Merry Tiller G80 Setup guide

"The Original Since 1947"
"Works the Garden - Not the Gardener"
u.s. Patent Numbers 2614474 and 2634666
OWNER'S
"INSTRUCTIONS M~ UAL
AND
ILLUSTRATED PARTS LIST
~ ,
/ •
SUBURBAN ·MERRY rlLLER
MODEL GSO
•
o Manufactured
by
• MERRY MANUFACTURING CO.
o
Box 370t •
EDMONDS. WASHINGTON 98020
o o !' -

SERIAL NUMBER STAMPED ON CASE
o
Tractor Serial Number ............................................. .
Write down the serial number of your Merry Tiller in the space pro-
vided above for quick reference in event that your Merry Tiller is stolen or
for
matters pertaining to service or warranty.
CONTENTS
Introduction and Operating Suggestions _____________________________________________ _
How to Set Up Your Merry Tiller Suburban
Handle Assembly Instructions ________________________________________________________________ 2
Transmission
Servicing Procedures
Service Notes
Belt and Clutch Adjustment ___________ ________________ ___ _____________ _ _______ ________ __ __ _____ 3
Figure I
____________ ____ __ __ ____________________ ___ _________________________________________ _________ _______ 4
Figure 2
______________________________________________ ___ _________________________ _ _________________________ 5
Figure 3
__________________________ _ __ _ ____________________ ___ ___________________ ___ _________________________ 6
Belt
Cover Assembly ______________________________ __ __ __________________ ___ ___ _ _____________________ 7
Illustrated Parts List
How to Order Parts
Rear Wheel Assembly _______ _ ______________________ __ ______________________________________________ 8
Handle Assembly ________________ _______ ___ ___ __ ________________________________ __ ______________ _______ 9
Engine
Mount Assembly _____ __ __________________ _______ __ _____________________ __ ______ ___________ 10
Transmission Case Assembly __ __ ____ __ __________________ _________ ___ ____________________________ I I
Numerical Parts List _________ _ ________________________ _ __________ _ _______________ _ 12, 13, 14, 15
Oil Change Record __ __________ __ _____ _________ _____________ _________ ___ __ ___ ____________ Back Cover
Warranty Card __ __ ______ _____________ _______ _________________________ _____________________ Back Cover

INTRODUCTION AND OPERATING SUGGESTIONS
Your Merry Tiller is the most versatile garden tractor ever developed
for the home gardener and does a soil preparation job second to none, so
a
few minutes spent in studying the following instructions will pay many
dividends.
The tiller will dig deeper and move forward slower by pushing down
on the handles, and it will go ahead faster but at a shallower depth by
raising up on the handles. The speed of the rotors is controlled by the use
of the throttle.
To control the depth of tilling, the Merry Tiller must be operated with
both the proper throttle speed and correct up-and-down hand pressure on
the handles. Raising up means going forward. This action releases the grip
of the skid in the soil, allowing the Merry Tiller to progress ahead. Pushing
down means slowing down or even standing still. This directs the skid into
the soil, thus holding the Merry Tiller back. Adjust throttle for desired
speed of rotors .
When a person is first learning the proper use of the Merry Tiller, it
is not unlikely that he will encounter an uneven or "bucking" action in the
operation of the machine. A little practice will accustom the operator on
how to overcome this. Never push on the machine if it has dug itself in to
a depth of six to ten inches in order to get it to move forward, This is ac-
complished by slightly raising up on the handles and tilting the machine
slowly from one side to the other.
To acquire the knack of letting the Merry Tiller do the work without
effort on the part of the operator, we offer the following suggestions:
I. Adjust tail skid and rear wheels so the handles are at such a height
that your arms hang straight down to contact them. Rear wheels
should be removed for deep talaqe or ease of turning in confined
areas.
Caution: Keep hands clear of belt while engine is running.
2. Operate the Merry Tiller at about half throttle.
3. Don't hurry the job - proceed at a slow walk - give the machine
time to do its job.
4. Concentrate on keeping your arms relaxed. (There is a natural
tendency for any beginner to tense up.) Operation actually takes
very little effort. Let the Tiller do the work.
5, When tilling on sloping ground, turn the front of the machine up
hill to sufficiently counteract the tendency to run down hill.
6. For best results, operate at reduced throttle settings when the
ground is extremely hard or rough.
7. When cultivating, raise the tail skid until the handles are the proper
height as described in Item 1 or set rear wheels in position. Pro-
ceed at a slow walk, watching the rotor as it tills along the row.
S. TIGHTEN ALL NUTS AND BOLTS PERIODICALLY

