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Troy-Bilt PONY 664DM manual

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Table of contents for the manual

  • Page 1

    '0 T RO BI£T°- --- Operator's Manual Rear-tine Tiller Model 664DmPony_ E666MmPony _ IMPORTANT:READ SAFETY RULES AND INSTRUCTIONS CAREFULLY Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-covered, brush- covered or grass-covered land unless the engine's exhaus[...]

  • Page 2

    TABLE OF CONTENTS Content Page Calling Customer Support .................................................... 2 Safety ................................................................... 3 Assembly ................................................................. 6 Features and Controls ....................................................... 11 Oper[...]

  • Page 3

    safety This machine meets voluntary safety standard B71.8 - 1996, which is sponsored by the Outdoor Power Equipment Institute, Inc., and is published by the American National Standards Institute. Safety Alert Symbol _ his is a safety alert symbol. It is used in this manual and on the unit to alert you to potential hazards. When you see this symbol,[...]

  • Page 4

    7. Take all possible precautions when leaving the machine unattended. Stop the engine. Remove ignition key on electric start models. Disconnect spark plug wire and move it away from the spark plug. Move Wheel Gear Lever to ENGAGE. 8. Before cleaning, repairing, or inspect- ing, stop the engine, remove the ignition key on electric start models, and [...]

  • Page 5

    4. To reduce the chances of a fire hazard,keep the enginefree of grass, leaves, or excessive grease. 5. Store gasoline in a cool, well-venti- lated area, safely away from any spark- or flame-producing equipment. Store gasoline in an approved container, safely away from the reach of children. 6. Refer to the Maintenance section of this Manual and in[...]

  • Page 6

    2 Assembly 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 operatinginstructions in this Manual. INTRODUCTION Carefully follow these assembly steps to correctly prepareyour tiller for use. It is recommended that you read this Section in its [...]

  • Page 7

    4. With the forward clutch cable (N, Figure 2-4) on the inside of handlebar, position the handlebar ends on the outside of the two mounting tabs (IVI, Figure 2-3) on the transmission top cover. NOTE: The curved handlebar height adjustment bracket appears as shown in C, Figure 2-3 for non-electric start units. For electric start units, the bracket i[...]

  • Page 8

    Incorrect cable adjustment could cause the wheels and tines to rotate unexpect- edly. Follow adjustment procedures carefully. Failure to do so could result in personal injury or property damage. 4. Check for correct spring/cable tension as instructed in Section 5, Checking and Adjusting Forward Clutch Belt Tension. 5. When tension is correct, tight[...]

  • Page 9

    3 Features and Controls Before operating your machine, care- fully read and understand all safety, controls and 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 injury. INTRODUCTION This Section describes the location[...]

  • Page 10

    REVERSE CLUTCH CONTROL The Reverse Clutch Control (C, Figure 3-1) controls the engagement of reverse drive to the wheels and tines. The revers- ing feature is used for maneuvering the tiller only - never engage the tines in the ground while going in the reverse direction. • Use extreme caution when reversing or pulling the machine towards you. Lo[...]

  • Page 11

    Operation Reverse Clutch Forward Clutch ControlLever Wheel Gear Lever Before operating your machine, care- fully 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 instructions ca[...]

  • Page 12

    STARTING THE ENGINE The following steps describe how to start and stop the engine, go not attempt to engage the tines or wheels until you have read all of the operating instruc- tions in this Section. Also review the safety rules in Section 1: "Safety" and the tiller and engine controls information in Section 3: "Features and Control[...]

  • Page 13

    Figure 4-2: Use one hand to guide tiller when moving forward. (b) As the tiller moves forward, relax and let the wheels pull the unit along while the tines dig. Walk behind and a little to one side of the tiller. Use a light but secure grip with one hand on the handlebars, but keep your arm loose. See Figure 4-2. Let the tiller move ahead at its ow[...]

  • Page 14

    Tilling Tips & Techniques Let the tiller do the work • While tilling, relax and let the wheels pull the tiller along while the tines do the digging. Walk on the side that is not yet finished (to avoid making foot- prints in the freshly tilled soil) and lightly, but securely grip the handlebar with just one hand. • Avoid pushing down on the [...]

  • Page 15

    Tilling Tips & Techniques Clearingthe tines The tines have a self-clearing action which eliminates most tangling of debris in the tines. However, occasionally dry grass, stringy stalks or tough vines may become tangled. Follow these proce- dures to help avoid tangling and to clean the tines, if necessary. • To reduce tangling, set the depth r[...]

