tilla manual

Operator’s Manual

Rear-tine PTO Tiller Models 682J—HorseTM

E686N—HorseTM

E682L—HorseTM

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

IMPORTANT:READ SAFETY RULES AND INSTRUCTIONS CAREFULLY

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

PRINTED IN USA FORM NO. 770-10598B(11/2002)

Model 682J Shown

2

For more details about your unit, visit our website at www.troybilt.com

TABLE OF CONTENTSContent 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 NUMBERThis Operator’s Manual is an important part of your new Rear-tine Tiller. It will help you assemble, prepare andmaintain 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 CustomerSupport 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 isexplained below. For future reference, please copy the model number and the serial number of the equipmentin the space below

ENGINE INFORMATIONThe 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.

CALLING CUSTOMER SUPPORTIf you have difficulty assembling this product or have any questions regarding the controls, operation or maintenanceof this unit, please call the Customer Support Department.

Call 1- (330) 558-7220 or 1- (866) 840-6483 to reach a Customer Support representative. Please haveyour unit’s model number and serial number ready when you call. See previous section to locate thisinformation. You will be asked to enter the serial number in order to process your call .

Copy Model Number Here

Copy Serial Number Here

www.troybilt.com

TROY-BILT LLCP. O. BOX 361131CLEVELAND, OH 44136

866-840-6483330-558-7220

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects or other reproductive harm.

WARNING

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

Safety Alert Symbol

This is a safety alert symbol. It is used in thismanual and on the unit to alert you topotential hazards. When you see this symbol,read and obey the message that follows it.

Failure to obey safety messages could result in personalinjury or property damage.

Section

1 Safety

Training1. Carefully read this Owner’s Manual, theseparate Engine Owner’s Manual, and anyother literature you may receive. Be thor-oughly familiar with the controls and theproper use of the tiller and its engine.Know how to stop the unit and disengagethe controls quickly.

2. Never allow children to operate thetiller. Never allow adults to operate thetiller without proper instruction.

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

4. Keep in mind that the operator or useris responsible for accidents or hazardsoccurring to other people, their property,and themselves.

Preparation1. Thoroughly inspect the area where thetiller is to be used and remove all foreignobjects.

2. Put the Wheels/Tines/PTO Drive Leverinto NEUTRAL before starting the engine.

3. Do not operate the tiller withoutwearing adequate outer garments. Avoidloose garments or jewelry that could getcaught in moving parts.

4. Do not operate the tiller when barefootor wearing sandals, sneakers, or lightfootwear. Wear protective footwear thatwill improve footing on slippery surfaces.

5. Do not till near underground electriccables, telephone lines, pipes or hoses. Ifin doubt, contact your telephone or utilitycompany.

6. Warning: Handle fuel with care; it ishighly flammable and its vapors areexplosive. Be sure to take the followingprecautions:

a. Store fuel in containers specificallydesigned for this purpose.

b. The gas cap shall never be removedor fuel added while the engine isrunning. Allow the engine to coolfor several minutes before addingfuel.

c. Keep matches, cigarettes, cigars,pipes, open flames, and sparksaway from the fuel tank and fuelcontainer.

d. Fill fuel tank outdoors with extremecare. Never fill fuel tank indoors.Use a funnel or spout to preventspillage.

e. Replace all fuel tank and containercaps securely.

f. If fuel is spilled, do not attempt tostart the engine, but move themachine away from the area ofspillage and avoid creating anysource of ignition until fuel vaporshave dissipated.

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

Operation1. Do not put hands or feet near or underrotating parts. Do not allow hands or anyother part of the body or clothing near therotating tines or near any other movingpart. The tines begin to rotate forward

once the engine starts, the Tines/PTOClutch Lever is in the ENGAGE position,the Forward Interlock Levers are squeezedclosed and the Wheels/Tines/PTO DriveLever is shifted to FORWARD. The tinesrotate in Reverse whether the InterlockLevers are closed or open.

2. Exercise extreme caution when on orcrossing gravel drives, walks, or roads.Stay alert for hidden hazards or traffic. Donot carry passengers.

3. After striking a foreign object, stop theengine, remove the wire from the sparkplug wire and prevent it from touching thespark plug. Thoroughly inspect themachine for any damage and repair thedamage before restarting and operatingthe machine.

4. Exercise caution to avoid slipping orfalling.

5. If the unit should start to vibrate abnor-mally, stop the engine, disconnect thespark plug wire and prevent it fromtouching the spark plug, and check imme-diately for the cause. Vibration isgenerally a warning of trouble.

6. Stop the engine, disconnect the sparkplug wire and prevent it from touching thespark plug whenever you leave theoperating position, before unclogging thetines, or when making any repairs, adjust-ments or inspections.

7. Take all possible precautions whenleaving machine unattended. Stop engine.Disconnect spark plug wire and move itaway from spark plug. Remove ignitionkey on electric start models

3

Section 1: Safety

8. Before cleaning, repairing, or inspect-ing, stop the engine and make certain allmoving parts have stopped. Disconnectthe spark plug wire and prevent it fromtouching the spark plug to prevent acci-dental starting.

9. The flap on the tine hood must bedown when operating the tiller, unlessusing the Hiller/Furrower attachment.

10. Never use the tiller unless properguards, plates, or other safety protectivedevices are in place.

11. Do not run engine in an enclosedarea. Engine exhaust contains carbonmonoxide gas, a deadly poison that isodorless, colorless, and tasteless.

12. Keep children and pets away.

13. Never operate the tiller under enginepower if the Wheel Speed Lever is in theFREEWHEEL position. In FREEWHEEL,the wheels will not hold the tiller back andthe revolving tines could propel the tillerrapidly, possibly causing loss of control.Always engage the Wheel Speed Lever ineither FAST or SLOW position beforestarting the engine or engaging the tineswith the Wheels/Tines/PTO Drive Lever.

14. Be aware that the tiller may unex-pectedly bounce upward or jumpforward if the tines should strikeextremely hard packed soil, frozenground, or buried obstacles like largestones, roots, or stumps. If in doubtabout the tilling conditions, always usethe following operating precautions toassist you in maintaining control of thetiller:

a. Walk behind and to one side of thetiller, using one hand on the han-dlebars. Relax your arm, but use asecure hand grip.

b. Use shallower depth regulatorsettings, working gradually deeperwith each pass.

c. Use slower wheel, tine and enginespeeds.

d. Clear the tilling area of all largestones, roots and other debris.

e. Avoid using downward pressure onhandlebars. If need be, use slightupward pressure to keep the tinesfrom digging too deeply.

f. Before contacting hard packed soilat the end of a row, reduce enginespeed and lift handlebars to raisetines out of the soil.

g. In an emergency, stop tines andwheels by shifting theWheels/Tines/PTO Drive Leverinto NEUTRAL. If you can notreach the lever or have lost controlof the tiller, let go of the handle-bars and all controls. Do notattempt to restrain the tiller.

15. Do not overload the tiller’s capacity byattempting to till too deeply at too fast arate.

16. Never operate the tiller at hightransport speeds on hard or slipperysurfaces. Look behind and use care whenbacking up.

17. Do not operate the tiller on a slopethat is too steep for safety. When onslopes, slow down and make sure youhave good footing. Never permit the tillerto freewheel down slopes.

18. Never allow bystanders near the unit.

19. Only use attachments and accessoriesthat are approved by the manufacturer ofthe tiller.

20. Use tiller attachments and acces-sories when recommended.

21. Never operate the tiller without goodvisibility or light.

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

23. Operators shall not tamper with theengine-governor settings on the machine;the governor controls the maximum safeoperating speed to protect the engine andall moving parts from damage caused byoverspeed. Authorized service shall besought if a problem exists.

24. Do not touch engine parts which maybe hot from operation. Let parts cooldown sufficiently.

25. POISON/DANGER—CAUSESSEVERE BURNS. The battery on electricstart models contains sulfuric acid. Avoidcontact with skin, eyes or clothing. Keepout of reach of children.

Antidotes:

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

26. DANGER– BATTERIES PRODUCEEXPLOSIVE GASES. Keep sparks, flameor smoking materials away. Ventilatewhen charging battery or using in anenclosed space. Always wear safetygoggles when working near battery.

27. Please remember: You can alwaysstop the tines and wheels by releasing allcontrols, or by moving the ignition switchand/or throttle control lever on the engineto OFF or STOP.

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

29. Use extreme caution when backing orpulling the machine towards you.

30. Start the engine carefully according toinstructions and with feet well away fromthe tines.

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

32. When loading or unloading the tiller,always disengage tines and use slowerwheel and engine throttle speeds. Usesturdy ramps wide and strong enough toeasily support the tiller (280-to-325 lbs.,depending on model) and operator.Never go down ramps in FORWARDdrive—the tiller could tip forward,exposing you to the tines (which shouldbe disengaged). Always use REVERSEdrive and back down ramps. To go upramps, use FORWARD drive and followthe tiller.

33. The Forward Interlock Safety Systemshould be tested for correct functioningevery time the tiller or PTO power unit isused. See Section 4 in this Manual.

34. If using the optional Dozer Blade,either remove the tine attachment, ordisengage the tines with the Tines/PTOClutch Lever. Revolving tines aredangerous.

4

Section 1: Safety

5

DecalsFor your safety and the safety of others,various safety and operational decals arelocated on your unit (Figure 1).

Keep the decals clean and legible at alltimes. Contact your local service dealeror the Factory for replacements if anydecals are damaged or missing.

Refer to the Parts List for decal locations,descriptions and part numbers.

Figure 1: Location of Safety and Operating Decals. (Briggs & Stratton engine shown)

Operating SymbolsVarious symbols (shown here, with worddescriptions) are used on the tiller and engine.Your unit may not have all of the symbols.

FAST SLOW CHOKEON

CHOKEOFF

STOP

STOP ROTATINGTINES

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

C) WARNING: Operating andSafety Instructions

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

D) Power UnitOperatingInstructions

F) Engine Stabilization.Top of fuel tank.

E) ForwardInterlockLever (2)

Maintenance and Storage1. Keep the tiller, attachments and acces-sories in safe working condition.

2. Check all nuts, bolts, and screws atfrequent intervals for proper tightness tobe sure the equipment is in safe workingcondition.

3. Never store the tiller with fuel in thefuel tank inside a building where ignitionsources are present such as hot waterand space heaters, furnaces, clothesdryers, stoves, electric motors, etc.).Allow engine to cool before storing in anyenclosure.

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

5. Store gasoline in a cool, well-ventilatedarea, safely away from any spark- orflame-producing equipment. Storegasoline in an approved container, safelyaway from the reach of children.

6. Refer to the Maintenance sections ofthis Manual and the separate EngineOwner’s Manual for instructions if thetiller is to be stored for an extendedperiod.

7. Never perform maintenance while theengine is running or the spark plug wire isconnected, except when specificallyinstructed to do so.

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

TO AVOID SERIOUS INJURY:• READ THE OWNER’S MANUAL.• KNOW LOCATIONS AND FUNCTIONS OF ALL CONTROLS.• KEEP ALL SAFETY DEVICES AND SHIELDS IN PLACE AND WORKING.• NEVER ALLOW CHILDREN OR UNINSTRUCTED ADULTS TO OPERATE TILLER.• SHUT OFF ENGINE AND DISCONNECT SPARK PLUG WIRE BEFORE MANUALLY UNCLOG-

GING TINES OR MAKING REPAIRS.• KEEP BYSTANDERS AWAY FROM MACHINE.• KEEP AWAY FROM ROTATING PARTS.• USE EXTREME CAUTION WHEN REVERSING OR PULLING THE MACHINE TOWARDS YOU.

WARNING

6

IntroductionCarefully follow these assembly steps tocorrectly prepare your tiller for use. It isrecommended that you read this Sectionin its entirety before beginning assembly.NOTE: Three different Horse model tillersare covered in this Manual. Use only theinformation applicable to your model.Tiller engines vary by model. Your enginemay appear differently than those foundin illustrations of this manual.

Inspect UnitInspect the unit and carton for damageimmediately after delivery. Contact thecarrier (trucking company) if you find orsuspect damage. Inform them of thedamage and request instructions for filinga claim. To protect your rights, put yourclaim in writing and mail a copy to thecarrier within 15 days after the unit hasbeen delivered. Contact us at the Factoryif you need assistance in this matter.

STEP 1: Unpacking Instructions

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

1. The tiller is heavy. Do not attempt toremove it from the shipping platform untilinstructed to do so in these Assemblysteps.

2. Remove all unassembled parts fromthe carton. The hardware bag is includedin your literature packaging.

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

Factory if any items are missing ordamaged).

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

Loose Parts List

Qty. Description1 Handlebar Assembly1 Wheels/Tines PTO Drive Lever

The following items are in the hardware bag:

2 20 oz. Bottles SAE 30W Oil1 Clutch Pawl Spring1 Belt Adjusting Tool2 Plastic Cable Ties1 Curved Head Screw, 1/4-20 x 21 Flanged Lock Nut, 1/4-201 Pan Head Screw, #10-32 x 1/2

The following parts (electric start modelsonly), packaged separately.2 Nuts, 1/4-20

(for battery terminals)2 Screws, 1/4-20 x 5/8

(for battery terminals)2 Keys

(in ignition switch)

NOTE: LEFT and RIGHT sides of thetil ler are as viewed from theoperator’s position behind the han-dlebars (unless otherwise noted).

Tools/Materials Needed for Assembly(1) 3/8" open-end wrench*(2) 7/16" open-end wrench*(2) 1/2" open-end wrench*(1) 9/16" open-end wrench*(1) 3/4" open-end wrench*(1) Flat blade screwdriver(1) Scissors (to trim plastic ties)(1) Tire pressure gauge(1) 4-1/2" high wood block to prop unit* Adjustable wrenches may be used.

STEP 2: Attach HandlebarIMPORTANT: When disassemblinghandlebar assembly, keep left-side clampand ratchet separated from the right-sideclamp and ratchet.

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

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

3. Install the height adjustment leverthrough the right-side clamp, handlebarend, ratchet, and base; then out throughthe left-side ratchet, handlebar end, andclamp (Figure 2-2). Secure with nut, butdon't fully tighten.

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

Section

2 Assembly

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

1

2

1

2

To prevent personal injury or propertydamage, do not start the engine untilall assembly steps are complete andyou have read and understand thesafety and operating instructions in thismanual.

WARNING

Section 2: Assembly

lever and could be damaged. You maygently move the wires aside if thiscondition occurs.

4. Raise handlebars to one of two heightsettings and tighten the height adjustmentlever. Also, make sure all other mountinghardware is securely tightened.

NOTE: Fully assembled handlebarassembly should appear as shown inFigure 2-3.STEP 3: Move Tiller Off ShippingPlatform1. Set the Depth Regulator Lever(A, Figure 2-4) to Travel position. Do thisby lifting the tiller by the handlebars, thenpulling straight back on the lever andsliding down to the highest notchedsetting.

2. Set the Wheel Speed Lever (B, Figure2-4) to Freewheel position. To do this,move the lever approximately halfwaybetween the Fast and Slow settings whileyou rock the tiller forward and backwarduntil the wheels move freely.

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

STEP 4: Connect ForwardInterlock Wire Harness1. Remove any dirt from the ForwardInterlock wire harness plug (C, Figure 2-5) and its receptacle (D).

2. Connect the Forward Interlock wireharness plug (C, Figure 2-5) to the recep-tacle (D).

STEP 5: AttachWheels/Tines/PTO Drive Lever

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

handlebar base and swing the handlebarsout to the right side.

2. Remove both sets of nuts, starwashers, screws, and one bushing (A, B, C, D, E, F, G, Figure 2-6) from theyoke plates (H). There is a bushing insidethe short link (I). Be careful not to lose itwhen removing screw (G).

3. Slide the plates at the end of theWheels/Tines/PTO Lever over the yokeplates (Figure 2-9). To aid in the nextstep, insert a screw temporarily into theforward most holes (J, Figure 2-7) of the

yoke plates and the lever.

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

5. Retrieve the clutch pawl spring (Figure2-8) from hardware bag.

Figure 2-2. Handlebar assembly.

LeftRatchet

RightRatchet

Handlebars

RightClamp

LeftClamp

HeightAdjustmentLever

WireHarness

BaseBolt

Base

FRONT OF TILLER

Nut

Figure 2-3. Fully assembled handle-bars.

Left-SideClampand Nut

Figure 2-4: Photo shows the DepthRegulator Lever (A) and the WheelSpeed Lever (B).

B

A

7

Figure 2-5. Forward Interlock WireHarness connection.

D

C

8

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

Figure 2-7: Drive Lever assembly.

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

AI

B

CH D

E

F

GFigure 2-10 Forward position; roller(T) rests under the adjustmentblock (U).

UT

T

U

Figure 2-8: Clutch pawl spring. TiltWheels\Tines\PTO Lever fullyforward before installing spring.

N

M

Section 2: Assembly

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

K

J L

QR

S

STEP 6: Check Gear Oil Levels Your tiller has two separate transmis-sions: one for the Power Unit (Figure 2-12), the other for the Tine Attachment(Figure 2-13). Both transmissions werefilled at the factory with SAE #85W–140weight gear oil (with an A.P.I rating ofGL-4). Check level in both transmis-sions to verify that they are still correct.See Section 5, Transmission Gear OilMaintenance for complete informationon how to check and fill the transmis-sions.

P

Remove the temporary screw (J, Figure 2-7) from the forward holes and move theWheels/Tines/PTO Lever fully forward.Install the wider hook end of the clutchpawl spring (M, Figure 2-8) down into thesmall hole at the end of the handle. Usepliers to insert the other end into the holein the long link bar (N).

NOTE: Do not bend or over stretch thespring while installing.

6. Pull the Wheels/Tines/PTO Lever backto align the forward most holes (Q, Figure2-9) in the yoke plate with the holes in thelever plates. Also align the bushing that isinside the short link bar (P). Install thescrew, star washer, and nut, then tightensecurely.

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

Completed assembly should appear asillustrated in Figure 2-9.

7. Test the operation of theWheels/Tines/PTO Lever. Push the leverdown until it engages in the Forwardposition. The clutch roller (T, Figure 2-10) must rest beneath the adjustmentblock (U). Next, move the lever up to theNeutral position. The clutch roller (T,Figure 2-11) should rest on the face of theadjustment block (U). To test Reverse, liftand hold the lever all the way up inReverse position, then let it go. The levershould automatically return to the Neutralposition (Figure 2-11). If not, do not usethe tiller. See your local authorized dealeror call the Factory Technical ServiceDepartment for instructions.

Section 2: Assembly

9

IMPORTANT: Check gear oil level in bothtransmissions after the first 2 hours ofnew til ler operation, then every 30operating hours thereafter. See Section 5for instructions.

STEP 7: Add Motor Oil to Engine1. Before adding motor oil, park the tilleron level ground. Level the engine byplacing a sturdy block under the tines orthe tines depth regulator bar.2. Refer to the Engine Owner’s Manualprovided with your tiller for detailed infor-mation on how to add motor oil and formotor oil specifications.IMPORTANT: Two 20 oz. bottles of motoroil are included with your tiller. Check theoil level as instructed in the EngineOwner’s Manual provided with your tillerBEFORE pouring the full amount of eachbottle into the engine.IMPORTANT:• Change engine oil after first 2 hours of

new operation.• Check engine oil level every 5 hours of

operation or each use.

STEP 8: Attach Engine ThrottleLever and CableFor shipping purposes, the throttle cable,together with the throttle lever, is woundaround the engine. Carefully unwind thecable. If the throttle control label iscovered with a clear protective coating,peel it off.

