Troy-Bilt 15009 User Manual

Owner/Operator Manual

ECONO-HORSE^ PONY® & JUNIOR® Model Tillers

• Safety

$4.50

Models

• Assembly

• Controls

• Operation

• Maintenance

15006 15008 15009

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GARDEN WAY INCORPORATED

Dear Owner,

You now own one of the finest reartine rototillers available. Your new ECONO-HORSE® Model, PONY® Model or JUNIOR® Model 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, perfor mance and high-quality engineering. We know you’ll enjoy using it.

Please carefully read this Manual. It tells you how to safely and easily assem ble, operate and maintain your machine.

Be sure that you and any other operators carefully follow the recommended safety

practices at all times. Failure to do so

could result in personal injury or prop erty damage.

Of course, if you should ever have any problems or questions, or for a replace ment copy of this Manual, please contact your local authorized service dealer or call us Toll-Free. Our telephone num bers and mailing addresses are listed on Page 3 and the back cover of this Owner/ Operator Manual.

This is a safety aiert

symbol. It is used in this Owner/Operator Manual to alert you

Whenever you see this symbol, read and obey the safety message that follows it. Failure to obey the safety message could result in persona! injury or property damage.

Be Sure To Return Your Warranty Registration Card

Be sure to fill out and mail your Warranty Registration Card, which is located in your literature pack age. The infor mation contained on this card will register your machine with us and entitle you to warranty coverage.

to potential hazards.

J'JJAW-

We want to be sure that you are com pletely satisfied at all times.

This machine meets voluntary safety stan dard 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 repro ductive harm.

-ioieMs

Owner’s Record

Please write the Mode! and Serial numbers of your machine in the spaces provided. You can find the location of these numbers by refer ring to the graphic below.

Model Number:

Serial Number:

SECTION 1: SAFETY INSTRUCTIONS..................................................................4

Safety Alert Symbol..............................................................................4

Training.................................................................................................4

Preparation...........................................................................................4

Operation..............................................................................................4

Maintenance and Storage.....................................................................6

Decals...................................................................................................6

SECTION 2; EASY ASSEMBLY................................................................................7

SECTION 3: TILLER ANO ENGINE CONTROLS................................................18

Tiller Controls......................................................................................18

Engine Controls..................................................................................22

SECTION 4: OPERATION OF TILLER..................................................................24

Before Starting....................................................................................25

To Begin Tilling...................................................................................25

Turning Around

Stopping the Tiller and Engine............................................................25

Changing Speeds (Econo-Horse only)

Tilling in the Garden............................................................................27

Guiding your Tiller.......................................................................27

Tilling Depths...............................................................................27

Tilling Patterns.............................................................................28

Choosing WheeJ and Tine Speeds

Avoid Making Footprints..............................................................29

Clearing Debris from the Tine Area

Power Composting......................................................................30

Using Reverse to Turn in Tight Areas.........................................30

Tilling Near Obstacles

Tilling Up and Down Slopes........................................................31

Tilling Across Slopes Using Terraces.........................................31

Tilling Across Slopes Without Terraces Loading and Unloading the Tiller

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

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

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

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

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

32 32

Model and Serial Number location

SECTION 5: TILLER AND ENGINE MAINTENANCE

Lubrication..........................................................................................33

Check for Oil Leaks.............................................................................34

Tightening Nuts and Bolts...................................................................34

Checking/Adding/Changing Transmission Gear Oil

Checking Engine Oil Level..................................................................35

Changing Engine Oil...........................................................................36

Air Cleaner Service.............................................................................36

Spark Plug Maintenance.....................................................................37

Ignition System Maintenance..............................................................37

Air Cooling System Maintenance........................................................37

Bolo Tines...........................................................................................37

Checking Tension on the Drive Belts..................................................38

Adjusting Forward Drive Belt Tension.................................................39

Removing and Installing Forward Drive Belt......................................41

Removing and Installing Reverse Drive Beit Adjusting Reverse Drive Belt Tension Wheel Gear Cable Adjustment

Engine Throttle Cable Adjustment......................................................44

Off-Season Storage............................................................................44

Troubleshoot Electric Start System.....................................................45

Battery Care and Maintenance...........................................................47

Carburetor Adjustment........................................................................47

Specifications......................................................................................48

Recommended Maintenance Intervals

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

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

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

TROUBLESHOOTING......................................................................................50-51

INDEX..........................................................................................................................52

42 43 43

A CAUTION

TO AVOID SERIOUS INJURY:

READ THE OWNER / OPERATOR MANUAL. KNOW LOCATIONS AND FUNCTIONS OF ALL

CONTROLS. KEEP ALL SAFETY DEVICES AND SHIELDS IN

PLACE AND WORKING. NEVER ALLOW CHILDREN OR UNIN

STRUCTED ADULTS TO OPERATE TILLER. SHUT OFF ENGINE AND DISCONNECT

SPARK PLUG WIRE BEFORE MANUALLY UN CLOGGING 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.

