Troy-Bilt 12204-10HP User Manual
Owner’s Manual
PTO HORSE TILLER
Safety
Assembly
Controls
Operation
Maintenance
$4.50
Models
12089- 8HP Standard
12090- 8HP Electric
Parts List
12204-10HP Electric
GARDEN WAY INCORPORATED
(8HP model shown)
Dear Owner:
You now own one of the finest rear-tine tiiiers avaiiabie.
SECTION 1: SAFETY
Training
Your new PTO Horse Model tiiler 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 uped in this
manual and on the unit to alert you to
A
potential hazards. When you see this symbol,
read and obey the message that follows it.
SECTION 2: ASSEMBLY
Step 1: Unpacking Instructions
Step 2: Attach Handlebar
Step 3: Move Tiller Off Shipping Platform
Step 4: Connect Forward Interlock Wire Harness
Step 5: Attach Wheels/Tines/PTO Drive Lever.............................. 7
Step 6: Check Gear Oil Levels..................................................... 8
Step 7: Add Motor Oil to Engine.................................................. 9
Step 8: Attach Engine Throttle Lever and Cable
Step 9: Adjust Air Pressure in Tires
Assembling The Electric Start System
SECTIONS: FEATURES & CONTROLS......................................... 13
PTO Attachments Feature......................................................... 13
Wheels/Tines/PTO Drive Lever.................................................. 13
Forward Interlock Levers.......................................................... 13
Wheel Speed Lever................................................................... 14
Tine/PTO Clutch Lever.............................................................. 14
Depth Regulator Lever
Handlebar Height Adjustment Lever
Engine Throttle Lever............................................................... 15
Engine Controls........................................................................ 15
SECTION4: OPERATION....
Break-In Operation................................................................... 16
Starting and Stopping the Engine
Operating the Tiller.................................................................. 18
Testing the Forward Interlock Safety System
Loading and Unloading the Tiller............................................... 20
Changing Speed Belts
Choosing Wheel and Tine Speeds.............................................. 22
Tilling Tips & Techniques.......................................................... 23
PTO Power Unit
SECTIONS: MAINTENANCE
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
Tighten Bolts and Nuts........................................................... 31
Tiller Lubrication...................................................................... 31
Transmission Gear Oil............................................................... 32
Adding or Changing Gear Oil..................................................... 33
Drive Belt Maintenance............................................................. 35
Reverse D isc Mai ntenance
Bolo Tine Maintenance.............................................................. 39
Tine Shaft Maintenance............................................................ 41
Tire and Wheel Maintenance..................................................... 41
Engine Oil Maintenance............................................................ 41
Air Cleaner Maintenance
Throttle Cable Maintenance................................................ 41
Spark Plug Maintenance.......................................................... 41
Battery Care and Maintenance.................................................. 41
Storing your Tiller..................................................................... 43
Inspecting Forward Interlock Wiring System
Testing the Forward Interlock Wiring System
The engine exhaust from this product contains
chemicais known to the State of California to cause
cancer, birth defects or other reproductive harm.
APPENDIX A: TROUBLESHOOTING
APPENDIX B: ATTACHMENTS & ACCESSORIES
TABLE OF CONTENTS
....................................................................................
Preparation............................................................................... 3
Operation.................................................................................. 3
Maintenance and Storage........................................................... 5
Decals....................................................................................... 5
Keyswitch Starter..................................................................... 15
PTO Power Unit Operating Instructions
Required Maintenance Schedule
Ignition System Maintenance
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37
...44
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9
10
14
14
16
16
20
21
27
28
30
41
41
43
43
3
3
6
6
6
7
7
9
PARTS LIST ......................................................................... A7
CUSTOMER SERVICE INFORMATION ..............Back Cover
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.
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
b.
c. Keep matches, cigarettes, cigars,
d. Fill fuel tank outdoors with extreme
e. Replace ail fuel tank and container
f. If fuel is spilled, do not attempt to
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
designed for this purpose.
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.
pipes, open flames, and sparks
away from the fuel tank and fuel
container.
care. Never fill fuel tank indoors.
Use a funnel or spout to prevent
spillage.
caps securely.
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.
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
failing.
