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

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Appendix A: Troubleshooting

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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Contents TROY-BILT LLC, P.O. BOX 361131, CLEVELAND, OH IMPORTANTREAD SAFETY RULES AND INSTRUCTIONS CAREFULLYPRINTED IN USA FORM NO. 770-10598AContent TABLE OF CONTENTSFINDING MODEL NUMBER ENGINE INFORMATIONSafety Alert Symbol 1 SafetySection TrainingAntidotes Section 1 Safetyc. Use slower wheel, tine and engine speeds Operating Symbols Maintenance and StorageDecals TO AVOID SERIOUS INJURYTools/Materials Needed for Assembly 2 AssemblyLoose Parts List Qty. Description IntroductionAdjustment Section 2 AssemblyWire STEP 4 Connect Forward Interlock Wire HarnessSTEP 6 Check Gear Oil Levels STEP 8 Attach Engine Throttle Lever and Cable STEP 9 Adjust Air Pressure in TiresSTEP 7 Add Motor Oil to Engine Oil Level HoleBattery produces explosive gases STEP 2 Install the Battery CablesSTEP 1 Connect the Wire Harness Receptacle ASSEMBLING THE ELECTRIC START SYSTEMPTO Attachments Feature 3 Features and ControlsG F A B E C D Wheels/Tines/PTO Drive LeverHandlebar Height Adjustment Lever Section 3 Features and ControlsWheel Speed Lever Tines/PTO Clutch LeverKeyswitch Starter Section 3 Features and ControlsEngine Controls Engine Throttle Lever4 Operation Pre-Start ChecklistINTRODUCTION Break-In OperationStarting the Engine Section 4 OperationTo help prevent serious personal injury or damage to equipment Avoid engine muffler and nearbyOperating the Tiller Cold Weather OperationStopping the Engine and Tiller Moving the Tiller Forward and TillingStopping Reverse Motion Moving the Tiller in ReverseTo Stop the Engine Making TurnsHow to Check the Interlock System Testing the Forward Interlock Safety SystemLoading and Unloading the Tiller Transporting The Tiller Around Your PropertyLoading the Tiller Changing Speed BeltsUnloading the Tiller Changing Belt From LOW Range to HIGH RangeChanging Belt From HIGH Range to LOW Range Choosing Wheel and Tine SpeedsTilling Tips & Techniques Use shallow depth regulator settings. Till gradually deeperTABLE 2-4 WHEEL SPEED AND BELT RANGE SELECTION GUIDE Let the tiller do the workAvoid making footprints Do not use FAST wheel speed position when on sloped groundSuggested tilling patterns Tilling on slopesB. Terrace Gardening Clearing the tinesWide-Row Planting POWER COMPOSTINGTilling Under Corn Soil Enrichment IdeaVERY IMPORTANT PTO POWER UNITRemoving And Replacing The Tine Attachment Removing Tine AttachmentInstalling the Tine Attachment PTO POWER UNIT OPERATING INSTRUCTIONSSetting Up Stationary Attachments Guide Pin Mounting HoleStarting The Engine Setting Up Non-Powered Attach- mentsOperating Stationary Attachments Stopping the EngineREQUIRED MAINTENANCE SCHEDULE 5 MaintenancePROCEDURE EveryTiller Lubrication Section 5 MaintenanceTighten Bolts and Nuts Checking the Power Unit Oil Level Transmission Gear Oil MaintenanceChecking for Oil Leaks Checking Gear Oil LevelsFor Dipsticks With Hot/Cold Markings Adding or Changing Gear OilChecking the Tine Attachment Oil Level Draining and Filling the PTO Power Unit Transmission Adding Gear Oil to the PTO Power Unit TransmissionAdding Gear Oil to the Tine Attachment Transmission Draining and Filling the Tine Attachment TransmissionMeasuring and Adjusting Drive Belt Tension Drive Belt MaintenanceHow to Measure Belt Tension 5/16 1/4 Belt Adjustment ToolRemoving the Belt Replacing the Drive BeltReplacing the Drive Belt Push Belt UPReverse Disc Inspection Reverse Drive System MaintenanceInstalling a New Reverse Disc Checking and Adjusting Reverse the Drive SystemChecking and Adjusting Reverse Disc Replacing the Reverse DiscAdjusting Reverse Drive Bolo Tine MaintenanceAdjustment Bolt Jam Nut Checking Tines for WearRemoving and Replacing A Tine Holder Assembly Single Tine ReplacementRemoving Tine Holder Assembly Replacing Tines Holder AssemblyTire and Wheel Maintenance Tine Shaft MaintenanceAir Cleaner Maintenance Spark Plug MaintenanceStoring Your Tiller Inspecting Forward Interlock Wiring SystemTesting the Forward Interlock Wiring System Troubleshooting Procedures Appendix A TroubleshootingPROBLEM CHECK OR TEST5 Tines Turn, But Wheels Won’t See Troubleshooting the Forward Interlock Safety System in SectionWheel Weights Appendix B Attachments & AccessoriesTroy-Bilt PTO Log Splitter Dozer/Snow Blade AttachmentWHEELS/TINES/PTO DRIVE LEVER & YOKE ASSEMBLY 6 Parts ListPART DESCRIPTIONFORWARD INTERLOCK SYSTEM Parts ListHANDLEBAR ASSEMBLY DEPTH REGULATOR & TINE HOOD ASSEMBLIES See Page See Page WHEEL SPEED LEVER, BELT DRIVE SYSTEM, ENGINES, WHEELSBELT DRIVE SYSTEM WHEEL SPEED LEVERENGINES AND ENGINE MOUNT WHEEL & TIRE ASSEMBLIESPOWER UNIT TRANSMISSION ASSEMBLIES PINION SHAFT ASSEMBLY DRIVE SHAFT ASSEMBLYBRACKET ASSEMBLIES continued on pageMODELS 682J & E682L POWER UNIT TRANSMISSION ASSEMBLIES Continued from pageMISCELLANEOUS PARTS TRANSMISSION HOUSINGTRANSMISSION ASSEMBLY NOTE 1 THESE SCREWS HAVE A SPECIAL SEALING DESIGN TILLER ATTACHMENT TRANSMISSION ASSEMBLIESTHAT CAN NOT BE REUSED WITHOUT RISKING THE LOSS OF TRANSMISSION OIL. IF THESE SCREWSTRANSMISSION HOUSING AND DIPSTICK TILLER DRIVE SHAFT ASSEMBLYBOLO TINE ASSEMBLIES CUSTOM TILLING TINES MODEL E682L ELECTRIC START SYSTEMPART BUMPER ATTACHMENT Page Page Page TROY-BILT LLC, P.O. Box 361131, Cleveland, Ohio TROY-BILT TILLER LIFETIME LIMITED WARRANTY