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Troy-Bilt 650 Lawn Mower User Manual

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2. 1 piece with integral single lead 9 1916522 Transmission Drive Pulley 1 work hardened front worm and 10 GW 1440 Support Washer 1 integral six lead work hardened 11 1983632 Oil Seal Input Pinion Shaft 1 rear worm Also includes pressed 12 1113527 Retaining Ring external 1 on GW 1714 and GW 9301 1 13 GW 9953 Thrust Wasfligr n ras 2 5 GW 1224 1 Shim Rear Bearing Cap 010 thick 14 GW 9428 BUSHING sese 1 see Note below A R 15 GW 9677 Set Screw 5 16 18 x 3 8 1 5 GW 1224 2 Shim same as above but 030 thick 16 GW 20791 Input Pinion steel shaft 1 see Note nace A R 17 GW 20792 Input Pinion 1 5 GW 1224 3 Shim same as above but 005 thick 18 GW 9093 Retaining Ring external l 1 E000 ots A R 19 GW 20799 Pinion Assy Incl one each Refs 16 GW 1325C Shim Set Incl two GW 1224 1 two dM arid 18 iaa A R 1224 2 and one GW 1224 3 A R 20 GW 9517 Retaining Ring internal 1 NOTE Shim between drive shaft rear bearing and rear bearing cap to achieve 5 to 10 thousandths of an inch 005 010 end play on drive shaft A R As Required Specify GRADE 5 if ordering part locally Model 664D WHEEL SHAFT ECCENTRIC SHAFT and TILLER SHAFT
3. HILLER FURROWER ATTACHMENT HILLER FURROWER OEM 290 251 Viewed from front of tiller REF PART REF PART No No DESCRIPTION QTY No No DESCRIPTION QTY 1 1900771001 Furrower Blade 1 9 GW 9725 Carriage Bolt 3 8 16 x 1 1 2 2 2 1186098 Carriage Bolt 5 16 18 x 3 4 4 10 1100243 Lockwasher 3 8 plated 2 3 1177548 Star Washer External Tooth 5 16 4 11 1186231 Hex Nut 3 8 16 plated 2 4 GW 9902 Plain Washer 5 16 A E 4 12 GW 9318 Clinichi Pita n ctis 1 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 p TROY BILT TILLER LIFETIME LIMITED WARRANTY WHAT PRODUCT All Troy Bilt branded rear tine walk behind tillers with gear drive transmissions IS COVERED 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 Troy Bilt LLC will at its option repair or replace any part found to be defective in material BY THIS WARRANTY or workmanship without charge for parts and labor This limited lifetime warranty also applies to non powered attachments and accessories Powered attachments and accessories are warranted separat
4. Sa E ee 35804 OSES 8g 29 CTI EDU 30 Warrany Information s srs ss ssip raas 2254 b u boda REES oY Rae ees Back Cover FINDING MODEL NUMBER This Operator s Manual is an important part of your new Rear tine Tiller It will help you assemble prepare and main tain the unit for best performance Please read and understand what it says Before you start assembling your new equipment please locate the model plate on the equipment and copy the infor mation from it in the space provided below This information is very important if you need help from our Customer Support Department or an authorized dealer You can locate the model number by looking at the rear surface of the tine shield 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 Copy Model Number Here They ey LLC Copy Serial Number Here OTROV BHT BOX 361131 py Serial www troybilt com CLEVELAND OH 44136 330 558 7220 866 840 6483 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 rately with your unit for more information CALLING CUSTOMER SUPPORT If you have difficulty assembling this product or have any questions regar
5. 16 1901118 Bolo Tine Replacement Set Incl eight 11 GW 9380 Clevis Pin 312 x 1 3 4 2 ea right hand and left hand tines 12 GW 9338 HitGhiPlpi idsi nt 2 and sixteen ea Refs 1 and 3 1 13 1917487 Wheel and Tire Assembly 2 Specify GRADE 5 if ordering part locally Model 664D ROW MARKER ATTACHMENT ROW MARKER ATTACHMENT OEM 290 257 e Complete Attaches to Furrower Attachment DETAIL A MAIN SUPPORT YOKE ASSEMBLY PART 1904522001 BUMPER ATTACHMENT 20 d BUMPER OEM 290 254 Model 664D ROW MARKER ATTACHMENT amp BUNPER ATTACHMENT REF PART REF PART No No DESCRIPTION QTY No No DESCRIPTION QTY Row Marker Attachment option OEM 290 254 Row Marker Main Support amp Yoke Assembly Part 1904522001 1 1904522001 Main Support amp Yoke Assy 10 1186349 Screw hex flanged locking complete Incl Ref No s 3 816 x 1 1 2 1 10 11 12 13 14 15 16 17 amp 18 1 11 GW 1593 StopBar 1 2 GW 1594 Marker Blade blade only 1 12 GW 1592 YOke 1 3 1904524001 Marker Arm main arm 1 13 GW 1591 Tube 5 1 4 1904523001 Marker Arm extension arm with 14 GW 1590 Washer frition 2 Stop Din an 1 15 GW 15
6. 1 25 1909404 Forward Clutch 1 54 736 0463 Flat 1 4 1 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 Model 664D TRANSMISSION HOUSING COVERS SEALS GASKETS PLUGS NOTE 1 These screws are a special sealing screw that cannot be reused without risking the loss of transmission oil If these screws are loosened or removed they must be replaced with new screws See Note 1 17 24 16 A XS die DM 15 7 BN REF PART REF PART No No DESCRIPTION QTY No No DESCRIPTION QTY 1 GW 9621 Oil Seal Double Lip Wheel Shaft 2 14 GW 1129 1 Gasket Tiller Housing Cover 010 2 1105620 Pipe Plug 1 4 2 fits all coVer A R 3 721 04001 Seal Transmission Bore 1 15 1915089 Screw Kit Incl three 1 4 20 x 7 8 4 1186329 Hex Flange Screw 5 16 18 3 4 6 Self Sealing Screws A R 5 1983632 Oil Seal Input Pinion Shaft 1 16 GW 1115 Rear Bearing 1 6 GW 11513 Transmission Cover Incl four Ref 18 17 GW 1124 2 Gasket Rear Bearing Cap 010 and two ea Refs 21 amp 22
7. 1 TMK 0 GW 20694 Gasket Transmission Top Cover 1 18 GW 90063 Hex Flange Screw 5 16 18 x 1 4 8 GW 20893 Transmission Case Assy Incl Tube 19 1915087 Screw Kit Incl five 1 4 20 x 5 8 and Rear HOUSING 1 Self Sealing Screws A R 9 GW 9467 UID REPRISE 1 21 736 0169 Lockwasher 3 8 2 10 GW 20889 Mounting Plate Wheel Clutch Cable 1 22 710 0216 Hex Hd Screw 3 8 16 x 3 4 2 11 GW 97073 Oil Seal Tiller 2 12 1186328 Hex Flange Screw 5 16 18 5 8 2 13 GW 20873 Tiller Housing Cover left side 1 Specify GRADE 5 if ordering part locally A R As Required Model 664D 5 DRIVE SHAFT INPUT PINION SHAFT and GEAR ASSEMBLIES MAIN DRIVE SHAFT ASSEMBLY INPUT PINION SHAFT amp GEAR ASSEMBLY REF PART REF PART No No DESCRIPTION QTY No No DESCRIPTION QTY MAIN DRIVE SHAFT INPUT PINION SHAFT amp GEAR ASSEMBLY 1 GW 1714 Bearing Tapered Roller with Race 1 6 GW 9572 Hex Hd Screw 5 16 24 x 1 1 8 1 2 GW 20718 Spur Gear 7 GW 9944 Washer Disc Spring concave 3 GW 9301 Key 3 16 sq x 1 surface faces pulley 1 4 GW 11603 Main Drive Shaft Drive shaft is one 8 1108841 Key 3 16 sq x 1 1 2
8. M Figure 2 10 STEP 6 ADD MOTOR OIL TO ENGINE The tiller is shipped without oil in the engine crankcase IMPORTANT Do not start the engine without first adding motor oil 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 notch is engaged This places the tines in the travel position STEP 7 ATTACH WHEEL GEAR LEVER 1 Insert the Wheel Gear Lever P Figure 2 12 up through the slot in the control panel that is labeled WHEEL GEAR 2 Insert two 10 32 x 1 2 round head screws down through the marks on the control panel decal and securely attach the wheel gear mounting bracket using two 10 lockwashers and 710 32 nuts Figure 2 13 Attach wheel gear cable and reverse clutch cable with cable ties S 3 Usea small board to tap the Wheel Gear Lever knob securely onto the lever 4 Secure the wheel gear cable and the reverse clutch control cable to the left side handlebar with two plastic ties S Figure 2 13 located about two feet apart Snip off any excess tie length with scissors STEP 8 CHECK AIR PRESSURE IN TIRES Use a tire pressure
9. 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 and acces sories when recommended 21 Never operate the tiller without good visibility or light 22 Never operate the tiller if you are tired or under the influence of alcohol drugs or medication 23 Operators shall not tamper with the engine governor settings on the machine the governor controls the maximum safe operating speed to protect the engine and all moving parts from damage caused by overspeed Authorized service shall be sought if a problem exists 24 Do not touch engine parts which may be hot from operation Let parts cool down sufficiently 25 The battery on electric start model tillers contains sulfuric acid Avoid contact with skin eyes or clothing Keep out of the reach of children Antidote External Contact Flush imme diately with lots of water Antidote Internal Drink large quantities of water or milk Follow with milk of magnesia beaten eggs or vegetable oil Call a doctor immediately Antidote Eye Contact Flush with water for 15 minutes Get prompt medical attention 26 Batteries produce explosive gases Keep sparks flame and smoking materials away Ventilate when charging batteries or when using a battery in an enc
10. Clutch Control put the Wheel Gear Lever in the ENGAGE position see WARNING below 2 Pull up and hold one or both of the levers against the handlebar grips to engage the wheels and tines 3 Release BOTH levers to disengage stop the wheels and tines All forward motion will stop the engine will continue to run A WARNING Never engage the wheels and tines with the Forward Clutch Control or the Reverse Clutch Control unless the Wheel Gear Lever is in ENGAGE Engaging the Forward Clutch Control or the Reverse Clutch Control when the wheels are not engaged could allow the tines to rapidly propel the tiller forward or backward Failure to follow this warning could result in personal injury or property damage 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 A WARNING Use extreme caution when reversing or pulling the machine towards you Look behind to avoid obstacles e Never attempt to till in reverse Failure to follow this warning could result in personal injury or property damage To Operate the Reverse Clutch Control 1 Put the Wheel Gear Lever in the ENGAGE position see the WARNING statement on previous page 2 Stop all tiller motion by releasin
11. PULLEYS BELTS BELT COVER REF PART REF PART No No DESCRIPTION QTY No No DESCRIPTION QTY 1 Engine standard recoil start 1 26 1900396 Self tapping Screw 10 32 x 1 2 4 xd Engine electric start 1 27 GW 20339 Guard Belts Pulleys 1 2 1917326 Bracket Clutch Cable 1 28 712 0267 Hex Nut 5 16 18 4 3 736 0119 5 1 6 6 29 1186329 Hex Flange Screw 5 16 18 x 3 4 4 4 710 0107 Hex Hd Screw 5 16 24 x 1 2 2 30 1916797 Engine Support Bracket left side 1 5 777830651 Decal Hot Surfaces Belt Warning 1 31 1916796 Engine Support Bracket right side 1 6 1917139 Cover Incl Ref 5 1 35 710 0805 Hex Hd Screw 5 16 18 x 1 1 2 5 7 712 3004 Flange Lock Nut 5 16 18 2 36 711120942 Decal Stabilization 1 8 1108841 Key 3 16 x 1 1 2 aerisire 2 37 1918774 Mounting 2 9 GW 1138 1 SHIM aa EH NDN 1 38 GW 90063 Hex Flange Screw 5 16 18 x 1 4 10 1916520 Pulley Engine Drive 1 39 710 3037 Hex Hd Screw 5 16 18 x 2 1 4 1 11 GW 9944 Belleville Washer 2 40 736 0275 Flat Washer 5 16 1 12 GW 9572 Hex Hd Screw 5 16 24 x
