MTD 12211, 12212 User Manual

Models

12211 – Recoil Start 12212 – Electric Start

OWNER’S MANUAL

7HP PONY

REAR-TINE TILLER

•

Safety

•

Assembly

•

Features and Controls

•

Operation

•

Maintenance

•

Parts List

GARDEN WAY INCORPORATED

(Recoil Start Model shown)

SAFETY FIRST!

Before operating this equipment, read this

Owner's Manual and the separate manual

supplied by the engine manufacturer.

Table of Contents

SECTION 1: SAFETY ........................................... 3

Safety Decals .................................................................... 5

SECTION 2: ASSEMBLY ....................................... 6

Attach Handlebars.............................................................. 6

Attach Reverse Clutch Control........................................... 7

Attach Forward Clutch Control Cable................................. 7

Check Transmission Gear Oil Level.................................... 8

Add Motor Oil to Engine..................................................... 8

Attach Wheel Gear Lever.................................................... 9

Check Air Pressure in Tires................................................ 9

Check Hardware for Tightness........................................... 9

Electric Start Assembly Steps............................................ 10

SECTION 3: FEATURES & CONTROLS........................ 13

Engine Controls................................................................. 13

Wheel Gear Lever............................................................... 13

Forward Clutch Control...................................................... 13

Reverse Clutch Control...................................................... 14

Depth Regulator................................................................. 14

Handlebar Height Adjustment............................................ 14

Engine Throttle Control Lever............................................ 15

Electric Start Keyswitch..................................................... 15

SECTION 4: OPERATION ...................................... 16

Starting and Stopping the Engine...................................... 16

Operating the Tiller............................................................ 17

Tilling Tips & Techniques .................................................. 19

Power Composting............................................................ 21

Loading and Unloading the Tiller....................................... 21

SECTION 5: MAINTENANCE .................................. 22

Required Maintenance Schedule........................................ 22

Tiller Lubrication................................................................ 22

Check Hardware................................................................. 23

Check Tire Pressure........................................................... 23

Check for Oil Leaks............................................................ 23

Transmission Gear Oil Service........................................... 23

Engine Oil Service.............................................................. 24

Air Cleaner Service............................................................. 24

Spark Plug Service............................................................. 24

Spark Arrester Screen Service........................................... 24

Engine Cleaning................................................................. 24

Carburetor/Governor Control Adjustments ........................ 24

Throttle Control Adjustment............................................... 24

Wheel Gear Cable Adjustment............................................ 25

Off Season Storage............................................................ 25

Bolo Tines.......................................................................... 25

Checking and Adjusting Tension on the Clutch Belts......... 26

Checking and Adjusting Forward Clutch Belt Tension........ 26

Checking and Adjusting Reverse Clutch Belt Tension........ 27

Forward Clutch Belt Removal/Replacement....................... 27

Reverse Clutch Belt Removal/Replacement ....................... 29

Battery Maintenance.......................................................... 30

TILLER ATTACHMENTS........................................ 31

TROUBLESHOOTING .......................................... 32

PARTS LIST ..................................................... 33

CUSTOMER SERVICE INFORMATION ............BACK COVER

Dear Owner: You now own one of the finest standard-rotating-tine tillers

available. Your new PONY® Model tiller allows you to till and cultivate your garden with ease, and accomplish dozens of other property management projects as well. Your tiller is famous for its ruggedness, performance and high-quality engineering. We know you’ll enjoy using it.

Please carefully read this Manual. It tells you how to safely and easily assemble, operate and maintain your machine.

Be sure that you and any other operators carefully follow the recommended safety practices at all times. Failure to do so could result in personal injury or property damage.

Of course, if you should ever have any problems or questions, please contact your local authorized service dealer or call the factory (see back cover of this Manual).

We want to be sure that you are completely satisfied at all times.

NOTE: Be sure to fill out and return the Warranty Registration Card that was supplied with this Manual.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

WARNING

This machine meets voluntary safety standard B71.8 – 1996, which is sponsored by the Outdoor Power Equipment Institute, Inc., and is published by the American National Standards Institute.

See Back Cover for

Customer Service information

Safety Alert Symbol

This is a safety alert symbol. It is used in this manual and on the unit to alert you to potential hazards. When you see this symbol, read and obey the message that follows it. Failure to obey safety messages could result in personal injury or property damage.

TRAINING

1. Carefully read this Owner’s Manual, the separate Engine Owner’s Manual, and any other literature you may receive. Be thoroughly familiar with the controls and the proper use of the tiller and its engine. Know how to stop the unit and disengage the controls quickly.

2. Never allow children to operate the tiller. Never allow adults to operate the tiller without proper instruction.

3. Keep the area of operation clear of all persons, particularly children and pets.

4. Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people, their property and themselves.