Awarning

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

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 covered, brush covered, or grass covered land, or on land covered with grain, hay, or other flammable agricultural crop, without an en gine spark arrester in continuous effective working order.

The engine on your power equipment, like most outdoor power equipment, is an internal combustion engine that burns gasoline, a hydrocarbon fuel. Therefore, your power equipment must be equipped with a spark arrester muffler in continuous effective working order. The spark arrester must be at tached to the engine exhaust system in such a manner that flames or heat from the system will not ignite flammable material. Contact your authorized engine dealer for information about obtaining a spark arrester. Failure of the owner / operator of the equipment to comply with this regulation is a misdemeanor under California law, and may also be a violation of other state and/or federal regula tions, laws, ordinances, or codes. Contact your local fire marshal or forest service for specific infor mation about what regulations apply in your area.

WARNING TO ALL CALIFORNIA AND OTHER POWER EQUIPMENT OPERATORS

ENGINE SERVICE

If your tiller engine ever needs service or re

pair, contact your nearest Briggs & Stratton or Tecumseh Service Dealer.

To find the nearest Service Dealer, look in the

Yellow Pages of your phone book under “Engines-Gasoline”, or “Gasoline Engines.”

If you have problems getting engine service or

parts locally, let us know so we can provide you with the name of the nearest Service Dealer.

QUESTIONS OR PROBLEMS?

1. Check this Owner/Operator Manual:

The answer to your question or problem may be in this Manual. Refer to the index at the back of this Manual to find the listing that concerns your problem. Turn to that page and read the informa tion provided.

For Fastest Service, Use The Numbers Below

In the U.S.A.:

Customer Service..................................................................1-800-437-8686

Technical Service..................................................................1-800-520-5520

Parts Orders...........................................................................1-800-648-6776

2. Call or write to us:

If you can't find the answer to your question or

problem in this Manual, please call us or write to

us. One of our helpful, friendly tiller experts will

gladly help you. Be sure to include your tiller model name and the serial number of your tiller.

3. If you need a part:

Call or write to our Parts Department (see the Toll-Free telephone number below). Please have your tiller model name and serial number at

hand. Use the Parts Catalog to find the part number and quantity of the part you need. Remember that you can purchase many of the

common hardware items at your local hardware store as well as ordering them from us.

Outside the U.S.A. and Canada:

Customer Service.....................................................................................(518) 391-7007

Technical Service

Parts Service.............................................................................................(518) 391-7006

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

(518) 391-7008

If you would rather write, our mailing address is:

Garden Way Incorporated 1 Garden Way Troy, New York 12180

IMPORTANT!

If you notice any freight damage or missing parts, either at the time of delivery or later during assembly, make sure that you put it in writing, within 15 days, and send your letter to the shipper to confirm that you intend to file a claim. Tell the driver, or inform the truck terminal, that you

intend to file a written claim. They will advise you as to how to proceed. However, if you

have any problems with this procedure, please call us so that we can help you get satisfaction.

Section 1: Safety Instructions

Your TROY-BILT Model Tiller has been designed with many safety features. However, as with any

other piece of powered equipment, the operator must follow safe operating practices at ali times. Failure to do so could result in personal injury or damage to the equipment or property.

Before assembling, operating or servicing the tiller or its engine, carefully read and follow all of the safety instructions found in this Owner / Operator Manuai, in the separate Engine Owner’s Manual, and in any other literature you may receive. If you ever have any questions, please call us at one of the numbers listed on page 3 of this manual.

If you ever lend your tiller to someone, make sure that he or she reads, understands, and follows the Safety Instructions. Always use your tiller carefully and keep safety in mind.

SAFETY ALERT SYMBOL. This symbol is used to alert you to

important safety messages in this Manual and on decals which

do so can result in personal injury or property damage.

are on your tiller regarding potential hazards. When you see this symbol, carefully read and follow its safety message. Failure to

TRAINING

1. Carefully read this Owner/Operator 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 disen gage the controls quickly.

2. Never allow children to operate the tiller. Let adults operate the tiller only if instructed properly.

3. Keep the area of operation clear of all persons (particularly children) and pets.

4. Keep in mind that the operator or user is respon sible 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 control levers are released and the

ECONO-HORSE or PONY Model Wheel Gear

Lever is in “ENGAGE” before starting the engine. On the JUNIOR Model, which does not have a Wheel Gear Lever, be sure the Wheel Drive Pins engage the wheels.

3. Do not operate the tiller without wearing ade quate outer garments. Avoid loose garments or jewelry that could get caught in moving parts of the tiller or its engine.

4. Do not operate the tiller when barefoot or wearing sandals, sneakers, or light footwear. Wear protective footwear which grips well on slippery surfaces.