12. 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 is loos ened and moved to one side 5 Loosely attach the handlebars to the mounting tabs with two 3 8 16 x 1 screws heads of screws go to inside of tabs 3 8 flat washers and 3 8 16 lock nuts 0 Figure 2 4 Figure 2 4 Attach handlebars 6 On electric start units reattach the height adjustment bracket A Figure 2 2 Tighten both screws securely Make sure the handlebar cross brace B Figure 2 3 is under the bracket 7 Move the handlebars up or down to align the threaded hole in the cross brace with one of the four slots in the curved height adjustment bracket Place the keyed washer E Figure 2 3 on the flange head height adjustment screw F with the raised keys edges of the washer facing down 8 Thread the height adjustment screw F Figure 2 3 into the hole in the handle bar cross brace making sure that the raised keys on the washer fit into the slot on the height adjustment bracket Tighten the height adjustment screw securely Next securely tighten the two screws and nuts in the ends of the han dlebar M Figure 2 3 9 To remove the tiller from its shipping platform first carefully unwrap the wheel gear cable with attached lever see Figure 2 5 from around the chassis Move the Wheel Gear Lever G to the DISENGAGE position this allows the wh
13. a good quality lubricating oil 30 weight engine oil is suitable and a good quality general purpose grease grease that has a metal lubricant is preferred if available e Remove wheels clean wheel shaft A Figure 5 1 and apply thin coating of grease to shaft e Grease back front and sides of depth regulator lever B Figure 5 1 e Remove tines clean tine shafts C Figure 5 1 and inspect for rust rough spots or burrs especially around holes File or sand smooth and coat ends of shaft with grease e Qil the threads the handlebar height adjustment screw D Figure 5 1 e Cil the threads on the handlebar attach ing screws E Figure 5 1 CHECK HARDWARE At least every 10 operating hours check the unit for loose or missing hardware screws bolts nuts hairpin cotters etc Loose or missing hardware can lead to equipment failure poor performance or oil leaks Be sure to check the three end cap mounting screws located at the rear of the transmission Figure 5 2 Lift the tine flap to service those screws Figure 5 2 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 Before inspecting cleaning or servicing the machine shut off engine wait for all moving parts to come to a compl
14. carton and remove the carton 2 Cutthe large plastic tie strap that secures the transmission tube to the ship ping pallet Leave the handlebars on top of the tiller to avoid damaging any cables 3 A bag with loose hardware is inside the literature envelope Check the con tents against the following list and Figure 2 1 Contact your local dealer or the factory if any items are missing or damaged NOTE For electric start units a second hardware bag is located near the battery 4 The tiller is heavy You should not attempt to remove it from the shipping platform until instructed to do so in these Assembly steps 2 Assembly HARDWARE BAG PARTS LIST Fig Ref Qty Description 1 2 3 8 16 1 Hex Hd Screw 2 1 Keyed Washer 3 1 Wheel Gear Lever Knob 4 1 Height Adjustment Flange Screw See Figure 2 1A 5 2 3 8 Flat Washer 6 2 10 Lockwasher 7 2 3 8 16 Nylock Lock Nut 8 2 10 32 x 1 2 Round Hd Screw 9 2 f10 32Nut 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 Clean oil funnel 1 Clean high quality motor oil Refer to the separate Engine Owner s Manual for
15. 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 Cutting Edge of Tine Cutting Edge of Tine Figure 5 7 Removing a tine assembly A WARNING Follow the belt adjustment instructions carefully An incorrect adjustment could result in the clutch control mechanism engaging too soon This could cause loss of tiller control and result in per sonal injury or property damage CHECKING AND ADJUSTING TENSION ON CLUTCH BELTS Maintaining correct belt tension is impor tant to good tilling performance and long belt life A loose belt will slip on the engine and transmission pulleys and cause the tines and wheels to slow down or stop even though the engine is running at full speed A loose belt will also result in premature belt wear While checking belt tension also check for cracks cuts or frayed edges A belt in poor condition should be replaced Tension on a new forward clutch belt C Figure 5 8 should be checked after the Figure 5 8 Forward clutch belt C Left side view no belt cover Figure 5 9 Reverse clutch belt D Right side view no belt cover first two 2 hours of operation and after every ten 10 hours of operation The reverse clutch belt D Figure 5 9 because it is used mo
16. dig deeper this takes weight off the wheels reduces traction and causes the tines to try and propel the tiller A WARNING Do not push down the handlebars to try to make the tiller till more deeply This prevents the wheels from holding the tiller back and can allow the tines to rapidly propel the tiller forward which could result in loss of control property damage or personal injury 5 For reverse motion of the wheels and tines a Look behind and exercise caution when operating in reverse Do not till while in reverse b Stop all forward motion before reversing Lift the handlebars with one hand until the tines are off the ground and then pull the Reverse Clutch Control knob out to engage reverse motion see Figure 4 3 To stop reverse motion let go of the Reverse Clutch Control knob Figure 4 3 Raise tines off ground and look behind when moving in reverse 6 To Turn the Tiller Around a Practice turning the tiller in a level open area Be very careful to keep your feet and legs away from the tines b To make a turn reduce the engine speed and then 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 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 Engin
17. four passes to thoroughly pulverize the soil e f the garden size will not permit lengthwise and then crosswise tilling then overlap the first passes by one half a tiller width followed by succes sive passes at one quarter width see Figure 4 8 e With planning you can allow enough room between rows to cultivate see Figure 4 9 Leave room for the hood width plus enough extra room for future plant growth Figure 4 6 Figure 4 7 o TES o imm Figure 4 8 lt lt ate alele 7 av Figure 4 9 Tilling Tips amp Techniques 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 To reduce tangling set the depth regu lator deep enough to get maximum chopping action as the tines chop the material against the ground Also try to till under crop residues or cover crops while they are green moist and tender While power composting try swaying the handlebars from side to side about 6 to 12 This fishtailing action often clears the tines of debris s f tangling occurs lift the tines out of the soil and run the tiller in reverse for a few feet This reversing action should unwind a good deal of debris f reversing the tiller doesn t c
18. gauge to check the air pressure in both tires Deflate or inflate both tires equally to 15 to 20 PSI pounds per square inch Be sure that both tires are inflated equally or the unit will pull to one side STEP 9 CHECK HARDWARE FOR TIGHTNESS Inspect the hardware on the unit and tighten any loose screws bolts and nuts IMPORTANT This completes assembly for recoil start tillers Read the rest of this Manual and the separate Engine Owner s Manual before operating the tiller Electric start models continue with the Assembly Steps 3 Features and Controls A 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 INTRODUCTION This Section describes the location and function of the controls on your tiller Refer to the following section Operation for detailed operating instructions Practice using these controls with the engine shut off until you understand the operation of the controls and feel confi dent with them IMPORTANT Refer to the separate engine manufacturer s Engine Owner s Manual for information about the controls on the engine WHEEL GEAR LEVER This lever A Figure 3 1 has two posi tions ENGAGE and DISENGAGE In the ENGAGE position th
19. leave it connected to the tiller so it will be recharged during engine operation Make sure the battery cells are filled to the UPPER LEVEL line with elec trolyte 2 f 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 tape to prevent electrical sparks 3 Putthe ignition key in the RUN position and then follow Steps 1 8 of Starting the Engine STOPPING THE ENGINE 1 To stop the wheels and tines release the Forward Clutch Control levers or the Reverse Clutch Control knob whichever control is engaged 2 To stop the engine on the recoil start model move the Engine Throttle Control Lever to the STOP position 3 To stop the engine on an electric start model move the ignition key to OFF IMPORTANT After stopping an electric start engine remove the ignition key from the switch to reduce the possibility of unauthorized starting of the engine OPERATING THE TILLER The following pages provide guidelines to using your tiller effectively and safely in various gardening applications Be sure to read Tilling Tips amp Techniques in this Section before you actually put the tines into the soil This is a traditional standard rotating tine tiller with forward rotating tines It operates compl
20. motor oil specifications and quantity required Adjustable wrenches may be used IMPORTANT Motor oil must be added to the engine crankcase before the engine is started Follow the instructions in this Assembly Section and in the separate Engine Owner s Manual NOTE LEFT and RIGHT sides of the tiller are as viewed from the operator s posi tion behind the handlebars STEP 2 ATTACH HANDLEBARS 1 On electric start units remove one screw and lockwasher from the curved Tro Boo 10 ET 11 190 Figure 2 1 Loose hardware shown in reduced size Figure 2 1A Handlebar height adjustment uses the flange head screw Figure 2 2 On electric start units move height adjustment bracket aside height adjustment bracket A Figure 2 2 loosen the second screw and swing the bracket to one side 2 Cutthe large plastic cable ties that secure the handlebar ends to the handle bar mounting tabs on the transmission top cover 3 Gently lift handlebar do not over stretch attached cable and place handle bar cross brace B Figure 2 3 in front of curved height adjustment bracket C Figure 2 3 Forward clutch control cable not shown for clarity Section 2 Assembly 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 M Figure 2 3 on the transmission top cover NOTE
