Troybilt 12212 Owner’s Manual

0 TRtlI BILT°

Before ( , read this

manual

OWNER'SMANUAL

,®

REAR-TINETILLER

• Safety

• Assembly

• FeaturesandControls

• Operation

• Maintenance

• Parts List

Model

12211- RecoilStart
12212- ElectricStart

(Recoil Start Model Shown)

GARDEN WAYINCORPORATED

DearOwner:
You now own one of the finest standard-rotating-tine tillers

available.Yournew PONY® Model tiller allows you to till
and cultivate your garden with ease,andaccomplish
dozensof other property managementprojects aswell.
Your tiller is famous for its ruggedness,performanceand
high-quality engineering. We know you'll enjoy using it.

Pleasecarefully readthis Manual. It tells you how to safely
and easilyassemble, operate andmaintain your machine.

Be sure that you and any other operators carefully follow
the recommendedsafetypractices atall times. Failureto
do so could result in personal injury or property damage.

Ofcourse, if you should ever haveany problems or ques-
tions, pleasecontact your local authorized servicedealeror
callthe factory (see back cover of this Manual).

Wewant to be surethat you arecompletely satisfied at all
times.

NOTE:Besureto fill out and return the Warranty Registra-
tion Cardthat was suppliedwith this Manual.

See Back Cover for

Customer Service information

SafetyAlert Symbol

This is a safetyalert symbol. It is usedin this

manualand on the unit to alertyou to potential
hazards. Whenyou seethis symbol, readand

obey the messagethat follows it. Failureto
obey safety messagescould result in personal

injury or property damage.

This machine meets voluntary safety standard B71.8

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

American National Standards Institute.

WARNING

The engine exhaust from this product contains
chemicals known to the State of California to cause

cancer, birth defects or other reproductive harm.

Table of Contents

SECTION1: SAFETY........................................... 3

SafetyDecals .................................................................... 5

SECTION2: ASSEMBLY....................................... 6

Attach Handlebars.............................................................. 6

Attach ReverseClutch Control ........................................... 7

Attach ForwardClutch Control Cable................................. 7

CheckTransmission GearOil Level.................................... 8

Add Motor Oil to Engine..................................................... 8

AttachWheelGearLever.................................................... 8

CheckAir Pressure in Tires................................................ 8

CheckHardwarefor Tightness........................................... 8

ElectricStart Assembly Steps............................................ 9

SECTION3: FEATURES& CONTROLS........................ 11

WheelGearLever............................................................... 11

ForwardClutch Control...................................................... 11

ReverseClutch Control ...................................................... 12

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

HandlebarHeightAdjustment............................................ 12

EngineControls ................................................................. 13

SECTION4: OPERATION...................................... 14

Starting and Stoppingthe Engine...................................... 14

OperatingtheTiller ............................................................ 15

Tilling Tips & Techniques.................................................. 17

PowerComposting ............................................................ 19

Loading and Unloadingthe Tiller ....................................... 19

SECTION5: MAINTENANCE.................................. 20

MaintenanceSchedule....................................................... 20

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

CheckHardware................................................................. 20

CheckTire Pressure........................................................... 20

Checkfor Oil Leaks............................................................ 21

Transmission GearOilService........................................... 21

EngineOilService.............................................................. 22

Air CleanerService............................................................. 22

SparkPlug Service............................................................. 22

SparkArrester Screen Service........................................... 22

EngineCleaning................................................................. 22

Carburetor/GovernorControlAdjustments ........................ 22

Throttle Control Adjustment............................................... 22

WheelGearCableAdjustment............................................ 23

Off Season Storage............................................................ 23

Bolo Tines.......................................................................... 23

Checkingand Adjusting Tension on the Clutch Belts......... 24

ForwardClutch Belt Removal/Replacement....................... 25

ReverseClutch Belt Removal/Replacement....................... 27

BatteryMaintenance.......................................................... 28

TILLERATTACHMENTS........................................ 28

TROUBLESHOOTING.......................................... 29

PARTSLIST..................................................... 30

CUSTOMERSERVICEINFORMATION ............ BACKCOVER

Safety

SPARKARRESTERWARNINGTORESIDENTSOF
CALIFORNIAAND SEVERALOTHERSTATES

UnderCalifornia law,and under the lawsof severalother
states,you are not permitted to operate an internalcom-

bustion engineusing hydrocarbon fuels on any forest,
brush, hay,grain, or grass covered land;or landcovered

by anyflammable agricultural crop without an engine
spark arrester in continuous effective working order.

The engineon the unit isan internal combustion engine
which burns gasoline, a hydrocarbon fuel, and must be

equippedwith a spark arrester muffler in continuous
effectiveworking order. The spark arrester must be
attachedto the engineexhaustsystem in such a manner

that flames or heatfrom the system will not ignite
flammable material. Failureof 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. Contactyour local fire marshal or

forest servicefor specific information about which regu-

lations apply in your area.

improvefooting onslippery surfaces.

1. Carefullyreadthis

TRAINING

Owner's Manual,the sepa-
rateEngineOwner's Manual,
and any other literature you may receive.
Bethoroughly familiar with thecontrols
andthe proper use of thetiller and its

engine.Know how to stop the unit and
disengagethe controls quickly.

2. Neverallow children to operatethe

tiller. Neverallow adults to operatethe
tiller without proper instruction.

3. Keepthearea of operation clear of all
persons, particularly children and pets.

4. Keepin mind thatthe operator or user
is responsible for accidents or hazards

occurring to other people,their property
andthemselves.

PREPARATION

1. Thoroughly inspect the areawherethe

tiller is to be used and remove all foreign

objects.

2. Besure all controls arereleasedand

the Wheel GearLever is in ENGAGE

beforestarting theengine.

