Troy-Bilt 664DM User Manual
Operator’s Manua
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 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. 770-10597A
(11/2002)
TOBLE OF COMTEMTS
Content Page
Calling Customer Support...................................................................................................................2
Safety.....................................................................................................................................................3
Assembly...............................................................................................................................................6
Features and Controls......................................................................................................................... 11
Operation...............................................................................................................................................14
Maintenance..........................................................................................................................................20
Tiller Attachments................................................................................................................................ 28
Troubleshooting................................................................................................................................... 29
Parts List...............................................................................................................................................30
Warrany Information.............................................................................................................................Back Cover
FIMPmC MODEL HUMBER
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
TROY-BILT LLC
P. 0. BOX 361131
www.trovbilt.com Cleveland, oh 44136
330-558-7220
Copy Serial Number Here
866-840-6483
EMBIME mFORMfiTIOM
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.
CALLIMB CUSTOMER SUPPORT
If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenance
of this unit, please call the Customer Support Department.
Call 1- (330) 558-7220 or 1- (866) 840-6483 to reach a Customer Support representative. Please have
your unit’s model number and serial number ready when you call. See previous section to locate this
information. You will be asked to enter the serial number in order to 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
manual and on the unit to alert you to potential
A
hazards. When you see this symbol, read and
obey the message that follows it. Failure to
obey safety messages could result in personal
injury or property damage.
TRAINtNG
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.
PREPARATtON
1. Thoroughly inspect the area where 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.
Section
T1 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.
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 fuel 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).
A WARNING
OPERATtON
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 whenever
you leave the operating position, before
unclogging the tines, or when making any
repairs, adjustments or inspections.
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.
Wheel Gear Lever to ENGAGE before
starting the engine or engaging the
tines/wheels with the Forward Clutch
Control or the Reverse Clutch Control.
Always move the
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 soli.
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
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
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
Antidote-Eye
for 15 minutes.
Contacf:
Flush imme
immediately.
Contact:
Flush with water
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 enclosed space.
ALWAYS wear safety goggles when
working near batteries.
27.
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 STORACE
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.
4.
To reduce the chances of a fire
hazard, keep the engine free of grass,
ieaves, or excessive grease.
5.
Store gasoiine in a cooi, weii-ventiiated area, safeiy away from any sparkorfiame-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.
7.
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.
^TOy
FAST
SLOW
STOP
DECALS
For your safety and the safety of others,
various safety message decals are on your
unit (see Figure below). Keep the decals
clean and legible at all times. Contact your
local service dealer or the factory for
Control Descriptions,
Tine Warning (on right
side of hood flap)
Starting Stabilization (on
top of engine or fuel tank)
Figure 1: Location of Safety and Operating Decais
replacements if any decals are damaged or
missing.
Refer to the Parts List pages for decal
locations and part numbers.
Operating Instructions and
Warning Messages
Surfaces/Moving Belts
(on top of belt cover)
STOP
START
l+ l ^
CHOKE ROTATING
OFF TINES
LEVER DIRECTION
TILLER DIRECTION
-[2i
ENGAGED DISENGAGED
hi
CHOKE
ON
R
REVERSE
A WARNING
TO AVOID SERIOUS INJURY:
• READ THE OWNER’S MANUAL.
• KNOW LOCATIONS AND FUNCTIONS OF ALL CONTROLS.
• KEEP ALL SAFETY DEVICES AND SHIELDS IN PLACE AND WORKING.
• NEVER ALLOW CHILDREN OR UNINSTRUCTED ADULTS TO OPERATE TILLER.
• SHUT OFF ENGINE AND DISCONNECT SPARK PLUG WIRE BEFORE MANUALLY UNCLOG
GING TINES OR MAKING REPAIRS.
• KEEP BYSTANDERS AWAY FROM MACHINE.
• KEEP AWAY FROM ROTATING PARTS.
• USE EXTREME CAUTION WHEN REVERSING OR PULLING THE MACHINE TOWARDS YOU.
Section
2 Assembly
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 mall 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 carton and remove the carton.