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
Section 1: Safety
8. Before cleaning, repairing, or inspect
f. Before contacting hard packed soil
ing, stop the engine and make certain all
moving parts have stopped. Disconnect
the spark plug w/ire and prevent it from
touching the spark plug to prevent acci
g. In an emergency, stop tines and
dental starting.
9. The flap on the tine hood must be
down when operating the tiller, unless
using the Hiller/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 tiller 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 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 han
dlebars. Relax your arm, 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.
15. Do not overload the tiller’s 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 accessories
that are approved by the manufacturer of
the tiller.
20. Use tiller attachments and acces
sories 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. PDISDN/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.
at the end of a row, reduce engine
speed and lift handlebars to raise
tines out of the soil.
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.
Antidotes:
External- Flush immediately with lots of
water.
Internal- Drink large quantities of water
or milk. Follow with milk of magnesia,
beaten eggs or vegetable oil. Call a
doctor immediately.
Eyes- Flush with water for 15 minutes.
Get prompt medical attention.
26. DANGER- BAHERIES PRDDUCE
EXPLDSIVE 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. When 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 tiller could tip forward,
exposing you to the tines (which should
be disengaged). Always use REVERSE
drive and back down ramps. To go up
ramps, use FORWARD drive and 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.
Section 1: Safety
Maintenance and Storage
1. Keep the tiller, attachments and acces
sories in safe working condition.
2. Check all nuts, bolts, and screws at
frequent intervals for proper tightness to
be sure the equipment is in safe working
condition.
3. Never store the tiller with fuel in the
fuel tank inside a building where ignition
sources are present such as hot water
and space heaters, furnaces, clothes
dryers, stoves, electric motors, etc.).
Allow engine to cool before storing in any
4. To reduce the chances of a fire hazard,
keep the engine free of grass, leaves, or
excessive grease.
5. Store gasoline in a cooi, well-ventiiated
area, safely away from any spark- or
flame-producing equipment. Store
gasoline in an approved container, safely
away from the reach of children.
6. Refer to the Maintenance sections of
this Manual and the separate Engine
Owner’s Manual for instructions if the
tiller is to be stored for an extended
period.
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.
A) WARNING: Hot Surfaces.
Top of the air cleaner housing.
F) Engine Stabilization
Top of fuel tank.
7. Never perform maintenance while the
engine is running or the spark plug wire is
connected, except when specifically
instructed to do so.
8. if the fuel tank has to be drained, do
this outdoors.
C) WARNING: Operating and
Safety Instructions
D) Power Unit
Operating
Instructions
B) WARNING: Engine Ignition.
Electric start models only.
Figure 1: Location of Safety and Operating Decais.
Operating Symbols
Various symbols (shown here, with word%
descriptions) are used on the tiller and engine.
FAST
Your unit may not have ali of the symbois.
A WARNING
• 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 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.
TO AVOID SERIOUS INJURY:
(Briggs & Stratton engine shown)
Kl
CHOKE
ON
SLOW
«TOM
STOP
w
CHOKE
OFF
ROTATING
TINES
Section
2
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.
Assembly
Factory if any items are missing or
damaged).
NOTE: Use the screw length template
(Figure 2-1) to identify screws.
Qty. Description
1 Handlebar Assembly
1 Wheels/Tines PTO Drive Lever
Introduction
Carefully follow these assembly steps to
correctly prepare your tiller tor 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 tor 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
1 Clutch Pawl Spring
1 Belt Adjusting Tool
2 Plastic Cable Ties
1 Curved Flead 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
2 Screws, 1/4-20x5/8
1 Battery Vent Tube
2 Keys
IMPORTANT: Motor oil must be added to
the engine crankcase before the engine is
started. Follow the instructions in this
Assembly Section and in the separate
Engine Owner’s Manual.
NOTE: LEFT and RIGHT sides of the tiller
are as viewed from the operator’s
position behind the handlebars (unless
otherwise noted).
Toois/Materials Needed for Assembly
(1) 3/8" open-end wrench*
(2) 7/16" open-end wrench*
(2) 1/2" open-end wrench*
(1) 9/16" open-end wrench*
(1) 3/4" open-end wrench*
Loose Parts List
The following items
are in the hardware bag:
(for battery terminals)
(for battery terminals)
(in ignition switch)
Flat blade screwdriver
(1)
Scissors (to trim plastic ties)
(1)
Tire pressure gauge
(1)
Clean oil funnel
(1)
Motor Oil. Refer to the Engine
(1)
Owner’s Manual for motor oil spec-
ifications and quantity.
