Troy-Bilt 7HP Pony 12211 User manual

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Technical Manual
PTO HORSE Tiller
Models 7HP
8HP
GARDEN WAY INC.

..

PTO HORSE MODEL
TECHNICAL MANUAL
4/90
TABLE OF CONTENTS
SECTION 1.
General Information 1-1
Safety First 1-1
Quick Reference Repair Index 1-2
SECTION 2.
Transmission Troubleshooting. . . . . . . . . . . . .. 2-1
Forward and Reverse Shifting Problems 2-1
Wheel Speed Shifting Problems 2-2
Wheels
and/or Tines Do Not Turn 2-3
Wheel Shaft Moves To
One Side. . . . . . . . .. 2-4
Noise From Rear
Tiller Bearing. . . . . . . . . .. 2-4
Oil Leaks 2-5
SECTION 3.
Pre-Service Inspection .... ............... .. 3-1
SECTION 4.
Transmission Removal and Installation 4-1
Removal 4-1
Separating/Attaching the PTa Power Unit
and Tiller Attachment Transmissions. . . . .. 4-2
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-3
SECTION 5.
Servicing the PTO Power Unit Transmission 5-1
PTa Power Unit Housing Cover 5-1
Removal 5-1
Inspection 5-2
Installation 5-2
Neutral
Plunger Assembly 5-2
PTa Power Unit Drive Shaft. . . . . . . . . . . . . . .. 5-3
Removal 5-3
Inspection 5-4
Installation. .......................... .. 5-4
Pinion Shaft
Assembly. .................. .. 5-5
Removal 5-5
Inspection 5-6
Installation 5-7
SECTION 5.
Servicing the PTO Power Unit Transmission
(continued)
Wheel Shaft Assembly 5-8
Removal 5-9
Inspection 5-9
Installation 5-9
Eccentric Shaft Assembly 5-10
Removal 5-10
Inspection 5-10
Installation 5-10
SECTION 6.
Servicing the Tiller Attachment Transmission 6-1
Tiller Drive Shaft Assembly. . . . . . . . . . . . . . . .. 6-1
Removal 6-1
Inspection 6-2
Installation 6-3
Tiller Tine Shaft Assembly '. . . . . . . . . . . . .. 6-3
Removal 6-3
Inspection 6-5
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-5
SECTION 7.
Special Repairs and Procedures 7-1
Installing a New Tines/PTa Clutch Lever
Assembly
7-1
Removing the Existing Assembly 7-1
Installing a New Assembly 7-1
Removing aRusted Wheel 7-2
Removing the Wheel Shaft
Without
Disassembling the Transmission 7-2
Removal 7-2
Installing the Wheel
Shaft. . . . . . . . . . . . . . .. 7-3
Identifying aBubbled Wheel Shaft 7-4
Testing
for aBubbled Wheel Shaft 7-4
Tightening the Castle Nut On the Wheel
Speed Lever 7-4
Index. .. . . .. . . . . . .. . . .. . . . . .. . . . .. . 8-1

SECTION 1: General Information
PTO HORSE MODEl
TECHNICAL MANUAL
Page 1-1 4/90
•This manual provides transmis-
sion service information
for the
PTO HORSE Model TROY-BILT®
Roto Tiller-Power Composter built
by TROY-BILT Manufacturing
Company, Troy, New York. Use
this manual
for tillers with serial
numbers 640000 and up.
•This manual was written
for and
intended to be used by profes-
sional service technicians
who
have been trained in the proper
servicing
of outdoor power
equipment.
•All information, illustrations, and
specifications contained in this
manual are based on the latest
information available at the time
of
publication. The right is reserved
to make changes at any time
without notice. If you have any
questions concerning the informa-
tion contained in this manual
please contact:
Technical Service Department
TROY-BILT® Manufacturing
Company
102nd Street and 9th Avenue
Troy, New York
12180
Call Toll-Free: 1-800-833-6990.
This symbol
is used to alert you to
important safety messages in this
manual and on decals affixed to
the tiller. When you see this sym-
bol, carefully read and follow its
safety message. Failure to
do so
could result in personal injury
or
property damage.
•This manual is divided into
seven sections
as shown in the
Table
of Contents. For best
results, read each section in its
entirety before attempting any
repair work.
•This manual
is designed to be
used in combination with the PTO
Horse Model Owner/Operator
Manual. The Owner/Operator
Manual contains additional service
and maintenance information that
is not covered in this manual.
Refer to
"Quick Reference Repair
Index"
in this section for alisting
of the service and maintenance
topics that are covered in the
Owner/Operator Manual.
•Service and maintenance infor-
mation regarding engines is
not
covered in this manual. Such
information can be obtained by
consulting the Service Repair
Manuals available from the engine
manufacturer. You should,
how-
ever, call our Technical Service
Department with questions
con-
cerning engine replacement or
interchangeability.
•
Throughout this manual, you
will
see references to the left and
right sides
of the tiller. This refers
to the left and right sides
of the
tiller
as you would see them stand-
ing in the operator's position.
Safety First
When working on the tiller or its
engine, closely follow operating
instructions and recommended
safety practices at all times.
Failure to
do so could result in
personal injury
or property dam-
age. Here are some basic safety
precautions you should keep in
mind at all times when doing
repair work:
KNOW THE TILLER AND
ENGINE! Read the
Owner/Operator Manual carefully.
Be sure you know what each tiller
and engine control does before
you attempt to operate it.
Read and follow all safety rules.
Never allow inexperienced per-
sons
or children to operate the
tiller
or its engine.
WEAR PROPER APPAREL!
Don't wear loose clothing
or
jewelry that could get caught in
moving parts
of the tiller or its
engine.
AVOID MOVING PARTS!
Keep hands, feet, hair, clothing,
and tools safely away from moving
parts when the engine
is running.
AVOID ACCIDENTAL STARTING!
When servicing the machine, pre-
vent unintentional starting
of the
engine by disconnecting the spark
plug wire and keeping the wire
away from the spark plug. Place
engine controls in the OFF posi-
tion and shift the Wheels/
Tines/PTO Drive Lever into
NEUTRAL.
WEAR
EYE PROTECTION!
Safety goggles
or afac shield
should be worn wh ver there is
the possibility
of danger to the
eyes from flying parts
or particles.
PREVENT FIRES AND
EXPLOSIONS! Gasoline
is
highly flammable and explosive
and should be used and stored
with extreme caution. Keep gaso-
line away from open flame, sparks,
and
do not smoke in the vicinity of
gasoline cans or fuel tanks. Do not
add gasoline to afuel tank when
the engine is running
or still hot.
Fill the fuel tank outdoors, in a
well-ventilated area. Store gaso-
line in acool, well-ventilated
place, safely away from any spark
or flame producing equipment.
Store
only in aU.L. approved con-
tainer and safely out of reach of
children. Wipe off any spilled gas-
oline and move the engine away
from gasoline fumes before start-
ing engine.
Use flammable cleaning solvents
only according to recognized
safety practices (never use gaso-
line
as acleaning solvent). Oily
rags and waste should be packed

