Troy-Bilt 683-Horse, Operator'S Manual

Page 1: ...rrester 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 by contacting the service department at Troy Bilt LLC P O Box 361131 Cleveland Ohio 44136 0...

Page 2: ...orized dealer You can locate the model number by looking at the rear surface of the tine shield A sample model plate is shown below For future reference please write down your model and serial number in the space provided below ENGINE INFORMATION The engine manufacturer is responsible for all engine related issues with regards to performance power rating speci fications warranty and service Please...

Page 3: ...he gas cap shall never be removed or fuel added while the engine is running Allow the engine to cool for several minutes before adding fuel c Keep matches cigarettes cigars pipes open flames and sparks away from the fuel tank and fuel container d Fill fuel tank outdoors with extreme care Never fill fuel tank indoors Use a funnel or spout to prevent spillage e Replace all fuel tank and container ca...

Page 4: ... have good footing Never permit the tiller to freewheel down slopes 18 Never allow bystanders near the unit 19 Only use attachments and accessories that are approved by the manufacturer of the tiller 20 Use tiller attachments and accesso ries when recommended 21 Never operate the tiller without good visibility or light 22 Never operate the tiller if you are tired or under the influence of alcohol ...

Page 5: ...ore the tiller with fuel in the fuel tank inside a building where ignition sources are present such as hot water and space heaters furnaces clothes dryers stoves electric motors etc Allow engine to cool before storing in any enclosure 4 To reduce the chances of a fire hazard keep the engine free of grass leaves or excessive grease 5 Store gasoline in a cool well venti lated area safely away from a...

Page 6: ...ad Screw 10 32 x 1 2 The following parts electric start models only packaged separately 2 Nuts 1 4 20 for battery terminals 2 Screws 1 4 20 x 5 8 for battery terminals 2 Keys in ignition switch NOTE LEFT and RIGHT sides of the tiller are as viewed from the opera tor s position behind the handlebars unless otherwise noted Tools Materials Needed for Assembly 1 3 8 open end wrench 2 7 16 open end wre...

Page 7: ...n the bolt Figure 2 2 on the handlebar base and swing the handlebars out to the right side 2 Remove both sets of nuts star washers screws and one bushing A B C D E F G Figure 2 6 from the yoke plates H There is a bushing inside the short link I Be careful not to lose it when removing screw G 3 Slide the plates at the end of the Wheels Tines PTO Lever over the yoke plates Figure 2 9 To aid in the n...

Page 8: ...y forward Install the wider hook end of the clutch pawl spring M Figure 2 8 down into the small hole at the end of the handle Use pliers to insert the other end into the hole in the long link bar N NOTE Do not bend or over stretch the spring while installing 6 Pull the Wheels Tines PTO Lever back to align the forward most holes Q Figure 2 9 in the yoke plate with the holes in the lever plates Also...

Page 9: ...rough the handlebar and the center hole in the throttle lever mounting bracket 3 Loosely install the flanged lock nut and move the throttle lever back to the STOP position 4 From the lever side of the bracket thread a pan head screw B Figure 2 14 through the small hole in the throttle lever bracket and into the handlebar Tighten the screw securely 5 Securely tighten both the flanged lock nut and t...

Page 10: ... cable connector Assembly is complete for electric start tillers See Section 3 Controls for information on tiller controls ASSEMBLING THE ELECTRIC START SYSTEM The following steps explain how to install and charge the battery on electric start tillers For your safety follow all steps and observe all accompanying safety messages Section 5 contains other general battery maintenance and recharging in...

Page 11: ...e the FORWARD setting to move the wheels and tines forward or to apply power to an optional PTO Power Take Off attachment See also Forward Interlock Levers To stop the wheels tines or any PTO attachment move the lever to NEUTRAL by tapping the lever upwards Figure 3 3 and releasing REVERSE is engaged when the lever is pushed with an open palm all the way up and held in that position Figure 3 4 Use...

Page 12: ...r from the transmission PTO clutch to the tines or any PTO attach ment This control has two operating positions ENGAGE and DISENGAGE ENGAGE Lever moved into detent slot farthest from engine Use this position to operate tines or other PTO attachments After shifting to ENGAGE briefly operate machine in FORWARD to help fully engage the PTO clutch DISENGAGE Lever moved into detent slot nearest engine ...

