Troy-Bilt 664D User manual

Brand: Troy-Bilt

Model: 664D

Category: Mini tillers

Type: User manual

This manual is also suitable for

E666M

0 TROY RILTr"

Operator's Manual

Rear-tine Tiller Model

664D--Pony _

E666M--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 attester

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. 770-10597B

(9/2003)

TABLEOF CONTENTS

Content Page Content Page

Customer Support 2 Maintenance 20

Safety 3 Tiller Attachments 28

Assembly 6 Troubleshooting 29

Features and Controls 11 Parts List 30

Operation 14 Warranty Information Back Cover

FINDINGMODELNUMBER

This Operator's Manual is an important part of your new rear-tine tiller. It will help you assemble, prepare and maintain

the unit for best performance. Please read and understand what it says.

O efore you start assembling your new equipment, please locate the model plate on the equipment and

copy the informationfrom itin the space provided below. A sample model plate is also given below. You can

locate the model plate by standing behind the unit and looking down at rear surface of the tine shield. This

information will be necessary to use the manufacturer's web site and/or help from the Customer Support

Department or an authorized service dealer.

copythemode,numberhere:

Copy the serial 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)

CUSTOMERSUPPORT

PleasedoNOTreturntheunittotheretailer 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 experts. Choose from the options below:

Visit troy-bilt.com for many useful suggestions. Click on Customer Support button and you

will get the four options reproduced here. Click on the appropriate button and help is

immediately available.

............. _e a_swer you are

_oo_ g'-"n for could oej s_"u- _"'" " _"°'_"..........'_'""'""'+"...... looking for could u_j _":u"_"

p_ofil÷.

a mouse crick away! a mouse crick away!

: _ Manuml_ On_ine

_ If you prefer to reach a Customer Support Representative, please call 1(800) 520-5520.

The engine manufacturer is responsible for all engine-related issues with regards to

:_erformance, power-rating, specifications, warranty and service. Please refer to the engine

manufacturer's Owner's/Operator's Manual, packed separately with your unit, for more

information.

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.

Safety AlertSymbol

This isa safety alert symbol. It is usedin this

manualandon the unitto alertyou to potential

hazards. When you seethis symbol, readand

obeythe messagethatfollows it. Failureto

obeysafetymessagescould result in personal

injuryor property damage.

WARNING

The engine exhaust from this product contains

chemicalsknowntothe Stateof Californiato cause

cancer,birthdefectsorotherreproductiveharm.

TRAINING

1. Carefullyreadthis

Owner's Manual,the sepa-

rateEngineOwner's

Manual,andany other literature you may

receive.Bethoroughly familiar with the

controls and the proper useof thetiller

and itsengine.Know how to stop the unit

and disengagethe controls quickly.

2. Neverallow children to operatethe

tiller. Neverallow adults to operatethe

tiller without proper instruction.

3. Keepthe areaof operationclearof all

persons,particularly children and pets.

4. Keepin mind that the operator or user

is responsiblefor accidents or hazards

occurring to other people,their property

and themselves.

PREPARATION

1. Thoroughly inspectthe areawherethe

tiller is to be usedandremoveall foreign

objects.

2. Be sureall controls arereleasedand

the WheelGearLeveris in ENGAGE

beforestarting the engine.

3. Do not operatethetiller without

wearing adequateouter garments. Avoid

loosegarments orjewelry that could get

caught in moving parts.

4. Donotoperatethetiller whenbarefoot

or wearingsandals,sneakers,or light

footwear.Wearprotectivefootwearthatwill

improvefooting on slipperysurfaces.

5. Donottill nearundergroundelectric

cables,telephonelines,pipesor hoses.If in

doubt, contactyourtelephoneor utility

company.

6. Warning: Handlefuelwith care;it is

highlyflammableand its vaporsareexplo-

sive. Takethefollowing precautions:

a. Storefuel in containersspecifically

designedfor this purpose.

b. Thegas capshall neverbe removed

or fuel addedwhile the engineis

running. Allow the engineto cool

for severalminutes beforeadding

fuel.

c. Keepmatches,cigarettes,cigars,

pipes, openflames, andsparks

awayfrom the fuel tank and fuel

container.

d. Fillfuel tank outdoors with extreme

care. Neverfill fuel tank indoors.

Useafunnel or spout to prevent

spillage.

e. Replaceall fuel tank and container

caps securely.

f. If fuel is spilled, do notattempt to

start the engine, but movethe

machine awayfrom the areaof

spillageand avoid creating any

source of ignition until fuel vapors

havedissipated.

7. Never makeadjustmentswhen engine

is running (unless recommendedby

manufacturer).

OPERATION

1. Do not put handsor feet near or under

rotating parts.

2. Exerciseextremecaution when on or

crossing graveldrives, walks, or roads.

Stayalert for hidden hazardsor traffic. Do

not carry passengers.

3. After striking a foreign object, stop the

engine(and removethe ignition key on

electricstart models), disconnect the

spark plug wire and prevent it from

touching the spark plug, carefully inspect

the tiller for anydamage,and repair the

damagebefore restarting and operating

the tiller.

4. Exercisecaution to avoid slipping or

falling.

5. If theunit shouldstartto vibrateabnor-

mally,stop theengine(andremovethe

ignition key onelectricstartmodels).Dis-

connectthespark plugwire andpreventit

from touching thespark plug,and check

immediatelyfor thecause.Vibration is

generallya warning of trouble.

6. Stopthe engine (and remove the igni-

tion keyon electric start models), discon-

nect thespark plug wire and prevent it

from touching the spark plug whenever

you leavethe operating position, before

unclogging thetines, or when makingany

repairs, adjustments or inspections.

7. Takeall possible precautionswhen

leavingthe machine unattended.Stop the

engine. Removeignition key on electric

start models. Disconnectspark plug wire

and move it awayfrom thespark plug.

MoveWheel GearLeverto ENGAGE.

8. Beforecleaning, repairing, or inspect-

ing,stop the engine,remove the ignition

keyonelectric start models,and make

certain all moving parts havestopped.

Disconnectthe spark plug wire and

prevent itfrom touching the spark plug to

preventaccidentalstarting. On electric

start models,always removethe cable

from the negativeside (-) ofthe battery.

9. Always keepthe tiller tine hood flap

down, unless using the hiller/furrower

attachment.

lB. Never usethe tiller unless proper

guards, plates,or othersafetyprotective

devicesare in place.

11. Do not run engine in an enclosed

area.Engineexhaustcontains carbon

monoxide gas,a deadlypoisonthat is

odorless,colorless, and tasteless.

12. Keepchildren andpets away.

13. Never operatethetiller under

enginepoweriftheWheel GearLever is

in DISENGAGE(FREEWHEEL).In this

position,thewheels will not holdthe

tiller backandthe revolvingtines could

propelthetiger rapidly, possibly

causinglossofcontrol.Always movethe

WheelGearLeverto ENGAGEbefore

starting theengine or engagingthe

tines/wheelswith the ForwardClutch

Control or the ReverseClutchControl.

14. Beawarethatthe tiller may unex-

pectedlybounceupwardor jump

forwardif thetines shouldstrike

extremelyhardpackedsoil, frozen

ground,or buriedobstacleslike large

stones,roots,or stumps.If in doubt

aboutthe tilling conditions,alwaysuse

thefollowingoperatingprecautionsto

assistyou in maintainingcontrolofthe

tiger:

a. Walk behindand toone sideofthe

tiller, usingone handon thehan-

dlebars. Relaxyourarm, butusea

securehandgrip.

b. Useshallowerdepthregulatorset-

tings, workinggraduallydeeper

with eachpass.

c. Useslowerenginespeeds.

d. Clearthetilling area ofall large

stones,rootsandotherdebris.

e. Avoidusingdownwardpressure

on handlebars.If needbe, use

slightupwardpressuretokeepthe

tinesfrom diggingtoodeeply.

f. Beforecontactinghardpackedsoil

at the endofa row, reduceengine

speedand lift handlebarstoraise

tinesout ofthesoil.

g. In an emergency,stoptines and

wheelsbyreleasingwhichever

ClutchLever isengaged.Do not

attemptto restrainthetiller.

15. Do not overloadthetiller's capacity

by attempting to till too deeplyat too fast

a rate.