5. Do not till near underground electric cables, tele

phone lines, pipes or hoses. If in doubt, contact your telephone or utility company.

6. Handle fuel with care; it is highly flammable and its vapors are explosive. Take the following precautions:

a. Use an approved fuel container.

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 se

curely.

f. If fuel is spilled, do not attempt to start the en

gine, 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 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 (and remove the Ignition Switch Key on electric

start models), disconnect the spark plug wire and

prevent it from touching the spark plug, carefully in

spect the tiller for any damage, and repair the dam age before restarting and operating the tiller.

4. Exercise caution to avoid slipping or falling.

5. If the machine should start to vibrate abnormally,

stop the engine (and remove the Ignition Switch Key on electric start models). Disconnect the spark plug wire and prevent it from touching the spark plug, and check immediately for the cause. Vibration is gener ally a warning of trouble.

6. Stop the engine (and remove the ignition Switch Key on electric start models), disconnect the spark plug wire and prevent it from touching the spark plug whenever you leave the operating position, before unclogging the tines, or when making any repairs, adjustments or inspections.

7. Take all possible precautions when leaving the machine unattended. Stop the engine. Remove

Ignition Key on electric start models. Disconnect

spark plug wire and move it away from the spark

plug. Move Wheel Gear Lever to “ENGAGE” on Econo-Horse and Pony models. On Junior models,

the Wheel Drive Pins must engage the wheels.

8. Before cleaning, repairing, or inspecting, stop the engine, remove the Ignition Switch Key on elec tric start models, and make certain all moving parts have stopped. Disconnect the spark plug wire and

prevent it from touching the spark plug to prevent

accidental starting. On electric start models, always

remove the cable from the negative side (-) of the battery.

9. Always keep the tiller tine hood flap down, un less using the hiller/furrower attachment.

10. Never use the tiller unless proper guards, plates, or other safety protective devices are in place.

11. Do not run engine in an enclosed area. Engine exhaust contains carbon monoxide gas, a deadly poison that is odorless, colorless, and tasteless.

12. Keep children and pets away.

13. Never operate the tiller under engine power if

the Econo-Horse or Pony Wheel Gear Lever is in

“DISENGAGE” (FREEWHEEL), or if the Junior

Wheel Drive Pins do not engage the wheels. In this

position, the wheels will not hold the tiller back and

the revolving tines could propel the tiller rapidly,

possibly causing loss of control. Always move the

Wheel Gear Lever to “ENGAGE” (or, on the Junior,

ENGAGE the wheels with the Wheel Drive Pins) before starting the engine or engaging the tines /

wheels with the Forward Clutch or the

Maneuvering Clutch.

14. Be aware that the tiller may unexpectedly bounce upward or jump forward if the tines should

strike extremely hardpacked soil, frozen ground, or

buried obstacles like large stones, roots, or stumps. If in doubt about the tilling conditions, al

ways use the following operating precautions to as sist you in maintaining control of the tiller:

a. Walk behind and to one side of the tiller, using

one hand on the handlebars. Relax your arm, but use a secure hand grip.

b. Use shallower depth regulator settings, work

ing gradually deeper with each pass.

c. Place the forward drive belt in its LOW Range

position (Econo-Horse only). Use slower en gine speeds.

d. Clear the tilling area of all large stones, roots

and other debris.

e. Avoid using downward pressure on handle

bars. If need be, use slight upward pressure to keep the tines from digging too deeply.

f. Before contacting hardpacked soil at the end

of a row, reduce engine speed and lift handle bars to raise tines out of the soil.

g. !n an emergency, stop tines and wheels by

releasing whichever Clutch Lever is en gaged. Do not attempt to restrain the tiller.

15. Do not overload the tiller’s capacity by attempt ing to till too deeply at too fast a rate.

16. Never operate the tiller at high transport speeds on hard or slippery surfaces. Look behind and use care when backing up.

17. Do not operate the tiller on a slope that is too steep for safety. When on slopes, slow down and make sure you have good footing. Never permit the tiller to freewheel down slopes.

18. Never allow bystanders near the unit.

19. Only use attachments and accessories that are approved by Garden Way Inc.

20. Use tiller attachments and accessories when recommended.

21. Don’t use the tiller in bad visibility or poor 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-gover nor settings on the machine; the governor controls the maximum safe operating speed to protect the engine and all moving parts from damage caused by over speed. Authorized service shall be sought if a prob lem exists.

24. Do not touch engine parts which may be hot from operation. Let parts cool down sufficiently.

25. The battery on electric start model tillers contains sulfuric acid. Avoid contact with skin, eyes, or cloth ing. Keep out of the reach of children.

Antidote-External Contact; Flush immediately

with lots of water.

Antidote-Internal: Drink large quantities of water or

milk. Follow with milk of magnesia, beaten eggs

or vegetable oil. Call a doctor immediately.

