Troy-Bilt 12090 User Manual

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Page 1

Owner's Manual

PTO HORSE TILLER

Safety Assembly Controls Operation Maintenance Parts List

Models

12089- 8HP Standard 12090- 8HP Electric 12204-10HP Electric

GARDEN WAY INCORPORATED

Page 2

Dear Owner: You now own one of the finest rear-tine tillers available.

Your new PTO Horse Model tiller enables you to till and cultivate your garden with ease, and accomplish dozens of other property management projects as well. Its PTO (Power Take Off) capability enables it to power a variety of attachments, including a chipper/shredder and a log splitter. Your tiller is famous for its ruggedness, perfor mance and high-quality engineering. We know you'll enjoy using it.

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

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

Of course, if you should ever have any problems or questions, please contact your local authorized service dealer or call the Factory (see back cover). We want to be sure that you are completely satisfied at all times.

NOTE: Be sure to fill out and return the Owner Registration Card included included with this manual.

See Back Cover for

Customer Service Information

Safety Alert Symbol

This is a safety alert symbol. It is used in this

manual and on the unit to alert you to

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

potential hazards. When you see this symbol, read and obey the message that follows it.

This machine meets voluntary safety standard B71.8

- 1996, which is sponsored by the Outdoor Power Equipment Institute, Inc., and is published by the American National Standards Institute.

A WARNING

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

TABLE OF CONTENTS

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

Training................................................................................................ 3

Preparation.......................................................................................... 3

Operation............................................................................................. 3

Maintenance and Storage

Decals................................................................................................... 5

SECTION 2: ASSEMBLY

Step 1: Unpacking Instructions............................................................ 6

Step 2: Attach Handlebar

Step 3: Move Tiller Off Shipping Platform........................................ 7

Step 4: Connect Forward Interlock Wire Harness

Step 5: Attach Whee!s/Tines/PTO Drive Lever................................... 7

Step 6: Check Gear Oil Levels Step 7: Add Motor Oii to Engine Step 8: Attach Engine Throttle Lever and Cable Step 9: Adjust Air Pressure in Tires Assembling The Electric Start System

SECTION 3: FEATURES & CONTROLS.....

PTO Attachments Feature................................................................. 13

Wheeis/Tines/PTO Drive Lever

Forward Interlock Levers................................................................... 13

Wheel Speed Lever............................................................................ 14

Tine/PTO Clutch Lever....................................................................... 14

Depth Regulator Lever

Handlebar Heig ht Adjustment Lever................................................ 14

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

Keyswitch Starter

Engine Controls

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

Break-In Operation............................................................................ 16

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

Operating the Tiller............................................................................ 18

Testing the Forward Interlock Safety System

Loading and Unloading the Tiller

Changing Speed Beits........................................................................ 21

Choosing Wheel and Tine Speeds

Tilling Tips & Techniques................................................................... 23

PTO Power Unit................................................................................. 27

PTO Power Unit Operating Instructions

SECTIONS: MAINTENMICE

Required Maintenance Schedule...................................................... 30

Tighten Bolts and Nuts...................................................................... 31

Tiller Lubrication

Transmission Gear Oil........................................................................ 32

Adding or Changing Gear Oil

Drive Belt Maintenance..................................................................... 35

Reverse Disc Maintenance................................................................ 37

Bolo Tine Maintenance...................................................................... 39

Tine Shaft Maintenance.................................................................... 41

Tire and Wheel Maintenance

Engine Oii Maintenance.................................................................... 41

Air Cleaner Maintenance

Throttle Cable Maintenance............................................................. 41

Ignition System Maintenance........................................................... 41

Spark Plug Maintenance................................................................... 41

Battery Care and Maintenance......................................................... 41

Storing your Tiller

Inspecting Forward Interlock Wiring System Testing the Forward Interlock Wiring System

APPENDIX A: TROUBLESHOOTING... APPENDIX B: AHACHMENTS & ACCESSORIES.

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15 15

20 20

43 43 43

8 9 9 9

PARTS LIST ................................................................... .....47

CUSTOMER SERVICE INFORMATHMU ..............Back Cover

Page 3

Section

1 Safety

SPARK ARRESTER WARNING TO RESIDENTS OF CALIFORNIA AND SEVERAL OTHER STATES

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

The engine on the unit is an internal combustion engine which burns gasoline, a hydrocarbon fuel, and must be equipped with a

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

\'^h^

--------------------------

Training

1. Carefully read this Owner's Manual, the

separate Engine Owner's Manual, and any other literature you may receive. Be thor oughly familiar with the controls and the

proper use of the tiller and its engine.

Know how to stop the unit and disengage the controls quickly.

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

3. Keep the area of operation clear of all

persons, particularly children and pets.

4. Keep in mind that the operator or user

is responsible for accidents or hazards occurring to other people, their property, and themselves.

Preparation

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

2. Put the Wheels/Tines/PTO Drive Lever

into NEUTRAL before starting the engine.

3. Do not operate the tiller without wearing adequate outer garments. Avoid

loose garments or Jewelry that could get

caught in moving parts.

4. Do not operate the tiller when barefoot or wearing sandals, sneakers, or light footwear. Wear protective footwear that will improve footing on slippery surfaces.

5. Do not till near underground electric cables, telephone lines, pipes or hoses. If

in doubt, contact your telephone or utility

company.

6. Warning: Handle fuel with care; it is

highly flammable and its vapors are explosive. Be sure to take the following precautions:

a. Store fuel in containers specifically

designed for this purpose.

b. The gas cap shall never be removed

or fuel added while the engine is running. Allow the engine to cool for several minutes before adding fuel.

c. Keep matches, cigarettes, cigars,

pipes, open flames, and sparks away from the fuel tank and fuel container.

d. Fill fuel tank outdoors with extreme

care. Never fill fuel tank indoors. Use a funnel or spout to prevent spillage.

e. Replace all fuel tank and container

caps securely.

f. If fuel is spilled, do not attempt to

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

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

Operation

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

2. Exercise extreme caution when on or crossing gravel drives, walks, or roads.

Stay alert for hidden hazards or traffic. Do not carry passengers.

3. After striking a foreign object, stop the engine, remove the wire from the spark plug wire and prevent it from touching the spark plug. Thoroughly inspect the machine for any damage and repair the damage before restarting and operating the machine.

4. Exercise caution to avoid slipping or falling.

5. If the unit should start to vibrate abnor mally, stop the engine, disconnect the spark plug wire and prevent it from touching the spark plug, and check imme diately for the cause. Vibration is generally a warning of trouble.

6. Stop the engine, disconnect the spark plug wire and prevent it from touching the spark plug whenever you leave the operating position, before unclogging the tines, or when making any repairs, adjust ments or inspections.

7. Take all possible precautions when leaving machine unattended. Stop engine. Disconnect spark plug wire and move it

away from spark plug. Remove ignition key on electric start models

Page 4

Section 1; Safety

8. Before cleaning, repairing, or Inspect ing, stop the engine and make certain all moving parts have stopped. Disconnect the spark plug wire and prevent it from touching the spark plug to prevent acci dental starting.

9. The flap on the tine hood must be down when operating the tiller, unless using the Hlller/Furrower attachment.

10. Never use the tiller unless proper

guards, plates, or other safety protective devices are in place.

11. Do not run engine in an enclosed

area. Engine exhaust contains carbon monoxide gas, a deadly poison that is odorless, colorless, and tasteless.

12. Keep children and pets away.

13. Never operate the tiller under engine power if the Wheel Speed Lever Is in the FREEWHEEL position. In FREEWHEEL, the wheels will not hold the tilier back and the revolving tines could propel the tiller rapidly, possibly causing loss of control. Always engage the Wheel Speed Lever in either FAST or SLOW position before starting the engine or engaging the tines with the Wheels/Tines/PTO Drive Lever.

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

a. Walk behind and to one side of the

tilier, using one hand on the han dlebars. Relax your ann, but use a secure hand grip.

b. Use shallower depth regulator

settings, working gradually deeper with each pass.

c. Use slower wheel, tine and engine

speeds.

d. Clear the tilling area of all large

stones, roots and other debris.

e. Avoid using downward pressure on

handlebars. If need be, use slight upward pressure to keep the tines from digging too deeply.

f. Before contacting hard packed soil

at the end of a row, reduce engine speed and lift handlebars to raise tines out of the soil.

g. In an emergency, stop tines and

wheels by shifting the Wheels/Tines/PTO Drive Lever into NEUTRAL. If you can not reach the lever or have lost control of the tiller, let go of the handle bars and all controls. Do not attempt to restrain the tiller.

15. Do not overload the tiller's capacity by attempting to till too deeply at too fast a rate.

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

17. Do not operate the tiller on a slope that is too steep for safety. When on slopes, slow down and make sure you

have good footing. Never permit the tiller to freewheel down slopes.

18. Never allow bystanders near the unit.

19. Only use attachments and accessories that are approved by the manufacturer of the tiller.

20. Use tiller attachments and acces sories when recommended.

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

22. Never operate the tilier if you are tired, or under the influence of alcohol, drugs or medication.

23. Operators shall not tamper with the engine-governor settings on the machine: the governor controls the maximum safe operating speed to protect the engine and ail moving parts from damage caused by overspeed. Authorized service shall be sought if a problem exists.

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

25. POISON/DANGER—CAUSES SEVERE BURNS. The battery on electric

start models contains sulfuric acid. Avoid contact with skin, eyes or clothing. Keep out of reach of children.

Antidotes: Externa!“ Flush immediately 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 minutes.

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. Please remember: You can always stop the tines and wheels by releasing all controls, or by moving the ignition switch and/or throttle control lever on the engine to OFF or STOP.

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

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

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

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

32. \A/hen loading or unloading the tiller, always disengage 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 FORWARD drive—the tilier 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 follow the tiller.

33. 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.

34. If using the optional Dozer Blade, either remove the tine attachment, or disengage the tines with the Tines/PTO Clutch Lever. Revolving tines are dangerous.

Page 5

Section 1; Safety

Maintenance and Storage

1. Keep the tiller, attachments and acces sories in safe working condition.

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

3. Never store the tiller with fuel in the fuel tank inside a building where ignition sources are present such as hot water and space heaters, furnaces, clothes dryers, stoves, electric motors, etc.). Aiiow engine to cool before storing in any enclosure.

Decals

For your safety and the safety of others, various safety and operational decals are located on your unit (Figure 1).

Keep the decals clean and legible at all times. Contact your local service dealer or the Factory for replacements if any decals are damaged or missing.

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

4. To reduce the chances of a fire hazard, keep the engine free of grass, leaves, or excessive grease.

5. Store gasoline in a cool, well-ventilated

area, safely away from any spark- or flame-producing equipment. Store gasoline In an approved container, safely away from the reach of children.

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

A) WARNING; Hot Surfaces. Top of the air cleaner housing.

F) Engine Stabilization. Top of fuel tank.

B) WARNING: Engine Ignition. Electric start models only.

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

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

C) WARNING: Operating and Safety Instructions

^ D) Power Unit

Operating Instructions

Operating Symbols

Various symbols (shown here, with word descripticns) are used cn the tiller and mgine. Your unit may not have all of the symbols.

READ THE OWNER'S MANUAL. KNOW LOCATIONS AND FUNCTIONS OF ALL CONTROLS. KEEP ALL SAFETY DEVICES AND SHIELDS IN PUCE AND WORKING. NEVER ALLOW CHILDREN OR UNINSTRUCTED ADULTS TO OPERATE TILLER. SHUT OFF ENGINE AND DISCONNECT SPARK PLUG WIRE BEFORE MANUALLY UNCLOG

GING TINES OR MAKING REPAIRS. KEEP BYSTANDERS AWAY FROM MACHINE. KEEP AWAY FROM ROTATING PARTS.

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

Figure 1: Location of Safety and Operating Decals.

(Briggs & Stratton engine shown)

CHOKE

FAST

SLOW

^TOy

STOP

WARNING

TO AVOID SERIOUS INJURY:

IFI

CHOKE

OFF

ROTATING

TINES

Page 6

Section

Assembly

A 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.

Introduction

Carefully follow these assembly steps to correctly prepare your tiller for use. It is recommended that you read this Section in its entirety before beginning assembly.

NOTE: Various tiller models are presented in this Manual. Use only the information appropriate for your tiller model.

inspect Unit

Inspect the unit and carton for damage immediately after delivery. Contact the carrier (trucking company) if you find or suspect damage. Inform them of the damage and request instructions for filing a claim. To protect your rights, put your claim in writing and mail a copy to the carrier within 15 days after the unit has been delivered. Contact us at the Factory if you need assistance in this matter.

STEP 1; Unpacking Instructions

NOTE: Do not severely bend any of the control cables on the unit.

1. The tiller is heavy. Do not attempt to remove it from the shipping platform until instructed to do so in these Assembly steps.

2. Remove all unassembled parts from

the carton. The hardware bag is included in your literature packaging.

3. If you ordered an Electric Start Tiller, remove the hardware bag from under the battery clamp (A, Figure 2-16).

4. Check that you have the items listed

below (contact your local dealer or the

Factory if any items are missing or damaged).

NOTE: Use the screw length template (Figure 2-1) to identify screws.

L(H>se Parts List

Qty. Description

1 Handlebar Assembly 1 Wheels/Tines PTO Drive Lever

The following items

are in the hardware bag:

1 Clutch Pawl Spring 1 Belt Adjusting Tool

2 Plastic Cable Ties

1 Curved Head Screw, 1/4-20 x 2 1 Flanged Lock Nut, 1/4-20 1 Pan Head Screw, #20-24 x 1/2

The following parts (electric start models only), packaged separately, are located under the battery clamp.

2 Nuts, 1/4-20

(for battery terminals)

2 Screws, 1/4-20x5/8

(for battery terminals)

1 Battery Vent Tube

2 Keys

(in ignition switch)

IMPORTANT: Motor oil must be added to

the engine crankcase before the engine is started. Follow the instructions in this

Assembly Section and in the separate

Engine Owner's Manual.

NOTE: LEFT and RIGHT sides of the tiller are as viewed from the operator's position behind the handlebars (unless otherwise noted).

Tools/Materials Needed for Assembly

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

(2) 7/16“ open-end wrench*

(2) 1/2" open-end wrench *

(1) 9/16" open-end wrench *

(1) 3/4" open-end wrench*

Flat blade screwdriver

(1)

Scissors (to trim plastic ties)

(1)

Tire pressure gauge

(1)

Clean oil funnel

(1)

Motor Oil. Refer to the Engine

(1)

Owner's Manual for motor oil spec ifications and quantity.

4-1/2" high wood block (or other

(1)

sturdy block) to prop unit

* Adjustable wrenches may be used.

place screw on template as shown and measure distance between bottom of screw head and tip of screw.

STEP 2: Attach Handlebar

IMPORTANT: When disassembling

handlebar assembly, keep left-side clamp and ratchet separated from the right-side clamp and ratchet.

1. Disassemble the handlebar assembly.

To do this, remove the height adjustment

lever by turning the lever in a counter clockwise direction (Figure 2-2).

Page 7

2. Place the handlebar ends on either side of the base, with the wire harness toward

the rear of the base (Figure 2-2).

3. Install the height adjustment lever

through the right-side clamp, handlebar

end, ratchet, and base; then out through

the left-side ratchet, handlebar end, and

clamp (Figure 2-2). Secure with nut, but don't fully tighten.

IMPORTANT: Do not force the height

adjustment lever through the handlebars.

The interlock wires may be blocking the

lever and could be damaged. You may gently move the wires aside if this condition occurs.

4. Raise handlebars to one of two height settings and tighten the height adjustment lever. Also, make sure all other mounting hardware is securely tightened.

NOTE: Fully assembled handlebar assembly should appear as shown in Figure 2-3.

Section 2; Assembly

Figure 2-2. Handlebar assembly.

Figure 2-3. Fully assembled handle bars.

STEP 3: Move Tiller Off Shipping Platform

1. Set the Depth Regulator Lever (A, Figure 2-4) to Travel position. Do this by lifting the tiller by the handlebars, then pulling straight back on the lever and sliding down to the highest notched setting.

2. Set the Wheel Speed Lever (B, Figure 2-4) to Freewheel position. To do this, move the lever approximately halfway between the Fast and Slow settings while

you rock the tiller forward and backward

until the wheels move freely.

3. Lift Flandlebars high enough to clear tiller tines and puli back firmly to dislodge the tiller from the platform wheel wells.

■

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

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

' B

A A ‘ .

■ 'a

Figure 2-4: Photo shows the Depth Regulator Lever (A) and the Wheel Speed Lever (B).

STEP 4: Connect Forward

Interlock Wire Harness

1. Remove any dirt from the Forward Interlock wire harness plug (C, Figure

2-5) and Its receptacle (D).

2. Connect the Forward Interlock wire

harness plug (C, Figure 2-5) to the recep tacle (D).

STEPS: Attach Wheels/Tines/PTO Drive Lever

1. Loosen the bolt (Figure 2-2) on the

handlebar base and swing the handlebars out to the right side.

Figure 2-5. Forward Interlock Wire Harness connection.

2. Remove both sets of nuts, star washers, screws, and one bushing

(A, B, C, D, E, F, G, Figure 2-6) from the yoke plates (H). There is a bushing inside the short link (I). Be careful not to lose it when removing screw (G).

3. Slide the plates at the end of the Wheels/Tines/PTO Lever over the yoke plates (Figure 2-9). To aid in the next step, insert a screw temporarily into the forward most holes (J, Figure 2-7) of the yoke plates and the lever.

4. Align the rear most holes of the yoke plates and the Wheels/Tines/PTO Lever.

Use long nose pliers to hold the bushing

(L, Figure 27) in place while Inserting the screw (K) through the lever and yoke plates. Install star washer (B, Figure 2-6) and nut (A), then hand tighten.

5. Retrieve the clutch pawl spring (Figure 2-8) from hardware bag.

Page 8

Section 2: Assembly

Remove the temporary screw (J, Figure 2-7) from the forward hoies and move the Wheels/Tines/PTO Lever fully forward. Install the wider hook end of the clutch pawl spring (M, Figure 2-8) down into the small hole at the end of the handle. Use pliers to insert the other end into the hole in the long link bar (N).

NOTE: Do not bend or over stretch the spring while installing.

6. Pull the Wheels/Tines/PTO Lever back to align the forward most holes (Q, Figure 2-9) in the yoke plate with the holes in the lever plates. Also align the bushing that is inside the short link bar (P). Install the screw, star washer, and nut, then tighten securely.

Securely tighten ail other hardware (0, R, Figure 2-9). Also ensure that the spring (S) is properly seated at both ends.

Completed assembly should appear as illustrated in Figure 2-9.

7. Test the operation of the

Wheels/Tines/PTO Lever. Push the lever down until it engages in the Forward position. The clutch roller (T, Figure 2

10) must rest beneath the adjustment block (U). Next, move the lever up to the Neutral position. The clutch roller (T, Figure 2-11) should rest on the face of the adjustment block (U). To test Reverse, lift and hold the lever all the way up in Reverse position, then let it go. The lever should automatically return to the Neutral position (Figure 2-11). If not, do not use the tiller. See your local authorized dealer or call the Factory Technical Service Department for instructions.