2.
Cut the 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.
HARDWARE BAG PARTS LIST
Fig.
Ref.
Qty.
1
2 3/8-16 X1“ Hex Hd. Screw
2
1
1 Wheel Gear Lever Knob
3
4
1 Height Adjustment Flange
2 3/8“ Flat Washer
5
2 #10 Lockwasher
6
7
2 3/8"-16Nylock Lock Nut
2 #10-32x1/2" Round Hd.
8
2 #10-32 Nut
9
1 Cotter Pin (not used)
10
11
4
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 motor oil specifications
and quantity required.
* Adjustable wrenches may be used.
iMPORTANT:
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: AHACH HANDLEBARS
1. On electric start units, remove one
screw and lockwasher from the curved
Description
Keyed Washer
Screw (See Figure 2-1 A)
Screw
Plastic Tie Strap (2 not used)
Motor oil must be added to
Figure 2-1: Loose hardware (shown in
reduced size).
Flange
H
mi
Figure 2- 1A Handlehar 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.
Cut the 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.
4. With the forward clutch cable (N,
Figure 2-4) on the inside of handlebar,
position the handiebar ends on the
outside of the two mounting tabs (M,
Figure 2-3) on the transmission top
cover.
NOTE: The curved handiebar height
adjustment bracket appears as shown in
C, Figure 2-3 for non-eiectric start units.
For eiectric start units, the bracket is loos
ened and moved to one side.
5.
Looseiy attach the handiebars to the
mounting tabs with two 3/8-16 x 1"
screws (heads of screws go to inside of
tabs), 3/8" fiat washers and 3/8"-16 iock
nuts (0, Figure 2-4).
Figure 2-5: Carefully unwrap Wheel Gear
Lever and move lever to DISENGAGE.
bars to roii the tiiier off the piatform.
NOTE: The Wheei Gear Lever wili be
instaiied later in this procedure.
IMPORTANT:
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).
Use the DISENGAGE posi
STEP 3: AHACH REVERSE CLUTCH CONTROL CABLE
1. Carefully unwrap the reverse clutch
control cable (FI, Figure 2-6) from its
shipping position and route it up along
the inside edge of the left side handiebar.
A knob and iarge hex nut (I) is instaiied
on the cable.
STEP 4: AHACH FORWARD CLUTCH CONTROL CABLE
1. Remove any fasteners (rubber bands,
tape, etc.) that may secure the Forward
Clutch Control levers (J, Figure 2-7) to the
handiebar.
Figure 2-7: Forward Clutch Control levers
(J). Forward clutch control linkage (K).
2. The forward clutch control cable (with
attached spring) is hanging iooseiy near
the right-side wheel. Being carefui not to
kink or stretch the cabie, insert the z-connector (L, Figure 2-8 - end of the spring)
into the hole at the end of the forward
clutch control linkage (K, Figure 2-7).
6
. On eiectric start units, reattach the
height adjustment bracket (A, Figure 2-2).
Tighten both screws secureiy. Make sure
the handiebar cross-brace (B, Figure 2-3)
is under the bracket.
7.
Move the handiebars up or down to
aiign the threaded hoie in the cross-brace
with one of the four siots 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 hoie 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
secureiy. Next, secureiy tighten the two
screws and nuts in the ends of the han
diebar (M, Figure 2-3).
9.
To remove the tiiler from its shipping
piatform, first carefuliy unwrap the wheel
gear cable (with attached iever - see
Figure 2-5) from around the chassis.
Move the Wheei Gear Lever (G) to the
DISENGAGE position-this allows the
wheels to rotate freely. Use the handle
Figure 2-6: Attach reverse clutch control
assembly to slotted hole In handlebar panel.
2.
Insert the cabie into the siot in the
control panel and fit the threaded assembiy into the hole in the siot (see Figure 2
6). Be sure that the flat side of the
threaded assembiy is aiigned with the flat
side of the hoie. Siide the hex nut (I) up
the cabie and tighten it secureiy.
3.
