Troy-Bilt JUNIOR, PONY, ECONO-HORSETM, ECONO-HORSE Technical Manual
$12.
50
. -
~
"
..
f<
•
•
,
~l
:
"J
'
i '
••.
•
'f
~.
J.
ilj, I
..~f·
~B1LT
Technical
Manual
•
JUNIOR®
•
PONY®
•
ECONO-HORSETM
..
\ t
.,
\
.-
...
, 1
..
.
,
.
I
t
GAF~DEN
WAY INC.
I
..
-~
.::.J
......
JUNIOR,
PONY&ECONO-HORSE
TECHNICAL
MANUAL
5/90
TABLE
OF
CONTENTS
SECTION 1
General Information..............................................................................................................................
1-1
Safety First..........................
1-1
Quick Reference Repair Index............... 1-2
SECTION 2
Transmission Troubleshooting
~
2-1
Forward and Reverse Shifting Problems..
2-1
Wheels and/or Tines Do Not Turn................................................
2-1
Wheel Shaft Moves..................................................................................................................... 2-2
Noise From Rear Tiller Bearing 2-2
Oil Leaks 2-3
SECTION 3
Pre-Service Inspection..........................................................................................................................
3-1
SECTION 4
Servicing the Transmission..................................................................................................................
4-1
Housing Cover............................................................................................................
4-1
Removal
4-1
Inspection...............................................................................................................................
4-1
Installation
4-1
Drive Shaft Assembly.............................................................................................................................. 4-2
Removal 4-2
Inspection : :...................................................... 4-3
Installation................................................................................................................................... 4-4
Input Pinion Shaft and Gear Assembly................................................................................................... 4-5
Removal 4-5
Inspection.................................................................................................................................... 4-6
Installation................................................................................................................................... 4-6
Wheel Shaft Assembly............................................................................................................................ 4-6
Removal 4-6
Inspection 4-7
Installation , 4-8
Eccentric Shaft Assembly................................................................................. 4-9
Removal 4-9
Inspection.................................................................................................................................... 4-9
Installation 4-9
Tiller Tine Shaft Assembly..................................................................................................................... 4-10
Removal
4-1
0
Inspection...................................................................................................................................
4-11
Installation.................. 4-12
INDEX
5-1
SECTION
1:
General
Information
.
JUNIOR,
PONY&ECONO-HORSE
TECHNICAL
MANUAL
Page
1-1
5/90
• This manual provides transmission
service information for the following
TROY-BILT® Roto Tiller-Power
Composters built by TROY-BILT
Manufacturing Company, Troy, New
York:
JUNIOR® Model
--
Serial Number
M67999 and
Up.
PONY® Model--Serial Number
S186072 and Up.
Econo-Horse
™ Model
--
Serial
Number
E1
001
and Up.
• This manual was written for and
intended to be used by professional
service technicians who have been
trained
in
the proper servicing of out-
door power equipment.
• All information, illustrations, and
specifications contained
in
this man-
ual are based
on
the latest information available at the time of publication. The right is reserved to make
changes at any time without notice.
If you have any questions concerning the information
in
this manual
please contact:
Technical Service Department
TROY-BILT Manufacturing Company
102nd
St.
& 9th Avenue
Troy, New York 12180
Call Toll-Free: 1-800-833-6990
A This symbol is used to alert
you to important safety mes-
sages
in
this manual andondecals
affixed to the tiller. When you see
this symbol, carefully read and follow
its safety message. Failure to do so
could result
in
·personal injury or
property damage.
• This manual is divided into four
sections as shown
in
the Table of
Contents. For best results, read
each section
in
its entirety before
attempting any repair work.
• This manual is designed to be
used
in
combination with the tiller's
Owner/Operator Manual.
The
Owner/Operator Manual contains
additional service
and
maintenance
information that
is
notcoveredinthis
manual.
Refer to "Quick Reference
Repair Index"
in
this section for a listing of the service and maintenance
topics that are covered
in
the
Owner/Operator Manual.
• Service and maintenance informa-
tion regarding engines is not covered
in
this manual. Such information can
be obtained by consulting the
Service Repair Manual available
from the engine manufacturer.
You
should, however, call our Technical
Service Department with questions
concerning engine replacement or
interchangeability.
• Throughout this manual, you will
see references to the left and right
sides of the tiller. This refers to the
left and right sides of the tiller as you
would see them when standing
in
the
operator's position.
Safety First!
When workingonthe tiller or its
engine, closely follow operating
instructions and recommended safe-
ty practices at all times. Failure to do
so could result
in
personal injury or
property damage. Here are some
basic safety precautions you should
keep
in
mind at all times when doing
repair work:
KNOW THE TILLER AND ENGINE!
Read the Owner/Operator Manual
carefully.
Be
sure you know what
each tiller and engine control does
before
you
attempttooperate
it.
