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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 exhaust system is equipped with a spark arrester meeting applicable local or state laws (if any).
If a spark arrester is used, it should be maintained in effective working order by the operator. In the State of California the above is required by law
(Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. A spark arrester
for the muffler is available by contacting the service department at Troy-Bilt LLC, P.O. Box 361131 Cleveland, Ohio 44136-0019.
TROY-BILT LLC, P.O. BOX 361131, CLEVELAND, OH 44136-0019
PRINTED IN USA
Operator's Manual
Rear-tine Tiller Model
664D—Pony
E666M—Pony
FROM NO. 770-10597B
®
®
(9/2003)
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Summary of Contents for Troy-Bilt E666M-Pony
- Page 1 (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. A spark arrester for the muffler is available by contacting the service department at Troy-Bilt LLC, P.O. Box 361131 Cleveland, Ohio 44136-0019.
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Page 2: Customer Support
Choose from the options below: Visit troy-bilt.com for many useful suggestions. Click on Customer Support button and you will get the four options reproduced here. Click on the appropriate button and help is immediately available. - Page 3 Safety Alert Symbol This 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, read and obey the message that follows it. Failure to obey safety messages could result in personal injury or property damage.
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Page 4: Maintenance And Storage
Section 1: Safety 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. - Page 5 4. To reduce the chances of a fire hazard, keep the engine free 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.
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Page 6: Inspect Unit
WARNING 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 operating instructions in this Manual. INTRODUCTION Carefully follow these assembly steps to correctly prepare your tiller for use. -
Page 7: Step 3: Attach Reverse Clutch Control Cable
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 (M, 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. -
Page 8: Step 5: Check Transmission Gear Oil Level
Section 2: Assembly CAUTION 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. -
Page 9: Features And Controls
Section Features and Controls WARNING 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. -
Page 10: Handlebar Height Adjustment
Section 3: Features and Controls 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. -
Page 11: Break-In Operation
WARNING 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 can result in serious personal injury. -
Page 12: Starting The Engine
Section 4: Operation STARTING THE ENGINE The following steps describe how to start and stop the engine. Do 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”... - 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.
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Page 14: Tilling Tips
Section 4: Operation Tilling Tips 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. - Page 15 Tilling Tips Clearing the 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.
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Page 16: Power Composting
Section 4: Operation 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. -
Page 17: Maintenance Schedule
Section WARNING Before inspecting, cleaning 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. -
Page 18: Check For Oil Leaks
Section 5: Maintenance Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to WARNING 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. -
Page 19: Spark Arrester Screen Service
Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to WARNING 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. -
Page 20: Wheel Gear Cable Adjustment
Section 5: Maintenance Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to WARNING 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. -
Page 21: Checking And Adjusting Tension On Clutch Belts
Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to WARNING 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. - Page 22 Section 5: Maintenance Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to WARNING 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.
- Page 23 Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to WARNING 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.
- Page 24 Section 5: Maintenance Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to WARNING 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.
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Page 25: Battery Maintenance
Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to WARNING 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. -
Page 26: Troubleshooting
Section 5: Maintenance Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to WARNING 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. -
Page 27: Tiller Attachments
Before inspecting, cleaning or servicing the machine, shut off engine, wait for all moving parts to WARNING 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. - Page 28 Parts List Models 664D & E666M HANDLEBAR ASSEMBLY and CONTROL LEVERS...
- Page 29 Models 664D & E666M HANDLEBAR ASSEMBLY and CONTROL LEVERS REF. PART DESCRIPTION 1918801 Handlebars ... GW-9126 Grip ... 777I22088 Decal, Control Panel ... 777D05553 Decal, Model Name/Logo ... 1916784 Reverse Clutch Control Cable ... 1186347 Height Adjustment Screw ... GW-9955 Washer, Keyed...
