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Troy-Bilt 675B-Pony Tiller User Manual

1. A 0 N ma i NS 10 32 x 1 2 Rnd Hd Screw 10 32 Nut Cotter Pin not used 4 Plastic Tie Strap 2 not used Tools Materials Needed for Assembly 3 8 open end wrench 9 16 open end wrench 7 8 open end wrench scissors to trim plastic ties Ruler Small board to tap plastic knob on lever Tire pressure gauge 1 Clean oil funnel 1 Clean high quality motor oil Refer to the separate Engine Owner s Manual for motor oil specifications and quan tity required Adjustable wrenches may be used IMPORTANT Motor oil must be added to the engine crankcase before the engine is Started Follow the instructions in this Assembly Section and in the separate Engine Owner s Manual NOTE LEFT and RIGHT sides of the O CO N O O1 i i N m_a wer NS Ne NSA es NS _ _ i tiller are as viewed from the operator s position behind the handlebars STEP 2 ATTACH HANDLEBARS 1 Cut the large plastic cable ties that se cure the handlebar ends to the handlebar mounting tabs on the transmission top cover 2 Gently lift handlebar do not overstretch attached cable and place handlebar cross brace B Figure 2 3 in front of curved height adjustment bracket C Figure 2 1 Loose hardware shown in re duced size Figure 2 2 Handlebar height adjustment uses the flange head screw Figure 2 3 Forward clutch control cable not shown for
2. Lift the tine flap to service those screws Figure 5 3 Transmission Gear Oil Service Check the transmission gear oil level after every 30 hours of operation or whenever you notice any oil leak Operating the tiller when the transmission is low on oil can re sult in severe damage A WARNING Before inspecting cleaning or servicing the machine shut off engine wait for all moving parts to come to a complete stop disconnect spark plug wire and move wire away from spark plug Failure to follow these instructions can result in serious personal injury or property damage A To Check Transmission 1 Check the gear oil level when the trans mission is cool Gear oil expands in warm operating temperatures and will result in an incorrect oil level reading 2 To check the gear oil level and to add oil if necessary refer to STEP 5 Check Gear Oil Level in Transmission in Section 2 of this manual B To Drain and Refill the Transmission The transmission gear oil does not need to be changed unless it has been contaminat ed with dirt sand or metal particles 1 Prop up the left side of the unit securely Remove the left side wheel by removing the wheel mounting hardware 2 Unscrew the plastic gear oil fill plug from the top of the transmission 3 Place a clean pan below the transmis sion drain plug Figure 5 4 and remove the drain plug The oil will start flowing out of the drain hole it may flow slowly espe
3. Preparing Seedbeds Avoid Making Footprints Whenever possible walk on the untilled Side of the unit to avoid making footprints in your freshly tilled or cultivated soil Foot prints cause soil compaction that can ham per root penetration and contribute to soil erosion They can also plant unwanted weed seeds back into the freshly tilled ground e 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 6 When fin ished in one direction make a second pass at a right angle as shown in Fig 4 7 Overlap each pass for best results in very hard ground it may take three or four passes to thoroughly pulverize the soil e f the garden size will not permit lengthwise and then crosswise tilling then over OES SEs lap the first passes by one half a tiller width followed by successive passes at one quarter width see Fig 4 8 Avoid Tilling Soggy Wet Soil Tilling wet soil often results in large hard clumps of soil that can interfere with plant ing If time permits wait a day or two after heavy rains to allow the soil to dry before tilling Test soil by squeezing it into a ball If it compresses too easily it is too wet to till Cultivating With planning you can AY allow enough room ita between rows to cultivate see Fig 4 9 Leave room for the hood width plus enough extra Fig 4 8 room for fut
4. cially in cold temperatures Figure 5 4 Remove drain plug to drain trans mission gear oil also remove oil fill plug and oil level check plug 4 Remove the transmission gear oil level check plug that is located a few inches above the left side wheel shaft N Figure 2 11 9 When the oil stops flowing tilt the transmission forward to drain oil from the rear of the transmission 6 After draining the oil clean the threads of the drain plug apply a non hardening removable gasket sealant to the threads and securely reinstall the drain plug 7 Use a clean funnel to slowly add SAE 140 or SAE 85W 140 weight gear oil with an API rating of GL 4 only to the trans mission The transmission holds approxi mately 3 14 pints 52 54 ounces Tilt the tiller slightly backwards to make sure the gear oil reaches the rear tine end of the transmission Stop adding gear oil when it begins to flow from the oil level check hole on the side of the ion 8 Securely reinstall the oil level check plug 9 Securely reinstall the gear oil fill plug on top of the transmission 10 Reinstall the wheel and remove the prop Engine Oil Service Check the motor oil level before starting the engine each day and after each 5 hours of continuous operation Running the en gine when the oil level is low will quickly ruin the engine lt is recommended that you change the motor oil after every 10 hours of operation and even soon
5. Depth Regulator Lever Counter Rotating Tines Figure 1 1 Training W 1 Carefully read this Own ers Manual the separate Engine Owner s Manual and any other literature you may receive Be thoroughly familiar with the controls and the proper use of the tiller and its engine Know how to stop the unit and disengage the controls quickly 2 Never allow children to operate the tiller Never allow adults to operate the tiller with out proper instruction 3 Keep the area of operation clear of all persons particularly children and pets 4 Keep in mind that the operator or user is responsible for accidents or hazards occur ring to other people their property and themselves Preparation 1 Thoroughly inspect the area where the tiller is to be used and remove all foreign objects 2 Be sure all control levers are released and the Wheel Gear Lever is in ENGAGE po sition before starting the engine 3 Do not operate the tiller without wearing adequate outer garments Avoid loose gar ments or jewelry that could get caught in moving parts 4 Do not operate the tiller when barefoot or wearing sandals sneakers or light footwear Wear protective footwear that will improve footing on slippery surfaces 5 Do not till near underground electric cables telephone lines pipes or hoses If in doubt contact your telephone or utility company 6 Warning Handle fuel with care it is highly flammable and its vap
6. In soft soil or weeds you may 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 Clearing the Tines The tines have a self clearing action which eliminates most tangling of debris in the tines However occasionally dry grass stringy stalks or tough vines may become tan gled Follow these procedures to help avoid tangling and to clean the tines if neces sary e To reduce tangling set the depth regulator deep enough to get maximum chop ping 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 e t may be necessary to remove the debris by hand a pocket knife will help you to cut away the material Be sure to stop the engine and disconnect the spark plug wire before clearing the tines by hand e While tilling try swaying the handlebars from side to side about 6 to 12 This fishtailing action often clears the tines of debris e f tangling occurs lift the tines out of the soil and run the tiller in reverse if unit is equipped with powered reverse for a few feet This reversing action should unwind a good deal of debris Loading and Unloading the Tiller T WARNING Loading and unloading the tiller into a vehicle is potentially hazardous and we don t recommend doing so unless absolutely necessary as this could resu
7. With use the tines Figure 5 6 will be come shorter narrower and pointed Bad ly worn tines will result in a loss of tilling depth and reduced effectiveness when chopping up and turning under organic matter Figure 5 6 Four tine gangs two per side Removing and Installing 1 Use a 9 16 socket 6 extension a ratchet and a 9 16 box wrench to loosen the nut A Figure 5 7 and bolt B that se cure the tine holder to the tine shaft 2 Use a rubber mallet to tap the tine hold er loose 3 Slide the tine assembly off the tine shaft 4 Repeat Steps 1 through 3 above to re move the other tine assembly 5 Installing the tine assembly is simply the reverse of its removal Be sure the cut ting edges face so they will enter the soil first when the tiller is moving forward this means the cutting edges face toward the operator position First be sure to remove any rust uneven spots or burrs from the tine shaft using fine sandpaper Then grease the tine shaft WARNING Before inspecting cleaning or servicing the machine shut off engine wait for all moving parts to come to a complete stop disconnect spark plug wire and move wire away from Spark plug Failure to follow these instructions can result in Serious personal injury or property damage ENGINE lt gt DENOTES CUTTING EDGE OF TINE Figure 5 7 Complete tine assemblies holders tines and hardware WARNING This is a CRT A counter rota
