Troy-Bilt PONY 664D Operator'S Manual Download | Manualshive

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Summary of Contents for PONY 664D

Page 1: ...rester 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 attester for the muffler is available by contacting the service ...

Page 2: ...l number here O_P_J_BX_ T TROY BILT LLC P O BOX 361131 www troybilt com CLEVELAHD OH44136 330 558 7220 1 800 520 5520 CUSTOMER SUPPORT Please doNOTreturnthe unitto the retailer from whereit waspurchased withoutfirstcontactingCustomerSupport If you have difficulty assembling this product or have any questions regarding the controls operation or maintenance of this unit you can seek help from the ex...

Page 3: ...f in doubt contactyour telephoneor utility company 6 Warning Handlefuel with care it is highly flammableand its vaporsareexplo sive Takethe following precautions a Store fuel in containers specifically designed for this purpose b The gas cap shall never be removed or fuel addedwhile the engine is running Allow the engineto cool for severalminutes before adding fuel c Keepmatches cigarettes cigars ...

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

Page 5: ...r the factory for Tine Warning on right side of hoodflap Starting Stabilization on topofengine orfueltank replacementsif any decalsare damaged or missing Referto the Parts List pagesfor decal locations and part numbers instructionsand WarningMessages OperatingSymbols Various symbols shown here with word descriptions maybe usedon the tillerandengine FAST SLOW STOP 8 I I CHOKE STOP START ON I 1 R RE...

Page 6: ...S LIST Fig Ref Qty Description 1 2 3 8 16 x 1 HexHd Screw 2 1 KeyedWasher 3 1 Wheel GearLever Knob 4 1 Height Adjustment Flange Screw SeeFigure 2 1A 5 2 3 8 FlatWasher 6 2 10 Lockwasher 7 2 3 8 16 Nylock Lock Nut 8 2 10 32 x 1 2 Round Hd Screw 9 2 10 32 Nut 10 1 Cotter Pin not used 11 4 PlasticTie Strap 2 not used Tools Materials Needed for Assembly 1 3 8 open end wrench 1 7 16 open endwrench elec...

Page 7: ...e Wheel GearLever will be installed later in this procedure IMPORTANT Usethe DISENGAGE posi tion only when the engineis not running Before starting the engine the Wheel Gear Lever must beplaced in the ENGAGE position see Section 3 for details STEP 3 ATTACHREVERSE CLUTCH CONTROL CABLE 1 Carefully unwrap the reverseclutch control cable H Figure2 6 from its shipping position and route it up along the...

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

Page 9: ...hesforward or back ward Moving the tiller helps to align the shift mechanismwith the transmission wheel drive gears To shift to DISENGAGE freewheel move the lever rearward without rolling the tiller The wheelswill roll freely when the lever is properly set in the DISENGAGE position FORWARD CLUTCH CONTROL The two interconnected levers B Figure 3 1 control the engagementof forward drive to the wheel...

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

Page 11: ...e 4 1 Location ofmaintillercontrols STARTINGANDSTOPPING THE ENGINE To help prevent serious personal injury ordamageto equipment Before starting engine put Wheel Gear Lever in ENGAGE position Before starting engine put Forward Clutch Control levers and Reverse Clutch Controlin neutral disengaged positionsby releasing controls Never run engine indoors or in enclosed poorly ventilated areas Engine ex...

Page 12: ... will berecharged during engine operation Make sure the battery cells are filled to the UPPERLEVELline with elec trolyte 2 If the battery is dead or damaged remove it refer to Battery Removal and Installation in Section 5 and have it tested Beforestarting engine cover the terminal on the loose end of the positive cable with the insulated boot and secure it in place with electrical tape to prevent ...

Page 13: ...in reverse b Stop all forward motion before reversing Lift the handlebarswith onehand until the tines are off the ground and then pull the Reverse Clutch Control knob out to engage reversemotion see Figure 4 3 To stop reverse motion let go of the ReverseClutch Control knob Figure4 3 Raise tines offgroundand look behindwhen movingin reverse 6 To Turn the Tiller Around a Practiceturning the tiller i...

Page 14: ...onandfaster plantgrowth 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 heavyrains to allow the soil to dry before tilling Test soil by squeez ing it into a ball If it compresses too easily it is too wet to till Avoidmakingfootprints When possible walk on the untilled side of the unit to avoid makingfootprints in ...

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

Page 16: ...icle is potentially hazardousand we don t recommenddoing so unlessabso lutely necessary as this could result in personal injuryor propertydamage However if you must load or unloadthe 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 keyon electr...

Page 17: ...maintenance program After every 10 operating hours oil or grease the lubrication points shown in Figure5 1 as described below Usea good quality lubricating oil 30 weight engine oil is suitable and a good quality generalpurpose grease grease that has a metal lubricant is preferred if available Removewheels clean wheel shaft A Figure 5 1 andapply thin coating of greaseto shaft Greaseback front and s...

