Troy-Bilt 682J-Horse manual Transmission Gear Oil Maintenance, Checking for Oil Leaks, Preparation

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Transmission Gear

Section 5: Maintenance

WARNING

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

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

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 connecting points on the Wheels/Tines/PTO Drive Lever and the Wheel Speed Lever (B, Figure 5-4).

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

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

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

8.Grease the zerk grease fitting located on the pivot point at the end of the Wheel Speed Lever (H, Figure 5-4). If Wheel Speed Lever has a grease fitting on pivot assembly, apply 2-to-3 strokes of multi- purpose grease at beginning and end of tilling season.

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

Transmission Gear

Oil Maintenance

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

Figure 5-6: Oil relief vent locations.

The vents allow small amounts of oil to seep out.

5. Oil the full length of the throttle cable

Checking for Oil Leaks

At 25-hour operation intervals, check the

casing (E, Figure 5-4).

 

 

tiller for oil leaks. Inspect for oil accumu-

6. Oil threads on Handlebar Height Adjust-

lations on the tiller or the floor where it’s

ment Lever (F, Figure 5-4).

 

stored.

 

 

 

 

 

 

A small amount of oil seepage or wetness

 

 

 

 

 

 

around a shaft opening or

 

 

 

 

 

 

cover is no cause for

 

 

 

 

F

 

 

B

 

alarm. But a heavy con-

 

E

 

centration of oil is more

D

C

 

 

serious. You should

 

 

 

 

 

 

 

 

tighten all bolts immedi-

 

 

 

 

 

 

ately, and replace any

 

H

 

G

worn seals or gaskets.

 

 

It may be impossible to

 

 

 

B

 

A

 

 

 

 

determine how much oil

 

 

 

 

 

 

Figure 5-4: Tiller lubrication points

 

has been lost, so check the

(wheel removed for clarity).

 

 

oil levels in the PTO trans-

 

 

 

 

 

 

mission and the tine

 

 

 

 

 

 

attachment before using

 

 

 

 

 

 

the tiller again. Add any

 

 

 

 

 

 

necessary gear oil.

 

 

 

 

 

 

Serious damage to the

 

 

 

 

 

 

transmission components

 

 

 

 

 

 

can result from operation

 

 

I

 

 

 

when gear oil levels are

 

 

 

 

 

 

 

 

 

 

 

 

low.

 

 

 

 

 

 

 

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

If a serious leak is discovered, please contact your authorized dealer or the Factory Technical Service Department for service advice.

Checking Gear Oil Levels

Every 30 hours of operation, check the gear oil level in both the power unit trans- mission and the tine attachment transmis- sion. Operating them while low on gear oil (even briefly) can cause serious damage to internal components.

Preparation

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

2.The power unit transmission and the tine attachment transmission must be connected when checking (or adding) gear oil.

Checking the Power Unit Oil Level

1.Move the tiller to level ground. Move the Depth Regulator up so the tines rest on the ground.

2.Use a 3/8" wrench to remove the oil level check plug on the left side of the

transmission housing (Figure 5-7).

