Troy-Bilt Econo-Horse, Pony, Junior Owner's/operator's Manual
$7.50
Owner/Operator
Manual
ECONO·HORSETM
PONY
Model
- Safety
- Assembly
- Controls
- Operation
-
Maintenance
®&
Tillers
JUNIOR
®
TABLE
OF
CONTENTS
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 AND
ENGINE
Tiller Controls 18
Engine Controls 22
SECTIO N 4: OPERATION OF TILLER 24
Be
To Begin Tilling 25
Turning Around 25
Stopping the Tiller and Engine 25
Changing Speeds (Econo-Horss only) 26
Tilling in the Garden 27
CONTROLS
Wheel Gear Lever (Econo-Horse
Wheel Drive Pins (Junior only) 19
Forw
ard
Clutch 20
Maneuvering Clutch 20
Depth Regulator 21
Handlebar Height Adjustment 21
Starting Your Engine 22
Starting the Electric Start Engine
With the Recoil Starter Rope 23
Stopping the Engine 23
for
e Starting 25
Change
To
To Change from HIGH Speed to LOW 27
Guiding Your Tiller. 27
Tilling Depths 27
Tilling Patterns 28
Choosing Wheel and Tine Speeds 29
Avoid Making Footprints 29
Clearing Debris from the Tine Area 29
Power
Use Reverse to Turn in Tight Areas 30
Tilling Near Obstacles 30
Tilling Up and Down Slopes 31
Tilling Across Slopes Using Terraces 31
Tilling Across Slopes Without Terraces 32
Loading and Unloading the Tiller 32
from LOW Speed to HIGH 26
Comp
osting 30
& Pony) 18
18
SECTION 5: TILLER AND
ENGINE MAINTEN ANCE.
Lubrication , 33
Check for Oil Leaks 34
Tightening Nuts and Bolts , 34
Checking, Adding or Chang ing
Gear
Transmission
To Check the Transmission
Gear Oil Level 34
To Add Gear Oil to the
Transmission 35
To Drain and Refill the
Transmission 35
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
Removing Bolo Tine Assemblies 38
Removing Individu al Bolo Tines 38
Checking Tension on the Drive Belts 38
Forward Drive Belt Tension 39
Reverse Drive Belt Tension 39
Adjusting Forward Drive Belt Tension 39
Removing Forward Drive Bel
Installing Forward Drive Belt .. .41
Removing Reverse Drive Belt.. .42
Installing Reverse Drive
Adjusting Reverse Drive Belt Tension .43
Wheel Gear Cable Adjustment .43
Engine Throttle Cable Adjustment .44
Off-Season Storage .44
Troubleshoot Electric Start System .45
Starter Motor Won't
Ignition Switch Doesn't Stop Engine 46
Battery Care and Maintenance .47
Care in Service .47
Battery Storage .47
Carburetor Adjustment .47
Specifications .48
Recommended Maintenance Intervals .49
INDEX REFERENCE 52
Oil 34
t..
BelL
Turn Over .45
33
.41
.42
TO THE OWNER:
Congratulations on the purchase of your new tiller! The ECONO-HORSE'" Model, the PONY®
Model and the JUNIOR ® Model, along with the rest of the TROY-BILT®models, make up the finest
family of tillers available anywhere.
The ECONO-HORSE'" , PONY® and JUNIOR®Tillers are covered in this manual. They have many
features in common, but there are substant ial differences too, and where differences occur, they are so
noted. Your new tiller is basically a simple machine to operate. However, as with all new equipment,
you should thoroughly read and understand this Owner/Operator Manual and any other product literature you received before you operate your tiller. Then,you should practice operating the tiller controls
and maneuvering the tiller in a safe area until you feel very comfortable using the tiller.
Your tiller was designed with the tines in the rear and the engine up front. This design, first perfected
in the larger Horse Model tiller, gives a superb balance combination which allows you to easily chop up,
shred, and bury all sorts of vegetation and organic matter directly into your garden's soil.
This is a rugged, dependable machine that will give you many years of use if properly maintained.
You can ensure long-lasting performance from your tiller by following the operating and maintenance
procedures in this manual and in the other literature sent to you.
Thank you,
afJ
UK
'/
edJ.
Dean Leith, Jr., Sales Manager
,
~
To help you as quickly as possible when you
write or call for parts or service assistance, we'll
need to know your tiller's serial number. This
number tells us when your tiller was made and
what features it has.
