Troybilt 12089 Tiller Owner's Manual

O TRO_YBILT

Owner'sManual

PTO HORSETILLER

• Safety

• Assembly

• Controls

• Operation

• Maintenance

• Parts List

Models

12089 - 8HP Standard

12090 - 8HP Electric

12204 - IOHP Electric

GARDEN WAYINCORPORATED

(8HP model shown)

2

DearOwner: yourgarden otherproperty including splitter.Yourtillerisfamous

usingit.

carefully assemble,

Be sure that you and any other operators carefully follow

the recommended safety practices at all times. Failure to do so could result in personal injury or property damage.

Of course, if you should ever haveany problems or questions, please contact your local authorized service dealer or call the Factory (see back cover). We want to be sure that you are completely satisfied at all times.

NOTE: Be sure to fill out and return the Owner Registration

Card included included with this manual.

See BackCoverfor

CustomerServiceInformation

Safety Alert Symbol

,_.

potential hazards, Whenyou seethis symbol, read and obey the messagethat follows it.

Failure to obey safety messages could 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.

TABLEOFCONTENTS

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

3

Training........................................................................................

3

Preparation..................................................................................

3

Operation .....................................................................................

3

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

5

Decals..........................................................................................

5

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

6

Step 1: Unpacking Instructions ....................................................

6

Step 2: Attach Handlebar .............................................................

6

Step 3: Move Tiller Off Shipping Platform....................................

7

Step 4: Connect Forward interlock Wire Harness.........................

7

Step 5: Attach Wheels/Tines/PTO Drive Lever..............................

7

Step 6: Check Gear Oil Levels ......................................................

8

Step 7: Add Motor Oil to Engine...................................................

9

Step 8: Attach Engine Throttle Lever and Cable ...........................

9

Step 9: Adjust Air Pressure in Tires .............................................

9

Assembling The Electric Start System .........................................

10

13

PTOAttachments Feature............................................................

13

Wheels/Tines/PTO Drive Lever.....................................................

13

Forward InterlockLevers .............................................................

13

Wheel Speed Lever ......................................................................

14

Tine/PTO Clutch Lever .................................................................

14

Depth Regulator Lever .................................................................

14

Handlebar Height Adjustment Lever.............................................

14

EngineThrottle Lever ...................................................................

15

Keyswitch Starter .........................................................................

15

EngineControls ...........................................................................

15

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

16

Break-In Operation .......................................................................

16

Starting and Stopping the Engine ................................................

16

Operating the Tiller ......................................................................

18

Testing the Forward Interlock Safety System............................... 20

Loadingand Unloading the Tiller .................................................

20

Changing Speed Belts ..................................................................

21

Choosing Wheel and Tine Speeds................................................

22

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

23

PTOPower Unit ...........................................................................

27

PTOPower Unit Operating Instructions ....................................... 28

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

30

RequiredMaintenance Schedule..................................................

30

Tighten Bolts and Nuts.................................................................

31

Tiller Lubrication ..........................................................................

31

Transmission Gear Oil..................................................................

32

Adding or Changing Gear Oil........................................................

33

Drive Belt Maintenance................................................................

35

ReverseDisc Maintenance...........................................................

37

Bolo Tine Maintenance.................................................................

39

Tine Shaft Maintenance................................................................

41

Tire and Wheel Maintenance........................................................

41

EngineOil Maintenance................................................................

41

Air Cleaner Maintenance ..............................................................

41

Throttle Cable Maintenance..........................................................

41

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

41

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

41

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

41

Storing your Tiller ........................................................................

43 inspecting Forward Interlock Wiring System ............................... 43

Testing the Forward interlock Wiring System .............................. 43

APPENDIX A: TROUBLESHOOTING......................................

44

APPENDIX B: ATTACHMENTS & ACCESSORIES.......................

PARTSLIST...............................................................

CUSTOMERSERVICEINFORMATION..............

46

47

Back Cover

S

SPARKARRESTERWARNING TO RESIDENTSOF CALIFORNIAAND SEVERALOTHERSTATES

Under California law, and under the laws of several other states, you are not permitted to operate an internal combustion engine using hydrocarbon fuels on any forest, brush, hay, grain, or grass covered land; or land covered by any flammable agricultural crop without an engine spark arrester in continuous effective working order.

The engine on the unit is an internal combustion engine which burns gasoline, a hydrocarbon fuel, and must be equipped with a spark arrester muffler in continuous effective working order. The spark arrester must be attached to the engine exhaust system in such a manner that flames or heat from the system will not ignite flammable material. 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. Contact your local fire marshal or forest service for specific information about which regulations apply in your area.

Training

1. Carefully read this Owner's Manual, the separate Engine Owner's Manual, and any other literature you may receive.Be thoroughly familiar with the controls and the proper use of the tiller and its engine.

Know how to stop the unit and disengage the controls quickly.

2. Never allow children to operate the tiller. Never allow adults to operate the tiller without proper instruction.

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

4. Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people,their property,

and themselves.

Preparation

1. Thoroughly inspect the area where the tiller is to be used and remove all foreign objects.

2. Put the Wheels/Tines/PTODrive Lever into NEUTRALbefore starting the engine.

3. Do not operate the tiller without wearing adequateouter garments. Avoid loose garments orjewelry that could get caught in moving parts.

4. Do not operate the tiller when barefoot or wearing sandals, sneakers, or light footwear. Wear protective footwear that will improve footing on slippery surfaces.

5. Do not till near underground electric cables, telephone lines, pipes or hoses. If in doubt, contact your telephone or utility company.

6. Warning: Handlefuel with care; it is highly flammable and its vapors are explosive. Be sure to take the following precautions:

a,

Store fuel in containers specifically designed for this purpose.

b.

The gas cap shall never be removed or fuel added while the engine is running. Allow the engine to cool for several minutes before adding fuel.

C,

Keep matches, cigarettes, cigars, pipes, open flames, and sparks away from the fuel tank and fuel container.

d. Fill fuel tank outdoors with extreme care. Never fill fuel tank indoors.

Use a funnel or spout to prevent spillage.

e. Replaceall fuel tank and container caps securely.

f. If fuel is spilled, do not attempt to start the engine, but move the machine away from the area of spillage and avoid creating any source of ignition until fuel vapors have dissipated.

7. Never make adjustments when engine is running (unless recommended by manufacturer).

Operation

I. Do not put hands or feet near or under rotating parts. Do not allow hands or any other part of the body or clothing near the rotating tines or near any other moving part. The tines begin to rotate forward once the engine starts, the Tines/PTO

Clutch Lever is in the ENGAGEposition, the Forward Interlock Levers are squeezed closed and the Wheels/Tines/PTODrive

Lever is shifted to FORWARD.The tines rotate in Reversewhether the Interlock

Levers are closed or open.

2. Exerciseextreme caution when on or crossing gravel drives, walks, or roads.

Stay alert for hidden hazards or traffic. Do not carry passengers.

3, After striking a foreign object, stop the engine, remove the wire from the spark plug wire and prevent it from touching the spark plug. Thoroughly inspect the machine for any damage and repair the damagebefore restarting and operating the machine.

4, Exercisecaution to avoid slipping or falling.

5. If the unit should start to vibrate abnormally, stop the engine, disconnect the spark plug wire and prevent it from touching the spark plug, and check immediately for the cause.Vibration is generallya warning of trouble.

6. Stop the engine, disconnect the spark plug wire and prevent it from touching the spark plug whenever you leavethe operating position, before unclogging the tines, or when making any repairs, adjustments or inspections.

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

Disconnect spark plug wire and move it away from spark plug. Remove ignition key on electric start models

Section 1: Safety

8. Before cleaning, repairing, or inspecting, stop the engine and make certain all moving parts have stopped. Disconnect the spark plug wire and prevent it from touching the spark plug to prevent accidental starting.

9. The flap on the fine hood must be down when operating the tiller, unless using the HillerlFurrower attachment.

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

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

12. Keep children and pets away.

13. Never operate the tiller under engine power if the Wheel Speed Lever is in the

FREEWHEELposition. In FREEWHEEL, the wheels will not hold the tiller back and the revolving tines could propel the tiller rapidly, possibly causing loss of control.

Always engage the Wheel Speed Lever in either FASTor SLOWposition before starting the engine or engaging the tines with the Wheels/TineslPTO Drive Lever.

14. Be aware that the tiller may unex- pectedly bounceupwardorjump forward if the tines shouldstrike

extremely hard packedsoil, frozen

ground,or buriedobstacleslike large stones,roots, or stumps. If in doubt aboutthe tilling conditions,always use

the following operating precautionsto

assistyou in maintaining controlof the tiller:

a. Walk behindand to one side of the

tiller, using one hand on the handlebars. Relax yourarm, but usea

secure handgrip.

b. Use shallower depthregulator settings, workinggradually deeper

with each pass.

c. Use slowerwheel, fine and engine speeds.

d. Clear the tilling area of all large

stones,rootsand otherdebris.

e. Avoid usingdownwardpressureon handlebars. If need be, use slight

upwardpressureto keepthe tines from diggingtoo deeply. f_

Beforecontactinghardpacked soil

at the end of a row, reduceengine

speed and lift handlebarsto raise

tines out of the soil.

g. In an emergency, stop tines and

wheels byshifting the

Wheels/Tines/PTODrive Lever

intoNEUTRAL.If you can not

reach the lever or have lost control of the tiller, let go of the handlebars and all controls. Do not attempt to restrain the tiller.

15. Do not overload the filler's capacity by attempting to till too deeply at too fast a rate.

Antidotes:

External- Flush immediately with lots of water=

Internal- Drink large quantities of water or milk= Follow with milk of magnesia, beateneggs or vegetable oil. Call a doctor immediately=

Eyes- Flush with water for 15 minutes=

Get prompt medical attention=

26. DANGER- BATTERIESPRODUCE

EXPLOSIVEGASES. Keepsparks, flame or smoking materials away. Ventilate when charging battery or using in an enclosed space. AIways wear safety goggles when workingnear battery.

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

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

18. Never allow bystanders near the unit.

19. Only use attachments and accessories that are approved by the manufacturer of the tiller.

20. Use tiller attachments and accessories when recommended.

21. Never operate the tiller without good visibility or light.

22. Never operate the tiller if you are tired, or under the influence of alcohol, drugs or medication.

23. Operators shall not tamper with the engine-governor settings on the machine; the governor controls the maximum safe operating speed to protect the engine and all moving parts from damage caused by overspeed. Authorized service shall be sought if a problem exists.

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

25. POISON/DANGER--CAUSES

SEVEREBURNS.The battery on electric start models contains sulfuric acid. Avoid contact with skin, eyes or clothing. Keep out of reach of children.

27. Pleaseremember: You can always stop the tines and wheels by releasing all controls, or by moving the ignition switch andlor throttle control lever on the engine to OFFor STOP.

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

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

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

31. Never pick up or carry a machine while the engine is running.

32. When loading or unloading the tiller, always disengage tines and use slower wheel and engine throttle speeds. Use sturdy ramps wide and strong enough to easily support the tiller (280-to-325 Ibs., depending on model) and operator.

Never go down ramps in FORWARD drive--the tiller could tip forward, exposing you to the tines (which should be disengaged). AIways use REVERSE drive and back down ramps. To go up ramps, use FORWARDdrive and follow the tiller.

33. The Forward Interlock Safety System should be tested for correct functioning every time the tiller or PTOpower unit is used. See Section 4 in this Manual.

34. If using the optional Dozer Blade, either remove the tine attachment, or disengage the tines with the TineslPTO

Clutch Lever= Revolvingtines are dangerous.

Section1: Safety

Maintenance and Storage

1. Keep the tiller, attachments and accessories in safe working condition.

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

3. Never store the tiller with fuel in the fuel tank inside a building where ignition sources are present such as hot water and space heaters,furnaces, clothes dryers, stoves, electric motors, etc.).

Allow engine to cool before storing in any enclosure.

4. To reduce the chancesof a fire hazard, keepthe engine free of grass, leaves, or excessivegrease.

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

6. Refer to the Maintenancesections of this Manual and the separate Engine

Owner's Manualfor instructions if the tiller is to be stored for an extended period.

7. Never perform maintenancewhilethe engine is running or the spark plug wire is connected, exceptwhen specifically instructed to do so.

8. If the fuel tank has to be drained, do this outdoors.

Decals

Foryour safety and the safety of others, various safety and operational decals are located on your unit (Figure 1)=

Keep the decals clean and legible at all times. Contact your local service dealer or the Factory for replacements if any decals are damaged or missing.

Refer to the Parts List for decal locations, descriptions and part numbers.

Topoftheair cleanerhousing. SafetyInstructions

D) Power Unit

F) EngineStabilization.

Top of fuel tank.

B) WARNING:EngineIgnition.

Electric start models only.

Figure 1: Locationof Safety and

(Briggs & Strattonengine shown)

OperatingSymbols

Various symbols (shown here, with word descriptions)areusedon thetillerand eroine.

Yourunitmaynot haveallof thesymbols.

FAST

SLOW

STOP

H

CHOKE

ON

I÷1

CHOKE

OFF

ROTATING

TINES

TO AVOID SERIOUS INJURY:

• READTHE OWNER'SMANUAL.

• KNOWLOCATIONSAND FUNCTIONSOF ALL CONTROLS.

• KEEPALL SAFETYDEVICESANDSHIELDSIN PLACEANDWORKING.

• NEVERALLOWCHILDRENOR UNINSTRUCTEDADULTSTO OPERATETILLER.

• SHUT OFF ENGINEAND DISCONNECTSPARKPLUGWIRE BEFOREMANUALLYUNCLOG-

GINGTINES OR MAKINGREPAIRS.

• KEEPBYSTANDERSAWAYFROM MACHINE.

• KEEPAWAYFROM ROTATINGPARTS.

• USE EXTREMECAUTIONWHEN REVERSINGOR PULLINGTHE MACHINETOWARDSYOU.

!1

Assembly

To prevent personal injury or property damage, do not start the engine until all assembly steps are complete and you have read and understand the safety and operating instructionsin this manual.

Factory if any items are missing or damaged).

NOTE: Use the screw length template

(Figure 2-1) to identify screws.

Introduction

Carefully follow these assembly steps to correctly prepare your tiller for use. It is recommended that you read this Section

in its entirety before beginning assembly.

NOTE:Various tiller models are presented

in this Manual. Use only the information appropriate for your tiller model,

Inspect

Unit

Inspect the unit and carton for damage

immediatelyafter delivery, Contact the carrier (trucking company) if you find or suspect damage. Inform them of the damage and request instructionsfor filing a claim. To protect your rights, put your claim in writing and mail a copy to the carrier within 15 days after the unit has been delivered. Contact us at the Factory if you need assistance in this matter.

LooseParts List

Qty.

Description

1 HandlebarAssembly

1 Wheels/TinesPTODrive Lever

Thefollowing items

are in the hard-warebag:

1 Clutch Pawl Spring

1 BeltAdJustingTool

2

Plastic CableTies

1 Curved HeadScrew, 1/4-20 x 2

1 FlangedLock Nut, 1/4-20

1 Pan HeadScrew, #20-24 x 1/2

Thefollowing parts (electric start models only/),packaged separately,are located under the battery clamp,

2 Nuts, I/4-20

(for battery terminals)

2 Screws, I14-20 x 518

(for battery terminals)

1 BatteryVent Tube

2

Keys

(Fnignition switch)

STEP 1: Unpacking Instructions

NOTE:Do not severely bend any of the control cables on the unit.

I. The tiller is heavy. Do not attempt to remove it from the shipping platform until instructed to do so in these Assembly steps.

2. Removeall unassembled parts from the carton. The hardware bag is included in your literature packaging.

3. If you ordered an Electric Start Tiller, remove the hardware bag from under the battery clamp (A, Figure 2-16).

4. Check that you havethe items listed below (contact your local dealer or the

6

(1) Flat blade screwdriver

(1) Scissors (to trim plastic ties)

(1) Tire pressure gauge

(1) Cleanoil funnel

(1) Motor Oil. Refer to the Engine

Owner's Manual for motor oil specifications and quantity.

(1) 4-1/2" high wood block (or other sturdy block) to prop unit

* Adjustable wrenchesmay be used.

IMPORTANT:Motor oil must be added to the engine crankcase before the engine is started.

Follow the instructions in this

Assembly Section and in the separate

Engine Owner's Manual.

NOTE:LEFTand RIGHT sides of the tiller are as viewed from the operator's position behind the handlebars (unless otherwise noted).

Tools/Materials Needed for Assembly

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

(2) 7/16" open-end wrench *


(1) 9/16° open-end wrench*


Figure2. I: Toidentify length of screw,

place screwon template as shownand measure distance between bottom of screw head and tip of screw.

STEP 2: Attach Handlebar

IMPORTANT: When disassembling handlebar assembly, keep left-side clamp and ratchet separated from the right-side clamp and ratchet.

I. Disassemblethe handlebar assembly.

To do this, remove the height adjustment lever by turning the lever in a counterclockwise direction (Figure 2-2).

2. Placethe handlebar ends on either side of the base, with the wire harness toward the rear of the base (Figure 2-2).

3. Install the height adjustment lever through the right-side clamp, handlebar end, ratchet, and base; then out through the left-side ratchet, handlebar end, and clamp (Figure 2-2). Securewith nut, but don't fully tighten.

IMPORTANT: Do not force the height adjustment lever through the handlebars.

The interlock wires may be blocking the lever and could be damaged. You may gently move the wires aside if this condition occurs.

4. Raise handlebars to one of two height settings and tighten the height adjustment lever. Also, make sure all other mounting hardware is securely tightened.

NOTE: Fully assembled handlebar assembly should appear as shown in

Figure 2-3.

Section2: Assembly

Handlebars

Right

Height

Adjustment

Lever

Base

FRONT

OF TILLER

Figure 2-2. Handlebar assembly.

Wire

Harness

Left

Clamp

Nut

Figure 2.5. Forward Interlock Wire

Harness connection.

Figure 2-3. Fully assembled handle.

bars.

STEP 3: Move Tiller Off Shipping

Platform

1. Set the Depth Regulator Lever

(A, Figure2-4) to Travel position. Do this by lifting the tiller by the handlebars, then pulling straight back on the lever and sliding down to the highest notched setting.

2. Set the Wheel Speed Lever (B, Figure

2-4) to Freewheelposition. To do this, move the lever approximately halfway between the Fastand Slow settings while you rock the tiller forward and backward until the wheels move freely.

3. Lift Handlebars high enough to clear tiller tines and pull back firmly to dislodge the tiller from the platform wheel wells.

Figure 2.4: Photo shows the Depth

Regulator Lever (,4) and the Wheel

Speed Lever (B).

STEP 4: Connect Forward

Interlock Wire Harness

I.

Removeany dirt from the Forward

Interlock wire harness plug (C, Figure

2-6) and its receptacle (D).

2. Connect the Forward Interlock wire harness plug (C, Figure2-6) to the receptacle (D).

STEP 5: Attach

Wheels/Tines/PTO Drive Lever

I. Loosen the bolt (Figure 2-2) on the handlebar baseand swing the handlebars out to the right side.

2. Removeboth sets of nuts, star washers, screws, and one bushing

(A, B, C, D, E, F, G, Figure2-6) from the yoke plates (H). There is a bushing inside the short link (I). Be careful not to lose it when removing screw (G).

3. Slide the plates at the end of the

Wheels/Tines/PTOLever over the yoke plates (Figure 2-9). To aid in the next step, insert a screw temporarily into the forward most holes (J, Figure2-7) of the yoke plates and the lever.

4. Align the rear most holes of the yoke plates and the WheelslTineslPTOLever.

Use long nose pliers to hold the bushing

(L, Figure 27) in place while inserting the screw (K) through the lever and yoke plates. Install star washer (B, Figure 2-6) and nut (A), then hand tighten.

5. Retrievethe clutch pawl spring (Figure

2-8) from hardware bag.


Removethe temporary screw (J, Figure

2-7) from the forward holes and move the

Wheels/Tines/PTOLever fully forward.

Install the wider hook end of the clutch pawl spring (M, Figure2-8) down into the small hole at the end of the handle. Use pliers to insert the other end into the hole in the long link bar (N).

NOTE:Do not bend or over stretch the spring while installing,

6. Pull the Wheels/Tines/PTOLever back to align the forward most holes (Q, Figure

2-9) in the yoke plate with the holes in the lever plates. Also align the bushing that is inside the short link bar (P). Install the screw, star washer, and nut, then tighten securely.

Securely tighten all other hardware (Q, R,

Figure 2-9). Also ensure that the spring

(S) is properly seated at both ends.

Completed assembly should appear as illustrated in Figure 2-9,

7. Test the operation of the

Wheels/Tines/PTOLever. Push the lever down until it engages in the Forward position. The clutch roller (T, Figure2-

10) must rest beneaththe adjustment block (U). Next, move the lever up to the

Neutral position. The clutch roller (T,

Figure2-I I) should rest on the face of the adjustment block (U). To test Reverse, lift and hold the lever all the way up in

Reverseposition, then let it go. The lever should automatically return to the Neutral position (Figure 2-11). If not, do not use the tiller. See your local authorized dealer or call the Factory Technical Service

Department for instructions.

Figure 2.9: Fully assembled

WheelslTines/PTO Lever assembly.

Figure 2.10

Forward position; roller

(T) rests under the adjustment block (U).

Figure 2-6: Illustration shows the yoke plates (H), nuts, washers, and

screws (A, E, B, F, D, G), bushing (C), and long and short links (I, J).

Figure 2-7: Drive Lever assembly.

Figure 2.8: Clutch pawl spring.

Tilt

Wheels\Tines_PTO Lever fully forward before installing spring.

Figure 2.11: Neutral position; roller

(T) rests against middle area of the

adjustment block (U).

STEP6: Check Gear Oil Levels

Your tiller has two separate transmissions: one for the Power Unit (Figure 2-

12), the other for the Tine Attachment

(Figure 2-13). Both transmissions were filled at the factory with SAE #85W-140 weight gear oil (with an A.P.I rating of

GL-4). Check level in both transmissions to verify that they are still correct.

See Section 5, Transmission Gear Oil

Maintenancefor complete information on how to check and fill the transmissions.


