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Troy-Bilt 664D-Pony Tiller User Manual

Contents

1. Safe Operation Practices Set Up Operation Maintenance Service Troubleshooting Warranty OTROY BILT OPERATOR S MANUAL Rear Tine Tiller Model 682 WARNING READ AND FOLLOW ALL SAFETY RULES AND INSTRUCTIONS IN THIS MANUAL BEFORE ATTEMPTING TO OPERATE THIS MACHINE FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY TROY BILT LLC P O BOX 361131 CLEVELAND OHIO 44136 0019 Printed In USA Form No 769 03557 November 6 2007 To The Owner Thank You Thank you for purchasing a Garden Tiller manufactured by Troy Bilt LLC It was carefully engineered to provide excellent performance when properly operated and maintained Please read this entire manual prior to operating the equipment It instructs you how to safely and easily set up operate and maintain your machine Please be sure that you and any other persons who will operate the machine carefully follow the recommended safety practices at all times Failure to do so could result in personal injury or property damage All information in this manual is relative to the most recent product information available at the time of printing Review this manual frequently to familiarize yourself with the machine its features and operation Please be aware that this Operator s Manual may cover a range of product specifications for various models Characteristics and features discussed and or illustrated in this manual may not be appl
2. 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 the 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 PTO Drive Lever in NEUTRAL when the tiller is not in use Keep the tension adjusted correctly e Don t speed shift when moving the Wheels Tines PTO Drive Lever between FORWARD and REVERSE SECTION 6 MAINTENANCE amp ADJUSTMENTS 31 32 How to Measure the Belt Tension a Without moving the clutch roller try inserting the 4 thick slotted end of the belt adjustment tool in between the roller and the upright bracket The flat edge of the tool must be facing the roller See Fig 6 14 1 Before taking a measurement be sure the linkages and pivot points on the Wheels Tines PTO Drive 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 received with your new tiller See Fig 6 12 Belt Adjustment Tool Figure 6 14 Figure 6 12 b If only the slotted portion of the tool will fit the belt 2 Move the Wheels Tines PTO Drive Lever fully down to the TENSION 1S COMEC FORWARD position The clutch roller
3. SECTION 7 SERVICE If badly worn they lose the ability to till deeply Worn tines leave an 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 See Fig 7 8 The tines can be replaced individually or as a complete set Figure 7 8 Replacing a Single Tine WARNING The tines or tine hooded edges may be sharp Wear thick gloves to protect your hands from cuts or scrapes WARNING Wear safety goggles to protect your eyes When loosening hardware do not hit a wrench with a metal tool This could shatter the tool or wrench sending metal particles into your eyes Move the Wheels Tines PTO Drive Lever to NEUTRAL the Wheel Speed Lever to either FAST or SLOW position and the Tines PTO Clutch Lever to ENGAGE 2 Gently tilt the tiller forward until the engine rests on the ground 3 Raise the hood flap at the back of the tiller and tie it up with string 1 4 Before removing a tine note in which direction the bent tip points The new tine must be installed in the same direction Use two 6 wrenches to remove the two bolts and nuts securing the tine to the tine holder plate See Fig 7 9 Use penetrating oil on the hardware if it is rusted or hard to remove Figure 7 9 Mount the new tine exactly the way the old tine was positioned The sharp edge of the tine which enters the soil first must face forward when
4. amp Set Up and the Controls amp Features sections Also be sure to read the Engine Operator s Manual Figure 4 20 SECTION 5 OPERATION 8 Then move the swing out bolts out See Fig 4 21 Figure 4 21 NOTE Loosening swing out bolts can be difficult Use an extra long wrench for leverage 9 the PTO power machine forward about one inch with one hand while pulling the tine attachment back Fig 4 22 og A je in ntina Hole x Ce Figure 4 22 10 The guide pin on the power unit will slide out of the guide hole in the tine attachment See Fig 4 23 Figure 4 23 Installing the Tine Attachment 1 Move the two PTO Power Unit swingout bolts outward and slide the washers up against the bolt heads Remove the support block from under the engine and slowly roll the power unit back next to the tine attachment Place the support block back under the engine Remove the dust cap or protective wrapping from the dog clutch coupling on the tine attachment Carefully align the guide pin on the PTO Power Unit with the alignment hole in the tine attachment and bring the two units together See Fig 4 23 Move the two swing bolts into the slots of the tine attachment Alternately tighten each bolt until they are tight enough to make the concave washers flat The bolts must be very tight if you have a torque wrench tighten each bolt to between 70 and 80 ft Ibs NOTE The swing bolts must
5. it is contaminated with dirt sand or other foreign particles Gear oil is available at authorized dealers and most service Stations power equipment centers or farm heavy equipment outlets Capacities The Power Unit transmission holds approximately 60 ounces and the Tine Attachment transmission holds approximately 12 2 ounces Adding Gear Oil to the PTO Power Unit Transmission 1 Do steps 1 and 2 of Checking the Power Unit Oil Level 2 Using a 3 4 wrench or socket remove the bolt securing the handlebar base to the top of the transmission prop the handlebars first to prevent them from falling Then unplug the Forward Interlock wire harness receptacle at 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 See Fig 6 7 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 See Fig 6 7 4 Reinstall the oil level check plug Tighten it securely 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 the operation of the Forward Interlock Safety System See Forward
6. Lever is in NEUTRAL or REVERSE positions The other two switches are located inside the handlebars directly above the 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 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 grease with 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 NOTE 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 tiller as follows 1 Oil the wheel shaft between the wheel hubs and the
7. above the tine shaft Replace the bolts and nuts and tighten them securely Replacing A Tine Holder Assembly The 16 Bolo Tines are mounted eight per side on left side and right side tine holders Here s how to replace the tines and holders as assemblies 1 2 Follow steps 1 3 in Single Tine Replacement above Identify the tine holders as left 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 grease pencil to mark them L and R Remove the two bolts and nuts securing each holder See Fig 7 9 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 When the holder is off clean all dirt and debris from the shaft and the holder Apply fresh grease to the tine shaft Replacing Tines Holder Assembly 1 Replace the holder so the sharp tine edges face forward toward the front of the tiller Tap tine holder back on the tine shaft Grease the threads on the mounting bolt s Install and tighten the bolt s securely SECTION 7 SERVICE 39 40 Troubleshooting Problem Engine does not start Engine runs poorly or overheats Engine runs well but labors under tillers load Engine shuts off when Wheels Tines PTO Drive Lever is in forward Cause Wheels Tines PTO Drive Lever not in Neutral position Fuel tank low or empty Fuel line restri
8. across slopes without terracing If vertical or terracing gardening 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 terraced rows or till vertically e Move the belt into LOW belt range and the Wheel Speed Gear Lever to SLOW position As in terrace gardening start at the top of the slope and overlap the first pass by half the width of the tiller For added stability keep the uphill wheel in the soft newly tilled soil Each succeeding terraced area is started by walking below the terrace you are preparing See Fig 4 16 Figure 4 16 Power Composting 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 WARNING 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 comply could result in loss of tiller control property damage or personal injury Begin by composting crop residues such
9. and debris that have accumulated on the tine shaft or inside the tine holders Please follow this maintenance recommendation as debris can cause premature wear to the tine shaft and its oil seals Refer to the previous tine holder removal instructions After cleaning away any debris and removing old grease from the tine shaft apply fresh grease to the tine shaft Wheel Shaft Maintenance After every 10 operating hours remove the wheels and clear away dirt and debris that has accumulated on the wheel shaft Please follow this maintenance recommendation as debris can cause premature wear to the wheel shaft and its oil seals 1 Prop the transmission up with a sturdy block to raise the wheels off the ground 2 Remove the wheels by removing the hex bolt and lock nut which secures each to the wheel shaft 3 After cleaning away any debris and removing old grease apply fresh grease to the wheel shaft before re installing the wheels Hardware Check for loose or missing hardware every ten 10 operating hours Failure to tighten or replace fasteners can cause poor performance equipment damage or oil leakage Most hardware on your tiller is visible Pay particular attention to hardware listed below SECTION 6 MAINTENANCE amp ADJUSTMENTS Transmission Pulley Mounting Bolt 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 b
10. be kept very tight to prevent damaging wear to the dog clutch coupling alignment pin or the alignment hole Check the bolt tightness every 2 operating hours Remove the engine support before moving the tiller in a forward direction SECTION 5 OPERATION 23 24 Moving the Tiller 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 FREEWHEEL position to roll the tiller to another location WARNING To help avoid personal injury from revolving tines always put the Tines PTO Clutch Lever in DISENGAGE position before transporting loading or unloading tiller 1 Place the Tines PTO Clutch Lever in DISENGAGE position 2 Move the Depth Regulator Lever down all the way into the Travel setting 3 If using engine power move Wheel Speed Lever to either SLOW or FAST and use the Wheels Tines PTO Drive Lever to drive the wheels 4 If the engine is stopped move Wheel Speed Lever to FREEWHEEL and manually push the tiller Loading amp Unloading the Tiller The following provides information on tiller loading unloading and requirements before loading and unloading the tiller Read the following instructions carefully before attempting to load or unload your tiller Follow these steps before loading or unloading the Tiller Ramps must be strong enough to support the combined weight of the tiller an
