Troy-Bilt 12208 User Manual

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Page 1

Owner’s Manual

REAR-TINE TILLERS

• Safety

• Assembly

• Controls

• Operation

• Maintenance

$4.50

Models

12217-3.5HPTUFFY®

• Parts List

12208- 4.5 HP Super TUFFY® 12209- 5.5 HP BRONCO™ 12210- 6.5 HP Super BRONCO™

GARDEN WAY INCORPORATED

Page 2

Dear Owner:

You now own one of the finest standard-rotating-tine tillers 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 (four tiller models are covered in this Manual... be sure to use only the information appropriate to your tiller model).

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 dealer or call the Factory (see back cover 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 Registra tion Card that was supplied with this Manual.

See Back Cover for

Customer Service Information

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

Safety Decals.............................................................................. 5

SECTION 2: ASSEMBLY................................................................ 6

Attach Flandlebar........................................................................ 7

Move Tiller Off Shipping Platform............................................... 7

Install Forward Clutch Cable....................................................... 8

Install Reverse Clutch Cable (Models 12209/12210) Check Level of Transmission Gear Oil

Add Motor Oil to Engine.............................................................. 9

Check Hardware for Tightness.................................................. 9

Check Air Pressure in Tires

SECTION 3: FEATURES & CONTROLS

Wheel Drive Pins....................................................................... 10

Forward Clutch Bail

Reverse Clutch Control (Models 12209/12210)

Depth Regulator........................................................................ 12

Handlebar Height Adjustment................................................... 12

SECTION 4: OPERATION

Break-In Operation.................................................................... 13

Starting and Stopping the Engine

Operating the Tiller.................................................................... 14

Tilling Tips & Techniques.......................................................... 16

Power Composting.................................................................... 18

Loading and Unloading the Tiller

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11 11

9 9

Safety Alert Symbol

This is a safety alert symbol, it is used in this

manual and on the unit to alert you to

Failure to obey safety messages could result in personal

injury or property damage.

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

This machine meets voluntary safety standard B71.8

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

American National Standards Institute.

A WARNING

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

SECTION 5: MAINTENANCE

Required Maintenance Schedule.............................................. 19

Tiller Lubrication........................................................................ 20

Check for Oil Leaks................................................................... 20

Check Hardware Check Tire Pressure

Transmission Gear Oil Service

Bolo Tines................................................................................. 21

Checking and Adjusting Forward Drive Beit Tension

Forward Clutch Bail Adjustment................................................ 22

Checking and Adjusting Reverse Drive Belt

Tension (Models 12209/12210)

Engine Cleaning....................................................................... 23

Air Cleaner Service

Engine Oil Service

Spark Plug Service.................................................................... 24

Spark Arrester Screen Service.................................................. 24

Carburetor/Governor Control Adjustments

Off Season Storage

Troubleshooting......................................................................... 25

Tiller Attachments

PARTS LIST

CUSTOMER SERVICE INFORMATION............... Back Cover

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Page 3

Section

il 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 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 abnor mally, 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, adjust

ments or inspections.

Page 4

Section 1: Safety

7. Take all possible precautions when leaving the nnachine 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 inspect ing, stop the engine and make certain all moving parts have stopped. Disconnect the spark plug wire and prevent it from touching the spark plug to prevent acci dental starting.

9. The flap on the tine hood must be

down when operating the tiller.

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 Ball (all Models) or the Reverse Clutch control (Models 12209/12210 only).

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 tollowing 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 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 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 acces

sories that are approved by the manufac turer 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. Please remember: You can always stop the tines and wheeis by releasing the Forward Clutch Bail or on Models 12209 and 12210 the Reverse Clutch control,

(whichever control is engaged), or by moving the ignition switch and/or throttie 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 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 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

Owner’s 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.

Page 5

Decals

For your safety and the safety of others, various safety and opera tional decals are located on your unit (see 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 pages in this Manual for decal locations, descrip tions and part numbers.

Forward Clutch Bail

Operating Instruction

Starting Stabilization Message (on engine)

Section 1: Safety

Reverse Clutch Control

Operating Instruction

(Models 12209/12210)

Warning Messages

Operating Symbols

Various symbols (shown here, with word descriptions) are used on the tiller and engine. Your unit m^ not have all of the symbols.

^oy

FAST

SLOW

STOP

• 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.

Hot Surtaces/Moving Beits

Warning (on belt cover)

Figure 1: Location of Safety and Operating Decals (5.5HP Model shown).

H M

CHOKEONCHOKE

OFF

TILLER DIRECTION

REVERSE

—T

ROTATING

TINES

O ^

LEVER DIRECTION

f l ^

BAIL BAIL

ENGAGED DISENGAGED

WARNING

TO AVOID SERIOUS INJURY:

Page 6

Section

2 Assembly

A WARNING

To prevent personal injury or property

damage, do not start the engine until

all assembly steps are complete and you have read and understand the safety and operating instructions in this

manual.

Introduction

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

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

Inspect unit

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

STEP 1: Unpacking Instructions

NOTE: Be careful not to severely bend any of the control cables on the unit.

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.

1 Handlebar Support (see A, Fig. 2-2,

1 Handlebar Assembly (see K, Fig. 2-2)

1 Slotted hd. screw, #10-24 x 2” 1 Hex hd. screw, 1/4-20 X1-1/4”

6 Hex hd. screw, 5/16-18 X1-1/2"

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 Hexnut, 5/16"-18

1 Hex nut, #10-24 2 Hex locknut, 3/8”-16 1 Spring, cable (see W, Fig. 2-5,

1 Bracket, forward clutch cable (see

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.

Description

page 7)

The following items

are in the hardware bag:

page 8)

P, Fig. 2-4, page 8)

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 (Models

12209/12210 only) (1) Scissors (to trim plastic ties) (1) Ruler (for belt tension check) (1) Biockof wood (to support tiller

when removing wheels) (1) Tire pressure gauge (for models with

pneumatic tires) (1) Clean oil funnel (1) Clean, high-quality motor oil. Refer

to the Engine Owner’s Manual for

motor oil specifications and quantity required.

* Adjustable wrenches may be used.

1. Remove any cardboard inserts and packaging material from the carton.

Remove any staples from the bottom of

the carton and remove the carton.

2. The tiller is heavy (approximately 133 lbs.). Do not attempt to remove it from the shipping platform until instructed to do so in these “Assembly” steps.

3. Remove all unassembled parts and

the separate hardware bag from the carton. Check that you have the items

NOTE: LEFT and RIGHT sides of the tiller

are as viewed from the operator’s

position behind the handlebars.

Figure 2-1: To identify length of screw,

place screw on template as shown and

measure distance between bottom of screw head and Up of screw.

Page 7

STEP 2: Attach Handlebar

1. Loosely attach the two legs of the handlebar support (A, Fig. 2-2) 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. There are three height adjustment holes

in the two handlebar support brackets (E and F, Fig. 2-2). Choose a setting that will position the handlebars at approximately waist level when the tines are 3“-4" into

the soil. Loosely attach the support

brackets to the handlebar support (A) using two 5/16"-18 X1-1/2" 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 (FI) and 5/16"-18 hex nuts (I).

Tighten the four screws securely.

4. Tighten all handlebar mounting

hardware securely.

Section 2: Assembly

STEP 3: Move Tiller Off Shipping Platform

To move the tiller without the engine running, put the wheels in the FREEWFiEEL position, as described below.

1. Use a sturdy block under the transmis sion to raise one wheel about 1” 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 through the wheel shaft only (not through the wheel hub) and secure it with the hairpin cotter (push hairpin cotter in as far as it will go). Repeat with the other wheel.

3. Using the handlebar as a lever, roil the

tiller to a flat area.

IMPORTANT: Before starting the engine,

the wheels must be placed in the 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 (5.5HP Model shown).

Fig. 2-3: Wheel in FREEWHEEL position (wheel drive pin through wheel shaft only).

Page 8

Section 2: Assembly

STEP 4: install Forward Clutch Cable

1. Attach the forward clutch cable bracket (P, Fig. 2-4) to the handlebar support (A) with 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

(cable without a knob) 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.

3. Insert the #10-24 x 2" slotted hd. screw (V,

Fig. 2-5) into the cable spring (W) until the screw threads extend through the spring.

4. Thread the #10-24 hex nut (Z, Fig. 2-5)

halfway onto the screw (V).

5. Thread the screw 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 the length of the cable spring (W) from fhe 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 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 prevent

ing the adjuster from turning.

c. If the spring length is incorrect, you must

adjust 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 ball is in

Neutral (tension too tight).

Fig. 2-4: Installing forward dutch cable bracket and cable.

Fig. 2-6: Install forward clutch cable.

spring and adjuster.

Fig. 2-7: To check forward belt tension, lake two measurements of the overall length ot the colls in the spring - first with the clutch bail open, then with the dutch bail dosed against the handlebar.

Page 9

Section 2: Assembly

STEP 5: Install Reverse Clutch Cable (Models 12209/12210)

1. Unwrap the reverse clutch cable (cable with a knob, a large hex nut and a bracket attached to it) from its shipping position and route the cabie (CC, Fig. 2-8 and Fig. 2-9) up to the handlebar. Be sure that the cable is routed beneath the Forward

Clutch Bail.

2. Remove the two self-tapping screws

(AA, Fig. 2-8) from the handlebars,

position the reverse cable mounting

bracket (BB, Fig. 2-8) as shown, and

reinstail the two self-tapping screws.

3. Insert the cable (CC) through the slot in the cable bracket and position the threaded

assembly so that the flat side is aligned with the flat side of the mounting hole.

Slide the large hex nut (DD) up the cable

and tighten it securely.

Fig. 2-8: Install reverse cable bracket and reverse clutch cable.

