Troy-Bilt 12180 User Manual

Model
12180
Owner’s Manual
BRONCO
TM
5 HP
Model Tiller
Safety
Controls
Operation
Maintenance
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GARDEN WAY INCORPORATED
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Table of Contents
SECTION 1: SAFETY ........................................... 3
Safety Decals .................................................................... 5
SECTION 2: ASSEMBLY ....................................... 6
Attach Handlebar............................................................... 7
Move Tiller Off Shipping Platform...................................... 7
Install Forward Clutch Cable.............................................. 8
Install Reverse Clutch Cable .............................................. 9
Check Level of Transmission Gear Oil................................ 9
Add Motor Oil to Engine..................................................... 9
Check Hardware for Tightness........................................... 9
Check Air Pressure in Tires................................................ 9
SECTION 3: FEATURES & CONTROLS........................ 10
Wheel Drive Pins ............................................................... 10
Forward Clutch Bail............................................................ 11
Reverse Clutch Control...................................................... 11
Depth Regulator................................................................. 12
Handlebar Height Adjustment............................................ 12
SECTION 4: OPERATION ...................................... 13
Break-In Operation............................................................. 13
Starting and Stopping the Engine...................................... 13
Operating the Tiller............................................................ 14
Tilling Tips & Techniques .................................................. 16
Power Composting............................................................ 18
Loading and Unloading the Tiller....................................... 18
SECTION 5: MAINTENANCE .................................. 19
Required Maintenance Schedule........................................ 19
Tiller Lubrication................................................................ 20
Check for Oil Leaks............................................................ 20
Check Hardware................................................................. 20
Transmission Gear Oil Service........................................... 20
Bolo Tines.......................................................................... 21
Checking and Adjusting Forward Drive Belt Tension.......... 22
Forward Clutch Bail Adjustment......................................... 23
Checking and Adjusting Reverse Drive Belt Tension.......... 23
Engine Oil Service.............................................................. 23
Check Hardware................................................................. 23
Engine Service................................................................... 24
Off Season Storage............................................................ 24
Specifications.................................................................... 25
Troubleshooting................................................................. 26
Customer Service Information ............................... 27
Dear Owner: You now own one of the finest rear-tine rototillers available.
Your new tiller allows you to till and cultivate your garden with ease, and accomplish dozens of other property man­agement projects as well. Your tiller is famous for its ruggedness, performance and high-quality engineering. We know you’ll enjoy using it.
Please carefully read this Manual. It tells you how to safely and easily 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 Page 27 of this manual).
We want to be sure that you are completely satisfied at all times.
NOTE: Be sure to fill out and return the Warranty Registra­tion Card that was supplied with this Manual.
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
WARNING
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.
MODEL CERTIFIED BY
INDEPENDENT LABORATORY
ANS B71.8- 1996 SAFETY STANDARD
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OUTDOOR POWER EQUIPMENT INSTITUTE
See Page 27 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
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.
3
Training
1. Carefully read this Owners Manual, the separate Engine Owner’s Manual, and any other literature you may receive. Be thoroughly 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. Be sure all tiller controls are released and both wheels are in the Wheel Drive position 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.
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 abnor­mally, stop the engine, disconnect the spark plug wire and prevent it from touching the spark plug, and check immediately 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, adjust­ments or inspections.
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 internal 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.
7. Take all possible precautions when leaving the machine unattended. Stop the engine. Disconnect spark plug wire and move it away from the spark plug. Be sure both wheels are in the Wheel Drive position.
8. Before cleaning, repairing, or inspect­ing, 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 acci­dental starting.
9. The flap on the tine hood must be down when operating the tiller.
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 wheels are in the Freewheel position. In the Freewheel
position, the wheels will not hold the tiller back and the revolving tines could propel the tiller rapidly, possibly causing loss of control. Always engage the wheels with the wheel drive pins in the Wheel Drive position before starting the engine or engaging the tines/wheels with the Forward Clutch control or the Reverse Clutch control.
14. Be aware that the tiller may unex­pectedly bounce upward or jump 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
tiller, using one hand on the han­dlebars. Relax your arm, but use a secure hand grip.
b. Use shallower depth regulator
settings, working gradually deeper with each pass.
c. Use slower 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 releasing whichever clutch control is engaged. Do not attempt to restrain the tiller.