11. find the balance point between the engine and the tines by lifting up the handlebars See Fig 4 4 Once you find the balance point 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 Figure 4 4 1 Atthe end of a row move the Wheels Tines PTO Drive Lever to NEUTRAL position and reduce the engine speed 2 Move the Tines PTO Clutch Lever into the DISENGAGE position 3 Resume forward operation and lift the handlebars until the tines are off the ground Refer to Fig 4 4 Find the balance point between the 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 disengaged Let the powered wheels do the hard work NOTE Use REVERSE if necessary to turn in a limited space 4 When the turn is complete shift to NEUTRAL and lower the handlebars Move the Tines PTO Clutch Lever back to ENGAGE position and resume forward operation SECTION 5 OPERATION 15 When tilling untilled or hard earth do not set the Depth Regulator too deep The tiller will buck and the engine will load down Choosing Wheel amp Tine Speeds 7 The tiller has four FORWARD wheel tine speed combinations for handling a variety of tilling tasks and garde
12. have to lift the handlebars slightly while going uphill When going downhill overlap the first pass by about one half the width of the tiller NOTE For the 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 SECTION 5 OPERATION Terrace Gardening When a slope is too steep or too short for vertical tilling it may be necessary to till across the slope and create terraced rows Terraces are rows that are cut into the side of a slope creating a narrow but flat area on which to plant On along slope you can make several terraces one below the other Terraces should 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 See Fig 4 15 ett 0 oE l 12 UNTILLED o jeer D REPEAT gt Figure 4 15 Each succeeding lower terrace is started by walking below the terrace you re preparing For added 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 Tilling
13. 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 See Fig 7 1 Figure 7 3 6 Push the Wheels Tines PTO Drive Lever down into the FORWARD position This increases the distance between the upper and lower pulleys Next lift and pull the entire belt out from between the pulleys See Fig 7 4 Figure 7 1 4 Push the belt upward to create slack in the belt See Fig 7 2 Figure 7 4 7 Place the Wheels Tines PTO Drive Lever in FORWARD position 8 Squeeze the belt in the middle and insert one end in between the pulleys See Fig 7 4 Figure 7 2 37 38 10 11 12 13 14 15 Reverse Disc Follow these steps to replace the reverse disc If your tiller has a Bumper Attachment mounted it must be removed first 1 2 Push the belt forward then down until it is looped over the 3 Use a 6 wrench to loosen the mounting bolt shown in lower pulley See Fig 7 2 Do not yet seat it in either of the Fig 7 6 Remember to immobilize the pulley with the wood lower pulley s grooves 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 lockwasher along with the disc Move the top half of the belt up and over the rubb
14. reduced handlebars don t have to be raised and organic matter most soils Mixing in fertilizers Tilling in stony ground DAYLE Building raised garden beds Mixing in fertilizer Using tiller wings in hard soil Mixing fertilizer and manure Tilling residues and organics Keeping large areas tilled and cultivated in the summer going too deep Tilling large areas Tilling organic matter in Tilling organic matter Cultivating between under raised beds with optional hiller furrower attachment Moving tiller quickly Cultivating between raised beds using the optional hiller furrower Figure 4 5 Changing Belt speed Your tiller has two belt driven speed ranges HIGH RANGE and 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 FAST and SLOW wheel speeds you obtain a choice of four different forward wheel speeds and two different tine speeds WARNING 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 down before changing the belt speeds 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 This change is done
15. the Wheels Tines PTO Drive Lever up in REVERSE position this lowers the rubberized reverse disc it s attached to the engine drive pulley until this rotating disc contacts the transmission drive pulley The friction between the rotating reverse disc and the transmission pulley causes the transmission drive shaft to be powered in a counterclockwise direction as viewed from the operator s position behind handlebars The drive shaft then turns the wheels and tine shafts in a reverse direction The reverse disc is made of steel with a special long lasting rubber compound bonded to the disc rim Since this is a wearing part it should be inspected after every 30 operating hours SECTION 6 MAINTENANCE amp ADJUSTMENTS 34 1 Measure the width of the outside edge of the disc as shown in Fig 6 18 Replace the disc before the rubber edge wears to a thickness of s or less Failure to do so could cause the steel underneath the rubber to damage the transmission pulley Figure 6 18 2 Look for big cracks or missing chunks of rubber from the disc If so damaged the disc should be replaced immediately See the Service section of this manual for instructions on replacing the disc NOTE 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 Checking and Adjust
16. the instructions provided in the Maintenance amp Adjustments section Reconnect the cables and securely tighten to the battery posts The engine will recharge the battery if the battery is still good WARNING To help avoid personal injury be aware that the tiller can unexpectedly bounce up or jump ahead and propel away from you if the tines strike hard or frozen ground or buried obstacles like large stones roots or stumps 1 Start the engine and gradually increase the engine speed to FAST Test the Forward Interlock Safety System See the Forward Interlock System in the Maintenance amp Adjusments section for more information WARNING The Forward Interlock Safety System is designed for the operator s safety Do not disconnect or attempt to defeat the purpose of the system If the system malfunctions immediately contact your local authorized dealer or the TROYBILT Technical Service Department for assistance Do not use the tiller or the PTO power feature until the e If you suspect the batter is dead or if the battery is damaged disconnect and remove it Have it checked by a qualified technician m If the battery has been removed wrap the cable terminals at the end of the 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 RUN position Move the Throttle Lever aw
17. to but not touching the lever Tine Hardware Check the four bolts and nuts securing left and right tine holders to the tine shaft See Fig 6 4 Figure 6 4 Transmission Gear Oil Checking for oil leaks At 25 hour operation intervals check the tiller for oil leaks Inspect for oil accumulations on the tiller or the floor where it is stored A small amount of oil seepage or 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 PTO transmission 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 SECTION 6 MAINTENANCE amp ADJUSTMENTS 27 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 tine attachment transmissions have oil relief vents See Fig 6 5 Figure 6 5 The vents allow small amounts of oil to seep out e If a serious leak is discovered please contact your authorized dealer or the Factory Technical Service Department for service advice Checking Gear Oil Levels Every 30 hours of operation check the ge
18. to safely hold the weight of the tiller and the operator combined your tiller weighs between 280 and 325 Ibs Move the Tines PTO Clutch Lever to DISENGAGE position Set the Depth Regulator Lever to the TRAVEL position Move Wheel Speed Lever to SLOW position and reduce the engine throttle speed NOTE Look behind you before you back down the ramp to ensure that all is clear While descending keep checking for obstacles behind you 5 Move and hold the Wheels Tines PTO Lever into REVERSE drive and back down the ramps Check the wheels as you move the tiller backward Ensure that they move down the center of each ramp Maintenance amp Adjustments 6 Maintenance Schedule Check Engine Oil Level Clean Engine Cooling System Test Operation of FWD Interlock Safety System FWD Interlock Safety System Check Wire Condition Connections Check Electrical Connections Recharge Battery Check Drive Belt Tension Check Nuts and Bolts Clean Tiller Tine Shaft Lubricate Tiller Change Engine Oil Clean Foam Element Air Filter Check Paper Element Filter Check Gear Oil Lever in Both Transmissions Check Bolo Tines for Wear Check Reverse Disc for Wear Check Air Pressure in Tire After 2 hour Before Each Every 10 Every 25 Every 30 Refer to En Break In Use Hours Hours Hours gine Manual ty 3 LESS TELE s sss LEN WARNING Before inspecting cleaning or Maintenance servici
19. wire and other foreign objects which could be tripped over and cause personal injury When practical remove gas powered equipment from the truck or trailer and refuel it on the ground If this is not possible then refuel such equipment on a trailer with a portable container rather than from a gasoline dispenser nozzle d Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete Do not use a nozzle lock open device e Extinguish all cigarettes cigars pipes and other sources of ignition f Never fuel machine indoors g Never remove gas cap or add fuel while the engine is hot or running Allow engine to cool at least two minutes before refueling h Never over fill fuel tank Fill tank to no more than 1 inch below bottom of filler neck to allow space for fuel expansion i Replace gasoline cap and tighten securely j If gasoline is spilled wipe it off the engine and equipment Move unit to another area Wait 5 minutes before starting the engine k To reduce fire hazards keep machine free of grass leaves or other debris build up Clean up oil or fuel spillage and remove any fuel soaked debris Never store the machine or fuel container inside where there is an open flame spark or pilot light as on a water heater space heater furnace clothes dryer or other gas appliances Operation 1 Donot put hands or feet near rotating parts Contac
20. F OF PURCHASE through your local authorized service dealer To locate the dealer in your area In the U S A Check your Yellow Pages or contact Troy Bilt LLC at P O Box 361131 Cleveland Ohio 44136 0019 or call 1 866 840 6483 1 330 558 7220 or log on to our Web site at www troybilt com In Canada Contact MTD Products Limited Kitchener ON N2G 4 1 or call 1 800 668 1238 or log on to our Web site at www mtdcanada com This limited warranty does not provide coverage in the following cases a The engine or component parts thereof These items may carry a Separate manufacturer s warranty Refer to applicable manufactur er s warranty for terms and conditions b Log splitter pumps valves and cylinders have a separate one year warranty c Routine maintenance items such as lubricants filters blade Sharpening tune ups brake adjustments clutch adjustments deck adjustments and normal deterioration of the exterior finish due to use or exposure d Service completed by someone other than an authorized service dealer e Troy Bilt does not extend any warranty for products sold or exported outside of the United States and or Canada and their respective possessions and territories except those sold through Troy Bilt s authorized channels of export distribution f Replacement parts that are not genuine Troy Bilt parts g Transportation charges and service calls h Troy Bilt does not warrant this product for com