PTO HORSE MODEL
TECHNICAL MANUAL
Page 1-2 4/90
in aU.L. approved covered metal
safety
container to prevent fire
from spontaneous combustion.
HANDLE BATTERIES WITH
CARE! Batteries contain
sulfuric
acid that can cause blindness,
burn skin, and eat
through
clothing. Wear safety goggles
when
working near the battery or
when handling battery acid.
Remove all rings and metal
jewelry when
working on the bat-
tery
or electrical system.
Batteries also
produce explosive
gases. Keep sparks, flames, and
cigarettes away. Ventilate when
charging or using in an enclosed
space.
Do not cause ashort circuit by
touching both battery terminals at
the same
time with tools or other
metallic objects. Also, do not allow
atool
or other metallic object to
touch aterminal that is not
grounded and an adjacent metallic
part that
is grounded. Aspark
from ashort
circuit could cause
an explosion of battery gases
or
gasoline.
AVOID ENGINE EXHAUST
FUMES!
Do not run the engine
in an enclosed area. Exhaust
gases contain carbon monoxide,
an odorless and deadly poison.
Provide adequate ventilation at all
times. After
running the engine,
don't touch the muffler or other
hot engine parts until they have
cooled down.
HANDLE PARTS CAREFULLY!
With continued use, the teeth on
gears and
worms may wear to
sharp, knife-like edges. Therefore,
when handling these parts, use
care
to avoid cutting yourself.
REPLACEMENT PARTS!
Use only genuine Troy-Bilt
replacement parts. Replacement
parts manufactured by others
could present safety hazards even
though they may fit on this tiller.
SECTION 1: General Information
Quick Reference Repair Index
To obtain service information for the following topics, please refer to
either this Technical Manual or the Owner/Operator Manual, as indicated
in the table below.
TECHNICAL OWNER/OPERATOR
MANUAL MANUAL
Air Cleaner X
Battery X
Bearing Cap,
PTa Power Unit
X
Bearing Cap, Tiller Attachment X
Bearings, Drive Shaft X
Bearings. Tiller Drive Shaft X
Bearings, Tiller Tine Shaft X
Bearings, Wheel Shaft X
Belts X
Bolo Tines X
Bronze Bushings X
Carburetor
X
Choke
X
Clutch
X
Clutch Roller X
Cover, Transmission X
Depth Regulator X
Dog Clutch, Tiller
Attachment
X
Dog Clutch,
PTa Power Unit X
Drive Shaft,
PTa Power Unit X
Drive Shaft, Tiller Attachment X
Eccentric Lever X
Electric Start System X
Engine X
Fuel X
Handlebar Height Adjustment X
Ignition System X
Lubrication Points X
Neutral Plunger X
Oil Drain Plug X
Oil (Engine and Transmission) X
Oil Level Check Plug X
Pinion Shaft X
Pinion Shaft Gears X
PTa Power Unit
X
Reverse Disc X
Solenoid X
Throttle Cable X
Tiller Attachment X
Tiller Drive Shaft X
Tiller Housing Cover X
Tiller Tine Shaft X
Tines/PTa Clutch Lever X
Tires/Wheels X
Transmission Pulley X
Wheel Shaft X
Wheel Speed Gears X
Wheel Speed Lever X
Worm,
PTa Power Unit Drive Shaft X
Worm, Tiller Drive Shaft X
Worm Gear, Wheel Shaft X
Worm Gear, Tiller Tine Shaft X

