Troy-Bilt Pony 12211 Owner'S Manual Download

Page: 32 / 48

TROUBLESHOOTING

Before performing any corrections, refer to the appropriate information in this Manual, or in the Engine Owner’s Manual, for the
correct safety precautions and operating or maintenance procedures. Contact your local authorized Engine Service Dealer for
engine service. Contact your local authorized equipment dealer or the factory for all other service problems.

PROBLEM POSSIBLE

CAUSE

CORRECTION

Engine does

1. Spark plug wire disconnected.

1. Reconnect wire.

not start.

2. Engine Throttle Control Lever incorrectly set.

2. Put lever in FAST 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(s).

6. Clean or replace filter(s).

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.

Keyswitch does

1. Electrical connections loose or disconnected.

1. Tighten or reconnect wiring.

not start engine

2. Battery discharged.

2. Charge battery (see “Battery Maintenance,” Section 5).

(electric start

3. Broken wire in wiring system.

3. Replace broken wiring.

model only)

4. Malfunctioning starter motor.

4. See Engine Service Dealer.

5. Corroded battery terminals.

5. Clean terminals (see “Battery Maintenance,” Section 5).

6. Poor contact on ground wire terminals.

6. Scrape paint off terminals.

Engine runs poorly.

1. Defective or incorrectly gapped spark plug.

1. Inspect spark plug (see Engine Owner’s Manual).

2. Dirty air filter(s).

2. Clean or replace (see Engine Owner’s Manual).

3. Carburetor out of adjustment.

3. See Engine Service Dealer.

4. Stale gasoline.

4. Replace with fresh gasoline.

5. Dirt or water in fuel tank.

5. See Engine Service Dealer.

6. Engine cooling system clogged.

6. Clean air cooling system (see Engine Owner’s Manual).

Engine overheats.

1. Engine cooling system clogged.

1. Clean air cooling area (see Engine Owner’s Manual).

2. Carburetor out of adjustment.

2. See Engine Service Dealer.

3. Oil level is low.

3. Check oil level (see Engine Owner’s Manual).

Engine does not

1. Misadjusted throttle control cable (recoil start model).

1. See Engine Owner’s Manual or Engine Service Dealer.

shut off.

2. Keyswitch wire harness malfunction (electric start model.)

2. See Engine Service Dealer.

Wheels and Tines

1. Improper use of controls.

1. Review Sections 3 and 4.

will not turn.

2. Forward Clutch: Misadjusted forward clutch control cable.

2. Adjust cable tension (Section 5).

3. Reverse Clutch: Misadjusted clutch control cable.

3. Adjust cable tension (Section 5).

4. Worn or broken clutch belt(s).

4. Check belts. Replace parts as needed (Section 5).

5. Internal transmission wear or damage.

5. Contact local dealer or the factory.

6. Bolt and key loose in transmission pulley.

6. Tighten bolt; check that key is in place.

Tines turn, but

1. Wheel mounting hardware missing.

1. Replace hardware.

wheels don’t.

2. Bolt and key loose in transmission pulley.

2. Tighten bolt; check that key is in place.

3. Internal transmission wear or damage.

3. Contact local Dealer or the Factory.

4. Misadjusted wheel gear cable.

4. See “Wheel Gear Cable Adjustment,” Section 5.

5. Wheel Gear Lever not fully engaged.

5. Engage lever (see Section 3).

Wheels Turn, but

1. Tine holder mounting hardware missing.

1. Replace hardware.

Tines Don’t.

2. Internal transmission wear or damage.

2. Contact local Dealer or the Factory.

Poor tilling

1. Worn tines.

1. See “Bolo Tines” (Section 5).

performance.

2. Improper Depth Regulator setting.

2. See “Tilling Tips & Techniques,” Section 4.

3. Incorrect throttle setting.

3. See Section 4.

4. Belt(s) slipping.

4. See “Checking Clutch Belt Tension,” Section 5.

Battery (if so

1. Broken wiring in engine recharging circuit.

1. Contact Engine Service Dealer.

equipped) does not

2. Malfunctioning engine recharging system.

2. Contact Engine Service Dealer.

charge during

3. Discharged or dead battery.

3. See “Battery Maintenance,” Section 5.

engine operation.

Summary of Contents for Pony 12211

Page 1: ...NY REAR TINE TILLER Safety Assembly Features and Controls Operation Maintenance Parts List GARDEN WAY INCORPORATED Recoil Start Model shown SAFETY FIRST Before operating this equipment read this Owner s Manual and the separate manual supplied by the engine manufacturer ...