8. see Tilling Tips amp Techniques 3 Start the engine and allow it to warm up When warm move the throttle control into the FAST speed setting 4 For forward motion of the wheels and power to the tines a Pull up and hold the Forward Clutch levers against the handlebars To Stop the wheels and tines release both levers WARNING Do not push down on the handlebars to try to make the tiller till more deeply This prevents the wheels from holding the tiller back and can allow the tines to rapidly propel the tiller backward toward the operator which could result in loss of control property damage or personal injury As the tiller moves forward relax and let the wheels pull the unit along while the tines dig Walk behind and a little to one side of the tiller Use a light but secure grip with one hand on the han dlebars but keep your arm loose See Figure 4 2 Let the tiller move ahead at its own pace Do not push down on the handlebars to try and force the tiller to dig deeper this takes weight off the wheels reduces traction and causes the tines to try and propel the tiller 9 For reverse motion of the wheels and tines a Look behind and exercise caution when operating in reverse Do not till while in reverse b Stop all forward motion before re versing Lift the handlebars with one hand until the tines are off the ground and then pull the Reverse Clutch con trol out see Figure 4 3 To st
9. this manual see Section 1 and in the separate Engine Owner s Manual Failure to follow gasoline safety instructions can resultin serious personal injury and property damage 7 Attach spark plug wire to spark plug Starting the Engine 1 Complete the Pre Start Checklist 2 Put the Wheel Gear Lever Figure 4 1 into the ENGAGE position CAUTION To help prevent serious personal injury or damage to equipment A e Before starting engine put Wheel Gear Lever into ENGAGE position e Before starting engine put Forward Clutch Levers and Reverse Clutch Control into neutral disengaged positions by releasing controls e Never run engine indoors or in an enclosed poorly ventilated area Engine exhaust contains carbon monoxide an odorless and deadly gas e Avoid engine muffler and nearby areas Temperatures in these areas may exceed 150 F 3 Put the Depth Regulator Lever into the travel position lever all the way down So that the tines are clear of the ground 4 Release all controls on the tiller 5 If the engine is equipped with a fuel Shutoff valve turn the valve to the open position as instructed in the separate En gine Owner s Manual T WARNING Keep away from rotating tines Rotating tines will cause injury 6 Move the Engine Throttle Lever into the START position 7 Choke or prime the engine as instructed in the separate Engine Owner s Manual 8 Check behind you to a
10. clarity 3 With the forward clutch cable N Fig ure 2 4 on the inside of handlebar posi tion the handlebar ends on the outside of the two mounting tabs M Figure 2 3 on the transmission top cover NOTE The curved handlebar height ad justment bracket appears as shown in C Figure 2 3 for non electric start units For electric start units the bracket is loosened and moved to one side 4 Loosely attach the handlebars to the mounting tabs with two 3 8 16 x 1 screws heads of screws go to inside of tabs 3 8 flat washers and 3 8 16 lock nuts O Fig ure 2 4 Figure 2 4 Attach handlebars 9 Move the handlebars up or down to align the threaded hole in the cross brace with one of the four slots in the curved height adjustment bracket Place the keyed washer E Figure 2 3 on the flange head height adjustment screw F with the raised keys edges of the washer facing down 6 Thread the height adjustment screw F Figure 2 3 into the hole in the handlebar cross brace making sure that the raised keys on the washer fit into the slot on the height adjustment bracket Tighten the height adjustment screw securely Next securely tighten the two screws and nuts in the ends of the handlebar M Figure 2 3 7 To remove the tiller from its shipping platform first carefully unwrap the wheel gear cable with attached lever see Figure 2 5 from around the chassis Move the Wheel Gear Lever G to the DISENGAGE posi
11. dealer OTROY BILT FFovsnt ttc SEIEN P O BOX 361131 www troybilt com CLEVELAND OH 44136 330 558 7220 1 800 520 5520 Page 16 18 23 24 Back Cover Before you start assembling your new equipment please locate the model plate on the equipment and copy the information from it in the space provided below A sample model plate is also given below You can locate the model plate by standing behind the unit and looking down at rear surface of the tine shield This information will be necessary to use the manufacturer s web site and or help from the Customer Support Copy the model number here Copy the serial number here CUSTOMER SUPPORT Please do NOT return the unit to the retailer from where it was purchased without first contacting Customer Support If you have difficulty assembling this product or have any questions regarding the controls operation or maintenance of this unit you can seek help from the experts Choose from the options below Visit troy bilt com for many useful suggestions Click on Customer Support button and you will get the four options reproduced here Click on the appropriate button and help is immediately available The answer you are looking for could be just a mouse Click away Find Answers C tk here to search our knowledge base Sear oduct keyword or phrase My Stuff Login to check the status of your questions modify your inquiries or update your personal profile Servic
12. engine forward pulley and bring lower half of belt down and in front of transmission pulley WARNING Before inspecting cleaning or servicing the machine shut off engine wait for all moving parts to come to a complete stop disconnect spark plug wire and move wire away from Spark plug Failure to follow these instructions can result in Serious personal injury or property damage 3 Slip the forward drive belt down and over the front of the transmission pulley C Figure 5 16 NOTE For additional working room loosen the reverse belt guide V Figure 5 12 and twist it out of the way 4 Put the lower half of the belt into the High speed groove middle groove or the Low speed groove rearmost groove of the transmission pulley C Figure 5 16 5 Put the upper half of the belt in the High speed groove groove closest to engine or the Low speed groove rearmost groove of the engine forward drive pulley D Fig ure 5 16 IMPORTANT Make sure that the forward drive belt is to the inside of the wire belt guide I Figure 5 12 and the forward idler pulley J 6 If you loosened the belt guide wait until the reverse drive belt is installed before se curing the belt guide 7 Install the reverse drive belt 8 Install the belt cover and secure it with the two nuts 9 If you installed a new belt check the ten sion after two hours of operation r Reverse Drive Belt Removal and Installation NOTE The forw
13. idler arm Hold the idler arm in this position and look at the position of the belt tension guide mark M Figure 5 14 that is stamped into the face of the reverse adjustable link N Figure 5 14 e The tension is correct if the guide mark M Figured5 14 is anywhere to the left of the guide pin 0 as viewed from the Figure 5 14 While pushing reverse idler arm in ward stand at engine end and check position of guide mark M and guide pin 0 WARNING Before inspecting cleaning or servicing the machine shut off engine wait for all moving parts to come to a complete stop disconnect spark plug wire and move wire away from Spark plug Failure to follow these instructions can result in Serious personal injury or property damage front of the unit not the operator s posi tion Ifthe belt tension is correct reinstall the belt cover and secure it with the two nuts e f the guide mark is aligned with the guide pin or moves to the right side of the guide pin then the belt is too loose and the tension must be readjusted as described next 3 The reverse idler pulley L Figure 5 13 regulates the tension that is applied to the reverse drive belt P The following ad justment will allow the reverse idler pulley to apply more tension to a loose belt 4 Remove the belt cover 9 Slip the reverse belt P Figure 5 13 off the engine driven reverse upper pulley 6 On the right side of the unit as viewe
14. not allow oil on the belts or pulleys Figure 5 2 Check Tire Air Pressure Check the air pressure in both tires De flate or inflate both tires evenly to between 15 and 20 PSI pounds per square inch Be sure that both tires have equal air pres Sure or the unit will pull to one side Check For Oil Leaks Before each use check your tiller for signs of an oil leak usually a dirty oily accumu 16 lation either on the unit or on the floor where it has been parked A little seepage around a cover or oil seal is usually not a cause for alarm However if the oil drips overnight then immediate attention is needed ignoring a leak can result in severe transmission damage lf a cover leaks try tightening any loose screws or bolts If the fasteners are tight anew gasket or oil seal may be required If the leak is from around a shaft and oil seal the oil seal probably needs to be replaced See your authorized dealer or contact the factory for service or advice IMPORTANT Never operate the tiller if the transmission is low on oil Check the oil level after every 30 hours of operation and whenever there is any oil leakage Check Hardware Check the unit for loose or missing hard ware after every 10 operating hours Loose or missing hardware can lead to equipment failure poor performance or oil leaks Be sure to check the three end cap mount ing screws located at the rear of the trans mission Figure 5 3
15. of break in operation 2 Before each use 3 Every 5 operating hours 4 Every 10 operating hours 5 Every 30 operating hours 6 Change more frequently in dusty or dirty conditions See Engine Owner s Manual for service recommendations 8 Whichever time interval occurs first Tiller Lubrication Proper lubrication of the tiller is an essen tial part of your maintenance program Af ter every 10 operating hours oil or grease the lubrication points shown in Figures 5 1 and 5 2 and described below FRAN NOON S NN BH HHP Use general purpose lubricating oil 30 weight motor oil is suitable and a general purpose grease metal lubricant is pre ferred if available e Remove wheels and clean wheel shaft A Figure 5 1 Apply a thin coating of grease to shaft before reinstalling wheels e Grease back front and sides of depth regulator lever B Figure 5 1 Figure 5 1 e Remove tines and clean tine shafts C Figure 5 1 Inspect for rust rough spots or burrs especially around holes File or sand smooth and coat ends of Shaft with grease e Qjil the threads on the handlebar height adjustment handle D Figure 5 1 e Qil the outer casings of the engine throt tle cable and the wheel gear cable E Figure 5 1 Allow oil to soak in and then wipe off any excess e Qil the various pivot points F Figure 5 2 on the shifting mechanism the han dlebar and the idler arms do