IMPORTANT: Check gear oil level in both transmissions after the first 2 hours of new tiller operation, then every 30 operating hours thereafter. See Section 5 for instructions.

STEP 8: Attach Engine Throttle

Lever and Cable

For shipping purposes, the throttle cable, together with the throttle lever, is wound around the engine. Carefully unwind the cable. If the throttle control label is covered with a clear protective coating, peel it off.

To avoid electric shock from a short

circuit (electric start tillers only), never allow the throttle cable to touch the battery. Routecable below the battery, on the outsideof the battery holder.

B

Figure 2-14: Engine Throttle Lever position and installation.

To attach the throttle lever and cable:

Figure 2-12: Checking oil level on

Power Unit Transmission.

Figure 2.13: Checking oil level on

Tine Attachment

Transmission.

STEP 7: Add Motor 0il to Engine

I.

Beforeadding motor oil, park the tiller on level ground. Levelthe engine by placing a sturdy block under the tines or the tines depth regulator bar.

2. Add high-quality, APl-rated motor oil to engine before starting. Refer to the

Engine Owner's Manual provided with your tiller for detailed information on how to add motor oil and for motor oil specifications.

IMPORTANT:

• Change engine oil after first 2 hours of new operation.

• Check engine oil level every 5 hours of operation or each use.

I.

Run the throttle cable up the inside edge of the right handlebar and position the lever as shown in Figure 2-I 4.

2. From the outside of the handlebar, insert the curved head screw (A, Figure 2-

14), through the handlebar and the center hole in the throttle lever mounting bracket.

3. Loosely install the flanged lock nut and move the throttle lever back to the

STOPposition.

4. From the lever side of the bracket, thread a pan head screw (B, Figure 2-14) through the small hole in the throttle lever bracket and into the handlebar. Tighten the screw securely.

5. Securely tighten both the flanged lock nut and the curved head screw.

6. Use two plastic ties to secure the throttle cable to the right handlebar in two places (Figure 2-15). Loop each tie around the handlebar and cable (serrated side faces in) and pull the ties tight. Trim the ends.

Figure 2.15: Plastic Ties placement

on handlebars.

STEP9: Adjust Air Pressure in

Tires

For shipping purposes, the tires may be overinflated. Checkthe air pressure in eachtire and adjust them to between 10 and 20 pounds per square inch= You must inflate each tire to equal air pressures to prevent the tiller from pulling to one side.

Assembly is complete for recoil start tillers. SeeAssembling TheElectric

Start System if you own an electric start tiller; otherwise, refer to Section

3, Controlsfor information on tiller controls.


10

ASSEMBLINGTHE ELECTRICSTARTSYSTEM

The following steps explain how to activate, charge, and install the battery on electric start tillers. For your safety, follow all steps and observe all accompanying safety messages. Section 5 contains other general battery maintenanceand recharging instructions.

STEP 1: Activating and

Charging the Battery

IMPORTANT: The battery is shipped dry.

It needs battery electrolytic fluid (batterygrade sulfuric acid). It must then be fully charged with a battery charger before use,

Adding electrolytic fluid to the battery and charging the battery can be dangerous.

Electrolytic fluid contains acid that can burn or blind you. Battery charging also produces explosive gases.

To ensurethat the battery is properly activated and charged, you should review these instructions with your battery technician.

Battery

electrolytic

fluid poisonous and burnsseverely. is

Electrolytic fluid is a sulfuric acid

solution. Avoid spills or contact with

skin, eyes, clothing.

• To prevent accidents, wear protective

clothes, rubber gloves and shield eyes with safety goggles when workingon or near the battery.

• Neutralize acid spills with a baking

soda and water solution. Neutralize electrolyte container with same solution. Thenrinse with clear water.

• Antidote: External- Flush with water;

Eyes- Flushwith water for 15 minutes

and get immediate medical attention.

• Antidote: InternalDrink

large

quantityof water or milk. Follow with milk of magnesia, beaten eggs, or vegetable oil. Call a doctor immediately.

Battery producesexplosive gases.

• Keep away sparks,

flames,

and cigarettes.

• Ventilate area when chargingor using battery in an enclosedspace.

• Make sure battery vent tube is always

open after battery is filled with acid.

TOACTIVATETHE BATTERY:

IMPORTANT: It is strongly recommended that you have the battery activated and charged by a trained professional (Troy-Bilt Dealer, service station, farm equipment dealer, etc.), if you are not experienced with these procedures.

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, a explosion.

shock, or battery gas

For shipping purposes, the battery and its hold-down clamp (A, Figure 2-16) were installed backwards at the factory. When reinstalling the battery and hold-down clamp, be sure to face them in the opposite direction from which they were shipped.

A

Figure 2.16: Batteryshown installed backwardsfor shippingpurposes amy.

I. Removethe two I-I12" long screws and the two I/4" whiz nuts that secure the front and rear hold-down clamp legs to the battery bracket (C, Figure 2-16).

Lift off the clamp and remove battery.

Savethe hardware.

2. If installed, remove and discard the short, plastic tubing (B, Figure2-16) that covers the vent fitting on the negativeside of the battery.

3. Place the battery on a levelwork surface, far away from heat or flame sources like stoves, water heaters,dryers, and furnaces.

4. Removethe six filler caps (D, Figure

2-17) on top of the battery.

IMPORTANT: Be sure to wearing protective clothes, rubber gloves, and eye protection.

5. Fill each cell to the Upper Level line printed on the battery case (E, Figure2-

17) using battery-grade electrolytic solution. (This is 1.265 specific gravity sulfuric acid.) Temperature of battery and electrolytic fluid is ideal when between

60°F and 80°F. Do not add water or any other liquid to the battery during this initial activation.

Figure 2-17: Illustration shows filler caps (D) and Upper Level fill line (E).

6. Let battery stand for 30 minutes.

Check electrolytic fluid level in each cell.

Add more fluid, if needed=Do not overfill battery - this could lead to flooding from the cells during charging=


TOCHARGETHE BATTERY:

1. Use one of the three charging methods described below for maximum starting capacity and longest battery life.

NOTE:Bubbling (gassing freely) electrolyte solution within the battery cells indicates that the battery is charged.

These bubbles emit toxic gases that escape from the cells when you remove the cell caps. Always wear safety goggles to protect your eyes when checking for bubbles. A flashlight makes the inspection easier. Inspect all cells.

To Avoid Personal Injury or Property

Damage:

• Batteries produce explosive gases -

always keep sparks and flame away from battery.

• Ventilate area when charging or using the battery.

• During charging, do not leave battery

unattended. Charging time need not

be continuous.

• Follow safety rules and instructions

supplied by battery and charger manufacturers.

• Do not charge battery at a rate higher

than 12 amperes to avoid generating

excessive heat and gassing which coulddamage the battery.

• First Alternative Charging Method:

Chargethe battery at a rate of 440-6 amperes until all cells bubble freely. Do not exceed 8 hours chargetime.

• SecondAlternative Charging Method:

Chargethe battery at a rate of

6-to-12 amperes until all cells bubble freely. Do not exceed 4 hours charge time.

2. Turn offthe charging equipment and disconnect the charger cables from the battery terminals.

3. Recheck electrolyte level in each cell.

Top off any low cells with electrolyte solution up to the "Upper" level line.

4. Securely replace all six filler caps. Use a baking soda and water mixture to rinse off electrolytic fluid that may have spilled on the battery.

STEP 2: Connect the Wire

Harness Receptacle

I. Before installing the battery and its hold-down clamp, insert the plastic wire harness receptacle (A, Figure 2-18) into the prongs of the keyswitch (B) located on the hold-down clamp.

2. Removethe ignition keys from the keyswitch and store them safelyaway=

Do not insert the key into the keyswitch until you complete this section and read

Section 3, Controls.

• Our Recommended Method:

Chargethe battery at a rate of 14o-2 amperes until all cells bubble freely. Do not exceed 24 hours charge time.

STEP 3: Installing the Battery

1. Carefully place the activated battery back on the battery mounting platform

(C, Figure 2-18). Facethe side of the battery with the terminals posts and the fill lines to the rear of the tiller. The positive terminal (marked +) should be on the left side of the tiller when standing behind the handlebars.

To Avoid Personal Injury or Property

Damage:

• Do not touch positive battery terminal

and any surrounding metal objects with tools, jewelry or other metal items. Failure to comply could cause a short circuit leading to electrical burnsor explosionof batterygases.

• Never bring a gas can near the positive

(+) battery terminal.

A short circuit could occur leading to an explosion of the gasoline or the battery gases.

Always fill the engine fuel tank from

the front or side of the engine.

2. Placethe battery hold-down clamp (D,

Figure 2-18) over the battery. Use two screws (H) and whiz nuts (I) to secure the two legs to the platform (C). Insert the screws up from the bottom. Tighten the hardware but do not overtighten. (The clamp tabs will bend if screws are overtightened.)

Improper battery venting can cause a battery to explode resulting in severe personal injury. Be sure the vent tube is

not crimped, pinched,folded, or blocked

in any way.

3. To install the vent tube (E, Figure 2-

18), slide one end of the tube over the vent fitting (F)= Uncoil the tube and slide the other end down into the black vent tube shield (G).

Neverjump

start the battery with a vehicle battery or chargingsystem. This

may produce a battery explosion,

causingacid or electrical bums.

Figure 2-18: Battery mounting and venting assembly.

11

12


STEP 4: Install the

Battery Cables

NOTE: The cable terminals should be toward the rear (keyswitch side) of the battery posts.

1. Use a 5/8" long screw and 1/4-20 hex nut to connect the positive (+) battery cable (J, Figure 2-19) to the positive

(marked +) battery post (K). Make sure that this is the cable on the left side, with one end attachedto the solenoid (Q).

2. Slide the black rubber boot (P) completely over the battery post and cable connector.

3. Use a 5/8" long screw and 1/4-20 hex nut to connect the negative (-) battery cable (L) to the negative (marked -) battery post (M) and secure with screw

(R) and nut (S),

4. Slide the black rubber boot (T) completely over the battery post and cable connector.

5. Make sure that the lower end of the vent tube shield (U) is positioned in front of the wheel shaft axle. Move it there if necessary.

Assembly is complete for electric start tillers. SeeSection 3, Controlsfor information on tiller controls.

N

Figure 2.19:

Battery cable assembly.

n

Featuresand Controls

zG

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

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

Failure to follow these instructionscan

result in seriouspersonal injury.

Introduction

This section describes the location and function of the controls and features on your tiller. Refer to Section 4, Operation for detailed operating instructions.

Practice using thesecontrols, with the engine shut off, until you completely understand the operation of the controls and feel confident with eachof them.

IMPORTANT:Refer to the separate engine manufacturer's Engine Owner's Manual for information about the controls on the engine.

NOTE: All referencesto left, right, front and rear of the machineare basedon a position behind the handlebarsand facing forward.

PTO Attachments Feature

In addition to powerful tilling capability, you can quickly convert your machine into a PTO(Power Take-Off) Power Unit that is capableof towing or powering various TROY-BILTattachments.

You can accessthis capability by removing the tines attachment (powered by the PTOPower Unit). The PTO Power

Unit is then availablefor engine powered attachments, or for pulling or towing nonpowered attachments. See Section 4,

PTO Power Unit for detailed information on installing and operating TROY-BILT

PTOattachments.

Figure 3-1:

A- WheelslTineslPTO Drive Lever

B- Forward Interlock Levers

C- Wheel Speed Lever

D- Tines/PTO Clutch Lever

This lever has three operating positions:

FORWARD,NEUTRALand REVERSE.

FORWARDis engaged when the lever is moved down until the clutch roller (G,

Figure 3-2) engages into the detent position under the adjustment block (H,

Figure 3-2). You will definitely feel the lever engage into this position.

Use the FORWARDsetting to move the wheels and tines forward, or to apply power to an optional PTO(Power Take

Off) attachment. (See also Forward

InterlockLevers.)

To stop the wheels, tines or any PTO attachment, move the leverto NEUTRAL by tapping the lever upwards (Figure

3-3) and releasing.

Wheels/TineslPTO Drive Lever

Use the Wheels/Tines/PTODrive Lever (A,

Figure 3-1) to engageand disengage power to the transmission.

• REVERSEis engagedwhen the lever is pushed (with an open palm) all the way up and held in that position (Figure 3-4).

Use this setting to move the wheels in reverse. To stop moving in reverse, releasethe lever; it automatically returns to the NEUTRALposition.

E- Depth Regulator Lever

F- Handlebar Height Adjustment Lever

G- Engine Throttle Lever

IMPORTANT: Do not operate the tines or any PTOattachment in REVERSE.

• NEUTRALis this control's normal nonoperating position. The lever returns to

NEUTRALwhen it is tapped out of the

FORWARDposition or releasedfrom the

REVERSEposition. NEUTRALposition is between FORWARDand REVERSE

(Figure 3-3). Use this setting to stop the wheels, tines or any PTOattachment.

IMPORTANT: Always shift to NEUTRAL before starting the engine or before engaging the wheels, tines or any PTO attachment.

Forward Interlock Levers

The Forward Interlock Levers (B,

Figure 3-1) are attached under each handlebar grip,

You must squeezeat least one of these interlock levers up against the handlebar grip whenever the Wheels/Tines/PTO

Drive Lever is engaged in FORWARD position.

13

Section3: FeaturesandControls

14

Figure3*2: FORWARD posi_on; mller

(G) rests under the adjustment block (H).

Figure 3.3: NEUTRAL posiUon; roller

(G) rests against middle area of b_ead*

jusbnent block (H).

Figure 3*4: REVERSEposiUon; roller

(G) rests against upper area of the ad*

jusb_ent block (H).

If both Forward Interlock Levers are releasedbefore first returning the

Wheels/Tines/PTODrive Lever to

NEUTRAL,the engine will stop.

IMPORTANT: The Forward Interlock

Levers are a safety control that stops the engine should you lose control while going forward and cannot shift into

NEUTRAL.

Wheel Speed Lever

Use the Wheel Speed Lever (C, Fig. 3-1) to select one of three operating positions:

SLOW, FASTor FREEWHEEL.

• SLOW- Lever moved all the way down.

Most effective for normal tilling or for low-speed transport.

• FAST- Lever moved all the way up.

Most effective for cultivating or for fastspeedtransport.

•

FREEWHEEL and FAST(wheelswill roll freely). Used whentransporting the machineon level ground without engine power, and when using stationary PTOattachments.

IMPORTANT: To avoid transmission damage, always move Wheels/Tines/PTO

Drive Lever into NEUTRALbefore shifting the Wheel Speed Lever.

IMPORTANT: When shifting into SLOW or FAST, gently roll the machine forward or backward to help fully engage the wheel gears. When engaged, the wheels will not turn unless the engine is running and the Wheels/Tines/PTO Drive Lever is engaged in FORWARDor REVERSE.

IMPORTANT: To avoid transmission damage, always move the Wheels/Tines/

PTO Drive Lever into NEUTRAL before shifting the Tines/PTOClutch Lever.

Depth Regulator Lever

Use this lever (E, Figure 3-1) to regulate the tilling depth of the tines. This control also has a TRAVELposition, which enables transport with the tines off the ground.

To operate the lever, lift up on the handlebars, pull the Depth Regulator Lever straight back, and then slide it up or down to one of the eight detent height settings.

The eight detent positions offer a range of fine height settings. This enablesyou to select the height that is most effective for a particular condition. The top detent position is the TRAVEL setting. Use the second or third detent from the top for shallow tilling and cultivating. Use the other detents for deeper tilling and for power composting.

To

avoid personal

injury, always place the tines in the TRAVEL

position before starting the engine.

This prevents the tines from touching

the ground until you are ready to begin tilling.

TineslPTO Clutch Lever

Use this lever (D, Figure3-1) to engageor disengagepower from the transmission

PTOclutch to the tines or any PTOattachment. This control has two operating positions: ENGAGEand DISENGAGE.

•

ENGAGE- Levermoved into detent slot farthest from engine. Usethis position to operatetines or other PTOattachments.

After shifting to ENGAGE,briefly operate machine in FORWARDto help fully engagethe PTOclutch.

•

DISENGAGE slot nearestengine. Usethis position to disengagepower to tines or other PTO attachmentsbeforetransporting, loading, turning, or operating in reverse.

Handlebar Height Adjustment

Lever

Use this lever (F, Figure 3-1) to adjust the handlebarsto one of two height settings.

1. To changethe height, hold the handlebarswith one hand and loosenthe leverin a counterclockwisedirection.

2. Move the handlebarsto one of the two preset height settings.

3. Retightenthe lever.

NOTE: You can swap the positions of the inside handlebar ratchets to change the two preset settings by approximately four inches higher or lower. See Section 2,

Step 2: Attach Handlebarfor detailed assembly information.

Section3: Featuresand Controls

The tiller handlebars can be swungout

30°to the right side for use onlywith the

PTO Chipper/Shredder attachment. This

is done by looseningthe mounting bolt

on the handlebar base. Never operate

your tiller or attachments,other than the

PTO Chipper/Shredder, with the handle-

bars in the right side position. Doing so could result in unsafe handling and personal injury.

EngineControls

Refer to the engine manufacturer's Engine

Owner's Manual (included in the tiller lit- erature package)to identifythe controls on yourengine.

IMPORTANT: An engine On/Off switch, a secondary throttle control, a choke lever and a fuel line shut-off control may be located on the engine.

Refer to your

Engine Owner's Manual for detailed information.

Engine Throttle Lever

Use the throttle lever (G, Figure 3-1) to adjust engine speed as well as to start and stop the engine.

Move the lever away from the STOP position before starting the engine,

Engine speeds are variable and range between the FASTand SLOW. Use the

STOPposition to turn the engine off.

NOTE: A secondary throttle lever is located on the front of the 8HP and IOHP engines, A separateOnlOff switch may also be availableon the engine, (See

EngineOwner's Manualfor information.)

Keyswitch Starter

The keyswitch starter on electric start models (A, Figure 3-5) has three positions: OFF,RUN and START. Turn the key to STARTto start the engine.

Releasethe key and it will return to the

RUN position= Turn the key to OFFto stop the engine.

(Another way to stop the engine is to move the engine throttle lever to the

Figure 3.5

STOPposition,)

To avoid serious personal injury

or damage to equipment, do not start your

engine at this time. Complete starting

instructionsare describedin Section4,

Operation.

15

n

16

Before operating your machine, carefully read and understandall 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 the machine.

Failure to follow these instructionscan

result in serious personalinjury.

INTRODUCTION

Readthis Section of the manual thoroughly before you start the engine.

Then, take the time to familiarize yourself with the basic operation of the tiller before using it in your garden. Find an open, level area and practice using the tiller controls without the tines engaging the soil (put tines in Travel setting--

Section 3, Depth Regulator Lever). Only after you've become completely familiar with the tiller should you begin using it in the garden.

Your tiller and its optional PTO Power

Unit attachments are capable of causing serious injury to untrained or careless operators.

To avoid serious personal injury or property damage, read the Owner's

Manual that is provided with any optional accessories or attachments before using the tiller or PTO Power

Unit.

Break-In

Operation

Perform the following maintenance during the first hours of new operation

(see MaintenanceSection in this Manual and maintenance information in the

EngineOwner's Manual).

1. Changeengine oil after first 2 hours of new engine operation.

2. Checkunit for loose or missing hardware. Service as required.

3. Checkengine oil level. See Engine

Owner's Manual.

4. Shift the Wheels/Tines/PTODrive lever

(Figure 4-2) into NEUTRALposition. See

Section 3, Controls for more information on this lever.

5. Check Safety Guards. All guards and covers must be securely in place.

Figure: 4.1

2. After the first 2 hours of new operation, check the gear oil levels in the

PTO Power Unit and the tine attachment transmissions.

6. Check air cleaner. See Engine Owner's

Manual.

7. Electric start systems only; ensure battery fluid is filled to the correct level.

Check cell caps and ensure that they are tight. Checkall electric wire connections; ensure they are tight and away from possible short-circuit conditions. See

Section 2, Assembling the Electric Start

System for more information.

3. Checkfor loose or missing hardware on unit. Tighten or replace as needed.

4. Checktension on forward drive belt after first 2 hours of operation.

Starting and Stopping the Engine

The following steps describe how to start and stop the engine.

IMPORTANT: Do not attempt to engage the tines, wheels, or any PTO attachment until you have read all of the operating instructions in this Section. Also review the safety rules in Section 1, Safety and the tiller and engine controls information in Section 3, Featuresand Controls.

Pre-Start Checklist

Make the following checks and perform the following services before starting the engine.

1. Readthe Safetyand Controls Sections in this Manual. Readthe separate Engine

Owner's Manual provided by the engine manufacturer,

8. Attach spark plug wire to spark plug.

9. Check Engine Cooling System. Clear cooling fins and air intake screen of debris.

10. Select High/Low Belt Speedrange.

11. Adjust Handlebar Height.

12. Fill the fuel tank with gasoline in accordance with the directions in the separate EngineOwner's Manual. Follow all instructions and safety rules carefully.

GASOLINEIS HIGHLY FLAMMABLEAND

ITS VAPORSARE EXPLOSIVE.

Follow gasoline safety rules in this

Manual (Section 1) and in the separate

EngineOwner's Manual.

Failure to follow gasolinesafety instruc-

tions can result in serious personal injury and propertydamage.

Wheels/Tines/PTO

DriveLever -_.

_

Section4: Operation

EngineThrottle

Lever

J

\

Depth

Regulator

Lever

/

RecoilStartRope

(at from of engine)

Figure 4.2: Tiller and engine controls.

Startingthe Engine:

3. Move the Wheel SpeedLever (Figure

4-2) to either the SLOWor FASTposition.

Be sure to roll the wheelswhile shifting the lever until the wheels engage.

To help prevent serious personalinjury or damage to equipment:

NOTE:If using a PTOstationary attachment, move the WheelSpeed Leverinto

• Always place Wheels/Tines/PTO Drive

Lever into NEUTRAL before starting

engine, and before engaging wheels, tines or other PTO-drivenattachments.

• 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 exceed 150OF.

preventthe equipmentfrom moving (Figure

4-29 on page29).

4. Movethe Tines/PTOClutchLeverinto the tinesto revolveor to applypowerto a

PTO-drivenstationaryattachment.