21. 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 soil Footprints cause soil compaction that can hamper root penetration and contribute to soil erosion They can also plant unwanted weed seeds back into the freshly tilled ground Choosing correct wheel and tine speeds With experience you will find the just right tilling depth and tilling speed com bination that is best for your garden Set the Engine Throttle Control Lever to a speed to give the engine adequate power and yet allow it to operate at the slowest possible speed at least until you have achieved the maximum tilling depth you desire Faster engine speeds may be desirable when making final passes through the seedbed or when cultivating Selection of the correct engine speed in relation to the tilling depth will ensure a sufficient power level to do the job without causing the engine to labor Suggested tilling patterns When preparing a seedbed go over the same path twice in the first row then overlap one half the tiller width on the rest of the passes see Figure 4 6 When finished in one direction make a second pass at a right angle as shown in Figure 4 7 Overlap each pass for best results in very hard ground it may take three or
22. tension 5 Tighten both jam nuts securely 6 Reinstall the belt cover 7 Move the unit to an open area and test the reverse operation Repeat this proce dure if the unit does not respond when the reverse clutch is engaged FORWARD CLUTCH BELT REMOVAL AND REPLACEMENT The forward clutch belt K Figure 5 15 engages the engine pulley I and the transmission pulley J when either Forward Clutch Control Lever is pulled up against the handlebar This tightens the forward clutch cable G which causes the forward clutch idler pulley H to apply pressure to the forward clutch belt This causes the pulleys to turn for Forward movement Figure 5 15 Forward clutch control assembly VN 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 N T DEN Forward Clutch Cable Connection Figure 5 17 Removing 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 two nuts C Figure 5 13 and remove the belt cover 3 Move the reverse clutch belt B Figure 5 16 out of the way You do not nee
23. the Depth Regulator Lever up or down as needed 3 Clean the area around the oil dipstick or oil fill tube to prevent dirt from falling into the crankcase 4 On engines with an oil fill tube remove the filler cap add oil if required until it reaches the top of the tube and reinstall the filler cap 5 On engines with a dipstick remove it wipe it clean and reinstall it finger tight Remove the dipstick and check the reading Add oil if required to bring the level to the FULL mark Do not overfill B To Change the Engine Oil Change the engine oil as instructed in the separate Engine Owner s Manual AIR CLEANER SERVICE The engine air cleaner filters dirt and dust out of the air before it enters the carbure tor Operating the engine with a dirty clogged air filter can cause poor perfor mance and damage to the engine Never operate the engine without the air cleaner installed Inspect and service the air cleaner more often if 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 If the engine was originally equipped with a resistor spark plug use the same type
24. 1 1 8 2 41 1918846 Belt Guide PONY 2 13 710 3103 Hex Hd Screw 5 16 18 x 2 1 42 GW 55088 Pivot Bushing 2 14 1918731 Reverse Idler Arm 1 43 736 0119 Lockwasher 5 16 2 15 1916535 Pulley Reverse ldler 1 44 712 0267 Hex Nut 5 16 18 2 16 1107382 Flat Washer 5 16 2 45 1917746 Washer Shoulder 2 17 1916725 Belt Guide Wire Formed 1 46 1918744 Idler Arm Forward Tiller Direction 1 18 710 0117 Hex Head Screw 5 16 24 x 1 1 47 1767754 Screw self tapping 10 24 1 19 1917746 Washer Shoulder 1 48 1916727 Springs ac oem 1 20 GW 9929 Washer Flat 1 1 8 3 49 712 3000 Hex Locknut 5 16 18 1 21 1916728 Spring Reverse 1 50 GW 9090 Idler Pulley Forward 1 22 1916522 Transmission Pulley 1 51 710 0347 Screw 3 8 16 x 1 3 4 1 23 GW 1440 Support 1 52 712 0158 Hex Lock Nut 5 16 18 1 24 1918812 Reverse Clutch Belt 1 53 1754128 Screw 1 4 20 x 3 4
25. 26 GUID mc 2 16 710 0216 Hex Hd Screw 3 8 16 x 3 4 2 3 777120938 Decal Control Panel 1 17 736 0169 Lockwasher 3 8 2 3A 777005553 Decal Model Name Logo 1 19 725 0157 Cable Ties Plastic 2 4 1916784 Reverse Clutch Control Cable 1 21 1114748 Round Hd Screw 10 32 x 1 2 6 5 1186347 Height Adjustment Screw 1 22 1100240 Lockwasher 10 2 5A GW 9955 Washer Keyed 1 23 1186208 Hex Nut 10 32 2 6 1900475 Bracket Handlebar Height Adjustment 1 24 GW 9390 c 2 T 710 0514 Hex Hd Screw 3 8 16 x 2 25 1918840 Bail Forward Clutch Control Incl 8 136 3050 Washer Plain flat 3 8 S A E 2 two Ref 24 nee 1 9 712 3000 Hex Locknut 3 8 16 2 35 GW 9853 Sems Nut 4 10 1918791 Cable Forward Clutch Control 1 36 GW 20806 Bracket Bail Support 2 13 GW 9442 Wheel Gear Control and Cable Assy 42 710 0599 Hex Flange Screw self tapping Incl Refs 14 15 19 21 22 amp 23 1 1 4 20 c 1 2 iri 2 14 GW 9057 Knob Wheel Gear Control Lever 1 Specify GRADE 5 if ordering part locally Model 664D ENGINE SUPPORT BRACKETS PULLEYS BELTS BELT COVER Reverse Clutch Cable l Screw Ref 47 secures Forward Clutch Cable page 30 Ref 10 53 Model 664D ENGINE SUPPORT BRACKETS
26. 88 MainSupport 1 5 GW 9347 Hitch Pin incl in Hardware Pkg 16 GW 1589 Washer square 1 GW 1837 nee 1 17 GW 9925 Washer disc spring 1 6 6W 9 86 Thumbscrew 1 4 20 x 1 2 not 18 1186231 Nut hex 3 8 16 1 avail sep see hardware pkg 2 7 GW 1596 Nut Bar incl in hardware pkg Bumper OEM 290 254 GW 1837 1 19 1918749001 Bumper includes Ref 20 1 8 GW 9828 Nut hex 10 24 w attached start 20 777530653 Decal aution 1 washers not avail sep see 21 710 3073 Screw hex hd 5 16 18 x 2 1 4 hardware pkg 1 837 EIER 2 not avail separately 9 1100135 Screw round hd 10 24 x 1 not order 1918781 hardware kit 4 avail sep see hardware pkg 22 736 0119 Lockwasher 5 16 not avail GW 1 837 MR E 2 separately order 1 91 8781 ES GW 1837 Hardware Package includes one hardware kit 4 GW 9347 hitch pin Ref 5 two 23 712 0267 Nut hex 5 16 18 not avail GW 9786 thumbscrews Ref 6 separately order 1918781 one GW 1596 nut bar Ref 7 hardware kit 4 two GW 9828 hex nuts Ref 8 1918781 Hardware Kit Incl four each of two 1100135 screws Ref 9 1 Refs 21 22 and 23 1 Note Common hardware list
27. ASSEMBLIES TILLER SHAFT ASSEMBLY WHEEL SHAFT ASSEMBLY 5 Assembled E Internally 13 12 10 A Wheel Shaft Parts ECCENTRIC S Es SHAFT ASSEMBLY A Y 1 REF PART REF PART No No DESCRIPTION QTY No No DESCRIPTION QTY 1 GW 9621 Ol Seal i iiec teens 2 9 GW 20712 Wheel Drive Clutch cast iron 1 2 1909950 Retaining Ring heavy duty external 2 10 GW 20879 Eccentric Shaft 1 3 GW 1166 1 Shim 1 1 64 I D 062 thick A R 11 GW 1442 Pin Eccentric Shaft 1 GW 1166 2 Shim as above but 030 thick A R 12 GW 9055 1 GW 1166 3 Shim as above but 015 thick A R 13 GW 9622 Oll Seal iiie oret 1 GW 1166 4 Shim as above but 010 thick A R 14 GW 20700 Eccentric Shaft Lever 1 4 GW 1086 BUS MIN e 2 15 710 3013 Hex Hd Screw 1 4 20 x 1 2 1 5 GW 2494 Wheel Shaft Incl Ref 6 1 16 741 3037 Ball 2 6 GW 9373 Hi Pro Key 1 4 x 1 5 16 1 17 GW 20896 Tiller Shaft Incl Ref 18 1 7 GW 20914 Wheel Drive Worm Gear cast iron 1 18 GW 1104 Woodruff Key 1 4 x 1 1 4 1 8 GW 9935 Shim between key and gear 19 GW 20913 Tiller Drive Worm Gear bronze 1 1 016 I D x 1 468 0 D x 062 niea b 1 Specif
28. 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 A DANGER GASOLINE IS HIGHLY FLAMMABLE AND ITS VAPORS ARE EXPLOSIVE Follow gasoline safety rules in this manual see Section 1 and in the sepa rate Engine Owner s Manual Failure to follow gasoline safety instruc tions can result in serious personal injury and property damage 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 L 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 and the tiller and engine controls information in Section 3 Features and Controls 1 Complete the Pre Start Checklist on the previous page 2 Put the Wheel Gear Lever Figure 4 1 in the ENGAGE position 3 Put the Depth Regulator Lever in the travel position lever all the way down so that the tines are clear of the ground 4 Release all controls on the tiller 5 Put the Engine Throttle Control Lever Figure 4 1 in the FAST setting 6 On engines equipped with a fuel valve turn valve
29. HE OWNER S MANUAL e KNOW LOCATIONS AND FUNCTIONS OF ALL CONTROLS e KEEP ALL SAFETY DEVICES AND SHIELDS IN PLACE AND WORKING e NEVER ALLOW CHILDREN OR UNINSTRUCTED ADULTS TO OPERATE TILLER SHUT OFF ENGINE AND DISCONNECT SPARK PLUG WIRE BEFORE MANUALLY UNCLOG GING TINES OR MAKING REPAIRS e KEEP BYSTANDERS AWAY FROM MACHINE e KEEP AWAY FROM ROTATING PARTS e USE EXTREME CAUTION WHEN REVERSING OR PULLING THE MACHINE TOWARDS YOU A 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 It is recommended that you read this Section in its entirety before beginning assembly INSPECT UNIT Inspect the unit and carton for damage immediately after delivery Contact the carrier trucking company if you find or suspect damage Inform them of the damage and request instructions for filing a claim To protect your rights put your claim in writing and mail a copy to the carrier within 15 days after the unit has been delivered Contact us at the factory if you need assistance in this matter UNPACKING AND ASSEMBLY INSTRUCTIONS STEP 1 UNPACKING INSTRUCTIONS 1 Remove any cardboard inserts and packaging material from the carton Remove any staples from the bottom of the
30. ION Engine does not start I gt Spark plug wire disconnected Engine Throttle Control Lever incorrectly set Fuel tank empty Choke control if so equipped in incorrect position Stale gasoline Dirty air filter s Defective or incorrectly gapped spark plug Carburetor out of adjustment Misadjusted throttle control 10 Dirt or water in fuel tank Reconnect wire Put lever in FAST position Add fuel See Engine Owner s Manual Drain fuel and add fresh fuel Clean or replace filter s Inspect spark plug See Engine Service Dealer 9 See Engine Service Dealer 10 See Engine Service Dealer gt C2 h5 Engine runs poorly Defective or incorrectly gapped spark plug Dirty air filter s Carburetor out of adjustment Stale gasoline Dirt or water in fuel tank Engine cooling system clogged 1 Inspect spark plug see Engine Owner s Manual 2 Clean or replace see Engine Owner s Manual 3 See Engine Service Dealer 4 Replace with fresh gasoline 5 See Engine Service Dealer 6 Clean air cooling system see Engine Owner s Manual Engine overheats Engine does not shut off Engine cooling system clogged Carburetor out of adjustment Oil level is low Misadjusted throttle control cable recoil start model Clean air cooling area see Engine Owner s Manual