To attach the throttle lever and cable:

1. Run the throttle cable up the insideedge of the right handlebar and positionthe lever as shown in Figure 2-14.2. From the outside of the handlebar,insert the curved head screw (A, Figure 2-14), through the handlebar and the centerhole in the throttle lever mountingbracket.3. Loosely install the flanged lock nutand move the throttle lever back to theSTOP position.4. From the lever side of the bracket,thread a pan head screw (B, Figure 2-14)through the small hole in the throttle leverbracket and into the handlebar. Tightenthe screw securely.5. Securely tighten both the flanged locknut and the curved head screw.6. Use two plastic ties to secure thethrottle cable to the right handlebar in twoplaces (Figure 2-15). Loop each tiearound the handlebar and cable (serratedside faces in) and pull the ties tight. Trimthe ends.

Figure 2-12: Checking oil level onPower Unit Transmission.

Figure 2-13: Checking oil level onTine Attachment Transmission.

To avoid electric shock from a shortcircuit (electric start tillers only), neverallow the throttle cable to touch thebattery. Route cable below the battery,on the outside of the battery holder.

WARNING

Figure 2-14: Engine Throttle Leverposition and installation.

Figure 2-15: Plastic Ties placementon handlebars.

Oil Level Hole

B A

Tie

Tie

Assembly is complete for recoil starttillers. See Assembling The ElectricStart System if you own an electricstart tiller; otherwise, refer to Section3, Controls for information on tillercontrols.

STEP 9: Adjust Air Pressure inTiresFor shipping purposes, the tires may beoverinflated. Check the air pressure ineach tire and adjust them to between 10and 20 pounds per square inch. Youmust inflate each tire to equal airpressures to prevent the tiller from pullingto one side.

Section 2: Assembly

10

NOTE: If the battery is put intoservice after the date shown on thetop of the battery, charge for aminimum of one hour at 6-10amps. Refer to the Maintenencesection of this manual for moredetailed instructions regardingproper battery charging procedure

STEP 1: Connect the WireHarness Receptacle1. Before installing the battery and itshold-down clamp, insert the plastic wireharness receptacle (A, Figure 2-18) intothe prongs of the keyswitch (M) locatedon the hold-down clamp.

2. Remove the ignition keys from thekeyswitch and store them safely away.Do not insert the key into the keyswitchuntil you complete this section and readSection 3, Controls.

STEP 2: Install the Battery CablesNOTE: The cable terminals should betoward the rear (keyswitch side) of thebattery posts.

1. Use a 5/8" long screw (K, Figure 2-18)and 1/4-20 hex nut (L) to connect thepositive (+) battery cable (B) to thepositive (marked +) battery post (C).Make sure that this is the cable on the leftside, with one end attached to thesolenoid (D).2. Slide the black rubber boot (E) com-pletely over the battery post and cableconnector.3. Use a 5/8" long screw and 1/4-20 hexnut to connect the negative (-) batterycable (F) to the negative (marked -)battery post (G) and secure with screw(H) and nut (I).4. Slide the black rubber boot (J) com-pletely over the battery post and cableconnector.

Assembly is complete for electric starttillers. See Section 3, Controls forinformation on tiller controls.

ASSEMBLING THE ELECTRIC START SYSTEMThe following steps explain how to install and charge the battery on electric start tillers. For your safety, follow all steps and observeall accompanying safety messages. Section 5 contains other general battery maintenance and recharging instructions.

Battery produces explosive gases.

• Keep away sparks, flames, andcigarettes.

• Ventilate area when charging or usingbattery in an enclosed space.

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

DANGER

Remove metal jewelry before workingnear the battery or near the electricalsystem. Failure to comply may cause ashort circuit, resulting in electricalburns, a shock, or battery gasexplosion.

WARNING

To Avoid Personal Injury or PropertyDamage:

• Do not touch positive battery terminaland any surrounding metal objectswith tools, jewelry or other metalitems. Failure to comply could causea short circuit leading to electricalburns or explosion of battery gases.

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

DANGER

Never jump start the battery with avehicle battery or charging system. Thismay produce a battery explosion,causing acid or electrical burns.

DANGER

Figure 2-18: Battery cable assembly.

OIL

BC (+)

F

G (-)K

H

M

IJ

E L

D

A

Section

3 Features and Controls

11

IntroductionThis section describes the location andfunction of the controls and features onyour tiller. Refer to Section 4, Operationfor detailed operating instructions.

Practice using these controls, with theengine shut off, until you completelyunderstand the operation of the controlsand feel confident with each of them.

IMPORTANT: Refer to the separate enginemanufacturer’s Engine Owner’s Manualfor information about the controls on theengine.

NOTE: All references to left, right, frontand rear of the machine are based on aposition behind the handlebars and facingforward.

PTO Attachments FeatureIn addition to powerful tilling capability,you can quickly convert your machineinto a PTO (Power Take-Off) Power Unitthat is capable of towing or poweringvarious TROY-BILT attachments.

You can access this capability byremoving the tines attachment (poweredby the PTO Power Unit). The PTO PowerUnit is then available for engine poweredattachments, or for pulling or towing non-powered attachments. See Section 4,PTO Power Unit for detailed informationon installing and operating TROY-BILTPTO attachments.

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

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

• FORWARD is engaged when the lever ismoved down until the clutch roller (G,Figure 3-2) engages into the detentposition under the adjustment block (H,Figure 3-2). You will definitely feel thelever engage into this position.

Use the FORWARD setting to move thewheels and tines forward, or to applypower to an optional PTO (Power TakeOff) attachment. (See also ForwardInterlock Levers.)

To stop the wheels, tines or any PTOattachment, move the lever to NEUTRALby tapping the lever upwards (Figure 3-3) and releasing.

• REVERSE is engaged when the lever ispushed (with an open palm) all the wayup and held in that position (Figure 3-4).Use this setting to move the wheels inreverse. To stop moving in reverse,release the lever; it automatically returnsto the NEUTRAL position.

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

• NEUTRAL is this control’s normal non-operating position. The lever returns toNEUTRAL when it is tapped out of theFORWARD position or released from theREVERSE position. NEUTRAL positionis between FORWARD and REVERSE(Figure 3-3). Use this setting to stopthe wheels, tines or any PTO attach-ment.

IMPORTANT: Always shift to NEUTRALbefore starting the engine or beforeengaging the wheels, tines or any PTOattachment.

Forward Interlock LeversThe Forward Interlock Levers (B, Figure 3-1) are attached under eachhandlebar grip.

You must squeeze at least one of theseinterlock levers up against the handlebargrip whenever the Wheels/Tines/PTODrive Lever is engaged in FORWARDposition.

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

A

G

B

C

D

E

FBefore operating your machine,carefully read and understand allsafety, controls, operating instructionsin this Manual, the separate EngineOwner’s Manual and on the decals onthe machine.

Failure to follow these instructions canresult in serious personal injury.

WARNING

Section 3: Features and Controls

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

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

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

GH

Verify Position of Clutch RollerWhen you shift between FORWARD,NEUTRAL and REVERSE, the clutchroller at the base of theWheels/Tines/PTO Drive Lever shouldbe positioned as shown in Figures 3-2,3-3 and 3-4. Verify the position of theclutch roller as you shift the lever. If itis not positioned correctly, contact theFactory or see your local authorizeddealer.

GH

GH

12

If both Forward Interlock Levers arereleased before first returning theWheels/Tines/PTO Drive Lever toNEUTRAL, the engine will stop.

IMPORTANT: The Forward InterlockLevers are a safety control that stops theengine should you lose control whilegoing forward and cannot shift intoNEUTRAL.

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

• SLOW – Lever moved all the way down.Most effective for normal tilling or forlow-speed transport.

• FAST – Lever moved all the way up.Most effective for cultivating or for fast-speed transport.

• FREEWHEEL – Lever in between SLOWand FAST (wheels will roll freely). Usedwhen transporting the machine on levelground without engine power, and whenusing stationary PTO attachments.

IMPORTANT: To avoid transmissiondamage, always move Wheels/Tines/PTODrive Lever into NEUTRAL before shiftingthe Wheel Speed Lever.

IMPORTANT: When shifting into SLOWor FAST, gently roll the machine forwardor backward to help fully engage thewheel gears. When engaged, the wheelswill not turn unless the engine is runningand the Wheels/Tines/PTO Drive Lever isengaged in FORWARD or REVERSE.

Tines/PTO Clutch LeverUse this lever (D, Figure 3-1) to engage ordisengage power from the transmissionPTO clutch to the tines or any PTO attach-ment. This control has two operatingpositions: ENGAGE and DISENGAGE.

• ENGAGE – Lever moved into detent slotfarthest from engine. Use this position tooperate tines or other PTO attachments.After shifting to ENGAGE, briefly operatemachine in FORWARD to help fullyengage the PTO clutch.

• DISENGAGE – Lever moved into detentslot nearest engine. Use this position todisengage power to tines or other PTOattachments before transporting, loading,turning, or operating in reverse.

IMPORTANT: To avoid transmissiondamage, always move the Wheels/Tines/PTO Drive Lever into NEUTRAL beforeshifting the Tines/PTO Clutch Lever.

Depth Regulator LeverUse this lever (E, Figure 3-1) to regulatethe tilling depth of the tines. This controlalso has a TRAVEL position, whichenables transport with the tines off theground.

To operate the lever, lift up on the handle-bars, pull the Depth Regulator Leverstraight back, and then slide it up or downto one of the eight detent height settings.

The eight detent positions offer a range oftine height settings. This enables you toselect the height that is most effective fora particular condition. The top detentposition is the TRAVEL setting. Use thesecond or third detent from the top forshallow tilling and cultivating. Use theother detents for deeper tilling and forpower composting.

Handlebar Height AdjustmentLeverUse this lever (F, Figure 3-1) to adjust thehandlebars to one of two height settings.

1. To change the height, hold the handle-bars with one hand and loosen the lever ina counterclockwise direction.2. Move the handlebars to one of the twopreset height settings.3. Retighten the lever.NOTE: You can swap the positions of theinside handlebar ratchets to change thetwo preset settings by approximately fourinches higher or lower. See Section 2,Step 2: Attach Handlebar for detailedassembly information.

To avoid personal injury, always place the tines in the TRAVELposition before starting the engine.This prevents the tines from touchingthe ground until you are ready to begintilling.

WARNING

Engine Throttle LeverUse the throttle lever (G, Figure 3-1) toadjust engine speed as well as to startand stop the engine.

Move the lever away from the STOPposition before starting the engine.Engine speeds are variable and rangebetween the FAST and SLOW. Use theSTOP position to turn the engine off.

NOTE: A secondary throttle lever islocated on the front of the 8HP and 10HPengines. A separate On/Off switch mayalso be available on the engine. (SeeEngine Owner’s Manual for information.)

Engine ControlsRefer to the engine manufacturer’s EngineOwner’s Manual (included in the tiller lit-erature package) to identify the controlson your engine.

IMPORTANT: An engine On/Off switch, asecondary throttle control, a choke leverand a fuel line shut-off control may belocated on the engine. Refer to yourEngine Owner ’s Manual for detailed information.

Section 3: Features and Controls

The tiller handlebars can be swung out30o to the right side for use only with thePTO Chipper/Shredder attachment. Thisis done by loosening the mounting bolton the handlebar base. Never operateyour tiller or attachments, other than thePTO Chipper/Shredder, with the handle-bars in the right side position. Doing socould result in unsafe handling andpersonal injury.

WARNING

To avoid serious personal injury ordamage to equipment, do not start yourengine at this time. Complete startinginstructions are described in Section 4,Operation.

WARNING

Keyswitch StarterThe keyswitch starter on electric startmodels (A, Figure 3-5) has threepositions: OFF, RUN and START. Turnthe key to START to start the engine.Release the key andit will return to theRUN position. Turnthe key to OFF tostop the engine.(Another way tostop the engine is tomove the enginethrottle lever to theSTOP position.)

Figure 3-5

A

13

Section

4 Operation

INTRODUCTIONRead this Section of the manual thoroughly before you start the engine.Then, take the time to familiarize yourselfwith the basic operation of the tillerbefore using it in your garden. Find anopen, level area and practice using thetiller controls without the tines engagingthe soil (put tines in Travel setting—Section 3, Depth Regulator Lever). Onlyafter you’ve become completely familiarwith the tiller should you begin using it inthe garden.

Break-In OperationPerform the following maintenance duringthe first hours of new operation (seeMaintenance Section in this Manual andmaintenance information in the EngineOwner’s Manual).1. Change engine oil after first 2 hours ofnew engine operation.

2. After the first 2 hours of newoperation, check the gear oil levels in thePTO Power Unit and the tine attachmenttransmissions.

3. Check for loose or missing hardwareon unit. Tighten or replace as needed.4. Check tension on forward drive beltafter first 2 hours of operation.

Starting and Stopping the EngineThe following steps describe how to startand stop the engine.IMPORTANT: Do not attempt to engagethe tines, wheels, or any PTO attachmentuntil you have read all of the operatinginstructions in this Section. Also reviewthe safety rules in Section 1, Safety andthe tiller and engine controls informationin Section 3, Features and Controls.

Pre-Start Checklist

Make the following checks and performthe following services before starting theengine.

1. Read the Safety and Controls Sectionsin this Manual. Read the separate EngineOwner’s Manual provided by the enginemanufacturer.

2. Check unit for loose or missinghardware. Service as required.3. Check engine oil level. See EngineOwner’s Manual.4. Shift the Wheels/Tines/PTO Drive lever(Figure 4-2) into NEUTRAL position. SeeSection 3, Controls for more informationon this lever.

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

6. Check air cleaner. See Engine Owner’sManual.7. Attach spark plug wire to spark plug.8. Check Engine Cooling System. Clearcooling fins and air intake screen ofdebris.

9. Select High/Low Belt Speed range.

10. Adjust Handlebar Height.

11. Fill the fuel tank with gasoline inaccordance with the directions in theseparate Engine Owner’s Manual. Followall instructions and safety rules carefully.

Your tiller and its optional PTO PowerUnit attachments are capable ofcausing serious injury to untrained orcareless operators.To avoid serious personal injury orproperty damage, read the Owner’sManual that is provided with anyoptional accessories or attachmentsbefore using the tiller or PTO PowerUnit.

WARNING

Figure: 4-1

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

Failure to follow these instructions canresult in serious personal injury.

WARNING

GASOLINE IS HIGHLY FLAMMABLE ANDITS VAPORS ARE EXPLOSIVE.

Follow gasoline safety rules in thisManual (Section 1) and in the separateEngine Owner’s Manual.

Failure to follow gasoline safety instruc-tions can result in serious personalinjury and property damage.

DANGER

14

Section 4: Operation

Starting the Engine:

1. With the engine off, place theWheels/Tines/PTO Drive Lever (Figure4-2) in the NEUTRAL position. If in theFORWARD position, tap the lever sharplyupward, it should automatically move intoNEUTRAL position.

2. Put the Depth Regulator Lever in theTravel position (lever all the way down)so that the tines are off the ground. To dothis, lift up on the handlebars, pull thelever (Figure 4-2) back, and push it downall the way to the top detent (notched)position.

3. Move the Wheel Speed Lever (Figure 4-2) to either the SLOW or FAST position.Be sure to roll the wheels while shifting thelever until the wheels engage.

NOTE: If using a PTO stationary attach-ment, move the Wheel Speed Lever intoFREEWHEEL and block the wheels toprevent the equipment from moving (Figure4-29 on page 29).

4. Move the Tines/PTO Clutch Lever intoDISENGAGE position (Figure 4-2).

NOTE: Use the ENGAGE position if you wantthe tines to revolve or to apply power to aPTO-driven stationary attachment.

5. If engine is equipped with a fuel valve,turn valve to OPEN position as instructedin the separate Engine Owner’s Manual.6. If engine is equipped with an ON/OFFswitch, move the switch to ON.7. Move engine throttle lever (Figure 4-2)away from STOP.8. Choke or prime engine as instructed inthe separate Engine Owner’s Manual.9. If not equipped with an electric startsystem, place one hand on the fuel tank tostabilize the unit when you pull the recoilstarter rope. Use the recoil starter rope tostart the engine as instructed in theseparate Engine Owner’s Manual.

10. If equipped with an electric startsystem, turn key to START position to crankengine then release when engine starts. Ifthe engine does not start right away, do nothold key at START for more than a fewseconds. Release then try again after a shortpause. Damage to starter motor can occur ifit is cranked more than 15 seconds perminute.11. If the engine does not start after anumber of tries, refer to the Engine Owner’sManual for specific instructions.12. When engine starts, move the ThrottleLever to the SLOW position and thengradually move choke lever (on engines soequipped) to OFF or RUN position.13. Move the throttle speed control toFAST setting when tilling.

Starting Electric Start Engines with the Recoil Starter RopeYou may, at some point, have to start anelectric start engine with the recoil starterrope. Before attempting to do so,perform the following applicable steps:

• If you suspect the battery charge isweak, and there is no visible damage.Disconnect cables from battery andclean both cable terminals, and thebattery posts in accordance with theinstructions provided in Section 5,Battery Care and Maintenance.

Figure 4-2: Tiller and engine controls.

Wheels/Tines/PTODrive Lever

ForwardInterlock Levers

DepthRegulatorLever

WheelSpeedLever

Engine ThrottleLever

Tines/PTO Clutch Lever

Recoil Start Rope (at front of engine)

15

To help prevent serious personal injury or damage to equipment:

• Always place Wheels/Tines/PTO DriveLever into NEUTRAL before startingengine, and before engaging wheels,tines or other PTO-driven attachments.

• Never run engine indoors or inenclosed, poorly ventilated areas.Engine exhaust contains carbonmonoxide, an odorless and deadlygas.

• Avoid engine muffler and nearbyareas. Temperatures in these areasmay exceed 150oF.

CAUTION


Reconnect the cables and securelytighten to battery posts. The engine willrecharge the battery if the battery is stillgood.

• If you suspect the batter is “dead”, or ifthe battery is damaged, disconnect, andremove it. Have it checked by aqualified technician.

• If battery has been removed, wrap cableterminals at end of positive cable withelectrical tape and secure the cable tothe battery bracket. This will preventelectrical discharge.

• Before pulling the recoil starter rope,turn the keyswitch to the RUN position.Move the Throttle Lever away fromSTOP position and set the choke asapplicable. See Engine Owner’s Manual.

Stopping the Engine and Tiller1. To stop the wheels and tines, move theWheels/Tines/PTO Drive Lever intoNEUTRAL position and then release bothForward Interlock Levers.

2. Move the engine Throttle Lever to theSTOP position. Then on electric startmodels, turn the key to OFF. Remove thekey for safekeeping.

NOTE: The engine may have a separateThrottle Control Lever and ON/OFF switchon the engine. These controls can also beused to stop the engine. See the EngineOwner’s manual for information specificto your engine.

Operating the TillerWhen first practicing, keep the Tines/PTOClutch Lever in DISENGAGE position andthe Wheel Speed Lever in SLOW position.

The following pages provide guidelinesfor using your tiller effectively and safelyin various gardening applications. Besure to read Tilling Tips & Techniques, inthis Section, before you actually put thetines into the soil.

This is a traditional standard-rotating-tine(SRT) tiller with forward rotating tines. Itoperates in a completely different mannerthan counter-rotating-tine (CRT) tillers, orfrom front-tine tillers.

Moving the Tiller Forward and Tilling1. Start the engine and gradually increaseengine speed to FAST (see Starting theEngine, this Section).