Fig. 2-9: Route reverse clutch cable (CC) as shown. Attach with cable tie (EE).

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). If it doesn’t, 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 transmis sion components.

1. With 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 cover and locate the main drive shaft situated inside the housing.

3. The gear oil level is correct if the gear oil is approximately halfway up the side of the main drive shaft.

4. If the gear oil level is low, add gear oil

by referring to “A. To Check the Transmis sion Gear Oil Level” in Section 5.

STEP 7: Add Motor Oil to Engine

The tiller is shipped without oW 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 separate Engine Owner’s Manual for engine oil specifications and capacities.

2. With the tiller on level ground, move

the Depth Regulator Lever (FF, Fig. 2-10)

up or down until the engine is level.

3. Add motor oil as described in the Engine Owner’s Manual.

Fig. 2-10: Adjust Depth Regulator Lever.

Fig. 2-11: Remove gear oil fill plug.

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 (units with pneumatic tires)

If the tires are equipped with air valves, check the air pressure with a tire gauge. Deflate or inflate the 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 Owner’s Manual:

• Section 1; “Safety”

• Section 3: “Features and Controls”

• Section 4; “Operation”

Page 10

Section

3 Features and Controls

A WARNING

Before operating your machine, carefully read and understand all safety, controls and operating instruc tions 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.

Forward

Clutch Bail

Depth Regulator

Reverse Clutch

Control (Models

12209/12210)

Introduction

This section describes the location and function of the controls on your tiller.

Refer to the following section “Operation” for detailed operating instructions.

Practice using these controls, with the engine shut off, until you 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.

Wheel Drive Pins

A WARNING

Never allow either of the wheels to be in the FREEWHEEL position when the engine is running. Always put both

wheels in the WHEEL DRIVE position

before starting the engine. Failure to comply could cause loss of

tiller control, property damage, or personal injury.

Each wheel is equipped with a Wheel

Drive Pin (A, Figures 3-2 and 3-3) that

secures the wheel to the wheel shaft (B). The wheels can be positioned in either a WHEEL DRIVE or a FREEWHEEL mode.

Figure 3-1: Features and controls (5.5HP Model shown)

Before starting the engine, put both wheels in the WHEEL DRIVE position by inserting the Wheel Drive Pins through the wheel hubs and the wheel shaft. This “locks” the wheels to the wheel shaft, causing the wheels to turn when either the Forward Clutch Bail or the Reverse Clutch Control (Models 12209/12210) is engaged.

Use the FREEWHEEL mode only when the engine is not running. In FREEWHEEL, the Wheel Drive Pins are placed only through the holes in the wheel shaft (not the wheel hubs), thus allowing the wheels to turn freely when the tiller is pushed or pulled by hand.

Handlebar Height

Adjustment

Wheel Drive Pin (on each wheel)

To Place the Wheels in WHEEL DRIVE or FREEWHEEL:

A WARNING

Do not place the tiller on its side when changing the wheel drive positions as doing so could result in gasoline leaking from the fuel tank.

Failure to follow this instruction could result in personal injury or property damage.

1. Stop the engine, disconnect the spark plug wire from the spark plug and allow

the engine to cool.

2. Raise one wheel off the ground and

place a sturdy support under the

transmission.

3. Remove the hairpin cotter (C, Figures

3-2 and 3-3) from the wheel drive pin (A).

Page 11

Section 3; Features and Controls

4. FOR WHEEL DRIVE mode (Figure 3-2): Slide the wheel outward and align the

holes in the wheel hub (D, Figure 3-2) and

the wheel shaft (B). insert the wheel drive

pin (A) through the wheel hub and the wheel shaft. Secure the wheel drive pin with the hairpin cotter (C) by pushing the

hairpin cotter in as far as it will go. Repeat

for the other wheel and then remove the

support from beneath the transmission.

5. FOR FREEWHEEL mode (Figure 3-3):

Slide the wheel inward and insert the

wheel drive pin (A, Figure 3-3) only

through the hole in the wheel shaft (B).

Secure the wheel drive pin with the

hairpin cotter (C) by pushing the hairpin

cotter in as far as it will go. Repeat for the

other wheel and then remove the support

from beneath the transmission.

A WARNING

Before starting the engine, be sure that both wheels are in the WHEEL DRIVE position. See “Wheel Drive Pins” for instructions.

Engaging the Forward Clutch Bail or the Reverse Clutch Control (if so equipped) when the wheels are not in the WHEEL DRIVE position could allow the tines to rapidly propel the tiller forward or backward.

Failure to comply could cause loss of tiller control, property damage, or personal injury.

Forward Clutch Bail

The Forward Clutch Bail (E, Figure 3-4) controls the engagement of forward drive to the wheels and tines.

To Operate the Forward Clutch Bail:

1. Put the wheels In the WHEEL DRIVE position (see the “WARNING” statement

above).

2. Lift and hold the bail against the handlebar. The wheels and tines will rotate in a forward direction.

3. Release the bail to disengage (stop)

the wheels and tines. All forward motion

will stop (the engine will continue to run).

Reverse Clutch Control (Models 12209/12210 only)

The Reverse Clutch Control (F, Figure 3-4) controls the engagement of reverse drive to the wheels and tines. This reversing

feature is used for maneuvering the tiller only - never engage the tines in the ground whiie going in the reverse

direction.

To Operate the Reverse Clutch Control:

A WARNING

• Use extreme caution when reversing or pulling the machine towards you. Look behind to avoid obstacles.

• Never attempt to till in reverse.

Failure to follow this warning could result in personal injury or property damage.

1. Put the wheels in the WHEEL DRIVE position (see the “WARNING” statement at the left).

2. Stop all tiller motion by releasing the Forward Clutch Ball.

3. Lift up the handlebar until the tines clear the ground, look behind you to avoid any obstacles, and then pull the reverse clutch control knob out. The wheels and

tines will rotate in a reverse direction.

4. Release the reverse clutch control knob to disengage (stop) the wheels and

tines. All reverse motion will stop (the

engine will continue to run).

Figure 3~4: All models have a Forward Clulch Bail (E). Only Models 12209/12210 have the Reverse Clutch Control (F).

Page 12

Section 3: Features and Controls

Depth Regulator Lever

This lever (G, Figure 3-5) controls the tilling depth of the tines. Pull the lever straight back and slide it up or down to engage the notched height settings.

The highest notch (lever all the way down)

raises the tines approximately 1-1/2" off the ground. This “travel” setting allows the tiller to be moved without the tines digging into the ground. Also use this setting when starting the engine.

Move the lever upward to increase the tilling depth. The lowest notch allows a tilling depth of approximately 6",

depending on soil conditions.

For best results, always begin tilling at

a very shallow depth setting and

gradually increase the tilling depth.

Handlebar Height Adjustment

The handlebar height is adjustable to three different settings (see Figure 3-6). As a general rule, adjust the handlebars

so they are at waist level when the tines are 3"-4” into the soil.

To Adjust the Handlebars:

1. Stop the engine, disconnect the spark plug wire from the spark plug and allow

the engine to cool. Z. Remove the screws, lockwashers and

nuts, reposition the handlebars, and reinstall the hardware.

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: The control for stopping the

engine is located on the engine.

Figure 3-5: Depth Regutator Lever (G).

A WARNING

• Do not attempt to till too deeply too quickly. Gradually work down to deeper tilling depths.

• Place the Depth Regulator Lever in the “travel” position before starting the engine. This position prevents the tines from touching the ground until you are ready to begin tilling.

Failure to follow this warning could result in personal injury or property damage.

Figure 3-6: Hanillebar height adjustment.

Page 13

Section

4 Operation

A WARNING

Before operating your machine, carefuiiy read and understand ail safety (Section 1), controls (Section 3) and operating instructions (Section 4) in

this Manual, in the separate Engine

Owner’s Manual, and on the decals on the machine.

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

INTRODUCTION

Read this Section of the manual thor oughly before you start the engine. Then, take the time to familiarize yourself with the basic operation of the tiller before using it in the garden. Find an open, level area and practice using the tiller controls without the tines engaging the soil (put tines in “travel” setting). Oniy after you’ve become completely familiar with the tiller should you begin using it in the garden.

BREAK-IN OPERATION

Perform the following maintenance during the first hours of new operation (see “Maintenance” Section in this Manual and in the Engine Owner’s Manual).

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

2. Check for loose or missing hardware

on unit. Tighten or replace as needed.

3. Check tension on forward drive belt

after first 2 hours of operation.

4. Check transmission gear oil level after

first 2 hours of operation.

STARTING AND STOPPING THE ENGINE

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.

2. Check that the wheels are in the WHEEL DRIVE position (wheel pins must

be through the wheel hubs and the wheel shaft holes).

3. Check unit for loose or missing hardware. Service as required.

4. Check engine oil level. See Engine Owner’s Manual,

5. Check that all safety guards and covers are in place.

6. Check air cleaner and engine cooling system. See Engine Owner’s Manual.

7. Attach spark plug wire to spark plug.

A DANGER

GASOLINE IS HIGHLY FLAMMABLE AND ITS VAPORS ARE EXPLOSIVE.

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

Failure to follow gasoline safety instructions can result in serious personal injury and property damage.

8. Fill the fuel tank with gasoline according to the directions in the separate

Engine Owner’s Manual. Follow all instructions and safety rules carefully.

Page 14

Section 4: Operation

Starting the Engine

The following steps describe how to start

and stop the engine. Do not attempt to

engage the tines or wheeis untii you

have read all of the operating instruc tions 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.”

A CAUTION

To help prevent serious personal injury or damage to equipment:

• Before starting engine, put both wheeis in the WHEEL DRIVE position. Never have the wheels in the FREEWHEEL position when the engine is running. When the wheels are in FREEWHEEL, they do not hold back the tiller and the tines could propel the tiller rapidly forward or backward.