- Page 30 Parts List Models 664D & E666M ENGINE, SUPPORT BRACKETS, PULLEYS, BELTS, BELT COVER Reverse Clutch Cable (Screw, Ref. 47, secures Forward Clutch Cable – page 28, Ref. 10)
- Page 31 Models 664D & E666M ENGINE, SUPPORT BRACKETS, PULLEYS, BELTS, BELT COVER REF. PART DESCRIPTION 710-0539 Screw, 3/8-24 x 1.75 ... 1917326 Bracket, Clutch Cable ... 736-0119 Lockwasher–5/16... 710-0107 Hex Hd. Screw, 5/16-24 x 1/2 ... 777S30651 Decal, Hot Surfaces/Belt Warning ... 1916659 Cover ...
- Page 32 Parts List TRANSMISSION HOUSING, COVERS, SEALS, GASKETS, PLUGS REF. PART DESCRIPTION 721-04031 Oil Seal (Double Lip), Wheel Shaft ... 1105620 Pipe Plug, 1/4, ... 721-04001 Seal, Transmission Bore ... 1186329 Hex Flange Screw, 5/16-18 x 3/4* ... 721-04044 Oil Seal, Input Pinion Shaft ... GW-20910 Transmission Cover ...
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Page 33: Main Drive Shaft
Models 664D & E666M REF. PART DESCRIPTION MAIN DRIVE SHAFT GW-1714 Bearing, Tapered Roller with Race ... GW-20718 Spur Gear ... GW-9301 Key, 3/16 sq. x 1 ... GW-20912 Main Drive Shaft (Drive shaft is one- piece with integral, single-lead, work-hardened front worm, and integral, six-lead, work-hardened rear worm. - Page 34 Parts List WHEEL SHAFT, ECCENTRIC SHAFT and TILLER SHAFT ASSEMBLIES REF. PART DESCRIPTION 721-04031 Oil Seal ... 1909950 Retaining Ring (heavy-duty, external) GW-1166-1 Shim, 1-1/64 I.D., .062" thick ... A/R GW-1166-2 Shim, as above, but .030" thick ... A/R GW-1166-3 Shim, as above, but .015"...
- Page 35 Models 664D & E666M REF. PART DESCRIPTION 710-0514 Hex Hd. Screw, 3/8-16 x 1* ... 16 GW-1270-2 Bolo Tine-single. Right hand tine used on left side of tiller... 712-3000 Hex Locknut, 3/8-16 ... 18 710-3096 Hex Hd. Screw, 3/8-16 x 2, Grade 8... GW-1270-1 Bolo Tine-single.
- Page 36 Parts List PART DESCRIPTION Bumper – OEM-290-254 1918749 Bumper ... 777S30653 Decal - Caution... 710-0395 Screw–hex hd., 5/16-18 x 2-1/4* (included in hardware kit) ... 736-0119 Lockwasher–5/16* (included in hardware kit) ... BUMPER ATTACHMENT BUMPER OEM-290-254 PART QTY. 712-0267 1918781 Models 664D &...
- Page 37 Models 664D & E666M REF. PART DESCRIPTION 686-04013 Tine Hood ... 710-0169 Lockwasher, 3/8... GW-2525 Bracket–hood & depth regulator ... 710-04049 Hex Flange Screw, 5/16-18 x 5/8* ... 712-0291 Hex Locknut, 1/4-20 ... 710-0597 Hex Hd. Screw, 1/4-20 x 1* ... GW-9384 Spring ...
- Page 38 Parts List Model E666M...
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Page 39: Electric Start Assembly
Model E666M REF. PART DESCRIPTION 1186073 Carriage Screw, 1/4-20 x 1.25... 1186211 Hex Nut, 5/16-24... 1186390 Flange Screw, 1/4-20 x .625... 1186389 Hex Locknut, 1/4-20... 1901202 Cable (ground wire to starter motor bracket)... 1901894 Recharge Wire Assembly ... 1908118 Wire Harness Assy. (available as complete assembly only). - Page 40 The provisions set forth in this warranty provide the sole and exclusive remedy arising from the sale. Troy-Bilt LLC shall not be liable for any incidental or consequential damage or expense of any kind, including but not limited to cost of equipment rental, loss of profits, or costs of hiring services to perform tasks normally performed by the equipment.