Antidote-Eye Contact: Flush with water for 15

minutes. Get prompt medical attention.

26. Batteries produce explosive gases. Keep sparks, flame, and smoking materials away. Ventilate when charging batteries or when using a battery in an en closed space. ALWAYS wear safety goggles when working near batteries.

27. Please remember; You can always stop the tines and wheels by releasing the Forward Clutch Lever or the Maneuvering Clutch Lever (whichever lever you have engaged) or by moving the Throttle Control Lever to STOP.

28. To load or unload the tiller, see the instructions in Section 4 of this Manual.

29. Use extreme caution when reversing or pulling the machine towards you.

30. Start the engine carefully according to instructions and with feet well away from the tines.

31. Never pick up or carry a machine while the en gine is running.

MAINTENANCE AND STORAGE

1. Keep the tiller, attachments and accessories

in safe working condition.

2. Check all nuts, bolts, and screws at frequent intervals for proper tightness to be sure the equipment is in safe working condition.

3. Never store the tiller with fuel in the fuel tank in side a building where fumes may reach an open flame or spark (hot water and space heaters, fur naces, clothes dryers, stoves, electric motors, etc.).

4. Allow the engine to cool before storing it.

5. To reduce the chances of a fire hazard, keep the engine free of grass, leaves, or excessive grease.

6. Store gasoline in a cool, well-ventilated area, safely away from any spark or flame-producing equipment. Store gasoline in an approved con tainer, safely away from the reach of children.

7. Refer to the Tiller and Engine Maintenance section of this Manual for instructions if the tiller is to be stored for an extended period.

8. Never perform maintenance while the engine is running or the spark plug wire is connected, ex cept when specifically instructed to do so.

9. If the fuel tank has to be drained, do this out doors.

DECALS

If any of the decals below become illegible, damaged, or missing, contact us or your authorized

dealer immediately for a replacement. Use the appropriate part number noted in your Parts Catalog.

Control Panel Decal (located on upper handlebars);

All Models

Starting Stabilization Decal (on top of engine or on air cieaner)

Warning - Belt Positions (on beit cover - not shown)

Econo-Horse Model only

Ail Models

Photo 1-1: Pony Model shown

Section 2: Easy Assembly

Please follow the steps in this Section to assemble your ECONO-HORSE™, PONY® or JUNIOR®

Model tiller and prepare it for use. Due to assembly similarities, we show one model in the as sembly photos to represent the three tiller models. Steps unique to any single model(s) are noted. These steps will not take long and will assure correct assembly of your new tiller. We recommend you read this Section all the way through first. Then begin the assembly steps.

STEP1: UNPACKING AND LOOSE PARTS

Your tiller was shipped fully assembled except for the parts shown in Photos 2-1 and 2-2. The small

hardware items are inside a plastic bag within the literature package.

If you ordered an electric start PONY® Model Tiller, you also get a second plastic bag with electric

start parts and hardware - it is near the battery. The battery will be in place on its platform or in its own carton. These parts are called out later in this section.

___ __ __ ___ __ __ _

WHEEL GEAR CABLE (Except Junior Model)

MANEUVERING CLUTCH LEVER

HANDLEBARS

FORWARD CLUTCH ROD

Photo 2-1: Contents of the shipping carton.

ENGINE THROTTLE CABLE

Pony Model shown

The items in the following list are found in your

hardware bag. They are keyed to Photo 2-2.

1. One Handlebar Height Adjustment Handle.

2. One keyed washer.

3. Four plastic tie straps (Junior requires two).

4. Three hairpin cotters.

5. Two 3/8" -16x1" hex head bolts.

6. Two 3/8" flat washers.

7. Two 3/8" -16 nylon insert lock nuts.

8. One Engine Throttle Lever Knob.

9. Four #10 - 32 X 1/2" slotted head screws

(Junior requires two).

10. Four #10 lockwashers (Junior requires two).

11. Four #10 - 32 nuts (Junior requires two).

12. One Wheel Gear Lever knob (Econo-Horse

and Pony).

(See detailed hardware list)

Photo 2-2: Contents of Hardware Package.

Compare the parts that you received to those shown in Photos 2-1 and 2-2. If you are missing any

items, please call us at one of the telephone numbers listed on page 3 of this Manual.

If you notice any freight damage, either at the time of delivery or later during assembly, contact the freight terminal and tell them you will be filing a written claim (do so within 15 days). The terminal will advise you as to how to proceed. However, if you meet any problems with this procedure, please call us so we can provide assistance.

Before you attempt to move the tiller off the shipping carton platform, please install the handlebars (Step 2). With the handlebars installed, you’ll have better leverage and be more easily able to move the

tiller to a level area so you can continue assembly. (Discard all rubber bands securing the handlebars.)