3. Donot operatethe tiller without

wearing adequateouter garments. Avoid

loosegarments orjewelry that could get
caught in moving parts.

4. Donotoperatethe tiller when barefoot
or wearing sandals,sneakers,or light

footwear. Wearprotectivefootwearthat will

5. Donottill nearundergroundelectric
cables,telephonelines,pipesor hoses. If in
doubt, contactyour telephoneor utility

company.

6. Warning:Handlefuelwith care;it is

highlyflammableandits vaporsareexplo-
sive. Takethefollowingprecautions:

a.

Storefuel in containers specifically

designedfor this purpose.

b.

Thegascap shall neverbe removed

or fuel addedwhile the engine is

running. Allow the engine to cool

for severalminutes beforeadding
fuel.

C,

Keepmatches, cigarettes,cigars,
pipes, openflames, and sparks

away from the fuel tank and fuel
container.

d. Fill fuel tank outdoors with extreme

care. Neverfill fuel tank indoors.

Usea funnel or spout to prevent
spillage.

e. Replaceall fuel tankand container

caps securely.

f. Iffuel is spilled, do not attempt to

start theengine, but move the
machineawayfrom the areaof
spillageand avoid creating any
source of ignition until fuel vapors
havedissipated.

7. Never makeadjustments when engine

is running (unless recommendedby
manufacturer).

Figure I

ForwardClutch

Control

Handlebar

HeightAdJuster

Wheel Gear

Lever

ForwardClutch

Contml Lever

Lever

_Standard

RotatingTines

OPERATION

1. Donot put handsor feet nearor under

rotating parts.

2. Exerciseextreme caution when on or
crossing graveldrives, walks, or roads.

Stay alert for hidden hazardsor traffic. Do
not carry passengers.

3. After striking aforeign object,stop the
engine (and remove the ignition keyon

electric start models), disconnect the
spark plug wire and prevent it from

touching the spark plug, carefully inspect
the tiller for any damage,and repairthe
damagebeforerestarting and operating

thetiller.

4. Exercisecautionto avoid slipping or

falling.

5. If the unit should start to vibrateabnor-
mally,stop the engine(and removethe

ignition key on electricstart models). Dis-
connectthe sparkplug wire and preventit
from touchingthespark plug, andcheck

immediatelyfor the cause.Vibration is
generallya warning of trouble.

6. Stop theengine (and removethe igni-
tion keyon electric start models), discon-
nect the spark plug wire and prevent it
from touching the spark plug whenever
you leavethe operating position, before
unclogging the tines,or when making any
repairs, adjustments or inspections.

7. Takeall possible precautionswhen
leavingthe machine unattended. Stop the
engine.Removeignition keyon electric
start models. Disconnectspark plug wire
and move it away from the spark plug.

Move Wheel GearLeverto ENGAGE.

8. Beforecleaning, repairing, or inspect-
ing, stop the engine, removethe ignition
key on electricstart models,and make
certain all moving parts havestopped.
Disconnectthe spark plug wire and
prevent it from touching the spark plug to
prevent accidental starting. On electric
start models, alwaysremove the cable
from the negativeside (-) of the battery.

9. Alwayskeepthetiller tine hood flap
down, unless using the hiller/furrower

attachment.

10. Neverusethe tiller unless proper
guards, plates,or othersafetyprotective

devicesarein place.

11. Donot run engine in an enclosed
area.Engineexhaust contains carbon

monoxide gas, a deadly poison that is
odorless, colorless, and tasteless.

12. Keepchildren and petsaway.

13. Never operatethe tiller under
enginepowerif the Wheel GearLever is

in DISENGAGE(FREEWHEEL).In this
position,the wheels will notboldthe

tiller backand therevolvingtinescould
propelthe tiller rapidly, possibly

causinglossofcontrol.Always move the

WheelGearLeverto ENGAGEbefore
starting the engine or engaging the

tines/wheelswith the Forward Clutch
Control or the ReverseClutch Control.

14. Beaware thatthetiller may unex-
pectedlybounceupwardorjump

forward if the tinesshouldstrike

extremelyhardpackedsoil, frozen
ground,or buriedobstacleslike large

stones,roots,or stumps.If in doubt
aboutthe tilling conditions,alwaysuse

thefollowing operatingprecautionsto
assistyou in maintainingcontrolof the

tiller:

a. Walk behindand toone sideofthe

tiller, usingonehandonthe han-
dlebars. Relax yourarm, butusea

securehandgrip.

b. Use shallower depthregulatorset-

tings, workinggraduallydeeper
with each pass.

c. Useslowerengine speeds.
d. Clear the tilling area of all large

stones,rootsandotherdebris.

e. Avoidusingdownwardpressure

on handlebars. If need be, use
slight upwardpressureto keepthe

tines from diggingtoodeeply.

f. Beforecontactinghardpackedsoil

at the endof a row, reduceengine
speedand lift handlebarstoraise

tines outofthe soil.

Inan emergency,stoptinesand

g_

wheels by releasing whichever
ClutchLeveris engaged. Do not
attempttorestrainthe tiller.

15. Donot overloadthetiller'scapacity
byattempting to till too deeplyattoo fast

arate.

16. Neveroperatethe tiller at high trans-
port speedson hardor slippery surfaces.

Look behind and usecarewhen backing
up.

17. Donot operatethe tiller on a slope

that is too steepfor safety.Whenon

slopes,slow down and makesure you
havegood footing. Neverpermit thetiller

to freewheeldown slopes.

18. Neverallow bystanders nearthe unit.

19. Only useattachments and acces-
soriesthat areapprovedby the tiller

manufacturer.

20. Usetiller attachments andacces-
sorieswhen recommended.

21. Neveroperatethe tiller without good

visibility or light.