Page 18: ...is expansionwill provide an incorrect oil level reading 2 To check the gear oil level and to add oil if necessary refer to STEP5 Check GearOil Level in Transmission in Section 2 of this manual B To Drainand Refill the Transmission The transmission gear oil does not need to be changed unless it has beencontami nated with dirt sand or metal particles 1 Prop up the left side of the unit so that it wi...

Page 19: ...rate the enginewithout the air cleaner installed Inspect and service the air cleaner more often if operating in very dusty or dirty conditions Servicethe air cleaneras instructed in the separateEngineOwner s Manual SPARK PLUG SERVICE Inspectand clean or replacethe spark plug after every 100 operating hours or annually Cleanthe plug and set the gap as described in the separateEngine Owner s Manual ...

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

Page 21: ...ndition should be replaced Tension on a new forward clutch belt C Figure5 8 should bechecked after the Figure5 8 Forward clutch belt C Left sideview nobeltcover Figure5 9 Reverseclutchbelt D Right side view no belt cover first two 2 hours of operation and after every ten 10 hours of operation The reverseclutch belt D Figure 5 9 becauseit is used more sparingly may not require tension adjustment un...

Page 22: ...s A Figure5 12 afew turns 3 Move cable adjuster B Figure 5 12 downward for more belt tension see Figure 5 12 4 Handtighten the jam nuts and pull the Forward Clutch Control leversup against the handlebar Measurethe spring coil Figure 5 11 The extendedlength of the coil should be 2 1 2 Repeatthis proce dure until the extendedspring length is correct 5 Tighten both jam nuts securely Checking andAdjus...

Page 23: ...ayfrom engine out from underthe belt guide D and completely off the pulley 6 Slip the belt off the front of the trans mission pulley F Figure 5 19 7 Work the belt out from betweenthe pulley and the frame around the trans mission cover spring then up and out of the machine Installing ForwardClutchBelt 1 Stop engine allow it to cool and dis connect spark plug wire before working nearbelts Also remov...

Page 24: ...plug wire before working near belts Also remove ignitionkeyon 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 reversebelt IMPORTANT The reversebelt has a V shape When installing the belt make sure that the widest flat side of the belt rides...

Page 25: ... of the unit with the dead battery Failure to use this procedure could cause sparking and the gas in either battery could explode Cleaning Cleanthe battery by removing it from the tractor and washing with a baking soda and water solution If necessary scrape the battery terminals with a wire brush to remove deposits Coat terminals and exposed wiring with grease or petroleum jelly to prevent corrosi...

Page 26: ...ewith fresh gasoline 5 SeeEngineServiceDealer 6 Cleanair coolingsystem seeEngineOwner sManual 1 Cleanair coolingarea seeEngineOwner sManual 2 SeeEngineServiceDealer 3 Checkoil level see EngineOwner sManual Engine doesnot 1 Misadjustedthrottle control cable recoil start model 1 SeeEngineOwner sManualor Engine ServiceDealer shutoff WheelsandTines 1 Improperuseof controls 1 ReviewSections3 and4 will ...

Page 27: ...perating hours 6 More frequently in dusty or dirty conditions 7 SeeEngine Owner sManualfor service recommendations 8 Whichever timeintervaloccursfirst TILLER ATTACHMENTS The attachments listed below are availablefor your tille Contact your authorizeddealer or the factory for current information BUMPER MODEL0EM 290 254 The tubular steel bumper helps to protect the enginefrom damage HILLER FURROWER ...

Page 28: ... Models 664D E666M HANDLEBAR ASSEMBLY andCONTROL LEVERS 21 10 21 16 35 35 _715 7 7 _TRANSMISSION TOP COVER ...

Page 29: ...ew 3 8 16 x 1 2 Washer Plain flat 3 8 S A E 2 HexLocknut 3 8 16 2 Cable ForwardClutch Control 1 Wheel Gear Control and CableAssy 1 Knob Wheel Gear Control Lever 1 REF PART NO NO DESCRIPTION QTY 15 1186211 16 GW 90064 17 736 0169 19 725 0157 21 1114748 22 1100240 23 1186208 24 GW 9390 25 1918802 35 GW 9853 36 GW 20806 42 710 0599 HexNut 5 16 24 2 HexHd Screw 3 8 16 x 5 8 2 Lockwasher 3 8 2 CableTie...

Page 30: ... Models 664D E666M 36 ENGINE SUPPORT BRACKETS PULLEYS BELTS BELT COVER 12 22 20 8 32 13 14 16 1 15 16 35 46 2 25 23 20 18 48 I 8 47 37 52 Screw Ref 47 secures ForwardClutchCable page 28 Ref 10 26_ 27 ...