PREPARATION

1. Thoroughly inspect the area where the tiller is to be used and remove all foreign objects.

2. Be sure all controls are released and the Wheel Gear Lever is in ENGAGE before starting the engine.

3. Do not operate the tiller without wearing 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. Warning: Handle fuel with care; it is highly flammable and its vapors are explosive. Take the following precautions:

a. Store fuel in containers specifically

designed for this purpose.

b. The 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

caps securely.

f. If fuel is spilled, do not attempt to

start the engine, but move the machine away from the area of spillage and avoid creating any source of ignition until fuel vapors have dissipated.

7. Never make adjustments when engine is running (unless recommended by manufacturer).

OPERATION

1. Do not put hands or feet near or under rotating parts.

2. Exercise extreme caution when on or crossing gravel drives, walks, or roads. Stay alert for hidden hazards or traffic. Do not carry passengers.

3. After striking a foreign object, stop the engine (and remove the ignition key on electric start models), disconnect the spark plug wire and prevent it from touching the spark plug, carefully inspect the tiller for any damage, and repair the damage before restarting and operating the tiller.

4. Exercise caution to avoid slipping or falling.

5. If the unit should start to vibrate abnormally, stop the engine (and remove the ignition key on electric start models). Disconnect the spark plug wire and prevent it from touching the spark plug, and check immediately for the cause. Vibration is generally a warning of trouble.

6. Stop the engine (and remove the ignition key on electric start models), disconnect the spark plug wire and prevent it from touching the spark plug whenever you leave the operating position, before unclogging the tines, or when making any repairs, adjustments or inspections.

Section

Safety

SPARK ARRESTER WARNING TO RESIDENTS OF CALIFORNIA AND SEVERAL OTHER STATES

Under California law, and under the laws of several other states, you are not permitted to operate an internal combustion engine using hydrocarbon fuels on any forest, brush, hay, grain, or grass covered land; or land covered by any flammable agricultural crop without an engine spark arrester in continuous effective working order.

The engine on the unit is an internal combustion engine which burns gasoline, a hydrocarbon fuel, and must be equipped with a spark arrester muffler in continuous effective working order. The spark arrester must be attached to the engine exhaust system in such a manner that flames or heat from the system will not ignite flammable material. Failure of the owner/operator of the unit to comply with this regulation is a misdemeanor under California law (and other states) and may also be a violation of other state and/or federal regulations, laws, ordinances or codes. Contact your local fire marshal or forest service for specific information about which regulations apply in your area.

7. Take all possible precautions when leaving the machine unattended. Stop the engine. Remove ignition key on electric start models. Disconnect spark plug wire and move it away from the spark plug. Move Wheel Gear Lever to ENGAGE.

8. Before cleaning, repairing, or inspecting, stop the engine, remove the ignition key on electric start models, 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. On electric start models, always remove the cable from the negative side (–) of the battery.

9. Always keep the tiller tine hood flap down, unless using the hiller/furrower attachment.

10. Never use the tiller unless proper guards, plates, or other safety protective devices are in place.

11. Do not run engine in an enclosed area. Engine exhaust contains carbon monoxide gas, a deadly poison that is odorless, colorless, and tasteless.

12. Keep children and pets away.

13. Never operate the tiller under engine power if the Wheel Gear Lever is in DISENGAGE (FREEWHEEL). In this position, the wheels will not hold the tiller back and the revolving tines could propel the tiller rapidly, possibly causing loss of control. Always move the

Wheel Gear Lever to ENGAGE before starting the engine or engaging the tines/wheels with the Forward Clutch Control or the Reverse Clutch Control.

14. Be aware that the tiller may unexpectedly bounce upward or jump forward if the tines should strike extremely hard packed soil, frozen ground, or buried obstacles like large stones, roots, or stumps. If in doubt about the tilling conditions, always use the following operating precautions to assist you in maintaining control of the tiller:

a. Walk behind and to one side of the

tiller, using one hand on the handlebars. Relax your arm, but use a secure hand grip.

b. Use shallower depth regulator set-

tings, working gradually deeper

with each pass. c. Use slower engine speeds. d. Clear the tilling area of all large

stones, roots and other debris. e. Avoid using downward pressure

on handlebars. If need be, use

slight upward pressure to keep the

tines from digging too deeply. f. Before contacting hard packed soil

at the end of a row, reduce engine

speed and lift handlebars to raise

tines out of the soil.

g. In an emergency, stop tines and

wheels by releasing whichever

Clutch Lever is engaged. Do not

attempt to restrain the tiller.

15. Do not overload the tiller’s capacity

by attempting to till too deeply at too fast a rate.

16. Never operate the tiller at high transport speeds on hard or slippery surfaces. Look behind and use care when backing up.

17. Do not operate the tiller on a slope that is too steep for safety. When on slopes, slow down and make sure you have good footing. Never permit the tiller to freewheel down slopes.

