Troy-Bilt 12087 User Manual

$4'

Owner/Operator

Manual PTO HORSE

Tiller

• Safety

• Assembly

Models

12087 (7HP Standard) 12088 (7HP Electric) 12089 (8HP Standard) 12090 (8HP Electric) 12204 (10HP Electric)

• Features and Controls

• Operation

• Maintenance

GARDEN WAY INCORPORATED

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 log splitter. Your tiller is famous for its ruggedness, performance and high-quality engineering. We know you’ll enjoy using it.

Please carefully read this Manual. It

tells you how to safely and easily 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, please contact your local authorized service dealer or call us Toll-Free. Our telephone num bers 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 tfie safety message could result in personal injury or property damage.

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

Be Sure To Return Your Owner Registration Card

Be sure to fill out and return your Owner

Registration

Card, which is

located in your

literature pack age. The infor

mation con tained on this card wiil register your machine with us and entitle you to full coverage under our Warranty.

i'jI; ■ ...

This machine meets voluntary safety stan dard B71.8 - 1996, which is sponsored by the Outdoor Power Equipment Institute, Inc., and is published by the American National

Standards Institute.

WARNING:

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth de fects, or other reproduc tive harm.

Owner’s Record

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.................................................4

SECTION 1: SAFETY.....................................................5

Training..................................................................................................5

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

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

Maintenance and Storage......................................................................8

Decals....................................................................................................8

SECTION 2: ASSEMBLY...................................................9

SECTION 3: FEATURES AND CONTROLS

Tiller Features and Controls Identification

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

SECTION 4: OPERATION

Break-In Operation Test Forward Interlock Safety System Starting and Stopping the Engine

Cold Weather Operation......................................................................28

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

Turning Around

Transporting Your Tiller.......................................................................31

To Change Belt Speeds.......................................................................32

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

The PTO Power Unit............................................................................40

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

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

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

SECTION 5: MAINTENANCE & REPAIRS

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

Tighten Bolts and Nuts.........................................................................45

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

Transmission Gear Oil Maintenance....................................................46

Drive Belt Maintenance........................................................................49

Reverse Drive Maintenance

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

Tine Shaft Maintenance.......................................................................56

Tire and Wheel Maintenance

Engine Oil Maintenance.......................................................................56

Air Cleaner, Throttle Cable, Ignition System, Spark Plug

Battery Care.........................................................................................58

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

Inspect Forward Interlock Wiring System

Troubleshooting Forward Interlock Safety System

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

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

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

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

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

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

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

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

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

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

25 26 27

60 60

TROUBLESHOOTING PROCEDURES..................................61

ATTACHMENTS & ACCESSORIES..

TILLER SPECIFICATIONS....

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

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

INDEX.................................................................. 66

If you have any

HOWTO

REACH

GARDEN WAY

INCORPORATED

1 Garden Way

Troy. NY 12180

USA and

Canada:

Customer

Service:

1-800-437-8686

Technical

Service-

1-800-520-5520

Parts Service:

1-800-648-6776

FAX:

(518) 391-7332

Outside the

USA and Canada:

Customer

Service:

(518) 391-7007

Technical

Service:

(518) 391-7008

Parts Service:

(518) 391-7006

FAX:

(518) 391-7332

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

If You Need Parts:

Factory specified replacement parts for your machine are avail able from either your TROYBILT® Tiller authorized dealer or directly from the Factory.

To order a part from the Factory, refer to your separate Parts Catalog to find the part number.

“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.

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

machine.

Our trained parts special ists will gladly assist you if you have any difficulty

in identifying the part that

you need.

Section

Please read and follow all of fhs 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 elsewhere in the Manual, please contact either your local authorised dealer or the factory for assistance.

WARNING TO ALL CALIFORNIA

AND OTHER POWER EQUIPMENT OPERATORS

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

you are not permitted to operate an internal combustion engine

using hydrocarbon fuels on any forest-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 law, 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. Keep in mind that the operator or user is responsible for accidents or hazards occurring to other peo ple, their property, and themselves.

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

5. Familiarize yourself with all of the safety and operating decals on this equipment and on any of its attachments or accessories.

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

7. 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

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

Safet^

is shifted to FORWARD. The tines rotate in Reverse whether the In terlock Levers are closed or open.

8. Before inspecting or servicing any part of the equipment, shut off

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.