4-1/2” high wood block (or other
(1)
sturdy block) to prop unit
* Adjustable wrenches may be used.
1
2-
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.
STEP 2: Attach Handlebar
IMPORTANT: When disassembling
handlebar assembly, keep left-side clamp
and ratchet separated from the right-side
clamp and ratchet.
1. Disassemble the handlebar assembly.
To do this, remove the height adjustment
lever by turning the lever in a counter
clockwise direction (Figure 2-2).
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.
Section 2: Assembly
FRONT
OF TILLER
Figure 2-2. Handlebar assembly.
Figure 2-3. Fully assembled handle
bars.
STEP 3: Move Tiller Off Shipping Platform
1. Set the Depth Regulator Lever
(A, Figure 2-4) to Travel position. Do this
by lifting the tiller by the handlebars, then
pulling straight back on the lever and
sliding down to the highest notched
setting.
2. Set the Wheel Speed Lever (B, Figure
2-4) to Freewheel position. To do this,
move the lever approximately halfway
between the Fast and Slow settings while
you rock the tiller forward and backward
until the wheels move freely.
3. Lift Handlebars high enough to clear
tiller tines and pull 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).
STEP 5: Attach
Wheels/Tines/PTO Drive Lever
1. Loosen the bolt (Figure 2-2) on the
handlebar base and swing the handlebars
out to the right side.
Figure 2-5. Forward Interlock Wire
Harness connection.
2. Remove both sets of nuts, star
washers, screws, and one bushing
(A, B, G, 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.
Section 2: Assembly
Remove the temporary screw (J, Figure
2-7) from the forward holes 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 all other hardware (Q, 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: Fully assembled
Wheels/Tines/PTO Lever assembly.
Figure 2-6: Illustration shows the yoke plates (H), nuts, washers, and
screws (A, E, B, F, D, G), bushing (C), and long and short links (I, J).
Figure 2-7: Drive Lever assembly.
Figure 2-8: Clutch pawl spring. Tilt
Wheels\Tines\PTO Lever fully
forward before installing spring.
X.-'^agup... »:'!.!
Figure 2-10 Forward position; roller
(T) rests under the adjustment
block (U).
Figure 2-11: Neutral position; roller
(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 ior complete information
on how to check and fill the transmis
sions.
Section 2: Assembly
IMPORTANT: Check gear oil level in both
transmissions after the first 2 hours of
STEP 8: Attach Engine Throttle Lever and Cable
new tiller operation, then every 30
operating hours thereafter. See Section 5
for instructions.
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.
To avoid electric shock from a short
circuit (electric start tillers only), never
allow the throttle cable to touch the
battery. Route cable below the battery,
on the outside of the battery holder.
To attach the throttle lever and cable:
Figure 2-12: Checking oii ievei on
Power Unit Transmission.
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)
Figure 2-13: Checking oil level on
Tine Attachment Transmission.
through the small hole in the throttle lever
bracket and into the handlebar. Tighten
the screw securely.
STEP 7: Add Motor Oil to Engine
1. Before adding motor oil, park the tiller
on level 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
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.
your tiller for detailed information on how
to add motor oil 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.
’-ST. ^
A WARNING
Figure 2-14: Engine Throttle Lever
position and installation.
Figure 2-15: Plastic Ties placement
on handlebars.
STEP 9: Adjust Air Pressure in Tires
For shipping purposes, the tires may be
overinflated. 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.
Section 2: Assembly
ASSEMBLING THE ELECTRIC START SYSTEM
The following steps explain how to activate, charge, and install the battery on electric start tillers. For your safety, follow all steps
and observe all accompanying safety messages. Section 5 contains other general battery maintenance and recharging instructions.
STEP 1: Activating and Charging the Battery
IMPORTANT: The battery is shipped dry.
It needs battery electrolytic fluid (batterygrade sulfuric acid). It must then be fully
charged with a battery charger before
use.
Adding electrolytic fluid to the battery and
charging the battery can be dangerous.