21. Interlock System on the next page Draining and Filling the PTO Power Unit Transmission 1 Place a shallow pan under the transmission gear oil drain plug See Fig 6 8 Fill Hole er 27 Oil Level Check Plug EIN Gear Oil SS Drain Figure 6 8 2 Remove the oil level check plug with a 3 wrench This vents the transmission for faster oil draining SECTION 6 MAINTENANCE amp ADJUSTMENTS 29 30 3 Using the 3s wrench remove the drain plug The gear oil will drain quite slowly since it is thick After about two quarts have drained tilt the tiller forward so any oil at the rear of the transmission will drain out 4 Clean the drain plug threads put non hardening gasket sealant on the threads and reinstall the 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 Adding Gear Oil to the Tine Attachment Transmission 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 tine attachment See Fig 6 6 3 Slowly add gear oil in the dipstick hole Add 2 ounce at a time to avoid overfilling It takes about 12 ounces 4 Take
22. Tap side of bowl lightly with handle of screwdriver or similar object 10 Drain old fuel and add new fuel 11 Open the valve up completely 12 Contact authorized service dealer 13 Charge battery 14 Contact authorized service dealer Contact authorized service dealer Contact authorized service dealer Contact authorized service dealer Inspect spark plug see Engine Operator s Manual See Engine Operator s Manual Contact authorized service dealer Contact authorized service dealer Contact authorized service dealer See Engine Operator s Manual Adjust tilling depth 4 Contact authorized service dealer Contact authorized service dealer Contact authorized service dealer See Engine Operator s Manual for instructions on adding oil Wheels and tines do not turn Wheels and tines turn on top of ground but stop or hesitate in soil Wheels turn but tines do not Tines turn but wheels do not Wheels Tines PTO Lever does not stay in forward Wheels Tines PTO Lever hard to shift into reverse Tiller stays in reverse or forward when Wheels Tines PTO Lever is released or lever is hard to shift Wheel Speed Lever is hard to shift Wheel Speed Lever shifts into FAST gear but not SLOW Wheel Speed Lever moves freely but does not change gears Cause 1 Misadjusted drive belt and or reverse disc 2 Loose bolt on transmission drive pulley 3 Worn worm gears 1 Loos
23. amiliar with all the controls and their proper operation Know how to stop the machine and disengage it quickly NOTE For detailed information on all engine controls refer to the seperate Engine Operator s Manual Wheels Tines PTO Drive Lever Use the Wheels Tones PTO Drive Lever to engage and disengage power to the transmission Forward Interlock Levers The Forward Interlock Levers are attached under the handlebar grip and will stop the engine if both levers are released Wheel Speed Lever The Wheels speed lever controls the speed at which the wheels spin Tines PTO Clutch Lever The Tines PTO Clutch Lever is used to engage or disengage power to the transmission Depth Regulator Lever The Depth Regulator Lever is used to regulate the tilling depth of the tines Handlebar Height Adjustment Lever The Handlebar Height Adjustment Lever is used to adjust the handlebars to one of two heights Engine Throttle Lever Use the throttle lever to adjust engine speed as well as to start and stop the engine Keyswitch Starter The keyswitch starter on electric start models is used to start run and stop the tiller Operation Starting the Engine The following steps describe how to start and stop the engine NOTE Do not attempt to engage the tines wheels or any PTO attachment until you have read all of the operating instructions in this section Pre Start Checklist Make the following checks and perform th
24. ar oil level in both the power unit transmission and the tine attachment transmission Operating them while low on gear oil even briefly can cause serious damage to internal components 1 The transmissions must be cool since hot gear oil expands and gives a false reading 2 The power unit transmission and the tine attachment transmission must be connected when checking or adding gear oil 3 Move the tiller to level ground Move the Depth Regulator up so the tines rest on the ground SECTION 6 MAINTENANCE amp ADJUSTMENTS 4 Use a3 wrench to remove the oil level check plug on the left side of the transmission housing See Fig 6 6 a gs CS gt SD P D NNN Bek Oil Leve ack 377 VIS J WIS as Figure 6 6 5 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 the check plug If no oil seeps out add oil as demonstrated in the Adding Oil Section on the next page Tine Attachment Oil Level NOTE 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 transmission to see which type dipstick yo
25. 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 Standing cornstalks of reasonable height can be power composted See Fig 4 17 Pushing over but not uprooting cornstalks will often make it easier for your tiller to chop up the stalks Keep the tines clear of excessive tangling by fishtailing or frequently using reverse Make several passes then return a few days later to finish off any remaining stubble Figure 4 17 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 Grow a crop of clover alfalfa buckwheat peas beans rye grass grain or kale and then till it into the soil prior to the planting season 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 aside for an area that has narro
26. ass by one half the width of the tiller 3 Till as deeply as possible Pull the Depth Regulator all the way UP and engage the lowest notch for deep tilling Use either LOW or HIGH belt range and SLOW wheel speed gear position Let the tilled in stalks decompose for a week or so Then till in the remaining residue as deep as possible PTO Power Feature Your tiller is a self contained PTO Power Take Off Power machine that was shipped with a tine attachment installed The tine attachment can be quickly removed and replaced with other optional attachments See Fig 4 18 The following instructions will familiarize you with your PTO Power machine Please read these pages carefully The following steps explain how to remove and replace the tine attachment You will need a 3 4 wrench minimum 12 long for leverage Figure 4 19 Place the Wheels Tines PTO Drive Lever into NEUTRAL Place Tines PTO Clutch Lever in DISENGAGE Place Wheel Speed Lever into FREE WHEEL Loosen the two swing out bolts that connect the power transmission to the tine attachment See Fig 4 20 Figure 4 12 NOTE Before operating your PTO Power machine for the first time make sure that you have Read all the safety instructions in the Safe Operation Practices section of this manual and in the as well as the manual supplied with any attachment Read the controls information and operating procedures for the tiller and engine described in the Assembly
27. 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 See Fig 4 7 Figure 4 8 6 Finish seating the belt from the right side of the tiller NOTE Proper belt tension is important for good performance See the Maintenance amp Adjustment Section for instructions on adjusting belt tension NOTE lf 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 7 Check both sides of the high range pulley grooves to verify that the belt is properly seated Changing Belt From High Range to Low Range 1 To avoid personal injury shut off the engine let all moving parts come to a complete stop then disconnect the spark plug wire from the spark plug and move the wire away Figure 4 7 from spark plug before making any adjustments Let engine and muffler cool 4 Goto the other side of the tiller to finish seating the belt onto the pulley groove 2 Move the Wheels Tines PTO Drive Lever into NEUTRAL SECTION 5 OPERATION 17 18 3 Stand on the left side of the tiller Use your right hand to hold the Wheels Tines PTO Drive Lever up into REVERSE position Use your left hand to move the belt off the top front engine pulley groove to top rear engine pulley groove See Fig 4 9 Figure 4 9 4 Goto the right side of tiller an
28. at the bottom of the c Ifthe slotted part of the tool will not fit in the belt is lever should be positioned underneath the belt adjustment too loose block See Fig 6 13 Don t let the clutch roller move during d If the full thickness of the tool easily fits in the the next few steps If it moves you ll get a false belt tension belt is too tight reading 4 If the belt tension is correct move the Wheels Tines PTO Drive Lever back to NEUTRAL How to Adjust the Belt Tension 1 As described in the following steps the drive belt tension is adjusted by moving the adjustment block up or down Moving it down will tighten the belt moving it up loosens the belt NOTE 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 2 Move the Wheels Tines PTO Drive Lever to NEUTRAL position 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 Figure 6 13 3 The belt tension is correct if the front of the clutch roller is 4 to 16 away from the face of the upright bracket that holds the adjustment block in place See Fig 6 13 To measure this distance SECTION 6 MAINTENANCE amp ADJUSTMENTS 3 Insert the belt adjustment tool through the h
29. ay from the STOP position and set the choke as applicable See the Engine Operator s Manual Cold Weather Operation Forward Interlock Safety System is functioning When temperatures fall below 40 F do the following steps to pepe protect your engine and transmission from damage 3 When practicing set the Depth Regulator Lever to Travel 1 Refer to the Engine Operator s Manual for the motor oil Dapi Regulator LEVE TOA desired depth specifications for cold weather operation 4 Move Tines PTO Clutch Lever to ENGAGE position if you want the tines to turn If practicing leave in DISENGAGE NOTE Do not move Tines PTO Clutch Lever to ENGAGE 2 Use winter blend gasoline Warm the engine up before putting it under a load 4 056 the correct weight gear oil in the PTO Power unless Wheels Tines PTO Drive Lever is in NEUTRAL Tiller transmission damage may occur 5 Warm up the transmission gear oil as follows 5 To move the tiller forward and engage the tines squeeze a With the engine running move the Wheel Speed and hold either Forward Interlock Lever against the Lever to FREEWHEEL then block the wheels so they handlebar grip See Fig 4 2 then move the Wheels Tines can t roll PTO Drive Lever down to FORWARD position b Putthe Tines PTO Clutch Lever into DISENGAGE then squeeze one of the Forward Interlock Levers and shift the Wheels Tines PTO Drive Lever to FORWARD 6 Ifthe wheels are frozen to the grou
30. bolt should be adjusted upward Moving the adjustment bolt upward will also solve problem of a tiller that goes into REVERSE on its own Reverse Disc 2 Figure 6 20 Use your left hand to hold the Wheels Tines PTO Drive Lever up in REVERSE while briefly pulling out engine recoil starter The reverse disc should turn the lower pulley See Fig 6 21 If not or it requires a lot of pressure to hold the lever up in REVERSE then the 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 6 21 Shift the Wheels Tines PTO Drive Lever to REVERSE and then let it go The lever should return to NEUTRAL If not the reverse adjustment bolt will have to be adjusted upward Adjusting the Reverse Drive 1 Place the Wheels Tines PTO Drive Lever in FORWARD position On the left side of the tiller put a 1 2 wrench on the plunger retaining bolt and another 2 wrench on the jam nut next to it See Fig 6 22 Figure 6 22 While holding the bolt steady loosen the jam nut counterclockwise until it touches the bolt head Turn the bolt in until it tightens against the plunger inside the spring The bolt must be tight to prevent the plunger from turning be careful not to overtighten and break the bolt Place a 78 wre