15. Do not overload the tillers capacity
by attempting to till too deeply at too fast a rate.
16. Never operate the tiller 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 acces-
sories that are approved by the manufac­turer of the tiller.
20. Use tiller attachments and acces­sories when recommended.
21. Never operate the tiller without good visibility or light.
22. Never operate the tiller 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 all 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. Please remember: You can always stop the tines and wheels by releasing the Forward Clutch control or the Reverse Clutch control (whichever control you have engaged), or by moving the ignition switch and/or throttle control lever on the engine to OFF or STOP”.
26. To load or unload the tiller, see the instructions in Section 4 of this Manual.
27. Use extreme caution when reversing or pulling the machine towards you.
28. Start the engine carefully according to instructions and with feet well away from the tines.
29. Never pick up or carry a machine while the engine is running.
Maintenance and Storage
1. Keep the tiller, attachments and acces­sories 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.). Allow engine to cool before storing in any enclosure.
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 Owners Manual for instructions if the tiller is to be stored for an extended period.
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.
4
Section 1: Safety
Section 1: Safety
5
Decals
For your safety and the safety of others, various safety and operational decals are located on your unit (see Figure 1 below).
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 separate parts catalog for decal locations, part numbers and ordering instructions.
BR
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Forward Clutch Control
Operating Instruction
Reverse Clutch Control
Operating Instruction
Warning Messages
(on tine hood)
Tine Warning
(on right side of
hood flap)
Hot Surfaces/Moving Belts
Warning (on belt cover)
Starting Stabilization Message (on engine)
Figure 1: Location of Safety and Operating Decals
TO AVOID SERIOUS INJURY:
• READ THE OWNER’S MANUAL.
• KNOW LOCATIONS AND FUNCTIONS OF ALL CONTROLS.
• KEEP ALL SAFETY DEVICES AND SHIELDS IN PLACE AND WORKING.
• NEVER ALLOW CHILDREN OR UNINSTRUCTED ADULTS TO OPERATE TILLER.
• SHUT OFF ENGINE AND DISCONNECT SPARK PLUG WIRE BEFORE MANUALLY UNCLOG­GING 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.
WARNING
Operating Symbols
Various symbols (shown here, with word descriptions) are used on the tiller and engine. Your unit may not have all of the symbols.
FAST
SLOW
CHOKE
ON
CHOKE
OFF
STOP
STOP
REVERSE
R
ROTATING
TINES
BAIL
ENGAGED
BAIL
DISENGAGED
TILLER DIRECTION
LEVER DIRECTION
6
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.
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
1. Remove any cardboard inserts and packaging material from the carton. Remove any staples from the bottom of the carton and then lift the carton up and off the unit.
2. The tiller is heavy and you should not attempt to remove it from the shipping platform until the handlebars are installed. The procedure for removing the tiller is explained in Step 3 of these assembly steps. NOTE: Be careful not to severely bend any of the control cables on the unit.
3. Remove all unassembled parts and the separate hardware bag from the
carton. 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 (Fig. 2-1) to identify screws.
Loose Parts List
Qty. Description
1 Handlebar Support (see A, Fig. 2-2,
page 7)
1 Handlebar Assembly
(see K, Fig. 2-2)
The following items are in the hardware bag:
1 Slotted hd. screw, #10-24 x 2" 1 Hex hd. screw, 1/4-20 x 1-1/4" 6 Screw, 5/16-18 x 1-1/2" 2 Hex hd. screw, 3/8-16 x 3/4" 2 Flat washer, 3/8" 6 Split lockwasher, 5/16" 1 Hex locknut, 1/4"-20 6 Hex nut, 5/16"-18 1 Hex nut, #10-24 2 Hex locknut, 3/8"-16 1 Spring, cable (see W, Fig. 2-5,
page 8)
1 Bracket, forward clutch cable (see
P, Fig. 2-4, page 8)
1 Bracket, reverse clutch cable (see
BB, Fig. 2-8, page 9)
IMPORTANT: Motor oil must be added to the engine crankcase before the engine is started. Follow the instructions in this Assembly section.
NOTE: LEFT and RIGHT sides of the tiller are as viewed from the operator’s position behind the handlebars.
Tools/Materials Needed for Assembly
(1) 3/8 open-end wrench* (2) 7/16" open-end wrench* (2) 1/2" open-end wrench* (2) 9/16" open-end wrench* (1) Large adjustable wrench (1) Scissors (to trim plastic ties) (1) Ruler (for belt tension check) (1) Block of wood (to support tiller
when removing wheels) (1) Automotive-type air pressure gauge (1) Clean oil funnel (1) Clean, high-quality engine oil. Refer
to the Engine Owner Manual for
engine oil specifications and quantity
required. Do not overfill.
* Adjustable wrenches may be used.
Section
2
Assembly
Figure 2-1: To identify length of screw, place screw on template as shown and measure distance between bottom of screw head and tip of screw.
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Section 2: Assembly
STEP 2: Attach Handlebar
1. Attach the two legs of the handlebar support (A, Fig. 2-2) loosely to the inner sides of the tiller frame using two 3/8"-16 x 3/4" hex hd. screws (B), 3/8" flat washers (C) and 3/8"-16 hex locknuts (D).
2. Using the middle holes in the handlebar support brackets (E and F, Fig. 2-2), loosely attach the support brackets to the handlebar support (A) using two 5/16"-18 x 1-1/2" screws (G), 5/16" split lockwash­ers (H) and 5/16"-18 hex nuts (I). NOTE: If a support bracket will not move, loosen attaching screw (J) and nut.
3. Attach the handlebar assembly (K) to the handlebar support (A) using four 5/16"-18 x 1-1/2" screws (G), 5/16" split lockwashers (H) and 5/16"-18 hex nuts (I). Tighten the four screws securely.
4. Tighten all handlebar mounting hardware securely.
STEP 3: Move Tiller Off Shipping Platform
To move the tiller without the engine running, put the wheels in their FREEWHEEL position, as described below.
1. Use a sturdy block to raise one wheel off the ground.
2. Remove the hairpin cotter (L, Fig. 2-3) and wheel drive pin (M). Slide the wheel inward on the wheel shaft (N). Reinstall the wheel drive pin and hairpin cotter through the wheel shaft only (not through the wheel hub). Repeat with the other wheel.
3. Using the handlebar as a lever, roll the tiller to a flat area.
IMPORTANT: Before starting the engine, the wheels must be placed in their WHEEL DRIVE position (pins through wheel hubs and wheel shaft). This procedure is described in Wheel Drive Pins in Section 3.
Fig. 2-2: Attach handlebar.
G
G
H
A
I
H
F
E
I
H
I
B
C
G
K
J
D
Fig. 2-3: Wheel in FREEWHEELING position (wheel drive pin through wheel shaft only).
M
N
L
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Section 2: Assembly
STEP 4: Install Forward Clutch Cable
1. Place the forward clutch cable bracket (P, Fig. 2-4) on the handlebar support (A). Attach the cable bracket using a 1/4"-20 x 1-1/4" hex hd. screw (R, Fig. 2-4) and 1/4"-20 hex locknut (S). Tighten securely.
2. Carefully unwrap the forward clutch cable (the cable without a knob attached to it) from its shipping position and slide the thin cable wire (T, Fig. 2-4) into the slot in the cable bracket. Push the cable connector (U, Fig. 2-4) up through the hole in the bracket until the groove in the connector snaps into place on the bracket.
3. Insert the #10-24 x 2" slotted hd. screw (V, Fig. 2-5) down into the cable spring (W). The screw threads will extend down through the spring.
4. Thread the #10-24 hex nut (Z, Fig. 2-5) on the screw (V). Thread the hex nut about halfway up the screw.
5. Thread the screw (V) into the cable adjuster (X).
6. Hook the cable spring (W, Fig. 2-6) into the V-shaped bend in the forward clutch bail (Y).
7. Check for correct tension on the forward drive belt by taking two measurements of the cable spring as follows:
a. With the forward clutch bail (Y, Fig. 2-6) in
an open (released) position, measure and carefully note the overall length of the cable spring (W) by measuring from the outermost coil to the outermost coil.
b. Lift and hold the forward clutch bail
against the handlebar (see Fig. 2-7) and re-measure the overall length of the coils while the spring is under tension. The belt tension is correct if this second measure­ment is between 1/16" -to- 3/16" longer than the first measurement. If so, turn the hex nut (Z, Fig. 2-7) tightly against the cable adjuster (X) while preventing the adjuster from turning.
c. If the spring length is incorrect, you must
make an adjustment to the cable tension as described in Checking and Adjusting Forward Drive Belt Tension in Section 5. Incorrect tension on the forward drive belt can result in belt slippage (tension too loose) or unintentional tine movement when the clutch bail is in Neutral (tension too tight).
Fig. 2-5: Assemble spring and adjuster.
Z
V
X
W
Fig. 2-6: Install forward clutch cable.
Fig. 2-4: Installing forward clutch cable bracket and cable.
Fig. 2-7: To check forward belt tension, take two measurements of the overall length of the coils in the spring – first with the clutch bail open, then with the clutch bail closed against the handlebar.
1
2
3
4
5
P
R
S
T
T
Y
W
X
Z
U
A
Hold bail against handlebar while
taking second measurement of
spring
9
Section 2: Assembly
Fig. 2-8: Install reverse cable bracket and reverse clutch cable.
STEP 5: Install Reverse Clutch Cable
1. Remove the two pre-installed self­tapping screws (AA, Fig. 2-8) from the handlebars. Position the reverse cable mounting bracket (BB, Fig. 2-8) as shown and reinstall the two self-tapping screws.
2. Unwrap the reverse clutch cable (the cable with a knob and a large hex nut attached to it) from around its shipping position and route the cable (CC, Fig. 2-8 and Fig. 2-9) up to the cable bracket (BB, Fig. 2-8). Be sure that the cable goes beneath the Forward Clutch Bail as it is routed up to the cable bracket.
3. Insert the cable up through the slot in the cable bracket and position the threaded assembly as shown in Fig. 2-8. Make sure that the flat side of the threaded assembly is aligned with the flat side of the mounting hole. Slide the large hex nut (DD) up the cable and tighten it securely.
4. Fasten the reverse clutch cable to the left side handlebar with a cable tie (EE, Fig. 2-9).
5. Test the function of the reverse clutch cable by pulling the knob out and releasing it. The knob should return to its neutral position (resting against bracket) when it is released. If it doesnt, contact your local dealer or the factory for
technical assistance.
STEP 6: Check Level of Transmission Gear Oil
The transmission was filled with gear oil at the factory. However, you should check the gear oil level to make certain it is correct.
IMPORTANT: Do not operate the tiller if the gear oil level is low. Doing so will result in severe damage to the transmis­sion components.
1. Put the tiller on level ground. Pull the Depth Regulator Lever (FF, Fig. 2-10) back and then all the way up until the lowest notch in the lever is engaged.
2. Remove the oil fill plug (GG, Fig. 2-11) from the transmission housing and look into the oil fill hole. You will see the main drive shaft on one side of the hole.
3. The gear oil level is correct if the gear oil is approximately halfway up the side of the drive shaft.
4. If the gear oil level is low, add gear oil by referring to A. To Check the Transmis­sion Gear Oil Level in Section 5.
STEP 7: Add Motor Oil to Engine
The tiller is shipped without oil in the engine.
IMPORTANT: Do not start the engine without first adding motor oil. Severe engine damage will result if the engine is run without oil.
1. Refer to the Engine Owner’s Manual (supplied with tiller) for engine oil specifi­cations and capacities.
2. With the tiller on level ground, pull the Depth Regulator Lever (FF, Fig. 2-10) back and then slide it up or down as necessary until the engine is level.
3. Add motor oil as described in the Engine Owners Manual.
CC
AA
AA
BB
Flat Side
DD
Fig. 2-9: Route reverse clutch cable (CC) as shown. Attach with cable tie (EE).
B
RO
N
C
O
CC
EE
Fig. 2-11: Remove gear oil fill plug.
Fig. 2-10: Adjust Depth Regulator Lever.
FF
GG
4. Move the Depth Regulator Lever all
the way down until the highest notch is engaged. This places the tines in the travel position.
STEP 8: Check Hardware for Tightness
Check all nuts and screws for tightness.
STEP 9: Check Air Pressure in Tires
Use a tire pressure gauge to check the air pressure in both tires. Deflate or inflate both tires equally to 15-to-20 PSI (pounds per square inch). Be sure that both tires are inflated equally or the unit will pull to one side.
IMPORTANT: This completes the assembly steps. Before operating your tiller, make sure you read the following Sections in this Manual, as well as the separate Engine Owners Manual:
Section 1: Safety
Section 3: Features and Controls
Section 4: Operation
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