1. With the engine off, place the

Wheels/Tines/PTODrive Lever (Figure

4-2) in the NEUTRALposition. If in the

FORWARDposition, tap the lever sharply upward, it should automatically move into

NEUTRALposition.

2. Put the Depth Regulator Lever in the

Travel position (lever all the way down) so that the tines are off the ground. To do this, lift up on the handlebars, pull the lever (Figure 4-2) back, and push it down all the way to the top detent (notched) position.

5. If engine is equipped with a fuel valve, turn valve to OPENposition as instructed in the separate Engine Owner's Manual.

6. If engine is equipped with an ON/OFF switch, move the switch to ON.

7. Move engine throttle lever (Figure4-2)

awayfrom STOP.

8. Choke or prime engine as instructed in the separate Engine Owner's Manual.

9. If not equipped with an electric start system, place one hand on the fuel tank to stabilize the unit when you pull the recoil starter rope. Use the recoil starter rope to start the engine as instructed in the separate Engine Owner's Manual.

10. If equipped with an electric start system, turn keyto STARTpositionto crank enginethen releasewhenenginestarts. If the enginedoes notstart right away,do not hold keyat STARTfor morethana few seconds. Releasethentry againafter a short pause. Damageto startermotor canoccur if it is crankedmorethan 15 secondsper minute.

11. If theenginedoesnotstart aftera numberof tries,referto theEngineOwner's

Manualfor specificinstructions.

12. When engine starts, move the Throttle

Leverto the SLOWposition and then gradually move choke lever (on enginesso equipped) to OFFor RUN position.

13. Move the throttle speed control to

FASTsetting when tilling.

Starting Electric Start Engines with the Recoil Starter Rope

You may, at some point, have to start an electric start engine with the recoil starter rope. Before attempting to do so, perform the following applicable steps:

• If you suspect the battery charge is weak, and there is no visible damage, check battery cells and fill to the proper level with electrolytic solution. Disconnect cables from battery and clean both cable terminals, and the battery posts in accordance with the instructions provided in Section 5, Battery Careand

Maintenance.

17

Section 4: Operation

18

Reconnect the cables and securely tighten to battery posts. The engine will recharge the battery if the battery is still good.

• If you suspect the batter is "dead", or if the battery is damaged, disconnect, and remove it. Have it checkedby a qualified technician.

• If battery has been removed, wrap cable terminals at end of positive cable with electrical tape and secure the cable to the battery bracket. This will prevent electrical discharge.

• Before pulling the recoil starter rope, turn the keyswitch to the RUNposition.

Move the Throttle Lever away from

STOPposition and set the choke as applicable. See Engine Owner's Manual.

Stopping the Engine and Tiller

1. To stop the wheels and tines, move the

Wheels/Tines/PTODrive Lever into

NEUTRALposition and then releaseboth

Forward Interlock Levers.

2. Move the engine Throttle Leverto the

STOPposition. Then on electric start models, turn the key to OFF=Removethe key for safekeeping.

NOTE: The engine may havea separate

Throttle Control Lever and ON/OFFswitch on the engine. These controls can also be used to stop the engine. Seethe Engine

Owner's manual for information specific to your engine.

Operating the Tiller

When first practicing, keepthe Tines/PTO

Clutch Lever in DISENGAGEposition and the Wheel Speed Lever in SLOWposition,

Moving the Tiller Forward and Tilling

I. Start the engine and gradually increase engine speed to FAST (see Starting the

Engine,this Section).

The Forward Interlock Safety System is

designedfor the operator's safety. Do

not disconnector attempt to defeat the purpose of the system. If the system malfunctions,immediately contact your local authorized dealer or the

TROY-BILT Technical Service Depart-

ment for assistance.

Do not use the tiller or the PTO power unit until the

Forward Interlock Safety System is

functioning properly. Always test the

system before using the tiller or PTO powerunit.

To avoid serious personal injury

or

damage to equipment:

• Always place Wheels/Tines/PTODrive

Lever in NEUTRAL before starting

engine, and before engaging wheels, tines or other PTOattachments.

• Be sure there are no obstaclesbehind

you beforemoving in reverse.

• Wheels/Tines/PTODrive Lever should

automatically

return to NEUTRAL

when released

from

REVERSE position. If it does not, move lever to

NEUTRAL manually and discontinue

use until you adjust the lever. See

Section 5, Checking and Adjusting

Reverse Drive System.

• No reverse motion should occur if

Wheels/Tines/PTO Drive Lever is not

held up in REVERSE. See Section 5,

Checking and Adjusting Reverse

Drive System for adjustment steps.

Do not use tiller unless properly adjusted.

• Always return to NEUTRALand let all

motion stop before shifting to

FORWARDor REVERSE.

The following pagesprovide guidelines for using your tiller effectively and safely in various gardening applications. Be sure to read Tilling Tips & Techniques,in this Section, before you actually put the tines into the soil.

2. Test the Forward Interlock Safety

System. See TestingForward Interlock

System, this Section.

Keep away from rotatingtines. Rotating

tines will cause injury.

3. When practicing, set the Depth

Regulator Leverto Travel position=

Otherwise, set the Depth Regulator Lever to a desired depth.

4. Move Tines/PTOClutch Leverto

ENGAGEposition if you want the tines to turn. If practicing, leavein DISENGAGE.

IMPORTANT: Do not move Tines/PTO

Clutch Lever to ENGAGE unless

Wheels/Tines/PTO Drive Lever is in

NEUTRAL.Tiller damagemay occur!

5. To move the tiller forward and engage the tines, squeezeand hold either Forward

Interlock Lever (Figure 4-3) against the handlebargrip, then move the

WheelslTineslPTODrive Leverdown to

FORWARDposition=

This is a traditionalstandard-rotating-0ne

(SRT) tiller with forward rotating tines. It operates in a completely different manner than counter-rotating-0ne (CRT)tillers, or from front-tine tillers.


Figure 4-3: Moving tiller forward:

squeeze one Forward Interlock Lever

and then move WheelslTineslPTO

Drive Lever down to FORWARD.

Figure 4.4: Guide tiller with one hand.

6. When the tiller moves forward, relax and let the wheels power the tiller along while the tines dig. Walk behind and to one side of the tiller. Walk on the side that is not yet tilled (Figure 4-4). Use a firm grip on the handlebars but keepyour arm relaxed.

IMPORTANT: Let the tiller move ahead at its own pace. Do not push it ahead--this reduces operator control and tilling efficiency. Do not push handlebars down in an attempt to dig deeper-this takes weight off the wheels, reduces traction, and causes the tines to try to propel the tiller.

Moving the Tiller in Reverse

IMPORTANT:

REVERSE.

Do not till while in

1. Shift the TineslWheels/PTODrive Lever

(Figure 4-2) into NEUTRALand move the

Wheel Speed Lever to the SLOW position.

2. Move Tines/PTOClutch Lever (Figure

4-2) into DISENGAGEposition.

3. Verify that the area behind you is clear.

4. Lift up the handlebarsuntil the tines are off the ground, then shift the

Wheels/TineslPTODrive Lever all the way up and hold. You do not need to squeeze the Forward Interlock Levers to use reverse.

Stopping Forward Motion and Tines

1. To stop forward motion, tap

Wheels/Tines/PTODrive Lever upward

into NEUTRAL=Then releasethe Forward

Interlock Levers. The wheels and tines will stop and the engine will continue running.

5. The unit immediately engages in reverse. Periodically check behind you while holding the handlebars up and the

Wheels/Tines/PTOLever in its upper-most position.

2. In an emergency, releaseall of the control levers. This stops forward motion and shuts-off the engine.

To Help Avoid Personal Injury or

Damage to Equipment:

• Be sure no obstaclesare behind you

before operatingthe tiller in REVERSE.

• Disengage the tines, reduce engine

speed, and move the Wheel Speed

Lever

to SLOW position before operating in REVERSE. Avoid using

FAST wheel speed until you are

familiar with backingthe tiller.

Stopping Reverse Motion

Releasethe Wheels/Tines/PTODrive

Lever- the lever automatically returns to the NEUTRALposition. This stops the wheels immediately. (TheForward

Interlock Levers will not stop REVERSE motion.)

To Stop the Engine

Move the engine Throttle Lever to the

STOPposition. Then, on electric start models, turn key to OFF. Remove the key for safekeeping.

Making Turns

Turning the tiller is easy andjust requires practice. First find the balancepoint betweenthe engine and the tines by lifting up the handlebars (Figure4-5). Onceyou find the balancepoint, then let the powered wheels do the turning as you push sideways on the handlebars in the direction of the turn. Practice the turning maneuver described here in a large open area. Once comfortable turning the tiller, you can then take it to the garden area.

I. At the end of a row, move the Wheels/

Tines/PTO Drive Lever (Figure 4-2) to

NEUTRALposition and reducethe engine speed.

2. Move the Tines/PTOClutch Lever

(Figure 4-2) into the DISENGAGE position.

3. Resume forward operation, and lift handlebarsuntil tines are off the ground

(Figure 4-5). Find the balancepoint betweenthe engine and the tines. Then push the handlebars in the direction of the turn. Be very careful to keep feet and legs

away from the tines (which should be dis-

engaged). Let the powered wheels do the hard work. The inside wheel will pivot in placewhile the outside wheel drives the tiller around in the direction of the turn.

Figure 4.5: Turning the tiller.

NOTE: Use REVERSEif necessaryto turn in a limited space.

19


4. When the turn is complete, shift to

NEUTRALand lower the handlebars.

Move Tines/PTOClutch Lever back to

ENGAGEposition and resume forward operation.

TransportingThe Tiller Around

YourProperty

When the engine is running, the tiller's powered wheels make moving the tiller to and from the garden easy. If the engine is not running set the Wheel Speed Lever to

FREEWHEELposition to roll the tiller to another location.

To help avoid personal injury from

revolving tines, always put the

Tines/PTO Clutch Lever in DISENGAGE

positionbefore transporting,loading, or unloadingtiller.

1. Placethe Tines/PTOClutch Lever in

DISENGAGEposition.

2. Move Depth RegulatorLeverdown all the way into the Travel setting.

The ForwardInterlock Safety System is

designed for the operator's safety. Do not disconnector attempt to defeat the purpose of the system. If the system malfunctions,immediately contactyour local authorized dealer or the

TROY-BILT Technical Service Department for assistance.

Do not use the tiller or the PTO power unit until the

Forward Interlock Safety System is functioning properly. Always test the system before using the tiller or PTO power unit.

How to Check the Interlock System

The Forward Interlock System has an electro-mechanical design, and so is subject to normal wear and possible malfunction. Checkthe system for proper operation each time prior to using the tiller or PTOpower unit.

4. Start engine as described under

Starting and Stopping the Engine,in this section. Set engine throttle lever to

SLOW, and let engine warm up.

5. Squeezeand holdjust one of the

Forward Interlock Levers against the handlebar grip while moving the Wheels/

Tines/PTO Drive Lever down to

FORWARD(Figure 4-3). As the tiller moves forward, releasethe Forward Interlock Lever briefly. The engine should start to stall out if the interlock system is working properly. If it does start to stall, quickly squeezethe lever up against the handlebar grip, and then return the

Wheels/Tines/PTO Drive Lever to

NEUTRAL. Repeatthis test to check that the engine begins to stall out when the other Forward Interlock Lever is released.

6. If the engine does not begin to shut off when either Forward Interlock lever is released, shut the engine off, remove the key (if electric start), and do not operate the tiller or PTOpower unit until the

system has been repaired and is functioning properly.

3. If using engine power, move Wheel

Speed Lever to either SLOWor FAST,and use the Wheels/Tines/PTODrive Leverto drive the wheels.

IMPORTANT: To avoid possible damage to the Forward Interlock Safety system, do not use high-pressure sprays near the wire harness receptacleor neutral plunger assembly.

4. If the engine is stopped, move Wheel

Speed Lever to FREEWHEEL,and manually push tiller.

Loading and Unloading the Tiller

The following provides information on tiller loading,unloading, and requirements before loading and unloading the tiller,

Readthe following instructionscarefully before attempting to load or unload your tiller.

Testing

the Forward

Interlock

Safety System

The Forward Interlock Safety System is designed to shut the tiller engine off immediately if you lose control and cannot stop moving FORWARDby shifting the Wheels/Tines/PTODrive Lever into NEUTRAL. When you releaseboth

Forward Interlock Levers,they send ground to the ignition system thereby stopping the engine. Squeezingone or both levers up against the handlebars enablesthe ignition system; therefore, you must squeezeat least one lever whenever the Wheels/Tines/PTODrive

Lever is engaged in FORWARD.

Figure 4.6: Plug and receptacle

of

Forward Interlock Safety System must be securely connected.

To test the Forward Interlock System:

1. Move tiller outside to level ground.

Removeany obstacles.

2. Checkthat the Forward Interlock wire harness plug, at the bottom of the handlebars (Figure4-6), is securely connected to the receptacleon the top, right side of the transmission.

2O

IMPORTANT: The interlock system also prevents the engine from starting if the

Wheels/Tines/PTODrive Lever is engaged in FORWARD.

3. Move Wheel Speed Lever (Figure 4-2) to SLOW position and move Tines/PTO

Clutch Lever to DISENGAGE.

Before Loading or Unloading the

Tiller

• Ramps must be strong enough to support the combined weight of the tiller and handlers. They should provide good traction to prevent slipping; they should have side rails to guide the tiller along the ramps; and they should have a locking device to secure them to the vehicle.

• Handlers should wear sturdy footwear that will help to prevent slipping.


• Turn the vehicle's engine off and apply its parking brake.

• Position the loading vehicle so that the ramp angle is as flat as possible (the less incline to the ramp, the better).

Loading the Tiller

I. Use loading ramps that are strong and wide enough to safely hold the weight of the tiller and the operator combined-your tiller weighs between 280 and 325

Ibs.

2. Move the Tines/PTO Clutch Lever

(Figure 4-2) into DISENGAGEposition.

3. Set the Depth Regulator lever (Figure

4-2) to the Travel position.

4. Move Wheel Speed Lever (Figure4-2) into SLOWposition and reduce the engine throttle speed.

5. Shift the Wheels/Tines/PTOLever

(Figure 4-2) into FORWARDposition and follow the tiller up the ramps (Figure 4-7).

Checkthe wheels as you move the tiller forward. Ensurethat they move up the center of each ramp.

6. Prevent tiller from rolling in vehicle.

LeaveWheel Speed Lever in FASTor

SLOW position, chock wheels with blocks and tie down the tiller.

Figure 4.7: To go up ramps, use

FORWARD drive.

Unloading the Tiller

IMPORTANT: Neverunload the tiller in

FORWARDdrive. The tiller could tip forward and expose you to the tines

(which should be disengaged as instructed).

I. Use loading ramps that are strong and wide enough to safely hold the weight of the tiller and the operator combined-your tiller weighs between 280 and 325

Ibs.

2. Move the Tines/PTOClutch Lever

(Figure 4-2) to DISENGAGEposition.

3. Set the Depth Regulator Lever (Figure

4-2) to the Travel position.

4. Move Wheel Speed Lever (Figure 4-2) to SLOWposition and reduce the engine throttle speed.

This change is done quickly and without tools (Figures 4-9 through 4-13).

IMPORTANT: Look behind you before you back down the ramp to ensure that all is clear. While descending, keepchecking for obstacles behind you.

5. Move and hold the Wheels/Tines/PTO

Lever into REVERSEdrive and back down the ramps (Figure 4-8). Checkthe wheels as you move the tiller backward. Ensure that they move down the center of each ramp.

Pulley

Figure 4.9: Be/t range positions.

When the tiller is moving in REVERSE,the wheels are powered by a rubber reverse disc, not by the belt. Therefore, you have only two reverse speeds SLOW and FAST, as set with the Wheel Speed Lever.

Table 4-I shows the range of wheel and tine speeds availablewhen using the two belt speed ranges and the FASTand

SLOWselections on the Wheel Speed

Lever.

Figure 4-8: To go down ramps, use

REVERSE drive.

Changing Speed

Belts

Your tiller has two belt-driven speed ranges - HIGH RANGEand LOW RANGE

- you pick one or the other by deciding which set of pulley grooves to move the forward belt into. By moving the belt from one speed range into the other, in combination with the FASTand SLOW wheel speeds,you obtain a choice of four different forward wheel speeds and two different tine speeds.

Table 4.1

Available wheel and tine speedsat 3000 RPM engine speed.

Belt

Low Range

Low Range

High Range

High Range

WheelSpeed Wheel

Tine

Lever J Speed J

Speed

Slow .5MPH

146RPM

Fast 1.2MPH

146RPM

Slow

Fast

.7MPH

1.72MPH

200RPM

200RPM

To help avoid serious personal injury,

stop the engine, remove the ignition key, disconnect spark plug wire and

move the wire away from the spark

plug, and let engine and muffler cool downbefore changingbelt speeds.

Changing Belt From LOW Range

to HIGH Range

1. To avoid personal injury, shut off engine, let all moving parts come to a complete stop, then disconnect spark plug wire from spark plug and move it away from spark plug before making any adjustments. Wait for the engine and muffler to cool down.

2. Move WheelslTines/PTODrive Lever into NEUTRAL.

Changing the belt from LOW range into

HIGH range (or back again) is a matter of moving the belt from one set of pulley grooves to a second set of pulley grooves.

21


22

The HIGH speed belt range position combined with a FAST wheel speed

setting propels the tiller at the fastest

pace. Reducethe engine throttle speed when starting out to help avoid personal injury or propertydamage if using this speed combination.

4. Go to right side of tiller and finish seating the belt.

5. Still holding the lever up in REVERSE position, and workingfrom the left side of the tiller, move the belt from the lowerfront transmission groove to the lowerrear transmission groove.

6. Go to the right side of the tiller and finish seating the belt (Figure 4-I 3).

3. Kneel on left side of tiller. To create belt slack, reach over to right side of the pulleys and push in at the center of the belt with a finger. At the same time, use your left hand to work the belt part-way onto the lower-front transmission pulley groove (Figure 4-10).

Figure 4-11: Low range to high range. Shows moving belt from top-

rear groove onto top.front groove.

7. Checkboth sides of the high range pulley grooves to verify that the belt is properly seated.

Figure 4.10: Low range to high range.

Shows moving belt from lower.rear

groove onto lower-front

groove.

4. Go to the other side of the tiller to finish seating the belt onto the pulley groove.

5. Working from the left side of the tiller, work the belt as much as possible onto the top-front engine pulley groove (Figure

4-11).

6. Finish seating the belt from the right

side of the tiller.

IMPORTANT:

Proper belt tension is important for good performance.

See

Section 5, Drive Belt Maintenance for information on belt maintenance schedule and procedures.

NOTE: If extra belt slack is needed to move the belt, just raise the

Wheels/Tines/PTO Drive Lever up into

REVERSE. This lowers the engine pulley, and creates more slack.

Changing Belt From HIGH Range to

LOW Range

1. To avoid personal injury, shut off engine, let all moving parts come to a complete stop, then disconnect spark plug wire from spark plug and move wire away from spark plug before making any adjustments. Let engine and muffler cool.

2. Move the Wheels/Tines/PTODrive

Lever into NEUTRAL.

3. Stand on left side of tiller. Use your right hand to hold the Wheels/Tines/PTO

Drive Lever up into REVERSEposition.

Use your left hand to move the belt off top-front engine pulley groove to top-rear engine pulley groove (Figure 4-12).

Figure 4.12: High range to low range.

Shows moving belt from top-

front groove onto top-rear pulley

groove.

Figure 4.13: High range to low range.

Shows moving belt from

lower-front onto lower-rear groove.

7. Checkthat the belt is fully seated in the pulley grooves. Checkthis from both sides of the tiller.

Choosing Wheel

andTine Speeds

Your tiller has four FORWARDwheel/tine speed combinations for handling a variety of tilling tasks and gardeningjobs. Experiment with the tine depth, engine speed, and wheel/tine speed and determine the combination that provides the best results. Hereare some tips:

1. Advance the throttle lever so the engine has sufficient power.

2. When tilling untilled or hard earth, do not set the Depth Regulator too deep. The tiller will buck and the engine will load down.

3. You will know your settings are ideal when the tines break-up the soil easily, the engine does not labor, and your progress is steadyand smooth.

See Table 2, WheelSpeedand Belt Range

Selection Guide for recommendations.


SLOWGEAR,LOWBELTRANGE

For:

Tilling in sod.

Tilling in hard clay.

Tilling under standing cornstalks in tough soil conditions.

Tilling under cover crops.

Preparinga deep seedbed.

Tilling in stony soil.

Tilling under residuesand organic matter.

Mixingin fertilizers,manure.

SLOWGEAR,HIGHBELTRa_NGE

For:

• Tilling in sod or hard clay.

• Tilling under standingcornstalks (slow, steadyspeed allows time to shred stalks).

• Tilling under cover crops

(best wheelspeedand belt speedrange in most soils).

• Preparingseedbeds(best speedchoice in most soils).

• Tilling in stony ground.

• Building raisedgardenbeds.

• Mixing in fertilizer.

FASTGEAR,LOWBELTRANGE

• Coveringoverseeds in wide row or plot planting (lift handlebarsto avoidgoing too deep).

Hilling and furrowing.

Makingraisedbeds.

Cultivating(lift handlebarsto avoid going too deep).

• Tilling largeareas.

• Tilling organic matterin.

FASTGEAR,HIGHBELTRANGE

For:

• Going over seedbedfor the last time beforeplantingcrops.

For: planting.

• Coveringseedswith less need to hold up the handlebars.

• Cultivating(tiller travelsfaster, rides higheron the soil; allows engineRPM to be reduced; handlebarsdon't haveto be raised).

• Keepinglarge areastilled and cultivatedin the summer.

• Tilling organicmatter under.

• Using hiller wings in hard soil

• Mixing fertilizer and manure.

• Tilling residuesand organics.

• Cultivatingbetweenraised bedswithoptional hillerlfurrower attachment.

• Moving tiller quickly.

• Cultivatingbetweenraised bedsusing the optional hillerlfurrower.

Tilling Tips& Techniques

Let the tiller do the work

With each succeeding pass, adjust the

• While tilling, relax and let the wheels pull the tiller along while the tines do the digging. Walk on the side that is not yet finished (to avoid making footprints in the freshly tilled soil) and lightly, but securely grip the handlebar with just one hand (Figure 4-4).

depth regulator to dig another inch or two deeper. (Watering the garden area a few days prior to tilling will make tilling easier, as will letting the newly worked soil set for a day or two before making a final, deep tilling pass.)