Figure 2-9: Fuily assembled

WheelsITinesIPTO Lever assembly.

Figure 2-6: Illustration shows the yoke plates (H), nuts, washers, and screws (A, E, B, F, D, G), bushing (C), and long and short links (I, J).

Figure 2-7: Drive Lever assembly.

Figure 2-8: Clutch pawl spring. Tilt

Wheels\Tines\PTO Lever fully

forward before installing spring.

Figure 2-10 Forward position; roller (T) rests under the adjustment

block (U).

Figure 2-11: Neutral position; roiler (T) rests against middle area of the adjustment block (U).

STEP 6: Check Gear Oil Levels

Your tiller has two separate transmis sions: one for the Power Unit (Figure 2

12), the other for the Tine Attachment (Figure 2-13). Both transmissions were filled at the factory with SAE #85W-140 weight gear oil (with an A.P.I rating of GL-4). Check level in both transmis sions to verify that they are still correct. See Section 5, Transmission Gear Oil Maintenance for complete information on how to check and fill the transmis sions.

Page 9

Section 2: Assembly

IMPORTANT: Check gear oil level in both

transmissions after the first 2 hours of

new tiller operation, then every 30 operating hours thereafter. See Section 5

for instructions.

Figure 2-13: Checking oii ievel on

Tine Attachment Transmission.

STEP 7: Add Motor Oil to Engine

1. Before adding motor oil, park the tiller on ievel ground. Level the engine by placing a sturdy block under the tines or

the tines depth regulator bar.

2. Add high-quality, API-rated motor oil

to engine before starting. Refer to the

Engine Owner’s Manual provided with

your tiller for detailed information on how to add motor oii and for motor oil

specifications.

IMPORTANT:

• Change engine oil after first 2 hours of new operation.

• Check engine oil level every 5 hours of operation or each use.

STEP 8: Attach Engine Throttle Lever and Cable

For shipping purposes, the throttle cable, together with the throttle lever, is wound around the engine. Carefully unwind the cable. If the throttle control label is covered with a clear protective coating, peel it off.

A WARNING

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

To attach the throttle lever and cable:

1. Run the throttle cable up the inside edge of the right handlebar and position the lever as shown in Figure 2-14.

2. From the outside of the handlebar, insert the curved head screw (A, Figure 2

14), through the handlebar and the center hole in the throttle lever mounting bracket.

3. Loosely install the flanged lock nut and move the throttle lever back to the STOP position.

4. From the lever side of the bracket, thread a pan head screw (B, Figure 2-14) through the small hole in the throttle lever bracket and Into the handlebar. Tighten the screw securely.

5. Securely tighten both the flanged lock nut and the curved head screw.

6. Use two plastic ties to secure the throttle cable to the right handlebar in two places (Figure 2-15). Loop each tie around the handlebar and cable (serrated side faces in) and pull the ties tight. Trim the ends.

Figure 2-14: Engine Throttle Lever

position and installation.

Figure 2-15: Plastic Ties placement on handlebars.

STEP 9: Adjust Air Pressure in Tires

For shipping purposes, the tires may be overinfiated. Check the air pressure in each tire and adjust them to between 10 and 20 pounds per square inch. You must inflate each tire to equal air pressures to prevent the tiller from pulling to one side.

Assembly is complete for recoil start tillers. See Assembling The Electric

Start System If you own an electric

start tiller; otherwise, refer to Section

3, Controls tor information on tiller

controls.

Page 10

Section 2: Assembly

ASSEMBLING THE ELECTRIC START SYSTEM

The following steps explain how to activate, charge, and Install the battery on electric start tillers. For your safety, follow all steps and observe all accompanying safety messages. Section 5 contains other general battery maintenance and recharging instructions.

STEP 1: Activating and Charging the Battery

IMPORTANT: The battery Is shipped dry.

It needs battery electrolytic fluid (batterygrade sulfuric acid). It must then be fully charged with a battery charger before use.

Adding electrolytic fluid to the battery and charging the battery can be dangerous. Electrolytic fluid contains acid that can burn or blind you. Battery charging also produces explosive gases.

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

IMPORTANT: It Is strongly recom

mended that you have the battery activated and charged by a trained profes sional (Troy-Bllt Dealer, service station, farm equipment dealer, etc.), if you are not experienced with these procedures.

À DANGER

Battery electrolytic fluid

poisonous and burns severely. Electrolytic fluid is a sulfuric acid

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

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

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

• Antidote: External- Flush with water; Eyes- Flush with water for 15 minutes and get immediate medical attention.

•Antidote: Internal- Drink large quantity of water or milk. Follow with milk of magnesia, beaten eggs, or vegetable oil. Call a doctor immedi ately.

A DANGER

Battery produces explosive gases.

•Keep away sparks, flames, and

cigarettes.

• Ventilate area when charging or using

battery in an enclosed space.

• Make sure battery vent tube is always

open after battery is filled with acid.

TO ACTIVATE THE BATTERY:

A 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 battery gas explosion.

For shipping purposes, the battery and its

hold-down ciamp (A, Figure 2-16) were

Installed backwards at the factory. When reinstalling the battery and hold-down clamp, be sure to face them in the opposite direction from which they were shipped.

Figure 2-16: Battery shown installed

backwards for shipping purposes only.

1. Remove the two 1-1/2" long screws and the two 1/4" whiz nuts that secure the front and rear hoid-down clamp legs to the battery bracket (C, Figure 2-16).

Lift off the clamp and remove battery. Save the hardware.

2. If installed, remove and discard the

short, plastic tubing (B, Figure 2-16) that covers the vent fitting on the negativeside of the battery.

3. Place the battery on a level work surface, far away from heat or flame sources like stoves, water heaters, dryers, and furnaces.

4. Remove the six filler caps (D, Figure

2-17) on top of the battery.

IMPORTANT: Be sure to wearing protec

tive clothes, rubber gloves, and eye protection.

5. Fill each cell to the Upper Level line

printed on the battery case (E, Figure 2

17) using battery-grade electrolytic solution. (This is 1.265 specific gravity sulfuric acid.) Temperature of battery and electrolytic fluid is ideal when between 60°F and 80” F. Do not add water or any other liquid to the battery during this initial activation.

Figure 2-17: Illustration shows fiiler caps (D) and Upper Levei fili iine (E).

6. Let battery stand for 30 minutes. Check electrolytic fluid levei in each cell. Add more fluid, if needed. Do not overfill battery - this could lead to flooding from the cells during charging.

Page 11

Section 2; Assembly

TO CHARGE THE BAnERY:

1. Use one of the three charging methods described beiow for maximum starting capacity and longest battery life.

NOTE: Bubbling (gassing freely) elec

trolyte solution within the battery cells

indicates that the battery is charged.

These bubbles emit toxic gases that

escape from the cells when you remove the cell caps. Always wear safety goggles to protect your eyes when checking for

bubbles. A flashlight makes the inspec tion easier. Inspect all cells.

A DANGER

To Avoid Personal Injury or Property

Damage:

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

• Ventilate area when charging or using the battery.

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

• Follow safety rules and instructions 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.

• Our Recommended Method: Charge the battery at a rate of 1 -to-2 amperes until all cells bubble freely. Do not exceed 24 hours charge time.

•

• First Alternative Charging Method: Charge the battery at a rate of 4-to-6 amperes until all cells bubble freely. Do not exceed 8 hours charge time.

• Second Alternative Charging Method: Charge the battery at a rate of 6-to-12 amperes until all cells bubble freely. Do not exceed 4 hours charge time.

2. Turn off the charging equipment and

disconnect the charger cables from the battery terminals.

3. Recheck electrolyte level in each ceil. Top off any low cells with electrolyte solution up to the "Upper" level line.

4. Securely replace ail six filler caps. Use

a baking soda and water mixture to rinse off electrolytic fluid that may have spilled on the battery.

STEP 2: Connect the Wire Harness Receptacle

1. Before installing the battery and Its hold-down clamp. Insert the plastic wire harness receptacle (A, Figure 2-18) into the prongs of the keyswltch (B) located on the hold-down clamp.

2. Remove the ignition keys from the

keyswitch and store them safely away. Do not Insert the key into the keyswitch until you complete this section and read Section 3, Controls.

STEP 3: Installing the Battery

1. Carefully place the activated battery back on the battery mounting platform

(C, Figure 2-18). Face the side of the

battery with the terminals posts and the

fill lines to the rear of the tiller. The positive terminal (marked +) should be on the left side of the tiller when standing behind the handlebars.

A DANGER

To Avoid Persona! Injury or Property Damage:

• Do not touch positive battery terminal and any surrounding 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 terminal. 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.

2. Place the battery hold-down damp (D,

Figure 2-18) over the battery. Use two screws (H) and whiz nuts (I) to secure the two legs to the platform (C). Insert the screws up from the bottom. Tighten the hardware but do not overtighten. (The clamp tabs will bend if screws are over tightened.)

A DANGER

Improper battery venting can cause a battery to explode resulting in severe personal injury. Be sure the vent tube is not crimped, pinched, folded, or blocked in any way.

Figure 2-18: Battery mounting and venting assembly.

3. To install the vent tube (E, Figure 2

18), slide one end of the tube over the vent fitting (F). Uncoil the tube and slide the other end down Into the black vent tube shield (G).

A DANGER

Never Jump start the battery with a vehicle battery or charging system. This may produce a battery explosion, causing acid or electrical bums.

Page 12

Section 2: Assembly

STEP 4: Install the Battery Cables

NOTE: The cabie terminals should be toward the rear (keyswitch side) of the battery posts.

1. Use a 5/8" long screw and 1/4-20 hex nut to connect the positive (+) battery cable (J, Figure 2-19) to the positive

(marked +) battery post (K). Make sure that this is the cable on the left side, with one end attached to the solenoid (Q).

2. Slide the black rubber boot (P) com pletely over the battery post and cable connector.

3. Use a 5/8" long screw and 1/4-20 hex nut to connect the negative (-) battery cable (L) to the negative (marked -) battery post (M) and secure with screw

(R) and nut (S).

4. Slide the black rubber boot (T) com pletely over the battery post and cabie connector.

5. Make sure that the lower end of the vent tube shield (U) Is positioned in front of the wheel shaft axle. Move it there if necessary.

Figure 2-19: Battery cable assembly.

Assembly is complete for electric start tillers. See Section 3, Co/7fro/s for information on tiller controls.

Page 13

Section

3 Features and Controls

A WARNING

Before operating your machine, carefully read and understand all safety, controls, operating instructions

in this Manual, the separate Engine

Owner's Manual and on the decals on the machine.

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

Introduction

This section describes the location and function of the controis and features on your tiller. Refer to Section 4, Operation for detailed operating instructions.

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

IMPORTANT: Refer to the separate engine

manufacturer's Engine Owner's Manual

for information about the controis on the

engine. NOTE: All references to left, right, front

and rear of the machine are based on a position behind the handlebars and facing

forward.

PTO Attachments Feature

In addition to powerful tilling capability,

you can quickly convert your machine

into a PTO (Power Take-Off) Power Unit that is capable of towing or powering various TROY-BILT attachments.

You can access this capability by

removing the tines attachment (powered

by the PTO Power Unit). The PTO Power

Unit is then available for engine powered

attachments, or for pulling or towing non

powered attachments. See Section 4,

PTO Power Unit for detailed information

on installing and operating TROY-BILT

PTO attachments.

Wheels/Tines/PTO Drive Lever

Use the Wheels/Tines/PTO Drive Lever (A,

Figure 3-1) to engage and disengage

power to the transmission.

CThh

Figure 3-1:

A— WheelsITinesIPTO Drive Lever B— Forward Interlock Levers

C- Wheel Speed Lever

D- TinesIPTO Clutch Lever

This lever has three operating positions: FORWARD, NEUTRAL and REVERSE.

• FORWARD is engaged when the lever is moved down until the clutch roller (G, Figure 3-2) engages into the detent position under the adjustment block (H, Figure 3-2). You will definitely feel the lever engage into this position.

Use the FORWARD setting to move the wheels and tines forward, or to apply

power to an optional PTO (Power Take Off) attachment. (See also Forward

Interlock Levers.)

To stop the wheels, tines or any PTO attachment, move the lever to NEUTIRAL by tapping the lever upwards (Figure 3-3) and releasing.

• REVERSE is engaged when the lever is pushed (with an open palm) all the way up and held in that position (Figure 3-4). Use this setting to move the wheels in reverse. To stop moving in reverse, release the lever; it automatically returns to the NEUTFRAL position.

E- Depth Regulator Lever F— Handlebar Height Adjustment Lever

G- Engine Throttle Lever

IMPORTANT: Do not operate the tines or

any PTO attachment in REVERSE.

• NEUTRAL is this control's normal non operating position. The lever returns to NEUTRAL when it is tapped out of the FORWARD position or released from the REVERSE position. NEUTRAL position is between FORWARD and REVERSE

(Figure 3-3). Use this setting to stop the wheels, tines or any PTO attach ment.

IMPORTANT: Always shift to NEUTRAL

before starting the engine or before engaging the wheels, tines or any PTO attachment.

Forward Interlock Levers

The Forward Interlock Levers (B,

Figure 3-1) are attached under each

handlebar grip. You must squeeze at least one of these

interlock levers up against the handlebar

grip whenever the Wheels/Tines/PTO

Drive Lever is engaged in FORWARD

position.

Page 14

Section 3: Features and Controls

|||^||ll|ii|||||^

Figure 3-2: FOF^AFS}posiHon; roller (G) rests under the adjustment block (H).

Figure 3-3: NEUTRAL position; roller (G) rests against middle area of the ad

justment Nock (H).

Figure 3-4: REVERSE position; roller (G) resis agNnst upper area of the ad

justment block (Hj.

If both Forward Interlock Levers are released before first returning the

Wheels/TInes/PTO Drive Lever to

NEUTRAL, the engine will stop.

IMPORTANT: The Forward Interlock

Levers are a safety control that stops the engine should you lose control while going forward and cannot shift into

NEUTRAL.

Wheel Speed Lever

Use the Wheel Speed Lever (C, Fig. 3-1) to select one of three operating positions:

SLOW, FAST or FREEWHEEL.

• SLOW - Lever moved all the way down. Most effective for normal tilling or for low-speed transport.

• FAST - Lever moved all the way up. Most effective for cultivating or for fast speed transport.

• FREEWHEEL - Lever in between SLOW

and FAST (wheels will roll freely). Used when transporting the machine on level ground without engine power, and when

using stationary PTO attachments.

IMPORTANT: To avoid transmission

damage, always move Wheeis/Tines/PTO

Drive Lever into NEUTRAL before shifting

the Wheel Speed Lever.

IMPORTANT: When shifting into SLOW

or FAST, gently roll the machine forward or backward 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.

Tines/PTO Clutch Lever

Use this lever (D, Figure 3-1) to engage or

disengage power from the transmission

PTO dutch to the tines or any PTO attach ment. This control has two operating positions: ENGAGE and DISENGAGE.

• ENGAGE - Lever moved Into detent slot

farthest from engine. Use this position to operate tines or other PTO attachments. After shifting to ENGAGE, briefly operate

machine in FORWARD to help fully

engage the PTO clutch.

• DISENGAGE - Lever moved into detent slot nearest engine. Use this position to

disengage power to tines or other PTO attachments before transporting, loading, turning, or operating in reverse.

IMPORTANT: To avoid transmission

damage, always move the Wheels/Tines/ PTO Drive Lever into NEUTRAL before shifting the Tines/PTO Clutch Lever.

Depth Regulator Lever

Use this lever (E, Figure 3-1) to regulate the tilling depth of the tines. This control also has a TRAVEL position, which enables transport with the tines off the ground.

To operate the lever, lift up on the handle bars, pull the Depth Regulator Lever straight back, and then slide it up or down to one of the eight detent height settings.

The eight detent positions offer a range of tine height settings. This enables you to select the height that Is most effective for a particular condition. The top detent position is the TRAVEL setting. Use the second or third detent from the top for shallow tilling and cultivating. Use the other detents for deeper tilling and for power composting.

A WARNING

avoid personal injury,

To always place the tines in the TRAVEL position before starting the engine. This prevents the tines from touching the ground until you are ready to begin tilling.

Handlebar Height Adjustment Lever

Use this lever (F, Figure 3-1) to adjust the handlebars to one of two height settings.

1. To change the height, hold the handle bars with one hand and loosen the lever in a counterclockwise direction.

2. Move the handlebars to one of the two preset height settings.

3. Retighten the lever. NOTE: You can swap the positions of the

inside handlebar ratchets to change the two preset settings by approximately four inches higher or lower. See Section 2, Step 2: Attach Handlebar for detailed assembly Information.

Page 15

Section 3: Features and Controls

A WARNING

The tiller handlebars can be swung out 30° to the fight side for use only with the PTO Chipper/Shredder attachment. This

is done by loosening the mounting bolt on the handlebar base. Never operate your tiller or attachments, other than the PTO Chipper/Shredder, with the handle bars in the right side position. Doing so could result in unsafe handling and personal injury.

Engine Throttle Lever

Use the throttle lever (G, Figure 3-1) to adjust engine speed as well as to start and stop the engine.

Move the lever away from the STOP position before starting the engine. Engine speeds are variable and range between the FAST and SLOW. Use the STOP position to turn the engine off.

NOTE: A secondary throttle lever is located on the front of the 8HP and 10HP engines. A separate On/Off switch may also be available on the engine. (See Engine Owner's Manual for information.)

Keyswitch Starter

The keyswitch starter on electric start

models (A, Figure 3-5) has three positions: OFF, RUN and START. Turn

the key to START to start the engine.

Release the key and it will return to the RUN position. Turn

the key to OFF to

stop the engine. (Another way to stop the engine is to move the engine

throttle lever to the

STOP position.)

Figure 3-5

Engine Controls

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

IMPORTANT: An engine On/Off switch, a

secondary throttle control, a choke lever and a fuel line shut-off control may be located on the engine. Refer to your Engine Owner's Manual for detailed information.

A WARNING

To avoid serious personal injury or damage to equipment, do not start your engine at this time. Complete starting instructions are described in Section 4,

Operation.

Page 16

Section

4 Operation

A WARNING

Before operating your machine, carefully read and understand all safety (Section 1), controls (Section 3) and operating instructions (Section 4) in this Manual, in the separate Engine Owner's Manual, and on the decals on the machine.

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

INTRODUCTION

Read this Section of the manual thoroughly before you start the engine. Then, take the time to familiarize yourself with the basic operation of the tiller before using it in your garden. Find an open, level area and practice using the tiller controls without the tines engaging the soil (put tines in Travel setting— Section 3, Depth Regulator Lever). Only after you've become completely familiar with the tiller should you begin using it in the garden.

A WARNING

Your tiller and its optional PTO Power Unit attachments are capable of causing serious injury to untrained or careless operators. To avoid serious personal injury or property damage, read the Owner's Manual that is provided with any optional accessories or attachments before using the tiller or PTO Power Unit.

Break-In Operation

Perform the following maintenance during the first hours of new operation

(see Maintenance Section in this Manual and maintenance information in the

Engine Owner's Manual).

1. Change engine oil after first 2 hours of new engine operation.

Figure: 4-1

2. After the first 2 hours of new

operation, check the gear oil levels in the

PTO Power Unit and the tine attachment

transmissions.