22. Neveroperatethetillerif youaretired,
or underthe influenceof alcohol,drugs or

medication.

23.Operatorsshallnottamperwith the
engine-governorsettingsonthe machine;

thegovernorcontrolsthe maximumsafe

operatingspeedto protecttheengineand
allmoving partsfrom damagecausedby

overspeed.Authorizedserviceshallbe
soughtif aproblem exists.

24. Donottouchenginepartswhich may
behotfrom operation.Letpartscooldown
sufficiently.

25. Thebatteryon electricstart modeltillers
containssulfuric acid.Avoidcontactwith

skin,eyes,or clothing.Keepout of the
reachof children.

Antidote-ExternalContact:Flushimme-
diatelywith lotsofwater.

Antidote-lntemal: Drinklargequantities
of wateror milk. Followwithmilk of

magnesia,beateneggs or vegetableoil.
Calla doctor immediately.

Antidote-EyeContact: Flushwith water
for 15 minutes.Getprompt medical

attention.

26. Batteriesproduceexplosivegases.Keep
sparks,flame,andsmokingmaterialsaway.
Ventilatewhen charging batteriesorwhen

usinga batteryin anenclosedspace.
ALWAYSwearsafetygoggleswhen

working nearbatteries.

27. Pleaseremember:Youcanalwaysstop
thetinesandwheelsbyreleasingthe
ForwardClutchControlLeveror the

ReverseClutchControlknob(whichever
controlyou haveengaged),or bymoving

theEngineThrottleControlLever(located
on engine)to STOPon recoil start models

or by turning the ignition keyto OFFon
electricstart models.

28. Toloador unloadthetiller, seethe
instructionsin Section4 of this Manual.

29. Useextremecautionwhen reversingor
pullingthe machinetowardsyou.

30. Starttheenginecarefullyaccordingto
instructionsandwith feetwellawayfrom
thetines.

31. Neverpickup orcarry amachinewhile
theengineis running.

MAINTENANCEANDSTORAGE

1. Keepthe tiller, attachmentsand acces-
sories in safe working condition.

2. Checkall nuts, bolts, and screws at
frequent intervals for proper tightness to

be sure the equipment is in safeworking
condition.

3. Neverstorethe tillerwith fuel in thefuel
tank insideabuildingwhereignition

sourcesarepresentsuch as hot waterand
spaceheaters,furnaces,clothesdryers,
stoves,electricmotors, etc. Allowengineto
coolbeforestoringin anyenclosure.

4. To reducethechancesof afire
hazard,keepthe enginefree of grass,
leaves,orexcessivegrease.

5. Storegasolinein a cool, well-venti-
latedarea,safely awayfrom any spark-
or flame-producing equipment. Store
gasolinein an approvedcontainer,
safelyawayfrom the reachof children.

6. Referto the Maintenancesection of

this Manualand intheseparateEngine

Owner'sManual for instructions if the

tiller isto be stored for anextended

period.

7. Neverperform maintenancewhile
the engine is running or the spark plug
wire is connected,exceptwhen specifi-

cally instructed to do so.

8. If the fuel tank hasto bedrained, do
this outdoors.

OperatingSymbols

Various symbols (shown here,with
worddescriptions)may beusedonthe
tillerandengine.

DECALS

Foryour safety and the safety of others,
various safety messagedecals are on your
unit (seeFigure2). Keepthe decalsclean
and legible atall times. Contactyour local
servicedealeror the factoryfor

TineWarning (on right

sideof hoodflap)

StartingStabilization(on

topofengine orfuel tank)

replacementsif anydecals aredamagedor
missing,

Referto the Parts List pagesfor decal
locationsand part numbers.

I KeyswitchWarning

(electrc start unton y)

Instructions and

Warning Messages

Surfaces/MovingBelts

(ontopofbeltcover)

FAST SLOW

STOP

6 8 I-'-I

STOP START

CHOKE

ON

I÷1 R

CHOKE ROTATING

OFF TINES

41BE--><--411

ENGAGED DISENGAGED

"_ REVERSE

o--->

LEVERDIRECTION

TILLERDIRECTION

Figure2: Locationof Safetyand OperatingDecals

TO AVOID SERIOUS INJURY:

• READTHEOWNER'SMANUAL.

• KNOWLOCATIONSAND FUNCTIONSOFALL CONTROLS.

• KEEPALL SAFETYDEVICESANDSHIELDSIN PLACEANDWORKING.

• NEVERALLOWCHILDRENOR UNINSTRUCTEDADULTSTOOPERATETILLER.

• SHUTOFFENGINEANDDISCONNECTSPARKPLUGWIRE BEFOREMANUALLYUNCLOG-

GINGTINES ORMAKINGREPAIRS.

• KEEPBYSTANDERSAWAYFROM MACHINE.

• KEEPAWAYFROM ROTATINGPARTS.

• USEEXTREMECAUTIONWHEN REVERSINGORPULLINGTHEMACHINETOWARDSYOU.

Assembly

HARDWARE BAG PARTS LIST

To prevent personal injury or property
damage, do notstartthe engineuntil all
assembly steps are complete and you
haveread and understandthe safetyand
operatinginstructionsin thisManual.

INTRODUCTION

Carefullyfollow these assembly stepsto
correctly prepareyour tiller for use. It is

recommendedthat you readthis Section
in its entirety beforebeginning assembly.

INSPECTUNIT

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
damageand request instructions for filing
a claim. To protect your rights, put your
claim in writing and mail a copy to the
carrier within 15 daysafter the unit has

beendelivered. Contactus at thefactory if
you needassistancein this matter.

UNPACKINGANDASSEMBLY
INSTRUCTIONS

STEP 1: UNPACKING INSTRUCTIONS

1. Removeanycardboardinserts and
packagingmaterial from thecarton.
Removeanystaplesfrom the bottom of

thecarton and remove the carton.