SECTION 2: Transmission Troubleshooting
PTO HORSE MODEL
TECHNICAL MANUAL
Page 2·1 4/90
The following charts list the
most
common problems expe-
rienced with the tiller drive
train. Symptoms
of problems
are listed along with possible
remedies. If following the
repair procedures does not
fix the problem, call the
TROY-BILT(R) Tiller Technical
Service Department at
TOLL-FREE: 1-800-833-6990.
Forward and Reverse
Shifting Problems
WARNING: When servicing the machine, preventuninten-
tional starting
of theenginebydisconnectingthe sparkplug
wire and keeping the wire away from the spark plug. Place
the engine throttle control in the OFF position and shift the
Wheelsrrines/PTO Drive Lever into NEUTRAL.
Symptom Remedy
WheelslTines/PTO Lever •Check the reverse disc
for wear. See the Owner/Operator Manual for instructions.
is hard
to shift into reverse. Check the adjustment
of the reverse disc and/or reverse spring and plunger
•
-assembly. See the
Owner/Operator Manual for instructions.
•Clean and re-Iubricate the
motor mount bars, belt adjustment block, and linkages
on lever. See the
Owner/Operator Manual for instructions.
WheelslTines/PTO Lever •Lubricate the
motor mount bars, belt adjustment block, and linkages on the lever.
sticks in forward. See the
Owner/Operator Manual for instructions.
•Check the tension on the drive belt. See the
Owner/Operator Manual
for instructions.
Tiller stays in reverse when •Lubricate the motor mount bars, belt adjustment block, and linkages on the lever.
the WheelslTines/PTO Lever See the Owner/Operator Manual for instructions.
is released. Check the adjustment
of the reverse disc and/or reverse spring and plunger assem-
•bly. See the
Owner/Operator Manual for instructions.
WheelslTines/PTO Lever •Raise the belt adjustment block
as the drive belt may be too tight.
jumps
out of forward. See the
Owner/Operator Manual for instructions.
•Install anew clutch pawl spring at the end of the lever. The old spring may be
overstretched.
WheelslTines/PTO Lever •Lubricate the
motor mount bars, belt adjustment block, and linkages on lever.
is hard
to shift into forward. See the
Owner/Operator Manual for instructions.

PTO HORSE MODEL
TECHNICAL MANUAL
Page 2-2 4/90
Wheel Speed
Shifting Problems
I
SECTION 2: Transmission Troubleshooting
Symptom Remedy
Wheel Speed Lever •Check the tension on on the Wheel Speed Lever's castle nut.
See
drops out of fast speed. "Tightening the Castle Nut On the Wheel Speed Lever" in Section 7of this manual.
Wheel Speed Lever hard •Inspect the Wheel Speed Lever:
to shift. •Lubricate the Wheel Speed Lever linkage where the connecting rod joins the
shift lever and the connecting rod swivel.
•The connecting rod at the bottom
of the lever may be backwards or bent in
towards the transmission and hitting it.
•Lubricate the washers and castle nut on the pivot point
of the lever.
•Check the tension on the Wheel Speed Lever's castle nut. See "Tightening
the Castle Nut On the Wheel Speed Lever" in Section 7
of this manual.
•Check if the clutch
is binding on the wheel shaft. See "Testing for aBubbled Wheel
Shaft"
in Section 7 of this manual.
Wheel Speed Lever •Check if the clutch
is binding on the wheel shaft. See "Testing for aBubbled
moves into slow speed Wheel Shaft"
in Section 7 of this manual.
but not into fast.
Wheel Speed Lever moves •Disconnect the shift linkage from the eccentric lever and try moving the
freely but the transmission eccentric lever by hand. If the lever rotates
360 degrees around the eccentric shaft,
does not shift out of or
the spirol pin that connects the lever and the shaft is broken or missing. Replace
into fast or slow speed. the spirol pin. If the lever and the shaft together rotate 360 degrees, the shaft
is
broken and must be replaced. (Although rare, the eccentric shifting pin could be
broken
or missing, which would also result in the lever and shaft being able to
rotate afull
360 degrees.)

SECTION 2: Transmission Troubleshooting
Wheels and/or Tines
Do Not Turn
PTO HORSE MODEL
TECHNICAL MANUAL
Page 2·3 4/90
Symptom
Wheels and tines
won't turn even though
Wheels/Tines/PTO Lever
seems to work properly.
Tines turn but the wheels
do not turn or turn only
in one speed.
The Wheel
Speed Lever moves the
clutch into either gear.
Remedy
•Inspect the drive belt for wear or mis-adjustment. See the Owner/Operator Manual
for instructions.
•Check condition and adjustment
of reverse disc. See the Owner/Operator Manual
for instructions.
•Inspect the
mounting bolt on the transmission drive pulley. It may be loose or
missing, which would allow the key in the pulley to fallout. If so, the drive belt or
reverse disc will turn the pulley but the pulley will not turn the power unit drive
shaft. Tighten the bolt (with the concave washer in place) securely.
•Check for play in the power
unit drive shaft. If there is play in the drive shaft, find
out why. It could be aloose bearing cap, improper shimming, damaged bearings or
worn worms.
•If the transmission is new
or rebuilt, the key on the transmission engine pulley may
not have been installed. If so, the pulley cannot transfer power to the drive shaft.
•If the transmission is new
or rebuilt, the internal keys in the pinion assembly may
not have been installed. If so, the pinion gears will not drive the wheel speed gears.
•Inspect the
hi-pro key that lets the clutch turn the wheel shaft. It may be missing
or broken.
•Inspect the lugs on each side
of the clutch; they may be worn.
•Inspect the fast and slow speed wheel gears. One or both may be worn.
•Inspect the fast and slow speed pinion gears. One
or both may be worn.
•Inspect the power unit drive shaft worm. It may
be worn and not meshing with the
bronze worm gear on the pinion shaft assembly.
•Inspect the bronze
worm gear on the pinion shaft assembly. It may be worn and not
meshing with the power unit drive shaft worm.
•If the transmission is new
or rebuilt, the key that holds the bronze worm gear to the
fast speed pinion gear may not have been installed. This means the bronze worm
gear will turn but it will not turn the pinion gear.
•If the wheels only turn in the fast wheel speed and if the transmission is new
or
rebuilt, the key may be missing from the stem pinion gear, preventing the trans-
mission from operating in slow gear. The key locks the stem pinion to the fast
speed pinion gear.