18. Never allow bystanders near the unit.

19. Only use attachments and acces-

sories that are approved by the tiller manufacturer.

20. Use tiller attachments and accessories 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, drugs or medication.

23. 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. Authorized service shall be sought if a problem exists.

24. Do not touch engine parts which may be hot from operation. Let parts cool down sufficiently.

25. The battery on electric start model tillers contains sulfuric acid. Avoid contact with skin, eyes, or clothing. Keep out of the reach of children.

Antidote–External Contact: Flush imme- diately with lots of water.

Antidote–Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten eggs or vegetable oil. Call a doctor immediately.

Antidote–Eye Contact: Flush with water for 15 minutes. Get prompt medical

attention.

26. Batteries produce explosive gases. Keep

sparks, flame, and smoking materials away. Ventilate when charging batteries or when using a battery in an enclosed space. ALWAYS wear safety goggles when working near batteries.

27. Please remember: You can always stop the tines and wheels by releasing the Forward Clutch Control Lever or the Reverse Clutch Control knob (whichever control you have engaged), or by moving the Engine Throttle Control Lever (located on engine) to STOP on recoil start models or by turning the ignition key to OFF on electric start models.

28. To load or unload the tiller, see the instructions in Section 4 of this Manual.

29. Use extreme caution when reversing or pulling the machine towards you.

30. Start the engine carefully according to instructions and with feet well away from the tines.

31. Never pick up or carry a machine while the engine is running.

MAINTENANCE AND STORAGE

1. Keep the tiller, attachments and accessories in safe working condition.

2. Check all nuts, bolts, and screws at frequent intervals for proper tightness to be sure the equipment is in safe working condition.

3. Never store 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.

Section 1: Safety

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-ventilated area, safely away from any sparkor flame-producing equipment. Store gasoline in an approved container, safely away from the reach of children.

6. Refer to the Maintenance section of this Manual and in the separate Engine Owner’s Manual for instructions if the tiller is to be stored for an extended period.

7. Never perform maintenance while the engine is running or the spark plug wire is connected, except when specifically instructed to do so.

8. If the fuel tank has to be drained, do this outdoors.

DECALS

For your safety and the safety of others, various safety message decals are on your unit (see Figure below). Keep the decals clean and legible at all times. Contact your local service dealer or the factory for

replacements if any decals are damaged or missing.

Refer to the Parts List pages for decal locations and part numbers.

Figure 1: Location of Safety and Operating Decals

TO AVOID SERIOUS INJURY:

• READ THE OWNER’S MANUAL.

• KNOW LOCATIONS AND FUNCTIONS OF ALL CONTROLS.

• KEEP ALL SAFETY DEVICES AND SHIELDS IN PLACE AND WORKING.

• NEVER ALLOW CHILDREN OR UNINSTRUCTED ADULTS TO OPERATE TILLER.

• SHUT OFF ENGINE AND DISCONNECT SPARK PLUG WIRE BEFORE MANUALLY UNCLOGGING TINES OR MAKING REPAIRS.

• KEEP BYSTANDERS AWAY FROM MACHINE.

• KEEP AWAY FROM ROTATING PARTS.

• USE EXTREME CAUTION WHEN REVERSING OR PULLING THE MACHINE TOWARDS YOU.

WARNING

Keyswitch Warning

(electric start unit only)

Control Descriptions

Starting Stabilization (on top of engine or fuel tank)

Operating Instructions and

Warning Messages

Tine Warning (on right

side of hood flap)

Hot Surfaces/Moving Belts

(on top of belt cover)

Various symbols (shown here, with word descriptions) may be used on the tiller and engine.

Operating Symbols

FAST

SLOW

STOP

START

CHOKE

OFF

REVERSE

ROTATING

TINES

ENGAGED

DISENGAGED

TILLER DIRECTION

LEVER DIRECTION

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.

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.

UNPACKING AND ASSEMBLY INSTRUCTIONS

STEP 1: UNPACKING INSTRUCTIONS

1. Remove any cardboard inserts and

packaging material from the carton. Remove any staples from the bottom of the carton and remove the carton.

2. Cut the large, plastic tie strap that secures the transmission tube to the shipping pallet. Leave the handlebars on top of the tiller to avoid damaging any cables.

3. A bag with loose hardware is inside the literature envelope. Check the contents against the following list and Figure 2-1. Contact your local dealer or the factory if any items are missing or damaged.

NOTE: For electric start units, a second hardware bag is located near the battery.

4. The tiller is heavy. You should not attempt to remove it from the shipping platform until instructed to do so in these “Assembly” steps.

HARDWARE BAG PARTS LIST

Fig. Ref. Qty. Description

1 2 3/8-16 x 1" Hex Hd. Screw 2 1 Keyed Washer 3 1 Wheel Gear Lever Knob

4 1 Height Adjustment Flange

Screw (See Figure 2-1A)

5 2 3/8" Flat Washer 6 2 #10 Lockwasher 7 2 3/8"-16 Nylock Lock Nut 8 2 #10-32 x 1/2" Round Hd.

