrom LOWrange into HIGHrange (or backagain) isa matter of moving the belt from one setof pulley grooves to a second set of pulleygrooves.

This changeis done quickly andwithout tools (Figures4-9 through 4-13).

Pulley

Figure 4-9: Belt range positions.

Whenthe tiller is moving inREVERSE,the wheels arepowered bya rubber reverse

disc, not bythe belt. Therefore,you have onlytwo reversespeedsSLOWand FAST,

as set with the WheelSpeedLever. Table4-1 showsthe rangeof wheeland

tine speedsavailablewhen using the two

beltspeed rangesand the FASTand SLOWselectionson theWheel Speed

Lever.

Table 4-1

AvailablewheelandUnespeedsat 3000RPM

enginespeed.

Belt WheelSpeedWheel Tine

Lever _ Speed _ Speed

Low Range Slow .5MPH _46RPM

Low Range Fast 1.2MPH 146RPM

High Range Slow .7MPH 200RPM High Range Fast 1.72MPH 200RPM

ChangingBeltFromLOWRange

to HIGHRange

1. To avoid personalinjury, shut off

engine,let all moving parts come to a completestop, then disconnect spark

plug wire from spark plug andmove it away from spark plug beforemaking any adjustments. Wait for the engineand

muffler to cool down.

2. MoveWheels/Tines/PTODriveLever

into NEUTRAL.

Section4: Operation

The HIGH speed belt range position combined with a FAST wheel speed setting propelsthe tiller at the fastest pace. Reducethe enginethrottle speed whenstartingoutto help avoidpersonal

injury or propertydamage if using this

speedcombination.

3. Kneelon left side of tiller. Tocreate

belt slack, reachoverto right side of the pulleys and push inatthe center of the belt with a finger. At the sametime, use your left hand to work the belt part-way onto the lower-front transmission pulley groove (Figure4-10).

4. Goto right side of tiller and finish seatingthe belt.

5. Still holding the lever up in REVERSE position, and working from the left side of

thetiller, movethe beltfrom the lower- front transmission grooveto the lower-

rear transmission groove.

6. Goto the right side of the tiller and finish seatingthe belt (Figure4-13).

Figure 4-11: Low range to high range. Shows moving belt from top- rear groove onto top-front groove.

7. Checkboth sidesof the high range pulley groovesto verify that the belt is properly seated.

Figure 4-10: Low range to high range. Shows moving belt from lower-rear groove onto lower-front groove.

4. Goto the other side of the tiller to finish seatingthe belt onto the pulley

groove.

5. Working from the left side of the tiller, work the beltas muchas possibleonto the top-front engine pulley groove (Figure 4-11).

6. Finish seatingthe beltfrom the right side of thetiller.

IMPORTANT: Proper belt tension is important for good performance. See

Section 5, Drive Belt Maintenance for information on belt maintenanceschedule

and procedures. NOTE: If extra belt slack is needed to

move the belt, just raise the Wheels/Tines/PTO Drive Lever up into REVERSE.This lowers the engine pulley,

and createsmore slack.

Changing Belt From HIGH Range to LOW Range

1. To avoid personalinjury, shut off

engine,let all moving parts come to a complete stop, thendisconnect spark

plug wire from spark plug and move wire awayfrom spark plug before makingany

adjustments. Let engineand muffler cool.

2. Move theWheels/Tines/PTODrive Lever into NEUTRAL.

3. Standon left side of tiller. Useyour right hand to hold the Wheels/Tines/PTO Drive Lever up into REVERSEposition. Useyour left handto movethe belt off top-front engine pulley grooveto top-rear

engine pulleygroove (Figure4-12).

Figure 4-12: High range to low range. Shows moving belt from top- front groove onto top-rear pulley

groove.

Figure 4-13: High range to low range. Shows moving belt from

Iower-frent onto lower-rear groove.

7. Checkthat the belt isfully seatedinthe pulley grooves. Checkthis from both

sides of thetiller.

ChoosingWheel

and Tine Speeds

Your tiller hasfour FORWARDwheel/tine speedcombinations for handling a variety

of tilling tasks and gardening jobs. Exper- iment with the tine depth, enginespeed,

and wheel/tinespeedanddeterminethe combination that provides the best

results. Herearesome tips:

1. Advancethe throttle leverso the engine hassufficient power.

2. When tilling untilled or hard earth, do not set the Depth Regulatortoo deep.The

tiller will buckand the enginewill load down.

3. You will know your settings are ideal whenthe tines break-up the soil easily,

the enginedoes not labor, and your progress issteadyand smooth.

SeeTable2, WheelSpeedand BeltRange Selection Guidefor recommendations.

Section4: Operation

SLOWGEAR,LOWBELTRANGE

For:

• Tillinginsod.

• Tillingin hardclay,

• Tilling understandingcorn- stalks intoughsoil conditions.

• Tilling undercovercrops.

• Preparingadeepseedbed,

• Tilling instonysoil.

• Tilling underresiduesand organicmatter,

• Mixingin fertilizers,manure.

SLOWGEAR,NIGHBELTRANGE

For:

• Tillingin sodor hardclay.

• Tillingunderstandingcorn- stalks(slow,steadyspeed

allowstime to shredstalks).

• Tillingundercovercrops (bestwheelspeedand belt

speedrangein mostsoils).

• Preparingseedbeds(best speedchoicein most soils).

• Tillingin stonyground.

• Buildingraisedgardenbeds.

• Mixingin fertilizer.

• Usinghiller wingsin hard soil.

• Mixingfertilizer andmanure.

• Tillingresiduesandorganics.

TillingTips& Techniques

Letthetiller dothework

• While tilling, relax and letthe wheels

pull the tiller along while the tinesdo the digging. Walk on theside that is not yet finished (to avoid making footprints

inthe freshly tilled soil) and lightly, but

securelygrip the handlebarwith just

one hand(Figure4-4).

• Avoid pushingdown on the handlebars inan attempt to forcethe tiller to dig deeper. Doing so takesthe weight off

the poweredwheels, causingthem to

losetraction. Without thewheels helping to hold the tiller back,the tines

will attempt to propel thetiller - often

causingthe tiller to skip rapidly across

the ground. (Sometimes, slight

downward pressureonthe handlebars

will helpget through aparticularly tough section of sod or unbroken

ground, but inmost casesthis won't be necessary.)

Tilling depths

• Avoid trying to dig too deeplytoo quickly, especiallywhenbusting sod or tilling soil that hasn't beentilled for some time. Useshallow depth settings

(only an inchor two deep)for the first passesthrough the gardenarea.

FASTGEAR,LOWBELTRANGE For:

Goingoverseedbedfor the lasttime beforeplantingcrops.

Coveringoverseedsinwide row or plot planting(lift han-

dlebarsto avoidgoingtoo deep).

Hillingandfurrowing. Makingraisedbeds.

Cultivating(lift handlebarsto avoidgoingtoo deep).

•Tilling largeareas.

•Tillingorganicmatterin. Cultivatingbetweenraised

bedswith optional hiller/furrowerattachment.

With eachsucceeding pass,adjust the depth regulatorto diganother inchor

two deeper. (Wateringthe gardenarea

afew daysprior to tilling will make

tilling easier,aswill letting the newly

worked soil set for a day or two before making afinal, deeptilling pass.)

• Whencultivating (breakingup the surfacesoil aroundplantsto help

destroyweeds), usevery shallowdepth settingsto preventinjuryto plantswhose

rootsoften growcloseto thesurface. If needed,lift uponthe handlebarsslightly

to preventthetinesfrom diggingtoo deeply. Cultivatingon aregularbasisnot

onlyeliminatesweeds,it alsoloosensand

aeratesthe soilfor bettermoisture absorptionandfasterplantgrowth.

Avoidtillingwet, soggysoil

Tilling wet soil often results in large,hard clumps of soil thatcan interferewith planting. Iftime permits, waitaday or

two after heavy rainsto allow the soil to

dry beforetilling. Testthe soil by squeezingit into a ball. If it compresses

too easily,it istoo wet to till.

FASTGEAR,HIGHBELTRANGE

For:

Preparingseedbedsfor planting.

Coveringseedswith lessneed

to holdup thehandlebars.

• Cultivating(tillertravelsfaster, rideshigheron thesoil;allows

engineRPMto bereduced; handlebarsdon't haveto be

raised).

• Keepinglargeareastilledand cultivatedin thesummer.

•Tilling organicmatter under.

• Movingtiller quickly.

• Cultivatingbetweenraised bedsusing theoptional

hiller/furrower.

To helpavoid personalinjury, beaware that the tiller can unexpectedlybounce

up orjumpaheadand propelawayfrom you if the tines strike hard or frozen ground, or buried obstacles like large stones, roots or stumps. Always use the following precautions to help

maintaincontrolofthetiller:

• Walk behind and to the side of the tiller. Useonehand onthe handlebars, relaxing your arm but with a secure

handgrip.

• Use shallow depthregulatorsettings. Till graduallydeeper.

• Use slower wheel, tine and engine speeds.

• Clear the tilling area of all large stones,rootsandotherdebris.

• Do not putdownwardpressureon the handlebars. If needed, apply slight upwardhandlebarpressureto keep the tinesfromdiggingtoodeeply.

• Avoid contacting hard soil or sod at the endof a row - reduceenginespeed and lift handlebarsto raise tinesoutof thesoil.

• In An Emergency, stop tines and wheels by movingWheels/Tines/PTO

DriveLeverto NEUTRAL. If youcannot reachthe lever or havelostcontrol, Let GoOfThe HandlebarsandAll Controls.

Section4: Operation

TillingTips& Techniques

Avoidmakingfootprints

When possible,walkonthe untilledside

of theunit to avoid making footprints in

the freshlytilled soil (Figure 4-4). Foot-

prints causesoil compactionthat can hamperroot penetrationandcontribute

to soil erosion. Theycanalso "plant"

unwantedweedseedsbackinto the newlytilled soil.

Suggestedtilling patterns

• When preparingaseedbed,go over

the same path twice inthe first row, then overlap one-halfthe tiller width

on the rest of the passes(Figure4-

14). Whenfinished in onedirection, makea secondpassata right angle as

shown in Figure4-15. Overlapeach passfor best results (in very hard

ground it may takethreeor four passesto thoroughly pulverizethe soil).

• If the gardensizewill not permit lengthwiseand then crosswise tilling,

then overlapthe first passesby one-

halfa tiller width, followed by succes- sive passesat one-quarterwidth (Figure4-16).

• With planning,you canallow enough room between rows to cultivate

(Figure4-17). Leaveroom for the hood width, plus enough extra room

for future plant growth.

Tilling onslopes

If you must garden on sloping ground, pleasefollow two very important guide-

lines:

1. Till only on moderateslopes, never on steepinclineswherefooting is difficult (review safety rules in the "Safety" Sectionofthis Manual).

2. Werecommendtilling up and down slopes rather thanterracing. Tilling vertically on aslope allows maximum planting areaand also leavesroom for cultivating.

IMPORTANT: When tilling on slopes,

be sure the correct oil level is main-

tained in the engine (check every one-

half hour of operation). The incline of

the slope will causethe oil to slant away from its normal levelandthis can starve

engine parts of required lubrication.

Keepthe engine oil levelat the full point

at all times!

A. Tilling upanddownslopes:

• To keepsoil erosion to aminimum, be sureto add enough organic matter to the soil so that it hasgood moisture- holding texture andtry to avoid leaving footprints or wheel marks.

To avoid serious personal injury or

damagetothe equipment:

• Do not operatetiller on a slope too steep for safe operation. Go slowly

on any slope. Make sure you have goodfooting.

• Wear footwear that increases stabilityand reducesslippage.

• Do not use FAST wheel speed positionwhenon slopedground.

• Do not shift the Wheel Speed Lever

when headingup or downa slope. If

lever is accidentally moved to FREE WHEELposition, the tiller could roll

outofcontrol.

• To prevent enginedamagedueto oil starvation (on slopes,the engine is inclined and oil moves away from surfaces that need lubrication), be

sure the correct oil level is main-

tained during all uphill/downhill tilling operations. Checkthe level of the oil in yourengineafter every one-

half hourofoperation.

• When tilling vertically, try to makethe first pass uphill asthe tiller digs more deeplygoing uphill than it does downhill. Insoft soil orweeds,you

may haveto lift the handlebarsslightly while going uphill. When going downhill, overlap the first pass by

about one-halfthe width of thetiller.

HINT: For best results, usethe HIGH belt rangeand SLOWwheelspeedlever

position. SeeChanging SpeedBelts in

this section for more information on

changingto high range.

Figure4-14

Figure4-15

Figure4-16

]

TillingTips& Techniques

Figure 4-18

B.Terrace Gardening:

• Whena slope is too steeportoo short

for vertical tilling, it may be necessary to till across the slopeand create

terraced rows. Terracesare rows that are cut into the sideof a slope,creating

a narrow, but flatareaonwhich to plant.

• Ona long slope, you can makeseveral terraces, onebelowthe other.

• Terracesshould be only 2-to-3 feet wide. Diggingtoo far into the side of

the slopewill exposepoorsubsoil that is unproductivefor plants.

• To createaterrace,start at thetop of the slopeandwork down. Go backand

forth across thefirst row as shown in Figure4-18.

• Eachsucceeding lowerterrace is started bywalking belowtheterrace

you're preparing. Foradded stability of thetiller, always keepthe uphill wheel

in thesoft, newlytilled soil. Do not till the last 12" or more of the downhill

outside edgeof eachterrace. This untilled strip helps prevents the

terracesfrom breakingapartand washing downhill. It also provides a

walking path betweenrows.

C. Tillingacrossslopes

withoutterracing

• If vertical orterracing gardening aren't practicalfor you, then you cantill

laterallyacrossa slope. Wedon't reallyrecommend this method asit

cancreate unsure footing and invites soil erosion.

• Studythe terrain to makecertain the

slope is not too steepfor safetilling.

If possible, maketerraced rowsor till

vertically.

• Movethe belt into LOWbelt rangeand

the WheelSpeedGearLeverto SLOW

position. As in terracegardening, start

atthe top of the slopeand overlapthe first pass by halfthe width of thetiller.

Foraddedstability, keepthe uphill

wheelin the soft, newlytilled soil. Each succeedingterraced areais started by

walking belowthe terrace you are

preparing (Figure4-19).

Section4: Operation

Clearingthe tines

Thetines havea self-clearing action which helps to eliminate most tangling

of debris. However,occasionally dry grass,stringy stalks or tough vines may becometangled.

Followthese proceduresto helpavoid

tangling and to clearthe tines, if

necessary.