31. Move cable adjuster B Figure 5 12 downward for more belt tension see Figure 5 12 4 Hand tighten the jam nuts and pull the Forward Clutch Control levers up against the handlebar Measure the spring coil Figure 5 11 The extended length of the coil should be 2 1 2 Repeat this proce dure until the extended 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 muffler to cool down disconnect the spark plug wire and remove the ignition key on elec tric start models Figure 5 13 Belt cover 2 Remove the two nuts C Figure 5 13 and remove the belt cover 3 Reverse belt tension adjustments are done with the reverse clutch cable adjuster located on the left side of the machine near the engine D Figure 5 14 Use two 1 2 open end wrenches to loosen the two adjuster jam nuts E a few turns Move cable adjuster away from pulleys to increase reverse l belt tension Ems iu ma Figure 5 14 Reverse clutch cable adjuster Left side view with belt cover removed 4 Move the cable adjuster D Figure 5 14 away from the pulleys to increase belt
32. OBTAIN Warranty service is available with proof of purchase through your local authorized SERVICE service dealer To locate a dealer in your area consult your Yellow Pages or contact Troy Bilt LLC at P O Box 361131 Cleveland Ohio 44136 0019 1 866 840 6483 or log on to our Web site at www troybilt com 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 Any implied warranties including any implied warranty of merchantability or fitness for a particular purpose shall be limited in duration to the period of ownership by the original purchaser and a maximum of 90 days from the date of sale if the tiller is purchased for commercial or other non residential use Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts so the above exclusions or limitations may not apply to you This limited warranty gives you specific legal rights and you may also have other rights which vary from state to state For customer assistance contact your nearest authorized dealer or contact us at TROY BILT LLC P O Box 361131 Cleveland Ohio 44136 0019 1 866 840 6483
33. OTROY BILT Operator s Manual Rear tine Tiller Model 664D Pony 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 FROM NO 770 10597 12 2001 TABLE OF CONTENTS Content Page Calling Customer Support sess rb EXTR ndr eee 4 134 L2 40009204 8 4 2 Sale ccc CM 3 ncc D PEUT 6 Features and Controls sss uuruuu ba iad reru 11 2 12611552216001 ucc t ee DC 14 l ti 1 EMT 20 PUT Rees S10 2 T EE E 28 Troublesbhootlg adu eorom 65072605
34. See Engine Service Dealer Check oil level see Engine Owner s Manual See Engine Owner s Manual or Engine Service Dealer Wheels and Tines will not turn Improper use of controls Forward Clutch Misadjusted forward clutch control cable Reverse Clutch Misadjusted clutch control cable Worn or broken clutch belt s Internal transmission wear or damage Bolt and key loose in transmission pulley Review Sections 3 and 4 Adjust cable tension Section 5 Adjust cable tension Section 5 Check belts Replace parts as needed Section 5 Contact local dealer or the factory Tighten bolt check that key is in place Tines turn but wheels don t Wheel mounting hardware missing Bolt and key loose in transmission pulley Internal transmission wear or damage Misadjusted wheel gear cable Wheel Gear Lever not fully engaged Replace hardware Tighten bolt check that key is in place Contact local Dealer or the Factory See Wheel Gear Cable Adjustment Section 5 Engage lever see Section 3 Wheels Turn but Tines Don t Tine holder mounting hardware missing Internal transmission wear or damage Replace hardware Contact local Dealer or the Factory Poor tilling performance The furrower blade attaches to the back of the depth regulator assembly and is used to create rows trenches and ditches up to 8 deep depending on soil con
35. an 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 short for vertical tilling it may be necessary to till across the slope and create ter raced rows Terraces are rows that are cut into the side of a slope creating a narrow but flat area on which to plant e On a long slope you can make several terraces one below the other Terraces should be only 2 to 3 feet wide Digging too far into the side of the slope will expose poor subsoil that is unproductive for plants To create a terrace start at the top of the slope and work down Go back and forth across the first row as shown in Figure 4 10 Each succeeding lower terrace is started by walking below the terrace you re preparing For added stability of the tiller always keep the uphill wheel in the soft newly tilled soil Do not till the last 12 or more of the downhill outside edge of each terrace This untilled strip helps prevents the ter races from breaking apart and washing downhill It also provides a walking path between rows 6 oE isa o 12 UNTILLED o ES REPEAT Figure 4 10 C Tilling across slopes without using terraces f vertical or terracing gardening aren t practical for you then you can till later ally acros
36. ans mission pulley F Figure 5 19 Now slip the top half of belt under the belt guide D Figure 5 18 and onto the large groove of engine drive pulley L Figure 5 19 5 Reconnect the forward clutch cable to the correct hole in the idler arm bracket as shown in Figure 5 17 NOTE Be sure to run the reverse clutch cable on the pulley side of the cover support brackets G Figure 5 21 Figure 5 21 Correct forward clutch cable positioning IMPORTANT Belt must be installed on the inside of the belt guide H Figure 5 21 6 Reinstall the reverse clutch belt Insert the bottom of the belt into the frame then 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 on the belt and roll it onto the large forward most groove of the trans mission pulley P Figure 5 20 7 Reinstall the belt cover 8 Test for correct tension on the forward clutch belt see Checking Forward Belt Tension REVERSE CLUTCH BELT REMOVAL AND REPLACEMENT Figure 5 22 Right side view The reverse clutch belt J Figure 5 22 is driven by the engine drive pulley I Figure 5 20 When the Reverse Clutch C
37. autho rized engine service dealer Ved 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 CABLE ADJUSTMENT When the Wheel Gear Lever is in DISEN GAGE the wheels will roll freely free wheel The wheels should not roll freely when the lever is in ENGAGE If the wheels roll freely when the Wheel Gear Lever is in ENGAGE the wheel gear cable needs to be adjusted as described below 1 With the engine shut off and the spark plug wire disconnected put the Wheel Gear Lever in ENGAGE 2 Loosen the top adjustment nut A Figure 5 4 on the wheel gear cable bracket that is located on the left side rear of the transmission 3 Push the wheel gear cable B down and roll the tiller slightly forward or back ward until the eccentric lever C engages locks the wheels Hold the cable in that position and tighten the top A and bottom D adjustment nuts 4 Move the Wheel Gear Lever to ENGAGE and DISENGAGE several times to check the adjustment The wheels should not roll when the lever is in ENGAGE but they should roll when the lever is in DISENGAGE Readjust the cable as required Figure 5 4 Whee
38. ced effectiveness when chopping up and turning under organic matter Use Figure 5 5 as a guide to when the tines should be replaced Moderate Wear Replace Figure 5 5 Checking tines for wear B Removing a Single Tine 1 Remove the two screws and nuts that attach a single tine to the tine holder Figure 5 6 If needed use penetrating oil to help free the nuts 2 When installing a single tine be sure to position it so that its cutting edge will enter the soil first as the tiller moves forward C Removing a Tine Assembly 1 If removing both tine assemblies mark them left and right before removal Doing so will help ensure that the assem blies are reinstalled on the correct sides of the tiller 2 Remove the screw and locknut that secure the tine assembly to the tine shaft Photo 5 7 Pull the tine assembly off the shaft if necessary use a rubber mallet to tap the tine assembly outward 3 Before reinstalling the tine assembly inspect the tine shaft for rust rough spots or burrs and file or sand as needed Apply a thin coat of grease to the shaft 4 Install each tine assembly so that the cutting edge of the tines will enter the soil first when the tiller moves forward Secure the tine assembly to the tine shaft using the screw and locknut previously removed Tighten securely NNI Before inspecting cleaning or servicing the machine shut off engine wait for all moving parts to
39. ces Tilt the tiller slightly backwards to make sure the gear oil reaches the rear tine end of the transmission Stop adding gear oil when it begins to flow from the oil level check hole on the side of the transmission 8 Securely reinstall the oil level check plug 9 Securely reinstall the gear oil fill plug on top of the transmission 10 Reinstall the wheel and remove the prop VN 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 Figure 5 3 Remove drain plug to drain transmission gear oil also remove oil fill plug and oil level check plug ENGINE OIL SERVICE Check the engine oil level before starting the engine each day and check it after each 5 hours of continuous operation Running the engine when it is low on oil will quickly ruin the engine It is recommended that you change the motor oil after every 10 hours of opera tion and even sooner when operating in extremely dirty or dusty conditions Refer to the separate Engine Owner s Manual for detailed service instructions A To Check the Engine Oil Level 1 Move the tiller to a level area and shut off the engine 2 Level the engine by moving
40. d to completely remove the belt Press the reverse idler pulley inward for slack and then slip the bottom half of the belt com pletely off the transmission pulley A Figure 5 16 Pull the bottom half of the belt out of the housing and let it hang off the outside of the unit B 4 Disconnect the forward clutch cable from the forward clutch idler arm bracket Figure 5 17 Note the hole from which you disconnect the cable It is important that you reconnect the cable to the same hole 5 Slide the belt off the engine pulley C Figure 5 18 away from engine out from under the belt guide D and completely off the pulley 6 Slip the belt 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 described in Removing Forward Clutch Belt Figure 5 20 Arrow K shows insertion point for installing new forward clutch belt 3 From the front of tiller insert the forward clutch belt in between the bottom of the engine drive pulley I and the top of transmission pulley K Figure 5 20 4 Insert the bottom half of belt into the smaller rear most groove of the tr
