Troy-Bilt 654J manual

D 0 7 7 4 9 A C Oper ator’ s Man ual Rear-tine Tiller 654J—Thoroughbred ™ PRINTED IN U.S.A. 769-01146.fm (3/17/2004) FORM NO. IMPORT ANT : READ SAFETY RULES AND INSTRUCTIONS CAREFULL Y WARNING: This unit is equipped with an internal combustion engine and should no t be used on or near any unimproved fore st-covered, brush -covered or grass-co[...]

2 TABLE OF CONTENTS FINDING MODEL NUMBER This Operator’s Manu al is an important part of your new rear-tine tiller. It will help yo u assemble, prepar e and maintain the unit for best performance. Please read and understand what it says. Before you start as sembling your new equipment , please locate the mod el plate on th e equipment and copy th[...]

3 SECTION 1: IMPORTANT SAFE OPERATION PRACTICES WARNING: This symbol points out import ant safety instructions which , if not followed, could endanger the personal safe ty and/or property of yourself and other s. Read and follow all instr uctions in this manual before attemptin g to operate this machine . Failure to comply with these instructions m[...]

4 8. Before cleaning, repair ing, or inspecting, stop the eng in e and make certain all moving pa rts ha ve stopped. 9. Always keep the tiller’s rear tine shield down. 10. Never use the tiller unless proper guards, pl a te s , o r other safety protective devices ar e in place. 11. Do not ru n engine in an enclos ed area. Engin e exhaust contains [...]

5 SAFETY LABELS FOUND ON YOUR TILLER W A R NING Hot surfaces can cause severe burns. Do not touch muffler or adjacent areas. S30647 WARNING TO AVOID SERIOUS INJURY 1. READ THE OPERATOR'S MANUAL. 2. KNOW LOCATION AND FUNCTIONS OF ALL CONTROLS. 3. KEEP ALL SAFETY DEVICES AND SHIELDS IN PLACE AND WORKING. 4. NEVER ALLOW CHILDREN OR UNINSTRUCTED A[...]

6 SECTION 2: ASSEMBLING THE TILLER NOTE: All referenc es to th e RIGHT o r LEFT sid e of the tiller are observed from operator’s position. T ools Needed for Assembly • 9/16” Wrench (Handle Mount Bracket) • 7/16” Wrench or Nutdriver (Control Box) • Two 1/2” Wrenches (Threaded Cable Adjuster) • Phillips Screwdriver (Control Box) Attac[...]

7 Attaching the Control Box 5. Remove the four Phillips screws and lock nuts from the control box plate. 6. Insert the en ds of the two springs into the holes found in the control levers located on t he underside of the handle pane l. 7. Using a Phillips screwdriver and a 7/16” wrench, secure the contr ol box to the under side of the handle panel[...]

8 Attaching the Shift Cable 8. Place the shift lever in th e forward position. Insert the end of the shift cable in to the hole in shift lever located on the underside t he handle panel. 9. Position the shift cable’s threaded adjuster in the slot found on the s hift lever moun t bracket. (o ne nut below the mount bracke t and the flat washer, loc[...]

9 SECTION 3: KNOW YOUR TILLER Read this operat or’s manual and safety rules before operating your tiller. Compar e the illustrations above with your unit to familiarize yourse lf with the location of various controls. Save th is manual for futur e reference . Engine See the Briggs & Stratton Owner/Operat or manual packed with your unit f or t[...]

10 Tine Direction Selector The tine direction selecto r (found in the lower left area the handle panel) is used to alternate tine rotation bet ween FRT mode (Forward Rotating Tines) to CRT mode (Counter Ro tating Ti nes). • Operate the tiller in CRT mode when tilling virgin ground, sod or hard soil. • Operate the tiller in FRT mode when cultiva[...]

11 SECTION 4: OPERATING YOUR TILLER WARNING: Read, understand, and follow all instructions and warnin gs on the machine, in this manual and the Briggs & Stratton Owner/ Operator manu al packed with your unit before operating the tiler. Safety Interlock System IMPORT ANT : Your tiller is equipp ed with an interlock system for the pr otection of [...]

