Troy-Bilt Pony 12211, Pony 12212 Owner's Manual

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Page 1

0 TRtlI BILT°

Before ( , read this

manual

OWNER'SMANUAL

,®

REAR-TINETILLER

• Safety

• Assembly

• FeaturesandControls

• Operation

• Maintenance

• Parts List

Model

12211- RecoilStart 12212- ElectricStart

(Recoil Start Model Shown)

GARDEN WAYINCORPORATED

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

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

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

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

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

Wewant to be surethat you arecompletely satisfied at all times.

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

See Back Cover for

Customer Service information

SafetyAlert Symbol

This is a safetyalert symbol. It is usedin this

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

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

injury or property damage.

This machine meets voluntary safety standard B71.8

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

American National Standards Institute.

WARNING

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

cancer, birth defects or other reproductive harm.

Table of Contents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Safety

SPARKARRESTERWARNINGTORESIDENTSOF CALIFORNIAAND SEVERALOTHERSTATES

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

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

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

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

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

that flames or heatfrom the system will not ignite flammable material. Failureof the owner/operator of the

unit to comply with this regulation is a misdemeanor under California law (and other states) and may also be a

violation of other state and/or federal regulations, laws,

ordinances or codes. Contactyour local fire marshal or

forest servicefor specific information about which regu-

lations apply in your area.

1. Carefullyreadthis

TRAINING

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

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

2. Neverallow children to operatethe

tiller. Neverallow adults to operatethe tiller without proper instruction.

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

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

occurring to other people,their property andthemselves.

PREPARATION

1. Thoroughly inspect the areawherethe

tiller is to be used and remove all foreign

objects.

2. Besure all controls arereleasedand

the Wheel GearLever is in ENGAGE

beforestarting theengine.

3. Donot operatethe tiller without

wearing adequateouter garments. Avoid

loosegarments orjewelry that could get caught in moving parts.

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

footwear. Wearprotectivefootwearthat will

ForwardClutch

Control

Handlebar

HeightAdJuster

Figure I

improvefooting onslippery surfaces.

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

company.

6. Warning:Handlefuelwith care;it is

highlyflammableandits vaporsareexplo- sive. Takethefollowingprecautions:

Storefuel in containers specifically

designedfor this purpose.

Thegascap shall neverbe removed

or fuel addedwhile the engine is

running. Allow the engine to cool

for severalminutes beforeadding fuel.

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

away from the fuel tank and fuel container.

d. Fill fuel tank outdoors with extreme

care. Neverfill fuel tank indoors.

Usea funnel or spout to prevent spillage.

e. Replaceall fuel tankand container

caps securely.

f. Iffuel is spilled, do not attempt to

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

7. Never makeadjustments when engine

is running (unless recommendedby manufacturer).

Wheel Gear

Lever

ForwardClutch

Contml Lever

Lever

_Standard

RotatingTines

OPERATION

1. Donot put handsor feet nearor under

rotating parts.

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

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

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

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

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

thetiller.

4. Exercisecautionto avoid slipping or

falling.

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

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

immediatelyfor the cause.Vibration is generallya warning of trouble.

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

Page 4

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

Move Wheel GearLeverto ENGAGE.

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

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

attachment.

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

devicesarein place.

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

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

12. Keepchildren and petsaway.

13. Never operatethe tiller under enginepowerif the Wheel GearLever is

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

tiller backand therevolvingtinescould propelthe tiller rapidly, possibly

causinglossofcontrol.Always move the

WheelGearLeverto ENGAGEbefore starting the engine or engaging the

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

14. Beaware thatthetiller may unex- pectedlybounceupwardorjump

forward if the tinesshouldstrike

extremelyhardpackedsoil, frozen ground,or buriedobstacleslike large

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

thefollowing operatingprecautionsto assistyou in maintainingcontrolof the

tiller:

a. Walk behindand toone sideofthe

tiller, usingonehandonthe han- dlebars. Relax yourarm, butusea

securehandgrip.

b. Use shallower depthregulatorset-

tings, workinggraduallydeeper with each pass.

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

stones,rootsandotherdebris.

e. Avoidusingdownwardpressure

on handlebars. If need be, use slight upwardpressureto keepthe

tines from diggingtoodeeply.

f. Beforecontactinghardpackedsoil

at the endof a row, reduceengine speedand lift handlebarstoraise

tines outofthe soil.

Inan emergency,stoptinesand

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

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

arate.

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

Look behind and usecarewhen backing up.

17. Donot operatethe tiller on a slope

that is too steepfor safety.Whenon

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

to freewheeldown slopes.

18. Neverallow bystanders nearthe unit.

19. Only useattachments and acces- soriesthat areapprovedby the tiller

manufacturer.

20. Usetiller attachments andacces- sorieswhen recommended.

21. Neveroperatethe tiller without good

visibility or light.

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

medication.

23.Operatorsshallnottamperwith the engine-governorsettingsonthe machine;

thegovernorcontrolsthe maximumsafe

operatingspeedto protecttheengineand allmoving partsfrom damagecausedby

overspeed.Authorizedserviceshallbe soughtif aproblem exists.

24. Donottouchenginepartswhich may behotfrom operation.Letpartscooldown sufficiently.

25. Thebatteryon electricstart modeltillers containssulfuric acid.Avoidcontactwith

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

Antidote-ExternalContact:Flushimme- diatelywith lotsofwater.

Antidote-lntemal: Drinklargequantities of wateror milk. Followwithmilk of

magnesia,beateneggs or vegetableoil. Calla doctor immediately.

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

attention.

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

usinga batteryin anenclosedspace. ALWAYSwearsafetygoggleswhen

working nearbatteries.

27. Pleaseremember:Youcanalwaysstop thetinesandwheelsbyreleasingthe ForwardClutchControlLeveror the

ReverseClutchControlknob(whichever controlyou haveengaged),or bymoving

theEngineThrottleControlLever(located on engine)to STOPon recoil start models

or by turning the ignition keyto OFFon electricstart models.

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

29. Useextremecautionwhen reversingor pullingthe machinetowardsyou.

30. Starttheenginecarefullyaccordingto instructionsandwith feetwellawayfrom thetines.

31. Neverpickup orcarry amachinewhile theengineis running.

MAINTENANCEANDSTORAGE

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

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

be sure the equipment is in safeworking condition.

3. Neverstorethe tillerwith fuel in thefuel tank insideabuildingwhereignition

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

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

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

6. Referto the Maintenancesection of

this Manualand intheseparateEngine

Owner'sManual for instructions if the

tiller isto be stored for anextended

period.

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

cally instructed to do so.

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

OperatingSymbols

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

DECALS

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

TineWarning (on right

sideof hoodflap)

StartingStabilization(on

topofengine orfuel tank)

replacementsif anydecals aredamagedor missing,

Referto the Parts List pagesfor decal locationsand part numbers.

I KeyswitchWarning

(electrc start unton y)

Instructions and

Warning Messages

Surfaces/MovingBelts

(ontopofbeltcover)

FAST SLOW

STOP

6 8 I-'-I

STOP START

CHOKE

I÷1 R

CHOKE ROTATING

OFF TINES

41BE--><--411

ENGAGED DISENGAGED

"_ REVERSE

o--->

LEVERDIRECTION

TILLERDIRECTION

Figure2: Locationof Safetyand OperatingDecals

TO AVOID SERIOUS INJURY:

• READTHEOWNER'SMANUAL.

• KNOWLOCATIONSAND FUNCTIONSOFALL CONTROLS.

• KEEPALL SAFETYDEVICESANDSHIELDSIN PLACEANDWORKING.

• NEVERALLOWCHILDRENOR UNINSTRUCTEDADULTSTOOPERATETILLER.

• SHUTOFFENGINEANDDISCONNECTSPARKPLUGWIRE BEFOREMANUALLYUNCLOG-

GINGTINES ORMAKINGREPAIRS.

• KEEPBYSTANDERSAWAYFROM MACHINE.

• KEEPAWAYFROM ROTATINGPARTS.

• USEEXTREMECAUTIONWHEN REVERSINGORPULLINGTHEMACHINETOWARDSYOU.

Page 6

Assembly

HARDWARE BAG PARTS LIST

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

INTRODUCTION

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

recommendedthat you readthis Section in its entirety beforebeginning assembly.

INSPECTUNIT

Inspect the unit and carton for damage immediately after delivery. Contact the carrier (trucking company) if you find or suspect damage. Inform them of the damageand request instructions for filing a claim. To protect your rights, put your claim in writing and mail a copy to the carrier within 15 daysafter the unit has

beendelivered. Contactus at thefactory if you needassistancein this matter.

UNPACKINGANDASSEMBLY INSTRUCTIONS

STEP 1: UNPACKING INSTRUCTIONS

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

thecarton and remove the carton.

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

ping pallet. Leavethe handlebarson top of thetiller to avoiddamaginganycables.

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

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

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

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

Fig. Ref. Qty. Description

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

3 1 WheelGear LeverKnob 4 1 HeightAdjustment Flange

Screw (SeeFigure2-1A)

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

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

Screw

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

11 4 Plastic Tie Strap (2 not used)

Tools/Materials Needed for Assembly

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

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

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

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

to the separateEngineOwner's Manualfor motor oil specifications

and quantity required.

* Adjustable wrenches may be used.

IMPORTANT:Motor oil must be addedto

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

"Assembly" Section andin the separate

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

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

STEP 2: ATTACHHANDLEBARS

1. Onelectric start units, remove one

screw and Iockwasherfrom the curved

60o

81 T

700 lo

Figure2-I: Loosehardware(shownin reducedsize).

Figure2.1,4: Handlebarheightadjustment usestheflangeheadscrew,

Figure2.2," Onelectricstart units, move heightadjustmentbracketaside.

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

bracketto one side.

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

bar mounting tabs on the transmission top cover.

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

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

Figure 2.3: Forwardclutch controlcable not

shownfor clarity.

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

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

Figure2-3) on the transmission top cover.

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

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

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

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

Figure2.4: Attachhandlebars.

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

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

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

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

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

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

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

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

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

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

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

Figure2.5: CarefullyunwrapWheelGear LeverandmovelevertoDISENGAGE.

NOTE: TheWheelGearLeverwill be installed later in this procedure.

IMPORTANT: UsetheDISENGAGEposi- tion only whentheengine is not running.

Beforestarting the engine,theWheelGear Levermust be placed in the ENGAGE

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

CLUTCH CONTROL CABLE

1. Carefully unwrapthe reverseclutch

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

on the cable.

Left Side ReverseClutch

Handlebar Control Knob

Figure2.6:Attachreverseclutchcontrol assemblytoslottedholeinhandlebarpanel.

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

bly into the hole in the slot (see Figure2-

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

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

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

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

assistance.

STEP4: ATTACHFORWARD CLUTCH CONTROL CABLE

1. Removeany fasteners (rubber bands,

tape, etc.) that may securethe Forward

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

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

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

the right-side wheel. Beingcareful not to

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

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

Figure2-8

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

dlebar. Usetwo 1/2"wrenches to loosen

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

handtighten thejam nuts.

Figure2.9

Page 8

Incorrectcable adjustment could cause thewheels and tines to rotate unexpect-

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

4. Checkfor correct spring/cabletension

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

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

STEP 5: CHECK TRANSMISSION GEAR OIL LEVEL

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

the oil level at this time to makecertain it

iscorrect. IMPORTANT:Donot operatethe tiller if

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

sion components.

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

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

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

and remove the tie.

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

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

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

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

Figure 2-11: Addinggear oil.

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

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

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

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

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

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

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

engine crankcase. IMPORTANT:Do not start the engine

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

run without oil=

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

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

13) up or down until the engine is level.

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

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

"travel" position.

Figure2.12: Attach Wheel Gear Lever.

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

3. Usea small board to tap the Wheel

Gear Lever knob securely onto the lever.

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

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

scissors. STEP 8: CHECK AIR

PRESSURE IN TIRES Usea tire pressuregaugeto check the air

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

will pull to oneside=

Figure2-10: Gearoil level checkplug.

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

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

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

plug.

STEP 7: ATTACHWHEEL GEAR LEVER

I. Insert theWheelGear Lever (P, Figure

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

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

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

nuts.

STEP 9: CHECK HARDWARE

FOR TIGHTNESS

Inspect the hardware on the unit and

tighten any loose screws, bolts and nuts=

IMPORTANT:

• This completesassembly for recoil start

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

before operatingthe tiller.