16. Neveroperatethe tiller at high trans-

port speedson hard or slippery surfaces.

Look behind and usecarewhen backing

up.

17. Do not operatethe tiller on a slope

that istoo steepfor safety.When on

slopes, slow down and makesureyou

havegood footing. Never permit the tiller

to freewheeldown slopes.

18. Neverallow bystandersnearthe unit.

19. Onlyuseattachments and acces-

sories that areapproved bythe tiller

manufacturer.

20. Usetiller attachments and acces-

sories when recommended.

21. Neveroperatethetiller without good

visibility or light.

22. Neveroperatethetiller ifyouaretired,

or underthe influenceof alcohol,drugsor

medication.

23. Operatorsshallnottamperwith the

engine-governorsettingsonthemachine;

thegovernorcontrolsthe maximumsafe

operatingspeedto protectthe engineand

all movingpartsfrom damagecausedby

overspeed.Authorizedserviceshallbe

soughtif aproblemexists.

24. Donottouch enginepartswhich may

be hotfrom operation.Letpartscooldown

sufficiently.

25. Thebatteryon electricstartmodeltillers

containssulfuricacid.Avoidcontactwith

skin,eyes,or clothing.Keepout ofthe

reachofchildren.

Antidote-External Contact:Flushimme-

diatelywith lots of water.

Antidote-Internal: Drinklargequantities

ofwateror milk.Followwith milk of

magnesia,beateneggs or vegetableoil.

Calla doctor immediately.

Antidote-EyeContact:Flushwith water

for 15 minutes.Getpromptmedical

attention.

26. Batteriesproduceexplosivegases.Keep

sparks,flame,andsmoking materialsaway.

Ventilatewhenchargingbatteriesor when

usingabatteryin an enclosedspace.

ALWAYSwearsafetygoggleswhen

working nearbatteries.

27. Pleaseremember:You canalwaysstop

thetinesand wheelsby releasingthe

ForwardClutchControlLeveror the

ReverseClutchControlknob(whichever

controlyou haveengaged),or by moving

theEngineThrottleControlLever(located

onengine)to STOPon recoilstartmodels

or byturningthe ignitionkeyto OFFon

electricstartmodels.

28. Toloador unloadthetiller, seethe

instructionsinSection4ofthis Manual.

29. Useextremecautionwhen reversingor

pullingthemachinetowardsyou.

30. Starttheenginecarefullyaccordingto

instructionsandwith feetwellawayfrom

thetines.

31. Neverpick up or carrya machinewhile

theengineis running.

MAINTENANCEANDSTORAGE

1. Keepthe tiller, attachments and acces-

sories in safeworking condition.

2. Checkall nuts, bolts, and screws at

frequent intervalsfor proper tightness to

besure the equipment is in safeworking

condition.

3. Neverstorethetillerwith fuel in thefuel

tankinsidea buildingwhereignition

sourcesarepresentsuchashotwaterand

spaceheaters,furnaces,clothesdryers,

stoves,electricmotors,etc. Allowengineto

coolbeforestoring in anyenclosure.

4.Toreducethechancesofafire

hazard,keeptheenginefreeofgrass,

leaves,orexcessivegrease.

5.Storegasolineinacool,well-venti-

latedarea,safelyawayfromanyspark-

orflame-producingequipment.Store

gasolineinanapprovedcontainer,

safelyawayfromthereachofchildren.

6.RefertotheMaintenancesectionof

thisManualandintheseparateEngine

Owner'sManualforinstructionsifthe

tilleristobestoredforanextended

period.

7.Neverperformmaintenancewhile

theengineisrunningorthesparkplug

wireisconnected,exceptwhenspecifi-

callyinstructedtodoso.

8.Ifthefueltankhastobedrained,do

thisoutdoors.

DECALS

Foryour safetyand the safety of others,

various safety messagedecalsare on your

unit (seeFigurebelow). Keepthe decals

cleanand legibleat all times. Contactyour

localservicedealer or the factory for

TineWarning(on right

side ofhoodflap)

StartingStabilization(on

topofengineorfueltank)

replacementsif any decalsare damagedor

missing.

Referto the Parts List pagesfor decal

locationsand part numbers.

instructionsand

WarningMessages

OperatingSymbols

Various symbols (shown here, with

worddescriptions)maybeusedon the

tillerandengine.

FAST SLOW

STOP

8 I-'-I

CHOKE

STOP START ON

I÷1 R

REVERSE

CHOKE ROTATING

OFF TINES

<--o-->

LEVERDIRECTION

<--qNE

TILLERDIRECTION

£r

ENGAGED DISENGAGED

hgBelts

(ontop ofbelt cover)

Figure1: LocationofSafetyand OperatingDecals

TOAVOIDSERIOUSINJURY:

• READTHEOWNER'SMANUAL.

• KNOWLOCATIONSANDFUNCTIONSOFALLCONTROLS.

• KEEPALLSAFETYDEVICESANDSHIELDSIN PLACEANDWORKING.

• NEVERALLOWCHILDRENORUNINSTRUCTEDADULTSTOOPERATETILLER.

• SHUTOFFENGINEANDDISCONNECTSPARKPLUGWIREBEFOREMANUALLYUNCLOG-

GINGTINESORMAKINGREPAIRS.

• KEEPBYSTANDERSAWAYFROMMACHINE.

• KEEPAWAYFROMROTATINGPARTS.

• USEEXTREMECAUTIONWHENREVERSINGORPULLINGTHEMACHINETOWARDSYOU.

Assembly

To prevent personal injury or property

damage,do not startthe engineuntil all

assembly steps are complete and you

havereadand understandthesafetyand

operatinginstructionsin this Manual.

INTRODUCTION

Carefullyfollow these assembly stepsto

correctly prepareyour tiller for use. It is

recommendedthat you read this Section

in its entirety before beginning assembly.

INSPECTUNIT

Inspectthe unit and carton for damage

immediately after delivery. Contactthe

carrier (trucking company) if you find or

suspect damage. Inform them of the

damageand request instructions for filing

a claim. To protectyour rights, put your

claim in writing and maila copy to the

carrier within 15 days after the unit has

been delivered.Contactusat the factory if

you needassistance inthis matter.

UNPACKINGANDASSEMBLY

INSTRUCTIONS

STEP 1: UNPACKING INSTRUCTIONS

1. Removeanycardboard insertsand

packaging materialfrom the carton.

Removeany staplesfrom the bottom of

the carton and removethe carton.

2. Cutthe large,plastictie strap that

securesthetransmission tube to theship-

ping pallet. Leavethe handlebarson top

of the tiller to avoid damaginganycables.

3. A bag with loose hardwareis inside

the literature envelope. Checkthe con-

tents against thefollowing list and Figure

2-1. Contactyour local dealeror the

factory if any items are missing or

damaged.

NOTE: Forelectric start units, a second

hardware bag is located nearthe battery.

4. Thetiller is heavy. You should not

attempt to remove it from the shipping

platform until instructed to do so in these

"Assembly" steps.

HARDWARE BAG PARTSLIST

Fig.

Ref. Qty. Description

1 2 3/8-16 x 1"HexHd. Screw

2 1 KeyedWasher

3 1 WheelGearLeverKnob

4 1 Height Adjustment Flange

Screw (SeeFigure2-1A)

5 2 3/8" FlatWasher

6 2 #10 Lockwasher

7 2 3/8"-16 Nylock Lock Nut

8 2 #10-32 x 1/2" RoundHd.

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* (electric

start unit only)

(2) 9/16" open-endwrench*

(1) 7/8" open-endwrench or 8" long

adjustablewrench

(1) Scissors (to trim plasticties)

(1) Ruler

(1) Small board (to tap plasticknob on

lever)

(1) Tire pressuregauge

(1) Cleanoilfunnel

(1) Clean,high-quality motor oil. Refer

to the separateEngineOwner's

Manualfor motor oil specifications

and quantity required.

* Adjustable wrenches may be used.

IMPORTANT:Motor oil must beadded to

the enginecrankcasebeforethe engine is

started. Follow the instructions in this

"Assembly" Sectionand in the separate

EngineOwner's Manual.

NOTE:LEFTand RIGHTsides of the tiller

areas viewedfrom the operator's posi-

tion behindthe handlebars.

STEP 2: ATTACHHANDLEBARS

1. On electric start units, remove one

screw and Iockwasherfrom the curved

600

7_ 8_' _ _9

10 _.

