Troy-Bilt PONY 664DM, Operator'S Manual

Page 1: ...ester meeting applicable local or state laws if any If a spark attester 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 d...

Page 2: ... future reference please copy the model number and the serial number of the equipment in the space below O _II__IpD m _ TROY BILT LLC P O BOX 361131 www troybilt com CLEVELAND OH 44136 330 558 7220 866 840 6483 Copy Model Number Here Copy Serial Number Here ENGINEINFORMATION The engine manufacturer is responsible for all engine related issues with regards to performance power rating speci fication...

Page 3: ...oses If in doubt contactyour telephoneor utility company 6 Warning Handlefuel with care it is highly flammableand itsvaporsareexplo sive Takethe 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 engineto cool for several minutes before adding fuel c Keepmatches cigarettes ...

Page 4: ... port speeds on hard or slippery surfaces Look behind and use care when backing up 17 Do not operatethe tiller on a slope that is too steepfor safety When on slopes slow down and makesure you have good footing Never permit the tiller to freewheel down slopes 18 Neverallow bystanders nearthe unit 19 Only use attachments and acces sories that areapproved by the tiller manufacturer 20 Usetiller attac...

Page 5: ... the Parts List pagesfor decal clean and legibleat all times Contactyour locations and part numbers local service dealer or the factory for ControlDescri Tine Warning on right side of hoodflap StartingStabilization on top of engine or fuel tank OperatingInstructionsand WarningMessages OperatingSymbols Various symbols shown here with word descriptions maybe usedon the tillerandengine FAST SLOW STOP...

Page 6: ...TS LIST Fig Ref Qty Description 1 2 3 8 16 x 1 HexHd Screw 2 1 KeyedWasher 3 1 Wheel GearLever Knob 4 1 Height Adjustment Flange Screw SeeFigure 2 1A 5 2 3 8 FlatWasher 6 2 10 Lockwasher 7 2 3 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 PlasticTie Strap 2 not used Tools Materials Needed for Assembly 1 3 8 open endwrench 1 7 16 open endwrench elec...

Page 7: ...Clutch Control levers J Figure2 7 to the handlebar Figure 2 5 Carefully unwrap WheelGear LeverandmovelevertoDISENGAGE bars to roll the tiller off the platform NOTE The Wheel GearLever will be installed later in this procedure IMPORTANT Usethe DISENGAGE posi tion only when the engine is not running Beforestarting the engine the Wheel Gear Lever must be placed inthe ENGAGE position see Section 3 for...

Page 8: ...oil level check hole N Figure2 11 d Reinstall and tighten securely the gear oil fill plug M Figure2 10 STEP 6 ATTACHWHEEL GEAR LEVER 1 Insert the Wheel GearLever P Figure 2 12 up through the slot in the control panelthat is labeled WHEELGEAR 2 Insert two 10 32 x 1 2 round head screws down through the marks on the control paneldecal and securely attach the wheel gear mounting bracket using two 10 I...

Page 9: ...w inchesforward or back ward Moving the tiller helps to align the shift mechanismwith the transmission wheel drive gears To shift to DISENGAGE freewheel movethe 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 engagementof forward drive to the ...

Page 10: ...e found in the Operation Section of this manual HANDLEBAR HEIGHT ADJUSTMENT The handlebarheight is adjustableto four different settings Set the handlebar height to a comfortable setting but keep in mind that the handlebarswill be lower when the tines are engagedin the soil ToAdjustthe HandlebarHeight F Figure3 3 Handlebarheightadjustment 1 Stop the engine wait for all parts to stop moving and then...

Page 11: ...ever Figure4 1 Locationof main tiller controls STARTINGANDSTOPPING THE ENGINE To help prevent serious personal injury or damageto equipment Before starting engine put Wheel Gear Lever in ENGAGE position Before starting engine put Forward Clutch Control levers and Reverse ClutchControl in neutral disengaged positionsby releasing controls Never run engine indoors or in enclosed poorly ventilated are...

Page 12: ...l be recharged during engine operation Makesure the battery cells are filled to the UPPERLEVELline 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 Beforestarting engine cover the terminal on the loose end of the positive cable with the insulated boot and secure it in place with electrical tape to prevent elec...