• Avoid pushing down on the handlebars in an attempt to force the tiller to dig deeper. Doing so takes the weight off the powered wheels, causing them to lose traction. Without the wheels helping to hold the tiller back, the tines will attempt to propel the tiller - often causing the tiller to skip rapidly across the ground. (Sometimes, slight downward pressure on the handlebars will help get through a particularly tough section of sod or unbroken ground, but in most cases this won't be necessary.)

• When cultivating (breakingup the surfacesoil around plants to help destroy weeds), use very shallow depth settingsto prevent injury to plants whose roots often grow close to the surface. If needed,lift up on the handlebarsslightly to preventthe tines from digging too deeply. Cultivatingon a regular basis not only eliminatesweeds,it also loosensand aeratesthe soil for batter moisture absorption and fasterplant growth.

Avoid tilling wet, soggy soil

Tilling depths

• Avoid trying to dig too deeply too

quickly, especially when busting sod or tilling soil that hasn't been tilled for

some time. Use shallow depth settings

(only an inch or two deep) for the first passesthrough the garden area.

Tilling wet soil often results in large, hard clumps of soil that can interfere with planting. If time permits, wait a day or two after heavy rains to allow the soil to dry before tilling. Test the soil by squeezing it into a ball. If it compresses too easily, it is too wet to till.

To help avoid personalinjury, be aware

that the tiller can unexpectedlybounce

up orjump ahead and propelaway from

you if the tines strike hard or frozen

ground, or buried obstacles like large stones, roots or stumps. Always use

the following

precautions to help maintain controlof the tiller:

• Walk behind and to the side of the

tiller. Use one handon the handlebars, relaxing your arm but with a secure handgrip.

• Use shallow depth regulator settings.

Till gradually deeper.

• Use slower wheel, tine and engine speeds.

• Clear the tilling area of all large stones, rootsand otherdebris.

• Do not put downwardpressureon the

handlebars.

If needed, apply slight upward handlebar pressureto keep the

tines from diggingtoodeeply.

• Avoid contacting hard soil or sod at

the end of a row - reduceengine speed

and lift handlebarsto raise tines out of

the soil.

• In An Emergency, stop tines and

wheels by moving Wheels/Tines/PTO

Drive Lever to NEUTRAL. If you cannot

roachthe lever or have lost control, Let

Go OfThe Handlebarsand All Controls.

23

24


Avoid

making footprints

When possible,walkon the untilled side of the unit to avoid making footprints in the freshly tilled soil (Figure 4-4). Footprints cause soil compaction that can hamper root penetrationand contribute to soil erosion. They can also "plant" unwantedweed seeds back into the newly tilled soil.

Tilling Tips & Techniques

IMPORTANT: When tilling on slopes, be sure the correct oil level is maintained in the engine (check every onehalf hour of operation)= The incline of the slope will cause the oil to slant away from its normal level and this can starve engine parts of required lubrication.

Keepthe engine oil level at the full point at all times!

• When tilling vertically, try to make the first pass uphill as the tiller digs more deeply going uphill than it does downhill. In soft soil or weeds, you may haveto lift the handlebars slightly while going uphill. When going downhill, overlap the first pass by about one-half the width of the tiller.

Suggestedtilling patterns

• When preparing a seedbed, go over the same path twice in the first row, then overlap one-half the tiller width on the rest of the passes (Figure 4-

14). When finished in one direction, make a second pass at a right angle as shown in Figure 4-15. Overlapeach pass for best results (in very hard ground it may take three or four passesto thoroughly pulverize the soil).

• If the garden size will not permit lengthwise and then crosswise tilling, then overlap the first passes by onehalf a tiller width, followed by successive passesat one-quarter width

(Figure 4-I 6).

A. Tilling up and down slopes:

• To keepsoil erosion to a minimum, be sure to add enough organic matter to the soil so that it has good moistureholding texture and try to avoid leaving footprints or wheel marks.

To avoid serious personal injury or

damage to the equipment:

• Do not operate tiller on a slope too steep for safe operation. Go slowly on any slope.

Make sure you have

good footing.

• Wear footwear

that increases stability and reducesslippage.

• Do not use FAST wheel speed

positionwhen on slopedground.

HINT: For best results, use the HIGH belt range and SLOW wheel speed lever position. See Changing Speed Belts in this section for more information on changing to high range.

Figure 4.14

Figure 4.15

• With planning, you can allow enough room between rows to cultivate

(Figure 4-17). Leaveroom for the hood width, plus enough extra room for future plant growth.

• Do not shift the Wheel Speed Lever

when heading up or down a slope. If lever is accidentally moved to FREE

WHEEL position, the tiller could roll out of control.

Tilling on slopes

If you must garden on sloping ground, pleasefollow two very important guidelines:

I= Till only on moderate slopes, never on steep inclines where footing is difficult (review safety rules in the

"Safety" Section of this Manual).

• To preventengine damage due to oil starvation (on slopes,the

engine is inclined and oil moves away from surfaces that need lubrication), be sure the correct oil level is maintained during all uphill/downhill

tilling operations. Check the level of

the oil in yourengine after every onehalf hourof operation.

Figure4-16

2. We recommend tilling up and down slopes rather than terracing. Tilling vertically on a slope allows maximum planting area and also leaves room for cultivating.



Clearing the tines

The tines have a self-clearing action which helps to eliminate most tangling of debris. However, occasionally dry grass, stringy stalks or tough vines may become tangled.

Follow theseprocedures to help avoid

tanglingand to clear the tines, if necessary.

Beforeclearing the tines by hand, stop the engine, allow all moving parts to stop and disconnect the spark plug wire.

Failure to follow this warning could result in personal injury.

Figure 4.18

B. Terrace Gardening:

• Whena slope is too steep or too short for verticaltilling, it may be necessary to till across the slope and create

terracedrows. Terracesare rows that are cut intothe side of a slope, creating a narrow, but flat area on whichto plant.

• On a long slope, you can make several terraces, one below the other.

• Terracesshould be only 2-to-3 feet wide. Digging too far into the side of the slope will expose poor subsoil that is unproductive for plants.

• To create a terrace, start at the top of the slope and work down, Go back and forth across the first row as shown in

Figure 4-18,

• Eachsucceeding lower terrace is started by walking below the terrace you're preparing. Foradded stability of the tiller, always keep the uphill wheel in the soft, newly tilled soil. Do not till the last 12" or more of the downhill outside edge of each terrace. This untilled strip helps prevents the terraces from breaking apart and washing downhill. It also provides a walking path between rows.

C. Tilling across slopes withoutterracing

• If vertical or terracinggardening aren't practical for you, then you can till laterally across a slope, We don't really recommend this method as it can create unsure footing and invites soil erosion.

• Study the terrain to make certain the slope is not too steep for safe tilling.

If possible, make terracedrows or till vertically.

• Move the belt into LOW belt range and

the Wheel Speed Gear Lever to SLOW position. As in terracegardening, start at the top of the slope and overlap the first pass by half the width of the tiller.

Foradded stability, keep the uphill wheel in the soft, newly tilled soil. Each succeeding terraced area is started by walking belowthe terrace you are preparing (Figure 4-19).

• To reduce tangling, set the Depth

Regulator deep enough to get maximum "chopping" action as the tines chop the material against the ground. Also, try to till under crop residues or cover crops while they are green, moist and tender.

• While power composting, try swaying the handlebarsfrom side to side (about

6" to 12"). This "fishtailing" action often clears the tines of debris.

• It may be necessaryto remove the debris by hand (a pocket knife will help you to cut away the material).

Figure 4.19: Make a terrace in just 4

or 5 passes with the tiller.

25

26


POWERCOMPOSTING


Power composting means tilling under and burying in the soil all manner of organic matter such as crop residues, leaves,grass clippings and cover crops.

This material will decompose during the non-growing season and add important natural nutrients to the soil.

After tilling under crop residues, add more organic matter such as leaves, grass clippings and even kitchen scraps.

When tilled into the soil, this organic matter will decompose and add even more important nutrients to the soil.

After power composting, you may want to plant a "green manure" cover crop to protect the soil during the off-season.

I. As you move forward into a row of stalks, aim the tiller so that the stalks go between the left wheel and the transmission case (Figure4-19). Do not use the right wheel becausedamage could occur to the air cleaner, carburetor or throttle linkage.

Grow a crop of clover, alfalfa, buckwheat, peas, beans, rye grass, grain, or kaleand then till it into the soil prior to the planting season.

When power composting,do not keep

the Depth Regulator Lever at a deep

setting if the tiller jumps or bucks.

If jumping

or bucking occurs, move

the Depth Regulator Lever down to

one of the shallower settings and then slowly increase the tilling depth on later passes.

Failure to complycould result in loss

of tiller control, property damage or

personal injury.

Begin by composting crop residues such as leftover vines, stalks, stems and roots. Power compost these crop residues as soon as they finish bearing.

The sooner this is done, the better, as tender green matter is easier to till under. Use the deepest depth regulator setting possible without causing the engine to labor or the tiller to jump ahead.

Wide-Row Planting

The wide-row planting technique is spreading seeds anywhere from 10 inches to 2 feet wide or more. As a result, you can grow anywhere from 3 to

4 times (or more) produce in the same space that is normally set asidefor an area that has narrow, single rows.

Wide-row planting automatically shades the ground which keeps weed growth down and also holds moisture in the soil. And of course, harvesting is much easier - everything is right at hand to be picked. Preparing wide rows is easy -after you prepare the seedbedand mark off the rows with string, hand-broadcast the seeds as if seeding a lawn (not quite as much as lawn seed). Cover with soil and tamp the area firmly with a hoe.

Figure 4.20: Tilling under corn stalks.

2. Eachnew pass should overlap the previous pass by one-half the width of the tiller.

3. Till as deeply as possible. Pull the

Depth Regulator all the way UP and engagethe lowest notch for deep tilling.

Use either LOW or HIGHbelt range and

SLOWwheel speedgear position.

Let the tilled-in stalks decompose for a week or so. Then till in the remaining residue as deep as possible.

Standing cornstalks of reasonableheight can be power composted (Figure 4-20).

Pushing over (but not uprooting) cornstalks will often make it easierfor your tiller to chop up the stalks. Keepthe tines clear of excessivetangling by "fishtailing" or frequently using reverse.

Make several passes, then return a few days later to finish off any remaining stubble.

Tilling Under Corn

After corn is harvested, the stalks should be tilled into the soil while still green.

Dry plants are more difficult to till under, and the roots break loose too easily.

IMPORTANT: Do not pull the roots out by hand or cut the stalks before tilling.

Stalks that are firmly anchored by their roots are much easier for the tines to chop, cut, and work under.

PTO POWERUNIT

Your tiller is a self-contained PTO(Power

Take-Off) Power Unit that was shipped with a tine attachment installed. The fine attachment can be quickly removed and replaced with other optional attachments,

The following instructions will familiarize you with your PTOPower Unit, Please read thesepagescarefully.


Removing And Replacing The Tine Attachment

Wheels/Tines/PTO

Drive Lever

Wheel

Speed,

Lever

\

\

\

\

Engine

ThrottleLever

\

\

/

Depth

Regulator

Lever

Figure 4-21: PTO Power Unit and tine attachment.

Figure 4-22: PTO Power Unit controls.

Before operating your PTO Power

Unit for the first time, make sure that you have:

• Read all the safety instructions in

Section 1 of this Manual and in the

Manual supplied with any attachment.

• Read the controls information and

operating procedures for the tiller and engine described in Sections 3 and 4 of this Manual and in the

EngineOwner's Manual.

• Read and understandthe assembly

instructions, controls information,

and operating procedures for the

attachment as described in the

Attachment Owner's Manual supplied

with the attachment.

TO AVOID PERSONAL INJURY OR

DAMAGETO EQUIPMENT:

• Stop the engine, remove the electric

start key, disconnect the spark plug

wire and let the engine and muffler

cool before removing or installing any attachment.

• Do not place hands, tools, or any

object near or inside the PTO access

area while the engine is running.

• When removingor replacing the tine

attachment, be careful of the sharp edges on the tiller hood. Wear thick

glovesfor handprotection.

• When

the fine attachment is removed, always prop it up with a

block to prevent the attachment from falling forward.

The following steps explain how to remove and replace the tine attachment.

You will need a 3/4" wrench (minimum

12" long for leverage).

Removing Tine Attachment

1. Move the tiller to levelground.

2. Be sure the engineis stopped,the

electricstart key is removed,and thespark plug wireis disconnectedand moved away from sparkplug.

3. Place a sturdy support under the engine to prevent the engine from tipping forward when the fine attachment is removed (Figure 4-23).

4. Placethe WheelslTineslPTODrive Lever into NEUTRAL(Figure4-22).

5. Place TineslPTOClutch Lever in

DISENGAGE(Figure 4-22).

Figure 4.23: Block up engine.

6. PlaceWheel Speed Lever into FREE

WHEEL(Figure 4-22).

7. Loosen the two swing-out bolts (Figure

4-24) that connect the power unit transmission to the tine attachment and swing out the bolts (Figure 4-25).

HINT: Loosening swing-out bolts can be difficult. Use an extra-long wrench for leverage.

8. Tip the PTOpower unit forward about one inch with one hand while pulling the tine attachment back (Figure 4-26). The guide pin on the power unit will slide out of the guide hole in the fine attachment

(Figure 4-27).

27


Figure 4.24: Loosening attachment swing-bolts.

10. The PTOPower Unit is now ready to install other powered or non-powered attachments. See the attachment's

Owner's Manual for installation and operation instructions specific to that attachment.

Installing the Tine Attachment

1. Move the two PTOPower Unit swingout bolts outward and slide the washers up against the bolt heads.

2. Removethe support block from under the engine and slowly roll the power unit back next to the Oneattachment. Place the support block back under the engine.

3. Removethe dust cap (or protective wrapping) from the dog clutch coupling on the tine attachment.

4. Carefully align the guide pin on the

PTO Power Unit with the alignment hole in the tine attachment and bring the two units together (Figure 4-27).

PTO POWERUNIT

OPERATINGINSTRUCTIONS

To help avoid

all control, operation

and safety

instructions.

personal injury

or

damage to equipment, read the attach-

ment's Owner's Manual supplied with each attachment before installing or operating an attachment. Please read

The following are operating instructions specifically for the PTOPower Unit. Read the separate Owner's Manual supplied with eachattachment before attempting to assemble, attach, transport or operate the attachment. If needed,pleasecontact us for a replacement manual. See the back cover for customer support information.

To help avoid personal injury, always

disengage the Tines/PTO Clutch Lever

beforetowing any attachment.

28

Figure 4.25: Moving swing-bolts

outward.

IMPORTANT: Store tine attachment in a level, upright position to prevent gear oil from leakingfrom the dipstick area.

Figure 4-26: Pulling attachment away from power unit.

9. To keepthe tine attachment dog clutch coupling clean, cover with the dust cap

(on some attachments) or plastic wrap.

Mounting

Figure 4.27: Aligning guide pin with mounting hole.

5. Move the two swing-bolts into the slots of the tine attachment. Alternately tighten each bolt until they are tight enough to make the concavewashers flat.

Thebolts must be very tight - if you have

a torque wrench, tighten each bolt to between 70 and 80 ft.-Ibs.

Some attachments have a drive shaft or a hydraulic pump that is powered by the engine on the PTO Power Unit. These units are called Stationary Attachments, since they remain in one location when operating. Attachments can be towed to a work site with the PTOPower Unit as described in OperatingNon-Powered

Attachments. Other attachments are pulled or towed behind the PTOPower

Unit. These attachments are called Non-

PoweredAttachments.

Setting Up Stationary

Attachments

To help avoid personal injury,

never

allow people to ride on any PTO Power

Unit or attachment.

IMPORTANT: The swing-bolts must be kept very tight to prevent damaging wear to the dog clutch coupling, alignment pin or the alignment hole= Check bolt tightness every 2-I 12 operating hours=

6. Removethe engine support before moving the tiller in a forward direction.

1. Move the Tines/PTOClutch Lever to

DISENGAGE.

2. Move Wheel Speed Lever (Figure4-22)

(Figure 4-29) to prevent the equipment from rolling.


Setting Up

Non-Powered Attach-

ments

1. Move the Tines/PTO Clutch Lever

(Figure 4-22) to DISENGAGE.

2. Move the Wheel Speed Lever (Figure

4-22) to either SLOWor FASTposition

To do this, roll the PTOPower Unit while shifting lever until wheels engage.

3. Verify that the Forward Interlock Wire

Harness plug at the base of the handlebars (A, Figure 4-28) is connectedto the

ForwardInterlock Wire Harnessreceptacle (B) on the top right side of the transmission.

2. To apply power to PTO-drivenattachments, move Wheels/Tines/PTOLever

(Figure4-22) down to FORWARDposition

(do not use REVERSEwith stationary

attachments).

3. To stop the PTOPower Unit, tap the

Wheels/Tines/PTODrive Lever upward into NEUTRALposition.

Figure 4.28: Forward Interlock Wiring

A.

PTO Power Unit Interlock Harness

B. Forward Interlock Receptacle

C - Attachment

Interlock Wire

3. On the PTOPower Unit, unplug the

Forward Interlock Wire Harnessthat leads from the baseof the handlebars (A, Figure

4-28) to the receptacle(B) located on the top, right side of the transmission cover.

4. On the Stationary Attachment, locate the interlock wire (C, Figure 4-28) and clean contacts on plug and receptacle (B).

This connection enablesyou to operate the Wheels/Tines/PTODrive Lever in

FORWARDwithout having to squeezea

Forward Interlock Lever.

5. Connectthe plug from the Stationary

Attachment (C, Figure4-28) to the receptacle on the PTO Power Unit (B). The connection must be tight.

Starting The Engine

IMPORTANT: Refer to Cold Weather

Operationinstructions, in this section, before operating in temperatures below

40°F.


Lever into NEUTRAL. To find NEUTRAL

(be sure engine is off), push lever down and engage it in FORWARDthen tap the lever upward to automatically move into

NEUTRAL.

2. Move the Tines/PTOClutch Lever into

DISENGAGEposition.

To avoid i_u_,do not run the enginein an enclosed or poorly vented area.

Engine exhaust contains carbon monoxide,an odorlessand deadly gas.

Operating Non-Powered Attachments

(or to Tow Stationary Attachments)

1. To move forward, squeezeand hold one Forward InterlockLever (Figure 4-30) up against the handlebars,and move the

Wheels/Tines/PTODrive Lever down to

FORWARD.

3. Start Engine. See Starting and

Stopping the Engine,in the beginning of this section, for detailed starting information. Also seethe Engine Owner's Manual.

4. For non-powered attachments only test the Forward Interlock SafetySystem. See

Testing the Forward Interlock Safety

System, in thissection, for a procedure.

Figure 4+30: Moving tiller forward: squeeze one Forward Interlock Lever and then move WheelslTineslPTO

Drive Lever down to FORWARD.

2. To stop forward motion, tap

Wheelsffines/PTO Drive Lever upward into NEUTRAL,then releasethe Forward

Interlock Levers.

Operating Stationary Attachments

1. Move Tines/PTOClutch Lever (Figure

4-22) into ENGAGE.

3. To stop forward motion in an emergency,releaseall PTO Power Unit controls (stops engine).

4. To move in reverse, reducethe engine speedthen shift theWheel Speed Lever into SLOW. Move and hold the

Wheels/Tines/PTODrive Lever all the way up. Ensurethat the area behind you is clearof all obstacles, before moving the lever into REVERSE.

5. To stop moving in REVERSE,release the Wheels/Tines/PTODrive Lever.

Stopping the Engine

Move the EngineThrottle Leverto STOP.

Turn keyswitch to OFFon electric start models.

Figure 4+29: Block wheels on PTO Power Unit and stationary

attachment.

29

30

n

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 personal injury or

propertydamage.

NOTE: All references to left, right, front and rear of the machine are determined by standing behind the handlebarsand facing the direction of forward travel.

REQUIRED MAINTENANCE SCHEDULE

PROCEDURE

Before Every Every Every

Each

10

25 30

Use Hours Hours Hours

As

Noted

Checkengine oil level

Every5 operating hrs.

Cleanengine cooling system

Test operation of Forward Interlock

Safety System

Forward Interlock Safety System checkwire condition,connections

Check battery electrolyte level and electrical connections

Recharge battery

Section 4

Checkdrive belt tension

Check nuts and bolts

Beforelafter long storage

After initial

2 hours

After initial

2 hours

Cleantiller fine shaft

Lubricate tiller

Changeengine oil*

Cleanfoam element air filter

Check paper element air filter

Checkfor oil leaks

More often in dusty or dirty areas

More often in dusty or dirty areas

After initial

2 hours

After initial

2 hours

Checkgear oil levelin both transmissions

Check bolo tines for wear

Check reversedisc for wear

Checkair pressure in tires

* During engine break-in period, change engine oil after first 2 hours of operation.

Section5: Maintenance

_

efore inspecting,cleaning or servicingthe machine, shut off engine, wait for all moving parts to come to a complete stop, disconnectspark plug wire and move wire away from spark plug. Remove ignition key, if so equipped.

Failure to follow these instructionscanresult in serious personalinjury or propertydamage.

Tighten

Bolts and Nuts

Checkfor loose or missing hardware every ten (10) operating hours. Failureto tighten or replacefasteners can cause poor performance, equipment damageor oil leakage. See your Parts Catalog for complete fastener descriptions.

Most hardware on your tiller is visible.

Pay particular attention to hardware shown in Figures 5-1, 5-2, 5-3 and 5-3A.

I. Checkthe transmission pulley mounting bolt (Figure 5-I).

If the washer behind the bolt head is loose, the bolt needs tightening. To do this, first insert a punch or thick screwdriver into the hole next to the bolt and wedge the tool against the side of the motor mount casting. This immobilizes the pulley while you tighten the bolt.

2. Checkjam nut on left side of neutral plunger assembly(Figure5-2). If loose, immobilize bolt head with one wrench and use another wrench to tighten the nut.

