Troy-Bilt 68J-Horse manual

Operator ’ s Manual Rear-tine PT O T iller Models 682J—Horse TM E686N—Horse TM E682L—Horse TM 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 meetin[...]

2 For more details about your unit, visit our website at www .troybilt.com T ABLE OF CONTENTS Content Page Calling Customer Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

The engine exhaust from this product contains chemicals known to the State of California to cause cancer , birth defects or other reproductive harm. W A R NING This machine meets voluntary safety standard B71.8 – 1996, w hich is sponsored by the Outdoor Power Equipment Institute, Inc., and is published by the American National Standards Institute[...]

Section 1: Safety 8. Before cleaning, repairing, or inspect- ing, stop the engine and make certain all moving parts have stopped. Disconnect the spark plug wire and prevent it from touching the spark plug to prevent acci- dental starting. 9. The flap on the tine hood must be down when operating the tiller, unless using the Hiller/Furrower attachmen[...]

Section 1: Safety 5 Decals For your safety and the safety of others, various safety and operational decals are located on your unit (Figure 1). Keep the decals clean and legible at all times. Contact your local service dealer or the Factory for replacements if any decals are damaged or missing. Refer to the Parts List for decal locations, descripti[...]

6 Introduction Carefully follow these assembly steps to correctly prepare your tiller for use. It is recommended that you read this Section in its entirety before beginning assembly. NOTE: Three different Horse model tillers are covered in this Manual. Use only the information applicable to your model. Tiller engines vary by model. Your engine may [...]

Section 2: Assembly lever and could be damaged. You may gently move the wires aside if this condition occurs. 4. Raise handlebars to one of two height settings and tighten the height adjustment lever. Also, make sure all other mounting hardware is securely tightened. NOTE: Fully assembled handlebar assembly should appear as shown in Figure 2-3. STE[...]

8 Figure 2-6: Illustration shows the yoke plates (H), nuts, washers, and screws (A, E, B, F, D, G), bushing (C), and long and short links (I, J). Figure 2-7: Drive Lever assembly. Figure 2-11: Neutral position; roller (T) rests against middle area of the adjustment block (U). A I B C H D E F G Fig ure 2- 10 Forward position; roller (T) rests under [...]

Section 2: Assembly 9 IMPORTANT: Check gear oil level in both transmissions after the first 2 hours of new tiller operation, then every 30 operating hours thereafter. See Section 5 for instructions. STEP 7: Add Motor Oil to Engine 1. Before adding motor oil, park the tiller on level ground. Level the engine by placing a sturdy block under the tines[...]

Section 2: Assembly 10 NOTE: If the battery is put into service after the date shown on the top of the battery, charge for a minimum of one hour at 6-10 amps. Refer to the Maintenence section of this manual for more detailed instructions regarding proper battery charging procedure STEP 1: Connect the Wire Harness Receptacle 1. Before installing the[...]

Section 3 Features and Controls 11 Introduction This section describes the location and function of the controls and features on your tiller. Refer to Section 4, Operation for detailed operating instructions. Practice using these controls, with the engine shut off, until you completely understand the operation of the controls and feel confident wit[...]

Section 3: Features and Controls Figure 3-2: FORWARD position; roller (G) rests un der 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). G H Verify Position of Clutch Roller When [...]

Engine Throttle Lever Use the throttle lever (G, Figure 3-1) to adjust engine speed as well as to start and stop the engine. Move the lever away from the STOP position before starting the engine. Engine speeds are variable and range between the FAST and SLOW. Use the STOP position to turn the engine off. NOTE: A secondary throttle lever is located [...]

Section 4 Operation INTRODUCTION Read this Section of the manual thoroughly before you start the engine. Then, take the time to familiarize yourself with the basic operation of the tiller before using it in your garden. Find an open, level area and practice using the tiller controls without the tines engaging the soil (put tines in Travel setting ?[...]

Section 4: Operation Starting the Engine: 1. With the engine off, place the Wheels/Tines/PTO Drive Lever (Figure 4-2) in the NEUTRAL position. If in the FORWARD position, tap the lever sharply upward, it should automatically move into NEUTRAL position. 2. Put the Depth Regulator Lever in the Travel position (lever all the way down) so that the tine[...]

Section 4: Operation Reconnect the cables and securely tighten to battery posts. The engine will recharge the battery if the battery is still good. • If you suspect the batter is “ dead ” , or if the battery is damaged, disconnect, and remove it. Have it checked by a qualified technician. • If battery has been removed, wrap cable terminals [...]