16. personal injury or property damage Handlebar Height Adjustment Handlebar height is adjustable to four dif ferent settings When setting the height keep in mind that the handlebars will be lower when the tines are engaged in the soil WARNING Whenever the handlebar height is changed the Forward Clutch shift mechanism must be readjusted Before adjusting or checking the Forward Clutch mechanism shut engine off disconnect spark plug wire and prevent it from touching spark plug Failure to follow this warning could cause the Forward Clutch mechanism to operate improperly which could result in personal injury or property damage To Adjust Handlebar Height 1 Stop engine wait for all parts to stop moving and then disconnect spark plug wire 2 Loosen the two screws at lower ends of handlebar 3 Loosen height adjustment screw F Figure 3 3 and pull keyed washer G free from slots in curved height adjustment bracket A Figure 3 3 Handlebar height adjustment 4 Move handlebars to a new slot setting and insert the raised key on the keyed washer into the slot Tighten the height adjustment screw securely 9 Retighten the two screws at ends of handlebar Engine Controls IMPORTANT The engine is equipped with either a choke control or a primer bulb Refer to the Engine Owner s Manual in cluded in tiller literature package to iden tify which device is on your engine Recoil Starter Th
17. pin is installed in the inner hole of the forward adjustable link the number of additional belt tension adjustments are limited If with future tension adjustments you find that you cannot screw the forward clutch rod any farther into the rectangular nut on the forward clutch bracket it means that the forward drive belt must be replaced Before doing so the clevis pin must be returned to the OUTSIDE hole in the forward adjustable link 8 Replace the forward drive belt in the High speed groove groove closest to en gine or the Low speed groove rearmost groove of the engine drive pulley and in the matching groove of the transmission pul ley Be sure the belt is to the inside of the wire formed belt guide Figure 5 12 and to the inside of the forward drive idler pul ley J Figure 5 12 Top view of belts and pulleys 9 Reinstall the belt cover and secure it with the two nuts 10 Readjust the forward drive belt tension by following the instructions in Section 3 Handlebar Height Adjustment 20 Figure 5 13 To Check and Adjust Tension on the Re verse Drive Belt 1 Remove the belt cover after first shut ting off the engine disconnecting the Spark plug wire and allowing the engine and muffler to cool down 2 Stand at the front of the tiller and use your left hand to push the reverse idler arm K Figure 5 13 inward as far as pos sible the reverse idler pulley L is at tached to the reverse
18. side view of engine and transmission pulleys engine is at right side of view Figure 4 11 Top view of forward drive pulley system engine is at left side of view TILLING TIPS amp TECHNIQUES e This is a CRT counter rotating tine tiller As the wheels pull forward the tines rotate back ward This creates an uppercut tine action which digs deeply uprooting soil and weeds Don t overload the engine but dig as deeply as possible on each pass On later passes the wheels may tend to spin in the soft dirt Help them along by lifting up slightly on the handle bar one hand palm up works most easily Tilling Depths A WARNING Before tilling contact your telephone or utilities company and inquire if underground equipment or lines are used on your property Do not till near buried electric cables telephone lines pipes or hoses When cultivating breaking up surface soil around plants to destroy weeds see Fig 4 9 a just the tines to dig only 1 to 2 deep Using Shallow tilling depths helps prevent injury 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 Watering the garden area a few days prior to tilling will make tilling easier as will letting the newly worked so
19. ENGAGE and reconnect spark plug wire before attempt ing to start the engine To Change from High to Low Speed 1 Stop the engine allow it to cool and dis connect the spark plug wire 2 Put Wheel Gear Lever in DISENGAGE 3 Remove the two nuts from the plastic belt cover on top of the transmission and remove the belt cover 4 From beneath the tiller move the for ward drive belt out of the transmission pul ley high speed groove D Figure 4 10 and into the low speed groove B 9 Pull upward on the belt to remove any Slack and slip the belt out of the engine drive pulley high speed groove C Figure 4 10 and into the low speed groove A NOTE If the belt is difficult to move pull on the engine start rope while pushing the belt with your finger engine drive pulley will turn as start rope is pulled 6 Check that the belt is within the forward belt guide E Figures 4 10 and 4 11 on the right side of the unit and is within the for ward idler F Figure 4 11 on the left side Be sure that the belt is situated in the rear grooves A and B Figure 4 10 of the en gine upper and transmission lower pul leys 7 Reinstall the plastic belt cover and se cure it with the two nuts 8 Put the Wheel Gear Lever in ENGAGE and reconnect the spark plug wire before attempting to start the engine A C Low High 4 iy amp Ko ZN P SEES SON Reverse Idler Low High Figure 4 10 Right
20. LUTCH CONTROL CABLE 1 Remove any fasteners rubber bands tape etc that may secure the Forward Clutch Control levers J Figure 2 7 to the handlebar o gee Figure 2 7 Forward Clutch Control levers J Forward clutch control linkage K 2 The forward clutch control cable with attached spring is hanging loosely near the right side wheel Being careful not to kink or stretch the cable insert the z con nector L Figure 2 8 end of the spring into the hole at the end of the forward clutch control linkage K Figure 2 7 Figure 2 8 3 Attach the cable adjuster A Figure 2 9 to the bracket on the right side handlebar Use two 1 2 wrenches to loosen the two jam nuts B just enough to slide the cable adjuster onto the bracket Then hand tighten the jam nuts Figure 2 9 CAUTION Incorrect cable adjustment could cause the wheels and tines to rotate unexpectedly Follow adjustment procedures carefully Failure to do so could result in personal injury or property damage A 4 Check for correct springcable tension as instructed in Section 5 Checking and Adjusting Forward Clutch Belt Tension 5 When tension is correct tighten the two jam nuts B securely STEP 5 CHECK TRANSMISSION GEAR OIL LEVEL 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 IMPORTANT Do not operate the tiller if the ge
21. OTROY BILT Operator s Manual 675B Pony Model 675B Shown bumper syles vary IMPORTANT READ SAFETY RULES AND INSTRUCTIONS CAREFULLY WARNING This unitis equipped with an internal combustion engine and should not be used on or near any unimproved forest covered brush covered or grass covered land unless the engine s exhaust system is equipped with a spark arrester meeting applicable local or state laws if any Ifa 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 TROY BILT LLC P O BOX 361131 CLEVELAND OHIO 44136 0019 PRINTED IN U S A FORM NO 769 00586A 9 22 03 TABLE OF CONTENTS Content Customer Support Safety Assembly Features and Controls Operation Page Content 2 Maintenance 3 Off season Storage 6 Troubleshooting 9 Parts List 11 Warranty Information FINDING MODEL NUMBER This Operator s Manual is an important part of your new rear tine tiller It will help you assemble prepare and maintain the unit for best performance Please read and understand what it says o Department or an authorized service
22. Then slip the upper end into the groove of the engine reverse pulley A Figure 5 18 4 If the reverse belt guide V Figure 5 12 was loosened previously center the belt guide on the belt and tighten the mounting screw securely 5 Install the belt cover and secure it with the two nuts If the lower transmission cover was removed reinstall it with the four self tapping screws moving parts to come to a complete stop disconnect spark plug wire and move wire away from Spark plug Failure to follow these instructions can result in Serious personal injury or property damage WARNING Before inspecting cleaning or servicing the machine shut off engine wait for all TROUBLESHOOTING PROBLEM POSSIBLE CAUSE CORRECTION Engine does not start Spark plug wire disconnected 1 Reconnect wire 2 Engine Throttle Control Lever incorrectly set 2 Put lever in START position 3 Fuel tank empty 3 Add fuel 4 Choke control if so equipped in incorrect position 4 See Engine Owner s Manual 5 Stale gasoline 5 Drain fuel and add fresh fuel 6 Dirty air filter 6 Clean or replace filter 7 Defective or incorrectly gapped spark plug 7 Inspect spark plug 8 Carburetor out of adjustment 8 See Engine Service Dealer 9 Misadjusted throttle control 9 See Engine Service Dealer 10 Dirt or water in fuel tank 10 See Engine Service Dealer Engine runs poorly Defective or incorrectly gapped spark plug 1 Inspect spark pl
23. ar oil level is low Doing so will result in severe damage to the transmission components 1 With the tiller on level ground pull the Depth Regulator Lever R Figure 2 13 back and then slide it to the second notch from the top NOTE If the lever does not move lift the tine hood flap and look for a plastic tie securing the lever in place Cut and remove the tie 2 Remove the oil level check plug M Fig ure 2 10 on the left side of the transmis sion Due to dried paint on the plug threads it may require some force to re move the plug the first time The gear oil level is correct if oil starts to flow out of the hole as the plug is removed If so securely reinstall the plug Figure 2 10 Gear oil level check plug 3 If oil does not flow from the check hole add oil as follows Figure 2 11 Adding gear oil NOTE Do not transmission a Clean area around the fill hole N Fig ure 2 11 and unscrew gear oil fill plug b If adding only a few ounces of gear oil use API rated GL 4 or GL 5 gear oil having a viscosity of SAE 140 SAE 85W 140 or SAE 80W 90 If refilling an empty trans mission use only GL 4 gear oil having a viscosity of SAE 85W 140 or SAE 140 c Using a clean funnel slowly add gear oil until it flows from the gear oil level check hole N Figure 2 11 d Reinstall and tighten securely the gear oil fill plug M Figure 2 10 STEP 6 ATTACH WHEEL GEAR LEVER 1 Insert the Wheel G