•Electric start models--continue with the

Assembly Steps.

Page 9

Electric Start

AssemblySteps

Thefollowing steps explain how to prepareand install the battery. FOR

YOURSAFETY,CAREFULLYFOLLOW ALL STEPSANDOBSERVEALL ACCOM-

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

I. Battery (installed on tiller)

2. Clearplastic vent tube

3. Two hex screws and hex nuts

2 3

Figure2.14

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

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

activating and charging instructions with your battery technician.

Battery electrolyte is a sulfuric acid

solution that is poisonous and causes severeburns.

• Avoidspills or contactwithskin, eyes,

clothing.

• To preventaccidents, wear protective

clothes, rubberglovesandshield eyes with safety goggles when working on

or nearthe battery.

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

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

ANTIDOTE:External- Flushwith water.

Eyes- Flush with water for 15 minutes

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

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

the UPPERLEVELline printed on the

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

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

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

Batteriesproduceexplosivegases!

• Keep sparks, flame and cigarettes

away.

• Ventilate area when chargingor using

batteryin an enclosedspace.

• Make sure venting path of battery is alwaysopenoncebatteryis filled with

acid.

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

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

becontinuous.

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

thecells.

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

system.

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

STEP 1: Battery Activation and Charging

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

beforeit canbe used. Adding electrolyte and charging the

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

Batterycharging produces potentially explosivegases.

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

Donot attempt to activate and charge

A. To Activatethe Battery:

I. Removethe batteryfrom thetiller by

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

(Figure2-15).

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

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

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

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

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

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

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

acidwith a specific gravity of 1.265) up to

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

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

Besureto follow all instructions provided

bythe manufacturer of the battery charg-

ing unit that is being used to charge the

battery.

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

nectthe charger cablesfrom the battery

terminals.

2. Checkthe electrolyte level in eachcell.

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

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

off any electrolyte that may havespilled. Thendry the battery.

Page 10

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

objects. Failure to complycouldcause

a shortcircuitthat couldcauseelectri-

cal burns or an explosion of battery gases.

• Incorrectinstallationofthe batterycan

result in electrical system damage. Follow installation instructions care-

fully to avoid damage.

Figure2.18: Checktightness of upper mountingscrew.

Figure2.16: Attachpositive (+) battery

cable. Coverconnectionwithrubber boot.

STEP2: Install Battery

1. Reinstallthebattery on the battery mounting basewith thetwo cablemount-

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

Figure2.15

2. Reinstallthe battery hold-down bracketoverthe batterywiththe ignition

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

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

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

ously. Tightenthe nuts securely,but not

so much as to bend thetabs on the hold-

down bracket.

STEP3: Attach Battery Cables

and Vent Tube

1. Locatethe positivebattery cable,

which is connectedto the starter solenoid

on the left-side of the battery post (a

rubber boot covers the connection). A

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

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

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

3. The negativebattery cableis con-

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

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

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

Figure2-17.

Figure2.17: Attachnegative (.) battery cable.

4. Checkthetightnessof the upper

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

5. Install one endof the clearplastic vent

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

Figure2.19: Instafl vent tube.

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

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

itsentire length.

STEP 4: Connect Wiring Harness

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

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

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

the separateEngineOwner'sManual, beforeyou operateyour tiller.

Figure2.20: Attachwiringharnessto keyswitch.

Page 11

FeaturesandControls

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

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

Failure to follow these instructionscan

resultin seriouspersonal injury.

INTRODUCTION

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

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

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

operationof the controls and feel confi- dentwith them.

IMPORTANT:Referto theseparate engine manufacturer's EngineOwner's

Manualfor information aboutthe con- trois on theengine.

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

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

start turning when eitherthe Forward ClutchControl or the ReverseClutch

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

engaged).

Figure3. I: Controlslocated onhandlebar.

TheDISENGAGEposition placesthe wheels in the freewheeling mode to allow

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

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

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

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

wheeldrive gears. To shift to DISENGAGE(freewheel),

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

whenthe lever is properly set in the DISENGAGEposition.

FORWARD CLUTCH CONTROL

Thetwo interconnectedlevers (B, Figure

3-1) control the engagementof forward

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

1. Beforeengagingthe Forward Clutch

Control, put the WheelGearLeverin the

ENGAGEposition (see"WARNING" below).

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

engagethe wheelsand tines.

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

to run).

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

engine is running. Having the Wheel Gear Lever in

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

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

thetiller rapidly forward or backward. Failure to follow this instructioncould

result in personal injury or property damage.

Never engage the wheels andtines with

the Forward Clutch Control or the

Reverse Clutch Control unless the

Wheel GearLever is in ENGAGE.

Engagingthe ForwardClutchControl or

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

tines to rapidly propel the tiller forward or backward.

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

damage.

Page 12

REVERSECLUTCHCONTROL

TheReverseClutch Control (C,Figure

3-1) controls the engagementof reverse

drive to the wheels and tines. The revers-

ingfeature is usedfor maneuveringthe

tiller only - neverengagethetines in thegroundwhile goinginthe reverse direction.

• Use extreme caution when reversing

or pulling the machine towards you.

Look behindto avoid obstacles.

• Never attemptto till inreverse.

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

To Operatethe ReverseClutch Control:

1. Put the WheelGearLeverinthe ENGAGEposition (seethe "WARNING"

statementon previous page).

2. Stop all tiller motion by releasingthe ForwardClutchControl levers=

3. Lift up the handlebarsuntil thetines

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

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

4. Releasethe ReverseClutchControl knobto disengage(stop) thewheelsand

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

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

deepertilling depths.

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

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

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

damage.

DEPTH REGULATOR

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

theleverstraight backand slide it upor down toengagethenotched height set-

tings.

Figure3.2: DepthRegulatorLever.

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

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

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

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

inches,depending on soil conditions.

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

details on using the Depth Regulator are

found in the "Operation" Section of this

manual. HANDLEBAR HEIGHT ADJUSTMENT

Figure3.3: Handlebar heightadjustment.

The handlebarheight is adjustableto four

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

in mind that the handlebarswill be lower

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

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

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

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

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

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

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

height adjustment screw securely.

5. Retightenthetwoscrews at the ends of the handlebar.

Page 13

ENGINECONTROLS

Referto the engine manufacturer's Engine

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

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

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

ENGINE THROTTLE CONTROL LEVER

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

ulatethe engine speed. Onthe recoil start

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

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

below.

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

instructions.

ELECTRIC START KEYSWITCH

(ELECTRIC START MODEL)

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

settings are described below.

Figure3.5: Electricstartkeyswitch.

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

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

position.

,_ FAST- Usefor most tilling and cul-

tivating projects.

SLOW- Usewhen idling engineor when slower tilling and cultivating

speeds areneeded.

O STOP- Stops the engine (onrecoil

start models only).

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

longer than 15 secondsfor eachattempt).

Page 14

Operation

ForwardClutch ControlLever

ReverseClutch

GearLever

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

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

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

Failure to follow these instructionscan resultin seriouspersonal injury.

INTRODUCTION

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

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

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

BREAK-IN OPERATION Perform the following maintenanceafter

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

EngineOwner's Manual).

1. Changeengine oil.

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

3. Checktransmission gear oil level.

4. Checktension on forward clutch belt.

HandlebarHeight

AdjustmentScrew

EngJ Control Lever

Figure 4- I: Locationof main tiller controls.

STARTINGANDSTOPPING THE ENGINE

To help prevent serious personalinjury or damagetoequipment:

• Before starting engine, put Wheel GearLeverin ENGAGEposition.

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

ClutchControlin neutral (disengaged) positionsby releasing controls.

• Never run engine indoors or in enclosed, poorly ventilated areas.

Engine exhaust contains carbon monoxide, an odorless and deadly

gas.

•Avoid engine muffler and nearby areas. Temperatures in these areas may exceed150OF.

PRE-START CHECKLIST: Make the following checks and perform

the following services beforestarting the engine.

ForwardClutch

Control Lever

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

Manual.

2. Checkunit for loose or missing hard-

ware. Serviceas required.

3. Checkengine oil level. SeeEngine

Owner's Manual.

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

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

6. Attachspark plug wire to spark plug.

GASOLINEIS HIGHLYFLAMMABLEAND

ITSVAPORSAREEXPLOSIVE.

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

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

injuryand propertydamage.

7. Fillthefuel tank with gasolineaccord-

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

Page 15

STARTING THE ENGINE

Thefollowing steps describe how to start and stop the engine. Donot attemptto

engagethe tines or wheelsuntil you haveread all oftheoperatinginstruc-

tionsinthis Section. Alsoreview thesafetyrulesin Section1: "Safety"

andthe tiller andenginecontrols informationin Section3: "Features and

Controls."

1. Completethe "Pre-Start Checklist"on the previous page.

2. Putthe WheelGearLever (Figure4-I) in the ENGAGEposition.

3. Put the Depth Regulator Leverin the "travel" position (lever all theway down)

so that the tines are clear of the ground.

4. Releaseall controls on thetiller.

5. Put the EngineThrottle Control Lever

(Figure4-I) in the "FAST" setting.

6. Onenginesequipped with a fuel valve, turn valve to open position as instructed in the separateengine manual.

7. Chokeor prime engineas instructed in the separateEngineOwner's Manual,

8. For recoil (non-electric) starting models:

(a) Place one hand on fuel tank to sta- bilizeunit when you pull the starter

handle.

(b) Use the recoil starter rope to start

the engine as instructed in the sepa-

rate Engine Owner's Manual. When

the engine starts, gradually move the

choke lever (on engines so equipped)

to the "NOCHOKE","CHOKEOFF"or

"RUN" position. (c) Leavethe EngineThrottleControl

Leverin the "FAST"setting.

9. For electric starting models: (a) Turn the engine ignition keyto the

"START"setting and allow the starter motor to crank the enginefor several

seconds. Avoid cranking the engine longer than 15 secondsat a time as

doing so could damagethe starter motor. NOTE: Referto the Engine

Owner'sManual for detailed starting instructions.

(b) When the engine starts, releasethe key and it will return to the "RUN" setting.

(d) Leavethe EngineThrottle Control Leverin the "FAST"setting.

To Start theElectricStart EngineWith theRecoil Starter Rope

Ifnecessary, the electric start engine can be started with the recoil starter rope by following the steps below:

1. Ifthe battery is not "dead" or damaged, leave it connected to the tiller

so itwill be recharged during engine operation. Make sure the battery cells are

filled to the UPPERLEVELline with elec- trolyte.

2. If the battery is "dead" or damaged, remove it (refer to "Battery Removaland

Installation" in Section5) andhaveit tested. Beforestarting engine,cover the terminal on the loose end of the positive

(+)cablewith the insulatedboot and secure it in placewith electrical tape to prevent electrical sparks.

3. Putthe ignition key inthe "RUN" position and then follow Steps1-8 of "Starting the Engine."

STOPPING THE ENGINE

1. To stop the wheels and tines, release

the Forward Clutch Control leversor the ReverseClutch Control knob (whichever

control is engaged).

2. To stop the engine on the recoil start model, move the EngineThrottle Control Leverto the"STOP" position.

3. To stop the engineon an electric start model, move the ignition keyto "OFF".

IMPORTANT:After stopping an electric start engine, removethe ignition key from the switch to reduce the possibility of

unauthorized starting of the engine.

OPERATINGTHETILLER

Thefollowing pages provide guidelines to

usingyour tiller effectivelyand safely in various gardening applications. Besure to read "Tilling Tips & Techniques" in this

Section before you actually put the tines

into the soil. This is atraditional "standard rotating

tine" tiller with forward rotating tines. It

operatescompletely differently from CRT

(Counter Rotating Tines) tillers or from

low-cost front fine tillers.

I. Follow the "Pre-StartChecklist" on the

previous page. Besurethat the Wheel

GearLeveris in the ENGAGEposition.

2. Putthe DepthRegulator Lever inthe

"travel" position (lever allthe way down)

sothat the tines are clear of the ground.

Usethis position when practicing with your tiller or when moving to or from the

garden. Whenyou are ready to begin tilling, you must move the Depth Regula- tor Leverto the desired depth setting (see

"Tilling Tips & Techniques").

3. Start the engine and allow it to warm

up. Whenwarm, put EngineThrottle

Control Lever in "FAST"speedsetting.

Keepaway from rotatingtines. Rotating

tineswill causeinjury.

