Troy-Bilt 683-Horse, E683G-Big Red manual Safety Alert Symbol, Before cleaning, repairing, or

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Section

1Safety

Safety Alert Symbol

This machine meets voluntary safety standard B71.8

1996, which is sponsored by the Outdoor Power Equipment Institute, Inc., and is published by the American National Standards Institute.

This is a safety alert symbol. It is used in this manual and on the unit to alert you to potential hazards. When you see this symbol, read and obey the message that follows it. Failure to obey safety messages could result in personal injury or property damage.

WARNING

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

Training

1.Carefully read this Owner’s Manual, the separate Engine Owner’s Manual, and any other literature you may receive. Be thoroughly familiar with the controls and the proper use of the tiller and its engine. Know how to stop the unit and disengage the controls quickly.

2.Never allow children to operate the tiller. Never allow adults to operate the tiller without proper instruction.

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

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

Preparation

1.Thoroughly inspect the area where the tiller is to be used and remove all foreign objects.

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

3.Do not operate the tiller without wearing adequate outer garments. Avoid loose garments or jewelry that could get caught in moving parts.

4.Do not operate the tiller when barefoot or wearing sandals, sneakers, or light footwear. Wear protective footwear that will improve footing on slippery surfaces.

5.Do not till near underground electric cables, telephone lines, pipes or hoses. If in doubt, contact your telephone or utility company.

6.Warning: Handle fuel with care; it is highly flammable and its vapors are explosive. Be sure to take the following precautions:

a. Store fuel in containers specifically designed for this purpose.

b. The gas cap shall never be removed or fuel added while the engine is running. Allow the engine to cool for several minutes before adding fuel.

c. Keep matches, cigarettes, cigars, pipes, open flames, and sparks away from the fuel tank and fuel container.

d. Fill fuel tank outdoors with extreme

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

e. Replace all fuel tank and container caps securely.

f.If fuel is spilled, do not attempt to start the engine, but move the machine away from the area of spillage and avoid creating any source of ignition until fuel vapors have dissipated.

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

Operation

1.Do not put hands or feet near or under rotating parts. Do not allow hands or any other part of the body or clothing near the rotating tines or near any other moving part. The tines begin to rotate forward once the engine starts, the Tines/PTO

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

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

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

4. Exercise caution to avoid slipping or falling.

5. If the unit should start to vibrate abnormally, stop the engine, discon- nect the spark plug wire and prevent it from touching the spark plug, and check immediately for the cause. Vibration is generally a warning of trouble.

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

7.Take all possible precautions when leaving machine unattended. Stop engine. Disconnect spark plug wire and move it away from spark plug. Remove ignition key on electric start models