Electrolytic fluid contains acid that can
burn or blind you. Battery charging also
produces explosive gases.
To ensure that the battery is properly
activated and charged, you should review
these instructions with your battery
technician.
IMPORTANT: It is strongly recom
mended that you have the battery
activated and charged by a trained profes
sional (Troy-Bilt Dealer, service station,
farm equipment dealer, etc.), if you are
not experienced with these procedures.
A DANGER
Battery electrolytic tluid is
poisonous and burns severely.
Electrolytic fluid is a sulfuric acid
solution. Avoid spills or contact with
skin, eyes, clothing.
• To prevent accidents, wear protective
clothes, rubber gloves and shield
eyes with safety goggles when
working on or near the battery.
• Neutralize acid spills with a baking
soda and water solution. Neutralize
electrolyte container with same
solution. Then rinse with clear water.
• Antidote: External- Flush with water;
Eyes- Flush with water for 15 minutes
and get immediate medical attention.
•Antidote: Internal- Drink large
quantity of water or milk. Follow with
milk of magnesia, beaten eggs, or
vegetable oil. Call a doctor immedi
ately.
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:
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 clamp (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 hold-down clamp legs to
the battery bracket (C, Figure 2-16).
A DANGER
A WARNING
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 filler
caps (D) and Upper Level fill line (E).
6. Let battery stand for 30 minutes.
Check electrolytic fluid level in each cell.
Add more fluid, if needed. Do not overfill
battery - this could lead to flooding from
the cells during charging.
10
Section 2: Assembly
TO CHARGE THE BAHERY:
1. Use one of the three charging methods
described below 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 ceil caps. Always wear safety goggles
to protect your eyes when checking for
bubbles. A flashlight makes the inspec
tion easier, inspect all cells.
• 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 cell.
Top off any low cells with electrolyte
A DANGER
To Avoid Personal Injury or Property
Damage:
• Batteries produce explosive gases always keep sparks and tiame 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.
•
solution up to the “Upper” level line.
4. Securely replace all 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 keyswitch (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
• 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.
1. Carefully place the activated battery
back on the battery mounting platform
(C, Figure 2-18). Face the side of the
battery with the terminals posts and the
fill lines to the rear of the tiller. The
positive terminal (marked +) should be on
the left side of the tiller when standing
behind the handlebars.
A DANGER
To Avoid Personal 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 clamp (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 overtightened.)
A DANGER
Improper battery venting can cause a
battery to explode resulting in severe
personal injury. Be sure the vent tube is
not crimped, pinched, folded, or blocked
in any way.
Figure 2-18: Battery mounting and venting assembly.
3. To install the vent tube (E, Figure 2-
18), slide one end of the tube over the
vent fitting (F). Uncoil the tube and slide
the other end down into the black vent
tube shield (G).
A DANGER
Never jump start the battery with a
vehicle battery or charging system. This
may produce a battery explosion,
causing acid or electrical burns.
11
Section 2: Assembly
STEP 4: Install the Battery Cables
NOTE: The cable 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 cable
connector.
5. Make sure that the lower end of the
vent tube shield (U) is positioned in front
of the wheel shaft axle. Move it there if
necessary.
Figure 2-19: Battery cable assembly.
Assembiy is complete for electric start
tillers. See Section 3, Controls ior
information on tiller controls.
12
Section
3 Features and Controls
A WARNING
Before operating your machine,
carefully read and understand all
safety, controls, operating instructions
in this Manual, the separate Engine
Owner’s Manual and on the decals on
the machine.
Failure to follow these instructions can
result in serious personal injury.
introduction
This section describes the location and
function of the controls 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 feel confident with each of them.
IMPORTANT: Refer to the separate engine
manufacturer’s Engine Owner’s Manual
for information about the controls 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 nonpowered attachments. See Section 4,
PTO Power UnittoT 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.
Figure 3-1:
A- Wheels/Tines/PTO Drive Lever
B- Forward Interlock Levers
C- Wheel Speed Lever
D- Tines/PTO 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 NEUTRAL
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 NEUTRAL position.
£- Depth Regulator Lever
F- Handlebar Height Adjustment Lever
G- Engine Throttle Lever
IMPORTANT: Do not operate the tines or
any PTO attachment in REVERSE.