3. Check for loose or missing hardware

on unit. Tighten or replace as needed.

4. Check tension on forward drive belt

after first 2 hours of operation.

Starting and Stopping the Engine

The following steps describe how to start and stop the engine.

IMPORTANT: Do not attempt to engage

the tines, wheels, or any PTO attachment

until you have read all of the operating

instructions in this Section. Also review the safety rules in Section 1, Safety and the tiller and engine controls information

in Section 3, Features and Controls.

Pre-Start Checklist

Make the following checks and perform the following services ¿te/ore starting the engine.

1. Read the Safety and Controls Sections

in this Manual. Read the separate Engine Owner's Manual provided by the engine

manufacturer.

2. Check unit for loose or missing

hardware. Service as required.

3. Check engine oil level. See Engine Owner's Manual.

4. Shift the Wheels/Tines/PTO Drive lever

(Figure 4-2) into NEUTRAL position. See Section 3, Coofro/s for more information on this lever.

5. Check Safety Guards. All guards and covers must be securely in place.

6. Check air cleaner. See Engine Owner's Manual.

7. Electric start systems only; ensure battery fluid is filled to the correct level. Check cell caps and ensure that they are tight. Check all electric wire connections: ensure they are tight and away from possible short-circuit conditions. See Section 2, Assembling the Electric Start System for more information.

8. Attach spark plug wire to spark plug.

9. Check Engine Cooling System. Clear cooling fins and air intake screen of debris.

10. Select High/Low Belt Speed range.

11. Adjust Handlebar Height.

12. Fill the fuel tank with gasoline in accordance with the directions in the separate Engine Owner's Manual. Follow all instructions and safety rules carefully.

A DANGER

GASOLINE IS HIGHLY FLAMMABLE AND ITS VAPORS ARE EXPLOSIVE.

Follow gasoline safety rules in this Manual (Section 1) and in the separate Engine Owner's Manual.

Failure to follow gasoline safety instruc tions can result in serious personal injury and property damage.

Page 17

Recoil Start Rope (at front of engine)

Wheels/Tines/PTO Drive Lever

/ '

$ '".Ây

CtJ ,

fines/PTO '

Clutch Lever*^

Figure 4~2: Tiller and engine controls.

? 1

Wheel [; Speed ' Lever /

- /

/ *

f \

Section 4: Operation

Engine Throttle Lever

Forward Interlock Levers

" Depth

Regulator Lever

Starting the Engine:

A CAUTION

To help prevent serious

personal injury or damage to equipment:

• Always place Wheels/Tines/PTO Drive Lever into NEUTRAL before starting engine, and before engaging wheels, tines or other PTO-driven attachments.

• Never run engine indoors or in enclosed, poorly ventilated areas. Engine exhaust contains carbon monoxide, an odorless and deadly gas.

•Avoid engine muffler and nearby areas. Temperatures in these areas may exceed 150°F.

1. With the engine off, place the

Wheels/Tines/PTO Drive Lever (Figure 4-2) in the NEUTRAL position, if in the FORWARD position, tap the lever sharply upward, it should automatically move into NEUTRAL position.

2. Put the Depth Regulator Lever in the

Travel position (lever ail the way down)

so that the tines are off the ground. To do

this, lift up on the handlebars, puli the

lever (Figure 4-2) back, and push it down all the way to the top detent (notched) position.

3. Move the Wheel Speed Lever (Figure 4-2) to either the SLOW or FAST position. Be sure to roll the wheels while shifting the lever until the wheels engage.

NOTE: If using a PTO stationary attach ment, move the Wheel Speed Lever into FREEWHEEL and block the wheels to prevent the equipment from moving (Figure 4-29 on page 29).

4. Move the Tines/PTO Clutch Lever into

DISENGAGE position (Figure 4-2). NOTE: Use the ENGAGE position if you want

the tines to revolve or to apply power to a PTO-driven stationary attachment.

5. If engine is equipped with a fuel valve, turn valve to OPEN position as instructed in the separate Engine Owner's Manual.

6. If engine is equipped with an ON/OFF switch, move the switch to ON.

7. Move engine throttle lever (Figure 4-2)

away from STOP.

8. Choke or prime engine as instructed in the separate Engine Owner's Manual.

9. If not equipped with an electric start

system, place one hand on the fuel tank to stabilize the unit when you pull the recoil starter rope. Use the recoil starter rope to start the engine as instructed in the separate Engine Owner's Manual.

10. If equipped with an electric start

system, turn key to START position to crank engine then release when engine starts. If the engine does not start right away, do not hold key at START for more than a few seconds. Release then try again after a short pause. Damage to starter motor can occur if

it is cranked more than 15 seconds per

minute.

11. If the engine does not start after a

number of tries, refer to the Engine Owner's Manual for specific instructions.

12. When engine starts, move the Throttle

Lever to the SLOW position and then gradually move choke lever (on engines so equipped) to OFF or RUN position.

13. Move the throttle speed control to

FAST setting when tilling.

Starting Electric Start Engines with the Recoil Starter Rope

You may, at some point, have to start an electric start engine with the recoil starter rope. Before attempting to do so, perform the following applicable steps:

• If you suspect the battery charge is weak, and there is no visible damage, check battery cells and fill to the proper level with electrolytic solution. Discon nect cables from battery and clean both cable terminals, and the battery posts in accordance with the instructions provided in Section 5, Battery Care and

Maintenance.

Page 18

Section 4: Operation

Reconnect the cables and securely tighten to battery posts. The engine will recharge the battery if the battery is still good.

' If you suspect the batter is "dead", or If

the battery is damaged, disconnect, and remove it. Have it checked by a qualified technician.

' If battery has been removed, wrap cable

terminals at end of positive cable with electrical tape and secure the cable to the battery bracket. This will prevent electrical discharge.

' Before pulling the recoil starter rope,

turn the keyswitch to the RUN position. Move the Throttle Lever away from STOP position and set the choke as applicable. See Engine Owner's Manual.

........

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

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Stopping the Engine and Tiller

1. To stop the wheels and tines, move the

Wheels/Tines/PTO Drive Lever into

NEUTRAL position and then release both Forward Interlock Levers.

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

....

..........

.... ' '

2. Move the engine Throttle Lever to the

STOP position. Then on electric start models, turn the key to OFF. Remove the key for safekeeping.

NOTE: The engine may have a separate Throttle Control Lever and ON/OFF switch on the engine. These controls can also be

used to stop the engine. See the Engine Owner's manual for information specific to your engine.

Operating the Tiller

When first practicing, keep the Tines/PTO Clutch Lever in DISENGAGE position and the Wheel Speed Lever in SLOW position.

A CAUTION

To avoid serious personal injury or damage to equipment:

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

• Be sure there are no obstacles behind you before moving in reverse.

• Wheels/Tines/PTO Drive Lever should automatically return to NEUTRAL when released from REVERSE position. If it does not, move lever to NEUTRAL manually and discontinue use until you adjust the lever. See Section 5, Checking and Adjusting

Reverse Drive System.

• No reverse motion should occur if Wheels/Tines/PTO Drive Lever is not held up in REVERSE. See Section 5,

Checking and Adjusting Reverse

Drive System for adjustment steps.

Do not use tiller unless properly adjusted.

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

The following pages provide guidelines for using your tiller effectively and safely

in various gardening applications. Be

sure to read Tilling Tips & Techniques, in this Section, before you actually put the tines into the soil.

This is a traditional standard-rotating-tine

(SRT) tiller with forward rotating tines. It operates in a completely different manner than counter-rotating-tine (CRT) tillers, or from front-tine tillers.

Moving the Tiller Forward and Tilling

1. Start the engine and gradually increase engine speed to FAST (see Starting the Engine, this Section).

A DANGER

The Forward Interlock Safety System is designed for the operator's safety. Do not disconnect or attempt to defeat the purpose of the system. If the system malfunctions, immediately contact your

local authorized dealer or the

TROY-BILT Technical Service Depart ment for assistance. Do not use the tiller or the PTO power unit until the Forward Interlock Safety System is functioning properly. Always test the system before using the tiller or PTO power unit.

2. Test the Forward Interlock Safety

System. See Testing Forward Interlock System, this Section.

A WARNING

Keep away from rotating tines. Rotating

tines will cause injury.

3. When practicing, set the Depth Regulator Lever to Travel position. Otherwise, set the Depth Regulator Lever to a desired depth.

4. Move Tines/PTO Clutch Lever to

ENGAGE position if you want the tines to turn. If practicing, leave in DISENGAGE.

IMPORTANT: Do not move Tines/PTO

Clutch Lever to ENGAGE unless Wheels/Tines/PTO Drive Lever is in NEUTRAL. Tiller damage may occur!

5. To move the tiller forward and engage the tines, squeeze and hold either Forward Interlock Lever (Figure 4-3) against the handlebar grip, then move the Wheels/Tines/PTO Drive Lever down to FORWARD position.

Page 19

Figure 4-3: Moving tilier forward: squeeze one Forward Interlock Lever and then move WheelsITinesIPTO Drive Lever down to FORWARD.

6. When the tiller moves forward, relax and let the wheels power the tiller along while the tines dig. Walk behind and to one side of the tiller. Walk on the side that is not yet tilled (Figure 4-4). Use a firm grip on the handlebars but keep your arm relaxed.

IMPORTANT: Let the tiller move ahead at

its own pace. Do not push it ahead—this

reduces operator control and tilling effi ciency. Do not push handlebars down in an attempt to dig deeper— this takes weight off the wheels, reduces traction, and causes the tines to try to propel the tilier.

Stopping Forward Motion and Tines

1. To stop forward motion, tap

Wheels/Tines/PTO Drive Lever upward

into NEUTRAL. Then release the Forward

Interlock Levers. The wheels and tines will stop and the engine will continue

running.

2. In an emergency, release ail of the control levers. This stops forward motion and shuts-off the engine.

A 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 familiar with backing the tiller.

Figure 4-4: Guide tilier with one hand.

Moving the Tiller in Reverse

IMPORTANT: Do not till while in

REVERSE.

1. Shift the TinesAA/heels/PTO Drive Lever (Figure 4-2) into NEUTRAL and move the

Wheel Speed Lever to the SLOW position.

2. Move Tines/PTO Clutch Lever (Figure

4-2) into DISENGAGE position.

3. Verify that the area behind you is clear.

4. Lift up the handlebars until the tines

are off the ground, then shift the Wheels/Tines/PTO Drive Lever all the way up and hold. You do not need to squeeze the Forward Interlock Levers to use reverse.

5. The unit immediately engages in

reverse. Periodically check behind you while holding the handlebars up and the Wheels/Tines/PTO Lever in its upper-most position.

Stopping Reverse Motion

Release the Wheels/Tines/PTO Drive Lever- the lever automatically returns 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. Then, on electric start models, turn key to OFF. Remove the key for safekeeping.

Section 4: Operation

Making Turns

Turning the tiller is easy and Just requires practice. First find the balance point between the engine and the tines by lifting up the handlebars (Figure 4-5). Once you find the balance point, then let the powered wheels do the turning as you push sideways on the handlebars in the direction of the turn. Practice the turning maneuver described here in a large open area. Once comfortable turning the tiller, you can then take it to the garden area.

1. At the end of a row, move the Wheels/ Tines/PTO Drive Lever (Figure 4-2) to NEUTRAL position and reduce the engine speed.

2. Move the Tines/PTO Clutch Lever (Figure 4-2) into the DISENGAGE

position.

3. Resume forward operation, and lift

handlebars until tines are off the ground

(Figure 4-5). Find the balance point

between the engine and the tines. Then push the handlebars in the direction of the turn. Be very careful to keep feet and legs

away from the tines (which should be dis engaged). Let the powered wheels do the

hard work. The inside wheel will pivot in place while the outside wheel drives the tilier around in the direction of the turn.

Figure 4-5: Turning the tilier.

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

Page 20

Section 4: Operation

4. When the turn Is complete, shift to NEUTRAL and lower the handlebars.

Move TInes/PTO Clutch Lever back to

ENGAGE position and resume forward

operation.

Transporting The Tiller Around Your Property

When the engine is running, the tiller's powered wheels make moving the tiller to and from the garden easy. If the engine is not running set the Wheel Speed Lever to

FREEWHEEL position to roil the tiller to

another location.

A WARNING

To help avoid personal injury from revolving tines, always put the Tines/PTO Clutch Lever in DISENGAGE position before transporting, loading, or unloading tiller.

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

2. Move Depth Regulator Lever down all the

way into the Travel ^tting.

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 FREEWHEEL, and manually push tiller.

Testing the Forward

Interlock Safety System

The Forward Interlock Safety System is designed to shut the tiller engine off

immediately if you lose control and

cannot stop moving FORWARD by shifting the Wheels/Tines/PTO Drive Lever

into NEUTRAL. When you release both Forward Interlock Levers, they send

ground to the ignition system thereby stopping the engine. Squeezing one or both levers up against the handlebars enables the ignition system; therefore, you must squeeze at least one lever whenever the Wheels/Tines/PTO Drive

Lever is engaged in FORWARD.

IMPORTANT: The interlock system also

prevents the engine from starting if the Wheels/Tines/PTO Drive Lever is engaged

in FORWARD.

A DANGER

The Forward Interlock Safety System is designed for the operator's safety. Do not disconnect or attempt to defeat the purpose of the system. If the system malfunctions, immediately contact your local authorized dealer or the TROY-BILT Technical Service Depart ment for assistance. Do not use the tiller or the PTO power unit until the Forward Interlock Safety System is functioning properly. Always test the system before using the tiller or PTO power unit.

How to Check the interlock System

The Forward Interlock System has an electro-mechanical design, and so is subject to normal wear and possible mal function. Check the system for proper operation each time prior to using the tiller or PTO power unit.

Figure 4-6: Plug and receptacle of Forward Interlock Safety System must be securely connected.

To test the Forward Interlock System:

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

2. Check that the Forward Interlock wire harness plug, at the bottom of the handle bars (Figure 4-6), is securely connected to the receptacle on the top, right side of the transmission.

3. Move Wheel Speed Lever (Figure 4-2} to SLOW position and move Tines/ PTO Clutch Lever to DISENGAGE.

4. Start engine as described under Starting and Stopping the Engine, in this

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

5. Squeeze and hoidjust one of the

Forward Interlock Levers against the handlebar grip while moving the Wheels/ Tines/ PTO Drive Lever down to FORWARD (Figure 4-3). As the tiller moves forward, release the Forward Inter lock 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 electric start), and do not operate

the tiller or PTO power unit until the system has been repaired and is func tioning properly.

IMPORTANT: To avoid possible damage

to the Forward Interlock Safety system, do not use high-pressure sprays near the wire harness receptacle or neutral plunger assembly.

Loading and Unloading the Tiller

The following provides information on tiller loading, unloading, and requirements before loading and unloading the tiller. Read the following instructions carefully before attempting to load or unload your tiller.

Before Loading or Unloading the Tiller

• Ramps must be strong enough to

support the combined weight of the tiller and handlers. They should provide good traction to prevent slipping; they should have side rails to guide the tiller along the ramps: and they should have a locking device to secure them to the vehicle.

• Handlers should wear sturdy footwear

that will help to prevent slipping.

Page 21

Section 4: Operation

• Turn the vehicle's engine off and apply its parking brake.

• Position the loading vehicle so that the ramp angle is as flat as possible (the less incline to the ramp, the better).

Loading Ihe 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

(Figure 4-2) into DISENGAGE position.

3. Set the Depth Regulator lever (Figure

4-2) to the Travel position.

4. Move Wheel Speed Lever (Figure 4-2)

into SLOW position and reduce the engine throttle speed.

5. Shift the Wheels/Tines/PTO Lever

(Figure 4-2) into FORWARD position and

follow the tiller up the ramps (Figure 4-7).

Check the wheels as you move the tiller

forward. Ensure that they move up the

center of each ramp.

6. Prevent tiller from rolling in vehicle.

Leave Wheel Speed Lever in FAST or SLOW position, chock wheels with blocks and tie down the tiller.

Figure 4-7: To go up ramps, use FORWARD drive.

Unloading the Tiller

IMPORTANT: A/ever unload the tiller in

FORWARD drive. The tiller could tip

forward and expose you to the tines

(which should be disengaged as instructed).

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 (Figure 4-2) to DISENGAGE position.

3. Set the Depth Regulator Lever (Figure

4-2) to the Travel position.

4. Move Wheel Speed Lever (Figure 4-2)

to SLOW position and reduce the engine throttle speed.

IMPORTANT: Look behind you before

you back down the ramp to ensure that all is clear. While descending, keep checking for obstacles behind you.

5. Move and hold the Wheels/Tines/PTO

Lever into REVERSE drive and back down the ramps (Figure 4-8). Check the wheels as you move the tiller backward. Ensure that they move down the center of each ramp.

Figure 4-8: To go down ramps, use REVERSE drive.

Changing Speed Belts

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 to move the forward belt into. By moving the belt from one speed range into the other, in combination with the FAST and SLOW wheel speeds, you obtain a choice of four different forward wheel speeds and two different tine speeds.

A WARNING

To help avoid serious personal injury, stop the engine, remove the ignition key, disconnect spark plug wire and move the wire away from the spark plug, and let engine and muffler cool down before changing belt speeds.

Changing the belt from LOW range into HIGH range (or back again) is a matter of moving the belt from one set of pulley grooves to a second set of pulley grooves.

This change Is done quickly and without tools (Figures 4-9 through 4-13).

Figure 4-9: Beit range positions.

When the tiller is moving in REVERSE, the wheels are powered by a rubber reverse disc, not by the belt. Therefore, you have only two reverse speeds SLOW and FAST, as set with the Wheel Speed Lever.

Table 4-1 shows the range of wheel and tine speeds available when using the two belt speed ranges and the FAST and SLOW selections on the Wheel Speed

Lever.

Tabie 4-1

Available wheel and tine speeds at 3000 RPM

Belt

PositicHi

Low Range Slow .5MPH 146RPM

Low Range Fast 1.2MPH 146RPy High Range Sfow .7yPH 200RPy High Range Fast 1.72MPH 200RPy

Changing Belt From LOW Range to HIGH Range

1. To avoid personal injury, shut off engine, let all moving parts come to a complete stop, then disconnect spark plug wire from spark plug and move it away from spark plug before making any adjustments. Wait for the engine and muffler to cool down.

2. Move Wheels/Tines/PTO Drive Lever

into NEUTRAL.

engine speed.

Wheel Speed

Lever

Wheel Speed

Tine

Speed

Page 22

Section 4: Operation

A WARNING

The HIGH speed belt range position combined with a FAST wheel speed setting propels the tiller at the fastest pace. Reduce the engine throttle speed when starting out to help avoid personal injury or property damage if using this speed combination.

3. Kneel on left side oi 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 onto the lower-front transmission pulley groove (Figure 4-10).

Figure 4-10: Low range to high range. Shows moving beit from lower-rear

groove onto lower-front groove.

4. Go to the other side of the tiller to

finish seating the belt onto the pulley groove.

5. Working from the left side of the tiller,

work the belt as much as possible onto the top-front engine pulley groove (Figure 4-11).

6. Finish seating the beit from the right

s/ife of the tiller.

IMPORTANT: Proper belt tension Is

Important for good performance. See

Section 5, Drive Belt Maintenance for

Information on belt maintenance schedule and procedures.

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, and creates more slack.

Figure 4-11: Low range to high range. Shows moving belt from toprear groove onto top-front groove.

1. Check both sides of the high range

pulley grooves to verify that the belt is properly seated.

Changing Beit From HIGH Range to LOW Range

1. To avoid personal injury, shut off engine, let all moving parts come to a complete stop, then disconnect spark plug wire from spark plug and move wire away from spark plug before making any adjustments. Let engine and muffler cool.

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

3. Stand on left side of tiller. Use your right hand to hold the Wheels/Tines/PTO Drive Lever up into REVERSE position. Use your left hand to move the beit off top-front engine pulley groove to top-rear engine puliey groove (Figure 4-12).

Figure 4-12: High range to low

range. Shows moving belt from top

front groove onto top-rear pulley

groove.

4. Go to right side of tiller and finish

seating the belt.

5. Still holding the lever up in REVERSE position, and working from the left side of the tiller, move the belt from the lower front transmission groove to the lowerrear transmission groove.

6. Go to the right side of the tiller and finish seating the belt (Figure 4-13).

■

I ;■ ■

Figure 4-13: High range to low

range. Shows moving belt from

lower-front onto lower-rear groove.

7. Check that the belt is fully seated in the

pulley grooves. Check this from both sides of the tiller.

Choosing Wheel and Tine Speeds

Your tiller has four FORWARD wheel/tine speed combinations for handling a variety of tilling tasks and gardening Jobs. Exper iment with the tine depth, engine speed, and wheel/tine speed and determine the combination that provides the best results. Here are some tips:

1. Advance the throttle lever so the engine has sufficient power.

2. When tilling untilled or hard earth, do not set the Depth Regulator too deep. The tiller will buck and the engine will load down.

3. You will know your settings are ideal when the tines break-up the soil easily, the engine does not labor, and your progress is steady and smooth.

See Table 2, Wheel Speed and Belt Range

Selection Guide for recommendations.

Page 23

Section 4: Operation

TABLE 2-4; WHEEL SPEED AND BELT RANGE SELECTION GUIDE

IF® attachments 'iip

SLOW GEAR, LOW BELT RANGE

For;

• Tilling in sod.

• Tilling in hard clay.

• Tilling under standing corn stalks in tough soil conditions.

• Tilling under cover crops.

• Preparing a deep seedbed.

• Tilling in stony soil.

• Tilling under residues and organic matter.

• Mixing in fertilizers, manure.

SLOW GEAR, HIGH BELT RANGE

For:

• Tilling in sod or hard clay.

• Tilling under standing corn stalks (slow, steady speed allows time to shred stalks).

• Tilling under cover crops (best wheel speed and belt speed range in most soils).

• Preparing seedbeds (best speed choice in most soils).

• Tilling in stony ground.

• Building raised garden beds.

• Mixing in fertilizer.

• Using hiller wings in hard soil.

• Mixing fertilizer and manure.

• Tilling residues and organics.

FAST GEAR, LOW BELT RANGE

For:

• Going over seedbed for the last time before planting crops.

• Covering over seeds in wide row or plot planting (lift han

dlebars to avoid going too deep).

• Hilling and furrowing.

• Making raised beds.

• Cultivating (lift handlebars to

avoid going too deep).

• Tilling large areas.

• Tilling organic matter in.

• Cultivating between raised beds with optional hiller/furrower attachment.

Tilling Tips & Techniques

Let the tiller do the work with each succeeding pass, adjust the

• While tilling, relax and let the wheels pull the tiller along while the tines do the digging. Walk on the side that is not yet finished (to avoid making footprints

In the freshly tilled soil) and lightly, but securely grip the handlebar with Just one hand (Figure 4-4).

• Avoid pushing down on the handlebars In an attempt to force the tiller to dig

deeper. Doing so takes the weight off the powered wheels, causing them to

lose traction. Without the wheels

helping to hold the tiller back, the tines will attempt to propel the tiller - often causing the tiller to skip rapidly across the ground. (Sometimes, slight downward pressure on the handlebars will help get through a particularly tough section of sod or unbroken ground, but in most cases this won't be necessary.)

Tilling depths

• Avoid trying to dig too deeply too guickly, especially when busting sod or tilling soil that hasn't been tilled for

some time. Use shallow depth settings

(only an Inch or two deep) for the first

passes through the garden area.

depth regulator to dig another inch or two deeper. (Watering the garden area a few days prior to tilling will make tilling easier, as will letting the newly worked soil set for a day or two before making a final, deep tilling pass.)

• When cultivating (breaking up the surface soil around plants to help destroy weeds), use very shallow depth settings to prevent injury to plants whose roots often grow close to the surface. If needed, lift up on the handlebars slightly to prevent the tines from digging too deeply. Cultivating on a regular basis not only eliminates weeds, it also loosens and aerates the soil for better moisture absorption and faster plant growth.

Avoid tilling wet, soggy soil

Tilling wet soil often results in large, hard clumps of soil that can interfere with planting. If time permits, wait a day or two after heavy rains to allow the soil to dry before tilling. Test the soil by squeezing It into a bail. If it compresses too easily, it Is too wet to till.

FAST GEAR, HIGH BELT RANGE

For;

• Preparing seedbeds for planting.

• Covering seeds with less need

to hold up the handlebars.

• Cultivating (tiller travels faster, rides higher on the soil; allows engine RPM to be reduced; handlebars don't have to be raised).

• Keeping large areas tilled and cultivated in the summer.

• Tilling organic matter under.

• Moving tiller quickly.

• Cultivating between raised beds using the optional hiller/furrower.

A WARNING

To help avoid personal injury, i№ aware that the tiller can unexpectedly bounce up or jump ahead and propel away from you if the tines strike hard or frozen ground, or buried obstacles like large stones, roots or stumps. Always use the following precautions to help maintain control of the tiller:

• Walk behind and to the side of the tiller. Use one hand on the handlebars, relaxing your arm but with a secure hand grip.

• Use shallow depth regulator settings. Till gradually deeper.

• Use slower wheel, tine and engine 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 Wheeis/Tinesf PTO Drive Lever to NEUTRAL. If you cannot reach the lever or have lost control, Let Go Of The Handlebars and All Controls.

Page 24

Section 4: Operation

Tilling Tips & Techniques

Avoid making footprints

When possible, walk on the untilled side of the unit to avoid making footprints in

the freshly tilled soil (Figure 4-4). Foot

prints cause soil compaction that can hamper root penetration and contribute

to soil erosion. They can also "plant"

unwanted weed seeds back into the newly tilled soil.

Suggested tilling patterns

• When preparing a seedbed, go over the same path twice in the first row, then overlap one-half the tiller width

on the rest of the passes (Figure 4

14). When finished in one direction, make a second pass at a right angle as shown in Figure 4-15. Overlap each pass for best results (in very hard ground it may take three or four passes to thoroughly pulverize the soil).

• If the garden size will not permit

lengthwise and then crosswise tilling,

then overlap the first passes by one-

half a tiller width, followed by succes sive passes at one-quarter width (Figure 4-16).

• With planning, you can allow enough

room between rows to cultivate (Figure 4-17). Leave room for the hood width, plus enough extra room

for future plant growth.

Tilling on slopes

If you must garden on sloping ground, please follow two very important guide

lines:

1. Till only on moderate slopes, never

on steep inclines where footing is difficult (review safety rules in the "Safety" Section of this Manual).

2. We recommend tilling up and down

slopes rather than terracing. Tilling

vertically on a slope allows maximum

planting area and also leaves room

for cultivating.

IMPORTANT: When tilling on slopes,

be sure the correct oil level is main

tained in the engine (check every one-

half hour of operation). The incline of the slope will cause the oil to slant away from its normal level and this can starve

engine parts of required lubrication.

Keep the engine oil level at the full point

at ail times!

A. Tilling up and down slopes:

• To keep soil erosion to a minimum, be sure to add enough organic matter to

the soil so that it has good moisture

holding texture and try to avoid leaving

footprints or wheel marks.

A WARNING

To avoid serious personal injury or damage to the 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 wheel speed position when on sloped ground.

• Do not shift the Wheel Speed Lever when heading up or down a slope. If

lever is accidentally moved to FREE

WHEEL position, the tiller could roll out of control.

• To prevent engine damage due to oil starvation (on slopes,the engine is

inclined and oil moves away from

surfaces that need lubrication), be sure the correct oil level is main tained during all uphill/downhill tilling operations. Check the level of the oil in your engine after every onehalf hour of operation.

• When tilling vertically, try to make the first pass uphill as the tiller digs more deeply going uphill than it does downhill. In soft soil or weeds, you

may have to lift the handlebars slightly while going uphill. When going downhill, overlap the first pass by about one-half the width of the tiller.

HINT; For best results, use the HIGH belt range and SLOW wheel speed lever position. See Changing Speed Belts in this section for more information on changing to high range.

Figure 4- IS

Figure 4-16

Figure4.i7I

Page 25

Figure 4-18

B. Terrace Gardening:

• When a slope is too steep or too short 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 narrow, but flat area on which to plant.

• On a long slope, you can make several terraces, one below the other.

• Terraces should be only 2-to-3 feet wide. Digging too far into the side of the slope will expose poor subsoil that is unproductive for plants.

• To create a terrace, start at the top of the slope and work down. Go back and forth across the first row as shown in Figure 4-18.

• Each succeeding lower terrace is started by walking below the terrace you're preparing. For added stability of the tiller, always keep the uphill wheel in the soft, newly tilled soil. Do not till the last 12" or more of the downhill outside edge of each terrace. This untllled strip helps prevents the terraces from breaking apart and washing downhill. It also provides a walking path between rows.

Tilling Tips & Techniques

Clearing the tines

The tines have a self-clearing action which helps to eliminate most tangling

of debris. However, occasionally dry grass, stringy stalks or tough vines may become tangled.

Follow these procedures to help avoid

tangling and to clear the tines, if

necessary.

Before clearing the tines by hand, stop

the engine, allow all moving parts to

stop and disconnect the spark plug

wire. Failure to follow this warning could result in personal injury.

C. Tilling across slopes

without terracing

• If vertical or terracing gardening aren't practical for you, then you can till

laterally across a slope. We don't really recommend this method as it can create unsure footing and invites soil erosion.

• Study the terrain to make certain the slope is not too steep for safe tilling.

If possible, make terraced rows or till

vertically.

• Move the belt into LOW belt range and the Wheel Speed Gear Lever to SLOW position. As in terrace gardening, start at the top of the slope and overlap the first pass by half the width of the tiller.

For added stability, keep the uphill wheel in the soft, newly tilled soil. Each succeeding terraced area is started by walking below the terrace you are preparing (Figure 4-19).

• To reduce tangling, set the Depth

maximum "chopping" action as the tines chop the material against the ground. Also, try to till under crop residues or cover crops while they are green, moist and tender.

• While power composting, try swaying the handlebars from side to side (about 6" to 12"). This "fishtailing" action often clears the tines of debris.

• It may be necessary to remove the debris by hand (a pocket knife will help you to cut away the material).

Section 4: Operation

A WARNING

Regulator deep enough to get

Figure 4-19: Make a terrace in just 4 or 5 passes with the tiller.

Page 26

Section 4: Operation

Tilling Tips & Techniques

POUKR COMPOSTING

Power composting means tilling under and burying in the soil all manner of organic matter such as crop residues, ieaves, grass clippings and cover crops.

This material will decompose during the

non-growing season and add important natural nutrients to the soil.

A WARNING

When power composting, do not keep the Depth Regulator Lever at a deep

setting if the tiller Jumps or bucks.

If Jumping or bucking occurs, move the Depth Regulator Lever down to one of the shallower settings and then slowly increase the tilling depth on later passes.

Failure to comply could result in loss of tiller control, property damage or

personal injury.

Begin by composting crop residues such as leftover vines, stalks, stems and roots. Power compost these crop

residues as soon as they finish bearing. The sooner this is done, the better, as tender green matter is easier to till

under. Use the deepest depth regulator

setting possible without causing the

engine to labor or the tiller to Jump

ahead.

Standing cornstalks of reasonable height

can be power composted (Figure 4-20).

Pushing over (but not uprooting) corn

stalks wiii often make it easier for your tiller to chop up the stalks. Keep the tines clear of excessive tangling by "fish tailing'' or frequentiy using reverse.

Make several passes, then return a few

days later to finish off any remaining

stubble.

After tilling under crop residues, add

more organic matter such as leaves, grass clippings and even kitchen scraps. When tilled into the soil, this organic matter will decompose and add even more important nutrients to the soil.

After power composting, you may want to plant a "green manure" cover crop to

protect the soil during the off-season. Grow a crop of clover, alfalfa,

buckwheat, peas, beans, rye grass, grain, or kale and then till it into the soil prior to the planting season.

Wide-Row Planling

The wide-row planting technique is

spreading seeds anywhere from 10 inches to 2 feet wide or more. As a result, you can grow anywhere from 3 to 4 times (or more) produce in the same space that is normally set aside for an area that has narrow, single rows.

Wide-row planting automatically 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, hand-broadcast

the seeds as if seeding a lawn (not quite

as much as lawn seed). Cover with soil and tamp the area firmly with a hoe.

Tilling Under Corn

After corn is harvested, the stalks should

be tilled into the soil while still green. Dry plants are more difficult to till under, and the roots break loose too easily.

IMPORTANT: Do not pull the roots out

by hand or cut the stalks before tilling. Stalks that are firmly anchored by their roots are much easier for the tines to chop, cut, and work under.

1. As you move forward into a row of stalks, aim the tiller so that the stalks go between the left wheel and the transmis sion case (Figure 4-19). Do not use the right wheel because damage could occur

to the air cleaner, carburetor or throttle

linkage.

Figure 4-20: Tilling under corn

stalks.

2. Each new pass should overlap the previous pass by one-half the width of the tiller.

3. Till as deeply as possible. Pull the Depth Regulator ail the way UP and

engage the lowest notch for deep tilling.

Use either LOW or HUGH belt range and

SLOW wheel speed gear position.

Let the tilled-in stalks decompose for a

week or so. Then till in the remaining residue as deep as possible.

Soil Enrichment Idea

Tr^n#iCc^|i^

Hiller-Furrower Attachment (Section

Page 27

Section 4: Operation

PTO POWER UNIT

Your tiller is a self-contained PTO (Power Take-Off) Power Unit that was shipped with a tine attachment installed. The tine

attachment can be quickly removed and

replaced with other optional attachments. The following instructions will familiarize you with your PTO Power Unit. Please

read these pages carefully.

Figure 4-21: PTO Power Unit end tine

Bttechment

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 attach ment.

• Read the controls information and operating procedures for the tiller and engine described in Sections 3 and 4 of this Manual and in the

Engine Owner's Manual.

• Read and understand the assembly

instructions, controls information, and operating procedures for the attachment as described in the Attachment Owner's Manual supplied with the attachment.

The following steps explain how to

remove and replace the tine attachment.

You will need a 3/4" wrench (minimum

12" long for leverage).

Removing Tine Attachment

1. Move the tiller to level ground.

2. Be sure the engine is stopped, the

electric start key is removed, and the spark

plug wire is disconnected and moved away

from sparkplug.

Removing And Replacing The Tine Attachment

A CAUTION

TO AVOID PERSONAL INJURY OR

DAMAGE TO EQUIPMENT:

• Stop the engine, remove the electric start key, disconnect the spark plug wire and let the engine and muffler cool before removing or installing any attachment.

• Do not place hands, tools, or any object near or inside the PTO access area while the engine is ninning.

• When removing or replacing 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 prop it up with a block to prevent the attachment from falling forward.

3. Place a sturdy support under the

engine to prevent the engine from tipping forward when the tine attachment Is removed (Figure 4-23).

4. Place the Wheels/TInes/PTO Drive Lever

into NEUTRAL (Figure 4-22).

5. Place Tines/PTO Clutch Lever in

DISENGAGE (Figure 4-22).

Wheels/Tinesfl>TO

Figure 4-23: Block up engine.

6. Place Wheel Speed Lever into FREE WHEEL (Figure 4-22),

7. Loosen the two swing-out bolts (Figure 4-24) that connect the power unit trans mission to the tine attachment and swing out the bolts (Figure 4-25).

HINT: Loosening swing-out bolts can be

difficult. Use an extra-long wrench for

leverage.

8. Tip the PTO power unit forward about one Inch with one hand while pulling the tine attachment back (Figure 4-26). The guide pin on the power unit will slide out of the guide hole in the tine attachment

(Figure 4-27).

Page 28

Section 4: Operation

¿:

■’■■■- .Jw w

■ ■ ■' •-^

Figure 4-24: Loosening attachment swing-bolts.

........

V”- '

10. The PTO Power Unit is now ready to

install other powered or non-powered attachments. See the attachment's Owner’s Manual for installation and operation instructions specific to that attachment.

Installing the Tine Attachment

1. Move the two PTO Power Unit swing

out bolts outward and slide the washers

up against the bolt heads.

2. Remove the support block from under

the engine and slowly roll the power unit

back next to the tine attachment. Place the support block back under the engine.

3. Remove the dust cap (or protective wrapping) from the dog clutch coupling on the tine attachment.

4. Carefully align the guide pin on the

PTO Power Unit with the alignment hole in the tine attachment and bring the two units together (Figure 4-27).

PTO POWER UNIT

OPERATING INSTRUCTIONS

A WARNING

To help avoid personal injury or damage to equipment, read the attach ment's Owner's Manual supplied with each attachment before installing or operating an attachment. Please read all control, operation and safety instructions.

The following are operating instructions

specifically for the PTO Power Unit. Read the separate Owner's Manual supplied with each attachment before attempting to assemble, attach, transport or operate the attachment. If needed, please contact

us for a replacement manual. See the

back cover for customer support

information.

A WARNING

To help avoid personal injury, always

disengage the Tines/ PTO Clutch Lever

before towing any attachment.

Figure 4-25: Moving swing-bolts outward.

IMPORTANT: Store tine attachment in a

level, upright position to prevent gear oil

from leaking from the dipstick area.

Figure 4-26: Pulling attachment away from power unit

9. To keep the tine attachment dog ciutch coupling clean, cover \with the dust cap

(on some attachments) or plastic \wrap.

Figure 4-27: Aligning guide pin with mounting hole.

5. 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 flat.

The bolts must be very tight - if you have a torque wrench, tighten each bolt to between 70 and 80 ft.-lbs.

IMPORTANT: The swing-bolts must be

kept very tight to prevent damaging wear

to the dog clutch coupling, alignment pin or the alignment hole. Check bolt tightness every 2-1/2 operating hours.

6. Remove the engine support before moving the tiller in a forward direction.

Some attachments have a drive shaft or a hydrauiic pump that is powered by the

engine on the PTO Power Unit. These

units are called Stationary Attachments,

since they remain in one location when operating. Attachments can be towed to a work site with the PTO Power Unit as described in Operating Non-Powered Attachments. Other attachments are

pulled or towed behind the PTO Power

Unit. These attachments are called Non

Powered Attachments.

Setting Up Stationary Attachments

A WARNING

To help avoid personal injury, never

allow people to ride on any PTO Power

Unit or attachment.

1. Move the Tines/PTO Clutch Lever to

DISENGAGE.

2. Move Wheel Speed Lever (Figure 4-22)

to FREEWHEEL, then biock all wheels

(Figure 4-29) to prevent the equipment from roiling.

Page 29

Section 4: Operation

Figure 4-28: Forward Interlock Wiring

A - PTO Power Unit Interlock Harness

B - Forward Interlock Receptacle C - Attachment Interlock Wire

3. On the PTO Power Unit, unplug the Forward Interlock Wire Flarness that leads

from the base of the handlebars (A, Figure

4-28) to the receptacle (B) located on the

top, right side of the transmission cover.

4. On the Stationary Attachment, locate

the interlock wire (C, Figure 4-28) and

clean contacts on plug and receptacle (B). This connection enables you to operate the Wheels/Tines/PTO Drive Lever in

FORWARD without having to squeeze a

Forward Interlock Lever.

5. Connect the plug from the Stationary Attachment (C, Figure 4-28} to the recep tacle on the PTO Power Unit (B). The

connection must be tight.

Setting Up Non-Powered Attach ments

1. Move the Tines/PTO Clutch Lever

(Figure 4-22) to DISENGAGE.

2. Move the Wheel Speed Lever (Figure

4-22) to either SLOW or FAST position

To do this, roll the PTO Power Unit while

shifting lever until wheels engage.

3. Verify that the Forward Interlock Wire Flarness plug at the base of the handle bars (A, Figure 4-28) is connected to the Forward Interlock Wire Harness recepta cle (B) on the top right side of the transmission.

Starting The Engine

IMPORTANT: Refer to Cold Weather

Operation instructions, in this section,

before operating in temperatures below 40°F.

1. Move the Wheels/Tines/PTO Drive Lever into NEUTRAL. To find NEUTRAL

(be sure engine is ofQ, push lever down and engage it in FORWARD then tap the lever upward to automatically move into NEUTRAL.

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

A WARNING

To avoid injury,do not run the engine in

an enclosed or poorly vented area.

Engine exhaust contains carbon

monoxide, an odorless and deadly gas.

3. Start Engine. See Starting and Stopping the Engine, in the beginning of

this section, for detailed starting informa tion. Also see the Engine Owner's Manual.

4. For non-powered attachments only test the Forward Interlock Safety System. See

Testing the Forward Interlock Safety

System, in this section, for a procedure.

Operating Stationary Attachments

1. Move Tines/PTO Clutch Lever (Figure 4-22) into ENGAGE.

2. To apply power to PTO-driven attach ments, move Wheels/Tines/PTO Lever

(Figure 4-22) down to FORWARD position

{do not use REVERSE with stationary

attachments).

3. To stop the PTO Power Unit, tap the Wheels/Tines/PTO Drive Lever upward

into NEUTRAL position.

Operating Non-Powered Attachments

(or to Tow Stationary Attachments)

1. To move forward, squeeze and hold one Forward Interlock Lever (Figure 4-30) up against the handlebars, and move the Wheels/Tines/PTO Drive Lever down to

FORWARD.

Figure 4-30: Moving tiller forward: squeeze one Forward Interlock Lever and then move WheelsITinesIPTO Drive Lever down to FORWARD.

2. To stop forward motion, tap Wheels/Tines/PTO Drive Lever upward

into NEUTRAL, then release the Forward Interlock Levers.

3. To stop forward motion in an emergency, release all PTO Power Unit controls (stops engine).

4. To move in reverse, reduce the engine speed then shift the Wheel Speed Lever

into SLOW. Move and hold the Wheels/Tines/PTO Drive Lever all the way up. Ensure that the area behind you is clear of all obstacles, before moving the

lever into REVERSE.

Figure 4-29: Block wheels on PTO Power Unit and stationary attachment.

5. To stop moving in REVERSE, release the Wheels/Tines/PTO Drive Lever.

Stopping the Engine

Move the Engine Throttle Lever to STOP. Turn key switch to OFF on electric start models.

Page 30

Section

5 Maintenance

A WARNING

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. Remove ignition key on electric start models.

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

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.

REQUIRED MAINTENANCE SCHEDULE

Before Every Every Every As

PROCEDURE Each 10 25 30 Noted

Use Hours Hours Hours

Check engine oil 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 Before/after

Check drive belt tension

Check nuts and bolts

Clean tiller tine shaft Lubricate tiller Change engine oil* More often

Clean foam element air filter Check paper element air filter

Check for oil leaks

Check gear oil level in

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

* During engine break-in period, change engine oii after first 2 hours of operation.

•

Every 5

operating hrs.

Section 4

long storage

After initial

2 hours

After initial

2 hours

in dusty or dirty areas

More often

In dusty or dirty areas

After initial

2 hours

After initial

2 hours

Page 31

Sections: Maintenance

A WARNING

*X?

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

Tighten Bolts and Nuts

Check for loose or missing hardware every ten (10) operating hours. Failure to

tighten or replace fasteners can cause

poor performance, 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 Figures 5-1, 5-2, 5-3 and 5-3A.

1. Check the transmission pulley mounting bolt (Figure 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 immobilizes the pulley while

you tighten the bolt.

2. Check Jam nut on left side of neutral plunger assembly (Figure 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 regulator mounting bracket (A, Figure 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 trans mission (B in Figure 5-3). Gear oil can

leak from a loose housing cover. To reach the bolts, remove the left side tine holder. See Bob Tine Maintenance in this Section for tine holder removal directions.

5. Check both swing-bolts (C, Figure 5-3) that connect the power unit transmission to the tine attachment. Both bolts should be checked every 2-1/2 hours of operation. If loose, wear can occur on the

locating pin on the power unit, and cause enlargement of the locating 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, Figure 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 transmission housing a coating of non-hardening gasket sealant to prevent gear oil from leaking.

Tiller Lubrication

Proper lubrication of the tiller's mechani

cal parts is an essential part of good

maintenance. Lubrication 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.

Figure 5‘3A: Tine holder hardware must be tight.

■ 4'

Figure 5-1: Check bolt on transmission pulley.

Figure 5-2: Check jam nut on plunger assembly.

Figure 5-3: Gently tilt tiller forward to check fasteners.

Page 32

Sections: Maintenance

A WARNING

t.p

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

IMPORTANT: Do not allow oil or grease

to contact the pulleys, drive belt or

reverse disc. This can cause the belt or

disc to slip on the pulleys.

Lubricate the numbered areas In Figures 5-4 and 5-5, as follows:

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

2. Oil all pivoting and connecting points on the Wheels/TInes/PTO Drive Lever and the Wheel Speed Lever (B, Figure 5-4).

3. Grease the face of the belt adjustment

block (C, Figure 5-4).

4. Oil the Depth Regulator Lever,

including the spring in the mounting bracket (D, Figure 5-4).

5. Oil the full length of the throttle cable casing (E, Figure 5-4).

6. Oil threads on Handlebar Height Adjust

ment Lever (F, Figure 5-4).

7. Grease left- and right-side engine mounting bars at the top, the middle, and bottom (G, Figure 5-4).

8. Grease the zerk grease fitting located on the pivot point at the end of the Wheel Speed Lever (H, Figure 5-4). If Wheel Speed Lever has a grease fitting on pivot assembly, apply 2-to-3 strokes of multi purpose grease at beginning and end of

tilling season.

9. Keep the PTO access area well-greased (I, Figure 5-5). if the Tines/PTO Clutch Lever becomes hard to move, squirt some oil into its access hole, and work it back and forth to disperse the oil.

Transmission Gear

Oil Maintenance

Checking for Oil Leaks

At 25-hour operation intervals, check the tiller for oil leaks. Inspect for oil accumu

lations on the tiller or the floor where it's stored.

If tilling during very hot weather, the gear oil may heat up and expand inside the transmissions. To allow for this oil expansion, both the power unit transmis sion and the tine attachment transmis sions have oil relief vents (Figure 5-6).

Figure 5-6: Oil relief vent locations.

The vents allow small amounts of oil to seep out.

If a serious leak is discovered, please contact your authorized dealer or the Factory Technical Service Department for service advice.

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

Figure 5-5: Use grease liberally in PTO access area.

A small amount of oil seepage or wetness

around a shaft opening or cover is no cause for alarm. But a heavy con centration of oil Is more serious. You should tighten all bolts immedi ately, and replace any worn seals or gaskets.

It may be impossible to determine how much oil has been lost, so check the oil levels in the PTO trans

mission and the tine attachment before using

the tiller again. Add any necessary gear oil. Serious damage to the transmission components can result from operation when gear oil levels are low.

Checking Gear Oil Levels

Every 30 hours of operation, check the gear oil level in both the power unit trans mission and the tine attachment transmis sion. Operating 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 transmission must be connected when checking (or adding) gear oil.

Checking the Power Unit OH 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 (Figure 5-7).

Page 33

Sections: Maintenance

A WARNING

♦ r?

Figure 5~7: Remove oil level check

plug. Gear oil should seep out if

the level is sufficient.

3. If the oil level Is correct, oil will seep out of the check hole (allow extra time in cold weather). If it does, the level is fine and you should replace the check plug. If no oil seeps out, see Adding or Changing

Gear OH.

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

Checking the Tine

Attachment Oil Level

IMPORTANT: Two different gear oil

checking procedures for the tine attach ment transmission are described next. Use the first procedure 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 dipstick from the tine attachment trans mission (Figure 5-8) to see which type dipstick you have. Then replace the dipstick with markings on dipstick facing

to rear.

Figure 5-8: Checking gear oil level;

markings on dipstick (tine attach ment transmission) must face rear.

For Dipsticks With 'Check Cold' Marking

(Cold means 2 hours has passed since

the tiller was used.)

1. Move the tiller to level ground.

2. Pull the Depth Regulator Lever back,

then push it down all the way (to engage its top notch).

3. Place a sturdy support under the

engine to prevent the tiller from tilting too far.

4. Now slide three pieces of 2" x 4"

lumber underneath the drag bar- raising the drag bar about 4-1/2" above ground. This elevation allows an accurate "cold" gear oil reading .

5. Wait two hours with tiller elevated

(allow more time if temperature Is below

40°F).

6. Loosen and remove transmission dipstick (Fig. 5-8). Wipe it clean with a rag.

7. Hold dipstick so its markings face to

rear of tiller. Lower It straight down Into the sump hole to touch the drive shaft inside (Fig. 5-8). Don't force or try to thread It back in; an Incorrect reading will result.

8. Remove dipstick and check oil level. It should be anywhere within the crosshatched area or even slightly above the Max marking. If correct, replace dipstick and remove the boards used as props.

9. If oil level was low, gear oil must be added before using the tiller. See Adding

or Changing Gear Oil next.

For Dipsticks With Hot/Coid Markings

1. Move the tiller to level ground.

2. Pull the Depth Regulator Lever back,

then push it down all the way (to engage its top notch).

3. Place a sturdy support under the

engine to prevent the tiller from tilting too far.

4. Cold reading (preferred method):

(Two hours has passed since the tiller was used.) Place a 2" x 4" board (on edge) under the drag bar- raising the tiller and drag bar about 3-1/2" above ground.

Hot reading: (Tiller was operated for

more than 30 minutes within the past hour.) Do not use the wood prop to elevate the tiller.

5. Follow Steps 4, 5 and 6 given for the

other dipstick type.

6. 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.

7. If the level is Incorrect, see Adding or

Changing Gear Oil.

Adding or Changing Gear Oil

For partial fill-ups (just a few ounces or

less), use SAE140, SAE 85W-140, or SAE 80W-90 weight gear oil with an API rating of GL-4 or GL-5. For full replacement, 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 automatic

transmission fluid or engine 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 authorized dealers and most service stations, power equipment centers, or farm/heavy equipment outlets.

Capacities: Power unit transmission

holds approximately 60 ozs.; Tine Attach ment transmission holds approximately

12-1/2" ozs.

Page 34

Sections: Maintenance

A WARNING

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 spailt plug. Remove ignition

*-p

key, if so equipped. Failure to follow these instructions can result in serious personal injury or property damage.

Adding Gear Oil to the

PTO Power Unit Transmission

1. Do steps 1 and 2 of Checking the Power Unit Oil Level on page 32.

2. Using a 3/4" wrench (or socket), remove the bolt securing the handiebar base to the top of the transmission (prop the handlebars first to prevent them from faiiing).

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 (A, 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 the left side of the trans mission (B, Figure 5-7).

4. Reinstall the oil level check plug. Tighten it securely.

5. Reinstall the handlebars using the mounting bolt previously removed. 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 receptacle. Be certain it's secure.

7. Test operation of the Forward Interlock Safety System. See Section 4 for a procedure.

Draining and Filling the PTO Power Unit Transmission

1. Place a shallow pan under the trans mission gear oil drain plug (B, Figure 5-9).

2. Remove the oii level check plug (Figure 5-7) with a 3/8" wrench. This vents the transmission for faster oil draining.

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

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 forward so any oil at the rear of the transmission wili 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.

Adding 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 Lever 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 attachment

(Figure 5-8).

3. Slowly add gear oil in the dipstick hole.

Add 1/2-ounce at a time to avoid overfill

ing. It takes about 12-1/2 ounces.

4. Take dipstick readings frequently. Stop when oil reaches "Cold" range marking on dipstick. Replace dipstick securely.

Draining and Filling the Tine

Attachment Transmission

1. The tine attachment transmission is not equipped with an oil drain plug. To

drainjust a small amount of gear oil,

remove the dipstick and tilt the attach ment forward (first uncoupling it from the Power Unit).

2. For complete drainage, remove the left side tine assembly (refer to Bolo Tine Maintenance for instructions), then remove just one of the lower screws from

the tiller housing cover (Figure 5-10). To

speed drainage, remove the tine attach ment dipstick to vent transmission.

Figure 5-10: Remove housing cover

screw to drain tine attachment

transmission gear oil.

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.

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 transmission with the correct amount of gear oil before operating the tilier again.

Page 35

Sections: Maintenance

A WARNING

Before iespectieg, 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. Remove ignition key, if so equipped.

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

Drive Belt Maintenance

Measuring and Adjusting Drive Belt Tension

On a new tiller (or if a new belt 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.

Maintaining the right tension is important

to good tiller performance and long belt

life. If too loose, the belt will slip on the pulleys, and be unable to deliver full power to the wheels and tines. A loose belt will also wear prematurely.

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/PTO Drive Lever in NEUTRAL when the tiller is not in

use.

• Keep tension adjusted correctly.

• Don't "speed shift" when moving 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 lubricated. If there is any binding, you won't get true measurements. Also, you'll need the belt adjustment tool you

received with your new tiller (Figure 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 under

neath the belt adjustment block (Figure

5-12). Don't let the clutch roller move during the next few steps. If it moves, you'll get a false belt tension reading.

3. The belt tension is correct if the front of the clutch roller is 1/4"-to-5/16" away from the face of the upright bracket that holds the adjustment block in place

(Figure 5-12). To measure this distance:

a. Without moving the clutch roller, try

inserting the 1/4"-thick, slotted end of the belt adjustment tool in between the roller and the upright bracket. (The flat edge of the tool must be facing the roller.) Refer to Figure 5-13.

b. If only the slotted portion of the tool

will fit, the belt tension is correct,

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.

Figure 5-11: Use this belt adjust ment tool to measure and adjust drive belt tension.

Figure 5-12: Shift into FORWARD and measure distance between roller and upright bracket using the belt adjustment tool.

4. If the belt tension is correct, move the

Wheels/Tines/PTO Drive Lever back to NEUTRAL.

Jit ■■

Figure 5-13: Insert slotted end of belt adjustment tool between roller and bracket, with the flat side of the slotted end facing the roller.

How to Adjust Belt Tension

1. As described in the following steps, drive belt tension is adjusted by moving the adjustment block up or down. Moving it down will tighten the belt; moving it up loosens the belt.

HINT: The distance the block moves approximately equals the distance the roller moves.

In most cases, the clutch roller will not have been very far out of position, so the adjustment block will only need to be moved slightly (up or down).

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

Page 36

Sections: Maintenance

A, WARNING

♦ r?

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 (Figure 5-14). Rotate the tool so the slotted end faces down.

Before iospectiiig, 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. Remove ignition key, if so equipped.

Failure to follow these instmctions can result in serious personal injury or property damage.

Figure 5-14: With WheelsITinesIPTO Drive Lever in NEUTRAL, insert tool

through hole in adjustment block.

4. Place the Wheels/Tines/PTO Drive Lever in FORWARD position. The arms of the clutch control yoke will be resting on the belt adjustment tool and the clutch roller should be engaged slightly beneath the adjustment block (Figure 5-15).

Figure 5-15: With Drive Lever in FORWARD position, clutch roller should be engaged slightly beneath

the adjustment block.

5. Use one hand to hold the drive lever in FORWARD while using a 9/16" wrench to loosen (don't remove) the bolt at the back of the belt adjustment block (Figure 5-16). The adjustment block should be free to move either up or down.

•>: ',K>

Figure 5-16: Hold Drive Lever while loosening bolt. Push lever down to tighten belt; pull up to loosen belt.

6. Push the drive lever down if the belt needs tightening. Pull the lever up if the belt needs to be loosened. Flold the drive lever in place and tighten the bolt in the adjustment block firmly.

7. Let go of the drive lever and remove the belt adjustment tool from the hole in the adjustment block.

8. Check the tension on the belt by following the previous instructions "Flow to Measure Belt Tension."

NOTE: If the adjustment block is aii the way down and the measurement between the clutch roller and the bracket is less than 1/4", then a new drive beit is needed.

Replacing the Drive Belt

Removing the 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 ieft side of the puiieys and pushing in on the center of the belt with your finger.

3. Use your right hand to move the beit down and away from the lower puiiey, in the direction of the engine (Figure 5-17).

4. Push the belt upward to create slack in the belt (Figure 5-18).

TO, I . ■

Figure 5-17: First move belt off the lower pulley.

nfm

Push Belt UP

Figure 5-18: Push belt upward to create slack.

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 Figure 5-19).

6. Push the Wheels/Tines/PTO Drive Lever down into the FORWARD position. This increases the distance between the upper and lower pulleys. Next, iift and puii the entire belt out between the pulleys

(Figure 5-20).

Replacing the Drive Belt

1. Piace Wheels/Tines/PTO Drive Lever in FORWARD position.

2. Squeeze the belt in the middle and insert one end in between the pulleys

(Figure 5-20).

Page 37

Sections: Maintenance

A WARNING

^X?

Failure to follow these instmctions can result in serious personal iigury or property damage.

Figure 5^19: Move top half of belt over pulley arid reverse disc.

il.

' *.**■

Figure 5-21: Seat belt in upper pulley, then in lower pulley (High Range position shown).

7. Move the bottom half of the belt into

the HIGH Range groove of the lower

pulley (groove closest to engine— Figure 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.

Reverse Disc Inspection

The reverse disc is made of steel with a special, long-lasting rubber 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 outside edge of the disc as shown in Figure 5-22. Replace the disc before the rubber edge wears to a thickness of 1/8" or less. Failure to do so could cause the steel underneath the rubber to damage the transmission pulley.