Beforeclearing the tines byhand, stop

the engine, allow all moving parts to

stop and disconnect the spark plug

wire. Failure to follow this warning

couldresultin personal injury.

• To reducetangling, setthe Depth Regulatordeepenough to get maximum "chopping" action as the

tines chopthe materialagainst the ground. Also, try to till under crop

residuesor covercrops while theyare

green, moist andtender.

• While power composting, try swaying

the handlebarsfrom side to side (about 6"to 12"). This"fishtailing" action

often clearsthe tines of debris.

• It may be necessaryto removethe

debris by hand(a pocketknife will help you to cut awaythe material).

Figure 4-19: Make a terrace in just 4 or 5 passes with the tiller.

Section4: Operation

TillingTips& Techniques

POWERCOMPOSTING

Powercomposting meanstilling under

and burying inthe soil all mannerof

organic matter suchas crop residues, leaves,grass clippings and covercrops.

This materialwill decomposeduring the

non-growing seasonand add important natural nutrients to the soil.

After tilling under crop residues,add

more organic matter suchas leaves, grass clippings andeven kitchenscraps.

When tilled into the soil, this organic

matterwill decomposeandadd even more important nutrients to the soil.

After power composting, you maywant to plant a "green manure" cover crop to

protect the soil during the off-season.

1. As you moveforward intoa row of stalks,aim the tiller sothat the stalks go

betweenthe left wheelandthe transmis- sion case(Figure4-19). Do not usethe

right wheel becausedamagecould occur

to theair cleaner, carburetor or throttle

linkage.

Whenpower composting, do not keep the DepthRegulator Lever at a deep

settingif thetiller jumpsorbucks. If jumping or bucking occurs, move

the Depth Regulator Lever down to one of the shallower settings and

then slowly increasethe tilling depth on later passes.

Failure to complycouldresult in loss of tiller control, propertydamage or personalinjury.

Begin by composting crop residues such

as leftover vines, stalks,stems and

roots. Power compost thesecrop residuesas soon asthey finish bearing.

The soonerthis is done,the better,as tender green matter is easierto till

under. Usethe deepestdepth regulator setting possible without causing the engineto labor or the tiller to jump

ahead.

Standingcornstalks of reasonableheight canbe powercomposted (Figure4-20).

Pushing over (but not uprooting) corn-

stalks will often makeit easierfor your tiller to chop up the stalks. Keepthe tines clear of excessivetangling by"fish- tailing" or frequently using reverse.

Makeseveral passes,then return a few

days laterto finish off any remaining

stubble.

Growa crop of clover,alfalfa, buckwheat,peas, beans,ryegrass, grain, or kaleand then till it into the soil prior to the plantingseason.

Wide-Row Planting

Thewide-row planting techniqueis

spreadingseedsanywherefrom 10 inchesto 2 feet wide or more. As a

result, you cangrow anywherefrom 3 to 4 times (or more) produce in the same spacethat is normally setaside for an

areathat has narrow, single rows. Wide-row planting automaticallyshades

the ground which keepsweed growth

down and also holds moisture in the soil. And of course, harvesting is much

easier- everything is right at handto be picked. Preparing wide rows iseasy --

after you preparethe seedbedand mark

off the rows with string, hand-broadcast the seedsas if seeding a lawn (not quite as much as lawnseed). Coverwith soil and tamp the areafirmly with a hoe.

Tilling Under Corn

After corn is harvested,thestalks should

betilled into the soil while still green.

Dry plantsare more difficult to till under, and the roots breakloosetoo easily.

IMPORTANT: Do not pull the roots out

by hand or cut the stalks before tilling.

Stalks that are firmly anchored by their

roots are much easier for the tines to

chop, cut, and work under.

Figure 4-20: Tilling under corn stalks.

2. Eachnew passshould overlapthe previous passby one-halfthe width of

the tiller.

3. Till as deeplyas possible. Pull the Depth Regulatorallthe way UPand engagethe lowest notch for deeptilling.

Useeither LOWor HIGHbelt rangeand SLOWwheel speedgear position.

Letthe tilled-in stalksdecomposefor a

week or so. Thentill inthe remaining

residueas deepas possible.

Section4: Operation

PTOPOWERUNIT

Your tiller isaself-contained PTO(Power Take-Off) PowerUnit that wasshipped

with atine attachment installed. Thetine attachment canbequickly removed and

replacedwith other optional attachments. Thefollowing instructions will familiarize you with your PTOPower Unit. Please read thesepagescarefully.

Figure 4-21: PTO Power Unit and tine attachment.

Before operating your PTO Power Unitforthe firsttime, make surethat

you have:

• Read all the safety instructionsin Section 1 of this Manual and in the

Manual supplied with any attach- ment.

• Read the controlsinformationand operating procedures for the tiller

and engine described in Sections 3 and 4 of this Manual and in the

EngineOwner'sManual.

• Read and understandthe assembly instructions, controls information,

and operating procedures for the attachment as described in the

AttachmentOwner'sManual supplied with theattachment.

Thefollowing stepsexplain howto remove andreplacethe tine attachment. You will needa 3/4" wrench (minimum 12"longfor leverage).

RemovingTineAttachment

1. Movethetiller to levelground.

2. Besurethe engineisstopped,the

electricstart keyis removed,andthespark plug wireis disconnectedandmovedaway from sparkplug.

RemovingAndReplacingTheTineAttachment

Wheel DriveLever

Speed, Engine Lever _ ThroHleLever

Figure 4-22: PTO Power Unit controls.

TO AVOID PERSONAL INJURY OR

DAMAGETOEQUIPMENT:

• Stop the engine, removethe electric start key, disconnect the spark plug wire and let the engine and muffler

cool before removing or installing any

attachment.

• Do not place hands, tools, or any

object near or inside the PTOaccess

area while the engineisrunning.

• When removingor replacingthe tine attachment, be careful of the sharp

edges on the tiller hood. Wear thick glovesforhand protection.

• When the tine attachment is removed, always prop it up with a

block to prevent the attachment from

falling forward.

3. Placeasturdy support underthe

engineto prevent the enginefrom tipping forward whenthe tine attachment is

removed (Figure4-23).

4. PlacetheWheels/Tines/PTODriveLever

into NEUTRAL(Figure4-22).

5. PlaceTines/PTOClutch Lever in

DISENGAGE(Figure 4-22).

Wheels/Tines/PTO

_ Forward

InterlockLevers

_Depth

Regulator Lever

Figure 4-23: Block up engine.

6. PlaceWheel SpeedLeverinto FREE

WHEEL(Figure4-22).

7. Loosenthe two swing-out bolts (Figure 4-24) that connectthe power unit trans- mission to the tine attachmentandswing out the bolts (Figure4-25).

HINT: Looseningswing-out bolts canbe difficult. Useanextra-longwrenchfor leverage.

8. Tip the PTOpower unit forward about one inch with onehandwhile pulling the

tine attachment back(Figure 4-26). The

guide pinon the power unit will slide out ofthe guide hole in the tine attachment (Figure4-27).

Section4: Operation

Figure 4-24: Loosening attachment

awing-bolts.

10. The PTOPowerUnit is now readyto install other poweredor non-powered

attachments. Seethe attachment's Owner's Manualfor installation and

operation instructions specific to that attachment.

Installing the Tine Attachment

1. Move the two PTOPower Unitswing- out bolts outwardandslide thewashers

up againstthe bolt heads.

2. Removethe support block from under the engineand slowly roll the power unit

back nextto the tine attachment. Place the support block backunderthe engine.

3. Removethe dust cap (or protective wrapping) from the dog clutch coupling

on the tine attachment.

4. Carefullyalign the guidepin on the PTOPower Unit with the alignment hole

in thetine attachment andbring thetwo units together (Figure 4-27).

PTOPOWERUNIT

OPERATINGINSTRUCTIONS

To help avoid personal injury or damage to equipment, read the attach- ment's Owner's Manual supplied with each attachment before installing or operatingan attachment. Please read all control, operation and safety

instructions.

Thefollowing are operating instructions specifically for the PTOPower Unit. Read

the separateOwner's Manual supplied with eachattachment before attempting

to assemble, attach,transport or operate the attachment. If needed,pleasecontact

usfor a replacement manual. Seethe backcover for customer support

information.

Figure 4-25: Moving swing-bolts outward.

IMPORTANT: Store tine attachment in a

level, upright position to prevent gear oil

from leakingfrom the dipstick area.

Figure 4-26: Pulling attachment away from power unit.

9. To keepthe tine attachmentdog clutch coupling clean,cover with the dust cap

(on someattachments)or plastic wrap.

Mounting

Figure 4-27: Aligning guide pin with mounting hole.

5. Move the two swing-bolts into the

slots ofthe tine attachment. Alternately tighten eachbolt until they aretight enough to makethe concavewashersflat.

Thebolts must be very tight - if you have

a torque wrench, tighten eachbolt to between 70and80 ft.-Ibs.

IMPORTANT: The swing-bolts must be kept very tight to prevent damaging wear to the dog clutch coupling, alignment pin or the alignment hole. Check bolt tightness every2-1/2 operating hours.

6. Removethe engine support before

moving the tiller in a forward direction.

To help avoid personal injury, always disengage the Tines/PTO Clutch Lever beforetowingany attachment.

Someattachments haveadrive shaft or a hydraulic pumpthat is powered by the

engine onthe PTOPowerUnit. These

units arecalled StationaryAttachments,

since they remain inonelocationwhen

operating. Attachments can betowed to a

work sitewith the PTOPower Unit as described in OperatingNon-Powered

Attachments. Otherattachments are

pulled ortowed behind the PTOPower Unit. Theseattachmentsare calledNon-

PoweredAttachments.

SettingUpStationaryAttachments

To help avoid personal injury, never allow people to ride on any PTO Power

Unitor attachment.

1. Move the Tines/PTOClutchLeverto DISENGAGE.

2. Move WheelSpeedLever (Figure4-22)

to FREEWHEEL,then block allwheels

(Figure4-29) to preventthe equipment

from rolling.

Section4: Operation

Figure 4-28: Forward Interlock Wiring A - PTO Power Unit Interlock Harness

B - Forward Interlock Receptacle C - Attachment Interlock Wire

3. Onthe PTOPowerUnit, unplugthe Forward InterlockWire Harnessthat leads

from the baseof the handlebars(A, Figure 4-28) to the receptacle(B)locatedon the top, right side ofthe transmission cover.

4. Onthe Stationary Attachment, locate the interlock wire (C,Figure4-28) and cleancontacts on plug and receptacle(B). This connection enablesyou to operate

the Wheels/Tines/PTODriveLeverin FORWARDwithout havingto squeezea Forward Interlock Lever.

5. Connectthe plugfrom the Stationary Attachment (C, Figure4-28) to the recep- tacle onthe PTOPowerUnit (B). The connection must betight.

Setting Up Non-Powered Attach- ments

1. Move the Tines/PTOClutch Lever (Figure4-22) to DISENGAGE.

2. Move the WheelSpeedLever(Figure 4-22) to either SLOWor FASTposition To do this, roll the PTOPowerUnit while shifting leveruntil wheels engage.

3. Verify that the Forward InterlockWire Harnessplug at the baseof the handle- bars (A, Figure4-28) is connectedto the Forward Interlock Wire Harnessrecepta- cle (B) on thetop right side of the

transmission.

Starting The Engine IMPORTANT:Referto Cold Weather

Operationinstructions, in this section,

before operating intemperatures below 40OF.

1. Move the Wheels/Tines/PTODrive Lever into NEUTRAL.Tofind NEUTRAL

(be sure engine is oft), push leverdown and engageit in FORWARDthen tap the lever upwardto automaticallymove into

NEUTRAL.

2. Move theTines/PTOClutch Leverinto DISENGAGEposition.

To avoid injury,donot run the enginein an enclosed or poorly vented area.

Engine exhaust contains carbon monoxide,an odorlessand deadlygas.

3. Start Engine. SeeStarting and

Stoppingthe Engine,in the beginning of this section,for detailedstarting informa- tion. Also seethe EngineOwner's Manual.

4. Fornon-powered attachments onlytest the Forward Interlock SafetySystem. See

Testingthe ForwardInterlockSafety System, in this section, for a procedure.

Operating Stationary Attachments

1. Move Tines/PTOClutchLever (Figure

4-22) into ENGAGE.

2. To applypowerto PTO-drivenattach- ments, moveWheels/Tines/PTOLever

(Figure4-22) down to FORWARDposition (do not useREVERSEwithstationary

attachments).

3. To stop the PTOPowerUnit, tap the Wheels/Tines/PTODriveLever upward

into NEUTRALposition.

Operating Non-Powered Attachments (or to Tow Stationary Attachments)

1. To moveforward, squeezeandhold oneForward InterlockLever(Figure4-30) up againstthe handlebars,and movethe

Wheels/Tines/PTODriveLever down to

FORWARD.

Figure 4-30: Moving tiller forward: squeeze one Forward Interlock Lever

and then move Wheels/Tines/PTO Drive Lever down to FORWARD.

2. To stopforward motion, tap

Wheels/Tines/PTODriveLever upward

into NEUTRAL,then releasethe Forward Interlock Levers.

3. To stop forward motion inan emergency,releaseall PTOPowerUnit controls (stops engine).

4. To move in reverse,reducethe engine speedthen shift theWheel SpeedLever

into SLOW. Move andholdthe

Wheels/Tines/PTODriveLever alltheway

up. Ensurethatthe areabehind you is clearof all obstacles,beforemoving the

leverinto REVERSE.

Figure 4-29: Block wheels on PTO Power Unit and stationary attachment.

5. To stopmoving in REVERSE,release

the Wheels/Tines/PTODrive Lever.

StoppingtheEngine

Movethe EngineThrottle Leverto STOP.

Turn keyswitch to OFFon electric start

models.

Maintenance

REQUIRED MAINTENANCE SCHEDULE

Before inspecting, cleaning or servicingthe machine, shutoffengine, wait for all movingparts to come to a complete stop, disconnect spark plug wire and move wire away from spark plug. Remove ignition key on electric

startmodels.

Failureto follow these instructionscan

result in serious personal injury or propertydamage.

NOTE: All referencesto left, right, front

and rearof the machinearedeterminedby standing behindthe handlebarsandfacing

thedirectionof forwardtravel.