PTO HORSE MOOEL
TECHNICAL MANUAL
Page 2-4 4/90
Wheels and/or Tines
Do Not Turn
SECTION 2: Transmission Troubleshooting
Symptom Remedy
Wheels turn but the tines •Make sure the Tines/PTO Clutch Lever is engaged.
do not. Adjust the Tines/PTO Clutch Lever.
•
•Make sure the power unit
or tiller attachment's dog clutch key is in place and that
each key
is fUlly seated. Both dog clutches must be able to slide lengthwise on their
shafts.
•Inspect the eccentric lever on the Tines/PTO Clutch; it may be broken.
•Inspect the tiller attachment drive shaft worm. It may
be worn and unable to mesh
with the bronze tiller shaft worm gear.
•Inspect the bronze tiller drive shaft worm gear. It may
be worn and unable to
mesh with the tiller drive shaft worm.
•Inspect the keys that hold the tine holders to the tine shaft; they may be sheared
or missing. Or, the holders may be worn. See the Owner/Operator Manual
for instructions.
•If the transmission has been
in service for along time, the key that holds the bronze
worm gear to the tiller shaft may be broken. If the transmission
is new or rebuilt; the
key may
be missing.
Wheels and tines turn on top •Check the drive belt for proper adjustment.
See the Owner/Operator Manual
of the ground but stop or
for instructions.
hesitate in the soil. Check if the mounting
bolt for the transmission drive pulley is missing. This would
•allow the key inside the pulley to
fallout.
•Follow the remedies for "Wheel and tines won't turn
thoughWheelslTines/PTO
Lever seems to work properly." See Page 2-3.
•Follow the remedies
for "Tines turn but the wheels do not turn or turn only in one
speed."
See Page 2-3.
Wheel Shaft Moves
To.One Side
Symptom Remedy "
The wheels and wheel shaft •Check for play in the wheel shaft. If there is more than .015" play, one or both
move to one side. snap rings are out of the groove(s).
Noise from Rear
Tiller Bearing
Symptom Remedy
Agrowling or whining noise •Inspect the bearing and bearing cup for wear or damage.
from the tiller attachment Inspect the tiller shaft bronze worm gear
for wear or damage.
•
rear bearing.

SECTION 2: Transmission Troubleshooting
Oil Leaks
PTO HORSE MODEL
TECHNICAL MANUAL
Page 2-5 4/90
..
Symptom
Oil leaks from the wheel
shaft oil seals.
Oil leaks from the rear
of the tiller attachment
housing.
Remedy
•An oil seal is worn or damaged. Check for side-to-side and vertical play in the
wheel shaft and replace seal.
•Give new seals time
to lap in.
•Inspect the wheel shaft
for minor damage at the oil seal location:
•Inspect
for corrosion, pitting, or scoring.
•Use emery
cloth to remove any minor defects.
•
Attempt to seat the seal so that it is on an undamaged part of the shaft.
•Replace the wheel shaft if necessary.
•
Determine if the seal fits loosely in the transmission bore Contact the TROY-SILT
Technical Service Department for aspecial seal.
•Be sure the transmission
is filled with SAE 90 or SAE 140 gear oil. A lighter viscosity
oil will cause leakage.
•Make sure that a
non-hardening gasket sealer was applied to the outside diameter
of the oil seal prior to its installation.
•Make sure the
housing bore has no nicks or scratches that would permit oil to
seep out between the seal and the housing.
If
the leak is from the oil seals on the tiller tine shaft:
•Make sure the seals have
non-hardening gasket sealer around the outside edges.
•An oil seal is
worn or damaged; replace the seal.
•Inspect the
tiller tine shaft for minor damage at the oil seal location:
•Inspect
for corrosion, pitting, or scoring.
•Use
emery cloth to remove any minor defects.
•Replace the
tiller tine shaft if necessary.
•
Check for sand holes (imperfections in the cast iron) or cracks in the
housing cover.
If the leak
is on the left side of the tiller housing:
•
Apply non-hardening gasket sealer to each of the tiller housing cover screws
and
tighten the screws.
•Replace any
worn or damaged gaskets.
•Make sure the
housing cover bore has no nicks or scratches that would permit oil
to seep out.
•Make sure the
housing bore has no nicks or scratches that would permit oil
to seep out beteen the seal and the housing.
If the leak is
from the rear bearing cap:
•Inspect the rear bearing cap:
•
Make sure the screws are the correct length.
•
Apply non-hardening gasket sealer to each of the rear bearing cap bolts
and tighten the bolts.
•Replace a
worn or damaged gasket.
•
Check for excessive play in the tiller tine shaft.

PTO HORSE MODEL
TECHNICAL MANUAL
Page 2-6 4/90
Oil Leaks
SECTION 2: Transmission Trouleshooting
Symptom Remedy
Oil leaks from the front oil seal •Replace aworn
or damaged oil seal and check for play in the shaft.
on the power unit drive shaft. •
Apply alayer of non-hardening gasket sealer to each of the front bearing cap bolts
Oil could appear in the base of and tighten the bolts.
the motor mount under the
pulley. (Make sure this
is not •Replace aworn or damaged gasket.
an oil leak from the neutral Make sure the leak
is at the front oil seal. You could be seeing oil that leaked from
•
plunger assembly, which is an the engine air cleaner,
power unit housing cover, or engine seal.
oil relief point.) •Check the transmission gear oil level when the
unit is cold.
If overfilled, drain it to
the
proper level.
Oil leaks from the handlebar •Loosen and remove the oil level check plug to make sure the oil level is correct.
base or the bottom of the If the transmission is overfilled, let the excess oil drain out.
reverse spring and plunger •See if oil is leaking
from the neutral plunger. If oil is leaking from here, take no
assembly. action; the neutral
plunger is an oil relief point.
Oil is leaking from the •Replace the oil seal.
eccentric shaft and lever.
Oil
is leaking from any •Remove the pipe plug and apply alayer of non-hardening gasket sealer. Then
pipe plug in the transmis- re-install the plug.
sion housing. •
Check to see if the plug is cross-threaded.
Oil is leaking between •Tighten the
housing cover bolts.
the power unit housing cover •Replace the gasket.
and the housing. •Aspecial transmission cover gasket (Part No. 9260) may be required if
the leak
continues.