Page 13: ...o your Engine Owner s Manual for detailed information Section 3 Features and Controls The tiller handlebars can be swung out 30 o to the right side for use only with the PTO Chipper Shredder attachment This is done by loosening the mounting bolt on the handlebar base Never operate your tiller or attachments other than the PTO Chipper Shredder with the handle bars in the right side position Doing s...

Page 14: ...rols Sections in this Manual Read the separate Engine Owner s Manual provided by the engine manufacturer 2 Check unit for loose or missing hardware Service as required 3 Check engine oil level See Engine Owner s Manual 4 Shift the Wheels Tines PTO Drive lever Figure 4 2 into NEUTRAL position See Section 3 Controls for more information on this lever 5 Check Safety Guards All guards and covers must ...

Page 15: ...ith an electric start system turn key to START position to crank engine then release when engine starts If the engine does not start right away do not hold key at START for more than a few seconds Release then try again after a short pause Damage to starter motor can occur if it is cranked more than 15 seconds per minute 11 If the engine does not start after a number of tries refer to the Engine O...

Page 16: ...heels Tines PTO Drive Lever is in NEUTRAL Tiller damage may occur 5 To move the tiller forward and engage the tines squeeze and hold either Forward Interlock Lever Figure 4 3 against the handlebar grip then move the Wheels Tines PTO Drive Lever down to FORWARD position To avoid serious personal injury or damage to equipment Always place Wheels Tines PTO Drive Lever in NEUTRAL before starting engin...

Page 17: ...diately The Forward Interlock Levers will not stop REVERSE motion To Stop the Engine Move the engine Throttle Lever to the STOP position Then on electric start models turn key to OFF Remove the key for safekeeping Making Turns Turning the tiller is easy and just requires practice First find the balance point between the engine and the tines by lifting up the handlebars Figure 4 5 Once you find the...

Page 18: ... and hold just one of the Forward Interlock Levers against the handlebar grip while moving the Wheels Tines PTO Drive Lever down to FORWARD Figure 4 3 As the tiller moves forward release the Forward Inter lock Lever briefly The engine should start to stall out if the interlock system is working properly If it does start to stall quickly squeeze the lever up against the handlebar grip and then retu...

Page 19: ...ard Ensure that they move down the center of each ramp Changing Speed Belts Your tiller has two belt driven speed ranges HIGH RANGE and LOW RANGE you pick one or the other by deciding which set of pulley grooves to move the forward belt into By moving the belt from one speed range into the other in combination with the FAST and SLOW wheel speeds you obtain a choice of four different forward wheel ...

Page 20: ...f tiller and finish seating the belt 5 Still holding the lever up in REVERSE position and working from the left side of the tiller move the belt from the lower front transmission groove to the lower rear transmission groove 6 Go to the right side of the tiller and finish seating the belt Figure 4 13 7 Check that the belt is fully seated in the pulley grooves Check this from both sides of the tille...

Page 21: ...ften causing the tiller to skip rapidly across the ground Sometimes slight downward pressure on the handlebars will help get through a particularly tough section of sod or unbroken ground but in most cases this won t be necessary Tilling depths Avoid trying to dig too deeply too quickly especially when busting sod or tilling soil that hasn t been tilled for some time Use shallow depth settings onl...

Page 22: ...gine check every one half hour of operation The incline of the slope will cause the oil to slant away from its normal level and this can starve engine parts of required lubrication Keep the engine oil level at the full point at all times A Tilling up and down slopes To keep soil erosion to a minimum be sure to add enough organic matter to the soil so that it has good moisture holding texture and t...

Page 23: ...eep for safe tilling If possible make terraced rows or till vertically Move the belt into LOW belt range and the Wheel Speed Gear Lever to SLOW position As in terrace gardening start at the top of the slope and overlap the first pass by half the width of the tiller For added stability keep the uphill wheel in the soft newly tilled soil Each succeeding terraced area is started by walking below the ...

Page 24: ...growth down and also holds moisture in the soil And of course harvesting is much easier everything is right at hand to be picked Preparing wide rows is easy after you prepare the seedbed and mark off the rows with string hand broadcast the seeds as if seeding a lawn not quite as much as lawn seed Cover with soil and tamp the area firmly with a hoe Tilling Under Corn After corn is harvested the sta...