PROCEDURE

Checkengine oil level

Cleanenginecooling system • Testoperation of Forward Interlock •

SafetySystem

Forward Interlock SafetySystem- •

checkwire condition,connections

Checkelectrical connections •

Rechargebattery Checkdrive belt tension Checknuts and bolts

Cleantiller tine shaft Lubricate tiller

Changeengineoil*

Cleanfoam element air filter Checkpaperelementair filter

Checkfor oil leaks

Checkgearoil levelin * After initial

both transmissions 2 hours

Checkbolo tines for wear • Checkreversedisc for wear *

Checkair pressure in tires •

• During enginebreak-in period, change engine oilafter first 2 hours of operation.

Before Every Every Every

Each 10 25 30

Use Hours Hours Hours

Noted

Every5

operating hrs.

Section4

Before/after

long storage

After initial

2 hours

After initial

2 hours

Moreoften in dusty or dirty areas Moreoften

in dusty or dirty areas

After initial

2 hours

Section5: Maintenance

_ efore inspecting,cleaning orservicingthe machine, shutoff engine, wait for all movingpartsto come

to a completestop,disconnectsparkplug wire and movewire away from sparkplug. Remove ignition

key,if soequipped. Failureto followthese instructionscanresultinseriouspersonalinjury or propertydamage.

Tighten Bolts and Nuts

Checkfor loose or missing hardware every ten (10) operating hours. Failureto tighten or replacefasteners cancause poor performance,equipment damage or oil leakage. Seeyour PartsCatalogfor complete fastenerdescriptions.

Most hardwareon your tiller isvisible. Payparticular attention to hardware shown inFigures5-1,5-2, 5-3 and5-3A.

1. Checkthe transmission pulley mounting bolt (Figure5-1). If the washer

behind the bolt headis loose,the bolt needstightening. To do this, first insert a

punch or thick screwdriver into the hole next to the bolt and wedgethetool against theside of the motor mount casting. This immobilizesthe pulleywhile you tighten the bolt.

2. Checkjam nut onleft side of neutral plungerassembly(Figure5-2). If loose,

immobilize bolt headwith one wrench and useanother wrenchto tighten the nut.

3. Checkthe three rear bearingcap screws underthe depth regulator mounting bracket (A,Figure5-3). Ifany

is loose, it cancausean oil leakor drive shaft end play.

4. Checkthe five bolts securing thetiller housing coverto the leftside of the trans- mission (B in Figure5-3). Gearoil can leakfrom a loose housing cover. To

reachthe bolts, removethe leftside tine holder. SeeBolo TineMaintenanceinthis

Section for tine holder removal directions.

5. Checkboth swing-bolts (C, Figure5-3)

that connectthe power unit transmission to the tine attachment. Both boltsshould

becheckedevery 2-1/2 hours of

operation. If loose,wearcan occur on the

locating pin onthe power unit, andcause

enlargement of the locating hole in the tine attachment. Using atorque wrench, tighten thesebolts to 70-to-80 ft.-Ibs.

6. Checkthe Iocknutthat fastensthe shifting linkageto the eccentric shifting

lever(D, Figure5-3). Do nottighten the Iocknut againsttheeccentric lever. It should be very closeto, but not touching

the lever.

7. Checkthe four bolts and nuts securing left and right tine holders to the tine shaft (Figure5-3A).

IMPORTANT: Give screws or bolts that go into the transmission housing a

coating of non-hardening gasket sealant

to prevent gear oilfrom leaking.

TillerLubrication

Proper lubrication of the tiller's mechani- cal parts is anessentialpart of good

maintenance. Lubrication should bedone after everyten (10) hours of operation.

Useordinary motor oil (#30 weight or lighter) where oil is specified. Usea quality greasewith a metal lubricant wheregrease is recommended(regular greaseis acceptable). Do not over lubricate. If there is a build-up of dirt, removethe build-up and re-applyoil or grease.

Figure 5-3A: Tine holder hardware must be tight.

Figure 5-1: Check bolt on transmission pulley.

Figure 5-2: Check jam nut on plunger assembly. 29

Figure 5-3: Gently tilt tiller forward to check fasteners.

Section5: Maintenance

Beforeinspecting,cleaningor servicingthe machine, shutoffengine, wait for all movingpartsto come J

to a completestop, disconnectspark plug wire andmove wire away from spark plug. Removeignition J

key, if soequipped. Fa ure tofo owthese nstructonscan resut n ser ouspersona njuryor propertydamage.

IMPORTANT: Do not allow oil or grease

to contact the pulleys, drive belt or

reverse disc. This can causethe belt or

disc to slip on the pulleys.

Lubricatethe numberedareas in Figures 5-4 and5-5, as follows:

1. Oil the wheelshaft betweenthe wheel hubsand the transmission housing

(A, Figure5-4).

2. Oil all pivoting and connecting points on the Wheels/Tines/PTODriveLeverand

the WheelSpeedLever (B, Figure5-4).

3. Greasethe face of the beltadjustment block (C,Figure5-4).

4. Oil the DepthRegulator Lever, including the spring inthe mounting bracket(D, Figure5-4).

5. Oil the full length of thethrottle cable

casing (E,Figure5-4).

6. Oil threads onHandlebarHeight Adjust- ment Lever(F, Figure5-4).

7. Greaseleft-andright-side engine mounting barsat the top, the middle,and bottom (G,Figure5-4).

8. Greasethe zerkgreasefitting located

on the pivot point atthe end of the Wheel Speed Lever(H, Figure5-4). If Wheel Speed Leverhasagreasefitting on pivot assembly, apply2-to-3 strokes of multi-

purposegreaseat beginning and endof

tilling season.

9. Keepthe PT0 accessareawell-greased (I, Figure5-5). If theTines/PTOClutch Leverbecomes hardto move, squirt some

oil into its accesshole, and work it back and forth to dispersethe oil.

Transmission Gear Oil Maintenance

Checkingfor Oil Leaks

At 25-houroperationintervals,checkthe tillerforoilleaks.Inspectforoil accumu-

lationson thetillerorthefloorwhereit's

stored.

If tilling during very hotweather,the gear oil mayheat up and expandinsidethe

transmissions. Toallow for this oil

expansion,both the power unit transmis- sion and thetine attachment transmis-

sions haveoil reliefvents (Figure5-6).

Figure 5-6: Oil relief vent locations.

Thevents allow small amounts of oil to seepout.

If aserious leak is discovered, please contact your authorized dealer or the FactoryTechnicalService Departmentfor

serviceadvice.

A small amount of oil seepageorwetness

Figure 5-4: Tiller lubrication points (wheel removed for clarity).

Figure 5-5: Use grease liberally in PTO access area.

around ashaft opening or cover is no causefor

alarm. Buta heavy con- centration of oil is more

serious. You should tighten all bolts immedi-

ately,and replaceany worn seals or gaskets.

it may be impossible to determine how much oil

hasbeen lost, so checkthe oil levelsin the PTOtrans-

mission and the tine attachmentbefore using

thetiller again. Add any necessarygear oil. Seriousdamage to the transmission components can result from operation whengear oil levels are

low.

Checking Gear Oil Levels

Every30 hours of operation, checkthe gear oil levelin boththe power unit trans-

mission and the tine attachmenttransmis- sion. Operatingthem while low ongear

oil (evenbriefly) cancause serious damageto internal components.

Preparation

1. The transmissionsmustbe cool, since hot gear oil expandsandgivesa

false reading.

2. The power unit transmission and the

tine attachmenttransmission must be

connectedwhen checking (or adding) gear oil.

CheckingthePower UnitOil Level

1. Move thetiller to levelground. Move

the Depth Regulatorup sothe tines rest

on the ground.

2. Usea 3/8" wrench to removethe oil levelcheck plugon the left side ofthe

transmission housing (Figure 5-7).

Section5: Maintenance

Beforeinspecting,cleaningor servicingthe machine, shutoffengine, wait for all movingpartsto come

to a completestop, disconnectspark plugwire and move wire away from spark plug. Remove ignition

key, if soequipped. Failureto follow theseinstructionscanresultin seriouspersonalinjury orpropertydamage.

Figure 5-7: Remove oil level check

plug. Gear oil should seep out if

the level is sufficient,

3. If the oil levelis correct, oil will seep out ofthe check hole (allow extra time in cold weather). If it does,the levelisfine and you should replace thecheck plug. If no oil seepsout, seeAdding or Changing

GearOil.

Checkingthe Tine AttachmentOilLevel

IMPORTANT: Two different gear oil checking procedures for the tine attach-

ment transmission are described next. Use the first procedure if the dipstick in

your tine attachment has only a 'Check Cold' marking. Usethe secondprocedure if the dipstick has both cold and hot markings at the end. First remove the dipstick from the tine attachment trans- mission (Figure 5-8) to see which type dipstick you have. Then replace the dipstick with markings on dipstick facing

to rear.

Figure 5=8: Checking gear oil level; markings on dipstick (tine attach-

ment transmission) must face rear.

ForDipsticksWith 'CheckCold' Marking

(Cold means 2 hours has passedsince thetiller was used.)

1. Move the tiller to levelground.

2. Pull the DepthRegulator Leverback, then push it down all theway (to engage its top notch).

3. Placeasturdy support underthe engineto prevent thetiller from tilting too

far.

4. Now slide three piecesof 2"x 4" lumber underneaththe drag bar- raising the drag barabout 4-1/2" above ground.

This elevationallows anaccurate "cold" gear oil reading.

5. Wait two hours with tiller elevated (allow moretime if temperatureis below

40°F).

6. Loosenand removetransmission dipstick (Fig.5-8). Wipe it cleanwith a

rag.

7. Hold dipstick so its markings faceto rear of tiller. Lower itstraight down into the sump holeto touch thedrive shaft inside (Fig. 5-8). Don't force or try to thread it backin; an incorrect readingwill

result.

8. Removedipstick and checkoil level. It should be anywherewithin the cross- hatchedarea or evenslightly abovethe Max marking. If correct, replacedipstick and removethe boards usedas props.

9. If oil level was low, gearoil must be added beforeusing the tiller. See Adding

or ChangingGearOil next.

For DipsticksWithHot/ColdMarkings

1. Move the tiller to levelground.

2. Pull the DepthRegulator Leverback, then push it down all theway (to engage its top notch).

3. Placeasturdy support underthe engineto prevent thetiller from tilting too

far.

4. Coldreading(preferred method): (Two hours haspassedsince thetiller

was used.) Placea2"x 4"board (on

edge)under the drag bar- raising the tiller

and drag barabout 3-1/2"aboveground.

Hotreading:(Tiller was operatedfor morethan 30 minutes within the past hour.) Do not usethe wood prop to

elevatethetiller.

5. FollowSteps 4, 5 and6 givenfor the other dipstick type.

6. Removedipstick and checklevel. It should be within or abovethe "Cold"

rangemarking if taking a cold reading. If

taking ahot reading,the level should be within or slightly above the "Hot" range.

7. If the level is incorrect,seeAdding or ChangingGearOil.

Addingor ChangingGearOil

Forpartial fill-ups (just a fewouncesor less), useSAE140,SAE85W-140, or SAE 80W-90weight gear oil with an API rating of GL-4 or GL-5. Forfull replacement, useSAE140 or SAE85W-140 gear oil

with anAPI rating of GL-4 only. (Atthe factory, SAE85W-140 weight gear oil is

used.) IMPORTANT: Do not use automatic

transmission fluid or engine oil. Theyare too light in weight andwill result intrans-

mission damage.

Thegear oil does not needto bechanged.

Doso only ifyou know, orsuspect, it is contaminatedwith dirt, sandor other

foreign particles.

Gearoil is availableat authorizeddealers

and most servicestations, power

equipment centers,orfarm/heavy equipment outlets.

Capacities: Powerunit transmission holdsapproximately 60 ozs.; TineAttach- ment transmission holds approximately

12-1/2" ozs.

Section5: Maintenance

_ Beforeinspecting,cleaningor servicingthe machine, shutoff engine, wait for all movingpartsto come

to a completestop, disconnectspark plug wire and move wire away fromsparkplug. Removeignition J key, if soequipped. J

Failureto followthese instructionscanresult inseriouspersonalinjuryor propertydamage. J

AddingGearOil to the

PTOPowerUnit Transmission

1. Dosteps 1and 2of Checking the PowerUnit Oil Levelon page32.

2. Using a 3/4" wrench (orsocket), removethe bolt securingthe handlebar baseto the top of the transmission (prop

the handlebarsfirst to prevent them from falling).

Then, unplugthe Forward Interlock wire

harnessreceptacleat the bottom ofthe handlebars. Setthe handlebar baseand bolt asideonaclean surface. The bolt

hole inthetop of the transmission isthe

gear oil fill hole(A, Figure5-9).

3. Slowly pourgearoil through aclean

funnel into the transmission. Stop when gear oil beginsto flow from the oil level

check hole on the left side of the trans-

mission (B, Figure5-7).

4. Reinstallthe oil level check plug.

Tighten it securely.

5. Reinstallthe handlebarsusing the mounting bolt previously removed. Align

the handlebarssothey point straight

backwards,not atan angle. Thentighten

the mounting bolt securely.

6. Reconnectthe Forward Interlock wire harnessto the receptacle. Be certain it's

secure.

7. Testoperation of the Forward Interlock

SafetySystem. SeeSection 4 for a

procedure.

Drainingand Filling the PTOPowerUnit Transmission

1. Placea shallow pan under the trans- mission gear oil drain plug (B, Figure

5-9).

2. Removethe oil levelcheck plug (Figure

5-7) with a 3/8" wrench. Thisvents the transmission for faster oil draining.

Figure 5=9: Gear oil fill hole (A) and

gear oil drain location (B).

3. Using the 3/8" wrench, removethe drain plug (B, Figure5-9). The gear oil will drain quiteslowly since it isthick. After about two quarts havedrained, tilt the tiller forward so any oil atthe rear of

the transmission will drain out.

4. Cleanthe drain plug threads, put non- hardening gasketsealant onthe threads, and reinstall plug.

5. Refillthe transmission withthe correct amount of gear oil beforeoperatingthe

tiller again. When oil seepsfrom the oil levelcheck hole,the right amount of gear oil has beenadded. Replaceall plugs.

AddingGear Oilto the Tine AttachmentTransmission

1. Selectthe right Depth Regulator Lever setting:

a. If filling an empty transmission, raise

the Depth Regulator Leverso tines are onthe ground.

b. If topping off thegear oil, move Depth

RegulatorLeverdown to engageits

top notch.

2. Removedipstickfrom tine attachment (Figure5-8).

3. Slowly addgearoil in the dipstick hole. Add 1/2-ounceat atimeto avoid overfill-

ing. It takesabout 12-1/2 ounces.