2. Cutthe large,plastictie strap that
securesthe transmission tube to the ship-

ping pallet. Leavethe handlebarson top
of thetiller to avoiddamaginganycables.

3. A bagwith loose hardware is inside
the literature envelope. Checkthecon-
tents againstthe following list and Figure
2-1. Contactyour localdealer orthe
factory if any items are missing or
damaged.

NOTE: Forelectric start units, a second
hardwarebag is locatednearthe battery.

4. Thetiller is heavy. You should not
attempt to remove it from the shipping

platform until instructed to doso in these
"Assembly" steps.

Fig.
Ref. Qty. Description

1 2 3/8-16 x 1"Hex Hd. Screw
2 1 KeyedWasher

3 1 WheelGear LeverKnob
4 1 HeightAdjustment Flange

Screw (SeeFigure2-1A)

5 2 3/8" FlatWasher
6 2 #10 Lockwasher

7 2 3/8"-16 Nylock Lock Nut
8 2 #10-32 x 1/2" RoundHd.

Screw

9 2 #10-32 Nut
10 1 Cotter Pin (not used)

11 4 Plastic Tie Strap (2 not used)

Tools/Materials Needed
for Assembly

(1) 3/8"open-end wrench*
(1) 7/16" open-end wrench* (electric

start unit only)
(2) 9/16" open-end wrench*
(1) 7/8" open-end wrenchor 8"long

adjustablewrench
(1) Scissors (to trim plastic ties)
(1) Ruler
(1) Small board (to tap plastic knobon

lever)
(1) Tire pressure gauge
(1) Cleanoil funnel
(1) Clean,high-quality motor oil. Refer

to the separateEngineOwner's
Manualfor motor oil specifications

and quantity required.

* Adjustable wrenches may be used.

IMPORTANT:Motor oil must be addedto

the engine crankcasebeforethe engine is
started. Follow the instructions in this

"Assembly" Section andin the separate

EngineOwner's Manual.
NOTE:LEFTand RIGHTsides of the tiller

are as viewed from the operator's posi-
tion behind the handlebars.

STEP 2: ATTACHHANDLEBARS

1. Onelectric start units, remove one

screw and Iockwasherfrom the curved

60o

81 T

700 lo

11

Figure2-I: Loosehardware(shownin
reducedsize).

Figure2.1,4: Handlebarheightadjustment
usestheflangeheadscrew,

Figure2.2," Onelectricstart units, move
heightadjustmentbracketaside.

height adjustment bracket (A, Figure 2-2),
loosenthe secondscrew, andswing the

bracketto one side.

2. Cutthe large, plastic cable ties that
securethe handlebarends to the handle-

bar mounting tabs on the transmission
top cover.

3. Gentlylift handlebar(do not over-
stretch attachedcable) and placehandle-

bar cross-brace (B, Figure2-3) in front of
curved height adjustment bracket (C).

Figure 2.3: Forwardclutch controlcable not

shownfor clarity.

4. With theforward clutchcable (N,
Figure2-4) onthe insideof handlebar,

position the handlebarends on the
outside of the two mounting tabs (M,

Figure2-3) on the transmission top
cover.

NOTE: Thecurved handlebarheight
adjustment bracket appearsas shown in
C, Figure 2-3 for non-electric start units.

Forelectric start units, the bracketis loos-
enedand movedto one side.

5. Loosely attachthe handlebarsto the
mounting tabs with two 3/8-16 x 1"

screws (heads of screws go to inside of
tabs),3/8" flat washers and 3/8"-16 lock
nuts (O, Figure2-4).

Figure2.4: Attachhandlebars.

6. On electric start units, reattach the
height adjustment bracket (A, Figure 2-2).

Tighten both screws securely. Makesure
the handlebarcross-brace (B, Figure2-3)
is under the bracket.

7. Move the handlebars up or down to
align the threaded hole in the cross-brace

with one of the four slots in the curved
height adjustment bracket. Placethe

keyedwasher (E,Figure 2-3) on the
flange headheight adjustment screw (F)

with the raised keys (edges) of the
washer facing down.

8. Threadthe height adjustment screw
(F, Figure2-3) into the hole in the handle-
bar cross-brace, making sure that the
raised keyson the washer fit into the slot
on the height adjustment bracket.
Tighten the height adjustment screw
securely. Next,securelytighten the two

screws and nuts in the endsof the han-
dlebar (M, Figure2-3)=

9. To remove the tiller from its shipping
platform, first carefully unwrap the wheel
gear cable (with attached lever- see
Figure2-5) from around the chassis.

Move the Wheel GearLever(G) to the
DISENGAGEposition--this allows the

wheelsto rotate freely. Usethe handle-
barsto roll the tiller off the platform.

Figure2.5: CarefullyunwrapWheelGear
LeverandmovelevertoDISENGAGE.

NOTE: TheWheelGearLeverwill be
installed later in this procedure.

IMPORTANT: UsetheDISENGAGEposi-
tion only whentheengine is not running.

Beforestarting the engine,theWheelGear
Levermust be placed in the ENGAGE

position (see Section 3 for details).
STEP 3: ATTACH REVERSE

CLUTCH CONTROL CABLE

1. Carefully unwrapthe reverseclutch

control cable (H, Figure2-6) from its
shipping position and route it up along
the inside edgeof theleft side handlebar.
A knob and large hex nut (I) is installed

on the cable.

Left Side ReverseClutch

Handlebar Control Knob

"H

Figure2.6:Attachreverseclutchcontrol
assemblytoslottedholeinhandlebarpanel.