Figure2-1:Loosehardware(shownin

reducedsize).

Figure2.1A Hand/ebarheightadjustment

usestheflangeheadscrew.

Figure2-2: Onelectricstartunits,move

heightadjustmentbracketaside.

heightadjustment bracket (A, Figure2-2),

loosenthe second screw, and swing the

bracketto oneside.

2. Cut the large,plastic cableties that

securethe handlebarendsto the handle-

bar mounting tabs on thetransmission

top cover.

3. Gently lift handlebar(do not over-

stretch attachedcable)and placehandle-

bar cross-brace (B, Figure2-3) in front of

curved height adjustment bracket (C).

Figure2-3: Forwardclutchcontrolcablenot

shownforclarity.

4. Withtheforwardclutchcable (N,

Figure2-4) on the insideofhandlebar,

position the handlebarendson the

outside of the two mounting tabs (M,

Figure2-3) on the transmission top

cover.

NOTE:Thecurved handlebarheight

adjustment bracketappearsasshown in

C,Figure2-3 for non-electric start units.

Forelectric start units, the bracket is loos-

enedandmoved to one side.

5. Loosely attachthe handlebarsto the

mounting tabs with two 3/8-16 x 1"

screws (headsof screws go to insideof

tabs), 3/8" flat washersand 3/8"-16 lock

nuts (O,Figure2-4).

Figure24: Attachhandlebars.

6. On electricstart units, reattachthe

heightadjustment bracket (A,Figure2-2).

Tighten both screws securely. Makesure

the handlebarcross-brace(B, Figure2-3)

is under the bracket.

7. Move the handlebarsup or down to

align the threadedhole in the cross-brace

with one of thefour slots in the curved

heightadjustment bracket. Placethe

keyedwasher(E,Figure2-3) on the

flange head heightadjustment screw (F)

with the raisedkeys (edges)of the

washer facing down.

8. Threadthe heightadjustment screw

(F, Figure2-3) into the hole in the handle-

bar cross-brace, making surethat the

raisedkeyson thewasher fit into the slot

on the height adjustment bracket.

Tighten the heightadjustment screw

securely. Next, securelytighten the two

screwsand nuts in the ends ofthe han-

dlebar (M, Figure2-3).

9. To removethe tiller from its shipping

platform, first carefully unwrapthe wheel

gearcable (with attachedlever- see

Figure2-5) from around the chassis.

Move theWheelGear Lever(G) to the

DISENGAGEposition--this allows the

wheels to rotatefreely. Usethe handle-

Figure25: CarefullyunwrapWheelGear

LeverandmovelevertoDISENGAGE.

barsto roll the tiller off the platform.

NOTE:TheWheelGearLeverwill be

installed later in this procedure.

IMPORTANT: Usethe DISENGAGEposi-

tion only when the engineis not running.

Beforestarting the engine,theWheel Gear

Levermust beplaced in the ENGAGE

position (seeSection 3 for details).

STEP3: ATTACHREVERSE

CLUTCH CONTROL CABLE

1. Carefullyunwrap the reverseclutch

control cable(H, Figure2-6) from its

shipping position and route it up along

the insideedge ofthe leftside handlebar.

A knoband large hexnut (I) is installed

on the cable.

LeftSide ReverseClutch

Handlebar ControlKnob

Figure2-6."Attachreverseclutchcontrol

assemblytoslottedholeinhandlebarpanel.

2. Insert the cableinto the slot in the

control paneland fit the threadedassem-

bly into the hole in theslot (seeFigure2-

6). Besurethat the flat sideof the

threaded assemblyis alignedwith the flat

side ofthe hole. Slide the hex nut (I) up

the cableand tighten it securely.

3. Testthe function of the reverseclutch

control cableby pulling the knob out and

releasingit. Theknob should returnto its

neutral position against the tapered

bushing. If it doesn't, contact your local

dealer or thefactory for technical

assistance.

STEP 4: ATTACHFORWARD

CLUTCH CONTROLCABLE

1. Removeanyfasteners (rubber bands,

tape, etc.)that may secure the Forward

Clutch Control levers (J, Figure2-7) to the

handlebar.

Figure2-7: ForwardClutchControllevers

(J). Forwardclutchcontrollinkage(K).

2. Theforward clutch control cable(with

attachedspring) is hanging loosely near

the right-side wheel. Beingcarefulnot to

kink or stretch the cable, insert the z-con-

nector (L, Figure2-8 - end of the spring)

into the hole at the end of theforward

clutch control linkage(K, Figure2-7).

Figure2-8

3. Attach thecableadjuster (A, Figure

2-9) to the bracket on the right-side han-

dlebar. Usetwo 1/2"wrenchesto loosen

thetwo jam nuts (B)just enough to slide

the cableadjuster onto the bracket. Then

hand tighten the jam nuts.

Figure2-9

Incorrect cable adjustment could cause

the wheels and tines to rotate unexpect-

edly. Follow adjustment procedures

carefully. Failure to do so could result

in personalinjuryorpropertydamage.

4. Checkfor correct spring/cable tension

as instructed in Section 5, Checkingand

Adjusting Forward ClutchBelt Tension.

5. Whentension is correct, tighten the

two jam nuts (B) securely.

STEP 5: CHECKTRANSMISSION

GEAROIL LEVEL

Thetransmission was filled with gearoil

at the factory. However,besure to check

the oil levelat this time to make certain it

is correct.

IMPORTANT:Do not operatethe tiller if

the gear oil level is low. Doing so will

result in severedamageto thetransmis-

sion components.

1. With thetiller on levelground, pull the

Depth Regulator Lever(R, Figure2-13)

backandthen slide it to the second notch

from thetop. NOTE:If the leverdoes not

move, lift thetine hood flap and look for a

plastictie securing the leverin place. Cut

and removethe tie.

2. Removethe oil levelcheck plug (M,

Figure2-10) on the left-side of the trans-

mission. (Dueto dried paint onthe plug

threads, it may require some force to

removethe plug thefirst time.) The gear

oil levelis correct if oil starts to flow out

of the hole asthe plug is removed. If so,

securelyreinstall the plug.

Figure2-1O:Gearoilleve/checkplug.

3. If oil doesnot flow from the check

hole,add oil as follows:

NOTE:Donot useautomatic transmission

fluid or motor oil in thetransmission.

{a) Cleanareaaround thefill hole(N,

Figure2-11) and unscrewgear oil fill

plug.

Figure2-11: Addinggear oil,

(b) If adding only a few ounces of gear

oil, useAPI ratedGL-4 or GL-5 gear oil

havinga viscosity of SAE140, SAE85W-

140 or SAE80W-90. If refilling an empty

transmission, useonly GL-4 gear oil

havinga viscosity of SAE85W-140 or

SAE140.

oil until itflows from the gearoil level

checkhole (N, Figure2-11).

(d) Reinstalland tighten securelythe gear

oil fill plug (M, Figure2-10).

STEP 6: ATTACHWHEEL GEAR

LEVER

1. Insertthe WheelGearLever(P, Figure

2-12) up through the slot in the control

panelthat is labeled"WHEELGEAR."

2. Inserttwo #10-32 x 1/2" round head

screws down through the "+" marks on

thecontrol paneldecaland securely

attachthe wheelgear mounting bracket

using two #10 Iockwashersand #10-32

nuts.

3. Usea small board to tap the Wheel

GearLeverknob securelyonto the lever.

4. Securethe wheel gearcableand the

reverseclutch control cableto the left-

side handlebarwith two plasticties (S,

Figure2-13) locatedabout two feet apart.

Snip off anyexcesstie lengthwith

scissors.

STEP 7 ATTACHINGTHE BATTERY

CABLES(MODELE666M)

Thepositive batteryterminal is marked

Pos. (+). The negativebatteryterminal is

marked Neg. (-).

1. Removethe hex bolt and hexnut from

the positive cable (heavyredwire).

2. Removethe plasticcover from the

positive batteryterminal and attachthe

positive cableto the positive batteryter-

minal (+) with the bolt and hexnut. Make

certainthat the rubber boot coversthe

Figure2-12: AttachWheel GearLever,

Figure2-13: Attachwheelgearcableand

reverseclutchcablewithcableties(S).

positive terminal to help protect itfrom

corrosion.