The arrow in the graphic to the right points to
the top of the transmission where the serial number is located. For your convenience and ready
reference, please enter the serial number below
and check the model you've purchased.
My Tiller Model Is:
o Econo-Horse 0 Pony
My Engine Make Is: _
o Junior
o Recoil Start 0 Electric Key Start
The Tiller Serial Number Is:
00000000
D
eli
ver
Date of Tiller
y:,
_
A CAUTION
TO
AVOID
•
READ
THE
OWNER/DPERATOR
•
KNOW
CONTROLS.
•
KEEPALL
IN
•
NEVERALLOWCHILOREN
STRUCTED
•
SHUT
SPARK
TINESOR
•
KEEP
CHINE
KEEP
•
LOCATION
SAFETY
PLACE.
ADULTSTOOPERATE
OFF
ENGINE
PLUG
MAKING
BYSTANDERS
.
AWAY
FROM
WIRE
INJURY:
AND
DEVICES
AND
BEFORE
REPAIRS.
ROTATING
FUNCT
AWAY
IONOFALL
ANO
ORUNIN-
DISCONNECT
UNCLOGGING
FROM
PART
MANUAL.
SHIELDS
TILLER.
MA·
S.
AWARNING TO ALL CALIFORNIA AND OTHER POWER EQUIPMENT OPERATORS
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 engine spark arrester in continuous effective working orde
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 attached to the engine exhaust system in such a manner that flames or heat from the system will not
ignite flammable material. Failure of the owner / operator of the equipment to comply with this regulation is a misdemeanor under California law, and may also be a violation of other state and/or fe
regulations, laws, ordinances, or codes. Contact your local fire marshal or forest service for specific
information about what regulations apply in your area.
2
r.
der
al
ENGINE SERVICE
If your tiller engine ever needs service or repair, contact your nearest Briggs
Tecumseh Service Dealer.
To find the nearest Service Dealer, look in the
Yell ow
"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.
Page
s of your ph one
& Stratton or
book
under
QUESTIONS OR PROBLEMS?
1. Check
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 information provided.
this
OwnerlOperator Manual:
For Fa
In the U.S.A.:
Technical Service 1-800-833-6990
Parts Orders 1-800-648-6776
Customer Service 1·800-437-8686
In Canada:
Local only (416 Area Code) 624-8423
From Ontario and Quebec 1-800-387-3351
From Western Canada
st
est Service, Use The Toll-Free Numbers Below
& the Maritimes 1-800-387-3316
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
Remember that you can purchase many of the
common hardware items at your local hardware
store as well as ordering them from us.
and quantity of the part you need.
Our H
In the U.S.A. InCanada
Mon - Fri.- 8 A.M. to 7 P.M. Mon - Fr
Saturday- 9 A.M. to 4 P.M.
If you w
TROY-BILTMfg. Co. Garden Way Canada, Inc.
102nd S
Troy, New York 12180 Mississauga. Ontario L4W 2P5
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 thedriver, 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.
ould
In the U.S.A. In Canada
our
s are (Eastern Standard Time):
rather
1.
& 9th Ave. 1
writ
e to us, our mailing addresses are:
IMPOR
i-
8 A.M. to 5 P.M.
51
5 Matheson Blvd.•Unit B11
TANT!
3
Section
1:
Safety
Instructions
Your TROY-BILT Model Tiller has been designed w
anyother piece of powered equipment, the operator
rso
times. Failure to do so could result in pe
Before assembling , operating or
the
of
O
please call us'at one of the numbers listed on page 3 of this manual.
lows the Safety Instructions. Always use
safety instructions found in this Owner / Operator Manual, in the separate Engine
wner's
If you ever lend yo
Manual, and in any ot
ur
tiller
to so meone, make sure that he or she reads, understands, and
her
servicing
literature
nal
the
you
your
tiller carefully and keep safety in mind.
ith
many safety features. However, as w
mustfollow
injury
or damagetothe
tiller
or its engine, care
may receive. If
safe operating practices at all
you
A SAFETY ALERT SYMBOL. This symbol is used to alert you to
..
symbol, carefully read and follow its safety message. Failure to do so can
result in personal injury or property damage.
TRAINI NG
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 disengage 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.
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 tillerwhen barefoot or wear-
ing sandals, sneakers , or light footwear. Wear
footwearwhichgripswell on slipperysurfaces.