3. Checkthe three rear bearing cap screws under the depth regulator mounting bracket (A, Figure 5-3). If any is loose, it can cause an oil leakor drive shaft end play.

4. Checkthe five bolts securing the tiller housing cover to the left side of the transmission (B in Figure 5-3). Gear oil can leakfrom a loose housing cover. To reach the bolts, remove the left side tine holder. See Bolo TineMaintenancein this

Section for tine holder removal directions.

5. Check both swing-bolts (C, Figure5-3) that connect the power unit transmission to the tine attachment. Both bolts should be checked every 2-1/2 hours of operation. If loose, wear can occur on the locating pin on the power unit, and cause enlargement of the locating hole in the tine attachment. Using a torque wrench, tighten these bolts to 70-to-80 ft.-Ibs.

6. Checkthe Iocknut that fastens the shifting linkage to the eccentric shifting lever (D, Figure5-3). Do not tighten the

Iocknut against the eccentric lever. It should be very close to, but not touching the lever.

7. Checkthe four bolts and nuts securing left and right fine holders to the fine shaft

(Figure 5-3A).

IMPORTANT: Give screws or bolts that go into the transmission housing a coating of non-hardening gasket sealant to prevent gear oil from leaking.

Tiller Lubrication

Proper lubrication of the tiller's mechanical parts is an essential part of good maintenance. Lubrication should be done after every ten (10) hours of operation.

Use ordinary motor oil (#30 weight or lighter) where oil is specified. Use a quality greasewith a metal lubricant where grease is recommended (regular grease is acceptable). Do not over lubricate. If there is a build-up of dirt, remove the build-up and re-apply oil or grease.

Figure 5-3A: Tine holder hardware

must be tight.

Figure 5-1: Check bolt on transmission pulley.

Figure 5-2: Check jam nut on plunger assembly.

Figure 5-3: Gently tilt tiller forward to check fasteners.

31


to a complete stop, disconnectspark plug wire and move wire away from spark plug. Remove ignition I

_

Fa ure to fo ow these nstructons can resu t n ser ous persona njury or propertydamage.

IMPORTANT: Do not allow oil or grease to contact the pulleys, drive belt or reverse disc. This can cause the belt or disc to slip on the pulleys.

Lubricate the numbered areas in Figures

5-4 and 5-5, as follows:

1. Oil the wheel shaft between the wheel hubs and the transmission housing

(A, Figure5-4).

2. Oil all pivoting and connecting points on the Wheels/Tines/PTODrive Lever and the Wheel Speed Lever (B, Figure5-4).

3. Greasethe face of the belt adjustment block (C, Figure 5-4).

4. Oil the Depth Regulator Lever, including the spring in the mounting bracket(D, Figure5-4).

5. Oil the full length of the throttle cable casing (E, Figure 5-4).

6. Oil threads on HandlebarHeight Adjustment Lever (F, Figure 5-4).

7. Grease left- and right-side engine mounting bars at the top, the middle, and bottom (G, Figure 5-4).

8. Greasethe zerk grease fitting located on the pivot point at the end of the Wheel

Speed Lever (H, Figure 5-4). If Wheel

Speed Lever has a greasefitting on pivot assembly, apply 2-to-3 strokes of multipurpose grease at beginning and end of tilling season.

9. Keepthe PTOaccess area well-greased

(I, Figure 5-5). If the Tines/PTOClutch

Lever becomes hard to move, squirt some oil into its access hole, and work it back and forth to disperse the oil.

Transmission Gear

Oil Maintenance

Checking for Oil Leaks

At 25-hour operation intervals, checkthe tiller for oil leaks. Inspect for oil accumulations on the tiller or the floor where it's stored.

If tilling during very hot weather, the gear oil may heat up and expand inside the transmissions. To allow for this oil expansion, both the power unit transmission and the Line attachment transmissions have oil relief vents (Figure 5-6).

Figure 5.6: Oil relief vent locations.

The vents allow small amounts of oil to seep out.

If a serious leak is discovered, please contact your authorized dealer or the

Factory Technical Service Department for service advice.

32

Figure 5.4: Tiller lubrication points

(wheel removed for clarity).

A small amount of oil seepageor wetness around a shaft opening or cover is no cause for alarm. But a heavy concentration of oil is more serious. You should tighten all bolts immediately, and replace any worn seals or gaskets.

It may be impossible to determine how much oil has been lost, so check the oil levels in the PTOtransmission and the tine attachment before using the tiller again. Add any necessary gear oil.

Serious damage to the transmission components can result from operation when gear oil levels are low.

Figure 5.5: Use grease liberally in PTO access area.

Checking Gear Oil Levels

Every 30 hours of operation, check the gear oil level in both the power unit transmission and the tine attachment transmission. Operatingthem while low on gear oil (even briefly) can cause serious damageto internal components.

Preparation

I. The transmissionsmustbe cool, since hot gear oil expands and gives a false reading.

2. The power unit transmission and the

Lineattachment transmission must be connected when checking (or adding) gear oil.

Checkingthe Power Unit Oil Level

I. Move the tiller to level ground. Move the Depth Regulator up so the tines rest on the ground.

2. Use a 3/8" wrench to remove the oil level check plug on the left side of the transmission housing (Figure 5-7).


_ efore inspecting,cleaningor servicingthe machine, shut off engine, wait for all movingparts to come

to a complete stop, disconnectspark plug wire and move wire away from spark plug. Remove ignition

key, if soequipped.

Failure to follow these instructionscan result in serious personalinjuryor propertydamage.

For Dipsticks With 'CheckCold"Marking

(Cold means 2 hours has passed since the tiller was used.)

I. Move the tiller to level ground.

2. Pull the Depth Regulator Lever back, then push it down all the way (to engage its top notch).

3. Place a sturdy support under the engine to prevent the tiller from tilting too far=

Figure 5-7: Remove oil level check

plug.

Gear oil should seep out if

the level is sufficient

3. If the oil level is correct, oil will seep out of the check hole (allow extra time in cold weather). If it does, the level is fine and you should replace thecheck plug. If no oil seeps out, seeAdding or Changing

Gear Oil.

Checkingthe Tine

AttachmentOil Level

IMPORTANT:

Two different gear oil checking procedures for the tine attachment transmission are described next.

Use the first procedure if the dipstick in your tine attachment has only a 'Check

Cold' marking. Use the second procedure if the dipstick has both cold and hot markings at the end.

First remove the dipstick from the tine attachment trans- mission (Figure 5-8) to see which type dipstick you have. Then replace the dipstick with markings on dipstick facing to rear.

4. Now slide three pieces of 2" x 4" lumber underneaththe drag bar- raising the drag bar about 4-112"above ground.

This elevation allows an accurate "cold" gear oil reading.

5. Wait two hours with tiller elevated

(allow more time if temperature is below

40°F).

6. Loosen and remove transmission dipstick (Fig. 5-8). Wipe it clean with a rag.

7. Hold dipstick so its markings face to rear of tiller. Lower it straight down into the sump hole to touchthe drive shaft inside (Fig. 5-8). Don't force or try to thread it back in; an incorrect reading will result.

8. Remove dipstick and check oil level. It should be anywhere within the crosshatched area or even slightly above the

Max marking. If correct, replace dipstick and remove the boards used as props.

9. If oil level was low, gear oil must be added before using the tiller. See Adding

or ChangingGear Oil next.

For Dipsticks WithHot/ColdMarkings

1. Move the tiller to level ground.

2. Pull the Depth Regulator Lever back, then push it down all the way (to engage its top notch).

3. Place a sturdy support under the engine to prevent the tiller from tilting too far=

4. Cold reading (preferred method):

(Two hours has passed since the tiller was used.) Place a 2" x 4" board (on edge) under the drag bar- raising the tiller and drag bar about 3-I12" aboveground.

Hot reading: (Tiller was operatedfor more than 30 minutes within the past hour.) Do not use the wood prop to elevatethe tiller.

5. Follow Steps 4, 5 and 6 given for the other dipstick type.

6. Removedipstick and check level. It should be within or above the "Cold" range marking if taking a cold reading. If taking a hot reading, the level should be within or slightly abovethe "Hot" range.

7. If the level is incorrect, see Adding or

Changing Gear Oil.

Adding or Changing Gear Oil

Forpartial fill-ups (just a few ounces or less), use SAE 140, SAE 85W-140, or SAE

80W-90 weight gear oil with an API rating ofGL-4or GL-5. Forfull replacement, use SAE 140 or SAE85W-140 gear oil with an API rating of GL-4 only. (At the factory, SAE85W-140 weight gear oil is used.)

IMPORTANT:

Do not use automatic transmission fluid or engine oil. They are too light in weight and will result in transmission damage=

The gear oil does not need to be changed.

Do so only if you know, or suspect, it is contaminated with dirt, sand or other foreign particles.

Gearoil is available at authorized dealers and most service stations, power equipment centers, or farm/heavy equipment outlets=

Capacities: Power unit transmission holds approximately 60 ozs.; Tine Attachment transmission holds approximately

12-112"ozs.

Figure 5-8: Checking gear oil level;

markings on dipstick (tine attach.

ment transmission) must face rear.

33


_ efore inspecting, cleaning or servicingthe machine, shut off engine, wait for all moving parts to come I

to a complete stop, disconnectspark plug wire and move wire away from spark plug. Remove ignition I

key, if so equipped.

Fa ure to fo ow these nstructons can resu t n ser ous persona njuryor propertydamage.

34

Adding Gear Oil to the

PTOPower Unit Transmission

1. Do steps 1 and 2 of Checking the

Power Unit Oil Levelon page 32.

2. Using a 3/4" wrench(or socket), remove the bolt securing the handlebar base to the top of the transmission (prop the handlebarsfirst to prevent them from falling).

Then, unplug the Forward Interlock wire harness receptacleat the bottom of the handlebars. Set the handlebar base and bolt aside on a clean surface. The bolt hole in the top of the transmission is the gear oil fill hole (A, Figure 5-9).

3. Slowly pour gear oil through a clean funnel into the transmission. Stop when gear oil begins to flow from the oil level check hole on the left side of the transmission (B, Figure 5-7).

4. Reinstall the oil level check plug.

Tighten it securely.

5. Reinstall the handlebars using the mounting bolt previously removed. Align the handlebars so they point straight backwards, not at an angle. Then tighten the mounting bolt securely.

6. Reconnect the Forward Interlock wire harness to the receptacle. Be certain it's secure.

7. Test operation of the Forward Interlock

Safety System. See Section 4 for a procedure.

Drainingand Filling the

PTOPower Unit Transmission

I. Placea shallow pan under the transmission gear oil drain plug (B, Figure

5-9).

2. Removethe oil levelcheck plug (Figure

5-7) with a 3/8" wrench. This vents the transmission for faster oil draining.

3. Slowly add gear oil in the dipstick hole.

Add I/2-ounce at a time to avoid overfilling. It takesabout 12-I12 ounces.

4. Take dipstick readings frequently. Stop when oil reaches "Cold" range marking on dipstick. Replacedipstick securely.

Figure 5-9: Gear oil fill hole (A) and

gear oil drain location (B).

3. Using the 3/8" wrench, remove the drain plug (B, Figure8-9).

The gear oil will drain quite slowly since it is thick.

After about two quarts havedrained, tilt the tillerforward so any oil at the rear of the transmissionwill drain out.

Drainingand Filling the Tine

AttachmentTransmission

I. The fine attachment transmission is not equipped with an oil drain plug. To drainjust a small amount of gear oil, remove the dipstick and tilt the attachment forward (first uncoupling it from the

Power Unit).

2. For complete drainage, remove the leftside fine assembly (refer to Bolo Tine

Maintenancefor instructions), then removejust one of the lower screws from the tiller housing cover (Figure8-10). To speeddrainage, remove the tine attachment dipstick to vent transmission.

4. Cleanthe drain plug threads, put nonhardening gasket sealant on the threads, and reinstall plug.

5. Refill the transmission with the correct amount of gear oil before operating the tiller again. When oil seeps from the oil level check hole, the right amount of gear oil has been added. Replace all plugs.

AddingGear Oil to the Tine

AttachmentTransmission

1. Select the right Depth Regulator Lever setting:

a. If filling an empty transmission, raise the Depth Regulator Lever so tines are on the ground.

b. If topping off the gear oil, move Depth

Regulator Lever down to engage its top notch.

2. Remove dipstick from fine attachment

(Figure 5-8).

Figure 5.10: Remove housing cover screw to drain tine attachment transmission

gear oil.

NOTE: If you find a plastic washer on the cover screw you remove, discard the washer. There is no need to install a replacementwasher.

3. Once all gear oil has drained, reinstall the housing cover screw securely (first coat its threads with non-hardening gasket sealant).

4. Be certain to refill the transmission with the correct amount of gear oil before operating the tiller again,


_

Drive Belt Tension

efore inspecting,cleaning or servicingthe machine, shut off engine, wait for all moving parts to come



Failure to follow these instructionscan result in seriouspersonal injuryor propertydamage.

Drive Belt Maintenance

Measuringand Adjusting

On a new tiller (or if a new belt is installed), the belt tension will probably need to be adjusted after thefirst two (2) hours of operation. Thereafter, check belt tension every ten (10) operating hours.

Maintaining the right tension is important to good tiller performance and long belt life. If too loose, the belt will slip on the pulleys, and be unable to deliver full power to the wheels and tines. A loose belt will also wear prematurely.

While checking belt tension,also inspect the belt for cuts, cracks, deterioration, etc. Don't continue using a belt that isn't in good shape. You're sacrificing tiller performance by doing so.

Tips on keeping the drive belt in top condition include:

• Always put the Wheels/Tines/PTODrive

Lever in NEUTRALwhen the tiller is not in use,

• Keep tensionadjusted correctly.

• Don't "speed shift" when moving the

Wheels/Tines/PTODrive Lever between

FORWARDand REVERSE.

3. The belt tension is correct if the front of the clutch roller is 1/4"-to-5/16" away from the face of the upright bracket that holds theadjustment block in place

(Figure 5-12). To measure this distance:

a_

Without moving the clutch roller, try inserting the 1/4"-thick, slotted end of the belt adjustment tool in betweenthe roller and the upright bracket. (The flat edge of the tool must be facing the roller.) Refer to

Figure 5-13.

b. If only the slotted portion of the tool will fit, the belt tension is correct.

c. If the slotted part of the tool will not fit in, the belt is too loose.

d. If the full thickness(5/16") of the tool easily fits in, the belt is too tight.

Figure 5-11: Use this belt adjust* ment tool to measure and adjust drive belt tension.

4. If the belt tension is correct, move the

Wheels/Fines/PTODrive Lever back to

NEUTRAL.

Figure 5-13: Insert slotted end of belt adjustment tool between roller

and bracket, with the flat side of the

slotted end facing the roller.

How to Measure Belt Tension

1. Before taking a measurement, be sure the linkages and pivot points on the

Wheels/Tines/PTODrive Lever are clean and lubricated. If there is any binding, you won't get true measurements. Also, you'll need the belt adjustment tool you receivedwith your new tiller (Figure

5-11).


Leverfully down to the FORWARD position. The clutch roller at the bottom of the lever should be positioned underneaththe belt adjustment block (Figure

5-12). Don't let the clutch roller move during the next few steps. If it moves, you'll get a false belt tension reading.

Figure 5-12: Shift into FORWARD and measure distance between roller and upright bracket using the belt adjustment tool.

How to Adjust Belt Tension

1. As described in thefollowing steps, drive belt tensionis adjusted by moving the adjustment block up or down.

Moving it down will tighten the belt; moving it up loosens the belt.

HINT: The distance the block moves approximately equals the distance the roller moves.

In most cases, the clutch roller will not have been very far out of position, so the adjustment block will only need to be moved slightly (up or down)=


Lever to NEUTRALposition. The clutch roller will come to rest anywhere on the face of the belt adjustment block, depending upon drive belt length and current belt tension adjustment.

35


_ efore inspecting,cleaning or servicingthe machine, shut off engine, wait for all moving parts to come I



Fa ure to fo ow these nstructons can resu t n ser ous persona njury or propertydamage.

3. Insert the belt adjustment tool through the hole in the side of the adjustment block, spacing the ends of the tool equally on both sides (Figure 5-14). Rotate the tool so the slotted end faces down.

36

Figure 5-14: With WheelslTineslPTO

Drive Lever in NEUTRAL, insert tool through hole in adjustment block.

4. Placethe Wheels/Tines/PTODrive

Lever in FORWARDposition. The arms of the clutch control yoke will be resting on the belt adjustment tool and the clutch roller should be engaged slightly beneath the adjustment block (Figure 5-15).

Figure 5-15: With Drive Lever in

FORWARD position, clutch roller should be engaged slightly beneath the adjustment block.

5. Use one hand to hold the drive lever in

FORWARDwhile using a 9/16" wrench to loosen (don't remove) the bolt at the back of the belt adjustment block (Figure 5-16).

The adjustment block should be free to move either up or down.

Figure 5.16: Hold Drive Lever while loosening bolt. Push lever down to tighten belt; pull up to loosen belt.

6. Push the drive lever down if the belt needstightening. Pull the lever up if the belt needsto be loosened. Hold the drive lever in place and tighten the bolt in the adjustment block firmly.

7. Let go of the drive lever and remove

the belt adjustment tool from the hole in

the adjustment block.

8. Check the tensionon the belt by following the previous instructions "How

to Measure Belt Tension."

NOTE: If the adjustment block is all the way down and the measurement between the clutch roller and the bracket is less

than 1/4",then a new drive belt is needed.

Replacing the Drive Belt

Removingthe Belt

1. Move Wheels/Tines/PTODrive Leverto

NEUTRALposition.

2. While kneeling on the right side of the tiller, create slack in the belt by reaching over to the left side of the pulleys and pushing in on the center of the belt with your finger.

3. Use your right hand to move the belt down and away from the lower pulley, in the direction of the engine (Figure5-17).

4. Push the belt upward to create slack in the belt (Figure 5-18).

Figure 5-17: First move belt off the

lower pulley.

Figure 5-18: Push belt upward to

create slack.

5. Lift the top half of the belt up and over the upper pulley and the rubber reverse disc, moving it in front of the reverse disc

(refer to Figure 5-19)=

6. Push the Wheels/Tines/PTODrive

Leverdown into the FORWARDposition.

This increasesthe distance between the upper and lower pulleys= Next, lift and pull the entire belt out between the pulleys

(Figure 5-20).

Replacingthe DriveBelt

1. PlaceWheels/Tines/PTODrive Lever in

FORWARDposition.

2. Squeezethe belt in the middle and insert one end in between the pulleys

(Figure 5-20).


_ efore inspecting,cleaning or servicingthe machine, shut off engine, wait for all moving parts to come I




Figure 5-19: Move top half of belt over pulley and reverse disc.

Figure 5_20: Shift into FORWARD and remove the belt.

3. Push belt forward then down until it is looped over the lower pulley (Figure

5-18). Do not yet seat it in either of the lower pulley's grooves.

HINT: A blunt object, like a ruler, can help you push the belt downward if needed.

4. Move the top half of the belt up and over the rubber reverse disc, but do not seat it in either of the grooves in the top pulley.

5. Placethe Wheels/Tines/PTODrive

Lever in NEUTRAL.

6. Move thetop half of the belt into the

HIGH Rangegroove (groove closest to the engine) on the top pulley (Figure

5-21).

Reverse Disc Inspection

The reverse disc is made of steel with a special, long-lasting rubber compound bonded to the disc rim. Since this is a

wearingpart, it should be inspectedafter every 30 operating hours.

1. Measurethe widthof the outside edge of the disc as shown in Figure 5-22.

Replace the disc before the rubber edge

wearsto a thicknessof 1/8" or less.

Failure to do so could cause the steel underneath the rubber to damagethe transmission pulley.

Figure 5-21: Seat belt in upper pulley, then in Iower pulley (High

Range position shown).

7. Move the bottom half of the belt into the HIGH Rangegroove of the lower pulley (groove closest to engine-- Figure

5-21). If extra shackis needed,hold up

Wheels/Tines/PTODrive Lever while moving the belt. Verify the belt is seated properly on the pulleys.

8. To move the belt to the LOW Range position, see Changing Belt Speedsin

Section 4.

9. After installing the belt, check and adjust for correct belt tension as explained previously.

Reverse Drive

System Maintenance

These instructions explain how to inspect, replace or adjust thevarious reverse drive components,

But first, here's how the reverse drive system works: When you raise the

Wheels/Tines/PTODrive Lever up in

REVERSEposition, this lowers the rubberized reverse disc (it's attached to the engine drive pulley) until this rotating disc contacts thetransmission drive pulley=

The friction between the rotating reverse disc and the transmissionpulley causes the transmissiondrive shaft to be powered in a counterclockwise direction

(asviewed from the operator's position behind handlebars)= The drive shaft then turns the wheels and tine shafts in a reverse direction.

Figure 5.22: Measure the edge of

the reverse disc for wear.

2. Look for big cracks or missing chunks of rubber from the disc. If so damaged, the disc should be replaced immediately.

IMPORTANT: Extend the life of the reverse disc by always pausing in

NEUTRAL before shifting between

FORWARD and REVERSE. Also - the reverse disc is not suited for continuous or sustained reverse operation.

Use reverse sparingly.

37



to a complete stop, disconnectspark plug wire and move wire away from spark plug. Remove ignition I



Replacing the Reverse Disc

Followthese steps to replace the reverse disc. (If your tiller has a Bumper Attachment mounted, it must be removed first.)

Removingthe ReverseDisc

1. Move Wheelsfrines/PTO Drive Lever in

NEUTRALposition.

2. Wedge a 5/16"-thick board between top of engine pulley (avoidcontacting reverse disc) and cast iron housing next to it.

This immobilizes pulley.

3. Use a 9/16" wrench to loosen the mounting bolt shown in Figure5-23.

Rememberto immobilize the pulley with the wood wedge while loosening the bolt.

If necessary,pry the disc from the pulley with the tip of a screwdriver. Back the bolt out as far as possible. Then angle the disc a little to remove it. Bring the bolt and Iockwasher along with the disc.

and engine mount move down to press on the reverse adjustment bolt (Figure 5-

24). This action compresses the reverse spring and plunger assembly, requiring you to hold the lever up in REVERSE.