You’ll need the following tools to assemble your tiller;

1. Two 9/16" wrenches. *

2. One medium-size flat blade screwdriver.

3. One open end 3/8" wrench.*

4. Scissors (to trim the plastic ties).

5. One 7/16" wrench (electric models only).*

7. Automotive-type tire pressure gauge.

8. Ruler.

9. Sturdy wood box or block 2-1/2"-3-1/2" high

(Junior Model only).

* You may substitute adjustable wrenches.

6. A piece of wood to tap the knobs securely on

the control levers.

To Remove Tiller From Shipping Platform:

Before moving the tiller off its shipping platform, you must move the Wheel Gear Lever (on

Econo-Horse and Pony models) to the “DISEN

GAGE” position. For shipping purposes, the Wheel Gear Cable is wrapped around the trans

mission tube, between the engine and the tine hood. Unwrap the Wheel Gear Cable and move

the Wheel Gear Lever at the end of the cable to

its “DISENGAGE” position as shown in Photo

2-3. On the Junior Model, a Wheel Drive Pin

must be removed from the hub of each wheel,

the wheels moved inward as far as possible, and the Wheel Drive Pins replaced through the wheel shaft holes and secured with their cotter pins.

Each wheel is then free to turn on the wheel

shaft. See Inset Photo at right.

Photo 2-3: Pull the Wheel Gear Lever back to “Disengage” position on Econo-Horse and Pony models. Inset Photo shows Wheel Drive Pins that

r ■i- W.

need to be moved on the Junior Model.

STEP 2: ATTACHING THE HANDLEBARS

1. On electric start models only, remove one of

the bolts and lockwashers that secures the lower end of the curved height adjustment bracket to the back of the transmission. Loosen the second

bolt so you can swing the curved height adjust ment bracket out of the way. See Photo 2-4.

T , s

Photo 2-4: Swing the Height Adjustment Bracket

down to one side (Electric start models only).

2. Remove the Maneuvering Clutch Lever from

the handlebars. See Photo 2-5.

Photo 2-5: Removing the Maneuvering Clutch Lever from the handlebars. Just slide it out.

3. Place the lower end of the handlebars on the outside of the two mounting tabs on the top of

the transmission. Be sure the handlebar cross

brace (on the lower end of the handlebars) goes under the curved height adjustment bracket.

4. Secure the lower ends of the handlebar to the two mounting tabs with a 3/8"-16 x 1" bolt, a 3/8" flat washer, and a 3/8"-16 nylon insert lock nut. Use 9/16" wrenches. Both bolt heads should be inserted from the inner side of the mounting tab.

5. On electric start models, move the curved height adjustment bracket back in place.

Reinstall the bolt and lockwasher you previously removed. Tighten both bolts very securely.

6. Move the handlebar up (or downward) to align the hole in the handlebar cross brace with one of

STEP 3: ATTACHING THE

MANEUVERING CLUTCH LEVER

1. Slide the Maneuvering Clutch Lever down

through the hole in the left-hand side of the han

dlebar control panel. Make sure that the Maneuvering Clutch Lever passes above the cross brace on the lower end of the handlebar.

2. Turn the Maneuvering Clutch Lever so the small bend on the lower side points inward.

3. Insert the lower end of the Maneuvering Clutch Lever into the hole in the pivot as shown in Photo 2-8. Secure the Maneuvering Clutch Lever in place by inserting a hairpin cotter down through the hole in the end of the Maneuvering Clutch Lever.

Photo 2-6: Attaching the handlebars.

the four slots in the curved height adjustment

bracket. See Photo 2-7. Place the keyed washer on the Height Adjustment Handle. Screw the handle into the hole in the handlebar cross brace. Make sure that both raised keys on the bottom of the keyed washer fit into one of the

four slots on the bracket. Tighten the Handlebar

Height Adjustment Handle securely. Also tighten

the hardware securing the ends of the handlebar to the two mounting tabs.

KEYED

WASHER lockwasher

Photo 2-7: Installing the Handlebar Height Ad

justment Handle.

Photo 2-8: Installing Maneuvering Clutch Lever.

STEP 4: CONNECTING THE

FORWARD CLUTCH ROD

1. Turn the Forward Clutch Rod so the small

bend at the lower end points inward.

2. Insert a hairpin cotter down into the inner hole

in the small bend of the Forward Clutch Rod.

7. With the handlebars installed, you can now easily move the tiller off its shipping platform.

Note: Out in the garden you may need to

readjust handlebar height again for comfort. See Handlebar Height Adjustment, page 21.

Photo 2-9: Connecting the Forward Clutch Rod.