Read and follow all safety rules.
Never allow inexperienced persons
or children
to
operate the tillerorits
engine.
WEAR PROPER APPAREL!
Do
not
wear loose clothing
or
jewelry that
could get caught
in
moving parts of
the tiller or its engine.
AVOID MOVING PARTS! Keep
hands, feet, hair, clothing, and tools
safely away from moving parts when
the engine
is
running.
AVOID ACCIDENTAL STARTING!
When servicing the machine, prevent
unintentional starting of the engine
by disconnecting the spark plug wire
and keeping the wire away from the
spark plug. Place the engine throttle
control
in
the OFF position and disengage the Maneuvering Clutch and
the Forward Clutch.
WEAR EYE PROTECTION! Safety
goggles or a face shield should be
worn whenever there is the possibili-
ty of danger to the eyes from flying
parts or particles.
PREVENT FIRES AND EXPLOSIONS!
Gasolineishighly
flammable and explosive and should
be used and stored with extreme
caution. Keep gasoline away from
open flame, sparks, and do not
smoke
in
the vicinity of gasoline cans
or fuel tanks. Do not add gasoline to
a fuel tank when the engine
is
run-
ning or still
hot. Fill the fuel tank out-
doors,
in
a well-ventilated area.
Store gasoline
in
a cool, well-ventilated place, safely away from any spark
or flame producing equipment. Store
only
in
a U.L. approved container
and safely out of reach of children.
Wipe off any spilled gasoline and
move the engine away from gasoline
fumes before starting engine.
Use
flammable cleaning solvents
only according
to
recognized safety
practices
(never
use
gasolineasa
cleaning solvent). Oily rags and
waste should
be
packedina U.L.
approved,
covered metal safety con-
tainer
to
prevent fire from sponta-
neous combustion.
JUNIOR,
PONY&ECONO-HORSE
TECHNICAL
MANUAL
Page
1-2
5/90
HANDLE BATTERIES WITH CARE!
Batteries contain sulfuric acid that
can cause blindness, burn skin, and
eat through clothing. Wear safety
goggles when working near the battery or when handling battery acid.
Removal all rings and metal jewelry
when working
on
the battery or elec-
trical system.
Batteries also produce explosive
gases. Keep sparks, flames, and
cigarettes away. Ventilate when
charging or using
inanenclosed
space.
Do
not cause a short circuit by
touching both battery terminals at the
same time with tools or other metallic
objects. Also, do not allow a tool or
other metallic object to touch a terminal that
is
not grounded andanadjacent metallic part that is grounded.
A spark from a short circuit could
cause
an
explosion of battery gases
or gasoline.
AVOID ENGINE EXHAUST FUMES!
Do
not
run
the engineinan
enclosed
area. Exhaust gases contain carbon
monoxide,
an
odorless and deadly
poison. Provide adequate ventilation
at all times. After running the
engine, don't touch the muffler or
other hot engine parts until they have
cooled down.
HANDLE PARTS CAREFULLY!
With continued use, the teeth
on
gears and worms may wear to sharp,
knife-like edges. Therefore, when
handling these parts, use care to
avoid cutting yourself.
REPLACEMENT PARTS! Use only
genuine Troy-Bilt replacement parts.
Replacement parts manufactured by
others could present safety hazards
even though they may fit
on
this tiller.
SECTION
1:
General
Information
Quick Reference Repair Index
To
obtain service information for the following topics, please refer to either
this Technical Manual or the tiller's Owner/Operator Manual, as indicated
in
the table below.
TECHNICAL
OWNER/OPERATOR
MANUAL
MANUAL
Air Cleaner
X
Battery
X
Bearing Cap, Tiller Housing
X
Bearings, Drive Shaft
X
Bearings, Tiller Tine Shaft
X
Bearings, Wheel Shaft
X
Belts
X
Bolo Tines
X
Bronze Bushings
X
Carburetor
X
Clutch
X
Cover, Transmission
X
Depth Regulator
X
Drive Shaft
X
Eccentric Lever
X
Electric Start System
X
Engine
X
Fuel
X
Handlebar Height Adjustment
X
Ignition System
X
Input Pinion Shaft Assembly
X
Lubrication Points
X
Oil (Engine and Transmission)
X
Gear Oil Level CheckPlug
X
Gear Oil Drain Plug
X
Throttle Cable
X
Tiller Housing Cover
X
Tiller Tine Shaft
X
TiresIWheels
X
Transmission Gear Oil
X
Wheel Shaft
X
Worm, Tiller Drive Shaft
X
Worm Gear, Wheel Shaft
X
Worm Gear, Tiller Shaft
X
SECTION2:Transmission
Troubleshooting
JUNIOR,
PONY&ECONO-HORSE
TECHNICAL
MANUAL
Page
2-1
5/90
The following charts list the
most common problems experienced with the tiller drive
train. Symptoms of problems
are listed along with possible
remedies. If following the
repair procedures does not
correct the problem. call the
TROY-SILT Tiller Technical
Service Department at TOLLFREE: 1-800-833-6990.