2. Test the Forward Interlock SafetySystem. See Testing Forward InterlockSystem, this Section.

3. When practicing, set the DepthRegulator Lever to Travel position.Otherwise, set the Depth Regulator Leverto a desired depth.

4. Move Tines/PTO Clutch Lever toENGAGE position if you want the tines toturn. If practicing, leave in DISENGAGE.

IMPORTANT: Do not move Tines/PTOClutch Lever to ENGAGE unlessWheels/Tines/PTO Drive Lever is inNEUTRAL. Tiller damage may occur!

5. To move the tiller forward and engagethe tines, squeeze and hold either ForwardInterlock Lever (Figure 4-3) against thehandlebar grip, then move theWheels/Tines/PTO Drive Lever down toFORWARD position.

To avoid serious personal injury ordamage to equipment:

• Always place Wheels/Tines/PTO DriveLever in NEUTRAL before startingengine, and before engaging wheels,tines or other PTO attachments.

• Be sure there are no obstacles behindyou before moving in reverse.

• Wheels/Tines/PTO Drive Lever shouldautomatically return to NEUTRALwhen released from REVERSEposition. If it does not, move lever toNEUTRAL manually and discontinueuse until you adjust the lever. SeeSection 5, Checking and AdjustingReverse Drive System.

• No reverse motion should occur ifWheels/Tines/PTO Drive Lever is notheld up in REVERSE. See Section 5,Checking and Adjusting ReverseDrive System for adjustment steps.Do not use tiller unless properlyadjusted.

• Always return to NEUTRAL and let allmotion stop before shifting toFORWARD or REVERSE.

CAUTION

The Forward Interlock Safety System isdesigned for the operator’s safety. Donot disconnect or attempt to defeat thepurpose of the system. If the systemmalfunctions, immediately contact yourlocal authorized dealer or theTROY-BILT Technical Service Depart-ment for assistance. Do not use thetiller or the PTO power unit until theForward Interlock Safety System isfunctioning properly. Always test thesystem before using the tiller or PTOpower unit.

DANGER

Keep away from rotating tines. Rotatingtines will cause injury.

WARNING

Cold Weather OperationWhen temperatures fall below 40oF, dothe following steps to protect yourengine and transmission from damage:

1. Refer to the Engine Owner’s Manualfor motor oil specifications for coldweather operation. Use winter blendgasoline.

2. Warm up the engine before putting itunder a load.

3. Use winter-blend gasoline.

4. Use the correct weight gear oil in PTOPower Unit transmission.

5. Warm up the transmission gear oil asfollows: With engine running, moveWheel Speed Lever (Figure 4-2) toFREEWHEEL (then block wheels so theycan’t roll), put Tines/PTO Clutch Leverinto DISENGAGE, then squeeze one ofthe Forward Interlock Levers and shiftthe Wheels/Tines/PTO Drive Lever toFORWARD.

6. If wheels are frozen to the ground,melt ice with warm water.

16


6. When the tiller moves forward, relaxand let the wheels power the tiller alongwhile the tines dig. Walk behind and toone side of the tiller. Walk on the sidethat is not yet tilled (Figure 4-4). Use afirm grip on the handlebars but keep yourarm relaxed.

IMPORTANT: Let the tiller move ahead atits own pace. Do not push it ahead—thisreduces operator control and tilling effi-ciency. Do not push handlebars down inan attempt to dig deeper— this takesweight off the wheels, reduces traction,and causes the tines to try to propel thetiller.

Stopping Forward Motion and Tines1. To stop forward motion, tapWheels/Tines/PTO Drive Lever upwardinto NEUTRAL. Then release the ForwardInterlock Levers. The wheels and tineswill stop and the engine will continuerunning.

2. In an emergency, release all of thecontrol levers. This stops forward motionand shuts-off the engine.

Moving the Tiller in ReverseIMPORTANT: Do not ti l l while inREVERSE.

1. Shift the Tines/Wheels/PTO Drive Lever(Figure 4-2) into NEUTRAL and move theWheel Speed Lever to the SLOW position.

2. Move Tines/PTO Clutch Lever (Figure4-2) into DISENGAGE position.

3. Verify that the area behind you is clear.

4. Lift up the handlebars until the tinesare off the ground, then shift the Wheels/Tines/PTO Drive Lever all the wayup and hold. You do not need to squeezethe Forward Interlock Levers to usereverse.

5. The unit immediately engages inreverse. Periodically check behind youwhile holding the handlebars up and theWheels/Tines/PTO Lever in its upper-mostposition.

Stopping Reverse MotionRelease the Wheels/Tines/PTO DriveLever– the lever automatically returns tothe NEUTRAL position. This stops thewheels immediately. (The ForwardInterlock Levers will not stop REVERSEmotion.)

To Stop the EngineMove the engine Throttle Lever to theSTOP position. Then, on electric startmodels, turn key to OFF. Remove the keyfor safekeeping.

Making TurnsTurning the tiller is easy and just requirespractice. First find the balance pointbetween the engine and the tines by liftingup the handlebars (Figure 4-5). Once youfind the balance point, then let thepowered wheels do the turning as youpush sideways on the handlebars in thedirection of the turn. Practice the turningmaneuver described here in a large openarea. Once comfortable turning the tiller,you can then take it to the garden area.

1. At the end of a row, move the Wheels/Tines/PTO Drive Lever (Figure 4-2) toNEUTRAL position and reduce the enginespeed.

2. Move the Tines/PTO Clutch Lever(Figure 4-2) into the DISENGAGEposition.

3. Resume forward operation, and lifthandlebars until tines are off the ground(Figure 4-5). Find the balance pointbetween the engine and the tines. Thenpush the handlebars in the direction of theturn. Be very careful to keep feet and legsaway from the tines (which should be dis-engaged). Let the powered wheels do thehard work. The inside wheel will pivot inplace while the outside wheel drives thetiller around in the direction of the turn.

NOTE: Use REVERSE if necessary to turnin a limited space.

17

Figure 4-4: Guide tiller with one hand.

Figure 4-3: Moving tiller forward:squeeze one Forward Interlock Leverand then move Wheels/Tines/PTODrive Lever down to FORWARD.

To Help Avoid Personal Injury orDamage to Equipment:

• Be sure no obstacles are behind youbefore operating the tiller in REVERSE.• Disengage the tines, reduce enginespeed, and move the Wheel SpeedLever to SLOW position beforeoperating in REVERSE. Avoid usingFAST wheel speed until you arefamiliar with backing the tiller.

CAUTIONFigure 4-5: Turning the tiller.


4. When the turn is complete, shift toNEUTRAL and lower the handlebars.Move Tines/PTO Clutch Lever back toENGAGE position and resume forwardoperation.

Transporting The Tiller Around Your PropertyWhen the engine is running, the tiller’spowered wheels make moving the tiller toand from the garden easy. If the engine isnot running set the Wheel Speed Lever toFREEWHEEL position to roll the tiller toanother location.

1. Place the Tines/PTO Clutch Lever inDISENGAGE position.

2. Move Depth Regulator Lever down all theway into the Travel setting.

3. If using engine power, move WheelSpeed Lever to either SLOW or FAST, anduse the Wheels/Tines/PTO Drive Lever todrive the wheels.

4. If the engine is stopped, move WheelSpeed Lever to FREEWHEEL, andmanually push tiller.

Testing the ForwardInterlock Safety SystemThe Forward Interlock Safety System isdesigned to shut the tiller engine offimmediately if you lose control andcannot stop moving FORWARD byshifting the Wheels/Tines/PTO Drive Leverinto NEUTRAL. When you release bothForward Interlock Levers, they sendground to the ignition system therebystopping the engine. Squeezing one orboth levers up against the handlebarsenables the ignition system; therefore,you must squeeze at least one leverwhenever the Wheels/Tines/PTO DriveLever is engaged in FORWARD.

IMPORTANT: The interlock system alsoprevents the engine from starting if theWheels/Tines/PTO Drive Lever is engagedin FORWARD.

How to Check the Interlock SystemThe Forward Interlock System has anelectro-mechanical design, and so issubject to normal wear and possible mal-function. Check the system for properoperation each time prior to using thetiller or PTO power unit.

To test the Forward Interlock System:

1. Move tiller outside to level ground.Remove any obstacles.

2. Check that the Forward Interlock wireharness plug, at the bottom of the handle-bars (Figure 4-6), is securely connectedto the receptacle on the top, right side ofthe transmission.

3. Move Wheel Speed Lever (Figure 4-2)to SLOW position and move Tines/ PTOClutch Lever to DISENGAGE.

4. Start engine as described underStarting and Stopping the Engine, in thissection. Set engine throttle lever toSLOW, and let engine warm up.

5. Squeeze and hold just one of theForward Interlock Levers against thehandlebar grip while moving the Wheels/Tines/ PTO Drive Lever down toFORWARD (Figure 4-3). As the tillermoves forward, release the Forward Inter-lock Lever briefly. The engine shouldstart to stall out if the interlock system isworking properly. If it does start to stall,quickly squeeze the lever up against thehandlebar grip, and then return theWheels/ Tines/ PTO Drive Lever toNEUTRAL. Repeat this test to check thatthe engine begins to stall out when theother Forward Interlock Lever is released.

6. If the engine does not begin to shut offwhen either Forward Interlock lever isreleased, shut the engine off, remove thekey (if electric start), and do not operatethe tiller or PTO power unit until thesystem has been repaired and is func-tioning properly.

IMPORTANT: To avoid possible damageto the Forward Interlock Safety system,do not use high-pressure sprays near thewire harness receptacle or neutral plungerassembly.

Loading and Unloading the TillerThe following provides information ontiller loading, unloading, and requirementsbefore loading and unloading the tiller.Read the following instructions carefullybefore attempting to load or unload yourtiller.

Before Loading or Unloading theTiller• Ramps must be strong enough to

support the combined weight of the tillerand handlers. They should provide goodtraction to prevent slipping; they shouldhave side rails to guide the tiller alongthe ramps; and they should have alocking device to secure them to thevehicle.

• Handlers should wear sturdy footwearthat will help to prevent slipping.

Figure 4-6: Plug and receptacle ofForward Interlock Safety Systemmust be securely connected.

The Forward Interlock Safety System isdesigned for the operator’s safety. Donot disconnect or attempt to defeat thepurpose of the system. If the systemmalfunctions, immediately contact yourlocal authorized dealer or theTROY-BILT Technical Service Depart-ment for assistance. Do not use thetiller or the PTO power unit until theForward Interlock Safety System isfunctioning properly. Always test thesystem before using the tiller or PTOpower unit.

DANGER

To help avoid personal injury fromrevolving tines, always put theTines/PTO Clutch Lever in DISENGAGEposition before transporting, loading, orunloading tiller.

WARNING

18


• Turn the vehicle’s engine off and applyits parking brake.

• Position the loading vehicle so that theramp angle is as flat as possible (theless incline to the ramp, the better).

Loading the Tiller1. Use loading ramps that are strong andwide enough to safely hold the weight ofthe tiller and the operator combined—your tiller weighs between 280 and 325lbs.

2. Move the Tines/PTO Clutch Lever(Figure 4-2) into DISENGAGE position.

3. Set the Depth Regulator lever (Figure4-2) to the Travel position.

4. Move Wheel Speed Lever (Figure 4-2)into SLOW position and reduce theengine throttle speed.

5. Shift the Wheels/Tines/PTO Lever(Figure 4-2) into FORWARD position andfollow the tiller up the ramps (Figure 4-7).Check the wheels as you move the tillerforward. Ensure that they move up thecenter of each ramp.

6. Prevent tiller from rolling in vehicle.Leave Wheel Speed Lever in FAST orSLOW position, chock wheels with blocksand tie down the tiller.

Unloading the TillerIMPORTANT: Never unload the tiller inFORWARD drive. The tiller could tipforward and expose you to the tines(which should be disengaged asinstructed).

1. Use loading ramps that are strong andwide enough to safely hold the weight ofthe tiller and the operator combined—your tiller weighs between 280 and 325lbs.

2. Move the Tines/PTO Clutch Lever(Figure 4-2) to DISENGAGE position.

3. Set the Depth Regulator Lever (Figure4-2) to the Travel position.

4. Move Wheel Speed Lever (Figure 4-2)to SLOW position and reduce the enginethrottle speed.

IMPORTANT: Look behind you beforeyou back down the ramp to ensure that allis clear. While descending, keep checkingfor obstacles behind you.

5. Move and hold the Wheels/Tines/PTOLever into REVERSE drive and back downthe ramps (Figure 4-8). Check the wheelsas you move the tiller backward. Ensurethat they move down the center of eachramp.

Changing Speed BeltsYour tiller has two belt-driven speedranges – HIGH RANGE and LOW RANGE– you pick one or the other by decidingwhich set of pulley grooves to move theforward belt into. By moving the beltfrom one speed range into the other, incombination with the FAST and SLOWwheel speeds, you obtain a choice of fourdifferent forward wheel speeds and twodifferent tine speeds.

Changing the belt from LOW range intoHIGH range (or back again) is a matter ofmoving the belt from one set of pulleygrooves to a second set of pulley grooves.

This change is done quickly and withouttools (Figures 4-9 through 4-13).

When the tiller is moving in REVERSE, thewheels are powered by a rubber reversedisc, not by the belt. Therefore, you haveonly two reverse speeds SLOW and FAST,as set with the Wheel Speed Lever.

Table 4-1 shows the range of wheel andtine speeds available when using the twobelt speed ranges and the FAST andSLOW selections on the Wheel SpeedLever.

Changing Belt From LOW Range to HIGH Range1. To avoid personal injury, shut offengine, let all moving parts come to acomplete stop, then disconnect sparkplug wire from spark plug and move itaway from spark plug before making anyadjustments. Wait for the engine andmuffler to cool down.

2. Move Wheels/Tines/PTO Drive Leverinto NEUTRAL.

19

Figure 4-7: To go up ramps, use

Figure 4-8: To go down ramps, useREVERSE drive.

Figure 4-9: Belt range positions.

To help avoid serious personal injury,stop the engine, remove the ignitionkey, disconnect spark plug wire andmove the wire away from the sparkplug, and let engine and muffler cooldown before changing belt speeds.

WARNING

Low RangePulley

GroovesHigh Range

PulleyGrooves

Table 4-1Available wheel and tine speeds at 3000 RPM

engine speed.

Belt Position

WheelSpeedLever

WheelSpeed

TineSpeed

Low Range Slow .5MPH 146RPM

Low Range Fast 1.2MPH 146RPM

High Range Slow .7MPH 200RPM

High Range Fast 1.72MPH 200RPM


3. Kneel on left side of tiller. To createbelt slack, reach over to right side of thepulleys and push in at the center of thebelt with a finger. At the same time, useyour left hand to work the belt part-wayonto the lower-front transmission pulleygroove (Figure 4-10).

4. Go to the other side of the tiller tofinish seating the belt onto the pulleygroove.

5. Working from the left side of the tiller,work the belt as much as possible ontothe top-front engine pulley groove (Figure4-11).

6. Finish seating the belt from the rightside of the tiller.

IMPORTANT: Proper belt tension isimportant for good performance. SeeSection 5, Drive Belt Maintenance forinformation on belt maintenance scheduleand procedures.

NOTE: If extra belt slack is needed tomove the belt, just raise theWheels/Tines/PTO Drive Lever up intoREVERSE. This lowers the engine pulley,and creates more slack.

7. Check both sides of the high rangepulley grooves to verify that the belt isproperly seated.

Changing Belt From HIGH Range toLOW Range1. To avoid personal injury, shut offengine, let all moving parts come to acomplete stop, then disconnect sparkplug wire from spark plug and move wireaway from spark plug before making anyadjustments. Let engine and muffler cool.

2. Move the Wheels/Tines/PTO DriveLever into NEUTRAL.

3. Stand on left side of tiller. Use yourright hand to hold the Wheels/Tines/PTODrive Lever up into REVERSE position.Use your left hand to move the belt offtop-front engine pulley groove to top-rearengine pulley groove (Figure 4-12).

4. Go to right side of tiller and finishseating the belt.

5. Still holding the lever up in REVERSEposition, and working from the left side ofthe tiller, move the belt from the lower-front transmission groove to the lower-rear transmission groove.

6. Go to the right side of the tiller andfinish seating the belt (Figure 4-13).

7. Check that the belt is fully seated in thepulley grooves. Check this from bothsides of the tiller.

Choosing Wheel and Tine SpeedsYour tiller has four FORWARD wheel/tinespeed combinations for handling a varietyof tilling tasks and gardening jobs. Exper-iment with the tine depth, engine speed,and wheel/tine speed and determine thecombination that provides the bestresults. Here are some tips:

1. Advance the throttle lever so the enginehas sufficient power.

2. When tilling untilled or hard earth, donot set the Depth Regulator too deep. Thetiller will buck and the engine will loaddown.

3. You will know your settings are idealwhen the tines break-up the soil easily,the engine does not labor, and yourprogress is steady and smooth.

See Table 2, Wheel Speed and Belt RangeSelection Guide for recommendations.

20

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

Figure 4-13: High range to lowrange. Shows moving belt fromlower-front onto lower-rear groove.

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

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

The HIGH speed belt range positioncombined with a FAST wheel speedsetting propels the tiller at the fastestpace. Reduce the engine throttle speedwhen starting out to help avoid personalinjury or property damage if using thisspeed combination.

WARNING


SLOW GEAR, LOW BELT RANGE

For:• Tilling in sod.• Tilling in hard clay.• Tilling under standing corn-

stalks in tough soil conditions.• Tilling under cover crops.• Preparing a deep seedbed.• Tilling in stony soil.• Tilling under residues and

organic matter.• Mixing in fertilizers, manure.

SLOW GEAR, HIGH BELT RANGE

For:• Tilling in sod or hard clay.• Tilling under standing corn-

stalks (slow, steady speedallows time to shred stalks).

• Tilling under cover crops(best wheel speed and beltspeed range in most soils).

• Preparing seedbeds (bestspeed choice in most soils).

• Tilling in stony ground.• Building raised garden beds.• Mixing in fertilizer.• Using hiller wings in hard

soil.• Mixing fertilizer and manure.• Tilling residues and organics.

FAST GEAR, LOW BELT RANGE

For:• Going over seedbed for the

last time before planting crops.• Covering over seeds in wide

row or plot planting (lift han-dlebars to avoid going toodeep).

• Hilling and furrowing.• Making raised beds.• Cultivating (lift handlebars to

avoid going too deep).• Tilling large areas.• Tilling organic matter in.• Cultivating between raised

beds with optionalhiller/furrower attachment.

FAST GEAR, HIGH BELT RANGE

For:• Preparing seedbeds for

planting.• Covering seeds with less need

to hold up the handlebars.• Cultivating (tiller travels faster,

rides higher on the soil; allowsengine RPM to be reduced;handlebars don’t have to beraised).

• Keeping large areas tilled andcultivated in the summer.

• Tilling organic matter under.• Moving tiller quickly.• Cultivating between raised

beds using the optionalhiller/furrower.

TABLE 2-4: WHEEL SPEED AND BELT RANGE SELECTION GUIDEIMPORTANT — For correct wheel speed and belt range choices when using attachments or accessories

other than tines, read the Owner/Operator Manual provided with the attachment or accessory.

Let the tiller do the work• While tilling, relax and let the wheels

pull the tiller along while the tines dothe digging. Walk on the side that is notyet finished (to avoid making footprintsin the freshly tilled soil) and lightly, butsecurely grip the handlebar with justone hand (Figure 4-4).