31. cted or clogged Choke control improperly set Water or dirt in fuel and or fuel system Spark plug fouled or worn loose or damaged Carburetor out of adjustment Air filter clogged with oil or dirt Carburetor float faulty or float valve leaking 10 Stale fuel clogs carburetor and valves 11 Fuel tank shut off valve if equipped not in fully Open position 12 Electrical connections loose or shorted to metal frames brackets or covers Electric Start tillers only 13 Battery discharged Electric Start tillers only 14 Electric starter motor faulty if equipped Broken flywheel fins under engine shroud Water or dirt in gasoline or carburetor Carburetor out of adjustment Defective or incorrectly gapped spark plug Loose or cracked carburetor Governor linkage not adjusted properly or binding Check pan gasket engine seals and drain plugs for leaks Governor linkage too tight Carburetor or throttle out of adjustment Tilling depth too deep 4 Worn tiller worm gear or loose drive shaft Short in key switch or key switch wire Starter motor mounting bolts loose Oil level low Remedy Put Wheels Tines PTO Drive Lever in Neutral Add Fuel Contact authorized sevice dealer 4 See Engine Operator s Manual 5 Drain Fuel and fresh fuel 6 Inspect spark plug replace if neccessary See Engine Operator s Manual See Engine Operator s Manual
32. d finish seating the belt Still holding the lever up in REVERSE position and working from the left side of the tiller move the belt from the lower front transmission groove to the lower rear transmission groove 6 Goto the right side of the tiller and finish seating the belt See Fig 4 10 pA s m E a Figure 4 10 7 Check that the belt is fully seated in the pulley grooves Check this from both sides of the tiller SECTION 5 OPERATION 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 these procedures to help avoid tangling and to clear the tines if necessary 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 handlebars from side to side about 6 to 12 This fishtailing action often clears the tines of debris It may be necessary to remove the debris by hand a pocket knife will help you to cut away the material WARNING Before clearing 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 Tilling Tips amp Tech
33. d or electrical burns gt Before installing the battery and its hold down clamp insert the plastic wire harness receptacle into the prongs of the keyswitch located on the hold down clamp See Fig Negative Negative Battery Keyswitch Cable Figure 3 14 2 Remove the ignition keys from the keyswitch and store them safely away Do not insert the key into the keyswitch until you complete this section and read the Operation section See Fig 3 14 Use a long screw and 4 20 hex nut to connect the positive battery cable to the positive battery post Make sure that this is the cable on the left side with one end attached to the solenoid See Fig 3 14 WARNING To Avoid Personal Injury or Property Damage Do not touch the 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 burns or an explosion of battery gases 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 Slide the black rubber boot completely over the battery post and cable connector See Fig 3 14 Use a long screw and 4 20 hex nut to connect the negative battery cable to the negative battery post and secure with screw and nut See Fig 3 14 Sl
34. d or grass covered land unless the engine s exhaust system is equipped with a spark arrester meeting applicable local or state laws if any If a spark arrester is used it should be maintained in effective working order by the operator In the State of California the above is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands A spark arrester for the muffler is available through your nearest engine authorized service dealer or contact the service department P O Box 361131 Cleveland Ohio 44136 0019 Average Useful Life According to the Consumer Products Safety Commission CPSC and the U S Environmental Protection Agency EPA this product has an Average Useful Life of seven 7 years or 130 hours of operation At the end of the Average Useful Life buy a new machine or have the machine inspected annually by an authorized service dealer to ensure that all mechanical and safety systems are working properly and not worn excessively Failure to do so can result in accidents injuries or death WARNING Your Responsibility Restrict the use of this power machine to persons who read understand and follow the warnings and instructions in this manual and on the machine SAVE THESE INSTRUCTIONS SECTION 2 IMPORTANT SAFE OPERATION PRACTICES 5 Assembly amp Set Up Contents of Carton s One Tiller One Handlebar Support s O
35. d the 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 gt Handlers should wear sturdy footwear that will help to prevent slipping gt 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 1 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 into DISENGAGE position Set the Depth Regulator lever to the Travel position 4 Move Wheel Speed Lever into SLOW position and reduce the engine throttle speed 5 Shift the Wheels Tines PTO Lever into FORWARD position and follow the tiller up the ramps Check the wheels as you move the tiller forward Ensure that they move up the center of each ramp 6 Prevent the tiller from rolling in vehicle Leave Wheel Speed Lever in FAST or SLOW position chock the wheels with blocks and tie down the tiller SECTION 5 OPERATION Unloading the Tiller NOTE Never unload the tiller in FORWARD drive The tiller could tip forward and expose you to the tines which should be disengaged as instructed 1 Use loading ramps that are strong and wide enough
36. date of original purchase and will at its option repair or replace free of charge any part found to be defective in materials or workmanship This limited warranty shall only apply if this product has been Operated and maintained in accordance with the Operator s Manual furnished with the product and has not been subject to misuse abuse commercial use neglect accident improper maintenance alteration vandalism theft fire water or damage because of other peril or natural disaster Damage resulting from the installation or use of any part accessory or attachment not approved by Troy Bilt for use with the product s covered by this manual will void your warranty as to any resulting damage Belts are warranted to be free from defects in material and workmanship for a period of thirty 30 days from the date of purchase Transmission Troy Bilt warrants the transmission including all gears shafts and housings against defects in material and workmanship for the life of the tiller to the original purchaser only commencing on the date of original purchase or lease Attachments Troy Bilt warrants attachments for this product against defects in material and workmanship for a period of one 1 year commencing on the date of the attachment s original purchase or lease Attachments include but are not limited to items such as grass collectors and mulch kits HOW TO OBTAIN SERVICE Warranty service is available WITH PROO
37. dipstick readings frequently Stop when oil reaches Cold range marking on dipstick Replace dipstick securely Draining and Filling the Tine Attachment Transmission 1 The tine attachment transmission is not equipped with an oil drain plug To drain just 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 left side tine assembly See Tine Replacement in the Service section then remove just one of the lower screws from the tiller housing cover See Fig 6 9 To speed drainage remove the tine attachment dipstick to vent transmission Figure 6 9 NOTE lf you find a plastic washer on the cover screw you remove discard the washer There is no need to install a replacement washer SECTION 6 MAINTENANCE amp ADJUSTMENTS 3 Once all the 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 Forward Interlock System The wiring circuit for the Forward Interlock Safety System 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
38. e drive belt 2 Loose bolt on transmission drive pulley 1 Tines PTO clutch lever not engage 2 Tines PTO clutch lever out of adjustment 3 Dog clutch key missing 4 Worn worm gears 5 Missing or broken tines or tine hardware 1 Missing Hi Pro key inside wheel clutch 2 Worn gears 3 Drive dogs on wheel clutch worn out or broken 1 Drive belt too tight 2 Clutch Pawl spring overstretched 1 Worn reverse disc 2 Motor mount bars sticking 1 Motor mount bars sticking 1 Eccentric lever is sticking 2 Clutch inside transmission binding 1 Connecting rod at back of lever backwards or bent in towards transmission and hitting it 2 Clutch inside transmission binding 1 Broken or worn eccentric shifting pin Remedy See Maintenance amp Adjustments Section Tighten bolt See authorized service dealer Adjust drive belt See Maintenance amp Adjustments Section Tighten bolt Engage lever See Maintenance amp Adjustments Section Contact authorized service dealer Contact authorized service dealer See Service Section Contact authorized service dealer Contact authorized service dealer Contact authorized service dealer See Maintenance amp Adjustments Section Replace spring Replace reverse disc Lubricate mount bars Lubricate motor mount bars Lubrictate the eccentric lever and linkage to wheel speed lever Contact authorized service deale
39. e following services before starting the engine 1 Read the Safe Operation Practices and Features amp Controls sections in this Manual Read the separate Engine Operator s Manual 2 Check the tiller for loose or missing hardware Service as required Check the engine oil level See Engine Operator s Manual 4 Shift the Wheels Tines PTO Drive lever into NEUTRAL position See the Controls and Features section for more information on this lever 5 Check the safety guards All guards and covers must be securely in place 6 Check the air cleaner See the Engine Operator s Manual Attach the spark plug wire to spark plug 8 Check Engine Cooling System Clear cooling fins and air intake screen of debris See the Engine Operator s Manual 9 Select High Low Belt Speed range 10 Adjust the Handlebar Height 11 Fill the fuel tank with gasoline in accordance with the directions in the separate Engine Operator s Manual Follow all instructions and safety rules carefully WARNING Never run the engine indoors or in an enclosed poorly ventilated are Engine exhaust contains carbon monoxide an odorless and deadly gas Avoid engine muffler and nearby areas Temperatures in these areas may exceed 150 F NOTE After the first two hours of operation perform the maintenance procedures shown in the Maintenance Schedule in the Maintenance amp Adjustments Section of this manual Starting the Engine 1 With