5. Do not till near underground electric cables,
telephone lines,pipesor hoses. If in doubt,contact
yourtelephoneor utility company.
6. Handlefuel with care; it is highly flammable and
itsvapors areexplosive.
a. Use an approved fuel container.
b. Never add fuel to a running or hot engine.
4
important safety messages in this Manual and on decals which
are on your tiller regarding potential hazards. When you see this
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 the fuel tank cap securely and
clean up any fuel before starting engine.
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
inspect the tiller for any damage, and repair the
damage before restarting and operating the tille
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 generally 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.
equipment or property.
fully
read and fo
ever have any questions,
llow
ith
tol
all
-
r.
7. Before leaving the tiller unattended, stop the
engine. Remove the Ignition Key on electric start
models. Disconnect the spark plug wire and prevent it from touching the spark plug. Move the
Wheel Gea r
Lever
to "ENGAGE" on EconoHorse 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
electric 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 nega-
-)
tive side (
of the battery.
9. Always keep the flap on the tine hood down
when operating the tiller, except when using the
hiller/furrower attachment.
Neveroperate
10.
the
till
er with
out
proper
guards, plates, or other protective safety devices
in place.
the
11. Do not run
engine indoors; exhaus t
fumes are dangerous.
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 "EN-
GAGE" (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 t
ines
should strike extremely hardpacked soil, frozen
round
g
, or
bur
ied
obstac
les such as
large
stones, roots, or stumps. If you are in doubt
about the tilling conditions, always use the following operating precautions to assist you in
maintaining control of the tiller:
a. Walk behind and to one side of the tiller,
using one hand on the handlebars. Relax
your arm, but use a secure hand grip.
b. Use sha llower depth regulator settings,
working gradually deeper with each pass.
c. Place the forwar d drive belt in its LOW
Range position (Econo-Horse only). Use
slower engine 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 handlebars to raise tines out of the soil.
g. In
wheels
Lever
you
to restrain the
ncy,stop
by
releasing
have engaged . Do
tiller
.
thetines
and
whicheverClutch
not
attempt
an
eme
rge
15. Do not overload the tiller's capacity by attempting to till too deeply at too fast a rate.
16. Never operate the tiller at high transport
speeds on 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 Troy-Bilt Manufacturing Co.
20. Use tiller attachments and accessories when
recommended.
21. Never operate the tiller without good visibility
or light.
22. Neveroperate the tillerif youare tired,or under
lcohol
the influenceofa
,drugsor medication.
23. Do not change the engine governor settings or
overspeed the engine.
24. Do not touch engine parts which may be hot
from operation. Allow parts to cool before inspecting,cleaningor repairing.
25. The battery on electric start model tillers con-
tains sulfuric acid. Avoid contactwith skin, eyes, or
clothing.Keepout of the reachof children.
Antidote-Externa l Contact: Flush immediately
with lotsof water.
Antidote-Internal: Drinklarge quantitiesofwater
or milk. Followwith milk of magnesia, beaten
egg orvegetable oil. CALL A PHYSICIAN IMMEDIATELY.
Antidote-Eye Contact: Flush with water for 15
minutes. GET PROMPT MEDICAL ATTENTION.
26. Batteries produce explosive gases. Keep
spar
ks, flame , and smoking materials away.
Ventilate when charging batteries or when using a
ALWA
batteryinan enclosed space.
goggleswhenworkingnearbatte
YS wearsafety
ries.
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 e
Control Leverto
ngaged
STOP.
) or by moving the T
hrottle
28.Toload or unload the tiller, see the instructions
in Section 4 ofthis Manual.
5
MAINTENANCE AND STORAGE
1. Keep the tiller, attachments and accessories
in safe working condition.
2. Check all nuts, bolts, and screws at frequent
intervals
for
proper
tightness
to be sure the
equipment is in safe working condition.
3. Never store the tiller with fuel in the fuel tank inside a building where fumes may reach an open
flame or spark (hot water and space heaters, furnaces, clothes dryers,stoves,electricmotors, etc.).
4. Allow the engineto cool before storing it.
5. Toreduce the chances of a fire hazard, keep the
engine freeof 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, except when specifically instructed to do so.
DECALS
If any of the decals below become illegible, damaged, or missing, contact us immediately for a re-
placement. Use the appropriate part number noted below for your particular model tiller.
