Troy-Bilt 12069-7HP User Manual

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Page 1

qtrov-bilt

$7“

Owner/Operator Manual

PTO HORSE Tiller

« Safety

• Assembly

12068 (7HP l/C Standard)

12069 (7HP l/C Electric)

12070 (8HP Standard)

12071 (8HP Electric)

• Features and Controls

• Operation

• Maintenance

Page 2

Dear Owner,

You now own one of the finest reartine rototillers available. Your new PTO Horse Model tiller allows you to till and cultivate your garden with ease, and ac complish dozens of other property man agement projects as well. Its PTO capa bility allows it to power a variety of at tachments, including a chipper/shredder and a generator. Your tiller is famous for its ruggedness, performance and highquality engineering. We know you’ll enjoy using it.

Please carefully read this Manual. It tells you how to safely and easily assem ble, 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 prop erty damage.

Of course, if you should ever have any

problems or questions, or for a free re placement copy of this Manual, please

contact your local authorized service dealer or call us Toll-Free. Our tele

phone numbers and mailing addresses

are listed on Page 4 and on the back cover of this Manual.

We want to be sure that you are com

pletely satisfied at all times.

This is a safety alert

this symbol, read and obey the safety message that follows it.

Failure to obey the safety message could result in personal injury or property damage.

symbol. It is used in this Owner/Operator Manual to alert you to potential iKuards. Whenever you see

Be Sure To Return Your Warranty

Registration Card

Be sure to fill

out and mail

your Warranty

Registration Card, which is located in your literature pack age. The infor mation contained on this card will register your ma chine with us and entitle you to full coverage under our Troy-Bilt Full No-Time-Limit Warranty.

NOTE: A Warranty Transfer Card is included in this Manual. This

card should be filled out and re turned to us ONLY if you transfer ownership of your machine to someone else.

This machine meets voluntary safety stan dard B71.8 - 1986, which is sponsored by the Outdoor Power Equipment Institute, Inc., and is published by the American National Standards Institute.

Page 3

Owner’s Oeeord

Please write the Model and Serial numbers of your machine in the spaces provided. You can find the location of these numbers by refer ring to the illustration below.

Model Number:

Serial Number:

Model and Serial Number location

SERVICE INFORMATION

SECTION 1: SAFETY

Training

Preparation.....................................................................6

Operation.......................................................................6

Maintenance and Storage Decals

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

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

SECTION 2: ASSEMBLY

SECTION 3: FEATURES AND CONTROLS

Tiller Features and Controls Identification

Engine Features and Controls Identification.............................23

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

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

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

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

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

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

SECTION 4: OPERATION........................................24

Break-In Operation...........................................................25

Test Forward Interlock Safety System

Starting and Stopping the Engine..........................................27

Cold Weather Operation

To Operate Tiller.............................................................29

Turning Around Transporting Your Tiller To Change Belt Speeds

Tilling in the Garden.........................................................34

The PTO Power Unit

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

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

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

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

SECTION 5: MAINTENANCE & REPAIRS

Required Maintenance Schedule...........................................44

Tighten Bolts and Nuts

Tiller Lubrication.............................................................46

Transmission Gear Oil Maintenance

Drive Belt Maintenance

Reverse Drive Maintenance.................................................52

Bolo Tine Maintenance......................................................54

Tine Shaft Maintenance Tire and Wheel Maintenance

Engine Oil Maintenance

Air Cleaner, Throttle Cable, Ignition System, Spark Plug..............57

Battery Care

Storing the Tiller.............................................................60

Inspect Forward Interlock Wiring System Troubleshooting Forward Interlock Safety System

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

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

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

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

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

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

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

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

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

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

8 8

56 56 56

60 60

TROUBLESHOOTING PROCEDURES

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

ATTACHMENTS & ACCESSORIES...............................64

TILLER SPECIFICATIONS........................................65

INDEX

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

NO-TIME-LIMIT WARRANTY .........................Back Cover

Page 4

vic^*

If you have any

HOW TO

REACH

U.S.A.

GARDEN WAY

INCORPORATED,

102nd St, &

9th Ave.,

Troy, N.Y.

12180

U.S.A. Canada

Mon.-Fri., Mon.-Fri..

8 A.M.to 7 P.M, 8 A.M, to 4:30 P.M.

Saturday

9 A.M. to 4 P.M.

Canada

GARDEN WAY

INCORPORATED,

320 Van Sickle Rd.,

Unit 12,

St. Catherines. Ont.

I.2R 6P7

Questions or Problems...

...Please contact your local TROY-BILT® Tiller authorized dealer or call or write the Factory. When calling or writing, please be sure to provide the Model and Serial

Numbers of your machine (refer to Page 3).

If You Need Engine Service;

If your engine should ever require service or re pair, contact your nearest authorized engine service dealer.

To find the name and address of your nearest authorized engine service dealer, look in the Yellow Pages of the telephone book under

“Engines-Gasoline” (call us if you need assistance in obtaining en gine service or parts).

Please remember that your engine is covered by the engine manufac turer’s Limited Warranty. Any unauthorized work performed on the engine during the warranty pe riod may void the warranty. For full details on the engine manufac turer’s Limited Warranty, refer to the separate Engine Owner’s Manual.

U.S.A.

(Toll Free)

For Technical

Service:

1-800-833-6990

For Parts

Service:

1-800-648-6776

Overseas callers

may use:

518-235-6010

Canada

(Toil Free)

For Technical

Service and Parts

Service:

1-800-225-3585

If You Need Parts:

Factory specified replacement parts for your machine are available from either your TROY-BILT® Tiller autho rized dealer or directly from the Factory.

To order a part from the Factory, refer to your separate Parts

Catalog to find the part

fY 1

TV A

X.J

number, description, and quantity

of the part you need. Then,

call or write our Parts

Department, being sure to

provide the Model and

Serial Numbers of your

—I machine.

Our trained parts special-

ists will gladly assist you if

you have any difficulty in

identifying the part that you need.

Page 5

Section

Please read and follow all of the safety rules in this Safety Section. Failure to comply could result in serious personal injury or prop erty damage.

If you should lend this equipment

to another person, make sure that

he or she reads, understands, and always follows these safety in structions.

If you are not completely sure about any of the information found here or elsevi/here in the Manual, please contact either your local authorized dealer or the factory for assistance.

WARNING TO ALL CALIFORNIA

ANO OTHER POWER EQUIPMENT OPERATORS

Under California law, and under the laws of several other states,

you are not permitted to operate an internai combustion engine

using hydrocarbon fuels on any forest-covered, brush-cov

ered, or grass-covered land, or on land covered with grain,

hay, or other flammable agricultural crop, without an en

gine spark arrester in continuous effective working order.

The engine on your power equipment, like most outdoor power equipment, is an internal combustion engine that burns gasoline, a hydrocarbon fuel. Therefore, your power equipment must be equipped with a spark arrester muffler in continu ous 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 ig nite flammable material. Failure of the owner/operator of the equipment to com ply with this regulation is a misdemeanor under California iaw, 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 what regulations apply in your area. Contact your authorized engine dealer for in formation about obtaining a spark arrester.

TRAINING

4. Familiarize yourself with all of the safety and operating decals on this equipment and on any of its

attachments or accessories.

This is a safety alert symbol. It is used

in this Owner/ Oper

ator Manual and on your equipment to alert you to poten tial hazards.

Whenever you see this symbol, read

and obey the safety message that fol lows it. Failure to obey those safety

messages could re sult in serious per sonal injury or cause

property damage.

1. Read this Owner/Operator Manual and the separate Engine Owner’s Manual carefully before operating this equipment. Be com

pletely familiar with the controls

and the proper use of this equip ment. Know how to stop the unit and disengage the controls quickly.

2. Never allow children or un trained adults to operate this equip ment.

3. Keep the area of operation clear of all persons, particularly small children and pets. Keep by standers at least 25 feet away from the area of operation.

5. Do not run engine in an en closed area. Engine exhaust con tains carbon monoxide gas, a

deadly poison that is odorless, col orless, and tasteless.

6. Do not allow hands or any other part of the body or clothing near the rotating tines or near any other moving part. The tines

begin to rotate

forward once

A WARNING

the engine starts, the Tines/PTO Clutch Lever is

in the ENGAGE

position, the

Forward Interlock Levers are squeezed closed and the Wheels/Tines/PTO Drive Lever is shifted to FORWARD. The tines rotate in Reverse whether the Interlock Levers are squeezed closed or left open.

Page 6

7. Before inspecting or servicing any part of the equipment, shut off the engine, wait for all moving parts to come to a complete stop, disconnect spark plug wire from

spark plug and move wire away from the spark plug.

8. Do not operate this equipment if you are under the influence of

alcohol, medication, or when you are tired or ill.

PREPARATION

1. Thoroughly inspect the area where the tiller will be used. Re move foreign objects before tilling.

2. Put the Wheels/Tines/PTO Drive Lever in NEUTRAL before starting the engine.

3. Do not operate the tiller without wearing suitable clothing. Avoid loose garments or jewelry that could get caught in moving parts of the tiller or its engine.

OPERATION

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

2. Use extreme caution when on or crossing driveways, walks or roads. Be alert for hidden hazards or traf fic. Do not carry passengers.

3. If you hit a foreign object, stop the engine (remove key on electric start models), let all moving parts come to a complete stop, discon nect spark plug wire and move wire away from the spark plug, and inspect for damage. Repair damage before restarting.

4. Do not operate the tiller when you are barefoot, in san dals, sneakers or other light footwear. Wear shoes that grip well on slippery surfaces.

5. Do not till near underground

electric cables, telephone lines, pipes, or hoses. Contact your tele phone or utility to verify locations of underground cables or lines.

6. Handle gasoline with care; it is flammable, the vapors explosive.

a. Use an approved gas container. b. Gas cap shall never be re

moved or fuel added with en gine running. Engine shall be

4. Exercise caution to avoid slip ping or falling.

5. If abnormal tiller vibration oc curs, stop engine immediately, dis connect the spark plug wire and move wire away from spark plug. Check for the cause. Carefully in spect for any damage. Fix the prob lem before using the tiller again.

6. Stop the engine, remove the key on electric start models, and dis connect the spark plug wire and move wire away from spark plug before leaving the operating posi tion, unclogging tines, or making repairs, adjustments or inspections.

7. Before leaving tiller unattended, shift to NEUTRAL, stop engine (remove key on electric start mod els), and disconnect spark plug wire and move wire away from plug to prevent accidental starting.

8. Before cleaning, repairing or in specting, stop the engine (remove

allowed to cool before refuel ing. Operators shall not smoke.

c. Keep matches, cigarettes,

cigars, pipes, open flames, or sparks away from the fuel

tank and fuel container.

d. Fill fuel tank outdoors using

extreme caution. Never add fuel indoors. Use a funnel or spout to prevent spillage.

e. Replace fuel cap securely and

clean up fuel spills before starting the engine.

7. Never attempt to make any ad

justments while the engine is run

ning or the spark plug wire is con nected, except when so instructed.

key on electric start models), let all moving parts stop, and disconnect spark plug wire and move wire away from spark plug to prevent accidental starting. For; electrical safety on electric start models, al ways disconnect the negative (-) cable from the battery post.

9. Flap on tine hood must be down when running tiller, unless using the hiller/furrower attachment.

10. Never operate the tiller unless safety guards or other protective devices are in place.

11. Do not run the engine in an en closed area. Engine exhaust con tains carbon monoxide gas, a deadly poison that is odorless, col orless, and tasteless.

12. Keep children and pets away.

Page 7

Safetf

13. Never operate the tiller under engine power if the Wheel Speed Lever is in the FREE WHEEL po sition. In EREE WHEEL, the wheels will not hold the tiller back and the revolving tines could pro pel the tiller rapidly, possibly caus ing loss of control. Always engage the Wheel Speed Lever in either EAST or SLOW position before starting the engine or engaging the tines with the Wheels/Tines/PTO Drive Lever.

14. The tiller could unexpectedly bounce upward or jump forward and be propelled away from you if the tines strike or catch very hardpacked soil, sod, frozen ground, or any buried obstacle such as large stones or roots. If in doubt about tilling conditions, use the follow ing precautions to assist you in maintaining tiller control;

a. Walk behind and on either

side of the tiller, using one hand on the handlebars. Relax your arm, but use a se cure hand grip.

b. Use shallow depth regulator

settings, gradually working deeper with each tilling pass.

c. Use slower wheel, tine and en

gine throttle speeds.

d. Clear the tilling area of big

stones, roots and other debris.

e. Avoid putting downward pres

sure on the handlebars. If necessary, apply slight upward pressure to prevent the tines from digging too deeply.

f. Avoid contacting hard-packed

soil or sod at the end of a row by reducing engine speed and lifting handlebars up to raise tines out of the soil.

g. In an emergency, stop the

tines and wheels by shifting the Wheels/Tines/PTO Drive Lever to NEUTRAL. If you can not reach the lever or have lost control of the tiller, let go of the handlebars and all con trols. Do not try to restrain it.

15. Do not overload the machine capacity by trying to till too deeply at too fast a rate.

16. Never use the tiller at high ground speeds on slippery surfaces.

17. Do not operate tiller on a slope too steep for safety. On slopes, slow down and be sure you have good footing. Don’t let the tiller “free-wheel” down slopes.

18. Clear the area of bystanders be fore tilling.

19. Use only attachments and ac cessories approved by Troy-Bilt Manufacturing Company.

20. Use tiller attachments and ac cessories when recommended.

21. Never operate the tiller without good visibility or light.

22. Never operate the tiller if you are fatigued, 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 and protects the engine and all moving parts from damage caused by over

speed. Authorized service shall be

sought if a problem exists.

24. Do not touch engine parts that may be hot from operation (muffler, fins, etc.). Make certain all parts have cooled down before inspect

ing, cleaning or repairing.

25. POISON/DANGER-

CAUSES SEVERE BURNS. The

battery on electric start models con tains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidotes: External- Elush imme diately with lots of water. Internal- Drink large quantities of water or milk. Follow with milk of magnesia, beaten eggs or vegetable oil. Call a doctor immediately. Eyes- Flush with water for 15 min utes. Get prompt medical attention. Keep out of reach of children.

26. DANGER- BATTERIES

PRODUCE EXPLOSIVE GASES. Keep sparks, flame or

smoking materials away. Ventilate when charging battery or using in an enclosed space. Always shield eyes when working near battery.

27. Remember—To stop tines and wheels, either put Wheels/ Tines/PTO Drive Lever in NEU TRAL, or move Throttle Lever to STOP position. If you lose control of the tiller and can not reach the levers, let go of the handlebars and controls and do not try to restrain the tiller. The Eorward Interlock Safety System will stop the engine.

28. Look behind and exercise cau tion when backing up. For added safety, put Wheel Speed Lever in SLOW position before reversing.

29. When loading or unloading the tiller, always disengage the tines and use slower wheel and engine throttle speeds. Use sturdy ramps wide and strong enough to easily support the tiller (280-to-325 lbs., depending on model) and operator.

Never go down ramps in FOR WARD drive—the tiller could tip forward, exposing you to the tines

(which should be disengaged). Always use REVERSE drive and back down ramps. To go up ramps,

use FORWARD drive and walk up following the tiller.

30. The Forward Interlock Safety

System should be tested for correct functioning every time the tiller or PTO power unit is used. See

Section 4 in this Manual for the test procedure to take.

31. If using the optional Dozer Blade, either remove the tine at tachment, or disengage the tines with the Tines/PTO Clutch Lever. Revolving tines are dangerous.

Page 8

%^Ж£

MAINTENANCE AND

2. Keep tiller, attachments and ac cessories in safe working condition.

STORAGE

3. Check all nuts, bolts, and screws frequently for proper tightness. Always verify your equipment is in safe working condition.

4. Never store the machine with

fuel in the fuel tank inside a build ing where fumes may reach an open flame or spark, or where igni

1. Never perform maintenance

when engine is running or spark plug wire is connected except when specifically directed to do so.

tion sources are present (such as hot water and space heaters, fur naces, clothes dryers, etc.).

5. Let the engine cool down before

SAFETY DECALS

Make certain that all safety decals on this equipment are kept clean and in good condition. The safety decal locations are shown (at a reduced size) below. There are other decals located on your equipment for

storing it in an enclosure.

6. To reduce fire hazard possibili

ties, keep the engine free of grass,

leaves or grease.

7. Store gasoline in a cool, wellventilated area, safely away from any spark- or flame-producing equipment. Store gasoline in an approved container, safely out of the reach of children.

8. Refer to the Maintenance sec tion in this Manual for storage in formation if your tiller is to be stored for an extended period.

operation and controls identification. They are also shown below and in your Parts Catalog. If you need a replacement decal, please refer to the Parts Catalog that accompanied this Manual.

A) WARNING: Hot Surfaces decal. On

8HP Kohler engines (shown), located

on top of the engine. On 7HP Briggs &

Stratton engines (not shown), located

on the side of the engine’s air cleaner.

F) Engine Stabilization

decal. On 8HP Kohler en

gines, located on top of the engine. On 7HP Briggs & Stratton engines, on the air cleaner.

Decal Locations

C) WARNING: Operating Instructions

decal. Five groups of safety state ments are provided along with tiller operating instructions.

B) WARNING: Engine Ignition. Provides

safety and operational information for

using the Keyswitch Ignition. On electric start models only.

E) Forward Interlock

Lever decals (2).

D) Power Unit Operating Instructions decal.

Page 9

Section

Ajseni

Please carefully follow the steps in this Section to properly assemble your new machine. These steps will not take very long and they will assure you of having assem

bled your machine correctly.

Subjects covered in this Section:

Inspection After Delivery Unpacking and Checking Contents Attach the Handlebars Remove Tiller from Shipping Platform

Connect Forward Interlock Wire Harness

Attach Wheels/Tines/PTO Drive Lever

Check Gear Oil Levels in Power Unit and Tine Attachment Transmissions

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 in this

Manual.

Tools Needed:

One 3/8" Open End or

Adjustable Wrench

One 9/16" Open End or

Adjustable Wrench

One 3/4" Open End or

Adjustable Wrench

Two 7/16" Open End or

Adjustable Wrenches

Two 1/2" Open End or

Adjustable Wrenches

One Flat Blade Screwdriver

(Briggs Engine Only) Scissors (to trim plastic ties) Quality Motor Oil (API Classi

fication SF or SG)-ap

prox. 2M pints for 7HP

Briggs engine; approx. 32

ozs. for 8F1P Kohler engine

Tire Pressure Gauge A strong 4V2 " high prop (a

wood box, a brick, or

boards)

Add Motor Oil to Tiller Engine Attach Engine Throttle Lever to Handlebar Adjust the Air Pressure in the Tires Assembling the Electric Start System

Inspection After Delivery

Inspect your machine immediately after it has been delivered. Make sure that neither the carton nor the contents have been damaged.

If you find or suspect any damage, contact the carrier (trucking com pany) right away. Inform them of the specific damage and that you wish to file a claim. To protect your rights, be sure to put this in writing to the carrier within 15 days after your machine amves. The carrier will let you know how to proceed with your claim. Please let us know if you need any assistance with this matter.

IMPORTANT: Motor oil must be added to the engine before it is started. The procedure for adding oil is explained later on in these assembly instructions.

STEP 1: Unpacking and

Checking Contents

If you haven’t done so, remove

the loose parts as listed in the table

on page 10. Contact us immedi ately if any parts are missing.

A. Remove the handlebars and the Wheels/Tines/PTO Drive Lever (Items 1 and 2 in Photo

2-1). Set them on a clean surface.

Do not get dirt on the wire harness

plug located at the bottom of the

handlebars!

B. Remove the loose parts from

the plastic envelope that contained

these instructions (Items 3 through

8 in Photo 2-2).

C. If you ordered an Electric Start

Tiller, take out all the items from a

sealed plastic hardware package

(Items 9 through 11 in Photo 2-3).

Page 10

Si.

■J r.

Wire Harness Plug

1- Handlebars

2- Wheels/Tines/

PTO Drive Lever

Photo 2-1. Put Handlebars (Item #1) and Wheels/Tines/PTO Lever (Item #2) aside.

Table 1 - Carton Contents Parts List

KEY QTY

1 Handlebars................................................................................

1 2 1

4 1

2 Plastic Cable Ties................................................................

7 8 1

DESCRIPTION

Photo 2-1:

Wheels/Tines/PTO Drive Lever...............................

Photo 2-2:

Clutch Pawl Spring

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

Belt Adjusting Tool.............................

Curved Head Bolt, 1/4"-20 x 2" (Grade 5).. Flanged Lock Nut, 1/4"-20

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

Panhead Screw, #20 -24 x 1/2" (Briggs &

Stratton engine only)....................................................

FDR IVIODEL:

7HP 7HP

8HP 8HP

Std Elec Std

•

• •

•

• •

• • •

• • «

• •

Elec

•

Use This Ruler

to Check the

Hardware Lengths:

—- 5

6 7

' - ,

Photo 2-2. Parts inside the litera

ture envelope.

iiii»

10 2

11 1

Photo 2-3:

Nuts, 1/4"-20, for battery terminals

Bolts, 1/4"-20 X 5/8", for battery terminals

Battery Vent Tube..............................................................

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

•

• •

•

Photo 2-3. Parts for Electric Start

Tiller models.

Page 11

STEP 2: Attach the Handlebars

Do not move tiller off shipping

platform unless handlebars are at

tached. This makes moving the tiller easier and more controllable.

All the parts shown in Figure 2-4 (except the handlebars) are shipped assembled. You must disassemble these parts in order to attach the handlebars.

A. Unwind the Handlebar Height Adjustment Lever (Figure 2-4) counterclockwise. Be prepared to catch the nut, left clamp and left ratchet as you remove the lever.

Completely withdraw the lever, taking with it the right clamp and right ratchet. Keep mating clamps and ratchets grouped together.

B. Place the handlebar ends on ei

ther side of the handlebar base and the wire harness at the bottom of the handlebars at the rear of the base (Fig. 2-4).

C. Hold the right-side ratchet and right-side clamp in position next to right handlebar arm. Insert adjust ment lever through the clamp, han dlebar, ratchet and the base. Let the adjustment lever protrude from the other side of the base.

Note: The lever should pass freely through the holes in the handlebar ends. If it won’t- do not force it. The wires to the Forward Interlock Safety System may be blocking the lever. Push a pencil through the holes to gently move the wires aside.

Figure 2-4. Unwind the Handiebar Height Adjustment Lever to separate the handiebar assembiy parts. Keep the mating left-side ratchet and damp

grouped together, and the right-side ratchet and damp grouped. Place the

handlebars so the ends are on either side of the handlebar base. Reas

semble all parts securely.

Left Side Clamp With Nut

D. Position the left-side ratchet

and left-side clamp next to the left handlebar arm (see Fig. 2-4). Move the adjustment lever all the way through these parts. Hold the nut in place and screw the lever into it. Don’t fully tighten the lever yet.

