Troy-Bilt E682J-Horse manual Adding Gear Oil to the PTO Power Unit Transmission, Maintenance

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Adding Gear Oil to the

Section 5: Maintenance

Draining and Filling the 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.

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 Interlock wire harness receptacle at the bottom of the handlebars. Set the handlebar base and bolt aside on a clean surface. The bolt hole in the top of the transmission is the gear oil fill hole (A, Figure 5-9).

3.Slowly pour gear oil through a clean funnel into the transmission. Stop when gear oil begins to flow from the oil level check 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 the mounting bolt previously removed. Align the handlebars so they point straight backwards, not at an angle. Then tighten the mounting bolt securely.

6.Reconnect the Forward Interlock wire harness to the receptacle. Be certain it’s secure.

7.Test operation of the Forward Interlock Safety System. See Section 4 for a procedure.

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 (Figure 5-7) with a 3/8" wrench. This vents the transmission for faster oil draining.

A

B

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

3.Using the 3/8" wrench, remove the drain plug (B, Figure 5-9). The gear oil will drain quite slowly since it is thick. After about two quarts have drained, tilt the tiller forward so any oil at the rear of the 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 correct amount of gear oil before operating the tiller again. When oil seeps from the oil level check hole, the right amount of gear oil has been added. Replace all plugs.

Adding Gear Oil to the Tine

Attachment Transmission

1.Select the right Depth Regulator Lever setting:

a.If filling an empty transmission, raise the Depth Regulator Lever so tines are on the ground.

b.If topping off the gear oil, move Depth Regulator Lever down to engage its top 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. Stop when oil reaches “Cold” range marking on dipstick. Replace dipstick securely.

Draining and Filling the Tine

Attachment Transmission

1.The tine attachment transmission is not equipped with an oil drain plug. To drain just a small amount of gear oil, remove the dipstick and tilt the attach- ment forward (first uncoupling it from the Power Unit).

2.For complete drainage, remove the left- side tine assembly (refer to Bolo Tine Maintenance for instructions), then remove just one of the lower screws from the tiller housing cover (Figure 5-10). To speed drainage, remove the tine attach- ment dipstick to vent transmission.

➧

Figure 5-10: Remove housing cover screw to drain tine attachment transmission gear oil.

NOTE: If you find a plastic washer on the cover screw you remove, discard the washer. There is no need to install a replacement washer.

3.Once all gear oil has drained, reinstall the housing cover screw securely (first coat its threads with non-hardening gasket sealant).

4.Be certain to refill the transmission with the correct amount of gear oil before

operating the tiller again.