SECTION 3: Pre-Service Inspection
PTO HORSE MODEL
TECHNICAL MANUAL
Page 3-1 4/90
WARNING: When servicing the machine, prevent uninten-
tional starting of the engine by disconnecting the spark plug
wire and keeping the wire away from the spark plug. Place
the engine throttle control in the OFF position and shift the
Wheels/Tines/PTa Drive Lever into NEUTRAL.
,
Before you begin your repair
or maintenance procedure
take a
moment to perform a
pre-service inspection
of the
following transmission parts.
In
doing so, you may dis-
cover additional problems
that can be corrected while
the tiller is in
your shop.
Wheel Shaft -Inspect the wheel
shaft for movement and oil leaks:
•Grasp the tiller's handlebars and
tilt the tiller forward so its weight
is resting entirely on the wheels
and move the tiller side-to-side.
See Figure 3-1.
Figure 3-1: Pre-Disassembly Inspection of
the Wheel Shaft.
If the tiller moves more than .015"
from side-to-side on the wheel
shaft, it indicates that the wheel
shaft needs either
to be shimmed
or that one or both of the snap
rings has become dislodged from
the snap ring groove(s).
•If oil is leaking from around one
or both of the wheel shaft oil seals,
replace the oil seal(s) and deter-
mine
why the oil seal(s) failed.
PTO Power Unit Drive Shaft
Pulley -Check the PTO driveshaft
pulley (see Figure 3-2) for end play
and oil leaks:
Drive Shaft
Pulley
Figure 3-2: Pre-Disassembly Inspection of
the Drive Shaft Pulley.
•Using two hands, grasp the drive
shaft pulley and pull it in and
out to
check
for end play.
There should be .005" to .010" play.
If the drive shaft pulley has more
play, the bolt that holds the pulley
may need
to be tightened. This bolt
should be tightened to
170 inch/lbs.
If tightening does
not reduce the
play, the PTO power unit drive
shaft needs to be shimmed.
•Look for oil leaks around the
pulley. If you see oil, make sure
that it did
not come from the neu-
tral plunger on the housing cover;
this
is an oil relief point.
If you suspect
an oil leak from
around the pulley, inspect the fol-
lowing:
a. The bolts holding the front
bearing cap may
not be suffi-
ciently tightened.
b. The washers on the bolts that
hold the front bearing cap may be
worn
or the bolts may not have
been coated with non-hardening
gasket sealer.
c. The front bearing cap gasket
may have failed.
d. The front drive shaft oil seal
may have failed; find
out why.
Tiller Attachment - Tip the tiller
so that you have afull view
of the
tiller attachment (see Figure 3-3).
Then check the following:
•Inspect the area around the
rear bearing cap
for oil leaks. If
you see an oil leak, inspect the
following:
HOUSING COVER GASKET
Figure 3-3: Pre-Disassembly Inspection of the Tiller Attachment.

PTO HORSE MODEL
TECHNICAL MANUAL
Page 3-2 4/90
SECTION 3: Pre-Service Inspection
a. The bolts holding the rear bear-
ing cap may not be sufficiently
tightened.
b. The washers on the bolts that
hold the rear bearing cap may be
worn
or the bolts may not have
been coated with non-hardening
gasket sealer.
c. The rear bearing cap gasket
may have failed.
• Inspect the left side
of the tilIer
tine shaft for oil leaks. If you see
an oil leak, inspect the following:
a. The tiller housing cover may
not be sufficiently tightened;
check all five bolts.
b. The washers on the bolts that
hold the tiller housing cover may
be worn
or the bolts may not have
been coated with non-hardening
gasket sealer.
c. The tiller housing cover
gasket(s) may have failed.
d. The tiller housing cover oil seal
may have failed; find out why.
•Inspect the right side
of the tiller
tine shaft for oil leaks. If you see
an oil leak, the oil seal needs to be
replaced. Then, discover why the
oil seal failed.
•Check the tiller tine shaft
for
play:
Using
two hands, grasp the tiller
tine shaft and rotate the shaft back
and forth.
You should be able to rotate the
shaft slightly and to hear asmall
click. This means the tiller tine
shaft
is shimmed correctly.
If you cannot rotate the shaft and
do not hear aclick, it means that
the side cover needs to be
shimmed outward using various
thicknesses of gaskets. This
procedure
is explained in Section
6
of this manual (see "Tiller Tine
Shaft Assembly").
Being able to rotate the shaft more
than asmall amount and hearing a
louder click means the tiller tine
shaft is either shimmed incorrectly
(too many gaskets)
or that the
bronze worm gear
is wearing out.
•There should be no end play,
vertical play
or diagonal play in
the tiller tine shaft. If you find such.
play, tighten the tiller housing
cover bolts.
If this does not eliminate the play,
ashim may need to be installed
on the tiller tine shaft,
as explained
in Section 6of this manual.
PTO Power Unit and Tiller
Attachment Drive Shaft
Connection -Engage the Tines/
PTO Clutch Lever and turn the
pulley at the front
of the PTO
power unit. The dog clutches
between the tiller attachment and
the PTO power unit should
engage and the tiller tine shaft
should move
as you turn the pul-
ley. If the dog clutches
do not
engage, the Tines/PTO Clutch
Lever may need to be adjusted.