3. Removethe hexbolt and hexnut from

the negativecable(heavy blackwire).

4. Removethe black plastic cover from

the negativebatteryterminal and attach

the negativecableto the negative battery

terminal (-) with the bolt and hexnut.

IMPORTANT:

• If the batteryis put into serviceafter the

dateshown on top of battery, chargethe

batteryas instructed in the Maintenence

section of this manual prior to operating

thetiller.

STEP 8: CHECKAIR

PRESSURE IN TIRES

Useatire pressuregauge to checkthe air

pressure in both tires. Deflateor inflate

both tires equallyto between15 PSIand

20 PSI). Besurethat both tires are

inflated equally or the unit will pull to one

side.

STEP 9: CHECK HARDWARE

FOR TIGHTNESS

Inspectthe hardwareon the unit and

tighten any loose screws, bolts and nuts.

FeaturesandControls

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 instructionscan

result inseriouspersonalinjury.

INTRODUCTION

This Sectiondescribesthe location and

function of the controls on your tiller.

Referto thefollowing section "Operation"

for detailedoperating instructions.

Practiceusing thesecontrols, with the

engine shut off, until you understandthe

operationof the controls and feelconfi-

dent with them.

IMPORTANT:Referto the separateengine

manufacturer's EngineOwner'sManual

for information aboutthe controls on the

engine.

WHEEL GEAR LEVER

This lever(A, Figure3-1) hastwo posi-

tions: ENGAGEand DISENGAGE.

Inthe ENGAGEposition, the wheelswill

startturning when either the Forward

ClutchControl or the ReverseClutch

Control is engaged(the tineswill also

startturning when either clutch is

engaged).

Figure3-1: Controlslocatedon handlebar.

The DISENGAGEposition placesthe

wheels in thefreewheeling modeto allow

the unitto be movedwithout the engine

running. Usethe DISENGAGEposition

only whenthe engine is not running. See

"DANGER"statementthat follows.

To shift to ENGAGE,gently (do notforce)

move the leverforward while also rolling

the tiller afew inchesforward or back-

ward. Moving the tiller helpsto align the

shift mechanismwith the transmission

wheel drive gears.

To shift to DISENGAGE(freewheel),

move the leverrearward, without rolling

the tiller. Thewheelswill roll freely

when the lever is properly set in the

DISENGAGEposition.

FORWARD CLUTCH CONTROL

Thetwo interconnected levers (B, Figure

3-1) control the engagementof forward

drive to the wheelsandtines.

To Operatethe ForwardClutchControl:

1. Beforeengaging the Forward Clutch

Control, put the WheelGearLeverin the

ENGAGEposition (see"WARNING"

below).

2. Pull up and hold one or both of the

levers against the handlebargrips to

engagethewheels and tines.

3. ReleaseBOTHleversto disengage

(stop) the wheels andtines. All forward

motion will stop (the enginewill continue

to run).

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 rapidlyforwardor backward.

Failure to follow this instruction could

result in personal injury or property

damage.

Never engagethe wheels and tines with

the Forward Clutch Control or the

Reverse Clutch Control unless the

Wheel GearLeveris in ENGAGE.

Engagingthe ForwardClutch Controlor

the Reverse Clutch Control when the

wheels are not engagedcouldallow the

tines to rapidly propelthe tiller forward

or backward.

Failure to follow this warning could

result in personal injury or property

damage.

REVERSECLUTCHCONTROL

TheReverseClutch Control (C, Figure

3-1) controls the engagementof reverse

drive to thewheels and tines. The revers-

ingfeature isusedfor maneuveringthe

tiller only- neverengagethetines in

thegroundwhile goingin the reverse

direction.

• Use extreme caution when reversing

or pulling the machine towards you.

Lookbehindto avoidobstacles.

• Neverattempttotill in reverse.

Failure to follow this warning could

result in personal injury or property

damage.

ToOperatetheReverseClutchControl:

1. Putthe WheelGearLeverin the

ENGAGEposition (seethe "WARNING"

statementon previous page).

2. Stopall tiller motion by releasingthe

Forward ClutchControl levers.

3. Lift up the handlebarsuntil the tines

clearthe ground, look behindyou to avoid

anyobstacles,and then pull the Reverse

ClutchControl knob out. Thetines and

wheelswill rotate in a reversedirection.

4. Releasethe ReverseClutch Control

knob to disengage(stop) the wheels and

tines. All reversemotion will stop (the

enginewill continue to run).

• Do not attempt to till too deeply too

quickly. Gradually work down to

deepertilling depths.

• Placethe DepthRegulatorLever in the

"travel" position before starting the

engine. This position prevents the

tines from touching the ground until

youare readyto begintilling.

Failure to follow this warning could

result in personal injury or property

damage.

DEPTHREGULATOR

TheDepth Regulator lever(D, Figure3-2)

controls the tilling depth ofthetines. Pull

the leverstraight backand slide it up or

down to engagethe notchedheight set-

tings.

Figure3-2: DepthRegulatorLever,

The highest notch (leverall the way

down) raises thetines 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 increasesthe tilling

depth. Thelowest notch allows a tilling

depthof approximately six to eight

inches,depending on soil conditions.

Forbestresults, alwaysbegintilling at

a veryshallowdepthsettingand gradu-

ally increasethetilling depth. Complete

details on using the Depth Regulatorare

found in the "Operation" Section of this

manual.

HANDLEBAR HEIGHT ADJUSTMENT

The handlebarheight is adjustableto four

different settings. Set the handlebar

heightto a comfortable setting, but keep

in mind that the handlebarswill belower

when the tines are engagedinthe soil.

To AdjusttheHandlebarHeight:

Figure3-3: Handlebarheightadjustment.

1. Stopthe engine,wait for all parts to

stop moving and then disconnect the

spark plug wire. Removethe ignition key

on electric start models.

2. Loosenthe two screws at the lower

endsof the handlebar.

3. Loosenthe height adjustment screw

(E,Figure3-3) and pull the keyedwasher

(F)free of theslots in the curved height

adjustment bracket.

4. Move the handlebarsto the newslot

setting and insert the raisedkeyson the

keyedwasher into theslot. Tighten the

heightadjustment screw securely.

5. Retightenthe two screws at the ends

of the handlebar.

ENGINECONTROLS

Referto the enginemanufacturer's Engine

Owner's Manual(included in the tiller lit-

erature package)to identify the controls

on your engine. Thefollowing two con-

trols are usedwhen stopping or starting

the engine.

IMPORTANT:Thecontrol for stopping

the recoil start engine is located on the

engine.

ENGINETHROTTLE CONTROLLEVER

TheEngineThrottleControlLever(located

on engine--seeFigure4-1) is usedto reg-

ulatethe engine speed. Onthe recoil start

modelonly, it isalso usedto stop the

engine (on the electric start model,the

electric start keyswitch is usedto stop the

engine). Thethrottle settings are shown

below.

IMPORTANT:See"Starting and Stopping

the Engine"in the "Operation" Sectionfor

detailedengine starting and stopping

instructions.

,_ FAST- Usefor most tilling and

cultivating projects.

,_b_ SLOW- Usewhen idling engine or

when slower tilling and cultivating

speedsareneeded.

_STOP - Stops theengine (on

recoil start models only).

ELECTRICSTART KEYSWITCH

(MODEL E666M)

Theignition keyswitch on the electricstart

model is usedto start and stop the

engine. Thekeyswitch settings are

described below.

IMPORTANT:See"Starting and Stopping

the Engine"in the "Operation" Sectionfor

detailed instructions.

OFF -Stops engine.

RUN- After starting, key returns to run

position.

START- Startsengine. Releasekeywhen

engine starts (avoidcranking enginefor

longer than 15 secondsfor eachattempt)

Operation

ReverseClutch

Control

ForwardClutch _,

ControlLever

Before operating your machine, care-

fully read and understand aii 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.

Failureto follow these instructionscan

result inseriouspersonalinjury.

INTRODUCTION

Readthis Section of the manualthor-

oughly beforeyou start the engine. Then,

take thetime to familiarize yourself with

the basic operation of thetiller before

using it in the garden.

Findan open,levelareaand practice

usingthe tiller controls without the tines

engaging the soil (put tines in "travel"

setting). Onlyafter you've becomecom-

pletelyfamiliar with the tiller should you

begin using it in the garden.