2. Insertthe cableinto the slot inthe
control paneland fit the threadedassem-

bly into the hole in the slot (see Figure2-

6)= Besure thatthe flat side of the
threadedassembly is aligned with theflat

side of thehole=Slide the hexnut (I) up
the cableand tighten it securely=

3. Testthe function of the reverse clutch
control cable by pulling the knob out and
releasingit. The knob should return to its

neutral position against thetapered
bushing. If it doesn't, contact your local
dealer or the factory for technical

assistance.

STEP4: ATTACHFORWARD
CLUTCH CONTROL CABLE

1. Removeany fasteners (rubber bands,

tape, etc.) that may securethe Forward

ClutchControl levers (J, Figure 2-7) to the
handlebar.

Figure2- 7: ForwardClutchControllevers
(J). Forwardclutch controllinkage (K).

2. Theforward clutch control cable (with
attachedspring) is hanging loosely near

the right-side wheel. Beingcareful not to

kink or stretch the cable, insert the z-con-
nector (L, Figure2-8 - end of the spring)

into the hole at the end of the forward
clutch control linkage (K, Figure2-7).

Figure2-8

3. Attach the cableadjuster (A, Figure
2-9) to the bracket on the right-side han-

dlebar. Usetwo 1/2"wrenches to loosen

the two jam nuts (B)just enoughto slide
the cableadjuster onto the bracket. Then

handtighten thejam nuts.

Figure2.9

Incorrectcable adjustment could cause
thewheels and tines to rotate unexpect-

edly. Follow adjustment procedures
carefully. Failure to do so could result
in personal injuryor propertydamage.

4. Checkfor correct spring/cabletension

as instructed in Section 5, Checkingand
Adjusting Forward Clutch Belt Tension.

5. Whentension is correct, tighten the
two jam nuts (B) securely.

STEP 5: CHECK TRANSMISSION
GEAR OIL LEVEL

Thetransmission wasfilled withgear oil
at thefactory. However,besure to check

the oil level at this time to makecertain it

iscorrect.
IMPORTANT:Donot operatethe tiller if

the gearoil levelis low=Doing sowill
result in severedamageto the transmis-

sion components.

I. With the tiller on levelground, pull the
DepthRegulator Lever(R, Figure2-13)

back and then slide it to the second notch
from the top. NOTE:If the leverdoesnot

move, lift the fine hood flap and look for a
plastic tie securing the lever in place. Cut

and remove the tie.

2. Removethe oil level check plug (M,
Figure2-I0) on the left-side of thetrans-

mission= (Dueto dried paint on the plug
threads, it may require some force to

remove the plug the first time.) Thegear
oil level is correct if oil starts to flow out

of the hole as the plug is removed. If so,
securely reinstall the plug.

Figure 2-11: Addinggear oil.

(b) If adding only a few ounces of gear
oil, useAPI ratedGL-4 or GL-5 gearoil

having aviscosity of SAE140, SAE85W-
140 or SAE80W-90. If refilling anempty

transmission, use only GL-4 gearoil
having aviscosity of SAE85W-140 or

SAE140.
(c) Using a clean funnel, slowly add gear

oil until it flows from the gear oil level
check hole (N, Figure2-11).

(d) Reinstall andtighten securely the gear
oil fill plug (M, Figure 2-10).

STEP 6: ADD MOTOR OIL TO ENGINE
Thetiller is shipped withoutoil in the

engine crankcase.
IMPORTANT:Do not start the engine

without first adding motor oil. Severe
engine damagewill result if the engineis

run without oil=

1. Referto the separateEngineOwner's
Manualfor motor oil specifications and
capacities.

2. With the unit on levelground, move
the Depth Regulator Lever(R, Figure 2-

13) up or down until the engine is level.

3. Add motor oil as described in the
EngineOwner's Manual.

4. Move the DepthRegulatorLever all
the way down until the highest notch is
engaged. This placesthe tines in the

"travel" position.

Figure2.12: Attach Wheel Gear Lever.

Figure2.13: Attachwheelgear cable and
reverse clutchcable withcable ties ($).

3. Usea small board to tap the Wheel

Gear Lever knob securely onto the lever.

4. Securethe wheelgear cable and the
reverseclutch control cableto the left-

sidehandlebarwith two plastic ties (S,
Figure2-I 3) locatedabout two feet apart.
Snip off anyexcesstie lengthwith

scissors.
STEP 8: CHECK AIR

PRESSURE IN TIRES
Usea tire pressuregaugeto check the air

pressure in both tires. Deflateor inflate
bothtires equally to 154o-20 PSI
(pounds per square inch). Besure that
bothtires are inflated equally or the unit

will pull to oneside=

Figure2-10: Gearoil level checkplug.

3. If oildoes not flow from the check
hole, addoil asfollows:

NOTE:Do not use automatic transmission
fluid or motor oil in the transmission.

(a) Cleanareaaround the fill hole (N,
Figure2-11) and unscrew gearoil fill

plug.

STEP 7: ATTACHWHEEL GEAR
LEVER

I. Insert theWheelGear Lever (P, Figure

2-I 2) upthrough the slot in thecontrol
panel that is labeled"WHEELGEAR."

2. Insert two #10-32 x I12"round head
screws down through the "+"marks on

the control panel decaland securely
attachthe wheelgear mounting bracket
using two #10 lockwashersand #10-32

nuts.

STEP 9: CHECK HARDWARE

FOR TIGHTNESS

Inspect the hardware on the unit and

tighten any loose screws, bolts and nuts=

IMPORTANT:

• This completesassembly for recoil start

tillers. Readthe rest of this Manual, and
the separateEngineOwner's Manual,

before operatingthe tiller.

•Electric start models--continue with the

Assembly Steps.