Page 31: ...lf tapping Screw 10 32 x 1 2 4 Guard Belts Pulleys 1 REF PART NO NO DESCRIPTION QTY 28 712 0267 29 1186329 30 1916797 31 1916796 32 736 0452 35 710 0395 36 777120942 37 1918774 38 GW 90063 39 710 0805 40 736 0275 41 1918846 42 GW 55088 43 736 0119 44 712 3010 45 1917746 46 1918744 47 1767754 48 1916727 49 712 3000 50 GW 9090 51 710 0347 52 712 0158 53 1754128 54 736 0463 55 714 04029 56 HexNut 5 1...

Page 32: ...2 PipePlug I 4 2 Seal Transmission Bore I Hex Flange Screw 5 16 18 x 3 4 6 Oil Seal Input Pinion Shaft I Transmission Cover I Gasket Transmission Top Cover I Transmission CaseAssy I Plug I Mounting Plate Wheel Clutch Cable 1 REF PART NO NO DESCRIPTION QTY 11 721 04035 12 710 04049 15 1915069 16 GW 1115 17 GW 1124 2 18 GW 90063 19 1915068 21 736 0169 22 710 0216 Oil Seal Tiller Shaft 2 Housing Cove...

Page 33: ...o GW 1224 1 two 1224 2 and one GW 1224 3 A R REF PART NO NO DESCRIPTION QTY INPUTPINIONSHAFT GEARASSEMBLY 6 GW 9572 HexHd Screw 5 16 24 x 1 1 8 1 7 GW 9944 Washer Disc Spring concave surface faces pulley 1 8 1108841 Key 3 16 sq x 1 1 2 1 9 1916522 Transmission Drive Pulley 1 10 GW 1440 Support Washer 1 11 721 04044 Oil Seal input Pinion Shaft 1 12 1113527 Retaining Ring external 1 13 GW 9953 Thrus...

Page 34: ...hick A R Shim as above but 010 thick A R Bushing 2 Wheel Shaft 1 Hi Pro Key 1 4 x 1 5 16 1 Wheel Drive Worm Sear cast iron 1 Shim betweenkey and gear 1 016 I D x 1 468 O D x 062 Thick 1 REF PART NO NO DESCRIPTION QTY 9 10 11 12 13 14 15 16 17 18 19 GW 20712 611 04002 GW 1442 GW 9055 721 04034 786 04001 710 3013 741 3037 711 04080 GW 1104 GW 20913 Wheel Drive Clutch cast iron 1 Eccentric Shaft 1 Pi...

Page 35: ...ller 8 Hex Locknut 3 8 16 18 Hex Hd Screw 3 8 16 x 2 Grade8 2 BoloTine single Left hand tine used on right side of tiller 8 Tine Holder Forleft and right sides 2 BoloTine ReplacementSet IncL eight ea right hand and left hand tines and sixteen ea Refs 1 and 3 1 REF PART NO NO DESCRIPTION QTY GW 2475 1 Custom Tilling Bolo Tine Left hand tine see Note 1 above 8 GW 2475 2 Custom Tilling Bolo Tine Righ...

Page 36: ...OEM 290 254 1918749 Bumper 1 777S30653 Decal Caution I 710 0395 Screw hexhd 5 16 18x 2 114 includedin hardware kit 4 736 0119 Lockwasher 5116 includedin hardware kit 4 REF PART NO NO DESCRIPTION QTY 5 712 0267 1918781 Nut hex 5 I6 I 8 includedinhardwarekit 4 Hardware Kit Incl four eachof Refs 3 4 and5 I ...

Page 37: ...ew 1 4 20x 1 1 Spring 1 Spacer 1 RollPin spiral 1 4x 1 1 DepthAdjustment BarAssembly IncLRefs 11and12 1 REF PART NO NO DESCRIPTION QTY 11 12 13 14 15 16 17 18 19 GW 9120 GW 9119 710 3005 GW 1113 1 712 3017 GW 20775 777S30649 710 0759 710 0599 Retaining Ring tolerance ring 1 Knob DepthRegulator Incl Ref 11 1 HexHd Screw 3 8 16x 1 1 4 2 Bushing DragBar 2 HexNut 3 8 16 2 DragBar 1 Decal operating ins...

Page 38: ...M 1 1 POSITIVE BATTERY CABLE GROUND WIRE STARTER SOLENIOD ACTIVATE WIRE REDI_ STARTER WIRE RED ENGINE WIRE GREEN 1 1 1 NEGATIVE BATTERY CABLE BATTERY RECHARGE WIRE REDI _ STARTER CABLE ENGINE GROUND CABLE TO ENGINE ...

Page 39: ...ing screw red wire wire assy w connector to engine ground shut off green wire plastic protector tube wire terminal 1 REF PART NO NO DESCRIPTION QTY 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1917262 686 04024 710 0599 712 3006 725 0157 725 0267 725 1706 736 0119 736 0147 736 0607 GW 2614 96510 96514 97020 9853 777S30648 Ground Wire Assy shut off 1 Battery BracketAssembly Pony 1 Self tapping Screw ...

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

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