Troy-Bilt 12204-10HP - Manual (Page 44)

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 Drive
Lever is in FORWARD
Throttle Lever in START position X
Wheels/Tines/PTO Drive Lever
in NEUTRAL position
X
Forward interlock Wire Harness
connector securely mated
X X
Forward Interlock Levers not being
squeezed prior to shifting Wheels/
Tines/PTO Drive Lever to
FORWARD position X
Visually inspect for bare, broken
or disconnected wires
X X
Check handlebar wire harness X X
Check transmission wire harness X X
Troubleshooting Procedures
1 Wheels/Tines/PTO Drive Lever:
A. Lever does not stay in FORWARD-
• Drive belt may be too tight. Raise belt
adjustment block a little (Sect. 5).
• Clutch pawl spring at end of lever may be
overstretched, install new spring.
B. Lever hard to shift into REVERSE-
• Check reverse disc for wear (Sect. 5).
• Check adjustment of reverse disc and/or
reverse spring and plunger assy. (Sect. 5).
• Clean and re-lubricate motor mount bars,
belt adjustment block and linkages on lever
(Sect. 5).
C. Titter stays in REVERSE when lever is
released-
• Lubricate motor mount bars, belt adjust­
ment block and linkages on lever (Sect. 5).
• Check adjustment of reverse spring and
plunger (Sect. 5). If problem persists,
contact Technical Service Department.
D. Lever sticks in FORWARD-
• Lubricate motor mount bars, belt adjust­
ment block, and linkages on lever (Sect. 5).
If problem continues, contact the Technical
Service Department.
E. Lever hard to shift into FORWARD-
• Follow advice for Problem 1-D. Also check
for possible bent motor mount bar that could
be binding in engine mount holes.
2 Wheel Speed Lever:
A. Lever hard to shift, or sticks in FAST or
SLOW wheel gear positions-
Figure 5-43: Check connecting rod,
shifting linkage and eccentric lever.
• Lubricate eccentric lever at rear of power
unit transmission (Figure 5-43). If rust is
present, use penetrating oil and work
eccentric lever back and forth by hand.
• Lubricate linkage to Wheel Speed Lever to
eccentric lever (Figure 5-43).
• Clutch inside transmission may be binding.
Disconnect linkage from eccentric lever and
work eccentric lever by hand. If difficult or
impossible to move, it may be due to a
damaged keyway on the wheel shaft.
Contact Technical Service Department.
• Lubricate washers and castle nut on pivot
of lever. If necessary, remove roll pin and
back nut off 1/6th turn. Replace roll pin and
test the movement.
• Apply grease to zerk fitting (If so equipped)
with grease gun until grease appears around
washers.
B. Lever shifts into FAST wheel gear, but
not into SLOW wheel gear-
• Connecting rod at end of lever might be
backwards, or bent in toward transmission
housing and hitting it. Other shifting linkage
might be bent. Straighten or replace linkage
(Figure 5-43).
• Clutch inside transmission may be binding
(Problem 2-A).
C. Lever moves freely, but won’t shift in or
outotgear-
• Eccentric shifting pin inside transmission
may be broken (rare) or worn. Disconnect
linkage from eccentric lever and try moving
eccentric lever by hand (Figure 5-43). If
lever moves easily, contact the Technical
Service Department.
3 Wheels and Tines Won’t Turn:
• Review operation of controls (Sect. 3 & 4).
• Check condition and adjustment of drive
belt and reverse disc (Sect. 5).
• Mounting bolt for transmission drive pulley
may be loose. (See Figure 5-1). If so, drive
belt or reverse disc will turn pulley, but
pulley won’t turn main drive shaft.
• Worm gears that drive wheel and tiller
shafts may be worn.
4 Wheels Turn, But Tines Won’t:
• Tines/PTO Clutch Lever must be in ENGAGE
position (Sect. 3).
• Tines/PTO Clutch Lever may need adjust­
ment.
• Key for dog clutch on tine attachment main
drive shaft may be missing, broken.
• Worm gears that drive the tine shaft may
be worn.
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