E. Raise the handlebars (jiggling them on the ratchets helps) to one of two pre-set height settings. Then tighten the lever (Photo 2-5).

Photo 2-5. When handlebars are in position, reassemble all the compo nents. Insert the Handlebar Adjustment Lever from right to ieft through ail the parts. As shown above, securely tighten the iever.

Page 12

STEP 3: Remove Tiller from Shipping Platform

A. The Depth Regulator Lever (Photo 2-6) may be secured to its own mounting bracket with a plas tic tie strap. Removing the tie strap lets you move the Depth Regulator Lever up or down. To check, lift the hinged flap at the end of the hood and look for a tie strap around the lever. Use a scis sors to cut it loose.

B. Move the Wheel Speed Lever (Photo 2-6) to FREE WHEEL po sition which lets the wheels turn

freely. FREEWHEEL position is midway be tween SLOW and FAST positions. Then lift the handlebars up to clear the tines from the platform. Pull the handlebars firmly back to roll the wheels out of the platform wheel wells.

C. Roll the tiller to a level area where you can complete the as sembly steps.

Photo 2-6. Move tiller off shipping platform. Move Wheel Speed Lever up or down to take wheels out of gear.

STEP 4: Connect Forward Interlock Wire Harness

B. Before connecting the plug, be sure that it and the receptacle it’s going into are clean.

A. Connect the plug on the wire harness that leads from the lower ends of the handlebars into the wire harness receptacle on the top, right side of the transmission (Photo 2-7). This connection com pletes the wiring circuit for the Forward Interlock Safety System. It must be connected or the engine will not start.

STEP 5: Attach the Wheels/Tines/PTO Drive Lever

^ WARNING

To avoid personal injury, test the Forward Interlock Safety System prior to each use of the tiller to be sure it is func tioning properly. See Section 4 in this Manual for the test

ing procedure to use.

This control lever is shown in Photo 2-1. To attach

it, you’ll need the clutch pawl spring (see Photo 2-2). A. Loosen the large bolt at the top

of the handlebar base (Photo 2-8) with a 3/4" wrench. Don’t remove it. Swing the handlebars out of the way to the right side of the tiller.

B. With two 1/2" wrenches, re move and save the nut, star washer, bushing and bolt from the hole at the rear of the clutch yoke assem bly plates (see Fig. 2-9, items A, B, C, D).

C. Using two 1/2" wrenches, re move (and save) the nut, star washer and bolt (items E, F, and G,

'■t ik

Figure 2-9) attaching the short ver tical link to the center of the yoke. Keep the short link (with a bushing inside it) upright after the bolt comes out. If it swings down,

Photo 2-8. Loosen the large bolt securing the handlebar base. Swing handiebars to right side.

reposition it upright again.

Photo 2-7. Connect forward inter lock wire harness plug to receptacle.

Tools required: one 3/4” and two 1/2" wrenches.

D. Slide the plates located at the end of the PTO drive lever over the yoke and align the upper hole in the plates with the hole at the rear of the yoke (refer to Photo 2-10). Insert the bushing (C, Figure 2-9) inside the yoke and install the bolt through the lever’s plates, bushing and yoke. (Tap the bolt if neces sary.) Add the star washer and nut and tighten the nut finger-tight.

Page 13

Figure 2-9. First remove hardware from rear of yoke piates (hardware items A, B, C, and D); then remove hardware securing short, upright steei iink to yoke plates (hardware items E, F, and G).

E. Look at both ends on the clutch pawl spring. One hook end has a wider opening. Insert the end with the wider opening fully into the small hole in the lever (hook point ing down). See A, Figure 2-11.

R Tilt the lever fully up and insert the other end of the spring in the hole in the top of the long steel link (B, Figure 2-11). A pliers may help. Do not overstretch the spring. (Note: push handlebars to

Figure 2-11. Install clutch pawl spring.

the right for extra clearance.) G. Pull the lever back down. See

Photo 2-12. Insert bolt removed earlier (per paragraph C) back in the

Adjustment

Block

remaining holes in the lever, yoke and short vertical link. Add star washer and nut.

H. Securely tighten both bolts.

I. Swing handlebars to the straight-ahead position and tighten the bolt in the handlebar base.

J. Test the operation of the lever. Push it down until it’s engaged in the FORWARD position. See Photo 2-13 (the roller at the end of

Photo 2-13. Push lever down into FORWARD position. The roller must go under the adjustment block.

Roller

the shift linkage must be engaged beneath the belt adjustment block). Next, move the lever up to the NEUTRAL position- lift or tap it up and let it go. The roller should be resting on the face of the belt

adjustment block (Photo 2-14). Last, lift and hold the lever all the way up in REVERSE positionthen let it go. It should automati cally return to the NEUTRAL po-

Photo 2-10. Insert bushing, then in stall bolt through upper hole in lever and yoke plates. Loosely add the star washer and the hex nut.

Photo 2-12. Pull lever back down. Reinstall last bolt, star washer and nut as shown above.

Roller

Photo 2-14. When lever Is In NEU

TRAL, roller rests against the face

of the adjustment block.

sition. If not, do not use the tiller. See your local authorized Dealer or call our Technical Service Department for instructions.

Page 14

STEP 6: Check Gear Oil Levels in Power Unit Transmission and Tine Attachment Transmission

Your tiller has two separate transmissions: one for the Power Unit; the other for the Tine Attach ment. Both were filled with SAE #85W-140 weight gear oil (with an A.P.I rating of GL-4) at the Factory. Please check level in both transmissions to verify that levels are still correct.

To Check Power Unit Transmission;

A. Put the tiller on level ground. B. Pull Depth Regulator Lever

back and then up so tines are rest ing on the ground (Photo 2-15).

C. Use a 3/8" wrench to remove oil level check plug on left side of the transmission (just above the wheel shaft). See Photo 2-16. You may need to break the grip of any dried paint on the check plug.

D. Oil should seep out hole if level is correct (in cold weather, it will seep out slowly). Reinstall plug securely if gear oil level is correct.

E. If no oil seeped out, see if tilt ing tiller slightly toward check hole (roll right wheel on a 1" thick board) causes oil to seep out. If oil starts to seep, only a small amount should be added. But - if there is still no oil seeping out, the oil level may be seriously low. In either case, add the correct amount of gear oil before using the tiller —

see “Adding or Changing Gear Oil” in Section 5 of this Manual.

To Check Tine Attachment Transmission:

Two different gear oil level checking procedures for the tine attachment transmission follow. Use the procedure described first for Tine Attachment dipsticks with a ‘Check Cold’ marking. Use the second procedure if dip stick has both ‘cold’ and ‘hot’ markings at end. First remove dipstick from tine transmission (Photo 2-17) to see which type dipstick you have. Then replace dipstick.

For Dipsticks With ‘Check Cold’ Markina:

A. Put the tiller on level ground. B. Pull Depth Regulator Lever

back, then push it down all the way to engage its top notch. This raises tines off ground and lets tiller rest on drag bar.

C. Place a support under engine to prevent tiller from tilting too far. Now slide three pieces of 2" x 4" lumber under drag bar - raising drag bar about 4-1/2" above ground. This elevation is needed to take an accurate “cold” gear oil reading (“cold” means tiller was never operated, or 2 hours have

passed since it was used last).

D. Wait two hours with tiller ele vated (allow more time if tempera ture is below 40°F).

E. Loosen and remove transmis sion dipstick. (Photo 2-17). Wipe with a clean rag.

F. Holding dipstick so markings face rear of tiller, lower it straight down into sump hole until it touches driveshaft inside (Photo 2-

17). Don’t force or try to thread it back in - or reading won’t be cor rect.

G. Remove dipstick and check oil level. It should be within crosshatched area or even slightly above the ‘Max’ marking. If correct, re place dipstick and remove boards.

H. If no oil showed on dipstick, correct amount of oil must be added to tine transmission. For complete instructions, see “Adding or Changing Gear Oil” in Section 5 of this Manual.

For Dipsticks With Hot/Cold Markinos:

A. Follow Steps A and B given for other type of dipstick.

B. Put one 2"x4" board under drag bar- raising tiller and drag bar about 3-1/2" above ground. This elevation is for a ‘cold’ gear oil reading (tiller never used or 2 hours since used last).

C. Follow Steps D, E, and F given for other dipstick type.

'' -

'..X

^ ^ i Photo 2-15: Pull Depth Regulator

Lever back and then up to lower the tines to the ground.

IV ! ■ .

^ ^

■ f-

Photo 2-16: Gear oil should seep out from oil level check hole in

power unit transmission.

1 |i£E ■

gjPiP: ^ ÉB li llipiftF ^

Photo 2-17: Remove dipstick to check gear oil in tine attachment transmission. Insert dipstick so markings face rear of tiiler.

Page 15

D. Remove dipstick and check that gear oil level is within or above ‘Cold’ range marking (use of ‘Hot’ marking is explained in Section 5). If correct, replace dip stick and remove the board.

E. If the level is incorrect, see “Adding or Changing Gear Oil” in Section 5 of this Manual.

IMPORTANT

Recheck gear oil level in both trans missions after the first two hours of new tiller operation, then every 30 operating hours thereafter. See Section 5 for instmctions.

STEP 7: Add Motor Oil to Tiller Engine

Add high-quality API-rated “SF” or “SG” motor oil to engine before starting.

For the Briggs & Stratton Engine:

A. Park tiller on level ground. Place a sturdy block(s) under drag bar at rear of tiller to level base of engine.

B. The Briggs & Stratton recoil start engine has two oil fill tubesone on each side of the engine. Use either. (The Briggs & Stratton electric start engine, has only one fill tube located as shown in Photo 2-18.)

C. Clean around oil fill tube and re move oil fill plug. Slowly pour motor oil into tube through a fuimel until oil reaches top of tube.

Engine Oil specifications:

40PF to 10(FF: SAE30W oil.

O^’F to 40°F: SAE5W30 oil or

SAE10W30 oil.

-20°F to 40°F: Synthetic SAE5W20 oil or SAE5W30 oil.

D. Reinstall oil fill plug and remove block under drag bar.

IMPORTANT - Change engine oil after first 5 hours of operation.

For the Kohler 8HP Engine:

A. Park tiller on level ground. Pull Depth Regulator Lever back and then push it down, engaging highest notch in lever. This places the engine base at a slight angle. Always use this angle when adding and checking oil - the dipstick is calibrated to account for angle.

B. Clean area around dipstick and

remove dipstick (see Photo 2-19). C. Insert a funnel into dipstick

hole and add engine oil. Check level frequently with dipstick while adding oil. Fill to “Full” mark. Do Not Overfill.

Engine Oil Specifications:

32^F to 100°F: SAE30W oil.

(fiF to 32°F: SAE10W30 oil.

-20°F to 32°F: SAE5W30 oil.

D. Replace dipstick securely. IMPORTANT - Change oil after

first 5 hours of initial operation.

Photo 2-18: Remove oil fill plug on Briggs & Stratton engine. Add oil so it reaches the top of

the fiii tube.

Photo 2-19: Remove 8HP Kohier engine dip stick to add motor oil.

STEP 8: Attach Engine Throttle Lever to Right Handlebar

The throttle cable (with throttle

lever) comes wrapped around en

gine for shipping purposes. Unwrap it and if your throttle con trol decal is covered with a protec tive coating, peel it off. Attach lever as follows.

A. Use curved head bolt, flanged locknut and two plastic ties shown in Photo 2-2. (Briggs & Stratton owners also need the #20-24 x 1/2" panhead screw).

B. Run throttle cable up inside edge of right handlebar, and posi tion lever as shown in Photo 2-20 or 2-21.

C. Place bolt on outside of handle

bar and slide it though handlebar

and center hole of throttle lever

bracket.

D. On the Kohler engine only: add

the locknut and tighten it with a

7/16" wrench. See Photo 2-20.

Then, skip to step “F”.

Photo 2-20: Attach Kohler engine throttle lever to handlebar.

E. On the Briggs engine only:

1. Put locknut on bolt but don’t

tighten it yet.

2. Move throttle lever to STOP position. From lever side, insert panhead screw into hole in throttle lever bracket and into handlebar. See Photo 2-21. Tighten screw.

3. Use a 7/16" wrench to tighten locknut you threaded on bolt.

F. For all engines, secure cable to right handlebar in two places using two plastic ties. Loop each tie around handlebar and cable (ser rated side faces in), and pull ties tight. Trim ends.

Page 16

Pan Head

i Screw

Curved Head Bolt and Nut

WARNING

Tie

On electric start tillers, to avoid electric shock from a short circuit, never allow throttle cable to touch the battery. Route cable below the battery, on the outside of the battery holder.

Photo 2-21: Attach Briggs engine

throttle lever to handlebar.

STEP 9: Adjust the Air Pressure

in the Tires

A. For shipping purposes only, the tires are overinflated.

Photo 2-22: Use plastic ties in two places to hold cable to handlebars.

B. Before using the tiller, check the air pressure and adjust it to be tween lO-to-20 psi (pounds per

square inch). Each tire should be

inflated to the same pressure.

IMPORTANT If you have a recoil start tiller, it is now completely assem bled. If you have an electric start tiller, please continue with the few remaining steps.

ASSEMBLING THE ELECTRIC START SYSTEM

The following steps explain battery activation, battery charging and installation. For your safety, follow

all steps and observe all accompanying safety messages. Section 5 has further general battery maintenance and

recharging instructions you will find helpful.

STEP 1: Activating and Charging the Battery

IMPORTANT

The battery was shipped

“dry.” It needs battery elec

trolyte fluid (battery-grade

sulfuric acid) added to it. It must then be fully charged

with a battery charger before

being used.

Adding electrolyte fluid to the battery and battery charging can be dangerous work. The electrolyte contains acid that can bum or blind you. Battery charging also pro duces explosive gases.

To ensure that the battery is properly activated and charged, you should review these instruc tions with your battery technician.

It is strongly recommended that you have the battery acti vated and charged by a trained professional (Troy-Bilt Dealer, service station, farm equipment dealer, etc.) if you are not experi enced with these procedures.

^ DANGER

Battery produces explosive gases.

• Keep sparks, flames, and cigarettes away.

• Ventilate area when charg ing or using battery in an en closed space.

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

DANGER

Battery electrolyte fluid is poisonous and burns severely.

Electrolyte is a sulfuric acid

solution. Avoid spills or con tact 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 solu

tion. 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 imme diate medical attention.

Antidote: Internal- Drink large

quantity of water or milk. Follow with milk of magnesia, beaten eggs, or vegetable oil.

Call a doctor immediately.

Page 17

To Activate the Battery:

WARNING

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, a shock, or explosion of battery gases.

(Battery Shown Backwards - As Shipped)

> nr

*6^

•

p ■"

Photo 2-23: Remove hold-down clamp (A).

Remove the piece of

clear plas

tic tubing

f '

(B) if so supplied.

For shipping purposes only, the unserviced battery and its hold down clamp were installed back wards at the factory. When rein stalling the battery and hold-down clamp, be sure to turn them around so they face in the opposite direc tion from which they were shipped.

A. Use a 7/16" wrench to remove the two 1-/4" long bolts and the two

1/4" whiz nuts securing the front and rear hold-down clamp legs to the battery bracket (Photo 2-23). Lift off the clamp. Remove battery. Save the hardware.

B. If there is a short piece of sealed plastic tubing covering the vent fitting on the negative side of the battery (see Photo 2-23), re move and discard it.

C. Put the battery on a level work surface, far away from heat- or flame-producing sources like stoves, water heaters, dryers, fur

naces, etc.

D. Take off the six filler caps on top of the battery. Put them aside. Refer to Photo 2-24.

E. Be sure you are wearing pro tective clothes, rubber gloves and eye protection. Fill each cell to the

“Upper Level” line printed on the battery case using battery-grade electrolyte solution. (This is 1.265 specific gravity sulfuric acid.) Temperature of battery and elec trolyte is ideal when between 60^F-to-80°F. Do not add water or any other liquid to the battery dur ing this initial activation.

F. Let battery stand for 30 min utes. Check electrolyte level in each cell. Add more electrolyte solution if needed. Don’t overfill

hattery-this could lead to flooding

from the cells during charging.

lì

Photo 2-24: Remove all six filler caps (A). Fill each cell up to the “Upper” level line (B).

To Charge the Battery:

A. Follow one of the three charg ing methods described next for maximum starting capacity and longest battery life.

Note: The electrolyte solution

within the cells is gassing freely when the surface of the electrolyte

is covered with small bubbles. When checking for bubbles, al ways wear safety goggles to pro tect eyes. A flashlight makes the inspection easier. Inspect all cells.

Our Recommended Method:

Charge the battery at a rate of 1 -to2 amperes until all cells gas freely. Do not exceed 24 hours charging.

First Alternative Charging Method:

Charge the battery at a rate of 4-to6 amperes until all cells gas freely.

Do not exceed 8 hours charging.

Page 18

Second Alternative Charging Method:

Charge the battery at a rate from 6-to-12 amperes until all cells gas freely. Do not exceed 4 hours charging time.

B. Turn off the charging equip ment and disconnect the charger cables from the battery terminals.

C. Recheck electrolyte level in each cell. Top off any low cells with electrolyte solution up to the “Upper” level line.

D. Securely replace all six filler caps. Use a baking soda and water mixture to rinse off electrolyte that may have spilled on the battery.

DANGER

Never jump start the battery

with a vehicle battery or charg

ing system. This may produce a battery explosion, causing acid or electricai burns.

DANGER

To Avoid Personai Injury or Property Damage:

• Batteries produce explosive gases - aiways keep sparks and flame away from battery.

• Ventilate area when charg ing or using the battery.

• During charging, don’t leave battery unattended. Charging time need not be continuous.

• Follow safety rules and in structions supplied by battery and charger manufacturers.

• Do not charge battery at a rate higher than 12 amperes to avoid generating excessive heat and gassing which could damage the battery.

DANGER

To Avoid Personal Injury or Property Damage:

• Do not touch positive bat tery terminal and any sur rounding metal objects with tools, jewelry or other metal items. Failure to comply could cause a short circuit leading to electrical burns or explosion of battery gases.

• Never bring a gas can near the positive (+) battery termi nal. A short circuit could occur leading to an explosion of the gasoline or the battery gases. Aiways fill the engine fuel tank from the front or side of the engine.

STEP 2: Connect the Wire Harness Receptacle

A. The keyswitch (A, Figure 2-25) is part of the hold-down clamp as sembly (D). The prongs at the

back of the keyswitch must be se curely inserted into the plastic wire harness receptacle (B).

B. Remove the pair of ignition keys from the keyswitch. Store

them safely away. Do not put a key in the keyswitch until you have read the sections in this Owner/Operator Manual covering features, controls and operation.

Figure 2-25: First connect Keyswitch (A) to wire harness (B). Then, the acti vated battery must be secured to mounting piatform (C) using the hoiddown damp (D) with its mounting hardware (H, I). Last, instaii plastic vent tube (E) over the vent fitting (F), and down into vent tube shield (G).

Page 19

STEP 3: Installing the Battery

A. Carefully place the activated battery back on the battery mount ing platform as seen in Fig. 2-25.

The side of the battery with the terminals (the posts) and the fill lines on it must face the rear of the tiller. [Another way to verify

the correct placement of the bat tery is when the positive (-I-) bat tery post is on the left side of the tiller as you face forward when standing behind the handlebars.]

CAUTION

Incorrect installation of the battery can result in electri cal system damage.

Follow these installation in structions carefully to avoid damage to your tiller.

B. Place the battery hold-down clamp (D, Figure 2-25) over the battery, and secure the two legs of the clamp to the platform (C) using the two bolts and whiz nuts (H, I) removed previously. Insert the bolts up from the bottom. Tighten the hardware to make the battery secure, but don’t overtighten the nuts or the clamp tabs will bend.

STEP 4: Installing the Battery Cables

A. Locate the two (2) 5/8" long bolts and 1/4"-20 hex nuts shown in Photo 2-3 on page 10. Use them to connect the loose ends of the

two battery cables to the two bat

tery terminals (posts).

B. On the left side of the tiller (as viewed from behind the handle bars), connect the loose end of the positive (-t-) battery cable (A, Figure 2-26 - this is the red cable

already attached at the other end to the solenoid) to the positive (-r) battery post (B). Hold the cable terminal against the side of the post facing the keyswitch. Install

and tighten a bolt (E) and nut (F) with two wrenches.

C. Slide the pre-installed black rubber boot (G) completely over the battery post and hardware.

D. Repeat this procedure on the

right side of the battery. Position

the end of the negative cable (C) against the negative battery post

(D) as shown, and secure it with the remaining bolt (E) and nut (F). Again, slide the black rubber boot

completely over the battery post.

E. Check the lower end of the

vent tube shield into which you in

serted the clear plastic vent tube. The lower end of the black shield

must be located in front of the

wheel shaft axle. Move it there if necessary. Your electric start tiller is now fully assembled.

C. The clear plastic vent tubing must be installed next. If coiled up, straighten it out. Slide one end

of the tube (E, Figure 2-25) over the vent fitting (F) at the top of the battery. Slide the other end down into the black vent tube shield (G).

WARNING

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

Be sure the vent tube is not

crimped, pinched or folded.

Figure 2-26: Connect positive (+) cable (A) to positive battery post (B). Connect negative (-) cable (C) to negative battery post (D). Be sure to posi tion bolts (E) and nuts (F) as shown. After the connections are secure, slide black rubber boots (G) completely over battery posts.

Page 20

Section

Learn the locations of the features

and controls on your machine

before starting the engine. Taking the time now to understand the lo cation, function and operation of these controls will greatly add to the productive use, safe operation, and enjoyment of your machine.

For detailed step-by-step operating

instructions, please refer to

“Section 4: Operation.”

TILLER FEATURES AND CONTROLS IDENTIFICATION

The major tiller controls and features are identified and illustrated on the next few pages. The use and operation of each control and feature is cov ered in detail in Section 4 “Operating Instructions.”

^ WARNING

TO AVOID PERSONAL INJURY OR

DAMAGE TO EQUIPMENT;

• Before using your tiller or PTO

Power Unit for the first time, be come thoroughly familiar with the

operation of the controls by mov

ing them to their various posi tions while the engine is not run

ning. The proper operation of

each control is discussed in detail

in Section 4.

NOTE: All references to left, right,

front and rear of the machine are

determined by standing behind the

handlebars and facing the direc tion of forward travel.

Figure 3-1: A- Wheels/Tines/PTO Drive Lever; B- Forward Interlock Levers; C- Wheel Speed Lever; D- Tines/PTO Clutch Lever; E- Depth Regulator Lever; F- Handlebar Height Adjustment Lever.

A) Wheels/Tines/PTO Drive Lever

This lever is used to engage and disengage power from the engine to the transmission. It has three operating positions: FORWARD, NEUTRAL and REVERSE. See “A” in Figure 3-1.