Whenyou releasethe lever, the spring automatically pushes the lever back into

NEUTRALposition.

The spring and plunger assembly is designedto prevent the reverse disc from making contact with the transmission pulley until you shift into REVERSE.

Whenthe lever is in NEUTRAL,the switch body on the bottom of the engine mount tab should be resting squarely on top of the reverse adjustment bolt (Figure 5-24).

The reverse adjustment bolt can be adjusted up or down to correct a number of reverse drive operating problems, as explainednext.

ment bolt should be adjusted upward (see instructions thatfollow). Moving adjustment bolt upward will also solve problem of a tiller that goes into REVERSEon its own.

Figure 5.25: Checking Reverse

Disc in NEUTRAL.

3. Use your left hand to hold

Wheels/Tines/PTODrive Lever up in

REVERSE,while briefly pulling out engine start rope. The reverse disc should turn lower pulley (see Figure 5-26). If not, or it requires a lot of pressure to hold lever up in REVERSE,then reverse adjustment bolt must be adjusted downward. When correctly adjusted, the Wheels/Tines/PTO

Drive Lever should pop out of reverse when the lever is released, but not require exceptional effort to hold it up in reverse position.

Figure 5-24: Spring and plunger assembly.

Figure 5-23: Removing Reverse Disc.

InstallingaNewReverseDise

1. Do steps 1-through-3, described previously, in reverse.

2. Tighten mounting bolt securely, and check for correct operation -- see

Checkingand Adjusting ReverseDrive

System.

38

Checking and Adjusting

Reverse the Drive System

Whenthe Wheels/Tines/PTODrive Lever is moved up into REVERSE,the engine

CheckingandAdjustingReverse Disc

1. Verify that linkagesfor

Wheels/Tines/PTODrive Lever are lubricated with oil and engine mount bars and belt adjustment block are lubricated with grease. (See Tiller Lubrication in this section.)


NEUTRAL. Briefly pull out engine recoil start rope while watching reverse disc.

The disc should turn, but lower pulley should not (Figure5-25). If reverse disc turns lower pulley, or if it is located closer than 3/16" to the pulley, reverse adjust-

Figure 5-26: Checking Reverse Disc in REVERSE.

4. Shift the Wheels/Tines/PTODrive Lever to REVERSEand then let it go. The lever should return to NEUTRAL. If not, the reverse adjustment bolt will have to be adjusted upward.


Before inspecting, cleaning or servicingthe machine, shut off engine, wait for all movingparts to come I




AdJustingReverse Drive:


FORWARDposition.

2. On left side of tiller, put a 1/2" wrench on the plunger retaining bolt and another

1/2" wrenchon thejam nut next to it

(Figure 5-27). While holding the bolt steady, loosen thejam nut (counterclock-

wise) until it touchesthe bolt head.

7. Placea chalk or pencil mark on the top edge of the plunger retaining bolt. Now,

whilewatchingthe mark, loosen the bolt

3/4-turn (Figure 5-29). Do not exceeda

3/4 turn (this would disengagethe bolt from the locking groove in the side of the plunger).

Bolo Tine Maintenance

Checking Tines for Wear

Inspectthe tinesfor wearor damage after every 30 operating hours. The rate of

weardepends upon hours of use and soil conditions. With use, the tinesget shorter, narrower and more pointed

(Figure 5-30). If badly worn, theylose the ability to till deeply.

Figure 5.27: Hold bolt steady while loosening or tightening jam nut.

Figure 5-28: Loosen jam nut before turning reverse adjustment bolt.

8. Hold the plunger retaining bolt steady with a wrenchwhiletightening thejam nut against the side of the plunger housing

(Figure5-27),

Figure 5-30: Check for wear every 30 operating hours.

Worn tines leavean ever-increasing gap in the middle of a tilled row. The normal gap is 3" between the tine tips - replace the tines when the gap widens to 5"

(Figure 5-31),

3. Turn the bolt in until it tightens against the plunger inside the spring, The bolt must be tight to prevent plunger from turning - but be careful not to overtighten

and break the bolt.

4. Placea 7/8" wrench on the head of the reverse adjustment bolt and a 9/16" wrench on thejam nut below it (Figure 5-

28), Hold the bolt steady while loosening thejam nut three or four turns.


Leverto NEUTRAL. The switch body on the bottom of the engine mount tab

(Figure 5-24) should be resting squarely on top of the reverse adjustment bolt, and the reverse disc should be at least 3/16" away from the transmission drive pulley.

If the reverse disc is any closer than this, raise the reverse adjustment bolt (turn it counterclockwise).

6. Check that reverse disc is at least 3/16" away from transmission drive pulley,

Then hold reverse adjustment bolt steady with one wrench while tighteningjam nut with a second wrench (Figure 5-28).

Figure 5-29: Loosen plunger retaining bolt about 314.turn, then tighten jam nut against plunger housing.

9. Checkthe action of the reversedisc as explainedpreviously.

IMPORTANT: If the above adjustments have not corrected an improperly working reverse drive, contact an authorized dealer or Factory Technical Service

Department for assistance.

Figure5.31: Replace tines when gap

between inner tines is 5" or more

(normal gap is 3").

Tines can be replaced individually or as a complete set. See replacement instructions that follow.

39


49





Single Tine Replacement

The tines or tine hood edges may be sharp.

Wear thick gloves to protect

your handsfrom cutsor scrapes.


Lever to NEUTRAL,the Wheel Speed

Lever to either FASTor SLOWposition, and the Tines/PTO Clutch Lever to

ENGAGE.

2. Gently tilt the tiller forward until the engine rests on the ground.

3. Raisethe hood flap at the back of the tiller and tie it up with string.

4. Beforeremoving a tine, note in which direction the bent tip points. The new tine must be installed in the same direction.

5. Usetwo 9/16" wrenchesto remove the two bolts and nuts securing the fine to the tine holder plate (Figure5-32). Use penetrating oil on the hardware if it is rusted or hard to remove.

Removingand ReplacingA Tine

HolderAssembly

• The tines or tine hood edges may be

sharp. Wear thick gloves to protect your hands.

4. Use a soft mallet to drive the holder off the tine shaft. (Use a heavy hammer and block of wood to knock off the immobilized tine holder.)

5. When the holder is off, clean all dirt and debris from the shaft and the holder.

Apply fresh grease to the fine shaft.

• Wear safety goggles to protect your eyes. When loosening hardware, do not hit a wrenchwith a metal tool- this could shatter the tool or wrench, sendingmetal particles into your eyes.

Replacing TinesHolder Assembly

1. Replacethe holder so the sharp tine edges face forward (toward front of tiller)=

Tapfine holder back on thefine shaft.

The 16 Bolo Tines are mounted eight per side on left-side and right-side fine holders - on either Style A or Style B holders (refer to Figures 5-33 and 5-34 to see which style tine holder you have).

Style A tines holders are secured to the fine shaft with two bolts and two nuts. Style B tines holders are secured with a single end bolt to the left and right sides of the tine shaft. Here's how to replacethe tines and holders as assemblies.

2. Greasethe threads on the mounting bolt(s). Installand tighten the bolt(s) securely=

Non-Tapered Tine Shaft

Figure 5-32: Removing a single tine

requires taking off lwo bolts and

lwo nuts.

RemovingTine HolderAssembly

1. Follow steps 1-through-3 in

Single TineReplacementabove.

2. Identify the tine holders as

Style A or Style B, then as left-

Right-Side

Tine Holder

side and right-side holders - they

must be replaced on the same side from which they were removed. Use a piece of chalk or a greasepencil to mark them L and

R.

Left-Side

Tine Holder

Figure 5.33: Style "A" Tine Holders.

6. Mount the newfine exactly the way the old tinewas positioned. (Thesharp edge of the fine, which enters the soil first, must face forward when abovethe tine shaft.)

Replacethe bolts and nuts and tighten them securely.

3. With Style A holders, remove the

two bolts and nuts securing each holder (Figure5-33). With Style B holders, remove the single bolt

(along with the washers) from the end of the fine shaft (Figure 5-34).

Right-Side

Tine Holder

Left-Side

Tine Holder

Figure 5.34: Style "B" Tine Holders.


_

Tine Shaft Maintenance

After every 10 operating hours, remove the left- and right-side Bolo Tine holders and clear away dirt and debris that have accumulated on the Oneshaft or inside the Oneholders. Pleasefollow this maintenance recommendation, as debris can cause premature wear to the Oneshaft and its oil seals. Refer to the previous tine holder removal instructions. After cleaning away any debris and removing old greasefrom the tine shaft, apply fresh grease to the tine shaft.

Tire and Wheel Maintenance

Checktire air pressure every 30 operating hours. The recommended pressure for tilling is 104o-20 psi (pounds per square inch). Both tires should be inflated equally. (Unequal pressure can cause the tiller to pull to one side.)

Removing the Wheels

Eachwheel is secured by a roll (spirol) pin that passesthrough the wheel hub and the wheel shaft. Drive the roll pin out to remove a wheel.

1. Prop the transmission up with a sturdy block to raise the wheel you want to remove off the ground.

2. Move the Wheel Speed Lever to either

SLOWor FASTposition to prevent the wheels from turning.

3. Use a 5/16" drift pin (or a blunt point

16-penny nail) to drive the roll pin free.

Wear safety goggles when driving the

roll pin into or from the wheel hub to

protectyour eyes from the possibilityof flying metal particles.

Engine

efore inspecting, cleaning or servicingthe machine, shut off engine, wait for all movingparts to come



Failure to follow these instructionscan result in serious personalinjuryor propertydamage.

Oil Maintenance

Checkthe engine oil level before starting the engine each day and after each 5 hours of continuous operation. Running the engine when it is low on oil will quickly ruin the engine.

It is recommended that you changethe oil every ten (I0) operating hours and even sooner when operating in extremely dirty or dusty conditions. Refer to the separate

Engine Owner's Manual for detailed service instructions.

Spark Plug Maintenance

The spark plug must be in good condition for proper engine operation. Remove and inspect the plug every 50 operating hours or annually, whichever occurs first.

Air Cleaner Maintenance

The engine is equipped with a dual element air cleanerthat filters the air twice before it enters the carburetor to mix with the fuel.

The engine air cleaner filters dirt and dust out of the air before it enters the carburetor. Operating the engine with a dirty, clogged air filter can cause poor performance and damage to the engine. Never operate the engine without the air cleaner installed. Inspect and servicethe air cleaner more often if operating in very dusty or dirty conditions.

It is critical that the filters be kept clean and properly installed at all times. See the location of the air cleanerassembly on your engine by referring to Figure5-39 or

Figure 5-40.

Refer to the engine manufacturer's literature supplied with your tiller for complete air cleaner service and maintenance information.

Throttle Cable Maintenance

The throttle lever settings are factoryadjusted, so unnecessary adjustments should not bemade. However, if the engine does not start or stop, or respond immediately to various throttle lever settings, then adjustments may be necessary. Pleaserefer to the engine manufacturer literature supplied with your tiller for specific adjustment instructions.

Ignition System Maintenance

Your engine is equipped with electronic ignition. It does not havea condenser or points, so there is no need to perform any regular tune-up maintenance on this system other than adjusting or replacing the spark plug.

The correct electrode gap is .030". Check the gap with a feeler gauge. Do not use a spark plug if the porcelain is cracked, the electrodesare pitted or burned, or if other visible damage is present.

NOTE: Do not wire brush or sandblast the spark plug to clean it - loose particles can enter the engine, causing damage!

To replacethe plug, first tighten it securely by hand, then use a spark plug wrench to tighten the plug an extra 114 turn.

Battery Care and Maintenance

Battery Care in Service

I. Every month or every ten (10) operating hours, whichever comes first, checkthe level of electrolyte solution in the battery cells:

a. If battery case has UPPERand

LOWERlevel lines on it, solution should be maintained at the UPPER level line.

b. If the battery does not havelevel lines on case, maintain solution levelat lowest part of the filler well within eachcell.

NOTE: Use only distilled or demineralized water to refill eachbattery cell.

c. After filling, replace battery caps securely, then wash off any spilled solution with baking soda and water mixture.

d. Run engine outdoors for about 20 minutes (at 3/4 throttle) to help recharge. For safety, do not leave the tiller unattended while the engine is running.

41


_

efore inspecting,cleaning or servicingthe machine, shut off engine, wait for all moving parts to come to a complete stop, disconnectspark plug wire and move wire away from spark plug. Remove ignition key, if so equipped.

Failure to follow these instructionscan result in serious personalinjury or propertydamage.

42

POISON- CAUSESSEVEREBURNS

• Electrolyteis a sulfuricacid solution.

• Avoid contact with skin, eyes and

clothing.

• To preventaccidents, wear protective

clothing, rubber gloves, and shield eyes with safetygoggles.

• Neutralize

acid spills with baking soda and water solution.

Neutralize

empty container with baking soda and rinse with water.

ANTIDOTE:External- Flush with water.

Eyes- Flush with water for 15 minutes

and get prompt medical attention.

ANTIDOTE:Internal- Drink large quantities of water or milk. Follow with milk of magnesia, beaten eggs or vegetable oil. Call physicianimmediately.

KEEPOUT OFREACHOF CHILDREN

DANGER-- BATTERIESPRODUCE

EXPLOSIVEGASES

• Keep sparks, flame, cigarettes away

at all times.

• Only charge or use the battery in a

well-ventilated area.

3. Periodically check entire electrical system for loose connections or loose hardware.

4. Check hardwaresecuring the battery holddown clamp. It should be secure, but not overly tight.

5. Checkvent tube. It must not be crimped or bent.

To help avoid personal injury, be sure the battery vent tube is not crimped or

pinched anywhere along its length.

Improper venting could result explosionof batterygases.

in an

Battery Care in Storage

Your engine has a recharging circuit that will properly maintain the battery's state of charge during the normal tilling season. However, prior to storing your tiller away during the off-season, we recommend the battery be fully charged.

At the end of the storage period, the battery should be recharged again=

• Make sure venting path (vent tube) of

battery is alwaysopen.

Never touchthe positive (+) battery post

and any other surrounding metal with

tools, jewelry,

or other metal objects.

Doing so can cause a short circuit that could result in electrical burns, an electrical shock,or explosionof battery gas.

2. Keep battery clean. If terminals are corroded, remove battery and clean terminals with wire brush, sandpaper or steel wool (Avoid getting any of this

corrosive material on your skin or in your

eyes.) Rinse battery with a solution of baking soda and water. Coat terminals with petroleum jelly or silicone greaseto prevent further corrosion.

2. Cleanbattery if needed. If battery is very cold, let it warm up to 60-to-80OF.

when filling and charging.

4. Carefully check electrolyte level. If low, add distilled or demineralized water (do

not add battery acid) to bring the check for gassing, wear protective goggles and inspect each cell with flashcharge battery:

a.

3. Removefiller caps. Keepthem off solution level in eachcell up to correct height. Avoid overfilling.

5. Charge battery (with caps removed) until all cells are gassing freely. (To light for bubbling of electrolyte solution.)

Use one of the following methods to

RecommendedMethod: charge the battery at a rate of 1-to-2 amperes until cells are gassing freely. Do not exceed24 hours charging time.

b. First Alternative Method: charge battery

C_

at 4-to-6 amperes until cells gas freely.

Do not exceed 8 hours charging time=

SecondAlternative Method: charge the battery at a rate of 6-to-12 amperes until cells gas freely. Do not exceed 4 hours charging time.

• While the battery is being charged,

do not leave it unattended. Charging

time does not have to be continuous.

• Carefullyfollow all charging instruc-

tions and safety rules provided by the manufacturer equipment.

of the charging

• Never attempt to "jump start" the

battery with an automobile battery or its charging system. This could result in serious personal injury or property

damage from causes such as a battery

explosion,or acid or electrical burns.

6. When battery is fully charged, turn charging equipment off and disconnect the cables. Check electrolyte level in all cells. Add distilled or demineralized water if necessary to adjust level to the correct height. Then reconnectthe charger cables to the battery and chargethe battery for one more hour.

1. Remove battery from tiller (see Battery

Removal instructions) and placeon a stable, level surface.

Do not charge the battery at a rate

higherthan 12 amperes. A chargerate greater than this generates excessive heat and gassing, and will permanently damage the battery.


_

7. Replacethe filler caps and wash off any spilled electrolyte with a baking soda and water solution.

efore inspecting,cleaning or servicingthe machine, shut off engine, wait for all moving parts to come



Failure to follow these instructionscanresult in serious personalinjury or propertydamage.

1. Check insulated wire harness from lower ends of handlebars to wire harness connector on top, right side of transmission cover. Be sure connector is secure.

8. Store the battery in a cool, dry location. Avoid freezing temperatures.

Batteries lose voltage when in storage, more so in hot weather than in cold.

Ideal storage temperature is 50OF.

2. Check insulated tubingfrom connector to cast iron motor mount/belt shroud.

Battery Removal and Replacement

1. Disconnect the negative (-) cable from the grounding screw on the right side of the battery bracket (A, Figure 5-42) and bend the cable away from all metal parts.

2. Disconnect negative cablefrom negative (-) battery post (B, Figure 5-42), and remove cable.

Figure 5.42

3. Protect the engine from deterioration or damage by referring to the engine storage instructions in your engine manual literature.

3. Check the wire leading from the tubing over to the switch assembly mounted on top of the tab on the cast iron motor mount-belt shroud. Also check the second wire that leads to the throttle cable mounting bracket on the right side, forward portion of the engine.

3. Disconnect positive (+) cablefrom positive battery post (C, Figure 5-42) and bend it safely away from metal parts.

Cover cable terminal with rubber boot.

4. Removethe battery holddown clamp and remove the battery.

5. Reversethe previous steps to replace the battery. The battery postsmustface the rear of the tiller.

(The positive post must be on the left side as you face forward from the handlebars.)

6. Insert the vent tube (on positive side of battery) into the vent tube shield. Be sure it is not crimped, pinched or folded along its length.

When removingthe battery, always dis-

connect the negative (-) cable first followed by the positive (+) cable. Re-

verse this procedure when reinstalling the battery.

Storing Your Tiller

When yourtiller won't be used during the off-season, prepare it for storage with the following steps:

1. Cleanthe tiller and engine.

2. Do routine tiller lubrication and check for loose hardware.

4.

When engine is still warm, drain oil from engine crankcase. Refill with flesh motor oil.

5. Protect internal cylinder against rust by removing spark plug and pouring one ounce of clean engine oil into spark plug hole. Then slowly pull out recoil start rope 2 or 3 times to distribute oil internally. Replace spark plug, but do not reconnect plug wire. Pull rope until resistance is felt -- let rope rewind.

6. Chargebattery (electric start option).

Store battery in cool, dry location.

7. Move Wheels/Tines/PTODrive Lever to

NEUTRALposition. Keep tiller in a clean, dry area.

8. Never store tiller with fuel in fuel tank in an enclosed area where gas fumes could reach an open flame or spark, or where ignition sources are present (space heaters, hot water heaters,furnaces, etc.).

Inspecting Forward Interlock

WiringSystem

Checkthe Forward interlock wiring system every ten (10) operating hours, for tight connections and to seethat the insulation on the wires is unbroken (to prevent the system from shorting out).

Testing the Forward

Interlock Wiring System

The wiringcircuit for the Forward

Interlock SafetySystem is designed to ground out the engine's ignition system.

There are three switches in the circuit which, when open, let the engine run.

One switch is on the neutral plunger tab of the cast iron motor mount. This switch is open whenever the Wheels/Tines/PTO

Drive Lever is in NEUTRALor REVERSE positions. The other two switches are located inside the handlebars, directly abovethe two Forward Interlock Levers.

The switches are wired so when squeezed

(open) the engine will run. There is a fourth switch located in the wiring harness connector on the top, right side of the transmission cover. It warns you if the connection is not mated by not letting the engine run while the Wheels/Tines/PTO

Drive Lever is in FORWARD.

1. A broken or disconnected wire could let the engine run without you having to press one of the Forward Interlock Levers.

2. A bare wire touching tiller or engine metal could ground out the engine's ignition.

3. A switch that has failed allows the engine to run. Or it may prevent the engine from running.

Refer to the Troubleshootingsection if your Forward Interlock SafetySystem is not operating correctly.

43

AppendixA: Troubleshooting

44

CHECK OR TEST

(Checkor test in sequence shown until problem is resolved.)

PROBLEM

Engine won't start

Engine shutsoff when

Wheels/Tines/PTO Drive

Lever is ahiRed into

FORWARD

Engine does not shutoff when Forward Interlock

Levers are released while

Wheels/Tines/PTO Drive

Lever is in FORWARD

Throttle Lever in START position

Wheels/Tines/PTO Drive Lever in NEUTRALposition

Forward Interlock Wire Harness connector securely mated

Forward Interlock Levers not being squeezed prior to shifting Wheels/

Tines/PTO Drive Lever to

FORWARDposition

Visually inspect for bare, broken or disconnected wires

Check handlebar wire harness

Check transmission wire harness

X

X

X

X

X

X

X

X

X

X

X

Troubleshooting Procedures

1 Wheels/Tines/PTO Drive Lever:

A. Lever does notstay in FORWARD-

. Drive belt may be too tight. Raise belt adjustment block a little (Sect. 5).

• Clutch pawl spring at end of lever may be overstretched, install new spring.

B. Lever hard to shift into REVERSE-

. Check reverse disc for wear (Sect. 5).

• Check adjustment of reverse disc and/or reverse spring and plunger assy. (Sect. 5).

• Clean and re-lubricate motor mount bars, belt adjustment block and linkages on lever

(Sect. 5).

C. Tiller staysin REVERSEwhenlever is released-

. Lubricate motor mount bars, belt adjustment block and linkages on lever (Sect. 5).

• Check adjustment of reverse spring and plunger (Sect. 5). If problem persists, contact Technical Service Department.

D. Leversticks in FORWARD-

. Lubricate motor mount bars, belt adjustment block, and linkages on lever (Sect. 5).

If problem continues, contact the Technical

Service Department.

E. Leverhard to shift into FORWARD-

. Follow advice for Problem 1-D. Also check for possible bent motor mount bar that could be binding in engine mount holes.

2 Wheel Speed Lever:

A. Lever hard to shift, or sticksin FAST or

SLOW wheel gear positions-

Figure 5-43: Check connecting rod, shifting linkage and eccentric lever.