SECTION 4: Transmission Removal and Installation
PTO HORSE MODEL
TECHNICAL MANUAL
Page 4-1 4/90
WARNING: When servicing the machine, prevent uninten-
tional starting of the engine by disconnecting the spark plug
wire and keeping the wire away from the spark plug. Place
the engine throttle control in the OFF position and shift the
WheelslTines/PTO Drive Lever into NEUTRAL.
The PTO Horse Model
transmission consists of two
separate transmission
assemblies: the PTO Power
Unit transmission and the
Tiller Attachment transmis-
sion (see Figure 4-1). The
transmission housings are
held together by alocking
collar, adowel pin and two
swing-bolts.
The PTO Power Unit trans-
mission and the Tiller Attach-
ment transmission can be
removed from the tiller
as a
complete assembly by fol-
lowing the instructions in this
section. Use Figure 4-2
as a
reference for part locations
in these instructions.
If only the Tiller Attachment
transmission needs to be
removed from the tiller, refer
to the Owner/Operator
Manual for instructions on
how to remove the transmis-
sion when the tiller
is fully
assembled.
WHEEL SHAFT ---,~
ADANGER
The battery produces in-
flammable and explosive
hydrogen gas and the elec-
trolyte solution contains
poisonous and corrosive
sulfuric acid. To avoid in-
jury, carefully follow the
safety precautions in the
Owner/Operator Manual
when removing and install-
ing the battery.
SWING·
BOLTS
Transmission Removal
1. On tillers equipped with the
Operator Presence Control For-
ward Interlock System (S/N
857307 and up). disconnect the
Forward Interlock Wire Harness
assembly
(1) located on the right
side of the handlebar base.
2. For electric start tillers only:
a. Remove the battery as de-
scribed
in the Owner/Operator
Manual.
b. Disconnect the red starter
cable from the starter motor on
the engine.
c. Disconnect the recharging
wire that leads from the keyswitch
wire harness to the engine.
d. For Briggs &Stratton engines
only: Disconnect the green shutoff
wire on the right side of the
engine.
TILLER ATTACHMENT
Figure 4-1: PTO Power Unit Transmission and Tiller Attachment Transmission.

PTO HORSE MODEL
TECHNICAL MANUAL SECTION 4: Transmission Removal and Installation
Page 4-2 4/90
Figure 4-2: Transmission Removal and Installation.
Separating the
Transmissions
1. Put the transmission (PTa
power unit and tiller attachment
assembly) on the floor, a work-
bench, or other surface that is
comfortable for you.
2. Loosen the swing bolts
(shown in Figure 4-1) that
join
the PTa power unit and tiller
attachment.
Tines/PTa Clutch Lever detent
shifting plate (15).
18. Remove the wheels from the
wheel shaft. See the
Owner/Oper-
ator Manual for instructions. Or, if
the wheel is rusted on the shaft,
see "Removing aRusted Wheel" in
Section 7
of this manual.
3. Swing the bolts off the tiller
attachment.
4. Separate the PTa power unit
from the tiller attachment.
7
4---==~~rh
6-------e.*'
11. Remove the other engine
mounting bar.
12. Remove the engine from
the tiller.
13. Remove the two final bolts
(7) that hold the yoke pivot links to
the
PTa power unit and remove
the yoke.
Note: Take care
to recover the
bushing in each side
of the yoke.
14. Remove the bolt (8) or
T -handle that holds the handlebar
mounting base to the transmission
housing cover and remove the
base and the attached handlebars.
15. Remove the bolt (9) that
holds the
Tines/PTa Clutch Lever
knob
(12) to the lever. Then
remove the knob.
16. Remove the locknut that
retains the wheel speed lever
con-
necting rod swivel to the eccentric
lever (10).
17. Remove the two final bolts
from the shift lever bracket (11).
one from the top left side and one
from the right side. Then remove
the bracket along with the
attached Wheel Speed Lever and
e. Remove the two mounting
bolts and lockwashers that secure
the legs
of the battery bracket to
the transmission cover and
remove the bracket.
3. Remove the forward bolt on
the right side of the shift lever
bracket. Remove the Forward
Interlock Wire Harness plug
con-
nector with bracket (2) on tillers
so equipped.
4. Wrap the engine half of the
Forward Interlock Wire Harness
assembly (on tillers so equipped)
around the engine.
5. Remove the throttle control
and cable (3) from the handlebar.
6. Remove the bolt (4) at the
forward end of each side of the
yoke. These are
the bolts that at-
tach the yoke to the engine mount.
After you remove these bolts, pull
the yoke back.
Note: Take care
to recover the
bushing in each side
of the yoke.
7. Remove the bumper/guard
attachment. Or, remove the red
plugs in the
top of the engine
mounting bars (5) if a bumper is
not attached.
8. Loosen the jam nut on the bolt
(6) that retains the engine
mount-
ing bar on each side of the PTa
power unit. Then remove the bolt
from each side.
9. Support the weight of the ~
engine by placing a block un@r
the engine. This is necessar.y to -
prevent the engine from falling-
when you remove the final engine
mounting bar.
10. Lubricate both engine mount-
ing bars. Then, using a punch and
taking care
to not damage the
threads in the
top of the engine
mounting bars, knock one of the
engine
mounting bars down and
out of the transmission housing
and
motor mount.