40. ectric start system place one hand on the fuel tank to stabilize the tiller when you pull the recoil starter rope If equipped with an electric start system turn the key to START position to crank the engine then release when the engine starts If the engine does not start right away do not hold the key at START for more than a few seconds Release then try again after a short pause Damage to the starter motor can occur if it is cranked more than 15 seconds per minute If the engine does not start after a number of tries refer to the Engine Operator s Manual for specific instructions When the engine starts move the Throttle Lever to the SLOW position and then gradually move the choke lever on engines so equipped to OFF or RUN position Move the throttle speed control to FAST setting when tilling 13 Starting Electric Start Engine with Recoil Starter Engaging the Drive amp Tines You may at some point have to start an electric start engine NOTE This is a traditional standard rotating tine SRT tiller with the recoil starter rope Before attempting to do so perform With forward rotating tines It operates in a completely different the following applicable steps manner than counter rotating tine CRT tillers or from front tine If you suspect the battery charge is weak and there is no tillers visible damage Disconnect the cables from the battery and clean both cable terminals and the battery posts in accordance with
41. er Installing a new Reverse Disc reverse disc but do not seat it in either of the grooves in the top pulley Place the Wheels Tines PTO Drive Lever in NEUTRAL NOTE A blunt object like a ruler can help you push the belt downward if needed Move the top half of the belt into the HIGH Range groove the groove closest to the engine on the top pulley See Fig Wood Wedge Figure 7 6 4 Do steps 1 through 3 in the opposite order to install the new reverse disc 5 Tighten the mounting bolt securely and check for correct operation see the Maintenance amp Adjustments section Figure 7 5 Tines Move the bottom half of the belt into the HIGH Range groove of the lower pulley If extra slack is needed hold up Wheels Tines PTO Drive Lever while moving the belt Verify the belt is seated properly on the pulleys Inspect the tines for wear or damage after every 30 operating hours The rate of wear depends upon the hours of use and soil conditions With use the tines get shorter narrower and more pointed See Fig 7 7 To move the belt to the Low Range position See Changing Belt Speed in the Operation Section After installing the belt check and adjust for correct belt tension as explained previously Move Wheels Tines PTO Drive Lever in NEUTRAL position Wedge a e thick board between top of engine pulley and cast iron housing next to it This immobilizes pulley Avoid contacting reverse disc Figure 7 7
42. following steps 1 Clean the tiller and the engine Do routine tiller lubrication and check for loose hardware 3 Protect the engine from deterioration or damage by referring to the engine storage instructions in your engine manual literature 4 When engine is still warm drain oil from engine crankcase Refill with fresh motor oil 5 Protect the internal cylinder against rust by removing the spark plug and pouring one ounce of clean engine oil into spark plug hole Then slowly pull out the recoil start rope 2 or 3 times to distribute the oil internally Replace spark plug but do not reconnect the plug wire Pull the rope until resistance is felt let rope rewind 6 Charge the battery electric start option Store the battery in cool dry location 7 Move the Wheels Tines PTO Drive Lever to NEUTRAL position Keep the tiller in a clean dry area 8 Never store the tiller with fuel in the 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 Service Belt Replacement 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 Drive Belt reverse disc See Fig 7 3 1 Move the Wheels Tines PTO Drive Lever to NEUTRAL position 2 While kneeling on the right side of the tiller create slack in the belt by reaching over to the left side of the
43. h 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 Loop each tie around the handlebar and cable serrated side faces in and pull the ties tight Trim the ends SECTION 2 ASSEMBLY amp Set Up Electric Start System If Equipped The following steps explain how to install and charge the battery on electric start tillers For your safety follow all steps and observe all accompanying safety messages The Maintenance amp Adjustments section contains other general battery maintenance and recharging instructions WARNING Battery produces explosive gases Keep away sparks flames and cigarettes Ventilate area when charging or using battery in an enclosed space Make sure battery vent tube is always open after battery is filled with acid WARNING 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 shock or battery gas explosion NOTE If the battery is put into service after the date shown on the top of the battery charge for a minimum of one hour at 6 10 amps Refer to the Maintenence amp Adjustments section of this manual for more detailed instructions regarding proper battery charging procedure WARNING Never jump start the battery with a vehicle battery or charging system This may produce a battery explosion causing aci
44. icable to all models Troy Bilt LLC reserves the right to change product specifications designs and equipment without notice and without incurring obligation Table of Contents Safe Operation 6 44 3 Assembly amp Set Up O Controls amp FEATULES cssssccsssrrcessssccsssrcccssssccsssees 12 DD CIT ON 10 Record Product Information Before setting up and operating your new equipment please locate the model plate on the equipment and record the information in the provided area to the right You can locate the model plate by standing at the operator s position and looking down at the rear of the deck This information will be necessary should you seek technical support via our web site Customer Support Department or with a local authorized service dealer Customer Support This product has met the rigid safety standards of the Outdoor Power Equipment Institute and an independent testing laboratory If you have any problems or questions concerning the machine phone a authorized Troy Bilt service dealer or contact us directly Troy Bilt s Customer Support telephone numbers website address and mailing address can be found on this page We want to ensure your complete satisfaction at all times Throughout this manual all references to right and left side of the machine are observed fr
45. ide the black rubber boot completely over the battery post and cable connector See Fig 3 14 Set Up Tires For shipping purposes the tires may be overinflated Check the air pressure in each tire 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 Gas amp Oil Fill Up Service the engine with gasolina and oil as instructed in the Engine Operator s Manual packed seperately with your tiller Read the instructions carefully WARNING Use extreme care when handling gasoline Gasoline is extremely flammable and the vapors are explosive neve fuel the machine indoors or while the engine is hot or running Extinguish cigarettes cigars pipes and any other sources of ignition Transmission Gear Oil The transmission was filled with gear oil at the factory However be sure to check the oil level at this time to make certain it is correct See the Maintenance amp Adjustments section for instructions on checking and adding transmission gear oil SECTION 2 ASSEMBLY amp Set Up 11 12 Controls and Features Handlebar Height Adjustment Lever J As 3 0 S 4 op Wheels Tines PTO Drive Lever Forward Interlock Levers Depth Regulator Lever A NAY y Speed Lever Figure 4 1 Tiller controls and features are described below and illustrated in Fig 4 1 WARNING Be f
46. ines will stop and the engine will continue running 2 Inan emergency release all of the control levers This stops forward motion and shuts off the engine Moving in Reverse WARNING To help avoid personal injury or damage to the equipment be sure no obstacles are behind you before operating the 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 backing the tiller NOTE Do not till while in REVERSE 1 Shift the Tines Wheels PTO Drive Lever into NEUTRAL and move the Wheel Speed Lever to the SLOW position 2 Move the Tines PTO Clutch Lever into DISENGAGE position 3 Verify that the area behind you is clear 4 Lift up the handlebars until the tines are off the ground then shift the Wheels Tines PTO Drive Lever all the way up and hold You do not need to squeeze the Forward Interlock Levers to use reverse 5 The tiller immediately engages in reverse Periodically check behind you while holding the handlebars up and the Wheels Tines PTO Lever in its upper most position Stopping Reverse Motion Release the Wheels Tines PTO Drive Lever the lever automatically returns to the NEUTRAL position This stops the wheels immediately The Forward Interlock Levers will not stop REVERSE motion Turning the Tiller Turning the tiller is easy and just requires practice First
47. ing the Reverse Drive System When the Wheels Tines PTO Drive Lever is moved up into REVERSE the engine and engine mount move down to press on the reverse adjustment bolt See Fig 6 19 Figure 6 19 SECTION 6 MAINTENANCE amp ADJUSTMENTS This action compresses the reverse spring and plunger assembly requiring you to hold the lever up in REVERSE When you release the lever the spring automatically pushes the lever back into NEUTRAL position The spring and plunger assembly is designed to prevent the reverse disc from making contact with the transmission pulley until you shift into REVERSE When the 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 See Fig 6 19 The reverse adjustment bolt can be adjusted up or down to correct a number of reverse drive operating problems as explained next Checking and Adjusting the Reverse Disc 1 Verify that the linkages for Wheels Tines PTO Drive Lever are lubricated with oil and engine mount bars and belt adjustment block are lubricated with grease See Lubrication earlier in this section 2 Place Wheels Tines PTO Drive Lever in NEUTRAL Briefly pull out the engine recoil starter handle while watching the reverse disc The disc should turn but lower pulley should not See Fig 6 20 If the reverse disc turns the lower pulley or if it is located closer than 316 to the pulley reverse adjustment
48. mercial use No implied warranty including any implied warranty of merchantability of fitness for a particular purpose applies after the applicable period of express written warranty above as to the parts as identified No other express warranty whether written or oral except as mentioned above given by any person or entity including a dealer or retailer with respect to any product shall bind Troy Bilt During the period of the warranty the exclusive remedy is repair or replacement of the product as set forth above The provisions as set forth in this warranty provide the sole and exclusive remedy arising from the sale Troy Bilt shall not be liable for incidental or consequential loss or damage including without limitation expenses incurred for substitute or replacement lawn care services or for rental expenses to temporarily replace a warranted product some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts so the above exclusions or limitations may not apply to you In no event shall recovery of any kind be greater than the amount of the purchase price of the product sold Alteration of safety features of the product shall void this warranty You assume the risk and liability for loss damage or injury to you and your property and or to others and their property arising out of the misuse or inability to use the product This limited wa
