Troy-Bilt 664D-Pony Operator'S Manual Download

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Parts List

Model 664D

ENGINE, SUPPORT BRACKETS, PULLEYS, BELTS, BELT COVER

Engine – standard recoil start ............

Engine – electric start ........................

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 .......

1917139

Cover (Incl. Ref. 5)..............................

712-3004A

Flange Lock Nut, 5/16-18....................

1108841

Key, 3/16 x 1-1/2 ................................

GW-1138-1

Shim ...................................................

1916520

Pulley, Engine Drive ............................

GW-9944

Belleville Washer.................................

GW-9572

Hex Hd. Screw, 5/16–24 x 1-1/8 .........

710-3103

Hex Hd. Screw, 5/16–18 x 2 ...............

1918731

Reverse Idler Arm ...............................

1916535

Pulley, Reverse Idler ...........................

1107382

Flat Washer, 5/16 ................................

1916725

Belt Guide, Wire Formed ....................

710-0117

Hex Head Screw, 5/16-24 x 1..............

1917746

Washer, Shoulder ...............................

GW-9929

Washer, Flat, 1-1/8..............................

1916728

Spring, Reverse Return.......................

1916522

Transmission Pulley............................

GW-1440

Support Washer ..................................

1918812

Reverse Clutch Belt .............................

1909404

Forward Clutch Belt.............................

1900396

Self-tapping Screw, #10-32 x 1/2, ......

GW-20339

Guard, Belts/Pulleys............................

712-0267

Hex Nut, 5/16–18 ................................

1186329

Hex Flange Screw, 5/16-18 x 3/4* ......

1916797

Engine Support Bracket, left side ........

1916796

Engine Support Bracket, right side......

710-0805

Hex Hd. Screw, 5/16–18 x 1-1/2 .........

777I20942

Decal, Stabilization..............................

1918774

Mounting Bar ......................................

GW-90063

Hex Flange Screw, 5/16-18 x 1 ...........

710-3037

Hex Hd. Screw, 5/16-18 x 2-1/4*........

736-0275

Flat Washer, 5/16' ...............................

1918846

Belt Guide, Pony .................................

GW-55088

Pivot Bushing......................................

736-0119

Lockwasher, 5/16................................

712-0267

Hex Nut, 5/16-18.................................

1917746

Washer, Shoulder ...............................

1918744

Idler Arm, Forward Tiller Direction ......

1767754

Screw, self tapping, #10-24 ................

1916727

Spring .................................................

712-3000

Hex Locknut, 5/16-18 .........................

GW-9090

Idler Pulley, Forward ..........................

710-0347

Screw, 3/8-16 x 1-3/4 .........................

712-0158

Hex Lock Nut, 5/16-18 ........................

1754128

Screw, 1/4-20 x 3/4 ............................

736-0463

Flat Washer–1/4 ..................................

REF.

PART

No.

DESCRIPTION

QTY.

REF.

PART

No.

DESCRIPTION

QTY.

* Specify GRADE 5 if ordering part locally.

** See your local authorized engine service dealer for engine parts or

service. Refer to engine nameplate for engine type and code
information.

Summary of Contents for 664D-Pony

Page 1: ...ter 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 ...

Page 2: ... A sample model plate is explained below For future reference please copy the model number and the serial number of the equipment in the space below ENGINE INFORMATION The engine manufacturer is responsible for all engine related issues with regards to performance power rating speci fications warranty and service Please refer to the engine manufacturer s Owner s Operator s Manual packed sepa ratel...

Page 3: ...hoses If in doubt contact your telephone or utility company 6 Warning Handle fuel with care it is highly flammable and its vapors are explo sive Take the following precautions a Store fuel in containers specifically designed for this purpose b The gas cap shall never be removed or fuel added while the engine is running Allow the engine to cool for several minutes before adding fuel c Keep matches ...

Page 4: ...n hard or slippery 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 ...

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: ...ck 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 pressure gauge 1 Cle...

Page 7: ... 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 Insert the...

Page 8: ...il Severe engine damage will result if the engine is run without oil 1 Refer to the separate Engine Owner s Manual for motor oil specifications and capacities 2 With the unit on level ground move the Depth Regulator Lever R Figure 2 13 up or down until the engine is level 3 Add motor oil as described in the Engine Owner s Manual 4 Move the Depth Regulator Lever all the way down until the highest n...

Page 9: ...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 control the engagement of forward drive to the wheels and tines To Operate the Forward Clut...

Page 10: ...nd then disconnect the spark plug wire Remove the ignition key on electric start models 2 Loosen the two screws at the lower ends of the handlebar 3 Loosen the height adjustment screw E Figure 3 3 and pull the keyed washer F free of the slots in the curved height adjustment bracket 4 Move the handlebars to the new slot setting and insert the raised keys on the keyed washer into the slot Tighten th...