4. Takedipstick readingsfrequently. Stop when oil reaches"Cold" rangemarking on dipstick. Replacedipstick securely.

Drainingand Filling the Tine

AttachmentTransmission

1. Thetine attachmenttransmission is not equippedwith an oil drain plug. To

drain just a small amount of gear oil,

removethe dipstick and tilt the attach- ment forward (first uncoupling it from the PowerUnit).

2. For complete drainage,remove the le_

side tine assembly(refer to Bolo Tine

Maintenancefor instructions), then removejust one of the lower screwsfrom

the tiller housing cover (Figure5-10). To speeddrainage, removethe tineattach-

ment dipstick to venttransmission.

Figure 5=10: Remove housing cover screw to drain tine attachment

transmission gear oil.

NOTE: If you find a plastic washeronthe

cover screw you remove,discardthe washer. There is noneedto installa

replacementwasher.

3. Onceall gear oil hasdrained, reinstall

the housing coverscrew securely (first coat itsthreads with non-hardening gasketsealant).

4. Be certain to refillthe transmission

with the correctamount of gear oil before

operatingthe tiller again.

Section5: Maintenance

_ efore inspecting,cleaningor servicingthe machine, shutoff engine,wait for all movingpartstocome

to a completestop, disconnectsparkplug wire andmove wire away from spark plug. Remove ignition

key, if so equipped. Failureto follow theseinstructionscanresultin seriouspersonalinjury orpropertydamage.

Drive Belt Maintenance

MeasuringandAdjusting DriveBeltTension

Onanewtiller (orifanewbeltis installed),thebelttensionwill probably

needtobeadjustedafterthefirst two (2) hoursofoperation.Thereafter,checkbelt

tensioneveryten (10)operatinghours.

Maintaining the right tension is important

to good tiller performanceand long belt

life. If too loose, the beltwill slip on the pulleys,and be unableto deliverfull

powerto the wheels andtines. A loose beltwill also wear prematurely.

While checking belttension, also inspect the belt for cuts,cracks, deterioration,

etc. Don't continue usinga belt that isn't

in good shape. You're sacrificing tiller performanceby doing so.

Tips onkeeping the drive belt intop condition include:

• Always put the Wheels/Tines/PTODrive Leverin NEUTRALwhen thetiller is not in

use.

• Keeptension adjusted correctly.

• Don't "speedshift" when movingthe

Wheels/Tines/PTODriveLever between

FORWARDand REVERSE.

HowtoMeasure Belt Tension

1. Beforetaking a measurement,besure

the linkages and pivot points on the Wheels/Tines/PTODriveLever areclean

and lubricated. If there isany binding, you won't get true measurements. Also, you'll needthe belt adjustmenttool you

receivedwith your new tiller (Figure 5-11).

2. Move the Wheels/Tines/PTODrive Leverfully downto the FORWARD

position. Theclutch roller at the bottom ofthe lever should be positioned under- neaththe belt adjustment block(Figure 5-12). Don't let the clutch roller move

during the nextfew steps. If it moves, you'll getafalse belt tension reading.

3. The belttension is correct if the front of the clutch roller is 1/4"4o-5/16" away

from the faceofthe upright bracket that

holds theadjustment block in place (Figure5-12). To measurethis distance:

Without moving the clutch roller, try

inserting the 1/4"-thick, slotted end of the beltadjustment tool in betweenthe roller and the upright bracket. (The flat edgeof the tool must be facing the roller.) Referto Figure5-13.

b. If only the slotted portion of thetool

will fit, the belt tension is correct.

c. If the slotted part of the tool will not

fit in,the belt istoo loose.

d. If the full thickness (5/16")of the

tool easilyfits in,the belt istoo tight.

Figure 5-11: Use this belt adjust- ment tool to measure and adjust

drive belt tension.

Figure 5-12: Shift into FORWARD and measure distance between

roller and upright bracket using the belt adjustment tool

4. If the belttension is correct, move the Wheels/Tines/PTODriveLever backto

NEUTRAL.

Figure 5-13: Insert slotted end of belt adjustment tool between roller

and bracket, with the flat side of the slotted end facing the roller.

How toAdjustBelt Tension

1. Asdescribed in thefollowing steps, drive belt tension isadjusted by moving theadjustment block upor down. Moving it down will tighten the belt; moving it uploosensthe belt.

HINT: The distance the block moves approximately equals the distance the

roller moves. In most cases,the clutch rollerwill not

havebeenvery far out of position, sothe adjustment blockwill only needto be moved slightly (up ordown).

2. Move theWheels/Tines/PT0 Drive Leverto NEUTRALposition. Theclutch

roller will cometo restanywhereonthe face of the belt adjustment block, depending upondrive belt length and current belttension adjustment.

Section5: Maintenance

Beforeinspecting,cleaningor servicingthe machine, shutoffengine, wait for all movingpartsto come to a completestop, disconnectspark plug wire and movewire away from spark plug. Remove ignition

key, if soequipped. Failureto follow theseinstructionscanresultin seriouspersonalinjury or propertydamage.

3. Insert the beltadjustment tool through

the hole in the side of the adjustment block, spacing the ends of the tool equally

on both sides (Figure5-14). Rotatethe tool so the slotted end facesdown.

Figure 5-14: With Wheels/Tines/PTO Drive Lever in NEUTRAL, insert tool

through hole in adjustment block.

4. Placethe Wheels/Tines/PTODrive Lever in FORWARDposition. Thearms of

the clutch control yoke will be resting on the beltadjustment tool andthe clutch roller should be engagedslightly beneath the adjustment block (Figure5-15).

Figure 5-15: With Drive Lever in FORWARD position, clutch roller

should be engaged slightly beneath the adjustment block.

5. Use onehand to hold the drive lever in FORWARDwhile usinga 9/16" wrench to

loosen (don't remove)the bolt at the back of the beltadjustment block(Figure 5-16). Theadjustment block should be freeto move either up or down.

Figure 5-16: Hold Drive Lever while loosening bolt. Push lever down to tighten belt; pull up to loosen belt.

6. Pushthe drive leverdown ifthe belt needstightening. Pullthe leverup if the

belt needsto be loosened. Hold the drive leverin placeand tighten the bolt inthe

adjustment block firmly.

7. Letgo of the drive leverand remove

the beltadjustment tool from the hole in the adjustment block.

8. Checkthe tension onthe beltby

following the previous instructions "How to MeasureBeltTension."

NOTE: If the adjustment block is all the

way down and the measurementbetween the clutch roller and the bracketis less

than 1/4",then a newdrive belt is needed.

Replacing the Drive Belt

Removingthe Belt

1. MoveWheels/Tines/PTODrive Leverto NEUTRALposition.

2. While kneeling onthe right side of the

tiller, createslack inthe belt by reaching

overto the leftside of the pulleysand pushing in on the center of the beltwith

your finger.

3. Useyour right handto movethe belt downand away from the lower pulley, in

the direction ofthe engine(Figure5-17).

4. Pushthe belt upwardto createslack in

the belt (Figure 5-18).

Figure 5-17: First move belt off the lower pulley.

Figure 5-18: Push belt upward to create slack.

5. Lift the top halfof the beltup and over the upper pulleyand the rubber reverse disc, moving it in front of the reversedisc

(referto Figure 5-19).

6. Pushthe Wheels/Tines/PTODrive Leverdown into the FORWARDposition.

This increasesthe distance betweenthe

upperand lower pulleys. Next, lift and pull the entire belt out betweenthe pulleys (Figure5-20).

Replacingthe Drive Belt

1. PlaceWheels/Tines/PTODrive Leverin FORWARDposition.

2. Squeezethe belt in the middleand insert oneendin betweenthe pulleys

(Figure5-20).

Beforeinspecting,cleaningor servicingthe machine, shutoffengine, wait for all movingpartsto come to a completestop, disconnectspark plug wire and movewire away from spark plug. Remove ignition

key, if soequipped. Failureto follow theseinstructionscanresultin seriouspersonalinjury or propertydamage.

Figure 5-19: Move top haft of belt over pulley and reverse disc.

Figure 5-21: Seat belt in upper

pulley, then in lower pulley (High

Range position shown).

Section5: Maintenance

Reverse Disc Inspection

The reversedisc is madeof steelwith a special, long-lasting rubber compound

bonded to the disc rim. Sincethis is a wearing part, it should beinspected after

every 30operating hours.

1. Measurethe width of the outside edge of thedisc asshown in Figure5-22.

Replacethe disc beforethe rubberedge

wears to a thickness of 1/8" or less. Failureto do so could causethe steel

underneaththe rubberto damagethe transmission pulley.

Figure 5-20: Shift into FORWARD

and remove the belt.

3. Push belt forward then down until it is looped over the lower pulley (Figure

5-18). Donot yetseat it in either ofthe lower pulley's grooves.

HINT: A blunt object, like a ruler, can help you push the belt downward if

needed.

4. Move thetop half of the belt upand overthe rubber reversedisc, but donot

seat it in either of the grooves inthe top pulley.

5. Placethe Wheels/Tines/PTODrive Lever in NEUTRAL.

6. Move thetop half of the belt into the HIGHRangegroove (groove closestto theengine) on thetop pulley (Figure 5-21).

7. Move the bottom half of the belt into the HIGHRangegroove of the lower

pulley (groove closestto engine-- Figure 5-21). Ifextraslack is needed,hold up

Wheels/Tines/PTODriveLever while moving the belt. Verify the belt is seated

properly onthe pulleys.

8. To movethe belt to the LOW Range position, seeChanging BeltSpeedsin

Section 4.

9. After installingthe belt, checkand adjust for correct belt tensionas explainedpreviously.

ReverseDrive

System Maintenance

Theseinstructions explainhow to inspect, replaceor adjust thevarious reversedrive

components. But first, here's how the reversedrive

systemworks: When you raisethe Wheels/Tines/PTODriveLever up in

REVERSEposition, this lowers the rub-

berizedreversedisc (it's attachedto the engine drive pulley) until this rotating disc

contacts thetransmission drive pulley. Thefriction betweenthe rotating reverse

disc andthe transmission pulleycauses thetransmission drive shaft to be

powered in a counterclockwise direction (asviewed from the operator's position

behind handlebars). The drive shaft then turns thewheels and tine shafts ina

reversedirection.

Figure 5-22: Measure the edge of the reverse disc for wear.

2. Lookfor bigcracksor missing chunks of rubber from the disc. If so damaged, the disc should be replacedimmediately.

IMPORTANT: Extend the life of the reverse disc by always pausing in

NEUTRAL before shifting between FORWARD and REVERSE. Also - the

reverse disc is not suited for continuous or sustained reverse operation. Use

reverse sparingly.

Section5: Maintenance

_ Beforeinspecting,cleaningor servicingthe machine, shutoff engine, wait for all movingpartsto come J

to a completestop, disconnectspark plug wire and move wire away fromsparkplug. Removeignition J key, if soequipped. J

Failureto followthese instructionscanresult inseriouspersonalinjuryor propertydamage. J

Replacingthe ReverseDisc

Followthese steps to replace the reverse

disc. (If your tiller hasa Bumper Attach-

ment mounted, it must beremovedfirst.)

Removingthe ReverseDisc

1. MoveWheels/Tines/PTODriveLeverin NEUTRALposition.

2. Wedgea 5/16"-thick boardbetweentop of engine pulley (avoid contacting reverse

disc) andcast iron housing nextto it. This immobilizespulley.

3. Usea 9/16"wrench to loosen the mounting bolt shown in Figure5-23.

Rememberto immobilize the pulleywith

the wood wedgewhile looseningthe bolt.

If necessary,pry the discfrom the pulley

with the tip of a screwdriver. Backthe

bolt out asfar aspossible. Thenangle

the disc a little to removeit. Bringthe

bolt and Iockwasheralongwith the disc.

and enginemount move down to press

on the reverseadjustment bolt (Figure5-

24). This action compressesthe reverse

spring and plunger assembly, requiring you to hold the lever upin REVERSE. Whenyou releasethe lever,the spring automatically pushesthe lever backinto

NEUTRALposition. Thespring and plunger assembly is

designedto preventthe reversedisc from

making contactwith the transmission

pulleyuntil you shift into REVERSE. Whenthe lever is in NEUTRAL,the switch

body onthe bottom of theengine mount tab should be resting squarely on top of the reverseadjustment bolt (Figure5-24). The reverseadjustment bolt can be adjusted upor down to correct a number

of reversedrive operating problems, as

explainednext.

merit bolt should be adjusted upward (see instructions that follow). Moving adjust- ment bolt upwardwill also solveproblem of a tiller that goes into REVERSEon its

own.

Reverse Disc

Figure 5-25: Checking Reverse Disc in NEUTRAL.

3. Useyour left hand to hold Wheels/Tines/PTODriveLever upin REVERSE,while briefly pulling out engine start rope. The reversediscshould turn lower pulley (seeFigure5-26). If not, or it requiresa lot of pressureto hold lever up inREVERSE,then reverseadjustment bolt must be adjusted downward. When correctly adjusted, theWheels/Tines/PTO Drive Levershould pop out of reverse whenthe lever is released,but not require exceptionaleffort to hold it up in reverse position.

Figure 5-23: Removing Reverse Disc.

Installinga New ReverseDisc

1. Dosteps 1-through-3, described previ- ously, in reverse.

2. Tighten mounting bolt securely,and

check for correct operation-- see

Checkingand Adjusting ReverseDrive System.

CheckingandAdjusting Reversethe DriveSystem

WhentheWheels/Tines/PTODriveLever is movedupinto REVERSE,theengine

Figure 5-24: Spring and plunger assembly.

CheckingandAdjustingReverseDisc

1. Verify that linkagesfor

Wheels/Tines/PTODriveLever arelubri-

catedwith oil and engine mount barsand beltadjustment block are lubricatedwith grease. (See Tiller Lubrication inthis section.)

2. PlaceWheels/Tines/PTODrive Leverin NEUTRAL.Briefly pull out engine recoil

start rope while watching reversedisc.

Thedisc should turn, but lower pulley

should not (Figure5-25). If reversedisc turns lower pulley,or if it is located closer than 3/16" to the pulley, reverseadjust-

Pulle

Figure 5-26: Checking Reverse Disc in REVERSE.

4. Shift the Wheels/Tines/PTODriveLever

to REVERSEandthen let it go. The lever

should return to NEUTRAL.If not, the reverseadjustment bolt will haveto be

adjusted upward.

Section5: Maintenance

Beforeinspecting,cleaningorservicingthe machine, shutoff engine,wait for all movingpartsto come to a completestop, disconnectsparkplug wire and movewire awayfromspark plug. Removeignition

key, if soequipped. Failureto follow theseinstructionscanresultin seriouspersonalinjuryor propertydamage.