• Avoid pushing down on the handlebarsin an attempt to force the tiller to digdeeper. Doing so takes the weight offthe powered wheels, causing them tolose traction. Without the wheelshelping to hold the tiller back, the tineswill attempt to propel the tiller – oftencausing the tiller to skip rapidly acrossthe ground. (Sometimes, slightdownward pressure on the handlebarswill help get through a particularlytough section of sod or unbrokenground, but in most cases this won’t benecessary.)

Tilling depths• Avoid trying to dig too deeply too

quickly, especially when busting sod ortilling soil that hasn’t been tilled forsome time. Use shallow depth settings(only an inch or two deep) for the firstpasses through the garden area.

With each succeeding pass, adjust thedepth regulator to dig another inch ortwo deeper. (Watering the garden areaa few days prior to tilling will maketilling easier, as will letting the newlyworked soil set for a day or two beforemaking a final, deep tilling pass.)

• When cultivating (breaking up thesurface soil around plants to helpdestroy weeds), use very shallow depthsettings to prevent injury to plants whoseroots often grow close to the surface. Ifneeded, lift up on the handlebars slightlyto prevent the tines from digging toodeeply. Cultivating on a regular basis notonly eliminates weeds, it also loosens andaerates the soil for better moistureabsorption and faster plant growth.

Avoid tilling wet, soggy soilTilling wet soil often results in large, hardclumps of soil that can interfere withplanting. If time permits, wait a day ortwo after heavy rains to allow the soil todry before tilling. Test the soil bysqueezing it into a ball. If it compressestoo easily, it is too wet to till.

Tilling Tips & Techniques

21

To help avoid personal injury, be awarethat the tiller can unexpectedly bounceup or jump ahead and propel away fromyou if the tines strike hard or frozenground, or buried obstacles like largestones, roots or stumps. Always usethe following precautions to helpmaintain control of the tiller:

• Walk behind and to the side of thetiller. Use one hand on the handlebars,relaxing your arm but with a securehand grip.

• Use shallow depth regulator settings.Till gradually deeper.

• Use slower wheel, tine and enginespeeds.

• Clear the tilling area of all largestones, roots and other debris.

• Do not put downward pressure on thehandlebars. If needed, apply slightupward handlebar pressure to keep thetines from digging too deeply.

• Avoid contacting hard soil or sod atthe end of a row – reduce engine speedand lift handlebars to raise tines out ofthe soil.

• In An Emergency, stop tines andwheels by moving Wheels/Tines/ PTODrive Lever to NEUTRAL. If you cannotreach the lever or have lost control, LetGo Of The Handlebars and All Controls.

WARNING


22

Avoid making footprintsWhen possible, walk on the untilled sideof the unit to avoid making footprints inthe freshly tilled soil (Figure 4-4). Foot-prints cause soil compaction that canhamper root penetration and contributeto soil erosion. They can also “plant”unwanted weed seeds back into thenewly tilled soil.

Suggested tilling patterns• When preparing a seedbed, go over

the same path twice in the first row,then overlap one-half the tiller widthon the rest of the passes (Figure 4-14). When finished in one direction,make a second pass at a right angle asshown in Figure 4-15. Overlap eachpass for best results (in very hardground it may take three or fourpasses to thoroughly pulverize thesoil).

• If the garden size will not permitlengthwise and then crosswise tilling,then overlap the first passes by one-half a tiller width, followed by succes-sive passes at one-quarter width(Figure 4-16).

• With planning, you can allow enoughroom between rows to cultivate(Figure 4-17). Leave room for thehood width, plus enough extra roomfor future plant growth.

Tilling on slopesIf you must garden on sloping ground,please follow two very important guide-lines:1. Till only on moderate slopes, never

on steep inclines where footing isdifficult (review safety rules in the“Safety” Section of this Manual).

2. We recommend tilling up and downslopes rather than terracing. Tillingvertically on a slope allows maximumplanting area and also leaves roomfor 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 ofthe slope will cause the oil to slant awayfrom its normal level and this can starveengine parts of required lubrication.Keep the engine oil level at the full pointat all times!A. Tilling up and down slopes:

• To keep soil erosion to a minimum, besure to add enough organic matter tothe soil so that it has good moisture-holding texture and try to avoid leavingfootprints or wheel marks.

• When tilling vertically, try to make thefirst pass uphill as the tiller digs moredeeply going uphill than it doesdownhill. In soft soil or weeds, youmay have to lift the handlebars slightlywhile going uphill. When goingdownhill, overlap the first pass byabout one-half the width of the tiller.

HINT: For best results, use the HIGHbelt range and SLOW wheel speed leverposition. See Changing Speed Belts inthis section for more information onchanging to high range.


Figure 4-14

Figure 4-15

Figure 4-17

12

3

Figure 4-16

To avoid serious personal injury ordamage to the equipment:

• Do not operate tiller on a slope toosteep for safe operation. Go slowlyon any slope. Make sure you havegood footing.

• Wear footwear that increasesstability and reduces slippage.

• Do not use FAST wheel speedposition when on sloped ground.

• Do not shift the Wheel Speed Leverwhen heading up or down a slope. Iflever is accidentally moved to FREEWHEEL position, the tiller could rollout of control.

• To prevent engine damage due to oilstarvation (on slopes,the engine isinclined and oil moves away fromsurfaces that need lubrication), besure the correct oil level is main-tained during all uphill/downhilltilling operations. Check the level ofthe oil in your engine after every one-half hour of operation.

WARNING

23

B. Terrace Gardening:

• When a slope is too steep or too shortfor vertical tilling, it may be necessaryto till across the slope and createterraced rows. Terraces are rows thatare cut into the side of a slope, creatinga narrow, but flat area on which toplant.

• On a long slope, you can make severalterraces, one below the other.

• Terraces should be only 2-to-3 feetwide. Digging too far into the side ofthe slope will expose poor subsoil thatis unproductive for plants.

• To create a terrace, start at the top ofthe slope and work down. Go back andforth across the first row as shown inFigure 4-18.

• Each succeeding lower terrace isstarted by walking below the terraceyou’re preparing. For added stability ofthe tiller, always keep the uphill wheelin the soft, newly tilled soil. Do not tillthe last 12" or more of the downhilloutside edge of each terrace. Thisuntilled strip helps prevents theterraces from breaking apart andwashing downhill. It also provides awalking path between rows.

C. Tilling across slopes without terracing

• If vertical or terracing gardening aren’tpractical for you, then you can tilllaterally across a slope. We don’treally recommend this method as itcan create unsure footing and invitessoil erosion.

• Study the terrain to make certain theslope is not too steep for safe tilling.If possible, make terraced rows or tillvertically.

• Move the belt into LOW belt range andthe Wheel Speed Gear Lever to SLOWposition. As in terrace gardening, startat the top of the slope and overlap thefirst pass by half the width of the tiller.For added stability, keep the uphillwheel in the soft, newly tilled soil. Eachsucceeding terraced area is started bywalking below the terrace you arepreparing (Figure 4-19).

Clearing the tinesThe tines have a self-clearing actionwhich helps to eliminate most tanglingof debris. However, occasionally drygrass, stringy stalks or tough vines maybecome tangled. Follow these procedures to help avoidtangling and to clear the tines, ifnecessary.

• To reduce tangling, set the DepthRegulator deep enough to getmaximum “chopping” action as thetines chop the material against theground. Also, try to till under cropresidues or cover crops while they aregreen, moist and tender.

• While power composting, try swayingthe handlebars from side to side (about6" to 12"). This “fishtailing” actionoften clears the tines of debris.

• It may be necessary to remove thedebris by hand (a pocket knife will helpyou to cut away the material).


Figure 4-18

Before clearing the tines by hand, stopthe engine, allow all moving parts tostop and disconnect the spark plugwire. Failure to follow this warningcould result in personal injury.

WARNING

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



24

POWER COMPOSTINGPower composting means tilling underand burying in the soil all manner oforganic matter such as crop residues,leaves, grass clippings and cover crops.This material will decompose during thenon-growing season and add importantnatural nutrients to the soil.

Begin by composting crop residues suchas leftover vines, stalks, stems androots. Power compost these cropresidues as soon as they finish bearing.The sooner this is done, the better, astender green matter is easier to tillunder. Use the deepest depth regulatorsetting possible without causing theengine to labor or the tiller to jumpahead.

Standing cornstalks of reasonable heightcan be power composted (Figure 4-20).Pushing over (but not uprooting) corn-stalks will often make it easier for yourtiller to chop up the stalks. Keep thetines clear of excessive tangling by “fish-tailing” or frequently using reverse.Make several passes, then return a fewdays later to finish off any remainingstubble.

After tilling under crop residues, addmore organic matter such as leaves,grass clippings and even kitchen scraps.When tilled into the soil, this organicmatter will decompose and add evenmore important nutrients to the soil.

After power composting, you may wantto plant a “green manure” cover crop toprotect the soil during the off-season.

Grow a crop of clover, alfalfa,buckwheat, peas, beans, rye grass,grain, or kale and then till it into the soilprior to the planting season.

Wide-Row PlantingThe wide-row planting technique isspreading seeds anywhere from 10inches to 2 feet wide or more. As aresult, you can grow anywhere from 3 to4 times (or more) produce in the samespace that is normally set aside for anarea that has narrow, single rows.

Wide-row planting automatically shadesthe ground which keeps weed growthdown and also holds moisture in thesoil. And of course, harvesting is mucheasier – everything is right at hand to bepicked. Preparing wide rows is easy —after you prepare the seedbed and markoff the rows with string, hand-broadcastthe seeds as if seeding a lawn (not quiteas much as lawn seed). Cover with soiland tamp the area firmly with a hoe.

Tilling Under CornAfter corn is harvested, the stalks shouldbe tilled into the soil while still green.Dry plants are more difficult to till under,and the roots break loose too easily.

IMPORTANT: Do not pull the roots outby hand or cut the stalks before tilling.Stalks that are firmly anchored by theirroots are much easier for the tines tochop, cut, and work under.

1. As you move forward into a row ofstalks, aim the tiller so that the stalks gobetween the left wheel and the transmis-sion case (Figure 4-19). Do not use theright wheel because damage could occurto the air cleaner, carburetor or throttlelinkage.

2. Each new pass should overlap theprevious pass by one-half the width ofthe tiller.3. Till as deeply as possible. Pull theDepth Regulator all the way UP andengage the lowest notch for deep tilling.Use either LOW or HIGH belt range andSLOW wheel speed gear position. Let the tilled-in stalks decompose for aweek or so. Then till in the remainingresidue as deep as possible.

Soil Enrichment Idea

Trench Composting — Trench com-posting is easy with the optionalHiller-Furrower Attachment (Section5). Dig a trench, put in all kinds oforganic matter, and cover with soil.Earthworms and microbes will break itdown quickly.

Figure 4-20: Tilling under cornstalks.


When power composting, do not keepthe Depth Regulator Lever at a deepsetting if the tiller jumps or bucks.

If jumping or bucking occurs, movethe Depth Regulator Lever down toone of the shallower settings andthen slowly increase the tilling depthon later passes.

Failure to comply could result in lossof tiller control, property damage orpersonal injury.

WARNING

Your tiller is a self-contained PTO (PowerTake-Off) Power Unit that was shippedwith a tine attachment installed. The tineattachment can be quickly removed andreplaced with other optional attachments.The following instructions will familiarizeyou with your PTO Power Unit. Pleaseread these pages carefully.

The following steps explain how toremove and replace the tine attachment.You will need a 3/4" wrench (minimum12" long for leverage).

Removing Tine Attachment1. Move the tiller to level ground.

2. Be sure the engine is stopped, theelectric start key is removed, and the sparkplug wire is disconnected and moved awayfrom spark plug.

3. Place a sturdy support under theengine to prevent the engine from tippingforward when the tine attachment isremoved (Figure 4-23).

4. Place the Wheels/Tines/PTO Drive Leverinto NEUTRAL (Figure 4-22).

5. Place Tines/PTO Clutch Lever inDISENGAGE (Figure 4-22).

6. Place Wheel Speed Lever into FREEWHEEL (Figure 4-22).

7. Loosen the two swing-out bolts (Figure4-24) that connect the power unit trans-mission to the tine attachment and swingout the bolts (Figure 4-25).

HINT: Loosening swing-out bolts can bedifficult. Use an extra-long wrench forleverage.

8. Tip the PTO power unit forward aboutone inch with one hand while pulling thetine attachment back (Figure 4-26). Theguide pin on the power unit will slide outof the guide hole in the tine attachment(Figure 4-27).

Removing And Replacing The Tine AttachmentPTO POWER UNIT

Figure 4-21: PTO Power Unit and tineattachment.

Before operating your PTO PowerUnit for the first time, make sure thatyou have:

• Read all the safety instructions inSection 1 of this Manual and in theManual supplied with any attach-ment.

• Read the controls information andoperating procedures for the tillerand engine described in Sections 3and 4 of this Manual and in theEngine Owner’s Manual.

• Read and understand the assemblyinstructions, controls information,and operating procedures for theattachment as described in theAttachment Owner’s Manual suppliedwith the attachment.


TO AVOID PERSONAL INJURY ORDAMAGE TO EQUIPMENT:

• Stop the engine, remove the electricstart key, disconnect the spark plugwire and let the engine and mufflercool before removing or installing anyattachment.

• Do not place hands, tools, or anyobject near or inside the PTO accessarea while the engine is running.

• When removing or replacing the tineattachment, be careful of the sharpedges on the tiller hood. Wear thickgloves for hand protection.

• When the tine attachment isremoved, always prop it up with ablock to prevent the attachment fromfalling forward.

CAUTION

Figure 4-23: Block up engine.

VERY IMPORTANT

Figure 4-22: PTO Power Unit controls.

Wheels/Tines/PTODrive Lever

ForwardInterlock Levers

DepthRegulatorLever

WheelSpeedLever

EngineThrottle Lever

Tines/PTOClutchLever

25

IMPORTANT: Store tine attachment in alevel, upright position to prevent gear oilfrom leaking from the dipstick area.

9. To keep the tine attachment dog clutchcoupling clean, cover with the dust cap(on some attachments) or plastic wrap.

10. The PTO Power Unit is now ready toinstall other powered or non-poweredattachments. See the attachment'sOwner’s Manual for installation andoperation instructions specific to thatattachment.

Installing the Tine Attachment1. Move the two PTO Power Unit swing-out bolts outward and slide the washersup against the bolt heads.

2. Remove the support block from underthe engine and slowly roll the power unitback next to the tine attachment. Placethe support block back under the engine.

3. Remove the dust cap (or protectivewrapping) from the dog clutch couplingon the tine attachment.

4. Carefully align the guide pin on thePTO Power Unit with the alignment holein the tine attachment and bring the twounits together (Figure 4-27).

5. Move the two swing-bolts into theslots of the tine attachment. Alternatelytighten each bolt until they are tightenough to make the concave washers flat.The bolts must be very tight – if you havea torque wrench, tighten each bolt tobetween 70 and 80 ft.-lbs.

IMPORTANT: The swing-bolts must bekept very tight to prevent damaging wearto the dog clutch coupling, alignment pinor the alignment hole. Check bolttightness every 2-1/2 operating hours.

6. Remove the engine support beforemoving the tiller in a forward direction.

PTO POWER UNITOPERATING INSTRUCTIONS

The following are operating instructionsspecifically for the PTO Power Unit. Readthe separate Owner’s Manual suppliedwith each attachment before attemptingto assemble, attach, transport or operatethe attachment. If needed, please contactus for a replacement manual. See theback cover for customer support information.

Some attachments have a drive shaft or ahydraulic pump that is powered by theengine on the PTO Power Unit. Theseunits are called Stationary Attachments,since they remain in one location whenoperating. Attachments can be towed to awork site with the PTO Power Unit asdescribed in Operating Non-PoweredAttachments. Other attachments arepulled or towed behind the PTO PowerUnit. These attachments are called Non-Powered Attachments.

Setting Up Stationary Attachments

1. Move the Tines/PTO Clutch Lever toDISENGAGE.

2. Move Wheel Speed Lever (Figure 4-22)to FREEWHEEL, then block all wheels(Figure 4-29) to prevent the equipmentfrom rolling.

Figure 4-26: Pulling attachmentaway from power unit.

Figure 4-27: Aligning guide pin withmounting hole.

Guide PinMounting Hole


Figure 4-25: Moving swing-boltsoutward.

Figure 4-24: Loosening attachmentswing-bolts.

To help avoid personal injury ordamage to equipment, read the attach-ment's Owner’s Manual supplied witheach attachment before installing oroperating an attachment. Please readall control, operation and safetyinstructions.

WARNING

To help avoid personal injury, alwaysdisengage the Tines/ PTO Clutch Leverbefore towing any attachment.

WARNING

26

To help avoid personal injury, neverallow people to ride on any PTO PowerUnit or attachment.

WARNING

3. On the PTO Power Unit, unplug theForward Interlock Wire Harness that leadsfrom the base of the handlebars (A, Figure4-28) to the receptacle (B) located on thetop, right side of the transmission cover.

4. On the Stationary Attachment, locatethe interlock wire (C, Figure 4-28) andclean contacts on plug and receptacle (B).This connection enables you to operatethe Wheels/Tines/PTO Drive Lever inFORWARD without having to squeeze aForward Interlock Lever.

5. Connect the plug from the StationaryAttachment (C, Figure 4-28) to the recep-tacle on the PTO Power Unit (B). Theconnection must be tight.

Setting Up Non-Powered Attach-ments1. Move the Tines/PTO Clutch Lever(Figure 4-22) to DISENGAGE.

2. Move the Wheel Speed Lever (Figure 4-22) to either SLOW or FAST positionTo do this, roll the PTO Power Unit whileshifting lever until wheels engage.

3. Verify that the Forward Interlock WireHarness plug at the base of the handle-bars (A, Figure 4-28) is connected to theForward Interlock Wire Harness recepta-cle (B) on the top right side of the transmission.

Starting The EngineIMPORTANT: Refer to Cold WeatherOperation instructions, in this section,before operating in temperatures below40oF.

1. Move the Wheels/Tines/PTO DriveLever into NEUTRAL. To find NEUTRAL(be sure engine is off), push lever downand engage it in FORWARD then tap thelever upward to automatically move intoNEUTRAL .

2. Move the Tines/PTO Clutch Lever intoDISENGAGE position.

3. Start Engine. See Starting andStopping the Engine, in the beginning ofthis section, for detailed starting informa-tion. Also see the Engine Owner's Manual.

4. For non-powered attachments only testthe Forward Interlock Safety System. SeeTesting the Forward Interlock SafetySystem, in this section, for a procedure.

Operating Stationary Attachments1. Move Tines/PTO Clutch Lever (Figure4-22) into ENGAGE.

2. To apply power to PTO-driven attach-ments, move Wheels/Tines/PTO Lever(Figure 4-22) down to FORWARD position(do not use REVERSE with stationaryattachments).

3. To stop the PTO Power Unit, tap theWheels/Tines/PTO Drive Lever upwardinto NEUTRAL position.

Operating Non-Powered Attachments (or to Tow Stationary Attachments)1. To move forward, squeeze and holdone Forward Interlock Lever (Figure 4-30)up against the handlebars, and move theWheels/Tines/PTO Drive Lever down toFORWARD.

2. To stop forward motion, tapWheels/Tines/PTO Drive Lever upwardinto NEUTRAL, then release the ForwardInterlock Levers.

3. To stop forward motion in anemergency, release all PTO Power Unitcontrols (stops engine).

4. To move in reverse, reduce the enginespeed then shift the Wheel Speed Leverinto SLOW. Move and hold theWheels/Tines/PTO Drive Lever all the wayup. Ensure that the area behind you isclear of all obstacles, before moving thelever into REVERSE.