• Before starting engine, put Forward Clutch Bail (all Models) and Reverse Clutch Control (Models 12209/12210 only) in neutral (disengaged) positions by releasing levers.

• 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 exceed150°F.

1. Complete the “Pre-Start Checklist” on

the previous page.

2. Put the wheels in the WHEEL DRIVE position (see “Wheel Drive Pins” in Section 3).

3. Put the Depth Regulator Lever in the “travel” position (lever all the way down) so that the tines are clear of the ground.

4. Release all controls on the tiller.

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

6. Put ignition switch and/or throttle control lever on engine in “ON”, “RUN”, “FAST” or “START” position as instructed in the separate Engine Owner’s Manual.

7. Choke or prime engine as instructed in the separate Engine Owner’s Manual.

8. Place one hand on the fuel tank to stabilize the unit when you pull the starter handle. Use the recoil starter rope to start the engine as instructed in the separate Engine Owner’s Manual. When engine starts, gradually move choke lever (on engines so equipped) to “NO CHOKE”, “CHOKE OFF” or “RUN” position.

9. Use the “FAST” throttle speed setting when tilling.

A WARNING

Keep away from rotating tines. Rotating

tines will cause injury.

Stopping the Engine and Tiller

1. To stop the wheels and tines, release the Forward Clutch Bail or the Reverse Clutch Control (on Models 12209/12210)

-whichevercontrol is in use.

2. To stop the engine, put the ignition

switch and/or the throttle control lever on the engine in the “OFF” or “STOP” position.

OPERATING THE TILLER

The following pages provide guidelines to 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-rotatingtine” (SRT) tiller with forward rotating tines. It operates completely differently from “counter-rotating-tine” (CRT) tillers or from front-tine tillers.

1. Follow the “Pre-Start Checklist” on the previous page. Be sure that the wheels

are in the WHEEL DRIVE position.

2. Put the Depth Regulator Lever in the “travel” position (lever all the way down) so that the tines are clear of the ground. Use this position when practicing with your tiller or when moving to or from the garden. When you are ready to begin tilling, you must move the Depth Regulator Lever to the desired depth setting (see “Tilling Tips & Techniques”).

3. Start the engine and allow it to warm up. When warm, put throttle control in

fast speed setting.

Figure 4-2: Use one hand to guide tilier

when moving forward.

4. For forward motion of the wheels and

tines:

(a) Pull the Forward Clutch Bail up and

hold it against the handlebar. Release

the bail to stop forward motion of the

wheels and tines.

(b) As the tiller moves forward, relax and

let the wheels pull the unit along while the tines dig. Walk behind and a little to one side of the tiller. Use a light

but secure grip with one hand on the

handlebars, but keep your arm loose.

See Figure 4-2. Let the tiller move

ahead at its own pace and do not push

down on the handlebars to try and

force the tiller to dig deeper - this

takes weight off the wheels, reduces

traction, and causes the tines to try

and propel the tiller.

Page 15

Section 4: Operation

A WARNING

Do not push down on the handlebars to try to make the tiller till more deeply. This prevents the wheels trom holding the tiller back and can allow the tines to rapidly propel the tiller forward, which could result in loss of control,

property damage, or personal injury.

5. For reverse motion of the wheels and tines (Models 12209/12210 only):

(a) Look behind and exercise caution

when operating in reverse. Do not till

while in reverse.

(b) Stop all forward motion before

reversing. Lift the handlebars with one hand until the tines are off the ground and then pull the Reverse Clutch Control knob out to engage reverse motion (see Figure 4-3). To stop reverse motion, let go of the Reverse Clutch Control knob.

NOTE: To move the Models 12208/12217 in reverse for short distances, use the

following procedure:

(a) Release the Forward Clutch Bail. (b) Tilt the handlebar slightly upward until

the tines are out of the soil.

right wheel takes a “step” backward. Next move the handlebar to the right so

the left wheel takes a “step” backward.

(d) Repeat to “walk” the tiller rearward. If

longer distances need to be covered in reverse, shut off the engine, then place the two wheels in FREEWHEEL.

6. To Turn the Tiller Around: (a) Practice turning the tiller in a level,

open area. Be very careful to keep your feet and legs away from the tines.

(b) To make a turn, lift the handlebars

until the engine and tines are balanced over the wheels (Figure 4-4). The tines must be out of the ground while turning the tiller.

Figure 4-3: Raise tines off ground and iook behind when moving in reverse. (Modeis

12209 and 12210 have powered reverse. Models 12208 and 12217 can be “fishtailed’’ backward manuaiiy for a short distance, or rolled backward when wheels are in FREEWHEEL)

on the handlebar to move the tiller in the direction of the turn (Figure 4-5). After completing the turn, slowly lower the tines into the soil to resume tilling.

Stopping the Tiller and Engine

1. To stop the wheels and tines, release the Forward Clutch Bail or the Reverse

Clutch Control (on Models 12209/12210)

-whichevercontrol is in use.

2. To stop the engine, put the ignition

switch and/or the throttle control lever on

the engine in the “OFF” or “STOP”

position.

A WARNING

Before tilling, contact your telephone or utilities company and inquire if under ground equipment or lines are used in your area. Their representative will be glad to answer your questions and tell you if any of their equipment or lines are buried underground on your property.

Turning the Tiller Around

Figure 4-4: To begin turn, lift handlebars until engine and tines are balanced over

wheels. Be sure tines are out of ground.

Figure 4-5: With tiller balanced over wheels (and tines out of the ground),

push handlebars sideways to turn tiller.

Page 16

Section 4: Operation

Tilling Tips & Techniques

Let the tiller do the work

• While tilling, relax and let the wheels pull the tiller along while the tines do the digging. Walk on the side that is not yet finished (to avoid making foot prints in the freshly tilled soil) and lightly, but securely grip the handlebar with just one hand. See Figure 4-2.

•Avoid pushing down on the handlebars in an attempt to force the tiller to dig deeper. Doing so takes the weight off the powered wheels, causing them to lose traction. Without the wheels helping to hold the tiller back, the tines will attempt to propel the tiller - often causing the tiller to skip rapidly across the ground. (Sometimes, slight downward pressure on the handlebars will help get through a particularly tough section of sod or unbroken ground, but in most cases this won’t be necessary at all.)

Tilling depths

• Avoid trying to dig too deeply too

quickly, especially when busting sod or tilling soil that hasn’t been tilled for some time. Use shallow depth settings

(only an inch or two deep) for the first passes through the garden area. With each succeeding pass, adjust the depth regulator to dig another inch or two deeper. (Watering the garden area a

few days prior to tilling will make tilling easier, as will letting the newly worked soil set for a day or two before making a final, deep tilling pass.)

• When cultivating (breaking up the

surface soil around plants to help destroy weeds), use very shallow depth settings to prevent injury to plants whose

roots often grow close to the surface. If needed, lift up on the handlebars slightly

to prevent the tines from digging too deeply. Cultivating on a regular basis not

only eliminates weeds, it also loosens

and aerates the soil for better moisture absorption and faster plant growth.)

Avoid tilling wet, soggy soil

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

Avoid making footprints

When possible, walk on the untilled side of the unit to avoid making footprints in the freshly tilled soil. Footprints cause soil compaction that can hamper root penetration and contribute to soil erosion. They can also “plant” unwanted weed seeds back Into the newly tilled soil.

Choosing correct wheel and tine speeds

With experience, you will find the “just right” tilling depth and tilling speed com bination that is best for your garden.

Set the engine throttle lever at a speed to give the engine adequate power and yet allow it to operate at the slowest possible speed...at least until you have achieved the maximum tilling depth you desire. Faster engine speeds may be desirable when making final passes through the seedbed or when cultivating. Selection of the correct engine speed, in relation to the tilling depth, will ensure a sufficient power level to do the job without causing the engine to labor.

Suggested tilling patterns

• When preparing a seedbed, go over the same path twice in the first row, then overlap one-half the tiller width on the rest of the passes (see Figure 4-6). When finished in one direction, make a second pass at a right angle as shown in Figure 4-7. Overlap each pass for best results (in very hard ground it may take three or four passes to thor oughly pulverize the soil).

’ If the garden size will not permit

lengthwise and then crosswise tilling,

then overlap the first passes by one-

half a tiller width, followed by succes

sive passes at one-quarter width (see

Figure 4-8).

• With planning, you can allow enough room between rows to cultivate (see

Figure 4-9). Leave room for the hood width, plus enough extra room for future plant growth.

Figure 4-7

Figure 4-8

Figure 4-1

Page 17

Tilling Tips & Techniques

Section 4: Operation

Clearing the tines

The tines have a self-clearing action which helps to eliminate most tangling of debris. However, occasionally dry grass, stringy stalks or tough vines may become tangled. Follow these proce dures to help avoid tangling and to clear the tines, if necessary.

• To reduce tangling, set the depth regulator deep enough to get maximum “chopping” action as the tines chop the material against the ground. Also, try

to till under crop residues or cover

crops while they are green, moist and

tender.

• While power composting, try swaying

the handlebars from side to side (about

6" to 12"). This “fishtailing” action often clears the tines of debris.

• If tangling occurs on models equipped with a powered reverse, lift the tines out of the soil and run the tiller in reverse for a few feet. This reversing action should unwind a good deal of debris.

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

A WARNING

Before clearing the tines by hand, stop

the engine, allow all moving parts to

stop and disconnect the spark piug

wire.

Failure to follow this warning could result in personal injury.

Tilling on slopes

if you must garden on sloping ground, please follow two very important guide lines:

1. Tiil oniy on moderate siopes, never on steep inclines where footing is difficult (review safety rules in the “Safety” Section of this Manual).