3. Note the four holes in the swivel plate on the shifting mechanism. The hole that you must in

sert the lower end of the Forward Clutch Rod into depends upon which handlebar height setting (on the curved handlebar height ad justment bracket) you have the handiebars set at. Refer to Photo 2-10 to determine which

hole in the swivel plate to use. For example: if you set the handlebar in slot number 1, then the Forward Clutch Rod must be installed in hole number 1 of the swivel plate.

c. If the gap is incorrect, reverify that the

Forward Clutch Rod is located in the cor

rect hole in the swivel plate. If it isn’t, move the lower end of the Forward Clutch Rod into the correct hole and then check the measurement gap again.

d. To reset the gap distance properly, you

must make a simple adjustment to the length of the Forward Clutch Rod. To do this,disconnect it from the swivel plate, then rotate it clockwise or counterclock wise to shorten or lengthen the rod. Reconnect it and measure the gap again as shown below in Photo 2-11. Adjust the length of the rod until the gap is within 3/16" to 5/16".

.-'s»

Photo 2-10: Handlebar Height setting and Forward Clutch Rod positioning are interrelated. They must both be set in the same numbered positions.

4. Insert the lower end of the Forward Clutch Rod into the proper hole in the swivel plate.

Secure it to the swivel plate by inserting a hairpin cotter through the outer hole in the small bend of the Forward Clutch Rod.

IMPORTANT

Whenever the handlebar height is changed, the position of the Forward Clutch Rod must be changed accordingly. Changing the han dlebar height changes the tension on the

Forward Clutch Rod. This tension must be

adjusted by relocating the rod in the appro priate hole in the clutch swivel plate.

To make sure the tension on the Forward

Clutch Rod (once connected) is correct:

a. Stand on the right-hand side of the tiller

and pull the Forward Clutch Lever up and

hold it in place. See Photo 2-11.

b. Check the gap between the “E-ring” and

the lower end of the bracket at the upper end of the Forward Clutch Rod. Refer to

Photo 2-11.The gap should be 3/16"-to5/16". If you do not have a ruler handy, the thickness of five pennies is approximately 5/16" thick.

Photo 2-11: Carefully measure the gap between the Forward Clutch Bracket and the “E-Ring. ”

STEP 5: CHECKING THE TRANSMISSION GEAR OIL LEVEL

Once the handlebars are securely installed on

the tiller, move the tiller to a level area.

We have installed gear oil in the tiller trans

mission here at the Factory. However, you

should make this very important check to be sure that the gear oil level is still correct.

1. Make sure that your tiller is on a level area.

2. Lower the depth regulator lever to the second notch to make sure that the transmission is as level as possible. (See Photo 2-12.). NOTE — For shipping purposes, the depth regulator lever might be secured with a plastic tie. If so, before the depth regulator lever can be lowered, you must lift the hood flap at the rear of the tiller and cut and re move the tie.

Photo 2-12: Move Depth Rcguldtor Level to second

notch.

3. Use a 3/8" open end wrench to remove the

transmission oil level check plug (on the lefthand side of the transmission). Due to dried

paint on the plug threads, it may require some force to remove the plug the first time. If the transmission oil level is correct, oil should start to flow out of the hole. If oil flows from the hole, your check is finished; reinstall the plug and tighten it securely with a 3/8" open end wrench.

Photo 2-13: Removing the transmission Oii Level

Check Plug. When the level is correct, gear oil will flow from this check hole.

Photo 2-14: Adding gear oil to transmission.

4. If no oil flowed from the transmission oil level

check hole, add SAE 140, SAE 85W-140 or

SAE 80W-90 weight gear oil to bring the oil up

to the correct level. Preferably use API rated GL4 gear oil (GL-5 is permissable for small topoffs). Use this procedure:

a. Unscrew filler plug from top left-hand side

of transmission. Clean around plug first.

b. Insert a clean funnel into the oil fill hole

and slowly add gear oil until it flows from the transmission oil check hole.

c. Reinstall the transmission oil check plug.

Tighten securely with the 3/8" wrench.

d. Reinstall the transmission oil fill plug.

Tighten it securely by hand.

STEP 6: ADD MOTOR OIL TO THE TILLER ENGINE

The tiller engine was shipped without motor oii in it. You must add motor oil before starting the engine. (See Figure 2-15A and Photo 2-15B on page 12.) Use quality motor oil

with API classification SF, SG, SH, or SH/CD. The viscosity depends upon whether you have a

Briggs & Stratton or a Tecumseh engine, and on

temperature. See Pages 48-49 or engine man

ufacturer literature for oil recommendations.

To add motor oil to the engine:

1. Make sure that the tiller is on level ground.

Lower the depth regulator lever to the second

notch (placing the tiller in a level position).

2. Wipe the area around the dipstick or oil fill

tube clean so no debris will fall into the engine.

3. On the Econo-Horse 6HP Tecumseh engine,

unscrew the engine oil dipstick from the fill hole. See Figure 2-15A. Add oil until the level reaches “Full” on the dipstick. Do not overfill with oil.