Electric Start

AssemblySteps

Thefollowing steps explain how to
prepareand install the battery. FOR

YOURSAFETY,CAREFULLYFOLLOW
ALL STEPSANDOBSERVEALL ACCOM-

PANYINGSAFETYMESSAGES.Checkfor
the following items (see Figure 2-14):

I. Battery (installed on tiller)

2. Clearplastic vent tube

3. Two hex screws and hex nuts

2 3

Figure2.14

the battery unlessyou arefully experi-
encedin battery activation and charging
procedures.

To ensurethat the battery is properly acti-
vated and charged,you should review the

activating and charging instructions with
your battery technician.

Battery electrolyte is a sulfuric acid

solution that is poisonous and causes
severeburns.

• Avoidspills or contactwithskin, eyes,

clothing.

• To preventaccidents, wear protective

clothes, rubberglovesandshield eyes
with safety goggles when working on

or nearthe battery.

• Neutralize acid spills with a baking
soda and water solution. Neutralize

electrolyte container with same solu-
tion. Then rinse with clear water.

ANTIDOTE:External- Flushwith water.

Eyes- Flush with water for 15 minutes

and get immediate medical attention.
ANTIDOTE: Internal - Drink a large

quantity of water or milk. Follow with
milk of magnesia, beaten eggs, or veg-
etable oil. Call physicianimmediately.

the UPPERLEVELline printed on the

battery. Do not add water or anyother
liquid during this initial activation.

6. Allow batteryto stand for 30minutes
and then recheck the electrolyte levelin
eachcell. Add more electrolyte solution if

needed. Donot overfill the battery as this
could result in flooding from the cells
during charging.

Batteriesproduceexplosivegases!

• Keep sparks, flame and cigarettes

away.

• Ventilate area when chargingor using

batteryin an enclosedspace.

• Make sure venting path of battery is
alwaysopenoncebatteryis filled with

acid.

• Follow safety rules and instructions
supplied by manufacturers of battery
andchargerunit.

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

becontinuous.

• When checking the battery for
gassing, always wear safety goggles
and use a flashlight to look down into

thecells.

Remove metal jewelry before working
near the battery or near the electrical

system.

Failure to comply may cause a short
circuit, resulting in electrical burns,
electrical shock, or an explosion of
batterygases.

STEP 1: Battery Activation and
Charging

Thebattery is shippeddry=It must be
filled with battery electrolyte (battery
grade sulfuric acid) and fully charged

beforeit canbe used.
Adding electrolyte and charging the

battery canbe dangerous. Theelectrolyte
contains acidthat can burn or blind you.

Batterycharging produces potentially
explosivegases.

It is strongly recommended that you have
the batteryserviced by atrained profes-
sional (your authorized tiller dealer, a reli-
ableservice station, abattery store, etc.).

Donot attempt to activate and charge

A. To Activatethe Battery:

I. Removethe batteryfrom thetiller by

removing the screws, lockwashers and
nuts from the battery hold-down clamp

(Figure2-15).

2. Placebattery on a levelsurface, safely
away from any spark- or flame-producing

sources such as stoves, heaters, electrical
switches, pilot lights, dryers, etc.

3. Removeand discard the short sealing
tube (if soequipped) that coversthe vent
fitting locatedon the negative(-) side of
the top of the battery.

4. Removethe six filler caps from the top
of the battery. Leavethe caps off while
activating and charging the battery.

5. Puton protectiveclothing, rubber
gloves and eyeprotection. For best

results, the temperature of the battery and
electrolyte should be between600 Fto

80° F. Carefully fill eachof the six cells
with electrolyte (batterygrade sulfuric

acidwith a specific gravity of 1.265) up to

B. To Chargethe Battery:
Formaximum battery life, charge the

batteryusing the following method until
all cells are gassingfreely. A battery is
gassing freely when the surfaceof the
electrolyte is covered with tiny bubbles.

Besureto follow all instructions provided

bythe manufacturer of the battery charg-

ing unit that is being used to charge the

battery.

1. Chargethe batteryapproximately three
to five hours at a rateof 1-to-2 amperes.
Turn the battery chargeroff and discon-

nectthe charger cablesfrom the battery

terminals.

2. Checkthe electrolyte level in eachcell.

If the electrolyte level hasfallen, refill the
batterywith distilled water until the level
reachesthe UPPERLEVELline.

3. Securelyreplaceall six filler caps. Use
a baking soda and water solution to rinse

off any electrolyte that may havespilled.
Thendry the battery.

• Do not touch positive (+) battery
terminal and any surrounding metal
with tools, jewelry or other metal

objects. Failure to complycouldcause

a shortcircuitthat couldcauseelectri-

cal burns or an explosion of battery
gases.

• Incorrectinstallationofthe batterycan

result in electrical system damage.
Follow installation instructions care-

fully to avoid damage.

Figure2.18: Checktightness of upper
mountingscrew.

Figure2.16: Attachpositive (+) battery

cable. Coverconnectionwithrubber boot.

STEP2: Install Battery

1. Reinstallthebattery on the battery
mounting basewith thetwo cablemount-

ingposts facing to the rear of the tiller=
Besure that thepositive (+) post ison the
left-sideof the tillerand the negative (-)
post is on theright-side (as viewedfrom
rear of tiller). SeeFigure 2-15.

Figure2.15

2. Reinstallthe battery hold-down
bracketoverthe batterywiththe ignition

switch (T, Figure2-15) toward thefront
of the unit. Attach the bracket to the

mounting base using the two 1/4-20 x 1-

1/4"carriage screws (insert screws up
from beneath mounting base), 1/4" lock-
washers and 1/4"-20 nuts removedprevi-

ously. Tightenthe nuts securely,but not

so much as to bend thetabs on the hold-

down bracket.

STEP3: Attach Battery Cables

and Vent Tube

1. Locatethe positivebattery cable,

which is connectedto the starter solenoid

on the left-side of the battery post (a

rubber boot covers the connection). A

second rubber boot is loosely installed on
the cable. Get the small screw and nut

from the hardware bag, connect the loose
end of the cable to the positive (+) post
on the battery. See Figure2-16.