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Contents IMPORTANTREAD SAFETY RULES AND INSTRUCTIONS CAREFULLY TROY-BILT LLC, P.O. BOX 361131, CLEVELAND, OHPRINTED IN USA FORM NO. 770-10598ATABLE OF CONTENTS ContentFINDING MODEL NUMBER ENGINE INFORMATION1 Safety Safety Alert SymbolSection TrainingAntidotes Section 1 Safetyc. Use slower wheel, tine and engine speeds Maintenance and Storage Operating SymbolsDecals TO AVOID SERIOUS INJURY2 Assembly Tools/Materials Needed for AssemblyLoose Parts List Qty. Description IntroductionSection 2 Assembly AdjustmentWire STEP 4 Connect Forward Interlock Wire HarnessSTEP 6 Check Gear Oil Levels STEP 9 Adjust Air Pressure in Tires STEP 8 Attach Engine Throttle Lever and CableSTEP 7 Add Motor Oil to Engine Oil Level HoleSTEP 2 Install the Battery Cables Battery produces explosive gasesSTEP 1 Connect the Wire Harness Receptacle ASSEMBLING THE ELECTRIC START SYSTEM3 Features and Controls PTO Attachments FeatureG F A B E C D Wheels/Tines/PTO Drive LeverSection 3 Features and Controls Handlebar Height Adjustment LeverWheel Speed Lever Tines/PTO Clutch LeverSection 3 Features and Controls Keyswitch StarterEngine Controls Engine Throttle LeverPre-Start Checklist 4 OperationINTRODUCTION Break-In OperationSection 4 Operation Starting the EngineTo help prevent serious personal injury or damage to equipment Avoid engine muffler and nearbyCold Weather Operation Operating the TillerStopping the Engine and Tiller Moving the Tiller Forward and TillingMoving the Tiller in Reverse Stopping Reverse MotionTo Stop the Engine Making TurnsTesting the Forward Interlock Safety System How to Check the Interlock SystemLoading and Unloading the Tiller Transporting The Tiller Around Your PropertyChanging Speed Belts Loading the TillerUnloading the Tiller Changing Belt From LOW Range to HIGH RangeChoosing Wheel and Tine Speeds Changing Belt From HIGH Range to LOW RangeUse shallow depth regulator settings. Till gradually deeper Tilling Tips & TechniquesTABLE 2-4 WHEEL SPEED AND BELT RANGE SELECTION GUIDE Let the tiller do the workDo not use FAST wheel speed position when on sloped ground Avoid making footprintsSuggested tilling patterns Tilling on slopesClearing the tines B. Terrace GardeningPOWER COMPOSTING Wide-Row PlantingTilling Under Corn Soil Enrichment IdeaPTO POWER UNIT VERY IMPORTANTRemoving And Replacing The Tine Attachment Removing Tine AttachmentPTO POWER UNIT OPERATING INSTRUCTIONS Installing the Tine AttachmentSetting Up Stationary Attachments Guide Pin Mounting HoleSetting Up Non-Powered Attach- ments Starting The EngineOperating Stationary Attachments Stopping the Engine5 Maintenance REQUIRED MAINTENANCE SCHEDULEPROCEDURE EveryTiller Lubrication Section 5 MaintenanceTighten Bolts and Nuts Transmission Gear Oil Maintenance Checking the Power Unit Oil LevelChecking for Oil Leaks Checking Gear Oil LevelsFor Dipsticks With Hot/Cold Markings Adding or Changing Gear OilChecking the Tine Attachment Oil Level Adding Gear Oil to the PTO Power Unit Transmission Draining and Filling the PTO Power Unit TransmissionAdding Gear Oil to the Tine Attachment Transmission Draining and Filling the Tine Attachment TransmissionDrive Belt Maintenance Measuring and Adjusting Drive Belt TensionHow to Measure Belt Tension 5/16 1/4 Belt Adjustment ToolReplacing the Drive Belt Removing the BeltReplacing the Drive Belt Push Belt UPReverse Drive System Maintenance Reverse Disc InspectionChecking and Adjusting Reverse the Drive System Installing a New Reverse DiscChecking and Adjusting Reverse Disc Replacing the Reverse DiscBolo Tine Maintenance Adjusting Reverse DriveAdjustment Bolt Jam Nut Checking Tines for WearSingle Tine Replacement Removing and Replacing A Tine Holder AssemblyRemoving Tine Holder Assembly Replacing Tines Holder AssemblyTine Shaft Maintenance Tire and Wheel MaintenanceAir Cleaner Maintenance Spark Plug MaintenanceStoring Your Tiller Inspecting Forward Interlock Wiring SystemTesting the Forward Interlock Wiring System Appendix A Troubleshooting Troubleshooting ProceduresPROBLEM CHECK OR TESTSee Troubleshooting the Forward Interlock Safety System in Section 5 Tines Turn, But Wheels Won’tAppendix B Attachments & Accessories Wheel WeightsTroy-Bilt PTO Log Splitter Dozer/Snow Blade Attachment6 Parts List WHEELS/TINES/PTO DRIVE LEVER & YOKE ASSEMBLYPART DESCRIPTIONParts List FORWARD INTERLOCK SYSTEMHANDLEBAR ASSEMBLY DEPTH REGULATOR & TINE HOOD ASSEMBLIES WHEEL SPEED LEVER, BELT DRIVE SYSTEM, ENGINES, WHEELS See Page See PageWHEEL SPEED LEVER BELT DRIVE SYSTEMENGINES AND ENGINE MOUNT WHEEL & TIRE ASSEMBLIESPOWER UNIT TRANSMISSION ASSEMBLIES DRIVE SHAFT ASSEMBLY PINION SHAFT ASSEMBLYBRACKET ASSEMBLIES continued on pagePOWER UNIT TRANSMISSION ASSEMBLIES Continued from page MODELS 682J & E682LMISCELLANEOUS PARTS TRANSMISSION HOUSINGTRANSMISSION ASSEMBLY TILLER ATTACHMENT TRANSMISSION ASSEMBLIES NOTE 1 THESE SCREWS HAVE A SPECIAL SEALING DESIGNTHAT CAN NOT BE REUSED WITHOUT RISKING THE LOSS OF TRANSMISSION OIL. IF THESE SCREWSTILLER DRIVE SHAFT ASSEMBLY TRANSMISSION HOUSING AND DIPSTICKBOLO TINE ASSEMBLIES CUSTOM TILLING TINES ELECTRIC START SYSTEM MODEL E682LParts List BUMPER ATTACHMENT Page Page Page TROY-BILT TILLER LIFETIME LIMITED WARRANTY TROY-BILT LLC, P.O. Box 361131, Cleveland, Ohio
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