BREAK+INOPERATION

Perform thefollowing maintenanceafter

the first two hours of newoperation (see

"Maintenance" in this manualand the

EngineOwner'sManual).

1. Changeengineoil.

2. Checkfor looseor missing hardware

on unit. Tighten or replaceasneeded.

3. Checktransmission gear oil level.

4. Checktension onforward clutch belt.

HandlebarHeight

AdjustmentScrew

ForwardClutch

ControlLever

RegulatorLever

EngineThrottle

ControlLever

Figure4-1: Locationofmaintillercontrols.

STARTINGANDSTOPPING

THE ENGINE

To help preventserious personal injury

ordamageto equipment:

• Before starting engine, put Wheel

GearLever in ENGAGEposition.

• Before starting engine, put Forward

Clutch Control levers and Reverse

Clutch Controlin neutral (disengaged)

positionsbyreleasingcontrols.

• Never run engine indoors or in

enclosed, poorly ventilated areas.

Engine exhaust contains carbon

monoxide, an odorless and deadly

gas.

• Avoid engine muffler and nearby

areas. Temperatures in these areas

may exceed150OF.

PRE-START CHECKLIST:

Makethe following checksand perform

thefollowing services before starting the

engine.

1. ReadSections1 and 3 in this Manual.

Readthe separateEngineOwner's

Manual.

2. Checkunit for looseor missing hard-

ware. Serviceas required.

3. Checkengineoil level. See Engine

Owner's Manual.

4. Checkthat all safety guards and

coversare in place.

5. Checkair cleanerand enginecooling

system. SeeEngineOwner's Manual.

6. Attach spark plug wire to spark plug.

GASOLINEIS HIGHLY FLAMMABLEAND

ITSVAPORSAREEXPLOSIVE.

Follow gasoline safety rules in this

manual(see Section1) and in the sepa-

rate EngineOwner'sManual.

Failureto follow gasolinesafetyinstruc-

tions can result in serious personal

injuryandpropertydamage_

7. Fillthe fuel tank with gasolineaccord-

ing to the directions in the separate

EngineOwner's Manual. Follow all

instructions and safety rules carefully.

STARTING THE ENGINE

Thefollowing steps describe how to start

and stop the engine. Donotattemptto

engage the tines orwheels until you

havereadall of the operatinginstruc-

tionsin this Section. Alsoreview

the safetyrulesin Section1: "Safety"

andthetiller and enginecontrols

informationinSection3: "Features and

Controls."

1. Completethe "Pre-Start Checklist" on

the previous page.

2. Putthe WheelGearLever(Figure4-1)

in the ENGAGEposition.

3. Putthe Depth Regulator Leverin the

"travel" position (leverall theway down)

sothat the tines are clearof the ground.

4. Releaseall controls on the tiller.

5. Putthe EngineThrottle Control Lever

(Figure4-1) in the "FAST"setting.

6. On enginesequippedwith afuel valve,

turn valveto open position as instructed

in the separateenginemanual.

7. Chokeor primeengine as instructed in

the separateEngineOwner's Manual.

8. Forrecoil (non-electric) starting

models:

(a) Placeone hand on fuel tankto stabi-

lizeunit when you pull the starter

handle.

(b) Usethe recoil starter rope to start

the engineas instructed in the sepa-

rateEngineOwner's Manual. When

the enginestarts, gradually move

the choke lever (on enginesso

equipped) to the "NO CHOKE",

"CHOKEOFF"or "RUN" position.

Leverin the "FAST"setting.

9. Forelectric starting models (E666M):

(a) Turn the engine ignition keyto the

"START"setting and allow the

starter motor to crank the enginefor

severalseconds. Avoid crankingthe

enginelongerthan 15 secondsat a

time as doing so could damagethe

starter motor. NOTE: Referto the

EngineOwner's Manualfor detailed

starting instructions.

(b) When theengine starts, releasethe

keyand itwill return to the "RUN"

setting.

enginesso equipped) to "NO

CHOKE","CHOKEOFF"or "RUN"

position.

(d) Leavethe EngineThrottle Control

Leverin the "FAST"setting.

ToStartthe ElectricStartEngineWith

theRecoil StarterRope

If necessary,the electric start engine can

be startedwith the recoil starter rope by

following the stepsbelow:

1. If the battery is not "dead" or

damaged,leaveit connectedto the tiller

so it will berechargedduring engine

operation. Make surethe battery cells are

filled to the UPPERLEVELline with elec-

trolyte.

2. If the battery is "dead" or damaged,

remove it (refer to "Battery Removaland

Installation" inSection 5) and haveit

tested. Beforestarting engine,cover the

terminal on the looseend of the positive

(+) cablewith the insulated boot and

secure it in placewith electricaltapeto

prevent electricalsparks.

3. Putthe ignition key in the "RUN"

position and thenfollow Steps 1-8 of

"Starting the Engine."

STOPPING THE ENGINE

1. To stop the wheels andtines, release

the Forward ClutchControl leversor the

ReverseClutch Control knob (whichever

control is engaged).

2. To stop the engine on the recoil start

model, movethe EngineThrottle Control

Leverto the "STOP" position.

3. Tostop the engineon an electricstart

model, move the ignition keyto "OFF".

IMPORTANT:After stopping an electric

start engine, removethe ignition keyfrom

the switch to reducethe possibility of

unauthorized starting of the engine.

OPERATINGTHETILLER

Thefollowing pagesprovideguidelines to

using your tiller effectively and safely in

various gardening applications. Besure

to read"Tilling Tips & Techniques"in this

Section beforeyou actually putthe tines

into the soil.

This isa traditional "standard rotating

tine" tiller with forward rotating tines. It

operatescompletely differentlyfrom CRT

(Counter RotatingTines) tillers or from

low-cost front tine tillers.

1. Followthe "Pre-StartChecklist" on the

previous page. Besure thatthe Wheel

GearLeveris in the ENGAGEposition.

2. Putthe Depth Regulator Leverin the

"travel" position (leverall the way down)

so that thetines areclear of the ground.

Usethis position when practicing with

your tiller or when moving to or from the

garden. Whenyou are readyto begin

tilling, you must movethe DepthRegula-

tor Leverto the desireddepth setting (see

"Tilling Tips & Techniques").

3. Start the engineand allow itto warm

up. When warm, put EngineThrottle

Control Leverin "FAST"speedsetting.

Keepawayfrom rotatingtines. Rotating

tineswill causeinjury.

4. For forwardmotion of thewheels and

tines:

(a) Pull one or both of the Forward

Clutch Control Levers up and hold

them againstthe handlebars. To

stop forward motion of the wheels

and tines, releasethe levers.

Figure4-2: Useonehandtoguidetiller

whenmovingforward.

Beforetilling, contactyourtelephoneor

utilities company and inquire if

underground equipment or lines are

used in your area. Their representative

will be glad to answer your questions

andtell you if any oftheir equipmentor

lines are buried underground on your

property.

(b) Asthe tiller movesforward, relax

and let the wheels pull the unit along

while the tines dig. Walk behind and

a little to oneside of the tiller. Usea

light but secure grip with one hand

onthe handlebars,but keepyour

arm loose. SeeFigure4-2. Letthe

tiller move aheadat its own pace

and do not push down on the han-

dlebars to try andforce the tiller to

dig deeper- this takesweight off the

wheels, reducestraction, andcauses

the tines to try and propel the tiller.

Do not push down on the

handlebarsto try to make the tiller till

more deeply. This preventsthe wheels

from holding the tiller back and can

allow the tines to rapidly propel the

tiller forward,whichcould resultin loss

ofcontrol,propertydamage, or personal

injury.

5. Forreverse motion of thewheels and

tines:

(a) Look behind and exercisecaution

when operating in reverse. Do not

till while in reverse.

(b) Stopall forward motion before

reversing. Lift the handlebarswith

onehanduntil thetines are off the

ground and then pull the Reverse

ClutchControl knobout to engage

reversemotion (seeFigure4-3). To

stop reverse motion, let go of the

ReverseClutch Control knob.

Figure4-3: Raise tinesoffgroundand look

behindwhen movingin reverse,

6. To Turn the Tiller Around:

(a) Practiceturning the tiller in a level,

openarea. Bevery careful to keep

your feet and legsawayfrom the

tines.