Page 11: ... 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 safety rules carefully Before operating your machine care fully read and unde...

Page 12: ...iller so it will be recharged during engine operation Make sure the battery cells are filled to the UPPER LEVEL line with elec trolyte 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 positive cable with the insulated boot and secure it in place with electrical t...

Page 13: ...e 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 or the Reverse Clutch Control knob whichever is engaged 2 To stop the recoil start engine move the Engine Throttle Control Lever to ...

Page 14: ...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 15: ...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 16: ... 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 17: ...e transmission Figure 5 2 Lift the tine flap to service those screws CHECK TIRE PRESSURE Check the air pressure in both tires Deflate or inflate both tires evenly to 15 to 20 PSI pounds per square inch Be sure that both tires have the same air pressure or the unit will tend to pull to one side Figure 5 1 Lubrication points Before inspecting cleaning or servicing the machine shut off engine wait fo...

Page 18: ...temperatures and this expansion will provide an incorrect oil level reading 2 To check the gear oil level and to add oil if necessary refer to STEP 5 Check Gear Oil Level in Transmission in Section 2 of this manual B To Drain and Refill the Transmission The transmission gear oil does not need to be changed unless it has been contami nated with dirt sand or metal particles 1 Prop up the left side o...

Page 19: ...f operating 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 ...

Page 20: ...ollow Battery 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 af...

Page 21: ...has passed A tension adjustment is required only if there is little or no reverse move ment when the Reverse Clutch Control knob is pulled out Checking and Adjusting Forward Clutch Belt Tension It is important to maintain correct tension on the forward clutch belt A loose belt will cause the tines and wheels to slow down or stop completely even though the engine is running at full speed A loose be...

Page 22: ...xtended spring length is correct 5 Tighten both jam nuts securely Checking and Adjusting Reverse Clutch Belt Tension Checking Reverse Clutch Belt Tension The reverse clutch belt D Figure 5 9 needs adjustment if the belt slips in reverse or if there is no reverse See Adjusting Reverse Clutch Belt below Adjusting Reverse Clutch Belt 1 Before adjusting the belt shut off engine allow the engine and mu...

Page 23: ...elt off the front of the trans mission pulley F Figure 5 19 7 Work the belt out from between the pulley and the frame around the trans mission cover spring then up and out of the machine Installing Forward Clutch Belt 1 Stop engine allow it to cool and dis connect spark plug wire before working near belts Also remove ignition key on electric start models 2 Remove the old forward clutch belt as des...

Page 24: ...ing near belts Also remove ignition key on electric start models IMPORTANT The forward clutch belt must be installed before the reverse clutch belt 2 Install the forward clutch belt see Installing Forward Clutch Belt in this section before installing reverse belt IMPORTANT The reverse belt has a V shape When installing the belt make sure that the widest flat side of the belt rides against the reve...

Page 25: ...ce 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 adj...

Page 26: ...26 Parts List Model 664D HANDLEBAR ASSEMBLY and CONTROL LEVERS 10 See page 32 Ref 47 for attachment screw ...

Page 27: ...nut 3 8 16 2 10 1918791 Cable Forward Clutch Control 1 13 GW 9442 Wheel Gear Control and Cable Assy Incl Refs 14 15 19 21 22 23 1 14 GW 9057 Knob Wheel Gear Control Lever 1 15 1186211 Hex Nut 5 16 24 2 16 710 0216 Hex Hd Screw 3 8 16 x 3 4 2 17 736 0169 Lockwasher 3 8 2 19 725 0157 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 28: ...TS BELT COVER Reverse Clutch Cable 1 2 6 5 7 7 3 4 13 14 15 16 17 16 52 21 25 24 23 8 39 46 20 20 43 53 54 41 44 51 43 44 37 38 47 35 45 45 49 50 40 42 48 12 26 27 3 28 29 30 9 22 18 12 11 20 10 9 8 35 36 Screw Ref 47 secures Forward Clutch Cable page 30 Ref 10 ...

Page 29: ...elf tapping Screw 10 32 x 1 2 4 27 GW 20339 Guard Belts Pulleys 1 28 712 0267 Hex Nut 5 16 18 4 29 1186329 Hex Flange Screw 5 16 18 x 3 4 4 30 1916797 Engine Support Bracket left side 1 31 1916796 Engine Support Bracket right side 1 35 710 0805 Hex Hd Screw 5 16 18 x 1 1 2 5 36 777I20942 Decal Stabilization 1 37 1918774 Mounting Bar 2 38 GW 90063 Hex Flange Screw 5 16 18 x 1 4 39 710 3037 Hex Hd S...