Control
(located on
#1900357 Econo-Horse & Pony Models
#1900356 Junior Model
Warning-Ignition Keysw itch
(on Electric Start Keysw
not
shown)
#97127
Panel
upper
.....
Econo-Horse &
Pony Models
handlebars)
itch
-
Starting Stabilizat
(on top01engine or on
#97125 Econo-Horse & Jun
#97126 Pony Model
ion
air
cleaner)
,j
Warning - Hot Surfaces &
Belts (on belt cover)
#20818 .... .AII Models
Warning - Belt Positions
(on belt cover)
#2730 ... . .Eco
ior
Models
no-
Horse
Model Only
Operat
ing
Instructions
(located on the
#2718 Econo-Horse Model
#20925 Pony Model
#50277
1-1: ECONO-HORSE MODEL SHOWN
6
hood)
Junio
r Model
Section
2:
Ea
sy
Assembly
Please
Model tiller and prepare it for use. Due to assembly similarities , we show one model in the assembly photos to represent the three tiller models. Steps unique to any single model(s) are
noted.These steps will
We recommend you read thi s Section all the way through
follow
the steps in this Section to assemble your ECONO·HORSE" , PONY" or JUNIOR®
not
take long and will assure correct assemblyofyour new tiller.
firs
t. Then begin the assemb ly steps.
STEP 1: 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 ECONO-HORSE'" or 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
stand or in its own carton . These parts are called out later in this section.
ENGINE
THROTTLE
WHEEL
GEAR CABLE
(Except Junior)
CABLE
-,
MANEUVERING
CLUTCH \
LEVER
Photo 2-1: Contents of the shipping carton.
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" - 16 x 1" 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
11.
12. One Wheel Gear Lever knob (Econo-Horsa
#1
Four#10
and Pony).
I
HANDLEBARS
0 lockwashers (Junior requires two).
- 32 nuts (Junior requires two).
FORWARD
CLUTCH ROD
"-°0'"
/
5
Photo
(Econo-Horse Model Shown)
2
I
•
-0
- 4
•
fI'""
~
,
"'6
2-2
: Contents of Hardware Package.
'\-a
-a
7 8 9 10 11
1
' t .
-
....
(See detailed hardware list)
0"
""
0 •
11 10 9
• • I
b
0-
..
.-
12
t
•
7
Compare the parts that you received to 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, 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 the assembly.
You'll need the following tools to assemb le 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).*
6. A piece of wood to tap the knobs securely on
*
the control levers.
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
substitu
te adj
ustablewrenche
s.
NOTE
Before moving the tiller off its shipping platform, you must move the Wheel Gear Lever (on
Econo-Horse and Pony models) to the "DISENG
AGE"position
. For shipping purposes, the
Wheel Gear Cable is wrapped around the transmission tube, between the engine and the tine
hood. Unwrap the Wheel Gear cable and move
the Wheel Gear Lever 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 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 : Move the Wheel
"Disengage"
models. Inset Photo shows Wheel Pins that need to
be moved on the Junior Model.
posit
ion on Econo-Horse
Gear
Lever
and
back
Pony
to
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 adjustment bracket out of the way. See Photo 2-4.
~
Photo 2-4: SWing the HeightAdjustm
down to one side (Electric start models only).
8
ent
Bracket
2. Remove the Maneuvering Clutch Lever from
the handlebars. See Photo 2-5.
Photo 2-5: Removing the Maneuvering Clutch Lever
from the handlebars.
3. Place the lower end of the handlebars on the
outside of the two mounting tabs on the top of
the transmission. Make sure that the handlebar
crossbrace (on the lower end of the handlebars)
goes underneath 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. The bolt head should be to
The
the inner side of the mounting tab.
flat
washer and lock nut must face out.
5. On electric start models, move the curved
heig
ht adjustment
brac
ket
back
in pl ace.
Reinstall the bolt and lockwasher you previously
removed. Tighten both bolts very securely.
STEP 3: ATTACHING THE
MANEUVERING CLUTCH LEVER
1. Slide the Maneuvering Clutch Lever down
through the hole in the left-hand side of the handlebar
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. I
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.
nsert
control
panel.Make
the lower end of the
sure
that
Maneuvering
the
Photo 2-6: Attaching the handlebars.
6. Note the four handlebar height settings (the
four
slots) in
the
curved
height ad
justment
bracket. Align the hole in the handlebar cross
brace with one of these slots. 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.
Photo 2-8: Installing Maneuvering Clutch Lever.