12 Stopping Engine • Move throttle control leve r to STOP position. See Figure 1. Figure 1 CAUTION: Never sto p the engine by movi ng the choke lever into the CH OKE position. Backfire, fire or engine damage could result. Operating the T iller WARNING: Before tilling new gr ound, contact your telephone and utilities company to inquire if undergro[...]

13 Preparing Seedbeds Tilling wet soil often results in large, hard clumps of soil that can inter fere with plant- ing. If time permits, wait a day or two after heavy rains to allow the s oil to dry before tilling. T est soil by squeezing it into a ball. If it compresses too easily , it i s too wet to till. Avoid Tilling Soggy, Wet Soil Whenever po[...]

14 Tilling On Slopes Read the following recomm endations before tilling on slopes: If you must garden on a moderate slope, please follow two ver y important guidelines: 1. Till only on moderate slopes, never on steep ground where footing is difficult (review safe - ty rules in Section 1 : Safety of this manual). 2. We recommend tilling up and down [...]

15 SECTION 5: MAINTENANCE AND ADJUSTMENTS WARNING: Before perf orming any maintenance, or repa irs, turn the engine off and allow it to cool, move th e tiller to a level surface, place the wheel shift lever in the FORWARD position and chock the tiller’s wheels. MAINTENANCE SCHEDULE PROCEDURE NO TES Check motor oil le vel 2, 3 Clean engine 2, 7 Ch[...]

16 Ignoring a leak can result in severe tran smission dam age. If a cover leaks, try tightening any loose screws or bolts. If the fasteners are tight, a new gasket or oil seal may be required. If th e leak is from around a shaft and oil seal, t he oil seal probably n eeds to be replaced. See a n authorized service dealer . Changing Oil Oil level sh[...]

17 Shift Cable If the tiller’s wheels do not “freewheel” when the wheel shift lever is in the NEUTRAL po sition, the shift cable is in need of adjustmen t. Refer to Step 10 on Page 8 for detailed instructions. Tine Engagement Cables If the tines fail to drive when th e tine engagement lever is placed in th e ON posi tion, or if th e tines fai[...]

18 SECTION 6: SERVICE Changing the Belts WARNING: Position the tiller on flat, level surface, chock th e wheels, shut the engine off and allow it to cool befo re removing the be lt(s). All belts on your tille r are subject to we ar and should be replaced if any signs of wear are present. IMPORT ANT : The belts found on your tiller are specially des[...]

19 4. Begin th e removal the rever se tine belt as follows: a. Apply pressure on the idler pulleys to relieve tension on the r everse tine cable and th e wheel drive cable. b. Carefully unhook each cable-end . 5. Unloop the whee l drive belt from around the engine pulley. 6. Unloop the reve rse tine belt from the engine pulley. NOTE: Replace the re[...]

20 Wheel Drive Belt NOTE: The wheel drive belt is under the least amount of load and will wear at a sl ower rate. It may not be necessary to re place the wheel dr ive belt as often a s the tine belts. In spect the belt and read the following steps before proceeding . 1. Remo ve the lef t wheel by removing the cotter pin and clevis pin which secure [...]

21 Tines The tines will wear with use and should be inspected at the beginning of each tilling season and after every 30 operating ho urs. WARNING: Position the tiller on flat, level surface, chock th e wheels, shut the engine off and allow it to cool before inspecting or removing the ti nes. NOTE: The tine shield en d-covers (l eft side and righ t[...]

22 TROUBLESHOOTING PROBLEM POSSIBLE CAUSE CORRECTION Engine does not start 1. Spark plug wire disconnected. 1. Reconn ect wire. (See E ngine Owner’ s Manual) 2. Engine Throttle Control L e ver incorre ctly set. 2. Put lever in ST ART position. 3. Fuel tank em pty . 3. Add fuel. 4. Choke control in incorr ect position. 4. See Page 11 , Starting th[...]

23 8 7 3 12 10 11 2 17 18 9 6 13 15 16 14 1 5 4 Wheels and Tines REF NO. P ART NO. DESCRIPTION 1 642-04015 Adapter Assembly, Tine 2 712-3054 Nut, 3/8-24, Hex, Lock 3 736-0169 Washer, Lock, 3/8, Regular Duty 4 736-0208 Washer, Flat, .51 x 1.5 x .07 5 736-0253 Washer, Bell, .525 x 1.00 x.050 6 738-0688 Screw, Shoulder 1/2 Dia x .325 7 738-0689 Screw,[...]