4. On the Pony 5HP Briggs & Stratton engine and on the Junior 4HP Tecumseh engine, re move the filler cap from the oil fill tube at the side

of the engine. See Photo 2-15B. Add oil until it

reaches the very top of the oil fill tube. Replace

the filler cap securely.

5. Snug the base of the throttle lever up against the bottom of the control panel. Install a lockwasher and a nut on each of the threaded ends of the screws. Use a 3/8" wrench and a flat tip screwdriver to tighten both screws.

Photo 2-16: Installing Engine Throttle Lever

Figure 2-15A (left): On 6HP Tecumseh engines, add oil and check the oil level with the dipstick. Photo 2-15B (right): On 5HP Briggs & Stratton and 4HP Tecumseh engines, add oil until it reaches the top of the oil fill tube. Replace the fill cap securely.

STEP 7: ATTACHING THE ENGINE THROTTLE LEVER TO THE CONTROL PANEL

The engine throttle cable (with lever) is

wrapped around the engine for shipping. Unwrap it and attach the cable as follows:

1. Locate two #10-32 x 1/2" slotted head

screws, two #10-32 nuts, and two #10 lockwashers in your hardware bag. Keep this hard ware at hand so you can attach the Engine Throttle Lever to the control panel.

2. Run the engine throttle cable alongside the right-hand handlebar.

3. Position the Engine Throttle Lever beneath the control panel. Insert the lever up through the slot in the control panel that is marked “ENGINE THROTTLE.”

4. Insert each of the screws through a “-i-” mark on the control panel decal. Align the holes in the Engine Throttle Lever base with the screws and be sure the screws go through the base.

6. Place the “T-shaped” Engine Throttle Lever knob on the end of the Engine Throttle Lever. Use the piece of wood to tap the knob until it seats firmly on the Engine Throttle Lever.

.. =•; ^ I

Photo 2-17: Install the Engine Throttle Lever Knob.

7. Move the Engine Throttle Lever forward and backward to check its movement. It should move smoothly through the full range of its travel. Please note there is a detent (a catch) at “SLOW.” This prevents you from unintentionally shutting off the engine when you are just trying to slow the engine down. If it is difficult to move the Engine Throttle Lever away from “STOP”, loosen both screws and move the lever assem bly slightly to the left. Tighten both screws and re-check the Engine Throttle Lever’s movement. Spend a couple of minutes adjusting this assem bly until the lever moves smoothly.

8. Take two of the red plastic ties from the hard ware bag. Locate them as shown in Photo 2-18.

Space them about two feet apart.

The serrated side of each plastic tie should be on the inside of the loop when you wrap the tie around the handlebar and Engine Throttle Lever cable. Tighten each tie by pulling on the free end. Snip off any excess with a scissor.

Photo 2-18: Secure Engine Throttle Cable to Handlebars with two plastic ties.

STEP 8: ATTACHING THE

WHEEL GEAR LEVER TO THE

CONTROL PANEL (Econo-Horse and Pony Models only)

The Wheel Gear cable is wrapped around the transmission for shipping purposes. Unwrap the cable and install it as follows:

1. Locate the last two #10-32 x 1/2" slotted head

screws, #10-32 nuts, and #10 lockwashers.

2. Position the Wheel Gear cable along the side and up the left handlebar.

3. Position the Wheel Gear Lever beneath the

control panel. Insert the lever up through the slot in the panel marked “WHEEL GEAR.”

4. Insert both of the screws through a “-h” mark

on the control panel decal. Align the holes in the Wheel Gear Lever base with the screws and place the base over the screws.

5. Double check to make sure that the screws go

through the holes in the lever’s base. Install a

lockwasher and nut on each of the screws. Use a 3/8" wrench and a flat tip screwdriver.

Photo 2-19: Installing the Wheel Gear Lever. (EconoHorse and Pony Models only.)

6. Place the Wheel Gear Lever knob on the end of the Wheel Gear Lever. Use the piece of wood to tap the knob until it seats on the lever.

Photo 2-20: Installing Wheel Gear Lever Knob. (Econo-Horse and Pony Models only.) \

7. Use the two remaining plastic ties in the hard ware bag to secure the Wheel Gear cable to the

left-hand handlebar. Position the ties as shown

in Photo 2-21. Remember that the serrated side of the tie should be on the inside when you loop the tie around the handlebar and Wheel Gear cable. After you’ve tightened the ties by pulling on the loose ends, snip off any excess.

Photo 2-21: Secure Wheel Gear Cable to Handlebar.

(Econo-Horse and Pony Models.)

STEP 9: ADJUSTING THE AIR

PRESSURE IN THE TIRES

To be sure of a good seal between the tires

and wheels, we’ve inflated your tiller’s tires

above the recommended operating pressure.

Before using your tiller, be sure to evenly de

flate both tires until their pressure is 15 to 20 psi

(pounds per square inch). You can check the air pressure with an automotive-type tire pressure

gauge.