Page 25: ...nit will slide out of the guide hole in the tine attachment Figure 4 27 Removing And Replacing The Tine Attachment PTO POWER UNIT Figure 4 21 PTO Power Unit and tine attachment Section 4 Operation TO AVOID PERSONAL INJURY OR DAMAGE TO EQUIPMENT Stop the engine remove the electric start key disconnect the spark plug wire and let the engine and muffler cool before removing or installing any attachme...

Page 26: ...k bolt tightness every 2 1 2 operating hours 6 Remove the engine support before moving the tiller in a forward direction PTO POWER UNIT OPERATING INSTRUCTIONS The following are operating instructions specifically for the PTO Power Unit Read the separate Owner s Manual supplied with each attachment before attempting to assemble attach transport or operate the attachment If needed please contact us ...

Page 27: ... 22 down to FORWARD position do not use REVERSE with sta tionary attachments 3 To stop the PTO Power Unit tap the Wheels Tines PTO Drive Lever upward into NEUTRAL position Operating Non Powered Attachments or to Tow Stationary Attachments 1 To move forward squeeze and hold one Forward Interlock Lever Figure 4 30 up against the handlebars and move the Wheels Tines PTO Drive Lever down to FORWARD 2 ...

Page 28: ...ent air filter More often Check paper element air filter in dusty or dirty areas Check for oil leaks After initial 2 hours Check gear oil level in After initial both transmissions 2 hours Check bolo tines for wear Check reverse disc for wear Check air pressure in tires NOTE All references to left right front and rear of the machine are determined by standing behind the handlebars and facing the di...

Page 29: ...of operation If loose wear can occur on the locating pin on the power unit and cause enlargement of the locating hole in the tine attachment Using a torque wrench tighten these bolts to 70 to 80 ft lbs 6 Check the locknut that fastens the shifting linkage to the eccentric shifting lever D Figure 5 3 Do not tighten the locknut against the eccentric lever It should be very close to but not touching ...

Page 30: ... to determine how much oil has been lost so check the oil levels in the PTO transmission and the tine attachment before using the tiller again Add any necessary gear oil Serious damage to the transmission components can result from operation when gear oil levels are low If tilling during very hot weather the gear oil may heat up and expand inside the transmis sions To allow for this oil expansion ...

Page 31: ...evel ground 2 Pull the Depth Regulator Lever back then push it down all the way to engage its top notch 3 Place a sturdy support under the engine to prevent the tiller from tilting too far 4 Cold reading preferred method Two hours has passed since the tiller was used Place a 2 x 4 board on edge under the drag bar raising the tiller and drag bar about 3 1 2 above ground Hot reading Tiller was opera...

Page 32: ...oil level check hole the right amount of gear oil has been added Replace all plugs Adding Gear Oil to the Tine Attachment Transmission 1 Select the right Depth Regulator Lever setting a If filling an empty transmission raise the Depth Regulator Lever so tines are on the ground b If topping off the gear oil move Depth Regulator Lever down to engage its top notch 2 Remove dipstick from tine attachme...

Page 33: ... in place Figure 5 12 To measure this distance a Without moving the clutch roller try inserting the 1 4 thick slotted end of the belt adjustment tool in between the roller and the upright bracket The flat edge of the tool must be facing the roller Refer to Figure 5 13 b If only the slotted portion of the tool will fit the belt tension is correct c If the slotted part of the tool will not fit in th...

Page 34: ...ck in the belt by reaching over to the left side of the pulleys and pushing in on the center of the belt with your finger 3 Use your right hand to move the belt down and away from the lower pulley in the direction of the engine Figure 5 17 4 Push the belt upward to create slack in the belt Figure 5 18 5 Lift the top half of the belt up and over the upper pulley and the rubber reverse disc moving i...

Page 35: ... and the transmission pulley causes the transmission drive shaft to be powered in a counterclockwise direction as viewed from the operator s position behind handlebars The drive shaft then turns the wheels and tine shafts in a reverse direction Reverse Disc Inspection The reverse disc is made of steel with a special long lasting rubber compound bonded to the disc rim Since this is a wearing part i...

Page 36: ...blems as explained next Checking and Adjusting Reverse Disc 1 Verify that linkages for Wheels Tines PTO Drive Lever are lubricated with oil and engine mount bars and belt adjust ment block are lubricated with grease See Tiller Lubrication in this section 2 Place Wheels Tines PTO Drive Lever in NEUTRAL Briefly pull out engine recoil start rope while watching reverse disc The disc should turn but lo...