  • Page 16

    POWER COMPOSTING Power composting simply means tilling under and burying in the soil all manner of organic matter such as crop residues, leaves, grass clippings and cover crops. This material will decompose during the non-growing season and add important natural nutrients to the soil. When power composting, do not keep the Depth Regulator Lever at [...]

  • Page 17

    5 Maintenance 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 instructions can result in serious personal injury or prop- erty damage. MAINT[...]

  • Page 18

    I 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 the key from the keyswitch on units so equipped. Failure to follow these instructions can result in serious personal injury or property damage. CHECK FOR[...]

  • Page 19

    I Ir!lv_vl._!:t_ll_[fll t q b 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 the key from the keyswitch on units so equipped. Failure to follow these instructions can result in serious personal injury o[...]

  • Page 20

    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 the key from the keyswitch on units so equipped. Failure to follow these instructions can result in serious personal injury or property damage. WHEEL GEAR [...]

  • Page 21

    I t q b 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 the key from the keyswitch on units so equipped. Failure to follow these instructions can result in serious personal injury or property damage. Fig[...]

  • Page 22

    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 the key from the keyswitch on units so equipped. Failure to follow these instructions can result in serious personal injury or property damage. Incorrect c[...]

  • Page 23

    I Ir!ly_vl._!:t_ll_[fll t q I Figure 5-16 Figure 5-17 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 the key from the keyswitch on units so equipped. Failure to follow these instructions can result in s[...]

  • Page 24

    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 the key from the keyswitch on units so equipped. Failure to follow these instructions can result in serious personal injury or property damage. pull down o[...]

  • Page 25

    I W!IW._!:t_II_[fll t q b 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 the key from the keyswitch on units so equipped. Failure to follow these instructions can result in serious personal injury or pr[...]

  • Page 26

    I 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 the key from the keyswitch on units so equipped. Failure to follow these instructions can result in serious personal injury or property damage. TROUBLESH[...]

  • Page 27

    I Ir!lv_vl._!:t_ll_[fll t q b 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 the key from the keyswitch on units so equipped. Failure to follow these instructions can result in serious personal injury o[...]

  • Page 28

    I Models 664D & E666M HANDLEBAR ASSEMBLY and CONTROL LEVERS (See page 30, //I/I/ Ref. 47, for j attachment sc,ewl.... J / 2 [ 35 21 ! 35 / / / / / / ! 2 / COVER[...]

  • Page 29

    Models 664D & E666M I HANDLEBAR ASSEMBLY and CONTROL LEVERS REF. PART No. No. DESCRIPTION QTY. 1 1918811 2 GW-9126 3 777122088 3A 777D05553 4 1916784 5 1186347 5A GW-9955 6 1900475 7 710-0514 8 736-3050 9 712-3000 10 1918791 13 GW-9442 14 GW-9057 Handlebars (Incl. Refs. 2, 3 & 3A) ....... 1 Grip .............................................[...]

  • Page 30

    I Models 664D & E666M 36 I I I 22 8 i ENGINE, SUPPORT BRACKETS, PULLEYS, BELTS, BELT COVER ,__Reverse Clutch Cable 14 16 16 52 7 q 24 25 40 42 48 20 _ 43 38 44 _ 37 47 18 21 (Screw, Ref. 47, secures Forward ClutchCable - page 28, Ref. 10) 53 54 26_ 30[...]

  • Page 31

    Models 664D & E666M I ENGINE, SUPPORT BRACKETS, PULLEYS, BELTS, BELT COVER REF. PART No. No. DESCRIPTION QTY. 1 ** Engine - standard recoil start ............ 1 ** Engine - electric start ........................ 1 2 1917326 Bracket, Clutch Cable.......................... 1 3 736-0119 Lockwasher-5/16 ................................ 6 4 710-010[...]

  • Page 32

    I Models 664D & E666M TRANSMISSION HOUSING, COVERS, SEALS, GASKETS, PLUGS REF. PART No. No. DESCRIPTION QTY. 1 2 3 4 5 6 GW-9621 1105620 721-04001 1186329 1983632 GW-11513 7 GW-20694 8 619-04010 9 GW-9467 10 GW-20889 11 721-04035 12 1186328 Oil Seal (Double Lip), Wheel Shaft ...... 2 Pipe Plug, 1/4 .................................... 2 Seal, T[...]

  • Page 33

    Models 664D & E666M I DRIVE SHAFT, INPUT PINION SHAFT and GEAR ASSEMBLIES MAIN DRIVE SHAFT ASSEMBLY INPUT PINION SHAFT& GEAR ASSEMBLY REF. PART No. No. DESCRIPTION QTY. MAIN DRIVE SHAFT 1 2 3 4 5 5 5 GW-1714 GW-20718 GW-9301 GW-20912 GW-1224-1 GW-1224-2 GW-1224-3 GW-1325C Bearing, Tapered Roller with Race .... 1 Spur Gear...................[...]