4. Forforwardmotion of the wheelsand

tines:

(a) Pull oneor both of the Forward

Clutch Control Leversup and hold them againstthe handlebars. To stop

forward motion of thewheels and tines, releasethe levers.

Page 16

Figure4.2: Useone handto guide tiller

whenmovingforward.

(b) As the tiller moves forward, relax

and let the wheels pull the unit along while the tines dig. Walk behind and a

little to one sideof the tiller. Usea light but secure grip with one hand on

the handlebars,but keepyour arm

loose. SeeFigure4-2. Letthe tiller move aheadat its own pace and do not pushdown on the handlebars to try and force the tiller to dig deeper- this takes weight off the wheels,

reduces traction, and causesthe tines to try and propel the tiller.

Do not push down on the handlebars to try to make the tiller till more deeply. This preventsthe wheels from holding the tiller back and can allow the tines to rapidly propel the

tiller forward, which couldresult in loss ofcontrol, propertydamage,or personal

injury.

5. Forreversemotion of thewheels and

tines:

(a) Look behind and exercise caution when operating in reverse. Donottill

while in reverse.

(b) Stop all forward motion before reversing. Lift the handlebars with

one hand until thetines are off the ground and then pull the Reverse

Clutch Control knob out to engage reverse motion (seeFigure4-3). To stop reversemotion, let go of the

ReverseClutch Control knob.

Figure4-3: Raise tinesoffgroundand look

behind whenmoving in reverse.

6. To Turnthe Tiller Around: (a) Practiceturning the tiller in alevel,

open area. Bevery carefulto keep

your feet and legs awayfrom the tines.

(b) To make a turn, reducethe engine speedandthen lift thehandlebars until the engine andtines are balanced overthe wheels (Figure4-4).

ways on the handlebar to move the tiller in the direction of the turn (Figure

4-5). After completing the turn, slowly lowerthe tines into the soil and increasethe enginespeed.

Stopping the Tiller and Engine I. To stop thewheels and tines, release

the ForwardClutch Control leversor the ReverseClutch Control knob (whichever

is engaged).

2. To stop the recoil start engine, move

the EngineThrottle Control Leverto "STOP". On electric start models, turn

the ignition keyswitch to "OFF"to stop the engine.

Before tilling, contactyour telephone or

utilities company and inquire if underground equipment or lines are

used in your area. Their representative will he glad to answer your questions and tell you if anyof their equipmentor lines are buried underground on your property.

Turningthe Tiller Around

Figure4.4: Tobegin turn,reduce engine speedand lift handlebarsuntil engine

and tines are balancedover wheels,

Figure4.5: Withtiller balancedover wheels(and tinesoutofthe ground).

push handlebarssidewaysto turntiller.

Page 17

TillingTips& Techniques

Let the tiller do the work

• While tilling, relaxand let thewheels pull the tiller along while the tines do

the digging. Walk on the side that is

notyet finished (to avoid making foot- prints in the freshly tilled soil) and

lightly, but securelygrip the handlebar

with just one hand.

•Avoid pushing down on the handlebars in an attempt to force the tiller to dig

deeper. Doingso takesthe weight off the poweredwheels, causing them to

losetraction. Without the wheels helping to hold thetiller back,the tines

will attempt to propel the tiller - often causing the tiller to skip rapidly across

the ground. (Sometimes, slight down- ward pressureon the handlebarswill

help get through a particularly tough sectionof sod or unbroken ground, but

in most casesthis won't benecessary

at all.)

Tilling depths

•Avoid trying to dig too deeplytoo

quickly, especially whenbusting sod or when tilling soilthat hasn't beentilled for some time. Use shallow depth reg-

ulator settings (only an inch or two

deep) for the first passesthrough the garden area. With eachsucceeding

pass,adjust the depth regulator to dig

another inch or two deeper. (Watering the garden areaa few days prior to tilling will maketilling easier, aswill

letting the newly worked soil set for a

day or two beforemaking afinal, deep tilling pass.)

•Whencultivating (breakingup the surfacesoil around plantsto help

destroyweeds),usevery shallowdepth

settingsto preventinjuryto plantswhose rootsoften growclosetothesurface. If needed,liftupon the handlebarsslightly

to preventthetinesfrom diggingtoo deeply. (Cultivatingon aregularbasis

notonlyeliminatesweeds,it alsoloosens

and aeratesthesoilfor bettermoisture absorptionandfaster plantgrowth.)

Avoidtillingsoggy, wetsoil

Tilling wet soil often results in large, hard clumps of soil that can interfere

with planting. If time permits, wait aday or two after heavyrainsto allow the soil

to dry beforetilling. Testsoil by squeez-

ing it into a ball. If it compresses too

easily, it is too wet to till.

Avoid making footprints

When possible,walk on the untilledside of the unit to avoid making footprints in the freshlytilled soil. Footprints cause soil compactionthat canhamper root penetration andcontribute to soil erosion. They canalso "plant" unwanted weedseedsback into thefreshly tilled ground.

Choosingcorrectwheel andtine speeds

With experience,you will find the 'Just right" tilling depth andtilling speedcom- bination that is best for your garden.

Set the EngineThrottle Control Lever to a speedto give the engineadequate power and yet allow it to operateatthe

slowest possible speed...atleast until you haveachievedthe maximum tilling

depth you desire. Fasterengine speeds may bedesirablewhen making final

passesthrough the seedbedor when cultivating. Selectionof the correct engine speed, in relation to the tilling depth, will ensure a sufficient power

levelto do thejob without causingthe

engine to labor.

Suggestedtilling patterns

•Whenpreparing a seedbed,go overthe same path twice in the first row, then overlap one-halfthe tiller width on the rest of the passes (see Figure 4-6).

Whenfinished in one direction, make a second pass ata right angle asshown

in Figure 4-7. Overlap each pass for best results (in very hard ground it may take three or four passesto thoroughly pulverizethe soil).

• If thegarden sizewill not permit lengthwiseand thencrosswise tilling,

then overlap thefirst passesby one-

halfa tiller width, followed by succes- sive passesat one-quarterwidth (see Figure4-8).

•With planning,you can allow enough room betweenrows to cultivate (see Figure4-9). Leaveroom for the hood

width, plus enough extra room for future plant growth.

Figure4.6

Figure4.7

Figure4.8

Figure4.9

Page 18

TillingTips& Techniques

Clearing the tines

Thetines havea self-clearing action which eliminates most tangling of debris in the tines. However,occasionally dry grass, stringy stalks or tough vines may become tangled. Followthese proce- dures to help avoid tangling and to clean the tines, if necessary.

• Toreducetangling, set the depth regu- lator deep enoughto getmaximum "chopping" action asthe tines chop the material against theground. Also, try to till under crop residues or cover crops while they are green, moist and

tender.

• While power composting, try swaying the handlebarsfrom sideto side (about 6"to 12"). This "fishtailing" action

often clearsthe tines of debris.

• If tanglingoccurs, lift the tinesout of the soil and run thetiller in reversefor

a few feet. This reversing action should unwind a good deal of debris.

• If reversingthe tiller doesn't clearthe debris, it may be necessaryto remove the debris by hand (a pocketknife will help you to cut awaythe material).

Beforeclearingthe tines by hand, stop the engine, allow all moving parts to stop and disconnect the spark plug wire. Removethe ignitionkey onelec-

tric start models. Failure to follow this warning could

resultin personal injury.

Tillingonslopes

If you must garden on amoderate slope, pleasefollow twovery important guidelines:

1. Till only on moderateslopes, neveron steepground wherefooting is difficult (review safety rules in the "Safety"

Section of this Manual).

2. Werecommendtillingup anddown slopes rather than terracing, Tilling vertically on a slope allows maximum planting areaand also leavesroom for cultivating.

IMPORTANT: Whentilling on slopes, be surethe correct oil level is maintained in

theengine (check everyone-half hour of operation). The incline of the slope will causethe oil to slantaway from its normal leveland this can starve engine

3artsof required lubrication. Keepthe

engineoil levelat the full point at all times!

A. Tilling upanddownslopes:

•To keepsoil erosion to aminimum, be

sureto add enoughorganic matterto

the soil sothat it has good moisture-

holding texture and try to avoid leaving

footprints or wheel marks,

•When tillingvertically, try to make the

first pass uphill as thetiller digs more deeplygoing uphill than it doesdown-

hill. In soft soil or weeds,you may

haveto lift the handlebarsslightly while going uphill. When going downhill, overlap thefirst pass by about one-half

the width of the tiller.

B. Terrace Gardening:

•When a slope istoo steepor too short for vertical tilling,it may be necessary to till acrosstheslope and createter-

racedrows, Terracesare rows that are

cut into the side of a slope, creating a

narrow, but flat areaon which to plant,

• On along slope,you can makeseveral terraces, one belowthe other.

•Terracesshould beonly 2-to-3 feet wide. Digging too far into the side of

the slopewill expose poor subsoil that is unproductive for plants.

•To createa terrace,start at thetop of the slopeand work down. Go backand

forth across the first row as shown in Figure4-10.

•Eachsucceedinglowerterraceis started bywalking below the terrace you're preparing. Foradded stability of the tiller, always keep the uphill wheel in the soft, newlytilled soil. Do not till

the last 12"or more of the downhill outside edge of eachterrace. This

untilled strip helps prevents the ter- racesfrom breakingapart and washing

downhill. It also provides awalking path betweenrows.

oliP,

Figure4_lO

C. Tilling acrossslopeswithout usingterraces:

• If vertical or terracing gardeningaren't practical for you, then you can till later- ally acrossa slope. Wedon't really

recommend this method as it can create unsure footing and invites soil

erosion.

•As in terracegardening,start atthe top of the slopeand overlapthe first pass

by halfthe width of the tiller. Foradded stability of the tiller, alwayskeepthe

uphill wheel in the soft, newlytilled soil.

Page 19

POWERCOMPOSTING

Powercomposting simply meanstilling under and burying in the soil all manner of organic matter such as crop residues, leaves,grass clippings and cover crops. This material will decomposeduring the non-growing seasonand addimportant

natural nutrients to the soil.

When power composting, do not keep the Depth Regulator Lever at a deep setting if thetillerjumps orbucks.

Ifjumping or buckingoccurs, move the Depth Regulator Lever down to one of

the shallower settings and then slowly

increase the tilling depth on later

passes.

Failure to follow this warning could

result inpersonalinjury.

Thefirst placeto begin is with crop residues such as leftover vines,stalks,

stems and roots. Powercompost these crop residuesas soonas they finish bearing. Thesooner this is done, the

better,as tendergreen matter is easier to till under. Usethe deepestdepth regula-

tor setting possible without causing the engineto labor or the tiller to jump ahead.

Standingcornstalks of reasonableheight canbe power composted. Pushing over (but not uprooting) cornstalks will often make it easier for your tiller to chop up the stalks. Keepthe tines clear of exces- sive tangling by "fishtailing" or frequently using reverse. Makeseveralpasses,then return a few days later to finish off any remaining stubble,

After tillingunder crop residues, add more organic matter such as leaves, grass clippings and even kitchen scraps. Whentilledinto the soil, thisorganic matter will decomposeand add even more important nutrients to the soil.

After power composting, you may want to plant a "green manure" covercrop to protect the soil during the off-season. You simply grow a crop of clover, alfalfa, buckwheat,peas, beans,rye grass,grain, or kale and thentill it into thesoil prior to the planting season.

LOADINGANDUNLOADING THETILLER

Loading and unloading the tiller into a

vehicle is potentially hazardousand we don't recommenddoingso unless abso-

lutely necessary,as this could result in personalinjuryor propertydamage.

However, if you must load or unloadthe

tiller, follow the guidelines given next.

• Beforeloading or unloading, stop the

engine,waitfor all parts to stop moving, disconnect the spark plug wire and let theengine and muffler cool. Remove the ignition keyon electric start models.

• Thetiller is too heavy (over 170 Ibs., depending on model) and bulky to lift safelyby one person. Two or more people should sharethe load.

• Usesturdy ramps and manually (engine shut off) roll the tillerinto and out of the vehicle. Two or more peopleare needed

to do this.

• Rampsmust be strong enough to support the combined weight of the tiller and any handlers.The ramps should provide good traction to prevent slip- ping; they should have side rails to guide the tiller along the ramps; and they should havea lockingdeviceto

secure them to the vehicle,

•Thehandlers shouldwear sturdy footwear that will help to prevent slipping.