Page 37: ...unger retaining bolt steady with a wrench while tightening the jam nut against the side of the plunger housing Figure 5 27 9 Check the action of the reverse disc as explained previously IMPORTANT If the above adjustments have not corrected an improperly working reverse drive contact an authorized dealer or Factory Technical Service Department for assistance Bolo Tine Maintenance Checking Tines for...

Page 38: ...grease pencil to mark them L and R 3 Remove the two bolts and nuts securing each holder Figure 5 33 4 Use a soft mallet to drive the holder off the tine shaft Use a heavy hammer and block of wood to knock off the immo bilized tine holder 5 When the holder is off clean all dirt and debris from the shaft and the holder Apply fresh grease to the tine shaft Replacing Tines Holder Assembly 1 Replace th...

Page 39: ...stalled at all times See the location of the air cleaner assembly on your engine by referring to Figure 5 39 or Figure 5 40 Refer to the engine manufacturer s litera ture supplied with your tiller for complete air cleaner service and maintenance infor mation Throttle Cable Maintenance The throttle lever settings are factory adjusted so unnecessary adjustments should not be made However if the engi...

Page 40: ...rom the tubing over to the switch assembly mounted on top of the tab on the cast iron motor mount belt shroud Also check the second wire that leads to the throttle cable mounting bracket on the right side forward portion of the engine Testing the Forward Interlock Wiring System The wiring circuit for the Forward Interlock Safety System is designed to ground out the engine s ignition system There a...

Page 41: ...rease 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 ge...

Page 42: ...ever not in NEUTRAL position Fuel tank low or empty Dirt or water in fuel or fuel system Fuel line is restricted Choke control not set properly Spark plug worn or fouled weak spark Air cleaner restricted with dirt and or oil Throttle cable adjustment Engine throttle lever not free to move through its full operating range Throttle wire and its linkage are binding or are bent and not free to move Lo...

Page 43: ...crop cultivation Instead of stirring the soil it slices through just below the surface to eliminate practically any weeds in its path The Sweep mounts easily to the optional Tow Hitch Attachment at the rear of the PTO Power Unit The blade is made of high carbon heat treated steel and measures 2 wide overall wing span is 20 The unique way the Sweep works skimming along just underneath the soil s su...

Page 44: ... tooth 5 16 3 6 712 3010 Nut hex 5 16 18 3 7 686 04006 Roller Assembly 1 8 GW 2165 1 Yoke left side 1 9 GW 2165 2 Yoke right side 1 10 GW 2164 Link yoke pivot left right 6 7 8 long 2 11 710 0514 Bolt hex hd 3 8 16 x 1 6 12 736 0169 Lockwasher spring lock 3 8 6 13 736 3050 Washer flat 3 8 S A E 6 15 712 3017 Nut hex 3 8 16 2 16 GW 1113 1 Bushing spacer 19 64 300 6 17 GW 2595 Knob 1 See Page 50 Sect...

Page 45: ...ngine 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 plastic 2 MODELS 683F E683G E683F Parts List 45 See Page 46 ...

Page 46: ...iz lock 1 4 20 1 16 1909286 Throttle Control Cable 66 1 17 777I20946 Decal Forward Interlock Lever 2 18 725 0157 Tie plastic 2 19 GW 9219 Plug wire harness retainer 2 20 725 04367 Handlebar Wire Harness Assy forward interlock system 1 21 GW 9250 Handlebar Switch forward interlock system 2 22 GW 9385 Lock Pin handlebar switch 2 23 GW 2543 Switch Housing handlebar switch 2 GW 2563 Switch Assembly 1 ...

Page 47: ...20 x 1 2 2 10 710 04043 Bolt flanged hex hd 5 16 18 x 3 4 2 12 GW 9929 Washer flat 5 16 2 13 1904563 Hood 1 14 777I22027 Decal hood operating inst LH 1 777S32049 Decal hood operating inst RH 1 15 GW 2525 Bracket 1 16 715 04034 Pin roll spirol 1 4 x 1 1 17 750 04556 Spacer Split 1 18 732 04320 Spring 1 19 710 0597 Bolt hex hd 1 4 20x1 1 20 712 04064 Locknut 1 4 20 1 REF PART No No DESCRIPTION QTY R...

Page 48: ...Parts List MODELS 683F E683G E683F WHEEL SPEED LEVER BELT DRIVE SYSTEM ENGINES WHEELS See Page 44 See Page 52 48 ...