Section 4: Operation 6. When the tiller moves forward, relax and let the wheels power the tiller along while the tines dig. Walk behind and to one side of the tiller. Walk on the side that is not yet tilled (Figure 4-4). Use a firm grip on the handlebars but keep your arm relaxed. IMPORTANT: Let the tiller move ahead at its own pace. Do not push it[...]

Section 4: Operation 4. When the turn is complete, shift to NEUTRAL and lower the handlebars. Move Tines/PTO Clutch Lever back to ENGAGE position and resume forward operation. T ransporting The Tiller Around Y our Property When the engine is running, the tiller ’ s powered wheels make moving the tiller to and from the garden easy. If the engine i[...]

Section 4: Operation • Turn the vehicle ’ s engine off and apply its parking brake. • Position the loading vehicle so that the ramp angle is as flat as possible (the less incline to the ramp, the better). Loading the Tiller 1. Use loading ramps that are strong and wide enough to safely hold the weight of the tiller and the operator combined ?[...]

Section 4: Operation 3. Kneel on left side of tiller. To create belt slack, reach over to right side of the pulleys and push in at the center of the belt with a finger. At the same time, use your left hand to work the belt part-way onto the lower-front transmission pulley groove (Figure 4-10). 4. Go to the other side of the tiller to finish seating[...]

Section 4: Operation 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 [...]

Section 4: Operation 22 Avoid making footprints When possible, walk on the untilled side of the unit to avoid making footprints in the freshly tilled soil (Figure 4-4). Foot- prints cause soil compaction that can hamper root penetration and contribute to soil erosion. They can also “ plant ” unwanted weed seeds back into the newly tilled soil. [...]

23 B. Terrace Gardening: • When a slope is too steep or too short for vertical tilling, it may be necessary to till across the slope and create terraced rows. Terraces are rows that are cut into the side of a slope, creating a narrow, but flat area on which to plant. • On a long slope, you can make several terraces, one below the other. • Ter[...]

Section 4: Operation 24 POWER COMPOSTING Power composting means tilling under and burying in the soil all manner of organic matter such as crop residues, leaves, grass clippings and cover crops. This material will decompose during the non-growing season and add important natural nutrients to the soil. Begin by composting crop residues such as lefto[...]

Your tiller is a self-contained PTO (Power Take-Off) Power Unit that was shipped with a tine attachment installed. The tine attachment can be quickly removed and replaced with other optional attachments. The following instructions will familiarize you with your PTO Power Unit. Please read these pages carefully. The following steps explain how to re[...]

IMPORTANT: Store tine attachment in a level, upright position to prevent gear oil from leaking from the dipstick area. 9. To keep the tine attachment dog clutch coupling clean, cover with the dust cap (on some attachments) or plastic wrap. 10. The PTO Power Unit is now ready to install other powered or non-powered attachments. See the attachment&ap[...]

3. On the PTO Power Unit, unplug the Forward Interlock Wire Harness that leads from the base of the handlebars (A, Figure 4-28) to the receptacle (B) located on the top, right side of the transmission cover. 4. On the Stationary Attachment, locate the interlock wire (C, Figure 4-28) and clean contacts on plug and receptacle (B). This connection ena[...]

NOTE: All references to left, right, front and rear of the machine are determined by standing behind the handlebars and facing the direction of forward travel. REQUIRED MAINTENANCE SCHEDULE Before Every Every Every As PROCEDURE Each 10 25 30 Noted Use Hours Hours Hours Check engine oil level • Every 5 operating hrs. Clean engine cooling system ?[...]

Tighten Bolts and Nuts Check for loose or missing hardware every ten (10) operating hours. Failure to tighten or replace fasteners can cause poor performance, equipment damage or oil leakage. See your Parts Catalog for complete fastener descriptions. Most hardware on your tiller is visible. Pay particular attention to hardware shown in Figures 5-1,[...]

Section 5: Maintenance IMPORTANT: Do not allow oil or grease to contact the pulleys, drive belt or reverse disc. This can cause the belt or disc to slip on the pulleys. Lubricate the numbered areas in Figures 5-4 and 5-5, as follows: 1. Oil the wheel shaft between the wheel hubs and the transmission housing (A, Figure 5-4). 2. Oil all pivoting and [...]

Section 5: Maintenance 3. If the oil level is correct, oil will seep out of the check hole (allow extra time in cold weather). If it does, the level is fine and you should replace the check plug. If no oil seeps out, see Adding or Changing Gear Oil . Checking the Tine Attachment Oil Level IMPORTANT: Two different gear oil checking procedures for th[...]

Section 5: Maintenance Adding Gear Oil to the PTO Power Unit Transmission 1. Do steps 1 and 2 of Checking the Power Unit Oil Level on page 32. 2. Using a 3/4" wrench (or socket), remove the bolt securing the handlebar base to the top of the transmission (prop the handlebars first to prevent them from falling). Then, unplug the Forward Interloc[...]