REVERSE - Lever moved all the way up and held in that position. Use for moving machine in re verse. Do not operate tines or PTO attachments when in REVERSE. To stop moving in reverse, release lever and it automatically returns to the NEUTRAL position.

FORWARD - Lever moved down until it engages in drive position. Use to start wheels and tines mov ing in forward direction, or to ap ply power to any optional PTO (Power Take Off) attachments. To stop wheels, tines, or any PTO at tachment, move lever to NEUTRAL

NEUTRAL - Lever moved in be tween FORWARD and REVERSE positions. Use to stop wheels, tines or any PTO attachment. Al ways place lever in NEUTRAL be fore starting engine, and before en gaging wheels, tines, or attachments.

by lifting it up and letting it go.

Page 21

^m^sm^sss-

Mrols

Note: When Wheels/Tines/PTO Drive Lever moves from one position to another, this moves the clutch roller (see Photos 3-lA, 3-lB, 3-lC) to its proper po-

Ailjuitment Block

■J¡

Photo 3-1 A: When Wheets/Tines/PTO Drive Lever is in FOR

WARD position - the dutch roller will be eng^ed below the

adjustment block. Verify this.

■

•mJr-d.

sition on the belt adjustment block. Check the clutch roller on your tiller to see it’s positioned as shown in the photos. If not positioned correctly, see your local authorized dealer.

B) Forward Interlock Levers

The two Forward Interlock Levers are located

below the handlebar grips (see B, Figure 3-1).

Operator must keep at least one lever squeezed against handlebar grip when Wheels/Tines/PTO Drive Lever is engaged in FORWARD. (The levers do not affect operation when Wheels/Tines/PTO Drive Lever is in REVERSE.) If both levers are released before first returning the Wheels/Tines/PTO Drive Lever to NEUTRAL, the engine will stop.

IMPORTANT- This is a safety feature should you lose control of your tiller and be unable to move the Wheels/Tines/ PTO Drive Lever to NEUTRAL.

C) Wheel Speed Lever

This lever (C, Fig. 3-1) is used to select from two wheel speeds and the free-wheeling mode. It has three operating positions: SLOW, FAST and FREE WHEEL.

Photo 3-1B: When Wheels/Tines/PTO Drive Lever is in NEU

TRAL position - dutch roller (G) must be located approxi

mately as shown on the face of the adjustment block (H).

Photo 3-1C: When WheelsJTines/PTO Drive Lever is held up

in REVERSE position- clutch roller (G) must be located higher on the face of the adjustment block (H).

To avoid damage to transmission, always put Wheels/Tines/PTO Drive Lever in NEUTRAL before shifting Wheel Speed Lever. When selecting SLOW or FAST positions, roll machine while shifting to fully engage wheel gears.

SLOW - Lever moved all the way down. Use for normal tilling or low speed transporting.

FAST - Lever moved all the way up. Use for cultivat ing, transporting.

FREE WHEEL - Lever in between SLOW and FAST positions (wheels will roll freely). Use for transporting without engine power and when using stationary PTO attachments.

Page 22

Figure 3-1 (Repeat) : A- Wheels/Tines/PTO Drive Lever; B- Forward Interlock Levers; C- Wheel Speed Lever; D- Tines/PTO Clutch Lever; E- Depth Regulator Lever; F- Handlebar Height Adjustment Lever.

D) Tines/PTO Clutch Lever

This lever (D, Figure 3-1) is used to engage or disengage power from the transmission’s PTO clutch to the tines or any optional PTO attachments. It has two oper ating positions: ENGAGE and DISENGAGE. To avoid damage to the transmission, always put Wheels/Tines/PTO Drive Lever in NEUTRAL before shifting Tines/ PTO Clutch Lever.

ENGAGE - Lever moved into de tent slot furthest from engine. Use to operate tines or other PTO attach ments. After shifting to ENGAGE, briefly operate machine in FOR WARD to fully engage PTO clutch.

DISENGAGE - Lever moved into detent slot nearest engine. Use to disengage power to tines or other PTO attachments before transport ing, loading, turning, or backing up.

E) Depth Regulator Lever

Used to regulate the tilling depth of the tines. It also has a TRAVEL position, which places

the tines out of the ground. Located at the rear of the tine hood. See E, Figure 3-1. To oper ate the lever, pull it straight back and then slide it up or down to any of 8 notched settings.

The highest notch places lever in the TRAVEL setting. For shallow tilling and cultivating, place lever in second or third notch from top. The other notches are for deeper tilling and for power composting.

WARNING

To avoid personal injury, al

ways place the tines in the TRAVEL position before start ing engine. This prevents tines from touching ground until you are ready to begin tilting.

F) Handlebar Height Adjustment Lever

Located near the bottom of the handlebars (F, Figure 3-1), this lever is used to adjust and lock the handlebars at any of four heights.

Note: Swapping the positions of

the inside handlebar ratchets ex pands the choice of handlebar heights from two to four settings.

^ WARNING

For use with the PTO Chipper/ Shredder attachment only, the handlebars can be swung 30° to the right side by loos ening the mounting bolt at the bottom of the handlebar base. Never operate your tiller or other attachments with the handlebars swung out to the right side. This could result in unsafe han dling and personal injury.

Page 23

Features aud

Figure 3-2A: 7HP Briggs & Stratton engine. A- Engine throttle lever; B- Choke control; C- Recoil starter; DKeyswitch starter; E- Fuel tank shut-off valve; F- Rotary switch; G~ Secondary engine throttle control lever.

Figure 3-2B: 8HP Kohler engine. A- Engine throttle lever; B- Choke control; C- Recoil starter; D- Keyswitch starter; E- Fuel tank shut-off valve.

ENGINE FEATURES AND CONTROLS IDENTIFICATION

The following are descriptions of the controls on your particular engine (see your engine shown above). Additional information on the engine is given in Section 4 “Operation” and in the engine manufacturer’s Owner’s Manual which was included in your literature package.

WARNINr

WARNING

Engine Throttle Lever

VVHItniliU Your engine’s manually oper-

To avoid serious personal in

jury or damage to equipment, do not start your engine at this time. Complete starting instructions are described in Section 4 “Operation.”

Located on right-side handlebar (“A” in Fig. 3-2A or 3-2B). Used

to adjust engine speed as well as

start and stop engine. (Briggs & Stratton engine also has a throttle

control lever on the front of the en gine.)

For faster engine speeds, move

lever toward FAST position. Move lever toward SLOW to re duce engine speed. Move lever to a halfway position to start a cold engine. Move lever to STOP to turn the engine off. Various speed adjustments lie between FAST and STOP.

ated choke control lever (see “B” in Fig. 3-2A or 3-2B) makes start ing a cold engine easier. The Choke increases or decreases the amount of air in fuel-air mixture inside carburetor. Move lever to CHOKE position before starting a cold engine. After starting, let en gine run for a few seconds in CHOKE position. Move lever to a halfway setting for another few seconds. After this, move lever to the position opposite CHOKE for normal operation.

Engine Recoil Starter

Located at front of engine. See “C” in Eig. 3-2A or 3-2B. Used to manually start engines not equipped with electric keyswitch. Before pulling out recoil starter rope, Wheels/Tines/PTO Drive Lever must be in NEUTRAL and your free hand must be on top of fuel tank to stabilize tiller.

Key Switch Starter

Electric start engines are started with Keyswitch Starter next to the 12-volt battery (see “D”, Eig. 3-2A or 3-2B). Keyswitch starter has three key positions- OFF, RUN and START. Turn key to START to start engine. Once started, key moves automatically to RUN posi tion. Turn key to OFF to stop en gine. (A second way to stop en gine is to move Engine Throttle Lever to STOP position.)

Fuel Tank Shut-Off Valve

Located underneath gas tank (“E”, Eig. 3-2A or B). Opening valve allows fuel to flow to carbu

retor. Valve must be open when

tiller is used. Close valve when tiller is transported or stored.

On/Off Switch

The 7 HP Briggs & Stratton en gine also has a rotary On/Off Switch (“F”, Fig. 3-2A) which should be turned to ON before op erating engine.

Page 24

Section

This Section explains how to:

• Perform Pre-Starting Break-In and Preparation

• Test the Forward Interlock Safety System

As with any other piece of outdoor

powered equipment, getting the “feel” for how your machine oper ates and getting to kno\¥ the best techniques for particular jobs are very important to overall good per formance.

Read this Section very thoroughly

before you start the engine. The

instructions given here will help you familiarize yourself with the tiller and have you operating it effi ciently in a short time.

A WARNING

Before operating your machine,

be sure you read and understand all safety, controls, and all operating instructions in this

Owner/Operator Manual and on the decals on your machine.

• Start and Stop the Engine

• Operate and Turn the Tiller Around

• Transport the Tiller

• Change Belt Range Speed (from High to Low and back)

• Till in the Garden

• Till Up and Down Slopes

• Use Special Tilling Techniques

• Remove and Replace the Tine Attachment

• Use the PTO Power Unit with Other Attachments

... .. .

Failure to follow these instructions

can result in serious injury or

property damage.

NOTE: All references to left, right,

front and rear of the machine are de termined by standing behind the

handlebars and facing the direction

of forward travel.

S’

Page 25

Before operating the tiller, be sure you have first read and under stood all Safety Instructions in Section 1 and Controls information

in Section 3. First practice using the tiller in an open, level area. Practice without the tines revolv

ing - disengage the tines with the

Tines/PTO Clutch Lever. After a thorough practice session, the tiller can then be moved to the garden.

^ WARNING

Your inter and its optional PTO attachments are capable of causing serious injury to untrained or careless opera tors.

To avoid serious personal in jury or property damage, read the Owner/Operator Manual provided with any op tional accessories or attach ments before using the tiller or PTO power unit.

Break-In Operation

During the first few hours of new tiller operation, the following maintenance steps are required. For subsequent maintenance pro cedures, refer to Section 5 — Maintenance.

Thereafter, check tension every 10

operating hours.

4. Check Hardware. After two hours of new operation, check for loose bolts and nuts. Thereafter, do this every 10 operating hours.

Preparation Before Starting

Make the following checks and

perform the following services be

fore starting the engine.

1. Check Engine Oil Level.

2. Check the Air Cleaner. It must be securely assembled and clean.

3. Check Safety Guards. All guards and covers must be se curely in place.

4. Attach Spark Plug Wire.

5. Check Engine Cooling System.

The cooling fins and air intake screen must be clear of debris.

6. Adjust Handlebar Height.

7. Check Battery Fluid Level.

Cells must be filled to proper level, cell caps must be on tight, and all electric wire connections secure.

8. Put Gasoline in the Euel Tank.

Use fresh, clean, unleaded fuel. Fuel goes stale if stored for more than six months. Do Not Mix Oil With Gasoline!

a. Clean the fuel cap area before removing the fuel cap.

b. Use a clean funnel to add gas.

c. Fill tank to within 1/2" of the top to prevent spills and allow for fuel expansion.

d. For 7H1P Briggs & Stratton engines: • lead-free gas is rec

ommended (leaded gas may be used); • minimum octane rating must be at least 77; • fuel con taining alcohol (such as gasohol) is not recommended; • if using gasohol, first see engine manufacturer literature enclosed for cautions and procedures. e. For 8HP Kohler engines: use unleaded regular gasoline with a minimum octane rating of 87 (leaded regular is accept able).

f. Replace fuel cap securely be

fore starting the engine.

1. Change Engine Oil. On Briggs & Stratton and on Kohler engines, change oil after the first 5 hours of use. Thereafter, change oil every

10 operating hours. Increase the frequency of oil changes under very dirty or dusty conditions.

2. Check Transmission Gear Oil Level. After the first two hours of

new operation, check the gear oil levels in the PTO power unit and the tine attachment transmissions.

Thereafter, check them every 30 hours.

3. Check Drive Belt Tension.

Due to belt seating, a tension ad justment may be needed after the

first 2-to-3 hours of new operation.

DANGER

Gasoline is highly flammable and its vapors are explosive. Follow these safety practices to prevent injury from fire or explosion;

• Never fill tank if engine is running or hot from use. Let engine and muffler cool down before refueling.

• Do not permit open flames, sparks, matches or smoking in the fueling area.

• Fill fuel tank outdoors in a well-ventilated area. Wipe up any fuel spills and move tiller away from fumes before starting the engine.

• Use only an approved fuel container and lock it safely away from children.

• Store fuel and the tiller in a well-ventilated area. Do not store fuel or tiller where fuel vapors may reach an open flame or spark, or an igni tion source (a hot water heater, furnace, clothes dryer, electric motor, or the like).

• Let engine cool before storing.

• Never bring a metal fuel can near battery post on electric start model tillers. An electrical short circuit could result, causing an explosion of the gasoline or of battery gases.

Page 26

Test Operation of Forward Interlock Safety System

The Forward Interlock Safety System is designed to shut the tiller engine off immediately if you loose control of the tiller or become separated from it.

Simply, it is an electrical ground ing system that connects the two Forward Interlock Levers on the handlebars to the engine’s ignition system. Either one (or both) of the Forward Interlock Levers must be kept squeezed against the handle bar grip(s) whenever the Wheels/ Tines/ PTO Drive Lever is en gaged in FORWARD. If you re

lease both the Forward Interlock Lever(s) before first moving the Wheels/Tines/PTO Drive Lever to NEUTRAL, the interlock system will ground out the engine’s igni tion system and stop the engine.

(The interlock system also prevents the engine from-starting if the Wheels/ Tines/PTO Drive Lever is engaged in FORWARD.)

This system has an electro-me chanical design, and so is subject to normal wear and possible malfunc tion. As such, it must be checked for proper operation before you use the tiller or PTO power unit each time.

How to Check the Interlock System:

1. Move tiller outside on level ground. Remove any obstacles.

2. Check that the Forward Interlock wire harness plug at the bottom of the handlebars is firmly connected to the receptacle on the top, right side of the transmission. See Photo 4-2.

Photo 4-2: Plug and receptacle of Forward Interlock Safety System must be securely connected.

3. Move Wheel Speed Lever to SLOW position and move Tines/ PTO Clutch Lever to DISENGAGE.

4. Start engine as described later in

this section. Set engine throttle lever to SLOW, and let engine warm up.

5. Squeeze and hold just one of the Forward Interlock Levers against the handlebar grip while moving the Wheels/ Tines/ PTO Drive Lever down to FORWARD. (See Photo 4-3). As the tiller moves forward, release the Forward Interlock 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 return the Wheels/ Tines/ PTO Drive Lever to NEUTRAL. Repeat this test to check that the engine begins to stall out when the other Forward Interlock Lever is released.

6. If the engine does not begin to

shut off when either Forward Interlock lever is released, shut the engine off, remove the key (if elec tric start), and do not operate the

tiller or PTO power unit until the

system has been repaired and is

functioning properly.

IMPORTANT - To avoid possible

damage to the Forward Interlock

Safety system, do not use high-

pressure sprays near the wire har

ness receptacle or neutral plunger

assemblv.

DANGER

The Forward Interlock Safety

System is designed for the operator’s safety. Do not dis connect or attempt to defeat

the purpose of the system. If the system malfunctions, im

mediately contact your local authorized dealer or the TROY-BILT Technical Service Department for assistance. Do not use the tiller or the PTO power unit until the Forward Interlock Safety System is functioning prop erly. Always test the system before using the tiller or PTO power unit.

Photo 4-3: Squeeze one Forward Interlock Lever and then move Wheels/Tines/PTO Drive Lever down to FOR

WARD.

Page 27

Figure 4-4: Tiller and engine controls.

Clutch Lever

Starting and Stopping the Engine

IMPORTANT- Use the follow ing steps to practice starting and stopping the engine ONLY. Do not attempt to drive tiller or PTO Power Unit until you have read all operating instructions in this Owner/Operator Manual.

To Start the Engine:

1. With engine off, place the

Wheels/Tines/PTO Drive Lever in NEUTRAL position (see Figure 4-4). If in FORWARD position, tap or lift the lever up and then re lease it to obtain NEUTRAL.

2. Lower Depth Regulator Lever (refer to Figure 4-4) until tines are

off the ground.

3. Move Wheel Speed Lever

(Figure 4-4) to either SLOW or FAST position. Be sure to roll the

wheels while shifting the lever until the wheels are engaged.

Note: If using a PTO stationary

attachment, move lever to FREE WHEEL and block the wheels to prevent the equipment from moving.

4. Move Engine Throttle Lever on the handlebars forward (away from the STOP position). On the Briggs & Stratton engine, the Throttle Control Lever on the engine will also move.

NOTE: On the Briggs & Stratton engine only, turn the rotary On/Off Switch to ON.

5. Put the Tines/PTO Clutch Lever in DISENGAGE position (see Figure 4-4). [Use the ENGAGE position if you want the tines to revolve or you wish to apply power to a PTO-driven stationary attachment.]

6. Move engine Choke Control Lever to CHOKE position (see Fig. 4-5 or Photo 4-6). Note: a watm en gine may start without choking it.

Note: Fuel tank shutoff valve must be in the OPEN position (see either Figure 3-2A or Figure 3-2B).

7. For recoil start engines: a.- Stabilize tiller by placing one

hand on the fuel tank of the Briggs engine or on the air cleaner of the Kohler engine.

b.- Use your other hand to slowly puU out the start rope until resis tance is felt. Then rapidly pull the rope out to start the engine. Let it rewind slowly.

8. For electric start engines: a. - Turn key to START position.

Do not hold key at START for more than a few seconds. Starter damage can occur if it is cranked more than 15 seconds per minute.

b. - Release key when engine starts. It will move to RUN posi tion automatically.

9. If engine does not start after

several tries, stop all attempts for about 10 minutes, then repeat start ing steps. See engine manufac turer literature for assistance.

10. After engine starts, slowly

move Choke Control Lever to a halfway position, then to the posi tion opposite the CHOKE position.

11. Move Throttle Lever to SLOW

position. Let engine warm up.

Page 28

Qpemtim.

Figure 4-5: Choke Control Lever on the 7HP engine. Left for CHOKE; right for RUN.

3? V- . -■ ^

To Stop the Engine:

IMPORTANT- If the engine does not stop after turning the keyswitch to OFF or moving the Throttle Lever to STOP, then stop the engine hy moving the Choke Control Lever to CHOKE position. This makes it stall out.

Use this procedure only in an emergency. Repair the keyswitch or Throttle Control Lever.

NOTE: The 7 HP Briggs & Stratton engine has a Throttle Control Lever on the front of the engine which can also be used to stop the engine.

1. To stop wheels and tines, move Wheels/Tines/PTO Drive Lever to NEUTRAL position, then release both Forward Interlock Levers.

2. Move engine Throttle Lever to STOP position, and on electric start models turn key to OFF. Remove the key for safekeeping.

Starting the Electric Start Engine with the Recoil Starter Rope

If necessary, an electric start en gine may be started with the recoil start rope. Before doing so, follow the procedure below applying to you.

1. If battery condition is OK (not “dead” or damaged), leave it con nected on the tiller so it gets

recharged during engine operation. Be sure battery cells are full and cables are connected before start ing the engine.

2. If battery is “dead” or damaged, disconnect and remove it for test ing by a qualified mechanic. Before starting engine, wrap metal terminal at end of positive cable with electrical tape and secure the cable to the battery bracket to pre vent electrical sparking.

3. Before starting engine with re coil start rope, turn keyswitch to RUN position. Throttle Lever must be in START position and choke lever in FULL CHOKE.

Photo 4-6: Choke Control Lever on the 8HP engine. Up for CHOKE; down for RUN.

Cold Weather Operation

Below 40°F, take the following steps to protect

your engine and transmission from damage:

1. Use a lighter weight motor oil.

2. Let engine warm up before putting it under a load.

3. Use winter-blend gasoline.

4. Use the correct weight gear oil in PTO Power Unit transmission.

5. Warm up the transmission gear oil as fol lows: with engine running, move Wheel Speed Lever (see Figure 4-4) to FREE WHEEL (then block wheels

so they can’t roll), put

Tines/PTO Clutch Lever

in DISENGAGE, then

squeeze one of the

Forward Interlock

Levers and shift the

Wheels/Tines/PTO

Drive Lever to FOR

WARD.

6. If wheels are frozen

to the ground, melt ice

with warm water.

Page 29

To Operate the Tiller

CAUTION

To avoid serious personai injury or

damage to equipment:

• Always place Wheels/Tines/PTO Drive Lever in NEUTRAL before starting engine, and before en gaging wheels, tines or other PTOdriven attachments.

• Be sure there are no obstacies behind you before reversing.

• Wheels/Tines/PTO Drive Lever should automatically return to NEU TRAL when released from RE VERSE position. If it does not, move lever to NEUTRAL manually and see Section 5 to adjust it.

• No reverse motion should occur if Wheels/Tines/PTO Drive Lever is not held up in REVERSE. See Section 5 for adjustment steps. Do not use tilier uniess properly ad justed.

• Always return to NEUTRAL and let all motion stop before shifting to FORWARD or REVERSE.

When first practicing, keep the Tines/PTO Clutch Lever in DIS ENGAGE position and the Wheel

Speed Lever in SLOW position.

To Begin Tilling:

1. Start the engine (see previous instructions). The Wheels/Tines/ PTO Drive Lever must be in NEU TRAL before starting the engine. The Wheel Speed Lever must be in either SLOW or EAST position.

2. Test the Forward Interlock Safety System. See page 26.

3. Set Depth Regulator Lever to desired depth and increase engine

speed. (When “practicing”, keep

tines in the “Travel” position.)

4. Move Tines/PTO Clutch Lever to ENGAGE position (if practic

ing, leave in DISENGAGE).

IMPORTANT - Do not move Tines/PTO Clutch Lever to EN

GAGE unless Wheels/Tines/PTO

Drive Lever is in NEUTRAL.

Tiller damage may occur!

5. For forward motion of wheels

and tines, squeeze and hold either

or both Forward Interlock Levers (see Photo 4-7) against the handle bar grip, then move the Wheels/ Tines/ PTO Drive Lever down to FORWARD position.

6. When the tiller moves forward, relax and let the wheels power the tiller along while the tines dig. Walk behind and a little to one side of the tiller (on the side that is not yet tilled - see Photo 4-8). Use a firm grip with one hand on the han dlebars, but keep your arm loose.

IMPORTANT- Let the tiller move ahead at its own pace. Do not push it ahead—this reduces operator control. Do not push handlebars down attempting deeper digging— this takes weight off the wheels, cuts trac tion, and causes the tines to try to propel the tiller.

WARNING

To avoid injury, keep hands, feet, iegs, and clothing away from revolving tines.

Photo 4-7: Squeeze either or both Forward Interlock Levers UP before moving Wheels/Tines/PTO Drive Lever down into FORWARD.