24. ard drive belt must be in stalled before installing the reverse drive belt Figure 5 18 Removing and installing reverse belt A Removing the Reverse Drive Belt 1 Stop the engine and allow it to cool be fore working near the belts Be sure the spark plug wire is disconnected and on electric start models the ignition key is re moved 2 Remove the belt cover by removing the two nuts For easier access to the trans mission lower pulley remove the trans mission cover located below the trans mission pulley 22 3 Slip the reverse belt off the engine re verse pulley A Figure 5 18 If necessary work the belt off the pulley with your left hand while pulling the engine recoil starter rope with your right hand 4 Push the upper half of the reverse belt downward to create slack in the belt Then reach underneath the transmission and slip the belt off the front of the transmis sion pulley B Figure 5 18 5 Pull the belt up and past the engine re verse pulley A Figure 5 18 B Installing the Reverse Drive Belt 1 Slip the reverse belt down between the engine reverse pulley A Figure 5 18 and the engine forward drive pulley C 2 Loop the bottom half of the belt over the front of the transmission pulley B Figure 5 18 and seat the belt in the front groove of the pulley 3 Place the belt to the inside of the reverse idler pulley D Figure 5 18 and the re verse belt guide V Figure 5 12
25. ase the Forward Clutch Levers 3 To move the tiller in reverse first stop all forward motion Lift up the handlebars until the tines clear the ground and pull the Reverse Clutch lever out The wheels will rotate in a reverse direction as long as the lever is held in REVERSE To Stop the wheels and tines release the lever and it will return to NEUTRAL Never at tempt to till while moving in reverse di rection Depth Regulator Lever This lever E Figure 3 2 controls the till ing depth of the tines Pull the lever Straight back and slide it up or down to en gage the notched height settings 6 Figure 3 2 Depth Regulator Lever The highest notch lever all the way down raises the tines approximately 1 1 2 inches off the ground This travel position al lows the tiller to be moved without the tines digging into the ground Moving the lever up increases the tilling depth The lowest notch allows a tilling depth of approximately six to eight inches depending on soil conditions For best results always begin tilling at a very shallow depth setting and gradually increase tilling depth T WARNING Place Depth Regulator Lever in travel position before starting engine This position prevents the tines from touching the ground until you are ready to begin tilling Do not attempt to till too deeply too quickly Gradually work down to deeper tilling depths Failure to follow this warning could result in
26. d from operator s position remove the hair pin cotter from the clevis pin R Figure 5 13 that connects the reverse idler arm K to the reverse adjustable link Push inward on the reverse idler arm K and remove the clevis pin R 7 There are two holes in the reverse ad justable link S Figure 5 15 Push inward on the reverse idler arm K and install the clevis pin R through the inner hole in the reverse adjustable link S and out through the single hole in the reverse idler arm K secure the clevis pin with the hairpin cot ter 8 Reinstall the reverse belt P Figure 5 13 on the reverse upper pulley making sure TP Figure 5 15 Installing clevis pin in inside hole of reverse adjustable link the belt is located to the inside of the re verse idler pulley L Figure 5 13 9 Reinstall the belt cover and secure It with the two nuts IMPORTANT If in future tests for reverse belt tension the guide mark Should again align with or move to the right side of the guide pin it means that the reverse belt is worn beyond adjustment Before installing a new belt you must return the clevis pin to the OUTSIDE hole in the reverse adjustable link Forward Drive Belt Removal and Installation This model has two forward speeds High Figure 5 16 Belt drive system and Low and one reverse speed The for ward engine pulley D Figure 5 16 has two grooves for the two forward speeds The reverse en
27. e decal locations part numbers and ordering instructions f Warning Messages on tine hood Hot Surfaces Moving Belts Warning on belt cover Figure 1 2 Location of Safety and Operating Decals Various symbols shown here with word descriptions Operating Symbols ba R may be used on the tiller and engine CHOKE CHOKE REVERSE 6 wD NOTE Yourunit may not have all of the symbols ON OFF Ag N A gt ESK lt 0 ROTATING TINES FAST SLOW STOP TILLER DIRECTION LEVER DIRECTION WARNING TO AVOID SERIOUS INJURY e READ THE OPERATOR S MANUAL e KNOW LOCATIONS AND FUNCTIONS OF ALL CONTROLS e KEEP ALL SAFETY DEVICES AND SHIELDS IN PLACE AND WORKING e NEVER ALLOW CHILDREN OR UNINSTRUCTED ADULTS TO OPERATE TILLER e SHUT OFF ENGINE AND DISCONNECT SPARK PLUG WIRE BEFORE MANUALLY UN CLOGGING TINES OR MAKING REPAIRS e KEEP BYSTANDERS AWAY FROM MACHINE e KEEP AWAY FROM ROTATING PARTS e USE EXTREME CAUTION WHEN REVERSING OR PULLING THE MACHINE TOWARDS YOU SECTION 2 ASSEMBLY T WARNING To prevent personal injury or property damage do not start the engine until all assembly steps are complete and you have read and understand the safety and operating instructions in this Manual Introduction Carefully follow these assembly steps to correctly prepare your tiller for use Itis recommended that you read this Section in its entirety before beginning assembly Inspect unit Inspect the
28. e Locator Need local assistance Click here to find authorized service centers in your area Manuals Online Need a manual and or parts list Download literature from recent model years The answer you are looking for could be just a mouse click away If you prefer to reach a Customer Support Representative please call 1 800 520 5520 Engine Manual A N information 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 manufacturers Owner s Operator s Manual packed separately with your unit for more SECTION 1 SAFETY This machine meets voluntary safety stan dard B71 8 1996 which is sponsored by the Outdoor Power Equipment Institute Inc and is published by the American National Standards Institute The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm Safety Alert Symbol A This is a safety alert symbol It is used in this manual and on the unit to alert you to potential hazards When you see this symbol read and obey the message that follows it Failure to obey safety messages could result in personal injury or property damage Wheel Gear Lever Reverse Clutch Control Forward Clutch Lever ELA Recoil Rope Forward Clutch Lever Starter
29. e or engaging the tinesAvheels with the Forward Clutch or the Reverse Clutch 14 Be aware that the tiller may unexpect edly bounce upward or jump backward if the tines should strike extremely hard packed soil frozen ground or buried ob Stacles like large stones roots or stumps If in doubt about the tilling conditions al ways use the following operating precau tions to assist you in maintaining control of the tiller a Walk behind and to one side of the tiller using one hand on the han dlebars Relax your arm but use a secure hand grip b Use slower engine speeds c Clear the tilling area of all large stones roots and other debris d Avoid using downward pressure on handlebars If need be use slight upward pressure to keep the tines from digging too deeply e Before contacting hard packed soil at the end of a row reduce engine speed and lift handlebars to raise tines out of the soil f In an emergency stop tines and wheels by releasing whichever Clutch Lever is engaged Do not at tempt to restrain the tiller 15 Do not overload the tiller s capacity by attempting to till too deeply at too fast a rate 16 Never operate the tiller at high trans port speeds on slippery surfaces Look be hind and use care when backing up 17 Do not operate the tiller on a slope that is too steep for safety When on slopes Slow down and make sure you have good footing Never permit the tiller to freewheel down s
30. e recoil starter H Figure 3 4 is used to oull start the engine See Engine Starting and Stopping in Section 4 for detailed en gine starting instructions Figure 3 4 Recoil starter handle Engine Throttle Lever The throttle lever D Figure 3 1 is used to adjust engine speed as well as stop the en gine Use the START position when start ing the engine Pull the lever all way back to the STOP position to shut the engine off SECTION 3 OPERATION T WARNING Before operating your machine carefully read and understand all safety Section 1 controls Section 3 and operating instructions Section 4 in this Manual in the separate Engine Owner s Manual and on the decals on the machine Failure to follow these instructions can result in serious personal injury Introduction Read this Section of the manual thorough ly before you start the engine Then take time to familiarize yourself with the basic operation of the tiller before using it Find an open level area and practice using the tiller controls without engaging the tines in the soil put tines in travel setting Only after you ve become completely familiar with the tiller should you begin using it in the garden Break In Operation Perform the following maintenance during the first hours of new operation see Sec tion 5 Maintenance and the maintenance section of the Engine Owner s Manual 1 Change motor oil after first 2 hours o