Page 13: ...ob Figure4 3 Raise tines offgroundand look behindwhen movingin reverse 6 To Turn the Tiller Around a Practiceturning the tiller in a level open area Bevery careful to keep your feet and legs awayfrom the tines b To makea turn reducethe engine speed andthen lift 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 handle...

Page 14: ...l often results in large hardclumps of soil that can interfere with planting If time permits wait a day or two after heavyrains 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 makingfootprints in the freshly tilled soil Footprintscaus...

Page 15: ...equired lubrication Keepthe engine oil level at the full point at all times A Tilling up anddownslopes To keepsoil erosion to a minimum be sure to add enough organic matter to the soil so that it has good moisture holding texture andtry to avoid leaving footprints or wheel marks When tilling vertically try to makethe first pass uphill as the tiller digs more deeply going uphill than it does down h...

Page 16: ...ngvehicle so that the the planting season ramp angle is as flat as possible the less incline to the ramp the better LOADING AND UNLOADING Turnthe vehicle s engine off and apply THETILLER its parking brake Loading and unloading the tiller into a vehicle is potentially hazardousand we don t recommenddoing so unlessabso lutely necessary as this could result in personal injuryor propertydamage However...

Page 17: ... maintenance program After every 10 operating hours oil or grease the lubrication points shown in Figure5 1 as described below Usea good quality lubricating oil 30 weight engine oil is suitable anda good quality general purpose grease grease that has a metal lubricant is preferred if available Removewheels clean wheel shaft A Figure5 1 andapply thin coating of greaseto shaft Greaseback front and s...

Page 18: ...d temperatures can result in severedamage 4 Removethe transmission gearoil level A To CheckTransmissionGear Oil Level 1 Checkthe gear oil level when the trans mission is cool Gearoil will expand in warm operating temperaturesand this expansion will provide an incorrect oil level reading 2 To check the gear oil level and to add oil if necessary refer to STEP5 Check GearOil Level in Transmission in ...

Page 19: ...f continuous operation SPARKPLUGSERVICE Running the enginewhen it is low on oil will quickly ruin the engine It is recommendedthat you changethe motor oil after every 10 hours of opera tion andeven sooner when operating in Owner s Manual extremely dirty or dusty conditions Refer to the separateEngineOwner s Manual In some areas local law requires using for detailed service instructions resistor sp...

Page 20: ...ons 4 On electric start units follow Battery Storage instructions in this Section 5 Store unit in a clean dry area 6 Neverstore the tiller with fuel in the fuel tank in an enclosedarea where gas fumes could reach an openflame or spark or where ignition sources are present spaceheaters hot water heaters furnaces etc BOLOTINES The tines will wear with use and should be inspected at the beginning of ...

Page 21: ... check for cracks cuts or frayed edges A belt in poor condition should be replaced Tension on a newforward clutch belt C Figure5 8 should bechecked after the Figure5 9 Reverse clutchbelt D Right side view no belt cover Figure 5 10 Location offorward clutch cable spring E andforward cableadjuster F 2 1 2 first two 2 hours of operation and after every ten 10 hours of operation Figure5 11 Correct spr...

Page 22: ... A Figure5 12 a few turns 3 Movecable adjuster B Figure5 12 downward for more belt tension see Figure5 12 4 Handtighten the jam nuts and pull the ForwardClutch Control leversup against the handlebar Measurethe spring coil Figure 5 11 The extendedlength of the coil should be2 1 2 Repeatthis proce dure until the extendedspring length is correct 5 Tighten both jam nuts securely Checking andAdjustingR...

Page 23: ...Figure5 18 awayfrom engine out from underthe belt guide D and completely off the pulley 6 Slip the belt off the front of the trans mission pulley F Figure5 19 7 Work the belt out from betweenthe pulley and the frame around the trans mission cover spring then up and out of the machine InstallingForwardClutchBelt 1 Stop engine allow it to cool and dis connect spark plug wire before working nearbelts...

Page 24: ...art models 2 Remove belt cover Figure5 13 by removingtwo flange Iocknuts 3 Pull the reverseclutch belt downward 2 Install the forward clutch belt see Installing Forward Clutch Belt in this section before installing reversebelt IMPORTANT The reversebelt has a V shape When installing the belt make sure that the widest flat side of the belt rides againstthe reverseidler pulley N Figure 5 22 andtransm...