4. Do not operate the tiller when you are barefoot, in sandals, sneak ers or other light footwear. Wear

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.

protective footwear that grips 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. Take the following precautions;

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

moved or fuel added with en gine running. Engine shall be allowed to cool before refuel ing. Operators shall not smoke.

c. Keep matches, cigarettes,

cigars, pipes, open flames, or

9. Do not operate this equipment if you are under the influence of alcohol, medication, or when you are tired or ill.

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 all fuel tank and con

tainer caps securely.

f. If fuel is spilled, do not at

tempt to start engine, but move the machine away from the area of spillage and avoid cre ating any source of ignition until fuel vapors dissipate.

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.

OPERATION

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

2. Use extreme caution when on or

crossing gravel driveways, walks or roads. Be alert for hidden hazards or traffic. 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 dam age before restarting.

■

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. Vibration is generally a warning sign of trouble.

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. Take all possible precautions when leaving the machine unat tended. Shift into neutral, stop en gine (remove key on electric start models), 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 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 safety devices are in place.

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

12. Keep children and pets away.

13. Never operate the tiller under engine power if the Wheel Speed Lever is in the FREEWHEEL posi tion. In EREEWHEEL, the wheels will not hold the tiller back and the revolving tines could propel the tiller rapidly, possibly causing 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 Wheel s/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. Let go of the han dlebars and all controls. Do not try to restrain it. If in doubt about till ing conditions, use the following precautions to assist you in main taining 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 hard or slippery surfaces. Look behind and use care when backing up.

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 acces

sories approved by Garden Way Inc.

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. Keep

out of reach of children.

Antidotes: External- Elush imme

diately with lots of water.

Internal- Drink large quantities of

water or milk. Eollow 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.

26. DANGER-BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame or smoking materials away. Ventilate when charging battery or using in an enclosed space. Always wear safety goggles 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 Forward 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 tines and

use slower wheel and engine throt

tle speeds. Use sturdy ramps wide

and strong enough to easily support

the tiller (280-to-325 lbs., depend

ing on model) and operator. Never go down ramps in FORWARD 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 FOR WARD drive and follow the tiller.

30. The Forward Interlock Safety System should be tested for correct

functioning every time the tiller or pro power unit is used. See

Section 4 in this Manual.

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

32. Use extreme caution when re versing or pulling machine towards you.

33. Start the engine carefully ac cording to instructions and with feet well away from the tines.

34. Never pick up or carry a ma chine while the engine is running.

MAINTENANCE AND

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

tion sources are present (such as

1. Never perform maintenance when engine is running or spark

plug wire is connected except

when specifically directed to do so.

2. Keep tiller, attachments and ac

cessories in safe working condition.

hot water and space heaters, fur

naces, clothes dryers, etc.).

5. Let the engine cool down before storing it in an enclosure.

6. To reduce fire hazard possibili

ties, keep the engine free of grass, leaves or grease.

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

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.

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

10. Follow manufacturer’s recom

mendations for safe loading, unload

ing, transport, and machine storage.

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

A) WARNING: Hot Surfaces decal.

On Briggs & Stratton engines, located on top of the air cleaner housing.

F) Engine Stabilization

decal. On Briggs & Stratton engines, located on the fuel tank.

Decal Locations

C) WARNING: Operating and

Safety Instructions decal.

B) WARNING: Engine Ignition. On elec

tric start models only.

E) Forward

Interlock Lever decals (2).

D) Power Unit Operating

Instructions decal.

Section

Please carefully follow the steps in

this Section to propeily assemble

your new machine. These steps will not take vciy long and they will assure you of having assem bled your machine correctly.

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

Scissors ito trim plastic ties) Quality Motor Oil (refer to the

Engine Owner Manual provided with your unit

for motor oil specifica

tions and capacities). Tire Pressure Gauge A strong 4 /7 high prop (a

w'ood box. a brick, or

boards)

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

• 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 arrives. 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.

STEP1; Unpacking Contents

If you haven’t done so, unpack and check the loose parts as listed in the table on page 10. Contact us if any parts are missing.

A. Remove the handlebars and the Wheels/Tines/PTO Drive Lever

(Items 1 and 2 in Photo 2-1). You may need to cut a plastic tie to free the handlebars from its shipping location. Set them on a clean sur face. 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 the items from a sealed plastic hardware package under the battery clamp (Items 9 through 11 in Photo 2-3). Your ig nition keys are in the keyswitch.

.sseiii

wmmmiimmiiimmMmsmmmin

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

DESCRIPTION FOR MODEL:

7HP 7HP 8HP 8HP

Elec. Std. Elec.

Std.

Photo 2-1:

1 1

2 1

Handlebars

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

Wheels/Tines/PTO Drive Lever

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

Photo 2-2:

3 1 Clutch Pa\A/l Spring.....................................