• Position the loadingvehicle sothat the ramp angle is as flat as possible (the

less incline to the ramp, the better),

Turn the vehicle'sengine off and apply

its parking brake,

•Whengoing up ramps, stand in the normal operatingposition and pushthe tiller aheadof you, Havea person at

eachside to turn the wheels,

•Whengoing down ramps, walk back- ward with the tiller following you, Keep alert for any obstacles behind you.

Position a person ateachwheelto control the speed of the tiller, Nevergo down ramps tiller-first, as the tiller could tip forward.

• Usewooden blocks to place on the downhill side of thewheels if you need to stop the tiller from rolling down the ramp. Also, usethe blocksto temporar-

ily keepthe tiller in placeon the ramps (if necessary),and to chock the wheels in place after the tiller is in the vehicle.

•Whenthe tiller is in thevehicle, prevent

itfrom rolling by engagingthe wheels in

the wheeldrive position (put Wheel Gear

Leverin ENGAGE).Chockthe wheels

with blocks and securelytie thetiller down.

Page 20

Maintenance

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

start models. Failure to follow these instructionscan

result in serious personalinjuryor prop- ertydamage.

MAINTENANCESCHEDULE

PROCEDURE NOTES

Check motor oil level 2, 3 Clean engine 2, 7

Checkdrive belt tension 1, 4 Check nutsand bolts 1, 4

Change motor oil 1, 4, 6 Lubricate tiller 4

Service foam pre_cleanerair filter 7

(if soequipped)

Service paperair filter (if so equipped) 7 Checkgear oil level in transmission 1, 5

Checktines for wear 5 Checkair pressure in tires 5

Service spark plug 7

NOTES

I - After first 2 hours of break-in operation.

2 - Beforeeach use. 3 - Every5 opet_ting hours. 4 - Every 10 operating hours. 5 - Every30 operating hours.

6 - More frequently in dusty or dirty conditions. 7 - SeeEngine Owner's Manual for service

recommendations.

8 - Whichevertime interval occurs first.

TILLER LUBRICATION

Figure5.1: Lubrication points.

Proper lubrication of thetiller is anessen-

tial part of your maintenanceprogram. After every 10 operating hours, oil or

greasethe lubrication points shown in

Figure5-1 asdescribed below. Usea goodquality lubricating oil (#30

weight engineoil is suitable) and a good quality generalpurpose grease(grease

that has a metal lubricant is preferred, if available).

• Removewheels, cleanwheelshaft (A, Figure5-1) and applythin coating of

greaseto shaft.

• Greaseback, front and sidesof depth regulator lever (B,Figure5-1).

• Removetines, cleantine shafts (C, Figure5-1) and inspect for rust, rough spots or burrs (especially around holes). Fileor sandsmooth and coat endsof shaft with grease.

• Oil thethreads on the handlebarheight adjustment screw (D, Figure5-1).

• Oil thethreads on the handlebarattach- ing screws (E,Figure5-1).

CHECK HARDWARE

At leastevery 10operating hours, check the unit for looseor missing hardware

(screws, bolts, nuts, hairpin cotters, etc.).

Looseor missing hardwarecan leadto equipment failure, poor performance or oil leaks.

Besureto checkthe threeend cap

mounting screws located at the rear of the transmission (Figure5-2). Lift the tine

flap to servicethose screws.

Figure5.2

CHECK TIRE PRESSURE

Checkthe air pressure in both tires.

Deflateor inflate both tires evenly to 15- to-20 PSi (pounds per square inch). Be

surethat both tires havethe same air

pressureor the unit will tend to pull to one side.

Page 21

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

come to a complete stop, disconnect spark plug wire and move wire away from spark plug.

Remove the key from the keyswitch on units so equipped. Failure to follow these instructionscan result in serious personal injury or propertydamage.

CHECK FOR OIL LEAKS

Beforeeachuse,check your tillerfor signs of anoil leak - usually a dirty, oily

accumulation either on theunit or on the floor where it hasbeenparked.

A little seepagearound a cover or oil seal is usually not a cause for alarm. However, if theoil drips overnight thenimmediate attention is neededasignoring a leakcan result in severetransmissiondamage.

If a cover is leaking, try tightening any loose screws or bolts. If the fasteners are

tight, a new gasket or oil seal may be required. If the leak is from around a shaft and oil seal,the oil sealprobably needsto be replaced. Seeyour autho- rizeddealer or contact the factory for

serviceor advice. IMPORTANT:Neveroperate the tiller if

thetransmissionis low on oil. Checkthe oil level after every 30 hours of operation

and wheneverthere is anyoil leakage.

TRANSMISSION GEAR OIL SERVICE

Checkthe transmissiongearoil levelafter every 30 hours of operation or whenever you notice any oil leak. Operatingthe

tiller whenthetransmissionis low on oil can result in severedamage.

A. To CheckTransmissionGearOil Level:

1. Checkthe gear oil level when the trans- mission is cool. Gearoil will expand in warm operating temperatures and this expansionwill providean incorrect oil levelreading.

2. Tocheck thegear oil level (andto add oil, if necessary),referto "STEP5: Check

GearOil Levelin Transmission" inSection 2 of thismanual.

B. To Drain and Refill the Transmission:

Thetransmissiongearoil does not need to bechangedunless it hasbeencontami- natedwith dirt, sandor metal particles.

1. Prop up the left side of the unit so that it will be securely supported whenthe left

side wheelis removed. Removethe left side wheelby removing the wheel mount-

ing hardware.

2. Unscrew the plastic gearoil fill plug from the top of the transmission.

3. Placea cleanpan below the transmis- sion drain plug (seeFigure5-3) and

removethe drain plug. Theoil will start

flowing out of the drain hole (it mayflow

slowly, especially in cold temperatures).

4. Removethe transmission gear oil level checkplug that is locateda few inches

abovethe left sidewheel shaft.

5. When theoil stops flowing, tilt the

transmission forward to drain oil from the

rear of the transmission.

6. After draining the oil, cleanthe threads of thedrain plug, apply a non-hardening

removablegasketsealantto the threads, andsecurely reinstall the drain plug.

7. Using acleanfunnel, slowly add SAE 140 or SAE85W-140 weight gear oil (with an API ratingof GL-4 only) to the

transmission. The transmission holds

approximately 3-1/4 pints (52-54 ounces). Tilt the tiller slightly backwards

to makesure the gearoil reachesthe rear

(tine) end of the transmission. Stop adding gearoil when it begins to flow

from the oil levelcheckhole on the sideof the transmission.

8. Securely reinstall the oil level check plug,

9. Securely reinstall the gear oil fill plug on top of the transmission.

10. Reinstallthe wheel and removethe prop.

Page 22

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all movingparts to come to a complete stop, disconnect spark plug wire and move wire away from spark plug.

Remove the key from the keyswitchon units so equipped. Failure to follow these instructions can result in serious personal injury or propertydamage.

Figure5.3: Removedrain plug to drain transmissiongear oil (alsoremoveoil fill

plug and oil level checkplug).

ENGINEOIL SERVICE

Checkthe engine oil level before starting the engine eachday and checkit after

each5 hours of continuous operation. Running the enginewhen it is low on oil

will quickly ruin the engine.

It is recommendedthat you changethe

motor oil after every 10 hours of opera- tion and evensooner when operating in

extremely dirty or dusty conditions. Refer to the separateEngineOwner's Manual

for detailedserviceinstructions.

A. To Check the EngineOil Level:

1. Move the tiller to a levelareaand shut off the engine.

2. Levelthe engineby moving the Depth Regulator Lever up or clownasneeded.

3. Cleanthe areaaround the oil dipstick or oil fill tubeto prevent dirt from falling

into the crankcase.

4. Onengineswith anoil fill tube, remove the filler cap,add oil (if required) until it reachesthe top of the tube and reinstall the filler cap.

5. Onengineswith adipstick, remove it, wipe it clean, and reinstall it finger-tight.

Removethe dipstick and checkthe reading. Add oil (if required) to bring the

levelto the FULLmark. Do not overfill. B. To Changethe EngineOil:

Changethe engineoil as instructed in the separateEngineOwner's Manual.

AIR CLEANER SERVICE

Theengine air cleanerfilters dirt and dust out of the air before it entersthe carbure-

tor. Operatingthe enginewith a dirty, clogged air filter can causepoor perfor- mance and damageto the engine. Never operatethe enginewithout the air cleaner installed. Inspectand service theair cleanermore often if operating in very dusty or dirty conditions.

Servicethe air cleaneras instructed inthe separateEngineOwner's Manual.

SPARK PLUG SERVICE

Inspect andcleanor replace the spark

plug after every 100 operating hours or annually. Cleanthe plug andset the gap

asdescribed in the separateEngine Owner's Manual.

In someareas, local lawrequires using resistor spark plugs to suppress ignition signals. If the enginewas originally

equippedwith aresistor spark plug, use the sametype for replacement.

SPARK ARRESTER SCREEN SERVICE

If the engine muffler isequipped with a spark arrester screen,remove and cleanit according to the time intervalsand instructions in the separateEngine Owner's Manual.

ENGINECLEANING

Theengine must be kept clean to assure smooth operation and to prevent damage from overheating. Referto the separate EngineOwner's Manualfor specific repair and cleaning instructions. All inspections

and services must be done with the engineshut off and cool to the touch.

CARBURETOR/GOVERNOR CONTROL ADJUSTMENTS

Operators shall not tamper with the engine governor settings on the

machine; the governor controls the maximum safe operating speed to

protectthe engine and all movingparts from damage caused by overspeed.

Authorized service shall he sought if a problemexists.

Thecarburetor was adjustedat the factory for best operating speed. Referto the separateEngineOwner's Manualfor anyadjustment information or seeyour authorized engineservicedealer.

Thegovernor controls the maximum safe operating speedandprotects the engine and all moving partsfrom damage caused by overspeeding. Do not tamper with the enginegovernor settings. Seekautho- rized serviceif a problem exists.

THROTTLE CONTROL ADJUSTMENT

If the enginedoes not respondto various throttle leversettings, refer to the sepa-

rate EngineOwner's Manualfor service information or contact your localautho-

rizedengine service dealer.

Page 23

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

come to a complete stop, disconnect spark plug wire and move wire away from spark plug.

Remove the key from the keyswitch on units so equipped. Failure to follow these instructionscan result in serious personal injury or propertydamage.

WHEELGEARCABLEADJUSTMENT

Whenthe WheelGearLeveris in DISEN-

GAGE,thewheels will roll freely (free-

wheel). The wheels should not roll freely when the lever is in ENGAGE.If the

wheels roll freely when the Wheel Gear

Leveris in ENGAGE,thewheel gearcable needsto be adjusted as described below.

1. With the engine shut off and the spark plug wire disconnected, put the Wheel

GearLeverin ENGAGE.

2. Loosenthetop adjustment nut (A, Figure5-4) on the wheelgear cable

bracketthat is located on the left siderear of the transmission.

3. Pushthe wheelgear cable (B) down and roll the tiller slightly forward or back-

ward until the eccentric lever (C) engages

(locks) the wheels. Hold thecable in that position and tighten the top (A) and bottom (D) adjustment nuts.

4. Move the Wheel GearLeverto ENGAGEand DISENGAGEseveraltimes

to checkthe adjustment. Thewheels

should not roll when the lever is in ENGAGE,but they should roll whenthe

leveris in DISENGAGE.Readjustthe cableasrequired.

Figure 5-4: Wheelgear cable assembly.

OFF SEASON STORAGE

When thetiller won't beused for extended periods, prepare it for storage

asfollows:

1. Cleanthe tiller and engine.

2. Do routine tiller lubrication and check

for loose parts and hardware.

3. Protect the engineand perform recom-

mendedenginemaintenancebyfollowing the engine storage instructions found in the separateEngineOwner's Manual.

NOTE:Besure to protect the fuel lines, carburetor and fuel tank from gum deposits by removing fuel or bytreating fuel with afuel stabilizer (follow engine

manufacturer's recommendations).

4. On electric start units, follow "Battery

Storage" instructions inthis Section.

5. Store unit in a clean, dry area.

6. Never store thetillerwith fuel in the fuel tank in an enclosed areawheregas

fumes could reachan openflame or

spark,or where ignition sources are

present (spaceheaters,hot water heaters, furnaces, etc.).