41. ding the controls operation or maintenance of this unit please call the Customer Support Department your unit s model number and serial number ready when you call See previous section to locate this RLW Call 1 330 558 7220 or 1 866 840 6483 to reach a Customer Support representative Please have information You will be asked to enter the serial number in order process your call For more details about your unit visit our website at www troybilt com Safety Alert Symbol This is a safety alert symbol It is used in this A 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 TRAINING injury or property damage 1 Carefully read this Owner s Manual the sepa rate Engine Owner s Manual and any other literature you may receive Be thoroughly familiar with the controls and the proper use of the tiller and its engine Know how to stop the unit and disengage the controls quickly 2 Never allow children to operate the tiller Never allow adults to operate the tiller without proper instruction 3 Keep the area of operation clear of all persons particularly children and pets 4 Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people their property and themselves PREPARATION 1 Thoroughly inspect the area wher
42. ditions The two hiller wings attach to the sides of the furrower blade and are used to make hilled rows and raised bed gardens ROW MARKER MODEL 0EM 290 257 The row marker attaches to the hiller furrower attachment and is used to scratch lines in the seedbed for laying out furrows trenches raised beds etc eliminates the need for stakes string and measuring tape The row marker is adjustable in length from Worn tines Improper Depth Regulator setting Incorrect throttle setting Belt s slipping See Bolo Tines Section 5 See Tilling Tips amp Techniques Section 4 See Section 4 See Checking Clutch Belt Tension Section 5 TILLER ATTACHMENTS The attachments listed below are available for your tille Contact your authorized dealer or the factory for current information BUMPER MODEL 0EM 290 254 The tubular steel bumper helps to protect the engine from damage HILLER FURROWER MODEL OEM 290 251 28 to 49 3 4 allowing you to vary the width of the marked rows as required Model 664D HANDLEBAR ASSEMBLY and CONTROL LEVERS See page 32 Ref 47 for attachment screw E Model 664D HANDLEBAR ASSEMBLY and CONTROL LEVERS REF PART REF PART No No DESCRIPTION QTY No No DESCRIPTION QTY 1 1918811 Handlebars Incl Refs 2 3 amp 3A 1 15 1186211 Hex Nut 5 16 24 2 2 GW 91
43. e 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 STOP On electric start models turn the ignition keyswitch to OFF to stop the engine A WARNING Before tilling contact your telephone or utilities company and inquire if underground equipment or lines are used in your area Their representative will be glad to answer your questions and tell you if any of their equipment or lines are buried underground on your property Turning the Tiller Around AE 297 Jy Figure 4 4 To begin turn reduce engine speed and lift handlebars until engine and tines are balanced over wheels 255 m ue Figure 4 5 With tiller balanced over wheels and tines out of the ground push handlebars sideways to turn tiller Tilling Tips amp 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 handlebars in an attempt to force the tiller to dig deeper Doing so takes the weight off the powered wheels causing them to lose traction Without the wheels helping to hold the
44. e is on the outside and the widest side is on the inside 3 Insert the belt down into the front of the transmission housing Slip the top half of the belt onto the reverse idler arm pulley N 4 Pull the belt downward and loop the bottom half of belt around the front groove of transmission pulley L Figure 5 22 5 Mount the belt guide between the two flat washers and tighten snugly The guide needs adjusting before fully tightening QAM o f gt i Figure 5 23 Reverse belt guide positioning 4 j i p _ 6 You will need an assistant to help with this step Pull the reverse idler pulley N up to its highest point and position the belt guide R horizontally level as shown in Figure 5 23 Securely tighten the screw and lock nut M Figure 5 22 7 Pull back on the Reverse Clutch Control knob and make sure that the reverse clutch belt fully contacts the groove in the engine pulley Release knob and make sure that the belt doesn t engage the reverse engine pulley This may cause the unit to move in reverse when the Wheel Gear Lever is engaged Adjust the cable for less tension if this condition occurs See Checking and Adjusting Reverse Belt Tension for more information 8 Reinstall the belt cover and secure it with two flange locknuts 9 Test the unit in an open location _ _ PROBLEM TROUBLESHOOTING POSSIBLE CAUSE CORRECT
45. e the tiller is to be used and remove all foreign objects 2 Be sure all controls are released and the Wheel Gear Lever is in ENGAGE before starting the engine 3 Do not operate the tiller without wearing adequate outer garments Avoid loose garments or jewelry that could get caught in moving parts 4 Do not operate the tiller when barefoot or wearing sandals sneakers or light footwear Wear protective footwear that will improve footing on slippery surfaces 1 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 Ay WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 5 Do not till near underground electric cables telephone lines pipes or 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 cigarettes cigars pipes open flames and sparks away from the fuel tank and fuel container d Fill f
46. e wheels will start turning when either the Forward Clutch Control or the Reverse Clutch Control is engaged the tines will also start turning when either clutch is engaged Figure 3 1 Conirols located on handlebar The DISENGAGE position places the wheels in the freewheeling mode to allow the unit to be moved without the engine running Use the DISENGAGE position only when the engine is not running See DANGER statement that follows To shift to ENGAGE gently do not force move the lever forward while also rolling the tiller a few inches forward or back ward Moving the tiller 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 Never place the Wheel Gear Lever in DISENGAGE Freewheel when the engine is running Having the Wheel Gear Lever in DISENGAGE and then engaging the tines wheels with either the Forward Clutch Control or the Reverse Clutch Control could allow the tines to propel the tiller rapidly forward or backward Failure to follow this instruction could result in personal injury or property damage 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 Clutch Control 1 Before engaging the Forward
47. ed above as not available separately can be found at most hardware stores Specify GRADE 5 if ordering part locally Model 664D HOOD BRACKET and DEPTH REGULATOR 1 13 REF PART REF PART No No DESCRIPTION QTY No No DESCRIPTION QTY 1 1917605 Tine Hood Incl hood flap and 11 GW 9120 Retaining Ring tolerance ring 1 RERIT nasi rere 1 12 GW 9119 Knob Depth Regulator Incl Ref 11 1 2 710 0169 Lockwasher 3 8 2 13 710 3005 Hex Hd Screw 3 8 16 x 1 1 4 2 3 GW 2527 Bracket hood amp depth regulator 14 GW 1113 1 X Bushing Drag 2 Incl Ref No 9 1 15 712 0798 Hex Nut 3 8 16 2 4 1186328 Hex Flange Screw 5 16 18 x 5 8 2 16 GW 20775 Drag 1 5 712 0291 Hex Locknut 1 4 20 1 17 777830649 Decal operating instructions 1 6 710 0597 Hex Hd Screw 1 4 20 x 1 18 GW 9553 Hex Hd Screw self tapping 7 GW 9384 Spiingiais a acsi eniti 1 56 18 1 2 insi 2 8 GW 9534 S paG hornen LII EE 1 19 710 0599 Hex Flange Screw self tapping 9 1185469 Roll Pin spiral 1 4 x 1 1 1 4 20 x 1 2 sss 2 10 GW 1117A Depth Adjustment Bar Assembly Incl Refs 11 and 12 1 Specify GRADE 5 if ordering part locally Model 664D
48. eed On the recoil start model only it is also used to stop the engine on the electric start model the electric start keyswitch is used to stop the engine The throttle settings are shown below IMPORTANT See Starting and Stopping the Engine in the Operation Section for detailed engine starting and stopping instructions FAST Use for most tilling and cultivating projects fii SLOW Use when idling engine or when slower tilling and cultivating speeds are needed STOP Stops the engine recoil start models only EH H4 Operation A 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 INTRODUCTION Read this Section of the manual thor oughly before you start the engine Then take the time to familiarize yourself with the basic operation of the tiller before using it in the garden Find an open level area and practice using the tiller controls without the tines engaging the soil put tines in travel setting Only after you ve become com pletely familiar with the tiller should you begin using it in the garden BREAK IN OPERATION Perform the following maintenance after the first two hours of n
49. eels to rotate freely Use the handle Figure 2 5 Carefully unwrap Wheel Gear Lever and move lever to DISENGAGE bars to roll the tiller off the platform NOTE The Wheel Gear Lever will be installed later in this procedure IMPORTANT Use the DISENGAGE posi tion only when the 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 1 is installed on the cable Left Side Handlebar Reverse Clutch Control Knob Slot in Control Figure 2 6 Attach reverse clutch control assembly to slotted hole in handlebar panel 2 Insert the cable into the slot in the control panel and fit the threaded assem bly into the hole in the slot see Figure 2 6 Be sure that the flat side of the threaded assembly is aligned with the flat side of the hole Slide the hex nut I up the cable and tighten it securely 3 Test the function of the reverse clutch control cable by pulling the knob out and releasing it The knob should return to its neutral position against the tapered bushing If it doesn t contact your local dealer or the factory for technical assistance STEP 4 ATTACH FORWARD CLUTCH CONTROL CABLE 1 R