HOW TO SEll' UP YOUR MERRY TILLER SUBURBAN
I. Remove the power unit and parts bag from the carton.
2. Assemble the rear wheels . Then after attachinq the rear wheels fo the
hitch ( shown in FIG. I ) the power unit can be supported on its
wood base and rear wheels to facilitate assembly.
3. Install the tail skid in the closed slot as shown in FIG. I.
HA'N'D1 LE ASS 'E'MBLY INSTRUCTIONS
I. Attach lower end of handles to hitch as shown in FIG. I & 2. (Do not
tighten bolts
at this time.
2. Attach the forwa rd ends of handle supports on transmission case as
shown in FIG. I. Also attach a clutch cable guide on the right hand
handle support as shown in FIG . 1 & 2.
3.
To each handle, assemble the cross brace, a handle support, and a
guide, as shown in FIG. 2. Do not tighten nuts at this time.
4. Slide throttle casing and clutch cable through guides as shown in
FIG. 2.
5.
Fasten throttle control to engine. Then attach the throttle control
lever to the left hand handle as shown in FIG . 2. Loosen the swivel
screw on said lever and move control lever down to low speed position.
Insert . wire through the swivel screw until carburetor throttle closes .
T.ighten swivel
screw and bend or cut off loose end of wire around
swivel.
6. Now tighten all the bolts and nuts on the handle assembly.
7. Attach center of clutch cable adjustment chain to spring as shown
in FIG. 2. Slip the belt off of the 10 inch pulley and slip lower cable
loop over adjustment clip as shown in FIG. I. Reinstall belt on the
10 inch pulley .
8.
Engage clutch lever and check adjustment . H clutch needs adjusting
refer to adjustment instructions .
9.
Remove the wood base and attach the rotors to your Merry Tiller.
10. Refer to engine manufacturer's manual for servicing engine.
2

TRANS, MISSION SERVICING PROC' EDU'RE
I. To fill transmission (unit in normal upright position). FIG. I.
A. Use 90 weight gear lube or 50 wt. motor oil. Approximately 1 pint.
B. Remove fill plug .
C. Remove check plug.
D. Fill until check plug hole overflows.
E. Replace plugs.
2. Periodic inspection of oil level.
A. Place Merry Tiller in normal upright position.
B. Oil level should be level with check plug as shown in FIG. I.
3. If excessive oil leakage appears around rotor shaft, the seals (No. 344)
must be replaced.
A. Removal and installation is accomplished from outside without any
disassembly of the transmission assembly. Write for instructions on
seal remover kit.
SERVICE N' OTES
I. Regularly check all bolts and nuts for tightness.
2. If the belt begins to bottom out on the engine pulley then replacement
of the pulley is needed. This is noticeable by the pulley "V" bottom be-
coming shinY.
BElT AI ND CLUrCH ADJU5rM 'ENT
Do Not Adjust The Clutch With The Engine Running
I. Proper clutch adjustment is very important. The friction type clutch
may need adjusting as the "V" belt stretches. Adjust as follows: Refer
to FIG. I.
A. Loosen nut holding adjustment link. (I)
B. Pull up on idler arm taking some slack out of the belt. (2)
C. Push down on the adiustment link taking the slack out of the clutch
cable. (3)
D. Tighten nut firmly. (I)
2. Check your adjustment by starting the Merry Tiller and holding the
rotors off the ground. If the rotors turn without any hand pressure on
the clutch, the adjustment is too tight. Loosen the nut and re-adjust. If
the cable spring on the clutch handle doesn't stretch when you hold the
clutch handle all the way in, the adjustment is too loose. Loosen nut
and re-adjust.
3. Additional adjustment is provided by slotted engine mount holes. Loosen
4 engine mount bolts, slide engine forward or backward as required.
Re- tighten engine mount bolts .
4. Final adjustment is then made as per instructions .
5.
Minor adjustment can be made by us in g the links on the adju sting chain .
FIG. 2.
3