BOLOTINES

Thetines will wear with use andshould

be inspected at the beginning of each tilling season and after every 30 operating

hours. Tinescan be replaced individually or as acomplete set. Neverinspector

servicethetines unless theengine is

stopped,the spark plug wire is discon-

nected,andthe ignition key is removed on electric start models.

A. Tine Inspection: With use,the tines will become shorter,

narrowerand pointed (Figure 5-5). Badly worn tines will result in aloss of tilling depth and reduced effectiveness when

chopping up and turning under organic

matter. UseFigure5-5 as a guide to when thetines should bereplaced.

ModerateWear

New

Replace

Figure5.5: Checkingtinesfor wear.

B. Removinga SingleTine:

1. Removethetwo screwsand nuts that

attacha single tine to the tine holder

(Figure5-6). If needed,use penetrating

oil to help free the nuts.

2. When installing a singletine, besure to position it so that its cutting edge will

enterthe soil first as thetiller moves forward.

C. Removinga Tine Assembly:

I. If removing both fine assemblies, mark

them "left" and "right" beforeremoval.

Doingso will help ensure that the assem-

blies are reinstalled on the correct sides of the tiller.

2. Removethescrew and Iocknut that secure the tine assembly to the tine shaft

(Photo5-7). Pull thetine assemblyoff the shaft (if necessary,use arubber mallet to tap the tine assembly outward).

3. Beforereinstalling the tine assembly,

inspectthe tineshaft for rust, rough spots or burrs andfile or sand as needed.

Apply athin coat of greaseto theshaft.

4. Installeachfine assembly so that the

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

Securethetine assembly to the tine shaft using the screw and Iocknut previously

removed. Tighten securely.

Page 24

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all movingparts to come to a complete stop, disconnect spark plug wire and move wire away from spark plug.

Remove the key from the keyswitchon units so equipped. Failure to follow these instructions can result in serious personal injury or propertydamage.

Figure5-6: Removingsingletine.

Figure5.8: Forwardclutchbelt (C). (Left. side view, nobelt cover.)

Figure5-10: Locationofforwardclutchcable spring(E)andforwardcableadjuster(F).

ofTine

Figure5-7,"Removinga tine assembly.

Follow the belt adjustment instructions carefully. An incorrectadjustmentcould

result in the clutch control mechanism engaging too soon. This could cause

loss of tiller control and result in per- sonalinjuryor propertydamage.

CHECKING AND ADJUSTING TENSION ON CLUTCH BELT

Maintainingcorrect belt tension isimpor- tantto good tilling performance and long

belt life. A loose beltwillslip on the engineand transmission pulleysand

causethe tines andwheels to slow down

- or stop - eventhough the engine is running at full speed. A loose belt will also result in premature belt wear,

Whilechecking belt tension, alsocheck for cracks, cuts or frayed edges.A belt in poor condition should be replaced,

Figure5.9: Reverseclutch belt (D).

(Right-sideview, nobelt cover.)

Tension on a new forward clutch belt (C, Figure5-8) should be checkedafter the

first two (2) hours of operation and after every ten (10) hours of operation.

Thereverseclutch belt (D, Figure5-9), becauseit is usedmore sparingly, may not requiretension adjustment until a sig- nificant number of operating hours has

passed. A tension adjustment is required only if there is little or no reverse move-

ment when the ReverseClutch Control

knobis pulled out.

2-1/2"

extended

Figure5.11: Correctspringlength when ForwardClutchLevers are engaged is2. I/2".

Checking andAdjusting

ForwardClutchBelt Tension

CheckingForwardBelt Tension

1. Beforeadjusting, shut off engine,allow

the engine and muffler to cool down, dis- connect the spark plug wire,and remove

the ignition key on electric start models=

2. Thecoiled part of the forward clutch spring (E, Figure5-10) measures2" in lengthwhenthe ForwardClutch Control levers (G)are not pulled up= Pull either ForwardClutch Control Lever up against

the handlebarand measurethe length of the extendedcoil. Tension iscorrect if

the length of the extendedcoil is 2-1/2"

(seeFigure5-11)=

Page 25

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

come to a complete stop, disconnect spark plug wire and move wire away from spark plug.

Remove the key from the keyswitch on units so equipped. Failure to follow these instructionscan result in serious personal injury or propertydamage.

Theforward clutch control cableneeds adjustment if the extendedlength of the

coil is not 2-1/2". SeeAdjusting the Forward Clutch Belt for a procedure.

Adjustingthe ForwardClutchBelt

Incorrectcable adjustment could cause thewheels and tines to rotate unexpect-

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

Dothis procedure if the forward clutch spring measurementis not correct (see

CheckingForward Belt Tension).

1. Beforeadjusting, shut off engine,allow the engineand muffler to cool down,dis- connect thespark plug wire, and remove theignition keyon electric start models.

2. Belt adjustmentsare done with the forward clutch cable adjuster (F, Figure

5-10). Usetwo 1/2",open-end wrenches to loosenthetwo jam nuts (A,Figure

5-12) a few turns. NOTE: Do not loosenthe nuts more than

a few turns for each adjustment check.

3. Move cable adjuster (B, Figure5-12) downward for more belt tension.

MoreBel

Tension.

Figure5.12: Moveforward clutchcable adjuster downfor more belt tension.

4. Handtighten the jam nuts and pull the Forward Clutch Control levers up against the handlebar. Measurethe spring coil (Figure 5-11). Theextended length of the

coil should be 2-1/2". Repeatthis proce- dure until the extendedspring length is

correct.

NOTE: A new belt is neededwhen the,jam nuts are adjusted closeto theend of the threadedadjuster=

5. Tighten bothjam nuts securely. Checking and AdjustingReverse

Clutch Belt Tension

CheckingReverseClutchBelt Tension

Thereverse clutch belt (D, Figure5-9) needsadjustment if the belt slips in

reverse or if there is no reverse. See Adjusting Reverse Clutch Belt below.

AdjustingReverseClutchBelt

1. Beforeadjusting the belt, shut off engine,allow the engine and muffler to

cool down, disconnect the spark plug wire,and remove the ignition key on elec-

tric start models.

2. Removethe two flange Iocknuts (C, Figure5-13) and remove the belt cover.

Figure5.13: Beltcover.

3. Reversebelt tension adjustmentsare done with thereverseclutch cable

adjuster locatedon the left side of the machine nearthe engine(D, Figure5-14).

Use two 1/2"open-end wrenchesto loosenthetwoadjuster jam nuts (E)a few

turns= NOTE: Do not loosenthenuts more than

a few turns for each adjustment check=

4. Move the cable adjuster (D, Figure 5-14) away from the pulleys to increase

belt tension= NOTE: A new belt is neededwhen the jam

nuts are adjusted closeto theend the threadedadjuster=

5. Tighten bothjam nuts securely.

6. Pull backon the ReverseClutch

Control knob and makesurethat the

Movecable

adjusteraway

from pulleysto

increasereverse

belt tension.

Figure5-14: Reverseclutchcable adjuster.

Left.side view with beltcoverremoved.

reverseclutch belt fully contacts the

groovein the enginepulley. Releaseknob

andmake sure thatthebelt doesn't

engagethe reverseengine pulley (L,

Figure5-14). If it does, it may causethe

unit to move in reversewhen the Wheel

GearLeveris engaged=Adjust the cable for lesstensionif thiscondition occurs=

SeeCheckingand Adjusting ReverseBelt

Tensionfor more information.

7. Reinstallthe belt cover=

8. Move the unit to an open areaand test

the reverse operation. Repeatthis proce-

dure if the unit does not respond when the reverse clutch is engaged.

FORWARD CLUTCH BELT REMOVAL AND REPLACEMENT Theforward clutch belt (K, Figure 5-15)

engagesthe enginepulley (I) andthe transmission pulley (J) when either

ForwardClutch Control Lever is pulledup

againstthe handlebar.

Figure 5-15: Forward clutchcontrol

assembly,

Page 26

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all movingparts to come to a complete stop, disconnect spark plug wire and move wire away from spark plug.

Remove the key from the keyswitchon units so equipped. Failure to follow these instructions can result in serious personal injury or propertydamage.

FigureS-16

PressForwardClutch Idler Arm inward to take pres-

sureoff Clutch Cable.

ForwardClutch

Cable

Connection

Figure5.17

Pulling the lever(s) tightens theforward clutch cable (G)which causesthe forward

clutch idler pulley (H) to apply tension to theforward clutch belt. This causesthe

belt totransfer power from the engine pulley to thetransmissionpulley for

Forward movement.

RemovingForwardClutch Belt

1. Stopengine, allow it tocool and dis- connectspark plug wirebefore working near belts. Also remove ignition keyon

electric start models.

2. Removethe two nuts (C, Figure5-13) and remove the beltcover.

3. Move the reverseclutch belt (A, Figure 5-16) out of the way= Presson the

reverse idler pulley to createslack. Then slip the bottom half of the belt completely

off thetransmissionpulley.

Figure5.18

Pull the bottom half of the belt out of the housing and let it hang outside the unit

(B).

4. On left-side of unit, disconnect the

forward clutch cable from theforward

clutch idler arm bracket (Figure 5-17). Notethe hole from which you disconnect

the cable. It is important to reconnectthe

cableto the samehole.

5. Slidetheforward clutch belt off the engine pulley (C, Figure5-18), awayfrom

engine (in the direction of arrow 1), out

from behind the belt guide (D), and com-

pletely off the pulley.

6. Slip the belt off thefront of the trans- mission pulley (E,Figure5-18, in the

direction of arrow 2).

7. Work the belt out from betweenthe pulley andthe frame, around the trans-

mission cover spring, then up and out of

the machine.

InstallingForwardClutchBelt

1. Stop engine,allow it to cool and dis- connectspark plug wire beforeworking near belts. Also remove ignition keyon

electric start models.

2. Removethe old forward clutch belt as described in RemovingForward Clutch

Belt.

Figure5.19

3. From the front of tiller, insert the forward clutch belt in betweenthe bottom

of the engine pulley (I, Figure5-19) and thetop of transmission pulley (P).

4. Insert the bottom halfof belt into the smaller, rear-most groove of the trans-

mission pulley (E,Figure5-18, in the direction of arrow 3). Nowslip thetop

half of belt behind the belt guide (D, Figure5-18, in the direction of arrow 4)

and onto the large grooveof enginepulley (C, Figure 5-18).

5. Reconnecttheforward clutch cableto thecorrect hole in the idler arm bracket,

asshown in Figure5-17. NOTE: Besure to position the clutch

cableon the pulley side (G, Figure 5-20) of the left-side cover support bracket (J).

IMPORTANT:Belt must be installed behindthe belt guide (H,Figure5-20).

Figure5.20: Correct forwardclutchcable

positioning.

Page 27

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

come to a complete stop, disconnect spark plug wire and move wire away from spark plug.

Remove the key from the keyswitch on units so equipped. Failure to follow these instructionscan result in serious personal injury or propertydamage.

6. Reinstallthe reverseclutch belt. Insert the bottom of the belt into the frame,then pull down on the beltand slip it onto the

large, forward-most groove of thetrans- mission pulley (P, Figure5-19).

7. Pull back on the ReverseClutch Control knob and makesure thatthe reverse clutch belt fully contacts the

groove in the engine pulley. Release knob and make surethat the belt doesn't

engagethe reverseengine pulley. If it does, it may causethe unit to move in

reversewhen the WheelGearLever is engaged. Adjust the cable for less

tension if this condition occurs. See

Checkingand Adjusting ReverseBelt

Tension.

Figure5.21: Right.side view,

8. Reinstallthe belt cover.

9. Testfor correct tension on the forward

clutch belt. See CheckingForward Belt

Tension.

10. Move the unit to an open areaand test thereverse operation. It needs adjustment if the belt slips in reverseor if there isno reverse. SeeAdjusting

ReverseClutchBelt.

REVERSE CLUTCH BELT REMOVAL AND REPLACEMENT

Thereverseclutch belt (J, Figure5-21) is driven by theengine pulley (I, Figure5-

19). Whenthe ReverseClutch Control

knob is pulled out, it pulls the reverse

idler arm and pulley (N, Figure5-21)

inward, which tightens the beltagainst the engine pulley. This drives the transmis- sion pulley (L), resulting in reverse

motion.

RemovingReverseClutchBelt

1. Stop engine,allow it to cool and dis- connect spark plug wire beforeworking near belts. Also remove ignition key on

electric start models.