Forward and Reverse
Shifting Problems
A
WARNING: When servicing the machine, prevent uninten-
tional starting of the engine by disconnecting the spark plug
wire and keeping the wire away from the spark plug. Place
the engine throttle control
in
the OFF position and disengage
the Maneuvering Clutch and the Forward Clutch.
Symptom Remedy
Forward Clutch
or
maneu- The pivot bolt on the Forward/Reverse Idler Assembly may be:
vering Clutch shifting levers
• over-tightened
~
do
not
engageordisengage.
• rusted
• broken
• misaligned
Wheels and/or Tines Do Not
Turn
Symptom Remedy
Wheels turn
but
the tines
do
• The rear bearing on the drive shaft may have failed.
not. • One or both of the bearings on the tiller tine shaft may have failed.
• The bronze worm gear on the tiller tine shaft may be damaged.
Wheelsdonot
turn
but
the For the Econo-Horse and Pony models:
tines do. • The clutch cable may be frozen, broken, kinked or out of adjustment.
• The bolt at the end of the eccentric shaft lever may be loose.
• The eccentric lever may be broken.
• The dogs on the wheel shaft clutch may be broken or severely worn.
• The teeth
on
the wheel shaft worm gear may be broken or severely worn.
For the Econo-Horse, Pony and Junior models:
• The teeth on the wheel shaft worm gear may
be
broken or severely worn.
• The drive shaft worm gear may be severely worn.
• On the Junior model only, the wheel drive pin may not
be
engaged through the wheel hubs.
Wheels and tinesdonot
• Check the tensiononthe drive belts (see Owner/Operator Manual).
turn.
• Make sure the bolt that holds the transmission drive pulleyistightened. the washer is present, and the transmission pulley key
is
installed.
JUNIOR,
PONY&ECONO-HORSE
TECHNICAL
MANUAL
Page
2-2
5/90
Wheels and/or Tines Do Not
Turn (continued)
SECTION2:Transmission
Troubleshooting
Symptom
Remedy
Wheels and tines turn on top
• Check the tensiononthe drive belts (see Owner/Operator Manual).
of the ground but hesitate or
• Make sure the input pinion assemblyisin
good condition and that all the parts are
stop when in soil. present.
-
• Check the condition of the bronze worm gearonthe tiller tine shaft and the worm
gear
on
the wheel shaft; one or both may be damaged.
Wheel Shaft Moves
To
One Side
Symptom
Remedy
The wheel shaft moves to
• One or both snap rings are out of the groove(s).
one side. • Check for excessive play
in
wheel shaft. End play should be .000" to .005".
Noise from Rear Tiller Bearing
Symptom
Remedy
A growling or whining noise
• Inspect the drive shaft bearing and bearing race for wear or damage.
from the tiller housing rear • Inspect the tine shaft bearings for wear or damage.
bearing. • Inspect the tiller shaft bronze worm gear for wear or damage.
Oil Leaks
Symptom
Oil is leaking from the wheel
shaft oil seals.
Remedy
•Anoil sealisworn or damaged. Check for side-to-side and vertical playinthe wheel
shaft and replace seal.
• Give new seals time
to
lap
in.
• Inspect the wheel shaft for minor damage at the oil seal location:
a.
Inspect for corrosion, pitting, or scoring.
b.
Use emery clothtoremove any minor defects.
c.
Attempt to seat the seal so thatitisonan
undamaged part of the shaft.
d.
Replace the wheel shaft if necessary.
•
Be
sure the transmissionisfilled with SAE 90 or 140 gear oil. A lighter viscosity oil
will cause leakage.
• Make sure that a non-hardening gasket sealer was applied to the outside diameter of the
oil seal prior to its installation.
• Make sure the housing bore has no nicks or scratches that would permit oil to seep out
between the seal and the housing.
SECTION2:Transmission
TroUbl~hooting
Oil Leaks (continued)
JUNIOR,
PONY&ECONO-HORSE
TECHNICAL
MANUAL
Page
2-3
5/90
,
..
J.
I
Symptom
Oil leaks from the rear of
the tiller housing.
Oil is leaking from the oil seal
on the input pinion shaft.
Oil
is
leaking from the
transmission housing cover.
Oil
is
leaking from the
eccentric shaft (Econo-Horse
and Pony models only).
Oil
is
leaking from any pipe
plug
in
the transmission
housing.
Oil
is
leaking from the front
bearing cap (older model
tillers) or the transmission
bore seal (newer model
tillers).
Remedy
If
the leakisfrom the oil sealsonthe tiller tine shaft:
• Make sure the seals have non-hardening gasket sealer around the outside edges.
