Troy-Bilt E682J-Horse manual Assembly, Introduction, Inspect Unit, Attach Handlebar, Section

Page 6
2Assembly

Section

2Assembly

WARNING

To prevent personal injury or property damage, do not start the engine until all assembly steps are complete and you have read and understand the safety and operating instructions in this manual.

Introduction

Carefully follow these assembly steps to correctly prepare your tiller for use. It is recommended that you read this Section in its entirety before beginning assembly.

NOTE: Various tiller models are presented in this Manual. Use only the information appropriate for your tiller model.

Inspect Unit

Inspect the unit and carton for damage immediately after delivery. Contact the carrier (trucking company) if you find or suspect damage. Inform them of the damage and request instructions for filing a claim. To protect your rights, put your claim in writing and mail a copy to the carrier within 15 days after the unit has been delivered. Contact us at the Factory if you need assistance in this matter.

NOTE: Use the screw length template (Figure 2-1) to identify screws.

Loose Parts List

Qty. Description

1Handlebar Assembly

1Wheels/Tines PTO Drive Lever

The following items are in the hardware bag:

220 oz. Bottles SAE 30W Oil

1Clutch Pawl Spring

1Belt Adjusting Tool

2Plastic Cable Ties

1Curved Head Screw, 1/4-20 x 2

1Flanged Lock Nut, 1/4-20

1Pan Head Screw, #10-32 x 1/2

The following parts (electric start models only), packaged separately.

2Nuts, 1/4-20

(for battery terminals)

2Screws, 1/4-20 x 5/8 (for battery terminals)

2Keys

(in ignition switch)

NOTE: LEFT and RIGHT sides of the tiller are as viewed from the operator’s position behind the han- dlebars (unless otherwise noted).

1

2

Figure 2-1: To identify length of screw, place screw on template as shown and measure distance between bottom of screw head and tip of screw.

STEP 2: Attach Handlebar

IMPORTANT: When disassembling handlebar assembly, keep left-side clamp and ratchet separated from the right-side clamp and ratchet.

1. Disassemble the handlebar assembly.

To do this, remove the height adjustment

lever by turning the lever in a counter-

STEP 1: Unpacking Instructions

NOTE: Do not severely bend any of the control cables on the unit.

1. The tiller is heavy. Do not attempt to remove it from the shipping platform until instructed to do so in these Assembly steps.

2.Remove all unassembled parts from the carton. The hardware bag is included in your literature packaging.

3.Check that you have the items listed below (contact your local dealer or the Factory if any items are missing or damaged).

Tools/Materials Needed for Assembly

(1)3/8" open-end wrench*

(2)7/16" open-end wrench*

(2) 1/2" open-end wrench*

(1) 9/16" open-end wrench*

(1) 3/4" open-end wrench*

(1) Flat blade screwdriver

(1) Scissors (to trim plastic ties)

(1) Tire pressure gauge

(1)4-1/2" high wood block to prop unit * Adjustable wrenches may be used.

clockwise direction (Figure 2-2).

2. Place the handlebar ends on either side

of the base, with the wire harness toward

the rear of the base (Figure 2-2).

3. Install the height adjustment lever

through the right-side clamp, handlebar

end, ratchet, and base; then out through

the left-side ratchet, handlebar end, and

clamp (Figure 2-2). Secure with nut, but

don't fully tighten.

IMPORTANT: Do not force the height adjustment lever through the handlebars. The interlock wires may be blocking the lever and could be damaged. You may gently move the wires aside if this condition occurs.

6

Image 6
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