2. Removebeltcover (Figure5-13) by removing two flange Iocknuts (C).

3. Pull the reverseclutch belt downward and slip it off the transmission pulley

(L, Figure5-21).

4. Usetwo 1/2"wrenches to loosenand remove wire belt guide (R, Figure 5-21)

from the reverseidler arm pulley. Donot remove Iocknut and screw.

5. Removethe reverse belt and pull it out through front of transmission housing.

InstallingReverseClutchBelt

1. Stop engine,allow it to cool and dis- connect spark plug wire beforeworking near belts. Also remove ignition key on

electric start models.

IMPORTANT:The forward clutch belt must be installed beforethe reverse clutch belt (seeInstalling Forward Clutch

Beltin this Section).

IMPORTANT:The reverse belthas a 'V" shape. When installing the belt, make

sure that the widest (flat) side of the belt rides against the reverseidler pulley (N,

Figure5-21) and transmission pulley (L).

If needed,the belt can betwisted "inside out" sothat the "V" shapedside is on the

outside and thewidest side is on the

inside.

2. Insert the belt down into the front of the transmission housing. Slip the top

half of the belt onto the reverse idler arm pulley (N, Figure 5-21).

3. Pull the belt downward and loopthe bottom half of beltaround the front

groove of transmission pulley (L, Figure 5-21).

When Reverse. Idler arm pulley

(Y) ispulled all the way up, belt

guide(Z) should be

horizontal.

Figure 5.22: Reversebelt guidepositioning.

4. Mount the belt guide betweenthe two flat washers andtighten snugly. The

guide needs adjusting before fully tightening.

5. (Youwill needan assistant to help with this step.) Pull the reverseidler pulley (Y) up to its highest point and posi- tion the belt guide (Z) horizontally levelas shown in Figure5-22. Securelytighten the screwand Iocknut (M, Figure 5-21).

6. Pull backon the ReverseClutch Control knob and makesure that the

reverseclutch beltfully contacts the groove in the engine pulley. Releaseknob

and makesure that the belt doesn't engagethe reverseenginepulley. If it

does, it may causethe unit to move in reversewhen theWheelGear Leveris

engaged. Adjust the cable for less tension if this condition occurs. See

CheckingandAdjusting ReverseBelt Tensionfor more information.

7. Reinstallthebelt cover and secure it with two flange Iocknuts.

8. Testthe unit in an open location.

9. Movethe unit to an openareaand test the reverseoperation. It needsadjust- ment if the belt slips in reverseor if there is no reverse. SeeAdjusting Reverse

ClutchBelt.

Page 28

Before inspecting, cleaning or servicing the machine, shut off engine, wait for all movingparts to come to a complete stop, disconnect spark plug wire and move wire away from spark plug.

Remove the key from the keyswitchon units so equipped. Failure to follow these instructions can result in serious personal injury or propertydamage.

BATTERYMAINTENANCE

Use extreme caution when working on or near batteries. To help preventper- sonalinjuryor propertydamage:

• Follow the battery safetyrules in Sec-

tions 1 and 2 of this Manual. Failure to follow all safetyrules may result in personal injury or property damage

from such causes as an explosion of batterygases, acidburnsor electrical

burns.

• Electrolyte is a sulfuric acid solution.

Avoid spillage and contactwith skin, eyes and clothing. Wear protective clothing, rubber gloves and shield eyes with safety goggles when workingnearthe battery.

• Batteries generate explosive gases. Keepsparksandflames away from the batteryat all times. Ventilate the area when chargingor using the battery in

an enclosedarea.

BatteryCarein Service

1. Oncea month or every 10 operating

hours, whichever occurs first, checkthe electrolyte level. If the electrolyte levelis

not at the UPPERLEVELline marked on the batterycase,add distilled or deminer-

alizedwater. NEVERUSEBATTERYACID TOREFILLTHEBATTERY.

Replacethe batterycaps securelyand wipe thebatterytop= Runthe engine out-

doors for about 20 minutes at 3/4 throttle speedto rechargeand recirculate the

electrolyte solution. Forsafety,do not leavethe tiller unattendedwhile the

engine is running.

2. Keepthe batteryclean. Any acid deposits should be neutralizedwith a baking sodaand water solution (remove battery from unit andtightenthe battery caps to prevent any solution from enter- ing the cells). Cleanany remaining solu- tion off the battery.

Cleanthe posts and terminals witha wire brush, sandpaperor steelwool= After cleaning, coat theterminalswith a thin coat of petroleum jelly or silicone grease to protect againstcorrosion.

3. Periodically check the electrical system for looseor dirty connections.

4. Periodically check that the battery clamp is tight. However,do not over- tighten theclamp asdoing so could damagethe batterycase.

5. Periodically check that the vent tube on the side of thebattery is not crimped or pinched anywherealong its length.

BatteryStorage

Theelectric start systemhasa recharging circuit that will maintain thebattery's state of chargeduring the tillingseason. When

storing the tillerfor extendedperiods,it is recommendedthat the batterybe fully

charged beforeplacingit in storage.

(Beforereinstallingthebattery after storage,giveit a thorough recharge.)

BatteryRemovalandInstallation

When removing and installing the battery, disconnect and connectthe cables in this

order to avoid sparking:

I. Disconnect the negative(-) cable from

the grounding screw on the backof the

batterybracket post. Bendthe cableaway

from any metal parts.

2. Disconnect the negative(-) cablefrom

the negative (-) battery post.

3. Disconnect the positive (+)cable from

the positive (+) batterypost andbend it away from any metal parts. Coverthe cableterminal with its rubber boot.

4. Removethe batteryclamp.

5. To install the battery, reversethe above

steps. Be surethat the battery posts face to the rear of the tiller and that the posi- tive (+) post is on the left side asyou face

forward from the handlebars=

6. Insertthe vent tube into the vent tube

shield. Make surethe vent tube is not crimped, pinchedor folded anywhere

along its length.

Theattachments listed below are availablefor your tiller. The information is the most current atthe time this manual was printed. Contactyour authorized dealeror the factory for current information.

BUMPER

Thetubular steel bumper helps to protect the engine from damage.

HILLER/FURROWER

Thefurrower bladeattachesto the backof the depth regulator assembly and is used to create

rows, trenchesand ditches up to 8"deep,dependingon soil conditions= Thetwo hiller wings

attach tothe sides of the furrower blade and are used to make hilled rows and raised bed gardens.

ROWMARKER

The row marker attachesto the hiller/furrower attachmentand is usedto scratch linesin the

seedbedfor laying out furrows, trenches, raised beds, etc=(eliminatesthe needfor stakes, string and measuring tape)= Therow marker is adjustablein length from 28" to 49-3/4",

allowing youto vary the width of themarked rows asrequired=

TILLERATTACHMENTS

Page 29

TROUBLESHOOTING

Beforeperforming any corrections, refer to the appropriate information inthis Manual,or in the EngineOwner's Manual,for the correct safety precautions and operating or maintenanceprocedures. Contactyour local authorized Engine ServiceDealerfor engineservice. Contactyour localauthorized equipmentdealeror thefactory for all other serviceproblems.

PROBLEM POSSIBLE CAUSE CORRECTION

Enginedoes not_art.

1, Sparkplug wiredisconnected, 2, EngineThrottleControlLeverincorrectlyset,

3, Fueltank empty. 4, Chokecontrol (if soequipped)in incorrectposition.

5, Stalegasoline. 6, Dirtyair filter(s). 7, Defectiveorincorrectlygappedsparkplug, 8, Carburetoroutofadjustment, 9, Misadjustedthrottle control

lO,Dirtor water in fueltank.

1. Reconnect wire,

2. Put lever in FASTposition.

3. Add fuel, 4, See Engine Owner's Manual.

5. Drain fuel and add fresh fuel.

6. Clean or replace filter(s),

7. inspect spark plug,

8. See Engine Service Dealer.

9. See Engine Service Dealer,

10, See Engine Service Dealer,

Keyswitchdoes 1, Electricalconnectionslooseor disconnected. 1. Tightenor reconnectwiring. netstartengine 2, Batterydischarged, 2. Chargebattery(see"BatteryMaintenance,"Section5),

(electric start 3, Brokenwire inwiring system. 3. Replacebrokenwiring. modelonly) 4, Malfunctioningstartermotor, 4. SeeEngineServiceDealer.

5, Corrodedbatteryterminals, 5, Cleanterminals(see"BatteryMaintenance,"Section5), 6, Poorcontacton groundwireterminals, 6. Scrapepaintoff terminals.

Enginerunspoorly. 1, Defectiveor incorrectlygappedspark plug, 1. Inspectsparkplug (see EngineOwner'sManual),

2, Dirtyair filter(s). 2. Cleanor replace(seeEngineOwner'sManual), 3, Carburetoroutofadjustment, 3. SeeEngineServiceDealer. 4, Stalegasoline. 4. Replacewith freshgasoline. 5, Dirtor waterin fueltank. 5. SeeEngineServiceDealer. 6, Enginecooling systemclogged. 6. Cleanair coolingsystem(seeEngineOwner'sManual),

Engineoverheats. 1, Enginecooling systemclogged. 1. Cleanair cooling area(seeEngineOwner'sManual).

2, Carburetoroutofadjustment, 2. SeeEngineServiceDealer. 3, Oillevelis low. 3. Checkoil level(seeEngineOwner'sManual).

Enginedoesnot 1, Misadjustedthrottle controlcable(recoilstart model), 1. SeeEngineOwner'sManualor EngineServiceDealer. shutoff. 2, Keyswitchwireharnessmalfunction(electricstart model.) 2. SeeEngineServiceDealer.

WheelsandTines 1, Improperuseof controls, 1. ReviewSections3and4. will notturn. 2, ForwardClutch:Misadjustedforwardclutchcontrolcable. 2. Adjustcabletension (Section5),

3, ReverseClutch:Misadjustedclutchcontrol cable, 3. Adjustcabletension(Section5). 4,Worn or brokenclutchbelt(s), 4. Checkbelts. Replaceparts as needed(Section5), 5, Internaltransmissionwearor damage, 5. Contactlocaldealeror thefactory, 6, Boltand keyloosein transmissionpulley, 6. Tightenbolt; checkthat keyis in place.

Tinesturn, but 1,Wheel mountinghardwaremissing, 1. Replacehardware. wheelsdon't. 2, Bottandkeyloosein transmissionpulley, 2. Tightenbolt; checkthat keyis in place.

3, Internaltransmissionwearor damage, 3. Contactlocal Dealeror theFactory. 4, Misadjustedwheel gearcable, 4. See"WheelGearCableAdjustment,"Section5, 5,Wheel GearLevernot fully engaged, 5. Engagelever(seeSection3),

WheelsTurn,but 1, Tineholdermounting hardwaremissing, 1. Replacehardware, TinesDon't. 2, internaltransmission wearor damage, 2. Contactlocal Dealeror the Factory.

Poortilling 1, Worn tines, 1. See"Bole Tines" (Section5). performance. 2, improper DepthRegulatorsetting, 2. See"Tilling Tips &Techniques,"Section4,

3, incorrectthrottle setting, 3. SeeSection4. 4, Belt(s)slipping. 4, See"CheckingClutchBeltTension,"Section5.

Battery(if so 1, Brokenwiring inenginerechargingcircuit, 1. ContactEngineServiceDealer, equipped)doesnot 2, Malfunctioningenginerechargingsystem, 2. ContactEngineServiceDealer,

chargeduring 3. Discharged or deadbattery, 3. See"Battery Maintenance," Section 5, engine operation.

Page 30

I Model 12211 & 12212

DRAWING 1

Page 31

Model 12211 & 12212 I

PARTS LIST - DRAWING 1

REF. PART No. No. DESCRIPTION QTY.

1 1918811 2 9126

3 1918770

3A 20924

4 1916784 8 1186347

5A 9955

6 1900475001 7 1100046 8 9904 9 9837

10 1918791 13 9442

14 9057

* Specify GRADE5 if ordering part locally,

Handlebars(Incl. Refs. 2, 3 & 3A) ....... 1

Grip ..................................................... 2

Decal,Control Panel ........................... 1

Decal,Model Name/Logo .................... 1

ReverseClutch Control Cable.............. 1

Height Adjustment Screw ................... 1

Washer,Keyed..................................... 1

Bracket,HandlebarHeight Adjustment 1

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

Washer,Plain (fiat) 3/8, S,A,E............. 2

Hex Locknut, 3/8-16 ............................ 2

Cable,forward Clutch Control............. 1

WheelGear Control andCableAssy.

