Troy-Bilt E682J-Horse Appendix A Troubleshooting, Troubleshooting Procedures, Problem, Linkage

Appendix A: Troubleshooting

		PROBLEM
CHECK OR TEST	Engine	Engine shuts off when	Engine does not shut off
(Check or test in sequence shown	won’t start	Wheels/Tines/PTO Drive	when Forward Interlock
		Lever is shifted into	Levers are released while
until problem is resolved.)		FORWARD	Wheels/Tines/PTO Drive
			Lever is in FORWARD
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
FORWARD position
Visually inspect for bare, broken
or disconnected wires	X		X
Check handlebar wire harness	X		X
Check transmission wire harness	X		X

Troubleshooting Procedures

1Wheels/Tines/PTO Drive Lever: A. Lever does not stay in FORWARD–

• Drive belt may be too tight. Raise belt adjustment block a little (Sect. 5).

• Clutch pawl spring at end of lever may be overstretched. Install new spring.

B.Lever hard to shift into REVERSE–

• Check reverse disc for wear (Sect. 5).

• Check adjustment of reverse disc and/or reverse spring and plunger assy. (Sect. 5).

• Clean and re-lubricate motor mount bars, belt adjustment block and linkages on lever (Sect. 5).

C.Tiller stays in REVERSE when lever is released–

• Lubricate motor mount bars, belt adjust- ment block and linkages on lever (Sect. 5).

• Check adjustment of reverse spring and plunger (Sect. 5). If problem persists, contact Technical Service Department.

D.Lever sticks in FORWARD–

•Lubricate motor mount bars, belt adjust- ment block, and linkages on lever (Sect. 5). If problem continues, contact the Technical Service Department.

E. Lever hard to shift into FORWARD–

•Follow advice for Problem 1-D. Also check for possible bent motor mount bar that could be binding in engine mount holes.

2 Wheel Speed Lever:

A.Lever hard to shift, or sticks in FAST or SLOW wheel gear positions–

Linkage

Eccentric

Connecting Rod

Figure 5-43: Check connecting rod, shifting linkage and eccentric lever.

•Lubricate eccentric lever at rear of power unit transmission (Figure 5-43). If rust is present, use penetrating oil and work eccentric lever back and forth by hand.

•Lubricate linkage to Wheel Speed Lever to eccentric lever (Figure 5-43).

•Clutch inside transmission may be binding. Disconnect linkage from eccentric lever and work eccentric lever by hand. If difficult or impossible to move, it may be due to a damaged keyway on the wheel shaft. Contact Technical Service Department.

•Lubricate washers and castle nut on pivot of lever. If necessary, remove roll pin and back nut off 1/6th turn. Replace roll pin and test the movement.

•Apply grease to zerk fitting (if so equipped) with grease gun until grease appears around washers.

B.Lever shifts into FAST wheel gear, but not into SLOW wheel gear–

• Connecting rod at end of lever might be backwards, or bent in toward transmission housing and hitting it. Other shifting linkage might be bent. Straighten or replace linkage (Figure 5-43).

• Clutch inside transmission may be binding (Problem 2-A).

C.Lever moves freely, but won’t shift in or out of gear–

• Eccentric shifting pin inside transmission may be broken (rare) or worn. Disconnect linkage from eccentric lever and try moving eccentric lever by hand (Figure 5-43). If lever moves easily, contact the Technical Service Department.

3 Wheels and Tines Won’t Turn:

•Review operation of controls (Sect. 3 & 4).

•Check condition and adjustment of drive belt and reverse disc (Sect. 5).

•Mounting bolt for transmission drive pulley may be loose. (See Figure 5-1). If so, drive belt or reverse disc will turn pulley, but pulley won’t turn main drive shaft.

•Worm gears that drive wheel and tiller shafts may be worn.

4 Wheels Turn, But Tines Won’t:

•Tines/PTO Clutch Lever must be in ENGAGE position (Sect. 3).

•Tines/PTO Clutch Lever may need adjust- ment.

•Key for dog clutch on tine attachment main drive shaft may be missing, broken.

•Worm gears that drive the tine shaft may be worn.

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