Photo 4-8: Guide tiller with one hand.

Page 30

7. To stop forward motion: tap or lift Wheels/Tines/PTO Drive Lever up to NEUTRAL and let go of the Forward Interlock Levers. The wheels and tines will stop and the en gine will continue running.

8. In an emergency, stop all for ward motion by letting go of all handlebar control levers- this shuts off the engine too.

9. For reverse motion: a. Do not till while in RE

VERSE.

b. Put Tines/Wheels/PTO

Drive Lever in NEUTRAL and reduce engine throttle speed. Verify that the area behind you is clear.

c. Move Wheel Speed Lever to

the SLOW position.

d. Move the Tines/PTO Clutch

Lever to DISENGAGE.

e. Lift up handlebars until tines

are off the ground, then move (and hold) Wheels/ Tines/PTO Drive Lever all the way up. The Forward Interlock Levers do not need to be squeezed to use reverse.

10. To stop reverse motion:

Release the Wheels/Tines/PTO Drive Lever- it automatically re turns to the NEUTRAL position. This stops the wheels immediately. (The Forward Interlock Levers will not stop REVERSE motion.)

To Stop the Engine

Move the engine throttle lever to the STOP position (and turn key to OFF on electric start models). Remove the key for safekeeping.

CAUTION

To Help Avoid Personal Injury

or Damage to Equipment:

• Be sure no obstacles are behind you before operating

the tiller in REVERSE.

• Disengage the tines, reduce

engine speed, and move the Wheel Speed Lever to SLOW position before operating in REVERSE. Avoid using FAST wheel speed until you are used to reversing.

Turning Around

Turning the tiller around is easy and just requires practice. First find the balance point between the engine and the tines by lifting up

the handlebars. Once you have found the balance point, then let the powered wheels do the “turn ing” as you push sideways on the handlebars in the direction of the turn. Practice the turning maneu ver described here in a large open area. Once comfortable turning the tiller, you can then take it to the garden area. See Photo 4-9 below.

Turning Procedure:

1. At the end of a row, move the Wheels/Tines/PTO Drive Lever to NEUTRAL position and reduce the engine speed.

2. Move the Tines/PTO Clutch Lever to DISENGAGE position.

away from the tines (which should be disengaged). Let the powered

wheels do the hard work. The in side wheel will pivot in place while the outside wheel drives the tiller around in the direction of the turn. Refer to Photo 4-9.

Note: Use REVERSE if necessary to turn in a limited space.

4. When the turn is complete, shift to NEUTRAL and lower the han

dlebars. Move Tines/PTO Clutch Lever back to ENGAGE position and resume forward operation.

WARNING

To help avoid personal injury from revolving tines, always put the Tines/PTO Clutch Lever in DISENGAGE before turning tiller around.

3. Resume forward operation, and lift handlebars until tines are above the ground. Find the balance point between the engine and the tines. Then PUSH the handlebars to swing the tiller around. Be very

careful to keep your feet and legs

Photo 4-9: To turn the tiller around most easily, lift up handlebars to find

“balance” point between engine and tines, then push against handlebars in the direction of the turn while the powered wheels do the hard work.

Page 31

Transporting Your Tiller

The tiller’s powered wheels make moving the tiller to and from the garden easy when the engine is running. If the engine is off, you can also roll the tiller to another lo cation if the Wheel Speed Lever is in FREE WHEEL position.

WARNING

To help avoid personal injury from revolving tines, always

move Tines/PTO Clutch Lever to DISENGAGE position be fore transporting, loading or

unloading tiller.

To Transport The Tiller Around Your Property:

1. Place the Tines/PTO Clutch Lever in DISENGAGE position.

2. Move Depth Regulator Lever down all the way (TRAVEL setting).

3. If using engine power, move Wheel Speed Lever to either SLOW or FAST, and use the Wheels/Tines/PTO Drive Lever to drive the wheels.

4. If the engine is stopped, move Wheel Speed Lever to FREE WHEEL, and manually push tiller.

To Load Or Unload The Tiller:

1. Use loading ramps that are strong and wide enough to safely hold the weight of the tiller and the operator combined— your tiller weighs between 280 and 325 lbs.

2. Move the Tines/PTO Clutch Lever to DISENGAGE position.

3. Move Wheel Speed Lever to SLOW position and reduce the en

gine throttle speed.

4. To go up ramps, use FOR

WARD drive and follow the tiller up the ramps (Figure 4-10).

5. To go down ramps, use RE

VERSE drive and back down the

ramps. Never go down the ramps in FORWARD drive since the tiller could tip forward, exposing you to the tines (which should be disengaged as we’ve recom mended). See Figure 4-11.

Page 32

To Change Belt Speeds

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 you move the for ward belt into. By moving the belt from one speed range into the other, in combination with the FAST and SLOW wheel speeds of fered by the Wheel Speed Lever, you obtain a choice of four differ ent forward wheel speeds and two different tine speeds.

Changing the belt from LOW range into HIGH range (or back again) is simply a matter of mov ing the belt from one set of grooves on the engine and trans mission pulleys to a second set of grooves. This change is done quickly without tools. See Photos 4-12 through 4-16 for reference.

By using the two belt speed ranges with the two Wheel Speed Lever positions (FAST and SLOW), here are the wheel speeds / tine

speeds available to you:

At 3000 RPM engine speed, the wheel

and tine speeds you can choose from are;

Wheel

Speed Belt Position Position Speed Speed

Low Range Slow .5IV1PH 146RPM Low Range High Range Slow High Range

Lever Wheel Tine

Fast

1.2MPH 146 RPM .7MPH 200 RPM

1.72MPH 200 RPM

When the tiller is moving in REVERSE, the wheels and tines are powered by the rubber reverse disc and not by the belt. So you have only two

reverse speeds as determined by the SLOW and FAST positions of the Wheel Speed Lever.

IMPORTANT: Proper belt ten sion is important to good perfor mance. Check tension after first 2 hours of new operation; then every 10 operating hours.

S.i Î

High Range

Photo 4-12: Belt range positions.

To Change From LOW Range to HIGH Range

1. To avoid personal injury, shut

off engine, let all moving parts come to a complete stop, then dis connect the spark plug wire and move it away from the spark plug before making any adjustments.

2. Place Wheels/Tines/PTO Drive Lever in NEUTRAL.

3. Kneel on left side of tiller. To create belt slack, reach over to right side of the pulleys and push in at the center of the belt with a finger. At the same time, use your left hand to work the belt part-way into the forward groove of the transmission (lower) pulley. See Photo 4-13. Now go to the other side of the tiller- finish seating the belt in the forward groove.

4. On the left side of the tiller,

work the belt as much as possible into the forward groove in the en gine (top) pulley. See Photo 4-14. Finish seating it from the right side of the tiller.

Note: If extra belt slack is needed to move the belt, just raise the Wheels/Tines/PTO Drive Lever up into REVERSE. This lowers the engine pulley, creating the slack.

5. Check both sides of the pulleys to see the belt is seated in HIGH range grooves of each pulley.

“•si

^ WARNING

To help avoid seri ous personal in jury, stop the en gine, remove the ignition key, dis connect spark plug

wire and move the wire away from the spark plug, and let engine and

Low Range

Photo 4-13: Move belt on transmis sion pulley into the forward groove.

Photo 4-14: Move belt on the engine

pulley into the forward groove.

muffler cool down

before changing

belt speeds.

Page 33

To Change From HIGH Range to LOW Range

1. To avoid personal injury, shut off engine, let all moving parts come to a complete stop, then dis connect spark plug wire and move it away from the spark plug before making any adjustments.

2. Move the Wheels/Tines/PTO Drive Lever to NEUTRAL.

3. Stand on left side of tiller. Use

your right hand to hold the Wheels/Tines/PTO Drive Lever UP in REVERSE position. Then use left hand to move belt from front groove to rear groove on the engine pulley (top pulley). Refer to Photo 4-15. Go to right side of tiller and finish seating the belt.

4. Still holding the lever up in RE

VERSE position, move the belt

Photo 4-15: With Wheels/Tines/PTO Drive Lever held UP in REVERSE,

move belt on engine (upper) pulley

over into its rear groove.

from the front groove to the rear groove on the lower transmission pulley. Start at the left side of the tiller and finish seating the belt from the right side (Photo 4-16).

Operation

Photo 4-16: Now move belt on transmission pulley (lower pulley) over into its rear pulley groove.

5. Check that the belt is fully seated in the pulley grooves. Look at this from both sides of the tiller.

Choosing Tiller Wheel and Tine Speeds

Your tiller offers/o«r wheel/tine speed combinations to handle ev ery tilling task and garden job. By experimenting, you’ll find the right tilling depth, engine speed, and wheel and tine speed combination that is best for the soil in your gar den. Here’s how to approach jobs:

WHEEL SPEED AND BELT RANGE SELECTION GUIDE

IMPORTANT — For correct wheel speed and belt range choices when using attachments or accessories

other than tines, read the Owner/Operator Manual provided with the attachment or accessory.

SLOW GEAR, LOW BELT RANGE

Till in sod. Till in hard clay. Till under standing cornstalks

in tough soil conditions.

Till under cover crops.

Prepare a deep seedbed. Till in stony soil. Till in residues and organic

matter.

Mix in fertilizers, manure.

SLOW GEAR, HIGH BELT RANGE

Till in sod or hard clay. Till under standing cornstalks

(slow, steady speed allows time to shred stalks).

Till under cover crops (best

wheel speed and belt speed range in most soils).

Prepare seedbeds (best speed

choice in most soils). Till in stony ground. Build raised garden beds. Mix in fertilizer. Use hiller wings in hard soil. Mix fertilizer and manure. Till residues, organic matter.

1. Advance the throttle lever so

the engine has sufficient power.

2. Do not set the depth regulator at too deep a setting to avoid having the engine labor or the tiller buck.

3. Your settings are “ideal” when the tines are breaking up the soil nicely, the engine is not laboring,

and your progress is steady and smooth. See the Selection Guide

below for hints.

FAST GEAR, LOW BELT RANGE

Go over seedbed for the last

time before planting crops.

Cover over seeds in wide row

or plot planting (raise han dlebars to avoid going too deep).

Best for hilling and furrowing.

Best for making raised beds.

Cultivate (raise handlebars to

avoid going too deep). Good for tilling large areas. Till organic matter in. Cultivating between raised

beds with hiller-furrower at

tachment.

WARNING

The HIGH speed belt range

position combined with a FAST wheel speed setting propels the tiller at the

fastest pace. To help avoid

personal injury or property damage if using this speed combination, reduce the en gine throttle speed.

FAST GEAR, HIGH BELT RANGE

Prepare seedbeds for planting. Cover seeds with less need to

hold up the handlebars.

Cultivate (tiller travels faster,

rides higher on the soil; al lows engine RPM to be re duced; handlebars don’t have to be raised).

Keep large areas tilled and

cultivated in the summer. Till under organic matter. Move tiller location quickly. Cultivate between raised beds

using the hiller/furrower.

Page 34

TILLING IN THE GARDEN

Here are tips and suggestions to help you get the most satisfaction and performance from your tiller.

Tilling Depths

When you begin tilling in the garden, please go slowly and easily at first. It’s very important that you not try to dig too deeply too quickly. Soil that hasn’t been tilled for some time must be tilled up gradually— it’s almost impossible to dig down 4"-to-5” on the first pass with the tiller in compact soil.

IMPORTANT — Start tilling at a very shallow depth regulator setting, only 1" or 2" deep the first time through the garden area.

With each succeeding pass, you can adjust the depth regulator lever upward so the tines will dig an other inch or two deeper. Hint -

water your garden area a few days before tilling to make the job much easier. If it is difficult to dig down

really deep, let the newly-worked soil “rest” for a day or two. It will then be easier to till.

Don’t till when the soil is too wet. Wet soil will leave large clumps after tilling - and will only harden later. Hint - test the soil by

squeezing it - if it compresses too easily it’s too wet to till.

Seedbed Preparation

In a well-prepared seedbed, the soil will be loose and fine-textured. Try to till the first time a few weeks before the planting date; till the second time a few days later; then till the third time on the day of planting. This will make the seedbed as loose and well-aerated as possible.

When preparing the soil, go down the same path twice in the

first row, then overlap each suc

ceeding row by one-half the tiller’s width. See Figure 4-18. Next, make a second pass through the seedbed at a right-angle to your earlier rows (refer to Figure 4-19). Again, overlap each row by onehalf the width of the tiller. (In very hard ground, several passes over the seedbed may be needed.)

If there is not enough room to make a second pass at a right-angle, go back and repeat the first pass, overlapping the rows by one-quar ter the width of the tiller.

Plan to expand your garden the following year? Bust up the sod in the Fall - the ground will be com pletely broken down when Spring arrives. You can also plant a cover crop in the Fall in that newly tilled area - the cover crop will keep the soil intact and enrichen it.

WARNING

To help avoid personal injury, be aware that the tiller can unexpect edly bounce up or jump ahead and be propelled away from you if the tines strike hard or frozen ground, or buried obstacles like iarge stones, roots or stumps. Always use the following precautions to heip maintain controi of the tiller:

• Walk behind and to the side of the tiiier. Use one hand on the han dlebars, relaxing your atm but with a secure hand grip.

• Use shallow depth regulator set tings. Till gradually deeper.

• Use slower wheel, tine and en gine speeds.

• Clear the tilling area of all large stones, roots and other debris.

• Do not put downward pressure on the handlebars. If needed, apply slight upward handlebar

pressure to keep the tines from digging too deeply.

•Avoid contacting hard soil or sod at the end of a row - reduce engine speed and lift handlebars to raise tines out of the soil.

• In An Emergency, stop tines and wheels by moving Wheels/Tines/

PTO Drive Lever to NEUTRAL. If

you cannot reach the lever or have

lost control, Let Go Of The Han

dlebars and All Controls. The Forward Safety Interlock System

will stop the engine.

Photo 4-17: Use shallow depth reg ulator settings when tilling at first.

Figure 4-18: With each new row, overlap half of the previous row.

Figure 4-19: Till entire garden in

one direction. Then at a 9(f angle.

Page 35

Avoid Making Footprints

When making final tilling or cultivating passes through the garden, try to walk on the side of the tiller where you will be on as-yet untilled soil. Don’t leave footprints as shown in Photo 4-20.

Eliminating footprints means more than just a good

appearance in your garden. The lack of footprints

aids in preventing soil erosion and keeps weed seeds from being “replanted” in the newly tilled soil. Soil that hasn’t been compacted by footprints is also easier

for plant roots to grow in.

Cultivating

If you plan carefully before planting, you can leave enough room between plant rows for later cultivating with the tiller. That will eliminate hand-weeding or hoeing chores during the growing season!

The tiller hood is 22-'A” across. Allow for that width between rows plus additional room for plant growth (particularly bushy crops like beans, tomatoes, peas, etc.) See Figure 4-21.

■'■'Hr'

'i.'.■ '■

.' >

Photo 4-20: Avoid leaving footprints.

Power Composting

For a garden to be bountiful, the soil must be re plenished regularly. Harvested produce removes ni

trogen, phosphorous, and potassium from the soil — these plant nutrients must be replaced.

An easy and effective way to do this is to use your

tiller to chop, blend, and turn under all kinds of or ganic matter (crop residues, leaves, grass clippings, etc.). This material decomposes during the off-season and releases nutrients into the soil. See Photo 4-22.

When power composting with your tiller, adjust the

depth regulator to the deepest setting possible (move it up so one of the bottommost notches is engaged) without causing the engine to labor or the tiller to jump ahead. Till under crop residues as soon as possible after crop harvesting, as they’ll till under more easily when green. Use the HIGH belt range and SLOW Wheel Speed Lever position when power composting. If necessary, move the belt to LOW range to slow down the tine speed.

Figure 4-21: Allow sufficient room between rows for cultivating.

Last, plant a cover crop to protect the soil during the non-growing season. Then, in the Spring, the cover crop can be tilled under a few weeks prior to planting, providing more organic matter to help feed the soil.

j ' ■ ifSij.

Photo 4-22: After harvesting produce, till under crop residues to add nutrients to the soil.

Page 36

SPECIAL TROY-BILT GARDENING TECHNIQUE— Till Under Standing Cornstalks

After com is harvested, the stalks should be tilled into the soil while still green. If you wait until they’ve dried out, they’ll be harder to till under, and the roots will break loose from the soil which you don’t want! {Don’tpull the

roots out by hand or cut the stalks before tilling — it is only when the

stalks are still firmly anchored by

their roots that the chopping and cutting action of the tines gets a chance to work best.)

Three Rules For Tilling Under Cornstalks

Knocking down cornstalks and tilling them into the soil is not hard to do if you understand three basic

principles: First - As you move forward into a row of stalks, aim the tiller so the stalks go between tbe left wheel and the transmission case (see Photo 4-24). Don’t use the right wheel because damage could occur to the air cleaner, car buretor or throttle linkage. Second- Each new pass should overlap the previous pass by onehalf the width of the tiller. Third - Till as deeply as possible.

Photo 4-23: FIRST PASS-

FIRST PASS- aKjrii ^ Till along first ' V’ji/i; " -

cornstalk row,

cornstalk row. '* with right tiller

wheel up against but not touching

cornstalks, to loosen the soil next to the

cornstalks.

, Vfe'A .,d

,v,*i

■ "-i

‘ - —

Pull the Depth Regulator all the way UP and engage the lowest notch for deep tilling. Use either LOW or HIGH belt range and SLOW wheel speed gear position.

Note: Depending upon the size and height of the stalks, you may be able to use LOW belt range and PAST wheel speed gear.

Let the tilled in stalks decom pose for a week or so. Then till in the remaining residue as deep as possible. Again, overlap your till ing passes so everything gets thor oughly processed. After another week, sow a cover crop, like an nual rye grass.

Photo 4-24: SECOND

PASS-

Approach the row of corn stalks from

the opposite direction. Align tiller so row of stalks is between left wheel and

.mm

transmission case. Knock down stalks, partially bury ing them.

Photo 4-25:

THIRD PASS Go back over the stalks you ^

knocked down

from the op

posite direc

tion. This

buries much

of the residue

3"-to-4" deep.

V. , - ■ ■ ■ ■ ■ .' ' ^ ■

...\ IP?

Photo 4-26: FOURTH PASS-Till between the buried row and the next standing row to loosen soil. Now re peat instruc tions given for the first three passes.

Page 37

*ra

t-aij

Clearing Debris From The Tines

The Bolo Tines have a self cleaning action which reduces most vegetation tangling in the tines. However, grass, string, or tough vines can get tangled. It’s not necessary to remove all the

material, but you should get enough out so the action of the tines isn’t impaired.

To avoid tangling:

• Set depth regulator lever for deep

Tilling Up And Down Slopes

Planting space may be so lim ited that you only have sloped ground available for your garden. If so, please follow two very im portant guidelines for tilling on

slopes: 1) till only on moderate slopes, never on steep ground where footing is difficult; 2) we

recommend you plant rows up and

down the slope (rather than terrac ing crossways) to get more plant ing room and also sufficient room for cultivating. See Photo 4-27.

Growing a garden vertically on

a slope doesn’t have to mean soil erosion will be a major problem. You just need to put in enough or ganic matter so the soil has good moisture-holding ability, and you need to avoid making footprints or leaving wheel marks. This keeps erosion to a minimum.

tilling- this results in maximum chopping action.

• Till under crop residues or cover crops while still green.

• Sway handlebars from side to side (6"-to-12" either way) when power composting - this can clear tangled tines.

If tangling occurs, stop the engine,

disconnect the spark plug wire, let all moving parts stop, then use a

pocket knife or linoleum knife to clear away the tangled materials.

CAUTION

TO AVOID SERIOUS PERSONAL INJURY OR DAMAGE TO EQUIPMENT:

• Do not operate tiller on a slope too steep for safe operation. Go slowly on any slope. Make sure you have good footing.

• Wear footwear that increases stability and reduces slippage.

• Do not use FAST wheei speed position when on sloped ground.

• Do not shift the Wheel Speed Lever when heading up or down

a slope, if lever is accidentaily

moved to FREE WHEEL position,

the tiller could roll out of control.

^ WARNING

To help avoid personal injury, stop the engine, remove the electric start key, then dis connect the spark plug wire and move the wire away from the spark plug before at tempting to clean the tiller tines hy hand.

• To prevent engine damage due to oil starvation (on slopes,the engine is inclined and oil moves away from surfaces that need lu brication), be sure the correct oil

level is maintained during all uphill/downhill tilling operations. Check the level of the oil in your engine after every one-half hour of operation.

When tilling vertically on a slope, try to make the first pass in an uphill direction. The tines will

dig more deeply than when going downhill. You may have to lift the handlebars slightly going uphill. When tilling down the slope, over lap the previous uphill pass by half

a tiller width. Hint: for best re

sults, use the HIGH belt range and SLOW wheel speed lever position.

Photo 4-27: Tilling on a moderate slope. (Don’t till on steep ground.)

Page 38

Terrace Gardening

If a slope is too steep or not long enough for vertical tilling, it may be necessary to till across the

slope and create terraced rows. Terraces are rows that are cut into the side of a slope, creating a nar row, but flat area on which to plant. On a long slope, you can make several terraces, one below the other on the slope.

IMPORTANT: Do not till across a slope without creating terraces.

Simply tilling across the slope and leaving unterraced rows on the slope creates hazardous foot ing for you, and invites soil ero sion. When you will be making rows across a slope, be sure they are terraced rows.

Terraces should be made about two-to-three feet wide. This will allow one or two rows of plants on the terrace, and allow enough room to till under crop residues. However, with a terrace this wide there may not be enough room for cultivating. Hint: If you make ter

races too wide, you’ll be digging

far into the hillside, exposing poor

subsoil in which plants will not be their most productive.

Move the belt into LOW belt range and the Wheel Speed Gear Lever to SLOW position. Start to terrace at the top of the slope. Go all the way across the slope several times until the first terrace is made. See Figure 4-28 and Photo 4-29. As you work down the slope, al ways keep the uphill wheel in the soft, newly tilled soil. Each suc

ceeding terraced area is started by walking below the terrace you are preparing. In four or five passes, the tiller can carve out a flat and wide enough terrace for planting.

Don’t till the last 12-inches (leave at least that much soil un tilled ) of the downhill outside edge of each terrace. Keeping this strip untilled helps prevents your terraces from breaking apart and washing downhill. This untilled strip also gives you a walking path between terraces.

i-i..

UPHILL

LEAVE 12 INCHES UNTIULED

A REPEAT PROCEDURE

DOWNHILL

Figure 4-28: How to make a terrace in just 4 or 5 passes with the tiiler.