(b) To makea turn, reducethe engine

speedand then lift the handlebars

until theengine and tines are bal-

ancedoverthe wheels (Figure4-4).

ways on the handlebarto move the

tiller in the direction ofthe turn

(Figure4-5). After completing the

turn, slowly lower the tines into the

soil and increasethe enginespeed.

StoppingtheTiller andEngine

1. To stop the wheels and tines, release

the ForwardClutch Controllevers or the

ReverseClutchControl knob (whichever

is engaged).

2. To stop the recoil start engine,move

the EngineThrottle Control Leverto

"STOP". On electricstart models,turn the

ignition keyswitch to "OFF"to stop the

engine.

Turningthe TillerAround

Figure4-4: Tobeginturn,reduceengine

speedandlift handlebarsuntilengine

andtinesarebalancedoverwheels.

Figure4-5: Withtiller balancedover

wheels(and tinesoutof theground),

pushhandlebarssidewaysto turntiller,

TillingTips& Techniques

Letthetiller dothework Avoidtilling soggy,wetsoil • If thegardensizewill not permit

• While tilling, relaxand letthe wheels

pull the tiller along while the tines do

the digging. Walk on the side that is

not yetfinished (to avoid makingfoot-

prints in the freshly tilled soil) and

lightly, but securelygrip the handlebar

with just one hand.

• Avoid pushing down on the handlebars

in an attempt to force the tiller to dig

deeper. Doingso takesthe weight off

the poweredwheels, causing them to

losetraction. Without the wheels

helping to hold thetiller back,the tines

will attempt to propel the tiller- often

causingthe tiller to skip rapidly across

the ground. (Sometimes, slight down-

ward pressure on the handlebarswill

help getthrough a particularly tough

section of sod or unbrokenground, but

in most casesthis won't be necessary

at all.)

Tilling depths

• Avoid trying to dig too deeplytoo

quickly, especiallywhen busting sod or

when tilling soil that hasn't beentilled

for some time. Use shallow depth reg-

ulator settings (only an inch or two

deep)for thefirst passesthrough the

gardenarea. With eachsucceeding

pass,adjust the depth regulatorto dig

another inch or two deeper. (Watering

the garden areaafew days prior to

tilling will maketilling easier,as will

letting the newly worked soil set for a

dayor two before makinga final, deep

tilling pass.)

• Whencultivating (breakingup the

surfacesoil around plantsto help

destroyweeds),usevery shallow depth

settingsto preventinjuryto plantswhose

roots oftengrow closetothesurface. If

needed,lift up onthe handlebarsslightly

to preventthetinesfrom diggingtoo

deeply. (Cultivatingonaregularbasis

notonlyeliminatesweeds,it alsoloosens

andaeratesthesoilfor bettermoisture

absorptionandfasterplantgrowth.)

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 heavyrainsto allow the soil

to dry beforetilling. Test soil by squeez-

ing it into a ball. If it compressestoo

easily, it is too wet to till.

Avoidmakingfootprints

When possible,walk on the untilledside

of the unit to avoid makingfootprints in

thefreshly tilled soil. Footprintscause

soil compactionthat canhamperroot

)enetrationandcontribute to soil

erosion. Theycanalso "plant" unwanted

weedseeds backinto thefreshly tilled

ground.

Choosingcorrectwheel

andtine speeds

With experience,you will find the "just

right" tilling depth and tilling speedcom-

binationthat is bestfor your garden.

Setthe EngineThrottle Control Leverto

a speedto give the engineadequate

)ower and yet allow it to operateat the

slowest possible speed...atleast until

you haveachievedthe maximum tilling

depth you desire. Fasterengine speeds

may bedesirablewhen making final

)assesthrough the seedbedor when

cultivating. Selection of thecorrect

engine speed, in relation to the tilling

depth, will ensurea sufficient power

levelto do the job without causing the

engine to labor.

Suggestedtilling patterns

• When preparinga seedbed,go overthe

same pathtwice in thefirst row, then

overlapone-half the tiller width on the

rest ofthe passes(see Figure4-6).

Whenfinished in onedirection, makea

second pass ata right angleas shown

in Figure4-7. Overlapeachpassfor

best results (in very hard ground it may

takethree or four passesto thoroughly

pulverizethe soil).

lengthwiseand then crosswisetilling,

then overlapthe first passesby one-

halfa tiller width, followed bysucces-

sive passesat one-quarter width (see

Figure4-8).

•With planning,you canallow enough

room between rows to cultivate (see

Figure4-9). Leaveroom for the hood

width, plusenough extra room for

future plantgrowth.

Figure4-6

Figure4-7

Figure4-8

Figure4-9

TillingTips& Techniques

Clearingthetines

Thetines havea self-clearingaction

which eliminatesmost tangling of debris

in the tines. However,occasionally dry

grass, stringy stalks or tough vines may

becometangled. Follow these proce-

duresto help avoidtangling and to clean

thetines, if necessary.

•To reducetangling, set the depth regu-

lator deepenoughto get maximum

"chopping" action asthe tines chop the

materialagainstthe ground. Also, try

to till under crop residues or cover

crops while they are green, moist and

tender.

•While powercomposting, try swaying

the handlebarsfrom sideto side (about

6"to 12"). This "fishtailing" action

often clears thetines of debris.

• If tangling occurs, lift the tines out of

the soil and run the tiller in reversefor

a few feet. This reversing action

should unwind a good deal of debris.

• If reversing thetiller doesn't clear the

debris, it may be necessaryto remove

the debris byhand (a pocket knife will

help youto cut away the material).

Beforeclearingthe tines byhand, stop

the engine, allow all moving parts to

stop and disconnect the spark plug

wire. Removethe ignitionkeyon elec-

tric startmodels.

Failure to follow this warning could

resultin personalinjury.

Tillingon slopes

If you must garden on a moderate

slope, pleasefollow two very important

guidelines:

1.Till only on moderate slopes, neveron

steepground wherefooting is difficult

(review safety rules in the "Safety"

Sectionof this Manual).

2.We recommendtilling up and down

slopes ratherthan terracing. Tilling

vertically on a slope allows maximum

plantingarea andalso leavesroom for

cultivating.

IMPORTANT:Whentilling on slopes, be

surethe correct oil levelis maintainedin

the engine (checkevery one-half hour of

operation). The inclineof the slopewill

causethe oil to slant awayfrom its

normal leveland this canstarveengine

parts of required lubrication. Keepthe

engine oil levelat thefull point atall

times!

A. Tilling upanddownslopes:

• 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.

• Whentilling vertically,try to makethe

first pass uphill asthe tiller digs more

deeplygoing uphill than it does down-

hill. In soft soil or weeds,you may

haveto lift the handlebarsslightly while

going uphill. Whengoing downhill,

overlapthe first pass by about one-half

the width of the tiller.

B.Terrace Gardening:

• Whena slope is too steepor too short

for verticaltilling, it may be necessary

to till across theslope and createter-

racedrows. Terracesare rows that are

cut into the side of a slope, creating a

narrow, but flat areaon which to plant.

• Ona long slope, you can makeseveral

terraces, onebelow the other.

•Terracesshould be only 2-to-3 feet

wide. Digging too far into the sideof

the slope will exposepoor subsoil that

is unproductive for plants.

•To createa terrace, startat the top of

the slope and work down. Goback and

forth acrossthe first row as shownin

Figure4-10.

• Eachsucceedinglower terrace is

startedby walking belowthe terrace

you're preparing. Foraddedstability of

the tiller, always keepthe uphill wheel

in the soft, newly tilled soil. Donot till

the last 12"or more of the downhill

outside edgeof eachterrace. This

untilled strip helps preventsthe ter-

racesfrom breakingapartand washing

downhill. It also provides a walking

path betweenrows.

ol ',

Figure4-10

C. Tilling acrossslopeswithout

usingterraces:

• If vertical or terracing gardeningaren't

practicalfor you, then you cantill later-

ally across a slope. We don't really

recommendthis method asit can

createunsurefooting and invites soil

erosion.

•As in terrace gardening,startat thetop

of theslopeand overlapthefirst pass

by halfthewidth of the tiller. Foradded

stability of thetiller, always keepthe

uphill wheelin the soft, newly tilled soil.

