Troy-Bilt E683G-Big Red manual

Oper ator’ s Man ual Rear-tine PT O Tiller Models 683F — Horse TM E683F — Horse TM ES E683G — Big Red W arning: This unit is equipped with an internal combustion engine and should not be used on or near any unimprov ed f orest-covered, brush- cov ered or grass-co vered land unless the engine’s exhaust system is equipped with a spark arres[...]

2 For more details about y our unit, visit our website at www .tr o ybilt.com T ABLE OF CONTENTS Content P age Calling Customer Suppor t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Saf ety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

This machine meets voluntary saf et y stand ard B71 .8 – 1996 , which is sponsored b y the Outdoor P o wer Equipment Institute , Inc., and is pub lished b y the American National Standards Institute. The e ngine e xhaust from t his pr oduct c ontain s chemi cals kn own to the St ate of Califo rnia t o cause cance r , bir th defe cts or other repr[...]

S e c t i o n 1 : S a f e t y inspecting, stop the engine and make certain all moving parts have stopped. Disconnect the spark plug wire and prevent it from touching the spark plug to prevent accidental starting. 9. The flap on the tine hood must be down when operating the tiller , unless using the Hiller/Furrower attachment. 10. Never use the till[...]

5 S e c t i o n 1 : S a f e t y Operating Symbols V ar io us sym bo ls (s ho wn her e, wi th wo rd d e s c r i p t i o n s ) a r e u s e d o n t h e t i l l e r a n d e n g i n e . Y o u r u n i t m a y n o t h a v e a l l o f t h e s y m b o l s . SLOW CHOKE ON CHOKE OFF STOP STOP ROT A TING TINES Decals For your safety and the safety of others, v[...]

6 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: Three different Horse model tillers are covered in this Manual. Use only the information applicable to your model. Tiller engines vary by model. Y our engine ma[...]

S e c t i o n 2 : A s s e m b l y 4. Raise handlebars to one of two height settings and tighten the height adjustment lever . Also, make sure all other mounting hardware is securely tightened. NOTE: Fully assembled handlebar assembly should appear as shown in Figure 2-3. STEP 3: Move Tiller Off Shipping Platform 1. Set the Depth Regulator Lever (A,[...]

8 Figure 2-6: Illustration shows the y oke plates (H), nuts, washers, and screws (A, E, B, F , D , G), bushing (C), and long and shor t links (I, J). A I B C H D E F G Figure 2-10 For war d p osit ion; ro ller (T) res ts under the adjustment bloc k (U). U T Figure 2-11: Neutral position; roller (T) rests against middle area of the adjustment bloc k[...]

S e c t i o n 2 : A s s e m b l y 9 IMPORT ANT : Check gear oil level in both transmissions after the first 2 hours of new tiller operation, then ever y 30 operating hours thereafter . See Section 5 for instructions. STEP 7: Add Motor Oil to Engine 1. Before adding motor oil, park the tiller on level ground. Level the engine by placing a sturdy blo[...]

S e c t i o n 2 : A s s e m b l y 10 NOTE: If the battery is put into service after the date shown on the top of the battery , charge for a minimum of one hour at 6-10 amps. Refer to the Maintenence section of this manual for more detailed instructions regarding proper battery charging procedure STEP 1: Connect the Wire Harness Receptacle 1. Before[...]

Section 3 Features and Controls 11 Introduction This section describes the location and function of the controls and features on your tiller . Refer to Section 4, Operation for detailed operating instructions. Practice using these controls, with the engine shut off, until you completely understand the operation of the controls and feel confident wi[...]

S e c t i o n 3 : F e a t u r e s a n d C o n t r o l s Verify Position of Clutch Roller When you shift between FORWARD, NEUTRAL and REVERSE, the clutch roller at the base of the Wheels/Tines/ PTO Drive Lever should be positioned as shown in Figures 3-2, 3-3 and 3-4. Verify the position of the clutch roller as you shift the lever . If it is not pos[...]

