Troy-Bilt 12204-10HP- Manuals

Page 2 - See Back Cover for; Safety Alert Symbol; This machine meets voluntary safety standard B71.8; WARNING; The engine exhaust from this product contains; TABLE OF CONTENTS

Dear Owner: You now own one of the finest rear-tine tiiiers avaiiabie. Your new PTO Horse Model tiiler enables you to till and cultivate your garden with ease, and accomplish dozens of other property management projects as well. Its PTO (Power Take Off) capability enables it to power a variety of at...

Page 3 - Safety; Training

1 Safety SPARK ARRESTER WARNING TO RESIDENTS OF CALIFORNIA AND SEVERAL OTHER STATES Under California law, and under the laws of several other states, you are not permitted to operate an internal combustion engine using hydrocarbon fuels on any forest, brush, hay, grain, or grass covered land; or lan...

Page 5 - Operating Symbols; TO AVOID SERIOUS INJURY:

Section 1: Safety Maintenance and Storage 1. Keep the tiller, attachments and accessories in safe working condition. 2. Check all nuts, bolts, and screws at frequent intervals for proper tightness to be sure the equipment is in safe working condition. 3. Never store the tiller with fuel in the fuel...

Page 6 - Section; To prevent personal injury or property; Introduction; Loose Parts List; STEP 2: Attach Handlebar

Section 2 Assembly A 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 you...

Page 7 - STEP 4: Connect Forward

Section 2: Assembly 2. Place the handlebar ends on either side of the base, with the wire harness toward the rear of the base (Figure 2-2). 3. Install the height adjustment lever through the right-side clamp, handlebar end, ratchet, and base; then out through the left-side ratchet, handlebar end, an...

Page 8 - STEP 6: Check Gear Oil Levels

Section 2: Assembly Remove the temporary screw (J, Figure 2-7) from the forward holes and move the Wheels/Tines/PTO Lever fully forward. Install the wider hook end of the clutch pawl spring (M, Figure 2-8) down into the small hole at the end of the handle. Use pliers to insert the other end into the...

Page 9 - STEP 7: Add Motor Oil to Engine; STEP 8: Attach Engine Throttle; To avoid electric shock from a short

Section 2: Assembly IMPORTANT: Check gear oil level in both transmissions after the first 2 hours of new tiller operation, then every 30 operating hours thereafter. See Section 5 for instructions. Figure 2-12: Checking oii ievei on Power Unit Transmission. Figure 2-13: Checking oil level on Tine Att...

Page 10 - ASSEMBLING THE ELECTRIC START SYSTEM; STEP 1: Activating and

Section 2: Assembly ASSEMBLING THE ELECTRIC START SYSTEM The following steps explain how to activate, charge, and install the battery on electric start tillers. For your safety, follow all steps and observe all accompanying safety messages. Section 5 contains other general battery maintenance and re...

Page 13 - Features and Controls; PTO Attachments Feature; Forward Interlock Levers

Section 3 Features and Controls A WARNING Before operating your machine, carefully read and understand all safety, controls, operating instructions in this Manual, the separate Engine Owner’s Manual and on the decals on the machine. Failure to follow these instructions can result in serious personal...

Page 14 - Section 3: Features and Controls; Wheel Speed Lever

Section 3: Features and Controls Verify Position of Clutch Roller When you shift bet\veen FORWARD, NEUTFtAL and REVERSE the clutch roller at the base of the WhecIs/Tines/PTO Drive Lever should be positioned as shown in Figures 3-2. 3-3 and 3-4. Verify the position of the clutch roller as you shift t...

Page 15 - Д WARNING

Section 3: Features and Controls Д WARNING The tiller handlebars can be swung out 30° to the right side for use only with the PTO Chipper/Shredder attachment. This is done by loosening the mounting bolt on the handlebar base. Never operate your tiller or attachments, other than the PTO Chipper/Shred...

Page 16 - Sectio n; Operation; A WARNING

Sectio n 4 Operation A WARNING Before operating your mactiine, 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 instructio...

Page 17 - CAUTION

Section 4: Operation Wheels/Tines/PTO Drive Lever Recoii Start Rope (at front of engine) Engine Throttie Lever Forward interlock Levers DepthRegulatorLever Tines/PTO Clutch Lever^ Starting the Engine: A CAUTION To help prevent serious personal injury or damage to equipment: • Always place Wheels/Tin...

Page 18 - DANGER

Section 4: Operation Reconnect the cables and securely tighten to battery posts. The engine wiil recharge the battery if the battery is still good. • If you suspect the batter is “dead”, or if the battery is damaged, disconnect, and remove it. Have it checked by a qualified technician. • if battery ...

Page 19 - A CAUTION

Section 4: Operation Figure 4-3: Moving tiiier forward: squeeze one Forward Interlock Lever and then move WheeisiTines/PTO Drive Lever down to FORWARD. 6 . When the tiiier moves forward, relax and let the wheels power the tiller along while the tines dig. Walk behind and to one side of the tiller. W...

Page 20 - Loading and Unloading the Tiller

Section 4: Operation 4. When the turn is complete, shift to NEUTRAL and lower the handlebars.Move Tines/PTO Clutch Lever back to ENGAGE position and resume forward operation. Transporting The Tiller Around Your Property When the engine is running, the tiller’s powered wheels make moving the tiller t...

Page 21 - Changing Speed Belts

Section 4: Operation •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 ...

Page 22 - Choosing Wheel

Section 4: Operation A 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. Kneel on left sid...

Page 23 - TABLE 2-4: WHEEL SPEED AND BELT RANGE SELECTIDN GUIDE; Tilling Tips & Techniques; Let the tiller do the work; Avoid tilling wet, soggy soil

Section 4: Operation TABLE 2-4: WHEEL SPEED AND BELT RANGE SELECTIDN GUIDE IMPORTANT — For correct wheel speed and belt range choices when using attachments or accessories other than tines, read the Owner/Operator Maniiai p’ovided with the attachment or accessory. SLOW GEAR, LOW BELT RANGE For: •Til...

Page 24 - Avoid making footprints

Section 4: Operation Tilling Tips & Techniques Avoid making footprints When possible, walk on the untilled side of the unit to avoid making footprints in the freshly tilled soil (Figure 4-4). Foot prints cause soil compaction that can hamper root penetration and contribute to soil erosion. They...

Page 25 - Clearing the tines

Section 4: Operation Tilling Tips & Techniques I P'OLi LfcAVt 12 INCHES UNTILLEO REPEAT PFtOCEDUPE rxy.VNHII.^ Figure 4-18 B. Terrace Gardening: • When a slope is too steep or too short for vertical tilling, it may be necessary to till across the siope and create terraced rows. Terraces are rows...

Page 27 - PTO POWER UNIT; Removing And Replacing The Tine Attachment; VERY IMPORTANT

Section 4; Operation PTO POWER UNIT Your tiller is a self-contained PTO (Power Take-Off) Power Unit that was shipped with a tine attachment installed. The tine attachment can be quickly removed and replaced with other optional attachments. The following instructions will familiarize you with your PT...

Page 30 - Maintenance; REQUIRED MAINTENANCE SCHEDULE

Section 5 Maintenance 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. Remove ignition key on electric start models. Failure to follow these instructio...

Page 31 - Sections: Maintenance; Tiller Lubrication

Sections: Maintenance A WARNING Before inspecting, cleaning or servicing the machine, shut off engine, wait for ail moving parts to come to a complete stop, disconnect spark plug wire and move wire away from spark plug. Remove ignition key, if so equipped. Failure to follow these instructions can re...

Page 32 - W A R N IN G; Transmission Gear; Checking for Oil Leaks

Sections: Maintenance A W A R N IN G * n Failure to follow these instructions can result in serious personal injury or property damage. Before inspecting, cieaning or servicing the machine, shut off engine, wait for aii moving parts to come to a compiete stop, disconnect spark piug wire and move wir...

Page 33 - Adding or Changing Gear Oii

Sections: Maintenance A W A R N IN G Before inspecting, cleaning or servicing the machine, shut off engine, wait for ali moving parts to come |to a complete stop, disconnect spark plug wire and move wire away from spark plug. Remove ignition key, if so equipped. I Failure to follow these instruction...

Page 35 - Drive Belt Maintenance; Measuring and Adjusting

Sections: Maintenance A W A R N IN G W Failure to follow these instructions can result in serious personal injury or property damage. 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 ...

Page 36 - Replacing the Drive Belt

Sections: Maintenance A W A R N IN G »n 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, if so equipped. Failure to follow these instruction...

Page 37 - Reverse Drive; Reverse Disc Inspection

Sections: Maintenance 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. Remove ignition key, if so equipped. Failure to follow these instructions can re...

Page 38 - Replacing the Reverse Disc; I Switch Body

Sections: Maintenance A W A R N IN G ♦ r? Before inspecting, cieaning or servicing the machine, shut off engine, wait for alt moving parts to come to a complete stop, disconnect spark plug wire and move wire away from spark plug. Remove ignition key, if so equipped. Failure to follow these instructi...

Page 39 - Checking Tines for Wear

Sections: Maintenance A W A R N IN G * n m» 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, if so equipped. Failure to follow these instruc...

Page 40 - in

Sections: Maintenance A W A R N IN G i in 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, if so equipped. Failure to follow these instructi...

Page 41 - Removing the Wheels; Wear safety goggles when driving the; Battery Care in Service

Sections: Maintenance A W A R N IN G W 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, if so equipped. Failure to follow these instructions...

Page 42 - Battery Care in Storage

Sections: Maintenance A W A R N IN G ♦ n ft ' Before inspecting, cieaning or servicing the machine, shut off engine, wait for ali moving parts to come to a complete stop, disconnect spark piug wire and move wire away from spark plug. Remove ignition key, if so equipped. Failure to follow these instr...

Page 43 - Battery Removal and Replacement; The battery posts must face; When removing the battery, always dis; Storing Your Tiller; Inspecting Forward Interlock

Sections: Maintenance A W A R N IN G W Failure to follow these instructions can result in serious personal injury or property damage. 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 ...

Page 44 - Appendix A Troubleshooting; CHECK OR TEST; Troubleshooting Procedures; Wheels and Tines Won’t Turn:

Appendix A; Troubleshooting CHECK OR TEST (Check or test in sequence shown until problem is resolved.) PROBLEM Engine won’t start Engine shuts off when Wheels/Tines/PTO Drive Lever is shifted into FORWARD Engine does not shut off when Forward Interlock Levers are released while Wheels/Tines/PTO Driv...

Page 45 - Appendix A: Troubleshooting

Appendix A: Troubleshooting • Hardware holding tine holders to tine shaft may be missing or broken. To check, remove holders (Sect. 5). • Key for bronze worm gear on tine attach ment main drive shaft may be missing or broken. 5 Tines Turn, But Wheels Won’t: • Check operation of Wheel Speed Lever (P...

Page 47 - Parts List; FORWARD INTERLOCK SYSTEM; 552 Engine Wire Harness Assy-forward

MODELS 12089, 12090, 12204 Parts List FORWARD INTERLOCK SYSTEM REF PART No. No. DESCRIPTION QTY. 1 2552 Engine Wire Harness Assy-forward interlock system (Incl. one red and one black wire, plug con nector, neutral switch and PVC tubing. Parts not available separately........................... REF ...

Page 48 - HANDLEBAR ASSEMBLY; Briggs & Stratton engine only

Parts List MODELS 12089, 12090, 12204 HANDLEBAR ASSEMBLY VIEW “A’ REF No. PART No. DESCRIPTION QTY. REF No. PART No. DESCRIPTION QTY 1 9548 Bolt-Hex hd., flanged self-locking 16A 1909286 Throttle Control & Cable-8HP Grade 5,1/2-13x3-1/2"......... 1 Briggs & Stratton engine only 2 9119 Kn...