•
An
oil sealisworn or damaged; replace the seal.
• Inspect the tiller tine shaft for minor damage at the oil seal location:
a.
Inspect for corrosion, pitting, or scoring.
b.
Use emery cloth to remove any minor defects.
c.
Replace the tiller tine shaft if necessary.
• Check for sand holes (imperfections
in
the cast iron) or cracksinthe housing.
If
the leakison the left side of the tiller housing:
• Apply non-hardening gasket sealer to each of the tiller housing cover screws and
tighten the screws.
• Replace any worn or damaged gaskets.
• Make sure the housing cover bore and the housing bore have no nicks or scratches that
would permit oil to seep out.
• Check for excessive play
in
the tiller tine shaft.
If
the leakisfrom the rear bearing cap:
• Inspect the rear bearing cap:
a.
Make sure the screws are the correct length.
b.
Apply non-hardening gasket sealer to each of the rear bearing cap screws and
tighten the screws.
• Replace a worn or damaged gasket.
• Make sure the leak
is
at the front oil seal.
You
could be seeing a leak from the air
cleaner, transmission housing cover, or an engine oil seal.
• Check the transmission gear oil level when the unit
is
cold.Ifitisoverfilled, drainitto
the proper level.
• Replace a worm or damaged oil seal.
• Make sure the housing cover bolts are tight.
• See if the oil level
is
too high;ifso, drain the oil to the proper level.
• Check to see
if
the threads on the plastic oil fill plug are stripped.
• Replace a worn or damaged gasket.
• Replace the oil seal.
• Inspect shaft for corrosion, pitting, or scoring.
• Check to see if the plug
is
cross-threaded.
• Remove the pipe plug and apply a layer of non-hardening gasket sealer. Then
reinstall the plug.
• On units equipped with a front bearing cap:
a.
Apply a coating of non-hardening gasket sealer to each of the front bearing
cap screws and tighten the screws.
b.
Replace a worn or damaged gasket.
c.Ifoil seeps through the cap, replace the cap.
• On units equipped with a transmission bore seal, replace the seal.
JUNIOR,
PONY&ECONO-HORSE
TECHNICAL
MANUAL
Page
3-1
5/90
Before you begin your repair or
maintenance procedure, take a
moment
to
perform a pre-service inspection of the following
transmission parts.
In
doing
so,
you may discover addition-
al
problems that can be cor-
rected while the tiller
isinyour
shop.
A
SECTION3:Pre-Service
Inspection
WARNING: When servicing the machine, prevent uninten-
tional starting of the engine by disconnecting the spark plug
wire and keeping the wire away from the spark plug.
Place
the engine throttle control in the OFF position and disengage
the Maneuvering Clutch and the Forward Clutch.
Input Pinion GearlTransmission
Drive Pulley
• Checkifoilisleaking from the
input pinion shaft oil seal. If you see
oil, make sure it
is
not originating
from the transmission bore seal (or
bearing cap
on
older model tillers),
which
is
located just above the input
pinion shaft oil seal.
If
the oilisleaking from the input pinion shaft oil
seal, replace the seal.
Wheel Shaft
• Grasp the tiller's handlebars and
tilt the tiller forward
so
its weight
is
resting entirely on the wheels. Then
move the handlebars from side-toside. See Figure
3-1
.
If
the transmission body moves from
side-to-side on the wheel shaft,
it
indicates that the wheel shaft needs
either to be shimmed or that one or
both of the snap rings has become
dislodged from the snap ring
groove(s).
• If oil
is
leaking from around one or
both of the wheel shaft oil seals,
replace the oil seal(s) and determine
why the oil seal(s) failed.
Tiller Shaft
Tip the tillersothat you have a full
view of the tiller housing area (see
Figure 3-2).
• Inspect the area around the rear
bearing cap for oil leaks.
If
you see
an
oil leak, inspect the following:
a.
The rear bearing cap gasket
may have failed.
b.
Make sure the rear bearing cap
screws are the correct length
and are securely tightened.
c.
The washersonthe rear bearing cap screws may
be
old or
the screws may not have been
coated with non-hardening gasket sealant.
• Inspect the left side of the tiller tine
shaft for oil leaks. If you see
an
oil
leak, inspect the following:
a.
The tiller housing cover may not
be
sufficiently tightened, check
all five screws.
b.
The washersonthe screws that
hold the housing cover may be
worn or the screws may not
have been coated with nonhardening gasket sealer.
c.
The tiller housing cover
gasket(s) may have failed.
d. The oil seal
in
the housing cover
may have failed; find out
why.
e.
Inspect the right side of the tiller
tine shaft for oil leaks.
If
you
see
an
oil leak, the oil seal
needs to be replaced. Then,
discover why the seal failed.
Figure 3-1: Testing
for
play
in wheel
shaft.
Loading...