AdjustingReverseDrive:

1. PlaceWheels/Tines/PTODrive Leverin FORWARDposition.

2. On left side oftiller, put a 1/2" wrench on the plunger retaining bolt andanother 1/2"wrench onthe jam nut nextto it (Figure5-27). While holdingthe bolt steady,loosenthe jam nut (counterclock-

wise) until ittouchesthe bolt head.

Figure 5-27: Hold bolt steady while loosening or tightening jam nut.

3. Turn the bolt inuntil ittightens against the plunger insidethe spring. The bolt

must betight to preventplungerfrom

turning - but becareful not to overtighten

and breakthe bolt.

7. Placeachalkor pencilmark on the top edge of the plunger retaining bolt. Now, while watching the mark, loosenthe bolt 3/4-turn (Figure5-29). Do not exceeda 3/4 turn (this would disengagethe bolt from the lockinggroove inthe side of the

plunger).

Figure 5-28: Loosen jam nut before

turning reverse adjustment bolt.

8. Holdthe plunger retaining bolt steady with awrench while tightening the jam

nut againstthe side of theplungerhousing (Figure5-27).

BoleTineMaintenance

CheckingTinesforWear

Inspect the tines for wear or damageafter every30 operating hours. Therate of

weardepends upon hours of useand soil conditions. With use,the tines get

shorter, narrower and more pointed (Figure5-30). If badlyworn, they losethe

ability to till deeply.

Figure 5-30: Check for wear

every 30 operating hours.

Worn tines leavean ever-increasinggap in the middle ofa tilled row. The normal

gap is 3" betweenthe tine tips - replace thetines whenthe gapwidensto 5"

(Figure5-31).

4. Placea7/8"wrench onthe headof the reverseadjustment bolt and a9/16"

wrench onthe jam nut below it (Figure5-

28). Hold the bolt steadywhile loosening

the jam nut three or four turns.

5. Movethe Wheels/Tines/PT0 Drive Leverto NEUTRAL. Theswitch bodyon

the bottom of the engine mounttab

(Figure5-24) should be resting squarely ontop of the reverseadjustment bolt, and

the reversedisc should beat least 3/16" away from the transmission drive pulley.

If the reversedisc isany closer than this, raisethe reverseadjustment bolt (turn it counterclockwise).

6. Checkthat reversedisc is at least3/16"

away from transmission drive pulley. Then hold reverseadjustment bolt steady with onewrench while tightening jam nut with asecond wrench (Figure5-28).

Figure 5-29: Loosen plunger retaining bolt about 3/4-turn, then

tighten jam nut against plunger

housing.

9. Checktheactionof the reversedisc as explainedpreviously.

IMPORTANT: If the above adjustments havenot corrected an improperly working

reverse drive, contact an authorized

dealer or Factory Technical Service

Departmentfor assistance.

Figure 531: Replace tines when gap between inner tines is 5" or more

(normal gap is 3").

Tinescan be replacedindividually or as a completeset. Seereplacementinstruc-

tions that follow.

Section5: Maintenance

_ Beforeinspecting,cleaningor servicingthe machine, shutoff engine, wait for all movingpartsto come

to a completestop, disconnectspark plug wire and move wire away fromsparkplug. Removeignition J key, if soequipped. J

Failureto followthese instructionscanresult inseriouspersonalinjuryor propertydamage. J

SingleTine Replacement

The tines or Une hood edges may be sharp. Wear thick gloves to protect yourhandsfrom cutsor scrapes.

1. Move theWheels/Tines/PTODrive Leverto NEUTRAL,the WheelSpeed

Leverto either FASTor SLOW position, andthe Tines/PTOClutchLeverto

ENGAGE.

2. Gentlytilt the tiller forward until the enginerestson theground.

3. Raisethe hoodflap atthe backof the tillerand tie it upwith string.

4. Beforeremovinga tine, notein which directionthe benttip points. Thenew tine

must beinstalled in thesamedirection.

5. Usetwo 9/16"wrenchesto removethe two boltsand nuts securingthe tineto the

tine holderplate(Figure5-32). Usepene- trating oil onthe hardwareif it is rustedor

hardto remove.

RemovingandReplacingA Tine HolderAssembly

• The tines or tine hood edges may be sharp. Wear thick gloves to protect

yourhands.

• Wear safety gogglesto protect your eyes. When loosening hardware, do

not hit a wrenchwith a metal tool- this could shatter the tool or wrench,

sendingmetal particlesintoyour eyes.

The16 Bolo Tinesare mountedeight per side on left-sideand right-side tine holders. Here's howto replacethe tines

and holdersas assemblies.

RemovingTineHolderAssembly

1. Follow steps 1-through-3 in Single TineReplacementabove.

2. Identify the fine holders as left-side

and right-side holders - they must be

replacedon thesame side from which they wereremoved. Useapiece of chalk or agreasepencil to markthem L and R.

3. Removethe two bolts and nuts securing eachholder (Figure5-33).

4. Useasoft mallet to drivethe holder off thetine shaft. (Usea heavyhammer

and block ofwood to knock off the immo- bilizedtine holder.)

5. When the holder is off, cleanalldirt and debris from the shaft andthe holder.

Apply fresh greaseto thetine shaft.

Replacing TinesHolderAssembly

1. Replacethe holder so the sharp tine edgesface forward (toward front of tiller). Taptine holderbackonthetine shaft.

2. Greasethe threads onthe mounting bolt(s). Installand tighten the bolt(s) securely.

Figure 5-32." Removing a single tine requires taking off two bolts and

two nuts.

6. Mount the newtine exactlythewaythe old tinewas positioned. (Thesharpedge

ofthe tine,which entersthe soil first, must

face forwardwhenabovethetine shaft.)

Replacethe boltsand nuts andtighten them securely.

Figure 5-33: "FineHolders.

Left-Side

Tine Holder

Right-Side TineHolder

Section5: Maintenance

_ eforeinspecting,cleaningor servicingthe machine,shotoff engine,wait for all movingpartsto come

to a completestop, disconnectspark plugwire and movewire away fromsparkplug. Removeignition key, if soequipped.

Failureto follow theseinstructionscanresultin seriouspersonalinjuryor propertydamage.

Tine Shaft Maintenance

After every10 operating hours,remove the left- and right-side BoloTine holders and clearaway dirt and debristhat have

accumulated onthe tine shaft or inside the tine holders. Pleasefollow this main-

tenance recommendation,asdebris can cause prematurewear to the tine shaft and its oil seals. Referto the previous

tine holder removal instructions. After cleaningaway anydebris and removing

old greasefrom thetine shaft, applyfresh greaseto thetine shaft.

Tire and Wheel Maintenance

Checktire air pressure every 30 operating hours. The recommended pressurefor

tilling is 10-to-20 psi (pounds per square inch). Bothtires should beinflated

equally. (Unequalpressurecan causethe tiller to pull to one side.)

RemovingtheWheels

Eachwheel is secured bya roll (spirol) pinthat passesthrough thewheel hub

and thewheel shaft. Drive the roll pin out to removea wheel.

1. Propthe transmission up with asturdy block to raisethe wheelyou want to

remove off the ground.

2. Move the WheelSpeedLeverto either SLOWor FASTposition to prevent the

wheels from turning.

3. Usea 5/16°drift pin (or ablunt point 16-penny nail) to drivethe roll pinfree.

Wear safety goggleswhen driving the roll pin into or from the wheel hob to protectyour eyesfrom the possibilityof flying metalparticles.

EngineOil Maintenance

Checkthe engineoil levelbeforestarting the engineeachdayand after each5

hours of continuous operation. Running the enginewhen it is low on oil will

quickly ruin the engine.

It is recommendedthat you changethe oil everyten (10) operating hours andeven soonerwhen operating in extremelydirty or dusty conditions. Referto theseparate EngineOwner's Manual for detailed

serviceinstructions.

Air Cleaner Maintenance

Theengine isequippedwith a dual elementair cleanerthat filters theair

twice before it entersthe carburetor to

mix with the fuel. Theengineair cleanerfilters dirt anddust

out of the air beforeit entersthe carbure-

tor. Operatingthe enginewith a dirty,

cloggedair filter cancause poor perfor- manceand damageto the engine. Never operatethe enginewithout the air cleaner installed. Inspectand service the air cleanermore oftenif operating in very dusty or dirty conditions.

It is critical that the filters be kept clean and properly installed at all times. See

the location of the air cleanerassemblyon

your engine by referring to Figure5-39 or Figure5-40.

Referto the enginemanufacturer's litera-

ture suppliedwith your tiller for complete

air cleanerserviceand maintenanceinfor- mation.

Throttle Cable Maintenance

Thethrottle lever settings arefactory- adjusted,so unnecessaryadjustments should not be made. However,if the enginedoes not start or stop, or respond immediately to various throttle lever settings, thenadjustments maybe necessary. Pleaserefer to the engine manufacturer literature suppliedwith your

tiller for specific adjustmentinstructions.

IgnitionSystemMaintenance

Your engineis equippedwith electronic ignition. It does not haveacondenseror

points, so there is no needto perform any regular tune-up maintenanceonthis

system otherthan adjusting or replacing thespark plug.

SparkPlugMaintenance

The spark plug must be in good condition for proper engineoperation. Removeand

inspectthe plug every 50 operating hours or annually,whichever occursfirst.

The correct electrodegap is .030". Check the gap with afeelergauge.Do not usea

spark plug if the porcelainis cracked, the electrodesare pitted or burned, or if other

visible damageis present.

NOTE:Do not wire brush or sandblastthe spark plugto cleanit- looseparticles

canenter the engine,causingdamage!

To replacethe plug, first tighten it

securelyby hand,then use aspark plug

wrench to tighten the plug anextra 1/4 turn.

Battery Care and Maintenance

Theb_teryissealedandis maintenence- free.Acidlevelscannotbechecked.

• Always keepthe battery cablesand terminals cleanandfree of corrosive

build-up.

• Aftercleaning the batteryand terminals, applya light coat of

petroleumjelly or greaseto the

terminals and cover both terminals with the rubber boots.

Whenremovingthe battery, alwaysdis- connect the negative (-) cable first

followed by the positive (+) cable. Re- verse this procedurewhen reinstalling

the battery.

Section5: Maintenance

_ Beforeinspecting,cleaningor servicingthe machine, shutoffengine, wait for all movingpartsto come

to a completestop, disconnectspark plugwire and movewire away from spark plug. Remove ignitionJ key, if soequipped. J

Failureto follow theseinstructionscanresultin seriouspersonalinjuryor propertydamage. J

StoringYour Tiller

Whenyour tiller won't be used duringthe off-season, prepareit for storagewiththe following steps:

1. Cleanthe tiller and engine.

2. Do routine tiller lubricationand check for loose hardware.

3. Protectthe enginefrom deterioration or damageby referring to the engine storage instructions in your engine

manualliterature.

4. Whenengine is still warm, drain oil from enginecrankcase. Refillwith fresh

motor oil.

5. Protect internal cylinderagainst rust by removing sparkplugand pouring one

ounce of cleanengineoil into sparkplug

hole. Thenslowly pull out recoil start rope2 or 3 times to distribute oil inter- nally. Replacespark plug, but do not reconnectplug wire. Pullropeuntil resis-

tance isfelt -- let roperewind.

6. Chargebattery (electric start option).

Store battery incool, dry location.

7. Move Wheels/Tines/PTODriveLever to NEUTRALposition. Keeptiller in a clean,

dry area.

8. Neverstore tiller with fuel infuel tank in anenclosedareawhere gasfumes

could reachan open flame or spark, or where ignition sources arepresent(space

heaters,hot water heaters,furnaces, etc.).

Inspecting Forward Interlock Wiring System

ChecktheForwardInterlockwiring

systemeveryten (10)operatinghours, for tightconnectionsandto seethatthe

insulationonthewiresisunbroken(to preventthesystemfromshortingout).

1. Checkinsulatedwire harnessfrom lower endsof handlebarsto wire harness

connector ontop, right side of transmis- sion cover. Besure connector is secure.

2. Checkinsulatedtubing from connector

to cast iron motor mount/belt shroud.

3. Checkthe wire leadingfrom thetubing overto the switch assemblymounted on

top of the tab onthe cast iron motor

mount-belt shroud. Also checkthe

second wire that leadsto the throttle cable mounting bracketon the right side, forward portion ofthe engine.

Testingthe Forward InterlockWiringSystem

Thewiring circuit for the Forward

Interlock SafetySystem is designedto

ground out the engine's ignition system. Thereare threeswitches inthe circuit

which, when open, letthe engine run.

Oneswitch is onthe neutral plunger tab of thecast iron motor mount. This switch

is openwhenever the Wheels/Tines/PTO Drive Leveris in NEUTRALor REVERSE

positions. Theother two switches are located insidethe handlebars,directly

abovethe two Forward Interlock Levers.

Theswitches arewired sowhen squeezed (open) the engine will run. There isa

fourth switch locatedin thewiring

harness connector on thetop, right side

of the transmission cover. Itwarns you if the connection is not mated by not letting the engine run while the Wheels/Tines/PTO

Drive Leveris in FORWARD.

1. A broken or disconnected wire could

let theenginerun without you havingto

press oneof the Forward Interlock Levers.

2. A barewire touching tiller or engine

metal could ground out the engine's

ignition.

3. A switch that hasfailed allows the

engineto run. Or it may prevent the

enginefrom running.

Referto the Troubleshootingsection if your ForwardInterlock SafetySystem is

not operating correctly.

AppendixA:Troubleshooting

PROBLEM

CHECK ORTEST

(Checkor test in sequenceshown

until problem is resolved.)

Throttle Leverin STARTposition X Wheels/Tines/PTO Drive Lever

in NEUTRAL position X

Forward Interlock Wire Harness

connector securely mated X X

Forward Interlock Levers not being

squeezed prior to shifting Wheels/ Tines/PTO Drive Leverto X

FORWARDposition

Visually inspectfor bare,broken or disconnected wires X X

Check handlebarwire harness X X Checktransmission wire harness X X

TroubleshootingProcedures

1 Wheels/Tines/PTODriveLever:

A, LeverdoesnotstayinFORWARD-

. Drivebeltmaybetoo tight. Raisebelt adjustmentblocka little(Sect.5).

•Clutchpawlspringat endof levermaybe overstretched.Installnewspring.

B, LeverhardtoshiftintoREVERSE-

. Checkreversediscfor wear(Sect.5).

•Checkadjustmentof reversediscand/or reversespringand plungerassy.(Sect.5).