TAIL SKID
FIGURE I
R/H S IDE VI EW
4
o 0

J
FIGURE 2
REAR V IE W
5

FIGURE 3
2659
2647

\
.J
BELT COVER ASSEMBLY
' Herpful Hint
When installing the Brackets on the Unit do not tighten capscrews
until step 3 is completed below.
Assembl.y
I. Attach No. 2659 Bracket on Case Fig. 3.
2. Attach No. 2648 Bracket on Engine Mount Fig. 3.
3.
Mount No. 2658 Cover over the Brackets, and No. 2647 Belt Release.
Fig. 3. Using 3 No. 2560 Capscrews, 3 No. 2661 Locknuts and one
No. 400 Washer on the Locknut side of the No 2647 Belt Release.
(To protect the slots from damage .)
COVER ASSEMBLY 2662
. -2560
~ -400
2 -2661
2 6 5
7
26 59
26 6 1 - ~ - t.
2 56 0 -- !! - ~
6'

ILLUSTRATED PARTS LIST-MODEL G80
HOW TO ORDER PARTS
I. THE MODEL NUMBER OF YOUR MERRY TILLER MUST BE GIVEN WHEN ORDERING
PARTS . THE MODEL NUMBER IS INDICATED ON THE UPPER L. H. CORNER OF
HANDLE CROSS BRACE NEXT TO THE MERRY TILLER OVAL.
MODEL NO.
2. HOW TO FIND THE CORRECT NUMBER OF PARTS YOU NEED.
Refer to the following pages illustrating parts and locate the part needed in the correct
exploded view and note the part number. All parts shown that have part numbers can
be purchased separately. After the part number has been identified, refer to the fol-
lowing Parts List, pages 12, 13, 14, 15, where these parts are listed in numerical order. ,
• • * * • •
REAR WHEEL ASSEMBLY 2479
10.3 3
I ~ ~ --' -r
8

HANDLE ASSEMBLY 2620
9

ENGINE MOUNT ASSEMBLY
361-.0- 0- 0- 0
939- ,, - e -¢- ~ /357
----~
137- : >367 401\ 695-:. "
1237-
!i
1962- '
2561
\
~
2573
';; '-
~' ~
tr 2647 . -1889
~I
r
~~
2049
1961 P
1368
10
502

TRANSMISSION CASE ASSEMBLY
1275 TRAN SM ISSION CASE ASSEMBLY
,
344 - --j ."-;,ilI
I
11f+-----.-----1 654
i
. I
I
343 ----- -t_
I
651 -~'
8:J--
344
"
1.........:- -- 295
,
I .
\
\
1484
348 ~ -. --34 5
342 ~