24 A A B C C D D B 2 2 8 1 13 17 34 17 30 27 19 29 14 14 9 18 11 13 36 3 25 22 38 26 22 12 13 23 20 37 22 13 35 20 5 6 28 15 4 13 26 22 31 32 16 13 13 10 10 Handlebar and Controls[...]

25 Handlebar and Controls REF NO. P ART NO. DESCRIPTION 1 647-04026 Bail Assemb ly, Control, Wheel 2 649-04014 Handle Assembly, Loop 3 686-04038 Lever Assemb ly, Control, Tine 4 686-04040 Lever Assembly, Pivot 5 710-3119 Hex Screw, 3/8-16, .75, Gr5 6 710-04198 Screw, Carriag e, 3/8-16, 6.00, Gr5 7 710-04202 Screw, Machine, 1/4-20, 2.500 8 710-0501 [...]

26 A B C D D E F G G F E C 8 Wheel Clutch Cable (Shown for Reference) Forward Tine Clutch Cable (Shown for Reference) Reverse Tine Clutch Cable (Shown for Reference) 22 6 20 23 25 21 44 30 33 37 26 39 7 13 44 18 19 21 3 38 41 12 2 18 32 7 1 10 34 28 40 29 36 35 4 23 46 6 23 15 18 49 47 50 45 9 24 51 18 43 48 11 17 14 9 4 31 16 21 5 18 27 38 11 38 1[...]

27 Drive System REF NO. P ART NO. DESCRIPTION 1 686-04034 Bracket Assembly, Clutch 2 710-0117 Hex Screw, 5/16-24, 1.00, Gr5 3 710-0378 Hex Screw, 5/16-18, 2.50, Gr5 4 710-0599 Screw, Self-tapping, 1/4-20, 0.500 5 710-0624 Hex Screw, 5/16-24, 1.50, Gr5 6 710-0642 Screw, Self-tapping, 1/4-20, 0.750 7 710-0723 Hex Screw, 3/8-16, 1.25, Gr5 8 710-0902 H[...]

28 8 55 68 9** 41*** 28 5** 38 64-67* 69 70 56 54 36 59-63* 57 27 13 51 23 19 49 37 17 25 22 17 53 39* 21 37 26 1 20 33 39 3 14 34 35 58* 42 12 40 48 47 30 10 31 53 38 36 54 59-63* 56 57 11 2 4 72 15 6 5 52 18 69 44 70 71 31 7** 50 43 51 16 7** 24 * Shims used "As Required" to obtain between .005" and .015" allowable end-play **[...]

29 T ransmission REF NO. P ART NO. DESCRIPTION 1 611-04033 Shaft Assembly, Detent 2 619-04069 Housing, Transmission 3 619-04070 Cover, Housing, Transmission 4 686-04039A Link Assembly, Shift 5 710-1880 Hex Screw, 5/16-18, .75, Gr5, Patch 6 710-0425 Screw, Machine, #10-24, 0.625 7 710-3015 Hex Screw, 1/4-20, .75, Gr5 8 710-04049 Flange Screw, 5/16-1[...]

30 A A 16 3 7 12 7 7 7 14 20 6 15 4 22 2 4 10 9 13 13 5 21 7 20 4 19 7 8 18 1 10 Tine Shield REF NO. P ART NO. Description 1 686-0044A Cover Assembly, End 2 710-0597 Hex Screw, 1/4-20, 1.00, Gr5 3 710-0604 Screw, Self-ta pping, 5/16-18, 0.625, 4 710-0874 Hex Screw, 5/16-18, 1.25, Gr5 5 710-3039 Hex Screw, 5/16-18, .50, Gr5 6 712-0324 Nut, Hex Lock,[...]

31 NOTES[...]

32 TR O Y -BIL T TILLER LIFETIME LIMITED W ARRANTY WHAT PRODUCT All Troy-Bil t brand ed rear tine wa lk-behind tillers with gear drive tran smissions. IS COVERED This warranty begins on the date of p urchase and is warranted by Troy-Bilt LLC for the life of the tiller, to the origin al purchaser only. WHAT IS COVERED Troy-Bilt LLC will, at its opti[...]