POWERCOMPOSTING

Powercomposting simply meanstilling

under and burying in the soil all manner

of organic matter such ascrop residues,

leaves,grass clippings and cover crops.

This materialwill decomposeduring the

non-growing season and add important

naturalnutrients to the soil.

When power composting, do not keep

the Depth Regulator Lever at a deep

settingifthetiller jumpsor bucks.

If jumping or buckingoccurs, 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

resultin personalinjury.

Thefirst placeto begin iswith crop

residues such as leftovervines, stalks,

stems and roots. Powercompost these

crop residues as soonasthey finish

bearing. Thesooner this isdone, the

better,astender green matter is easierto

till under. Usethe deepestdepth regula-

tor setting possiblewithout causing the

engine to labor or the tiller to jump ahead.

Standing cornstalks of reasonableheight

can be power composted. Pushing over

(but not uprooting) cornstalkswill often

makeit easierfor your tiller to chop up

the stalks. Keepthe tines clear of exces-

sive tangling by "fishtailing" or frequently

using reverse. Make severalpasses,then

return afew dayslaterto finish off any

remainingstubble.

After tilling under crop residues,add

more organic matter such as leaves,

grass clippings and evenkitchen scraps.

Whentilled into the soil, this organic

matter will decomposeand add even

more important nutrients to the soil.

After powercomposting, 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,ryegrass, grain,

or kaleand then till it into the soil prior to

the planting season.

LOADINGANDUNLOADING

THETILLER

Loading and unloading the tiller into a

vehicle is potentially hazardousand we

don't recommenddoingso unlessabso-

lutely necessary,as this could result in

personalinjuryor propertydamage.

However, if you mustload or unloadthe

tiller, follow theguidelines given next.

• Beforeloading 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 electric start models.

•Thetiller istoo heavy(over 170 Ibs.,

depending on model) and bulky to lift

safelyby one person. Two or more

peopleshould sharethe load.

• Usesturdy ramps and manually (engine

shut off) roll thetiller into andout of the

vehicle. Two or more peopleareneeded

to do this.

• Ramps must bestrong enoughto

support the combined weight of the tiller

and anyhandlers. Theramps should

provide good traction to preventslip-

ping; they should haveside rails to

guide the tiller along the ramps;and

they should havea locking deviceto

securethem to the vehicle.

• Thehandlersshould wear sturdy

footwear that will helpto prevent

slipping.

• Position the loading vehicle sothat the

ramp angle isas flat as possible (the

less incline to the ramp, the better).

Turn thevehicle's engineoff and apply

its parking brake.

• Whengoing up ramps, stand in the

normal operating position and push the

tiller ahead ofyou. Havea personat

eachsideto turn the wheels.

• Whengoing down ramps,walk back-

ward with thetiller following you. Keep

alertfor any obstacles behindyou.

Position a personat eachwheelto

control the speedof thetiller. Nevergo

down ramps tiller-first, asthetiller could

tip forward.

• Usewooden blocks to placeon the

downhill sideof the wheels if you need

to stop thetiller from rolling down the

ramp. Also, usethe blocksto temporar-

ily keepthetiller in placeon the ramps

(if necessary),and to chockthe wheels

in placeafter thetiller is in the vehicle.

• Whenthe tiller is in the vehicle, prevent

it from rolling byengaging thewheels in

thewheel drive position (put WheelGear

Leverin ENGAGE).Chockthe wheels

with blocks and securelytie the tiller

down.

Maintenance

Before inspecting, cleaning or

servicingthe 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

startmodels.

Failure to follow these instructionscan

resultin seriouspersonalinjuryor prop-

ertydamage.

MAINTENANCESCHEDULE

PROCEDURE ROTES

Check motor oil level 2, 3

Clean engine 2, 7

Checkdrive belt tension 1,4

Check nuts and bolts 1,4

Change motor oil 1,4, 6

Lubricatetiller 4

Service foam pro-cleaner air filter 7

(if so equipped)

Service paper air filter (if so equipped) 7

Checkgear oil level intransmission 1, 5

Checktines for wear 5

Checkair pressure intires 5

Service spark plug 7

NOTES

1- After first 2 hours of break-in operation.

2 - Beforeeachuse.

3 - Every5 operating hours,

4 - Every 10operating hours,

5 - Every30 operating hours,

6 - More frequently in dustyor dirty conditions,

7 - SeeEngineOwner'sManualforservice

recommendations.

8 - Whichevertimeintervaloccursfirst,

TILLERLUBRICATION

Figure5-1: Lubricationpoints.

Proper lubrication of the tiller isan essen-

tial part of your maintenanceprogram.

After every 10 operating hours, oil or

greasethe lubrication points shown in

Figure5-1 asdescribed below.

Useagood quality lubricating oil (#30

weight engine oil is suitable) and a good

quality generalpurpose grease(grease

that hasa metal lubricant is preferred, if

available).

• Removewheels,cleanwheel shaft (A,

Figure5-1) andapply thin coating of

greaseto shaft.

• Greaseback,front and sides of depth

regulator lever (B,Figure5-1).

• Removetines, cleantine shafts (C,

Figure5-1) and inspectfor rust, rough

spots or burrs (especiallyaround

holes). Fileor sandsmooth and coat

endsof shaft with grease.

• Oilthe threads on the handlebarheight

adjustment screw (D, Figure5-1).

• Oilthe threads on the handlebarattach-

ing screws (E,Figure5-1).

CHECKHARDWARE

At leastevery10 operating hours, check

the unit for looseor missing hardware

(screws, bolts, nuts, hairpin cotters, etc.).

Looseor missing hardwarecan leadto

equipmentfailure, poor performanceor

oil leaks.

Besure to checkthe threeend cap

mounting screws located atthe rear ofthe

transmission (Figure5-2). Liftthe tine

flap to servicethose screws.

Figure5-2

CHECKTIREPRESSURE

Checkthe air pressure in both tires.

Deflateor inflate both tires evenlyto 15-

to-20 PSI(pounds per squareinch). Be

surethat both tires havethe same air

pressure or the unit will tend to pull to

oneside.

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. J

Remove the key from the keyswitch on units soequipped. J

Failure to follow these instructionscan result in serious personal injury or propertydamage.

CHECKFOROILLEAKS

Beforeeachuse, checkyour tiller for

signs of an oil leak- usuallya dirty, oily

accumulation either on the unit or on the

floor where it has beenparked.

A little seepagearound a cover or oil seal

is usually not a causefor alarm. However,

if the oil drips overnight then immediate

attention is neededas ignoring a leakcan

result in severetransmission damage.

If a cover is leaking,try tightening any

loosescrews or bolts. Ifthe fastenersare

tight, a new gasketor oil seal may be

required. If the leakisfrom around a

shaft and oil seal,the oil seal probably

needsto be replaced. Seeyourautho-

rizeddealeror contact thefactory for

service or advice.

IMPORTANT:Neveroperatethetiller if

the transmission is low on oil. Checkthe

oil levelafter every30 hours of operation

and wheneverthere is any oil leakage.

TRANSMISSIONGEAROILSERVICE

Checkthe transmission gear oil levelafter

every30 hours of operation or whenever

you notice anyoil leak. Operatingthe

tiller when the transmission is low on oil

can result in severedamage.

A. To CheckTransmissionGearOil

Level:

1. Checkthegear oil levelwhen thetrans-

mission is cool. Gearoil will expandin

warm operating temperaturesandthis

expansionwill provide an incorrect oil

levelreading.

2. To checkthe gear oil level(and to add

oil, if necessary),referto "STEP5: Check

GearOil Levelin Transmission" in Section

2 of this manual.

B. To Drainand Refill theTransmission:

Thetransmission gear oil doesnot need

to be changedunless it hasbeencontami-

natedwith dirt, sandor metal particles.

1. Prop up the left sideof the unit sothat

it will be securelysupported when the left

sidewheel is removed. Removethe left

sidewheel by removing the wheelmount-

ing hardware.

2. Unscrewthe plasticgear oil fill plug

from the top of the transmission.

3. Placea clean pan belowthetransmis-

sion drain plug (seeFigure5-3) and

remove the drain plug. Theoil will start

flowing out of thedrain hole (it may flow

slowly, especiallyin cold temperatures).

4. Removethe transmission gear oil level

check plug that is locatedafew inches

abovethe left side wheelshaft.