(Inck Refs, 14, 15, 19, 21, 22 & 23) 1

Knob, Wheel GearControl Lever.......... 1

REF. PART No. No. DESCRIPTION QTY.

15 1186211 16 1100068

17 1100243

19 1735531 21 1114748 22 1100240 23 1186208

24 9390 25 1918840

38 9853 36 20806

42 9552

Hex Nut, 5/16-24 ................................. 2

Hex Hd. Screw, 3/8-16 x 314",............. 2

Lockwasher, 3/8 .................................. 2

CableTies, Plastic................................ 2

Round Hd.Screw, #10-32 x 1/2 .......... 6

Lockwasher, #10 ................................. 2

Hex Nut,#10-32 .................................. 2

Grip ..................................................... 2

Bail,forward ClutchControl (IncL

two Ref.24)..................................... 1

SeresNut............................................. 4

Bracket,Bail Support ........................... 2

Hex FlangeScrew,self-tapping,

1/4-20 x 1/2", .................................. 2

Page 32

I Model 12211 & 12212

DRAWING 2

_ R_everse

ClutchCable

).49

26_¢"

i-_4 Cable.

Secures Forward Clutch

See Drawing 1,

Ref. 10.

Page 33

Model 12211 & 12212 I

PARTS LIST - DRAWING 2

REF. PART No. No. DESCRIPTION QTY.

1 ** Engine- standard recoil start ............ 1

** Engine- electric start ........................ 1

2 1917326 Bracket,Clutch Cable.......................... 1

3 1100242 Lockwasher-5/16................................ 6

4 1111696 HexHd, Screw, 5/16-24 x 1/2............. 2

5 1904557 Decal,Hot Surfaces/BeltWarning ....... 1

6 1917139 Cover(IncL Ref, 5).............................. 1

7 1186391 FlangeLock Nut,5/16-18 .................... 2

8 1108841 Key,3/16 x 1-1/2 ................................ 2

9 1138-1 Shim ................................................... 1

10 1916520 Pulley, Engine Drive............................ 1

11 9944 BellevilleWasher................................. 2

12 9872 Hex H& Screw, 5/16-24 x 1-1/8......... 2

13 1111606 Hex H& Screw, 8/16-18 x 2............... 1

14 1918731 ReverseIdler Arm ............................... 1

15 1916535 Pulley, Reverse Idler ........................... 1

16 1107382 Flat Washer,5/16................................ 2

17 1916725 BeltGuide, Wire Formed .................... 1

18 1100005 Hex HeadScrew, 5/16-24 x 1.............. 1

19 1917746 Washer, Shoulder............................... 1

20 9929 Washer, Flat,1-1/8 .............................. 2

21 1916728 Spring, ReverseReturn....................... 1

22 1916522 Transmission Pulley............................ 1

23 1440 Support Washer .................................. 1

24 1918812 ReverseClutch Belt............................. 1

25 1909404 Forward Clutch Belt............................. 1

26 1900396 Hex Hd, Screw, #10-32 x 112,

self-tapping..................................... 4

REF. PART

No. No. DESCRIPTION QTY.

27 1916189001 28 1186230 29 1186329 30 1916797001

31 1916796001 32 1107381 33 1754128 35 1100799 36 1915810

37 1918774001 38 1186331 39 1111607 40 1107382 41 1918846

42 55088 43 1100242 44 1186230 45 1917746 46 1918744

47 1767754 48 1916727 49 1110107 50 9090 51 1100086

52 1110108

Guard,Belts/Pulleys............................ 1

Hex Nut, 5/16-18 ................................ 4

Hex flange Screw,5/16-18 x 3/4". ..... 4

EngineSupport Bracket,left side........ 1

EngineSupport Bracket,right side...... 1

FlatWasher, 1/4 .................................. 1

Hex FlangeScrew,1/4-20 x 3/4 .......... 1

Hex Hd, Screw, 5/16-18 x 1-1/2 ......... 3

Decal,Stabilization.............................. 1

Mounting Bar ...................................... 2

Hex FlangeScrew,5/16-18 x 1........... 2

Hex Hd, Screw, 5/16-18 x 2-1/4", ....... 2

FlatWasher, 5/16'. .............................. 1

Belt Guide,Wire Formed,FwdBelt...... 1

Pivot Bushing...................................... 2

Lockwasher, 5/16................................ 2

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

Washer,Shoulder ............................... 2

idler Arm, Forward Tiller Direction ...... 1

Screw,self tapping, #10-24 ................ 1

Spring ................................................. 1

Hex Locknut, 5/16-18 ......................... 1

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

Screw,3/8-18 x 1-3/4 ......................... 1

Hex Locknut, 3/8-16 ........................... 1

* Specify GRADE5 if ordering part locally.

** See your local authorized engineservice dealerfor engine parts or

service, Referto engine nameplatefor enginetype andcode information.

Page 34

I Model 12211 & 12212

DRAWING 3

1 22

21 22

NOTE1: Thesescrews are a specialsealing screw

that cannot be reused without risking the loss of transmission oil. If these screws areloosened or

removed,they must bereplaced with newscrews.

See NoteI

REF. PART No. No. DESCRIPTION QTY.

1 2 3

10 11

12 13

9621 9726

97076

1186329 85030 11513

20694 1916197001

9467

1916198001

97073 90038

1916273001

Oil Seal (Double Lip), Wheel Shaft...... 2

PipePlug, 1/4.................................... 2

Seal,Transmission Bore ..................... 1

Hexflange Screw, 5/16-18 x 314". ..... 6

Oil Seal,input Pinion Shaft ................. 1

Transmission Cover(IncL four Ref, 18

andtwo ea, Refs. 21 & 22).............. 1

Gasket,Transmission Top Cover ........ 1

Transmission CaseAssy, (IncL Tube

and RearHousing) .......................... 1

Plug.................................................... 1

Mounting Plate, WheelClutch Cable.., 1

Oil Seal,Tiller Shaft............................. 2

HexRangeScrew, 5/16-18 x 518". ..... 2

Tiller Housing Cover, left side ............. 1

See N_el

REF. PART

No. No. DESCRIPTION QTY.

16 17

18 19

21 22

1129-1

1915089

1115 1124-2

1186331 1915087

1100243 1100068

Gasket,Tiller Housing Cover, ,010"

(fits all covers) ................................ A/R

Screw Kit: IncL three 1/4-20 x 718

Self-Sealing Screws ........................ NR

RearBearing Cap ................................ 1

Gasket,RearBearingCap,,010"

Thick ............................................... AIR

Hex FlangeScrew, 5/16-18 x 1*, ........ 4

Screw Kit: IncL five 1/4-20 x 518

Self-Sealing Screws ........................ NR

Lockwasher,3/8.................................. 2

Hex Hd, Screw, 318-16x 3/4", ............ 2

* Specify GRADE5 if ordering part locally,

A/R- As Required

Page 35

Model 12211 & 12212 I

DRAWING 4

MAIN DRIVE SHAF] ASSEMBLY

INPUT PINION SHAFT &

GEAR ASSEMBLY

REF. PART No. No. DESCRIPTION QTY.

MAIN DRIVESHAFT

1714

20718

9301

11603

1224-1

1224-2

1224-3

1325C

Bearing, TaperedRoller with Race .... 1

Spur Gear.......................................... 1

Key,3116sq. x 1............................... 1

Main Drive Shaft (Driveshaft is one-

piecewith integral, single-lead,

work-hardened front worm, and

integral, six-lead,work-hardened rear worm, Also includes pressed- on #1714 bearingand #9301 key), 1

Shim, RearBearingCap,,010" thick

(seeNote below) ........................... AIR

Shim, sameas above,but ,030"thick

(seeNote)...................................... AIR

Shim, sameas above,but ,005"thick

(seeNote)...................................... AIR

Shim Set (IncL two #1224-1; two

1224-2 and one#1224-3) ............. AIR

REF. PART No. No. DESCRIPTION QTY.

INPUTPINIONSHAFT& GEARASSEMBLY

6 9572 HexHd, Screw, 5/16-24 x 1-1/8", ..... 1

7 9944 Washer,Disc Spring (concave

surface faces pulley)...................... 1

8 1108841 Key,3/16 sq. x 1-1/2......................... 1

9 20880 Transmission Drive Pulley................. 1

10 1440 Support Washer ................................ 1

11 85030 Oil Seal,Input Pinion Shaft................ 1

12 9500 Retaining Ring(external) .................. 1

13 9953 Thrust Washer................................... 2

14 9428 Bushing............................................. 1

15 9677 Set Screw, 5/16-18 x 3/8" ................. 1

16 20791 input Pinion (steel shaft) ................... 1

17 20792 Input Pinion Gear .............................. 1

18 9093 Retaining Ring(external) I................. 1

19 20799 PinionAssy. (Incl. one each Refs,16,

17 and 18 ...................................... AIR

20 9517 Retaining Ring (internal) .................. 1

NOTE:Shim betweendrive shaftrear bearingand rear bearing capto achieve54o-10 thousandths of an inch (,005-,010) end playon drive shaft, AIR- As Required

* Specify GRADE5 if ordering part locally.

Page 36

I Model 12211 & 12212

DRAWING 5

Internally

__/Assembled

15 _

ECCENTRIC

SHAFT ASSEMBLY

\ 2

REF. PART

No. No. DESCRIPTION QTY.

1 9621 2 9511 3 1166-1

--- 1166-2

--- 1166-3

--- 1166-4 4 1086 5 2494 6 9373 7 20914

8 9935

Oil Seal.............................................. 2

RetainingRing (heavy-duty, external) 2

Shim, 1-1/64 I.D..062 °thick ............ AIR

Shim, asabove, but .030"thick ......... #JR

Shim, asabove, but .015"thick ......... AIR

Shim, asabove, but .010"thick ......... #JR

Bushing ............................................. 2

WheelShaft (Incl. Ref. 6) .................. 1

Hi-Pro Key,1/4 x 1-5/16.................... 1

Wheel DriveWorm Gear (cast-iron) _ 1 Shim (between keyand gear),

1.016 I.D. x 1.468 O.D.x .062

Thick.............................................. 1

WHEEL

SHAFT ASSEMBLY

Wheel Shaft Parts

REF. PART

No. No. DESCRIPTION QTY.

9 10 11

12 13

14 15 16

17 18

20712 20879 1442 9055 9622

20757 1100804 97074 20896 1104

20913

Wheel DriveClutch (cast-iron) .......... 1

EccentricShaft .................................. 1

Pin, Eccentric Shaft........................... 1

Spring ............................................... 1

Oil Seal.............................................. 1

EccentricShaft Lever......................... 1

Hex Hd. Screw, 114-20x 112'_........... 1

BallBearing....................................... 2

Tiller Shaft (IncL Ref.18) .................. 1

Woodruff Key,1/4 x 1-1/4 ................. 1

Tiller DriveWorm Gear(bronze) ....... 1

* Specify GRADE5 if ordering part locally. #JR- As Required

Page 37

Model 12211 & 12212 I

DRAWING 6

BLtJNT END TOWARCS YOU

_). NOTE1: Custom Tilling Tines are

REF. PART

No. No. DESCRIPTION QTY.

3 5

1100043 1270-2A

1733398 1982612

1270qA

1902154010 1901118

HexHd. Screw,318-16x 1-1/4". ......... 16

BoloTine-single. Right handtine

usedon left sideof tiller. (IncL

two ea. Refs. 1 and 3) ..................... 8

Hex Locknut, 3/8-16 ........................... 18

HexHd. Screw,318-16x 2, Grade8.... 2

BoloTine-single. Left hand tine

usedon right side of tiller. (IncL

two ea. Refs. 1 and 3) ..................... 8

Tine Holder. for left and right sides.... 2

BoloTine ReplacementSet (IncL eight

ea. right handand left handtines,

13 availablefor your tiller. Theseare

IMPORTANT:Left and right sides of tiller are determined by standing in

operator position and facing direc-

tionof forward travel,

REF. PART

No. No. DESCRIPTION QTY.

andsixteen ea. Refs. 1 and 3) ......... 1

11 12

2475-1

2475-2

10802

9380 9338

1917487

Custom Tilling Bolo Tine, Left hand

tine (see Note 1 above) ................... 8

Custom Tilling Bolo Tine, Right hand

tine (see Note 1 above) ................... 8

Custom Tilling Bolo Tine Replacement

Set (IncL eight ea.right handand left handcustom tines, and sixteen

eachof Refs. 1and 3) ..................... 1

Clevis Pin, .312 x 1-314...................... 2

Hitch Pin ............................................. 2

Wheel andTireAssembly ................... 2

* Specify GRADE5 if ordering part locally.