2. We recommend tilling up and down slopes rather than terracing. Tilling verticaiiy on a slope allows maximum planting area and also leaves room for cultivating.

IMPORTANT: When tilling on slopes, be

sure the correct oil level is maintained in

the engine (check every one-half hour of

operation). The incline of the slope will cause the oil to slant away from its normal level and this can starve engine parts of required lubrication. Keep the engine oil level at the full point at all times!

A. Tilling up and down slopes:

• To keep soil erosion to a minimum, be

sure to add enough organic matter to the soil so that it has good moisture

holding texture and try to avoid leaving

footprints or wheel marks.

• When tilling vertically, try to make the

first pass uphill as the tiller digs more

deeply going uphill than it does downhill. In soft soil or weeds, you may have to lift the handlebars slightly

while going uphill. When going

downhill, overlap the first pass by about one-half the width of the tiller.

B. Terrace Gardening:

• When a slope is too steep or too short

for vertical tilling, it may be necessary to till across the slope and create terraced rows. Terraces are rows that

are cut into the side of a slope, creating a narrow, but flat area on which to plant.

• On a long slope, you can make several

terraces, one below the other.

> Terraces should be only 2-to-3 feet

wide. Digging too far into the side of the siope wiii expose poor subsoil that

is unproductive for plants.

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

Figure 4-10.

• Each succeeding lower terrace is

started by walking below the terrace you’re preparing. For added stability of the tiller, always keep the uphill wheel

in the soft, newly tilled soil. Do not till

the last 12” or more of the downhill

outside edge of each terrace. This

untilled strip helps prevents the

terraces from breaking apart and

washing downhill. It also provides a

walking path between rows.

i: UNTILLID

REPEAT

Figure 4-10

C. Tilling across slopes without using terraces:

• If vertical or terracing gardening aren’t practical for you, then you can till laterally across a slope. We don’t really recommend this method as it can create unsure footing and invites soil erosion.

• As in terrace gardening, start at the top of the slope and overlap the first pass by half the width of the tiller. For added stability of the tiller, always keep the uphill wheel In the soft, newly tilled soil.

Page 18

Section 4: Operation

POWER COMPOSTING

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

This material will decompose during the

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

A WARNING

When power composting, do not keep the Depth Regulator Lever at a deep setting if the tiller jumps or bucks.

If jumping or bucking occurs, move the Depth Regulator Lever down to one ot

the shallower settings and then slowly

increase the tilling depth on later

passes.

Failure to comply could result in loss

of tiller control, property damage or

personal injury.

After power composting, you may want to

plant a “green manure” cover crop to protect the soil during the off-season.

You simply grow a crop of clover, alfalfa,

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

the planting season.

LOADING AND UNLOADING THE

TILLER

A WARNING

Loading and unloading the tiller into a vehicle is potentially hazardous and we don’t recommend doing so unless

absolutely necessary, as this could

result in personal injury or property

damage.

However, it you must load or unload the tiller, follow the guidelines given

* •

next.

' Position the loading vehicle so that the

ramp angle is as flat as possible (the less incline to the ramp, the better).

Turn the vehicle’s engine off and apply

its parking brake.

• When going up ramps, stand in the normal operating position and push the

tiller ahead of you. Have a person at

each side to turn the wheels.

• When going down ramps, walk backward with the tiller following you. Keep alert for any obstacles behind you. Position a person at each wheel to control the speed of the tiller. Never go down ramps tiller-first, as the tiller could tip forward.

• Use wooden blocks to place on the downhill side of the wheels if you need to stop the tiller from rolling down the

ramp. Also, use the blocks to temporar ily keep the tiller in place on the ramps (if necessary), and to chock the wheels in place after the tiller is in the vehicle.

The first place to begin is with crop

residues such as leftover vines, stalks, stems and roots. Power compost these crop residues as soon as they finish bearing. The sooner this is done, the better, as tender green matter is easier to till under. Use the deepest depth

regulator setting possible without causing the engine to labor or the tiller to jump ahead.

Standing cornstalks of reasonable height can be power composted. Pushing over

(but not uprooting) cornstalks will often

make it easier for your tiller to chop up the stalks. Keep the tines clear of excessive tangling by “fishtailing” or fre

quently using reverse. Make several

passes, then return a few days later to finish off any remaining stubble.

After tilling under crop residues, add more organic matter such as leaves, grass clippings and even kitchen scraps. When tilled into the soil, this organic matter will

decompose and add even more important

nutrients to the soil.

’ Before loading or unloading, stop the

engine, wait for all parts to stop moving, disconnect the spark plug wire and let the engine and muffler cool.

> The tiller is too heavy and bulky to lift

safely by one person. Two or more people should share the load.

• Use sturdy ramps and manually (engine shut off) roll the tiller into and out of the vehicle. Two or more people are needed to do this.

' Ramps must be strong enough to

support the combined weight of the tiller and any handlers. The ramps 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.

• The handlers should wear sturdy footwear that will help to prevent

slipping.

> When the tiller is in the vehicle, prevent

it from rolling by engaging the wheels in the WHEEL DRIVE position. Chock the wheels with blocks and securely tie the tiller down.

Page 19

Section

vuuui mm ■ ■

5 Maintenance

A WARNING

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to come to a complete stop, disconnect spark plug wire and move wire away from spark plug. Remove ignition key on electric start models.

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

REQUIRED MAINTENANCE SCHEDULE

PROCEDURE Each 10 30 Noted

Check engine oil level

Clean engine

Check drive belt tension Check nuts and bolts

Change engine oil Lubricate tiller Service engine air cleaner system

Check gear oil level in transmission

Check tines for wear Check tire pressure

(pneumatic tires only)

Before Every Every As

Use Hours Hours

•

And every 5

operating hours

t t

Service spark plug

* Change more frequently in dusty or dirty conditions. Change after first 2 hours of

break-in operation.

t Check after first 2 hours of break-in operation.

A See Engine Owner’s Manual for service intervals and instructions.

Page 20

Sections: Maintenance

A WARNING

Before inspecting, cieaning or servicing the machine, shut off engine, wait for all moving parts to come to a complete stop, disconnect spark plug wire and move wire away from spark plug. Remove ignition

♦ n

key on electric start models. Failure to tollow these instructions can result in serious personal injury or property damage.

TILLER LUBRICATION

Proper lubrication of the tiller is an essential part of your maintenance program. After every 10 operating hours, oil or grease the lubrication points shown in Figure 5-1 and described below.

Use a good quality lubricating oil (#30

weight engine oil is suitable) and a good

quality general purpose grease (grease that has a metal lubricant is preferred, if available).

• Remove wheels, clean wheel shaft (A,

Fig. 5-1) and apply thin coating of grease to shaft.

• Grease back, front and sides of depth

regulator lever (B, Fig. 5-1).

• Remove tines, clean tine shafts (C, Fig.

5-1) and inspect for rust, rough spots or burrs (especially around holes). File or sand smooth and coat ends of shaft with grease.

• Oil the threads on the handlebar height

adjustment screws and the handlebar attaching screws (D, Fig. 5-1).

Figure 5-1

CHECK FOR OIL LEAKS

Before each use, check your tiller for signs of an oil leak - usually a dirty, oily accumulation either on the unit or on the floor where it has been parked.

A little seepage around a cover or oil seal is usually not a cause for alarm. However, if the oil drips overnight then immediate attention is needed as ignoring a leak can

result In severe transmission damage.

If a cover is leaking, check for loose screws. If the screws are tight, a new gasket or oil seal may be required. If the

leak is from around a shaft and oil seal, the oil seal probably needs to be replaced. See your authorized dealer or contact the factory for service or advice.

IMPORTANT: Never operate the tiller if the

transmission is low on oil. Check the oil

level after every 30 hours of operation and whenever there is any oil leakage.

CHECK HARDWARE

Check for loose or missing hardware after every 10 operating hours. Tighten or

replace hardware before using the tiller.

Be sure to check the screws underneath the tiller hood (lift the hood flap) that secure the transmission cover and the

Depth Regulator Lever to the transmis sion.

CHECK TIRE PRESSURE (Models with pneumatic tires)

Check the air pressure in both tires.

Deflate or inflate both tires evenly from

15-to-20 PSI (pounds per square inch).

Be sure that both tires have the same air

pressure or the unit will tend to pull to

one side.

TRANSMISSION GEAR OIL SERVICE

Check the transmission gear oil level after

every 30 hours of operation or whenever you notice any oil leak. Operating the tiller when the transmission is low on oil can result in severe damage.

A. To Check the Transmission

Gear Oil Level:

1. Check the gear oil level when the trans mission is cool. Gear oil will expand in warm operating temperatures and this expansion will provide an incorrect oil level reading.

2. With the tiller on level ground, pull the

Depth Regulator Lever all the way up.

3. Remove the oil fill plug (A, Fig. 5-2) from the transmission housing and locate the main drive shaft situated inside the

housing.

4. The gear oil level is correct if the gear

oil is approximately halfway up the side of the main drive shaft.

5. If the gear oil level Is low, add gear oil

as described next. If the gear oil level is okay, securely replace the oil fill plug.

IMPORTANT: Do not operate the tiller If

the gear oil level is low. Doing so will

result in severe damage to the transmis sion components.

6. If adding only a few ounces of gear oil, use API rated GL-4 or GL-5 gear oil having a viscosity of SAE 140, SAE 85W140 or SAE 80W-90. If refilling an empty

transmission, use only GL-4 gear oil

having a viscosity of SAE 85W-140 or SAE 140.

IMPORTANT: Do not use automatic

transmission fluid or motor oil in the transmission.

7. While checking frequently to avoid overfilling, slowly add gear oil into the oil fill hole until it reaches the halfway point on the drive shaft.

8. Securely replace the oil fill plug.

B. To Drain the Transmission Gear Oil:

The transmission gear oil does not need to be changed unless it has been contam inated with dirt, sand or metal particles.

1. Drain gasoline from the fuel tank or run the engine until the fuel tank is

empty. See “DANGER” statement that follows.

Page 21

Sections: Maintenance

A WARNING

A|nv||^l

♦ r?

n’

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

A DANGER

Gasoline is highly flammable and its vapors are explosive. Follow these satety practices to prevent personal

injury or property damage from fire or

explosion.

• Allow the engine and muffler to cool for at least two minutes before draining the tiller’s gasoline tank.

• Do not allow open tiames, sparks, matches or smoking in the area.

• Wipe away spills and push tiller away

from spilled fuel.

• Use only an approved fuel container and store it safely out of the reach of children.

• Do not store gasoline in an area

where its vapors could reach an open

flame or spark, or where ignition sources are present (such as hot water and space heaters, turnaces, clothes dryers, stoves, electric motors, etc.)

2. Drain the oil from the engine.

3. Remove four scre\ws (B, Figure 5-2) and remove transmission cover and gasket.

4. Remove the left-side wheel.

5. Tilt the left-side wheel shaft into a drain pan and allow the gear oil to drain through the top of the transmission.

6. Reinstall the wheel, install a new gasket cover (do not reuse old gasket) and reinstall the transmission cover.

7. Refill the transmission using GL-4 gear oil (SAE 85W-140 or SAE 140).

8. Refill the engine with motor oil and

replenish the fuel tank with gasoline.

Figure 5-2: Remove oil fill plug (A) to check gear oil level and to add gear oil. Remove

four cover screws (B) to drain gear oii.

A. Tine Inspection:

With use, the tines will become shorter, narrower and pointed. Badly worn tines will result in a loss of tilling depth and reduced effectiveness when chopping up and turning under organic matter.

B. Removing a Single Tine:

1. With the engine shut off and the spark plug wire disconnected, remove the two screws (A, Figure 5-3) and locknuts (B)

that attach a single tine to the tine holder. If needed, use penetrating oil on the nuts.

2. When installing a single tine, be sure to position it so that its cutting edge will

enter the soil first as the tiller moves

forward.

C. Removing a Tine Assembly:

1. A tine assembly consists of eight tines mounted on a tine holder.

2. If removing both tine assemblies, mark them “left” and “right” before removal.

Remove the screw (C, Figure 5-3) and locknut (D) that secure the tine assembly

to the tine shaft. If necessary, use a

rubber mallet to tap the tine assembly outward off the shaft.

3. Before reinstalling the tine assembly, inspect the tine shaft for rust, rough spots or burrs and file or sand as needed.

Apply a thin coat of grease to the shaft.

4. Install each tine assembly so that the

cutting edge of the tines will enter the soil first when the tiller moves forward.

Secure the tine assembly to the tine shaft using the screw and locknut previously removed.

BOLD TINES

The bolo tines will wear with use and they should be inspected at the beginning of each tilling season and after every 30 operating hours. The tines can be replaced individually or as a complete set. See the Parts List for tine identification and part numbers.

Figure 5-3: Install lines so that cutting edge of tines enter soil first when tiller moves forward.

Page 22

Sections; Maintenance

A WARNING

* n

key on electric start models. Failure to follow these instructions can result in serious personal injury or property damage.

CHECKING AND ADJUSTING FORWARD DRIVE BELT TENSION

Maintaining correct tension on the forward drive beit is important to good tilling performance and long belt life.

A loose belt will slip on the engine and transmission pulleys and cause the tines and wheels to slow down - or stop com pletely - even though the engine is running at full speed. A belt that is too tight can result in unintentional tine movement when the clutch bail is in the Neutral (released) position.

Also check the belt for cracks, cuts or frayed edges and replace it as soon as possible.

• Check belt tension after the first two hours of break-in operation (new beit).

• Check belt tension after every 10 operating hours.

To Check Forward Belt Tension:

1. Stop the engine, wait for all parts to

stop moving and disconnect the spark plug wire.

2. With the forward ciutch bail in an open

(released) position, measure and carefully note the overall length of the cable spring (A, Figure 5-4) by measuring from the outermost coil to the outermost coil.

3. Lift and hold the forward clutch bail

against the handlebar (see Figure 5-4) and re-measure the overall length of the coils while the spring is under tension. The belt tension is correct if this second measure ment is between 1/16" -to- 3/16” longer than the first measurement.

4. If the spring is too short (less than

1/16“ greater than the first measurement), the tension is too loose. If the spring is too long (more than 3/16" greater than the first measurement), the tension is too tight.

To adjust the length of the spring: a. Release the Forward Clutch Bail. b. Unthread the hex nut (C, Figure 5-4)

about halfway up the adjustment screw (D).

c. Unhook the top of the spring from

the forward clutch bail.

d. Use pliers to prevent the adjuster (B)

from turning and turn the slotted screw located inside the screw clockwise (viewed from operator’s

position) to increase tension on the spring. Turn the screw counter clockwise to decrease tension on the spring. Once adjusted, re-hook the top of the spring to the forward

clutch bail. (Continue to Step 5e.)

e. Repeat Steps 2 and 3 to re-measure

the length of the spring coils. When the second measurement (with bail

closed against handlebar) is between 1/16" -to- 3/16" longer than the first measurement, retighten the hex nut (C) against the top of the adjuster (B).

Figure 5-4: To check forward heft tension, take two measurements of

the overati tength of the coils in the spring - first with the dutch bail open, then with the ctutch bail closed against the handlebar.

Replacement Belt Information

If the drive belt needs to be replaced, see your local authorized dealer or refer to the Parts List for ordering information. Use only a factory-authorized belt as an “over the counter” belt may not perform satis factorily. The procedure requires average mechanical ability and commonly available tools.

FORWARD CLUTCH BAIL ADJUSTMENT

If fhe Forward Clutch Bail does not function properly, first check that the forward drive belt is adjusted properly

(see “Checking and Adjusting Forward

Drive Belt Tension”). If this fails to correct the problem, contact the factory technical service department or your authorized dealer for service advice.

Page 23

Sections: Maintenance

A WARNING

* n

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to come to a compiete stop, disconnect spark plug wire and move wire away from spark plug. Remove ignition key on electric start models.

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

CHECKING AND ADJUSTING REVERSE DRIVE BELT TENSION (Models 12209/12210 only)

Maintaining correct tension on the reverse drive belt is important to good performance and long belt life. A loose belt \will slip on the engine and transmis sion pulleys and cause the tines and wheels to slow down - or stop com pletely - even though the engine is running at full speed. A loose belt can also result in premature belt wear.

If there is no reverse action when the Reverse Clutch Control knob is pulled out, then the belt tension is too loose.

When checking belt tension, also check the belt for cracks, cuts or frayed edges and replace it as soon as possible.

• Check belt tension after the first two hours of break-in operation (new belt).

• Check belt tension after every 10 operating hours.

To Check Reverse Belt Tension:

1. Be sure that the engine is stopped and

the spark plug wire is disconnected and moved away from the spark plug.

2. Remove the screw in the plastic belt

cover and slide the cover (which is attached to the forward clutch cable) out of the way.

3. Have an assistant pull the Reverse

Clutch Control knob all the way out and hold it in that position. Measure the length of the cable wire between the end of the threaded cable adjuster (A, Figure 5-5) and the end of the Z-fItting (B) to which the cable wire is attached.

4. The belt tension is ideal if the cable

wire length measures between 1/8" to

1/4". If the length is less than 1/8" (and if

there is no reverse action when the tiller is

running), then make the following adjust ments. NOTE: If the length is more than 1/4", no adjustment is needed, as long as

the reverse action functions properly.

5. Release the Reverse Clutch Control knob. Unthread the inner jam nut (C, Figure 5-6) one to two turns and pull the

threaded cable adjuster (A, Figure 5-6) to the left until the inner jam nut rests against the bracket.

6. Prevent the inner jam nut (C) from

turning and tighten the outer jam nut (D)

against the bracket. Prevent the outer

jam nut (D) from turning and tighten the

inner jam nut (C) against the bracket.

7. Measure the gap by repeating Step 3. Readjust as needed by repeating Steps 5 and 6.

8. Reinstall the belt cover.

Replacement Belt Information

If the drive belt needs to be replaced, see your local authorized dealer or refer to the Parts List for ordering information. Use only a factory-authorized belt as an “over the counter” belt may not perform satisfactorily. The procedure requires average mechanical ability and commonly available tools.

Figure 5-5: Measure cable wire length to check for correct reverse belt tension.

Figure 5-6: Move threaded adjuster (A) to left to increase belt tension.

ENGINE CLEANING

Keep the engine clean to assure smooth operation and to prevent damage from overheating. Refer to the separate Engine

Owner’s Manual for specific repair and cleaning instructions. All inspections and services must be done with the engine shut off and cool to the touch.

AIR CLEANER SERVICE

The engine air cleaner filters dirt and dust

out of the air before it enters the carbure tor. Operating the engine with a dirty,

clogged air filter can cause poor perfor

mance and damage to the engine. Never

operate the engine without the air cleaner

installed. Inspect and service the air

cleaner more often if operating in very

dusty or dirty conditions.

Service the air cleaner as instructed in the

separate Engine Owner’s Manual.

Page 24

Sections: Maintenance

A WARNING

* r?

W~T

Before inspecting, cleaning or servicing the machine, shut otf engine, wait for all moving parts to come

to a complete stop, disconnect spark plug wire and move wire away trom spark plug. Remove ignition

key on electric start models. Failure to tollow these instructions can result in serious personal injury or property damage.

ENGINE OIL SERVICE

Check the engine oil level before starting

the engine each day and check it after each

5 hours of continuous operation. Running

the engine when it is low on oil will quickly

ruin the engine. It is recommended that you change the

engine oil after every 10 hours of operation

and even sooner when operating in

extremely dirty or dusty conditions. Refer

to the separate Engine Owner’s Manual for

detailed service instructions.

A. To Check the Engine Oil Level:

1. Move the tiller to a level area and shut off the engine.

2. Level the engine by putting the Depth Regulator Lever in the second notch from

the top.

3. Clean the area around the oil dipstick or oil fill tube to prevent dirt from falling into

the crankcase.

4. On engines with an oil fill tube, remove

the filler cap, add oil (if required) until it

reaches the top of fhe tube and reinstall the

filler cap.

5. On engines with a dipstick, remove it,

wipe it clean, and reinstall it finger-tight.

Remove the dipstick and check the reading.

Add oil (if required) to bring the level to the

FULL mark. Do not overfill.

B. To Change the Engine Oil:

Change the engine oil as instructed in the separate Engine Owner’s Manual.

SPARK PLUG SERVICE

Inspect and clean or replace the spark plug after every 100 operating hours or annually. Clean the plug and set the gap as described in the separate Engine Owner’s

Manual. In some areas, local law requires using

resistor spark plugs to suppress ignition signals. If the engine was originally equipped with a resistor spark plug, use the same type for replacement.

SPARK ARRESTER SCREEN SERVICE

If the engine muffler is equipped with a

spark arrester screen, remove and clean it according to the time intervals and instruc tions in the separate Engine Owner’s

Manual.

THROTTLE LEVER ADJUSTMENT

If the engine does not respond to various throttle lever settings, refer to the separate

Engine Owner’s Manual for service infor

mation or contact your local authorized

engine service dealer.

A WARNING

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.

CARBURETOR/GOVERNOR CONTROL ADJUSTMENTS

The carburetor was adjusted at the factory for best operating speed. Refer to the separate Engine Owner’s Manual for any adjustment information or see your authorized engine service dealer.

The governor controls the maximum safe operating speed and protects the engine and all moving parts from damage caused by overspeeding. Do not tamper with the engine governor settings.

OFF SEASON STORAGE

When the tiller won’t be used for extended periods, prepare it for storage as follows:

1. Clean the tiller and engine.

2. Do routine tiller lubrication and check for loose parts and hardware.

3. Protect the engine and perform rec ommended engine maintenance by following the engine storage instruc tions found in the separate Engine Owner’s Manual. NOTE: Be sure to protect the fuel lines, carburetor and fuel tank from gum deposits by removing fuel or by treating fuel with a fuel stabilizer (follow engine manufac turer’s recommendations).

4. Store unit in a clean, dry area.

5. Never store the tiller with fuel in the fuel tank in an enclosed area where gas fumes could reach an open flame or spark, or where ignition sources are present (space heaters, hot water heaters, furnaces, etc.).

Page 25

Sections: Maintenance

TROUBLESHOOTING

Before performing any corrections, refer to the appropriate information in this Manual, or in the Engine Owner’s Manual, for the correct safety precautions and operating or maintenance procedures. Contact your local authorized Engine Service Dealer for engine service. Contact your local authorized equipment dealer or the factory for all other service problems.

PROBLEM

Engine does not start.

Engine runs pooriy.

Engine overheats.

Engine does not

shut ott. 1. Misadjusted throttle control or ignition switch. 1. See Engine Owner’s Manual or Engine Service Dealer.

Wheeis and Tines wiii not turn.

POSSIBLE CAUSE CORRECTION

1. Spark plug wire disconnected.

2. Engine Throttle Control Lever incorrectly set.

3. Fuel tank empty.

4. Choke control (if so equipped) in incorrect position.

5. Stale gasoline.

6. Dirtyairfilter(s).

7. Defective or incorrectly gapped spark plug.

8. Carburetor out of adjustment.

9. Misadjusted throttle control.

10. Dirt or water in fuel tank.

1. Defective or incorrectly gapped spark plug.

2. Dirty air filter(s).

3. Carburetor out of adjustment.

4. Stale gasoline.

5. Dirt or water in fuel tank.

6. Engine cooling system clogged.

1. Engine cooling system clogged.

2. Carburetor out of adjustment.

3. Oil level is low.

1. Improper use of controls.

2. Worn, broken, or misadjusted drive belt(s).

3. Internal transmission wear or damage.

4. Bolt loose in transmission pulley.

1. Reconnect wire.

2. Put lever in START position.

3. Add fuel.

4. See Engine Owner’s Manual.

5. Drain fuel and add fresh fuel.

6. Clean or replace filter(s).

7. Inspect spark plug.

8. See Engine Service Dealer.

9. See Engine Service Dealer

10. See Engine Service Dealer.

1. Inspect spark plug (see Engine Owner’s Manual).

2. Clean or replace (see Engine Owner’s Manual).

3. See Engine Service Dealer.

4. Replace with fresh gasoline.

5. See Engine Service Dealer.

6. Clean air cooling system (see Engine Owner’s Manual).

1. Clean air cooling area (see Engine Owner’s Manual).

2. See Engine Service Dealer.

3. Check oil level (see Engine Owner’s Manual).

1. Review Sections 3 and 4.

2. See “Checking Drive Belt Tension,” Section 5. 3 Contact local dealer or the factory.

4. Tighten bolt.

Tines turn, but wheeis don’t.

Wheeis Turn, but Tines Don’t.

Poor tilling performance.

1. Wheel Drive Pins not in WHEEL DRIVE.

2. Bolt loose in transmission pulley.

3. Internal transmission wear or damage.

1. Tine holder mounting hardware missing.

2. Bolt loose in transmission pulley.

3. Internal transmission wear or damage.

1. Worn tines.

2. Improper Depth Regulator setting.

3. Incorrect throttle setting.

4. Forward Drive Belt slipping.

1. See “Wheel Drive Pins” in Section 3.

2. Tighten bolt.

3. Contact local Dealer or the Factory.

1. Replace hardware.

2. Tighten bolt.

3. Contact local Dealer or the Factory.

1. See “Bolo Tines” (Section 5).

2. See “Tilling Tips & Techniques,” Section 4.

3. See Section 4.

4. See “Checking Forward Drive Belt Tension,” Section 5.

TILLER ATTACHMENTS

The attachments listed below are available for your tiller. The information is the most current at the time this manual was printed.

Contact your authorized dealer or the factory for current information.

BUMPER

A tubular steel bumper surrounds the engine to protect the air cleaner, starter assembly and fuel tank from damage. The bumper is easy to install using existing engine mounting hardware.

FRAME WEIGHTS

Solid steel weights attach to the sides of the frame to provide added traction to the wheels. Installation hardware is included.

Page 26

PARTS LIST

Models 12208,12209,12210 and 12217

HANDLEBARS, CLUTCH CABLES AND HANDLEBAR MOUNTING HARDWARE

Page 27

Models 12208,12209,12210 and 12217

HANDLEBARS, CLUTCH CABLES AND HANDLEBAR MOUNTING HARDWARE

PARTS LIST

REF. No.

10 1186230 11 12 55048 Cable Assy, Forward Clutch 13 1100068 Hex Hd. Screw, 3/8-16 x 3/4 14 15 1107383

(A) For Model 12208 (B) For Model12209 (C) For Model12210 (D) For Model 12217

PART

No.

1 55104 Upper Handlebar (Incl. Ref. 2) (A)(D; 1 17

1916996

2 1916928 Decal, Forward Clutch Bail 3 1100799 4

1100806 55044 Bracket, Forward Clutch Cable

1916106001 Bail, Forward Clutch

6 7 9855

1916712 Spring, Forward Clutch

8 9 1100242

9811

9837 Hex Lock Nut, 3/8-16

1100044 Hex Hd. Screw, 5/16-18 x 3/4

DESCRIPTION QTY.

Upper Handlebar Ónci. Refs. 2 &

28) (B)(C).................................

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

HexHd. Screw, 5/16-18x1-1/2 HexHd. Screw, 1/4-20x1-1/4

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

Screw, #10-24x2

Lock Washer, 5/16 Hex Lock Nut, 5/16-18 Hex Lock Nut, 1/4-20

Flat Washer, 3/8

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

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

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

...........

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

.........

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

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

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

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

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

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

...........

.. 1 19 1916108001 Lower Handlebar

1 .. 6 .. 1 22 9552

1 9552 Hex Screw, 1/4-20 x 1/2, Self-Tap (A)(D) 4 .. 1 23 1901273010 Panel .. 1 24

.. 1 1916818 Decal, Model Name/Logo (B)............. 1

.. 6 1917555 Decal, Model Name/Logo (C) .. 6 .. 1 25 1916674001 Bracket, Reverse Clutch Cable (B)(C).. .. 1 26 1916719 Cable Assy, Reverse Clutch (B)(C) .. 2 .. 2 .. 2 .. 2

REF. No.

20 9386 21 9856

PART

No.

1916107001 1110107

1917563 Decal, Model Name/Logo (A)

DESCRIPTION

Handlebar Support

Hex Lock Nut, 5/16-18.......................... 2

Klip Ring

Clevis Pin..............................................

Hex Screw, 1/4-20 x 1/2, Self-Tap (B)(C) 6

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

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

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

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

QTY

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

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

55097

Decal, Model Name/Logo (D)

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

....

1186227 Hex Nut, #10-24

28 1916929 Decal, Reverse Drive Control (B)(C).... 1

29 1735531 Cable Tie (B)(C)

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

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

1 1 1

1 1

1 1 1 1 1

DRIVE SHAFT ASSEMBLY

REF. No.