5. To stop moving in REVERSE, releasethe Wheels/Tines/PTO Drive Lever.

Stopping the EngineMove the Engine Throttle Lever to STOP.Turn keyswitch to OFF on electric startmodels.

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

Figure 4-28: Forward Interlock WiringA - PTO Power Unit Interlock HarnessB - Forward Interlock Receptacle C - Attachment Interlock Wire


Figure 4-30: Moving tiller forward:squeeze one Forward Interlock Leverand then move Wheels/Tines/PTODrive Lever down to FORWARD.

A

B

C

To avoid injury,do not run the engine inan enclosed or poorly vented area.Engine exhaust contains carbonmonoxide, an odorless and deadly gas.

WARNING

27

NOTE: All references to left, right, frontand rear of the machine are determined bystanding behind the handlebars and facingthe direction of forward travel.

REQUIRED MAINTENANCE SCHEDULEBefore Every Every Every As

PROCEDURE Each 10 25 30 NotedUse Hours Hours Hours

Check engine oil level • Every 5operating hrs.

Clean engine cooling system •Test operation of Forward Interlock • Section 4

Safety SystemForward Interlock Safety System – •

check wire condition,connectionsCheck electrical connections •

Recharge battery Before/afterlong storage

Check drive belt tension • After initial2 hours

Check nuts and bolts • After initial 2 hours

Clean tiller tine shaft •Lubricate tiller •Change engine oil* • More often

in dusty or dirty areas

Clean foam element air filter • More often Check paper element air filter • in dusty or

dirty areasCheck for oil leaks • After initial

2 hoursCheck gear oil level in • After initial

both transmissions 2 hoursCheck bolo tines for wear •Check reverse disc for wear •Check air pressure in tires •* During engine break-in period, change engine oil after first 2 hours of operation.

28

Section

5 Maintenance

Before inspecting, cleaning orservicing the machine, shut off engine,wait for all moving parts to come to acomplete stop, disconnect spark plugwire and move wire away from sparkplug. Remove ignition key on electricstart models.

Failure to follow these instructions canresult in serious personal injury orproperty damage.

WARNING

Tighten Bolts and NutsCheck for loose or missing hardwareevery ten (10) operating hours. Failure totighten or replace fasteners can causepoor performance, equipment damage oroil leakage. See your Parts Catalog forcomplete fastener descriptions.

Most hardware on your tiller is visible.Pay particular attention to hardwareshown in Figures 5-1, 5-2, 5-3 and 5-3A.

1. Check the transmission pulleymounting bolt (Figure 5-1). If the washerbehind the bolt head is loose, the boltneeds tightening. To do this, first insert apunch or thick screwdriver into the holenext to the bolt and wedge the toolagainst the side of the motor mountcasting. This immobilizes the pulley whileyou tighten the bolt.

2. Check jam nut on left side of neutralplunger assembly (Figure 5-2). If loose,immobilize bolt head with one wrench anduse another wrench to tighten the nut.

3. Check the three rear bearing capscrews under the depth regulatormounting bracket (A, Figure 5-3). If anyis loose, it can cause an oil leak or driveshaft end play.

4. Check the five bolts securing the tillerhousing cover to the left side of the trans-mission (B in Figure 5-3). Gear oil canleak from a loose housing cover. Toreach the bolts, remove the left side tineholder. See Bolo Tine Maintenance in thisSection for tine holder removal directions.

5. Check both swing-bolts (C, Figure 5-3)that connect the power unit transmissionto the tine attachment. Both bolts shouldbe checked every 2-1/2 hours ofoperation. If loose, wear can occur on thelocating pin on the power unit, and causeenlargement of the locating hole in thetine attachment. Using a torque wrench,tighten these bolts to 70-to-80 ft.-lbs.

6. Check the locknut that fastens theshifting linkage to the eccentric shiftinglever (D, Figure 5-3). Do not tighten thelocknut against the eccentric lever. Itshould be very close to, but not touchingthe lever.

7. Check the four bolts and nuts securingleft and right tine holders to the tine shaft(Figure 5-3A).

IMPORTANT: Give screws or bolts thatgo into the transmission housing acoating of non-hardening gasket sealantto prevent gear oil from leaking.

Tiller LubricationProper lubrication of the tiller’s mechani-cal parts is an essential part of goodmaintenance. Lubrication should be doneafter every ten (10) hours of operation.

Use ordinary motor oil (#30 weight orlighter) where oil is specified. Use aquality grease with a metal lubricantwhere grease is recommended (regulargrease is acceptable). Do not overlubricate. If there is a build-up of dirt,remove the build-up and re-apply oil orgrease.

Figure 5-1: Check bolt on transmission pulley.

Figure 5-3A: Tine holder hardwaremust be tight.

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

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

A

B

C

D

Section 5: Maintenance

29

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to cometo a complete stop, disconnect spark plug wire and move wire away from spark plug. Remove ignitionkey, if so equipped.

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

WARNING


IMPORTANT: Do not allow oil or greaseto contact the pulleys, drive belt orreverse disc. This can cause the belt ordisc to slip on the pulleys.Lubricate the numbered areas in Figures5-4 and 5-5, as follows:

1. Oil the wheel shaft between the wheelhubs and the transmission housing (A, Figure 5-4).

2. Oil all pivoting and connecting pointson the Wheels/Tines/PTO Drive Lever andthe Wheel Speed Lever (B, Figure 5-4).

3. Grease the face of the belt adjustmentblock (C, Figure 5-4).

4. Oil the Depth Regulator Lever,including the spring in the mountingbracket (D, Figure 5-4).

5. Oil the full length of the throttle cablecasing (E, Figure 5-4).

6. Oil threads on Handlebar Height Adjust-ment Lever (F, Figure 5-4).

7. Grease left- and right-side enginemounting bars at the top, the middle, andbottom (G, Figure 5-4).

8. Grease the zerk grease fitting locatedon the pivot point at the end of the WheelSpeed Lever (H, Figure 5-4). If WheelSpeed Lever has a grease fitting on pivotassembly, apply 2-to-3 strokes of multi-purpose grease at beginning and end oftilling season.

9. Keep the PTO access area well-greased(I, Figure 5-5). If the Tines/PTO ClutchLever becomes hard to move, squirt someoil into its access hole, and work it backand forth to disperse the oil.

Transmission Gear Oil MaintenanceChecking for Oil LeaksAt 25-hour operation intervals, check thetiller for oil leaks. Inspect for oil accumu-lations on the tiller or the floor where it’sstored.

A small amount of oil seepage or wetnessaround a shaft opening orcover is no cause foralarm. But a heavy con-centration of oil is moreserious. You shouldtighten all bolts immedi-ately, and replace anyworn seals or gaskets.

It may be impossible todetermine how much oilhas been lost, so check theoil levels in the PTO trans-mission and the tineattachment before usingthe tiller again. Add anynecessary gear oil.Serious damage to thetransmission componentscan result from operationwhen gear oil levels arelow.

If tilling during very hot weather, the gearoil may heat up and expand inside thetransmissions. To allow for this oilexpansion, both the power unit transmis-sion and the tine attachment transmis-sions have oil relief vents (Figure 5-6).

The vents allow small amounts of oil toseep out.

If a serious leak is discovered, pleasecontact your authorized dealer or theFactory Technical Service Department forservice advice.

Checking Gear Oil LevelsEvery 30 hours of operation, check thegear oil level in both the power unit trans-mission and the tine attachment transmis-sion. Operating them while low on gearoil (even briefly) can cause seriousdamage to internal components.

Preparation

1. The transmissions must be cool,since hot gear oil expands and gives afalse reading.

2. The power unit transmission and thetine attachment transmission must beconnected when checking (or adding)gear oil.

Checking the Power Unit Oil Level

1. Move the tiller to level ground. Movethe Depth Regulator up so the tines reston the ground.

2. Use a 3/8" wrench to remove the oillevel check plug on the left side of thetransmission housing (Figure 5-7).

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

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

I

Figure 5-6: Oil relief vent locations.

➨ ➨

E

F

G

D

H

CB

B A

30

➨➨



WARNING


3. If the oil level is correct, oil will seepout of the check hole (allow extra time incold weather). If it does, the level is fineand you should replace the check plug. Ifno oil seeps out, see Adding or ChangingGear Oil.

Checking the Tine Attachment Oil Level

IMPORTANT: Two different gear oilchecking procedures for the tine attach-ment transmission are described next.Use the first procedure if the dipstick inyour tine attachment has only a ‘CheckCold’ marking. Use the second procedureif the dipstick has both cold and hotmarkings at the end. First remove thedipstick from the tine attachment trans-mission (Figure 5-8) to see which typedipstick you have. Then replace thedipstick with markings on dipstick facingto rear.

For Dipsticks With ‘Check Cold’ Marking

(Cold means 2 hours has passed sincethe tiller was used.)

1. Move the tiller to level ground.

2. Pull the Depth Regulator Lever back,then push it down all the way (to engageits top notch).

3. Place a sturdy support under theengine to prevent the tiller from tilting toofar.

4. Now slide three pieces of 2" x 4"lumber underneath the drag bar– raisingthe drag bar about 4-1/2" above ground.This elevation allows an accurate “cold”gear oil reading .

5. Wait two hours with tiller elevated(allow more time if temperature is below40oF).

6. Loosen and remove transmissiondipstick (Fig. 5-8). Wipe it clean with arag.

7. Hold dipstick so its markings face torear of tiller. Lower it straight down intothe sump hole to touch the drive shaftinside (Fig. 5-8). Don’t force or try tothread it back in; an incorrect reading willresult.

8. Remove dipstick and check oil level. Itshould be anywhere within the cross-hatched area or even slightly above theMax marking. If correct, replace dipstickand remove the boards used as props.

9. If oil level was low, gear oil must beadded before using the tiller. See Addingor Changing Gear Oil next.

For Dipsticks With Hot/Cold Markings

1. Move the tiller to level ground.

2. Pull the Depth Regulator Lever back,then push it down all the way (to engageits top notch).

3. Place a sturdy support under theengine to prevent the tiller from tilting toofar.

4. Cold reading (preferred method):(Two hours has passed since the tillerwas used.) Place a 2" x 4" board (onedge) under the drag bar– raising the tillerand drag bar about 3-1/2" above ground.Hot reading: (Tiller was operated formore than 30 minutes within the pasthour.) Do not use the wood prop toelevate the tiller.

5. Follow Steps 4, 5 and 6 given for theother dipstick type.

6. Remove dipstick and check level. Itshould be within or above the “Cold”range marking if taking a cold reading. Iftaking a hot reading, the level should bewithin or slightly above the “Hot” range.

7. If the level is incorrect, see Adding orChanging Gear Oil.

Adding or Changing Gear OilFor partial fill-ups (just a few ounces orless), use SAE 140, SAE 85W-140, or SAE80W-90 weight gear oil with an API ratingof GL-4 or GL-5. For full replacement,use SAE 140 or SAE 85W-140 gear oilwith an API rating of GL-4 only. (At thefactory, SAE 85W-140 weight gear oil isused.)

IMPORTANT: Do not use automatictransmission fluid or engine oil. They aretoo light in weight and will result in trans-mission damage.

The gear oil does not need to be changed.Do so only if you know, or suspect, it iscontaminated with dirt, sand or otherforeign particles.

Gear oil is available at authorized dealersand most service stations, powerequipment centers, or farm/heavyequipment outlets.

Capacities: Power unit transmissionholds approximately 60 ozs.; Tine Attach-ment transmission holds approximately12-1/2" ozs.

Figure 5-7: Remove oil level checkplug. Gear oil should seep out ifthe level is sufficient.

Figure 5-8: Checking gear oil level;markings on dipstick (tine attach-ment transmission) must face rear.

➧



WARNING

31


Adding Gear Oil to the PTO Power Unit Transmission

1. Do steps 1 and 2 of Checking thePower Unit Oil Level on page 32.

2. Using a 3/4" wrench (or socket),remove the bolt securing the handlebarbase to the top of the transmission (propthe handlebars first to prevent them fromfalling).

Then, unplug the Forward Interlock wireharness receptacle at the bottom of thehandlebars. Set the handlebar base andbolt aside on a clean surface. The bolthole in the top of the transmission is thegear oil fill hole (A, Figure 5-9).

3. Slowly pour gear oil through a cleanfunnel into the transmission. Stop whengear oil begins to flow from the oil levelcheck hole on the left side of the trans-mission (B, Figure 5-7).

4. Reinstall the oil level check plug.Tighten it securely.

5. Reinstall the handlebars using themounting bolt previously removed. Alignthe handlebars so they point straightbackwards, not at an angle. Then tightenthe mounting bolt securely.

6. Reconnect the Forward Interlock wireharness to the receptacle. Be certain it’ssecure.

7. Test operation of the Forward InterlockSafety System. See Section 4 for aprocedure.

Draining and Filling the PTO Power Unit Transmission

1. Place a shallow pan under the trans-mission gear oil drain plug (B, Figure 5-9).

2. Remove the oil level check plug (Figure5-7) with a 3/8" wrench. This vents thetransmission for faster oil draining.

3. Using the 3/8" wrench, remove thedrain plug (B, Figure 5-9). The gear oilwill drain quite slowly since it is thick.After about two quarts have drained, tiltthe tiller forward so any oil at the rear ofthe transmission will drain out.

4. Clean the drain plug threads, put non-hardening gasket sealant on the threads,and reinstall plug.

5. Refill the transmission with the correctamount of gear oil before operating thetiller again. When oil seeps from the oillevel check hole, the right amount of gearoil has been added. Replace all plugs.

Adding Gear Oil to the Tine Attachment Transmission

1. Select the right Depth Regulator Leversetting:

a. If filling an empty transmission, raisethe Depth Regulator Lever so tinesare on the ground.

b. If topping off the gear oil, move DepthRegulator Lever down to engage itstop notch.

2. Remove dipstick from tine attachment(Figure 5-8).

3. Slowly add gear oil in the dipstick hole.Add 1/2-ounce at a time to avoid overfill-ing. It takes about 12-1/2 ounces.

4. Take dipstick readings frequently. Stopwhen oil reaches “Cold” range marking ondipstick. Replace dipstick securely.

Draining and Filling the Tine Attachment Transmission

1. The tine attachment transmission isnot equipped with an oil drain plug. Todrain just a small amount of gear oil,remove the dipstick and tilt the attach-ment forward (first uncoupling it from thePower Unit).

2. For complete drainage, remove the left-side tine assembly (refer to Bolo TineMaintenance for instructions), thenremove just one of the lower screws fromthe tiller housing cover (Figure 5-10). Tospeed drainage, remove the tine attach-ment dipstick to vent transmission.

NOTE: If you find a plastic washer on thecover screw you remove, discard thewasher. There is no need to install areplacement washer.

3. Once all gear oil has drained, reinstallthe housing cover screw securely (firstcoat its threads with non-hardeninggasket sealant).

4. Be certain to refill the transmissionwith the correct amount of gear oil beforeoperating the tiller again.

Figure 5-9: Gear oil fill hole (A) andgear oil drain location (B).

B



WARNING

A

Figure 5-10: Remove housing coverscrew to drain tine attachmenttransmission gear oil.

➧

32


Drive Belt MaintenanceMeasuring and Adjusting Drive Belt TensionOn a new tiller (or if a new belt isinstalled), the belt tension will probablyneed to be adjusted after the first two (2)hours of operation. Thereafter, check belttension every ten (10) operating hours.

Maintaining the right tension is importantto good tiller performance and long beltlife. If too loose, the belt will slip on thepulleys, and be unable to deliver fullpower to the wheels and tines. A loosebelt will also wear prematurely.

While checking belt tension, also inspectthe belt for cuts, cracks, deterioration,etc. Don’t continue using a belt that isn’tin good shape. You’re sacrificing tillerperformance by doing so.

Tips on keeping the drive belt in topcondition include:• Always put the Wheels/Tines/PTO DriveLever in NEUTRAL when the tiller is not inuse. • Keep tension adjusted correctly.

• Don’t “speed shift” when moving theWheels/Tines/PTO Drive Lever betweenFORWARD and REVERSE.

How to Measure Belt Tension

1. Before taking a measurement, be surethe linkages and pivot points on theWheels/Tines/PTO Drive Lever are cleanand lubricated. If there is any binding,you won’t get true measurements. Also,you’ll need the belt adjustment tool youreceived with your new tiller (Figure 5-11).

2. Move the Wheels/Tines/PTO DriveLever fully down to the FORWARDposition. The clutch roller at the bottomof the lever should be positioned under-neath the belt adjustment block (Figure5-12). Don’t let the clutch roller moveduring the next few steps. If it moves,you’ll get a false belt tension reading.

3. The belt tension is correct if the frontof the clutch roller is 1/4"-to-5/16" awayfrom the face of the upright bracket thatholds the adjustment block in place(Figure 5-12). To measure this distance:

a. Without moving the clutch roller, tryinserting the 1/4"-thick, slotted endof the belt adjustment tool inbetween the roller and the uprightbracket. (The flat edge of the toolmust be facing the roller.) Refer toFigure 5-13.

b. If only the slotted portion of the toolwill fit, the belt tension is correct.

c. If the slotted part of the tool will notfit in, the belt is too loose.

d. If the full thickness (5/16") of thetool easily fits in, the belt is tootight.

4. If the belt tension is correct, move theWheels/Tines/PTO Drive Lever back toNEUTRAL.

How to Adjust Belt Tension

1. As described in the following steps,drive belt tension is adjusted by movingthe adjustment block up or down.Moving it down will tighten the belt;moving it up loosens the belt.

HINT: The distance the block movesapproximately equals the distance theroller moves.

In most cases, the clutch roller will nothave been very far out of position, so theadjustment block will only need to bemoved slightly (up or down).

2. Move the Wheels/Tines/PTO DriveLever to NEUTRAL position. The clutchroller will come to rest anywhere on theface of the belt adjustment block,depending upon drive belt length andcurrent belt tension adjustment.

Figure 5-12: Shift into FORWARDand measure distance betweenroller and upright bracket using thebelt adjustment tool.

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

Belt Adjustment Tool

1/4"5/16"



WARNING

Figure 5-13: Insert slotted end ofbelt adjustment tool between rollerand bracket, with the flat side of theslotted end facing the roller.

33


3. Insert the belt adjustment tool throughthe hole in the side of the adjustmentblock, spacing the ends of the tool equallyon both sides (Figure 5-14). Rotate thetool so the slotted end faces down.

4. Place the Wheels/Tines/PTO DriveLever in FORWARD position. The arms ofthe clutch control yoke will be resting onthe belt adjustment tool and the clutchroller should be engaged slightly beneaththe adjustment block (Figure 5-15).

5. Use one hand to hold the drive lever inFORWARD while using a 9/16" wrench toloosen (don’t remove) the bolt at the backof the belt adjustment block (Figure 5-16).The adjustment block should be free tomove either up or down.

6. Push the drive lever down if the beltneeds tightening. Pull the lever up if thebelt needs to be loosened. Hold the drivelever in place and tighten the bolt in theadjustment block firmly.

7. Let go of the drive lever and removethe belt adjustment tool from the hole inthe adjustment block.

8. Check the tension on the belt byfollowing the previous instructions “Howto Measure Belt Tension.”

NOTE: If the adjustment block is all theway down and the measurement betweenthe clutch roller and the bracket is lessthan 1/4", then a new drive belt is needed.

Replacing the Drive Belt

Removing the Belt

1. Move Wheels/Tines/PTO Drive Lever toNEUTRAL position.

2. While kneeling on the right side of thetiller, create slack in the belt by reachingover to the left side of the pulleys andpushing in on the center of the belt withyour finger.