Engine Throttle Lever Use the throttle lever (G, Figure 3-1) to adjust engine speed as well as to start and stop the engine. Move the lever away from the STOP position before starting the engine. Engine speeds are variable and range between the F AST and SLOW . Use the STOP position to turn the engine off. NOTE: A secondary throttle lever is locate[...]

Section 4 Operation INTRODUCTION Read this Section of the manual thoroughly before you start the engine. Then, take the time to familiarize yourself with the basic operation of the tiller before using it in your garden. Find an open, level area and practice using the tiller controls without the tines engaging the soil (put tines in T ravel setting?[...]

S e c t i o n 4 : O p e r a t i o n Starting the Engine: 1. With the engine off, place the Wheels/ Tines/PTO Drive Lever (Figure 4-2) in the NEUTRAL position. If in the FORWARD position, tap the lever sharply upward, it should automatically move into NEU TRAL pos itio n. 2. Put the Depth Regulator Lever in the T ravel position (lever all the way do[...]

S e c t i o n 4 : O p e r a t i o n Reconnect the cables and securely tighten to battery posts. The engine will recharge the battery if the batter y is still good. • If you suspect the batter is “dead”, or if the battery is damaged, disconnect, and remove it. Have it checked by a qualified technician. • If battery has been removed, wrap cab[...]

S e c t i o n 4 : O p e r a t i o n 6. When the tiller moves forward, relax and let the wheels power the tiller along while the tines dig. Walk behind and to one side of the tiller . Walk on the side that is not yet tilled (Figure 4-4). Use a firm grip on the handlebars but keep your arm relaxed. IMPORT ANT : Let the tiller move ahead at its own pa[...]

S e c t i o n 4 : O p e r a t i o n 4. When the turn is complete, shift to NEUTRAL and lower the handlebars. Move Tines/PTO Clutch Lever back to ENGAGE position and resume forward operation. T ransporting The Tiller Around Y our Property When the engine is running, the tiller’ s powered wheels make moving the tiller to and from the garden easy . [...]

S e c t i o n 4 : O p e r a t i o n • T urn the vehicle’ s engine off and apply its parking brake. • Position the loading vehicle so that the ramp angle is as flat as possible (the less incline to the ramp, the better) Loading the Tiller 1. Use loading ramps that are strong and wide enough to safely hold the weight of the tiller and the opera[...]

S e c t i o n 4 : O p e r a t i o n 3. Kneel on left side of tiller . T o create belt slack, reach over to right side of the pulleys and push in at the center of the belt with a finger . At the same time, use your left hand to work the belt part-way onto the lower -front transmission pulley groove (Figure 4-10). 4. Go to the other side of the tille[...]

S e c t i o n 4 : O p e r a t i o n SL OW GEA R, LO W B EL T RA NGE Fo r: • Tilling in sod. • Tilling in hard clay . • Tilling under standing corn - stalks in tough soil conditions. • Tilling under cover crops. • Preparing a deep seedbed. • Tilling in stony soil. • Tilling under residues and organic matter . • Mixing in fertilizers,[...]

S e c t i o n 4 : O p e r a t i o n 22 Avoid making footprints Whe n po ssi ble, wa lk o n th e u ntil led sid e of the uni t to av oid maki ng foot pri nts in the fre shl y ti lle d so il ( Fig ure 4-4 ). Foot - pri nts cau se s oil com pact ion tha t c an ham per roo t pe net rati on a nd cont rib ute to soil er osio n. The y ca n a lso “pl ant[...]

23 B. T errace Gardening: • When a slope is too steep or too short for vertical tilling, it may be necessary to till across the slope and create terraced rows. T erraces are rows that are cut into the side of a slope, creating a narrow , but flat area on which to plant. • On a long slope, you can make several terraces, one below the other . •[...]

S e c t i o n 4 : O p e r a t i o n 24 POWER COMPOSTING Power composting means tilling under and burying in the soil all manner of organic matter such as crop residues, leaves, grass clippings and cover crops. This material will decompose during the non-growing season and add important natural nutrients to the soil. Begin by composting crop residue[...]