Page 38

I Model 12211 & 12212

DRAWING 7

10 --8

2,2A

ENGINE

TO ENGINE

Page 39

Model 12211 & 12212 I

PARTS LIST - DRAWING 7

REF. PART No. No. DESCRIPTION QTY.

1 96512 Battery, 12 Volt, 9 Amp (IncL

Ref.7) ........................................... 1

9462 BatteryCap (yellow) .......................... AIR

9248 BatteryCap (white)............................ A/R

9009 Vent Tube.......................................... 1

3 4

1475 Shield,Vent Tube (hard plastic) ........ 1

9224 Clamp................................................ 1

9552 HexFlangeScrew, Self-Threading,

1/4-20 x 1/2", ................................ 3

7 11361 Battery Hardware Kit- Includes two

M6 x 11ram Bolts and two M6

Nuts (metric sizes)........................ 1

8 1908112 Ignition Switch (incl. two ignition keys

[Ref, 11], one Iockwasherand one nut (Iockwasher and nut not

availableseparately)...................... 1

9 1904570 BatteryHold-DownClamp/Switch

Mounting PlateAssy, (IneL Ref,lO) 1

10 1904548 Decal,Ignition Switch........................ 1

11 96520 Ignition Key(pair) ............................. 1

12 96509 BatteryCable..................................... 2

13 96510 Cable (solenoid to starter motor) ...... 1

14 1908118 Wire HarnessAssy, (available as

complete assembly only), Incl, wire assy. w/connector to large

solenoid stud (red wire); wire assy. w/connector to small

solenoid stud (red wire); wire assy. w/connector to solenoid grounding screw (red wire); wire assyw/connector to engine ground shut-off (greenwire); plastic

protector tube; wire terminal ......... 1

REF. PART No. No. DESCRIPTION QTY.

15 97020 Boot, Insulating................................. 2

16 96514 Solenoid (Incl. nuts andwashers

for cablesand wires) ..................... 1

1918831001 Battery Bracket.................................. 1

1186023 Round Hd,Screw, SquareNeck,

1/4-20 x 1-1/4 ............................... 2

1186331 Hex FlangeScrew, 5/16-18 x 1". ....... 2

1177548 Lockwasher, ExternalTooth .............. 2

1186389 Hex Locknut, 1/4-20 .......................... 2

21 22

1100242 Lockwasher, 5/16.............................. 2

1186211 Hex Nut, 5/16-24 ............................... 2

23 24

9853 HexLocknut, #10-32 ......................... 1

- Lockwasher, #10 (not available

from factory) ................................. 1

-- Hex Nut, #10-24 (not available

from factory) ................................. 1

1901894 RechargeWire Assembly .................. 1

9218 Clip (holds recharging line)............... 1

9265 Plastic Wire Tie ................................. 1

9202 Plastic Wire Tie ................................. 1

30 31

1901202 Cable(ground wire to starter

motor bracket)............................... 1

1917262 Ground Wire Assy, (shut off) ............ 1

* Specify GRADE5 if ordering part locally.

A/R - AsRequired

Page 40

I Model 12211 & 12212

DRAWING8

ROW MARKER ATTACHMENT

(See

ROWMARKERATTACHMENT- PART# 12589

(Complete- Attachesto Furrower Attachment)

DETAILA _ _

8 8

MAINSUPPORT/YOKEASSEMBLY

PART# 1904522001

BUMPER ATTACHMENT

BUMPER

PART#12593

Page 41

Model 12211 & 12212 I

PARTS LIST - DRAWING 8

REF PART No. No. DESCRIPTION QTY.

Row Marker Attachment (option) - Part #12589

1 1904522001 MainSupport & Yoke Assy-

complete, (IncL Ref. No;s

10,11,12,13,14,15,16,17 & 18).......... 1

2 1594 3 1904524001 4 1904523001

5 9347

6 9786

1596

9828

1100135

1837

12582

12589

Marker Blade-blade only ................... 1

Marker Arm-main arm ...................... 1

Marker Arm-extension arm with

stop pin ......................................... 1

Hitch Pin-(incL in Hardware Pkg

#1837)........................................... 1

Thumbscrew-l/4-20 x 1/2, not

avail,sep. (seehardwarepkg.

#1837)........................................... 2

Nut Bar-(ind. in hardware pkg

#1837)........................................... 1

Nut-hex, 10-24 w/attached start

washers, not avail, sep.(see

hardwarepkg #1837) .................... 2

Screw-round hd.10-24 x 1, not

avail,sep. (seehardwarepkg

#1837)........................................... 2

Hardware Package-includes:one

#9347 hitch pin (Ref.5), two #9786 thumbscrews (Ref.6),

one#1596 nut bar (Ref.7), two #9828 hex nuts (Ref. 8),

two 1100135screws (Ref. 9) ......... 1

Row Marker Attachment & Pony

Hiller/Furrower Attachment - complete: incl. #12579 Pony

Hiller/Furrower and #12589

Row Marker................................... 1

Row Marker Attachment -

complete:attaches to furrower attachment#12579, includes

#1904522001 Main Support &

Yoke Assy...................................... 1

REF PART

No. No. DESCRIPTION QTY.

RowMarkerMain Supped& YokeAssembly- Part #1904522001

10 1186349 Screw-hexflangedlocking,

3/8-16 X1-112" ............................. 1

11 12 13 14 15 16

17 18

19 2O

1593 1592

1591 1590 1588 1589

9925

1186231

1918749001 1448

1111607

1100242

1186230

1918781

Stop Bar............................................ 1

Yoke.................................................. 1

Tube Key-square............................... 1

Washer-friction ................................. 2

MainSupport .................................... 1

Washer-square hole.......................... 1

Washer-disc spring .......................... 1

Nut-hex 3/8-16 ................................. 1

Bumper Attachment - Part #12593

Bumper (includes Ref.20) ............... 1

Decal- Caution.................................. 1

Screw-hex hd., 5/16-18 x 2-1/4%

not avail, separately

(order#1918781 hardware kit) 4

Lockwasher-5118*, not avail.

separately (order #I 918781

hardwarekit) ............................... 4

Nut-hex, 5118-18", not avail.

separately (order #I 918781

hardwarekit) ............................... 4

HardwareKit: Incl. four each of

Refs.21, 22 and 23 ....................... I

Note: Common hardware listed aboveas "not availableseparately" can be found at most hardwarestores,

* Specify GRADE5 if ordering part locally.

Page 42

I Model 12211 & 12212

DRAWING 9

1 17

\\\\

TRANSMISSION

REF. PART

No. No. DESCRIPTION QTY.

1 1917605 Tine Hood (Incl. hood flap and

Ref.17) ............................................ 1

2 1100243 Lockwasher, 3/8.................................. 2

3 2527 Bracket-hood & depth regulator

(Incl. Ref.No. 9)............................. 1

90038 Hex FlangeScrew, 5/16-18 x 5/8". ..... 2

9811 HexLocknut, 1/4-20 ........................... 1

1100069 Hex Hd. Screw, 1/4-20 x 1". ............... 1

9384 Spring ................................................. 1

9438 Spacer................................................. 1

9308 Roll Pin (spiral), 1/4 x 1 ..................... 1

1117A DepthAdjustment Bar Assembly

(Incl, Refs.11 and 12) .................... 1

REF. PART

No. No. DESCRIPTION QTY.

11 12

13 14 15 16

17 18

9120 9119

1100043 1113-1 1186231 20775 1917536

9553

9552

RetainingRing (tolerance ring) ........... 1

Knob, Depth Regulator(Incl. Ref, 11). 1

Hex Hd, Screw, 3/8-16 x 1-114".......... 2

Bushing, Drag Bar............................... 2

Hex Nut, 318-16................................... 2

DragBar ............................................. 1

Decal,operating instructions .............. 1

Hex Hd. Screw, self-tapping,

5/16-18 x 1/2". ............................... 2

Hex FlangeScrew, self-tapping,

114-20x 112".................................. 2

* Specify GRADE5 if ordering part locally.

Page 43

Model 12211 & 12212 I

DRAWING 10

3 12 8

HILLER/FURROWER- PART#12879

(Viewedfrom front of tiller)

'° i

REF. PART

No. No. DESCRIPTION QTY.

1 2

3 4

5 6

7 8

1900771001 1186098 1177548

9902 9824

1900773001 1900774001 1900772001

Furrower Blade.................................. 1

CarriageBolt, 5/16-18 x 3/4 .............. 4

StarWasher, ExternalTooth, 5116..... 4

PlainWasher, 5/16 S,A,E................... 4

Wing Nut, 5/16-18 ............................. 4

Hiller Wing, left.................................. 1

Hiller Wing, right ............................... 1

BladeMounting Bracket.................... 1

REF. PART

No. No. DESCRIPTION QTY.

9 9725 10 1100243 11 1186231

12 9318

12579

CarriageBolt, 3/8-16 x 1-112............. 2

Lockwasher,3/8, plated .................... 2

HexNut, 3/8-16, plated ..................... 2

Clinch Pin .......................................... 1

Complete Hiller/Furrower Attachment

(incl. blade, bracket, hiller wings

andmounting hardware)............... 1

Page 44

CUSTOMERSERVICEINFORMATION

OwnerRegistrationCard

Pleasefill out and mail the enclosed owner registration card. The purpose of this card is to register each unit at the factory so that we

canprovide you with warranty benefits and informational bulletins,

Warranty Service Thewarranty statementisincluded in the unit'sliterature

package.

Model/Serial Numbers

A Model/Serial Numbers decalis located on top of the trans- mission. For ready reference, record thesenumbers in the spacesbelow.

Dateof Purchase: Model Number: Serial Number:

AuthorizedDealer Information

If you purchasedyour unit from an authorizeddealer,record the dealer'saddressand phonenumber below for ready reference:

DealerName: Address: Phone:

IMPORTANT:

Leftandrightsides oftheunitare determinedby standing

behindtheunit, intheoperator'sposition,andfacing inthe

directionofforward travel.

CustomerServiceandTechnical Service

If you havequestions or problemswith the

unit, contact your local dealeror thefactory.

(Whencalling or writing, provide the

Model/Serial Numbers of the unit.)

ReplacementParts

Factoryspecifiedreplacementparts are availablefrom your authorized dealeror directly from the factory. When ordering parts, be sure to provide the following:

• Model/Serial Numbers of the unit.

• Partnumber of the part needed.

• PartDescription.

•Quantityneeded.

NOTE:All replacement parts must conform to our rigid quality specifications. Although some replacement parts we provide may vary slightly in shape,color or texture from theoriginal parts, anyvariations will not affect the fit or performance of these parts on your unit.

EngineServiceand Repair

Forengineserviceor repair, contactyour nearest authorizedengine dealer (look in the

Yellow Pagesunder "Engines-Gasoline"). Theengine is warranted by the engineman-

ufacturer. Any unauthorized work performed on the engine during the warranty period

may void this warranty. For complete details on the enginewarranty, referto the

EngineOwner'sManual.

NOTICE:

We reservetheright tochangespecifications,add

improvementsor discontinuethemanufactureof any of our

equipmentwithoutnotice or obligationto purchasersofour

equipment.

Forcustomerassistance,contactyour nearestauthorizeddealer or:

GARDEN WAY INCORPORATED • 1 GardenWay • Troy, NewYork 12180

CustomerService:1-800-437-8686 • TechnicalService:1-800-520-5520 • PartsService:1-800-648-6776

• FAX:(518)233-4622 • WEBSITE:www.troybilt.com

CustomerService:(518)233-4807 • TechnicalService:(518) 233-4808 • PartsService:(518) 233-4806 • FAX(518) 233-4622

We urge using only genuine replacement parts, which meet all the latest requirements. Replacement parts manufactured by others could present safety hazards,

even thoughthey may fit on the unit.

Outside the United Statesand Canada:

Troy-Bilt Pony 12211, Pony 12212 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual