Troy-Bilt 12090 User Manual

Owner's Manual

PTO HORSE TILLER

Safety

Assembly

Controls

Operation

Maintenance

Parts List

Models

120898HP Standard

120908HP Electric

12204-10HP Electric

GARDEN WAY INCORPORATED

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 A manual and on the unit to alert you to

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

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

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...................................................................	5
Decals...................................................................................................	5
SECTION 2: ASSEMBLY .......................... ..............................	. 6
Step 1: Unpacking Instructions............................................................	6
Step 2: Attach Handlebar....................................................................	6
Step 3: Move Tiller Off Shipping Platform........................................	7
Step 4: Connect Forward Interlock Wire Harness............................	7
Step 5: Attach Whee!s/Tines/PTO Drive Lever...................................	7
Step 6: Check Gear Oil Levels..............................................................	8
Step 7: Add Motor Oii to Engine.........................................................	9
Step 8: Attach Engine Throttle Lever and Cable.................................	9
Step 9: Adjust Air Pressure in Tires.....................................................	9
Assembling The Electric Start System...............................................	10
SECTION 3: FEATURES & CONTROLS..........................................	13
PTO Attachments Feature.................................................................	13
Wheeis/Tines/PTO Drive Lever.........................................................	13
Forward Interlock Levers...................................................................	13
Wheel Speed Lever............................................................................	14
Tine/PTO Clutch Lever.......................................................................	14
Depth Regulator Lever......................................................................	14
Handlebar Heig ht Adjustment Lever................................................	14
Engine Throttle Lever........................................................................	15
Keyswitch Starter..............................................................................	15
Engine Controls.................................................................................	15
SECTION 4: OPERATION................................................................	16
Break-In Operation............................................................................	16
Starting and Stopping the Engine......................................................	16
Operating the Tiller............................................................................	18
Testing the Forward Interlock Safety System...................................	20
Loading and Unloading the Tiller......................................................	20
Changing Speed Beits........................................................................	21
Choosing Wheel and Tine Speeds.....................................................	22
Tilling Tips & Techniques...................................................................	23
PTO Power Unit.................................................................................	27
PTO Power Unit Operating Instructions...........................................	28
SECTIONS: MAINTENMICE .....................................................	30
Required Maintenance Schedule......................................................	30
Tighten Bolts and Nuts......................................................................	31
Tiller Lubrication...............................................................................	31
Transmission Gear Oil........................................................................	32
Adding or Changing Gear Oil.............................................................	33
Drive Belt Maintenance.....................................................................	35
Reverse Disc Maintenance................................................................	37
Bolo Tine Maintenance......................................................................	39
Tine Shaft Maintenance....................................................................	41
Tire and Wheel Maintenance...........................................................	41
Engine Oii Maintenance....................................................................	41
Air Cleaner Maintenance..................................................................	41
Throttle Cable Maintenance.............................................................	41
Ignition System Maintenance...........................................................	41
Spark Plug Maintenance...................................................................	41
Battery Care and Maintenance.........................................................	41
Storing your Tiller..............................................................................	43
Inspecting Forward Interlock Wiring System...................................	43
Testing the Forward Interlock Wiring System..................................	43
APPENDIX A: TROUBLESHOOTING.......................................	.....44
APPENDIX B: AHACHMENTS & ACCESSORIES........................	.....46
PARTS LIST ...................................................................	.....47
CUSTOMER SERVICE INFORMATHMU . . . . . . . . . . . . . .	B a c k Cover

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.

\ ' ^ h ^

'--------------------------

^

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.

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

Section1;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. DANGERBATTERIES 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.

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 sparkor 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.

Section1;Safety

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.

	A) WARNING; Hot Surfaces.	C) WARNING: Operating and
		Safety Instructions
	Top of the air cleaner housing.

U s

^ D) Power Unit

Operating

Instructions

F) Engine Stabilization.	B) WARNING: Engine Ignition.
Top of fuel tank.	Electric start models only.

Figure 1: Location of Safety and Operating Decals. (Briggs & Stratton engine shown)

Operating Symbols			^TOy	hi	IFI
Various symbols (shown here, with word
descripticns) are used cn the tiller and mgine.	FAST	SLOW	STOP	CHOKE	CHOKE
Your unit may not have all of the symbols.				ON	OFF

WARNING

TO AVOID SERIOUS INJURY:

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.

ROTATING

TINES

Section

2 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		(1)	Flat blade screwdriver
	damaged).		(1)	Scissors (to trim plastic ties)
	NOTE: Use the screw length template
			(1)	Tire pressure gauge
	(Figure 2-1) to identify screws.		(1)	Clean oil funnel
		L(H>se Parts List	(1)	Motor Oil. Refer to the Engine
				Owner's Manual for motor oil spec­
	Qty. Description
				ifications and quantity.
	1 Handlebar Assembly		(1)	4-1/2" high wood block (or other
	1 Wheels/Tines PTO Drive Lever
				sturdy block) to prop unit
		The following items
			* Adjustable wrenches may be used.
		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)

1Battery Vent Tube

2Keys

(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.		place screw on template as shown and
	NOTE: LEFT and RIGHT sides of the tiller		measure distance between bottom of screw
	are as viewed from the operator's		head and tip of screw.
	position behind the handlebars (unless		STEP 2: Attach Handlebar
	otherwise noted).
			IMPORTANT:	When	disassembling
	Tools/Materials Needed		handlebar assembly, keep		left-side clamp
			and ratchet separated from the right-side
	for Assembly
			clamp and ratchet.
	(1)	3/8" open-end wrench*	1. Disassemble the handlebar assembly.
	(2)	7/16“ open-end wrench*	To do this, remove the height adjustment
	(2)	1/2" open-end wrench *	lever by turning the lever in a counter­
			clockwise direction (Figure 2-2).
	(1)	9/16" open-end wrench *
	(1)	3/4" open-end wrench*

6

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.

Figure 2-2. Handlebar assembly.

■ ............... ....................

' B
A A ‘	.

■'a

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.

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.

Section2;Assembly

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.

Section2: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 2-10 Forward position; roller

(T) rests under the adjustment block (U).

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 2-11: 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.

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.

Section2:Assembly

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.

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.

AWARNING

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.

Figure 2-14: Engine Throttle Lever position and installation.

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 2-15: 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.

Section2: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 I S

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: ExternalFlush with water; EyesFlush with water for 15 minutes

and get immediate medical attention.

•Antidote: InternalDrink large quantity of water or milk. Follow with milk of magnesia, beaten eggs, or

vegetable oil. Call a doctor immedi­ ately.

ADANGER

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:

AWARNING

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.

10

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.

ADANGER

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

Section2;Assembly

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.

ADANGER

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.)

ADANGER

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.

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).

ADANGER

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

causing acid or electrical bums.

Figure 2-18: Battery mounting and venting assembly.

11

Section2: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.

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

Figure 2-19: Battery cable assembly.

12

Section

3 Features and Controls

AWARNING

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:	E- Depth Regulator Lever
A— WheelsITinesIPTO Drive Lever
B— Forward Interlock Levers	F— Handlebar Height Adjustment Lever
C- Wheel Speed Lever	G- Engine Throttle 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.

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.

13

Section3:FeaturesandControls

|||^||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.

AWARNING
To avoid	personal	injury,

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.

14

Figure 3-5

Section3:FeaturesandControls

AWARNING

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.)

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.

AWARNING

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.

15

Section

4 Operation

AWARNING

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.

AWARNING

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.

rr

.

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.

ADANGER

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.

16

Section4:Operation

Wheels/Tines/PTO

Drive Lever

Engine Throttle

Lever

				Forward
/ '				Interlock Levers
	$ '".Ây	'n
		? 1
		Wheel [;	/'	" Depth
		Speed '	f /\*
	CtJ ,	Lever /		Regulator
				Lever
Recoil Start Rope		- /
(at front of engine)

fines/PTO ' Clutch 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.

Figure 4~2: Tiller and engine controls.

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.

17

Section4: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.

18

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.

ACAUTION

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).

ADANGER

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.

AWARNING

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.

Section4:Operation

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.

ACAUTION

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 Leverthe 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.

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.

MM

Figure 4-5: Turning the tilier.

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

19

Section4: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.

AWARNING

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.

ADANGER

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.

t

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.

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