Tilling Across Slopes Without Terraces

Tilling across a slope without forming terraces is not recommended. Of course it can be done, but do study your terrain carefully and try to avoid going across a slope without making terraces. See if it isn’t possible to till vertically up and down the slope or, as a second option, to create terraces.

begin making unterraced passes across the slope by starting at the very top of the slope. Make your sec ond pass by overlapping half the width of the first pass. Always keep the uphill wheel in the soft, newly tilled soil. This will increase the stability of the tiller. For best results, move the belt into LOW belt range and the Wheel Speed Gear Lever into the SLOW po sition.

Again, you should make certain that the slope is not too steep to till on at all. If it’s safe, you can

Photo 4-29: Make a terrace in just 4 or 5 passes with the tiiler.

Soil Enrichment Idea

Trench Composting — Trench composting is easy with the op tional Hiller-Furrower Attach ment (see Section 5). .Just dig a trench, put in all kinds of or ganic matter, and cover with soil. Earthworms and microbes

will break it down quickly.

Page 39

SPECIAL TROY-BILT GARDENING TECHNIQUE— Making Raised Beds For Pianting

If you have wet soil or heavy clay soil, most crops won’t grow well due to a lack of air and nutri ents. Raised beds can help solve these problems. In addition, they provide a good irrigation system,

give more sun to the plants, and foster good root growth. Raised

beds are easily made too with the

optional Hiller-Furrower attach

ment.

You can even try wide-row

planting on raised beds. Wide

Photo 4-30: Step 1 — Work soil to a deep, smooth, loose seedbed.

rows can be spaced from 30 inches to 36 inches apart, and from 8 inches to 10 inches high.

Photos 4-30 through 4-33 at

right show you the steps to take to create raised beds. After working the soil to a fine seedbed, attach

your Hiller-Furrower and use it to make your rows. The hiller wings will raise up the soil, creating the

foundation for the raised beds.

After you plant seeds on the ridges

of each row, rake the ridges flat.

Then use the tiller with the furrower to make irrigation trenches

at the end of each row.

Photo 4-32: Step 3 — After planting seeds on the ridges, rake loose soil over the top. Firm the soil per seed directions.

SPECIAL TROY-BILT GARDENING TECHNIQUE— Wide-Row Planting

Wide-row planting is a very productive gardening

technique we suggest you try. As the name implies,

seeds are broadcast in bands anywhere from 10 inches to 2 feet wide or more, rather than in traditional, nar row single rows. As a result, you’ll typically grow

anywhere from 3 to 4 times (or more) produce in the

same space normally set aside for an area that has nar row, single rows.

Photo 4-31: Step 2 — Put row mark er stakes at proper intervals. At tach Hiller-Furrower to make rows.

■i ■■ ^^4*

K=!W-

Photo 4-33: Step 4 — Use furrower blade attachment to make irrigation

trenches at the ends of each row.

Photo 4-34:

Wide-row

planting on the right com pared to sin gle-row plant ing on the left.

Wide-row planting (see photos at right) automati cally shades the ground which keeps weed 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, just hand-broadcast the seeds as seeding a

lawn (not quite as much as lawn seed). Cover with

soil and tamp the area firmly with a hoe.

Photo 4-35: After prepar ing seedbed, mark off the row area as wide as you want, up to 4feet across.

Page 40

THE PTO POWER UNIT

As explained on Page 2 of this Manual, your tiller is really a selfcontained PTO power unit that was shipped to you with a tine attach ment connected to it. The tine at tachment is quickly removed and replaced by other attachments that are available from us. The instruc tions given here will familiarize you with your PTO Power Unit. Please read these pages carefully.

VERY IMPORTANT

Before operating your PTO Power Unit for the first time, make sure

that you have:

• Read all the safety instructions in Section 1 of this Manual and in

the Manual supplied with any at tachment.

• Read the controls information and operating procedures for the

tiller and engine described in

Sections 3 and 4 of this Owner/ Operator Manual.

• Read and understand the assem bly instructions, controls informa

tion, and operating procedures for the attachment as described in the

Owner/Operator Manual that is supplied with the attachment.

Removing And Replacing The Tine Attachment

The following steps explain

how to remove and replace the tine

attachment. The only tool you will

need is a 3/4" wrench (minimum

12" long for good leverage).

There are two optional acces

sories that make the following

steps easier. The Kickstand acces sory prevents the PTO Power Unit (engine end) from falling forward

when an attachment is removed

(Photo 4-37). The Tine Attach ment Cradle accessory gives you a handy support in which to rest the tine attachment when it is removed from the tiller (see Photo 4-38). For more information about other

accessories, refer to “Accessories”

at the back of this Manual.

CAUTION

TO AVOID PERSONAL INJURY OR DAMAGE TO EQUIPMENT:

• Stop the engine, remove the electric start key, discon nect the spark plug wire and let the engine and muffler cool before removing or in stalling any attachment.

• Do not place hands, tools, or any object near or inside the PTO access hole when the engine is running.

• When removing or replac ing the tine attachment, be careful of the sharp edges on the tiller hood. Wear thick gloves for hand protection.

• When the tine attachment is removed, always place it in the Tine Cradle or prop it up to prevent the attachment from falling forward.

Photo 4-37: The Kickstand acces sory prevents engine from tipping.

r ;

Photo 4-38: The Tine Attachment

Cradie accessory is a handy option.

>'■

■ iT

■'S-' !

¥;■

Photo 4-36: The PTO Power Unit with the tine attachment removed.

To Remove Tine Attachment;

1. First be sure the engine is

stopped, the electric start key is re

moved, and the spark plug wire is

disconnected.

2. Place tiller on level ground.

3. Place the Wheels/Tines/PTO

Drive Lever in NEUTRAL (refer to

Photo 4-39).

Page 41

TILLER LUBRICATION

can cause the belt or disc to slip on the pulleys.

WARNING

To help avoid personal injury,

stop the engine, remove the electric start key, disconnect the spark plug wire and move the wire away trom the spark plug, and let the engine and muffler cool before inspect ing or lubricating the tiller.

Lubricate the numbered areas in

Photos 5-4 and 5-5, as follows:

1. Oil the wheel shaft between the wheel hubs and the transmission housing (Photo 5-4).

2. Oil all pivoting and connecting points on the Wheels/Tines/PTO Drive Lever and the Wheel Speed Lever (Photo 5-4). If Wheel Speed

Proper lubrication of the tiller’s mechanical parts is an essential part of good maintenance. Lubri cation should be done after every ten (10) hours of operation.

Use ordinary motor oil (#30 weight or lighter) where oil is

specified. Use a quality grease with a metal lubricant where grease is recommended (regular grease is acceptable). Do not over lubricate. If there is a build-up of dirt, remove the build-up and re

apply oil or grease.

IMPORTANT - Do not allow oil

or grease to contact the pulleys,

drive belt or reverse disc. This

Photo 5-4: Tiller lubrication points (wheel removed for clarity).

Lever has a grease fitting on pivot assembly, apply 2-to-3 strokes of multi-purpose grease at beginning and end of tilling season.

3. Grease the face of the belt ad justment block (Photo 5-4).

4. Oil the Depth Regulator Lever, including the spring in the mount ing bracket (Photo 5-4).

5. Oil the full length of the throttle cable casing (Photo 5-4).

6. Oil threads on Handlebar Height Adjustment Lever (Photo 5-4).

7. Grease left- and right-side en gine mounting bars at the top, the middle, and bottom (Photo 5-4).

8. Grease the zerk grease fitting lo cated on the pivot point at the end of the Wheel Speed Lever (Photo 5-4).

9. Keep the PTO access hole wellgreased (Photo 5-5). If the Tines/PTO Clutch Lever be comes hard to move, squirt some oil into its access hole, and work it back and forth to disperse the oil.

TRANSMISSION GEAR OIL MAINTENANCE

A. Checking for Oil Leaks

check the tiller for oil leaks. In

spect for oil accumulations on the

tiller or the floor where it’s stored.

or wetness around a shaft opening or cover is no cause for alarm. But a heavy concentration of oil is more serious. You should tighten all bolts immediately, and replace any worn seals or gaskets.

mine how much oil has been lost, so check the oil levels in the PTO transmission and the tine attach ment before using the tiller again. Add any necessary gear oil. Serious damage to the transmission components can result from opera tion when gear oil levels are low.

weather, the gear oil may heat up and expand inside the transmis

sions. To allow for this oil expan sion, both the power unit transmis

sion and the tine attachment trans missions have oil relief vents (see Figure 5-6).

WARNING

To help avoid personal injury, stop the engine, remove the electric start key, disconnect the spark plug wire and move

it away from the spark plug,

and let the engine and muf fler cool before inspecting or servicing the tiller.

At 25-hour operation intervals,

A small amount of oil seepage

It may be impossible to deter

If tilling during very hot

Photo 5-5: Use grease liberally In PTO access hole.

Figure 5-6: Oil relief vent locations.

Page 42

TIGHTEN BOLTS AND NUTS

^ WARNING

To help avoid personal injury, stop the engine, remove the electric start key, disconnect the spark piug wire and move the wire away from the spark plug, and let the engine muf fler cool before inspecting or servicing the tiller or engine.

Check for loose or missing hardware every ten (10) operating hours. Failure to tighten or replace fasteners can cause poor perfor mance, equipment damage or oil leakage. See your Parts Catalog for complete fastener descriptions.

Most hardware on your tiller is visible. Pay particular attention to hardware shown in Photos 5-1, 5-2, 5-3, and Figure 5-3A.

1. Check the transmission pulley mounting bolt (Photo 5-1). If the washer behind the bolt head is loose, the bolt needs tightening. To do this, first insert a punch or thick screwdriver into the hole next to the bolt and wedge the tool

against the side of the motor mount casting. This “freezes” the pulley while you tighten the bolt.

2. Check jam nut on left side of neutral plunger assembly (Photo 5-

2). If loose, immobilize bolt head

with one wrench and use another wrench to tighten the nut.

3. Check the three rear bearing cap screws under the depth regula tor mounting bracket (“A”, Photo 5-3). If any is loose, it can cause an oil leak or drive shaft end play.

4. Check the five bolts securing the tiller housing cover to the left

side of the transmission (“B” in Photo 5-3). Gear oil can leak from a loose housing cover. To reach the bolts, remove the left side tine holder. See “Bolo Tine Maintenance” in this Section for tine holder removal directions.

5. Check both swing-bolts (“C”, Photo 5-3) that connect the power unit transmission to the tine attach ment. Both bolts should be checked every 2-1/2 hours of oper ation. If loose, wear can occur on the locating pin on the power unit,

and cause enlargement of the locat

ing 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”, Photo 5-3). Do not tighten the locknut against the eccentric lever. It should be very close to, but not touching the lever.

7. Check the four bolts and nuts

securing left and right tine holders to the tine shaft (Figure 5-3A).

IMPORTANT- Give screws or bolts that go into the transmis sion housing a coating of non hardening gasket sealant to pre vent gear oil from leaking.

Figure 5-3A: Tine hoider hardware must be tight.

Page 43

Section

Carefully read this Section on tiller and engine maintenance and service. Performing the required mainte nance according to schedule will ensure the proper performance and long life of your machine.

A CAUTION

Before inspecting, cleaning or

servicing the machine, shut off

engine, wait for all moving parts to come to a complete stop, disconnect spark plug

wire and move wire away from

spark plug.

Failure to follow these instruc tions can result in personal in jury or property damage.

NOTE: All references to left, right, front and rear of the ma chine are determined by standing

behind the handlebars and facing the direction of forward travel.

Subjects covered in this Section include:

• Tiller Maintenance

• Engine Maintenance

• Storing Your Tiller

• Troubleshooting

• Specifications

• Attachments

REQUIRED MAINTENANCE SCHEDULE

Before Every Every Every As

PROCEDURE Each 10 25 30 Noted

Check engine oii level

Clean engine cooling system Test operation of Forward Interlock

Safety System

Forward Interlock Safety System -

check wire condition,connections

Check battery electrolyte level and

electrical connections

Recharge battery

Check drive belt tension

Check nuts and bolts

Clean tiller tine shaft Lubricate tiller Change engine oil*

Clean foam element air filter Check paper element air filter

Check for oil leaks

Check gear oil level in

both transmissions Check boio tines for wear Check reverse disc for wear Check air pressure in tires

* During engine break-in period, change engine oil after first 5 hours of operation.

Use Hours Hours Hours

•

Every 5

operating hrs.

See Sec 4

Before/after

long storage

After initial

2 hours

After initial

2 hours

More often in dusty or dirty areas

After initial

2 hours

After initial

2 hours

Page 44

Figure 4-46: Disconnect the Forward interlock Wire Harness coming from the handlebars that

connects to the recepta cle on top of the trans mission. Then connect

the wire from your Stationary Attachment to the receptacle on top of the transmission. Verify the connection is secure.

INTERLOCK WIRE HARNESS FROM

HANDLEBARS

c. On the Stationary Attach

ment, locate the interlock wire and be sure the plug is clean.

d. Connect the plug from the

Stationary Attachment to the re ceptacle on the Power Unit. See Figure 4-46. The connection must be tight. This connection allows you to operate the Wheels/Tines/ PTO Drive Lever in FORWARD without having to constantly

squeeze one of the Forward Inter lock Levers.

4. For Non-Powered Attachments Only:

a. Move the Tines/PTO Clutch

Lever to DISENGAGE.

b. Move the Wheel Speed

Lever to either SLOW or EAST position (roll tiller power unit while shifting lever until wheels are engaged.) See Photo 4-39.

c. Verify that the Forward

Interlock Wire Harness plug at the bottom of the handlebars is con nected to the Forward Interlock Wire Harness receptacle on the top right side of the transmission (Figure 4-46).

5. Move the Engine Throttle Lever away from the STOP posi tion and use the Choke Control if

engine is cold. Pull out the Recoil Start Rope (or use keyswitch on electric start models). When en gine starts, move Choke Control to CHOKE OFE and let engine warm up. (See Section 4 - Page 27 for detailed starting steps).

6. For non-powered attachments only, test the Forward Interlock Safety System (Section 4 - Page 26).

WARNING

To avoid injury, do not run the

engine in an enclosed or poorly vented area. Engine exhaust contains carbon monox ide, an odoriess and deadiy gas.

To Operate Stationary Attachments:

1. Put Tines/PTO Clutch in ENGAGE.

2. To apply power to PTO-driven attachments, move Wheels/Tines/

PTO Lever down to FORWARD position (do not use REVERSE

with stationary attachments).

3. To Stop PTO Power: Tap or lift the Wheels/Tines/PTO Drive

Lever up to NEUTRAL position.

To Operate Non-Powered

Attachments (or to Tow Stationary Attachments):

1. To go forward, squeeze and

hold one Forward Interlock Lever

(refer to Photo 4-39) up against the handlebars, and move the Wheels/ Tines/PTO Drive Lever down to FORWARD.

2. To Stop Forward Motion: Tap or lift the Wheels/Tines/PTO Drive Lever up to NEUTRAL, then re lease Eorward Interlock Levers.

3. To stop forward motion in an emergency- Let go of all power unit controls (this stops the engine).

4. Eor reverse motion, first reduce the engine speed and put the Wheel Speed Lever in SLOW. Then move and hold the Wheels/ Tines/PTO Drive Lever up for re verse motion (the area behind you must be clear of all obstacles).

5. To Stop Reverse Motion:

Release the Wheels/Tines/PTO Drive Lever.

To Stop The Engine:

Move the Engine Throttle Lever to STOP (and turn Keyswitch to OFF on electric start models).

Page 45

6. Move the two swing-bolts into the slots of the tine attachment. Alternately tighten each bolt until they are tight enough to make the

concave washers on the bolts flat.

The bolts must be very tight - if

you have a torque wrench, tighten

each one to between 70-80ft.-lbs.

See Photo 4-44.

IMPORTANT - The swing-bolts must be kept very tight to pre vent damaging wear to the ‘dog’ clutch couplings, alignment pin or the alignment hole. Check bolt tightness every 2-‘4 operat ing hours.

7. Remove the engine support be fore moving the tiller in a forward direction.

Photo 4-44: Tighten both swing-bolts

very securely with a long 3/4" wrench. Tighten them to between 70-to-80 ft. lbs.

PTO POWER UNIT OPERATING INSTRUCTIONS

WARNING

To help avoid personal injury or damage to equipment, read the Owner/Operator

Manual supplied with each

attachment before installing

or operating the attachment. See all detailed use and op eration information and all safety instructions.

The following instructions de

scribe how to operate the PTO

Power Unit only. Read the sepa rate Owner/Operator Manual sup plied with each attachment before

attempting to assemble, attach, transport or operate the attach ment. If needed, please contact us

for a replacement manual.

Some attachments have a drive shaft or a hydraulic pump that is powered by the engine on the PTO Power Unit. These attachments are called “Stationary Attachments,” since they must re main in one location when being operated (they can be towed to a work site by the PTO Power Unit as described in “To Operate NonPowered Attachments”).

Other attachments are simply pulled or towed behind the PTO Power Unit. These attachments

are called “Non-Powered Attachments.”

Before Starting The Engine:

IMPORTANT - Before operat ing in temperatures below 40®F, refer to “Cold Weather Oper ation” instructions in Section 4.

1. Move the Wheels/Tines/PTO

Drive Lever to NEUTRAL. To find NEUTRAL (be sure engine is off), push lever down to engage it in EORWARD, then tap or lift the lever up and release it (Photo 4-39).

2. Move the Tines/PTO Clutch Lever to DISENGAGE.

3. For Stationary Attachments Only;

FREE WHEEL, then block all wheels to prevent the equipment from rolling. Refer to Photo 4-39 and Figure 4-45.

the Forward Interlock Wire Harness that leads from the bottom

of the handlebars to the receptacle located on the top, right side of the transmission cover (see Figure

4-46).

WARNING

To help avoid personal injury, always disengage the Tines/ PTO Clutch Lever before tow

ing any attachment.

a. Move Wheel Speed Lever to

b. On the Power Unit, unplug

Ua— L/f f—

Figure 4-45: Block wheels on power unit and stationary attachment.

Page 46

Photo 4-39: PTO Power Unit controls.

Engine Throttle

Forward interlock Levers

‘ Jr- ■

Wheels/Tines/ PTO Drive Lever

Tines/PTO Clutch Lever

4. Place Tines/PTO Clutch Lever in DISENGAGE (Photo 4-39).

5. Place Wheel Speed Lever in FREE WHEEL (Photo 4-39).

6. Place a strong support under the engine or use the Kickstand acces sory (if so equipped) to prevent the engine from tipping forward when the tine attachment is removed. See Photo 4-40.

Photo 4-40: Block up engine.

I «

Wheel Speed

Lever

'r-

Photo 4-41: Move both of the swing-bolts outward.

Note - Store tine attachment at level position to avoid gear oil leak age around dipstick.

9. Place the dust cap (comes with certain attachments; plastic wrapping will substitute) over the “dog” clutch coupling of the tine attachment to keep it clean.

10. The power unit is now ready

to accept any other powered or non-powered attachment. See that attachment’s Owner/Operator Manual for installation and opera tion instructions.

To Replace Tine Attachment;

1. Follow Steps 1-through 5 of the

previous tine attachment removal

instructions.

2. Move the two swing-out bolts on the power unit to their outward position (slide the washers next to the bolt heads too).

3. Slowly roll the power unit back to the tine attachment. Move the Kickstand down (or support the engine with a wood block).

4. Remove the dust cap (or protec tive wrapping) from the clutch coupling on the tine attachment.

5. Carefully align the alignment pin on the power unit with the alignment hole in the tine attach ment and bring the two units to gether (see Photo 4-43).

7. With a 3/4" wrench, loosen the two swing-out bolts that connect the power unit transmission to the tine attachment and swing the bolts outward. See Photo 4-41. Hint:

an extra-long wrench for leverage is very helpful.

8. Use one hand on the handlebars to tip the power unit forward about one inch while pulling the tine at tachment backward. The guide pin on the power unit will release from the guide hole in the tine attach ment. See Photos 4-42 and 4-43.

■ i ”i...

% ■■

^■1

Photo 4-42: Lift handlebars while

pulling attachment away from power unit.

■

Guide Pin

Mounting Hole

Photo 4-43: Align the guide pin with

the mounting hole.

Page 47

The vents allow small amounts of

oil to seep out.

If a serious leak is discovered, please contact our Technical Service Department for parts and service advice.

B. Checking Gear Oil Levels

Every 30 hours of operation, check the gear oil level in both the power unit transmission and the tine attachment transmission. Op erating them while low on gear oil (even briefly) can cause serious damage to internal components.

Preparation:

1. The transmissions must be

cool, since hot gear oil expands

and gives a false reading.

2. The power unit transmission and the tine attachment transmis

sion must be connected when

checking (or adding) gear oil.

To Check the Power Unit Oil Level:

1. Move the tiller to level ground. Move the Depth Regulator up so the tines rest on the ground.

2. Use a 3/8" wrench to remove the oil level check plug on the left

side of the transmission housing (refer to Figure 5-7).

3. If the oil level is correct, oil

will seep oiii ol ilie lIiccL hole (allow e\lr.i lime m cold wealhei i. If it does, llie level is line and >oii

should replace the check plug. If no oil seeps out, see “C. Adding or Changing Gear Oil.”

To Check the Tine

Attachment Oil Level:

Two different gear oil check ing procedures for the tine at tachment transmission are de scribed next. Use the first proce dure if the dipstick in your tine attachment has only a ‘Check Cold’ marking. Use the second procedure if the dipstick has both ‘cold’ and ‘hot’ markings at the end. First remove the dip

stick from the tine attachment transmission (Figure 5-8) to see

which type dipstick you have. Then replace the dipstick.

For Dipsticks With ‘Check Cold’ Marking:

1. Put the tiller on level ground.

2. Pull the Depth Regulator Lever

back, then push it down all the way

(to engage its top notch). This lifts the tines off the ground and lets the tiller rest on its drag bar.

3. As you’ll be propping up the rear of the tiller next, first place a support under the engine to pre vent the tiller from tilting too far. Now slide three pieces of 2"x4" lumber underneath the drag bar raising the drag bar about 4-V2"

above ground. This elevation al lows an accurate “cold” gear oil reading (“cold” means 2 hours has passed since the tiller was used).

4. Wait two hours with tiller ele vated (allow more time if tempera ture is below dO'^F).

5. Loosen and remove transmis sion dipstick (Fig. 5-8). Wipe it clean with a rag.

6. Hold dipstick so its markings face rear of tiller. Lower it straight down into the sump hole to touch the driveshaft inside (Fig. 5-8). Don’t force or try to thread it back in...an incorrect reading will result.

7. Remove dipstick and check oil level. It should be anywhere with in the cross-hatched area or even slightly above the “Max” marking. If correct, replace dipstick and re move the boards used as props.

8. If oil level was low, gear oil must be added before using the tiller. See “C. Adding or Chang ing Gear Oil” next.

For Dipsticks With Hot/Cold Markings:

1. Follow Steps 1 and 2 given for

the other type of dipstick.