• Lubricateeccentricleverat rearof power unit transmission(Figure5-43). If rust is present,usepenetratingoil and work eccentricleverbackandforth by hand.

• Lubricatelinkageto WheelSpeedLeverto eccentriclever(Figure543).

• Clutchinsidetransmissionmay be binding.

Disconnectlinkagefrom eccentricleverand work eccentricleverby hand. If difficult or impossibleto move,it may be dueto a damagedkeywayon thewheelshaft.

ContactTechnicalServiceDepartment.

• Lubricatewashersandcastlenut on pivot of lever. If necessary,removeroll pin and back nut off 1/6thturn. Replaceroll pin and test the movement.

• Applygreaseto zerkfitting (if so equipped) with greasegun until greaseappearsaround washers.

B. Levershifts into FASTwheel gear, but not into SLOW wheel gear-

. Connecting rod at end of lever might be backwards, or bent in toward transmission housing and hitting it. Other shifting linkage might be bent. Straighten or replace linkage

(Figure 5_43).

• Clutch inside transmission may be binding

(Problem 2_A).

C. Levermoves freely, but won't shift in or

out of gear-

• Eccentric shifting pin inside transmission may be broken (rare) or worn Disconnect linkage from eccentric lever and try moving eccentric lever by hand (Figure 543).

If lever moves easily, contact the Technical

Service Department.

3 Wheels and Tines Won't Turn:

• Review operation of controls (Sect. 3 & 4).

• Check condition and adjustment of drive belt and reverse disc (Sect. 5).

• Mounting bolt for transmission drive pulley may be loose. (See Figure 5q).

If so, drive belt or reverse disc will turn pulley, but pulley won't turn main drive shaft.

• Worm gears that drive wheel and tiller shafts may be worn.

4 Wheels Turn, But Tines Won't:

• Tines/PTO Clutch Lever must be in ENGAGE position (Sect. 3).

• Tines/PTO Clutch Lever may need adjustment.

• Keyfor dog clutch on fine attachmentmain driveshaft may be missing,broken.

• Wormgearsthat drivethe tine shaft may be worn.

AppendixA: Troubleshooting

• Hardware holding tine holders to tine shaft may be missing or broken. To check, remove holders (Sect. 5).

• Key for bronze worm gear on tine attachment main drive shaft may be missing or broken.

5 Tines Turn, But Wheels Won't:

• Check operation of Wheel Speed Lever

(Problem 2).

• Hi-Pro key inside wheel clutch may be missing, broken, if so, clutch will not turn wheel shaft.

• FASTand SLOW speed wheel gears may be worn. if only one gear is worn, there will only be one wheel speed.

• Worm gear that drives pinion shaft and pinion gears may be worn.

• FASTand SLOW speed pinion gears may be worn. if only one gear is worn, there will only be one wheel speed.

• Drive "dogs" on sides of wheel clutch may be worn or broken, if only one side of clutch is affected, there will only be one wheel speed.

6 Wheels And Tines Turn On Top Of

Ground, But Stop Or Hesitate In Soil:

• Drive belt may be loose (Sect. 5).

• Mounting bolt for transmission drive pulley may be loose (Figure 5-1).

7 Tiller Jumps While Tilling:

• Depth Regulator Lever set too deep for soil conditions.

Use a shallower setting.

• Engine throttle speed too fast.

• Tiller wheel speed too fast for soil conditions. Change to LOW belt range or SLOW wheel speed.

8 Depth Regulator Lever

Difficult To Move:

• Lubricate spring assembly and depth adjustment bar (Sect. 5).

• Check for bent depth adjustment bar.

9 Wheel And Shaft Move

Out To One Side:

• Snap ring on wheel shaft may be dislodged. Raisewheelsoffground and check for back and forth play in shaft, if there is play, one or both snap rings is loose.

10 Tiller Pulls To One Side:

• Check tire pressure (Sect. 5).

11 Tine Holder Bolt

Breaks Or Loosens:

• Earlier models have fine holder keys.

Check that keys are in keyways of tine shaft.

Without key in holder, left-side tine bolt will tighten and break; right-side bolt will loosen

(Sect. 5).

12 Poor Traction:

• Bar tread tires, tire chains, or wheel weights may be needed.

13 Gear Oil Leak From Power Unit Or Tine

Attachment Transmissions:

• See Section 5.

14 Engine Lacks Power:

• *Air cleaner restricted with dirt and/or oil.

• Spark plug wire loose or damaged. Spark plug worn or fouled.

• Engine under excessive work load. Use

SLOW wheel speed and LOW belt range.

• *Throttle cable may be loose or misadjusted.

• Verify that engine isn't running with choke partially engaged.

• * Check Carburetor adjustment.

• *Engine overheating. Check oil level and clean cooling fins. Oil may be very dirty. Let hot engine cool before restarting.

• *Dirt or water in fuel or fuel system.

• Engine crankcase low in oil, or overfilled with oil. Check and adjust level.

• * Low engine compression.

15 Engine Difficult To Start:

• Wheels/Tines/PTO Drive Lever not in

NEUTRALposition.

• Fuel tank low or empty.

• Dirt or water in fuel or fuel system.

• Fuelline is restricted.

• Choke control not set properly.

• Spark plug worn or fouled (weak spark).

• Air cleaner restricted with dirt and/or oil.

• Throttle cable adjustment.

Engine throttle lever not free to move through its full operating range.

Throttle wire and its linkage are binding, or are bent and not free to move.

Low engine compression.

16 Engine Won't Start:

See Troubleshootingthe Forward Interlock

Safety System in Section 5.

Wheels/Tines/PTO Drive Lever not in

NEUTRALposition.

Fuel tank low or empty. Or fuel line restricted or clogged.

• Choke control improperly set.

• *Water or dirt in fuel, and/or fuel system.

• *Spark plug fouled or worn. Spark plug wire loose or damaged.

• *Carburetor may need adjustment.

• *Air filter clogged with oil or dirt.

• Carburetor float faulty (or float valve leaking)- if so, tap side of bowl lightly with handle of screwdriver (or similar object).

• Stale fuel clogs carburetor, and valves.

Drain old fuel and add new fuel.

• *Fueltank shut-off valve (if soequipped) not in fully Openposition.

• On Briggs & Strattonengine,On/Offswitch not in ONposition.

ElectricStartEnginesOnly:

• Electricalconnectionslooseor shortedto metalframes,bracketsor covers(Sect.5).

• Batterydischarged(Sect.5).

• Electricstartermotor faulty.

17 EngineShutsOff WhenWheels/

Tines/PTODriveLever Is In Forward:

• See Troubleshootingthe ForwardInterlock

SafetySystemin Section5.

• Shortin key switch or key switch wire harness.

• Check starter motor mounting bolts for looseness. Have Authorized Engine Service

Dealer inspect the starter motor.

• Check oil level for correct amount.

18 EngineOverheats

• Cleantheenginecoolingfins, shroudand covers(Sect.5).

• Checkfor brokenflywheelfins (under engineshroud). SeeAuthorizedEngine

Dealer.

19 EngineRunsErratically:

• Water or dirt in gasolineor carburetor.

• Carburetormay needadjustment. See

EngineOwner'sManual.

• *Spark plug fouledor dirty. Sparkplug wire looseor damaged.

• *Loose or crackedcarburetor.

• Governorlinkagenot adjustedproperlyor binding. SeeAuthorizedEngineService

Dealer. Don't attemptto repairby yourself.

• Checkpan gasket,enginesealsand drain plugsfor leaks. Seeyour AuthorizedEngine

ServiceDealer.

20 EngineRunsWell,

ButLaborsUnderTillerLoad

• *Checkgovernorlinkagefor freedomof movement.

• Checkthrottle settingand carburetor adjustment. SeeEngineOwner'sManual.

• Tilling depthis possiblytoo deep. To correct,lowerthe depth regulatorlever.

• Possibleworntiller worm gearor loose driveshaft.

21 Key Switch Will Not

Start The Engine

• Check battery terminals for corrosion

(Sect. 5).

• Dischargedbattery(Sect.5).

• Defectivesolenoid.

45

* SeeEngineOwner'sManualor contactan authorizedenginedealerfor information.

46

Troy-Bilt® PTO Chipper/Shredder

The Troy-Bilt_ PTOChipper/Shredder provides a convenient, easy means of cleaning up unsightly brush piles and other organic matter on your property, with the added bonus of providing an unending supply of useful wood chips, mulch and compost for your landscaping and gardening needs.

The unit connects quickly to your tiller and goes wherever your tiller can go. The swivel wheel on the back of the unit rotates for extra maneuverability. When you've finished your chores, the

Chipper/Shredder stands by itself on its own built-in stand.

The PTOChipper/Shredder can chip limbs, stalks and vines up to 3" in diameter, and can shred the same materials up to 1/2" in diameter. The unit also handles all manner of organic material including lumber, leaves,grass, weeds, brush, paper and sod.

Dozer/Snow Blade Attachment

In the winter, moves up to one foot of light snow (or 6"-to-8" of heavy snow); at other times use it to move or spread sand, gravel, loose dirt, grain, sawdust, etc. Attaches easily to the front of the

Wrap-Around Bumper Guard. Set the blade to several angles. Weighs 41-1bs.; measures 15"x 32".

HilleriFurrower Attachment

The most popular attachment because it does so many-jobs. Mounts to the rear of the depth regulator bracket. Furrower blade easily makes plant rows, trenches, ditches to 8" deep. When hiller wings are attached to furrower blade, attachment makes hilled rows and raised bed gardens. Converts from a furrower to a hiller and back again, in seconds, without tools.

Troy-Bilt® PTO Log Splitter

The Troy-Bilt_ PTOLog Splitter provides you with a convenient and easy means of splitting about a half a cord of wood per hour when working alone. When connected to the PTOPower Unit, the tiller's engine runs the splitter's hydraulic pump, providing you with 13 tons of steady, unhurried and predictable splitting force.

Row Marker Attachment

Do you like very straight, even, neat rows in your garden? If so, the Row Marker is a must attachment. Hooks quickly to the

HillerlFurrower attachment- eliminates the need for string, stakes, measuring tape, etc. You'll like the straight rows it helps you make if you lay out furrows, dig compost trenches, or make raised beds.

The Row Marker extends from 28"-to-

49_ ", letting you vary the width between rows to suit the crop you're planting.

As an added benefit, the power-driven mobility provided by the PTOPower Unit allows you to move the splitter to and from your wood pile, over to a neighbor's place, or along the woodpile to a fresh supply of logs.

Featuresinclude a 15 second splitting cycle; can handle log sizes up to 26" long; a two-stage hydraulic pump that automatically shifts into low gear to provide fourtimes greater pressure when needed; slim-cut wedge design for splitting green, stringy wood; and an auto-control valve for automatic return stroke.

Tire Chains

Chains provide extra traction when snowplowing, or under wet or slick conditions.

Tow Hitch Attachment

Converts your tiller to a tractor-type hauling machine. Connects quickly to the rear of the tiller Power Unit. This is a standard-type tow hitch so it can tow many kinds of equipment.

V-Sweep

Cultivator

The V-SweepCultivator is a specialized tool designed for between-row crop cultivation. Instead of stirring the soil, it slices through just below the surface to eliminate practically any weeds in its path.

The Sweepmounts easily to the optional

Tow Hitch Attachment at the rear of the

PTOPower Unit. The blade is made of high carbon, heat treated steel and measures 2"wide (overall wing span is

20"),

The unique way the Sweepworks, skimming along.just underneath the soil's surface without turning the soil over, makes this the ideal tool for use in dry, dusty conditions where it is important to keep soil disturbance to a minimum.

And, becauseof its 20" wide cutting path, it does an effective cultivation job at a fast speed.

The Sweep's natural shallow cultivation helps to prevent weed seeds from being brought to the soil's surface. This shallow cultivation feature also means there's less chance of damaging the roots of your vegetables. For deeper or more shallow cultivating, the blade depth can be changedwith a simple adjustment_

Wheel Weights

Help increasetraction by putting extra weight directly on the wheels. They reduce bucking and-jumping when deeptilling in heavy soil. They're shipped empty- fill them with material like concrete, sand, gravel, etc. They bolt directly to the tiller wheels.

Wrap-Around Bumper Guard

Order this Bumper Guard by itself or receive it as one of the components if you order the combination Dozer/Snow Blade attachment. Protects the engine from damage by wrapping around and protecting many of the engine components. 1" diameter, high-strength steel tubing.

MODELS 12089, 12090, 12204

FORWARD INTERLOCK SYSTEM

!

SeePage 48

Parts List

REF

No.

PART

No.

2552

BRIGGS & STRATTON

DESCRIPTION

Engine Wire HarnessAssy-forward interlock system (Incl. one red and one black wire, plug connector, neutral switch and PVC tubing. Parts not available separately.................................

QTY.

REF

No.

PART

No.

DESCRIPTION

QTY.

6

7

2

3

8

9971

1186246

9205

9202

2551

Lockwasher-external tooth, 7/16"......1

Nut-hex, 7/16"-20 .......................

1

Clip-for plug connector ...............

1

Tie-plastic ...................................

1

HandlebarWire HarnessAssy-

(seepage 48, Ref. No. 20) .......

1

47

Parts List

HANDLEBAR ASSEMBLY

11

MODELS 12089, 12090, 12204

Handlebar -

13

t

12

20

48

3

_--'24

REF

No.

PART

No.

DESCRIPTION QTY.

REF

No.

PART

No.


9

10

11

7

8

1

2

5

6

3

4

12

13

14

15

9548

9119

Bolt-Hex hd., flanged self-locking

Grade 5, 1/2-13 x 3-1/2". ...........

1

Knob-handlebar height adjustment

(Incl. Ref. No. 3) ........................

1

9120

1881

1186233

Ring-retaining (tolerance ring) ......

1

Stud-handlebar height adjustment

(Incl. Ref. No.'s 2, 3 and 5) ........

1

Nut-hex, 1/2"-13............................

1

1900854001 Clamp-left, handlebar height adjustment .................................

1

1900856001 Ratchet-left, handlebar height adjustment .................................

1

1900857001 Ratchet-right, handlebar height adjustment .................................

1

1900855001 Clamp-right, handlebar height adjustment .................................

1

1900858001 Base-handlebar mounting .............

1

2704 Handlebars-(Includes two of each

Ref. Nos. 12, 17 and 28 and one

Ref. No. 13)................................

1

9125

2715

9547

1186389

Grip-handlebars ............................

2

Decal-operator control panel.........

1

Bolt-curved hd, GR5, 1/4-20 x 2"..

1

Nut-hex, flanged self-locking, whiz lock, 1/4"-20 ...............................

1

25

26

27

28

16B 9650

17

18

19

20

21

1900763

9202

9219

2551

9250

22

23

24

9385

2543

1186009

24A 9733

2546

9199

9514

9387

16A 1909286 Throttle Control & Cable-8HP

Briggs & Stratton engine only

(also see Ref. No. 24A) ..............

I

Throttle Control & Cable-8HP

Kohler engine only ....................

I

Decal-Forward Interlock Lever......

2

Tie-plastic .....................................

2

Plug-wire harness retainer............

2

HandlebarWire HarnessAssyforward interlock system............

I

HandlebarSwitch-forward interlock system.........................

2

Lock Pin-handlebar switch ............

2

Switch Housing-handlebar switch.

2

Screw-pan head, 10-24 x I12", thread-forming ...........................

2

Screw-phillips head, 10-32 x I12", thread-forming ...........................

I

Lever-forward interlock .................

2

Pivot Pin-forward interlock lever...

2

Retaining Ring-klip ring-forward interlock lever.............................

2

Return Spring-fwd interlock lever.

2

MODELS 12089, 12090, 12204

DEPTH REGULATOR & TINE HOOD ASSEMBLIES

9

Parts List

13

SeePage 56

8

9

10

1

2

3

4

5

6

7

REF

No.

PART

No.


1100043

1113-1

1100243

1186231

8olt-hex hd., 3/8-16 x 1-1/4". .......

2

Bushing-19/64" (.300° Ig.) ............

2

Lockwasher-spring lock, 3/8".......

2

Nut-hex, 3/8"-16 ...........................

2

1117A

9120

9119

Bar-depth regulator (incl. Ref.

No.'s 6 and 7) ............................

1

Ring-retaining ..............................

1

Knob-depth regulator (incl. Ref.

No. 6) ........................................

1

1900867001 Bar-drag, depth regulator .............

1

9552 Screw-thread-forming,

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

2

1186329 Bolt-flanged hex hd.,

5/16-18 x 3/4"............................

2

REF

No.

PART

No.

16

17

18

19

12

13

14

15

20

21

9929

1904563

1904543

2527

9308

9534

9384

1100069

9811

1186328


Washer-flat, 5/16°.........................

2

Hood-(incl. Ref. No. 14) ...............

1

Decal-hood, operating instructions.

1

Bracket-(incl. Ref. No. 16) ............

1

Pin-roll (spirol) 1/4" x 1°. ..............

1

Spacer...........................................

1

Spring ...........................................

1

Bolt-hex hd., 1/4-20x1".................

1

Locknut-1/4"-20 ...........................

1

Bolt-flanged hex hd.,

5/16-18 x 5/8"............................

2

49

50

Parts List

MODELS 12089, 12090, 12204

WHEEL SPEED LEVER, BELT DRIVE SYSTEM, ENGINES, WHEELS

SeePage60

[FOR ELECT,

START

SYSTEMS]

18B

35-.-_

45A

32

"-'43 _

SeePage52

12

MODELS 12089, 12090, 12204

Parts List

19

20

25

26

26

27

13

14

15

17

9

10

11

12

18

6

7

8

3

4

1

2

5

21

22

23

24

REF

No.

PART

No.

DESCRIPTION

QTY.

REF

No.

PART

No.

DESCRIPTION

QTY.

9362

9838

9934

9932

2628

1902240

9317

1231

1033

1107382

9338

1110107

1100046

1100243

1107383

1113-1

9120

1920

2100

1915810

1100011

1919

9245

1483

1138-1

1138-2

9303

WHEELSPEEDLEVER

Pin-spring, 1/8"................................ 1

Nut-castle (slotted), 1/2"-20 ............ 1

Washer-shoulder, 1/2"..................... 1

Washer-disc spring ......................... 2

Lever-wheel speedshift (incl.

Ref No.'s 6 and 18) ....................... 1

Knob-wheel speed shift lever........... 1

Pin-cotter, 3/32" x 1"........................ 1

Rod-connecting rod, wheel speed shift lever...................................... 1

Swivel-connecting rod ..................... 1

Washer-fiat, 5/16°, S.A.E................. 1

Pin-hair cotter.................................. 1

Locknut-hex hd., 5/16°-18 ............... 1

Bolt-flanged hex hd., 3/8-16 x 1" ..... 5

Lockwasher-spring lock, 3/8". ......... 5

Washer-fiat, 3/8", S.A.E................... 7

Bushing-spacer, 19/64" (.300"lg.).... 4

Ring-retaining (tolerance ring) ........ 1

BELTDRIVESYSTEM

Block- belt adjustment, 3-7/8" (incl.

Ref. No.'s 13,15, and 20) .............. 1

Rod- belt adjust., 7"with measuring gauge .......................... 1

Decal- engine stabilization, for

Briggs & Stratton engines.............

Bolt-hex hd., 3/8-24 x 1-1/2". .......... 1

Disc-reverse, (incl. Ref. No. 19) ...... 1

Belt-forward drive (no substitute due to extra strength required) ..... 1

Pulley-engine power take off ........... 1

Shim-engine pulley, 1/16°

Shim-as above, 1/32"

As Req'd

As Req'd

Key-engine pulley, 3/16"sq. x 2-1/2" 1

28

30

31

32

1100045

1034

9147

9572

ENGINESAND ENGINEMOUNT

Bolt-hex hd., 5/16-18x 1",Grade5...... 2

Bar-engine mounting ....................... 2

Plug-thread protector, red plastic.... 2

Bolt-hex hd., 5/16-24 x 1-1/8". ........ 4

33

34

35

35

38B

1100242 Lockwasher-spring lock, 5/16". ....... 4

1916274001 Mount- engine to tiller ..................... 1

* 8HP Briggs & Stratton Engine-

Recoil or electric start. (Electric start requires key switch

*

1904565 starting system.) .......................... 1

10HP Briggs & Stratton Engine-

Electric start (has key switch starting system) ........................... 1

Decal-hot surface safety warning .... 1

43

45

45A

46

9322

2709-01

WHEEL& TIRE ASSEMBLIES

Pin- roll, 5/16" x 1-1/2". ................... 2

**Wheel & Tire Assy- bar tread, left side, 4:80 x 8" tubeless tire

2709-02

1902020 with valve stem, on one-piece steel wheel...................................

1

**Wheel & Tire Assy-bar tread, right side. Same as above but for right side of tiller ..................... 1

Cap-wheel hub ................................ 2

* Contact an authorized engine dealer, Troy-Bilt dealer or the Factory for replacement engine information.

Contact an authorized engine dealer for engine service or parts. Refer to the engine nameplate for engine model and type information.

** For correct traction and directional control, Bar TreadTires should be mounted on the tiller so the closed end of the "V" in the tire tread on top of the tire faces forward.

51

Parts List

POWER UNIT TRANSMISSION ASSEMBLIES

MODELS 12089, 12090, 12204

14

14

SeePage50

fl

15

16

65

64

4O

45

46

74

75

47

38

t

71

72

34

80

MODELS 12089, 12090, 12204

Parts List

REF

No.

PART

No.

DESCRIPTION

1

2

3

4

5

TRANSMISSIONCOVER& SHIFT LEVER

BRACKETASSEMBLIES

1186299 Bolt-hex hd., #10-32 x 3/8",

9463

2263

1900758

1186347 self-locking flange .....................

3

Knob-tines/PTO clutch lever, tapered, plastic ..........................

1

Detent Plate-tines/PTOclutch lever

(incLRef. No. 4) .........................

1

Decal-operating instructions, detent plate................................

1


3/8-16 x 1-1/2". .........................

4

7

9

10

11

12

1186329 Bolt-flanged hex hd.,

5/16-18 x 3/4", Grade 5 ............

1

1107382 Washer-fiat, 5/16", S.A.E..............

1

1900870001 Bracket-shift levers (incl. Ref.

No. 86) ......................................