1 1100004 Hex Screw, 5/16-24 x 3/4, Grade 5 (A)(D)

1100005 Hex Screw, 5/16-24 x 1, Grade 5 (B)(C) 2 9944 3 1911321 Transmission Pulley (A)

1916532

55031 Transmission Pulley (D) 4 9301 Key, Transmission Puiley, 3/16x1

50027

9517

6 7 1714 Bearing, Tapered Roller (with race) 8

50043

9 1904281 Drive Shaft Assy.....................................

1224-1

1224-2 Shim, same as above, except

1224-3 Shim, same as above, except

1224-4

1325C Shim Set (Incl. the following shims:

PART

No. DESCRIPTION QTY.

Bellevilie Washer

Transmission Pulley (B)(C)

Support Washer, Front

Snap Ring............................................... 1

Support Washer, Rear

Shim, Rear Bearing Cap, .010" thick

.030" thick

.005" thick..........................................

Shim, same as above, except

.062" thick.......................................... A/R

two #1224-1, two 1224-2, one 1224-3, and one #1224-4)

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

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

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

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

..........

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

.......

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

.....

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

..........

A/R

1 1 1 1 1 1 1 1

2 1 1

(A) For Model 12208 (B) For Model 12209 (C) For Model 12210 (D) For Model 12217

A/R-As Required

Page 28

PARTS LIST

Models 12208,12209,12210 and 12217

WHEEL AND TILLER SHAFT ASSEMBLIES

REF.

No.

1 9512 Retainer, Snap Ring, “E” Type 2 9511 3 1166-1

(A) For Model 12208 (B) For Model 12209 (C) For Model 12210 (D) For Model 12217

PART

No.

1166-2 Shim, 0.030" thick.........................

1166-3 Shim, 0.015" thick......................... .... A/R 8

1166-4 Shim, 0.010" thick......................... .... A/R 9

1166-5 Shim, 0.005" thick.........................

1086

DESCRIPTION QTY.

.....

Retainer, Snap Ring

Shim, 0.062" thick......................... .... A/R 6

Bronze Bushing

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

.... A/R 7 1132-2

.... A/R

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

A/R - As Required

REF.

No.

2 4

PART

No.

1916741 Wheel Shaft (A)(B)(C)

55004 Wheel Shaft (D) 9305 Key, Fli-Pro, 1/4 X 1

1904278

1915074 Tiller Shaft..................................

1104 Woodruff Key 1904279

DESCRIPTION

Spacer........................................

Worm Gear, Wheel Shaft...........

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

Worm Gear, Tiller Shaft

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

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

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

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

.......

QTY.

1 1 1 4 1 1 1 1

Page 29

Models 12208,12209,12210 and 12217

TRANSMISSION HOUSING, COVERS, SEALS, GASKETS ANO PLUG

PARTS LIST

REF. No.

6 7

PART

No. DESCRIPTION

9727 Plug, Transmission Oil Fill 1186328 Hex Hd. Flange Screw, 5/16-18x5/8,

Grade 5

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

1916641001 50074

50032 Gasket, Housing Cover........................

9617

9621 Oil Seal, Wheel Shaft...........................

Front Cover, Transmission Rear Cover, Transmission

Oil Seal, Drive Shaft

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

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

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

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

QTY.

8 1 1 2 1 2

REF. No.

9 10 11

12 1916111001 Rear Bearing Cap 13 1186331 14 15

PART

No. DESCRIPTION

1915084010 1909374

55011-1 Bearing Cap Gasket, .010" thick.......... 1

55011-2

1100044 1100242

Transmission Housing Assy.................

Oil Seal, Tine Shaft

Bearing Cap Gasket, .030" thick.......... 1

Hex Hd. Flange Screw, 5/16-18 x 1 ... Hex Hd. Flange Screw, 5/16-18 x 3/4. 1 Lock Washer, 5/16

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

QTY

Page 30

PARTS LIST Models 12208,12209 and 12210

ENGINE, ENGINE BRACKETS AND BELT DRIVE SYSTEMS

(For Models 12208,12209 and 12210 Only)

Page 31

Models 12208,12209 and 12210

PARTS LIST

ENGINE, ENGINE BRACKETS AND BELT DRIVE SYSTEMS

(For Models 12208,12209 and 12210 Only)

REF. No.

1 2 1917326001 3 1100242

4 1111696

5 6 7 9552

9 50027 10 1916795001

11 1138-2 Shim..................................................

12 9301 13

14 1916559001 15 1100005 16 17 1100799 18 19 1916726 Forward Belt Guide (B){C) 20 9558 21 9090 22 1916116001 23

PART

No.

1904557 Decal, Hot Surfaces Warning 1917128

1186230

1911322 Pulley, Engine Drive (A) 1916531 Pulley, Engine Drive (B)(C)

1916794001

1916652001 Guard, Belts/Pulleys

1110108 Lock Nut, 3/8-16

DESCRIPTION QTY.

Engine, Recoil Start..........................

Bracket, Belt Cover........................... 1 25 9386

Lock Washer, 5/16 (A)...................... 8 26

Lock Washer, 5/16 (B)(C)

Hex Hd. Scre\w, 5/16-24 x 1/2 (A).... .. 2 28 55033

Hex Hd. Screw, 5/16-24 x 1/2 (B)(C) 3

Belt Cover (Incl. Ref. 5) Hex Hd. Flange Screw, Self-Tapping,

1/4-20x1/2.....................................

Hex Nut, 5/16-18

Support Washer................................ .. 1

Engine Bracket, Right.......................

Key, 3/16" xr

Reverse Idler Bracket (B)(C) Hex Hd. Screw, 5/16-24 x 1 Engine Bracket, Left Hex Hd. Screw, 5/16-18 x 1-1/2

Hex Hd. Screw, 3/8-16x1-1/2

Forward Idler Pulley.......................... .. 1

Forward Idler Lever

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

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

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

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

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

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

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

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

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

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

..........

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

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

.......

...........

REF. No.

1 24 1107382 Flat Washer

.. 9

.. 1 30 .. 1 31

.. 7 32 1916117001 Bracket, Cable Mounting .. 4 33 1900766

.. A/R 36 1107383 Flat Washer, 3/8

.. 1 40 1111606 Hex Hd. Screw, 5/16-18 x 2 (B)(C)

.. 3 .. 1 42 1916725 Belt Guide (B)(C) .. 5 43 .. 1

.. 1

27 55034 Forward Return Spring

29 1916658 Reverse Drive Belt (B)(C)

1 35 9856 Clevis Pin

1 1

1 39 1916535 Pulley, Reverse Idler (B)(C)............

41 1110107 Lock Nut, 5/16-18 (B)(C)................. .... 2

44 1108841 Key, 3/16“ X1-1/2"........................... .... 1

1 45 1

46 1916706 Forward Belt Guide (A)

47 1100004 Hex Hd. Screw, 5/16-24 x 3/4 (A).. .... 2

PART

No.

1916657 Forward Drive Belt

9944 Belleville Washer 1911321 Transmission Pulley (A) 1916532 Transmission Pulley (B)(C)

1186328

1916536 1916578001 Reverse Idler Arm (B)(C)

1916724 Reverse Return Spring (B)(C)

1916574

DESCRIPTION QTY.

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

Klip Ring

Bushing, Forward Idler Lever............... 1

Decal, Stabilization Hex Hd. Screw, 5/16-18x5/8

Bushing (B)(C)

Spacer(A)........................................

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

........

.... 2

.... 1

.... 4

.... 1

(A) For Model 12208 (B) For Model 12209 (C) For Model 12210

A/R-As Required

^ Contact your local authorized engine service dealer for engine parts and

service. Refer to your engine namepiate for engine model/type number.

Page 32

PARTS LIST

Model 12217

ENGINE, ENGINE BRACKETS AND BELT DRIVE SYSTEM

(For Model 12217 Only)

Page 33

Model 12217 PARTS LIST

ENGINE, ENGINE BRACKETS AND BELT DRIVE SYSTEM

REF. No.

1 2 1916112001 3 4 1111696 5 1904549 6 1904573 7

8 1186230

9 10 1916795001 11 1138-2 12 55036

12A

13 55035 14 9925 Belleville Washer 15 1100009 16 1916794001 17

PART

No.

1100242 Lock Washer, 5/16............................... 8 20 9558

9552

50027

9301

1100799

DESCRIPTION

Engine, Recoil Start............................

Bracket, Belt Cover.............................

HexHd. Screw, 5/16-24x1/2 Decal, Hot Surfaces Warning Belt Cover (incl. Ref. 5) Hex Hd. Flange Screw, Self-Tapping,

1/4-20 X 1/2....................................

Hex Nut, 5/16-18.................................

Support Washer.................................. 1 27 55034 Return Spring

Engine Bracket, Right......................... 1 28 55033 Bushing, Idler Lever............................. 1

Shim................................................... ...A/R 29

Spacer

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

Key, 3/16" x1" Pulley, Engine Drive

Hex Hd. Screw, 3/8-24 x 1, Grade 5.. Engine Bracket, Left

HexHd. Screw, 5/16-18x1-1/2, 36 1107383 Flat Washer, 3/8

Grade 5.......................................... . 5

(For Model 12217 Only)

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

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

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

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

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

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

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

* *

PART

No.

DESCRIPTION QTY

QTY.

REF. No.

1 18 1916652001 Guard, Belt /Pulley............................... 1

. 1

. 2 21 9090 Idler Pulley........................................... 1

. 1 22 1916116001 . 1

. 7 25 9386 Klip Ring . 4

. 2 31 55031

. 1 33 1900766 Decal, Stabilization . 1 34

19 55039 Belt Guide............................................ 1

HexHd. Screw, 3/8-16x1-1/2

Idler Lever............................................