3. Use your right hand to move the beltdown and away from the lower pulley, inthe direction of the engine (Figure 5-17).

4. Push the belt upward to create slack inthe belt (Figure 5-18).

5. Lift the top half of the belt up and overthe upper pulley and the rubber reversedisc, moving it in front of the reverse disc(refer to Figure 5-19).

6. Push the Wheels/Tines/PTO DriveLever down into the FORWARD position.This increases the distance between theupper and lower pulleys. Next, lift andpull the entire belt out between the pulleys(Figure 5-20).

Replacing the Drive Belt

1. Place Wheels/Tines/PTO Drive Lever inFORWARD position.

2. Squeeze the belt in the middle andinsert one end in between the pulleys(Figure 5-20).

Figure 5-14: With Wheels/Tines/PTODrive Lever in NEUTRAL, insert toolthrough hole in adjustment block.

Figure 5-15: With Drive Lever inFORWARD position, clutch rollershould be engaged slightly beneaththe adjustment block.

Figure 5-16: Hold Drive Lever whileloosening bolt. Push lever down totighten belt; pull up to loosen belt.



WARNING

Figure 5-18: Push belt upward tocreate slack.

Figure 5-17: First move belt off thelower pulley.

➧Push Belt UP

34


3. Push belt forward then down until it islooped over the lower pulley (Figure 5-18). Do not yet seat it in either of thelower pulley’s grooves.

HINT: A blunt object, like a ruler, canhelp you push the belt downward ifneeded.

4. Move the top half of the belt up andover the rubber reverse disc, but do notseat it in either of the grooves in the toppulley.

5. Place the Wheels/Tines/PTO DriveLever in NEUTRAL.

6. Move the top half of the belt into theHIGH Range groove (groove closest tothe engine) on the top pulley (Figure 5-21).

7. Move the bottom half of the belt intothe HIGH Range groove of the lowerpulley (groove closest to engine— Figure5-21). If extra slack is needed, hold upWheels/Tines/PTO Drive Lever whilemoving the belt. Verify the belt is seatedproperly on the pulleys.

8. To move the belt to the LOW Rangeposition, see Changing Belt Speeds inSection 4.

9. After installing the belt, check andadjust for correct belt tension asexplained previously.

Reverse Drive System MaintenanceThese instructions explain how to inspect,replace or adjust the various reverse drivecomponents.

But first, here’s how the reverse drivesystem works: When you raise theWheels/Tines/PTO Drive Lever up inREVERSE position, this lowers the rub-berized reverse disc (it’s attached to theengine drive pulley) until this rotating disccontacts the transmission drive pulley.The friction between the rotating reversedisc and the transmission pulley causesthe transmission drive shaft to bepowered in a counterclockwise direction(as viewed from the operator’s positionbehind handlebars). The drive shaft thenturns the wheels and tine shafts in areverse direction.

Reverse Disc InspectionThe reverse disc is made of steel with aspecial, long-lasting rubber compoundbonded to the disc rim. Since this is awearing part, it should be inspected afterevery 30 operating hours.

1. Measure the width of the outside edgeof the disc as shown in Figure 5-22.Replace the disc before the rubber edgewears to a thickness of 1/8" or less.Failure to do so could cause the steelunderneath the rubber to damage thetransmission pulley.

2. Look for big cracks or missing chunksof rubber from the disc. If so damaged,the disc should be replaced immediately.

IMPORTANT: Extend the life of thereverse disc by always pausing inNEUTRAL before shifting betweenFORWARD and REVERSE. Also – thereverse disc is not suited for continuousor sustained reverse operation. Usereverse sparingly.

Figure 5-21: Seat belt in upperpulley, then in lower pulley (HighRange position shown).

Figure 5-20: Shift into FORWARDand remove the belt.

Figure 5-19: Move top half of beltover pulley and reverse disc.

➦

➦



WARNING

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

35

Replacing the Reverse DiscFollow these steps to replace the reversedisc. (If your tiller has a Bumper Attach-ment mounted, it must be removed first.)

Removing the Reverse Disc

1. Move Wheels/Tines/PTO Drive Lever inNEUTRAL position.

2. Wedge a 5/16"-thick board between topof engine pulley (avoid contacting reversedisc) and cast iron housing next to it.This immobilizes pulley.

3. Use a 9/16" wrench to loosen themounting bolt shown in Figure 5-23.Remember to immobilize the pulley withthe wood wedge while loosening the bolt.If necessary, pry the disc from the pulleywith the tip of a screwdriver. Back thebolt out as far as possible. Then anglethe disc a little to remove it. Bring thebolt and lockwasher along with the disc.

Installing a New Reverse Disc

1. Do steps 1-through-3, described previ-ously, in reverse.

2. Tighten mounting bolt securely, andcheck for correct operation — seeChecking and Adjusting Reverse DriveSystem.

Checking and Adjusting Reverse the Drive SystemWhen the Wheels/Tines/PTO Drive Leveris moved up into REVERSE, the engine

and engine mount move down to presson the reverse adjustment bolt (Figure 5-24). This action compresses the reversespring and plunger assembly, requiringyou to hold the lever up in REVERSE.When you release the lever, the springautomatically pushes the lever back intoNEUTRAL position.

The spring and plunger assembly isdesigned to prevent the reverse disc frommaking contact with the transmissionpulley until you shift into REVERSE.When the lever is in NEUTRAL, the switchbody on the bottom of the engine mounttab should be resting squarely on top ofthe reverse adjustment bolt (Figure 5-24).The reverse adjustment bolt can beadjusted up or down to correct a numberof reverse drive operating problems, asexplained next.

Checking and Adjusting Reverse Disc

1. Verify that linkages forWheels/Tines/PTO Drive Lever are lubri-cated with oil and engine mount bars andbelt adjustment block are lubricated withgrease. (See Tiller Lubrication in thissection.)

2. Place Wheels/Tines/PTO Drive Lever inNEUTRAL. Briefly pull out engine recoilstart rope while watching reverse disc.The disc should turn, but lower pulleyshould not (Figure 5-25). If reverse discturns lower pulley, or if it is located closerthan 3/16" to the pulley, reverse adjust-

ment bolt should be adjusted upward (seeinstructions that follow). Moving adjust-ment bolt upward will also solve problemof a tiller that goes into REVERSE on itsown.

3. Use your left hand to holdWheels/Tines/PTO Drive Lever up inREVERSE, while briefly pulling out enginestart rope. The reverse disc should turnlower pulley (see Figure 5-26). If not, orit requires a lot of pressure to hold leverup in REVERSE, then reverse adjustmentbolt must be adjusted downward. Whencorrectly adjusted, the Wheels/Tines/PTODrive Lever should pop out of reversewhen the lever is released, but not requireexceptional effort to hold it up in reverseposition.

4. Shift the Wheels/Tines/PTO Drive Leverto REVERSE and then let it go. The levershould return to NEUTRAL. If not, thereverse adjustment bolt will have to beadjusted upward.

Figure 5-23: Removing Reverse Disc.

OIL

Figure 5-25: Checking ReverseDisc in NEUTRAL.

Figure 5-26: Checking Reverse Discin REVERSE.

Both PulleysShould Turn




WARNING

Figure 5-24: Spring and plungerassembly.

Switch Body

Spring &Plunger

AdjustmentBolt

➧➧

➧

ReverseDisc

36

Adjusting Reverse Drive:

1. Place Wheels/Tines/PTO Drive Lever inFORWARD position.

2. On left side of tiller, put a 1/2" wrenchon the plunger retaining bolt and another1/2" wrench on the jam nut next to it(Figure 5-27). While holding the boltsteady, loosen the jam nut (counterclock-wise) until it touches the bolt head.

3. Turn the bolt in until it tightens againstthe plunger inside the spring. The boltmust be tight to prevent plunger fromturning – but be careful not to overtightenand break the bolt.

4. Place a 7/8" wrench on the head of thereverse adjustment bolt and a 9/16"wrench on the jam nut below it (Figure 5-28). Hold the bolt steady while looseningthe jam nut three or four turns.

5. Move the Wheels/Tines/PTO DriveLever to NEUTRAL. The switch body onthe bottom of the engine mount tab(Figure 5-24) should be resting squarelyon top of the reverse adjustment bolt, andthe reverse disc should be at least 3/16"away from the transmission drive pulley.If the reverse disc is any closer than this,raise the reverse adjustment bolt (turn itcounterclockwise).

6. Check that reverse disc is at least 3/16"away from transmission drive pulley.Then hold reverse adjustment bolt steadywith one wrench while tightening jam nutwith a second wrench (Figure 5-28).

7. Place a chalk or pencil mark on the topedge of the plunger retaining bolt. Now,while watching the mark, loosen the bolt3/4-turn (Figure 5-29). Do not exceed a3/4 turn (this would disengage the boltfrom the locking groove in the side of theplunger).

8. Hold the plunger retaining bolt steadywith a wrench while tightening the jamnut against the side of the plunger housing(Figure 5-27).

9. Check the action of the reverse disc asexplained previously.

IMPORTANT: If the above adjustmentshave not corrected an improperly workingreverse drive, contact an authorizeddealer or Factory Technical ServiceDepartment for assistance.

Bolo Tine MaintenanceChecking Tines for WearInspect the tines for wear or damage afterevery 30 operating hours. The rate ofwear depends upon hours of use and soilconditions. With use, the tines getshorter, narrower and more pointed(Figure 5-30). If badly worn, they lose theability to till deeply.

Worn tines leave an ever-increasing gapin the middle of a tilled row. The normalgap is 3" between the tine tips – replacethe tines when the gap widens to 5"(Figure 5-31).

Tines can be replaced individually or as acomplete set. See replacement instruc-tions that follow.

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

Figure 5-29: Loosen plungerretaining bolt about 3/4-turn, thentighten jam nut against plungerhousing.

Figure 5-28: Loosen jam nut beforeturning reverse adjustment bolt.

Figure 5-30: Check for wearevery 30 operating hours.

Figure 5-31: Replace tines when gapbetween inner tines is 5" or more(normal gap is 3").

1 2 3 4 5 6 7 8

Worn New

Retaining Bolt

Jam Nut




WARNING

AdjustmentBolt

Jam Nut

37

Single Tine Replacement

1. Move the Wheels/Tines/PTO DriveLever to NEUTRAL, the Wheel SpeedLever to either FAST or SLOW position,and the Tines/PTO Clutch Lever toENGAGE.

2. Gently tilt the tiller forward until theengine rests on the ground.

3. Raise the hood flap at the back of thetiller and tie it up with string.

4. Before removing a tine, note in whichdirection the bent tip points. The new tinemust be installed in the same direction.

5. Use two 9/16" wrenches to remove thetwo bolts and nuts securing the tine to thetine holder plate (Figure 5-32). Use pene-trating oil on the hardware if it is rusted orhard to remove.

6. Mount the new tine exactly the way theold tine was positioned. (The sharp edgeof the tine, which enters the soil first, mustface forward when above the tine shaft.)Replace the bolts and nuts and tightenthem securely.

Removing and Replacing A TineHolder Assembly

The 16 Bolo Tines are mounted eight perside on left-side and right-side tineholders. Here’s how to replace the tinesand holders as assemblies.

Removing Tine Holder Assembly

1. Follow steps 1-through-3 in SingleTine Replacement above.

2. Identify the tine holders as left-sideand right-side holders – they must bereplaced on the same side from whichthey were removed. Use a piece of chalkor a grease pencil to mark them L and R.

3. Remove the two bolts and nutssecuring each holder (Figure 5-33).

4. Use a soft mallet to drive the holderoff the tine shaft. (Use a heavy hammerand block of wood to knock off the immo-bilized tine holder.)

5. When the holder is off, clean all dirtand debris from the shaft and the holder.Apply fresh grease to the tine shaft.

Replacing Tines Holder Assembly

1. Replace the holder so the sharp tineedges face forward (toward front of tiller).Tap tine holder back on the tine shaft.

2. Grease the threads on the mountingbolt(s). Install and tighten the bolt(s)securely.

Figure 5-33: Tine Holders.

Left-Side Tine Holder

Tine Shaft

Right-Side Tine Holder




WARNING

Figure 5-32: Removing a single tinerequires taking off two bolts andtwo nuts.

The tines or tine hood edges may besharp. Wear thick gloves to protectyour hands from cuts or scrapes.

WARNING

• The tines or tine hood edges may besharp. Wear thick gloves to protectyour hands.

• Wear safety goggles to protect youreyes. When loosening hardware, donot hit a wrench with a metal tool– thiscould shatter the tool or wrench,sending metal particles into your eyes.

WARNING

38

Tine Shaft MaintenanceAfter every 10 operating hours, removethe left- and right-side Bolo Tine holdersand clear away dirt and debris that haveaccumulated on the tine shaft or insidethe tine holders. Please follow this main-tenance recommendation, as debris cancause premature wear to the tine shaftand its oil seals. Refer to the previoustine holder removal instructions. Aftercleaning away any debris and removingold grease from the tine shaft, apply freshgrease to the tine shaft.

Tire and Wheel MaintenanceCheck tire air pressure every 30 operatinghours. The recommended pressure fortilling is 10-to-20 psi (pounds per squareinch). Both tires should be inflatedequally. (Unequal pressure can cause thetiller to pull to one side.)

Removing the Wheels Each wheel is secured by a roll (spirol)pin that passes through the wheel huband the wheel shaft. Drive the roll pin outto remove a wheel.

1. Prop the transmission up with a sturdyblock to raise the wheel you want toremove off the ground.

2. Move the Wheel Speed Lever to eitherSLOW or FAST position to prevent thewheels from turning.

3. Use a 5/16" drift pin (or a blunt point16-penny nail) to drive the roll pin free.

Engine Oil MaintenanceCheck the engine oil level before startingthe engine each day and after each 5hours of continuous operation. Runningthe engine when it is low on oil willquickly ruin the engine.

It is recommended that you change the oilevery ten (10) operating hours and evensooner when operating in extremely dirtyor dusty conditions. Refer to the separateEngine Owner’s Manual for detailedservice instructions.

Air Cleaner MaintenanceThe engine is equipped with a dualelement air cleaner that filters the airtwice before it enters the carburetor tomix with the fuel.

The engine air cleaner filters dirt and dustout of the air before it enters the carbure-tor. Operating the engine with a dirty,clogged air filter can cause poor perfor-mance and damage to the engine. Neveroperate the engine without the air cleanerinstalled. Inspect and service the aircleaner more often if operating in verydusty or dirty conditions.

It is critical that the filters be kept cleanand properly installed at all times. Seethe location of the air cleaner assembly onyour engine by referring to Figure 5-39 orFigure 5-40.

Refer to the engine manufacturer’s litera-ture supplied with your tiller for completeair cleaner service and maintenance infor-mation.

Throttle Cable MaintenanceThe throttle lever settings are factory-adjusted, so unnecessary adjustmentsshould not be made. However, if theengine does not start or stop, or respondimmediately to various throttle leversettings, then adjustments may benecessary. Please refer to the enginemanufacturer literature supplied with yourtiller for specific adjustment instructions.

Ignition System MaintenanceYour engine is equipped with electronicignition. It does not have a condenser orpoints, so there is no need to perform anyregular tune-up maintenance on thissystem other than adjusting or replacingthe spark plug.

Spark Plug MaintenanceThe spark plug must be in good conditionfor proper engine operation. Remove andinspect the plug every 50 operating hoursor annually, whichever occurs first.

The correct electrode gap is .030". Checkthe gap with a feeler gauge. Do not use aspark plug if the porcelain is cracked, theelectrodes are pitted or burned, or if othervisible damage is present.

NOTE: Do not wire brush or sandblast thespark plug to clean it – loose particlescan enter the engine, causing damage!

To replace the plug, first tighten itsecurely by hand, then use a spark plugwrench to tighten the plug an extra 1/4turn.

Battery Care and Maintenance The battery is sealed and is maintenence-free. Acid levels cannot be checked.

• Always keep the battery cables andterminals clean and free of corrosivebuild-up.

• After cleaning the battery andterminals, apply a light coat ofpetroleum jelly or grease to theterminals and cover both terminalswith the rubber boots.




WARNING

Wear safety goggles when driving theroll pin into or from the wheel hub toprotect your eyes from the possibility offlying metal particles.

WARNING

39

When removing the battery, always dis-connect the negative (-) cable firstfollowed by the positive (+) cable. Re-verse this procedure when reinstallingthe battery.

WARNING

Storing Your TillerWhen your tiller won’t be used during theoff-season, prepare it for storage with thefollowing steps:

1. Clean the tiller and engine.

2. Do routine tiller lubrication and checkfor loose hardware.

3. Protect the engine from deteriorationor damage by referring to the enginestorage instructions in your enginemanual literature.

4. When engine is still warm, drain oilfrom engine crankcase. Refill with freshmotor oil.

5. Protect internal cylinder against rust byremoving spark plug and pouring oneounce of clean engine oil into spark plughole. Then slowly pull out recoil startrope 2 or 3 times to distribute oil inter-nally. Replace spark plug, but do notreconnect plug wire. Pull rope until resis-tance is felt — let rope rewind.

6. Charge battery (electric start option).Store battery in cool, dry location.

7. Move Wheels/Tines/PTO Drive Lever toNEUTRAL position. Keep tiller in a clean,dry area.

8. Never store tiller with fuel in fuel tankin an enclosed area where gas fumescould reach an open flame or spark, orwhere ignition sources are present (spaceheaters, hot water heaters, furnaces, etc.).

Inspecting Forward InterlockWiring SystemCheck the Forward Interlock wiringsystem every ten (10) operating hours,for tight connections and to see that theinsulation on the wires is unbroken (toprevent the system from shorting out).

1. Check insulated wire harness fromlower ends of handlebars to wire harnessconnector on top, right side of transmis-sion cover. Be sure connector is secure.

2. Check insulated tubing from connectorto cast iron motor mount/belt shroud.

3. Check the wire leading from the tubingover to the switch assembly mounted ontop of the tab on the cast iron motormount–belt shroud. Also check thesecond wire that leads to the throttlecable mounting bracket on the right side,forward portion of the engine.

Testing the Forward Interlock Wiring SystemThe wiring circuit for the ForwardInterlock Safety System is designed toground out the engine’s ignition system.

There are three switches in the circuitwhich, when open, let the engine run.One switch is on the neutral plunger tabof the cast iron motor mount. This switchis open whenever the Wheels/Tines/PTODrive Lever is in NEUTRAL or REVERSEpositions. The other two switches arelocated inside the handlebars, directlyabove the two Forward Interlock Levers.

The switches are wired so when squeezed(open) the engine will run. There is afourth switch located in the wiringharness connector on the top, right sideof the transmission cover. It warns you ifthe connection is not mated by not lettingthe engine run while the Wheels/Tines/PTODrive Lever is in FORWARD.

1. A broken or disconnected wire couldlet the engine run without you having topress one of the Forward Interlock Levers.

2. A bare wire touching tiller or enginemetal could ground out the engine’signition.

3. A switch that has failed allows theengine to run. Or it may prevent theengine from running.

Refer to the Troubleshooting section ifyour Forward Interlock Safety System isnot operating correctly.



WARNING


40

Appendix A: Troubleshooting

CHECK OR TEST

(Check or test in sequence shownuntil problem is resolved.)