50. ely by their manufacturers Refer to the applicable manufacturer s warranty on these items for terms and conditions WHAT IS NOT This warranty does not apply to parts that have been damaged by accident alteration COVERED BY THIS misuse abuse neglect improper maintenance vandalism theft fire water or damage WARRANTY because of peril or other natural disaster The following items are not covered after the first year of this residential use limited warranty belts batteries bushings seals tines tires wheels paint appearance items and similar items that are nor mally replaced through periodic maintenance Charges for pick up delivery and service calls are not covered by this warranty Service completed by someone other than an authorized service dealer is not covered by this warranty Parts that are not genuine Troy Bilt LLC service parts are not covered by this warranty The engine is warranted separately by the engine manufacturer Refer to the engine manufacturer s warranty for terms and conditions LIMITED If used for 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
51. emove any fasteners rubber bands tape etc that may secure the Forward Clutch Control levers J Figure 2 7 to the handlebar Figure 2 7 Forward Clutch Control levers J Forward clutch control linkage K 2 The forward clutch control cable with attached spring is hanging loosely near the right side wheel Being careful not to kink or stretch the cable insert the z con nector L Figure 2 8 end of the spring into the hole at the end of the forward clutch control linkage K Figure 2 7 Figure 2 8 3 Attach the cable adjuster A Figure 2 9 to the bracket on the right side han dlebar Use two 1 2 wrenches to loosen the two jam nuts B just enough to slide the cable adjuster onto the bracket Then hand tighten the jam nuts Figure 2 9 A 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 5 When tension is correct tighten the two jam nuts B securely STEP 5 CHECK TRANSMISSION GEAR OIL LEVEL The transmission was filled with gear oil at the factory However be sure to check the oil level at this time to make certain it is correct IMPORTANT Do not operate the tiller if the gear o
52. engaging the tines wheels with the Forward Clutch Control or the Reverse Clutch Control 14 Be aware that the tiller may unex pectedly bounce upward or jump forward if the tines should strike extremely hard packed soil frozen ground or buried obstacles like large stones roots or stumps If in doubt about the tilling conditions always use the following operating precautions to assist you in maintaining control of the tiller a Walk behind and to one side of the tiller using one hand on the han dlebars Relax your arm but use a secure hand grip b Use shallower depth regulator set tings working gradually deeper with each pass c Use slower engine speeds d Clear the tilling area of all large stones roots and other debris e Avoid using downward pressure on handlebars If need be use slight upward pressure to keep the tines from digging too deeply f Before contacting hard packed soil at the end of a row reduce engine speed and lift handlebars to raise tines out of the soil g In an emergency stop tines and wheels by releasing whichever Clutch Lever is engaged Do not attempt to restrain the tiller 15 Do not overload the tiller s capacity by attempting to till too deeply at too fast a rate 16 Never operate the tiller at high trans port speeds on 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
53. erating 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 of the unit so that it will be securely supported when the left side wheel is removed Remove the left side wheel by removing the wheel mount ing hardware 2 Unscrew the plastic gear oil fill plug from the top of the transmission 3 Place a clean pan below the transmis sion drain plug see Figure 5 3 and remove the drain plug The oil will start flowing out of the drain hole it may flow slowly especially in cold temperatures 4 Remove the transmission gear oil level check plug that is located a few inches above the left side wheel shaft 5 When the oil stops flowing tilt the transmission forward to drain oil from the rear of the transmission 6 After draining the oil clean the threads of the drain plug apply a non hardening removable gasket sealant to the threads and securely reinstall the drain plug T Using a clean funnel slowly add SAE 140 or SAE 85W 140 weight gear oil with an API rating of GL 4 only to the transmission The transmission holds approximately 3 1 4 pints 52 54 oun
54. ete 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 OIL LEAKS Before each use check your tiller for signs of an oil leak usually a dirty oily accumulation either on the unit or on the floor where it has been parked A little seepage around a cover or oil seal is usually not a cause for alarm However if the oil drips overnight then immediate attention is needed as ignoring a leak can result in severe transmission damage If a cover is leaking try tightening any loose screws or bolts If the fasteners are tight a new gasket or oil seal may be required If the leak is from around a shaft and oil seal the oil seal probably needs to be replaced See your autho rized dealer or contact the factory for service or advice IMPORTANT Never operate the tiller if the transmission is low on oil Check the oil level after every 30 hours of operation and whenever there is any oil leakage TRANSMISSION GEAR OIL SERVICE Check the transmission gear oil level after every 30 hours of operation or whenever you notice any oil leak Operating the tiller when the transmission is low on oil can result in severe damage A To Check Transmission Gear Oil Level 1 Check the gear oil level when the trans mission is cool Gear oil will expand in warm op
55. etely differently from CRT Counter Rotating Tines tillers or from low cost front tine tillers 1 Follow the Pre Start Checklist on the previous page Be sure that the Wheel Gear Lever is in the ENGAGE position 2 Put the Depth Regulator Lever in the travel position lever all the way down so that the tines are clear of the ground Use this position when practicing with your tiller or when moving to or from the garden When you are ready to begin tilling you must move the Depth Regula tor Lever to the desired depth setting see Tilling Tips amp Techniques 3 Start the engine and allow it to warm up When warm put Engine Throttle Control Lever in FAST speed setting wi gt Keep away from rotating tines Rotating tines will cause injury 5 6 N 4 For forward motion of the wheels and tines a Pull one or both of the Forward Clutch Control Levers up and hold them against the handlebars To stop forward motion of the wheels and tines release the levers 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 Usea 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 own pace and do not push down on the han dlebars to try and force the tiller to
56. ew operation see Maintenance in this manual and the Engine Owner s Manual 1 Change engine oil 2 Check for loose or missing hardware on unit Tighten or replace as needed 3 Check transmission gear oil level 4 Check tension on forward clutch belt Reverse Clutch Control Forward Clutch Control Lever Handlebar Height Adjustment Screw alit Engine Throttle Control Lever LS Pe _ Wheel Gear Lever 7 Forward Clutch Control Lever Depth Regulator Lever Figure 4 1 Location of main tiller controls STARTING AND STOPPING THE ENGINE A CAUTION To help prevent serious personal injury or damage to equipment e Before starting engine put Wheel Gear Lever in ENGAGE position e Before starting engine put Forward Clutch Control levers and Reverse Clutch Control in neutral disengaged positions by releasing controls eNever run engine indoors or in enclosed poorly ventilated areas Engine exhaust contains carbon monoxide an odorless and deadly gas e Avoid engine muffler and nearby areas Temperatures in these areas may exceed 150 F PRE START CHECKLIST Make the following checks and perform the following services before starting the engine 1 Read Sections 1 and 3 in this Manual Read the separate Engine Owner s Manual 2 Check unit for loose or missing hard ware Service as required 3 Check engine oil level See Engine Owner s Manual 4
57. for replacement SPARK ARRESTER SCREEN SERVICE If the engine muffler is equipped with a spark arrester screen remove and clean it according to the time intervals and instructions in the separate Engine Owner s Manual ENGINE CLEANING The engine must be kept clean to assure smooth operation and to prevent damage from overheating Refer to the separate Engine Owner s Manual for specific repair and cleaning instructions All inspections and services must be done with the engine shut off and cool to the touch CARBURETOR GOVERNOR CONTROL ADJUSTMENTS A WARNING Operators shall not tamper with the engine governor settings on the machine the governor controls the maximum safe operating speed to protect the engine and all moving parts from damage caused by overspeed Authorized service shall be sought if a problem exists The carburetor was adjusted at the factory for best operating speed Refer to the separate Engine Owner s Manual for any adjustment information or see your authorized engine service dealer The governor controls the maximum safe operating speed and protects the engine and all moving parts from damage caused by overspeeding Do not tamper with the engine governor settings Seek autho rized service if a problem exists THROTTLE CONTROL ADJUSTMENT If the engine does not respond to various throttle lever settings refer to the sepa rate Engine Owner s Manual for service information or contact your local
58. g the Forward Clutch Control levers 3 Lift up the handlebars until the tines clear the ground look behind you to avoid any obstacles and then pull the Reverse Clutch Control knob out The tines and wheels will rotate in a reverse direction 4 Release the Reverse Clutch Control knob to disengage stop the wheels and tines All reverse motion will stop the engine will continue to run A WARNING Do not attempt to till too deeply too quickly Gradually work down to deeper tilling depths e Place the Depth Regulator Lever in the travel position before starting the engine This position prevents the tines from touching the ground until you are ready to begin tilling Failure to follow this warning could result in personal injury or property damage DEPTH REGULATOR The Depth Regulator lever D Figure 3 2 controls the tilling depth of the tines Pull the lever straight back and slide it up or down to engage the notched height set tings Figure 3 2 Depth Regulator Lever The highest notch lever all the way down raises the tines approximately 1 1 2 inches off the ground This travel position allows the tiller to be moved without the tines digging into the ground Moving the lever up increases the tilling depth The lowest notch allows a tilling depth of approximately six to eight inches depending on soil conditions For best results always begin tilling at a very shallow depth setting and grad