Page 25: ... the frame of the unit with the dead battery Failureto use this procedure could cause sparking and the gas in either battery could explode BatteryRemoval and Installation When removing and installing the battery disconnect and connect the cables in this order to avoid sparking 1 To remove the battery first disconnect the negative cable from the grounding screw on the back of the battery bracket po...

Page 26: ...dthrottle control cable recoil start model Improper useof controls ForwardClutch Misadjustedforward clutchcontrol cable ReverseClutch Misadjustedclutch controlcable Worn or brokenclutch belt s 4 Internal transmissionwearor damage 5 Bolt and keyloose intransmissionpulley 6 1 Wheelmountinghardwaremissing 2 Bolt and keyloose intransmissionpulley 3 Internal transmissionwearor damage 4 Misadjustedwheel...

Page 27: ...hours 5 Every 30 operating hours 6 More frequently in dusty or dirty conditions 7 SeeEngine Owner s Manual for service recommendations 8 Whichevertime interval occurs first TILLERATTACHMENTS The attachments listed below are availablefor your tille Contactyour authorized dealeror the factory for current information BUMPER MODEL0EM 290 254 The tubular steel bumper helpsto protect the enginefrom dama...

Page 28: ...I Models 664D E666M HANDLEBARASSEMBLY and CONTROL LEVERS See page30 I I Ref 47 for j attachment sc ewl J 2 35 21 35 2 COVER ...

Page 29: ...Washer Plain flat 3 8 S A E 2 HexLocknut 3 8 16 2 Cable Forward Clutch Control 1 Wheel GearControl and CableAssy Incl Refs 14 15 19 21 22 23 1 Knob Wheel GearControl Lever 1 REF PART No No DESCRIPTION QTY 15 1186211 16 710 0216 17 736 0169 19 725 0157 21 1114748 22 1100240 23 1186208 24 GW 9390 25 1918840 35 GW 9853 36 GW 20806 42 710 0599 Hex Nut 5 16 24 2 Hex Hd Screw 3 8 16 x 3 4 2 Lockwasher 3...

Page 30: ...66M 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 ForwardClutchCable page28 Ref 10 53 54 26_ 30 ...

Page 31: ... tapping Screw 10 32 x 1 2 4 REF PART No No DESCRIPTION QTY 27 GW 20339 28 712 0267 29 1186329 30 1916797 31 1916796 35 710 0805 36 777120942 37 1918774 38 GW 90063 39 710 3037 40 736 0275 41 1918846 42 GW 55088 43 736 0119 44 712 0267 45 1917746 46 1918744 47 1767754 48 1916727 49 712 3000 50 GW 9090 51 710 0347 52 712 0158 53 1754128 54 736 0463 55 714 04029 56 710 0539 Guard Belts Pulleys 1 Hex...

Page 32: ...over 1 Transmission CaseAssy 1 Plug 1 Mounting Plate Wheel Clutch Cable 1 Oil Seal Tiller Shaft 2 Hex FlangeScrew 5 16 18 x 5 8 2 REF PART No No DESCRIPTION QTY 13 GW 20873 14 GW 1129 1 15 1915089 16 GW 1115 17 GW 1124 2 18 GW 90063 19 1915087 21 736 0169 22 710 0216 Tiller Housing Cover left side 1 Gasket Tiller Housing Cover 010 fits all covers A R Screw Kit Incl three 1 4 20 x 7 8 Self Sealing ...

Page 33: ... two GW 1224 1 two 1224 2 and one GW 1224 3 A R REF PART No No DESCRIPTION QTY INPUTPINIONSHAFT GEARASSEMBLY 6 7 GW 9572 GW 9944 8 1108841 9 1916522 10 GW 1440 11 721 04044 12 1113527 13 GW 9953 14 GW 9428 15 GW 9677 16 GW 20791 17 GW 20792 18 GW 9093 19 GW 20799 20 GW 9517 HexHd Screw 5 16 24 x 1 1 8 1 Washer Disc Spring concave surface faces pulley 1 Key 3 16 sq x 1 1 2 1 Transmission Drive Pull...

