Poulan 163661 User Manual

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OWNER'S MANUAL

MODEL NO. HDR500F

5 HP 17 Inch

Tiller

Assembiy

• Operation ® Customer Responsibilities

• Service and Adjustments

• Storage

• Troubleshooting

• Repair Parts

For Parts and Service, contact our authorized distributor: call 1-800-849-1297

For Technical Assistance; cai! 1 -800-829-5886

Poulan

163661 11.20.97TR PRINTED IN U.S.A.

SAFETY RULES

Safe Operation Practices for Walk-Behind Powered Rotary Tillers

TRAINING

® Read the Owner’s Manual carefully. Be thoroughly

familiar with the controls and the proper use of the equipment. Know how to stop the unit and disengage the controls quickly.

® Never allow children to operate the equipment. Never

allow adults to operate the equipment without proper instruction,

« Keep the area of operation clear of ail persons, particu

larly small children, and pets.

PREPARATION

® Thoroughly inspect the area where the equipment is to

be used and remove all foreign objects.

« Disengage all clutches and shift into neutral before

starting the engine (motor).

» Do not operate the equipment without wearing ad

equate outer garments. Wear footwear that will im prove footing on slippery surfaces.

• Handle fuel with care; it is highly flammable. » Use an approved fuel container, ® Never add fuel to a running engine or hot engine. » Fill fuel tank outdoors with extreme care. Never fill fuel

tank indoors.

» Replace gasoline cap securely and clean up spilled

fuel before restarting,

o Use extension cords and receptacles as specified by

the manufacturer for all units with electric drive motors or electric starting motors.

* Never attempt to make any adjustments while the

engine (motor) is running (except where specifically recommended by manufacturer).

OPERATION

Do not put hands or feet near or under rotating parts. Exercise extreme caution when operating on or cross

ing gravel drives, walks, or roads. Stay alert for hidden

hazards or traffic. Do not carry passengers.

After striking a foreign object, stop the engine (motor),

remove the wire from the spark plug, thoroughly in spect the tiller for any damage, and repair the damage before restarting and operating the tiller.

Exercise caution to avoid slipping or falling.

If the unit should start to vibrate abnormally, stop the engine (motor) and check immediately for the cause. Vibration is generally a warning of trouble.

Stop the engine (motor) when leaving the operating position.

Take all possible precautions when leaving the ma chine unattended. Disengage the tines, shift into neutral, and stop the engine.

Before cleaning, repairing, or inspecting, shut off the engine and make certain all moving parts have stopped.

Disconnect the spark plug wire, and keep the wire away from the plug to prevent accidental starting.

Disconnect the cord on electric motors.

Do not run the engine indoors; exhaust fumes are dangerous.

Never operate the tiller without proper guards, plates, or other safety protective devices in place.

Keep children and pets away. Do not overload the machine capacity by attempting to

till too deep at too fast a rate. Never operate the machine at high speeds on slippery

surfaces. Look behind and use care when backing. Never allow bystanders near the unit. Use only attachments and accessories approved by

the manufacturer of the tiller (such as wheel weights, counterweights, cabs, and the like).

Never operate the tiller without good visibility or light.

Be careful when tilling in hard ground. The tines may catch in the ground and propel the tiller forward. If this occurs, let go of the handlebars and do not restrain the machine.

MAINTENANCE AND STORAGE

« Keep machine, attachments, and accessories in safe

working condition.

« Check shear pins, engine mounting bolts, and other

bolts at frequent intervals for proper tightness to be sure the equipment is in safe working condition.

» Never store the machine with fuel in the fuel tank inside

a building where ignition sources are present, such as hot water and space heaters, clothes dryers, and the like. Allow the engine to cool before storing in any

enclosure.

» Always refer to the operator’s guide instructions for

important details if the tiller is to be stored for an extended period.

- IMPORTANT -

CAUTIONS, IMPORTANTS, AND NOTES ARE A MEANS OF ATTRACTING ATTENTION TO IMPORTANT OR CRITICAL INFORMATION IN THIS MANUAL.

IMPORTANT: USED TO ALERT YOU THAT THERE IS A

POSSIBILITY OF DAMAGING THIS EQUIPMENT.

NOTE: Gives essentia) information that will aid you to

better understand, incorporate, or execute a particular set of instructions.

CONGRATULATIONS on your purchase of a new tiller. It

has been designed, engineered and manufactured to give you the best possible dependability and performance.

PRODUCT SPECIFICATIONS

HORSEPOWER:

5,0 HP

Should you experience any problems you cannot easily remedy, please contact your nearest authorized service center. We have competent, well-trained technicians and the proper tools to service or repair this unit.

Please read and retain this manual. The instructions will enable you to assemble and maintain your tiller properly.

Always observe the “SAFETY RULES”.