Page 30: ... 1 8 GW 20893 Transmission Case Assy Incl Tube and Rear Housing 1 9 GW 9467 Plug 1 10 GW 20889 Mounting Plate Wheel Clutch Cable 1 11 GW 97073 Oil Seal Tiller Shaft 2 12 1186328 Hex Flange Screw 5 16 18 x 5 8 2 13 GW 20873 Tiller Housing Cover left side 1 14 GW 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 GW 1115...

Page 31: ...4 x 1 1 8 1 7 GW 9944 Washer Disc Spring concave surface faces pulley 1 8 1108841 Key 3 16 sq x 1 1 2 1 9 1916522 Transmission Drive Pulley 1 10 GW 1440 Support Washer 1 11 1983632 Oil Seal Input Pinion Shaft 1 12 1113527 Retaining Ring external 1 13 GW 9953 Thrust Washer 2 14 GW 9428 Bushing 1 15 GW 9677 Set Screw 5 16 18 x 3 8 1 16 GW 20791 Input Pinion steel shaft 1 17 GW 20792 Input Pinion Gea...

Page 32: ...94 Wheel Shaft Incl Ref 6 1 6 GW 9373 Hi Pro Key 1 4 x 1 5 16 1 7 GW 20914 Wheel Drive Worm Gear cast iron 1 8 GW 9935 Shim between key and gear 1 016 I D x 1 468 O D x 062 Thick 1 9 GW 20712 Wheel Drive Clutch cast iron 1 10 GW 20879 Eccentric Shaft 1 11 GW 1442 Pin Eccentric Shaft 1 12 GW 9055 Spring 1 13 GW 9622 Oil Seal 1 14 GW 20700 Eccentric Shaft Lever 1 15 710 3013 Hex Hd Screw 1 4 20 x 1 ...

Page 33: ... Note 1 above 8 GW 2475 2 Custom Tilling Bolo Tine Right hand tine see Note 1 above 8 GW 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 9 712 3017 Hex Nut 3 8 16 16 10 736 0169 Lock Washer 3 8 16 11 GW 9380 Clevis Pin 312 x 1 3 4 2 12 GW 9338 Hitch Pin 2 13 1917487 Wheel and Tire Assembly 2 REF PART No No DESCRI...

Page 34: ...l 664D ROW MARKER ATTACHMENT ROW MARKER ATTACHMENT OEM 290 257 Complete Attaches to Furrower Attachment MAIN SUPPORT YOKE ASSEMBLY PART 1904522001 DETAIL A 19 20 23 22 21 BUMPER OEM 290 254 See Detail A BUMPER ATTACHMENT ...

Page 35: ...7 two GW 9828 hex nuts Ref 8 two 1100135 screws Ref 9 1 Row Marker Main Support Yoke Assembly Part 1904522001 10 1186349 Screw hex flanged locking 3 8 16 x 1 1 2 1 11 GW 1593 Stop Bar 1 12 GW 1592 Yoke 1 13 GW 1591 Tube Key square 1 14 GW 1590 Washer friction 2 15 GW 1588 Main Support 1 16 GW 1589 Washer square hole 1 17 GW 9925 Washer disc spring 1 18 1186231 Nut hex 3 8 16 1 Bumper OEM 290 254 1...

Page 36: ...Pin spiral 1 4 x 1 1 10 GW 1117A Depth Adjustment Bar Assembly Incl Refs 11 and 12 1 11 GW 9120 Retaining Ring tolerance ring 1 12 GW 9119 Knob Depth Regulator Incl Ref 11 1 13 710 3005 Hex Hd Screw 3 8 16 x 1 1 4 2 14 GW 1113 1 Bushing Drag Bar 2 15 712 0798 Hex Nut 3 8 16 2 16 GW 20775 Drag Bar 1 17 777S30649 Decal operating instructions 1 18 GW 9553 Hex Hd Screw self tapping 5 16 18 x 1 2 2 19 ...

Page 37: ... Washer External Tooth 5 16 4 4 GW 9902 Plain Washer 5 16 S A E 4 5 GW 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 GW 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 GW 9318 Clinch Pin 1 REF PART No No DESCRIPTION QTY REF PART No No DESCRIPTION QTY ...

Page 38: ...38 Notes ...

Page 39: ...Notes 39 ...

Page 40: ...r commercial institutional industrial rental or demonstrator purposes the COMMERCIAL warranty on the tiller is limited in duration to 90 days from the date of purchase USE WARRANTY This warranty does not apply to parts that have been damaged by accident alteration misuse abuse neglect improper maintenance vandalism theft fire water or damage because of peril or other natural disaster HOW TO OBTAIN...

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