2. Slidethe rubber boot over thepositive
(+) batterypost.

3. The negativebattery cableis con-

nected to the upper mounting screw that
attachesthe starter solenoidto the back

of thebattery post. This is the ground for
the negativecable. Usingthe second

screw and nut, attachthe looseend of the
cableto thenegative (-) battery post. See

Figure2-17.

Figure2.17: Attachnegative (.) battery
cable.

4. Checkthetightnessof the upper

mounting screw that securesthe negative
cableand starter solenoid to the battery
post. SeeFigure2-18, Scrapeaway any
paint betweenthe cableand the screw as
the paint canprevent a good electrical
ground.

5. Install one endof the clearplastic vent

tube overthe vent fitting (U, Figure2-19)
on the battery= Insertthe other end down
into thevent tube shield (V)=

Figure2.19: Instafl vent tube.

Improper ventingcan causea battery to
explode, resulting in severe personal
injuryor propertydamage.

Be sure that the vent tube does not
becomekinked, folded or pinchedalong

itsentire length.

STEP 4: Connect Wiring Harness

Attachthe wiring harness receptacleto
the prongs on the back of the ignition

switch (seeFigure2-20).
IMPORTANT: This completes the assem-

bly steps for the electric start tiller. Be
sureto read the rest of this Manual, and

the separateEngineOwner'sManual,
beforeyou operateyour tiller.

Figure2.20: Attachwiringharnessto
keyswitch.

FeaturesandControls

Before operating your machine, care-
fully read and understand all safety,
controls and operating instructions in
this Manual, the separate Engine

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

Failure to follow these instructionscan

resultin seriouspersonal injury.

INTRODUCTION

This Section describesthe location and
function of the controls on your tiller.

Referto thefollowing section "Opera-
tion" for detailedoperating instructions,

Practiceusing these controls, withthe
engine shut off, until you understandthe

operationof the controls and feel confi-
dentwith them.

IMPORTANT:Referto theseparate
engine manufacturer's EngineOwner's

Manualfor information aboutthe con-
trois on theengine.

WHEEL GEAR LEVER
Thislever (A, Figure 3-1) hastwo posi-

tions: ENGAGEand DISENGAGE.
In the ENGAGEposition, the wheels will

start turning when eitherthe Forward
ClutchControl or the ReverseClutch

Control is engaged (thetines will also
start turning when eitherclutch is

engaged).

Figure3. I: Controlslocated onhandlebar.

TheDISENGAGEposition placesthe
wheels in the freewheeling mode to allow

the unit to be moved without the engine
running. Usethe DISENGAGEposition
only whenthe engine is not running. See

"DANGER"statementthat follows.
To shift to ENGAGE,gently (do not force)

move the lever forward whilealso rolling
thetiller a few inchesforward or back-

ward. Moving thetiller helps to align the
shift mechanismwith the transmission

wheeldrive gears.
To shift to DISENGAGE(freewheel),

move the lever rearward, without rolling
thetiller. The wheels will roll freely

whenthe lever is properly set in the
DISENGAGEposition.

FORWARD CLUTCH CONTROL

Thetwo interconnectedlevers (B, Figure

3-1) control the engagementof forward

drive to the wheels and tines.
To Operate the ForwardClutch Control:

1. Beforeengagingthe Forward Clutch

Control, put the WheelGearLeverin the

ENGAGEposition (see"WARNING"
below).

2. Pull up and hold one or both of the
leversagainst the handlebargrips to

engagethe wheelsand tines.

3. ReleaseBOTHlevers to disengage
(stop) the wheels and tines. All forward
motion will stop (theenginewill continue

to run).

Never place the Wheel Gear Lever in
DISENGAGE (Freewheel) when the

engine is running.
Having the Wheel Gear Lever in

DISENGAGE and then engaging the
tines/wheels with either the Forward

Clutch Control or the Reverse Clutch
Control could allow the tines to propel

thetiller rapidly forward or backward.
Failure to follow this instructioncould

result in personal injury or property
damage.

Never engage the wheels andtines with

the Forward Clutch Control or the

Reverse Clutch Control unless the

Wheel GearLever is in ENGAGE.

Engagingthe ForwardClutchControl or

the Reverse Clutch Control when the
wheels are not engagedcould allow the

tines to rapidly propel the tiller forward
or backward.

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

damage.

REVERSECLUTCHCONTROL

TheReverseClutch Control (C,Figure

3-1) controls the engagementof reverse

drive to the wheels and tines. The revers-

ingfeature is usedfor maneuveringthe

tiller only - neverengagethetines in
thegroundwhile goinginthe reverse
direction.

• Use extreme caution when reversing

or pulling the machine towards you.

Look behindto avoid obstacles.

• Never attemptto till inreverse.

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

To Operatethe ReverseClutch Control:

1. Put the WheelGearLeverinthe
ENGAGEposition (seethe "WARNING"

statementon previous page).

2. Stop all tiller motion by releasingthe
ForwardClutchControl levers=

3. Lift up the handlebarsuntil thetines

cleartheground, look behind you to avoid
any obstacles,andthen pullthe Reverse

Clutch Control knob out. Thetines and
wheels will rotate in a reversedirection=

4. Releasethe ReverseClutchControl
knobto disengage(stop) thewheelsand

tines=All reversemotion will stop (the
engine will continue to run).

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

deepertilling depths.

• Place the Depth RegulatorLever in the
"travel" position before starting the

engine. This position prevents the
tines from touching the ground until
youare readyto begintilling.

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

damage.