MERRY TILLER
NUMERICAL PARTS LIST
NOTE: WHEN ORDERING PARTS BE SURE TO GIVE THE FOLLOWING:
(a) Tractor Model Number
(c) Part Name (e) Shipping
(b) Part Number
(d) Quantity
Instruction,
FOR NUMERICAL LISTING OF ATTACHMENTS AND ATTACHMENT
PARTS, REFER TO AnACHMENTS CATALOGUE
Part
No. Part Name
137 Adjustment link
147
Rotor control assembly _____ __ ___ __ __ _ _____ _ _______ ___ _________ _ ______ _
Q u antity
Per Mach.
152 Clutch control spring ___________________ _ ______________ ___ _______________ I
165 U
Spacer ¥.!" __________ _ __ ______ __ __ ___ __ _____________ ___ __ ____ _______ _ ___ __ _ 2
295 Soft plus __ _ ___ __ _____________________ _ ______ _ ___________ __ __ __ - -------------- ---
332 Nut Hex if4" NC _ ____________ __ __________ _ __ _______________ _____ _ __ _ ________ 21
336 Clutch control rivet ________ _ _____ _ _____ ___ ___________ ____ ___ _ _____ _ ___ __ _
338
342
343
344
345
347
Handle G r ip _________ _ __ __ _ ____ ___ _______________ ___ _ __ ___ ________ --- --- ------
Drive shaft sea I ____ ____ __ __ __ _ __ _ __ _ __ ____ _ __________ _ ________ __ __ __ __ _ _____ _
Rotor shaft bearings -------------------- - ------ - ----------- - --- -- ---- -- -- -
Rotor shaft seals __ _________________ ____ __ _ __ _ _______ ____ _ __ _ _________ ______ _
Drive shaft bea ri ngs -- - -- -------- -- - -- - --- - -- --- ---- --------- ----- --- -----
Chain, #50 _____ _____ __ __ ____ __ _____ ____ ______ _ ____________ _ __ _ _______________ _
348 Cha in, # 35 ___ _____ ____ _____ _ ___ ____ __ ____ _____ __ _ ___ __ ___ _ ____ __ -- --------- __ _
2
2
4
2
350 Lock washer if 4" ___ _ ___________ _____ ___ ________ ___ __ __ ____ __ ___ _ _______ _ ____ 24
351 Idler sprocket bearing ____ ___ ____ _____ _ __ __ __ _____ _ ____________ _ ___ ____ _ 2
352 Idler sprocket bearing race __ __ ____ ____ ___ ____ _ ___ __________ ___ __ _ __ _
357 Drive pulley , I 0" ____ _ ___ ___ ____ __ ____ ___ __ __ ______ __ ____ ______________ --- _
361 Lock
washer, 5/ 16" __ ___ __ ___ _ _______ __ ____ _____ __ __ ______ __ ___ ___ ___ ____ 15
363 Seal Puller Kit _____ _________ __ _____ _ ___ __ _ ___ _ __ ___ ____ ____________ _-__ _____ __
367
Nut l/S" NF _ ___ ____ _________ ___ _ __ _ _________ _ ____ _ ____ _________ ___________ ____ _ 2
12

Part
No. Part Name
396
400
401
421
501
508
Lock Washer 3/
S" ____________ __
_______ _____ __ __ ______ _ ____________ _
Washer Flat 1/4" ___ ______ ___ ___ __ _ ______ ___
Drive shaft washer 5/
S"
_____ - __ _ __ ____ _ _ ______ __ _____ __ _____ ______ _
Roll Pin 1/4" X 1_ Y4" _____ ___ _____ ______ __ -- - ____ _ __ _ ___ _ __ __ ___ _
Cap screw 5/16" NF x 21 /2" ____________________ _ _________ _
Engine pulley key _ ______ ___ _________ _ ___ _
651 Spacer-Rotor shaft _ ____ ___ ____ _ __ _ __ ______ __ __ __ _ ______ __ _ _____ __ __ __
695 Set Screw 5/16" NC x 3/.1" _ ___ ____ ___ __ __ __ _ _________ __ ___ __ _____ _
895
924
925
926
Rear Skid ____ _ _____ _ __________ ____ _______ __ __ _ ___ ___ _ ___ _ ___ _ __ ------ - -- -- -- -- ---
Hairpin cotter __ ____ _ ______ ______ __ _ __ __ ____ __ ___ __ ___ - -- - ---- -- - -------
Drive
shaft w/ sprocket _ _________ __ _____ ___ __ ___ __ __ __ _____ ___ ____ __ __
Drive shaft w/o sprocket _______ _ __ ___. _ __ ___ __ __ ____ ___ _
927 Sprocket -Drive shaft __ __ ____
939
940
1024
1033
1080
1085
1237
1275
1368
1484
1539
1548
1550
1608
1615
1654
Nut 5/16"
Check plug gasket 5/16" ID __ _
Pin,
3Ja" x 21/4" _ __ _ __ _ __ ____ __ __ ____ _._. __ . __ __ _.._ __ .. ___ ._ ..._.._..__.. __
Wheel, 10 x 1.75 .. _______ _. .. _ _
Nut, sq. 3/
S"
NC __ ___..._ __ _ __ __ ___ __
Idler sprocket w/o bearing ___ ___ _.._ .. . __ . ____ __ ._ __ _._
Spring-compression idler arm __ __ .___ __ _._ __ .
Replacement case assembly ._ __ ___... ___ ___ ._ . __ .. ___ _
Engine pulley, %" bore _________ __ .. __ _.. __ _.. ___. ___ .
Oil filler plug __ . ___ ...__ ._ ___ __ _ __ ____ ___
Nut -Keps-I 032
Screw, cap 5/16" NF x 1" __ ____
Screw-cap hx hd. 5/16" NF x 1-1/2 " Pltd. __
Screw, rd. Hd. 5/16" NF x 1/
2"
___ _ _
Idler sprocket assembly with brgs.
Gasket __ __ __ __________ __ __ __
1711 Case assy. -L.H. w/brg. & seals_
1712 Case assy. -R.H. w /brg. & seals _
13
Quantity
Per Mach.
2
I
3
4
I
5
15
I
5
2
2
.I
2
2
4