8.Before cleaning, repairing, or

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Contents Operator’s Manual Table of Contents Before cleaning, repairing, or Safety Alert SymbolRestrain the tiller SafetyTines/PTO Drive Lever into All controls. Do not attempt toDescriptions are used on the tiller and engine Operating SymbolsVarious symbols shown here, with word Your unit may not have all of the symbolsAttach Handlebar Tools/Materials Needed for AssemblyIntroduction Inspect UnitLeft-Side Clamp Nut AssemblyConnect Wire Harness Move Tiller Off Shipping PlatformRemove the temporary screw J, Figure Check Gear Oil LevelsOil Level Hole Adjust Air Pressure in TiresAttach Engine Throttle Lever and Cable Add Motor Oil to EngineNever bring a gas can near the positive Install Battery CablesConnect the Wire Harness Receptacle To Avoid Personal Injury or Property DamageEngine PTO Attachments FeatureWheels/Tines/PTO Drive Lever Forward Interlock LeversTines/PTO Clutch Lever Features and ControlsHandlebar Height Adjustment Lever Wheel Speed LeverEngine Controls Engine Throttle Lever Keyswitch StarterStarting and Stopping the Engine Following steps describe how to start and stop the enginePre-Start Checklist Break-In OperationOperation Starting the EngineMove engine throttle lever -2 away from Stop Moving the Tiller Forward and Tilling Cold Weather OperationOperating the Tiller Stopping the Engine and TillerMaking Turns Moving the Tiller in ReverseStopping Reverse Motion To Stop the EngineTransporting The Tiller Around Your Property Testing the Forward Interlock Safety SystemHow to Check the Interlock System Loading and Unloading the TillerChanging Belt From LOW Range to High Range Changing Speed BeltsLoading the Tiller Unloading the TillerGo to right side of tiller and finish seating the belt Choosing Wheel Tine SpeedsChanging Belt From High Range to LOW Range Move the Wheels/Tines/PTO Drive Lever into NeutralTo help avoid personal injury, be aware Let the tiller do the workTilling depths Avoid tilling wet, soggy soilTilling up and down slopes Avoid making footprintsSuggested tilling patterns Tilling on slopesTerrace Gardening Clearing the tinesAs you move forward into a row Power CompostingWide-Row Planting Tilling Under CornTo Avoid Personal Injury or Damage to Equipment Removing And Replacing The Tine AttachmentRemoving Tine Attachment Move the tiller to level groundInstalling the Tine Attachment PTO Power Unit Operating InstructionsMove Tines/PTO Clutch Lever -22 into Engage Setting Up Non-Powered Attach- mentsOperating Stationary Attachments Stopping the EngineProcedure EveryHours Maintenance Tighten Bolts and NutsTiller Lubrication Checking Gear Oil Levels Transmission Gear Oil MaintenanceChecking the Power Unit Oil Level Checking for Oil LeaksFor Dipsticks With Hot/Cold Markings Adding or Changing Gear OilChecking the Tine Important TwoAdding Gear Oil to the Tine Attachment Transmission Adding Gear Oil to PTO Power Unit TransmissionReinstall the oil level check plug. Tighten it securely Draining and Filling PTO Power Unit TransmissionBelt Adjustment Tool Drive Belt MaintenanceMeasuring and Adjusting Drive Belt Tension How to Measure Belt TensionPush the belt upward to create slack in the belt Figure Replacing the Drive BeltPlace the Wheels/Tines/PTO Drive Removing the BeltReverse Disc Inspection Reverse Drive System MaintenanceReplacing the Reverse Disc Checking and Adjusting Reverse the Drive SystemInstalling a New Reverse Disc Checking and Adjusting Reverse DiscBolo Tine Maintenance Adjusting Reverse DriveChecking Tines for Wear Replacing Tines Holder Assembly Single Tine ReplacementRemoving and Replacing a Tine Holder Assembly Removing Tine Holder AssemblyThrottle Cable Maintenance Tine Shaft MaintenanceTire and Wheel Maintenance Air Cleaner MaintenanceInspecting Forward Interlock Wiring System Testing the Forward Interlock Wiring SystemStoring Your Tiller Eccentric Troubleshooting ProceduresConnecting Rod LinkageTines Turn, But Wheels Won’t Appendix a TroubleshootingSweep Cultivator OEM-290-260 Wheel Weights OEM-290-266Troy-BiltPTO Log Splitter OEM-290-258 Row Marker Attachment OEM-290-257Part Description Description QTYParts List GW-9119 725-04367 Handlebar Wire Harness AssyGW-9250 Handlebar Switch-forward GW-9548 Bolt-Hex hd., flanged self-locking1900864 710-3005710-04049 712-04065Wheel Speed LEVER, Belt Drive SYSTEM, ENGINES, Wheels Wheel Assemblies Wheel Speed LeverBelt Drive System Engines and Engine MountPower Unit Transmission Assemblies Pinion Shaft Assembly Drive Shaft AssemblyFrom Miscellaneous Parts Transmission HousingTransmission Assembly Part Description QTYParts List Transmission Housing and Dipstick Tiller Drive Shaft AssemblyBolo Tine Assemblies Description QTY Custom Tilling Tines Description QTY Standard Tilling TinesModels E683G & E683F GW-97020 GW-96515 Cable-battery, positive and negativeWashers for cables and wires 736-0119 725-04346 Wire Harness & ConnectingTROY-BILT LLC, P.O. Box 361131, Cleveland, Ohio 44136-0019 TROY-BILT Tiller Lifetime Limited Warranty