2. Put a 2"x4" board under the drag bar- raising the tiller and drag bar about 3-V2" above ground. This elevation is for a “cold” read ing which is preferable- 2 or more hours since tiller was last used. (If taking a “hot” reading- tiller was operated for more than 30 minutes

within the past hour, do not use the wood prop to elevate the tiller.).

Figure 5-7: Remove oil level check plug. Gear oil should seep out if the level Is sufficient.

Figure 5-8: Remove dipstick with a

9 16" wrench to check gear oil level in tine attachment transmission. Markings on dipstick must face rear of tiller when checking oil level.

4. Follow Steps 4, 5 and 6 given for the other dipstick type.

5. Remove dipstick and check level. It should be within or above the “Cold” range marking if taking

a ‘cold’ reading. (If taking a “Hot”

reading, the level should be within

or slightly above the “Hot” range.)

6. If the level is incorrect, see Adding or Changing Gear Oil next.

Page 48

C. Adding or Changing Gear Oii

For partial fill-ups (a few ounces or less), use SAE 140, SAE 85W-140, or SAE 80W-90 weight

gear oil with an API rating of GL-

3, GL-4 or GL-5. Vor full replace

ment, use SAE 140 or SAE 85W-

140 gear oil with an API rating of

GL-4 only. (At the Factory, SAE

85W-140 weight gear oil is used.)

IMPORTANT - Do not use auto matic transmission fluid or en gine oil. They are too light in weight and will result in trans mission damage.

The gear oil does not need to be changed. Do so only if you know, or suspect, it is contaminated with dirt, sand or other foreign particles.

Gear oil is available at wellstocked service stations, power equipment centers, or farm/heavy equipment outlets. (It may also be ordered from Troy-Bilt.)

Capacities: Power unit transmis sion holds approximately 60 ozs.; Tine Attachment transmission holds approximately 12-Pi ounces.

To Add Gear Oil to the Power Unit Transmission:

1. Follow steps 1 and 2 of “To Check the Power Unit Oil Level:” on the previous page.

2. Using a 3/4" wrench (or socket), remove the bolt securing

the handlebar base to the top of the transmission (prop the handlebars first to prevent them from falling).

Then, unplug the Forward Interlock wire harness receptacle at the bottom of the handlebars. Set the handlebar base and bolt aside on a clean surface. The bolt hole in the top of the transmission is the gear oil fill hole. See Figure 5-9.

3. Slowly pour gear oil through a clean funnel into the transmission. Stop when gear oil begins to flow from the oil level check hole on

Figure 5-9: Gear oil fill hole (A) and gear oil drain location (B).

the left side of the transmission (Figure 5-7).

4. Reinstall the oil level check

plug. Tighten it securely.

5. Reinstall the handlebars using the mounting bolt previously re moved. Align the handlebars so they point straight backwards, not at an angle. Then tighten the

mounting bolt securely.

6. Reconnect the Forward Interlock wire harness to the recep tacle. Be certain it’s secure.

7. Test operation of the Forward Interlock Safety System — refer to Section 4 for procedure.

forward so any oil at the rear of the transmission will drain out.

4. Clean the drain plug threads,

put non-hardening gasket sealant

on the threads, and reinstall plug.

5. Refill the transmission with the correct amount of gear oil before operating the tiller again. When oil seeps from the oil level check hole, the right amount of gear oil has been added. Replace all plugs.

To Add 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 Lev

To Drain and Fill the Power Unit Transmission:

1. Place a shallow pan under the transmission gear oil drain plug (refer to B, Figure 5-9).

2. Remove the oil level check plug (see Figure 5-7) with a 3/8" wrench. This vents the transmis sion for faster oil draining.

3. Using the 3/8" wrench, remove the drain plug (B, Figure 5-9). The gear oil will drain quite slowly since it is thick. After about two quarts have drained, tilt the tiller

er 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 at tachment (see Figure 5-8).

3. Slowly add gear oil in the dip stick hole. Add 1/2-ounce at a time to avoid overfilling. It takes about 12-'/2 ounces.

4. Take dipstick readings fre quently. Stop when oil reaches “Cold” range marking on dipstick. Replace dipstick securely.

Page 49

To Drain and Fill the Tine Attachment Transmission:

1. The tine attachment transmis sion is not equipped with an oil drain plug. To drain just a small amount of gear oil, remove the dipstick and tilt the attachment for ward (first uncoupling it from the Power Unit).

2. For complete drainage, remove the left-side tine assembly (refer to Bolo Tine Maintenance for instruc tions), then remove just one of the lower screws from the tiller hous ing cover (Photo 5-10). To speed drainage, remove the tine attach ment dipstick to vent transmission.

DRIVE BELT MAINTENANCE

A. Measuring and Adjusting

Drive Belt Tension

is installed), the belt tension will probably need to be adjusted after the first two (2) hours of operation. Thereafter, check belt tension every ten (10) operating hours.

WARNING

To help avoid personal injury, stop the engine, wait for all moving parts to come to a complete stop, remove the electric start key, disconnect the spark plug wire and move the wire away from the spark plug, and let the engine and muffler cool before inspect ing, adjusting or replacing the drive belt.

On a new tiller (or if a new belt

Photo 5-10: Remove housing cover screw to drain tine attachment transmission gear oii.

Note: If you find a plastic washer on the cover screw you remove, discard the washer. There is no need to install a replacement washer.

While checking belt tension, also inspect the belt for cuts, cracks, deterioration, etc. Don’t continue using a belt that isn’t in good shape. You’re sacrificing tiller performance by doing so.

Tips on keeping the drive belt in top condition include:

• Always put the Wheels/Tines/ pro Drive Lever in NEUTRAL

when the tiller is not in use.

• Keep tension adjusted correctly.

• Don’t “speed shift” when mov ing the Wheels/Tines/PTO Drive

Lever between FORWARD and REVERSE.

How to Measure Belt Tension:

1. Before taking a measurement, be sure the linkages and pivot points on the Wheels/Tines/PTO Drive Lever are clean and lubri

3. Once all gear oil has drained, reinstall the housing cover screw securely (first coat its threads with non-hardening gasket sealant).

4. Be certain to refill the transmis sion with the correct amount of gear oil before operating the tiller again.

cated. If there is any binding, you won’t get true measurements. Also, you’ll need the belt adjust ment tool you received with your new tiller (see Photo 5-11).

2. Move the Wheels/Tines/PTO Drive Lever fully down to the FORWARD position. The clutch roller at the bottom of the lever should be positioned underneath the belt adjustment block (Photo 5-12). Don’t let the clutch roller move during the next few steps. If it moves, you’ll get a false belt ten sion reading.

Maintaining the right tension is

important to good tiller perfor mance and long belt life. If too loose, the belt will slip on the pul

leys, and be unable to deliver full power to the wheels and tines. A loose belt will also wear prema turely.

Photo 5-11: Use this beit adjust ment tool to measure and adjust drive belt tension.

Photo 5-12: Shift into FORWARD and measure distance between roller and upright bracket using the belt adjustment tool.

Page 50

3. The belt tension is correct if the front of the clutch roller is l/4"-to5/16" away from the face of the upright bracket that holds the ad

justment block in place (Photo

5-12). To measure this distance: a) Without moving the clutch

roller, try inserting the 1/4”thick, slotted end of the belt ad

justment tool in between the

roller and the upright bracket. (The flat edge of the tool must be facing the roller.) Refer to Photo 5-13.

b) If only the slotted portion of the

tool will fit, the belt tension is correct as is.

c) If the slotted part of the tool will

not fit in, the belt is too loose.

d) If the full thickness (5/16") of

the tool easily fits in, the belt is too tight.

4. If the belt tension is correct, move the Wheels/Tines/PTO Drive Lever back to NEUTRAL.

Sî-.

Ilf

How to Adjust Belt Tension:

1. You adjust the drive belt tension by loosening the bolt securing the belt adjustment block, then moving the block up or down. Moving it down will tighten the belt; moving it up loosens the belt. (Hint: the

distance the block moves approxi mately equals the distance the roller moves.) In most cases, the

clutch roller will not have been very far out of position, so the ad justment block will only need to be moved slightly (up or down).

2. Move the Wheels/Tines/PTO Drive Lever to NEUTRAL posi tion. The clutch roller will come to rest anywhere on the face of the belt adjustment block, depending upon drive belt length and current belt tension adjustment.

3. Insert the belt adjustment tool through the hole in the side of the adjustment block, spacing the ends of the tool equally on both sides (see Photo 5-14). Rotate the tool so the slotted end faces down.

4. Place the Wheels/Tines/PTO Drive Lever in FORWARD posi tion. The arms of the clutch con trol yoke will be resting on the belt adjustment tool and the clutch roller should be engaged slightly beneath the adjustment block (see Photo 5-15).

.k-- '

Ait-

'.y

Photo 5-14: With Wheeis/Tines/PTO Drive Lever in NEUTRAL, insert tool through hole in adjustment biock.

Photo 5-15: With Drive Lever in FORWARD position, dutch roller should be engaged slightly beneath the adjustment block.

sSir

ri' ■

Photo 5-13: Insert slotted end of belt adjustment tool between roller and bracket, with the flat side of the slotted end facing the rolier.

5. Use one hand to hold the drive lever in FORWARD while using a 9/16" wrench to loosen (don’t re move) the bolt at the back of the belt adjustment block (Photo 5-16). The adjustment block should be free to move either up or down.

6. Push the drive lever down if the

belt needs tightening. Or pull the

lever up if the belt needs to be loosened. Hold the drive lever in place and tighten the bolt in the ad

justment block firmly.

7. Let go of the drive lever and re move the belt adjustment tool from the hole in the adjustment block.

Photo 5-16: Hold Drive Lever while loosening bolt. Push lever down to tighten belt; pull up to loosen belt.

8. Check the tension on the belt by following the previous instructions “How to Measure Belt Tension.”

Note: If the adjustment block is all

the way down and the measure ment between the clutch roller and the bracket is less than 1/4", then a new drive belt is needed.

Page 51

'lai

B. Replacing the Drive Beit

To Remove the Belt:

WARNING

To help avoid personal injury, stop the engine, remove the electric start key, disconnect the spark plug wire and move the wire away from the spark

plug, and let the engine and muffler cool before removing or replacing the drive belt.

1. Move Wheels/Tines/PTO Drive

Lever to NEUTRAL position.

2. While kneeling on the right side of the tiller, create slack 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 pLilk‘\. in ihc iliiei-lion ol ilie engine (I’hnlo ."'-I “).

4. As shown in Photo 5-18, push the belt upward to create slack in the belt.

5. Lift the top half of the belt up and over the upper pulley and the rubber reverse disc, moving it in front of the reverse disc (refer to Photo 5-19).

6. Push the Wheels/Tines/PTO Drive Lever down into the FOR WARD position. This increases the distance between the upper and lower pulleys. Next, lift and pull the entire belt out between the pul leys (Photo 5-20).

3. Push belt forward then down until it is looped over the lower pulley (refer to Photo 5-18). Do not yet seat it in either of the lower pulley’s grooves. (Hint: a blunt

object, like a ruler, can help you

push the belt downward if needed.)

4. Move the top half of the belt up and over tbe rubber reverse disc, but do not seat it in either of the grooves in the top pulley.

5. Place the Wheels/Tines/PTO Drive Lever in NEUTRAL.

6. Move the top half of the belt into the HIGH Range groove (groove closest to the engine) on the top pulley. See Photo 5-21.

7. Move the bottom half of the belt into the HIGH Range groove

Photo 5-17: First move belt off the lower pulley.

Photo 5-18: Push belt upward to create slack.

Photo 5-19: Move top half of belt

over pulley and reverse disc.

Photo 5-20: Shift into FORWARD

and remove the belt.

To Replace the Drive Belt:

1. Place Wheels/Tines/PTO Drive

Lever in FORWARD position.

2. Squeeze the belt in the middle and insert one end in between the

pulleys (see Photo 5-20).

Photo 5-21: Seat belt in upper pul ley, then in lower pulley (“High Range”position shown).

of the lower pulley (groove closest to engine). Photo 5-21. If extra

slack is needed, hold up Wheels/ Tines/PTO Drive Lever while moving the belt. Verify the belt is

seated properly on the pulleys.

8. To move the belt to the LOW Range position, see “Changing Belt Speeds” in Section 4.

9. After installing the belt, check

and adjust for correct belt tension

as explained previously.

Page 52

REVERSE DRIVE MAINTENANCE

WARNING

To help avoid personal injury, stop the engine, wait for all

moving parts to come to a complete stop, remove the

electric start key, disconnect the spark plug wire and move the wire away from the plug, and let the engine and muf fler cool before inspecting, adjusting or replacing the re verse drive components.

These instructions explain how to inspect, replace or adjust the various reverse drive components.

But first, here’s how the reverse drive system works: When you raise the WheelsITinesIPTO Drive

Lever up in REVERSE position,

this lowers the rubberized reverse disc (it’s attached to the engine drive pulley) until this rotating disc contacts the transmission drive

pulley. The friction between the

rotating reverse disc and the trans

mission pulley causes the transmis sion drive shaft to be powered in a

counterclockwise direction (as

viewed from the operator’s posi tion behind handlebars). The drive shaft then turns the wheels and tine shafts in a reverse direction.

A. Reverse Disc Inspection

The reverse disc is made of steel

with a special, long-lasting rubber

-V- .

r-'

Photo 5-22: Measure the edge of

the reverse disc for wear.

compound bonded to the disc rim. Since this is a wearing part, it should be inspected after every 30

operating hours.

1. Measure the width of the out

side edge of the disc as shown in Photo 5-22. Replace the disc be fore the rubber edge wears to a thickness of 1/8" or less. Failure to do so could cause the steel un derneath the rubber to damage the transmission pulley.

2. Look for big cracks or missing chunks of rubber from the disc. If so damaged, the disc should be re placed immediately.

IMPORTANT - Extend the life of the reverse disc by always pausing in NEUTRAL before shifting between FORWARD and REVERSE. Also - the re verse disc is not suited for con tinuous or sustained reverse op eration. Use reverse sparingly.

B. Replacing the Reverse Disc

Follow these steps to replace the

reverse disc. (If your tiller has a

Bumper Attachment mounted, it

must be removed first.)

To Remove the Reverse Disc:

1. Move Wheels/Tines/PTO Drive

Lever in NEUTRAL position.

2. Wedge a 5/16"-thick board be tween the top of the engine pulley

(avoid contacting the reverse disc) and the cast iron housing next to it. This “freezes” the pulley.

3. Use a 9/16" wrench to loosen the mounting bolt shown in Figure 5-23. Remember to freeze the pul ley with the wood wedge while loosening the bolt. If necessary,

separate the disc from the pulley with the tip of a screwdriver. Back

the bolt out as far as possible. Then angle the disc a little to re move it. Bring the bolt and lockwasher along with the disc.

To Install a New Reverse Disc:

Just reverse steps l-through-3 described previously. Tighten the mounting bolt securely, and check for correct operation — see next page for checking instructions.

Figure 5-23: immobiiize the puiiey with a wood wedge, then loosen the bolt

so you can remove the rubber reverse disc. (The disc may need to be pried away from the puiiey.)

Page 53

C. Checking and Adjusting the Reverse Drive System

WARNING

To help avoid personal injury, stop the engine, remove the electric start key, disconnect the spark plug wire and move the wire away from the plug, and let the engine and muf fler cool down before inspect

ing or adjusting the reverse drive parts.

When the Wheels/Tines/PTO Drive Lever is moved up into RE VERSE, the engine and engine

mount move down to press on the

reverse adjustment bolt (see Photo

5-24). This action compresses the

reverse spring and plunger assem

bly, requiring you to hold the lever up in REVERSE. When you re lease the lever, the spring automat ically pushes the lever back into NEUTRAL position.

number of reverse drive operating problems, as explained next.

Check Action

Reverse Disc:

1. Verify that the linkages for the Wheel s/Tines/PTO Drive Lever are lubricated with oil and the en gine mount bars and the belt ad

justment block are lubricated with

grease. (See “Tiller Lubrication” in this section.)

2. Place the Wheels/Tines/PTO Drive Lever in NEUTRAL. Briefly pull out the engine recoil

start rope while watching the re verse disc. The disc should turn, but the lower pulley should not

(refer to Photo 5-25). If the re

verse disc turns the lower pulley,

or if it is located closer than 3/16"

to the pulley, the reverse adjust

ment bolt should be adjusted up

ward (see instructions that follow).

Moving the adjustment bolt up

ward will also solve the problem of

a tiller that goes into REVERSE on its own.

3. Use your left hand to hold the Wheels/Tines/PTO Drive Lever up

in REVERSE, while briefly pulling out the engine start rope. The reverse disc should turn the lower pulley (see Photo 5-26). If not, or it requires a lot of pressure to hold the lever up in REVERSE, then the reverse adjustment bolt must be adjusted downward. When correctly adjusted, the Wheels/Tines/PTO Drive Lever

should “pop” out of reverse when

the lever is released, but not re

quire exceptional effort to hold it

up in the reverse position.

4. Shift the Wheels/Tines/PTO

Drive Lever to REVERSE and

then let it go. The lever should re

turn to NEUTRAL. If not, the re

verse adjustment bolt will have to

be adjusted upward.

4 Switch Body <$ Adjustment

Bolt

I Spring &

Plunger

- ■ ■ ;.v

•1 ■

Photo 5-24: Spring and plunger as sembly.

The spring and plunger assem bly is designed to prevent the re verse disc from making contact with the transmission pulley until you shift into REVERSE. When the lever is in NEUTRAL, the switch body on the bottom of the engine mount tab should be resting squarely on top of the reverse ad

justment bolt (Photo 5-24). The

reverse adjustment bolt can be ad

justed up or down to correct a

Both Piiilevs

■ Shoiiid Tji!-

• r

Reverse Disc

fá.

Photo 5-25: With shift lever in NEU

TRAL, only the re verse disc should

turn when starter rope Is pulled out.

Photo 5-26: With shift lever in RE VERSE, the reverse disc should turn the transmission pulley when the starter rope is pulled out.

Page 54

Adjusting Reverse Drive:

1. Place Wheels/Tines/PTO Drive

Lever in FORWARD position.

2. On left side of tiller, put a 1/2" wrench on the plunger retaining bolt and another 1/2" wrench on the jam nut next to it (Photo 5-27). While holding the bolt steady, loosen the jam nut (counterclock wise) until it touches the bolt head.

loosening or tightening jam nut.

3. Turn the bolt in until it tightens against the plunger inside the spring. The bolt must be tight to prevent plunger from turning - but

he careful not to overtighten and break the bolt.

4. Place a 7/8" wrench on the head of the reverse adjustment bolt and a 9/16" wrench on the jam nut below it (see Photo 5-28). Hold

Adjustment

Bolt

Jam Nut

Photo 5-28: Loosen jam nut before turning reverse adjustment bolt.

the bolt steady while loosening the

jam nut three or four turns.

5. Move the Wheels/Tines/PTO Drive Lever to NEUTRAL. The switch body on the bottom of the engine mount tab (see Photo 5-24) should be resting squarely on top of the reverse adjustment bolt, and the reverse disc should be at least 3/16" away from the transmission drive pulley. If the reverse disc is any closer than this, raise the re verse adjustment bolt (turn it coun terclockwise).

6. Check that the reverse disc is at least 3/16" away from the trans mission drive pulley. Then hold the reverse adjustment bolt steady with one wrench while tightening the jam nut with a second wrench (see Photo 5-28).

7. Place a chalk or pencil mark on the top edge of the plunger retain ing bolt. Now, while watching the mark, loosen the bolt 3/4-tum (see Photo 5-29). Do not exceed a 3/4 turn (this would disengage the bolt from the locking groove in the side of the plunger).

8. Hold the plunger retaining bolt steady with a wrench while tight ening the jam nut against the side of the plunger housing (Photo 5-27).

9. Check the action of the reverse disc as explained previously.

Photo 5-29: Loosen plunger retain ing bolt about 3/4-turn, then tighten

jam nut against plunger housing.

IMPORTANT - If the above ad

justments have not corrected an

improperly working reverse drive, please contact our Tech nical Service Dept, for assistance.

BOLD TINE MAINTENANCE

^ WARNING

ing, removing or replacing

the tines or tine holders.

A. Checking Tines for Wear

Inspect the tines for wear or damage after every 30 operating hours. The rate of wear depends upon hours of use and soil condi tions. With use, the tines get shorter, narrower and more pointed (see Photo 5-30). If badly worn, they lose the ability to till deeply. Also, worn tines leave an ever-increasing “gap” in the middle of a tilled row. The normal gap is 3" between the tine tips - replace the tines when the gap widens to 5".

Tines can be replaced individually or as a complete set. See replace ment instructions that follow.

- i } J.f)

J III'

Worn

"1^

New

Photo 5-30: Check for tine wear every 30 operating hours.

Figure 5-31: Replace tines when the gap be tween inner tines is 5" or more. (Normal gap is 3".)

Page 55

B. Single Tine Replacement

WARNING

The tines or tine hood edges

may be sharp. Wear thick gioves to protect your hands from cuts or scrapes.

1. Move the Wheels/Tines/PTO Drive Lever to NEUTRAL, the Wheel Speed Lever to either FAST

or SLOW position, and the Tines/ pro Clutch Lever to ENGAGE.

2. Gently tilt the tiller forward

until the engine rests on the ground.

3. Raise the hood flap at the back of the tiller and tie it up with string.

4. Before removing a tine, note in which direction the bent tip points. The new tine must be installed in the same direction.

5. Use two 9/16” wrenches to re move the two bolts and nuts secur ing the tine to the tine holder plate (see Photo 5-32). Use penetrating oil on the hardware if it is rusted or hard to remove.

6. Mount the new tine exactly the way the old tine was positioned. (The sharp edge of the tine, which

Photo 5-32: Removing a single tine requires taking off two bolts and

two nuts.

enters the soil first, must face for ward when above the tine shaft.) Replace the bolts and nuts and tighten them securely.

C. Removing and Replacing the Tine Holders

WARNING

The tines or tine hood edges

may be sharp. Wear thick gloves to protect your hands.

The 16 Bolo Tines are mounted eight per side on left-side and right-side tine holders - on either Style A or Style B holders (refer to Figures 5-33A and 5-33B to see which style tine holder you have).

Style “A” tine holders are secured to the tine shaft with two bolts and two nuts. Style “B” tine holders are secured with a single end bolt to the left and right sides of the tine shaft. Here’s how to replace the tines and holders as assemblies.

Removal Steps:

1. Follow steps l-through-3 in

“Single Tine Replacement” above.

2. Identify the tine holders as

Style A or Style B, then as left-side

and right-side holders - they must

be replaced on the same side from

which they were removed. Use a

piece of chalk or a grease pencil to

mark them “L” and “R.”