Part
No. Part Name
1783
1784
1815
1850
1874
1889
Pin, easy lock __ _
Spring, easy lock
Clutch lever _ __ ___ _ ___ ____ __ __ _ ___ _____ ________ ____ _________ __ __ _ _______ ____ _
Cross Brace Assy . _ ________ _____ ____ __ ___ _._ _____ _ __ ________ __ ___ _ ____ _ __ _
Shoulder bolt 1 12 " x 2 \/4 " ___ _______ ____ __ _ _________ __ __ _______ ____ ___ _
Key 3/16" x 3/16" x I ________ ____ ___ ___ _ __ ______ __ __ _ ____ __ __ _____ _
1937
Set Screw -Soc. Hx. Hd. 5/16" NC x 5/16 " cup pt.
1961 Idler arm asembly complete _ _____________ _ __ __ __ ___ ____ _____ ___ _
1962
2049
2059
Idler arm _ __________ ___ _ __ _ _______ __ ___ _ __ __ ____________ _ ____ ____ _____ __________ _
Screw-Cap Hx. Hd. 5/16" NF x 1/2" plated _____ ________ __ _
Belt 50" _ _____ _______ __ __ __ _ ____________ __ ___ _ __ _0 __ __ _____ ______ __ _ __ ___ _ __ _ _ _ _ _
2205 Engine Mount L.H. ____ ______ ____ ____ ___ _ __ _ ___________ __ __ ____________ _ __ _
2208
2225
2227
2243
Eng ine Mount R.H. _ ___ ___ ____ _ ___ _ ____ _ ___________ ____ _______ __ ____ ______ _
Tie Bar L.H. ___ _ ____ __ _____ __ _____ _ ____ __ _ ___ _ ___ ___ _ ___ _ ____ ___ __ __ _______ ___
Tie Bar R.H. ______ __ _____ __ ___ ____ _ __ __ __ _ __ ___ ___ __ ____________ _ _______ ____ ._
Cable Guide , (Clutch & Throttle) __ __ - _______________ ___ ___ __ _ __ _
2250 Clutch cable Assembly _ __ _____ __ __ __ _ ___ _ __ _____. __ _____________ __ ___ _
2252 Screw-Cap Hx Hd 5/16" NF x 2 1
/
2" ptd. ___ _______ __ _ ___ ___ _
2479 Wheel Assembly _____ _. ____ _. ___ __ __ __ ___ _ __ _._ ___ ___ _ ___ ___ _ ___________ _
2480 Rear Wheel Frame Weld Assembly _ __ __ ___ __ _________ _ _______ _
2502 Rea r Hitch _
__ ____ _____ ____ ___ _ ________ ___ ._ __ __ _ ___ _______ ___ __ __ ___ ___ __ _
2529
2560
2561
2573
2620
2621
2625
2647
2648
2658
Scr ew-Cap Hx Hd 1 /4" NG x Sfs" HT _ ____ ___ __ _ __________ _ ___ _
Screw-Cap Hx Hd 1 /4 " NC x 1 12 " Pltd. _ __ _ _______ _ ____ _ __ ____ _
Idler
Wheel _ __ ----. ----- --- -.- -- -- -- --
Jam Nut 3/
S" NF Hex _
Handle As s embly-Complete ____ _____ _____ _.. ______ __. _____ _____ _
Handle Assembly L.H . __ __ __ ___ ___ _____ __
Handle Asembly R. Ho __
Belt Release Br ac ket _
En gine Mount Br acket
Cov er
14
Quantity
Per Mach.
2
2
I
3
18
3