• NEUTRAL is this control’s normal non
operating position. The lever returns to
NEUTRAL when it is tapped out of the
FORWARD position or released from the
REVERSE position. NEUTRAL position
is between FORWARD and REVERSE
(Figure 3-3). Use this setting to stop
the wheels, tines or any PTO attach
ment.
IMPORTANT: Always shift to NEUTRAL
before starting the engine or before
engaging the wheels, tines or any PTO
attachment.
Forward Interlock Levers
The Forward Interlock Levers (B,
Figure 3-1) are attached under each
handlebar grip.
You must squeeze at least one of these
interlock levers up against the handlebar
grip whenever the Wheels/Tines/PTO
Drive Lever is engaged in FORWARD
position.
13
Section 3: Features and Controls
Verify Position of Clutch Roller
When you shift bet\veen FORWARD,
NEUTFtAL and REVERSE the clutch
roller at the base of the
WhecIs/Tines/PTO Drive Lever should
be positioned as shown in Figures 3-2.
3-3 and 3-4. Verify the position of the
clutch roller as you shift the lever. If it
is not positioned correctly, contact the
Factory or see your local authori7ed
dealer.
Figure 3-2: FORWARD position; rc^ler
(G) rests under the adjustment biock (H).
Figure 3-3: NEUTRAL position; n^ier
(G) rests against middie area of the ad
justment block (H).
Figure 3-4: REVERSE position; roller
(G) rests against upper area of the ad
justment block (H).
14
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 fastspeed 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
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.
using stationary PTO attachments.
IMPORTANT: To avoid transmission
damage, always move Wheels/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
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.
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 clutch 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
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 Handlebarior detailed
assembly information.
disengage power to tines or other PTO
attachments before transporting, loading,
turning, or operating in reverse.
A WARNING
Section 3: Features and Controls
Д WARNING
The tiller handlebars can be swung out
30° to the right 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 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.
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.)
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.
Keyswitch Starter
The keyswitch starter on electric start
models (A, Figure 3-5) has three
positions: OFF, RUN and START. Turn
the key to START to start the engine.
Release the key and
it will return to the
RUN position. Turn
the key to OFF to
stop the engine.
(Another way to
stop the engine is to
move the engine
throttle lever to the
STOP position.)
Figure 3-5
A WARNING
15
Sectio
n
4 Operation
----------------------—..............................
A WARNING
Before operating your mactiine,
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.
^ "'p
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 Level). Only
after you’ve become completely familiar
with the tiller should you begin using it in
the garden.
A WARNING
Your tiller and its optional PTO Power
Unit attachments are capable of
causing serious injury to untrained or
careless operators.
To avoid serious personal injury or
property damage, read the Owner’s
Manual that is provided with any
optional accessories or attachments
before using the tiller or PTO Power
Unit.
_____________________________
Break-In Operation
Perform the following maintenance
during the first hours of new operation
(see Maintenance Section in this Manual
and maintenance information in the
Engine Owner’s Manual).
1. Change engine oil after first 2 hours of
new engine operation.
Figure: 4-1
2. After the first 2 hours of new
operation, check the gear oil levels in the
PTO Power Unit and the tine attachment
transmissions.
3. Check for loose or missing hardware
on unit. Tighten or replace as needed.
4. Check tension on forward drive belt
after first 2 hours of operation.
Starting and Stopping the Engine
The following steps describe how to start
and stop the engine.
IMPORTANT: Do not attempt to engage
the tines, wheels, or any PTO attachment
until you have read all of the operating
instructions in this Section. Also review
the safety rules in Section 1, Safety and
the tiller and engine controls information
in Section 3, Features and Controls.
Pre-Start Checklist
Make the following checks and perform
the following services before 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.
I
..............................
^
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, Controls tor 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 Flandlebar Height.
12. Fill the fuel tank with gasoline in
accordance with the directions in the
separate Engine Owner’s Manual. Follow
all instructions and safety rules carefully.
A DANGER
GASOLINE IS HIGHLY FLAMMABLE AND
ITS VAPORS ARE EXPLOSIVE.
Follow gasoline safety rules in this
Manual (Section 1) and in the separate
Engine Owner’s Manual.