•Cleanand re-lubricatemotormount bars, beltadjustmentblockand linkagesonlever

(Sect.5).

C. TillerstaysinREVERSEwhenleveris released-

. Lubricatemotormount bars,beltadjust- mentblockandlinkageson lever(Sect.5).

•Checkadjustmentof reversespringand plunger(Sect.5). If problempersists,

contactTechnicalServiceDepartment.

D. Leversticksin FORWARD-

. Lubricatemotormount bars,beltadjust- mentblock,andlinkagesonlever(Sect.5).

If problemcontinues,contacttheTechnical ServiceDepartment.

E. LeverhardtoshiftintoFORWARD-

. Followadvicefor Problem1-D. Alsocheck for possiblebentmotormountbarthatcould

bebindingin enginemount holes.

2 WheelSpeedLever:

A. Leverhardtoshift,orsticksin FASTor SLOWwheelgearpositions-

Engine won'tstart

Figure 543: Check connecting rod, shifting linkage and eccentric lever.

Engineshutsoffwhen Wheels/Tines/PTODrive

Leveris shifted into FORWARD

LConnecting RO(J_

• Lubricateeccentricleverat rearof power unittransmission(Figure5-43). If rust is

present,usepenetratingoil andwork eccentricleverbackandforth byhand.

• Lubricatelinkageto WheelSpeedLeverto eccentriclever(Figure5-43).

• Clutchinsidetransmissionmaybebinding. Disconnectlinkagefrom eccentricleverand workeccentricleverby hand. If difficult or impossibleto move,it maybedueto a damagedkeywayonthewheelshaft. ContactTechnicalServiceDepartment.

• Lubricatewashersandcastlenuton pivot of lever. If necessary,removeroll pinand

backnutoff 1/6thturn. Replaceroll pinand testthe movement.

• Applygreaseto zerkfitting (if soequipped) with greasegununtilgreaseappearsaround

washers.

Enginedoesnotshutoff

whenForwardInterlock

Leversarereleasedwhile

Wheels/Tines/PTODrive

LeverisinFORWARD

B. Levershiftsinto FASTwheelgear,but notintoSLOWwheelgear-

* Connectingrodatendof levermightbe

backwards,or bentin towardtransmission housingandhitting it. Othershifting linkage

mightbebent. Straightenor replacelinkage (Figure5-43).

• Clutchinsidetransmissionmaybebinding (Problem2-A).

C, Levermovesfreely,butwon'tshiftin or outofgear-

* Eccentricshiftingpininsidetransmission

maybebroken(rare)or worn. Disconnect linkagefromeccentricleverandtry moving

eccentricleverbyhand(Figure5-43). If levermoveseasily,contacttheTechnical ServiceDepartment.

3 WheelsandTinesWon'tTurn:

• Reviewoperationofcontrols(Sect.3 &4).

• Checkconditionandadjustmentof drive beltandreversedisc(Sect.5).

• Mountingbolt fortransmissiondrivepulley maybeloose. (SeeFigure5-1). If so,drive

beltor reversediscwill turn pulley,but pulleywon'tturn maindriveshaft.

• Wormgearsthat drivewheelandtiller shaftsmaybeworn.

4 WheelsTorn,ButTinesWon't:

• Tines/PTOClutchLevermustbeinENGAGE position(Sect.3).

• Tines/PTOClutchLevermayneedadjust- ment.

• Keyfor dogclutch ontineattachmentmain driveshaft maybemissing,broken.

• Wormgearsthat drivethe tineshaftmay beworn.

AppendixA: Troubleshooting

• Hardwareholdingtine holdersto tineshaft maybemissingor broken. Tocheck,

removeholders(Sect.5).

• Keyfor bronzeworm gearontineattach- mentmaindriveshaftmaybemissingor

broken.

5 TinesTurn,ButWheelsWon't:

• CheckoperationofWheelSpeedLever (Problem2).

• Hi-Prokeyinsidewheelclutchmaybe missing,broken. Ifso,clutchwill not turn

wheelshaft.

• FASTandSLOWspeedwheelgearsmay beworn. If only onegearisworn,therewill onlybeonewheelspeed.

• Worm gearthatdrivespinionshaftand piniongearsmaybeworn.

• FASTandSLOWspeedpiniongearsmay beworn. If only onegearisworn,therewill onlybeonewheelspeed.

• Drive"dogs" onsidesof wheelclutch may bewornor broken. If onlyonesideofclutch isaffected,therewill onlybeonewheel

speed.

6 WheelsAndTinesTurnOnTopOf Ground,ButStopOrHesitateInSoil:

• Drivebelt rnaybeloose(Sect.5).

• Mountingbolt for transmissiondrivepulley maybeloose(Figure5-1).

7 TillerJumpsWhileTilling:

• DepthRegulatorLeversettoodeepfor soil conditions. Useashallowersetting.

• Enginethrottlespeedtoofast.

• Tiller wheelspeedtoo fastfor soil condi- tions. Changeto LOWbeltrangeor SLOW

wheelspeed.

8 DepthRegulatorLever DifficultToMove:

• Lubricatespringassemblyanddepth adjustmentbar (Sect.5).

• Checkfor bentdepthadjustmentbar.

9 WheelAndShaftMove OutToOneSide:

• Snapringon wheelshaftmaybe dislodged. Raisewheelsoff groundand checkfor backandforthplayinshaft. If

thereis play,oneorbothsnapringsisloose.

10 Tiller PullsToOneSide:

• Checktire pressure(Sect.5).

11 TineHolderBolt BreaksOrLoosens:

• Earliermodelshavetine holderkeys. Checkthat keysarein keywaysof tine shaft. Withoutkeyin holder,left-sidetineboltwill

tightenandbreak;right-sideboltwill loosen (Sect.5).

12 PoorTraction:

• Bartreadtires,tire chains,or wheel weightsmaybeneeded.

13 GearOilLeakFromPowerUnitOrTine

AttachmentTransmissions:

• SeeSection5. 14 EngineLacksPower:

• *Air cleanerrestrictedwithdirt and/oroil.

• Sparkplugwire looseordamaged.Spark plugworn orfouled.

• Engineunderexcessivework load. Use SLOWwheelspeedandLOWbeltrange.

• *Throttlecablemaybelooseor misad-

lusted.

• Veritythat engineisn'trunningwith choke partiallyengaged.

• *CheckCarburetoradjustment.

• *Engineoverheating.Checkoil leveland cleancoolingfins. Oil maybeverydirty. Let hotenginecool beforerestarting.

• *Dirt orwaterin fuel orfuelsystem.

• Enginecrankcaselow in oil, or overfiiled with oil. Checkandadjustlevel.

• *Low enginecompression.

15 EngineDifficultToStart:

• WheelsTrines/PTODriveLevernot in NEUTRALposition.

• Fueltanklowor empty. *Dirt orwaterin fuelorfuelsystem.

*Fuellineis restricted.

*Chokecontrolnot setproperly. *Sparkplugwornor fouled(weakspark).

*Aircleanerrestrictedwith dirt and/oroil. *Throttlecableadjustment.

Enginethrottle levernotfreeto move

throughitsfull operatingrange.

• Throttlewireandits linkagearebinding,or

arebentandnot freeto move.

• Low enginecompression.

16 EngineWon'tStart:

• SeeTroubleshootingtheForwardInterlock

SafetySysteminSection5.

• Wheels/Tines/PTODriveLevernot in

NEUTRALposition.

• Fueltanklowor empty. Orfuelline

restrictedor clogged.

• *Chokecontrolimproperlyset.

• *Water or dirt infuel,and/or fuelsystem.

• *Sparkplugfouled orworn. Sparkplug

wirelooseor damaged.

• *Carburetormayneedadjustment.

• *Air filtercloggedwith oil ordirt.

• Carburetorfloatfaulty(or floatvalve

leaking)-if so,tap sideof bowllightlywith handleofscrewdriver(orsimilar object).

• Stalefuelclogscarburetor,andvalves.

Drainoldfuel andaddnewfuel.

• *Fueltankshut-offvalve(if so equipped) notinfully Openposition.

• OnBriggs& Strattonengine,On/Offswitch notin ONposition.

ElectricStartEnginesOnly:

• Electricalconnectionslooseor shortedto metalframes,bracketsor covers(Sect.5).

• Batterydischarged(Sect.5).

• Electricstartermotorfaulty.

17 EngineShotsOffWhenWheels/ TinesiPTODriveLeverIsInForward:

• SeeTroubleshootingtheForwardInterlock SafetySystemin Section5.

• Short in keyswitchorkeyswitchwire harness.

• Checkstartermotor mountingboltsfor looseness.HaveAuthorizedEngineService Dealerinspectthestartermotor.

• Checkoil levelfor correctamount.

18 EngineOverheats

• Cleantheenginecoolingfins,shroudand

covers(Sect.5).

• Checkfor brokenflywheelfins(under

engineshroud). SeeAuthorizedEngine

Dealer.

19 EngineRunsErratically:

• Wateror dirt ingasolineor carburetor.

• Carburetormayneedadjustment.See EngineOwner'sManual.

• *Sparkplugfouledordirty. Sparkplug

wire looseordamaged.

• *Looseor crackedcarburetor.

• Governorlinkagenotadjustedproperlyor binding. SeeAuthorizedEngineService

Dealer.Don'tattemptto repairby yourself.

• Checkpangasket,enginesealsanddrain plugsfor leaks.SeeyourAuthorizedEngine

ServiceDealer.

20 EngineRunsWell,

ButLaborsUnderTiller Load

• *Checkgovernorlinkageforfreedomof rnovement.

• Checkthrottlesettingandcarburetor

adjustment.SeeEngineOwner'sManual.

• Tilling depthis possiblytoo deep.To

correct,lowerthe depthregulatorlever.

• Possibleworntiller wormgearor loose

driveshaft.

21 KeySwitchWill Hot StartTheEngine

• Checkbatteryterminalsfor corrosion (Sect.5).

• Dischargedbattery(SecL5).

• Defectivesolenoid.

42 * SeeEngine Owner'sManual or contact anauthorized enginedealer for information.

AppendixB:Attachments&Accessories

Troy-Bilte PTO Log Splitter

290-258-081

TheTroy-Bilt@PTOLog Splitter provides you with a convenientand easy meansof

splitting abouta halfacord of wood per hour when working alone. When

connectedto the PTOPowerUnit,the tiller's engineruns the splitter's hydraulic

pump, providing you with 13 tons of steady, unhurriedandpredictablesplitting

force.

Asan added benefit,the power-driven mobility provided by the PTOPower Unit

allows you to movethe splitter to and

from your wood pile, overto a neighbor's

place, oralongthe woodpile to afresh supply of logs.

Featuresinclude a 15second splitting cycle; can handlelog sizes up to 26"long; atwo-stage hydraulic pump thatautomat- ically shifts into low gear to providefour- times greaterpressurewhen needed; slim-cut wedgedesign for splitting green, stringy wood; and anauto-control valve

for automatic return stroke.

Dozer/Snow Blade Attachment

290-259-081

In the winter, moves up to onefoot of light snow (or 6"-to-8"of heavysnow); at othertimes use itto move orspread sand, gravel,loosedirt, grain, sawdust, etc. Attacheseasily to the front of the Wrap-Around BumperGuard. Setthe bladeto severalangles. Weighs 41-1bs.;

measures15"x 32". speed.

RowMarkerAttachment

290-257-081

Do you likevery straight, even,neat rows in your garden? If so, the Row Markeris a mustattachment. Hooks quickly to the

Hiller/Furrower attachment- eliminates the needfor string, stakes, measuring

tape, etc. You'll likethe straight rows it helps you makeif you lay outfurrows, dig compost trenches,or make raisedbeds.

The Row Marker extendsfrom 28"-to- 49¾",lettingyou varythe width between rows to suit the crop you're planting.

V-SweepCultivator

290-260-081

TheV-Sweep Cultivatoris a specialized tool designedfor between-rowcrop culti- vation. Instead of stirring the soil, it slices through just belowthe surfaceto eliminate practically anyweeds in itspath.

TheSweep mounts easily to the optional Tow HitchAttachment at the rear of the

PTOPower Unit. The bladeis madeof

high carbon, heattreated steeland measures2" wide (overall wing span is 20").

The uniqueway the Sweepworks, skimming alongjust underneaththe soil's surfacewithout turning the soil over, makesthis the idealtool for usein dry, dusty conditions where it is important to keepsoil disturbance to a minimum. And, becauseof its 20"wide cutting path, it doesan effective cultivation job at afast

TheSweep's natural shallow cultivation helpsto preventweedseedsfrom being brought to the soil's surface. This

shallow cultivation featurealso means there's less chance of damagingthe roots

of your vegetables. Fordeeper or more shallow cultivating, the blade depthcan be changedwith a simple adjustment..

WheelWeights

290-266-081

Helpincreasetraction by puttingextra

weight directly onthe wheels. They

reducebucking and jumping whendeep-

tilling in heavysoil. They're shipped

empty- fill them with materiallike concrete,sand, gravel,etc. They bolt directlyto the tiller wheels.

Wrap-AroundBumperGuard

290-255-081

Orderthis Bumper Guardby itself or receiveit as oneof the components if you

order the combination Dozer/Snow Blade

attachment. Protects the enginefrom

damageby wrapping around and protect- ing manyof the engine components. 1" diameter,high-strength steeltubing.

Hiller/FurrowerAttachment

290-250-081

The most popularattachment becauseit

doesso manyjobs. Mountsto the rearof

the depth regulator bracket. Furrower

bladeeasily makesplant rows, trenches, ditchesto 8" deep. Whenhiller wings are

attachedto furrower blade,attachment

makeshilled rows and raised bed gardens. Convertsfrom a furrower to a

hiller and backagain, inseconds,without

tools.

PartsList

WHEELS/TINES/PTODRIVELEVER& YOKEASSEMBLY

9 16

13-

-5 4

REF PART NO. NO. DESCRIPTION QTY.

GW-2555

1908156

710-0805

GW-2447

1177548

712-0267

1916265

GW-2165-1

GW-2165-2 Yoke-right side.............................. 1

Lever-Wheels/Tines/PTODrive..... 1

Spring-clutch pawl........................ 1

Bolt-hex hd., 5/16-18 x 1-1/2"....... 3

Bushing-3/8". ................................ 3

Lockwasher-externaltooth, 5/16". 3

Nut-hex, 5/16"-18.......................... 3

RollerAssembly ............................ 1

Yoke-left side................................ 1

REF PART NO. NO. DESCRIPTION QTY.