SECTION 4: Transmission Removal and Installation
PTO HORSE MODEL
TECHNICAL MANUAL
Page 4-3 4/90
Attaching the Transmissions
1. Clean the surfaces of the
transmissions where they join
together.
2. Make sure the dog clutches
have been greased. Fill the dog
clutch cavity on the
PTa power
unit with grease up to where the
rear of the
PTa power unit widens
to accept the tiller attachment.
Then grease the
dog clutch on the
tiller attachment so that the
dog
clutch is covered with grease.
3. Align the locating pin on the
PTa Power Unit housing with the
locating hole on the tiller attach-
ment housing and join the PTa
power unit and tiller attachment. If
necessary, turn the pulley
on the
front of the PTa power unit to
adjust the dog clutch until it fits
the tiller attachment dog clutch.
Note: If you put the Tines/PTa
Clutch in neutral you will not have
to line up the dog clutches.
4. Swing the bolts so that they
connect to the tiller attachment.
5. Tighten the bolts. Use a
torque wrench and tighten the
bolts
to 70-80 ft/lbs.
Transmission Installation
1. Install the wheels.
2. Install the shift lever bracket
(11) with the left-side bolt and
right-side
bolt (the one that goes
in horizontally). Be sure that the
Tines/PTa Clutch Lever (13) is
installed
through the slot in the
detent plate (15). Make sure to
tighten the bolts securely.
3. Install the Wheel Speed Lever
connecting rod swivel on the
eccentric lever (10).
4. Install the locknut that retains
the swivel
to the lever. Tighten the
nut securely and then loosen it 1/8
turn.
5. Install the knob (12) on the
Tines/PTa Clutch Lever (13) with
the
bolt (9).
6. Install the handlebar mounting
base and the attached handlebars
to the transmission housing cover
with the long bolt
(8) or T-handle.
7. Install the bolt, bushing, and
washer (7) that holds the yoke
pivot links
to each side of the PTa
power unit.
8. Apply aliberal coating of
grease to the engine mounting
bars (5).
9. Position the engine on the
PTa power unit and support the
engine with ablock.
10. Install one of the engine
mounting bars halfway. Use a
rubber
hammer to tap the bar
down. Take care
to not damage
the threads in the
top of the bar.
11. Back off the jam nut and
install the locking bolt (6)
for the
bar. Turn the bolt until it
is finger
tight and you feel it strike the bar.
Then maintain very light pressure
on the bolt with awrench.
12. Slowly tap the engine mount-
ing bar the rest of the way in.
When the groove in the bar
reaches the bolt, the pressure on
the bolt will
be relieved.
13. Tighten the bolt until it is
snug and then back
off 1/4 turn.
Next, hold the bolt with one
wrench while tightening the jam
nut with asecond wrench.
14. Repeat the previous four
steps for the other engine mount-
ing bar.
15. Install the bumper on the
tiller. If the tiller did
not have a
bumper, install the red plugs in the
top of the engine mounting bars to
protect the threads in the
bumper
mounting holes.
16. Set the yoke in the necessary
position and install the bolt, bush-
ings, and washers
(4) that hold
each side of the
yoke to the motor
mount. If necessary, temporarily
detach the clutch pawl spring
before attaching the yoke. Be sure
to reattach the spring after the
yoke is installed.
17. Attach the throttle control
cable (3) to the handlebar. Use
plastic wire ties
to secure the
cable
to the handlebar.
18. an tillers so equipped, attach
the Forward Interlock System plug
connector with bracket (2) to the
top of the shift lever bracket and
install the forward bolt on the right
side of the shift lever bracket.
19. an tillers so equipped, con-
nect the Forward Interlock System
engine wire harness assembly to
the handlebar wire harness
assembly (1).
AWARNING:
To help avoid personal in-
jury, the Forward Interlock
Safety System should be
tested for proper function-
ing every time the tiller or
PTO Power Unit is used.
After completing all of the
assembly steps, refer to
"Test Operation of Forward
Interlock Safety System"
in the PTO Horse Model
Owner/Operator Manual.
20. For electric start tillers only:
a. Attach the battery bracket to
the transmission cover and attach
the
two mounting bolts and lock-
washers that secure the legs of the
bracket.
b. For Briggs &Stratton engines
only:
Connect the green shutoff
wire on the right side of the
engine.

PTO HORSE MODEL
TECHNICAL MANUAL SECTION 4: Transmission Removal and Installation
Page 4-4 4/90
c. Connect the recharging wire
that leads from the keyswitch wire
harness to the engine.
d. Connect the red starter cable
to the starter
motor on the engine.
e. Install the battery as described
in the Owner/Operator Manual.
21. Loosen the two bolts (14)
that secure the Tines/PTO Clutch
Lever detent plate
(15) to the shift
lever bracket.
22. Loosen the bolt (16) that
secures the Tines/PTO Clutch
Lever
(13) to the eccentric shaft.
23. Move the lever until it is
inside one of the two detent slots
in the detent plate. Then tighten
the bolt
(16) that holds the lever to
the shaft. Acorrectly installed
lever will have to be pulled out
before you are able to slide the
lever to the other detent slot.
24. With the lever in the ENGAGE
position (both dog clutches must
be fully engaged), slide the detent
plate to the rear
of the housing
against the lever until it can go no
further. Move the plate forward
1/16
of an inch and tighten the two
detent plate mounting bolts
(14).
You should feel some lever play in
either the ENGAGE
or DISEN-
GAGE position.
25. Install the drive belt on the
engine and transmission pulleys
and adjust the belt tension accord-
ing to the directions found in the
Owner/Operator Manual.
26. Check the operation of the
Wheels/Tines/PTO Lever by shift-
ing it into Forward, then Neutral
and Reverse. The lever should
hold properly in Forward and
should release
quickly from
Reverse when you release the
lever. Refer
to the Owner/Operator
Manual for information on making
final adjustments to this important
control lever.
27. Make sure that the transmis-
sions
for the power unit and the
tiller attachment are correctly filled
with gear oil.
.-