Failure to follow gasoline safety instruc
tions can result in serious personal
injury and property damage.
16
Recoii Start Rope
(at front of engine)
Section 4: Operation
Wheels/Tines/PTO
Drive Lever
Engine Throttie
Lever
Forward
interlock Levers
Depth
Regulator
Lever
Tines/PTO
Clutch Lever^
Figure 4-2: Tiller and engine controis.
Starting the Engine:
3. Move the Wheel Speed Lever (Figure
4-2) to either the SLOW or FAST position.
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.
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.
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 all the way down)
so that the tines are off the ground. To do
this, lift up on the handlebars, pull the
lever (Figure 4-2) back, and push it down
all the way to the top detent (notched)
6. If engine is equipped with an ON/OFF
switch, move the switch to ON.
7. Move engine throttle lever (Figure 4-2)
awayfrom 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 recoii
starter rope. Use the recoil starter rope to
start the engine as instructed in the
separate Engine Owner’s Manual.
position.
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. 7
Section 4: Operation
Reconnect the cables and securely
tighten to battery posts. The engine wiil
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.
Cold Weather Operation
When temperatures fall below 40'f. do
the follow'ing stops to protect your
engine and transmission from damage:
1. Refer to the Engine Owner's Manual
for motor oil specifications for cold
weather operation Use winter blend
gasoline.
2. Warm up the engine before putting it
under a load
3. Use winter-blend gasoline.
4. Use the correct weight gear oil in PTO
Power Unit 'transmission.
5. Warm up the transmission gear oil as
follows: With engine running, move
Wheel Speed Lever (Figure 4-2) to
FREEWHEEL (then block wheels so they
can't roll). putTines/PTO Clutch Lever
into DISENGAGE, then squeeze one of
the Forward Interlock Levers and shift
the WheelS/Tines/PTO Drive Lever to
FORWARD.
6. If wheels are frozen to the ground,
melt ice with warm water.
Stopping the Engine and Tilier
1. To stop the wheels and tines, move the
Wheels/Tines/PTO Drive Lever into
NEUTRAL position and then release both
Forward Interlock Levers.
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2. Move the engine Throttle Lever to the
STOP position. Then on electric start
models, turn the key to OFF. Remove the
key for safekeeping.
NOTE: The engine may have a separate
Throttle Control Lever and ON/OFF switch
on the engine. These controls can also be
used to stop the engine. See the Engine
Owner’s manual for information specific
to your engine.
Operating the Tiller
When first practicing, keep the Tines/PTO
Clutch Lever in DISENGAGE position and
the Wheel Speed Lever in SLOW position.
A CAUTION
To avoid serious personai injury or
damage to equipment:
• Aiways piece Wheeis/Tines/PTO Drive
Lever in NEUTRAL before starting
engine, and before engaging wheeis,
tines or other PTO attachments.
• Be sure there are no obstacies behind
you before moving in reverse.
• Wheeis/Tines/PTO Drive Lever should
automaticaiiy return to NEUTRAL
when reieased from REVERSE
position, if it does not, move iever to
NEUTRAL manuaiiy and discontinue
use untii you adjust the fever. See
Section 5, Checking and Adjusting
Reverse Drive System.
• No reverse motion shouid occur if
Wheeis/Tines/PTO Drive Lever is not
heid up in REVERSE. See Section 5,
Checking and Adjusting Reverse
Drive System for adjustment steps.
Do not use filter untess property
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).
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.
Keep away from rotating tines. Rotating
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, ieave 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.
A DANGER
A WARNING
i
tines will cause injury.
Figure 4-3: Moving tiiier forward:
squeeze one Forward Interlock Lever
and then move WheeisiTines/PTO
Drive Lever down to FORWARD.
6. When the tiiier 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
tiiier.
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 all of the
control levers. This stops forward motion
and shuts-off the engine.
Figure 4-4: Guide tiiier with one hand.
Moving the Tiller in Reverse
IMPORTANT: Do not till while in
REVERSE.
1. Shift the Tines/Wheels/PTO Drive Lever
(Figure 4-2) into NEUTRAL and move the
Wheel Speed Lever to the SLOW position.
2. Move Tines/PTO Clutch Lever (Figure
4-2) into DISENGAGE position.