Page 2: ...HOOTING 32 PARTS LIST 33 CUSTOMER SERVICE INFORMATION BACK COVER Dear Owner You now own one of the finest standard rotating tine tillers available Your new PONY Model tiller allows you to till and cultivate your garden with ease and accomplish dozens of other property management projects as well Your tiller is famous for its ruggedness performance and high quality engineering We know you ll enjoy ...

Page 3: ...ts when engine is running unless recommended by manufacturer 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 Stay alert for hidden hazards or traffic Do not carry passengers 3 After striking a foreign object stop the engine and remove the ignition key on electric start models disconnect the spark plug wir...

Page 4: ...surfaces Look behind 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 slopes 18 Never allow bystanders near the unit 19 Only use attachments and acces sories that are approved by the tiller manufacturer 20 Use tiller attachments and acces sories wh...

Page 5: ...any decals are damaged or missing Refer to the Parts List pages for decal locations and part numbers Figure 1 Location of Safety and Operating Decals TO AVOID SERIOUS INJURY READ THE OWNER S MANUAL KNOW LOCATIONS AND FUNCTIONS OF ALL CONTROLS KEEP ALL SAFETY DEVICES AND SHIELDS IN PLACE AND WORKING NEVER ALLOW CHILDREN OR UNINSTRUCTED ADULTS TO OPERATE TILLER SHUT OFF ENGINE AND DISCONNECT SPARK P...

Page 6: ... 8 16 Nylock Lock Nut 8 2 10 32 x 1 2 Round Hd Screw 9 2 10 32 Nut 10 1 Cotter Pin not used 11 4 Plastic Tie Strap 2 not used Tools Materials Needed for Assembly 1 3 8 open end wrench 1 7 16 open end wrench electric start unit only 2 9 16 open end wrench 1 7 8 open end wrench or 8 long adjustable wrench 1 Scissors to trim plastic ties 1 Ruler 1 Small board to tap plastic knob on lever 1 Tire press...

Page 7: ... 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 shipping position and route it up along the inside edge of the left side handlebar A knob and large hex nut I is installed on the cable 2 I...

Page 8: ...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 3 If oil does not flow from the check hole add oil as follows NOTE Do not use automatic transmission fluid or motor oil in the transmission a Clean area around the fill hole N Figure 2 12 and unscrew gear oil fill plug b If adding only a few ounces of gea...

Page 9: ...ssors STEP 8 CHECK AIR PRESSURE IN TIRES Use a tire pressure gauge to check the air pressure in both tires Deflate or inflate both tires equally to 15 to 20 PSI pounds per square inch Be sure that both tires are inflated equally or the unit will pull to one side STEP 9 CHECK HARDWARE FOR TIGHTNESS Inspect the hardware on the unit and tighten any loose screws bolts and nuts IMPORTANT This completes...

Page 10: ...pped that covers the vent fitting located on the negative side of the top of the battery 4 Remove the six filler caps from the top of the battery Leave the caps off while activating and charging the battery 5 Put on protective clothing rubber gloves and eye protection For best results the temperature of the battery and electrolyte should be between 60o F to 80o F Carefully fill each of the six cel...

Page 11: ...tach Battery Cables and Vent Tube 1 Locate the positive battery cable which is connected to the starter solenoid on the left side of the battery post a rubber boot covers the connection A second rubber boot is loosely installed on the cable Using the small screw and nut from the hardware bag connect the loose end of the cable to the positive post on the battery See Figure 2 18 2 Slide the rubber b...

Page 12: ...ttach the wiring harness receptacle to the prongs on the back of the ignition switch see Figure 2 22 IMPORTANT This completes the assem bly steps for the electric start tiller Be sure to read the rest of this Manual and the separate Engine Owner s Manual before you operate your tiller 12 Figure 2 20 Check tightness of upper mounting screw Figure 2 21 Install vent tube Figure 2 22 Attach wiring har...

Page 13: ...ard while also rolling the tiller a few inches forward or back ward Moving the tiller helps to align the shift mechanism with the transmission wheel drive gears To shift to DISENGAGE freewheel move the lever rearward without rolling the tiller The wheels will roll freely when the lever is properly set in the DISENGAGE position FORWARD CLUTCH CONTROL The two interconnected levers B Figure 3 1 contr...