Screw

9 2 #10-32 Nut 10 1 Cotter Pin (not used) 11 4 Plastic Tie Strap (2 not used)

Tools/Materials Needed for Assembly

(1) 3/8" open-end wrench* (1) 7/16" open-end wrench* (electric

start unit only) (2) 9/16" open-end wrench* (1) 7/8" open-end wrench or 8" long

adjustable wrench (1) Scissors (to trim plastic ties) (1) Ruler (1) Small board (to tap plastic knob on

lever) (1) Tire pressure gauge (1) Clean oil funnel (1) Clean, high-quality motor oil. Refer

to the separate Engine Owner’s Manual for motor oil specifications and quantity required.

* Adjustable wrenches may be used.

IMPORTANT: Motor oil must be added to the engine crankcase before the engine is started. Follow the instructions in this “Assembly” Section and in the separate Engine Owner’s Manual.

NOTE: LEFT and RIGHT sides of the tiller are as viewed from the operator’s position behind the handlebars.

STEP 2: ATTACH HANDLEBARS

1. On electric start units, remove one

screw and lockwasher from the curved height adjustment bracket (A, Figure 2-2), loosen the second screw, and swing the bracket to one side.

2. Cut the large, plastic cable ties that secure the handlebar ends to the handlebar mounting tabs on the transmission top cover.

3. Gently lift handlebar (do not overstretch attached cable) and place handlebar cross-brace (B, Figure 2-3) in front of curved height adjustment bracket (C).

Figure 2-2: On electric start units, move height adjustment bracket aside.

Section

Assembly

Figure 2-1: Loose hardware (shown in reduced size).

Figure 2-1A Handlebar height adjustment uses the flange head screw.

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.

WARNING

Flange

3. With forward clutch cable (N, Figure 2-4) on inside of handlebar, position

handlebar ends on outside of the two mounting tabs (M, Figure 2-3) on transmission top cover.

NOTE: The curved handlebar height adjustment bracket appears as shown in C, Figure 2-3 for non-electric start units. For electric start units, the bracket is loosened and moved to one side.

5. Loosely attach the handlebars to the mounting tabs with two 3/8-16 x 1" screws (heads of screws go to inside of tabs), 3/8" flat washers and 3/8"-16 lock nuts (O, Figure 2-4).

6. On electric start units, reattach the height adjustment bracket (A, Figure 2-2). Tighten both screws securely. Make sure the handlebar cross-brace (B, Figure 2-3) is under the bracket.

7. Move the handlebars up or down to align the threaded hole in the cross-brace with one of the four slots in the curved height adjustment bracket. Place the keyed washer (E, Figure 2-3) on the flange head height adjustment screw (F) with the raised keys (edges) of the washer facing down.

8. Thread the height adjustment screw (F, Figure 2-3) into the hole in the handlebar cross-brace, making sure that the raised keys on the washer fit into the slot on the height adjustment bracket. Tighten the height adjustment screw securely. Next, securely tighten the two screws and nuts in the ends of the handlebar (M, Figure 2-3).

9. To remove the tiller from its shipping platform, first carefully unwrap the wheel gear cable (with attached lever - see Figure 2-5) from around the chassis. Move the Wheel Gear Lever (G) to the DISENGAGE position--this allows the wheels to rotate. Use the handlebars to roll the tiller off the platform. NOTE: The Wheel Gear Lever will be installed later in this procedure.

IMPORTANT: Use the DISENGAGE position only when the engine is not running. Before starting the engine, the Wheel Gear Lever must be placed in the ENGAGE position (see Section 3 for details).

STEP 3: ATTACH REVERSE CLUTCH CONTROL CABLE

1. Carefully unwrap the reverse clutch

control cable (H, Figure 2-6) from its shipping position and route it up along the inside edge of the left side handlebar. A knob and large hex nut (I) is installed on the cable.

2. Insert the cable into the slot in the control panel and fit the threaded assembly into the hole in the slot (see Figure 2-

6). Be sure that the flat side of the threaded assembly is aligned with the flat side of the hole. Slide the hex nut (I) up the cable and tighten it securely.

3. Test the function of the reverse clutch control cable by pulling the knob out and releasing it. The knob should return to its neutral position against the tapered bushing when it is released. If it doesn’t, contact your local dealer or the factory for technical assistance.

STEP 4: ATTACH FORWARD CLUTCH CONTROL CABLE

1. Remove any fasteners (rubber bands,

tape, etc.) that may secure the Forward Clutch Control levers (J, Figure 2-7) to the handlebar.

2. The forward clutch control cable is connected to the right-side handlebar (P, Figure 2-4). Uncoil the cable wire and insert the z-connector (at the end of the spring - R, Figure 2-8) into the hole at the end of the forward clutch control linkage (K, Figure 2-7). You may need to move the spring to a different angle in order to get the z-connector into the hole.

Figure 2-6: Attach reverse clutch control assembly to slotted hole in handlebar panel.

Figure 2-4: Attach handlebars.

Figure 2-5: Carefully unwrap Wheel Gear Lever and move lever to DISENGAGE.

Figure 2-3: Forward clutch control cable not shown for clarity.

Section 2: Assembly

➥

Left Side

Handlebar

Reverse Clutch

Control Knob

Slot in Control Panel

Figure 2-7: Forward Clutch Control levers (J). Forward clutch control linkage (K).

3. The cable is pre-adjusted at the

factory, but must be checked for correct tension as explained next:

The forward clutch spring coil (between points “A” in Figure 2-9) measures 2" in length when neither Forward Clutch Control Lever is pulled up. Lift either Forward Clutch Control Lever up against the handlebar and measure the length of the coil. Tension is correct if the length of the extended coil is 2-1/2" (points A, Figure 2-9). The forward clutch cable needs adjustment if the extended coil length is less than 2-1/2". See Checking

and Adjusting Forward Clutch Belt Tension in Section 5 for a procedure. If

the measurement is greater, there is no need to adjust as long as the unit operates correctly when moving Forward.

STEP 5: CHECK TRANSMISSION GEAR OIL LEVEL

The transmission was filled with gear oil at the factory. However, be sure to check the oil level at this time to make certain it is correct.

IMPORTANT: Do not operate the tiller if the gear oil level is low. Doing so will result in severe damage to the transmission components.

1. With the tiller on level ground, pull the Depth Regulator Lever (L, Figure 2-10) back and then slide it to the second notch from the top. NOTE: If the lever does not move, lift the tine hood flap and look for a plastic tie securing the lever in place. Cut and remove the tie.

2. Remove the oil level check plug (M, Figure 2-11) on the left-side of the transmission. (Due to dried paint on the plug threads, it may require some force to remove the plug the first time.) The gear oil level is correct if oil starts to flow out of the hole as the plug is removed. If so, securely reinstall the plug.

3. If oil does not flow from the check hole, add oil as follows:

NOTE: Do not use automatic transmission fluid or motor oil in the transmission.

(a) Clean area around the fill hole (N,

Figure 2-12) and unscrew gear oil fill plug.

(b) If adding only a few ounces of gear

oil, use API rated GL-4 or GL-5 gear oil having a viscosity of SAE 140, SAE 85W-140 or SAE 80W-90. If refilling an empty transmission, use only GL-4 gear oil having a viscosity of SAE 85W-140 or SAE 140.

oil until it flows from the gear oil level check hole (N, Figure 2-12).

(d) Reinstall and tighten securely the gear

oil fill plug (M, Figure 2-11).

STEP 6: ADD MOTOR OIL TO ENGINE

The tiller is shipped without oil in the engine.

IMPORTANT: Do not start the engine without first adding motor oil. Severe engine damage will result if the engine is run without oil.

1. Refer to the separate Engine Owner’s Manual for motor oil specifications and capacities.

2. With the unit on level ground, move the Depth Regulator Lever (L, Figure 2-

10) up or down until the engine is level.

3. Add motor oil as described in the Engine Owner’s Manual.

4. Move the Depth Regulator Lever all the way down until the highest notch is engaged. This places the tines in the “travel” position.

Figure 2-12: Adding gear oil.

Section 2: Assembly

Figure 2-10: Put lever in second notch.

Figure 2-11: Gear oil level check plug.

Figure 2-9: Adjusting forward clutch control cable.

Figure 2-8: Forward clutch control spring connection to forward control linkage.

Completed

Connection

STEP 7: ATTACH WHEEL GEAR LEVER

1. Insert the Wheel Gear Lever (P, Figure

2-13) up through the slot in the control panel that is labeled “WHEEL GEAR.”

2. Insert two #10-32 x 1/2" round head screws down through the “+” marks on the control panel decal and securely attach the wheel gear mounting bracket using two #10 lockwashers and #10-32 nuts.

3. Using a board, tap the Wheel Gear Lever knob securely onto the lever.

4. Secure the wheel gear cable and the reverse clutch control cable to the leftside handlebar with two plastic ties (S, Figure 2-14) located about two feet apart. Snip off any excess tie length with scissors.

STEP 8: CHECK AIR PRESSURE IN TIRES

Use a tire pressure gauge to check the air pressure in both tires. Deflate or inflate both tires equally to 15-to-20 PSI (pounds per square inch). Be sure that both tires are inflated equally or the unit will pull to one side.

STEP 9: CHECK HARDWARE FOR TIGHTNESS

Inspect the hardware on the unit and tighten any loose screws, bolts and nuts.

IMPORTANT:

• This completes the assembly steps for the standard (recoil) start tiller. Be sure to read the rest of this Manual, and the separate Engine Owner’s Manual, before you operate your tiller.

• If you have an electric start model, continue with the following electric start assembly steps.

Figure 2-14: Attach wheel gear cable and reverse clutch cable with cable ties (S).

Figure 2-13: Attach Wheel Gear Lever.

Section 2: Assembly

Electric Start

Assembly Steps

The following steps explain how to prepare and install the battery. FOR YOUR SAFETY, CAREFULLY FOLLOW ALL STEPS AND OBSERVE ALL ACCOMPANYING SAFETY MESSAGES. Before beginning, check that you have received the following items (see Figure 2-16):

1. Battery (installed on tiller)

2. Clear plastic vent tube

3. Two hex screws and hex nuts

STEP 1: Battery Activation and Charging

The battery is shipped dry. It must be filled with battery electrolyte (battery grade sulfuric acid) and fully charged before it can be used.

Adding electrolyte and charging the battery can be dangerous. The electrolyte contains acid that can burn or blind you. Battery charging produces potentially explosive gases.

It is strongly recommended that you have the battery serviced by a trained professional (your authorized tiller dealer, a reliable service station, a battery store, etc.). Do not attempt to activate and charge the battery unless you are fully experienced in battery activation and charging procedures.

To ensure that the battery is properly activated and charged, you should review the activating and charging instructions with your battery technician.

A. To Activate the Battery:

1. Remove the battery from the tiller by

removing the screws, lockwashers and nuts from the battery hold-down clamp.

2. Place battery on a level surface, safely away from any spark- or flame-producing sources such as stoves, heaters, electrical switches, pilot lights, dryers, etc.

3. Remove and discard the short sealing tube (if so equipped) that covers the vent fitting located on the negative (-) side of the top of the battery.

4. Remove the six filler caps from the top of the battery. Leave the caps off while activating and charging the battery.

5. Put on protective clothing, rubber gloves and eye protection. For best results, the temperature of the battery and electrolyte should be between 60oF to 80o F. Carefully fill each of the six cells with electrolyte (battery grade sulfuric acid with a specific gravity of 1.265) up to the UPPER LEVEL line printed on the battery. Do not add water or any other liquid during this initial activation.

6. Allow battery to stand for 30 minutes and then recheck the electrolyte level in each cell. Add more electrolyte solution if needed. Do not overfill the battery as this could result in flooding from the cells during charging.

Figure 2-16

Remove metal jewelry before working near the battery or near the electrical system.

Failure to comply may cause a short circuit, resulting in electrical burns, electrical shock, or an explosion of battery gases.

WARNING

Battery electrolyte is a sulfuric acid solution that is poisonous and causes severe burns.

• Avoid spills or contact with skin, eyes, clothing.

• To prevent accidents, wear protective clothes, rubber gloves and shield eyes with safety goggles when working on or near the battery.

• Neutralize acid spills with a baking soda and water solution. Neutralize electrolyte container with same solution. Then rinse with clear water.

ANTIDOTE: External – Flush with water. Eyes – Flush with water for 15 minutes and get immediate medical attention.

ANTIDOTE: Internal – Drink a large quantity of water or milk. Follow with milk of magnesia, beaten eggs, or vegetable oil. Call physician immediately.

DANGER

Section 2: Assembly

B. To Charge the Battery:

To obtain maximum battery life, charge the battery using the following method until all cells are gassing freely. A battery is gassing freely when the surface of the electrolyte is covered with tiny bubbles.

Be sure to follow all instructions provided by the manufacturer of the battery charging unit that is being used to charge the battery.

1. Charge the battery approximately three to five hours at a rate of 1-to-2 amperes. Turn the battery charger off and disconnect the charger cables from the battery terminals.

2. Check the electrolyte level in each cell. If the electrolyte level has fallen, refill the battery with distilled water until the level reaches the UPPER LEVEL line.

3. Securely replace all six filler caps. Use a baking soda and water solution to rinse of any electrolyte that may have spilled. Then dry the battery.

STEP 2: Install Battery

1. Reinstall the battery on the battery mounting base with the two cable mounting posts facing to the rear of the tiller. Be sure that the positive (+) post is on the left-side of the tiller and the negative (-) post is on the right-side (as viewed from rear of tiller). See Figure 2-17.

2. Reinstall the battery hold-down bracket over the battery with the ignition switch (T, Figure 2-17) toward the front of the unit. Attach the bracket to the mounting base using the two 1/4-20 x 11/4" carriage screws (insert screws up from beneath mounting base), 1/4" lockwashers and 1/4"-20 nuts removed previously. Tighten the nuts securely, but not so much as to bend the tabs on the holddown bracket.

STEP 3: Attach Battery Cables and Vent Tube

1. Locate the positive battery cable, which is connected to the starter solenoid on the left-side of the battery post (a rubber boot covers the connection). A second rubber boot is loosely installed on the cable. Using the small screw and nut from the hardware bag, connect the loose end of the cable to the positive (+) post on the battery. See Figure 2-18.

2. Slide the rubber boot over the positive (+) battery post.

3. The negative battery cable is connected to the upper mounting screw that attaches the starter solenoid to the back of the battery post. This is the ground for the negative cable. Using the second screw and nut, attach the loose end of the cable to the negative (-) battery post. See Figure 2-19.

Batteries produce explosive gases!

• Keep sparks, flame and cigarettes away.

• Ventilate area when charging or using battery in an enclosed space.

• Make sure venting path of battery is always open once battery is filled with acid.

• Follow safety rules and instructions supplied by manufacturers of battery and charger unit.

• During charging, do not leave battery unattended. Charging time need not be continuous.

• When checking the battery for gassing, always wear safety goggles and use a flashlight to look down into the cells.

DANGER

• Do not touch positive (+) battery terminal and any surrounding metal with tools, jewelry or other metal objects. Failure to comply could cause a short circuit that could cause electrical burns or an explosion of battery gases.

• Incorrect installation of the battery can result in electrical system damage. Follow installation instructions carefully to avoid damage.

DANGER

Figure 2-17: Attach hold-down clamp.

(+)

(–)

Figure 2-18: Attach positive (+) battery cable. Cover connection with rubber boot.

Rubber Boot

Figure 2-19: Attach negative (-) battery cable.

Section 2: Assembly

4. Check the tightness of the upper

mounting screw that secures the negative cable and starter solenoid to the battery post. See Figure 2-20. Scrape away any paint between the cable and the screw as the paint can prevent a good electrical ground.

5. Install one end of the clear plastic vent tube over the vent fitting (U, Figure 2-21) on the battery. Insert the other end down into the vent tube shield (V).

STEP 4: Connect Wiring Harness

Attach the wiring harness receptacle to the prongs on the back of the ignition switch (see Figure 2-22).

IMPORTANT: This completes the assembly steps for the electric start tiller. Be sure to read the rest of this Manual, and the separate Engine Owner’s Manual, before you operate your tiller.

Figure 2-20: Check tightness of upper mounting screw.

Figure 2-21: Install vent tube.

Figure 2-22: Attach wiring harness to keyswitch.

Keyswitch

Wiring Harness

Improper venting can cause a battery to explode, resulting in severe personal injury or property damage.

Be sure that the vent tube does not become kinked, folded or pinched along its entire length.

WARNING

Before operating your machine, carefully read and understand all safety, controls and operating instructions in this Manual, the separate Engine Owner’s Manual, and on the decals on the machine.

Failure to follow these instructions can result in serious personal injury.

WARNING

INTRODUCTION

This Section describes the location and function of the controls on your tiller. Refer to the following section “Operation” for detailed operating instructions.

Practice using these controls, with the engine shut off, until you understand the operation of the controls and feel confident with each of them.

IMPORTANT: Refer to the separate engine manufacturer’s Engine Owner’s Manual for information about the controls on the engine.

ENGINE CONTROLS

Refer to the engine manufacturer's Engine Owner’s Manual (included in the tiller literature package) to identify the controls on your engine.

IMPORTANT: The control for stopping the engine is located on the engine.

WHEEL GEAR LEVER

This lever (A, Figure 3-1) has two positions: ENGAGE and DISENGAGE.

In the ENGAGE position, the wheels will start turning when either the Forward Clutch Control or the Reverse Clutch Control is engaged (the tines will also start turning when either clutch is engaged).

The DISENGAGE position places the wheels in the freewheeling mode to allow the unit to be moved without the engine running. Use the DISENGAGE position only when the engine is not running. See “DANGER” statement that follows.

To shift to ENGAGE, gently (do not force) move the lever forward while also rolling the tiller a few inches forward or backward. Moving the tiller helps to align the shift mechanism with the transmission wheel drive gears.

To shift to DISENGAGE (freewheel), move the lever rearward, without rolling the tiller. The wheels will roll freely when the lever is properly set in the DISENGAGE position.

FORWARD CLUTCH CONTROL

The two interconnected levers (B, Figure 3-1) control the engagement of forward drive to the wheels and tines.

To Operate the Forward Clutch Control:

1. Before engaging the Forward Clutch

Control, put the Wheel Gear Lever in the ENGAGE position (see “WARNING” below).

2. Pull up and hold one or both of the levers against the handlebar grips to engage the wheels and tines.

3. Release BOTH levers to disengage (stop) the wheels and tines. All forward motion will stop (the engine will continue to run).

Section

Features and Controls

Figure 3-1: Controls located on handlebar.

Never place the Wheel Gear Lever in DISENGAGE (Freewheel) when the engine is running.