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

2 6 1 7 1 8 1

Plastic Cable Ties Curved Head Bolt, 1/4“-20 x 2" (Grade 5).. Flanged Lock Nut, 1/4"-20 Panhead Screw, #20 -24 x 1/2"

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

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

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

•

• • •

•

• • •

• • • •

• • •

•

• • • •

• • •

•

Use This Ruler to Check the Hardware Lengths

Photo 2-2. Parts inside the litera ture envelope.

Photo 2-3:

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

10 2

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

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

Keys for Electric Start Models......................

(located in ignition keyswitch)

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

•

• •

•

Photo 2-3. Parts for Electric Start

Tiller models. (Ignition keys are

not shown.)

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.

Asseiiiblv

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.

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).

Figure 2-4. Unwind the Handlebar Height Adjustment Lever to separate the handiebar assembly parts. Keep the mating ieft-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 ail parts securely.

Left Side Clamp With Nut

Photo 2-5. When handlebars are in position, reassemble all the compo nents. Insert the Handlebar Adjustment Lever from right to left through all

the parts. As shown above, securely tighten the lever.

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 FREEWHEEL posi tion which lets the wheels turn

freely. FREEWHEEL position is midway be tween SLOW and EAST 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.

^ WARNING

To avoid personal injury, test the Forward Interlock Satety 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.

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

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, E, and G, Eigure 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

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

comes out. If it swings down, reposition it upright again.

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

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.

Figure 2-9. First remove hardware from rear of yoke plates (hardware items A, B, C, and D); then remove hardware securing short, upright steel link 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.

F. 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 earher (per paragraph C) back in the 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.

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.

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 instmctions.

Asseiniii?

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’ IVIarkina:

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 Markings:

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.

Photo 2-15: Pull Depth Regulator

Lever back and then up to lower

the tines to the ground.

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

power unit transmission.

Photo 2-17: Remove dipstick to check gear oil in tine attachment

transmission. Insert dipstick so

markings face rear of tiller.

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 instructions.

STEP 7: Add Motor Oil to Engine

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

Owner Manual provided with your unit for motor oil specifications and capacities.

To Add Oil:

A. Park the tiller on level ground.

Place a sturdy block under the drag bar at the rear of the tiller to level the base of the engine.

B. An oil fill tube is located on each side of the engine. Either can be used. See Photo 2-18.

C. Clean around the oil fill tube and remove the oil fill plug. Use a clean funnel and slowly pour motor oil

into the tube until the oil reaches the

top of the fill hole.

D. Reinstall the oil fill plug and re

move the block under the drag bar.

IMPORTANT:

> Always maintain oil level at the

overflow point in the oil fill tube.

' Check engine oil level every 5

hours of operation or daily.

' Change engine oil after first 5

hours of new operation.

Photo 2-18: Add oil until it reaches

top of oil fill tube.

STEP 8: Attach Engine Throttle

Lever to Right Handlebar

The throttle cable (with throttle lever) is wound around the engine for shipping purposes. Carefully

unwind the cable. If the throttle control decal is covered with a pro tective coating, peel it off. Attach the lever as follows.

A. You will need the curved head bolt, flange locknut, panhead screw and two plastic ties which are shown in Photo 2-2, Page 10.

B. Run the throttle cable up the in side edge of the right handlebar and position the lever as shown in Photo 2-19.

C. From the outside of the handle

bar, insert the curved head bolt

through the handlebar and the cen ter hole in the throttle lever mount ing bracket.

D. Loosely install the locknut. E. Move the throttle lever to the

STOP position. F. From the lever side of the

bracket, thread the panhead screw into the small hole in the throttle lever bracket and into the handle bar. See Photo 2-19. Tighten the

screw securely. G. Use a 7/16" wrench to securely

tighten the locknut and the curved head bolt.

H. Using two plastic ties, secure the throttle cable to the right han dlebar in two places, as shown in Photo 2-20. Loop each tie around the handlebar and cable (serrated

side faces in) and pull the ties

tight. Trim the ends.

Photo 2-19: Attach engine throttle lever to handlebar.

¿4 Cl

Photo 2-20: Use plastic ties in two places to hold cable to handlebars.

WARNING

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.

STEP 9; Adjust the Air Pressure in the Tires

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

B. Before using the tiller, check the air pressure and adjust it to betiveen 10-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 burn 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.

To Activate the Battery:

WARNIHG

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.

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 WA” 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 bO^^F-to-SO^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

battery-this could lead to flooding

from the cells during charging.

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

Remove the piece of clear plastic tub ing (B)if so supplied.

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 Chai^g Method:

Charge the battery at a rate of 4-to6 amperes until all cells gas freely. Do not exceed 8 hours charging.

Second Alternative Charging Mdhod:

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.