Section 5: Maintenance Drive Belt Maintenance Measuring and Adjusting Drive Belt T ension On a new tiller (or if a new belt is installed), the belt tension will probably need to be adjusted after the first two (2) hours of operation. Thereafter, check belt tension every ten (10) operating hours. Maintaining the right tension is important to good ti[...]

Section 5: Maintenance 3. Insert the belt adjustment tool through the hole in the side of the adjustment block, spacing the ends of the tool equally on both sides (Figure 5-14). Rotate the tool so the slotted end faces down. 4. Place the Wheels/Tines/PTO Drive Lever in FORWARD position. The arms of the clutch control yoke will be resting on the bel[...]

Section 5: Maintenance 3. Push belt forward then down until it is looped over the lower pulley (Figure 5-18). Do not yet seat it in either of the lower pulley ’ s grooves. HINT: A blunt object, like a ruler, can help you push the belt downward if needed. 4. Move the top half of the belt up and over the rubber reverse disc, but do not seat it in e[...]

Replacing the Reverse Disc Follow these steps to replace the reverse disc. (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 in NEUTRAL position. 2. Wedge a 5/16"-thick board between top of engine pulley (avoid contacting reverse disc) and cast iron hous[...]

Adjusting Reverse Drive: 1. Place Wheels/Tines/PTO Drive Lever in FORWARD position. 2. On left side of tiller, put a 1/2" wrench on the plunger retaining bolt and another 1/2" wrench on the jam nut next to it (Figure 5-27). While holding the bolt steady, loosen the jam nut (counterclock- wise) until it touches the bolt head. 3. Turn the b[...]

Single Tine Replacement 1. Move the Wheels/Tines/PTO Drive Lever to NEUTRAL, the Wheel Speed Lever to either FAST or SLOW position, and the Tines/PTO Clutch Lever to ENGAGE. 2. Gently tilt the tiller forward until the engine rests on the ground. 3. Raise the hood flap at the back of the tiller and tie it up with string. 4. Before removing a tine, n[...]

Tine Shaft Maintenance After every 10 operating hours, remove the left- and right-side Bolo Tine holders and clear away dirt and debris that have accumulated on the tine shaft or inside the tine holders. Please follow this main- tenance recommendation, as debris can cause premature wear to the tine shaft and its oil seals. Refer to the previous tin[...]

Storing Y our Tiller When your tiller won ’ t be used during the off-season, prepare it for storage with the following steps: 1. Clean the tiller and engine. 2. Do routine tiller lubrication and check for loose hardware. 3. Protect the engine from deterioration or damage by referring to the engine storage instructions in your engine manual litera[...]

Appendix A: T roubleshooting CHECK OR TEST (Check or test in sequence shown until problem is resolved.) Throttle Lever in START position X Wheels/Tines/PTO Drive Lever in NEUTRAL position X Forward Interlock Wire Harness connector securely mated X X Forward Interlock Levers not being squeezed prior to shifting Wheels/ Tines/PTO Drive Lever to X FOR[...]

• Hardware holding tine holders to tine shaft may 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 or broken. 5 Tines Turn, But Wheels Won ’ t: • Check operation of Wheel Speed Lever (Problem 2). • Hi-Pro key inside wheel clutch may be missing, broken[...]

43 T roy-Bilt ® PTO Log Splitter 290-258-081 The Troy-Bilt ® PTO Log Splitter provides you with a convenient and easy means of splitting about a half a cord of wood per hour when working alone. When connected to the PTO Power Unit, the tiller ’ s engine runs the splitter ’ s hydraulic pump, providing you with 13 tons of steady, unhurried and [...]

44 REF PART No. No. DESCRIPTION QTY. REF PART No. No. DESCRIPTION QTY. 1 647-04006 Lever Assembly – Wheels/Tines/ PTO Drive (Includes Ref. 17) ......... 1 2 1908156 Spring – clutch pawl ........................ 1 3 710-0805 Bolt – hex hd., 5/16-18 x 1-1/2" ....... 3 4 GW-2447 Bushing – 3/8" ................................. 3 5 11[...]

REF PART No. No. DESCRIPTION QTY. REF PART No. No. DESCRIPTION QTY. 1 629-04017 Engine Wire Harness Assy – forward interlock system (Incl. one red and one black wire, plug con- nector, neutral switch and PVC tubing. Parts not available separately................................. 1 2 GW-9971 Lockwasher – external tooth, 7/16" ......1 3 1186[...]