SECTION 5: PTO Power Unit Transmission
PTO HORSE MODEL
TECHNICAL MANUAL
Page 5-1 4/90
The following subsections
explain how to service
various items
on the PTO
Horse Model Power Unit
Transmission.
r1't
t14
15
Figure 5-1: PTa Power Unit Housing Cover.
WARNING: When servicing the machine, prevent uninten-
tional starting of the engine by disconnecting the spark plug
wire and keeping the wire away from the spark plug. Place
the engine throttle control in the OFF position and shift the
Wheels/Tines/PTa Drive Lever into NEUTRAL.
5~C
6 ~ . --------------{
~ /11 "
~
e'
PTa Power Unit
Housing Cover
These instructions describe how
to service the PTO power unit
housing cover. Use Figure 5-1 as a
reference
for part locations in
these instructions.
Removal
1. Remove the bolt (1) that holds
the Tines/PTO Clutch Lever knob
(2) to the Tines/PTO Clutch Lever.
Then remove the knob.
2. Remove the two bolts (3) and
washers (if present)
from the top
of the shift lever bracket (4).
3. Remove the bolt (5), lock-
washer (if present), and the
washer (6)
from the side of the
shift lever bracket.
4. Remove the shift lever bracket.
5. Remove the locknut (7) that
holds the speed shift lever con-
necting rod swivel (see inset) (8)
to the eccentric lever (9).
6. Separate the tiller attachment
from the PTO power unit. See
"Separating the PTO Power
Unit
and Tiller Attachment Transmis-
sion Assembly" in Section 4
for
instructions.
7. Set the PTO power unit on a
bench
or other comfortable work
area.
8. If necessary, drain the trans-
mission gear oil
from the PTO
power unit by loosening and re-
moving the oil drain plug, which is
located
below the wheel shaft on
the left side of the transmission
housing.
After the oil is drained,
apply a coating of non-hardening
gasket sealer on the threads and
reinstall
the oil plug. If the plug is
damaged, use a
new plug.
9. Remove the remaining two
bolts (3) and lockwashers (if pres-
ent)
that secure the PTO power
unit housing cover (11), and
remove
the cover.
10. Discard the gasket (12).

PTO HORSE MODEL
TECHNICAL MANUAL
Page 5-2 4/90
SECTION 5: PTO Power Unit Transmission
Inspection
These instructions describe how
to inspect vital parts on the PTO
power unit housing cover. In addi-
tion
to inspecting the parts you
have removed, you should also
inspect any replacement parts.
Note: Thoroughly degrease and
clean all parts before inspection.
Plunger Bolt -You must replace
the neutral
plunger assembly if it
is frozen (penetrating oil will
sometimes free afrozen bolt)
or if
the plunger bolt
(13) has snapped
off. To determine if the
plunger
bolt is frozen, perform the follow-
ing test:
1. Loosen the hex jam nut (14).
2. Gently tighten the plunger
locking bolt
(15) until it stops, then
add a1/4 turn
to lock it.
3. Loosen the flange locknut (16).
4. Loosen the plunger bolt (13).
If you
cannot loosen the bolt or if
the bolt snaps off, replace the neu-
tral plunger assembly with anew
one.
If the plunger bolt
is not frozen on
the plunger, restore the
plunger
assembly to its previous settings
by reversing steps
1, 2and 3.
Cover -Inspect the cover for
cracks. Also, make sureJhe
threads in the handlebar mounting
base are not damaged.
Installation
1. Affix the gasket (12) to the
cover.
2. Start the four bolts (3) and the
lockwashers (if present) in the
cover.
3. Tighten the two forward bolts
but leave the
two rear bolts loose.
4. Reattach the tiller attachment
to the PTO power unit and then
reinstall the transmission assem-
bly on the tiller. See Section 4for
instrucitions.
5. Refill the transmission with
gear oil if it was previously
drained. See the
Owner/Operator
Manual for instructions on how to
refill the transmission with oil.
Neutral Plunger
Assembly
You would disassemble the PTO
power
unit housing cover if you
found the neutral plunger assem-
bly
to be frozen or if the bolt
snapped off.
Disassembly
1. Place the housing cover on an
arbor press and press down on
the neutral plunger bolt
(13).
2. Loosen the hex jam nut (14)
then loosen the plunger locking
bolt
(15) until it clears the groove
in the neutral plunger (17).
3. Let the arbor press up.
4. Remove the spring (18).
Note: If you are servicing an 8
HP Kohler engine you may want
to discard the spring and install a
new one if the same spring has
been in use for several years.
5. If you are installing anew
plunger assembly, discard the old
plunger, clip ring
(19), flange nut
(16), and neutral plunger bolt (13).
Assembly
1. Use ahammer to seat the clip
ring (19) in the groove of the neu-
tral plunger (17).
2. Thread the flange nut (16)
onto the plunger bolt (13) about
three quarters of the way.
3. Apply acoating of nickel-
based anti-locking
compound to
the threads of the plunger bolt.
4. Lubricate the inside threads of
the neutral plunger
(17).
5. Thread the plunger bolt (13)
and the attached flanged
nut into
the neutral plunger.
6. Slip the spring (18) on the
neutral plunger.
7. Apply acoating of nickel-
based anti-locking
compound on
the bottom
of the neutral plunger
and insert the neutral plunger into
the housing cover.
8. Place the housing cover on an
arbor press.
9. Turn the plunger locking bolt
(15) until it is finger tight and you
feel it strike the neutral plunger.
Then maintain very light pressure
on the bolt with awrench.
10. Slowly press the plunger
assembly down. When the groove
in the neutral
plunger reaches the
plunger locking bolt, the pressure
on the bolt will be relieved.
11. Tighten the plunger locking
bolt until it
is seated and then
back
it off 1/2 turn.
12. Release the arbor press pres-
sure from the plunger assembly.
13. Hold the plunger locking bolt
in place and tighten the hex jam
nut (14).
14. Adjust the plunger assembly
for proper reverse action by refer-
ring to the adjustment instructions
in the
Owner/Operator Manual.
"