3. With Style A holders, remove

the two bolts and nuts securing

each holder (Fig. 5-33A). With

Style B holders, remove the single

bolt (along with the washers) from

the very end of the tine shaft (Fig. 5-33B).

4, Use a soft mailet to drive the holder off the tine shaft. (Use a heavy hammer and block of wood to drive off a “frozen” tine holder.)

5. When the holder is off, clean all dirt and de bris from the shaft and

the holder. Apply fresh grease to the tine shaft.

Replacement Steps:

1. Replace the holder so

the sharp tine edges face

Figure 5-33A: Style “A ” Tine Holders— Left and

right-side tine holders are secured to the tine

forward (toward front of

tiller). Tap tine holder back on the tine shaft.

2. Grease the threads on

the mounting bolt(s). Install and tighten the bolt(s) securely.

Style B Tine Holder

Lett-Side

Tine Holder ^

WARNING

Wear safety goggles to pro tect your eyes. When loosening hardware, hit a wrench with a metal toolthis could shat ter the tool or wrench, sending

metal particles into your eyes.

not

Figure 5-33B: Style “B” Tine Holders— Left and

right-side tine holders are each secured with a

single mounting bolt into the end of the tine shaft.

shaft with two bolts and two nuts.

Right-Side Tine Holder

Tapered Tine Shaft

Page 56

TINE SHAFT MAINTENANCE

After every 10 operating hours, remove the left- and right-side Bolo Tine holders and clear away dirt and debris that have accumu

TIRE AND WHEEL MAINTENANCE

Check tire air pressure every 30

operating hours. The recom mended pressure for tilling is 10to-20 psi (pounds per square inch). Both tires should be inflated equally. (Unequal pressure can cause the tiller to pull to one side.)

WARNING

To help avoid personal injury, stop the engine, wait for all

moving parts to come to a complete stop, remove the electric start key, disconnect the spark plug wire and move the wire away from the spark plug, and let the engine and

muffler cool before removing or replacing the wheels.

Removing the Wheels

Each wheel is secured by a roll

(spirol) pin that passes through the

lated on the tine shaft or inside the tine holders. Please follow this

maintenance recommendation, as

debris can cause premature wear to the tine shaft and its oil seals.

Refer to the previous tine holder

wheel hub and the wheel shaft. Drive the roll pin out to remove a wheel.

1. Prop the transmission up with a sturdy block to raise the wheel you want to remove off the ground.

2. Move the Wheel Speed Lever to either SLOW or FAST position to prevent the wheels from turning.

3. Use a 5/16" drift pin (or a blunt point 16-penny nail) to drive the roll pin free. See Photo 5-34.

WARNING

Wear safety goggles when

driving the roll pin into or from the wheel hub to protect your eyes from the possibility

of flying metal particles.

removal instructions (see previous page). After cleaning away any debris and removing old grease from the tine shaft, apply fresh grease to the tine shaft.

Photo 5-34: Drive roll pin out to re

move wheel. Grease wheel shaft

before replacing wheel.

ENGINE OIL MAINTENANCE

Change engine oil after first five (5) hours of new operation. There after, change the oil every ten (10) operating hours. This may be more often than your engine manu facturer literature recommends, however your tiller may be operat ing in dirty or very dusty condi

tions.

Follow engine manufacturer lit

erature for specific oil changing

procedure, quantity of oil, and par ticular grade and viscosity of oil to

use in your engine. Locations to

check the oil level and to drain the

oil are shown at right. Note that

there are two oil fill plugs (one on each side) on the 7HP Briggs & Stratton recoil start engine.

Figure 5-35: Oil fill plug on 7HP Briggs & Stratton engine.

fi-

Photo 5-36: Checking oil level on

8HP Kohler engine.

Figure 5-37: Oil drain plug location on 7HP Briggs & Stratton engine.

Photo 5-38: Location of oil drain plug on 8HP Kohler engine.

Page 57

AIR CLEANER MAINTENANCE

Your engine is equipped with a dual element air cleaner that filters the air twice before it enters the

carburetor to mix with the fuel. The outer foam pre-cleaner filters the air first; then the inner paper element filters the air again.

It is very important that the fil ters be kept clean and properly in stalled at all times. See the air fil ter system on your engine by refer ring to Figure 5-39 or Photo 5-40.

Refer to the engine manufac turer literature supplied with your

tiller for complete service and maintenance information for the air cleaner on your engine.

Figure 5-39: Air cleaner on the 7HP

Briggs & Stratton engine.

Photo 5-40: Foam filter on the 8HP Kohler engine.

THROTTLE CABLE

MAINTENANCE

WARNING

To help avoid personal injury,

stop the engine, wait for all moving parts to come to a complete stop,remove the electric start key, disconnect the spark plug wire and move the wire away from the spark piug, and let the engine and

muffler cool before adjusting

the throttle cable.

SPARK PLUG

MAINTENANCE

The spark plug (see Figure 5-41 or 5-42) must be in good condition for proper engine operation. Re move and inspect the plug every

50 operating hours or annually, whichever occurs first.

The throttle lever settings are factory-adjusted, so unnecessary adjustments should not be made. However, if the engine does not start or stop, or respond immedi ately to various throttle lever set tings, then adjustments may be necessary. Please refer to the en gine manufacturer literature sup plied with your tiller for specific adjustment instructions.

Of course, you may contact your nearest authorized engine ser vice dealer for throttle cable ad

justments by a qualified service representative.

IGNITION SYSTEM MAINTENANCE

Your engine is equipped with electronic ignition. It does not have a condenser or points, so there is no need to perform any regular “tune-up” maintenance on this system other than adjusting or replacing the spark plug.

The correct electrode gap for the Briggs & Stratton engine is .030" and for the Kohler engine .025". Check the gap with a feeler gauge. Do not use a spark plug if the

porcelain is cracked, the electrodes

are pitted or burned, or other visi ble damage is present. Note: Do not wire brush or sand blast spark plug to clean it - loose particles can enter engine, causing damage!

Figure 5-41: Sparkplug (with boot on) on the 7HP Briggs & Stratton engine.

To replace the plug, first tighten

it securely by hand, then use a

spark plug wrench to tighten the

plug an extra 1/4 turn.

Photo 5-42: Spark plug on the 8HP Kohler engine.

Page 58

BATTERY CARE

AND MAINTENANCE

DANGER

POISON- CAUSES SEVERE BURNS

• Electrolyte is a sulfuric acid solution.

• Avoid contact with skin, eyes and clothing.

• To prevent accidents, wear protective clothing, rubber gloves, and shield eyes with safety goggles.

• Neutralize acid spills with baking soda and water solu tion. Neutralize empty con tainer with baking soda and rinse with water.

ANTIDOTE: External- Flush

with water. Eyes- Flush with water for 15 minutes and get prompt medical attention.

ANTIDOTE: Internal- Drink

large quantities of water or milk. Follow with milk of magnesia, beaten eggs or

vegetable oil. Call physician

immediately. KEEP OUT OF REACH OF CHILDREN

DANGER — BATTERIES

PRODUCE EXPLOSIVE GASES

• Keep sparks, flame, cigarettes away at all times.

• Only charge or use the bat tery in a well-ventilated area.

• Make sure venting path (vent tube) of batfery is always open.

DANGER

Never touch the positive (+) battery post and any other surrounding metal with tools, jewelry, or other metal ob jects. Doing so can cause a short circuit that could result in electrical burns, an electri cal shock, or explosion of battery gas.

A. Battery Care in Service

1. Every month or every ten (10)

operating hours, whichever conies first, check the level of electrolyte solution in the battery cells: a) If the battery case has UPPER

and LOWER level lines on it, the solution should be maintained at the UPPER level line.

b) If the battery does not have

level lines on the case, maintain the solution level at the lowest part of the filler well within each cell. See Figure 5-43.

Figure 5-43: Keep battery cells

filled up so the solution reaches the

bottom of each filler well.

Only use distilled or demineral

ized water to refill each battery cell. After filling, replace the bat tery caps securely, then wash off any spilled solution with a baking soda and water mixture. Next, run the engine outdoors for about 20 minutes (at 3/4 throttle) to help recharge and recirculate the elec trolyte solution. For safety, do not leave the tiller unattended while the engine is running.

2. Keep the battery clean. If ter minals are corroded, remove bat tery and clean terminals with a wire brush, sandpaper or steel wool. {Avoid getting any of this

corrosive material on your skin or in your eyes.) Rinse battery with a

solution of baking soda and water. Coat the terminals with petroleum

jelly or silicone grease to prevent

further corrosion.

3. Periodically check entire elec trical system for loose connections or loose hardware.

4. Check hardware securing the battery holddown clamp. It should be secure, but not overly tight.

5. Check the vent tube. It must not be crimped or bent.

WARNING

To help avoid personal injury, be sure the battery vent tube is not crimped or pinched anywhere along its length. Improper venting could result in an explosion of battery gases.

B. Battery Care in Storage

Your engine has a recharging circuit that will properly maintain the battery’s state of charge during the normal tilling season. However, prior to storing your

tiller away during the off-season,

we recommend the battery be fully charged. At the end of the storage

period, the battery should be recharged again.

^ DANGER

• While the battery is being charged, do not leave it unat

tended. Charging time does

not have to be continuous.

• Carefully follow all charg ing instructions and safety rules provided by the manu

facturer of the charging

equipment.

• Never attempt to “jump

start” the battery with an au tomobile battery or its charg

ing system. This could result in serious personal injury or property damage from causes

such as a battery explosion, or acid or electrical burns.

Page 59

1. Remove the battery from the

tiller (see “Battery Removal” in

structions on this page) and place on a stable, level surface.

2. Clean the battery if needed. If the battery is very cold, let it warm up to between 60-to-80°F.

3. Remove filler caps. Keep them off when filling and charging.

4. Carefully check the electrolyte level. If low, add distilled or dem ineralized water (do not add bat tery acid) to bring the solution level in each cell up to the correct height. Avoid overfilling.

5. Charge the battery (with caps removed) until all cells are gassing freely. (To check for gassing, wear protective goggles and inspect each cell with a flashlight for bub bling of the electrolyte solution.) Use one of the following methods to charge the battery:

a) Recommended Method: charge

the battery at a rate of l-to-2 amperes until cells are gassing freely. Do not exceed 24 hours charging time.

b) First Alternative Method: charge

battery at 4-to-6 amperes until

cells gas freely. Do not exceed 8 hours charging time.

c) Second Alternative Method:

charge the battery at a rate of 6-

to-12 amperes until cells gas

freely. Do not exceed 4 hours

charging time.

necessary to adjust level to the cor

rect height. Then reconnect the

charger cables to the battery and charge the battery for one more hour.

7. Replace the filler caps and wash off any spilled electrolyte with a baking soda and water solution.

8. Store the battery in a cool, dry location. Avoid freezing tempera tures. Batteries lose voltage when in storage, more so in hot weather than in cold. Ideal storage temper ature is 50‘’F.

C. Battery Removal and Replacement

WARNING

To help avoid personal injury, stop the engine, wait for all moving parts to come to a complete stop, remove the electric start key, disconnect the spark plug wire and move wire away from spark plug, and let the engine and muf fler cool before removing or

replacing the battery.

1. Disconnect the negative (-) cable from the grounding screw on the right side of the battery bracket

(A, Photo 5-44) and bend the cable away from all metal parts.

2. Disconnect the negative cable from the negative (-) battery post (B, Photo 5-44), and remove cable.

3. Disconnect positive (-t) cable from positive battery post (C, Photo 5-44) and bend it safely away from metal parts. Cover cable terminal with rubber boot.

4. Remove the battery holddown

clamp and remove the battery.

5. Reverse the previous steps to

replace the battery. The battery

posts must face the rear of the tiller. (The positive post must be

on the left side as you face forward from the handlebars.)

6. Insert the vent tube (on positive side of battery) into the vent tube shield. Be sure it is not crimped, pinched or folded along its length.

A WARNING

When removing the battery,

always disconnect the nega tive (-) cable first followed by the positive (+) cable. Re verse this procedure when re

installing the battery.

^ CAUTION

Do not charge the battery at a rate higher than 12 amperes. A charge rate greater than this generates excessive heat and gassing, and wiil perma nently damage the battery.

6. When battery is fully charged, turn charging equipment off and disconnect the cables. Check elec trolyte level in all cells. Add dis tilled or demineralized water if

Photo 5-44: Follow battery removal and replacement instructions carefully.

Page 60

STORING YOUR TILLER

4. When engine is still warm, drain oil from engine crankcase.

When your tiller won’t be used

Refill with fresh motor oil.

during the off-season, prepare it for storage with the following steps:

5. Protect the internal cylinder against rust by removing the spark

1. Clean the tiller and engine.

2. Do routine tiller lubrication and check for loose hardware.

3. Protect the engine from deterio ration or damage by referring to the engine storage instructions in your engine manual literature.

plug and pouring one ounce of clean engine oil into the spark plug hole. Then slowly pull out the re coil start rope 2 or 3 times to dis tribute the oil internally. Replace the spark plug, but do not recon nect the plug wire. Pull the rope until resistance is felt — let rope rewind. The valves are seated.

INSPECT FORWARD INTERLOCK WIRING SYSTEM

Every ten (10) operating hours, check the Forward Interlock wiring system for tight connections and to see that the insulation on the wires is unbroken (to prevent the system

from shorting out).

1. Check the insulated wire har

ness leading from the lower ends

of the handlebars over to the wire harness connector on the top, right side of the transmission cover (Photo 5-47). Be sure the connec tor is securely mated.

2. Check the insulated tubing leading from the connector to the cast iron motor mount/belt shroud.

6. Charge the battery (if your tiller has the electric start option). Store battery in a cool, dry location.

7. Move Wheels/Tines/PTO Drive Lever to NEUTRAL position. Keep tiller in a clean, dry area.

8. Never store tiller with fuel in

fuel tank in an enclosed area where gas fumes could reach an open flame or spark, or where ignition

sources are present (space heaters, hot water heaters, furnaces, etc.).

3. Check the wire leading from the tubing over to the switch assembly mounted on top of the tab on the cast iron motor mount-belt shroud (see Photo 5-45). Also check the second wire that leads to the throt tle cable mounting bracket on the right side, forward portion of the engine.

TROUBLESHOOTING THE FORWARD INTERLOCK SAFETY SYSTEM

The wiring circuit for the For

ward Interlock Safety System is designed to ground out the engine’s ignition system.

There are three switches in the circuit which, when open, let the engine run. One switch is on the neutral plunger tab of the cast iron motor mount (see Photo 5-45). This switch is open whenever the Wheels/Tines/PTO Drive Lever is in NEUTRAL or REVERSE posi tions. The other two switches are located inside the han dlebars, directly above the two Forward Inter

lock Levers (see Photo

5-46). The switches are wired in series, so when any are opened (by squeezing one of

the Forward Interlock Levers), the engine will run. There is a fourth

switch located in the

wiring harness connec

Photo 5-45: switch.

tor on the top, right side of the transmission cover (Photo 5-47). It warns you if the connection is not mated by not letting the engine run while the Wheels/Tines/PTO Drive Lever is in FORWARD.

Only a few things can go wrong

with this circuit;

1. A broken or disconnected wire could let the engine run without you having to press one of the Forward Interlock Levers.

........

r 7

^ V ' \ \ t

Neutral plunger Photo 5-46: Forward Interlock photo 5-47: Wiring harness

Levers. connector.

2. A bare wire touching tiller or engine metal could ground out the

engine’s ignition.

3. A switch that has failed may act as an open switch and allow the

engine to run. Or it may act as a ground and prevent the engine from running.

Refer to the Troubleshooting pages at the end of this Manual if your Forward Interlock Safety System is not operating coixectly.

■■■*. >e . j

Page 61

PROBLEM

CHECK OR TEST

(Check or test in se quence shown until problem is resolved.)

Throttle Lever in START position

Wheels/Tines/PTO Drive Lever

in NEUTRAL position

Forward Interlock Wire Harness connector securely mated

Forward Interlock Levers not being squeezed prior to shifting Wheels/

TInes/PTO Drive Lever to

FORWARD position

Visually Inspect for bare, broken or disconnected wires

Check handlebar wire harness

Check transmission wire harness

Engine won’t start

Engine shuts off when IWheeis/Tines/

PTO Drive Lever is

shifted into Forward

Engine does not shut off when Forward Interlock Levers are released while Wheels/Tines/ PTO Drive Lever

is in Forward

X X

TROUBLESHOOrrNG PROCEDURES

The following pages list possible problems (each one is numbered) that you might encounter with the tiller or its engine. After the problem, we list possible solutions, along with a reference location if appropriate. If you have a problem not listed here, or find that a solution doesn’t work, contact us for further assistance, or contact your local TROY-BILT Dealer or an Authorized Engine Service Dealer.

1 W heels/Tines/PTO Drive Lever:

A. Lever does not stay in FORWARD-

• Drive belt may be too tight. Raise belt adjustment block a little. See Section 5.

• Clutch pawl spring at end ot lever

may be overstretched. Install new

spring.

B. Lever hard to shift into REVERSE-

• Check reverse disc for wear. See

Section 5.

• Check adjustment of reverse disc and/or reverse spring and plunger as

sembly. See Section 5.

• Clean and re-lubricate motor mount bars, belt adjustment block and link ages on lever. See Section 5.

C. Tiller stays in REVERSE when lever is released-

• Lubricate motor mount bars, belt ad justment block and linkages on lever. See Section 5,

• Check adjustment of reverse spring and plunger. See Section 5. If problem

persists, contact Technical Service Department.

D. Lever sticks in FORWARD-

• Lubricate motor mount bars, belt ad justment block, and linkages on lever.

WARNING

To help avoid personal injury, stop the engine, wait for all

moving parts to come to a full stop, remove the electric start key, disconnect spark

plug wire and move the wire away from the spark plug,

and let the engine and muf fler cool before performing

any trouble-shooting checks.

See Section 5. If problem continues, contact the Technical Service Department.

E. Lever hard to shift into FORWARD-

• Follow advice for Problem 1-D. Also check for possible bent motor mount bar

that could be binding in engine mount

holes.

2 Wheel Speed Lever:

A. Lever hard to shift, or sticks in FAST

or SLOW wheel gear positions-

• Lubricate eccentric lever at rear of power unit transmission. See Photo 5-

48. If rust Is present, use penetrating

Page 62

oil and work eccentric lever back and

forth by hand.

• Lubricate linkage that connects Wheel Speed Lever to eccentric lever. Photo 5-48.

• Clutch Inside transmission may be

binding. Disconnect linkage from ec centric lever and work eccentric lever

by hand. If difficult or Impossible to move, it may be due to a damaged key

way on the wheel shaft. Contact Technical Service Dept.

• Lubricate washers and castle nut on

pivot of lever. If necessary, remove roll pin and back nut off 1/6th turn. Re place roll pin and test the movement.

• Apply grease to zerk fitting (if so

equipped) with grease gun until grease appears around washers.

Linkage

Eccentric

Connecting Rod

Photo 5-48: Check connecting rod, shifting iinkage and eccentric iever.

B. Lever shifts into FAST wheei gear, but not into SLOW wheel gear-

• Connecting rod at end of lever might be backwards, or bent in toward trans mission housing and hitting it. Other

shifting linkage might be bent. Straighten or replace linkage. See

Photo 5-48.

• Clutch inside transmission may be binding. See Problem 2-A.

C. Lever moves freely, but won’t shift

in or out of gear-

• Eccentric shifting pin inside transmis

sion may be broken (rare) or worn. Disconnect linkage from eccentric iever and try moving eccentric lever by hand.

See Photo 5-48. If lever moves easily, contact the Technical Service Department.

3 Wheels and Tines Won’t Turn:

• Review operation of controls. See

Sections 3 and 4.

• Check condition and adjustment of drive belt and reverse disc. See Section 5.

• Mounting bolt for transmission drive pulley may be loose. (See Photo 5-1). If so, drive belt or reverse disc will turn pulley, but pulley won’t turn main drive shaft.

• Worm gears that drive wheel and

tiller shafts may be worn.

4 Wheels Turn, But Tines Won’t:

•Tines/PTO Clutch Lever must be in ENGAGE position. See Section 3.

• Tines/PTO Clutch Lever may need

adjustment.

• Key for “dog” clutch on tine attach ment main drive shaft may be missing, broken.

• Worm gears that drive the tine shaft may be worn.

• Hardware holding tine holders to tine

shaft may be missing or broken. To check, remove holders. See Section 5.

• Key for bronze worm gear on tine at

tachment main drive shaft may be

missing or broken.

5 Tines Turn, But Wheels Won’t:

• Check operation of Wheel Speed

Lever. Refer back to Problem 2.

• Hi-Pro key inside wheel clutch may

be missing, broken, if so, clutch will not turn wheel shaft.

• FAST and SLOW speed wheel gears

may be worn. If only one gear is worn,

there will only be one wheel speed.

• Worm gear that drives pinion shaft and

pinion gears may be worn.

• FAST and SLOW speed pinion gears

may be worn. If only one gear is worn,

there will only be one wheel speed.

• Drive “dogs” on sides of wheel clutch

may be worn or broken. If only one side of clutch is affected, there will only be one

wheei speed.

6 Wheels And Tines Turn On Top Of Ground, But Stop Or Hesitate In Soil:

• Drive belt may be loose. See Section

• Mounting bolt for transmission drive pulley may be loose. See Photo 5-1.

7 Tiller Jumps While Tilling:

® Depth Regulator Lever set too deep for soil conditions. Lower lever for shallower setting.

• Engine throttle speed too fast.

• Tiller wheel speed too fast for soil

conditions. Change to LOW belt range or SLOW wheel speed.

8 Depth Regulator Lever

Difficult To Move:

• Lubricate spring assembly and depth

adjustment bar. See Section 5.

• Check for bent depth adjustment bar.

9 Wheel And Shaft Move

Out To One Side:

• Snap ring on wheel shaft may be dis

lodged from its groove. Raise wheels off ground and check for back and

forth play in shaft. If there is play, one

or both snap rings is loose.

10 Tiller Pulls To One Side:

• Check tire pressure. See Section 5.

11 Tine Holder Boit

Breaks Or Loosens:

• Earlier models have tine holder keys.

Check that keys are in keyways of tine

shaft. Without key in holder, left-side tine bolt will tighten and break; rightside bolt will loosen. See Section 5.

12 Poor Traction:

• Bar tread tires, tire chains, or wheel weights may be needed. See

“Attachments.”

13 Gear Oil Leak From Power Unit

Or Tine Attachment Transmissions:

• See Section 5.

14 Engine Lacks Power:

» Air cleaner restricted with dirt and/or oil. See Section 5.

Page 63

• Spark plug wire loose or damaged. Spark plug worn or fouled. See Section 5.

• Engine under excessive work load. Use SLOW wheel speed and LOW belt range.

• Throttle cable may be loose or misadjusted. See Section 5.