  • Page 34

    I Models 664D & E666M WHEEL SHAFT, ECCENTRIC SHAFT and TILLER SHAFT ASSEMBLIES 19 16 Assembled Internally 15 / / / "_'_'_/l'_ll _ 12 10 ECCENTRIC SHAFT ASSEMBLY 2 1 4 3 1 2 [] Wheel Shaft Parts REF. PART No. No. DESCRIPTION QTY. 1 721-04031 2 1909950 3 GW-1166-1 --- GW-1166-2 --- GW-1166-3 --- GW-1166-4 4 GW-1086 5 711-040[...]

  • Page 35

    Models 664D & E666M I BOLO TINES, WHEELS FRON_ FORWARD TINE SHAFT 12 J FRONT/ FORWARD 13 NOTE1 : Custom Tilling Tines are available for your tiller. These are special hard-faced tines that are thicker than standard tines. IMPORTANT: Left and right sides of tiller are determined by standing in operator position and facing direc- tion of forward [...]

  • Page 36

    I Models 664D & E666M ROW MARKER ATTACHMENT 9 2 m 8 8 ) (See Detail A) DETAIL A ROW MARKER ATTACHMENT- 0EM-290-257 (Complete - Attaches to Furrower Attachment) MAIN SUPPORT/YOKE ASSEMBLY PART# 1904522001 BU MPER ATTACHMENT 19 20 BUMPER 0EM-290-254[...]

  • Page 37

    Models 664D & E666M I ROW MARKER ATTACHMENT & BUMPER ATTACHMENT REF PART No. No. DESCRIPTION QTY. Row Marker Attachment (option) - 0EM-290-254 1 1904522001 Main Support & Yoke Assy- complete. (Incl. Ref. No.'s 10,11,12,13,14,15,16,17 & 18) .......... 1 2 GW-1594 Marker Blade-blade only ................... 1 3 1904524001 Marker [...]

  • Page 38

    I Models 664D & E666M HOOD, BRACKET and DEPTH REGULATOR 18 % 18 1 17 19 TRANSMISSION 13 6 lO 11 16 13 REF. PART No. No. DESCRIPTION QTY. 1 1917605 Tine Hood (Incl. hood flap and Ref.17) ............................................ 1 2 Lockwasher, 3/8 .................................. 2 3 Bracket-hood & depth regulator (Incl. Ref. No. 9) ..[...]

  • Page 39

    Models 664D & E666M I HILLER/FURROWER ATTACHMENT 7 5 4 12 8 ( 11 10 , 6 HILLER/FURROWER - 0EM-290-251 (Viewed from front of tiller) REF. PART No. No. DESCRIPTION QTY. 1 2 3 4 5 6 7 8 1900771001 1186098 1177548 GW-9902 GW-9824 1900773001 1900774001 1900772001 Furrower Blade .................................. 1 Carriage Bolt, 5/16-18 x 3/4 ....[...]

  • Page 40

    I Model E666M (+l POSITIVE BATTERY CABLE GROUND WIRE STARTER SOLENIOD ACTIVATE WIRE (RED) STARTER WIRE (RED) ENGINE WIRE (GREEN) BATTERY RECHARGE f"_'___ WIRE (RED) _ /-e / / # (-) NEGATIVE BATTERY CABLE STARTER CABLE GROUND CABLE TO ENGINE ENGINE[...]

  • Page 41

    Model E666M I ELECTRIC START ASSEMBLY REF. PART No. No. DESCRIPTION QTY. 1 2 3 4 5 6 7 1186073 1186211 1186390 1186389 1901202 1901894 1908118 Carriage Screw, 1/4-20 x 1.25 ........... 2 Hex Nut, 5/16-24 ............................... 2 Flange Screw, 1/4-20 x .625 .............. 2 Hex Locknut, 1/4-20 .......................... 2 Cable(ground wire [...]

  • Page 42

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  • Page 44

    TROY-BILT TILLER LIFETIME LIMITED WARRANTY WHAT PRODUCT IS COVERED All Troy-Bilt branded rear tine walk-behind tillers with gear drive transmissions. This warranty begins on the date of purchase and is warranted by Troy-Bilt LLC for the life of the tiller, to the original purchaser only. WHAT IS COVERED BY THIS WARRANTY Troy-Bilt LLC will, at its o[...]