Page 49 - DEPTH REGULATOR

MODELS 12089,12090,12204 Parts List DEPTH REGULATOR i TINE HOOD ASSEMBLIES REF No. PART No. DESCRIPTION QTY. REF No. PART No. DESCRIPTION QTY 1 1100043 Bolt-hex hd„ 3/8-16x1-1/4"... . 2 12 9929 Washer-flat, 5/16".................. 2 2 1113-1 Bushing-19/64" (.300" Ig.).... . 2 13 1904...

Page 51 - start requires key switch

MODELS 12089,12090,12204 Parts List REF PART REF PART No. No. DESCRIPTION QTY. No. No. DESCRIPTION QTY WHEEL SPEED LEVER ENGINES AND ENGINE MDUNT 1 9362 Pin-spring, 1/8"......................... 1 28 1100045 Bolt-hex hd., 5/16-18x1", Grade 5... ... 2 2 9838 I\lut-castle (slotted), 1/2"-2...

Page 52 - POWER UNIT TRANSMISSION ASSEMBLIES

Parts List MODELS 12089, 12090, 12204 POWER UNIT TRANSMISSION ASSEMBLIES 52 26 — 4 28

Page 57 - integral worm gear, plus two

MODELS 12089, 12090, 12204 Parts List REF No. PART No. DESCRIPTION QTY. 1 1915087 Screw Kit, includes five (5) 1/4"-20 X 5/8“ seif-sealing screws......................... As Req’d 2 20873 Cover-tiller housing.......... 1 3 1129-1 Gasket-tiller housing cover, .010". As thick.....................

Page 58 - BOLO TINE ASSEMBLIES

Parts List MODELS 12089, 12090, 12204 BOLO TINE ASSEMBLIES 58

Page 60 - ELECTRIC START SYSTEM

Parts List MODELS 12090, 12204 ELECTRIC START SYSTEM 2 j I Starter-Solenoid Activate Wire (Red) ^ Cabfe To Engine Base 60

Page 61 - REF

MODELS 12090,12204 Parts List REF No. PART No. DESCRIPTION QTY. REF No. PART No. DESCRIPTION QTY. 1 96515 Cable-battery, positive and negative 23 9265 Tie-plastic, wire retaining.... 1 terminals............................ 2 24 9009 Vent T ube-5/16" diameter... 1 2 97020 Boot-terminal insulating...

Page 62 - PART

Parts List MODELS 12089, 12090, 12204 WHEELS^INES/PTO DRIVE LEVER & YOKE ASSEMBLY 40. PART No. DESCRIPTION QTY. REFNo. PART No. DESCRIPTION QTY 1 2574 1еуег-\/\/Ьее15Я1пе5/РТ0 Drive 10 1900860001 Link-yoke pivot, ieft & right. (Incl. knob w/decal)........... 1 6-7/8” long.......................

Page 63 - BUMPER ATTACHMENT; Bumper Attachment. Includes

MODELS 12089, 12090, 12204 Parts List BUMPER ATTACHMENT REF No. PART No. DESCRIPTION QTY. REF No. PART No. DESCRIPTION QTY 12588 Bumper Attachment. Includes 6 1100242 Lockwasher - spring lock, 5/16".. 2 Ref. Nos. 1 through 11)... 1 7 1186230 Nut-hex,5/16"-18................... 2 1 1910730001...

Page 64 - CUSTOMER SERVICE INFORMATION; V v; GARDEN WAY INCORPORATED

CUSTOMER SERVICE INFORMATION Owner Registration Card Please fill out and mail the enclosed owner registration card. The purpose of this card is to register each unit at the Factory so that we can provide you with warranty benefits and informational bulletins. Warranty Service The warranty statement ...