Troy-Bilt Thoroughbred 654J, Operator'S Manual

Page 1: ...ped with a spark arrester meeting applicable local or state laws if any If a spark arrester is used it should be maintained in effective working order by the operator In the State of California the above is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands A spark arrester for the muffler is available through...

Page 2: ...e of this unit you can seek help from the experts Choose from the options below Visit troy bilt com for many useful suggestions Click on Customer Support button and you will get the four options reproduced here Click on the appropriate button and help is immediately available If you prefer to reach a Customer Support Representative please call 1 800 520 5520 The engine manufacturer is responsible ...

Page 3: ...earing adequate outer garments Avoid loose garments or jewelry that could get caught in moving parts 4 Do not operate the tiller when barefoot or wearing sandals sneakers or light footwear Wear protective footwear that will improve footing on slippery surfaces 5 Do not till near underground electric cables telephone lines pipes or hoses If in doubt contact your telephone or utility company 6 Never...

Page 4: ...approved by Troy Bilt LLC 20 Never operate the tiller without good visibility or light 21 Never operate the tiller if you are tired or under the influence of alcohol drugs or medication 22 Operators shall not tamper with the engine governor settings on the machine the governor controls the maximum safe operating speed to protect the engine and all moving parts from damage caused by overspeed Autho...

Page 5: ...G 4 NEVER ALLOW CHILDREN OR UNINSTRUCTED ADULTS TO OPERATE TILLER 5 SHUT OFF ENGINE BEFORE UNCLOGGING TINES OR MAKING REPAIRS 6 KEEP BYSTANDERS AWAY FROM MACHINE 7 KEEP AWAY FROM ROTATING PARTS 8 USE EXTREME CAUTION WHEN REVERSING OR PULLING THE MACHINE TOWARDS YOU WARNING KEEP AWAY FROM ROTATING TINES ROTATING TINES WILL CAUSE INJURY DEPTH STAKE SHALLOW TRANSPORT POSITION DEEP FINAL TILLING POSIT...

Page 6: ... of the following steps 1 Remove the lower handle hardware two hex screws two lock washers one carriage screw one handle crank from the tiller s frame 2 Position the handle mount bracket over the tiller frame 3 Align the handle mount bracket s rear holes either upper or lower depending on the operator s height with the holes in the tiller frame Insert the carriage bolt through the holes from right...

Page 7: ... plate 6 Insert the ends of the two springs into the holes found in the control levers located on the underside of the handle panel 7 Using a Phillips screwdriver and a 7 16 wrench secure the control box to the underside of the handle panel with the four screws and lock nuts removed earlier 6 7 5 ...

Page 8: ...s a Using a wrench thread the bottom nut upward until the cable is taut b Using a wrench thread the top nut downward to secure the adjuster to the mount bracket Position the shift cable and three other cables against the left handle tube Secure them to the handle with the cable tie provided as shown in the illustration at the top of the page Gas and Oil Fill up Gasoline Service the engine with gas...

Page 9: ...ways bring the tiller to a complete stop prior to moving the shift lever from FORWARD to REVERSE or vice versa IMPORTANT Never force the shift lever Doing so may result in serious damage to the tiller s transmission Wheel Engagement Handle The wheel engagement handle is located below the tiller s upper handle Closing the wheel engagement handle with the wheel shift lever in either FORWARD or REVER...

Page 10: ...oximately six to eight inches depending on soil conditions Tine Engagement Lever The tine engagement lever is located on the left side of the handle panel and has two positions ON and OFF To engage the tines and begin tilling place the lever in the ON position To disengage the tines move the lever into the OFF position NOTE The tIne engagement lever cannot be placed in the ON position without firs...

Page 11: ... the fuel tank with gasoline as instructed in the separate Briggs Stratton Operator Owner Manual packed with your tiller Read instructions carefully WARNING Gasoline is highly flammable and its vapors are explosive Follow gasoline safety rules found on Page 3 in this manual and in the separate Briggs Stratton Operator Owner Manual Failure to follow gasoline safety instructions can result in seriou...

Page 12: ...CRT position or FRT position NOTE Operate the tiller in CRT mode when tilling virgin ground sod or hard soil Operate the tiller in FRT mode when cultivating or tilling soft ground or previously tilled soil b Place the wheel shift lever in the FORWARD position c Close the wheel engagement handle against the handlebar to cause the wheels to drive d Place the tine engagement lever in the ON position ...