Throttle Lever in START position X

Wheels/Tines/PTO Drive Leverin NEUTRAL position X

Forward Interlock Wire Harnessconnector securely mated X X

Forward Interlock Levers not beingsqueezed prior to shifting Wheels/Tines/PTO Drive Lever to XFORWARD position

Visually inspect for bare, brokenor disconnected wires X X

Check handlebar wire harness X X

Check transmission wire harness X X

PROBLEM

Troubleshooting Procedures1 Wheels/Tines/PTO Drive Lever:A. Lever does not stay in FORWARD–• Drive belt may be too tight. Raise beltadjustment block a little (Sect. 5).• Clutch pawl spring at end of lever may beoverstretched. Install new spring.B. Lever hard to shift into REVERSE–• Check reverse disc for wear (Sect. 5).• Check adjustment of reverse disc and/orreverse spring and plunger assy. (Sect. 5).• Clean and re-lubricate motor mount bars,belt adjustment block and linkages on lever(Sect. 5).C. Tiller stays in REVERSE when lever isreleased–• Lubricate motor mount bars, belt adjust-ment block and linkages on lever (Sect. 5).• Check adjustment of reverse spring andplunger (Sect. 5). If problem persists,contact Technical Service Department.D. Lever sticks in FORWARD–• Lubricate motor mount bars, belt adjust-ment block, and linkages on lever (Sect. 5).If problem continues, contact the TechnicalService Department.E. Lever hard to shift into FORWARD–• Follow advice for Problem 1-D. Also checkfor possible bent motor mount bar that couldbe binding in engine mount holes.

2 Wheel Speed Lever:A. Lever hard to shift, or sticks in FAST orSLOW wheel gear positions–

• Lubricate eccentric lever at rear of powerunit transmission (Figure 5-43). If rust ispresent, use penetrating oil and workeccentric lever back and forth by hand.• Lubricate linkage to Wheel Speed Lever toeccentric lever (Figure 5-43).• Clutch inside transmission may be binding.Disconnect linkage from eccentric lever andwork eccentric lever by hand. If difficult orimpossible to move, it may be due to adamaged keyway on the wheel shaft.Contact Technical Service Department.• Lubricate washers and castle nut on pivotof lever. If necessary, remove roll pin andback nut off 1/6th turn. Replace roll pin andtest the movement.• Apply grease to zerk fitting (if so equipped)with grease gun until grease appears aroundwashers.

B. Lever shifts into FAST wheel gear, butnot into SLOW wheel gear–• Connecting rod at end of lever might bebackwards, or bent in toward transmissionhousing and hitting it. Other shifting linkagemight be bent. Straighten or replace linkage(Figure 5-43).• Clutch inside transmission may be binding(Problem 2-A).C. Lever moves freely, but won’t shift in orout of gear–• Eccentric shifting pin inside transmissionmay be broken (rare) or worn. Disconnectlinkage from eccentric lever and try movingeccentric lever by hand (Figure 5-43). Iflever moves easily, contact the TechnicalService Department.

3 Wheels and Tines Won’t Turn:• Review operation of controls (Sect. 3 & 4).• Check condition and adjustment of drivebelt and reverse disc (Sect. 5).• Mounting bolt for transmission drive pulleymay be loose. (See Figure 5-1). If so, drivebelt or reverse disc will turn pulley, butpulley won’t turn main drive shaft.• Worm gears that drive wheel and tillershafts may be worn.

4 Wheels Turn, But Tines Won’t:• Tines/PTO Clutch Lever must be in ENGAGEposition (Sect. 3).• Tines/PTO Clutch Lever may need adjust-ment.• Key for dog clutch on tine attachment maindrive shaft may be missing, broken.• Worm gears that drive the tine shaft maybe worn.

Figure 5-43: Check connecting rod,shifting linkage and eccentric lever.

Connecting Rod

Linkage

Eccentric

Enginewon’t start

Engine shuts off whenWheels/Tines/PTO DriveLever is shifted intoFORWARD

Engine does not shut offwhen Forward InterlockLevers are released whileWheels/Tines/PTO DriveLever is in FORWARD

41

• Hardware holding tine holders to tine shaftmay be missing or broken. To check,remove holders (Sect. 5).• Key for bronze worm gear on tine attach-ment main drive shaft may be missing orbroken.

5 Tines Turn, But Wheels Won’t:• Check operation of Wheel Speed Lever(Problem 2).• Hi-Pro key inside wheel clutch may bemissing, broken. If so, clutch will not turnwheel shaft.• FAST and SLOW speed wheel gears maybe worn. If only one gear is worn, there willonly be one wheel speed.• Worm gear that drives pinion shaft andpinion gears may be worn.• FAST and SLOW speed pinion gears maybe worn. If only one gear is worn, there willonly be one wheel speed.• Drive “dogs” on sides of wheel clutch maybe worn or broken. If only one side of clutchis affected, there will only be one wheelspeed.

6 Wheels And Tines Turn On Top OfGround, But Stop Or Hesitate In Soil:• Drive belt may be loose (Sect. 5).• Mounting bolt for transmission drive pulleymay be loose (Figure 5-1).

7 Tiller Jumps While Tilling:• Depth Regulator Lever set too deep for soilconditions. Use a shallower setting.• Engine throttle speed too fast.• Tiller wheel speed too fast for soil condi-tions. Change to LOW belt range or SLOWwheel speed.

8 Depth Regulator Lever Difficult To Move:• Lubricate spring assembly and depthadjustment bar (Sect. 5).• Check for bent depth adjustment bar.

9 Wheel And Shaft Move Out To One Side:• Snap ring on wheel shaft may bedislodged. Raise wheels off ground andcheck for back and forth play in shaft. Ifthere is play, one or both snap rings is loose.

10 Tiller Pulls To One Side:• Check tire pressure (Sect. 5).

11 Tine Holder Bolt Breaks Or Loosens:• Earlier models have tine holder keys.Check that keys are in keyways of tine shaft.Without key in holder, left-side tine bolt willtighten and break; right-side bolt will loosen(Sect. 5).

12 Poor Traction:• Bar tread tires, tire chains, or wheelweights may be needed.

13 Gear Oil Leak From Power Unit Or TineAttachment Transmissions:• See Section 5.

14 Engine Lacks Power:• *Air cleaner restricted with dirt and/or oil.• Spark plug wire loose or damaged. Sparkplug worn or fouled.• Engine under excessive work load. UseSLOW wheel speed and LOW belt range.• *Throttle cable may be loose or misad-justed.• Verify that engine isn’t running with chokepartially engaged.• *Check Carburetor adjustment.• *Engine overheating. Check oil level andclean cooling fins. Oil may be very dirty. Lethot engine cool before restarting.• *Dirt or water in fuel or fuel system.• Engine crankcase low in oil, or overfilledwith oil. Check and adjust level.• *Low engine compression.

15 Engine Difficult To Start:• Wheels/Tines/PTO Drive Lever not inNEUTRAL position.• Fuel tank low or empty.• *Dirt or water in fuel or fuel system.• *Fuel line is restricted.• *Choke control not set properly.• *Spark plug worn or fouled (weak spark).• *Air cleaner restricted with dirt and/or oil.• *Throttle cable adjustment.• Engine throttle lever not free to movethrough its full operating range.• Throttle wire and its linkage are binding, orare bent and not free to move.• Low engine compression.

16 Engine Won’t Start:• See Troubleshooting the Forward InterlockSafety System in Section 5.• Wheels/Tines/PTO Drive Lever not inNEUTRAL position.• Fuel tank low or empty. Or fuel linerestricted or clogged.• *Choke control improperly set.• *Water or dirt in fuel, and /or fuel system.• *Spark plug fouled or worn. Spark plugwire loose or damaged.• *Carburetor may need adjustment.• *Air filter clogged with oil or dirt.• Carburetor float faulty (or float valveleaking)– if so, tap side of bowl lightly withhandle of screwdriver (or similar object).• Stale fuel clogs carburetor, and valves.Drain old fuel and add new fuel.

• *Fuel tank shut-off valve (if so equipped)not in fully Open position.• On Briggs & Stratton engine, On/Off switchnot in ON position.Electric Start Engines Only:• Electrical connections loose or shorted tometal frames, brackets or covers (Sect. 5).• Battery discharged (Sect. 5).• Electric starter motor faulty.

17 Engine Shuts Off When Wheels/Tines/PTO Drive Lever Is In Forward:• See Troubleshooting the Forward InterlockSafety System in Section 5.• Short in key switch or key switch wireharness.

• Check starter motor mounting bolts forlooseness. Have Authorized Engine ServiceDealer inspect the starter motor.

• Check oil level for correct amount.

18 Engine Overheats• Clean the engine cooling fins, shroud andcovers (Sect. 5).• Check for broken flywheel fins (underengine shroud). See Authorized EngineDealer.

19 Engine Runs Erratically:• Water or dirt in gasoline or carburetor.• Carburetor may need adjustment. SeeEngine Owner’s Manual.• *Spark plug fouled or dirty. Spark plugwire loose or damaged.• *Loose or cracked carburetor.• Governor linkage not adjusted properly orbinding. See Authorized Engine ServiceDealer. Don’t attempt to repair by yourself.• Check pan gasket, engine seals and drainplugs for leaks. See your Authorized EngineService Dealer.

20 Engine Runs Well, But Labors Under Tiller Load• *Check governor linkage for freedom ofmovement.• Check throttle setting and carburetoradjustment. See Engine Owner’s Manual.• Tilling depth is possibly too deep. Tocorrect, lower the depth regulator lever.• Possible worn tiller worm gear or loosedrive shaft.

21 Key Switch Will Not Start The Engine• Check battery terminals for corrosion(Sect. 5).

• Discharged battery (Sect. 5).

• Defective solenoid.

*See Engine Owner’s Manual or contact an authorized engine dealer for information.

Appendix A: Troubleshooting

42

43

Troy-Bilt® PTO Log Splitter290-258-081

The Troy-Bilt® PTO Log Splitter providesyou with a convenient and easy means ofsplitting about a half a cord of wood perhour when working alone. Whenconnected to the PTO Power Unit, thetiller’s engine runs the splitter’s hydraulicpump, providing you with 13 tons ofsteady, unhurried and predictable splittingforce.

As an added benefit, the power-drivenmobility provided by the PTO Power Unitallows you to move the splitter to andfrom your wood pile, over to a neighbor’splace, or along the woodpile to a freshsupply of logs.

Features include a 15 second splittingcycle; can handle log sizes up to 26" long;a two-stage hydraulic pump that automat-ically shifts into low gear to provide four-times greater pressure when needed;slim-cut wedge design for splitting green,stringy wood; and an auto-control valvefor automatic return stroke.

Dozer/Snow Blade Attachment290-259-081

In the winter, moves up to one foot oflight snow (or 6"-to-8" of heavy snow); atother times use it to move or spreadsand, gravel, loose dirt, grain, sawdust,etc. Attaches easily to the front of theWrap-Around Bumper Guard. Set theblade to several angles. Weighs 41-lbs.;measures 15" x 32".

Row Marker Attachment290-257-081

Do you like very straight, even, neat rowsin your garden? If so, the Row Marker isa must attachment. Hooks quickly to theHiller/Furrower attachment– eliminatesthe need for string, stakes, measuringtape, etc. You’ll like the straight rows ithelps you make if you lay out furrows, digcompost trenches, or make raised beds.The Row Marker extends from 28"-to-493⁄4", letting you vary the width betweenrows to suit the crop you’re planting.

V-Sweep Cultivator290-260-081

The V-Sweep Cultivator is a specializedtool designed for between-row crop culti-vation. Instead of stirring the soil, itslices through just below the surface toeliminate practically any weeds in its path.

The Sweep mounts easily to the optionalTow Hitch Attachment at the rear of thePTO Power Unit. The blade is made ofhigh carbon, heat treated steel andmeasures 2" wide (overall wing span is20").

The unique way the Sweep works,skimming along just underneath the soil’ssurface without turning the soil over,makes this the ideal tool for use in dry,dusty conditions where it is important tokeep soil disturbance to a minimum.And, because of its 20" wide cutting path,it does an effective cultivation job at a fastspeed.

The Sweep’s natural shallow cultivationhelps to prevent weed seeds from beingbrought to the soil’s surface. Thisshallow cultivation feature also meansthere’s less chance of damaging the rootsof your vegetables. For deeper or moreshallow cultivating, the blade depth canbe changed with a simple adjustment..

Wheel Weights290-266-081

Help increase traction by putting extraweight directly on the wheels. Theyreduce bucking and jumping when deep-tilling in heavy soil. They’re shippedempty– fill them with material likeconcrete, sand, gravel, etc. They boltdirectly to the tiller wheels.

Wrap-Around Bumper Guard290-255-081

Order this Bumper Guard by itself orreceive it as one of the components if youorder the combination Dozer/ Snow Bladeattachment. Protects the engine fromdamage by wrapping around and protect-ing many of the engine components. 1"diameter, high-strength steel tubing.

Hiller/Furrower Attachment290-250-081

The most popular attachment because itdoes so many jobs. Mounts to the rear ofthe depth regulator bracket. Furrowerblade easily makes plant rows, trenches,ditches to 8" deep. When hiller wings areattached to furrower blade, attachmentmakes hilled rows and raised bedgardens. Converts from a furrower to ahiller and back again, in seconds, withouttools.

Appendix B: Attachments & Accessories

44

REF PARTNo. No. DESCRIPTION QTY.


1 647-04006 Lever Assembly–Wheels/Tines/PTO Drive (Includes Ref. 17) ......... 1

2 1908156 Spring–clutch pawl........................ 13 710-0805 Bolt–hex hd., 5/16-18 x 1-1/2"....... 34 GW-2447 Bushing–3/8" ................................. 35 1177548 Lockwasher–external tooth, 5/16" . 36 712-0267 Nut–hex, 5/16"-18.......................... 37 1916265 Roller Assembly ............................ 18 GW-2165-1 Yoke–left side ................................ 1

9 GW-2165-2 Yoke–right side.............................. 110 GW-2164 Link–yoke pivot, left & right,

6-7/8" long ................................. 211 710-0514 Bolt–hex hd., 3/8-16 x 1" ............... 612 736-0169 Lockwasher–spring lock, 3/8"........ 613 736-3050 Washer–flat, 3/8", S.A.E................. 615 712-0798 Nut–hex, 3/8"-16............................ 216 1113-1 Bushing–spacer, 19/64" (.300") ..... 617 GW-2595 Knob.............................................. 1

See Page 50

Section

6 Parts ListWHEELS/TINES/PTO DRIVE LEVER & YOKE ASSEMBLY



1 629-04017 Engine Wire Harness Assy–forwardinterlock system (Incl. one redand one black wire, plug con-nector, neutral switch and PVCtubing. Parts not availableseparately................................. 1

2 GW-9971 Lockwasher–external tooth, 7/16" ......13 1186246 Nut–hex, 7/16"-20 ....................... 16 GW-9205 Clip–for plug connector ............... 17 725-0157 Tie–plastic ................................... 28 GW-2551 Handlebar Wire Harness Assy–

(see page 46, Ref. No. 20) ....... 1

FORWARD INTERLOCK SYSTEM

See Page 46

MODELS 682J. E686N & E682L Parts List

45

Parts List MODELS 682J. E686N & E682L



1 GW-9548 Bolt–Hex hd., flanged self-locking Grade 5, 1/2-13 x 3-1/2" ............ 1

2 GW-9119 Knob–handlebar height adjustment 13 GW-9120 Ring–retaining (tolerance ring)...... 14 GW-2657 Stud–handlebar height adjustment 15 1186233 Nut–hex, 1/2"-13............................ 16 GW-1021-1 Clamp–left, handlebar height

adjustment ................................. 17 GW-2542-1 Ratchet–left, handlebar height

adjustment ................................. 18 GW-2542-2 Ratchet–right, handlebar height

adjustment ................................. 19 1901784 Clamp–right, handlebar height

adjustment ................................. 110 GW-2534A Base–handlebar mounting............. 111 GW-2717 Handlebars .................................... 112 GW-9125 Grip–handlebars ............................ 213 777I22026 Decal–Control panel ...................... 114 1918111 Bolt–curved hd, GR5, 1/4-20 x 2" .. 115 1186389 Nut–hex, flanged self-locking, whiz

lock, 1/4"-20............................... 116 1909286 Throttle Control & Cable ................ 1

17 777I20946 Decal–Forward Interlock Lever ...... 218 725-0157 Tie–plastic ..................................... 219 GW-9219 Plug–wire harness retainer ............ 220 GW-2551 Handlebar Wire Harness Assy–

forward interlock system............ 121 GW-9250 Handlebar Switch–forward

interlock system......................... 222 GW-9385 Lock Pin–handlebar switch............ 223 GW-2543 Switch Housing–handlebar switch. 2— GW-2563 Switch Assembly ........................... 1

(Includes Ref. 21-23)24 1186009 Screw–pan head, 10-24 x 1/2",

thread-forming........................... 224A GW-9733 Screw–phillips head, 10-32 x 1/2",

thread-forming........................... 125 786-04003 Lever–Operator Presence Control.. 226 GW-9199 Pivot Pin–forward interlock lever... 227 GW-9514 Retaining Ring–klip ring–forward

interlock lever............................. 228 GW-9387 Return Spring–fwd interlock lever . 2– 777D06526 Label – Troy-Bilt Horse.................. 1– 777D06527 Label – Troy-Bilt Horse “Big Red” . 1

HANDLEBAR ASSEMBLY

46

1 710-3005 Bolt–hex hd., 3/8-16 x 1-1/4" ........ 22 GW-1113-1 Bushing–19/64" (.300" lg.) ............ 23 736-0169 Lockwasher–spring lock, 3/8" ....... 24 712-3017 Nut–hex, 3/8"-16 ........................... 25 GW-20795 Bar–depth regulator ...................... 16 GW-9120 Ring–retaining .............................. 17 GW-9119 Knob–depth regulator ................... 18 GW-2121 Bar–drag, depth regulator ............. 19 710-0599 Screw–thread-forming,

1/4-20 x 1/2".............................. 210 1186329 Bolt–flanged hex hd.,

5/16-18 x 3/4"............................ 2

12 GW-9929 Washer–flat, 5/16"......................... 213 686-04027 Hood ............................................. 114 777I22027 Decal–hood, operating inst. (LH) .. 1

777S32049 Decal–hood, operating inst. (RH).. 115 GW-2525 Bracket.......................................... 116 1185469 Pin–roll (spirol) 1/4" x 1" ............... 117 GW-9534 Spacer........................................... 118 GW-9384 Spring ........................................... 119 710-0597 Bolt–hex hd., 1/4-20x1"................. 120 1110106 Locknut–1/4"-20 ........................... 121 710-04049 Bolt–flanged hex hd.,

5/16-18 x 5/8"............................ 2



DEPTH REGULATOR & TINE HOOD ASSEMBLIES

See Page 54


47


WHEEL SPEED LEVER, BELT DRIVE SYSTEM, ENGINES, WHEELS

See Page 62

See Page 52

48

WHEEL SPEED LEVER1 GW-9362 Pin–spring, 1/8"................................ 12 GW-9838 Nut–castle (slotted), 1/2"-20 ............ 13 GW-9934 Washer–shoulder, 1/2" ..................... 14 GW-9932 Washer–disc spring ......................... 25 GW-2178 Lever–wheel speed shift................... 16 1902240 Knob–wheel speed shift lever........... 17 GW-9317 Pin–cotter, 3/32" x 1"........................ 18 GW-1231 Rod–connecting rod, wheel speed

shift lever...................................... 19 GW-1033 Swivel–connecting rod..................... 1

10 736-0275 Washer–flat, 5/16", S.A.E. ................ 111 GW-9338 Pin–hair cotter.................................. 112 712-0158 Locknut–hex hd., 5/16"-18 ............... 113 710-0514 Bolt–flanged hex hd., 3/8-16 x 1" ..... 514 736-0169 Lockwasher–spring lock, 3/8" .......... 515 736-3050 Washer–flat, 3/8", S.A.E. .................. 817 GW-1113-1 Bushing–spacer, 19/64" (.300"lg.).... 418 GW-9120 Ring–retaining (tolerance ring) ........ 1

BELT DRIVE SYSTEM19 GW-2102 Block– belt adjustment, 3-7/8" ......... 120 GW-2100 Rod– belt adjust., 7" with

measuring gauge .......................... 121 777I20942 Decal– engine stabilization ............... 122 1100012 Bolt–hex hd., 3/8-24 x 1-1/2" ........... 123 GW-2111 Disc–reverse .................................... 124 GW-9245 Belt–forward drive (no substitute

due to extra strength required) ..... 125 GW-1483 Pulley–engine power take off ........... 126 GW-1138-1 Shim–engine pulley, 1/16" As Req'd26 GW-1138-2 Shim–as above, 1/32" As Req'd27 GW-9303 Key–engine pulley, 3/16"sq. x 2-1/2" 1

ENGINES AND ENGINE MOUNT28 710-0376 Bolt–hex hd., 5/16-18 x 1", Grade 5.. .... 229 712-3010 Nut, hex, 5/16-18 .............................. 130 GW-1034 Bar–engine mounting....................... 231 GW-9147 Plug–thread protector, red plastic .... 232 GW-9572 Bolt–hex hd., 5/16-24 x 1-1/8" ......... 433 736-0119 Lockwasher–spring lock, 5/16" ........ 434 GW-2553 Mount– engine to tiller ..................... 135 * Briggs & Stratton Engine–

Recoil or electric start. (Electricstart requires key switch starting system.) .......................... 1

36 736-3052 Washer, flat, .406 x 1.0 x .105......... 1– 777S30647 Decal–hot surface warning .............. 1

WHEEL & TIRE ASSEMBLIES43 1915072 Pin– roll, 5/16" x 1-1/2".................... 245 1915056 **Wheel & Tire Assy– bar tread,

left side, 4:80 x 8" tubeless tire with valve stem, on one-piece steel wheel. .................................. 1

45A 1915057 **Wheel & Tire Assy–bar tread, right side. Same as above but for right side of tiller..................... 1

46 1902020 Cap–wheel hub ................................ 2



* Contact an authorized engine dealer, Troy-Bilt dealer or the Factory for replacement engineinformation.Contact an authorized engine dealer for engine service or parts. Refer to the engine name-plate for engine model and type information.