Parts List MODELS 682J. E686N & E682L REF PART No. No. DESCRIPTION QTY. REF PART No. No. DESCRIPTION QTY. 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 1 3 GW-9120 Ring – retaining (tolerance ring) ...... 1 4 GW-2657 Stud – handlebar height adjust[...]

1 710-3005 Bolt – hex hd., 3/8-16 x 1-1/4" ........ 2 2 GW-1113-1 Bushing – 19/64" (.300" lg.) ............ 2 3 736-0169 Lockwasher – spring lock, 3/8" ....... 2 4 712-3017 Nut – hex, 3/8"-16 ........................... 2 5 GW-20795 Bar – depth regulator ...................... 1 6 GW-9120 Ring – retaining ......[...]

Parts List MODELS 682J. E686N & E682L WHEEL SPEED LEVER, BEL T DRIVE SYSTEM, ENGINES, WHEELS See Page 62 See Page 52 48[...]

WHEEL SPEED LEVER 1 GW-9362 Pin – spring, 1/8"................................ 1 2 GW-9838 Nut – castle (slotted), 1/2"-20 ............ 1 3 GW-9934 Washer – shoulder, 1/2" ..................... 1 4 GW-9932 Washer – disc spring ......................... 2 5 GW-2178 Lever – wheel speed shift ................... 1 6 1902240 Kn[...]

POWER UNIT TRANSMISSION ASSEMBLIES See Page 50 ,1 6A Parts List MODELS 682J. E686N & E682L 50[...]

REF PART No. No. DESCRIPTION QTY. REF PART No. No. DESCRIPTION QTY. TRANSMISSION COVER & SHIFT LEVER BRACKET 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 l[...]

POWER UNIT TRANSMISSION ASSEMBLIES (Continued from page 53) 52 See Page 50 Parts List MODELS 682J & E682L[...]

REF PART No. No. DESCRIPTION QTY. REF PART No. No. DESCRIPTION QTY. (continued from page 53) WHEEL SHAFT ASSEMBLY 61 721-04031 Seal – oil, wheel shaft ..................... 2 62 1909950 Retaining ring – external ................. 2 63 GW-1166-1 Shim – wheel shaft, 1-1/64" inner dia., .062" thick .......................... As Req ’[...]

TILLER A TT ACHMENT TRANSMISSION ASSEMBLIES NOTE 1: THESE SCREWS HA VE A SPECIAL SEALING DESIGN THA T CAN NOT BE REUSED WITHOUT RISKING THE LOSS OF TRANSMISSION OIL. IF THESE SCREWS ARE LOOSENED OR REMOVED, THEY MUST BE REPLACED WITH NEW HARDWARE. Parts List MODELS 682J & E682L 54[...]

1 1915068 Screw – self-sealing,1/4"-20 x 5/8" 5 2 GW-20873 Cover – tiller housing ..................... 1 3 GW-1129-1 Gasket – tiller housing cover, .010" . As thick...........................................Req ’ d 3 GW-1129-2 Gasket – same as above, .030" As thick...........................................Req'd [...]

BOLO TINE ASSEMBLIES Parts List MODELS 682J & E682L 56[...]

STANDARD TILLING TINES 1 1901975 Tine Holder – welded steel, fits left or right sides ...................... 2 2 710-3096 Bolt – hex hd., 3/8-16 x 2" ............. 4 3 712-3000 Locknut – hex, 3/8"-16 6 GW-1270-1A Bolo Tine – single, left hand. Used on left and right side tine assy. Tine is stamped either “ EL" or “ AL&quo[...]

Parts List MODELS E686N & E682L ELECTRIC ST ART SYSTEM 58[...]

MODELS E686N & E682L Parts List 1 GW-96515 Cable – battery, positive and negative terminals .................................. 2 2 GW-97020 Boot – terminal insulating ............. 3 3 GW-9552 Screw – self-threading, 1/4-20 x 1/2" ............................ 3 4 1186309 Bolt – hex hd., 1/4-20 x 5/8" .......... 2 5 1901894 Wir[...]

BUMPER A TT ACHMENT --- 290-255-081 Bumper Attachment. Includes Ref. Nos. 1 through 11) ........... 1 1 1910730 Brace - bumper bottom ............... 1 2 710-3181 Bolt - hex hd., 1/2-13 x 1-1/2" ..... 1 3 736-0921 Lockwasher - spring lock, 1/2" .... 1 4 1909748 Spacer, 1/2" ................................. 1 5 710-0805 Bolt - hex hd[...]

Notes 61[...]

Notes[...]

Notes[...]

TROY -BIL T TILLER LIFETIME LIMITED W ARRANTY 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 [...]