Page 14: ...crease the tilling depth Complete details on using the Depth Regulator are found in the Operation Section of this manual HANDLEBAR HEIGHT ADJUSTMENT The handlebar height is adjustable to four different settings Set the handlebar height to a comfortable setting but keep in mind that the handlebars will be lower when the tines are engaged in the soil To Adjust the Handlebar Height 1 Stop the engine ...

Page 15: ...ing the Engine in the Operation Section for detailed engine starting and stopping instructions FAST Use for most tilling and cul tivating projects SLOW Use when idling engine or when slower tilling and cultivating speeds are needed STOP Stops the engine on recoil start models only ELECTRIC START KEYSWITCH ELECTRIC START MODEL The ignition keyswitch on the electric start model H Figure 3 5 is used ...

Page 16: ...t for loose or missing hard ware Service as required 3 Check engine oil level See Engine Owner s Manual 4 Check that all safety guards and covers are in place 5 Check air cleaner and engine cooling system See Engine Owner s Manual 6 Attach spark plug wire to spark plug 7 Fill the fuel tank with gasoline accord ing to the directions in the separate Engine Owner s Manual Follow all instructions and ...

Page 17: ... below 1 If the battery is not dead or damaged leave it connected to the tiller so it will be recharged during engine oper ation Make sure the battery cells are filled to the UPPER LEVEL line with electrolyte 2 If the battery is dead or damaged remove it refer to Battery Removal and Installation in Section 5 and have it tested Before starting engine cover the terminal on the loose end of the posit...

Page 18: ...ft the handlebars until the engine and tines are bal anced over the wheels Figure 4 4 c With the tiller balanced push side ways on the handlebar to move the tiller in the direction of the turn Figure 4 5 After completing the turn slowly lower the tines into the soil and increase the engine speed Stopping the Tiller and Engine 1 To stop the wheels and tines release the Forward Clutch Control levers...

Page 19: ...illing wet soil often results in large hard clumps of soil that can interfere with planting If time permits wait a day or two after heavy rains to allow the soil to dry before tilling Test soil by squeez ing it into a ball If it compresses too easily it is too wet to till Avoid making footprints When possible walk on the untilled side of the unit to avoid making footprints in the freshly tilled so...

Page 20: ...and try to avoid leaving footprints or wheel marks When tilling vertically try to make the first pass uphill as the tiller digs more deeply going uphill than it does down hill 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 B Terrace Gardening When a slope is too steep or too ...

Page 21: ... off roll the tiller into and out of the vehicle Two or more people are needed to do this Ramps must be strong enough to support the combined weight of the tiller and any handlers The ramps should provide good traction to prevent slip ping 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 The handlers should wear stu...

Page 22: ... 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 WARNING TILLER LUBRICATION Proper lubrication of the tiller is an essen tial part of your maintenance program After every 10 operating hours oil or grease the lubrication points shown in Figure 5 1 as described below Use a go...

Page 23: ...ion 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 result in severe damage A To Check Transmission Gear Oil Level 1 Check the gear oil level when the trans mission is cool Gear oil will expand in warm operating temperatures and this expansion will provide an incorrect oil level reading 2 To check the...

Page 24: ...ng 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 annually Clean the plug and set the gap as described in the separate Engine Owner s Manual In some areas local law requires using resistor spark plugs to suppress ignition signals If the en...

Page 25: ...tery Storage instructions in this Section 5 Store unit in a clean dry area 6 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 BOLO TINES The tines will wear with use and should be inspected at the beginning of each tilling season and after every...

Page 26: ... first two hours of break in operation and after every 10 operating hours At the end of each tilling season check the belt for cracks cuts or frayed edges and replace it as soon as possible Checking Forward Belt Tension 1 Before checking shut off engine allow the engine and muffler to cool down dis connect the spark plug wire remove the ignition key on electric start models Figure 5 10 Location of...

Page 27: ...Clutch Belt below Adjusting Reverse Clutch Belt 1 Before adjusting the belt shut off engine allow the engine and muffler to cool down disconnect the spark plug wire and remove the ignition key on elec tric start models 2 Remove the two nuts C Figure 5 13 and remove the belt cover 3 Reverse belt tension adjustments are done with the reverse clutch cable adjuster located on the left side of the mach...

Page 28: ...s 2 Remove the old forward clutch belt as described in Removing Forward Clutch Belt 3 From the front of tiller insert the forward clutch belt in between the bottom of the engine drive pulley I and the top of transmission pulley K Figure 5 20 4 Insert the bottom half of belt into the smaller rear most groove of the trans mission pulley F Figure 5 19 Now slip the top half of belt under the belt guid...