31. ear Lever P Figure 2 12 up through the slot in the control panel that is labeled WHEEL GEAR 2 Insert two 10 32 x 1 2 round head screws down through the marks on the control panel decal and securely attach the wheel gear mounting bracket using two 10 lockwashers and 10 32 nuts 3 Use a small board or rubber mallet to tap the Wheel Gear Lever knob securely onto the lever R Figure 2 13 4 Secure the wheel gear cable and the re verse clutch control cable to the left side handlebar with two plastic ties S Figure 2 13 located about two feet apart Snip off any excess tie length with ors STEP 7 CHECK AIR Use a tire pressure gauge to check the air pressure in both tires Deflate or inflate both tires equally to between 15 PSI and 20 PSI Be sure that both tires are inflated equally or the unit will pull to one side use automatic transmission fluid or motor oil in the oe A Figure 2 13 Attach wheel gear cable and re verse clutch cable with cable ties S STEP 8 CHECK HARDWARE Inspect the hardware on the unit and tight en any loose screws bolts and nuts SECTION 3 FEATURES AND CONTROLS WARNING Before operating your machine carefully read and understand all safety controls and operating instructions in this Manual the separate Engine Owner s Manual and on the decals on the machine Failure to follow these instructions can result in Serious personal injury Tiller Featur
32. er when operating in ex tremely dirty or dusty conditions A To Check the Motor Oil Level 1 Move the tiller to a level area and stop the engine 2 Level the engine by moving the Depth Regulator Lever into the second notch from the top 3 Clean the area around the oil dipstick or oil fill tube whichever applies to prevent dirt from falling into the crankcase 4 On engines with an oil fill tube remove the filler cap and add oil if required until it reaches the top of the tube Reinstall the filler cap 5 On engines with a dipstick remove it wipe it clean and reinstall it finger tight Remove the dipstick again and check the reading Add oil if required to bring the level to the FULL mark Do not overfill B To Change the Motor Oil Change the motor oil as instructed in the separate Engine Owner s Manual Air Cleaner Service The engine air cleaner filters dirt and dust out of the air before it enters the carbure tor Operating the engine with a dirty clogged air filter can cause poor perfor mance and damage to the engine Never operate the engine without the air cleaner installed Inspect and service the air clean er more often if operating in very dusty or dirty conditions Service the air cleaner as instructed in the separate Engine Owner s Manual Spark Plug Service Inspect and clean or replace the spark plug after every 100 operating hours or annual ly Clean the plug and set the ga
33. es This section describes the location and function of the controls on your tiller Re fer to Section 4 Operation for detailed op erating instructions Practice using these controls with the en gine shut off until you understand the op eration of the controls and feel confident with each of them IMPORTANT Refer to the separate engine manufacturer s Engine Owner s Manual for information about the controls on the engine A Wheel Gear Lever This lever A Figure 3 1 has two posi tions ENGAGE and DISENGAGE In the ENGAGE position the wheels will start turning when either the Forward Clutch or the Reverse Clutch is engaged NOTE The tines will also start turning when either clutch is engaged Ay DANGER Never place the Wheel Gear Lever in DISENGAGE Freewheel when the engine is running Having the Wheel Gear Lever in engaging the tinesAwheels with either the Forward Clutch or the Reverse Clutch could allow the tines to propel the tiller rapidly backward Failure to follow this instruction could result in personal injury or property damage The DISENGAGE freewheel position plac es the wheels in freewheeling mode to al low the wheels to turn without starting the engine Use the DISENGAGE position only when the engine is not running Figure 3 1 Control panel To shift to ENGAGE gently do not force move the lever forward while rolling the tiller a few inches forward or backward Mo
34. f new engine operation 2 Check for loose or missing hardware on unit Tighten or replace as needed 3 Check tension on forward drive belt af ter first 2 hours of operation 4 Check transmission gear oil level after first 2 hours of operation STARTING AND STOPPING ENGINE The following steps describe how to start and stop the engine Do not engage the tines or wheels until you have read all of the operating instructions inthis Section Also review the safety rules in Section 1 Safety and the tiller and engine controls information in Section 3 Features and Controls Pre Start Checklist Do the following before starting the en gine 1 Check unit for loose or missing hard ware Service as required Reverse Clutch Control Wheel Gear Lever Forward Clutch Lever Recoil Rope Starter Forward Clutch Lever Depth Regulator Lever Counter Rotating Tines Figure 4 1 2 Check motor oil level See Engine Own ers Manual 3 Check that all safety guards and covers are in place 4 Check air cleaner and engine cooling system See Engine Owner s Manual 9 Select a forward belt speed range see Changing Belt Speed Ranges in this Sec tion 6 Fill the fuel tank with gasoline according to the directions in the separate Engine Owner s Manual Follow all instructions and safety rules carefully DANGER GASOLINE IS HIGHLY FLAMMABLE AND ITS VAPORS ARE EXPLOSIVE Follow gasoline safety rules in
35. from the clevis pin F Figure 5 11 that connects the forward idler arm G to the forward adjustable link H Push inward on the forward idler arm G and remove the clevis pin F 7 There are two holes in the forward ad justable link H Figure 5 11 Push in ward on the forward idler arm G and install the clevis pin F through the inner hole in the forward adjustable link H and out through the single hole in the forward idler arm G Secure the clevis pin with the hairpin cotter WARNING Before inspecting cleaning or servicing the machine shut off engine wait for all moving parts to come to a complete stop disconnect spark plug wire and move wire away from Spark plug Failure to follow these instructions can result in Serious personal injury or property damage E Remove belt from groove Figure 5 9 Disconnect Forward Clutch Rod and move forward drive belt out of groove in engine forward drive pulley M EN v e A Figure 5 10 One or two threads on Forward Clutch Rod should be exposed above rectan gular nut Figure 5 11 Remove clevis pin from outer hole in forward adjustable link and move to in ner hole in link NOTE While pushing inward on the forward idler arm be sure that the forward drive belt is moved off to the right side of the tiller This creates more room to install the clevis pin when the forward idler arm is pushed inward IMPORTANT When the clevis
36. gine pulley A Figure 5 16 has one groove for the one reverse speed The transmission pulley C Figure 5 16 has three grooves The groove closest to the engine is for the reverse belt The mid dle groove is for the High speed forward 21 belt range the rearmost groove is for the Low speed forward belt range A Removing the Forward Drive Belt 1 Stop the engine allow it to cool and dis connect the spark plug wire before work ing near the belts 2 Remove the reverse drive belt following the Removing the Reverse Drive Belt instructions in this section 3 Move the forward drive belt B Figure 5 16 completely off the engine forward drive pulley D 4 Slip the forward drive belt completely off the transmission drive pulley C Figure 9 16 by moving it to the front of the pul ley 9 Pull the forward drive belt up and off the pulleys by feeding the bottom half of the belt in between the engine and transmis sion pulleys B Installing the Forward Drive Belt 1 The reverse drive belt must be removed before installing the forward drive belt 2 Slip the forward drive belt down between the rear of the engine forward drive pulley D Figure 5 16 and feed the bottom half in between the engine and transmission pul leys See Figure 5 17 Be sure that the belt is to the inside of the forward idler pulley and forward belt guide see J and Figure 9 12 Figure 5 17 Install forward drive belt over rear of
37. il set for a day or two before making a final deep tilling pass e Avoid the temptation to push 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 to hold the tiller back the tines will attempt to propel the tiller backward towards the operator 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 Choosing Correct Wheel amp Tine Speeds With experience you will find the just right tilling depth and tilling speed combination that is best for your garden Set the engine throttle lever at a speed to give the engine adequate power and yet allow it to operate at the slowest possible speed at least until you have achieved the maximum tilling depth you desire Faster engine speeds may be desirable when making final passes through the seedbed or when cultivating Selection of the correct engine speed in relation to the tilling depth will ensure a sufficient power level to do the job without causing the engine to labor 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 han dlebar with just one hand
38. ing in DISENGAGE freewheel position when the tines are rotating Before starting the engine test the function of the mechanical interlock as follows 1 Put Wheel Gear Lever into DISENGAGE position and roll tiller back and forth a few inches Wheels should roll freely 2 Without rolling the tiller squeeze either Forward Clutch Lever against the handle bar grips As the levers move upward the mechanical interlock automatically moves the Wheel Gear Lever forward into the EN GAGE position roll tiller back and forth a few inches If it does the wheels will not roll freely when you push and pull on the handlebars 3 The mechanical interlock works proper ly if it functions as described in Step 2 If the mechanical interlock does not function properly do not operate the tiller until it has been corrected see your authorized dealer or contact the factory Reverse Clutch Control This control C Figure 3 1 engages the reverse drive to the wheels and power to the tines It is used for moving the tiller short distances in a reverse direction To Operate Reverse Clutch WARNING Use extreme caution when reversing or pulling the machine towards you Look behind to avoid obstacles Never attempt to till in reverse Failure to follow this warning could result in personal injury or property damage A 1 Before engaging the Reverse Clutch put the Wheel Gear Lever into ENGAGE see WARNING at left 2 Rele