Figure 5-20: Shift into FORWARD and remove the belt

3. Push belt forward then down until It is looped over the lower pulley (Figure

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 the 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 (Figure 5-21).

8. To move the belt to the LOW Range position, see Changing Beit Speeds in Section 4.

9. After installing the belt, check and

adjust for correct belt tension as explained previously.

Reverse Drive System Maintenance

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

Wheeis/Tines/PTO Drive Lever up in

REVERSE position, this lowers the rub berized 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 transmission pulley causes the transmission drive shaft to be

powered in a counterclockwise direction (as viewed from the operator's position behind handlebars). The drive shaft then

turns the wheels and tine shafts in a

reverse direction.

Figure 5-22: Measure the edge of the reverse disc for wear.

2. Look for big cracks or missing chunks

of rubber from the disc. If so damaged, the disc should be replaced immediately.

IMPORTANT: Extend the life of the reverse disc by always pausing in NEUTRAL before shifting between FORWARD and REVERSE. Also - the reverse disc is not suited for continuous or sustained reverse operation. Use reverse sparingly.

Page 38

Sections: Maintenance

A WARNING

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 spailt plug. Remove ignition key, if so equipped.

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

Replacing the Reverse Disc

Follow these steps to replace the reverse

disc. (If your tiller has a Bumper Attach

ment mounted, it must be removed first.)

Removing the Reverse Disc

1. Move Wheeis/Tines/PTO Drive Lever in NEUTRAL position.

2. Wedge a 5/16"-thick board between top

of engine pulley (avoid contacting reverse disc) and cast iron housing next to It. This immobilizes pulley.

3. Use a 9/16" wrench to loosen the mounting bolt shown in Figure 5-23. Remember to immobilize the pulley with

the wood wedge while loosening the bolt.

If necessary, pry 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 remove it. Bring the

bolt and lockwasher along with the disc.

and engine mount move down to press on the reverse adjustment bolt (Figure 5

24). This action compresses the reverse spring and plunger assembly, requiring you to hold the lever up in REVERSE. When you release the lever, the spring automatically pushes the lever back into NEUTRAL position.

The spring and plunger assembly is designed to prevent the reverse 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 adjustment bolt (Figure 5-24). The reverse adjustment bolt can be adjusted up or down to correct a number of reverse drive operating problems, as explained next.

ment bolt should be adjusted upward (see instructions that follow). Moving adjust ment bolt upward will also solve problem of a tiller that goes Into REVERSE on its own.

Figure 5-25: Checking Reverse Disc in NEUTRAL.

3. Use your left hand to hold Wheels/Tines/PTO Drive Lever up in REVERSE, while briefly pulling out engine start rope. The reverse disc should turn lower pulley (see Figure 5-26). If not, or it requires a lot of pressure to hold lever up In REVERSE, then 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 require exceptional effort to hold it up In reverse position.

Figure 5-23: Removing Reverse Disc.

Installing a New Reverse Disc

1. Do steps 1-through-3, described previ

ously, In reverse.

2. Tighten mounting bolt securely, and

check for correct operation — see

Checking and Adjusting Reverse Drive

System.

Checking and Adjusting Reverse the Drive System

When the Wheels/Tines/PTO Drive Lever is moved up into REVERSE, the engine

Figure 5-24: Spring and piunger assembly.

Checking and Adjusting Reverse Disc

1. Verify that linkages for Wheels/Tines/PTO Drive Lever are lubri cated with oil and engine mount bars and belt adjustment block are lubricated with grease. (See Tiller Lubrication \n this section.)

2. Place Wheels/Tines/PTO Drive Lever In NEUTRAL. Briefly pull out engine recoil start rope while watching reverse disc. The disc should turn, but lower pulley should not (Figure 5-25). If reverse disc turns lower pulley, or If it is located closer than 3/16" to the pulley, reverse adjust

Figure 5-26; Checking Reverse Disc in REVERSE.

4. Shift the Wheels/Tines/PTO Drive Lever

to REVERSE and then let it go. The lever should return to NEUTRAL. If not, the reverse adjustment bolt will have to be adjusted upward.

Page 39

Sections: Maintenance

A WARNING

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

Adjusting Reverse Drive:

1. Place Wheeis/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

(Figure 5-27). While holding the bolt steady, loosen the Jam nut (counterclock wise) until it touches the bolt head.

. Jam Nut

I Retaining I

Figure 5-27: Hold bolt steady while 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 be 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 thejam nut below it (Figure 5

28). Hold the bolt steady while loosening thejam nut three or four turns.

......

7. Place a chalk or pencil mark on the top edge of the plunger retaining bolt. Now, while watching the mark, loosen the bolt 3/4-turn (Figure 5-29). Do not exceed a 3/4 turn (this would disengage the bolt from the locking groove in the side of the plunger).

. Adjustment

Bolt ‘ ^

i,; ^ W

* ■

Jam Nut

Figure 5-28: Loosen Jam nut before turning reverse adjustment bolt

8. Hold the plunger retaining bolt steady with a wrench while tightening thejam nut against the side of the plunger housing

(Figure 5-27).

, ► -a

i PJ '

Bolo Tine Maintenance

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 conditions. With use, the tines get shorter, narrower and more pointed (Figure 5-30). If badly worn, they lose the ability to till deeply.

Figure 5-30: Check for wear every 30 operating hours.

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" (Figure 5-31).

5. Move the Whee!s/Tines/PTO Drive

Lever to NEUTRAL. The switch body on the bottom of the engine mount tab

(Figure 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 reverse adjustment bolt (turn it counterclockwise).

6. Check that reverse disc is at least 3/16" away from transmission drive pulley. Then hold reverse adjustment bolt steady with one wrench while tightening Jam nut with a second wrench (Figure 5-28).

Figure 5-29: Loosen plunger retaining bolt about 314-turn, then dghten jam nut against plunger housing.

9. Check the action of the reverse disc as explained previously.

IMPORTANT: If the above adjustments have not corrected an improperly working reverse drive, contact an authorized dealer or Factory Technical Service Department for assistance.

Figure 5-31: Replace tines when gap between inner Ones is 5" or more (normal gap is 3").

Tines can be replaced individually or as a complete set. See replacement instruc tions that follow.

Page 40

Sections: Maintenance

A WARNING

*-p

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

Single Tine Replacement

A WARNING

The tines or tine hood edges may be sharp. Wear thick gloves 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/PTO Clutch Lever to ENGAGE.

2. Gently tilt the tiller forward until the

engine rests on the ground.

3. Raise the hood fiap 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 remove the two bolts and nuts securing the tine to the tine holder plate (Figure 5-32). Use pene trating oil on the hardware if it is rusted or hard to remove.

Removing and Replacing A Tine Holder Assembly

A WARNING

• The tines or tine hood edges may be sharp. Wear thick gloves to protect

your hands.

• Wear safety goggles to protect your eyes. When loosening hardware, do not hit a wrench with a metal tool- this

could shatter the tool or wrench,

sending metal particles into your eyes.

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 5-33 and 5-34 to see which style tine holder you have).

Style A tines holders are secured to the tine shaft with two bolts and two nuts. Style B tines holders are secured with a single end bolt to the left and right sides of the tine shaft. Flere's how to replace the tines and holders as assemblies.

Non-Tapered Tine Shaft

4. Use a soft mallet to drive the holder off the tine shaft. (Use a heavy hammer and block of wood to knock off the immo bilized tine holder.)

5. When the holder is off, clean all dirt and debris from the shaft and the holder. Apply fresh grease to the tine shaft.

Replacing Tines Holder Assembly

1. Replace the holder so the sharp tine

edges face forward {lowarb 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.

i;—

Figure 5~32: Removing a single tine

requires taking off two bolts and

two nuts.

6. Mount the new tine exactly the way the old tine was positioned. (The sharp edge of the tine, which enters the soil first, must face forward when above the tine shaft.) Replace the bolts and nuts and tighten them securely.

Removing Tine Hoider Assembly

1. Follow steps 1-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

3. With Style A holders, remove the

two bolts and nuts securing each holder (Figure 5-33). With Style B holders, remove the single bolt

(along with the washers) from the end of the tine shaft (Figure 5-34).

fc. "L

Right-Side Tine Holder

Left-Side Tine Holder

Figure 5-33; Style “A ” Tine Holders.

Figure 5-34: Style “B" Tine Holders.

Page 41

Sections: Maintenance

A WARNING

^-p

Before iiispecting, cleaniiig 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. Remove ignition

key, if so equipped. Failure to follow these instmctions can result in serious personal injury or property damage.

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

accumulated on the tine shaft or inside the tine holders. Please follow this main tenance recommendation, as debris can

cause premature wear to the tine shaft

and its oil seals. Refer to the previous tine holder removal instructions. After

cleaning away any debris and removing

old grease from the tine shaft, apply fresh

grease to the tine shaft.

Tire and Wheel Maintenance

Check tire air pressure every 30 operating

hours. The recommended pressure for tilling is 10-to-20 psi (pounds per square

inch). Both tires should be inflated

equally. (Unequal pressure can cause the tiller to pull to one side.)

Removing the Wheels

Each wheel is secured by a roll (spirol)

pin that passes through the 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.

A 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.

Engine Oil Maintenance

Check the engine oil level before starting the engine each day and after each 5

hours of continuous operation. Running the engine when it Is low on oil will

quickly ruin the engine.

It Is recommended that you change the oil every ten (10) operating hours and even sooner when operating In extremely dirty

or dusty conditions. Refer to the separate Engine Owner's Manual for detailed service instructions.

Air Cleaner Maintenance

The 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 engine air cleaner filters dirt and dust out of the air before it enters the carbure tor. Operating the engine with a dirty, clogged air filter can cause poor perfor mance and damage to the engine. Never operate the engine without the air cleaner installed. Inspect and service the air cleaner more often if operating in very dusty or dirty conditions.

It is critical that the filters be kept clean and properly installed at all times. See the location of the air cleaner assembly on your engine by referring to Figure 5-39 or Figure 5-40.

Refer to the engine manufacturer's litera ture supplied with your tiller for complete air cleaner service and maintenance infor mation.

Throttle Cable Maintenance

The throttle lever settings are factoryadjusted, so unnecessary adjustments should not be made. However, if the engine does not start or stop, or respond immediately to various throttle lever settings, then adjustments may be necessary. Please refer to the engine manufacturer literature supplied with your tiller for specific adjustment instructions.

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.

Spark Plug Maintenance

The spark plug must be in good condition for proper engine operation. Remove and

Inspect the plug every 50 operating hours or annually, whichever occurs first.

The correct electrode gap is .030". 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 if other

visible damage is present.

NOTE: Do not wire brush or sandblast the spark plug to clean It - loose particles can enter the engine, causing damage!

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.

Battery Care and Maintenance

Battery Care in Service

1. Every month or every ten (10)

operating hours, whichever comes first,

check the level of electrolyte solution In the battery cells:

a. If battery case has UPPER and

LOWER level lines on it, solution should be maintained at the UPPER level line.

b. If the battery does not have level

lines on case, maintain solution level at lowest part of the filler well

within each cell.

NOTE: Use only distilled or demineralized water to refill each battery cell.

c. After filling, replace battery caps

securely, then wash off any spilled solution with baking soda and water mixture.

d. Run engine outdoors for about 20

minutes (at 3/4 throttle) to help recharge. For safety, do not leave

the tiller unattended while the

engine is running.

Page 42

Sections: Maintenance

A WARNING

• n

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

A 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 solution. Neutralize empty container 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 quanti ties 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 battery in a well-ventilated area.

• Make sure venting path (vent tube) of battery is always open.

A DANGER

Never touch the positive (4^} battery post and any other surrounding metal with tools. Jewelry, or other metal objects.

Doing so can cause a short circuit that could result in electrical burns, an elec trical shock, or explosion of battery gas.

2. Keep battery clean. If terminals are corroded, remove battery and clean terminals with wire brush, sandpaper or steel wool. {A void getting any of this

corrosive materiai on your skin or in your

eyes.) Rinse battery with a solution of

baking soda and water. Coat terminals with petroleum Jelly or silicone grease to

prevent further corrosion.

3. Periodicaiiy check entire electrical 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 vent tube. It must not be

crimped or bent.

A 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.

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.

A DANGER

• While the battery is being charged,

do not leave it unattended. Charging time does not have to be continuous.

• Carefully follow all charging instruc

tions and safety rules provided by the

manufacturer of the charging equipment.

• Never attempt to "Jump start" the battery with an automobile battery or its charging system. This could result in serious personal injury or property

damage from causes such as a battery

explosion, or acid or electrical bums.

1. Remove battery from tiller (see Battery Removal instructions) and place on a

stable, level surface.

2. Clean battery if needed. If battery is

very cold, let it warm up to 60-to-80®F.

3. Remove filler caps. Keep them off

when filling and charging.

4. Carefully check electrolyte level. If low,

add distilled or demineralized water (do

not add battery acid) to bring the

solution level In each cell up to correct height. Avoid overfilling.

5. Charge battery (with caps removed)

until all cells are gassing freely. (To check for gassing, wear protective goggles and inspect each cell with flash

light for bubbling of electrolyte solution.)

Use one of the following methods to charge battery:

a. Recommended Method: charge the

battery at a rate of 1 -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.

A 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 will permanently

damage the battery.

6. When battery is fully charged, turn charging equipment off and disconnect the cables. Check electrolyte level in all cells. Add distilled or demineralized water

if necessary to adjust level to the correct

height. Then reconnect the charger cables to the battery and charge the

battery for one more hour.

Page 43

Sections: Maintenance

A WARNING

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

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 temperatures. Batteries lose voltage when in storage, more so in hot weather than in cold. Ideal storage temperature is 50®F.

Battery Removal and Replacement

1. Disconnect the negative (-) cable from the grounding screw on the right side of the battery bracket (A, Figure 5-42} and

bend the cable away from all metal parts.

2. Disconnect negative cable from

negative (-} battery post (B, Figure 5-42), and remove cable.

3. Disconnect positive (+) cable from

positive battery post (C, Figure 5-42) 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 dis connect the negative (-) cable first followed by the positive {+) cable. Re verse this procedure when reinstalling the battery.

Storing Your Tiller

When your tiller won't be used during the off-season, prepare it for storage with the

following steps;

1. Clean the tiller and engine.

2. Do routine tiller lubrication and check for ioose hardware.

Figure 5-42

3. Protect the engine from deterioration or damage by referring to the engine storage instructions in your engine manual literature.

4. When engine is stiii warm, drain oil from engine crankcase. Refill with fresh motor oil.

5. Protect internal cylinder against rust by removing spark piug and pouring one ounce of clean engine oil into spark plug hole. Then slowly pull out recoil start rope 2 or 3 times to distribute oil inter nally. Replace spark plug, but do not reconnect plug wire. Pull rope until resis tance is felt — let rope rewind.

6. Charge battery (electric start option). Store battery in 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 enc/osec/area where gas fumes could reach an open flame or spark, or where ignition sources are present (space heaters, hot water heaters, furnaces, etc.).

Inspecting Forward Interlock

Wiring System

Check the Forward Interlock wiring system every ten (10) operating hours, for tight connections and to see that the insulation on the wires is unbroken (to prevent the system from shorting out).

1. Check insulated wire harness from

lower ends of handlebars to wire harness connector on top, right side of transmis sion cover. Be sure connector is secure.

2. Check insulated tubing from connector to cast iron motor mount/belt shroud.

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. Also check the second wire that leads to the throttle cable mounting bracket on the right side, forward portion of the engine.

Testing the Forward

Interlock Wiring System

The wiring circuit for the Forward

Interlock Safety System is designed to ground out the engine's ignition system.

There are three switches in the circuit which, when open, iet the engine run. One switch is on the neutral plunger tab of the cast iron motor mount. This switch

is open whenever the Wheels/Tines/PTO

Drive Lever is in NEUTRAL or REVERSE positions. The other two switches are

iocated inside the handlebars, directly above the two Forward Interlock Levers. The switches are wired so when squeezed

(open) the engine will run. There is a fourth switch located in the wiring harness connector on the top, right side of the transmission cover. 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.

1. A broken or disconnected wire could

let the engine run without you having to press one of the Forward Interlock Levers.

2. A bare wire touching tiller or engine metal could ground out the engine's

ignition.

3. A switch that has failed allows the engine to run. Or it may prevent the engine from running.

Refer to the Troubleshooting section if your Forward Interlock Safety System is not operating correctly.

Page 44

Appendix A: Troubleshooting

PROBLEM

CHECK OR TEST

(Check or test in sequence 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 X X

Check handlebar wire harness Check transmission wire harness X X

Troubleshooting Procedures

1 Wheels/Tines/PTO Drive Lever:

A. Lever does not Stay in FORWARD-

• Drive belt may be too tight. Raise belt

adjustment block a little (Sect. 5).

• Clutch pawl spring at end of lever may be

overstretched. Install new spring.

B. Lever hard to shift into REVERSE-

• Check reverse disc for wear (Sect. 5).

• Check adjustment of reverse disc and/or reverse spring and plunger assy. (Sect. 5).

• Clean and re-lubricate motor mount bars, bell adjustment block and linkages on lever (Sect. 5).

C. Tiller stays in REVERSE when lever is reieased-

• Lubricate motor mount bars, belt adjust ment block and linkages on lever (Sect. 5).

• Check adjustment of reverse spring and plunger (Sect. 5). If problem persists,

contact Technical Service Department.

D. Lever sticks in FORWARD-

• Lubricate motor mount bars, belt adjust ment block, and linkages on lever (Sect. 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 shifi, or sticks in FAST or

SLOW wheei gear positions-

Engine won't start

X X

Engine shuts off when Wheels/Tines/PTO Drive Lever is shifted into FORWARD

X X

S, ' ■ Lmka^e

■ i

Eccontnc

Connecting Rod I

Figure 5-43: Check connecting rod, shifting linkage and eccentric lever.

• Lubricate eccentric lever at rear of power

unit transmission (Figure 5-43). If rust is present, use penetrating oil and work eccentric lever back and forth by hand.

• Lubricate linkage to Wheel Speed Lever to eccentric lever (Figure 5-43).

• Clutch inside transmission may be binding. Disconnect linkage from eccentric lever and

work eccentric lever by hand. If difficult or

impossible to move, it may be due to a damaged keyway on the wheel shaft. Contact Technical Service Department.

• Lubricate washers and castle nut on pivot of lever. If necessary, remove roll pin and back nut off 1/6th turn. Replace roll pin and

test the movement.

• Apply grease to zerk fitting (if so equipped) with grease gun until grease appears around washers.

* •

Engine does not shut off when Forward Interlock

Levers are released while

Wheels/Tines/PTO Drive

Lever is in FORWARD

B. Lever shifts into FAST wheel gear, but not into SLOW wheel gear-

• Connecting rod at end of lever might be backwards, or bent in toward transmission housing and hitting it. Other shifting linkage might be bent. Straighten or replace linkage (Figure 5-43).

• Clutch inside transmission may be binding (Problem 2-A).

C. Lever moves freely, but won't shih in or out ofgear-

• Eccentric shifting pin inside transmission may be broken (rare) or worn. Disconnect linkage from eccentric lever and try moving eccentric lever by hand (Figure 5-43). If lever moves easily, contact the Technical Service Department.