DEPTH REGULATOR

TheDepth Regulator lever (D, Figure 3-2)
controls thetillingdepthof the tines. Pull

theleverstraight backand slide it upor
down toengagethenotched height set-

tings.

Figure3.2: DepthRegulatorLever.

Thehighest notch (leverall the way
down) raises the tines approximately

1-1/2 inches offthe ground= This"travel"
position allows the tiller to be moved

without the tines digging into theground.
Moving the lever up increasesthe tilling

depth. The lowest notch allows a tilling
depth of approximately six to eight

inches,depending on soil conditions.

Forbestresults, alwaysbegintilling at
a very shallowdepthsetting andgradu-
ally increasethe tilling depth. Complete

details on using the Depth Regulator are

found in the "Operation" Section of this

manual.
HANDLEBAR HEIGHT ADJUSTMENT

Figure3.3: Handlebar heightadjustment.

The handlebarheight is adjustableto four

different settings. Setthe handlebar
heightto a comfortable setting, but keep

in mind that the handlebarswill be lower

when the tines are engagedin thesoil.
To Adjust the HandlebarHeight:

I. Stop the engine, wait for all partsto
stop moving and then disconnect the

spark plug wire. Removethe ignition key
on electric start models.

2. Loosenthe two screws at the lower
endsof the handlebar=

3. Loosenthe height adjustment screw
(E,Figure3-3) and pull the keyedwasher

(F)free of theslots in the curved height
adjustment bracket.

4. Move the handlebars to the new slot
setting and insert the raised keyson the
keyedwasher into the slot. Tightenthe

height adjustment screw securely.

5. Retightenthetwoscrews at the ends
of the handlebar.

ENGINECONTROLS

Referto the engine manufacturer's Engine

Owner's Manual (included inthe tiller lit-
erature package)to identify the controls

on your engine. The following two con-
trols areusedwhen stopping or starting
the engine.

IMPORTANT:Thecontrol for stopping
the recoil start engine is located on the
engine.

ENGINE THROTTLE CONTROL LEVER

TheEngineThrottleControlLever(located
on engine--see Figure4-1) is usedto reg-

ulatethe engine speed. Onthe recoil start

modelonly, it is also used to stop the
engine (on the electricstart model, the

electric start keyswitch is used to stop the
engine). Thethrottle settings areshown

below.

IMPORTANT: See"Starting andStopping
the Engine"in the "Operation" Section for
detailedengine starting andstopping

instructions.

ELECTRIC START KEYSWITCH

(ELECTRIC START MODEL)

The ignition keyswitch on the electric
start model (H, Figure 3-5) is usedto
start and stop the engine. The keyswitch

settings are described below.

Figure3.5: Electricstartkeyswitch.

IMPORTANT: See"Starting and Stopping
the Engine"in the "Operation" Section for
detailedengine starting and stopping

instructions.
OFF-Stops engine.
RUN - After starting, keyreturns to run

position.

,_ FAST- Usefor most tilling and cul-

tivating projects.

SLOW- Usewhen idling engineor
when slower tilling and cultivating

speeds areneeded.

O STOP- Stops the engine (onrecoil

start models only).

START- Starts engine. Releasekey when
engine starts (avoid cranking enginefor

longer than 15 secondsfor eachattempt).

Operation

ForwardClutch
ControlLever

ReverseClutch

GearLever

Before operating your machine, care-
fully read and understand all safety

(Section 1), controls (Section 3) and
operating instructions (Section 4) in

this Manual, in the separate Engine
Owner's Manual, and on the decals on
themachine.

Failure to follow these instructionscan
resultin seriouspersonal injury.

INTRODUCTION

Readthis Sectionof the manualthor-
oughly beforeyou start theengine, Then,

takethe time to familiarizeyourself with
the basicoperation of the tiller before
using it in the garden.

Findan open, level areaand practice
using thetillercontrols without the tines
engagingthe soil (put tines in"travel"
setting). Only after you've becomecom-
pletely familiar with the tiller should you
begin using it in the garden.

BREAK-IN OPERATION
Perform the following maintenanceafter

thefirst two hours of new operation (see
"Maintenance" in this manual andthe

EngineOwner's Manual).

1. Changeengine oil.

2. Checkfor loose or missing hardware
on unit. Tighten or replaceas needed.

3. Checktransmission gear oil level.

4. Checktension on forward clutch belt.

HandlebarHeight

AdjustmentScrew

EngJ
Control Lever

Figure 4- I: Locationof main tiller controls.

STARTINGANDSTOPPING
THE ENGINE

To help prevent serious personalinjury
or damagetoequipment:

• Before starting engine, put Wheel
GearLeverin ENGAGEposition.

• Before starting engine, put Forward
Clutch Control levers and Reverse

ClutchControlin neutral (disengaged)
positionsby releasing controls.

• 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 exceed150OF.

PRE-START CHECKLIST:
Make the following checks and perform

the following services beforestarting the
engine.

\

ForwardClutch

Control Lever

1. ReadSections 1 and 3 in this Manual.
Readthe separateEngineOwner's

Manual.

2. Checkunit for loose or missing hard-

ware. Serviceas required.

3. Checkengine oil level. SeeEngine

Owner's Manual.

4. Checkthat all safety guards and
covers are in place.

5. Checkair cleanerand engine cooling
system. See EngineOwner's Manual.

6. Attachspark plug wire to spark plug.

GASOLINEIS HIGHLYFLAMMABLEAND

ITSVAPORSAREEXPLOSIVE.

Follow gasoline safety rules in this
manual (see Section1) and in the sepa-
rate EngineOwner'sManual.

Failure tofollow gasoline safety instruc-
tions can result in serious personal

injuryand propertydamage.

7. Fillthefuel tank with gasolineaccord-

ing to the directions in the separate
EngineOwner's Manual. Follow all
instructions andsafety rules carefully.