59. il level is low Doing so will result in severe damage to the transmis sion components 1 With the tiller on level ground pull the Depth Regulator Lever R Figure 2 13 back and then slide it to the second notch from the top NOTE If the lever does not move lift the tine hood flap and look for a plastic tie securing the lever in place Cut and remove the tie 2 Remove the oil level check plug M Figure 2 10 on the left side of the trans mission Due to dried paint on the plug threads it may require some force to remove the plug the first time The gear oil level is correct if oil starts to flow out of the hole as the plug is removed If so securely reinstall the plug yor ri A Figure 2 10 Gear oil level check plug 3 If oil does not flow from the check hole add oil as follows NOTE Do not use automatic transmission fluid or motor oil in the transmission a Clean area around the fill hole N Figure 2 11 and unscrew gear oil fill plug Figure 2 11 Adding gear oil b If adding only a few ounces of gear oil use API rated GL 4 or GL 5 gear oil having a viscosity of SAE 140 SAE 85W 140 or SAE 80W 90 If refilling an empty transmission use only GL 4 gear oil having a viscosity of SAE 85W 140 or SAE 140 c Using a clean funnel slowly add gear oil until it flows from the gear oil level check hole N Figure 2 11 d Reinstall and tighten securely the gear oil fill plug
60. l gear cable assembly OFF SEASON STORAGE When the tiller won t be used for extended periods prepare it for storage as follows 1 Clean the tiller and engine 2 Do routine tiller lubrication and check for loose parts and hardware 3 Protect the engine and perform recom mended engine maintenance by following the engine storage instructions found in the separate Engine Owner s Manual NOTE Be sure to protect the fuel lines carburetor and fuel tank from gum deposits by removing fuel or by treating fuel with a fuel stabilizer follow engine manufacturer s recommendations 4 On electric start units follow 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 after every 30 operating hours Tines can be replaced individually or as a complete set Never inspect or service the tines unless the engine is stopped the spark plug wire is discon nected and the ignition key is removed on electric start models A Tine Inspection With use the tines will become shorter narrower and pointed Figure 5 5 Badly worn tines will result in a loss of tilling depth and redu
61. lear the debris it may be necessary to remove the debris by hand a pocket knife will help you to cut away the material A WARNING Before clearing the tines by hand stop the engine allow all moving parts to stop and disconnect the spark plug wire Remove the ignition key on elec tric start models Failure to follow this warning could result in personal injury Tilling on slopes If you must garden on a moderate slope please follow two very important guidelines 1 Till only on moderate slopes never on steep ground where footing is difficult review safety rules in the Safety Section of this Manual 2 We recommend tilling up and down slopes rather than terracing Tilling vertically on a slope allows maximum planting area and also leaves room for cultivating IMPORTANT When tilling on slopes be sure the correct oil level is maintained in the engine check every one half hour of operation The incline of the slope will cause the oil to slant away from its normal level and this can starve engine parts of required lubrication Keep the engine oil level at the full point at all times A Tilling up and down slopes To keep soil erosion to a minimum be sure to add enough organic matter to the soil so that it has good moisture holding texture 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 th
62. losed space ALWAYS wear safety goggles when working near batteries 21 Please remember You can always stop the tines and wheels by releasing the Forward Clutch Control Lever or the Reverse Clutch Control knob whichever control you have engaged or by moving the Engine Throttle Control Lever located on engine to STOP on recoil start models or by turning the ignition key to OFF on electric start models 28 To load or unload the tiller see the instructions in Section 4 of this Manual 29 Use extreme caution when reversing or pulling the machine towards you 30 Start the engine carefully according to instructions and with feet well away from the tines 31 Never pick up or carry a machine while the engine is running MAINTENANCE AND STORAGE 1 Keep the tiller attachments and acces sories in safe working condition 2 Check all nuts bolts and screws at frequent intervals for proper tightness to be sure the equipment is in safe working condition 3 Never store the tiller with fuel in the fuel tank inside a building where ignition sources are present such as hot water and space heaters furnaces clothes dryers stoves electric motors etc Allow engine to cool before storing in any enclosure S 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 fla
63. me 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 the separate Engine Owner s Manual for instructions if the tiller is to be stored for an extended period T Never perform maintenance while the engine is running or the spark plug wire is connected except when specifi cally instructed to do so 8 If the fuel tank has to be drained do this outdoors Operating Symbols Various symbols shown here with word descriptions may be used on the tiller and engine e bd REVERSE ROTATING TINES lt gt LEVER DIRECTION a gt lt e TILLER DIRECTION wr YT ENGAGED DISENGAGED DECALS For your safety and the safety of others replacements if any decals are damaged or various safety message decals are on your missing unit see Figure below Keep the decals Refer to the Parts List pages for decal clean and legible at all times Contact your locations and part numbers local service dealer or the factory for Control Descriptions Keyswitch Warning electric start unit only Tine Warning on right side of hood flap Starting Stabilization on top of engine or fuel tank Operating Instructions and Warning Messages Hot Surfaces Moving Belts on top of belt cover Figure 1 Location of Safety and Operating Decals AX WARNING TO AVOID SERIOUS INJURY READ T
64. ontrol knob is pulled out it pulls the reverse idler arm and pulley N which tightens the belt against the engine drive pulley This drives the transmission drive pulley L resulting in reverse motion Removing Reverse 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 belt cover Figure 5 13 by removing two flange locknuts 3 Pull the reverse clutch belt downward and slip it off the transmission pulley L Figure 5 22 4 Use two 1 2 wrenches to loosen and remove wire belt guide R Figure 5 22 from the reverse idler arm pulley Do not remove locknut and screw 5 Remove the reverse belt and pull it out through front of transmission housing Installing Reverse 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 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 reverse idler pulley N Figure 5 22 and transmission pulley L If needed the belt can be twisted inside out so that the V shaped sid
65. re sparingly may not require tension adjustment until a sig nificant number of operating hours 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 Figure 5 10 Location of forward clutch cable spring E and forward cable adjuster F extended spring length Figure 5 11 Correct spring length when Forward Clutch Levers are engaged is 2 1 2 A loose belt will also result in premature belt wear e Check belt tension after the first two hours of break in operation and after every 10 operating hours e At the end of each tilling season check the belt for cracks cuts or frayed edges A belt in poor condition should be replaced 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 A CAUTION Incorrect cable adjustment could cause the wheels and tines
66. s a slope We don t really recommend this method as it can create unsure footing and invites soil erosion As in terrace gardening start at the top of the slope and overlap the first pass by half the width of the tiller For added stability of the tiller always keep the uphill wheel in the soft newly tilled soil _ 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 A WARNING When power composting do not keep the Depth Regulator Lever at a deep setting if the tiller jumps or bucks If jumping or bucking occurs move the Depth Regulator Lever down to one of the shallower settings and then slowly increase the tilling depth on later passes Failure to follow this warning could result in personal injury The first place to begin is with crop residues such as leftover vines stalks stems and roots Power compost these crop residues as soon as they finish bearing The sooner this is done the better as tender green matter is easier to till under Use the deepest depth regula tor setting possible without causing the engine to labor or the tiller to jump ahead Standing cornstalks of reasonable height can be power composted Pushing over but not uprooting cornstalk
67. s will often make it easier for your tiller to chop up the stalks Keep the tines clear of exces sive tangling by fishtailing or frequently using reverse Make several passes then return a few days later to finish off any remaining stubble After tilling under crop residues add more organic matter such as leaves grass clippings and even kitchen scraps When tilled into the soil this organic matter will decompose and add even more important nutrients to the soil After power composting you may want to plant a green manure cover crop to protect the soil during the off season You simply grow a crop of clover alfalfa buckwheat peas beans rye grass grain or kale and then till it into the soil prior to the planting season LOADING AND UNLOADING THE TILLER A WARNING Loading and unloading the tiller into a vehicle is potentially hazardous and we don t recommend doing so unless abso lutely necessary as this could result in personal injury or property damage However if you must load or unload the tiller follow the guidelines given next Before loading or unloading stop the engine wait for all parts to stop moving disconnect the spark plug wire and let the engine and muffler cool Remove the ignition key on electric start models e The tiller is too heavy over 170 Ibs depending on model and bulky to lift safely by one person Two or more people should share the load Use sturdy ramps and manuall