** For correct traction and directional control, Bar Tread Tires should be mounted on the tiller so the closed end of the “V” in the tire tread on top of the tire faces forward.


49

POWER UNIT TRANSMISSION ASSEMBLIES

See

,16A


50



TRANSMISSION COVER & SHIFT LEVERBRACKET ASSEMBLIES

1 1186299 Bolt–hex hd., #10-32 x 3/8", self-locking flange ..................... 3

2 GW-9463 Knob–tines/PTO clutch lever,tapered, plastic .......................... 1

3 GW-2124 Detent Plate–tines/PTO clutch lever 14 777I20945 Decal–operating instructions,

detent plate................................ 15 1186349 Bolt–flanged hex hd.,

3/8-16 x 1-1/2" .......................... 47 1186329 Bolt–flanged hex hd.,

5/16-18 x 3/4", Grade 5 ............ 19 736-0275 Washer–flat, 5/16", S.A.E. ............. 1

10 GW-2149 Bracket–shift levers....................... 111 GW-9362 Pin–spring, 1/8" ............................ 112 GW-9838 Nut–castle (slotted), 1/2"-20, call

Tech Service for tightening instructions. ............................ 1

13 GW-9934 Washer–shoulder, 1/2" ................. 114 GW-9932 Washer–disc spring ...................... 215 GW-2178 Lever–wheel speed shift................ 116 GW-2523 Cover–power unit transmission .... 117 GW-1123 Gasket–transmission cover........... 118 710-0376 Bolt–hex hd., 5/16-18 x 1", Grade 5,

(remove with care) ................... 119 712-0267 Nut–hex, 5/16"-18 ......................... 120 1901439 Spring–neutral plunger (remove

with care).................................. 121 GW-1035-1 Plunger–neutral (remove with care) 122 1901440 Clip Ring–retains neutral plunger.. 123 1186393 Nut–hex, flange locknut, 3/8"-16... 124 1902004 Bolt–hex hd., 3/8-16x1-1/2",

threaded full length.................... 1

TINES/PTO CLUTCH LEVER ASSEMBLY25 786-04002 Lever–eccentric, tines/PTO clutch. 126 710-3013 Bolt–hex hd., 1/4-20 x 1/2" ........... 127 GW-2123 Bushing–tines/PTO clutch lever

eccentric shaft ........................... 128 GW-9516 Retaining Ring–(snap ring),

external...................................... 229 GW-2461 Eccentric–shaft, tines/PTO clutch

lever........................................... 130 GW-9911 Lockwasher–hi-collar, 1/4"............ 131 GW-9672 Screw–socket hd., 1/4-20 x 3/8" ... 1

DRIVE SHAFT ASSEMBLY33 716-0101 Retaining Ring–external ................ 134 1909139 Dog Clutch–power unit ................. 1

35 GW-9301 Key–3/16 sq. x 1" .......................... 336 1100004 Bolt–hex hd., 5/16-24 x 3/4", self-

locking flange, Grade 5.............. 137 GW-9944 Washer–disc spring (concave)...... 138 GW-2107 Pulley–transmission drive, cast iron 139 GW-50027 Washer–flat, hardened shoulder

1-1/4"......................................... 140 1186310 Bolt–hex hd., 1/4-20 x 3/4", front

bearing cap................................ 342 718-04007 Cap–front bearing ......................... 143 1983632 Seal–oil, front bearing cap ............ 144 GW-1124-2 Gasket–front bearing cap .............. 145 GW-1224-1 Shim–front bearing cap, .

010" thick ..............................As Req'd45 GW-1224-2 Shim–as above, .030"...............As Req'd45 GW-1224-3 Shim–as above, .005" ...............As Req'd45 GW-1224-4 Shim–as above, .062" ...............As Req'd46 GW-1714 Bearing & Race

(incl. one bearing GW-9400and one cup (race) GW-9401) ... 2

47 GW-2655 Shaft–main drive, power unit ........ 148 721-04030 Seal–oil, drive shaft, rear .............. 149 GW-9517 Retaining Ring–(snap ring), internal........1

PINION SHAFT ASSEMBLY50 715-0121 Pin–roll (spirol), 1/4 x 2" ............... 251 718-04006 Plug–retaining, pinion bearing ...... 252 GW-9604 O-Ring–retaining plug................... 253 GW-1132-1 Shim–retaining plug, 1-1/64" inner

dia., .033" thick (on right sideonly one GW-1132-1 shim is alsoused between bearing and washer,Ref. No.’s 54 & 55).................... As

Req'd53 GW-1132-2 Shim–same as GW-1132-1, .062" . As

Req’d53 GW-1132-3 Shim–same as GW-1132-1, .010" As

Req'd54 GW-9404 Bearing–ball, pinion shaft ............. 255 GW-1126 Washer–pinion shaft ..................... 256 GW-1222 Stem Pinion–slow speed gear &

shaft .......................................... 157 GW-9502 Ring–retaining, external ................ 158 GW-2656 Worm Gear–bronze, wheel drive ... 159 GW-9300 Key–3/16" x 5/8"............................ 160 GW-1233 Gear–fast speed pinion ................. 1

(continued on page 55)


51

POWER UNIT TRANSMISSION ASSEMBLIES(Continued from page 53)

52

See Page 50

Parts List MODELS 682J & E682L



(continued from page 53)WHEEL SHAFT ASSEMBLY

61 721-04031 Seal–oil, wheel shaft ..................... 262 1909950 Retaining ring–external ................. 263 GW-1166-1 Shim–wheel shaft, 1-1/64" inner

dia., .062" thick.......................... AsReq’d

63 GW-1166-2 Shim–as above, .030" thick ....... AsReq’d

63 GW-1166-3 Shim–as above, .015" thick ........ AsReq’d

63 GW-1166-4 Shim–as above, .010" thick ........ AsReq’d

63 GW-1166-5 Shim–same as above, .005" thick AsReq’d

64 GW-1086 Bushing–bronze, wheel shaftbearing ...................................... 2

65 611-04025 Shaft–wheel, 15-5/8"...................166 GW-9357 Key–Hi Pro, 1/4" x 1-3/4"............... 167 GW-1223 Gear–slow speed, wheel drive....... 168 GW-1232 Gear–fast speed, wheel drive ........ 169 GW-1237 Dog Clutch–wheel drive ................ 170 GW-1112 Pin–clutch guide, 1/4" diameter .... 3

ECCENTRIC SHAFT ASSEMBLY71 1911372 Pin–roll, 3/16" x 1-1/4" (spirol) ..... 172 619-04000 Lever–eccentric, wheel speed

shifting ...................................... 173 721-04034 Seal–oil, eccentric shaft ................ 174 GW-1442 Pin–eccentric shaft, wheel speed

shifting ...................................... 1

75 611-04003 Eccentric Shaft–wheel speed shifting ...................................... 1

76 GW-1441 Spring–eccentric shaft .................. 1

TRANSMISSION HOUSING78 GW-2109 Housing–power unit transmission

(Empty housing without covers, shafts, gears, seals, etc.) ........... 1

79 GW-9359 Pin–alignment ............................... 1

MISCELLANEOUS PARTS80 1100067 Bolt–hex hd., 1/2-13 x 2" Grade 5 . 281 GW-9928 Washer–disc spring (concave),

domed side faces bolt head ....... 282 GW-2126 Post–with threaded hole for Ref.

No. 80........................................ 283 1105620 Plug–pipe, 1/4".............................. 284 GW-9122 Plug–red plastic, thread protector. 185 GW-9205 Clip–forward interlock system plug

connector (see page 47)............ 186 777I20944 Decal–forward interlock wire

harness...................................... 1TRANSMISSION ASSEMBLY

— 618-04004 Transmission –power unit (Does NOT include Ref. 35-39. DoesNOT include Shift Lever and BracketAssemblies, Ref. 3, 4, 10, 15, 85, 86,etc.) ........................................... 1

MODELS 682J & E682L Parts List

53

TILLER ATTACHMENT TRANSMISSION ASSEMBLIES

NOTE 1: THESE SCREWS HAVE A SPECIAL SEALING DESIGNTHAT CAN NOT BE REUSED WITHOUT RISKING THELOSS OF TRANSMISSION OIL. IF THESE SCREWSARE LOOSENED OR REMOVED, THEY MUST BEREPLACED WITH NEW HARDWARE.


54

1 1915068 Screw–self-sealing,1/4"-20 x 5/8" 52 GW-20873 Cover–tiller housing ..................... 13 GW-1129-1 Gasket–tiller housing cover, .010". As

thick...........................................Req’d3 GW-1129-2 Gasket–same as above, .030" As

thick...........................................Req'd4 711-04082 Shaft–tiller tine.............................. 15 741-3037 Ball Bearing................................... 26 1901976 Worm Gear–bronze, tiller tine

shaft .......................................... 17 GW-1104 Key–tiller tine shaft, woodruff key. 18 721-04035 Seal–oil, tiller tine shaft................. 2

TILLER DRIVE SHAFT ASSEMBLY9 716-0101 Retaining Ring–external ................ 2

10 1909138 Dog Clutch–tiller drive shaft.......... 111 GW-9301 Key–3/16" x 1" ............................... 112 GW-2127 Spring–dog clutch......................... 113 GW-1138-1 Shim–dog clutch, 1/16"(.62") thick.. 114 1915069 Screw–self-sealing,1/4"-20 x 7/8" 315 GW-1115 Cap–rear bearing........................... 116 GW-1124-2 Gasket–rear bearing cap ............... 117 GW-1224-1 Shim–front bearing cap, .010" As

thick...........................................Req'd

17 GW-1224-2 Shim–same as above, .030" Asthick...........................................Req'd



18 GW-1714 Bearing & Race ............................. 2(incl. one bearing GW-9400and one cup (race) GW-9401)

19 GW-2653 Shaft–main tiller drive ................... 120 721-04030 Seal–oil, drive shaft, front ............. 121 GW-9517 Retaining Ring–internal................. 1

TRANSMISSION HOUSING AND DIPSTICK23 1901971 Housing–tiller attachment (Empty

housing without shafts, gears, seals,dipstick, etc.) ................................ 1

24 1909157 Dipstick–oil, tiller attachment........ 1TRANSMISSION ASSEMBLY

— 618-04003 Transmission –Tiller (Includes Ref. 1-24) .................. 1




55

BOLO TINE ASSEMBLIES


56

STANDARD TILLING TINES

1 1901975 Tine Holder–welded steel, fitsleft or right sides...................... 2

2 710-3096 Bolt–hex hd., 3/8-16 x 2" ............. 43 712-3000 Locknut–hex, 3/8"-166 GW-1270-1A Bolo Tine–single, left hand. Used

on left and right side tine assy.Tine is stamped either “EL" or“AL". (incl Ref 8 & 10, two each) 8

7 GW-1270-2A Bolo Tine–single, right hand. Usedon left and right side tine assy.Tine is stamped either “ER" or“AR” (incl Ref 8 & 10, two each) 8

8 710-3005 Bolt–hex hd., 3/8-16 x 1" ............. 1610 712-0375 Locknut–hex, 3/8"-16 .................. 20--- 290-253-081 Tine Replacement Kit–unassembled

(Incl. eight each of Ref. No.’s 6,and 7, sixteen each of Ref. No.'s8 and 10). Includes easy-to-follow installation instruction. DOES NOT INCLUDE tine holders, holdermounting hardware, or tineshaft keys................................. 1

CUSTOM TILLING TINES

Special hard-faced, high-chrome carbon alloy tines that arethicker than standard Bolo Tines. These tines better resist theabrasive action of rocky, gritty or sandy soil as compared tostandard Bolo Tines, and are especially suited for customtilling or market gardening.

--- GW-10802 Custom Tilling Tine Kit–(Incl.eight each of Part GW-2475-1and GW-2475-2 tines and sixteeneach of Ref. No.’s 8 and 10...... 1

--- GW-2475-1 Bolo Tine, Custom Tilling–single,left hand................................... 8

--- GW-2475-2 Bolo Tine, Custom Tilling–single,right hand ................................ 8




57

Parts List MODELS E686N & E682L

ELECTRIC START SYSTEM

58

MODELS E686N & E682L Parts List

1 GW-96515 Cable–battery, positive and negativeterminals .................................. 2

2 GW-97020 Boot–terminal insulating ............. 33 GW-9552 Screw–self-threading,

1/4-20 x 1/2" ............................ 34 1186309 Bolt–hex hd., 1/4-20 x 5/8" .......... 25 1901894 Wire–recharge (red) .................... 16 GW-2614 Battery Hold-down Clamp–with

attached Key Switch Plate ........ 17 777S30648 Decal–ignition switch instruc....... 18 725-0267A Key Switch–includes two

ignition keys (Ref. No. 9), onelockwasher, and one mountingnut (lock-washer and nut notavailable separately)................. 1

9 725-0201 Key–ignition, one pair.................. 110 1186073 Bolt–carriage, 1/4-20 x 1-1/4" ..... 211 1100241 Lockwasher–spring lock, 1/4"...... 212 712-3006 Nut–hex, 1/4"-20 ......................... 213 725-1706 Battery–12 volt, 270 CCA................ 1

14 GW-96514 Solenoid–starter, includes nuts andwashers for cables and wires... 1

15 736-0119 Lockwasher–5/16" ....................... 316 1186211 Nut–hex, 5/16"-24 ....................... 217 736-0147 Lockwasher–external tooth, #10.. 118 GW-9853 Nut–hex, #10-32,......................... 119 GW-96510 Cable–solenoid to starter motor .. 120 GW-2557 Battery Bracket ............................ 121 1186349 Bolt–flanged hex hd.,

3/8-16 x 1-1/2" ......................... 223 GW-9265 Tie–plastic, wire retaining............ 127 725-0157 Tie–plastic ................................... 228 1908118 Wire Harness & Connecting

Terminal Assembly .................. 129 712-3010 Nut–flange lock, 5/16"-18 ............ 130 1186389 Locknut–hex, 1/4"-20 .................. 331 629-04018 Ground Wire Assembly................ 132 1901202 Cable–ground, solenoid to engine

block ........................................ 133 710-3180 Bolt–flange lock, 5/16-18 x 1"...... 1



59

BUMPER ATTACHMENT

--- 290-255-081 Bumper Attachment. Includes Ref. Nos. 1 through 11) ........... 1

1 1910730 Brace - bumper bottom ............... 12 710-3181 Bolt - hex hd., 1/2-13 x 1-1/2" ..... 13 736-0921 Lockwasher - spring lock, 1/2" .... 14 1909748 Spacer, 1/2" ................................. 15 710-0805 Bolt - hex hd., 5/16-18 x 1-1/2" ... 2

6 736-0119 Lockwasher - spring lock, 5/16" .. 27 712-3010 Nut - hex, 5/16"-18 ...................... 28 1910731 Bumper wraparound.................... 19 710-0514 Bolt - hex hd., 3/8-16 x 1"............ 2

10 736-0169 Lockwasher - spring lock, 3/8" .... 211 777S30653 Decal - for bumper ...................... 1



1

5

8

11

2

7

9

10

6

3

4


60

Notes

61

TROY-BILT TILLER LIFETIME LIMITED WARRANTY

WHAT PRODUCT All Troy-Bilt branded rear tine walk-behind tillers with gear drive transmissions.IS COVERED This warranty begins on the date of purchase and is warranted by Troy-Bilt LLC for the life

of the tiller, to the original purchaser only.

WHAT IS COVERED Troy-Bilt LLC will, at its option, repair or replace any part found to be defective in materialBY THIS WARRANTY or workmanship without charge for parts and labor.

This limited lifetime warranty also applies to non-powered attachments and accessories. Poweredattachments and accessories are warranted separately by their manufacturers. Refer to the applicablemanufacturer’s warranty on these items for terms and conditions.

WHAT IS NOT This warranty does not apply to parts that have been damaged by accident, alteration,COVERED BY THIS misuse, abuse, neglect, improper maintenance, vandalism, theft, fire, water, or damageWARRANTY 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 arenormally 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 If used for commercial, institutional, industrial, rental, or demonstrator purposes, the COMMERCIAL warranty on the tiller is limited in duration to 90 days from the date of purchase. USE WARRANTY

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 naturaldisaster.

HOW TO OBTAIN Warranty service is available, with proof of purchase, through your local authorized SERVICE service dealer. To locate a dealer in your area, consult your Yellow Pages, or contact Troy-Bilt LLC at

P.O. Box 361131, Cleveland, Ohio 44136-0019, 1-866-840-6483, or log on to our Web site atwww.troybilt.com.

The provisions set forth in this warranty provide the sole and exclusive remedy arising from the sale. Troy-Bilt LLC shallnot be liable for any incidental or consequential damage or expense of any kind, including but not limited to cost ofequipment 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 purpose, shall be limited induration to the period of ownership by the original purchaser (and a maximum of 90 days from the date of sale if the tiller is

purchased for commercial or other non-residential use).

Some states do not allow the exclusion or limitation of incidental or consequential damages, or limitations on how long animplied 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:

TROY-BILT LLC, P.O. Box 361131, Cleveland, Ohio 44136-0019, 1-866-840-6483

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