Part No. Part Name
Quantity
Per Mach.
2659 Case Bracket
2661
2662
2665
Nyock Locknut '/4 " NC _ _________ __ ___ _____ ________ ___ ___ __
Cover Assembly ___ ______ __________ _ __ _ ____ _ __ _____ _______________ __ _ _____ __
Screw-Cap Hx Hd ' /4 " NC x 1' /4 " Pltd. -HT __._ ___ ..___
2666 Throttle Control _____ .. __ _ ___ __ _ _______ _ ._ ___ ___ _. __ _ __ __ _ __ ____ .
15
3
3

OIL CHANGE RECORD
16

IRJMMMIMM~ WAR RAN TV CE RT I Fie ATE M~~~
:J0R ONE YEAR from purchase date, Merry Manufacturing Company will replace
for the original purchaser, FREE OF CHARGE, any part or parts found, upon
examination
at our factory at Edmonds, Washington, to be defective under normal
use and service, on
account of defects in material or workmanship.
ALL TRANSPORTATION CHARGES ON PARTS SUBMITIED FOR REPLACEMENT
UNDER THIS WARRANTY MUST BE BORNE BY PURCHASER.
THIS WARRANTY shall not be effective If the product has been subject to misuse,
negligence or accident, nor if the product has been repaired or altered outside of
our Edmonds Factory, or Authorized. Service Station, in any respect which, in our
judgment,
affects its condition or operation.
FOR COMMERCIAL USE, WARRANTY LIMITED TO THIRTY DAYS.
The engine is covered under separate Warranty from Engine Manufacturer.
MERRY MANUFACTURING COMPANY
Th;s Warranty shall be
e ff e c t i v e only providing
ottached Warranty Card is
properly filled oul and
returned to Merry Manu-
facturing Co. ot time of
purchase.
SAVE THIS WARRANTY CARD
Fill in this information and retain for
your own record.
Serial No...............................................
IMPORTANT
(Not engine Serial No.)
Model No..............................................
To make Warranty valid. fill in
and return attached card.
Purchased from ..._......... ________ . _____ . __ .. ___ ..
.' Date Purchased .. ______________________ .. __ ... ____ ..
For Prompt and Accurate Service
Serial Number must always be given
when ordering parts or writing for any
information.
r-
)
Merry Manufacturing Co •
Box 370
Edmonds, Wash. 98020

Be sure to fill in the attached
Warranty Card below and
mail it immediately!
WARRANTY CARD
Please print carefully In IDk
Serial No.__ _____ __ __ __ _______ _ ___ Model No._ ___________ _ ___________ Date Purchased ________________ _
I Not engine S.ri ,al No.!
De aIer Pu rch ased f rom ____ ___________ __ ___________ _ ____________________________________________________________ _
, Address
______ ____ ________________________ __ ____________________________ State ________________ Zip _______________ _
OwnerI s Name _
________ __ _______________ _ ____ _ _______________________________________________________________________ _
i Add re ss ---- - --------- ---- _ --- -- ----- -- ------ -- ---- ---- --- :.. -- --- - ---- --- _ -- - ----- .. ----- - --- ----- ---- ---- - ---------- _____ _
I
I Town ---- -- - ------------ -- ---------------- -- ----- County ---- --- -- - -------- -- ------ -- -- - ----- State ----------------
Please Check One of the Following:
Suburban 0 Rural 0 Commercial 0