STEP 4: INSTALLING 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.
Phot
o
2-7
: Insta
Adjustment Handle.
ll
ing the Ha
ndlebarHeight
7. With the handlebars installed, you can now
easily move the tiller off its shipping platform.
Photo 2-9: Installing the Forward Clutch Rod.
9
3. Note the four holes in the swivel plate on the
shifting mechanism. The hole that you'd insert
the lower end of the Forward Clutch Rod into de-
pends upon which handlebar height setting (on
the curved handlebar height adjustment bracket)
you have the handlebars 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, check to make sure
that you have the Forward Clutch Rod located in the correct hole in the swivel
plate. If it isn't, move the lower end of the
Forward Clutch Rod into the correct hole
and check the measurement again.
d. If the Forward Clutch Rod is in the correct
hole in
swivel
plate
(and
the
gap
the
remains incorrect) you must make a simple adjustment to the Forward Clutch Rod.
Please refer to handlebar height adjustment in Chapter 3 for fine tuning this important adjustment.
Photo 2-10: Handlebar Height setting
Clutch Rod positioning.
and
Forward
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 handlebar height changes the tension on the
Forward Clutch Rod. This tension must be
adjusted by relocating the rod in the appropriate hole in the clutch swivel plate.
5. To make sure the tension on the Forward
Clutch Rod 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. The gap
should be 3/16"-to-5/16". If you do not
have a ruler handy, the thickness of five
pennies is approximately 5/16" thick. Refer
to Photo 2-11.
3/16" -10-5/16"
GAP REQUIRED
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 transmission here at the
shou
ld make t
his
Factory
very important checkto be
sure that the oil level is sti ll correct.
1. Make sure that your tiller is on a level area.
2. Lower the depth regulator to the second notch
to make sure that the transmission is as level as
possible. (See Photo 2-12.)
NOTE
For
shipping
purposes
only, the
lever may be secured with a plastic tie. If so,
before
moving
the
depth
hoodflapattherearofthetillerandcutthetie.
. However,you
depth
reguiator
lever,
regulator
liftthe
10
Photo 2-12: Move Depth Regulator Lever to second
notch.
4. If no oil flowed from the transmission oil level
igh
check hole, add SAE 140 or 90 we
(never use multi-v
iscosity
oil) to bring the gear
t gear oil
oil up to the correct level. 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 140 weight gear oil until it
flows from the transmission oil check hole.
3. Use a 3/8" open end wrench to remove the
transmission oil level check plug (on the lefthand side of the transmiss ion). 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 transmis sion Oil Level
Check Plug. When the level
flow from this check hole.
is correct, gear oil will
Photo 2-14:
Add
ing gear oil to transmission.
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: CHECKING THE
ENGINE OIL LEVEL
Your till
SAE 30 weight classified engine oil here at the
factory. However, check the engine oil level
again to be certain it is correct.
Tocheck the engine oil level:
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's 6HP Tecumseh engine,
unscrew the engine oil dipstick from the fill hole.
II is at the top left rear of the engine. See Photo
2-15A. Wipe it clean, screw it back in, take it out
and check the level. Add oil to "Full" mark.
er'
s engine was filled with a quality
11
4. On the Pony's 5HP Briggs engine and the
Junior's 4HP Tecumseh engine, remove the filler
cap from the oil fill tube at the side of the engine.
See Photo 2-15B. Add oil unti l overflowing.
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 2-15A: On 6HP Tecumseh engine, check oil
level with the dipstick. Photo 2-15B: On 5HP Briggs
and 4HP Tecumseh engines, oil must overflow from
the oil fill tube to be correct.
5. If oil needs to be added, use quality SAE 30
SF.
weight oil with an API rating of
Add a little oil
at a time, and check the oil level. Keep adding oil
until the oil level is cor rect. Be careful not to
overfill the engine as this can cause engine damage-drain
out any excess oil.
STEP 7: ATTACHING THE
TT
ENGINE THRO
LE LEVER
TO THE CONTROL PANEL
The
engine
wrapped around the engine for shipping purposes. Unwrap it from the engine and install it as
follows:
Locate
1.
screws, two
washers in your hardware bag. Keep this hardware 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
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.
two
#10-32
throttle
#10-32
cable
x 1
/2"
(with
slotted
lever)
head
is
nuts, and two #10 lock-
"+" mark
Photo 2-16: Installing Engine Throttle Lever.