10 GW-2164

11 710-0514 12 736-0169 13 736-3050 15 712-0798 16 1113-1 17 GW-2595

Link-yoke pivot, left & right,

6-7/8" long ................................. 2

Bolt-hex hd., 3/8-16 x 1"............... 6

Lockwasher-spring lock, 3/8"........ 6

Washer-flat, 3/8", S.A.E................. 6

Nut-hex, 3/8"-16............................ 2

Bushing-spacer, 19/64"(.300")..... 6

Knob.............................................. 1

MODELS682J8,E682L PartsList

FORWARDINTERLOCKSYSTEM

SeePage48

REF PART

NO. NO. DESCRIPTION QTY.

GW-2552

EngineWire HarnessAssy-forward

interlock system (Incl. onered and oneblackwire, plugcon-

nector, neutral switch and PVC tubing. Parts not available

separately.................................

BRIGGS & STRATTON

REF PART

NO. NO. DESCRIPTION QTY.

2 3 6 7 8

GW-9971 1186246 GW-9205 725-0157 GW-2551

Lockwasher-external tooth, 7/16"......1

Nut-hex, 7/16"-20 ....................... I

Clip-for plugconnector ............... 1

Tie-plastic ................................... 2

HandlebarWire HarnessAssy-

(seepage46, Ref.No. 20) ....... 1

PartsList MODELS682J&,E682L

HANDLEBARASSEMBLY

REF PART

NO. NO. DESCRIPTION QTY.

1 GW-9548 Bolt-Hex hd., flangedself-locking

Grade5, 1/2-13 x 3-1/2". ........... 1

2 GW-9119 Knob-handlebar heightadjustment 1

3 GW-9120 Ring-retaining (tolerance ring)...... 1

4 GW-2657 Stud-handlebar height adjustment 1

5 1186233 Nut-hex, 1/2"-13............................ 1

6 GW-1021-1 Clamp-left, handlebarheight

adjustment ................................. 1

7 GW-2542-1 Ratchet-left, handlebarheight

adjustment ................................. 1

8 GW-2542-2 Ratchet-right, handlebar height

adjustment ................................. 1

1901784

10 GW-2534A 11 GW-2717 12 GW-9125 13 777120947

777122000 14 1918111 15 1186389

Clamp-right, handlebar height

adjustment ................................. 1

Base-handlebarmounting ............. 1

Handlebars.................................... 1

Grip-handlebars ............................ 2

Decal-Control panel...................... 1

Decal-Control panel("Big Red") ... 1 Bolt-curved hd,GR5,1/4-20 x 2".. 1

Nut-hex, flanged self-locking, whiz

lock, 1/4"-20............................... 1

REF PART

NO. NO. DESCRIPTION QTY.

16 1909286

17 777120946 18 725-0157 19 GW-9219 20 GW-2551

21 GW-9250

22 GW-9385 23 GW-2543

-- GW-2563

24 1186009

24A GW-9733

25 GW-2546 26 GW-9199 27 GW-9514

28 GW-9387

Throttle Control & Cable................ 1

Decal-Forward Interlock Lever...... 2

Tie-plastic ..................................... 2

Plug-wire harness retainer............ 2

HandlebarWire HarnessAssy-

forward interlock system............ 1

HandlebarSwitch-forward

interlock system......................... 2

Lock Pin-handlebar switch............ 2

Switch Housing-handlebar switch. 2

Switch Assembly ........................... 1

(Includes Ref.21-23)

Screw-pan head, 10-24 x 1/2",

thread-forming ........................... 2

Screw-phillips head, 10-32 x 1/2",

thread-forming ........................... 1

Lever-forward interlock................. 2

Pivot Pin-forward interlocklever... 2 Retaining Ring-klip ring-forward

interlock lever............................. 2

ReturnSpring-fwd interlocklever. 2

MODELS682J8,E6B2L PartsList

DEPTH REGULATOR& TINE HOOD ASSEMBLIES

, SeePage 54

REF PART NO. NO. DESCRIPTION QTY.

1 2

3 4 5 6 7 8 9

710-3005 GW-1113-1 736-0169 712-0798 GW-20795 GW-9120 GW-9119 GW-2121 GW-9552

Bolt-hex hd., 3/8-16 x 1-1/4"........ 2

Bushing-19/64" (.300" Ig.)............ 2

Lockwasher-spring lock, 3/8". ...... 2

Nut-hex, 3/8"-16........................... 2

Bar-depth regulator...................... 1

Ring-retaining .............................. 1

Knob-depth regulator ................... 1

Bar-drag, depth regulator............. 1

Screw-thread-forming,

1/4-20 x 1/2".............................. 2

1186329

Bolt-flanged hex hd.,

5/16-18 x 3/4"............................ 2

REF PART

NO. NO. DESCRIPTION QTY.

12 GW-9929 13 GW-2468 14 777S32000 15 GW-2525 16 1185469 17 GW-9534 18 GW-9384 19 710-0597 20 1110106 21 1186328

Washer-flat, 5/16"......................... 2

Hood............................................. 1

Decal-hood, operating instructions. 1

Bracket.......................................... 1

Pin-roll (spirol) 1/4"x 1"............... 1

Spacer........................................... 1

Spring........................................... 1

Bolt-hex hd., 1/4-20x1"................. 1

Locknut-1/4"-20 ........................... 1

Bolt-flanged hex hd.,

5/16-18 x 5/8"............................ 2

ParisList MODELS682J&,E682L

WHEELSPEEDLEVER,BELTDRIVESYSTEM,ENGINES,WHEELS

See Figure 9

[FOR ELECT. START

SYSTEMS]

45A

SeePage52

46----_

MODELS 682J &, E682L PallsList

REF PART

NO. NO.

GW-9362

GW-9838

GW-9934

GW-9932

GW-2178

1902240

GW-9317

GW-1231

GW-1033

736-0275

GW-9338

712-0158

710-0514

736-0169

736-3050

GW-1113-1

GW-9120

GW-2102

GW-2100

777120942

1100012

GW-2111

GW-9245

GW-1483

GW-1138-1

GW-1138-2

GW-9303

DESCRIPTION QTY.

WHEELSPEEDLEVER

Pin-spring, 1/8"................................ 1

Nut-castle (slotted), 1/2"-20 ............ 1

Washer-shoulder, 1/2"..................... 1

Washer-disc spring ......................... 2

Lever-wheel speedshift................... 1

Knob-wheel speedshift lever........... 1

Pin-cotter, 3/32" x 1"........................ 1

Rod-connecting rod, wheelspeed

shift lever...................................... 1

Swivel-connecting rod ..................... 1

Washer-flat, 5/16", S.A.E................. 1

Pin-hair cotter.................................. 1

Locknut-hex hd., 5/16"-18............... 1

Bolt-flangedhex hal.,3/8-16 x 1"..... 5

Lockwasher-spring lock, 3/8". ......... 5

Washer-fiat, 3/8", S.A.E................... 8

Bushing-spacer, 19/64"(.300"lg.).... 4

Ring-retaining (tolerance ring) ........ 1

BELTDRIVESYSTEM

Block- belt adjustment, 3-7/8". ........ 1

Rod- beltadjust., 7" with

measuring gauge.......................... 1

Decal- enginestabilization............... 1

Bolt-hex hd., 3/8-24 x 1-1/2"........... 1

Disc-reverse .................................... 1

Belt-forward drive (no substitute

due to extra strength required)..... 1

Pulley-engine powertakeoff ........... 1

Shim-engine pulley, 1/16" As Req'd Shim-as above, 1/32" As Req'd Key-engine pulley, 3/16"sq. x 2-1/2" 1

REF PART

NO. NO.

ENGINESAND ENGINEMOUNT

28 710-0376 29 712-0267

30 GW-1034 31 GW-9147 32 GW-9572 33 736-0119 34 GW-2553

35 *

36 736-3052 38B 777S30647

777S30650

43 1915072 45 1915056

45A 1915057

46 1902020

DESCRIPTION QTY.

Bolt-hexhd, 5/16-18x 1",Grade5...... 2

Nut, hex,5/16-18.............................. 1

Bar-engine mounting....................... 2

Plug-thread protector, redplastic.... 2

Bolt-hex hd., 5/16-24 x 1-1/8"......... 4

Lockwasher-spring lock, 5/16". ....... 4

Mount- engineto tiller ..................... 1

Briggs & Stratton Engine-

Recoilor electric start. (Electric start requireskey switch

starting system.) .......................... 1

Washer,flat, .406 x 1.Ox .105......... 1

Decal-hot surfacewarning (E682L). 1

Decal-hot surfacewarning (682J)

WHEEL&TIREASSEMBLIES

Pin- roll, 5/16" x 1-1/2".................... 2

**Wheel & TireAssy- bar tread,

left side,4:80 x 8"tubelesstire with valvestem, on one-piece

steerwheel................................... 1

**Wheel & TireAssy-bar tread,

right side. Sameas above but

for right sideof tiller..................... 1

Cap-wheel hub................................ 2

* Contactan authorizedengine dealer,Troy-Bilt dealer orthe Factoryfor replacementengine

information. Contactan authorizedenginedealerfor engineserviceor parts. Referto the enginename-

platefor engine model andtype information.

** Forcorrect traction anddirectional control, BarTreadTires should bernounted onthe

tiller so the closedend of the "V" in thetire tread ontop of the tire facesforward.

PartsList MODELS682J&,E682L

POWER UNIT TRANSMISSION ASSEMBLIES

S V_ SeePage50

+-16,16A

62 _'

MODELS 682J &, E682L PartsList

REF PART NO. NO. DESCRIPTION

QTY. No.

TRANSMISSIONCOVER& SHIFTLEVER

BRACKETASSEMBLIES

1 1186299 Bolt-hex hd., #10-32 x 3/8",

self-locking flange..................... 3

2 GW-9463 Knob-tines/PTOclutch lever,

tapered, plastic.......................... 1

3 GW-2124 DetentPlate-tines/PTOclutch lever 1 4 777120945 Decal-operating instructions,

detent plate................................ 1

5 1186349 Bolt-flanged hex hd.,

3/8-16 x 1-1/2". ......................... 4

7 1186329 Bolt-flanged hex hd.,

5/16-18 x 3/4", Grade5 ............ 1

9 736-0275 Washer-flat, 5/16", S.A.E.............. 1

10 GW-2149 Bracket-shift levers....................... 1

11 GW-9362 Pin-spring, 1/8"............................ 1

12 GW-9838 Nut-castle (slotted), 1/2"-20,call

Tech Servicefor tightening

instructions............................. 1

13 GW-9934 Washer-shoulder, 1/2". ................ 1

14 GW-9932 Washer-disc spring ...................... 2

15 GW-2178 Lever-wheel speedshift ................ 1

16 GW-2523 Cover-power unit transmission .... 1

17 GW-1123 Gasket-transmission cover........... 1

18 710-0376 Bolt-hex hd., 5/16-18 x 1",Grade5,

(remove withcare) ................... 1

19 712-0267 Nut-hex, 5/16"-18......................... 1

20 1901439 Spring-neutral plunger (remove

with care).................................. 1

21 GW-1035-1 Plunger-neutral (remove withcare) 1 22 1901440 Clip Ring-retains neutral plunger.. 1

23 1186393 Nut-hex, flange Iocknut,3/8"-16... 1 24 1902664 Bolt-hex hd., 3/8-16x1-1/2",

threaded full length.................... 1

TINES/PTOCLUTCHLEVERASSEMBLY

25 786-04002 Lever-eccentric, tines/PTOclutch. 1

26 741-04008 Bolt-hex hd., 1/4-20x 1/2"........... 1

27 GW-2123 Bushing-tines/PTOclutch lever

eccentric shaft........................... 1

28 GW-9516 RetainingRing-(snap ring),

external...................................... 2

29 GW-2461 Eccentric-shaft, tines/PTOclutch

lever........................................... 1

30 GW-9911 Lockwasher-hFcollar, 1/4"............ 1

31 GW-9672 Screw-socket hd., 1/4-20 x 3/8"... 1

DRIVESHAFTASSEMBLY

33 716-0101 RetainingRing-external ................ 1

34 1909139 DogClutch-power unit ................. 1

REF

35 36

37 38 39

42 43 44 45

45 45 45 46

47 48 49

5O 51 52 53

54 55 56

57 58 59 6O

PART

No. DESCRIPTION QTY.

GW-9301 Key-3/16 sq. x 1".......................... 3

1100004 Bolt-hex hd., 5/16-24 x 3/4",self-

locking flange,Grade5.............. 1

GW-9944 Washer-disc spring (concave)...... 1

GW-2107 Pulley-transmission drive, cast iron 1 GW-50027 Washer-flat, hardenedshoulder

1-1/4"......................................... 1

1186310 Bolt-hex hd., 1/4-20 x 3/4",front

bearingcap................................ 3

718-04007 Cap-front bearing......................... 1

1983632 Seal-oil, front bearingcap............ 1

GW-1124-2 Gasket-front bearingcap.............. 1

GW-1224-1 Shim-front bearing cap,.

010"thick ..............................As Req'd

GW-1224-2 Shim-as above, .030"...............As Req'd

GW-1224-3 Shim-as above, .005"...............As Req'd

GW-1224-4 Shim-as above, .062"...............As Req'd

GW-1714 Bearing& Race

(incl. onebearing GW-9400

and onecup (race) GW-9401)... 2

GW-2655 Shaft-main drive, power unit ........ 1

GW-9617 Seal-oil, drive shaft, rear.............. 1

GW-9517 RetainingRing-(snapring),internal........1

PINIONSHAFTASSEMBLY

715-0121 Pin-roll (spirol), 1/4 x 2"............... 2

718-04006 Plug-retaining, pinion bearing...... 2

GW-9604 O-Ring-retaining plug................... 2

GW-1132-1 Shim-retaining plug, 1-1/64"inner

dia., .033"thick (on right side

only one GW-1132-1shim is also usedbetweenbearing and washer,

Ref.No.'s 54 & 55).................... As

Req'd

GW-1132-2 Shim-sameasGW-1132-1,.062". As

Req'd

GW-1132-3 Shim-sameasGW-1132-1,.010" As

Req'd

GW-9404 GW-1126 GW-1222

Bearing-ball, pinion shaft ............. 2

Washer-pinion shaft ..................... 2

Stem Pinion-slow speedgear &

shaft .......................................... 1

GW-9502 GW-2656 GW-9300 GW-1233

Ring-retaining, external................ 1

Worm Gear-bronze,wheeldrive... 1

Key-3/16" x5/8"............................ 1

Gear-fast speedpinion ................. 1

(continuedon page55)

PartsList MODELS 682J & E682L

POWERUNITTRANSMISSIONASSEMBLIES

(Continuedfrompage53)

/ _ SeePage 50

35 57

62 1

67 '

MODELS 682J & E682L PartsList

REF PART

NO. NO. DESCRIPTION QTY.