MODEL

DISPLACEMENT:

GASOLINE CAPACITY:

OIL (API-SF/SG/SH): (CAPACITY: 20 OZ./0.6L)

12.57 cu. in. (206cc)

3 Quarts (2.8L) Unleaded Regular

SAE 30 (Above 32”F/0“C) SAE 5W-30 (Below 32T/0°C)

NUMBER HDR500F SERIAL

NUMBER

SPARK PLUG: (GAP: .030‘70.76mm) J19LM

Champion

DATE OF PURCHASE

THE MODEL AND SERIAL NUMBERS WILL BE

FOUND ON THE MODEL PLATE ATTACHED TO

THE TOP OF THE TRANSMISSION, YOU SHOULD RECORD BOTH SERIAL NUMBER

AND DATE OF PURCHASE AND KEEP IN A SAFE

PLACE FOR FUTURE REFERENCE.

IMPORTANT: THIS UNIT IS EQUIPPED WITH AN INTERNAL COMBUSTION ENGINE AND SHOULD NOT BE USED ON OR

NEAR ANY UNIMPROVED FOREST-COVERED, BRUSH-COVERED OR GRASS COVERED LAND UNLESS THE ENGINE’S EXHAUST SYSTEM IS EQUIPPED WITH A SPARK ARRESTER MEETING APPLICABLE LOCAL 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, A SPARK ARRESTER IS REQUIRED BY LAW (SECTION 4442 OF THE CALIFORNIA PUBLIC RESOURCES CODE). OTHER STATES MAY HAVE SIMILAR LAWS. FEDERAL LAWS APPLY ON FEDERAL LANDS. SEE YOUR AUTHORIZED SERVICE CENTER FOR SPARK ARRESTER.

CUSTOMER RESPONSIBILITIES

• Read and observe the safety rules. » Followareguiarschedule in maintaining, caringfor and

using your tiller.

» Follow instructions under “Customer Responsibilities”

- and “Storage” sections of this Owner’s Manual.

LIMITED WARRANTY

The Manufacturer warrants to the original consumer purchaser that this product as manufactured is free from defects in materials and workmanship. For a period of two (2) years from date of purchase by the original consumer purchaser, we will repair or replace, at our option, without charge for parts or labor incurred in replacing parts, any part which we find to be defective due to materials or workmanship. This Warranty is subject to the following limitations and exclusions.

1. This warranty does not apply to the engine or components parts thereof. Please refer to the applicable manufacturer's warranty on these items. Transportation charges for the movement of any power equipment unit or attachment are the responsibility of the

purchaser. Transportation charges for any parts submitted for replacement under this warranty must be paid by the purchaser unless such return is requested by American Yard Products. The Warranty period for any products used for rental or commercial purposes is limited to 90 days from the date of

3. original purchase. This Warranty applies only to products which have been properly assembled, adjusted, operated, and maintained in

4. accordance with the instructions furnished, This Warranty does not apply to any product which has been subjected to alteration, misuse, abuse, improper assembly or installation, delivery damage, or to normal wear of the product.

Exclusions: Excluded from this Warranty are belts, tines, tine adapters, normal wear, normal adjustments, standard

hardware and norma! maintenance. In the event you have a claim under this Warranty, you must return the product to an authorized service dealer.

Should you have any unanswered questions concerning this Warranty, please contact;

American Yard Products in Canada contact: Service Department American Yard Products

P.O, Box 1687 1040 Jayson Court Orangeburg.se 29116 USA Mississauga, Ontario

L4VÍ/2V5 giving the model number, serial number and date of purchase of your product and the name and address of the authorized dealer from whom it was purchased,

THIS WARRANTY DOES NOT APPLY TO INCIDENTAL OR CONSEQUENTIAL DAMAGES AND ANY IMPLIED WARRAN TIES ARE LIMITED TO THE SAME TIME PERIODS STATED HEREIN FOR OUR EXPRESSED WARRANTIES. Some areas do not allow the limitation of consequential damages or limitations of how long an implied Warranty may last, so the above limitations or exclusions may not apply to you, This Warranty gives which vary from locale to locale.

This is a limited Warranty within the meaning of that term as defined in the Magnuson-Moss Act of 1975.

yoi. t specific legal rights, and you may have other rights

TABLE OF CONTENTS

SAFETY RULES CUSTOMER RESPONSIBILITIES PRODUCT SPECIFICATIONS

WARRANTY .......................................................................

ASSEMBLY

OPERATION

........

............

.............................................................

............................................................. 8-12

.....

................

......................

....

.................................... 3

......................

.....

3,13-15

....5-7

INDEX

Adjustments:

Depth Stake Handle Height Side Shields Throttle

Tines....................................... 17

V-Be!t (Ground Drive) Wheels

Air Cleaner

................................

..........................

.............................

......................................

..............

...............................

......................................

Belt:

Belt Guard Repair Parts

V-Belt (Ground Drive)............... 16

.................................

..............................

15 10

12,15

16 22

Engine (cont’d)

Fuel:

Finish:

Lubrication

Oil Level................................

Oil Type Spark Plug Starting

Stopping..................................... 9

Storage

Winter Operation.................... 14

Filling Tank Storage

Type......................................... 10

Maintenance

.....................................

...................................

..................................

Cooling System Controls:

Choke

Throttle .......................................8

Tines (Drive Control)

Cultivating .......................................

Customer Responsibilities:

Air Cleaner

Cooling System

Finish........................................ 15

Maintenance Schedule

Muffler

Oil Change................................ 14

Spark Plug

Tines

Transmission

V-Belt (Ground Drive)............... 16

Depth Stake:

Adjustment...................................9

Repair Parts.

Engine:

Air Cleaner................................ 14

Cooling System ....................... 14

Fuel Type

................................

........................................

...................

.............................

......................

............

....................................

...............................

.........................................

............................

.............................

.................................

14 8

14 14

15 17 15

Handle:

Height Adjustment Repair Parts

Lubrication:

Lubrication Chart

Engine.................................... 14

Muffler:

Maintenance

Spark Arrester.............................3

Oil:

Level........................................ 10

Type

....................................

Operation:

Cultivating

Fill Fuel Tank Starting Engine

Stopping Tines & Engine

Tilling...........................................9

Tilling Hints Tine Operation

Transporting Tiller

Winter Operation

. 2

............................

.............................

..............................

MAINTENANCE SCHEDULE... SERVICE & ADJUSTMENTS

STORAGE ..................................................................... .19

TROUBLESHOOTING

REPAIR PARTS-TILLER............................................ 21-27

10,14

.............................

............................

..................

.............................

.....................

IVI

..........................

............................. 12

...........................

..................... 11

..............................

............................

.....................

............

....................

14 10

10,14

10 14

..........................................13

......................................

....

................................................

Repair Parts ..............................

Rules for Safe Operation

Service & Adjustments:

Handle Height

Side Shields

Throttle.....................................

Tines

........................................

V-Belt (Ground Drive) Wheels..

Service:

Repair Parts

Service Record .......................

Shear Pins:

Operation

Repair Parts...........................

Spark Plug:

Gap.............................................. 3

Maintenance .........................

Storage:

Fuel System Tiller..

.............................

............................

.........................

.................................

.............................

........................................

...................

..........................

Tilling

.........................................

Tines:

Arrangement/Replacement Operation

Repair Parts Shear Pins

Transmission:

Maintenance ............................

Repair Parts

Troubleshooting.................................20

Transporting......................................

.....................................

..............................

.................................

...............................

Warranty

Wheels:

.......

....................................

Adjustments................................ 12

Removal......................................15

Repair Parts................................23

...

15-18

..........

12,15

;... 9,11

.......

21-27

15 10 18 17

21-27

19 19

9 26 11

ASSEMBLY

Your new tiller has been assembled at the factory with exception of those parts left unassembled for shipping purposes. To ensure safe and proper operation of your tiller, ail parts and hardware you assemble must be tightened securely. Use the correct tools as necessary to insure proper tightness.

TOOLS REQUIRED FOR ASSEMBLY

A socket wrench set will make assembly easier. Standard wrench sizes are listed.

(1) Utility knife (1) Tire pressure gauge (1) Pair of pliers (1) 9/16” wrench (1) 7/16” wrench

OPERATOR’S POSITION (See Fig. 1)

When right or left hand is mentioned in this manual, it means when you are in the operating position (standing behind tiller handles).

ASSEMBLY

ÜNPACKiNG CARTON (See Fig. 2)

CAUTION: Be careful of exposed

staples when handling or disposing of cartoning materia).

lyPORTANT: WHEN UNPACKiNG AND ASSEMBLiNG TILLER, BE CAREFUL NOT TO STRETCH OR KINK CABLES.

* While holding handle assembly, cuicable ties securing

handle assembly to top frame. Lei handle assembly

rest on tiller. » Remove top frame of carton. " Slowly ease handle assembly up and place on top of

carton.

« Cut down right hand front and right hand rear corners

of carton, lay side carton wall down.

® Remove packing material from handle assembly.

INSTALL HANDLE (See Figs. 3, 4, and 5)

« Insert one handle lock (with teeth facing outward) in

gearcase notch. (Apply grease on smooth side of handle lock to aid in keeping lock in place until handle assembly is lowered into position.)

Grasp handle assembly. Hold in “up” position. Be sure handle lock remains in gearcase notch. Slide handle assembly into position.

Rotate handle assembly down. Insert rear carriage bolt first, with bolt head on L.H. side of tiller and loosely assemble locknut (See Fig. 5).

insert pivot bolt in front part of plate and tighten. Cut down remaining corners of carton and lay panels

flat. Lower the handle assembly. Tighten nut on carriage

bolt bolt so handle moves with some resistance. This will allow for easier adjustment.

Place flat washer on threaded end of handle lock lever. Insert handle lock lever through handle base and

gearcase. Screw in handle lock lever just enough to hold lever in place.

Insert second handle lock (with teeth inward) in the slot of the handle base (just inside of washer).

With handle assembly in lowest position, securely tighten handle lock lever by rotating clockwise. Leav

ing handle assembly in lowest position will make it easier to remove tiller from carton.

ASSEMBLY

ATTACH CLUTCH CABLE (See Fig. 7)

• Hook end of clutch cable through hole in control bar bracket.

REMOVE TILLER FROM CRATE

• Make sure shift lever indicator is in “N” position {See Fig. 6)

• Tilt tilier forward by lifting handle. Separate cardboard cover from leveling shield.

• Rotate tiller handle to the right and pull tiller out of carton.

CHECK TIRE PRESSURE

The tires on your unit were overinflaied at the factory for shipping purposes. Correct and equal tire pressure is

important for best tilling performance.

• Reduce tire pressure to 20 PSI {1.4 kg/cm^).

HANDLE HEIGHT

• Handle height may be adjusted to better suit operator. (See “TO ADJUST HANDLE HEIGHT” in the Service and Adjustments section of this manual).

OPERATION

KNOW YOUR TILLER

READ THIS OWNER'S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR TILLER. Compare the illustrations with your tiller to familiarize yourself with the location of various controls and adjustments. Save

this manual for future reference.

These symbols may appear on your Tiller or in literature supplied with the product. Learn and understand their

meaning.

RUN

mUNG FORWARD NEUTRAL REVERSE CAUTION ENGINE ENGINE

OR WARNING ON OFF

FAST

SLOW CHOKE

FUEL

OIL

STOP

MEETS ANSI SAFETY REQUIREMENTS

Our tillers conform to the safety standards of the American National Standards Institute.

THROTTLE CONTROL - Used to control engine speed.

DRIVE CONTROL BAR - Used to engage tiller. DEPTH STAKE - Controls depth at which tiller will dig. LEVELING SHIELD - Levels tilled soil.

OUTER SIDE SHIELD - Adjustable to protect small plants

from being buried.

SHIFT LEVER - Used to shift transmission gears.

RECOIL STARTER HANDLE - Used to start the engine.

CHOKE CONTROL - Used when starting a cold engine.

OPERATION

The operation of any tiller can result in foreign objects thrown into the eyes, which can result in severe eye damage. Always wear safety glasses or eye shields before starting your tiller and while tilling. We recommend a wide vision safety mask over the spectacles or standard safety glasses.

HOWTO USE YOUR TILLER

Know how to operate all controls before adding fuel and

oil or attempting to start engine.

STOPPING (See Fig. 9)

TINES AND DRIVE

• Release drive control bar to stop movement. “ Move shift lever to “N” (neutral) position.

ENGINE

• Move throttle control to “STOP” position. If equipped with stop switch, move switch to “STOP” position.

• Never use choke to stop engine.

TINE OPERATION - WITH WHEEL DRIVE

• Always release drive control bar before moving shift lever into another position.

• Tine movement is achieved by moving shift leverto (^)

till position and engaging drive control bar.

DEPTH STAKE (See Fig. 10)

The depth stake can be raised or lowered to allow you more versatile tilling and cultivating, or to more easily transport your tiller.

TILLING (See Fig. 11)

• Release depth stake pin. Pull the depth stake up for increased tilling depth. Place depth stake pin in hole of depth stake to lock in position.

• Place shift lever indicator in till position.

• Hold the drive control bar against the handle to start

tilling movement. Tines and wheels will both turn.

• Move throttle control to “FAST” position tor deep tilling.

To cultivate, throttle control can be set at any desired speed, depending on how fast or slow you wish to cultivate,

IMPORTANT: ALWAYS RELEASE DRIVE CONTROL BAR

BEFORE MOVING SHIFT LEVER INTO ANOTHER

POSITION.

FORWARD-WHEELSONLY/TINES STOPPED

“ Release drive control bar and move shift lever indicator

to “F” (forward) position. Engage drive control bar and tiller will move forward.

REVERSE - WHEELS ONLY/TSNES STOPPED

DO NOT STAND DIRECTLY BEHIND TILLER. Release the drive control bar. Move throttle control to “SLOW” position. Move shift lever indicator to “R” (reverse) position. Hold drive control bar against the handle to start tiller

movement.

FIG. 11

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