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Contents PRINTED IN USA IMPORTANTREAD SAFETY RULES AND INSTRUCTIONS CAREFULLYTROY-BILT LLC, P.O. BOX 361131, CLEVELAND, OH FORM NO. 770-10598AFINDING MODEL NUMBER TABLE OF CONTENTSContent ENGINE INFORMATIONSection 1 SafetySafety Alert Symbol TrainingSection 1 Safety c. Use slower wheel, tine and engine speedsAntidotes Decals Maintenance and StorageOperating Symbols TO AVOID SERIOUS INJURYLoose Parts List Qty. Description 2 AssemblyTools/Materials Needed for Assembly IntroductionWire Section 2 AssemblyAdjustment STEP 4 Connect Forward Interlock Wire HarnessSTEP 6 Check Gear Oil Levels STEP 7 Add Motor Oil to Engine STEP 9 Adjust Air Pressure in TiresSTEP 8 Attach Engine Throttle Lever and Cable Oil Level HoleSTEP 1 Connect the Wire Harness Receptacle STEP 2 Install the Battery CablesBattery produces explosive gases ASSEMBLING THE ELECTRIC START SYSTEMG F A B E C D 3 Features and ControlsPTO Attachments Feature Wheels/Tines/PTO Drive LeverWheel Speed Lever Section 3 Features and ControlsHandlebar Height Adjustment Lever Tines/PTO Clutch LeverEngine Controls Section 3 Features and ControlsKeyswitch Starter Engine Throttle LeverINTRODUCTION Pre-Start Checklist4 Operation Break-In OperationTo help prevent serious personal injury or damage to equipment Section 4 OperationStarting the Engine Avoid engine muffler and nearbyStopping the Engine and Tiller Cold Weather OperationOperating the Tiller Moving the Tiller Forward and TillingTo Stop the Engine Moving the Tiller in ReverseStopping Reverse Motion Making TurnsLoading and Unloading the Tiller Testing the Forward Interlock Safety SystemHow to Check the Interlock System Transporting The Tiller Around Your PropertyUnloading the Tiller Changing Speed BeltsLoading the Tiller Changing Belt From LOW Range to HIGH RangeChoosing Wheel and Tine Speeds Changing Belt From HIGH Range to LOW RangeTABLE 2-4 WHEEL SPEED AND BELT RANGE SELECTION GUIDE Use shallow depth regulator settings. Till gradually deeperTilling Tips & Techniques Let the tiller do the workSuggested tilling patterns Do not use FAST wheel speed position when on sloped groundAvoid making footprints Tilling on slopesClearing the tines B. Terrace GardeningTilling Under Corn POWER COMPOSTINGWide-Row Planting Soil Enrichment IdeaRemoving And Replacing The Tine Attachment PTO POWER UNITVERY IMPORTANT Removing Tine AttachmentSetting Up Stationary Attachments PTO POWER UNIT OPERATING INSTRUCTIONSInstalling the Tine Attachment Guide Pin Mounting HoleOperating Stationary Attachments Setting Up Non-Powered Attach- mentsStarting The Engine Stopping the EnginePROCEDURE 5 MaintenanceREQUIRED MAINTENANCE SCHEDULE EverySection 5 Maintenance Tighten Bolts and NutsTiller Lubrication Checking for Oil Leaks Transmission Gear Oil MaintenanceChecking the Power Unit Oil Level Checking Gear Oil LevelsAdding or Changing Gear Oil Checking the Tine Attachment Oil LevelFor Dipsticks With Hot/Cold Markings Adding Gear Oil to the Tine Attachment Transmission Adding Gear Oil to the PTO Power Unit TransmissionDraining and Filling the PTO Power Unit Transmission Draining and Filling the Tine Attachment TransmissionHow to Measure Belt Tension Drive Belt MaintenanceMeasuring and Adjusting Drive Belt Tension 5/16 1/4 Belt Adjustment ToolReplacing the Drive Belt Replacing the Drive BeltRemoving the Belt Push Belt UPReverse Drive System Maintenance Reverse Disc InspectionChecking and Adjusting Reverse Disc Checking and Adjusting Reverse the Drive SystemInstalling a New Reverse Disc Replacing the Reverse DiscAdjustment Bolt Jam Nut Bolo Tine MaintenanceAdjusting Reverse Drive Checking Tines for WearRemoving Tine Holder Assembly Single Tine ReplacementRemoving and Replacing A Tine Holder Assembly Replacing Tines Holder AssemblyAir Cleaner Maintenance Tine Shaft MaintenanceTire and Wheel Maintenance Spark Plug MaintenanceInspecting Forward Interlock Wiring System Testing the Forward Interlock Wiring SystemStoring Your Tiller PROBLEM Appendix A TroubleshootingTroubleshooting Procedures CHECK OR TESTSee Troubleshooting the Forward Interlock Safety System in Section 5 Tines Turn, But Wheels Won’tTroy-Bilt PTO Log Splitter Appendix B Attachments & AccessoriesWheel Weights Dozer/Snow Blade AttachmentPART 6 Parts ListWHEELS/TINES/PTO DRIVE LEVER & YOKE ASSEMBLY DESCRIPTIONParts List FORWARD INTERLOCK SYSTEMHANDLEBAR ASSEMBLY DEPTH REGULATOR & TINE HOOD ASSEMBLIES WHEEL SPEED LEVER, BELT DRIVE SYSTEM, ENGINES, WHEELS See Page See PageENGINES AND ENGINE MOUNT WHEEL SPEED LEVERBELT DRIVE SYSTEM WHEEL & TIRE ASSEMBLIESPOWER UNIT TRANSMISSION ASSEMBLIES BRACKET ASSEMBLIES DRIVE SHAFT ASSEMBLYPINION SHAFT ASSEMBLY continued on pagePOWER UNIT TRANSMISSION ASSEMBLIES Continued from page MODELS 682J & E682LTRANSMISSION HOUSING TRANSMISSION ASSEMBLYMISCELLANEOUS PARTS THAT CAN NOT BE REUSED WITHOUT RISKING THE TILLER ATTACHMENT TRANSMISSION ASSEMBLIESNOTE 1 THESE SCREWS HAVE A SPECIAL SEALING DESIGN LOSS OF TRANSMISSION OIL. IF THESE SCREWSTILLER DRIVE SHAFT ASSEMBLY TRANSMISSION HOUSING AND DIPSTICKBOLO TINE ASSEMBLIES CUSTOM TILLING TINES ELECTRIC START SYSTEM MODEL E682LDESCRIPTION BUMPER ATTACHMENT Page Page Page TROY-BILT TILLER LIFETIME LIMITED WARRANTY TROY-BILT LLC, P.O. Box 361131, Cleveland, Ohio