(continued from page 53)

WHEELSHAFTASSEMBLY

61 GW-9621 62 1909950 63 GW-1166-1

Seal-oil, wheelshaft ..................... 2

Retaining ring-external ................. 2

Shim-wheel shaft, 1-1/64" inner

dia., .062"thick .......................... As

Req'd

63 GW-1166-2

Shim-as above, .030"thick ....... As

Req'd

63 GW-1166-3

Shim-as above, .015"thick ........ As

Req'd

63 GW-1166-4

Shim-as above, .010"thick ........ As

Req'd

63 GW-1166-5

Shim-same asabove, .005"thick As

Req'd

64 GW-1086

Bushing-bronze, wheelshaft

bearing...................................... 2

65 GW-2145 66 GW-9357 67 GW-1223 68 GW-1232 69 GW-1237 70 GW-1112

Shaft-wheel, 15-5/8"...................1

Key-Hi Pro, 1/4" x 1-3/4"............... 1

Gear-slow speed,wheel drive....... 1

Gear-fast speed,wheel drive ........ 1

Dog Clutch-wheel drive................ 1

Pin-clutch guide, 1/4" diameter.... 3

ECCENTRICSHAFTASSEMBLY

71 1911372 Pin-roll, 3/16" x 1-1/4" (spirol) ..... 1

72 619-04000 Lever-eccentric, wheel speed

shifting ...................................... 1

73 GW-9622 Seal-oil, eccentric shaft................ 1

74 GW-1442 Pin-eccentric shaft, wheel speed

shifting ...................................... 1

REF PART

NO. NO. DESCRIPTION QTY.

75 611-04003 EccentricShaft-wheel speed

shifting ...................................... 1

76 GW-1441 Spring-eccentric shaft.................. 1

TRANSMISSIONHOUSING

78 GW-2109 Housing-power unit transmission

(Empty housingwithout covers,

shafts,gears, seals,etc.)........... 1

79 GW-9359 Pin-alignment ............................... 1

MISCELLANEOUSPARTS

80 1100067 Bolt-hex hd., 1/2-13 x 2"Grade5. 2 81 GW-9928 Washer-disc spring (concave),

domedside faces bolt head....... 2

82 GW-2126 Post-with threaded hole for Ref.

No.80........................................ 2

83 1105620 Plug-pipe, 1/4".............................. 2

84 GW-9122 Plug-red plastic, thread protector. 1 85 GW-9205 Clip-forward interlock system plug

connector (seepage47)............ 1

86 777120944 Decal-forward interlock wire

harness...................................... 1

TRANSMISSIONASSEMBLY

-- 618-04004 Transmission-power unit (Does NOTinclude Ref.35-39. Does NOTinclude Shift Leverand Bracket

Assemblies, Ref.3, 4, 10, 15, 85, 86,

etc.)........................................... 1

PartsList MODELS682J&E682L

TILLERATTACHMENTTRANSMISSIONASSEMBLIES

See NoteI

I I

NOTE1: THESESCREWSHAVEASPECIALSEALINGDESIGN

THATCANNOTBEREUSEDWITHOUTRISKINGTHE

LOSSOFTRANSMISSIONOIL. IFTHESESCREWS

ARELOOSENEDORREMOVED,THEYMUSTBE

REPLACEDWITHNEWHARDWARE.

MODELS 682J & E682L PartsList

REF PART

NO. NO. DESCRIPTION QTY.

1 2 3

1915068 GW-20873 GW-1129-1

Screw-self-sealing,I/4"-20 x 5/8" 5

Cover-tiller housing ..................... 1

Gasket-tiller housing cover, .010". As

thick...........................................Req'd

GW-1129-2

Gasket-same asabove,.030" As

thick...........................................Req'd

4 5 6

1901972

741-3037

1901976

Shaft-tiller tine.............................. 1

Ball Bearing................................... 2

Worm Gear-bronze,tiller tine

shaft .......................................... 1

7 8

GW-1104 GW-97073

Key-tiller tine shaft,woodruff key. 1

Seal-oil, tiller tine shaft................. 2

TILLERDRIVESHAFTASSEMBLY

10 11 12 13 14 15 16 17

716-0101

1909138 GW-9301 GW-2127 GW-1138-1 1915069 GW-1115 GW-1124-2 GW-1224-1

Retaining Ring-external................ 2

DogClutch-tiller drive shaft.......... 1

Key-3/16" x1"............................... 1

Spring-dog clutch......................... 1

Shim-dog clutch, 1/16"(.62")thick.. 1 Screw-self-sealing,I/4"-20 x 7/8" 3

Cap-rear bearing........................... 1

Gasket-rear bearingcap............... 1

Shim-front bearingcap,.010" As

thick...........................................Req'd

REF PART

NO. NO. DESCRIPTION QTY.

17 GW-1224-2

Shim-same as above,.030" As

thick...........................................Req'd

17 GW-1224-3

Shim-same as above,.005" As

thick...........................................Req'd

17 GW-1224-4

Shim-same as above,.062" As

thick...........................................Req'd

18 GW-1714

Bearing& Race............................. 2

(incl. one bearingGW-9400 and onecup (race) GW-9401)

19 GW-2653 20 GW-9617 21 GW-9517

Shaft-main tiller drive................... 1

Seal-oil, drive shaft, front ............. 1

Retaining Ring-internal................. 1

TRANSMISSIONHOUSINGANDDIPSTICK

23 1901971 Housing-tiller attachment (Empty

housing without shafts, gears,seals,

dipstick, etc.) ................................ 1

24 1909157 Dipstick-oil, tiller attachment........ 1

TRANSMISSIONASSEMBLY

-- 618-04003 Transmission-Tiller

(Includes Ref.1-24) .................. 1

PartsList MODELS 682J & E682L

BOLOTINE ASSEMBLIES

i_D p_

7 6

i \

RIGHT SIDE

LEFT SIDE

NOTE: Make sure Sharp Edge ,'_ of tines

faces FORWARD to enter soil first

Sharp

LEGEND:

/_ = Sharp Edge

L = Left Bolo Tine R = Right Bo_o Tine

LEFT HAND TINE RIGHT HAND TINE

(As viewed with blunt edge facing you.)

MODELS 682J & E682L PartsList

REF PART

NO. NO. DESCRIPTION QTY.

STANDARDTILLINGTINES

1 1901975 TineHolder-welded steel,fits

left or right sides...................... 2

2 1982612 Bolt-hex hd., 3/8-16 x 2"............. 4

6 GW-1270-1 BoloTine-single, left hand.Used

on left andright side tine assy.

Tine is stampedeither "EL" or

"AL".......................................... 8

7 GW-1270-2 BoloTine-single, right hand. Used

on left andright side tine assy.

Tine is stampedeither "ER"or

"AR'. ........................................ 8

8 710-3005 Bolt-hex hd., 3/8-16 x 1"............. 16

10 712-0375 Locknut-hex, 3/8"-16 .................. 20

--- 290-253-081 TineReplacementKit-unassembled (IncL eight eachof Ref.No.'s 6,

and 7, sixteeneach of Ref.No.'s

8 and10). Includeseasy-to-

follow installation instruction. DOES

NOTINCLUDEtine holders, holder mounting hardware,or tine

shaft keys................................. 1

REF PART

NO. NO. DESCRIPTION QTY.

CUSTOMTILLINGTINES

Specialhard-faced, high-chrome carbonalloy tines that are thicker than standardBolo Tines.Thesetines better resistthe

abrasiveaction of rocky, gritty or sandy soil as comparedto standard BoloTines,and are especiallysuited for custom tilling or market gardening.

GW-10802

Custom Tilling Tine Kit-(Incl.

eight eachof Part GW-2475-1 and GW-2475-2tines and sixteen

eachof Ref. No.'s8and 10...... 1

GW-2475-1

BoloTine, CustomTilling-single,

left hand................................... 8

GW-2475-2

BoloTine, CustomTilling-single,

right hand ................................ 8

PartsList MODELE682L

ELECTRICSTARTSYSTEM

Positive

8artery Cable

Wire (Red)

Activate Wire (R_)

MODEL E682L PartsList

REF PART

NO. NO. DESCRIPTION QTY.

GW-96515

Cable-battery, positiveandnegative

terminals.................................. 2

GW-97020 GW-9552

Boot-terminal insulating ............. 3

Screw-self-threading,

1/4-20 x 1/2"............................ 3

4 5 6

1186309 1901894 GW-2614

Bolt-hex hd., 1/4-20 x 5/8".......... 2

Wire-recharge (red) .................... 1

BatteryHold-down Clamp-with

attachedKey Switch Plate........ 1

777830648 725-0267A

Decal-ignition switch instruc....... 1

KeySwitch-includes two

ignition keys (Ref. No.9), one

Iockwasher,and onemounting

nut (lock-washer and nut not

availableseparately)................. 1

9 725-0201 10 1180673 11 1100241 12 712-0287 13 725-1706

Key-ignition, one pair.................. 1

Bolt-carriage, 1/4-20 x 1-1/4". .... 2

Lockwasher-spring lock, 1/4"...... 2

Nut-hex, 1/4"-20 ......................... 2

Battery-12 volt, 270 CCA................ 1

REF PART

NO. NO. DESCRIPTION QTY.

14 GW-96514 Solenoid-starter, includes nutsand

washers for cablesand wires... 1

15 736-0119 Lockwasher-5/16"....................... 3

16 1186211 Nut-hex, 5/16"-24 ....................... 2

17 736-0147 Lockwasher-externaltooth, #10.. 1

18 GW-9853 Nut-hex, #10-32.......................... 1

19 GW-96510 Cable-solenoid to starter motor.. 1

20 GW-2557 BatteryBracket............................ 1

21 1186349 Bolt-flanged hex hd.,

3/8-16 x 1-1/2"......................... 2

23 GW-9265 Tie-plastic, wire retaining............ 1

27 725-0157 Tie-plastic ................................... 2

28 1908118 Wire Harness& Connecting

Terminal Assembly.................. 1

30 1186389 Locknut-hex, 1/4"-20 .................. 3

31 1917269 Ground WireAssembly................ 1

32 1901202 Cable-ground, solenoid to engine

block........................................ 1

33 710-3180 Bolt-flange lock, 5/16-18 x 1"...... 1

34 712-3010 Nut-flange lock,5/16"-18 ............ 1

ParisList MODELS682J&E682L

BUMPERATTACHMENT

REF PART NO. NO. DESCRIPTION

290-255-081 BumperAttachment. Includes

Ref. Nos.1through 11)...........

1 2

3 4

1910730 710-3181 736-0921 1909748 710-0805

Brace- bumper bottom ...............

Bolt- hex hd., 1/2-13 x 1-1/2".....

Lockwasher- spring lock, 1/2"....

Spacer, 1/2".................................

Bolt- hex hd., 5/16-18 x 1-1/2"...

REF

QTY. No.

1 7 1 8

1 9 1 10

1 11 2

PART

No. DESCRIPTION QTY.

736-0119 Lockwasher- spring lock, 5/16".. 2

712-0267 Nut- hex, 5/16"-18...................... 2

1910731 Bumperwraparound.................... 1

710-0514 Bolt - hexhd., 3/8-16 x 1"............ 2

736-0169 Lockwasher- spring lock, 3/8".... 2

777S30653 Decal- for bumper ...................... 1

Notes

TROY-BILT TILLER LIFETIME LIMITED WARRANTY

WHATPRODUCT ISCOVERED

WHATISCOVERED BY THIS WARRANTY

WHAT IS NOT COVERED BY THIS WARRANTY

All Troy-Bilt branded rear tine walk-behind tillers with gear drive transmissions. This w_ranly begins on the dale of purchase and is warranted by Troy-Bilt LLC for the life of the tiller, to the original purchaser only.

Troy-Bilt LLC will, at its option, repair or replace any part found to be defective in material or workmanship without charge for parts and labor_

This limited lifetime warranty also applies to non-powered attachments and accessories. Powered attachments and accessories are warranted separately by their manufacturers. Refer to the applicable manufacturer's warranty on these items for terms and conditions.

This warranty does not apply to parts that have been damaged by accident, alteration, misuse, abuse, neglect, improper maintenance, vandalism, theft, fire, water, or damage

because of peril or other natural disaster.

The following items are not covered after the first year of this residential use limited warranty: belts, batteries, bushings, seals, tines, tires, wheels, paint, appearance items, and similar items that are

normally replaced through periodic maintenance_

Charges for pick-up, delivery, and service calls are not covered by this warranty_

Service completed by someone other than an authorized service dealer is not covered by this warranty.

Parts that are not genuine Troy-Bilt LLC service parts are not covered by this warranty_

The engine is warranted separately by the engine manufacturer_ Refer to the engine manufacturer's warranty for terms and conditions.

LIMITED COMMERCIAL

USE WARRANTY

if used for commercial, institutional, industrial, rental, o1"demonstrator purposes, the warranty on the tiller is limited in duration to 90 days from the date of purchase.

This warranty does not apply to parts that have been damaged by accident, alteration, misuse, abuse, neglect, improper maintenance, vandalism, theft, fire, water, or damage because of peril o1"other natural

disaster.

HOW TO OBTAIN SERVICE

Warranty service is available, with proof of purchase, through your local authorized service dealer. To locate a dealer in your area, consult your Yellow Pages, o1"contact Troy-Bilt LLC at P.O. Box 36113 i, Cleveland, Ohio 44136-0019, 1-866-840-6483, o1"log on to our Web site at www.troybilt.com.

The provisions set forth in this warranty provide the sole and exclusive remedy arising from the sale. Troy-Bilt LLC shall

not be liable for any incidental or consequential damage or expense of any kind, including but not limited to cost of equipment rental, loss of profits, or costs of hiring services to perform tasks normally performed by the equipment.

Any implied warranties, including any implied warranty of merchantability or fitness for a particular propose, shall be limited in

duration to the period of ownership by the original purchaser (and a maximum of 90 days from the dale of sale if the tiller is

purchased for commercial or other non-residential use),

Some states do not allgw the exclusion o1"limitation of incidental or consequential damages, or limitations on how long an

implied warranty lasts, so the above exclusions or limitations may not apply to you.

This limited warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

For customer assistance, contact your nearest authorized dealer, or contact us at:

TIqOY-BILT LLG, P.O. Box 361131, Gleveland, Ohio 44136-0019, 1-866-840-6483

Troy-Bilt Horse E682L Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual