Troy-Bilt Pro-Line User Manual

Safe Operation Practices • Set-Up • Operation • Maintenance • Service • Troubleshooting • Warranty

Operator’s Manual

Rear Tine Tiller — Pro Line

WARNING

READ AND FOLLOW ALL SAFETY RULES AND INSTRUCTIONS IN THIS MANUAL

BEFORE ATTEMPTING TO OPERATE THIS MACHINE.

FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.

TROY-BILT LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019

Printed In USA	Form No. 769-03523
	(November 26, 2007)

To The Owner

Thank You

Thank you for purchasing a Garden Tiller manufactured by Troy-Bilt LLC. It was carefully engineered to provide excellent performance when properly operated and maintained.

Please read this entire manual prior to operating the equipment. It instructs you how to safely and easily set up, operate and maintain your machine. Please be sure that you, and any other persons who will operate the machine, carefully follow the recommended safety practices at all times. Failure to do so could result in personal injury or property damage.

All information in this manual is relative to the most recent product information available at the time of printing. Review this manual frequently to familiarize yourself with the machine, its features and operation. Please be aware that this Operator’s Manual may cover a range of product specifications for various models. Characteristics and features discussed and/or illustrated in this manual may not be applicable to all models. Troy-Bilt LLC reserves the right to change product specifications, designs and equipment without notice and without incurring obligation.

1

This product has met the rigid safety standards of the Outdoor Power Equipment Institute and an independent testing laboratory. If you have any problems or questions concerning the machine, phone a authorized Troy-Bilt service dealer or contact us directly. Troy-Bilt’s Customer Support telephone numbers, website address and mailing address can be found on this page. We want to ensure your complete satisfaction at all times.

Throughout this manual, all references to right and left side of the machine are observed from the operating position

The engine manufacturer is responsible for all engine-related issues with regards to performance, power-rating, specifications, warranty and service. Please refer to the engine manufacturer’s Owner’s/Operator’s Manual, packed separately with your machine, for more information.

Table of Contents

Safe Operation Practices	......................................... 3	Maintenance & Adjustment	..................................17
Assembly & Set-Up...................................................	6	Service.....................................................................	22
Controls....................................................................	10	Troubleshooting.....................................................	26
Operation................................................................	11	Replacement Parts.................................................	27

Record Product Information

Model Number

Before setting up and operating your new equipment, please

locate the model plate on the equipment and record the

information in the provided area to the right. You can locate the

model plate by standing at the operator’s position and looking

Serial Number

down at the front, right corner of the tine shield. This information

will be necessary, should you seek technical support via our web

site, Customer Support Department, or with a local authorized

service dealer.

Customer Support

Please do NOT return the machine to the retailer or dealer without first contacting our Customer Support Department.

If you have difficulty assembling this product or have any questions regarding the controls, operation, or maintenance of this machine, you can seek help from the experts. Choose from the options below:

◊Visit us on the web at www.troybilt.com

◊Call a Customer Support Representative at [phone] or [phone]

◊Write us at Troy-Bilt LLC • P.O. Box 361131 • Cleveland, OH • 44136-0019

Important Safe Operation Practices	2

WARNING! This symbol points out important safety instructions which, if not followed, could endanger the personal safety and/or property of yourself and others. Read and follow all instructions in this manual before attempting to operate this machine. Failure to comply with these instructions may result in personal injury.

When you see this symbol. HEED ITS WARNING!

California Proposition 65

WARNING! Engine Exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to State of California to cause cancer and birth defects or other reproductive harm.

WARNING! Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling

DANGER! This machine was built to be operated according to the safe operation practices in this manual. As with any type of power equipment, carelessness or error on the part of the operator can result in serious injury. This machine is capable of amputating fingers, hands, toes and feet. Failure to observe the following safety instructions could result in serious injury or death.

Training

1.Read, understand, and follow all instructions on the machine and in the manual(s) before attempting to assemble and operate. Keep this manual in a safe place for future and regular reference and for ordering replacement parts.

2.Be familiar with all controls and their proper operation. Know how to stop the machine and disengage them quickly.

3.Never allow children under 14 years of age to operate this machine. Children 14 and over should read and understand the instructions and safe operation practices in this manual and on the machine and be trained and supervised by an adult.

4.Never allow adults to operate this machine without proper instruction.

5.Keep the area of operation clear of all persons, particularly small children and pets. Stop machine if anyone enters the area.

Preparation

1.Thoroughly inspect the area where the equipment is to be used. Remove all stones, sticks, wire, and other foreign objects which could be tripped over and cause personal injury.

2.Wear sturdy, rough-soled work shoes and close fitting slacks and shirt. Loose fitting clothes or jewelry can be caught in moving parts. Never operate this machine in bare feet or sandals.

3.Disengage clutch levers and shift (if provided) into neutral (“N”) before starting the engine.

4.Never leave this machine unattended with the engine running.

5.Never attempt to make any adjustments while engine is running, except where specifically recommended in the operator’s manual.

Safe Handling of Gasoline:

To avoid personal injury or property damage use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive. Serious personal injury can occur when gasoline is spilled on yourself or your clothes which can ignite. Wash your skin and change clothes immediately.

a.Use only an approved gasoline container.

b.Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before filling.

c.When practical, remove gas-powered equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment on a trailer with a portable container, rather than from a gasoline dispenser nozzle.

d.Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device.

e.Extinguish all cigarettes, cigars, pipes and other sources of ignition.

f.Never fuel machine indoors.

g.Never remove gas cap or add fuel while the engine is hot or running. Allow engine to cool at least two minutes before refueling.

h.Never over fill fuel tank. Fill tank to no more than ½ inch below bottom of filler neck to allow space for fuel expansion.

i.Replace gasoline cap and tighten securely.

j.If gasoline is spilled, wipe it off the engine and equipment. Move unit to another area. Wait 5 minutes before starting the engine.

k.To reduce fire hazards, keep machine free of grass, leaves, or other debris build-up. Clean up oil or fuel spillage and remove any fuel soaked debris.

l.Never store the machine or fuel container inside where there is an open flame, spark or pilot light as on a water heater, space heater, furnace, clothes dryer or other gas appliances.

Operation

1.Do not put hands or feet near rotating parts. Contact with the rotating parts can amputate hands and feet.

2.Do not operate machine while under the influence of alcohol or drugs.

3.Never operate this machine without good visibility or light. Always be sure of your footing and keep a firm hold on the handles.

4.Keep bystanders away from the machine while it is in operation. Stop the machine if anyone enters the area.

5.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 handle bars and do not restrain the machine.

6.Exercise extreme caution when operating on or crossing gravel surfaces. Stay alert for hidden hazards or traffic. Do not carry passengers.

7.Never operate the machine at high transport speeds on hard or slippery surfaces.

8.Exercise caution to avoid slipping or falling.

9.Look down and behind and use care when in reverse or pulling machine towards you.

10.Start the engine according to the instructions found in this manual and keep feet well away from the tines at all times.

11.After striking a foreign object, stop the engine, disconnect the spark plug wire and ground against the engine. Thoroughly inspect the machine for any damage. Repair the damage before starting and operating.

12.Disengage all clutch levers (if fitted) and stop engine before you leave the operating position (behind the handles). Wait until the tines come to a complete stop before unclogging the tines, making any adjustments, or inspections.

13.Never run an engine indoors or in a poorly ventilated area. Engine exhaust contains carbon monoxide, an odorless and deadly gas.

14.Muffler and engine become hot and can cause a burn. Do not touch.

15.Use caution when tilling near fences, buildings and underground utilities. Rotating tines can cause property damage or personal injury.

16.Do not overload machine capacity by attempting to till soil too deep at too fast of a rate.

17.If the machine should start making an unusual noise or vibration, stop the engine, disconnect the spark plug wire and ground it against the engine. Inspect thoroughly for damage. Repair any damage before starting and operating.

18.Keep all shields, guards, and safety devices in place and operating properly.

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

20.Use only attachments and accessories approved by the manufacturer. Failure to do so can result in personal injury.

21.If situations occur which are not covered in this manual, use care and good judgement. Contact Customer Support for assistance and the name of you nearest servicing dealer..

Maintenance & Storage

1.Keep machine, attachments and accessories in safe working order.

2.Allow a machine to cool at least five minutes before storing. Never tamper with safety devices. Check their proper operation regularly.

3.Check bolts and screws for proper tightness at frequent intervals to keep the machine in safe working condition. Also, visually inspect machine for any damage.

4.Before cleaning, repairing, or inspecting, stop the engine and make certain the tines and all moving parts have stopped. Disconnect the spark plug wire and ground it against the engine to prevent unintended starting.

5.Do not change the engine governor settings or over-speed the engine. The governor controls the maximum safe operating speed of engine.

6.Maintain or replace safety and instruction labels, as necessary.

7.Follow this manual for safe loading, unloading, transporting, and storage of this machine.

8.Always refer to the operator’s manual for important details if the machine is to be stored for an extended period.

Section 2 — Important Safe Operation Practices

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

10.Observe proper disposal laws and regulations for gas, oil, etc. to protect the environment.

Notice Regarding Emissions

Engines which are certified to comply with California and federal EPA emission regulations for SORE (Small Off Road Equipment) are certified to operate on regular unleaded gasoline, and

may include the following emission control systems: Engine Modification (EM) and Three Way Catalyst (TWC) if so equipped.

Spark Arrestor

Warning! This machine is equipped with an internal combustion engine and should not be used on or near any unimproved forest-covered, brushcovered or grass-covered land unless the engine’s exhaust system is equipped 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 your nearest engine authorized service dealer or contact the service department, P.O. Box 361131 Cleveland, Ohio 44136-0019.

Average Useful Life

According to the Consumer Products Safety Commission (CPSC) and the U.S. Environmental Protection Agency (EPA), this product has an Average Useful Life of seven (7) years, or 130 hours of operation. At the end of the Average Useful Life, buy

a new machine or have the machine inspected annually by an authorized service dealer to ensure that all mechanical and safety systems are working properly and not worn excessively. Failure to do so can result in accidents, injuries or death.

warning! Your Responsibility—Restrict the use of this power machine to persons who read, understand and follow the warnings and instructions in this manual and on the machine.

SAVE THESE INSTRUCTIONS!

Section 2 — Important Safe Operation Practices

Assembly & Set-Up	3
Contents of Carton

•	One Tiller	•	One Handlebar Support	•	One Handlebar Assembly
•	One Hardware Pack	•	One Operator’s Manual	•	One Engine Operator’s Manual

warning! 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.

Recommended Tools for Assembly

•3⁄8” open-end wrench

•9⁄16” open-end wrench

•7⁄8” open-end wrench

•Scissors (to trim plastic ties)

•Ruler

•Small board (to tap plastic knob on lever)

•Tire pressure gauge

•Clean oil funnel

•Clean, high-quality motor oil. Refer to the separate Engine Operator’s Manual for motor oil specifications and quantity.

Contents of Hardware pack

•3⁄8-16 x 1” Hex Hd. Screw (2)

•Keyed Washer (1)

•Wheel Gear Lever Knob (1)

•Height Adjustment Flange Screw (1)

•3⁄8” Flat Washer (2)

•#10 Lockwasher (2)

•3⁄8”-16 Nylock Lock Nut (2)

•#10-32 x 1⁄2” Round Hd. Screw (2)

•#10-32 Nut (2)

•Cotter Pin (1)

•Cable Tie (4)

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

Handle

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

2.Gently lift the handlebar (do not overstretch the attached cable) and place the handlebar cross-brace in front of the curved height adjustment bracket. See Fig. 3-1.

Keyed

Washer

Mounting

Tabs

	Adjustment
	Screw
Height Adjustment
Bracket	Handlebar Cross Brace
	Figure 3-1

Assembly

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.The hardware pack is is inside the literature envelope. Check the contents with the list above.

4.With the forward clutch cable on the inside of the handlebar, See Fig, 3-2, position the handlebar ends on the outside of the two mounting tabs shown in Fig. 3-1 on the transmission top cover.

9.To remove the tiller from its shipping platform, first carefully unwrap the wheel gear cable with the attached lever from around the chassis. Move the Wheel Gear Lever to the DISENGAGE position, this allows the wheels to rotate freely. See Fig. 3-3. Use the handlebars to roll the tiller off the platform.

Mounting Tabs

Wheel

Gear

Level

Forward

Clutch Lock Nuts

Cable

Figure 3-2

NOTE: The curved handlebar height adjustment bracket appears as shown in Fig. 3-1.

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. See Fig. 3-2.

6.Tighten both screws securely. Make sure the handlebar cross-brace is under the bracket.

7.Move the handlebars up or down to align the threaded hole in the crossbrace with one of the four slots in the curved height adjustment bracket. Place the keyed washer on the flange head height adjustment screw with the raised edges of the washer facing down. See Fig. 3-1.

8.Thread the height adjustment screw 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.

Figure 3-3

NOTE: 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 Operation Section for details).

Reverse Clutch Control

1.Carefully unwrap the reverse clutch control cable from its shipping position and route it up along the inside edge of the left side handlebar. See Fig. 3-4. A knob and large hex nut is installed on the cable.

Left Side

Handlebar

		Reverse
		Clutch
	Slot in	Control
		Knob
	Control
Hex
	Panel
Nut

Reverse Clutch

Control Cable

Figure 3-4

Section 2 — Assembly & Set-Up

2.Insert the cable into the slot on the control panel and fit the threaded assembly into the hole in the slot. Be sure that the flat side of the threaded assembly is aligned with the flat side of the hole. Slide the hex nut 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. If it does not, contact your local dealer or the factory for technical assistance.

Forward Clutch Cable

1.Remove any fasteners (rubber bands, tape, etc.) that may secure the Forward Clutch Control levers to the handlebar. See Fig. 3-5.

Forward Clutch

Control Levers

Figure 3-5

2.The forward clutch control cable (with attached spring) is hanging loosely near the right-side wheel. Being careful not to kink or stretch the cable, insert the Z-connector into the hole at the end of the forward clutch control linkage. See Fig. 3-6.

Z-Connector

Forward Clutch

Control Spring

Figure 3-6

3.Attach the cable adjuster to the bracket on the right-side handlebar. See Fig. 3-7. Use two 1⁄2” wrenches to loosen the two jam nuts just enough to slide the cable adjuster onto the bracket. Then hand tighten the jam nuts.

Cable

Adjuster

Jam Nuts

Figure 3-7

warning! Incorrect cable adjustment could cause the wheels and tines to rotate unexpectedly. Follow adjustment procedures carefully. Failure to do so could result in personal injury or property damage.

4.Check for the correct spring/cable tension as instructed in the Maintenance & Adjustments Section.

5.When the tension is correct, tighten the two jam nuts securely.

Section 2— Assembly & Set-Up

Wheel Gear Lever

1.Insert the Wheel Gear Lever up through the slot in the control panel that is labeled “WHEEL GEAR.” See Fig. 3-8.

Wheel Gear

Lever

Figure 3-8

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.Use a small board to 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 located about two feet apart. Snip off any excess with scissors. See Fig. 3-9.

Set-Up

Tires

Use a tire pressure gauge to check the air pressure in both tires. Deflate or inflate both tires equally to between 15 PSI and 20 PSI. Be sure that both tires are inflated equally or the tiller will pull to one side.

Gas & Oil Fill-Up

Service the engine with gasoline and oil as instructed in the Engine Operator’s Manual packed seperately with your tiller. Read the instructions carefully.

Warning! Use extreme care when handling gasoline. Gasoline is extrememly flammable and the vapors are explosive. Never fuel the machine indoors or while the engine is hot or running. Extinguish cigarettes, cigars, pipes and any other sources of ignition.

Transmission Gear Oil

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. See the Maintenance & Adjustments Section for instructions on checking and adding transmission gear oil.

Cable

Ties

Figure 3-9

Section 2 — Assembly & Set-Up