Page 49: ...6 736 04192 Shim engine pulley 1 16 As Req d 26 736 04187 Shim as above 1 32 As Req d 27 GW 9303 Key engine pulley 3 16 sq x 2 1 2 1 ENGINES AND ENGINE MOUNT 28 710 0376 Bolt hex hd 5 16 18 x 1 Grade 5 2 29 712 3010 Nut hex 5 16 18 1 30 GW 1034 Bar engine mounting 2 31 GW 9147 Plug thread protector red plastic 2 32 710 04458 Bolt hex hd 5 16 24 x 1 1 8 4 33 736 0119 Lockwasher spring lock 5 16 4 3...

Page 50: ...POWER UNIT TRANSMISSION ASSEMBLIES Parts List MODELS 683F E683G E683F 50 ...

Page 51: ...T ASSEMBLY 33 716 0101 Retaining Ring external 1 34 1909139 Dog Clutch power unit 1 35 GW 9301 Key 3 16 sq x 1 3 36 1100004 Bolt hex hd 5 16 24 x 3 4 self locking flange Grade 5 1 37 GW 9944 Washer disc spring concave 1 38 GW 2107 Pulley transmission drive cast iron 1 39 GW 50027 Washer flat hardened shoulder 1 1 4 1 40 1186310 Bolt hex hd 1 4 20 x 3 4 front bearing cap 3 42 718 04007 Cap front be...

Page 52: ...POWER UNIT TRANSMISSION ASSEMBLIES Continued from page 51 52 Parts List MODELS 683F E683G E683F ...

Page 53: ... ASSEMBLY 71 1911372 Pin roll 3 16 x 1 1 4 spirol 1 72 619 04000 Lever eccentric wheel speed shifting 1 73 721 04034 Seal oil eccentric shaft 1 74 GW 1442 Pin eccentric shaft wheel speed shifting 1 75 611 04003 Eccentric Shaft wheel speed shifting 1 76 GW 1441 Spring eccentric shaft 1 TRANSMISSION HOUSING 78 GW 2109 Housing power unit transmission Empty housing without covers shafts gears seals et...

Page 54: ...IES NOTE 1 THESE SCREWS HAVE A SPECIAL SEALING DESIGN THAT 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 Parts List MODELS 683F E683G E683F 54 ...

Page 55: ...aring 1 17 GW 1224 1 Shim front bearing cap 010 As thick Req d 17 GW 1224 2 Shim same as above 030 As thick Req d 17 GW 1224 3 Shim same as above 005 As thick Req d 17 GW 1224 4 Shim same as above 062 As thick Req d 18 GW 1714 Bearing Race 2 incl one bearing GW 9400 and one cup race GW 9401 19 GW 2653 Shaft main tiller drive 1 20 721 04030 Seal oil drive shaft front 1 21 GW 9517 Retaining Ring int...

Page 56: ...BOLO TINE ASSEMBLIES Parts List MODELS 683F E683G E683F 56 3 3 ...

Page 57: ...gh chrome carbon alloy tines that are thicker than standard Bolo Tines These tines better resist the abrasive action of rocky gritty or sandy soil as compared to standard Bolo Tines and are especially suited for custom tilling or market gardening GW 10802 Custom Tilling Tine Kit Incl eight each of Part GW 2475 1 and GW 2475 2 tines and sixteen each of Ref No s 8 and 10 1 GW 2475 1 Bolo Tine Custom...

Page 58: ...Parts List MODELS E683G E683F ELECTRIC START SYSTEM 58 ...

Page 59: ...e 1 4 20 x 1 1 4 2 11 1100241 Lockwasher spring lock 1 4 2 12 712 3006 Nut hex 1 4 20 2 13 725 1706A Battery 12 volt 270 CCA 1 14 GW 96514 Solenoid starter includes nuts and washers for cables and wires 1 15 736 0119 Lockwasher 5 16 3 16 1186211 Nut hex 5 16 24 2 17 736 0147 Lockwasher external tooth 10 1 18 GW 9853 Nut hex 10 32 1 19 GW 96510 Cable solenoid to starter motor 1 20 GW 2557 Battery B...

Page 60: ...mmercial institutional industrial rental or demonstrator purposes the COMMERCIAL warranty 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 impropermaintenance vandalism theft fire water ordamagebecauseofperilorothernatural disaster HOW TO OBTAIN Warranty se...