49. nch on the head of the reverse adjustment bolt and a 6 wrench on the jam nut below it See Fig 6 23 Hold the bolt steady while loosening the jam nut three or four turns y djustment Bolt Figure 6 23 SECTION 6 MAINTENANCE amp ADJUSTMENTS 35 36 6 Move the Wheels Tines PTO Drive Lever to NEUTRAL The switch body on the bottom of the engine mount tab should be resting squarely on top of the reverse adjustment bolt and the reverse disc should be at least 346 away from the transmission drive pulley See Fig 6 19 If the reverse disc is any closer than this raise the reverse adjustment bolt turn it counterclockwise 7 Check that reverse disc is at least 746 away from transmission drive pulley Then hold reverse adjustment bolt steady with one wrench while tightening the jam nut with a second wrench See Fig 6 23 8 Place a chalk or pencil mark on the top edge of the plunger retaining bolt Now while watching the mark loosen the bolt 34 turn See Fig 6 24 Do not exceed a 3 4 turn This would disengage the bolt from the locking groove in the side of the plunger Figure 6 24 9 Hold the plunger retaining bolt steady with a wrench while tightening the jam nut against the side of the plunger housing See Fig 6 22 10 Check the action of the reverse disc as explained previously NOTE lf the above adjustments have not corrected an improperly working reverse drive contac
50. nd melt the ice with warm water Stopping the Engine and the Tiller 1 Tostop the wheels and tines move the Wheels Tines PTO Drive Lever into NEUTRAL position and then release both Forward Interlock Levers 2 Move the engine Throttle Lever to the STOP position Then on electric start models turn the key to OFF Remove the key for safekeeping NOTE The engine may have a separate Throttle Control Lever and ON OFF switch on the engine These controls can also be used to stop the engine See the Engine Operator s Manual for information specific to your engine Figure 4 2 14 SECTION 5 OPERATION 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 Use a firm grip on the handlebars but keep your arm relaxed See Fig 4 3 Sere ok Lae fy sree ji AZ NZ ly tf 4 iY 3 2 Figure 4 3 NOTE Let the tiller move ahead at its own pace Do not push it ahead this reduces operator control and tilling efficiency Do not push the 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 Stopping Forward Motion amp Tines 1 To stop forward motion tap Wheels Tines PTO Drive Lever upward into NEUTRAL Then release the Forward Interlock Levers The wheels and t
51. ne Handlebar Assembly e One Hardware Pack One Wheels Tines PTO Lever e One Operator s Manual damage do not start the engine until all assembly steps are complete and you have read and this manual Resommended Tools for Assembly 78 open end wrench 1 746 open end wrench 2 Yo open end wrench 2 716 open end wrench 1 34 open end wrench 1 Flat blade screwdriver 1 Scissors to trim plastic ties Tire pressure gauge 1 4 2 high wood block to prop machinne Contents of Hardware Pack 26 oz Bottle SAE 30W Oil 1 Clutch Pawl Spring 1 Belt Adjusting Tool 1 Plastic Cable Ties 2 Curved Head Screw 20 x 2 1 Flanged Lock Nut 14 20 1 Pan Head Screw 10 32 x 1 1 The following parts electric start models only packaged separately Nuts 20 for battery terminals 2 Screws 4 20 x for battery terminals 2 Keys in ignition switch 2 Assembly Unpacking Instructions NOTE Do not severely bend any of the control cables on the tiller 1 The tiller is heavy Do not attempt to remove it from the shipping platform until instructed to do so in these assembly steps Remove all unassembled parts from the carton The hardware bag is included in your literature packaging WARNING To prevent personal injury or property understand the safety and operating instructions in 3 Check that you have the items listed above contact your local dealer or the Factory if any i
52. ng the tiller shut off the engine and wait for all the parts to come to a complete stop Disconnect Engine the spark plug wire and move the wire away from the spark plug Remove the ignition key on the electric start models Failure to follow these Refer to the Engine Operator s Manual packed with your machine for all engine maintenance instructions can result in serious personal injury or property damage 25 26 Tire Pressure Check the air pressure in both tires every 30 operating hours Deflate or inflate both tires evenly to 15 to 20 PSI pounds per square inch Be sure that both tires have the same air pressure or the tiller will tend to pull to one side Air Filter Refer to the Engine Operator s Manual supplied with your tiller for complete air cleaner service and maintenance information Battery WARNING When removing the battery always disconnect the negative cable first followed by the positive cable Reverse this procedure when reinstalling the battery The battery is sealed and is maintenence free Acid levels cannot be checked Always keep the battery cables and terminals clean and free of corrosive build up After cleaning the battery and terminals apply a light coat of petroleum jelly or grease to the terminals and cover both terminals with the rubber boots Tine Shaft After every 10 operating hours remove the left and right side Bolo Tine holders and clear away dirt
53. ning jobs Experiment with the tine depth engine speed and wheel tine speed to determine the combination that provides the best results Here are some tips 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 steady and smooth See Fig 4 5 1 Advance the throttle lever so the engine has sufficient power WHEEL SPEED AND BELT RANGE SELECTION GUIDE SLOW GEAR LOW BELT RANGE SLOW GEAR HIGH BELT RANGE FAST GEAR LOW BELT RANGE FAST GEAR HIGH BELT RANGE 16 For L Tilling in sod Tilling in hard clay Tilling under standing cornstalks in tough soil conditions Tilling under cover crops Preparing a deep seedbed Tilling in stony soil Tilling under residues Tilling in sod or hard clay Tilling under standing cornstalks slow steady speed allows time to shred stalks Tilling under cover crops best wheel speed and belt speed range in most soils Preparing seedbeds best speed choice in Going over seedbed for the last time before planting crops Covering over seeds in wide row or plot planting lift handlebars to avoid going too deep Hilling and furrowing Making raised beds Cultivating lift handlebars to avoid Preparing seedbeds for planting Covering seeds with less need to hold up the handlebars Cultivating tiller travels faster rides higher on the soil allows engine RPM to be
54. niques Let the Tiller Do the Work 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 Refer to Fig 4 3 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 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 passes through the garden area With each succeeding pass adjust the 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 When cultivating breaking up the surface soil around plants to help destroy weeds use very shallow depth settings to prevent injur
55. nnect the tiller s main harness connection to the neutral safety switch receptacle See Fig 3 5 Figure 3 2 2 Set the Wheel Speed Lever to the Freewheel position To do this move the lever approximately halfway between the Fast and Slow settings while you rock the tiller forward and backward until the wheels move freely See Fig 3 2 3 Lift the Handlebars high enough to clear the tiller tines and pull back firmly to dislodge the tiller from the platform wheel wells Wire Harness 1 Ground the green and red for electric start tillers wire s to the engine block See Fig 3 3 pi Figure 3 5 Figure 3 3 SECTION 2 ASSEMBLY amp Set Up 7 Wheels Tines PTO Drive Lever 1 Loosen the bolt on the handlebar base and swing the handlebars out to the right side See Fig 3 1 Remove both sets of nuts star washers screws and one bushing from the yoke plates See Fig 3 6 There is a bushing inside the short link Be careful not to lose it when removing screw Bushing Yoke T 5 2 Short Lin a 3 6 Slide the plates at the end of the Wheels Tines PTO Lever over the yoke plates See Fig 3 7 To aid in the next step insert a screw temporarily into the forward most holes of the yoke plates and the lever Wheels Tines PTO Drive Lever Pate Forward Hole Figure 3 7 SecTION 2 ASSEMBLY amp Set Up Align the rear most holes of the yoke plates and the Wheels Tines PTO Le
56. ole in the side of the adjustment block spacing the ends of the tool equally on both sides See Fig 6 15 Rotate the tool so the slotted end faces down iii TEEF lt LLETRA Figure 6 15 4 Place the Wheels Tines PTO Drive Lever in FORWARD position 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 See Fig 6 16 5 Use one hand to hold the drive lever in FORWARD while using a 6 wrench to loosen don t remove the bolt at the back of the belt adjustment block See Fig 6 17 The adjustment block should be free to move either up or down Figure 6 17 6 Push the drive lever down if the belt needs tightening Pull the lever up if the belt needs to be loosened Hold the drive lever in place and tighten the bolt in the adjustment block firmly 7 Letgo ofthe drive lever and remove the belt adjustment tool from the hole in the adjustment block 8 Check the tension on 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 4 then a new drive belt is needed Reverse Drive System These instructions explain how to inspect and adjust the various reverse drive components But first here s how the reverse drive system works When you raise
57. olt and wedge the tool against the side of the motor mount casting This immobilizes the pulley while you tighten the bolt See Fig 6 1 Figure 6 1 Neutral Plunger Assembly Jam Nut e The jam nut is located is located on the left side of the neutral plunger If loose immobilize bolt head with one wrench and use another wrench to tighten the nut See Fig 6 2 Figure 6 2 Rear Bearing Cap Screws 5 The three rear bearing cap screws are located under the depth regulator mounting bracket If any are loose it can cause an oil leak or drive shaft end play See Fig 6 3 Transmission Figure 6 3 Housing Cover Bolts Check the five bolts securing the tiller housing cover to the left side of the transmission Gear oil can leak from a loose housing cover To reach the bolts remove the left side tine holder See Tine Replacement in the Service section Swing Bolts e Check both of the swing bolts that connect the power unit transmission to the tine attachment Both bolts should be checked every 2 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 lbs Lock Nut on the Shifting Linkage Check the locknut that fastens the shifting linkage to the eccentric shifting lever See Fig 6 3 Do not tighten the locknut against the eccentric lever It should be very close
58. om the operating position The engine manufacturer is responsible for all engine related issues with regards to performance power rating specifications warranty and service Please refer to the engine manufacturer s Owner s Operator s Manual packed separately with your machine for more information Maintenance 4 6 1 25 DOI CE OF Troubleshooting 40 Replacement Parts 42 MopeL NUMBER WWW SERIAL NUMBER JOCO Please do NOT return the machine to the retailer or dealer without first contacting our Customer Support Department If you have difficulty assembling this product or have any questions regarding the controls operation or maintenance of this machine you can seek help from the experts Choose from the options below 0 Visit us on the web at www troybilt com 0 Calla Customer Support Representative at 800 828 5500 or 330 558 7220 0 Write us at Troy Bilt LLC P O Box 361131 Cleveland OH 44136 0019 Important Safe Operation Practices 2 WARNING This symbol points out important safety instructions which if not followed could endanger the personal safety and or property of yourself and others Read and follow all instructions in this manual before at