• Verify that engine isn’t running with choke partially engaged. See Section 3.

• Carburetor may need adjustment.

See Section 5.

• Engine overheating. Check oil level and clean cooling fins. Oil may be very dirty. Let hot engine cool before

restarting.

• Dirt or water in fuel or fuel system.

• Engine crankcase low in oil, or over filled with oil. Check and adjust level.

• Low engine compression.

15 Engine Difficult To Start:

• Wheels/Tines/PTO Drive Lever not in NEUTRAL position.

• Fuel tank low or empty.

• Dirt or water in fuel or fuel system.

• Fuel line is restricted.

• Choke not set properly. See Section 3.

• Spark plug worn or fouled (weak spark). See Section 5.

• Air cleaner restricted with dirt and/or oil. See Section 5.

• Throttle cable not properly adjusted. See Section 5.

• Engine throttle lever not free to move

through its full operating range. « Throttle wire and its linkage are bind

ing, or are bent and not free to move.

» Low engine compression.

16 Engine Won’t Start:

• See “Troubleshooting the Forward Interlock Safety System” in Section 5.

• Wheels/Tines/PTO Drive Lever not in NEUTRAL position.

• Fuel tank low or empty. Or fuel line restricted or clogged.

• Choke improperly set. See Section 3.

• Water or dirt in fuel, and /or fuel sys tem.

• Spark plug fouled or worn. Spark plug wire loose or damaged. See Section 5.

• Carburetor may need adjustment.

• Air filter clogged with oil or dirt. See Section 5.

• Carburetor float faulty (or float valve leaking)- if so, tap side of bowl lightly

with handle of screwdriver (or similar object).

• Fuel is stale- won’t vaporize prop erly, gums up carburetor float, chan nels and valves. Drain old fuel and add new fuel.

• Fuel tank shut-off valve not in “Open” position. See Section 3.

• On Briggs & Stratton engine, On/Off switch not in ON position.

On Electric Start Engines Only;

» Electrical connections loose or shorted against metal frames, brackets or covers. See Section 5.

• Battery discharged. See Section 5.

® Electric starter motor faulty.

17 Engine Shuts Off When Wheels/ Tines/PTO Drive Lever Is In Forward:

• See “Troubleshooting the Forward

Interlock Safety System” in Section 5.

18 Engine Overheats

• Clean the engine cooling fins, shroud and covers. See Section 5.

• Check for broken flywheel fins (under engine shroud). See Authorized Engine

Dealer.

® Check oil level for correct amount.

19 Engine Runs Erratically:

• Water or dirt in gasoline or carbure tor.

® Carburetor may need adjustment. See Engine Manufacturer literature.

• Spark plug fouled or dirty. Spark plug wire loose or damaged. See Section 5.

• Loose or cracked carburetor.

• Governor linkage not adjusted prop erly or binding. See Authorized Engine Service Dealer. Don’t attempt to repair by yourself.

• Check pan gasket, engine seals and drain plugs for leaks. See your

Authorized Engine Service Dealer.

20 Engine Runs Well, But Labors Under Tiller Load

• Check governor linkage for freedom

of movement.

• Check throttle setting and carburetor adjustment. See Engine Manufacturer literature.

• Tilling depth is possibly too deep. To correct, lower the depth regulator lever.

• Possible worn bronze tiller worm gear or loose drive shaft (on well-used tiller).

21 Key Switch Will Not

Start The Engine

• Check battery terminals for corro sion. See Section 5.

• Discharged battery. See Section 5.

• Defective solenoid.

• Short in key switch or key switch wire harness.

• Check starter motor mounting bolts for looseness. Have Authorized Engine

Service Dealer inspect the starter motor.

Page 64

Attaciments

ATTACHMENTS AND ACCESSORIES FOR YOUR TILLER

Hiller-Furrower Attachment

The most popular attachment

because it does so many jobs.

■'^ .iT ■■

Mounts to the rear of the depth regulator bracket. Furrower blade easily makes plant rows, trenches,

ditches to 8" deep. When hiller

wings are attached to furrower blade, attachment makes hilled

rows and raised bed gardens. Converts from a furrower to a hiller and back again, in seconds, without tools.

Row Marker Attachment

Do you like very straight, even, neat rows in your garden? If so, the Row Marker is a must attach-

Wheel Weights

Help increase traction by putting extra weight directly on the wheels. They reduce bucking and

Jumping when deep-tilling in

heavy soil. They’re shipped empty- fill them with material like concrete, sand, gravel, etc. They bolt directly to the tiller wheels.

Wrap-Around Bumper Guard

Order this Bumper Guard by it self or receive it as one of the com ponents if you order the combina tion Dozer/ Snow Blade attach-

■-i

ment. Protects the engine from damage by wrapping around and protecting many of the engine

components. 1" diameter, highstrength steel tubing.

Hardened-Face Tilling Tines

Our standard Bolo Tines do a fine job. But if you do custom till ing or lots of tilling for long hours

- consider these hardened-face tines that are 1/4" thick and made of a special cast, high chrome car bon alloy. They can last 2-1/2 times longer.

Tire Chains

Chains provide extra traction when snowplowing, or under wet or slick conditions.

Tow Hitch Attachment

Converts your tiller to a tractor-

type hauling machine. Connects quickly to the rear of the tiller

Power Unit. This is a standardtype tow hitch so it can tow many

kinds of equipment.

PTO Chipper/Shredder

Tiller engine, the PTO Chipper/

Shredder is a work horse. Chips

branches to 3" in diameter and

shreds materials to 1/2" thick.

A -

ment. Hooks quickly to the Hiller/Furrower attachment- elimi nates the need for string, stakes, measuring tape, etc. You’ll like the straight rows it helps you make if you lay out furrows, dig compost trenches, or make raised beds. The Row Marker extends from 28"-to49X", letting you vary the width between rows to suit the crop you’re planting.

Dozer/Snow Blade Attachment

In the winter, moves up to one

foot of light snow (or 6"-to-8" of heavy snow); at other times use it to move or spread sand, gravel, loose dirt, grain, sawdust, etc. Attaches easily to the front of the Wrap-Around Bumper Guard. Set the blade to several angles. Weighs 41-lbs.; measures 15" x 32".

'it

OTHER WORK-SAVING TROY-BILT ATTACHMENTS:

• Troy-Bilt® PTO Generator

• Sweep Cultivator Attachment

• Troy-Bilt® Kickstand

• Tine Attachment Cradle

Page 65

TILLER SPECIFICATIONS

^ 1 1 ^ Cl

Iiwâ

Height —

(Approximate minimum heights)

Handlebars in lowest setting: 37X" * Handlebars in highest setting: 49‘^' * Without Handlebars: 33W **

* Tines resting on ground. ** Measured from knob on Wheels/Tines/

PTO Drive Lever to the ground.

Length —

(Approximate minimum lengths)

With Handlebars: 60” Without Handlebars: 5614”

Width —

Hood width: 2214" Tilling width: 20"

Weight —

(Approximate weight of assembled tiller including motor oil in engine, but exclud ing gasoline in fuel tank and weight of

shipping container)

7HDP Recoil Start Model: 284 lbs. *

7HP Electric Start Model: 310 lbs. *

8HP Recoil Start Model: 296 lbs. *

8HP Electric Start Model: 324 lbs. *

Transmission —

Consists of two separate trans missions, the Power Unit transmis sion and the Tine Attachment transmission. Both transmissions are encased in cast iron housings and operate in separate baths of gear oil. The housings are se curely connected by a locking col lar, a dowel pin, and two large

swing-bolts. By loosening the swing-bolts, the Power Unit can be disconnected from the Tine Attachment and used as a separate

power source for optional powered

and non-powered PTO attachments.

Transmission Gear Oil —

Small Top-Offs: use SAE 140, SAE 85W-140, or SAE 80W-90. Must have an API rating of GL-3, GL-4 or GL-5.

Full Replacement: use SAE 140 or SAE 85W-140 with an API rat ing of GL-4 only.

Power Unit Gear Oil Capacity: approximately 60 ounces. Impor tant- use the oil level check hole as your final guide for gear oil level correctness.

Tine Attachment Gear Oil Capacity: approximately I2V2 ounces, but use the transmission dipstick as the final guide.

Transmission Gear Oil

Capacity —

PTO Power Unit: 60 ozs (approx.) Tine Attachment: I2V2 ozs (ap

prox.)

Wheels —

One-piece steel; 8" in diameter.

Tires —

7HP Model and 8HP Model are equipped with 4:80 x 8" bar tread tires.

Recommended air pressure is

lO-to-20 pounds/square inch.

Engine Specifications —

Please see the engine manufac turer literature supplied with your tiller for complete specifications

and details regarding the engine.

Wheel And Tine Speeds

At 3000 RPM (revolutions per minute) engine speed, the wheel and tine speeds are as follows:

BELT

POSITION

Low Range

Low Range High Range High Range

WHEEL SPEED

LEVER POSITION

Slow .5 MPH

Fast 1.2 MPH

Slow .7 MPH

Fast 1.72 MPH

WHEEL

SPEED

TINE

SPEED 146 RPM 146 RPM 200 RPM 200 RPM

Page 66

Index

^ Air Cleaner

Foam Pre-Cleaner, 57 Paper Element, 57 Service Schedule, 44

Air Cooling System, En^e

Check Air Cooling, 25 Service Schedule, 44

Air Pressure, Tires, 16,44,56,65 Assembly

Carton Contents, 9 Electric Start System, 16-19 Engine Throttle Lever, 15 Forward Interlock Wire Harness, 12 Gear Oil Levels, 14-15 Handlebars, 11 Inspection on Delivery, 9 Motor Oil Adding, 15

Tire Air Pressure, 16 Wheels/Tlnes/PTO Drive Lever, 12-13

Attachments and Accessories

Bar Tread Tires, 65 Custom Tilling Tines, 64 Dozer/Snow Blade, 64 HiHer/Furrower, 39,64 Kickstand, 40 pro Chipper/Shredder, 64 Row Marker, 64 Sweep Cultivator, 64

Tine Cradle, 40

lire Chains, 64 Tow Hitch, 64 Wheel Weights, 64

Wrap-Around Bumper Guard, 64

Authorized Engine Service, 4

g Bar Tread Tires, 65

Battery,

Activation, 17 Care in Service, 58 Care in Storage, 58-59 Charging, 17-18 Installation, 19 Removal/Replacement, 59 Service Schedule, 44 Troubleshooting, 61-63

Beds, Raised, 39 Belt,

Adjusting Tension, 49-50

Changing Speed Ranges, 32-33

Inspection, 49 Replacement, 51

Bolo Tines (see ‘ Tines”) Bolts and Nuts, 45 Break-In Operation, 25 Bumper/Guard, 64

Cable, Throttle (see “Throttle Lever Chains, Tire, 64 Chart, Maintenance, 44 Choke Control,

Function, 23

Operation, 23,27-28

Chipper/Shredder, 64 Clutch Roller, 13,21,49 Cold Weather Operation, 28 Composting, 35 Controls,

Engine, 23 TTller/Power Unit, 20-22

Cornstalks, 36 Cover Crops, 34-35 Cradle, Tine, 40 Crop Residues, 35 Cultivating, 35 Custom Tilling Tines, 64

jQ Decals, 8

Depth Regulator Lever,

Function, 22 Operation, 22,27 Tiller Depths, 22 Troubleshooting, 46,62

Disc Reverse,

Inspection, 52 Replacement, 52

Dozer/Snow Blade, 64 Drive Belt (see “Belt”)

^ Eccentric Lever, 45, 62

Electric Start System,

Assembly, 16-19 Maintenance, 58-59 Operation, 23,27 Starting with Recoil Rope, 28

Troubleshooting, 61-63

(Also see “Batteiy”)

Engine,

Air Cleaner, 57 Air Cooling System, 25 Authorized Service, 4 Choke Control, 23 Cold Weather Operation, 28 Controls, 23 Fuel, 25 Fuel Valve, 23 Ignition System, 23,57 Key Switch Starter, 23 Model Code Number, 3 Off-Season Storage, 60 011,15,25,56

Operation, 23,25,27-28 Recoil Starter, 23 SpaikPlug, 57 Specifications, 65

Starting and Stopping, 27-28 Throttle Cable, 15,57 Throttle Lever, 15,23,57 Troubleshooting, 61-63

jP Factory Service, 4

Footprints, 35

Forward Interlock Levers,

Function, 26 Inspection, 26 Operation, 26 TestPitcedure, 26

Forward Operation, 20,29-30 Free Wheel, 21 Fuel, 25 Fuel Valve, 23 Furrower, 39,64

G Gardening,

Cornstalks, 36

Cover Crops, 34-35 Crop Residues, 35 Cultivating, 35 Green Manures, 35 Leaves, 35 Power Composting, 35 Raised Beds, 39 Seedbeds, 34 SlopesTerraces, 37-38 Wide Rows, 39

Gasoline, 25 Gear Oil,

Adding, 48 Changing, 48^9 Checking for Leaks, 46 Checking the Level, 47 Type and Capacity, 48

Generator, 64 Grease, 46 Green Manures, 34-35

H Handlebar Height Adjustment, 22

Height, Tiller, 65 High Range Speed, 33 Hiller/Furrower, 39,64 Hitch, Tow, 64 Housing Cover, Tiller, 45,49

J ^ration System, 57

Introduction, 2 Inspection After Delivery, 9

K Key Switch Starter,

Connecting Keyswitch, 18 Function, 23 Operation, 23,27-28 Troubleshooting, 63

Kickstand, 40 Kohler (see “Engine”)

Leaks, Oil, 46 Leaves, 35

Length, Tiller, 65 Levers,

Choke Control, 23,27-28

Page 67

Depth Regulator, 22,27,46,62

Engine Throttle, 15,23,57

Forward Interlock, 26 Handlebar Height, 22 Tmes/PID Clutch, 22,27,42,46

Wheels/Tines/Pro Drive, 20,27,29,61

Loading/Unloading, 31 Low Rai^e Speed, 32 Lubrication Points, 46

A/f Maintenance

Air Cleaner, 57

Air Cooling System, 25 Batteiy, 58-59 Bolo lines, 54-55 Bolts and Nuts, 45 Chart,44

Drive Belt, 49-51 Engine Oil, 56 Forward Interlock System, 60 Ignition System, 57 Lubrication Points, 46 Maintenance Schedule, 44 Reverse Drive, 52-54

Spark Plug, 57

Storage, 8,60

Throttle Cable, 57

Tine Shaft, 56

Tines, 54-55

Tires, 56

Transmission Gear Oil, 46-49

Manures, Green, 34-35 Model Number, 3 Motor Oil (see “Oil, Engine”)

"VT Neutral (see “Wheels/Tines/PTO Drive

Lever”)

Non-Powered Attachments, Use, 43 Nuts and Bolts, 10,45

/A Oa, Engine,

Adding, 15

Changing, 56 Checking Level, 56

Service &hedule, 44 Type and Capacity, 15

oa, Transmission Gear

Adding, 4849

Changing, 48-49 Checking for Leaks, 46 Checking Level, 14-15,47 Type and Capacity, 48,65

Operating Instructions,

Power Unit, 4243 Tiller, 29-39

Options/Attachments (see “Attachments

and Accessories”)

p Parts Ordering, 4

Power Composting, 35 Preparation, Safety, 6

pro Power Unit,

Description, 2 Operation, 4043

PuBey, Transmission, 32-33

p Raised Beds, 39

RecoB Starter, 23,27-28 Reverse Drive Maintenance,

Adjustments, 53-54 Replacement, 52 Reverse Disc, 52-54

Reverse Operation (see

“Wheels/Tines/PTO Drive Levef’)

Row Marker, 64 Safety Decals, 8

Safety Instructions, 5-8 Seedbeds, 34 Serial Number, TBler, 3 Service,

Engine, 4 Factory, 4

Shredder/Chipper, 64 Slope Gardening, 37 Solenoid, 63 Spark Plug, 57,63 Specifications, 65 Speeds, 32-33,65 Stationary Attachments Operation, 42-

Starting/Stoppii^

Bigine, 23,27-28 PTO Power Unit, 29-30,4243 Tdler, 28-29

Storage, 60 Sweep Cultivator, 64 Swing Bolts, 4142,45

'p Table of Contents, 3

Terraces, 38 Throttle Cable, 15,57 Throttle Lever, 15,57 TBler,

Controls, 20-22 Maintenance, 44-56,58-63 Operation, 29-30 Safety, 5-8 Specifications, 65 Troubleshooting, 61-63 TBIing, 34-39

Tfiling Depths, 34 Tine Attachment, 4042,55 Tine Cradle, 40 Tine Holders, 55 Tine Shaft, 56 Tme Speeds, 33 Tines,

Qeaning, 37 Custom Tilling, 64 Inspection, 54 Single Tine Replacement, 55

Tines/PTO Clutch Lever

Function, 22 Operation, 27,29-31 Nfeintenance, 46

Tires

Air Pressure, 56 Bar Tread, 65 Chains, 64 Wheel Removal, 56

Tow Hitch, 64 Ihaining, Safety, 5 Transmission Gear 03 (see “OB,

Transmission Geari’)

Transporting Taier, 31 Travel Setting, 22,29 Troubleshooting, 61-63 Turning Around, 30

Unloading/Loading, 31

Untangfing Tmes, 37 Uphill Taiii^, 37

Vertical Tilling, 37

Viscosity,

Engine OB, 15 Gear OB, 14,48,65

Warranty, TBler and Engine, Back Cover

Warranty Registration Card, 2 Warranty Transfer Card, 2 Weight, TBler, 65 Wheel Speed Lever,

Function, 21 Operation, 27,29 Troubleshooting, 61-62

Wheel/Tine Speeds, 21,32-33 Wheel We^hts, 64 Wheels (see “Tires”) Wheels/Tines/PTO Drive Lever,

Function, 20-21 Forward Operation, 29

Neutral, 30 Reverse Operation, 30 Troubleshooting, 61

Wide Rows, 39 Width, TBler, 65 Wrench, PTO, 4042

Page 68

FULL NO-TIME-LIMIT WARRANTY

Your TROY-BILT® Roto Tiller - Power Composter is warranted by Garden Way Incorporated to be free from defects in materials and workmanship. This warranty will remain in effect for the life of the machine and will be transferred automatically to any and all subsequent owners.

We or your authorized dealer will repair or replace, at no cost to you, any part we find to be defective with the exception of the engine, which is warranted separately by the engine manu

facturer. Garden Way Incorporated does, however, extend the length of the engine manufactur

er’s warranty, providing you with coverage for a total of three(3) years. (Call or write to us for a FREE copy of the engine warranty.)

This FULL NO-TIME-LIMIT WARRANTY also applies to all non-powered attachments.

Powered attachments are warranted separately by their manufacturers.

If we determine them defective, even parts that wear in normal use, such as belts, bearings,

blades, tires, and tines are covered under this warranty and will be replaced or repaired without charge. Failures or malfunctions caused by normal wear and tear, use of unauthorized acces sories or attachments, misuse, or accident are not covered.

FULL ONE-YEAR COMMERCIAL USE WARRANTY: If used for commercial, institutional, in dustrial, rental or demonstrator purposes, the warranty on this product is limited in duration to one (1) year from date of purchase. The engine warranty for commercial use is a LIMITED WARRANTY also in effect for one (1) year from date of purchase. Proof of purchase is required to obtain commercial warranty service.

How to Get Service:

Your Rights Under State Law:

To obtain warranty service, contact Garden Way Incorporated at 102nd Street & 9th Avenue, Troy, NY 12180, or call us TOLL FREE at 1-800-833-6990, or consult your Yellow Pages for the name of the

authorized TROY-BILT product dealer nearest you.

This warranty gives you specific legal rights, and you may also have

other rights which vary from state to state.

Plus...You can try a TROY-BILT® Tiller for 30 days

and then decide!

If for any reason you are not satisfied with your TROY-BILT® Tiller within 30 days from the time you receive it, notify us and return it.

We will refund the original price you paid for the product, plus we will pay shipping both ways!

Half-Price Factory Rebuilding Agreement

At any time, no matter how new or old your TROY-BILT® Roto Tiller-Power Composter may be, we will rebuild and repaint it, replac ing every worn part (such as bearings, gears, seals, tines, belts, and including a new engine) for one-half the current retail price at the time of repair of that model or its equiva-

lent (if that exact model has been changed); owner to pay shipping and container costs to

and from the factory. If any other than wearing

parts need replacement, an estimate will be submitted to owner for approvai. This offer, of course, is subject to fire, war, strikes, and other contingencies beyond our control.

Troy-Bilt 12069-7HP User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

U.S.A.

U.S.A. Canada

Canada

Canada

TRAINING

PREPARATION

OPERATION

Safetf

SAFETY DECALS

Decal Locations

Ajseni

Inspection After Delivery

STEP 2: Attach the Handlebars

STEP 3: Remove Tiller from Shipping Platform

STEP 4: Connect Forward Interlock Wire Harness

STEP 5: Attach the Wheels/Tines/PTO Drive Lever

^ WARNING

STEP 6: Check Gear Oil Levels in Power Unit Transmission and Tine Attachment Transmission

STEP 7: Add Motor Oil to Tiller Engine

STEP 8: Attach Engine Throttle Lever to Right Handlebar

WARNING

ASSEMBLING THE ELECTRIC START SYSTEM

STEP 1: Activating and Charging the Battery

^ DANGER

WARNING

DANGER

DANGER

DANGER

STEP 2: Connect the Wire Harness Receptacle

STEP 3: Installing the Battery

CAUTION

STEP 4: Installing the Battery Cables

WARNING

TILLER FEATURES AND CONTROLS IDENTIFICATION

A) Wheels/Tines/PTO Drive Lever

Mrols

B) Forward Interlock Levers

C) Wheel Speed Lever

D) Tines/PTO Clutch Lever

E) Depth Regulator Lever

WARNING

F) Handlebar Height Adjustment Lever

^ WARNING

WARNING

Engine Throttle Lever

Engine Recoil Starter

Key Switch Starter

Fuel Tank Shut-Off Valve

On/Off Switch

Break-In Operation

Preparation Before Starting

Test Operation of Forward Interlock Safety System

DANGER

Starting and Stopping the Engine

Cold Weather Operation

WARNING

CAUTION

Turning Around

WARNING

Transporting Your Tiller

WARNING

To Change Belt Speeds

To Change From LOW Range to HIGH Range

^ WARNING

To Change From HIGH Range to LOW Range

Operation

Choosing Tiller Wheel and Tine Speeds

TILLING IN THE GARDEN

Tilling Depths

Seedbed Preparation

Avoid Making Footprints

Cultivating

Power Composting

SPECIAL TROY-BILT GARDENING TECHNIQUE— Till Under Standing Cornstalks

Three Rules For Tilling Under Cornstalks

Clearing Debris From The Tines