Having the Wheel Gear Lever in DISENGAGE and then engaging the tines/wheels with either the Forward Clutch Control or the Reverse Clutch Control could allow the tines to propel the tiller rapidly forward or backward.

Failure to follow this instruction could result in personal injury or property damage.

DANGER

Never engage the wheels and tines with the Forward Clutch Control or the Reverse Clutch Control unless the Wheel Gear Lever is in ENGAGE.

Engaging the Forward Clutch Control or the Reverse Clutch Control when the wheels are not engaged could allow the tines to rapidly propel the tiller forward or backward.

Failure to follow this warning could result in personal injury or property damage.

WARNING

REVERSE CLUTCH CONTROL

The Reverse Clutch Control (C, Figure 3-

1) controls the engagement of reverse drive to the wheels and tines. The revers-

ing feature is used for maneuvering the tiller only – never engage the tines in the ground while going in the reverse direction.

To Operate the Reverse Clutch Control:

1. Put the Wheel Gear Lever in the

ENGAGE position (see the “WARNING” statement on previous page).

2. Stop all tiller motion by releasing the Forward Clutch Control levers.

3. Lift up the handlebars until the tines clear the ground, look behind you to avoid any obstacles, and then pull the Reverse Clutch Control knob out. The tines and wheels will rotate in a reverse direction.

4. Release the Reverse Clutch Control knob to disengage (stop) the wheels and tines. All reverse motion will stop (the engine will continue to run).

DEPTH REGULATOR

This lever (D, Figure 3-2) controls the tilling depth of the tines. Pull the lever straight back and slide it up or down to engage the notched height settings.

The highest notch (lever all the way down) raises the tines approximately 1-1/2 inches off the ground. This “travel” position allows the tiller to be moved without the tines digging into the ground.

Moving the lever up increases the tilling depth. The lowest notch allows a tilling depth of approximately six to eight inches, depending on soil conditions.

For best results, always begin tilling at a very shallow depth setting and gradually increase the tilling depth. Complete

details on using the Depth Regulator are found in the “Operation” Section of this manual.

HANDLEBAR HEIGHT ADJUSTMENT

The handlebar height is adjustable to four different settings. Set the handlebar height to a comfortable setting, but keep in mind that the handlebars will be lower when the tines are engaged in the soil.

To Adjust the Handlebar Height:

1. Stop the engine, wait for all parts to

stop moving and then disconnect the spark plug wire. Remove the ignition key on electric start models.

2. Loosen the two screws at the lower ends of the handlebar.

3. Loosen the height adjustment screw (E, Figure 3-3) and pull the keyed washer (F) free of the slots in the curved height adjustment bracket.

4. Move the handlebars to the new slot setting and insert the raised keys on the keyed washer into the slot. Tighten the height adjustment screw securely.

5. Retighten the two screws at the ends of the handlebar.

Figure 3-3: Handlebar height adjustment.

Figure 3-2: Depth Regulator Lever.

Section 3: Features and Controls

• Use extreme caution when reversing or pulling the machine towards you. Look behind to avoid obstacles.

• Never attempt to till in reverse.

Failure to follow this warning could result in personal injury or property damage.

WARNING

• Do not attempt to till too deeply too quickly. Gradually work down to deeper tilling depths.

• Place the Depth Regulator Lever in the “travel” position before starting the

engine. This position prevents the tines from touching the ground until you are ready to begin tilling.

Failure to follow this warning could result in personal injury or property damage.

WARNING

Section 3: Features and Controls

ENGINE CONTROLS

Refer to the engine manufacturer’s Engine Owner’s Manual (included in the tiller literature package) to identify the controls on your engine. The following two controls are used when stopping or starting the engine.

ENGINE THROTTLE CONTROL LEVER

The Engine Throttle Control Lever (located on engine--see Figure 4-1) is used to regulate the engine speed. On the recoil start model only, it is also used to stop the engine (on the electric start model, the electric start keyswitch is used to stop the engine). The throttle settings are shown below.

IMPORTANT: See “Starting and Stopping the Engine” in the “Operation” Section for detailed engine starting and stopping instructions.

FAST - Use for most tilling and cultivating projects.

SLOW - Use when idling engine or when slower tilling and cultivating speeds are needed.

STOP - Stops the engine (on recoil start models only).

ELECTRIC START KEYSWITCH (ELECTRIC START MODEL)

The ignition keyswitch on the electric start model (H, Figure 3-5) is used to start and stop the engine. The keyswitch settings are described below.

IMPORTANT: See “Starting and Stopping the Engine” in the “Operation” Section for detailed engine starting and stopping instructions.

OFF - Stops engine. RUN - After starting, key returns to run

position. START - Starts engine. Release key when

engine starts (avoid cranking engine for longer than 15 seconds at a time).

Figure 3-5: Electric start keyswitch.

STOP

+ 33 hidden pages