Page 13: ... t be necessary With experience you will find the just right tilling depth and tine rotation combination that is best for your garden under specific conditions Operate the tiller in CRT mode when tilling virgin ground sod or hard soil Operate the tiller in FRT mode when cultivating or tilling soft ground or previously tilled soil IMPORTANT When operating the tiller in FRT mode always lower the dep...

Page 14: ...the tiller in reverse for a few feet This reversing action should unwind a good deal of debris It may be necessary to remove the debris by hand a pocket knife will help you to cut away the material WARNING Before clearing the tines by hand stop the engine allow all moving parts to stop Failure to follow this warning could result in personal injury Clearing the Tines Loading and Unloading the Tille...

Page 15: ... and debris to accumulate around the cooling fins of the engine or on any other part of the machine especially around the bottom frame cover under the belt cover around the belts pulleys shifter linkage and other moving parts Remove the belt cover at least once a season and clean any debris away from belts and pulleys Clean around the bottom frame cover and the underside of the tine shield and wit...

Page 16: ...sion and may result in serious damage to the transmission Checking Hardware Check the unit for loose or missing hardware after every 10 operating hours Loose or missing hardware can lead to equipment failure poor performance or oil leaks Be sure to check the three mounting screws located on each of two end caps found at the rear of the transmission See Figure 3 Lift the tine flap to service those ...

Page 17: ...asher and loosening the side screws which secure it 2 To adjust the cable a Loosen the inside hex nut found on the cable adjuster b Loosen the outside hex nut found on the cable adjuster c Grasp the metal cable housing and gently pull outward to take up slack usually no more than 1 4 inch in the cable before retightening both hex nuts loosened earlier Wheel Engagement Cable 1 Adjust the wheel enga...

Page 18: ...can be dangerous by not disengaging completely For a proper working machine always use factory approved belts To replace the belts on your tiller proceed as follows Tine Drive Belts 1 Remove the belt cover by removing the top screw and washer and loosening the side screws which secure it 2 Remove the belt keeper rod by removing the screw and washers which secure it 3 Remove the forward tine belt a...

Page 19: ...ly unhook each cable end 5 Unloop the wheel drive belt from around the engine pulley 6 Unloop the reverse tine belt from the engine pulley NOTE Replace the reverse tine belt first and the forward tine belt second Lastly reattach the wheel drive belt to the engine pulley or proceed by replacing it NOTE To install replacement belts perform steps 1 6 in reverse order 6 5 a b 4 ...

Page 20: ...bottom frame cover and pivot it downward 3 Remove the wheel drive belt from around the lower idler pulley as follows a Loosen but do not remove the hex bolt which secures the lower idler pulley b Unloop the belt from around the lower idler pulley and transmission pulley 4 Remove the wheel drive belt from around the upper idler pulley as follows a Carefully remove the small spring from the upper pu...

Page 21: ... s and bolts that secure each tine to the tine holder NOTE It is recommended that tines be changed one at a time for ease in reassembling 4 Install a replacement tine in the exact orientation as the tine just removed Note the location and orientation of washers were applicable 5 Repeat Steps 1 through 4 above to remove the other tine assembly and individual tines 6 When reinstalling the tine assem...

Page 22: ...lean air cooling area see Engine Owner s Manual 2 Carburetor out of adjustment 2 See Engine Service Dealer 3 Oil level is low 3 Check oil level see Engine Owner s Manual Engine does not shut off 1 Misadjusted throttle control 1 See Engine Owner s Manual or Engine Service Dealer Wheels and Tines will not turn 1 Improper use of controls 1 Review Section 3 and Section 4 2 Worn Broken or misadjusted b...

Page 23: ...89 Screw Shoulder 1 2 Dia x 180 3 8 2 8 742 0305 Tine Articulating 9 618 04120 Transmission Assembly Dual Direction 10 710 1194 Screw Machine 10 24 1 00 Gr5 11 712 0161 Nut Hex Lock 10 24 Gr2 Nylon 12 746 04150 Cable Shift Wheel 13 634 0240 Wheel Complete 14 x 4 5 x 6 RH Gray 14 634 0241 Wheel Complete 14 x 4 5 x 6 LH Gray 15 711 1017 Pin Clevis 250 x 1 53 16 714 0104 Pin Cotter 072 Dia x 1 13 Lg ...