Be sure that both tires have the same air pres

sure or the tiller will pull to one side when you

are using it.

If you have a standard start ECONO-HORSE™, PONY® or JUNIOR® Tiller, it is now completely assembled and ready to be used.

Please read the rest of this Owner/Operator Manual before you begin to operate your tiller.

You should become very familiar with, and follow all the safety rules, the tiller operating instructions, and the engine operating instructions at all times.

If you have an Electric Start PONY® Tiller, you will have to perform the following steps to assemble the elec tric starting system on your tiller.

ASSEMBLING THE PONY ELECTRIC START SYSTEM

Compare the parts in your tiller’s electric start hardware package with the parts shown in Photo 2-22. The parts listed below are keyed to the hardware items in the photo.

1. Battery (for shipping purposes, it is either se cured to the battery support bracket or in a pro tective carton).

2. Vent tube.

3. Screws and nuts (used to attach battery ca bles to battery).

STEP 10: BATTERY ACTIVATION AND CHARGING

NOTE

Your battery was shipped to you DRY. You must have battery electrolyte solution (battery grade sulfuric acid) added to the battery. You then must

have the battery fully charged before using it on

your tiller.

A DANGER

Electrolyte is a sulfuric acid solution.

Avoid spillage and contact with skin, eyes,

and clothing.

To prevent accidents, wear protective cloth

ing, rubber gloves, and shield eyes with safety goggles when working near battery.

Neutralize acid spills with baking soda and

water solution. Neutralize empty container with baking soda and rinse with water.

Photo 2-22: The Electric Start parts.

ANTIDOTE: External contact: Flush with water.

Eyes—Flush with water for 15 minutes and get

prompt medical attention.

ANTIDOTE: Internal: Drink large quantities of

water or milk. Follow with milk of magnesia,

beaten eggs, or vegetable oil. Call physician im mediately.

A DANGER

BATTERIES PRODUCE

EXPLOSIVE GASES!

• Keep sparks, flame, and cigarettes away.

• Ventilate area when charging or using bat tery in an enclosed space.

5. Allow the battery to stand for thirty minutes. Then check the electrolyte level in each cell. If needed, add more electrolyte to bring the elec

trolyte level up to the “UPPER LEVEL” line on the battery. Do not overfill the battery as this could lead to flooding from the cells when the battery is being charged.

6. Charge the battery by following the next set of

instructions.

• Make sure venting path of battery is al ways open once battery is filled with acid.

Adding electrolyte to the battery and charging the battery can be dangerous. The sulfuric acid in the electrolyte can severely burn you or blind you. Also, a battery that is charging gives off gases that could explode if a spark or flame should contact the gases.

We strongly recommend that you take your battery to a TROY-BILT tiller dealer, a reliable service station, battery store, or farm equipment store where a trained battery technician can complete the job safely.

PLEASE DO NOT ATTEMPT TO ACTI

VATE THE BATTERY UNLESS YOU ARE

FULLY EXPERIENCED IN BATTERY SET UP AND CHARGING PROCEDURES.

To ensure proper activation of your battery, we suggest you review the following activating and charging instructions with your battery technician and make sure that he follows the instructions.

To Activate the Battery:

1. Place the battery on a level area away from any spark- or flame-producing sources such as a gas stove, heater, electrical switch, pilot light, (etc.).

2. Remove and discard the short sealing tube (if installed) on the battery side vent.

3. Remove the six filler caps that are on top of the battery. Leave the caps off while activating and charging the battery.

4. Carefully fill each of the six cells in the battery with electrolyte (battery grade sulfuric acid that

has a specific gravity of 1.265) until the level reaches the “UPPER LEVEL” line on the battery.

To Charge the Battery

To obtain maximum battery life, charge the battery by the following method until all cells are gassing freely. A battery is gassing freely when the surface of the electrolyte is covered with tiny bubbles.

When checking the battery for gassing, AL

WAYS wear safety goggles and use a flash

light to look down into the cells.

Failure to do so could result in serious per

sonal injury.

Be sure to follow all instructions given by the manufacturer of the battery charging equipment that is being used to charge the battery.

1. Hook up the battery charger and charge the battery approximately three to five hours at one to two amperes. Turn the battery charger OFF.

2. If the electrolyte level has fallen after charging, refill the battery with distilled water until the elec trolyte level reaches the “UPPER LEVEL” line on the battery.

3. After charging, reinstall the six filler caps on the battery.

4. Unplug the battery charger from the electrical outlet (or turn the battery charger OFF). Then disconnect the cables from the battery posts.

5. Wash any acid spillage off the battery with water. Then dry the battery.

DANGER

NOTE

• The battery and electrolyte should be between 60° and 80° F for best results.

• Do not add water or any other liquid to activate the battery.

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