Test the function of the reverse clutch
control cable by pulling the knob out and
reieasing it. The knob shouid return to its
neutral position against the tapered
bushing. If it doesn’t, contact your local
dealer or the factory for technical
assistance.
3.
Attach the cabie adjuster (A, Figure
2-9) to the bracket on the right-side han
diebar. Use two 1/2" wrenches to ioosen
the two jam nuts (B) just enough to slide
the cabie adjuster onto the bracket. Then
hand tighten the jam nuts.
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 dutch Beit 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:
the gear oil 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.
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)
Cl ean area around the fill hole (N,
Figure 2-11) and unscrew gear oil fill
plug.
Do not operate the tiller if
(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 85W140 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 (M, Figure 2-10).
STEP 6: AnACH 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 #10-32x1/2" 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 #10-32
nuts.
3. Use a 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 7 AHACHING THE BAnERY
CABLES (MODEL E666M)
The positive battery terminal is marked
Pos. (+). The negative battery terminal is
marked Neg. (-).
1. Remove the hex bolt and hex nut from
the positive cable (heavy red wire).
2. Remove the plastic cover from the
positive battery terminal and attach the
positive cable to the positive battery ter
minal (+) with the bolt and hex nut. Make
certain that the rubber boot covers the
Figure 2-12: Attach Wheel Gear Lever.
Figure 2-13: Attach wheel gear cable and
reverse clutch cable with cable ties (S).
positive terminal to help protect it from
corrosion.
3. Remove the hex bolt and hex nut from
the negative cable (heavy black wire).
4. Remove the black plastic cover from
the negative battery terminal and attach
the negative cable to the negative battery
terminal (-) with the bolt and hex nut.
IMPORTANT:
• If the battery is put into service after the
date shown on top of battery, charge the
battery as instructed in the Maintenence
section of this manual prior to operating
the tiller.
STEPS: CHECK AIR
PRESSURE IN TIRES
Use a tire pressure gauge to check the air
pressure in both tires. Deflate or inflate
both tires equally to between 15 PSI and
20 PSI). Be sure that both tires are
inflated equally or the unit will pull to one
side.
STEP 9: CHECK HARDWARE
FDR TIGHTNESS
Inspect the hardware on the unit and
tighten any loose screws, bolts and nuts.
? Features and Controls
A WARNING
Before operating your machine, carefuiiy read and understand aii safety,
controis and operating instructions in
this Manuai, the separate Engine
Owner’s Manuai, and on the decais on
the machine.
Faiiure to foiiow these instructions can
resuit in serious personai injury.
INTRODUCTION
This Section describes the iocation and
function of the controis on your tiiier.
Refer to the foiiowing section “Operation”
for detaiied operating instructions.
Practice using these controis, with the
engine shut off, untii you understand the
operation of the controis and feei confi
dent with them.
iMPORTANT:
manufacturer’s Engine Owner’s Manuai
for information about the controis on the
engine.
WHEEL GEAR LEVER
This iever (A, Figure 3-1) has two posi
tions: ENGAGE and DISENGAGE.
In the ENGAGE position, the 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).
Refer to the separate engine
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.
A DANGER
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 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.
L
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
tiiier oniy - never engage the tines in
the ground whiie going in the reverse
direction.
A WARNING
• Use extreme caution when reversing
or puiiing the machine towards you.
Look behind to avoid obstacies.
• Never attempt to tiii in reverse.
Faiiure to foiiow this warning couid
resuit in personai injury or property
damage.
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 resuits, aiways begin tiiiing at
To Operate the Reverse Ciutch Controi:
1. Put the Wheel Gear Lever In the
ENGAGE position (see the “WARNING”
statement on previous page).
2.
Stop all tiller motion by releasing 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 very shaiiow depth setting and graduaiiy increase the tiiiing depth.
details on using the Depth Regulator are
found In the “Operation” Section of this
manual.
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:
A WARNING
Complete
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.
ENGtNE 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.
iWIPORTANT:
the recoil start engine Is located on the
engine.