Page 24: ...24 A A B C C D D B 2 2 8 1 13 17 34 17 30 27 19 29 14 14 9 18 11 13 36 3 25 22 38 26 22 12 13 23 20 37 22 13 35 20 5 6 28 15 4 13 26 22 31 32 16 13 13 10 10 Handlebar and Controls ...

Page 25: ...x 05 x 7 4 16 731 04616 Box Control Select Tine 17 731 04644 Block Mounting Bail 18 732 0193 Spring Compression 39x 60 x 88 Lg 19 732 0590A Spring Compression 20 736 0105 Washer Bell 375 x 870 x 063 22 736 3012 Washer Wave 390 x 625 x 016 23 736 3052 Washer Flat 406 x 1 00 x 105 25 738 04072 Screw Shoulder 373 x 830 1 4 20 26 738 04088 Screw Shoulder 373 x 180 x 1 4 20 27 741 0862 Ball Detent 250 ...

Page 26: ...ch Cable Shown for Reference Reverse Tine Clutch Cable Shown for Reference 22 6 20 23 25 21 44 30 33 37 26 39 7 13 44 18 19 21 3 38 41 12 2 18 32 7 1 10 34 28 40 29 36 35 4 23 46 6 23 15 18 49 47 50 45 9 24 51 18 43 48 11 17 14 9 4 31 16 21 5 18 27 38 11 38 11 11 11 42 A B Drive System ...

Page 27: ... 22 736 0452 Washer Bell 396 x 1 140 x 095 23 736 3090 Washer Flat 260 x 720 x 060 24 1918749 Bumper 25 747 04191 Keeper Belt 26 750 04221 Spacer 330 x 1 25 x 1 605 27 750 04223 Spacer 390 x 750 x 812 28 750 04225 Spacer 1 030 x 1 375 x 830 Lg 29 750 04258 Hub Pulley Input 5 8 30 750 04259 Hub Pulley Input 1 2 31 750 04261 Spacer 330 x 1 250 x 845 32 750 0943 Spacer 33 x 1 0 OD 33 754 0346 V belt ...

Page 28: ... 51 16 7 24 Shims used As Required to obtain between 005 and 015 allowable end play If loosened or removed a sealant Loctite Ultra Black Silicone 5900 must be applied to these screws before they can be reused without risking the loss of transmission oil These washers are found only on replacement transmissions Remove and discard the washers when mounting the transmission to the tiller s tine shiel...

Page 29: ...t x 1 500 Bore 37 736 04153 Washer Flat 751 x 975 x 01 38 736 0119 Washer Lock 5 16 Regular Duty 39 736 0492 Washer Flat 760 x 1 500 x 010 40 736 0419 Washer Flat 62 x 1 12 x 03 41 736 3008 Washer Flat 344 x 750 x 120 42 736 04102 Washer Flat 5685 x 875 x 04 43 736 0495 Washer Thrust 1 00 x 632 x 025 44 736 0617 Washer Thrust 750 x 1 250 x 0615 45 737 0356 Grease Seal 46 737 0353 Oil 85w 140 47 74...

Page 30: ...429 Nut Hex Lock 5 16 18 Gr5 Nylon 8 715 0108 Pin Spring 1 4 Dia x 1 00 Lg 9 726 0106 Nut Speed Cap 1 4 Rod 10 736 3089 Washer Flat 345 x 1 00 x 100 11 738 0849 Screw Hex 5 16 18 x 75 12 747 0432 Rod Tiller Flap 13 786 0113 Shield Tine Rear 14 786 04171 Bar Depth 15 786 04172 Bar Drag Depth 16 786 04179 Shield Tine 17 786 04184 Bracket Shield Tine 18 786 04215 Bracket Mounting Bar Depth LH 19 786 ...

Page 31: ...31 NOTES ...

Page 32: ...or commercial institutional industrial rental or demonstrator purposes the warranty COMMERCIAL on the tiller is limited in duration to 90 days from the date of purchase USE WARRANTY This warranty does not apply to parts that have been damaged by accident alteration misuse abuse neglect improper maintenance vandalism theft fire water or damage because of peril or other natural disaster HOW TO OBTAI...