39. ive belt should be checked after the first two 2 hours of operation Thereafter check the tension after every ten 10 hours of operation The reverse drive belt because it is used infrequently will not require an initial ten sion adjustment until a significant num ber of operating hours has passed To Check and Adjust Tension on the Forward Drive Belt 1 Checking for correct belt tension is the Same as that described in item 5 Step 4 Attach Forward Clutch Rod Before checking shut off the engine disconnect the spark plug wire and allow the engine and muffler to cool down If after follow ing the adjustment procedures you can not get the correct gap on the forward clutch rod adjustment bracket you will need to make a secondary adjustment as described next 2 Disconnect the Forward Clutch Rod A Figure 5 9 from the swivel plate B by removing the innermost hairpin cotter C 3 Unthread the Forward Clutch Rod in a counterclockwise direction as viewed from the front of the unit until one or two threads on the rod extend above the rect angular nut D Figure 5 10 on the for ward clutch bracket 4 Remove the belt cover 9 Slip the forward drive belt E Figure he engine driven forward drive pulley by pushing it off away from engine with your left hand while pulling engine starter rope with your right hand 6 On the left side of the unit from oper ator s position remove the hairpin cotter
40. lopes 18 Never allow bystanders near the unit 19 Only use attachments and accessories that are approved by Garden Way Inc 20 Use tiller attachments and accessories when recommended 21 Never operate the tiller without good vis ibility or light 22 Never operate the tiller if you are tired or under the influence of alcohol drugs or medi cation 23 Operators shall not tamper with the engine governor settings on the machine the governor controls the maximum safe operating speed to protect the engine and all moving parts from damage caused by overspeed Authorized ser vice shall be sought if a problem exists 24 Do not touch engine parts which may be hot from operation Let parts cool down 25 Please remember You can always stop the tines and wheels by releasing the Forward Clutch Lever or the Reverse Clutch Control whichever lever you have engaged or by mov ing the Throttle Control Lever to STOP 26 To load or unload the tiller see the instruc tions in Section 4 of this Manual 21 Use extreme caution when reversing or pulling the machine towards you 28 Start the engine carefully according to in structions and with feet well away from the tines 29 Never pick up or carry a machine while the engine is running Maintenance and Storage 1 Keep the tiller attachments and acces sories in safe working condition 2 Check all nuts bolts and screws at fre quent intervals for proper tightne
41. lt in personal injury or property damage However if you must load or unload the tiller follow the guidelines given next e Before loading or unloading stop the engine wait for all parts to stop moving disconnect the spark plug wire and let the en gine and muffler cool e The tiller is too heavy and bulky to lift safely by one person Two or more people should Share the load e Use sturdy ramps and manually engine shut off roll the tiller into and out of the vehicle Two or more people are needed to do this e The ramps must be strong enough to sup port the combined weight of the tiller and any handlers The ramps should provide good trac tion 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 e The handlers should wear sturdy footwear that will help to prevent slipping e Position the loading vehicle so that the ramp angle is as flat as possible the less incline to the ramp thebetter Turn the vehicle s engine off and apply its parking brake A WARNING Before clearing the tines by hand stop the engine allow all moving parts to stop and disconnect the Spark plug wire Remove the ignition key on electric start models Failure to follow this warning could result in personal injury e When going up ramps stand in the normal operating position and push the tiller ahead of you Have a person at each
42. not roll when the lever is in ENGAGE but they should roll when the lever is in DISENGAGE Readjust the cable as required Off Season Storage When the tiller won t be used for extended periods prepare it for storage as follows 1 Clean the tiller and engine 2 Do routine tiller lubrication see Tiller Lubrication and check for loose parts and hardware see Check Hardware 3 Protect the engine by performing the engine storage instructions in the separate Engine Owner s Manual NOTE Be sure to protect the fuel lines car buretor and fuel tank from gum deposits by removing fuel or by treating fuel with a fuel stabilizer follow engine manufactur ers recommendations 4 Store unit in a clean dry area 5 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 Tines The tines will wear with use and should be inspected at the beginning of each tilling season and after every 30 operating hours Tines can be replaced individually or as a complete set Never inspect or service the tines unless the engine is stopped and the Spark plug wire is disconnected NOTE The tiller hood must be removed to take off either a single tine holder or individual tines The hood is secured to the transmission housing with two rear bolts and two front bolts Tine Inspection
43. nsmission drive pulley NOTE The High speed belt range is recom mended for all tilling purposes The Low speed belt range will operate the tines and wheels at a slower forward speed which may be suitable in some conditions such as tilling in very hard ground To Change from Low to High Speed 1 Stop the engine allow it to cool and dis connect the spark plug wire 2 Move the Wheel Gear Lever into the DIS ENGAGE position 3 Remove the two nuts from the plastic belt cover on top of the transmission and remove the belt cover 4 From beneath the tiller move the for ward drive belt out of the transmission low speed groove B Figure 4 10 and into the high speed groove D 9 Pull upward on the belt to remove any Slack and slip the belt out of the engine drive pulley low speed groove A Figure 4 10 and into the high speed groove C NOTE If the belt is difficult to move pull on the engine start rope while pushing the belt with your finger engine drive pulley will turn as start rope is pulled 6 Check that the belt is within the forward belt guide E Figures 4 10 and 4 11 onthe right side of the unit and is within the for ward idler F Figure 4 11 on the left side Be sure that the belt is situated in the center grooves C and D Figure 4 10 of the en gine upper and transmission lower pul leys 7 Reinstall the plastic belt cover and se cure it with the two nuts 8 Put Wheel Gear Lever in
44. nty provide the sole and exclusive remedy arising from the sale Troy Bilt LLC shall not be liable for any incidental or consequential damage or expense of any kind including but not limited to cost of equipment rental loss of profits or costs of hiring services to perform tasks normally performed by the equipment Any implied warranties including any implied warranty of merchantability or fitness for a particular purpose shall be limited in duration to the period of ownership by the original purchaser and a maximum of 90 days from the date of sale if the tiller is purchased for commercial or other non residential use 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 This limited warranty gives you specific legal rights and you may also have other rights which vary from state to state For customer assistance contact your nearest authorized dealer or contact us at TROY BILT LLC P O Box 361131 Cleveland Ohio 44136 0019 1 866 840 6483
45. op re verse motion let go of the Reverse Clutch Control 6 To turn the tiller around a Practice turning in a level open area Be very careful to keep your feet and legs away from the tines b To start a turn reduce the engine Speed and then lift the handlebars un til the engine and tines are balanced over the wheels Figure 4 4 With the tiller balanced push side ways on the handlebar to move the tiller in the direction of the turn Fig ure 4 5 After completing the turn Slowly lower the tines into the soil and increase the engine speed 12 Figure 4 2 moving forward Use one hand to guide tiller when Stopping the Tiller and Engine 1 To stop the wheels and tines release the Forward Clutch levers or the Reverse Clutch Control whichever is engaged 2 To stop the engine move the Engine Throttle Lever to STOP 3 If the engine is equipped with a fuel shut off valve close the valve as instructed in the Engine Owner s Manual T WARNING Before changing belt speeds stop engine wait for all parts to stop moving let engine cool and disconnect spark plug wire Failure to follow these instructions could result in personal injury Changing Belt Range Speeds The tiller has two forward belt range speeds for the wheels and tines Low and High The two ranges are obtained by moving the forward drive belt between two sets of grooves on the forward drive pulley and the tra
46. ors are explosive Take the following precautions a Store fuel in containers specifically designed for this purpose b The gas cap shall never be removed or fuel added while the engine is run ning Allow the engine to cool for Several minutes before adding fuel c Keep matches cigarettes cigars pipes open flames and sparks away from the fuel tank and fuel container d Fill fuel tank outdoors with extreme care Never fill fuel tank indoors Use a funnel or spout to prevent spillage e Replace all fuel tank and container caps securely f If fuel is spilled do not attempt to Start the engine but move the ma chine away from the area of spillage and avoid creating any source of igni tion until fuel vapors have dissipated 7 Never make adjustments when engine is running unless recommended by manu facturer Operation 1 Do not put hands or feet near or under rotating parts 2 Exercise extreme caution when on or crossing gravel drives walks or roads otay alert for hidden hazards or traffic Do not carry passengers 3 After striking a foreign object stop the engine remove the wire from the spark plug wire and prevent it from touching the Spark plug thoroughly inspect the machine for any damage and repair the damage be fore restarting and operating the machine 4 Exercise caution to avoid slipping or fall ing 5 Ifthe unit should start to vibrate abnormally Stop the engine disconnect the s
47. p as de scribed in the separate Engine Owner s Manual In some areas local law requires using re sistor spark plugs to suppress ignition sig nals If the engine was originally equipped with a resistor spark plug use the same type for replacement Spark Arrester Screen Service If the engine muffler is equipped with a Spark arrester screen remove and clean it according to the time intervals and instruc tions in the separate Engine Owner s Man ual Engine Cleaning The engine must be kept clean to assure Smooth operation and to prevent damage from overheating Refer to the separate Engine Owner s Manual for specific repair and cleaning instructions All inspections and services must be done with the engine shut off and cool to the touch WARNING Before inspecting cleaning or servicing the machine shut off engine wait for all moving parts to come to a complete stop disconnect spark plug wire and move wire away from Spark plug Failure to follow these instructions can result in Serious personal injury or property damage Carburetor Governor Adjustment T WARNING Operators shall not tamper with the engine governor settings the governor controls the maximum safe operating speed to protect the engine and all moving parts from damage caused by overspeed Authorized service shall be sought if a problem exists The carburetor was adjusted at the factory for best operating speed Refer to the sep a
48. park plug wire and prevent it from touching the spark plug and check immediately for the cause Vi bration is generally a warning of trouble 6 Stop the engine disconnect the spark plug wire and prevent it from touching the Spark plug whenever you leave the operat ing position before unclogging the tines or when making any repairs adjustments or inspections 7 Take all possible precautions when leav ing the machine unattended Stop the en gine Disconnect spark plug wire and move it away from the spark plug Move Wheel Gear Lever to ENGAGE 8 Before cleaning repairing or inspect ing stop the engine and make certain all moving parts have stopped Disconnect the spark plug wire and prevent it from touching the spark plug to prevent acci dental starting 9 Always keep the tiller tine hood flap down 10 Never use the tiller unless proper guards plates or other safety protective de vices are in place 11 Do not run engine in an enclosed area Engine exhaust contains carbon monoxide gas a deadly poison that is odorless col orless and tasteless 12 Keep children and pets away 13 Never operate the tiller under engine power if the Wheel Gear Lever is in DIS ENGAGE FREEWHEEL In this position the wheels will not hold the tiller back and the revolving tines could propel the tiller rapidly backward possibly causing loss of control Always move the Wheel Gear Lever to ENGAGE before starting the engin
49. rate Engine Owner s Manual for any ad justment information or see your authorized engine service dealer The governor controls the maximum safe operating speed and protects the engine and all moving parts from damage caused by overspeeding Do not tamper with the engine governor settings Seek authorized service if a problem exists Throttle Control Adjustment If the engine does not respond to various throttle lever settings refer to the separate Engine Owner s Manual for service infor mation or contact your local authorized en gine service dealer Wheel Gear Cable Adjustment When the Wheel Gear Lever is in DISEN GAGE the wheels will roll freely free wheel The wheels should not roll freely when the lever is in ENGAGE Ifthe wheels roll freely when the Wheel Gear Lever is in ENGAGE the wheel gear cable needs to be adjusted as described below 1 With the engine shut off and the spark plug wire disconnected put the Wheel Gear Lever in ENGAGE 2 Loosen the top adjustment nut the wheel gear cable bracket located on the left side rear of the transmission 3 Push wheel gear cable B down and roll tiller slightly forward or backward until ec centric lever C engages locks wheels Figure 5 5 Wheel gear cable assembly Hold cable in that position and tighten top A and bottom D adjustment nuts 4 Move Wheel Gear Lever to ENGAGE and DISENGAGE several times to check adjust ment The wheels should
50. side to turn the wheels e When going down ramps walk backward with the tiller following you Keep alert for any obstacles behind you Position a person at each wheel to control the speed of the tiller Never go down ramps tiller first as the tiller could tip forward e Place wooden blocks on the downhill side of the wheels if you need to stop the tiller from rolling down the ramp Also use the blocks to temporarily keep the tiller in place on the ramps if necessary and to chock the wheels in place after the tiller is in the vehicle e After loading the tiller prevent it from rolling by engaging the wheels in the WHEEL DRIVE position Chock the wheels with blocks and Securely tie the tiller down SECTION 5 MAINTENANCE WARNING Before inspecting cleaning or servicing the machine shut off engine wait for all moving parts to come to a complete stop disconnect spark plug wire and move wire away from Spark plug Remove ignition key on electric start models Failure to follow these instructions can result in Serious personal injury or property damage MAINTENANCE SCHEDULE PROCEDURE NOTES Check motor oil level 2 3 Clean engine Check drive belt tension Check nuts and bolts Change motor oil Lubricate tiller Service foam pre cleaner air filter Service paper air filter Check gear oil level in transmission Check tines for wear Check air pressure in tires Service spark plug NOTES 1 After first 2 hours
51. ss to be Sure the equipment is in safe working con dition 3 Never store the tiller with fuel in the fuel tank inside a building where ignition sources are present such as hot water and space heaters furnaces clothes dryers stoves electric mo tors etc Allow engine to cool before storing in any enclosure 4 To reduce the chances of a fire hazard keep the engine free of grass leaves or excessive grease 5 Store gasoline in a cool well ventilated area Safely away from any spark or flame producing equipment Store gasoline in an approved container safely away from the reach of children 6 Refer to the storage instructions in the Maintenance section of this Manual and the separate Engine Owner s Manual for in structions if the tiller is to be stored for an extended period 7 Never perform maintenance while the en gine is running or the spark plug wire is connected except when specifically in structed to do so 8 If the fuel tank has to be drained do this outdoors Safety Decals Control Description For your safety and the safety of others om control Panal various safety and operational decals are located on your unit see Figure 1 2 be low Keep the decals clean and legible at all times Contact your local service dealer or Tine Warning the factory for replacements if any decals are damaged or missing Starting Stabilization Refer to the Parts List in this manual for Message on engin
52. theft fire water or damage because of peril or other natural disaster The following items are not covered after the first year of this residential use limited warranty belts batteries bushings seals tines tires wheels paint appearance items and similar items that are normally replaced through periodic maintenance Charges for pick up delivery and service calls are not covered by this warranty Service completed by someone other than an authorized service dealer is not covered by this warranty Parts that are not genuine Troy Bilt LLC service parts are not covered by this warranty The engine is warranted separately by the engine manufacturer Refer to the engine manufacturer s warranty for terms and conditions If used for commercial institutional industrial rental or demonstrator purposes the warranty on the tiller is limited in duration to 90 days from the date of purchase This warranty does not apply to parts that have been damaged by accident alteration misuse abuse neglect improper maintenance vandalism theft fire water or damage because of peril or other natural disaster Warranty service is available with proof of purchase through your local authorized service dealer To locate a dealer in your area consult your Yellow Pages or contact Troy Bilt LLC at P O Box 361131 Cleveland Ohio 44136 0019 1 866 840 6483 or log on to our Web site at www troybilt com The provisions set forth in this warra
53. ting tine tiller and its tines must be mounted in the direction shown in Figure 5 7 Failure to comply could result in personal injury Or property damage 2 When installing individual tines install them inthe reverse order from which they were removed The two sets of inboard tines are installed so one tine faces to ward the transmission housing and the other tine faces away from it The single outboard tine on each side faces toward the transmission housing Also be sure the cutting edges face so they will enter the soil first when the tiller is moving for ward this means the cutting edges face toward the operator position Checking And Adjusting Tension On Drive Belts While checking belt tension also check for cracks cuts or frayed edges A belt that is in poor condition should be re placed WARNING Follow the belt adjustment instructions carefully An incorrect adjustment could result in the Forward Clutch mechanism engaging too soon This could cause loss of tiller control and result in personal injury or property damage Maintaining correct tension on the drive belts is important to good tilling perfor mance and long belt life A loose belt will slip on the engine and transmission pul leys and cause the tines and wheels to Slow down or stop completely even though the engine is running at full speed A loose belt will also result in premature wear to the belt The tension on a new forward dr