Page 34: ... thick A R Shim as above but 010 thick A R Bushing 2 Wheel Shaft Incl Ref 6 1 Hi Pro Key 1 4 x 1 5 16 1 Wheel Drive Worm Gear cast iron 1 Shim between key and gear 1 016 I D x 1 468 0 D x 062 Thick 1 REF PART No No DESCRIPTION QTY 9 GW 20712 10 611 04002 11 GW 1442 12 GW 9055 13 721 04034 14 GW 20700 15 710 3013 16 741 3037 17 711 04080 18 GW 1104 19 GW 20913 Wheel Drive Clutch cast iron 1 Eccentr...

Page 35: ...lo Tine single Left hand tine used on right side of tiller Incl two ea Refs 1 9 and 10 8 8 Tine Holder For left and right sides 2 Bolo Tine ReplacementSet Incl eight ea right hand and left hand tines and sixteen ea Refs 1 and 3 1 712 0375 710 3096 GW 1270 1A 1902154010 1901118 REF NO 9 10 11 12 13 PART No DESCRIPTION QTY GW 2475 1 GW 2475 2 GW 10802 712 3017 736 0169 GW 9380 GW 9338 1917487 Custom...

Page 36: ...666M ROW MARKER ATTACHMENT 9 2 m 8 8 See Detail A DETAIL A ROWMARKERATTACHMENT 0EM 290 257 Complete Attaches to FurrowerAttachment MAIN SUPPORT YOKE ASSEMBLY PART 1904522001 BUMPER ATTACHMENT 19 20 BUMPER 0EM 290 254 ...

Page 37: ...ws Ref 6 one GW 1596 nut bar Ref 7 two GW 9828 hex nuts Ref 8 two 1100135 screws Ref 9 1 REF PART No No DESCRIPTION QTY RowMarkerMain Support YokeAssembly Part 1904522001 10 1186349 Screw hexflangedlocking 11 GW 1593 12 GW 1592 13 GW 1591 14 GW 1590 15 GW 1588 16 GW 1589 17 GW 9925 18 1186231 3 8 16 x 1 1 2 1 Stop Bar 1 Yoke 1 Tube Key square 1 Washer friction 2 Main Support 1 Washer square hole 1...

Page 38: ...1 1 10 Depth Adjustment Bar Assembly Incl Refs 11 and 12 1 710 0169 GW 2527 1186328 712 0291 710 0597 GW 9384 GW 9534 1185469 GW 1117A REF PART No No DESCRIPTION QTY 11 GW 9120 12 GW 9119 13 710 3005 14 GW 1113 1 15 712 0798 16 GW 20775 17 777S30649 18 GW 9553 19 710 0599 Retaining Ring tolerance ring 1 Knob Depth Regulator Incl Ref 11 1 Hex Hd Screw 3 8 16 x 1 1 4 2 Bushing Drag Bar 2 Hex Nut 3 8...

Page 39: ...9902 GW 9824 1900773001 1900774001 1900772001 Furrower Blade 1 Carriage Bolt 5 16 18 x 3 4 4 Star Washer ExternalTooth 5 16 4 Plain Washer 5 16 S A E 4 Wing Nut 5 16 18 4 Hiller Wing left 1 Hiller Wing right 1 Blade Mounting Bracket 1 REF PART No No DESCRIPTION QTY 9 GW 9725 10 1100243 11 1186231 12 GW 9318 Carriage Bolt 3 8 16 x 1 1 2 2 Lockwasher 3 8 plated 2 Hex Nut 3 8 16 plated 2 Clinch Pin 1...

Page 40: ...M 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: ...ding screw red wire wire assy w connector to engineground shut off greenwire plastic protector tube wire terminal 1 REF PART No No DESCRIPTION QTY 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1917262 686 04024 710 0599 712 3006 725 0157 725 0267 725 1706 736 0119 736 0147 736 0607 GW 2614 96510 96514 97020 9853 777S30648 Ground Wire Assy shut off 1 Battery BracketAssembly Pony 1 Self tapping Screw 1...

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Page 44: ...nd conditions If used for commercial institutional industrial rental or demonstrator purposes the warranty on the tiller is limited in duration to 90 days from the date of purchase 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...