59. on regularly Check bolts and screws for proper tightness at frequent intervals to keep the machine in safe working condition Also visually inspect machine for any damage Before cleaning repairing or inspecting stop the engine and make certain the tines and all moving parts have stopped Disconnect the spark plug wire and ground it against the engine to prevent unintended starting Do not change the engine governor settings or over speed the engine The governor controls the maximum safe operating speed of engine Maintain or replace safety and instruction labels as necessary Follow this manual for safe loading unloading transporting and storage of this machine Always refer to the operator s manual for important details if the machine is to be stored for an extended period 9 If the fuel tank has to be drained do this outdoors 10 Observe proper disposal laws and regulations for gas oil etc to protect the environment Notice Regarding Emissions Engines which are certified to comply with California and federal EPA emission regulations for SORE Small Off Road Equipment are certified to operate on regular unleaded gasoline and may include the following emission control systems Engine Modification EM and Three Way Catalyst TWC if so equipped Spark Arrestor WARNING This machine is equipped with an internal combustion engine and should not be used on or near any unimproved forest covered brushcovere
60. psticks With Hot Cold Markings 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 above ground Hot reading Tiller was operated for more than 30 minutes within the past hour Do not use the wood prop to elevate the tiller Follow Steps 4 5 and 6 given for the other dipstick type 6 Remove the dipstick and check the 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 above the Hot range 7 Ifthe level is incorrect see Adding or Changing Gear Oil Adding or Changing Gear Oil For partial 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 of GL 4 or GL 5 For full replacement use SAE 140 or SAE 85W 140 gear oil with an API rating of GL 4 only At the factory SAE 85W 140 weight gear oil is used NOTE Do not use automatic transmission fluid or engine oil They are too light in weight and will result in transmission damage NOTE The gear oil does not need to be changed Do so only if you know or suspect
61. quickly and without tools SECTION 5 OPERATION 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 Fig 4 6 shows the range of wheel and tine speeds available when using the two belt speed ranges and the FAST and SLOW selections on the Wheel Speed Lever Position Lever Speed Low Range Slow 5 MPH 146RPM 1 2 MPH 146RPM 7 MPH 200RPM 1 72 MPH 200RPM Low Range Fast High Range Slow High Range Fast Figure 4 6 Changing Belt From Low Range to High Range 5 Working from the left side of the tiller work the belt as much as possible onto the top front engine pulley groove See Fig 4 8 1 To avoid personal injury shut off the engine let all moving parts come to a complete stop then disconnect the spark plug wire from the spark plug and move the wire away from the spark plug before making any adjustments Wait for the engine and muffler to cool down 2 Move the Wheels Tines PTO Drive Lever into NEUTRAL WARNING The HIGH speed belt range position combined with a FAST wheel speed setting propels the tiller at the fastest pace Reduce the engine throttle speed when starting out to help avoid personal injury or property damage if using this speed combination 3 Kneelon the left side of tiller To create belt slack reach over to the right side of the pulleys and push in
62. r Straighten or replace linkage Contact authorized service dealer Contact authorized service dealer Tiller jumps while tilling 1 Depth Regulator Lever is too deep for soil 1 Use a shallower setting conditions Depth Regulator Lever 1 Depth Regulator Lever bent 1 Straighten lever difficult to move 2 Lubricate lever 2 Depth Regulator Lever sticking SECTION 8 TROUBLESHOOTING 41 42 Replacement Parts 0 Component Part Number and Description 742 04119 Bolo Tine LH 12 742 04118 Bolo Tine RH 12 634 04231 Wheel 16 x 4 6 x 8 756 04171 Reverse Disc 1909286 Throttle Cable Phone 800 800 7310 to order replacement parts or a complete Parts Manual have your full model number and serial number ready Parts Manual downloads are also available free of charge at www mtdproducts com Notes MANUFACTURER S LIMITED WARRANTY FOR OTROVY BILT The limited warranty set forth below is given by Troy Bilt LLC with respect to new merchandise purchased and used in the United States and or its territories and possessions and by MTD Products Limited with respect to new merchandise purchased and used in Canada and or its territories and possessions either entity respectively Troy Bilt Troy Bilt warrants this product excluding its Belts Transmission and Attachments as described below against defects in material and workmanship for a period of two 2 years commencing on the
63. rranty shall not extend to anyone other than the Original purchaser or to the person for whom it was purchased as a gift HOW STATE LAW RELATES TO THIS WARRANTY This limited warranty gives you specific legal rights and you may also have other rights which vary from state to state IMPORTANT Owner must present Original Proof of Purchase to obtain warranty coverage Troy Bilt LLC P O BOX 361131 CLEVELAND OHIO 44136 0019 Phone 1 866 840 6483 1 330 558 7220 MTD Canada Limited KITCHENER ON N2G 4J1 Phone 1 800 668 1238 GDOC 100023 REV C
64. rst passes by onehalf a tiller width followed by successive passes at one quarter width See Fig 4 13 Figure 4 13 SECTION 5 OPERATION 19 20 With planning you can allow enough room between rows to cultivate Leave room for the hood width plus enough extra room for future plant growth See Fig 4 14 Figure 4 14 Tilling on Slopes If you must garden on sloping ground please follow two very important guidelines 1 Till only on moderate slopes never on steep inclines where footing is difficult Review the safety rules in the Safe Operation Practices section It is recommend that you till up and down slopes rather than terracing Tilling vertically on a slope allows maximum planting area and also leaves room for cultivating NOTE When tilling on slopes be sure the correct oil level is maintained in the engine check every one half 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 Keep the engine oil level at the full point at all times Tilling up and down slopes To keep soil 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 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
65. t an authorized dealer or Factory Technical Service Department for assistance Throttle Cable The throttle lever settings are factory adjusted so unnecessary adjustments should not be made However if the engine does not start or stop or respond immediately to various throttle lever settings then adjustments may be necessary Please refer to the Engine Operator s Manual supplied with your tiller for specific adjustment instructions SECTION 6 MAINTENANCE amp ADJUSTMENTS Ignition System Your engine is equipped with an electronic ignition It does not have a 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 Spark Plug 1 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 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 electrodes are 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 replace the plug first tighten it securely by hand then use a spark plug wrench to tighten the plug an extra turn Off Season Storage When your tiller will not be used during the off season prepare it for storage with the
66. t with the rotating parts can amputate hands and feet 2 Do not operate machine while under the influence of alcohol or drugs 3 Never operate this machine without good visibility or light Always be sure of your footing and keep a firm hold on the handles 4 Keep bystanders away from the machine while it is in operation Stop the machine if anyone enters the area 5 Be careful when tilling in hard ground The tines may catch in the ground and propel the tiller forward If this occurs let go of the handle bars and do not restrain the machine 6 Exercise extreme caution when operating on or crossing gravel surfaces Stay alert for hidden hazards or traffic Do not carry passengers 7 Never operate the machine at high transport speeds on hard or slippery surfaces Exercise caution to avoid slipping or falling Look down and behind and use care when in reverse or pulling machine towards you 10 Start the engine according to the instructions found in this manual and keep feet well away from the tines at all times SECTION 2 IMPORTANT SAFE OPERATION PRACTICES 11 12 13 14 15 16 17 18 19 20 21 After striking a foreign object stop the engine disconnect the spark plug wire and ground against the engine Thoroughly inspect the machine for any damage Repair the damage before starting and operating Disengage all clutch levers if fitted and stop engine before you leave the opera
67. tempting to operate this machine Failure to comply with these instructions may result in personal injury When you see this symbol HEED ITS WARNING CALIFORNIA PROPOSITION 65 WARNING Engine Exhaust some of its constituents and certain vehicle components contain or emit chemicals known to State of California to cause cancer and birth defects or other reproductive harm WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling DANGER This machine was built to be operated according to the safe operation practices in this manual As with any type of power equipment carelessness or error on the part of the operator can result in serious injury This machine is capable of amputating fingers hands toes and feet Failure to observe the following safety instructions could result in serious injury or death A Training 2 Wear sturdy rough soled work shoes and close fitting slacks and shirt Loose fitting clothes or jewelry can be 1 Read understand and follow all instructions on the caught in moving parts Never operate this machine in bare machine and in the manual s before attempting to feet or sandals assemble and operate Keep this manual in a safe place for future and regular reference and for ordering replacement parts Disengage clutch levers and shift if provided into neu
68. tems are missing or damaged Handle NOTE When disassembling the handlebar assembly keep the left side clamp and ratchet separated from the right side clamp and ratchet 1 Disassemble the handlebar assembly To do this remove the height adjustment lever by turning the lever ina counterclockwise direction See Fig 3 1 a Adjustment Lever Figure 3 1 2 Place the handlebar ends on either side of the base with the wire harness toward the rear of the base See Fig 3 1 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 See Fig 3 1 Secure with the nut but do not fully tighten NOTE 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 the handlebars to one of two height settings and tighten the height adjustment lever Also make sure all other mounting hardware is securely tightened Moving the Tiller off the Shipping Platform 2 Connect the safety wire assembly green and yellow wires See Fig 3 4 1 Set the Depth Regulator Lever to travel position Do this 3 by lifting the tiller by the handlebars then pulling straight back on the lever and sliding down to the highest notched setting See Fig 3 2 ulator ver Figure 3 4 3 Co