Y our tiller is a self-contained PTO (Power T ake-Off) Power Unit that was shipped with a tine attachment installed. The tine attachment can be quickly removed and replaced with other optional attachments. The following instructions will familiarize you with your PTO Power Unit. Please read these pages carefully . The following steps explain how to[...]

IMPORT ANT : Store tine attachment in a level, upright position to prevent gear oil from leaking from the dipstick area. 9. T o keep the tine attachment dog clutch coupling clean, cover with the dust cap (on some attachments) or plastic wrap. 10. The PTO Power Unit is now ready to install other powered or non-powered attachments. See the attachment[...]

Setting Up Non-Powered Attach- ments 1. Move the Tines/PTO Clutch Lever (Figure 4-22) to DISENGAGE. 2. Move the Wheel Speed Lever (Figure 4-22) to either SLOW or F AST position T o do this, roll the PTO Power Unit while shifting lever until wheels engage. 3. Verify that the Forward Interlock Wire Harness plug is connected to the recep- tacle. Start[...]

REQUIRED MAINTENANCE SCHEDULE Before Every Ever y Every As PROCEDURE Each 10 25 30 Noted Use Hours Hours Hours Check engine oil level • Every 5 operating hrs. Clean engine cooling system • T est operation of Forward Interlock • Section 4 Safety System Forward Interlock Safety System – • ch eck w ir e c on dit io n, con ne cti on s Check e[...]

Tighten Bolts and Nuts Check for loose or missing hardware every ten (10) operating hours. Failure to tighten or replace fasteners can cause poor performance, equipment damage or oil leakage. See your Parts Catalog for complete fastener descriptions. Most hardware on your tiller is visible. Pay particular attention to hardw are shown in Figu res 5-[...]

S e c t i o n 5 : M a i n t e n a n c e IMPORT ANT : 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. Oi[...]

S e c t i o n 5 : M a i n t e n a n c e 3. If the oil level is correct, oil will seep out of the check hole (allow extra time in cold weather). If it does, the level is fine and you should replace the check plug. If no oil seeps out, see Adding or Changing Gear Oil . Checking the Tine Attachment Oil Level IMPORT ANT : T wo different gear oil checki[...]

S e c t i o n 5 : M a i n t e n a n c e Adding Gear Oil to the PTO Power Unit T ransmission 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 th[...]

S e c t i o n 5 : M a i n t e n a n c e Drive Belt Maintenance Measuring and Adjusting Drive Belt T ension On a new tiller (or if a new belt is installed), the belt tension will probably need to be adjusted after the first two (2) hours of operation. Thereafter , check belt tension every ten (10) operating hours. Maintaining the right tension is im[...]

S e c t i o n 5 : M a i n t e n a n c e 3. Insert the belt adjustment tool through the hole in the side of the adjustment block, spacing the ends of the tool equally on both sides (Figure 5-14). Rotate the tool so the slotted end faces down. 4. Place the Wheels/Tines/PTO Drive Lever in FORWARD position. The arms of the clutch control yoke will be r[...]

S e c t i o n 5 : M a i n t e n a n c e 3. Push belt forward then down until it is looped over the lower pulley (Figure 5-18). Do not yet seat it in either of the lower pulley’ s grooves. HINT : A blunt object, like a ruler , can help you push the belt downward if needed. 4. Move the top half of the belt up and over the rubber reverse disc, but d[...]

Replacing the Reverse Disc Follow these steps to replace the reverse disc. (If your tiller has a Bumper Attach- ment mounted, it must be removed first.) Removing the Reverse Disc 1. Move Wheels/Tines/PTO Drive Lever in NEUTRAL position. 2. Wedge a 5/16"-thick board between top of engine pulley (avoid contacting reverse disc) and cast iron hous[...]

Adjusting Reverse Drive: 1. Place Wheels/Tines/PTO Drive Lever in FORWARD position. 2. On left side of tiller , put a 1/2" wrench on the plunger retaining bolt and another 1/2" wrench on the jam nut next to it (Figure 5-27). While holding the bolt steady , loosen the jam nut (counter clock - wise) until it touches the bolt head. 3. T urn [...]

Single Tine Replacement 1. Move the Wheels/Tines/PTO Drive Lever to NEUTRAL, the Wheel Speed Lever to either F AST or SLOW position, and the Tines/PTO Clutch Lever to ENGAGE. 2. Gently tilt the tiller forward until th e eng ine res ts o n t he g roun d. 3. Rai se t he hood fl ap a t th e b ack of the til ler and tie it up with st ring . 4. Bef ore [...]

Tine Shaft Maintenance After every 10 operating hours, remove the left- and right-side Bolo Tine holders and clear away dirt and debris that have accumulated on the tine shaft or inside the tine holders. Please follow this main- tenance recommendation, as debris can cause premature wear to the tine shaft and its oil seals. Refer to the previous tin[...]

Storing Y our Tiller When your tiller won’t be used during the off-season, prepare it for sto rag e wi th the fol lowi ng step s: 1. Clean the tiller and engine. 2. Do routine tiller lubrication and check for loose hardware. 3. Protect the engine from deterioration or damage by referring to the engine storage instructions in your engine manual li[...]

A p p e n d i x A : T r o u b l e s h o o t i n g T roubleshooting Procedures 1 Wheels/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– ?[...]

• Hardware holding tine holders to tine shaft may be missing or broken. T o check, remove holders (Sect. 5). • Key for bronze worm gear on tine attach- ment main drive shaft may be missing or broken. 5 Tines T urn, But Wheels Won’t: • Check operation of Wheel Speed Lever (Problem 2). • Hi-Pro key inside wheel clutch may be missing, broken[...]

43 T roy-Bilt ® PTO Log Splitter OEM-290-258 The T roy-Bilt ® PTO Log Splitter provides you with a convenient and easy means of splitting about a half a cord of wood per hour when working alone. When connected to the PTO Power Unit, the tiller’ s engine runs the splitter’ s hydraulic pump, providing you with 13 tons of steady , unhurried and [...]

44 REF P ART No. No. DESCRIPTION QTY . REF P ART No. No. DESCRIPTION QTY . 1 647-04006 Lever Assembly–Wheels/Tines/ PTO Drive (Includes Ref. 17) ........ 1 2 1908156 Spring–clutch pawl ....................... 1 3 710-0805 Bolt–hex hd., 5/16-18 x 1-1/2" ...... 3 4 GW-2447 Bushing–3/8" ................................ 3 5 1177548 Lo[...]

FORWARD INTERLOCK SYSTEM REF P ART No. No. DESCRIPTION QTY . 1 725-04368 Engine Wire Harness Assy–forward interlock system (Incl. one red and one black wire, plug con- nector , neutral switch and PVC tubing. Parts not available separately ................................ 1 2 736-0508 Internal L-Washer 9/16" .............. 1 3 725-0157 Tie–[...]

P a r t s L i s t MODELS 683F . E683G & E683F REF P ART No. No. DESCRIPTION QTY . REF P ART No. No. DESCRIPTION QTY . 1 GW-9548 Bolt–Hex hd., flanged self-locking Grade 5, 1/2-13 x 3-1/2" ........... 1 2 GW-9119 Knob–handlebar height adjustment 1 3 GW-9120 Ring–retaining (tolerance ring) ..... 1 4 GW-1881 Stud–handlebar height adju[...]

1 710-3005 Bolt–hex hd., 3/8-16 x 1-1/4" ........ 2 2 GW-1113-1 Bushing–19/64" (.300" lg.) ............ 2 3 710-04049 Bolt–flanged hex, 5/16-18 x 5/8" ... 2 4 712-04065 Nut–hex, 3/8"-16 ........................... 2 5 1900864 Bar–depth regulator ...................... 1 6 GW-9120 Ring–retaining .................[...]

P a r t s L i s t MODELS 683F . E683G & E683F WHEEL SPEED LEVER, BEL T DRIVE SYSTEM, ENGINES, WHEELS See Page 44 See Page 52 48[...]

WHEEL SPEED LEVER 1 GW-9362 Pin–spring, 1/8" ............................... 1 2 GW-9838 Nut–castle (slotted), 1/2"-20 ............ 1 3 GW-9934 Washer–shoulder , 1/2" ..................... 1 4 GW-9932 Washer–disc spring ......................... 2 5 GW-2628 Lever–wheel speed shift .................. 1 6 1902240 Knob–wheel[...]

POWER UNIT TRANSMISSION ASSEMBLIES P a r t s L i s t MODELS 683F . E683G & E683F 50[...]

TRANSMISSION COVER & SHIFT LEVER BRACKET ASSEMBLIES 1 1186299 Bolt–hex hd., #10-32 x 3/8", self-locking flange ..................... 3 2 GW-9463 Knob–tines/PTO clutch lever , tapered, plastic .......................... 1 3 GW-2263 Detent Plate–tines/PTO clutch lever 1 4 777I20945 Decal–operating instructions, detent plate .........[...]

POWER UNIT TRANSMISSION ASSEMBLIES (Continued from page 51) 52 53 P a r t s L i s t MODELS 683F . E683G & E683F[...]

REF P ART No. No. DESCRIPTION QTY . REF P ART No. No. DESCRIPTION QTY . (continued from page 51) WHEEL SHAFT ASSEMBL Y 61 721-04031 Seal–oil, wheel shaft ..................... 2 62 1909950 Retaining ring–external ................. 2 63 GW-1166-1 Shim–wheel shaft, 1-1/64" inner dia., .062" thick .......................... As Req’d [...]

TILLER A TT ACHMENT TRANSMISSION ASSEMBLIES NOTE 1: THESE SCREWS HA VE A SPECIAL SEALING DESIGN THA T CAN NOT BE REUSED WITHOUT RISKING THE LOSS OF TRANSMISSION OIL. IF THESE SCREWS ARE LOOSENED OR REMOVED, THEY MUST BE REPLACED WITH NEW HARDWARE. P a r t s L i s t MODELS 683F . E683G & E683F 54[...]

1 1915068 Screw–self-sealing,1/4"-20 x 5/8" 5 2 GW-20873 Cover–tiller housing ..................... 1 4 711-04082 Shaft–tiller tine ............................. 1 5 741-3037 Ball Bearing ................................... 2 6 1901976 Worm Gear–bronze, tiller tine shaft .......................................... 1 7 GW-1104 Key?[...]

BOLO TINE ASSEMBLIES P a r t s L i s t MODELS 683F . E683G & E683F 56 3 3[...]

ST ANDARD TILLING TINES 1 1901975 Tine Holder–welded steel, fits left or right sides ..................... 2 2 710-3096 Bolt–hex hd., 3/8-16 x 2" ............ 4 3 712-3000 Locknut–hex, 3/8"-16 .................. 20 6 GW-1270-1 Bolo Tine–single, left hand. Tine is stamped either “EL" or “AL". .........................[...]

P a r t s L i s t MODELS E683G & E683F ELECTRIC ST ART SYSTEM 58[...]

MODELS E683G & E683F P a r t s L i s t 1 GW-96515 Cable–batter y , positive and negative terminals ................................. 2 2 GW-97020 Boot–terminal insulating ............. 3 3 710-0599 Screw–TT , 1/4-2 x 1/2" ................ 3 4 1186309 Bolt–hex hd., 1/4-20 x 5/8" ......... 2 5 1901894 Wire–recharge (red) .....[...]

TRO Y -BIL T TILLER LIFETIME LIMITED W ARRANT Y WHA T PRODUC T All T roy-Bilt branded rear tine walk-behind tillers with gear driv e transmissions. IS COVERED This warranty begins on the date of pur chase and is warranted by T r oy-Bilt LL C for the life of the tiller , to the original purchaser only . WHA T IS COVERED Tr oy-Bilt LL C will, at its [...]