54. tion this allows the wheels to rotate freely Use the handlebars to roll the tiller off the platform Fi Fp Figure 2 5 Carefully unwrap Wheel Gear Le ver and move lever to DISENGAGE NOTE The Whee Gear Lever will be installed later in this procedure wrae Har IMPORTANT Use the DISENGAGE position only when the engine is not running Before starting the engine the Wheel Gear Lever must be placed in the ENGAGE position see Section 3 for details STEP 3 ATTACH REVERSE CLUTCH CONTROL CABLE 1 Carefully unwrap the reverse clutch control cable H Figure 2 6 from its ship ping position and route it up along the in side edge of the left side handlebar A knob and large hex nut I is installed on the ca ble Left Side Handlebar Reverse Clutch Control Knob Figure 2 6 Attach reverse clutch control as sembly to slotted hole in handlebar panel 2 Insert the cable into the slot in the con trol panel and fit the threaded assembly into the hole in the slot See Figure 2 6 Be sure that the flat side of the threaded assembly is aligned with the flat side of the hole Slide the hex nut 1 up the cable and tighten it securely 3 Test the function of the reverse clutch control cable by pulling the knob out and releasing it The knob should return to its neutral position against the tapered bush ing If it doesn t contact your local dealer or the factory for technical STEP 4 ATTACH FORWARD C
55. ug see Engine Owner s Manual Dirty air filter s 2 Clean or replace see Engine Owner s Manual Carburetor out of adjustment 3 See Engine Service Dealer Stale gasoline 4 Replace with fresh gasoline Dirt or water in fuel tank 5 See Engine Service Dealer Engine cooling system clogged 6 Clean air cooling system see Engine Owner s Manual Engine overheats Engine cooling system clogged 1 Clean air cooling area see Engine Owner s Manual Carburetor out of adjustment 2 See Engine Service Dealer Oil level is low 3 Check oil level See Engine Owner s Manual Engine does not shut off 1 See Engine Owner s Manual or Engine Service Dealer Wheels and Tines will not turn 1 Improper use of controls 1 Review Sections 3 and 4 Forward Drive Misadjusted forward clutch rod 2 see Handlebar Height Adjustment Section 3 Reverse Drive Broken or misadjusted belt 3 Replace belt or adjust belt tension Section 5 Worn Broken or misadjusted Drive Belt s 4 See Checking Drive Belt Tension Section 5 Internal transmission wear or damage 5 Contact local dealer or the factory Bolt and key loose in transmission pulley 6 Tighten bolt Check that key is in place Tines turn but wheels don t Wheel Drive Pins not in WHEEL DRIVE 1 See Wheel Drive Pins in Section 3 Bolt loose in transmission pulley 2 Tighten bolt Internal transmission wear or damage 3 Contact local Dealer or the Factory Wheels T
56. unit and carton for damage im mediately after delivery Contact the carri er trucking company if you find or suspect damage Inform them of the dam age and request instructions for filing a claim To protect your rights put your claim in writing and mail a copy to the car rier within 15 days after the unit has been delivered Contact us at the factory if you need assistance in this matter Unpacking and Assembly Instrutions STEP1 UNPACKING INSTRUCTIONS 1 Remove any card board inserts and packaging material from the carton Re move any staples from the bottom of the carton and remove the carton 2 Cut the large plastic tie strap that se cures the transmission tube to the shipping pallet Leave the handlebars on top of the tiller to avoid damaging any cables 3 A bag with loose hardware is inside the literature envelope Check the contents against the following list and Figure 2 1 Contact your local dealer or the factory if any items are missing or damaged NOTE For electric start units a second hardware bag is located near the battery 4 The tiller is heavy You should not at tempt to remove it from the shipping plat form until instructed to do so in these Assembly steps Hardware Bag Parts List Oty Description 3 8 16 x 1 Hex Hd Screw Keyed Washer Wheel Gear Lever Knob Height Adjustment Flange See Figure 2 2 2 3 8 Flat Washer 2 10 Lockwasher 2 8 16 Nylock Lock Nut 2 2 1 Ref
57. ure plant growth TILLING TIPS amp TECHNIQUES CON T A Tilling On Slopes Read the following recommendations before tilling on slopes WARNING Do not operate tiller on a slope too steep for safe operation Till slowly and be sure you have good footing Never permit tiller to freewheel down slopes Failure to follow this warning could result in personal injury lf you must garden on a moderate slope please follow two very important guidelines 1 Till only on moderate slopes never on steep ground where footing is difficult review safe ty rules in Section 1 Safety of this manual 2 We recommend tilling up and down slopes rather than terracing Tilling vertically on a slope allows maximum planting area and also leaves room for cultivating IMPORTANT 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 motor oil level at the full point at all times Tilling Up and Down Slopes Vertical Tilling e To keep soil erosion to a minimum be sure to add enough organic matter to the soil so that it has good moisture holding texture and try to avoid leaving footprints or wheel marks e When tilling vertically try to make the first pass uphill as the tiller digs more deeply going uphill than it does downhill
58. urn but Tines Don t Tine holder mounting hardware missing 1 Replace hardware Internal transmission wear or damage 2 Contact local Dealer or the Factory Poor tilling performance 1 Worn tines 1 See Tines Section 5 2 Improper Depth Regulator setting 2 See Tilling Tips amp Techniques Section 4 3 Incorrect throttle setting or belt range speed 3 See Section 4 4 Belt s slipping 4 See Checking Forward Drive Belt Tension Section 5 23 TROY BILT TILLER LIFETIME LIMITED WARRANTY WHAT PRODUCT IS COVERED WHAT IS COVERED BY THIS WARRANTY WHAT IS NOT COVERED BY THIS WARRANTY LIMITED COMMERCIAL USE WARRANTY HOW TO OBTAIN SERVICE All Troy Bilt branded rear tine walk behind tillers with gear drive transmissions This warranty begins on the date of purchase and is warranted by Troy Bilt LLC for the life of the tiller to the original purchaser only Troy Bilt LLC will at its option repair or replace any part found to be defective in material or workmanship without charge for parts and labor This limited lifetime warranty also applies to non powered attachments and accessories Powered attachments and accessories are warranted separately by their manufacturers Refer to the applicable manufacturer s warranty on these items for terms and conditions This warranty does not apply to parts that have been damaged by accident alteration misuse abuse neglect improper maintenance vandalism
59. ving the tiller helps align the transmis sion shift mechanism The wheels will not freewheel when the lever is properly set in the ENGAGE position To shift to DISENGAGE move the lever rearward without rolling the tiller The wheels roll freely when the lever is proper ly set in the DISENGAGE position Forward Clutch Levers Two interconnected levers B Figure 3 1 control engagement of the forward drive to the wheels and power to the tines A WARNING Never engage wheels and tines with Forward Clutch or Reverse Clutch unless Wheel Gear Lever is in ENGAGE Engaging the Forward Clutch or Reverse Clutch when wheels are not engaged could allow the tines to rapidly propel tiller backward Failure to follow this warning could result in personal injury or property damage To Operate Forward Clutch 1 Before engaging the Forward Clutch put the Wheel Gear Lever into the ENGAGE position see WARNING above 2 Lift and hold one or both levers against the handlebar grips to engage the wheels and tines 3 Release BOTH levers to disengage wheels and tines All forward motion will Stop engine will continue to run IMPORTANT The Forward Clutch Levers are connected to a mechanical interlock that automatically shifts a separate Wheel Gear Lever A Figure 3 1 into ENGAGE position when either Forward Clutch Lever is pulled up against the handlebars This is a Safety feature designed to prevent the wheels from be
60. void contacting yY J V ng any obstacles when pulling the starter rope Place one hand on the fuel tank to Stabilize the unit and use the recoil starter to start the engine as instructed in the En gine Owner s Manual When the engine Starts gradually move the choke lever on engines so equipped to the NO CHOKE CHOKE OFF or RUN position whichever ap plies 9 Use the FAST throttle speed setting when tilling Stopping the Engine 1 To stop the wheels and tines release the Forward Clutch levers or the Reverse Clutch Control whichever control is in use 2 To stop the engine move the Engine Throttle Lever into the STOP position Operating Tiller WARNING Before tilling contact your telephone and utilities company to inquire if underground ines are on your property The following pages provide guidelines to using your tiller effectively and safely in various gardening applications Be sure to read Tilling Tips amp Techniques in this Sec tion before you actually put the tines into the soil 1 Follow the Pre Start Checklist on the previous page Be sure that the Wheel Gear Lever is in the ENGAGE position 2 Move the Depth Regulator Lever into the travel position lever all the way down so that the tines clear the ground Use this position when practicing with or transporting the tiller When you are ready to begin tilling move the Depth Regulator Lever into the desired depth setting

Troy-Bilt 675B-Pony Tiller User Manual

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