69. the engine off place the Wheels Tines PTO Drive Lever in the NEUTRAL position If in the FORWARD position tap the lever sharply upward it should automatically move into NEUTRAL position 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 back and push it down all the way to the top detent notched position 3 Move the Wheel Speed Lever to either the SLOW or FAST position Be sure to roll the wheels while shifting the lever until the wheels engage 10 mM tleo NOTE If using a PTO stationary attachment move the Wheel Speed Lever into FREEWHEEL and block the wheels to prevent the equipment from moving See Fig 4 1 77 ee Ifa a Blocks 8 0 5 lt Aun baa me LA Lu e ANAL Figure 4 1 Move the Tines PTO Clutch Lever into DISENGAGE position NOTE Use the ENGAGE position if you want the tines to revolve or to apply power to a PTO driven stationary attachment If the engine is equipped with a fuel valve turn the valve to the OPEN position as instructed in the separate Engine Operator s Manual If the engine is equipped with an ON OFF switch move the switch to ON Move engine throttle lever away from STOP Choke or prime the engine as instructed in the separate Engine Operator s Manual If not equipped with an el
70. ting position behind the handles Wait until the tines come to a complete stop before unclogging the tines making any adjustments or inspections Never run an engine indoors or in a poorly ventilated area Engine exhaust contains carbon monoxide an odorless and deadly gas Muffler and engine become hot and can cause a burn Do not touch Use caution when tilling near fences buildings and underground utilities Rotating tines can cause property damage or personal injury Do not overload machine capacity by attempting to till soil too deep at too fast of a rate If the machine should start making an unusual noise or vibration stop the engine disconnect the spark plug wire and ground it against the engine Inspect thoroughly for damage Repair any damage before starting and operating Keep all shields guards and safety devices in place and operating properly Never pick up or carry machine while the engine is running Use only attachments and accessories approved by the manufacturer Failure to do so can result in personal injury If situations occur which are not covered in this manual use care and good judgement Contact Customer Support for assistance and the name of you nearest servicing dealer Maintenance amp Storage 1 Keep machine attachments and accessories in safe working order Allow a machine to cool at least five minutes before storing Never tamper with safety devices Check their proper operati
71. tral N before starting the engine 4 Never leave this machine unattended with the engine 2 Be familiar with all controls and their proper operation running Know how to stop the machine and disengage them quickly 5 Never attempt to make any adjustments while engine is running except where specifically recommended in the 3 Never allow children under 14 years of age to operate this J p P y machine Children 14 and over should read and understand operator s manual the instructions and safe operation practices in this manual Safe Handling of Gasoline and on the machine and be trained and supervised by an adult To avoid personal injury or property damage use extreme care in handling gasoline Gasoline is extremely flammable and the vapors are explosive Serious personal injury can occur when gasoline is spilled on yourself or your clothes which can ignite 5 Keep the area of operation clear of all persons particularly Wash your skin and change clothes immediately small children and pets Stop machine if anyone enters the 4 Never allow adults to operate this machine without proper instruction a Use only an approved gasoline container area b Never fill containers inside a vehicle or on a truck Preparation or trailer bed with a plastic liner Always place containers on the ground away from your vehicle 1 Thoroughly inspect the area where the equipment is to before filling be used Remove all stones sticks
72. transmission housing See Fig 6 10 Wheels Tines PTO N Lever Ti Belt Adjustment Block Engine Mounting Bars Figure 6 10 2 Oil all pivoting and connecting points on the Wheels Tines PTO Drive Lever and the Wheel Speed Lever See Fig 6 10 Grease the face of the belt adjustment block See Fig 6 10 4 Oil the Depth Regulator Lever including the spring in the mounting bracket See Fig 6 10 5 Oil the full length of the throttle cable casing Oil threads on Handlebar Height Adjustment Lever See Fig 6 10 6 Grease the left and right side engine mounting bars at the top middle and bottom See Fig 6 10 7 Grease the zerk grease fitting located on the pivot point at the end of the Wheel Speed Lever See Fig 6 10 If the Wheel Speed Lever has a grease fitting on the pivot assembly apply 2 to 3 strokes of multipurpose grease at beginning and end of tilling season 8 Keep the PTO access area well greased See Fig 6 11 If the Tines PTO Clutch Lever becomes hard to move squirt some oil into its access hole and work it back and forth to disperse the oil Figure 6 11 Adjustments Drive Belt On a new tiller or if a new belt is installed the belt tension will probably need to be adjusted after the first two 2 hours of operation Thereafter check the belt tension every ten 10 operating hours Maintaining the right tension is important to good tiller performance and long belt life
73. u have See Fig 6 7 Then replace the dipstick with the markings on dipstick facing to rear DOY ey Gear Oil Dipstick Back of Tine Shield Figure 6 7 For dipsticks With Check Cold Marking Cold means 2 hours have passed since the tiller was used 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 Nowstlide three pieces of 2 x 4 lumber underneath the drag bar raising the drag bar about 4 2 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 on the back of the tine shield See Fig 6 7 Wipe it clean with a rag 7 Hold the dipstick so its markings face to rear of tiller Lower it straight down into the sump hole to touch the drive shaft inside See Fig 6 7 Don t force or try to thread it back in an incorrect reading will result 8 Remove the dipstick and check the oil level It should be anywhere within the crosshatched area or even slightly above the Max marking If correct replace the dipstick and remove the boards used as props 9 Ifthe oil level was low gear oil must be added before using the tiller See Adding or Changing Gear Oil the next page For Di
74. ure 3 12 Figure 3 10 7 Test the operation of the Wheels Tines PTO Lever Push the lever down until it engages in the Forward position The clutch roller must rest beneath the adjustment block Next move the lever up to the Neutral position See Fig 3 11 Figure 3 11 SECTION 2 ASSEMBLY amp Set Up 10 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 WARNING To avoid electric shock from a short circuit electric start tillers only never allow the throttle cable to touch the battery Route the cable below the battery on the outside of the battery holder To attach the throttle lever and cable 1 Run the throttle cable up the inside edge of the right handlebar and position the lever as shown in Fig 3 13 Pan Head Curved Head Screw Figure 3 13 2 From the outside of the handlebar insert the curved head screw through the handlebar and the center hole in the throttle lever mounting bracket See Fig 3 13 3 Loosely install the flanged lock nut and move the throttle lever back to the STOP position 4 From the lever side of the bracket thread a pan head screw through the small hole in the throttle lever bracket and into the handlebar Tighten the screw securely 5 Securely tighten bot
75. ver Use long nose pliers to hold the bushing in place while inserting the screw through the lever and yoke plates See Fig 3 8 Install the star washer and the nut then hand tighten N Figure 3 8 Retrieve the clutch pawl spring from hardware bag Remove the temporary screw from the forward holes inserted in Step 3 and move the Wheels Tines PTO Lever fully forward Install the wider hook end of the clutch pawl spring 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 See Fig 3 9 Clutch Pawl Figure 3 9 NOTE Do not bend or over stretch the spring while installing 6 Pull the Wheels Tines PTO Lever back to align the forward 8 10 test Reverse lift and hold the lever all the way up in most holes in the yoke plate with the holes in the lever the Reverse position then let it go The lever should plates Also align the bushing that is inside the short link automatically return to the Neutral position See Fig bar Install the screw star washer and nut then tighten 3 12 If not do not use the tiller See your local authorized securely Securely tighten all other hardware Also ensure dealer or call the Factory Technical Service Department for that the spring is properly seated at both ends Completed instructions assembly should appear as illustrated in Fig 3 10 Clutch Pawl Spring X FX N OL Forward Hole Short Link Bar Fig
76. w 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 seedbed and 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 SECTION 5 OPERATION 21 22 Tilling Under Corn Removing the Tine Attachment After corn is harvested the stalks should be tilled into the soil 1 Move the tiller to level ground ai cael Dry plants ate more difficult to till under and 2 Be sure the engine is stopped the electric start key is removed and the spark plug wire is disconnected and NOTE Do not pull the roots out by hand or cut the stalks before moved away from spark plug tilling Stalks that are firmly anchored by their roots are much 3 Place a sturdy support under the engine to prevent the easier for the tines to chop cut and work under engine from tipping forward when the tine attachment is 1 As you move forward into a row of stalks aim the tiller removed See Fig 4 19 so that the stalks go between the left wheel and the transmission case See Fig 4 17 Do not use the right wheel because damage could occur to the air cleaner carburetor or throttle linkage 2 Each new pass should overlap the previous p
77. y to plants whose roots often grow close to the surface If needed lift up on the handlebars slightly to prevent the tines from digging too deeply Cultivating on a regular basis not only eliminates weeds it also loosens and aerates the soil for better moisture absorption and faster plant growth Avoid Tilling Wet Soggy Soil 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 Avoid Making Footprints When possible walk on the untilled side of the tiller to avoid making footprints in the freshly tilled soil See Flg 4 3 Footprints cause soil compaction that can hamper root penetration and contribute to soil erosion They can also plant unwanted weed seeds back into the newly tilled soil Suggested Tilling 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 See Fig 4 11 Figure 4 11 When finished in one direction make a second pass at a right angle See Fig 4 12 Overlap each pass for best results In very hard ground it may take three or four passes to thoroughly pulverize the soil Figure 4 12 If the garden size will not permit lengthwise and then crosswise tilling then overlap the fi

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