Page 29: ... flat side of the belt rides against the reverse idler pulley N Figure 5 22 and transmission pulley L If needed the belt can be twisted inside out so that the V shaped side is on the outside and the widest side is on the inside 3 Insert the belt down into the front of the transmission housing Slip the top half of the belt onto the reverse idler arm pulley N 4 Pull the belt downward and loop the bo...

Page 30: ...art system has a recharging circuit that will maintain the battery s state of charge during the tilling season When storing the tiller for extended periods it is recommended that the battery be fully charged before placing it in storage Before reinstalling the battery after storage give it a thorough recharge Battery Removal and Installation When removing and installing the battery disconnect and ...

Page 31: ...enches and ditches up to 8 deep depending on soil conditions The two hiller wings attach to the sides of the furrower blade and are used to make hilled rows and raised bed gardens ROW MARKER The row marker attaches to the hiller furrower attachment and is used to scratch lines in the seedbed for laying out furrows trenches raised beds etc eliminates the need for stakes string and measuring tape Th...

Page 32: ...ir cooling system see Engine Owner s Manual Engine overheats 1 Engine cooling system clogged 1 Clean air cooling area see Engine Owner s Manual 2 Carburetor out of adjustment 2 See Engine Service Dealer 3 Oil level is low 3 Check oil level see Engine Owner s Manual Engine does not 1 Misadjusted throttle control cable recoil start model 1 See Engine Owner s Manual or Engine Service Dealer shut off ...

Page 33: ...308 Roll Pin spiral 1 4 x 1 1 10 1117A Depth Adjustment Bar Assembly Incl Refs 11 and 12 1 11 9120 Retaining Ring tolerance ring 1 12 9119 Knob Depth Regulator Incl Ref 11 1 13 1100043 Hex Hd Screw 3 8 16 x 1 1 4 2 14 1113 1 Bushing Drag Bar 2 15 1186231 Hex Nut 3 8 16 2 16 20775 Drag Bar 1 17 1917536 Decal operating instructions 1 18 9553 Hex Hd Screw self tapping 5 16 18 x 1 2 2 19 9552 Hex Flan...

Page 34: ...34 PARTS LIST Models 12211 and 12212 HANDLEBAR ASSEMBLY and CONTROL LEVERS 10 See page 36 Ref 47 for attach ment screw ...

Page 35: ...Hex Locknut 3 8 16 2 10 1918791 Cable Forward Clutch Control 1 13 9442 Wheel Gear Control and Cable Assy Incl Refs 14 15 19 21 22 23 1 14 9057 Knob Wheel Gear Control Lever 1 15 1186211 Hex Nut 5 16 24 2 16 1100068 Hex Hd Screw 3 8 16 x 3 4 2 17 1100243 Lockwasher 3 8 2 19 1735531 Cable Ties Plastic 2 21 1114748 Round Hd Screw 10 32 x 1 2 6 22 1100240 Lockwasher 10 2 23 1186208 Hex Nut 10 32 2 24 ...

Page 36: ...verse Clutch Cable 1 2 6 5 7 3 4 13 14 15 16 17 16 49 21 25 24 35 45 46 20 49 50 51 43 43 44 37 47 37 40 42 48 41 44 38 40 39 20 23 8 12 26 27 3 28 29 30 31 9 22 18 45 12 11 10 9 8 35 36 ENGINE SUPPORT BRACKETS PULLEYS BELTS BELT COVER 36 ...

Page 37: ... Forward Clutch Belt 1 26 1900396 Hex Hd Screw 10 32 x 1 2 self tapping 4 27 1916189001 Guard Belts Pulleys 1 28 1186230 Hex Nut 5 16 18 4 29 1186329 Hex Flange Screw 5 16 18 x 3 4 4 30 1916797001 Engine Support Bracket left side 1 31 1916796001 Engine Support Bracket right side 1 35 1100799 Hex Hd Screw 5 16 18 x 1 1 2 3 36 1915810 Decal Stabilization 1 37 1918774001 Mounting Bar 2 38 1186331 Hex...

Page 38: ...over 1 8 1916197001 Transmission Case Assy Incl Tube and Rear Housing 1 9 9467 Plug 1 10 1916198001 Mounting Plate Wheel Clutch Cable 1 11 97073 Oil Seal Tiller Shaft 2 12 90038 Hex Flange Screw 5 16 18 x 5 8 2 13 1916273001 Tiller Housing Cover left side 1 14 1129 1 Gasket Tiller Housing Cover 010 fits all covers A R 15 1915089 Screw Kit Incl three 1 4 20 x 7 8 Self Sealing Screws A R 16 1115 Rea...