A DANGER

Never jump start the battery with a vehicle battery or charg ing system. This may produce a battery explosion, causing acid or electrical burns.

DANGER

To Avoid Personal Injury or Property Damage;

• Batteries produce explosive gases - always 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. Always 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 platform (C) using the hold down clamp (D) with its mounting hardware (H, I). Last, install plastic vent tube (E) over the vent fitting (F), and down into vent tube shield (G).

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.]

B. Place the battery hold-down

CAUTION

Incorrect installation of the battery can resuit in eiectrical system damage.

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

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 (FI, 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 l/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 (+) battery cable (A, Figure 2-26 - this is the red cable already attached at the other end to the solenoid) to the positive (+) battery post (B). Flold 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 inserted 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 neces sary. 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.

Section

Learn the locations of the features and controls on your machine before slatting the engine, laking the time now to understand the lo cation. tunction and opeiation of

these controls Vi/ill 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.”

A 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 direction 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.

Wheels/Tines/PTO Drive Lever

This lever (A, Figure 3-1) engages and disengages power from the engine to the transmis sion. It has three operating posi tions: FORWARD, NEUTRAL and REVERSE.

To stop the wheels, tines or any PTO attachment, move the lever to NEUTRAL by lifting or tapping the lever upwards and letting it go (in NEUTRAL the clutch roller will be located on the face of the adjustment block, as shown in

Photo 3-lB). FORWARD - Lever moved down until it engages in drive position (clutch roller at end of lever is en gaged below adjustment block, as shown in Photo 3-1 A). Use this setting for forward motion of the wheels and tines, or to apply power to any optional PTO (Power Take Off) attachment.

REVERSE - Lever moved all the

way up and held in that position

(clutch roller will be located higher

on the face of the adjustment

block, as shown in Photo 3-lC). Use this setting for moving the machine in reverse. To stop mov ing in reverse, let go of the lever and it will automatically return to the NEUTRAL position.

Check Position of Clutch Rolier

• Do not operate the tines or any PTO attachment when in REVERSE.

A'^ you shill hoiwoL'ii i'ORWARI). NI A.' I RAI.

;inJ Kl A'liRSt'. iho diildi rolli.-r the hoUtuii of

iho Icwr should Iv fK'sitioiiod as shown in Pholos

1 \. Ò-1 f5 and A-IC. Chix’k iho posilion of ilio

diitoh rollor as you shill the le\er. IT ii is noi po-

siiioncd eonvelly. eontael the I’aclory or see \i'iir loeal aulhoii/od dealer.

Photo 3-1 A: When the Wheels/Tines/PTO Drive Lever is in

the FORWARD position, the clutch roller will be engaged

b^ow the adjustment block.

NEUTRAL - Lever moved in between FORWARD and REVERSE positions. Use this setting to stop the wheels, tines or any PTO attachment.

• Always shift to NEUTRAL before starting the engine or before engaging the wheels, tines or any

PTO attachment.

Forward Interlock Levers

A Forward Interlock Lever (B, Figure 3-1) is

located below each handlebar grip.

At least one of these interlock levers must be kept

squeezed against a handlebar grip whenever the 'N^eels/Tines/PTO Drive Lever is engaged in FOR WARD. (The levers do not affect operation when the Wheels/Tines/PTO Drive Lever is in REVERSE.)

If both interlock 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 cannot stop forward mo tion by moving the Wheels/Tines/PTO Drive Lever into NEUTRAL.

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

the NEUTRAL position, the clutch roller (G) must be located

approximately as shown on the face of toe adjustment block

Photo 3-1C: When the Wheeis/Tines/PTO Drive Lever is held up in the REVERSE position, the clutch roller (G) must be

located higher on the face of the adjustment block (H).

Wheel Speed Lever

Use this lever (C, Fig. 3-1) to select a wheel speed

or the freewheel position. There are three operating positions; SLOW, FAST and FREEWHEEL.

SLOW - Lever moved all the way down. Use for nor mal tilling or for low-speed transporting.

FAST - Lever moved all the way up. Use for cultivat ing or for fast-speed transporting.

FREEWHEEL - Lever in between SLOW and FAST positions (wheels will roll freely). Use for transporting the machine on level ground without engine power and when using stationary PTO attachments.

• To avoid transmission damage, always put the Wheels/Tines/PTO Drive Lever in NEUTRAL before shifting the Wheel Speed Lever.

• When shifting into SLOW or FAST, gently roll the machine to help fully engage the wheel gears. When engaged, the wheels will not turn unless the engine

is running and the Wheels/Tines/PTO Drive Lever is engaged in FORWARD or REVERSE.

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