1

9362

9838

Pin-spring, 1/8". ...........................

1

Nut-castle (slotted), 1/2"-20, call

13 9934

14

15

17

9932

....

1123

Washer-disc spring ......................

2

Lever-wheel speed shift (see page

16

16A 2566

51, Ref. No. 5 for part number).

1

1900869001 Cover-power unit transmission ....

Cover-power unit transmission

(incl. Ref. No.'s 18,19, 20, 21, 22,

1

23 and 24) .................................

1

Gasket-transmission cover ...........

1

18 1100045

19 1186230

Bolt-hex hd., 5/16-18 x 1",Grade 5,

(remove with care) ...................

1

Nut-hex, 5/16"-18 .........................

1

20 1901439

Tech Service for tightening instructions .............................

1

Washer-shoulder, 1/2". ................

1

21 1035

Spring-neutral plunger (remove with care) ..................................

1

Plunger-neutral (remove with care)

(incl. Ref. No. 22) ......................

1

22

23

24

1901440

1186393

1902004

Clip Ring-retains neutralplunger..

1

Nut-hex, flangelocknut, 3/8"-16...

1

Bolt-hex hd., 3/8-16x1-1/2", threaded full length....................

1

25

26

27

TINES/PTOCLUTCHLEVERASSEMBLY

1900878001 Lever-eccentric, tines/PTO clutch.

(also see Ref. No.'s 1, 2,3 and

1100804

4 listed above)...........................

1

Bolt-hex hd., 1/4-20 x 1/2". ..........

1

2123 Bushing-tines/PTO clutch lever eccentric shaft ...........................

1

QTY.

REF

No.

PART

No.

DESCRIPTION

QTY.

50

51

52

53

45

45

45

46

42

43

44

45

33

34

35

36

37

38

39

40

28

29

3O

31

47

48

49

9516

2461

9911

9672

Retaining Ring-(snap ring), external......................................

2

Eccentric-shaft, tineslPTO clutch lever...........................................

1

Lockwasher-hi-collar, 1/4"............

1

Screw-socket hd., 1/4-20 x 3/8" ... 1

9500

1909139

9301

1100004

9944

2107

50027

1186310

1224-2

1224-3

1224-4

1714

11601

9617

9517

DRIVESHAFTASSEMBLY

1900879001

1983632

1124-2

1224-1

Retaining Ring-external ................

1

Dog Clutch-power unit .................

1

Key-3/16 sq. x 1". .........................

3

Bolt-hex hd., 5/16-24 x 3/4", selflocking flange, Grade 5 ..............

1

Washer-disc spring (concave)......

1

Pulley-transmission drive, cast iron 1

Washer-flat, hardened shoulder

1-1/4".........................................

1

Bolt-hex hd., 1/4-20 x 3/4", front bearing cap ................................

3

Cap-front bearing .........................

1

Seal-oil, front bearing cap ............

1

Gasket-front bearing cap ..............

1

Shim-front bearing cap,.

010" thick ..............................As Req'd

Shim-as above, .030"...............As Req'd



Bearing & Cup-tapered cone roller bearing with cup (race). Coneand cup sold as set only ...................

2

Shaft-main drive, power unit. Incl.

integral worm, plus two pressedon cone roller bearings, two bearing cups and two shoulder washers .....................................

1

Seal-oil, drive shaft, rear ..............

1

RetainingRing-(snapring), intemal........1

9309

1060A

9604

1132-1

PINION SHAFTASSEMBLY

Pin-roll (spirol), 114x 2". ..............

2

Plug-retaining, pinion bearing (incl.

Ref. No. 62) ...............................

2

O-Ring-retaining plug ...................

2

Shim-retaining plug, I-I164" inner dia., .033" thick (on right side only one #1132-I shim is also used between bearing and washer,

Ref. No.'s 54 & 55) .................... As

Req'd

(continued on page 55)

53

PartsList

POWER UNIT TRANSMISSION ASSEMBLIES

(Continued from page 53)

MODELS 12089, 12090, 12204 t

38

47

!8

58

6O

68

55

53

54

53

f

10

64

t

71

72

48

MODELS 12089, 12090, 12204

Parts List

REF

No.

PART

No.

DESCRIPTION

QTY.

REF

No.

PART

No.

DESCRIPTION

QTY.

64

65

66

67

68

69

70

63

63

63

63

53

53

54

55

56

57

58

59

60

61

62

63

1132-2

1132-3

9404

1126

1222

9502

2656

9300

1233

(continuedfrom page 53)

PINION SHAFTASSEMBLY

Shim-same as 1132-1, .062"........

As

Req'd

Shim-same as1132-1, .010" ..... As

Req'd

Bearing-ball, pinion shaft .............

2

Washer-pinion shaft .....................

2

Stem Pinion-slow speed gear & shaft ..........................................

1

Ring-retaining, external ................

1

Worm Gear-bronze, wheeldrive...

1

Key-3/16" x 5/8"............................

1

Gear-fast speed pinion .................

1

9621

9511

1166-1

1166-2

1166-3

1166-4

1166-5

1086

1878

9357

1223

1232

1237

1112

WHEELSHAFTASSEMBLY

Seal-oil, wheel shaft .....................

2

Retaining ring-external .................

2

Shim-wheel shaft, 1-1/64" inner dia., .062" thick.......................... As

Req'd

Shim-as above, .030" thick ....... As

Req'd

Shim-as above, .015" thick ........ As

Req'd

Shim-as above, .010" thick ........ As

Req'd

Shim-same as above, .005"thick As

Req'd

Bushing-bronze, wheel shaft bearing ......................................

2

Shaft-wheel, 15-5/8", (IncL two of

Ref. No. 62 and one Ref. No. 66) 1

Key-Hi Pro, 1/4" x 1-3/4"...............

1

Gear-slow speed, wheel drive.......

1

Gear-fast speed, wheel drive ........

1

Dog Clutch-wheel drive ................

1

Pin-clutch guide, 1/4" diameter ....

3

71

72

73

74

75

76

78

79

80

81

82

83

84

85

86

ECCENTRICSHAFTASSEMBLY

9307 Pin-roll, 3/16"x 1-1/4" (spirol) .....

1

1900880001 Lever-eccentric,wheelspeed

9622 shifting ......................................

1

Seal-oil, eccentric shaft ................

I

1442

2712

1441

Pin-eccentric shaft, wheel speed shifting ......................................

I

Eccentric Shaft-wheel speed shifting ......................................

I

Spring-eccentric shaft ..................

I

2260

9359

TRANSMISSIONHOUSING

Housing-power unit transmission

(incl. Ref. No. 79). Empty housing without covers, shafts, gears, seals,etc. (Call Factory before ordering) ...................................

I

Pin-alignment ...............................

1

9560

9928

2126

1105620

9122

9205

1900759

MISCELLANEOUSPARTS

Bolt-hex hd., I12-13 x 2" Grade 5.

2

Washer-disc spring (concave), domed side faces bolt head.......

2

Post-with threaded hole for Ref.

No. 80 ........................................

2

Plug-pipe, 1/4"..............................

2

Plug-red plastic, thread protector.

1

Clip-forward interlock system plug connector (see page 47) ............

I

Decal-forward interlock wire harness......................................

1

55

Parts List

TILLER ATTACHMENT TRANSMISSION ASSEMBLIES

MODELS 12089, 12090, 12204

IS

17

See Note1

10

11

\_.

5

sooHoleI 2

3

)

5

i

56

L--J_

8

NOTE 1: THESE SCREWS HAVE A SPECIAL SEALING DESIGN

THAT CAN NOT BE REUSED WITHOUT RISKING THE

LOSS OF TRANSMISSION OIL. IF THESE SCREWS

ARE LOOSENED OR REMOVED, THEY MUST BE

REPLACEDWITH NEW HARDWARE.

MODELS 12089, 12090, 12204

Parts List

REF

No.

PART

No.

DESCRIPTION

QTY.

REF

No.

PART

No.

DESCRIPTION

QTY.

9

10

11

12

13

14

16

16

4

6

6

7

8

2

3

3

1915087

20873

1129-1

1129-2

1901972

97074

1901976

1104

97073

Screw Kit, includes five (5)

1/4"-20 x 5/8" self-sealing screws .............................. As Req'd

Cover-tiller housing .....................

1

Gasket-tiller housing cover, .010". As thick ...........................................Req'd

Gasket-same as above, .030" As thick ...........................................Req'd

Shaft-tiller tine..............................

1

Ball Bearing...................................

2

Worm Gear-bronze, tiller tine shaft ..........................................

1

Key-tiller tine shaft, woodruff key.

1

Seal-oil, tiller tine shaft .................

2

TILLERDRIVESHAFTASSEMBLY

9500

1909138

Retaining Ring-external ................

Dog Clutch-tiller drive shaft..........

2

1

9301

2127

Key-3/16" x 1"...............................

Spring-dog clutch .........................

1

1

1138-1

1915089

Shim-dog clutch, 1/16"(.62")thick..

Screw Kit, includes three (3)

1

1900881001

1124-2

1/4"-20 x 7/8" self-sealing screws.............................. As Req'd

Cap-rear bearing...........................

1

Gasket-rear bearing cap ...............

1

20

21

23

24

17

17

17

17

18

19

1224-1

1224-2

1224-3

1224-4

1714

11602

9617

9517

Shim-front bearing cap, .010" As thick ...........................................Req'd

Shim-same as above, .030" As thick ...........................................Req'd



Bearing & Cup-sold as set only ....

2

Shaft-main tiller drive (incl. an integral worm gear, plus two pressed-on cone roller bearings, two bearing cups (Ref, No. 18) and one shoulder washer .................

1

Seal-oil, drive shaft, front .............

1

Retaining Ring-internal .................

1

TRANSMISSIONHOUSINGANDDIPSTICK

1902000

1909157

Housing-tiller attachment (incl.

pressed-on sleeve in front of housing). Empty housing without shafts, gears, seals, dipstick, etc. Call Factory before ordering ..........................

1

Dipstick-oil, tiller attachment........

1

57

Parts List

BOLO TINE ASSEMBLIES

MODELS 12089, 12090, 12204

58

RIGHT SIDE

6

I

LEFT SIDE

LEGEND:

Z_ Sharp Edge

L Left Bolo Tine

R Right BOtOTine

NOTE: Make sure Sharp Edge .'% of tines faces FORWARD to enter soil first

Sharp

LEFT HAND TINE RIGHT HAND TINE

(As viewed with blunt edge facing you.)

MODELS 12089, 12090, 12204

Parts List

REF

No.

PART

No.

DESCRIPTION

QTY.

REF

No.

PART

No.

DESCRIPTION

QTY.

1

2

6

7

8

10

---

STANDARDTILLING TINES

1901975001 Tine Holder-welded steel,fits

1982612

1270-1A

1270-2A

1100046

1110108

1901118 left or right sides ......................

2

Bolt-hex hd., 3/8-16 x 2". ............

4

Bolo Tine-single, left hand. Used on left and right side tine assy.

Tine is stamped either "EL* or

"AL". (Incl. two each of Ref. No.'s

8 and 10) .................................

Bolo Tine-single, right hand. Used on left and right side tine assy.

Tine is stamped either "ER" or

"AR". (Incl. same hardware as

8

Ref. NO,6)

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

8

BoIt-hex hd., 3/8-16 x 1". ............

16

Locknut-hex, 3/8"-16 ..................

20

Tine Replacement Kit-unassembled

(Incl. eight each of Ref. No.'s 6, and 7, sixteeneach of Ref. No.'s

8 and 10). Includes easy-tofollow installation instruction. DOES

NOT INCLUDEtine holders, holder mounting hardware, or tine shaft keys.................................

1

CUSTOMTILLINGTINES

Special hard-faced, high-chrome carbon alloy tines that are thicker than standard Bolo Tines. These tines better resist the abrasive action of rocky, gritty or sandy soil as compared to standard 8olo Tines, and are especially suited for custom tilling or market gardening.

10802

2475-1

2475-2

Custom Tilling Tine Kit-(Incl.

eight each of Part #2475-1 and #2475-2 tines and sixteen each of Ref. No.'s 8 and 10 ......

Bolo Tine, Custom Tilling-single, left hand ...................................

Bolo Tine, Custom Tilling-single, right hand ................................

1

8

8

59

60

PartsList

RIGHT SlOE

G

I XX_31

12--.._I

i i i i

Wire

(Red)

3

TO

STARTER

I

MOTOR

ELECTRIC START SYSTEM

MODELS 12090, 12204

(+)

Activate

Wire (Red)

MODELS 12090, 12204

Parts List

REF

No.

PART

No.

DESCRIPTION

QTY.

REF

No.

PART

No.

DESCRIPTION

QTY.

1

2

3

4

5

96515

97020

9552

1186309

1901894

1904564

1904548

1908112

9

10

11

12

13

14

16

16

17

18

19

2O

21

96520

9566

1100241

1186229

9092B

96514

1100242

1186211

1187559

1186208

96510

2571

1186349

Cable-battery, positive and negative terminals ..................................

Boot-terminal insulating .............

Screw-self-threading,

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

Bolt-hex hd., 1/4-20 x 5/8"..........

3

2

2

3

Wire-recharge (red) for Briggs and Stratton engine (incl.

terminal and eyelet) .................

Battery Hold-down Clamp-with attached Key Switch Plate (incl.

Ref. No. 7) ...............................

Decal-ignition switch instruc.......

Key Switch-includes two ignition keys (Ref. No. 9), one

Iockwasher, and one mounting nut (lock-washer and nut not availableseparately).................

Key-ignition, one pair ..................

Bolt-carriage, 1/4-20 x 1-1/4". ....

Lockwasher-spring lock, 1/4"......

Nut-hex, 1/4"-20 .........................

Battery-12 volt, 30 amps., sidevented. (incl. Ref. No.24, 4, 12)

Solenoid-starter, includes nuts and washers for cables and wires...

Lockwasher-5/16". ......................

Nut-hex, 5/16"-24 .......................

Lockwasher-external tooth, #10_

Nut-hex, #10-32 ..........................

Cable-solenoid to starter motor..

Battery Bracket............................


3/8-16 x 1-1/2".........................

1

1

2

2

2

4

1

1

1

1

1

1

2

1

1

2

1

23

24

25

26

27

28

29

9265

9009

1475

9224

9202

1908118

1908117

30

32

33

34

35

1186389

1901202

1186331

1186391

1917269

Tie-plastic, wire retaining ............

I

Vent Tube-5/16" diameter ..........

I

Shield-vent tube, I12" diameter...

I

Clamp-vent tube shield ...............

Tie-plastic ...................................

Wire Harness & Connecting

Terminal Assy-for Briggs & Stratton

I

2 engines(available as complete assembly only). Incl.

wire assy., wlconnector to large solenoid stud (red wire); wire assy. wlconnector to small solenoid stud (red wire); wire assy. wlconnector to solenoid grounding screw (red wire); wire assy wlconnector to engine ground shut-off (green wire); plastic protector tube; wire harness; connector; wire terminal ..........

1

Wire Harness-for Kohler engine.

Incl. two receptacles;three red wires (solenoid activate, battery recharge, and starter switch); two green (ground)(shutoff) wires; plastic harness tube.......

1

Locknut-hex, 1/4"-20 ..................

2

Cable-ground, solenoid to engine block ........................................

1

Bolt-flange lock, 5/16-18 x 1"......

1

Nut-flange lock, 5/16"-18 ............

1

Ground Wire Assembly ................

1

61

Parts List

MODELS 12089, 12090, 12204

WHEELS/TINES/PTO DRIVE LEVER & YOKE ASSEMBLY

10

12

15

I1

2

11

8

5

See Page 52

62

REF

No.

PART

No.

DESCRIPTION

QTY.

REF

No.

PART

No.

7

8

5

6

9

2

3

4

2574 Lever-Wheels/Tines/PTO Drive

(Incl. knob w/decal) ...................

1

1908156

1100799

2447

Spring-clutch pawl........................

Bolt-hex hd., 5/16-18 x 1-1/2".......

1

3

1177548

1186230

Bushing-3/8", ................................

3

Lockwasher-externaltooth, 5/16",

Nut-hex, 5/16"-18..........................

3

3

1916265001 Roller Assembly ............................

1

1900468001 Yoke-left side ................................

1

1900469001 Yoke-right side..............................

1

10

11

12

13

15

16

17

DESCRIPTION

QTY.

1900860001 Link-yoke pivot, left & right,

6-7/8" long .................................

2

1100046

1100243

1107383

1186231

1113-1

....

Bolt-hex hd,, 3/8-16 x 1". ..............

6

Lockwasher-spring lock, 3/8",.......

Washer-flat, 318",S,A.E.................

Nut-hex, 3/8"-16............................

Bushing-spacer, 19/64" (.300") .....

Knob-not avail, separately, See

Ref No. 1 .......................................

6

6

2

6

MODELS 12089, 12090, 12204

BUMPER ATTACHMENT

Parts List m

4

3

\

1

2

REF

No.

PART

No.


REF

No.

PART

No.


---

1

2

3

4

5

12588 Bumper Attachment. Includes

Ref. Nos. 1 through 11) ...........

1910730001 Brace - bumper bottom ...............

1909765 Bolt - hex hd., 1/2-13 x 1-1/2". ....

1100245

1909748

1100799

Lockwasher - spring lock, 1/2" ....

Spacer, 1/2".................................

Bolt - hex hd., 5/16-18 x 1-1/2" ...

1

1

2

1

1

1

10

11

8

9

6

7

1100242

1186230

Lockwasher - spring lock, 5/16" ..

2

Nut - hex, 5/16"-18 ......................

2

1910731001 Bumper wraparound ....................

1

1100046 Bolt - hex hd., 3/8-16 x 1"............

2

1100243

1448

Lockwasher - spring lock, 3/8" ....

2

Decal - for bumper ......................

1

63

CUSTOMERSERVICEINFORMATION

Owner RegistrationCard

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 can provide you with warranty benefits and informational bulletins.

Warranty Service

The warranty _atementisincludedin the unit'sliterature package.

Model/Serial Numbers

A Model/Serial Numbers decal is located on top of the transmission. For ready reference,record these numbers in the spacesbelow.

Date of Purchase:

Model/Serial Numbers:

AuthorizedDealer Information

If you purchased your unit from an authorized dealer, record the dealer's address and phone number below for ready reference:

DealerName:

Address:

Phone:

IMPORTANT:

Left and right sides of the unit are determined by standing

behindthe unit, in the operator's position,and facing in the

directionof forward travel.

CustomerService and Technical Service

If you have questions or problems with the unit, contact your local dealer or the Factory.

(When calling or writing, provide the

Model/Serial Numbers of the unit.)

ReplacementParts

Factory specified replacement parts are availablefrom your authorized dealer or directly from the Factory. When ordering parts, be sure to provide the following:

• Model/Serial Numbers of the unit.

• Part number of the part needed.

• Part Description.

• Quantity needed.

NOTE:All replacementparts must conform to our rigid quality specifications. Although some replacement parts we provide may vary slightly in shape, color or texture from the original parts, any variations will not affect the fit or performance of these parts on your unit.

EngineService and Repair

For engine service or repair, contact your ..........

Yellownearest "Engines-Gasoline").dealer

The engine is warranted by the engine manufacturer. Any unauthorized work performed on the engine during the warranty period may void this warranty. For complete details on the engine warranty, refer to the engine owner manual.

:

NOTICE:

We reserve the right to change specifications,add improvementsor discontinuethe manufactureof any of our equipmentwithout noticeor obligation to purchasersof our equipment.

We urge using only genuine replacement parts, which meet all the latest requirements. Replacement parts manufacturedby otherscould presentsafety hazards, even

thoughtheymay fit on the unit.

For customerassistance,contactyour nearest authorizeddealer or:

GARDEN WAY INCORPORATED • 1 Garden Way • Troy, New York 12180

CustomerService:1-800-437-8686 • TechnicalService:1-800-520-5520 • PartsService:1-800-648-6776

• FAX:(518)391-7332 • WEBSITE:www.troybilt.com

Outside the United States and Canada:

CustomerService:(518) 391-7007 • TechnicalService:(518) 391-7008 • Parts Service:(518) 391-7006 • FAX(518) 391-7332

1905444 Rev. A (01/00) Printed in U,S.A.

o 2000 Garden Way Incorporated

Troybilt 12089 Tiller Owner's Manual

Owner'sManual

PTO HORSETILLER

• Safety

• Assembly

• Controls

• Operation

• Maintenance

• Parts List

Models

12089 - 8HP Standard

12090 - 8HP Electric

12204 - IOHP Electric

DearOwner: yourgarden otherproperty including splitter.Yourtillerisfamous

usingit.

carefully assemble,

See BackCoverfor

CustomerServiceInformation

WARNING

Training

Preparation

Operation

Maintenance and Storage

Decals

OperatingSymbols

Assembly

Introduction

Inspect

STEP 1: Unpacking Instructions

STEP 2: Attach Handlebar

STEP 3: Move Tiller Off Shipping

Platform

STEP 4: Connect Forward

Interlock Wire Harness

STEP 5: Attach

Wheels/Tines/PTO Drive Lever

STEP6: Check Gear Oil Levels

STEP 8: Attach Engine Throttle

Lever and Cable

STEP 7: Add Motor 0il to Engine

STEP9: Adjust Air Pressure in

Tires

ASSEMBLINGTHE ELECTRICSTARTSYSTEM

STEP 1: Activating and

Charging the Battery

A

STEP 3: Installing the Battery

N

Featuresand Controls

zG

Introduction

Depth Regulator Lever

EngineControls

Keyswitch Starter

INTRODUCTION

Operation

TransportingThe Tiller Around

YourProperty

Loading and Unloading the Tiller

Testing

Safety System

Changing Speed

Choosing Wheel

andTine Speeds

Tilling Tips& Techniques

Let the tiller do the work

Avoid tilling wet, soggy soil

Tilling depths

making footprints

Tilling Tips & Techniques

Suggestedtilling patterns

Tilling on slopes

Tilling Tips & Techniques

Tilling Tips & Techniques

PTO POWERUNIT

Removing And Replacing The Tine Attachment

PTO POWERUNIT

OPERATINGINSTRUCTIONS

Setting Up

Maintenance