Page 39: ...crew 5 16 24 x 1 1 8 1 7 9944 Washer Disc Spring concave surface faces pulley 1 8 1108841 Key 3 16 sq x 1 1 2 1 9 20880 Transmission Drive Pulley 1 10 1440 Support Washer 1 11 85030 Oil Seal Input Pinion Shaft 1 12 9500 Retaining Ring external 1 13 9953 Thrust Washer 2 14 9428 Bushing 1 15 9677 Set Screw 5 16 18 x 3 8 1 16 20791 Input Pinion steel shaft 1 17 20792 Input Pinion Gear 1 18 9093 Retai...

Page 40: ...Bushing 2 5 2494 Wheel Shaft Incl Ref 6 1 6 9373 Hi Pro Key 1 4 x 1 5 16 1 7 20914 Wheel Drive Worm Gear cast iron 1 8 9935 Shim between key and gear 1 016 I D x 1 468 O D x 062 Thick 1 9 20712 Wheel Drive Clutch cast iron 1 10 20879 Eccentric Shaft 1 11 1442 Pin Eccentric Shaft 1 12 9055 Spring 1 13 9622 Oil Seal 1 14 20757 Eccentric Shaft Lever 1 15 1100804 Hex Hd Screw 1 4 20 x 1 2 1 16 97074 B...

Page 41: ...illing Bolo Tine Left hand tine see Note 1 above 8 2475 2 Custom Tilling Bolo Tine Right hand tine see Note 1 above 8 10802 Custom Tilling Bolo Tine Replacement Set Incl eight ea right hand and left hand custom tines and sixteen each of Refs 1 and 3 1 11 9380 Clevis Pin 312 x 1 3 4 2 12 9338 Hitch Pin 2 13 1917487 Wheel and Tire Assembly 2 REF PART No No DESCRIPTION QTY REF PART No No DESCRIPTION ...

Page 42: ...42 PARTS LIST Models 12211 and 12212 ELECTRIC START ASSEMBLY 30 31 ...

Page 43: ...d red wire wire assy w connector to small solenoid stud red wire wire assy w connector to solenoid grounding screw red wire wire assy w connector to engine ground shut off green wire plastic protector tube wire terminal 1 15 97020 Boot Insulating 2 16 96514 Solenoid Incl nuts and washers for cables and wires 1 17 1918831001 Battery Bracket 1 18 1186023 Round Hd Screw Square Neck 1 4 20 x 1 1 4 2 1...

Page 44: ...211 and 12212 ROW MARKER ATTACHMENT ROW MARKER ATTACHMENT PART 12589 Complete Attaches to Furrower Attachment MAIN SUPPORT YOKE ASSEMBLY PART 1904522001 DETAIL A 19 20 23 22 21 BUMPER PART 12593 See Detail A BUMPER ATTACHMENT ...

Page 45: ...e incl 12579 Pony Hiller Furrower and 12589 Row Marker 1 12589 Row Marker Attachment complete attaches to furrower attachment 12579 includes 1904522001 Main Support Yoke Assy 1 Row Marker Main Support Yoke Assembly Part 1904522001 10 1186349 Screw hex flanged locking 3 8 16 x 1 1 2 1 11 1593 Stop Bar 1 12 1592 Yoke 1 13 1591 Tube Key square 1 14 1590 Washer friction 2 15 1588 Main Support 1 16 158...

Page 46: ...lain Washer 5 16 S A E 4 5 9824 Wing Nut 5 16 18 4 6 1900773001 Hiller Wing left 1 7 1900774001 Hiller Wing right 1 8 1900772001 Blade Mounting Bracket 1 9 9725 Carriage Bolt 3 8 16 x 1 1 2 2 10 1100243 Lockwasher 3 8 plated 2 11 1186231 Hex Nut 3 8 16 plated 2 12 9318 Clinch Pin 1 12579 Complete Hiller Furrower Attachment Incl blade bracket hiller wings and mounting hardware 1 REF PART No No DESC...

Page 47: ...47 NOTES ...

Page 48: ...Replacement Parts Factory specified replacement parts are available from your authorized dealer or directly from the factory When ordering parts be sure to provide the following Model Serial Numbers of the unit Part number of the part needed Part Description Quantity needed NOTE All replacement parts must conform to our rigid quality specifications Although some replacement parts we provide may va...

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Troy-Bilt Pony 12211, Owner'S Manual

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