3. Verify that the area behind you is clear.
4. Lift up the handlebars until the tines
are off the ground, then shift the
Wheels/Tines/PTO Drive Lever all the way
up and hold. You do not need to squeeze
the Forward Interlock Levers to use
reverse.
5. The unit immediately engages in
reverse. Periodically check behind you
while holding the handlebars up and the
Wheels/Tines/PTO Lever in its upper-most
position.
Stopping Reverse Motion
Release the Wheels/Tines/PTO Drive
Lever-the lever automatically returns to
the NEUTRAL position. This stops the
A CAUTION
To Help Avoid Personal Injury or
Damage to Equipment:
• Be sure no obstacles are behind you
before operating the tiller in REVERSE.
• Disengage the tines, reduce engine
speed, and move the Wheel Speed
Lever to SLOW position before
operating in REVERSE. Avoid using
FAST wheel speed until you are
familiar with backing the tiller.
wheels immediately. (The Forward
Interlock Levers will not stop REVERSE
motion.)
To Stop the Engine
Move the engine Throttle Lever to the
STOP position. Then, on electric start
models, turn key to OFF. Remove the key
for safekeeping.
Section 4: Operation
Making Turns
Turning the tiller is easy and just requires
practice. First find the balance point
between the engine and the tines by lifting
up the handlebars (Figure 4-5). Once you
find the balance point, then let the
powered wheels do the turning as you
push sideways on the handlebars in the
direction of the turn. Practice the turning
maneuver described here in a large open
area. Once comfortable turning the tiller,
you can then take it to the garden area.
1. At the end of a row, move the Wheels/
Tines/PTO Drive Lever (Figure 4-2) to
NEUTRAL position and reduce the engine
speed.
2. Move the Tines/PTO Clutch Lever
(Figure 4-2) into the DISENGAGE
position.
3. Resume forward operation, and lift
handlebars until tines are off the ground
(Figure 4-5). Find the balance point
between the engine and the tines. Then
push the handlebars in the direction of the
turn. Be very careful to keep feet and legs
away from the tines (which should be dis
engaged). Let the powered wheels do the
hard work. The inside wheel will pivot in
piace while the outside wheel drives the
tiller around in the direction of the turn.
Figure 4-5: Turning the tiller.
NOTE: Use REVERSE if necessary to turn
in a limited space.
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Section 4: Operation
4. When the turn is complete, shift to
NEUTRAL and lower the handlebars.
Move Tines/PTO Clutch Lever back to
ENGAGE position and resume forward
operation.
Transporting The Tiller Around Your Property
When the engine is running, the tiller’s
powered wheels make moving the tiller to
and from the garden easy. If the engine is
not running set the Wheel Speed Lever to
FREEWHEEL position to roll the tiller to
another location.
A WARNING
To help avoid personal injury from
revolving tines, always put the
TInes/PTO Clutch Lever in DISENGAGE
position before transporting, loading, or
unloading tiller.
1. Place the Tines/PTO Clutch Lever in
DISENGAGE position.
2. Move Depth Regulator Lever down all the
way into the Travel setting.
3. If using engine power, move Wheel
Speed Lever to either SLOW or FAST, and
use the Wheels/Tines/PTO Drive Lever to
drive the wheels.
4. If the engine is stopped, move Wheel
Speed Lever to 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.
20
The Forward Interlock System has an
function. Check the system for proper
To test the Forward Interlock System:
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
A DANGER
The Forward Interlock Safety System is
designed for the operator’s safety. Do
not disconnect or attempt to defeat the
purpose of the system. If the system
malfunctions, immediately contact your
local authorized dealer or the
TROY-BILT Technical Service Depart
ment for assistance. Do not use the
tiller or the PTO power unit until the
Forward Interlock Safety System is
functioning properly. Always test the
system before using the tiller or PTD
power unit.
How to Check the Interlock System
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 hold just 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 stali,
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
electro-mechanical design, and so is
subject to normal wear and possible mal
operation each time prior to using the
tiller or PTO power unit.
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 PTD 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
Figure 4-6: Plug and receptacle of
Forward Interlock Safety System
must be securely connected.
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
Clutch Lever to DISENGAGE.
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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