5. Whenthe oil stops flowing, tilt the

transmission forward to drain oil from the

rear of the transmission.

6. After draining the oil, cleanthe threads

of the drain plug, applya non-hardening

removablegasket sealantto the threads,

and securelyreinstall the drain plug.

7. Using a cleanfunnel, slowly add SAE

140 or SAE85W-140 weight gearoil

(with an API rating of GL-4 only)to the

transmission. Thetransmission holds

approximately 3-1/4 pints (52-54

ounces). Tilt thetiller slightly backwards

to makesurethe gear oil reachesthe rear

(tine) endof thetransmission. Stop

adding gear oil when it beginsto flow

from the oil levelcheck hole on the side of

the transmission.

8. Securelyreinstallthe oil levelcheck

plug.

9. Securelyreinstallthe gearoil fill plug

on top of thetransmission.

18. Reinstallthe wheeland remove the

prop.

Sefore 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 keyswitchon units so equipped.

Failure to follow these instructionscan result in serious personal injury or property damage.

Figure5-3: Removedrainplug todrain

transmissiongear oil (alsoremove oil fill

plugand oil level checkplug).

ENGINEOILSERVICE

Checktheengine oil levelbeforestarting

the engineeachday and checkit after

each5 hours of continuous operation.

Runningthe enginewhen it is low on oil

will quickly ruin the engine.

It is recommendedthat you changethe

motor oil after every 10 hours of opera-

tion and evensoonerwhen operating in

extremely dirty or dusty conditions. Refer

to the separateEngineOwner's Manual

for detailedservice instructions.

A. To ChecktheEngineOil Level:

1. Move the tiller to a levelareaand shut

off the engine.

2. Levelthe engine by moving the Depth

RegulatorLever upor down asneeded.

3. Cleanthe areaaround the oil dipstick

or oil fill tube to prevent dirt from falling

into the crankcase.

4. On engineswith an oil fill tube, remove

the filler cap, add oil (if required) until it

reachesthe top ofthe tube and reinstall

the filler cap.

5. On engineswith a dipstick, remove it,

wipe it clean,andreinstall it finger-tight.

Removethe dipstick andcheck the

reading. Add oil (if required)to bring the

levelto the FULLmark. Do not overfill.

B. To ChangetheEngineOil:

Changethe engine oil as instructed in the

separateEngineOwner's Manual.

AIR CLEANERSERVICE

Theengineair cleanerfilters dirt and dust

out of theair before it enters the carbure-

tor. Operatingthe engine with a dirty,

clogged air filter cancausepoor perfor-

mance and damageto the engine. Never

operatethe enginewithout the air cleaner

installed. Inspect and servicethe air

cleanermore often if operating in very

dusty or dirty conditions.

Servicethe air cleaneras instructed in the

separateEngineOwner's Manual.

SPARKPLUGSERVICE

Inspectandclean 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.

In someareas,locallaw requiresusing

resistor spark plugs to suppressignition

signals. If the enginewas originally

equipped with a resistor spark plug, use

the sametypefor replacement.

SPARK ARRESTER SCREEN

SERVICE

If the engine muffler is equippedwith a

spark arrester screen, removeandclean it

according to thetime intervals and

instructions in the separateEngine

Owner's Manual.

ENGINECLEANING

Theengine must be kept cleanto assure

smooth operationand to preventdamage

from overheating. Referto the separate

EngineOwner's Manualfor specific repair

and cleaninginstructions. All inspections

and services must be done with the

engine shut off and cool to thetouch.

CARBURETOR/GOVERNOR

CONTROLADJUSTMENTS

Operators shall not tamper with the

engine governor settings on the

machine; the governor controls the

maximum safe operating speed to

protectthe engine and all moving parts

from damage caused by overspeed.

Authorized service shall be sought if a

problemexists.

Thecarburetor was adjusted at the

factory for best operatingspeed. Refer to

the separateEngineOwner's Manualfor

anyadjustment information or seeyour

authorizedengineservice dealer.

Thegovernor controls the maximum safe

operating speedand protects the engine

and all moving parts from damagecaused

by overspeeding. Donot tamper with the

engine governor settings. Seekautho-

rized serviceif a problemexists.

THROTTLE CONTROL ADJUSTMENT

If the enginedoes not respond to various

throttle leversettings, referto the sepa-

rate EngineOwner's Manualfor service

information or contact your localautho-

rized engineservicedealer.

[

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. J

Remove the key from the keyswitch on units soequipped. J

Failure to follow these instructionscan result in serious personal injury or propertydamage.

WHEELGEARCABLEADJUSTMENT

Whenthe WheelGearLeveris in DISEN-

GAGE,the wheels will roll freely (free-

wheel). Thewheels should not roll freely

whenthe lever is in ENGAGE.If the

wheels roll freely whenthe WheelGear

Leveris in ENGAGE,the wheel gearcable

needsto be adjustedas described below.

1. With the engine shut off and the spark

plug wire disconnected,put the Wheel

GearLeverin ENGAGE.

2. Loosenthe top adjustment nut (A,

Figure5-4) on the wheelgear cable

bracketthat is located on the left side rear

of the transmission.

3. Pushthe wheelgear cable(B) down

and roll thetiller slightly forward or back-

ward until the eccentric lever (C)engages

(locks) the wheels. Holdthe cable in that

position and tighten the top (A) and

bottom (D) adjustment nuts.

4. Move theWheelGear Leverto

ENGAGEand DISENGAGEseveraltimes

to checkthe adjustment. Thewheels

should not roll when the lever is in

ENGAGE,butthey should roll whenthe

leveris in DISENGAGE.Readjustthe

cableas required.

Figure5-4: Wheelgearcableassembly.

OFF SEASON STORAGE

Whenthe tiller won't be usedfor

extendedperiods,prepare it for storage

asfollows:

1. Cleanthe tiller and engine.

2. Doroutine tiller lubrication and check

for loose parts and hardware.

3. Protectthe engineand perform recom-

mendedengine maintenancebyfollowing

the engine storage instructions found in

the separateEngineOwner's Manual.

NOTE:Besure to protect the fuel lines,

carburetor and fuel tank from gum

deposits byremoving fuel or bytreating

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. Neverstorethe tiller with fuel in the

fuel tank in an enclosed areawheregas

fumes could reachan openflame or

spark,or where ignition sourcesare

present (spaceheaters,hot water heaters,

furnaces, etc.).

BOLOTINES

Thetines will wear with useand should

be inspectedat the beginning of each

tilling seasonand after every 30 operating

hours. Tines can be replacedindividually

or as a completeset. Neverinspect or

servicethe tines unless the engineis

stopped,the spark plug wire is discon-

nected,and the ignition keyis removed

on electric start models.

A. TineInspection:

With use, the tines will become shorter,

narrowerand pointed (Figure5-5). Badly

worn tines will result in a loss of tilling

depthand reducedeffectivenesswhen

chopping up and turning under organic

matter. UseFigure5-5 as a guide to

when the tines should be replaced.

ModerateWear

Replace

Figure5-5: Checkingtinesforwear.

B. Removinga SingleTine:

1. Removethe two screws and nuts that

attacha singletine to the tine holder

(Figure 5-6). If needed,use penetrating

oil to helpfree the nuts.

2. Wheninstalling a single tine, be sure

to position it sothat its cutting edgewill

enterthe soil first as the tiller moves

forward.

C. Removinga Tine Assembly:

1. If removing both tine assemblies,mark

them "left" and "right" before removal.

Doing so will help ensurethat the assem-

blies are reinstalled on the correct sides

of the tiller.

2. Removethe screwand Iocknut that

secure thetine assembly to the tine shaft

(Photo 5-7). Pull thetine assembly off

the shaft (if necessary,usea rubber

mallet to tap the tine assembly outward).

3. Beforereinstalling thetine assembly,

inspect thetine shaftfor rust, rough

spots or burrs and file or sandas needed.

Apply a thin coat of greaseto the shaft.

4. Installeachtine assembly sothat the

cutting edge of the tines will enter the

soil first whenthe tiller moves forward.

Securethetine assembly to the tine shaft

using the screw and Iocknut previously

removed. Tighten securely.

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Troy-Bilt 664D User manual

Brand: Troy-Bilt

Model: 664D

Category: Mini tillers

Type: User manual

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