3 Wheels and Tines Wrai't Turn:

• Review operation of controls (Sect. 3 & 4).

• Check condition and adjustment of drive belt and reverse disc (Sect. 5).

• Mounting bolt for transmission drive pulley may be loose. (See Figure 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 (Sect. 3).

• Tines/PTO Clutch Lever may need adjust ment.

• Key for dog clutch on tine attachment main drive shaft may be missing, broken.

• Worm gears that drive the tine shaft may be worn.

Page 45

Appendix A: Troubleshooting

• Hardware holding tine holders to tine shaft may be missing or broken. To check, remove holders {Sect. 5).

• Key for bronze worm gear on tine attach ment main drive shaft may be missing or broken.

5 Tines Turn, But Wheels Won't:

• Check operation of Wheel Speed Lever (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 wheel speed.

6 Wheels And Tines Turn On Top Of Ground, But Stq) Or Hesitate In Soil:

• Drive belt may be loose (Sect. 5).

• Mounting bolt for transmission drive pulley may be loose (Figure 5-1).

7 Tiller Jumps While Tilling:

• Depth Regulator Lever set too deep for soil conditions. Use a shallower setting.

• Engine throttle speed too fast.

• Tiller wheel speed too fast for soil condi tions. Change to LOW belt range or SLOW wheel speed.

8 Depth Regulator Lever Difficult To Move:

• Lubricate spring assembly and depth

adjustment bar (Sect. 5).

• Check for bent depth adjustment bar.

9 Wheel And Shaft Move Out To One Side:

• Snap ring on wheel shaft may be

dislodged. 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 (Sect. 5).

11 Tine Holder Bolt Breaks Or Loosens:

• Earlier models have tine holder keys.

Check that keys are in keyways of line shaft. Without key in holder, left-side tine bolt will

lighten and break; right-side bolt will loosen

(Sect. 5).

12 Poor Traction:

• Bar tread tires, tire chains, or wheel

weights may be needed.

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. Spark plug wire loose or damaged. Spark

plug worn or fouled.

Engine under excessive work load. Use

SLOW wheel speed and LOW belt range.

Throttle cable may be loose or misad-

Justed.

Verify that engine isn't running with choke

partially engaged.

*Check Carburetor adjustment. * 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 overfilled

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 control not set properly. *Spark plug worn or fouled (weak spark). *Air cleaner restricted with dirt and/or oil. "Throttle cable adjustment. Engine throttle lever not free to move

through its full operating range.

Throttle wire and its linkage are binding, 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 control improperly set. "Water or dirt in fuel, and /or fuel system. "Spark plug fouled or worn. Spark plug

wire loose or damaged.

"Carburetor may need adjustment. "Air filter clogged with oil or dirt.

Carburetor float faulty (or float valve leaking)- if so, lap side of bowl lightly with handle of screwdriver (or similar object).

• Stale fuel clogs carburetor, and valves. Drain old fuel and add new fuel.

• "Fuel tank shut-off valve (if so equipped) not in fully Open position.

• On Briggs & Stratton engine, On/Off switch not in ON position.

Elecftic Start Engines Only:

• Electrical connections loose or shorted to metal frames, brackets or covers (Sect. 5).

• Battery discharged (Sect. 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 m Section 5.

• 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.

• Check oil level for correct amount.

18 Engine Overheats

• Clean the engine cooling fins, shroud and covers (Sect. 5).

• Check for broken flywheel fins (under engine shroud). See Authorized Engine Dealer.

19 Engine Runs Erratically:

• Water or dirt in gasoline or carburetor.

• Carburetor may need adjustment. See Engine Owner's Manual.

• "Spark plug fouled or dirty. Spark plug

wire loose or damaged.

• "Loose or cracked carburetor.

• Governor linkage not adjusted properly 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 Owner's Manual.

• Tilling depth is possibly too deep. To correct, tower the depth regulator lever.

• Possible worn tiller worm gear or loose drive shaft.

21 Key Switch Will Not Start The Engine

• Check battery terminals for corrosion (Sect. 5).

• Discharged battery (Sect. 5).

• Defective solenoid.

" See Engine Owner's Manual or contact an authorized engine dealer for Information.

Page 46

Appendix B: Attachments & Accessories

Troy-Bilt® PTO Chipper/Shredder

The Troy-Bilt® PTO Chipper/Shredder provides a convenient, easy means of cleaning up unsightly brush piles and other organic matter on your property, w/ith the added bonus of providing an unending supply of useful wood chips, mulch and compost for your landscaping and gardening needs.

The unit connects quickly to your tiller and goes wherever your tiller can go. The swivel wheel on the back of the unit rotates for extra maneuverability. When you've finished your chores, the Chipper/Shredder stands by itself on its own built-in stand.

The PTO Chipper/Shredder can chip

limbs, stalks and vines up to 3" in diameter, and can shred the same materials up to 1/2" in diameter. The unit also handles all manner of organic material including lumber, leaves, grass, weeds, brush, paper and sod.

Troy-Bilt® PTO Log Splitter

The Troy-Bilt® PTO Log Splitter provides you with a convenient and easy means of splitting about a half a cord of wood per hour when working alone. When connected to the PTO Power Unit, the tiller's engine runs the splitter’s hydraulic pump, providing you with 13 tons of steady, unhurried and predictable splitting force.

As an added benefit, the power-driven mobility provided by the PTO Power Unit allows you to move the splitter to and from your wood pile, over to a neighbor's place, or along the woodpile to a fresh supply of logs.

Features include a 15 second splitting cycle: can handle log sizes up to 26" long; a two-stage hydraulic pump that automat

ically shifts into low gear to provide fourtimes greater pressure when needed: slim-cut wedge design for splitting green, stringy wood; and an auto-control valve for automatic return stroke.

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".

Hiller/Furrower Attachment

The most popular attachment because it

does so many jobs. 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 attachment. Hooks quickly to the

Hiller/Furrower attachment- eliminates 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"-to-

49YY, letting you vary the width between

rows to suit the crop you're planting.

Tire Chains

Chains provide extra traction when snow

plowing, 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

standard-type tow hitch so it can tow

many kinds of equipment.

V-Sweep Cultivator

The V-Sweep Cultivator is a specialized tool designed for between-row crop culti vation. Instead of stirring the soil, it slices through just below the surface to eliminate practically any weeds in its path.

The Sweep mounts easily to the optional Tow Hitch Attachment at the rear of the PTO Power Unit. The blade is made of high carbon, heat treated steel and measures 2" wide (overall wing span is

20'j.

The unique way the Sweep works, skimming alongjust underneath the soil's surface without turning the soil over, makes this the ideal tool for use in dry, dusty conditions where it is important to keep soil disturbance to a minimum. And, because of its 20" wide cutting path, it does an effective cultivation Job at a fast speed.

The Sweep's natural shallow cultivation helps to prevent weed seeds from being brought to the soil's surface. This shallow cultivation feature also means there's less chance of damaging the roots of your vegetables. For deeper or more shallow cultivating, the blade depth can be changed with a simple adjustment..

Wheel Weights

Help increase traction by putting extra weight directly on the wheels. They reduce bucking and jumping when deeptilling 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 itself or receive it as one of the components if you order the combination Dozer/ Snow Blade attachment. Protects the engine from damage by wrapping around and protect ing many of the engine components. 1" diameter, high-strength steel tubing.

Page 47

MODELS 12089, 12090, 12204

Parts List

FORWARD INTERLOCK SYSTEM

REF PART No. No. DESCRIPTION QTY.

1 2552 Engine Wire Harness Assy-forward

interlock system (Incl. one red and one black wire, plug con

nector, neutrai switch and PVC tubing. Parts not available

separately.....................................

REF No.

2 9971 Lockwasher-external tooth, 7/16"......1

3 1186246 Nut-hex, 7/16"-20................................. 1

6 9205 Clip-for plug connector

7 9202 Tie-plastic........

8 2551 Handlebar Wire Harness Assy-

PART

No. DESCRIPTION QTY.

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

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

(see page 48, Ref. No. 20)

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

1 1

Page 48

Parts List

MODELS 12089, 12090, 12204

HANDLEBAR ASSEMBLY

REF No.

2 9119

3 9120 4

5 1186233

6 1900854001

7 1900856001

8 1900857001

10 1900858001 11 2704

12 13 2715 14 9547 15 1186389

PART

No. DESCRIPTION QTY.

9548

1881

1900855001

9125

Boit-Hex hd., flanged self-locking

Grades, 1/2-13x3-1/2"

Knob-handlebar height adjustment

(Incl. Ref. No. 3) Ring-retaining (tolerance ring) Stud-handlebar height adjustment

(Incl. Ref. No.'s 2, 3 and 5)........ 1

Nut-hex, 1/2"-13.................................. 1

Clamp-left, handlebar height

adjustment..

Ratchet-left, handlebar height

adjustment

Ratchet-right, handlebar height

adjustment

Clamp-right, handlebar height

adjustment.. Base-handlebar mounting Handlebars-(lncludes two of each

Ref. Nos. 12,17 and 28 and one

Ref. No. 13)

Grip-handlebars.................................... 2

Deca l-operator control pane I Bolt-curved hd, GR5,1/4-20 x 2".. 1 Nut-hex, flanged self-locking, whiz

lock, 1/4"-20.................................. 1

.................................... 1

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

.................................... 1

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

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

....

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

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

...........

....... 1

VIEW “A’

REF PART No. No. DESCRIPTION QT\

16A

1909286

16B

9650

1900763 9202

18 19 9219 Plug-wire harness retainer

20 2551 Handlebar Wire Harness Assy-

9250

9385 23 2543 24 1186009 Screw-pan head, 10-24 x 1/2",

24A

9733

25 2546

9199 Pivot Pin-forward interlock lever... 2

26 27 9514 Retaining Ring-klip ring-forward

9387 Return Spring-fwd interlock lever. 2

Throttle Control & Cable-8HP

Briggs & Stratton engine only (also see Ref. No. 24A)

Throttle Control & Cable-8HP

Kohler engine only Decal-Forward Interlock Lever

Tie-plastic ........................................

forward interlock system...

Handlebar Switch-forward

interlock system Lock Pin-handlebar switch. Switch Housing-handlebar switch. 2

thread-forming

Screw-phi Hips head, 10-32 x 1/2",

thread-forming

Lever-forward interlock......

interlock lever.

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

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

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

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

................2

..............................2

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

...............2

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

...........

1 2 2 2

Page 49

MODELS 12089, 12090, 12204

Parts List

DEPTH REGULATOR & TiNE HOOD ASSEMBLIES

REF No.

PART

No. DESCRIPTION QTY.

1100043

1113-1 3 1100243 4

1186231

1117A Bar-depth regulator (Ind. Ref.

6 9120 7

9119

8 1900867001

9 9552 Screw-thread-forming, 5/16-18x5/8"..........

1186329 Bolt-flanged hex hd..

Bolt-hex hd., 3/8-16x1-1/4" Bushing-19/64" (.300" Ig.)

Lockwasher-sprlnglock, 3/8".....

Nut-hex, 3/8"-16

No.'s6and 7)...........

Ring-retaining Knob-depth regulator (inci. Ref.

No. 6)....

Bar-drag, depth regulator

1/4-20x1/2"

5/16-18x3/4"...........

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

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

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

............................. 2

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

.........

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

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

................ 2

. 2 12 . 2

. 2 14 . 2

. 1 17 9534 Spacer........

. 1

. 1 21

REF No.

13 1904563

15 16 9308

18 19 1100069 20 9811 Locknut-1/4"-20

PART

No. DESCRIPTION QTY.

9929

1904543 2527

9384 Spring................................................. 1

1186328 Bolt-flanged hex hd..

Washer-flat, 5/16"

Hood-(incl. Ref. No. 14) Decal-hood, operating instructions.

Bracket-(incl. Ref No. 16)...................

Pin-roll (spirol) 1/4" x1"

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

Bolt-hex hd., 1/4-20x1"

....

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

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

. .

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

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

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

2 1 1 1 1 1

1 1

Page 50

Parts List

See Pac/e 60

i(=OR ELECT. START

SYSTEMS!

MODELS 12089, 12090, 12204

WHEEL SPEED LEVER, BELT DRIVE SYSTEM, ENGINES, WHEELS

Page 51

MODELS 12089, 12090, 12204

REF PART REF PART No. No. DESCRIPTION QTY.

WHEEL SPEED LEVER ENGINES AND ENGINE MOUNT

1 9362 Pin-spring, 1/8"

9838

9934 Washer-shoulder, 1/2".......................... 1

3 4 9932 5 2628

6 1902240

7 9317 Pin-cotter, 3/32" X1".......

8 1231

9 1033

1107382 Washer-flat, 5/16“, S.A.E

10 11

9338 12 1110107 13 1100046 Bolt-flanged hex hd., 3/8-16x1" 14

1100243 15 1107383 17

1113-1 18

9120

1920

20 2100

1915810

1100011

1919

23 24

9245 Belt-forward drive (no substitute

25 1483 Pulley-engine power take off 26 1138-1

1138-2

26 27

9303

Nut-castle (slotted), 1/2"-20

Washer-disc spring Lever-wheel speed shift (incl.

Ref No.’s 6 and 18)

Knob-wheel speed shift lever

Rod-connecting rod, wheel speed

shift lever...........................................

Swivel-connecting rod

Pin-hair cotter Locknut-hex hd., 5/16"-18

Lockwasher-spring lock, 3/8" Washer-flat, 3/8", S.A.E.

Bushing-spacer, 19/64" (,300"lg.)....

Ring-retaining (tolerance ring)

BELT DRIVE SYSTEM

Block- belt adjustment, 3-7/8" (incl. 45A 2709-02

Ref. No.'s 13,15, and 20)

Rod- belt adjust., 7" with for right side of tiller...........

measuring gauge

Decal- engine stabilization, for

Briggs & Stratton engines Bolt-hex hd., 3/8-24x1-1/2" Disc-reverse, (incl. Ref. No. 19)

due to extra strength required)

Shim-engine pulley, 1/16" As Req'd Shim-as above, 1/32" As Req'd Key-engine pulley, 3/16"sq. x 2-1/2" 1

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

.........

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

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

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

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

....

...

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

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

.....

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

..........

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

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

..........

..............41

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

..........

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

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

........

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

No. No. DESCRIPTION QTY.

28 1100045

2 32 9572

1 34 1 1

1 starting system.)............................ .. 1

1 1 Electric start (has key switch

1 starting system)............................. .. 1

1 38B 5 5 7

1 1

1034

9147 Plug-thread protector, red plastic. ... 2

1100242 Lockwasher-spring lock, 5/16"

1916274001 Mount- engine to tiller

43 45

46 1902020 Cap-wheel hub

1904565

9322 Pin- roll, 5/16 X 1-1/2 2709-01

Parts List

Bolt-hex hd., 5/16-18x1", Grade 5.. ... 2

Bar-engine mounting..........

Bolt-hex hd., 5/16-24x1-1/8"

8HP Briggs & Stratton Engine-

Recoil or electric start. (Electric start requires key switch

10HP Briggs & Stratton Engine-

Decal-hot surface safety warning.. .. 1

WHEEL & TIRE ASSEMBLIES

**Wheel & Tire Assy- bar tread,

left side, 4:80 x 8" tubeless tire with valve stem, on one-piece

steel wheel...................................

**Wheel & Tire Assy-bar tread.

right side. Same as above but

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

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

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

..........

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

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

...........

... 2

... 4 ... 4 ... 1

.. 2

.. 1

.. 1 .. 2

Contact an authorized engine dealer, Troy-Bilt dealer or the Factory for replacement engine

information. Contact an authorized engine dealer for engine service or parts. Refer to the engine name plate for engine model and type information.

For correct traction and directional control. Bar Tread Tires should be mounted on the tiller so the closed end of the "V" in the tire tread on top of the tire faces forward.

Page 52

Parts List

MODELS 12089, 12090, 12204

POWER UNIT TRANSMISSION ASSEMBLIES

Page 53

MODELS 12089, 12090, 12204

Parts List

REF No.

1 1186299

3 2263 Detent Plate-tines/PTO clutch lever

7 1186329

11 9362 Pin-spring, 1/8".................................. 1

13 14 9932 15

16A

17 18 1100045

19 1186230 Nut-hex, 5/16"-18

22 23 1186393 Nut-hex, flange locknut, 3/8"-16... 24 1902004

26 27

PART

No. DESCRIPTION QTY.

TRANSMISSION COVER & SHIFT LEVER

BRACKET ASSEMBLIES

Bolt-hex hd„ #10-32x3/8",

self-locking flange

9463

1900758

1186347 Bolt-flanged hex hd.,

1107382 1900870001 Bracket-shift levers (incl. Ref. 39 50027 Washer-flat, hardened shoulder

9838 Nut-castle (slotted), 1/2"-20, call

9934 Washer-shoulder, 1/2"

—- Lever-wheel speed shift (see page 010" thick..................................As Reg'd

1900869001 Cover-power unit transmission.... 1

2566

1123

Knob-tines/PTO clutch lever.

tapered, plastic

(incI.Ref. No. 4)

Decal-operating instructions.

detent plate

3/8-16x1-1/2"

Bolt-flanged hex hd., locking flange. Grade 5

5/16-18x3/4", Grades............

Washer-flat, 5/16", S.A.E

No. 86)

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

Tech Service for tightening

instructions

Washer-disc spring

51, Ref. No. 5 for part number). 1

Cover-power unit transmission

(incl. Ref. No.'s 18,19, 20,21,22, 46

23 and 24)..........................

Gasket-transmission cover Bolt-hex hd., 5/16-18 x 1", Grade 5, 47 11601

(remove with care)

1901439 Spring-neutral plunger (remove bearing cups and two shoulder

with care)

1035 Plunger-neutral (remove with care) 48

(incl. Ref. No. 22)

1901440

Clip Ring-retains neutral plunger..

Bolt-hex hd., 3/8-16x1-1/2", 50 9309 Pin-roll (Spirol), 1/4x2"

threaded full length

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

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

...

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

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

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

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

.....

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

......

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

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

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

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

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

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

..........

TINES/PTO CLUTCH LEVER ASSEMBLY 52 9604 0-Ring-retaining plug

1900878001

1100804 2123

Lever-eccentric, tines/PTO clutch. 53

(also see Ref. No.'s 1, 2,3 and dia., .033" thick (on right side

4 listed above)

Bolt-hex hd., 1/4-20x1/2"...........

Bushing-tines/PTO clutch lever

eccentric shaft

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

REF No.

29 2461 Eccentric-shaft, tines/PTO clutch

30 9911

1 DRIVE SHAFT ASSEMBLY

33 9500 Retaining Ring-external

1 34 1909139 Dog Clutch-power unit

35 9301

1 37 9944 1

1 1-1/4".....

40 1186310

43 1 44 1124-2 2

45 1224-3 Shim-as above, .005"...............As Reg'd

1 1 cup sold as set only

1 integral worm, plus two pressed1

1 49 9517 1

1 PINION SHAFT ASSEMBLY

1 only one #1132-1 shim is also 1 used between bearing and washer

1 Reg'd

PART

No. DESCRIPTION QTY.

9516 Retaining Ring-(snap ring).

external..

lever

Lockwasher-hi-collar, 1 /4"............ 1

9672 Screw-socket hd., 1/4-20 x 3/8"... 1

Key-3/16sq. x 1".........

1100004 Bolt-hex hd., 5/16-24 x 3/4", self-

Washer-disc spring (concave)......

2107 Pulley-transmission drive, cast iron 1

Bolt-hex hd., 1/4-20 x 3/4", front

bearing cap 1900879001 Cap-front bearing 1983632 Seal-oil, front bearing cap

Gasket-front bearing cap

1224-1

1224-2

1224-4 1714 Bearing & Cup-tapered cone roller

9617

1060A Plug-retaining, pinion bearing (inci.

1132-1 Shim-retaining plug, 1-1/64" inner

Shim-front bearing cap,.

Shim-as above, .030"

Shim-as above, .062"

bearing with cup (race). Cone and

Shaft-main drive, power unit. Incl.

on cone roller bearings, two

washers. Seal-oil, drive shaft, rear Retaining Ring-(snap ring), internal

Ref. No. 52)

Ref. No.'s 54 & 55)

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

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

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

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

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

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

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

.......

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

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

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

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

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

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

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

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

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

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

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

As Reg'd

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

......

1 1 3

1 1

3 1 1 1

1 1

..1

2 2

Page 54

Parts List

MODELS 12089, 12090, 12204

POWER UNIT TRANSMISSION ASSEMBLIES

(Continued from page 53)

Page 55

MODELS 12089, 12090, 12204

Parts List

REF No.

PART

No. DESCRIPTION QTY.

(continued from page 53)

PINION SHAFT ASSEMBLY

1132-2 Shim-same as 1132-1, .062"

53 1132-3

54 9404 55 1126 56 1222 Stem Pinion-slow speed gear &

57 9502 Ring-retaining, external 58 2656 59 9300 Key-3/16"x5/8"

1233

Shim-same asl 132-1, .010" ....

Bearing-ball, pinion shaft

Washer-pinion shaft.........................

shaft

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

Worm Gear-bronze, wheel drive..

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

Gear-fast speed pinion ....

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

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

....

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

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

Req'd

Req'd 73

71 9307 72 1900880001 Lever-eccentric, wheel speed

2 74 1442

2 shifting .........................................

75 1 shifting 1 76 1441 1

1 TRANSMISSION HOUSING

1 78

WHEEL SHAFT ASSEMBLY

9621

61 62

9511

63 1165-1 Shim-wheel shaft, 1-1/64" inner 79

1165-2

63 1165-3

1165-4

63 1165-5 Shim-same as above, .005" thick As

1086

65 1878

9357 Key-HIPro, 1/4" X1-3/4"

66 67

1223 1232

1237

69 70 1112 Pin-clutch guide, 1/4" diameter...

Seal-oil, wheel shaft Retaining ring-external

dla., .062" thick...

Shim-as above, .030" thick

Shim-as above, .015" thick

Shim-as above, .010" thick

Bushing-bronze, wheel shaft connector (see page 47}..

bearing.......................................... 2 86

Shaft-wheel, 15-5/8", (Incl.twoof

Ref. No. 62 and one Ref. No. 66) 1

Gear-slow speed, wheel drive. Gear-fast speed, wheel drive Dog Clutch-wheel drive

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

....

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

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

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

.......

......

.......

......

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

.........

.....

......

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

2 ordering)......................................

Req’d MISCELLANEOUS PARTS

As 80 9560

Req’d

Req’d 83

Req’d

84 9122 Plug-red plastic, thread protector. 1

85 9205

1 1 1 1 3

REF No.

PART

No. DESCRIPTION QTY.

ECCENTRIC SHAFT ASSEMBLY

9522

2712

2250

9359 Pin-alignment

9928

2126

1105620

1900759

Pin-roll, 3/16" X 1-1/4" (spirol)

shifting .........................................

Seal-oil, eccentric shaft Pin-eccentric shaft, wheel speed

Eccentric Shaft-wheel speed

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

Spring-eccentric shaft

Housing-power unit transmission

(Incl. Ref No. 79). Empty housing

without covers, shafts, gears.

seals, etc. (Call Factory before

Bolt-hex hd„ 1/2-13 x 2" Grade 5. 2 Washer-disc spring (concave).

domed side faces bolt head...........

Post-with threaded hole for Ref

No. 80...........

Plug-pipe, 1/4"...

Clip-forward Interlock system plug

Decal-forward interlock wire

harness..........................................

.....

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

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

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

.....

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

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

.............1

.........

1 1

2 2

Page 56

Parts List

MODELS 12089, 12090, 12204

TILLER AHACHMENT TRANSMISSION ASSEMBLIES

See Note 1

NOTE 1; THESE SCREWS HAVE A SPECIAL SEALING DESIGN

THAT CM NQI BE REUSED WITHOUT RISKING THE LOSS OF TRANSMISSION OIL. IF THESE SCREWS ARE LOOSENED OR REMOVED, THEY MUST BE REPLACED WITH NEW HARDWARE.

Page 57

MODELS 12089, 12090, 12204

Parts List

REF No.

1 1915087

2 3 1129-1

4 1901972 5 6 1901976

7 1104 Key-tiller tine shaft, woodruff key. 1 8 97073

9 9500 Retaining Ring-external 10 1909138 11

12 2127 Spring-dog clutch............................... 1 pressed-on sleeve in front of

13 1138-1 14 1915089

15 16

PART

No. DESCRIPTION QTY.

Screw Kit, includes five (5)

1/4"-20 X 5/8" self-sealing thick

screws................................... As Req'd

20873

1129-2

97074 Ball Bearing.............................. 2 19 11602 Shaft-main tiller drive (incl. an

9301

1900881001 Cap-rear bearing........

1124-2 Gasket-rear bearing cap

Cover-tiller housing Gasket-tiller housing cover, .010". As 17

thick

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

Gasket-same as above, .030" As

thick

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

Shaft-tiller tine................................... 1 18

Worm Gear-bronze, tiller tine

shaft............................................... 1

Seal-oil, tiller tine shaft...................... 2 one shoulder washer

TILLER DRIVE SHAFT ASSEMBLY 21 9517 Retaining Ring-internal..

Dog Clutch-tiller drive shaft Key-3/16"x1".

Shi m-dog c lutch, 1 /16"(.62") th ick.. 1 housing). Empty housing Screw Kit, includes three (3) without shafts, gears, seals.

1/4"-20 X 7/8" self-sealing dipstick, etc. Cali Factory

screws..................................As Req'd

....

............. 1 thick.........

Req'd thick

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

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

....

....................... 1

............... 1 24 1909157

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

1 TRANSMISSION HOUSING AND DIPSTICK

REF No.

17 1224-1 Shim-front bearing cap, .010"

17 1224-2

17 1224-4

23 1902000

PART

No. DESCRIPTION QTY.

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

Shim-same as above, .030" As

...................................Req'd

1224-3 Shim-same as above, .005" As

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

Shim-same as above, .062"

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

1714

9617 Seal-oil, drive shaft, front............... .. 1

Bearing & Cup-sold as set only.

integral worm gear, plus two

pressed-on cone roller bearings.

two bearing cups (Ref. No. 18) and

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

................. 1

Housing-tiller attachment (incl.

before ordering

Dipstick-oil, tiller attachment.....

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

..Req'd

As ..Req'd .. 2

.. 1

.. 1 .. 1

Page 58

Parts List

MODELS 12089, 12090, 12204

BOLO TiNE ASSEMBLIES

Page 59

MODELS 12089, 12090, 12204

Parts List

REF No.

PART

No. DESCRIPTION QTY.

STANDARD TILLING TINES

1 1901975001 Tine Hoider-weided Steel, fits

left or right sides.

2 1982612 Bolt-hex hd., 3/8-16x2"

6 1270-1A Bolo Tine-single, left hand. Used

on left and right side tine assy.

Tine is stamped either "EL" or

"AL". (Incl. two each of Ref No.'s 8 and 10)

7 1270-2A Bolo Tine-single, right hand. Used

on left and right side tine assy.

Tine is stamped either "ER" or

"AR". (Incl. same hardware as

Ref No. 6)..........

8 1100046 Bolt-hex hd., 3/8-16x1"............. 16

10 1110108 Locknut-hex, 3/8"-16........................... 20

— 1901118 Tine Replacement Kit-unassembled

(Incl. eight each of Ref. No.'s 6, and 7, sixteen each of Ref No.'s 8 and 10). Includes easy-to-

follow installation instruction. DOES

NOT INCLUDE tine holders, holder mounting hardware, or tine shaft keys

...

.............. 2

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

........................ 8

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

........................................ 1

REF No.

PART

No. DESCRIPTION QTY.

CUSTOM TILLING TINES

Special hard-faced, high-chrome carbon alloy tines that are thicker than standard Bolo Tines. These tines better resist the abrasive action of rocky, gritty or sandy soil as compared to standard Bolo Tines, and are especially suited for custom tilling or market gardening.

— 10802 Custom Tilling Tine Kit-(lncl.

eight each of Part #2475-1 and #2475-2 tines and sixteen

each of Ref No.'s 8 and 10...... 1

— 2475-1 Bolo Tine, Custom Tilling-single,

left hand

— 2475-2 Bolo Tine, Custom Tilling-single,

right hand ....................................... 8

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

Page 60

Parts List

ELECTRIC START SYSTEM

MODELS 12090, 12204

''^<+SPosi!lve

B«^t$ery Cable

To Engine Beae

2 ] I Slarter-^ol^noid

/ # Activate Wire (Red)

Page 61

MODELS 12090, 12204

Parts List

REF No.

2 97020 3

4 1186309 5

7 8

9 10 9566 11 1100241 Lockwasher-spring lock, 1/4" 12 1186229 13

14 96514

15 16 17 18 1186208 19 20 21 1186349 Bolt-flanged hex hd..

PART

No. DESCRIPTION QTY.

96515

9552

1901894

1904564 Battery Hold-down Clamp-with

1904548 1908112

96520 Key-ignition, one pair....................... 1

9092B

1100242 1186211 Nut-hex, 5/16"-24 1187559 Lockwasher-external tooth, #10..

96510 Cable-solenoid to starter motor.. 1 2571

Cabie-battery, positive and negative

terminals Boot-terminal insulating Screw-se If-th read i ng,

1/4-20x1/2"..................................

Bolt-hex hd., 1/4-20 x 5/8".

Wire-recharge (red) for Briggs

and Stratton engine (incl.

terminal and eyelet)

attached Key Switch Plate (incl. solenoid stud (red wire): wire

Ref. No. 7) Decal-ignition switch instruc Key Switch-includes two

ignition keys (Ref No. 9), one grounding screw (red wire): wire

lockwasher, and one mounting assy w/connector to engine ground

nut (lock-washer and nut not

available separately)........

Bolt-carriage, 1/4-20 x 1-1/4"

Nut-hex, 1/4"-20 Battery-12 volt, 30 amps., side-

vented, (incl. Ref No. 24,4,12)

Solenoid-starter, includes nuts and wires; plastic harness tube.

washers for cables and wires...

Lockwasher-5/16"

Nut-hex, #10-32

Battery Bracket

3/8-16x1-1/2"

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

....

...

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

...

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

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

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

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

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

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

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

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

..........

...........

..........

.........

REF No.

23 9265

2 24

3 25 1475

26 27 9202

3 2 28 1908118

1 1

2 4 wires (solenoid activate, battery

1 two green (ground)(shutoff)

30 1186389 2 32 1901202 Cable-ground, solenoid to engine 2 block 1

33 1186331 Bolt-flange lock, 5/16-18 x 1"

1 34

35 1917269

PART

No. DESCRIPTION QTY.

Tie-plastic, wire retaining......

9009

9224 Clamp-vent tube shield

1908117 Wire Harness-for Kohler engine.

1186391

Vent Tube-5/16" diameter .............. 1

Shield-vent tube, 1/2" diameter...

Tie-plastic.........................................

Wire Harness & Connecting

Terminal Assy-for Briggs & Stratton engines(available as complete assembly only). Incl. wire assy., w/connector to large

assy, w/connector to small solenoid stud (red wire): wire assy, w/connector to solenoid

shut-off (green wire); plastic protector tube; wire harness: connector: wire terminal

Incl. two receptacles; three red

recharge, and starter switch);

Locknut-hex, 1/4"-20

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

Nut-flange lock, 5/16"-18......

Ground Wire Assembly................ 1

..........

....

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

...

.........

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

..........

1 1 2

1 2

1 1 1

Page 62

Parts List

MODELS 12089, 12090, 12204

WHEELS/TINES/PTO DRIVE LEVER & YOKE ASSEMBLY

REF \lo.

2 3 4 2447 5 1177548 Lockwasher-external tooth, 5/16" 3 15 1186231 6 7 8 9

PART

No. DESCRIPTION QTY.

2574

1908156

1100799 Bolt-hex hd., 5/16-18x1-1/2".....,

1186230

1916265001 Roller Assembly.................................

1900468001 Yoke-left side 1900469001 Yoke-right side

Lever-Wheels/TInes/PTO Drive 10 1900860001

(Incl. knob w/decal)

Spring-clutch pawl

Bushing-3/8"

Nut-hex, 5/16"-18

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

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

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

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

........

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

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

1 1 11

3 13 1107383 Washer-flat, 3/8", S.A.E

3 16 1113-1

1 17 —- Knob-not avail, separately. See

1 Ref No. 1.......................................

REF No.

PART

No. DESCRIPTION QT\

Link-yoke pivot, left & right,

1100046 1100243

6-7/8" long Bolt-hex hd., 3/8-16x1"

Lockwasher-spring lock, 3/8"......

Nut-hex, 3/8"-16 Bushing-spacer, 19/64" (.300")...

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

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

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

. 2 . 6 . 6 . 6 . 2 . 6

Page 63

MODELS 12089, 12090, 12204

Parts List

BUMPER AHACHMENT

REF No.

3 1100245

4 5

PART

No. DESCRIPTION QTY.

12588 Bumper Attachment, Includes 6 1100242 Lockwasher - spring lock, 5/16".. 2

Ref. Nos. 1 through 11)

1910730001

1909765

1909748 1100799 Bolt-hex hd., 5/16-18x1-1/2".. 2

Brace - bumper bottom

Bolt-hex hd„ 1/2-13x1-1/2".... 1

Lockwasher - spring lock, 1/2"... 1 Spacer, 1/2"

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

.....

.........

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

REF No.

1 7 1 8

9 1100046 Bolt-hex hd., 3/8-16x1“

10 1100243

1 11 1448 Decal - for bumper

PART

No. DESCRIPTION QTY

1186230

1910731001

Nut-hex, 5/16"-18

Bumper wraparound

Lockwasher - spring lock, 3/8".... 2

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

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

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

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

Page 64

CUSTOMER SERVICE INFORMATION

Owner Registration Card

Please fill out and mail the enclosed owner

registration card. The purpose of this card is to register each unit at the Factory so that we can provide you with warranty benefits and

informationai bulletins.

Warranty Service

The warranty statement is included In the unit's literature

package.

Model/Serial Numbers

A Modei/Serial Numbers decal is located on top of the trans

mission. For ready reference, record these numbers in the

spaces beiow.

Date of Purchase:

Model/Serial Numbers:__________________________________

Authorized Dealer Information

If you purchased your unit from an authorized dealer, record the dealer's address and phone number below for ready

reference:

Dealer Name: Address:

Phone: _

______________________________________

__________________________________________

IMPORTANT:

Left and right sides of the unit are determined by standing

behind the unit, in the operator's position, and facing in the

direction of forward travel.

Customer Service and Technical Service

If you have questions or problems with the

unit, contact your local dealer or the Factory.

(When calling or writing, provide the

Model/Serial Numbers of the unit.)

Replacement Parts

Factory specified replacement parts are .. . available from your authorized dealer or directly from the Factory. When ordering parts, be sure to provide the following:

• Model/Serial Numbers of the unit. '

• Part number of the part needed.

• Part Description.

• Quantity needed. NOTE: All replacement parts must conform to our rigid quality

specifications. Although some replacement parts we provide may vary slightly in shape, color or texture from the original parts, any variations will not affect the fit or performance of these parts on your unit.

Engine Service and Repair

For engine service or repair, contact your nearest authorized engine dealer (look in the Yellow Pages under "Engines-Gasoline"). The engine Is warranted by the engine man ufacturer. Any unauthorized work performed i:; :... on the engine during the warranty period may void this warranty. For complete details on the engine warranty, refer to the engine owner manual.

NOTICE:

We reserve the right to change specifications, add

improvements or discontinue the manufacture of any of our

equipment without notice or obligation to purchasers of our

equipment.

For customer assistance, contact your nearest authorized deaier or:

GARDEN WAY INCORPORATED • 1 Garden Way • Troy, New York 12180

Customer Service: 1-800-437-8686 • Technical Service: 1-800-520-5520 • Parts Service: 1-8(X)-648-6776

• FAX: (518) 391-7332 • WEBSITE: vmw.troybllt.com Outside the United States and Canada:

Customer Service: (518) 391-7007 • Technical Service: (518) 391-7008 • Parts Service: (518) 391-7006 • FAX (518) 391-7332

1905444 Rev. A (01/00)

Printed in U.S.A.

We urge using only genuine replacement parts, which meet all the latest requirements. Replacement parts manufactured by others could present safety hazards, even though they may fit on the unit.

A WARNING

Troy-Bilt 12090 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Safety

Training

Preparation

Operation

Maintenance and Storage

Decals

Operating Symbols

WARNING

Assembly

A WARNING

Introduction

inspect Unit

STEP 1; Unpacking Instructions

Tools/Materials Needed for Assembly

STEP 2: Attach Handlebar

STEP 3: Move Tiller Off Shipping Platform

STEPS: Attach Wheels/Tines/PTO Drive Lever

STEP 6: Check Gear Oil Levels

STEP 7: Add Motor Oil to Engine

STEP 8: Attach Engine Throttle Lever and Cable

A WARNING

STEP 9: Adjust Air Pressure in Tires

ASSEMBLING THE ELECTRIC START SYSTEM

STEP 1: Activating and Charging the Battery

À DANGER

A DANGER

A WARNING

A DANGER

STEP 2: Connect the Wire Harness Receptacle

STEP 3: Installing the Battery

A DANGER

A DANGER

A DANGER

STEP 4: Install the Battery Cables

3 Features and Controls

A WARNING

Introduction

PTO Attachments Feature

Wheels/Tines/PTO Drive Lever

Forward Interlock Levers

Wheel Speed Lever

Tines/PTO Clutch Lever

Depth Regulator Lever

A WARNING

Handlebar Height Adjustment Lever

A WARNING

Engine Throttle Lever

Keyswitch Starter

Engine Controls

A WARNING

4 Operation

A WARNING

INTRODUCTION

Break-In Operation

Starting and Stopping the Engine

A DANGER

A CAUTION

Operating the Tiller

A CAUTION

A DANGER

A WARNING

Loading and Unloading the Tiller

Changing Speed Belts

A WARNING

A WARNING

Choosing Wheel and Tine Speeds

Tilling depths

Avoid tilling wet, soggy soil

A WARNING

Avoid making footprints

Suggested tilling patterns

Tilling on slopes

A WARNING

A WARNING

A WARNING

PTO POWER UNIT