68. tiller back the tines will attempt to propel the tiller often causing the tiller to skip rapidly across the ground Sometimes slight down ward pressure on the handlebars will help get through a particularly tough section of sod or unbroken ground but in most cases this won t be necessary at all Tilling depths e Avoid trying to dig too deeply too quickly especially when busting sod or when tilling soil that hasn t been tilled for some time Use shallow depth reg ulator settings only an inch or two deep for the first passes through the garden area With each succeeding pass adjust the depth regulator to dig another inch or two deeper Watering the garden area a few days prior to tilling will make tilling easier as will letting the newly worked soil set for a day or two before making a final deep tilling pass When cultivating breaking up the surface soil around plants to help destroy weeds use very shallow depth settings to prevent injury to plants whose roots often grow close to the surface If needed lift up on the handlebars slightly to prevent the tines from digging too deeply Cultivating on a regular basis not only eliminates weeds it also loosens and aerates the soil for better moisture absorption and faster plant growth Avoid tilling soggy wet soil Tilling 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
69. to open position as instructed in the separate engine manual 7 Choke or prime engine as instructed in the separate Engine Owner s Manual 8 For recoil non electric starting models a Place one hand on fuel tank to stabi lize unit when you pull the starter handle b Use the recoil starter rope to start the engine as instructed in the sepa rate Engine Owner s Manual When the engine starts gradually move the choke lever on engines so equipped to the NO CHOKE CHOKE OFF or RUN position c Leave the Engine Throttle Control Lever in the FAST setting 9 For electric starting models a Turn the engine ignition key to the START setting and allow the starter motor to crank the engine for several seconds Avoid cranking the engine longer than 15 seconds at a time as doing so could damage the starter motor NOTE Refer to the Engine Owner s Manual for detailed starting instructions b When the engine starts release the key and it will return to the RUN setting c Gradually move choke lever on engines so equipped to NO CHOKE CHOKE OFF or RUN position d Leave the Engine Throttle Control Lever in the FAST setting To Start the Electric Start Engine With the Recoil Starter Rope If necessary the electric start engine can be started with the recoil starter rope by following the steps below 1 If the battery is not dead or damaged
70. to rotate unexpect edly Follow adjustment procedures carefully Failure to do so could result in personal injury or property damage Checking Forward Belt Tension 1 Before checking shut off engine allow the engine and muffler to cool down dis connect the spark plug wire remove the ignition key on electric start models 2 The coiled part of the forward clutch spring E Figure 5 10 measures 2 in length when the Forward Clutch Control levers are not pulled up Pull either Forward Clutch Control Lever up against the handlebar and measure the length of the coil on the forward clutch spring Tension is correct if the length of the extended coil is 2 1 2 see Figure 5 11 The forward clutch control cable needs adjustment if the extended length of the coil is not 2 1 2 See Adjusting the Forward Clutch Belt for a procedure Adjusting the Forward Clutch Cable Do this procedure if the forward clutch spring measurement is not correct see Checking Forward Belt Tension 1 Before adjusting the belt shut off engine allow the engine and muffler to cool down disconnect the spark plug wire and remove the ignition key on elec tric start models E Tension Figure 5 12 Move forward clutch cable adjuster down for more belt tension 2 Belt adjustments are done with the forward clutch cable adjuster F Figure 5 10 Use two 1 2 open end wrenches to loosen the two jam nuts A Figure 5 12 a few turns 3
71. u ally increase the tilling depth Complete details on using the Depth Regulator are found in the Operation Section of this manual Figure 3 3 Handlebar height adjustment The handlebar height is adjustable to four different settings Set the handlebar height to a comfortable setting but keep in mind that the handlebars will be lower when the tines are engaged in the soil To Adjust the Handlebar Height 1 Stop the engine wait for all parts to stop moving and 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 the height adjustment screw securely 5 Retighten the two screws at the ends of the handlebar ENGINE CONTROLS Refer to the engine manufacturer s Engine Owner s Manual included in the tiller lit erature package to identify the controls on your engine The following two con trols are used when stopping or starting the engine IMPORTANT The control for stopping the recoil start engine is located on the engine ENGINE THROTTLE CONTROL LEVER The Engine Throttle Control Lever located on engine see Figure 4 1 is used to reg ulate the engine sp
72. uel tank outdoors with extreme care Never fill fuel tank indoors Use a funnel or spout to prevent spillage e Replace all fuel tank and container caps securely f If fuel is spilled do not attempt to start the engine but move the machine away from the area of spillage and avoid creating any source of ignition until fuel vapors have dissipated 7 Never make adjustments when engine is running unless recommended by manufacturer OPERATION 1 Do not put hands or feet near or under rotating parts 2 Exercise extreme caution when on or crossing gravel drives walks or roads Stay alert for hidden hazards or traffic Do not carry passengers 3 After striking a foreign object stop the engine and remove the ignition key on electric start models disconnect the spark plug wire and prevent it from touching the spark plug carefully inspect the tiller for any damage and repair the damage before restarting and operating the tiller 4 Exercise caution to avoid slipping or falling 5 If the unit should start to vibrate abnor mally stop the engine and remove the ignition key on electric start models Dis connect the spark plug wire and prevent it from touching the spark plug and check immediately for the cause Vibration is generally a warning of trouble 6 Stop the engine and remove the igni tion key on electric start models discon nect the spark plug wire and prevent it from touching the spark plug
73. ut Wheel Gear Lever in ENGAGE Chock the wheels with blocks and securely tie the tiller down 5 Maintenance A WARNING 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 PROCEDURE Check motor oil level Clean engine Check drive belt tension Check nuts and bolts Change motor oil Lubricate tiller Service foam pre cleaner air filter if so equipped Service paper air filter if so equipped Check gear oil level in transmission Check tines for wear Check air pressure in tires Service spark plug NOTES 1 After first 2 hours of break in operation 2 Before each use j Every 5 operating hours 4 Every 10 operating hours 5 Every 30 operating hours B More frequently in dusty or dirty conditions 7 See Engine Owner s Manual for service recommendations 8 Whichever time interval occurs first TILLER LUBRICATION Figure 5 1 Lubrication points Proper lubrication of the tiller is an essen tial part of your maintenance program After every 10 operating hours oil or grease the lubrication points shown in Figure 5 1 as described below Use
74. whenever you leave the operating position before unclogging the tines or when making any repairs adjustments or inspections 2 S O 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 make certain all moving parts have stopped Disconnect the spark plug wire and prevent it from touching the spark plug to prevent accidental starting On electric start models always remove the cable from the negative side of the battery 9 Always keep the tiller tine hood flap down unless using the hiller furrower attachment 10 Never use the tiller unless proper guards plates or other safety protective devices are in place 11 Do not run engine in an enclosed area Engine exhaust contains carbon monoxide gas a deadly poison that is odorless colorless and tasteless 12 Keep children and pets away 13 Never operate the tiller under engine power if the Wheel Gear Lever is in DISENGAGE FREEWHEEL In this position the wheels will not hold the tiller back and the revolving tines could propel the tiller rapidly possibly causing loss of control Always move the Wheel Gear Lever to ENGAGE before starting the engine or
75. y engine shut 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 sturdy footwear that will help to prevent slipping Position the loading vehicle so that the ramp angle is as flat as possible the less incline to the ramp the better Turn the vehicle s engine off and apply its parking brake When going up ramps stand in the normal operating position and push the tiller ahead of you Have a person at each side to turn the wheels When going down ramps walk back ward with the tiller following you Keep alert for any obstacles behind you Position a person at each wheel to control the speed of the tiller Never go down ramps tiller first as the tiller could tip forward Use wooden blocks to place on the downhill side of the wheels if you need to stop the tiller from rolling down the ramp Also use the blocks to temporar ily keep the tiller in place on the ramps if necessary and to chock the wheels in place after the tiller is in the vehicle When the tiller is in the vehicle prevent it from rolling by engaging the wheels in the wheel drive position p
76. y GRADE 5 if ordering part locally A R As Required Model 664D BOLO TINES WHEELS BLUNT END TOWARDS YOU 2 RIGHT HAND TINE LEFT HAND TINE FRONT FORWARD NOTE 1 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 travel REF PART REF PART No No DESCRIPTION QTY No No DESCRIPTION QTY 1 710 3105 Hex Hd Screw 3 8 16 x 1 1 4 16 GW 2475 1 Custom Tilling Bolo Tine Left hand 2 GW 1270 2A Bolo Tine single Right hand tine tine see Note 1 above 8 used on left side of tiller Incl es GW 2475 2 Custom Tilling Bolo Tine Right hand two ea Refs 1 and 3 8 tine see Note 1 above 8 3 712 0375 Hex Locknut 3 8 16 2 GW 10802 Custom Tilling Bolo Tine Replacement 5 710 3096 Hex Hd Screw 3 8 16 x 2 Grade 8 2 Set Incl eight ea right hand and 7 GW 1270 1A Bolo Tine single Left hand tine left hand custom tines and sixteen used on right side of tiller Incl each of Refs 1 and 3 1 two ea Refs 1 9 and 10 8 9 712 3017 Hex Nut 3 8716 inei 16 8 1902154010 Tine Holder For left and right sides 2 10 736 0169 Lock Washer 3 8

Troy-Bilt 650 Lawn Mower User Manual

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