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.
Photo 2
Knob.
-17
: Installing the Engine Throttle
Lever
7. Move the Engine Throttle Lever forward and
backward to check its movement. It should move
smoothly through the full range of its travel.
lease
P
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 assembly slightly to the left. Tighten both screws and
re-check the Engine Throttle Lever's movement.
Spend a couple of minutes adjusting this assembly until the lever moves smoothly.
12
8. Take two of the red plastic ties from the hardware bag. Locate them as shown in Photo
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.
2-18.
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
Handlebars with two plastic ties.
2-
18: Se
cure
Engine
Throttle
Cable
to
STEP 8: ATTACHING THE
WHEELGEARLEV
ER
TOTHE
CONTROL PANEL (Econo-Horse
and Pony Models only)
The Wheel Gear cabie is wrapped around the
transmission for shipping purposes. Unwrap the
cable and install it as follows:
1. Locate the last two
#10
screws,
2. Position the Wheel Gear cable along the side
and up the left handlebar.
3. Position the Wheei 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
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
3/8"wrench and a flat tip screwdriver.
a
Photo 2-19: Installing the Wheel Gear Lever. (EconoHorse and Pony Models
-32
#10-32
nuts, and #10 lockwashers.
only)
x 1/2" slotted head
"+" mark
Photo2-20:
(Econo-Horse and Pony Models only.)
7. Use the two remaining plastic ties in the hardware bag to secure the Wheel Gear cable to the
left-hand handlebar. Position the ties as shown
in Photo
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.
IEcono-Horse
Installing
Wheel Gea r
Lever
Knob
2-21. Remember that the serrated side
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 you r till er's tires
above the recommended operating pressure.
Before using your tiller, be sure to evenly deflate both tires until their pressure is 15 to
(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 pressure or the tiller wilt pull to one side when you
are using it.
20 psi
13
.
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 yo u have an E
PONY
steps to assemble the electric starting system on your
tiller.
'"
Tiller, you will have to perform the following
lectricStart
ASSEMBLING THE ECONO-HORSE
OR PONY ELECTRIC START SYSTEM
Compare the parts in your tiller's electric start
hardware package with the parts shown
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
tective carton).
2. Vent tube.
3. Screws and nuts (used to attach battery ca-
bles to battery).
in Photo
in
a pro-
ECONO-HORSE'" or
STEP 10: BATTERY ACTIVATION
AND CHARGING
NOTE
Your battery was shipped to you
have battery electrolyte solution (battery grade
sulfuric acid) added to the battery.
have the battery fully charged before using it on
your tiller.
A
• Electrolyte is a sulfuric acid solution.
DANGER
DRY.
You
You must
then must
Photo 2-22: The Electric Start parts.
14
• Avoid spillage and contact with skin, eyes,
and clothing.
• To prevent accidents, wear protective clothing, rubber gloves, and shield eyes with
2
t
3
n
•
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.
ANTIDOTE: External contact: Flush with water.
s-
Eye
prompt medical attention.
ANTIDOTE : Internal: Drink large quantities of
wate r or milk . Follow with milk of magnesia,
beaten eggs, or vegetable oil. Call physician immediately.
Flush with water for 15 minutes and get
A
BATTERIES PRODUCE
EXPLOSIVE
• Keep sparks, flame, and cigarettes away.
• Ventilate area when charging or using battery in an enclosed space.
DANGER
GAS
ES!
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 electrolyte 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 always 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.
PL
EASE
VATE THE BATTERY U
FULLY EXPERIENCED IN BATTERY SET-
AND
UP
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.
Activate the Batte ry:
To
1. Placethe battery on a level area awayfrom any
spark- or flame-producing sources such as a gas
stove, heater,electricalswitch, pilotlight, (etc.).
DO N
CHARGING PROCEDURES.
OT
ATTEMPT
NLESS
TO
YOU ARE
ACTI-
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.
A
When checking the battery for gassing, ALWAYSwear safety goggles and use a flashlight to look down into the cells.
Failure to do so could result in serious personalinjury.
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
2. If the electrolyte level has fallen after charging,
refill the battery with distilled water until the electrolyte 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.
DANGER
OFF.
5. Wash any acid spillage off the battery with
water. Then dry the battery.
NOTE
• The battery and electrolyte should be between
0
and 800F for best results.
60
• Do not add water or any other liquid to activate
the battery.
15
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