1110108 Lock Nut, 3/8-16

23 24 1107382 Flat Washer

55037 V-Belt

1100004

1 30

1 32

1 35

9944

1916117001

1186328 Hex Hd. Screw, 5/16-18 x 5/8.............. 4

9856 Clevis Pin.............................................

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

Hex Hd. Screw, 5/16-24 x 3/4, Grade 5 2 Belleville Washer

Transmission Pulley.............................

Bracket, Cable Mount

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

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

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

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

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

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

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

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

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

1 1 2 1 1 1

1 1 1 1

1 1

A/R - As Required

* Contact your local authorized engine service dealer for engine parts and service. Refer to your engine nameplate for engine model/type

number.

Page 34

PARTS LIST

Hold Tine With Blunt End Toward You

Models 12208,12209,12210 and 12217

BOLO TINES AND WHEELS

Left Hand Tine

NOTE: Identify Left and Right sides of tiller by standing in operator position and facing direction of forward travel.

LEFTSIDE

Right Hand Tine

—3

FRONT/

FORWARD

FRONT/

FORWARD

RIGHT SIDE

REF. No.

—-

(A) For Model 12208 - SN122081100101 -122081199999 (B) For Model 12209 - SN122091100101 -122091199999 (C) For Model 12210 - SN122101100101-122101199999 (D) For Model 12208 - SN122081200101-122081299999

PART

No.

1 9711 Hex Hd. Screw, 3/8-16 x 1, Grade 5 2

50049-01

3 1733398 4

9555 1901

5 50049-02 Boio Tine - Left Hand. Single tine used

DESCRIPTION QTY.

Boio Tine - Right Hand. Single tine used

on left side of tiller. (Incl. two each

Refs. 1 &3) Hex Lock Nut, 3/8-16

Hex Hd. Screw, 3/8-16x1-3/4................. 2

Boio Tine Replacement Set (Incl. eight

right hand tines, eight left hand tines

and required hardware

on right side of tiller. (Inci. two each

Refs. 1 &3)

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

......

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

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

REF. No.

(E) For Model 12209 - SN122091200101-122091299999 (F) For Model 12210 - SN122101200101-122101299999 (G) For Model 12217 - SN122171100101-122171199999

6 1916747001

7 20918-01

9 9380 10 9338 11 1917486

PART

No.

1915075001

2706-01 55095-01 20918-02 2706-02 55095-02

1917487 Wheel & Tire Assy (F)

DESCRIPTION QTY.

Tine Holder (A)(B)(C)(D)(E)(F)

Tine Holder (G)......................................

Wheel & Tire Assy-Left Side (A)(B) Wheel & Tire Assy-Left Side (C) Wheel & Tire Assy-Left Side (G) Wheel & Tire Assy-Right Side (A)(B)... Wheel & Tire Assy-Right Side (C) Wheel & Tire Assy-Right Side (G) Clevis Pin, .312“ X1-3/4”

Hair Pin Cotter.......................................

Wheel & Tire Assy (D)(E)

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

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

.......

...........

.........

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

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

. 2 . 2

1 . 1 . 1

1 . 1

. 2 . 2

. 2

Page 35

Models 12208,12209,12210 and 12217

TINE HOOD, DEPTH REGULATOR AND DRAG BAR

PARTS LIST

REF. No.

8A 9308

(A) For Model 12208

(B) For ModeM2209

PART

No.

1 9552

3 1917536

1917594 Tine Hood (Incl. tine flap and

1904572 Tine Hood (Incl. tine flap and

6 1100088 7 1186391

1916118001 Depth Regulator Lever

9384

DESCRIPTION QT¥.

Hex Hd. Flange Screw, Self-Tapping, 10

1/4-20x1/2

Decal, Hood ......................................

Ref. 3) (A)(B)(C)

Ref. 3) (D)......................................

Hex Hd. Screw, 5/16-18x1/2

Hex Flange Lock Nut, 5/16-18...........

Spirol Pin Spring, Depth Regulator

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

(D) For Model 12217

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

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

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

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

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

REF. No.

. 2

. 1

. 2 17 1186230 Hex Nut, 5/16-18............................... 2

. 2

. 2 . 1

1 12 9811 Hex Lock Nut, 1/4-20

13 1916119001 Hood Bracket, Right Hand

1 14 1916120001 Hood Bracket, Left Hand

15 11000242 Lock washer, 5/16.............................

16 1186331 Hex Hd. Flange Screw, 5/16-18x1. 2

18 1100808

1 19 55088 Bushing............................................. .. 2

20 1916121001 Drag Bar

PART

No. DESCRIPTION QTY

9534 Spacer................................................

1100069

Hex Hd. Screw, 1/4-20x1

Hex Hd. Screw, 5/16-18x1-1/4

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

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

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

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

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

.........

.. 1 .. 1 .. 1 .. 1 .. 1

.. 2

.. 1

Page 36

CUSTOMER SERVICE INFORMATION

Owner Registration Card

Please fill out and mail the enclosed owner

registration card. The purpose of this card is to register each unit at the factory so that we can provide you with warranty benefits and

informational bulletins.

Warranty Service

The warranty statement is included in the unit’s literature

package.

Modei/Seriai Numbers

A Model/Serial Numbers decal is located on top of the trans mission. For ready reference, record these numbers in the spaces below.

Model Number: ______________________________________ Serial Number:

___________________________________

Authorized Deaier Information

If you purchased your unit from an authorized dealer, record

the dealer's address and phone number below for ready

reference: Dealer Name: Address: Phone:______________________________________________

________________________________________

____________________________________________

IMPORTANT:

Left and right sides of the unit are determined by standing

behind the unit, in the operator’s position, and facing in the

direction of forward travel.

Customer Service and Technical Service

If you have questions or problems with the unit, contact your local dealer or the factory. (When calling or writing, provide the Model/Serial Numbers of the unit.)

Replacement Parts

Factory specified replacement parts are available from your authorized dealer or directly from the factory. When ordering parts, be sure to provide the following:

• Model/Serial Numbers of the unit.

• Part number of the part needed.

• Part Description.

• Quantity needed. NOTE: All replacement parts must conform to our rigid quality

specifications. Although some replacement parts we provide may vary slightly in shape, color or texture from the original parts, any variations will not affect the fit or performance of these parts on your unit.

Engine Service and Repair

For engine service or repair, contact your nearest authorized engine dealer (look in the f- Yellow Pages under “Engines-Gasoline”). The engine is warranted by the engine man ufacturer. Any unauthorized work performed on the engine during the warranty period may void this warranty. For complete details on the engine warranty, refer to the engine owner manual.

NOTICE:

We reserve the right to change specifications, add

improvements or discontinue the manufacture of any of our

equipment without notice or obligation to purchasers of our

equipment.

for customer assistance, contact your nearest authorized deaier or:

We urge using only genuine replacement parts, which

meet all the latest requirements. Replacement parts manufactured by others could present safety hazards,

even though they may fit on the unit.

GARDEN WAY INCORPORATED • 1 Garden Way • Troy, New York 12180

Customer Service: 1-800-437-8686 • Technical Service: 1-800-520-5520 • Parts Service: 1-800-648-6776

• FAX: (518)391-7332 • WEBSITE: www.troybilt.com Outside the United States and Canada:

Customer Service: (518) 391-7007

1905412 Rev. A (3/00) Printed in U.S.A.

Technical Service: (518)391-7008 • Parts Service: (518) 391-7006 FAX (518) 391-7332

A WARNING

> 2000 Garden Way Incorporated

Troy-Bilt 12208 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Owner’s Manual

Table of Contents

Safety Alert Symbol

il Safety

SPARK ARRESTER WARNING TO RESIDENTS OF CALIFORNIA AND SEVERAL OTHER STATES

Training

Preparation

Operation

Maintenance and Storage

Decals

Operating Symbols

WARNING

2 Assembly

A WARNING

Introduction

Inspect unit

STEP 1: Unpacking Instructions

Tools/Materials Needed for Assembly

STEP 2: Attach Handlebar

STEP 3: Move Tiller Off Shipping Platform

STEP 4: install Forward Clutch Cable

STEP 5: Install Reverse Clutch Cable (Models 12209/12210)

STEP 6: Check Level of Transmission Gear Oil

STEP 7: Add Motor Oil to Engine

STEP 8: Check Hardware for Tightness

STEP 9: Check Air Pressure in Tires (units with pneumatic tires)

3 Features and Controls

A WARNING

Introduction

Wheel Drive Pins

A WARNING

A WARNING

A WARNING

Forward Clutch Bail

Reverse Clutch Control (Models 12209/12210 only)

A WARNING

Depth Regulator Lever

Handlebar Height Adjustment

ENGINE CONTROLS

A WARNING

4 Operation

A WARNING

INTRODUCTION

BREAK-IN OPERATION

STARTING AND STOPPING THE ENGINE

A DANGER

A CAUTION

A WARNING

OPERATING THE TILLER

A WARNING

A WARNING

Avoid tilling wet, soggy soil

Avoid making footprints

Choosing correct wheel and tine speeds

Suggested tilling patterns

Clearing the tines

A WARNING

Tilling on slopes

POWER COMPOSTING

A WARNING

A WARNING

vuuui mm ■ ■

5 Maintenance

A WARNING

TILLER LUBRICATION

CHECK FOR OIL LEAKS

CHECK HARDWARE

CHECK TIRE PRESSURE (Models with pneumatic tires)

TRANSMISSION GEAR OIL SERVICE

A DANGER

BOLD TINES

CHECKING AND ADJUSTING FORWARD DRIVE BELT TENSION

FORWARD CLUTCH BAIL ADJUSTMENT

CHECKING AND ADJUSTING REVERSE DRIVE BELT TENSION (Models 12209/12210 only)

ENGINE CLEANING

AIR CLEANER SERVICE