The control for stopping
ENGINE THROHLE CONTROL LEVER
The Engine Throttle Control Lever (located
on engIne-see Figure 4-1) Is used to reg
ulate the engine speed. 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.
iWIPORTANT:
the Engine” In the “Operation” Section for
detailed engine starting and stopping
instructions.
See “Starting and Stopping
FAST
- Use for most tilling and
cultivating projects.
.SLOW
- Use when idling engine or
when slower tilling and cultivating
speeds are needed.
• Do not attempt to tiii too deeply too
quickly. Gradually work down to
deeper tilling depths.
• 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 3-3: Handlebar height adjustment.
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
STOP
- Stops the engine (on
recoil start models only).
ELECTRIC START KEYSWITCH
(MODEL E666M)
The ignition keyswitch on the electric start
model is used to start and stop the
engine. The keyswitch settings are
described below.
IMPORTANT:
the Engine” in the “Operation” Section for
detailed instructions.
OFF
- Stops engine.
RUN
- After starting, key returns to run
position.
START
engine starts (avoid cranking engine for
longer than 15 seconds for each attempt)
See “Starting and Stopping
- Starts engine. Release key when
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.
Section
41 Operation
Forward Clutch
Control Lever
Handlebar Height
Adjustment Screw
Engine Throttle
Control Lever
Reverse Clutch
ControL
-Wheel Gear Lever
^ Forward Clutch
Control Lever
Depth Regulator Lever
INTRODUCTION
Read this Section of the manuai thoroughiy before you start the engine. Then,
take the time to famiiiarize yourseif with
the basic operation of the tiller before
using it in the garden.
Find an open, ievei area and practice
using the tiiier controis without the tines
engaging the soil (put tines in “travei”
setting). Only after you’ve become com
pletely familiar with the tiiier should you
begin using it in the garden.
BREAK-IN OPERATION
Perform the foiiowing maintenance after
the first two hours of new 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 oii ievei.
4.
Check tension on forward clutch belt.
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:
• Before starting engine, put Wheel
Gear Lever in ENGAGE position.
• Before starting engine, put Forward
Clutch Control levers and Reverse
Clutch Control in neutral (disengaged)
positions by releasing controls.
• 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 exceed 150°F.
PRE-START CHECKLIST:
Make the following checks and perform
the foiiowing services before starting the
engine.
_______________
1. Read Sections 1 and 3 in this Manual.
Read the separate Engine Owner’s
Manuai.
2.
Check unit for ioose or missing hard
ware. Service as required.
3.
Check engine oil ievei. See Engine
Owner’s Manual.
4.
Check that all safety guards and
covers are in piace.
5.
Check air cleaner and engine cooiing
system. See Engine Owner’s Manuai.
6
. Attach spark piug wire to spark piug.
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.
Fiii the fuel tank with gasoline accord
ing to the directions in the separate
Engine Owner’s Manual. Follow all
Instructions and safety rules carefully.
__________
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 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 CFIOKE”,
“CHOKE OFF” or “RUN” position.
(c) Leave the Engine Throttle Control
Lever in the “FAST” setting.
9.
For electric starting models (E666M):
(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, 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.
If the battery is “dead” or damaged,
remove it (refer to “Battery Removal and
Installation” in Section 5) and have it
tested. Before starting engine, cover the
terminal on the loose end of the positive
(+) cable with the insulated boot and
secure it in place with electrical tape to
prevent electrical sparks.
3.
Put the 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:
start engine, remove the ignition key from
the switch to reduce the possibility of
unauthorized starting of the engine.
After stopping an electric
OPERMING THE TILLER
The following pages provide guidelines to
using your tiller effectively and safely in
various gardening applications. Be sure
to read “Tilling Tips & 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 completely 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 & Techniques”).
3.
Start the engine and allow it to warm
up. When warm, put Engine Throttle
Control Lever in “FAST” speed setting.
A WARNING
i
Keep away from rotating tines. Rotating
tines wiii cause injury.
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.
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.
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 tiiler. Use a
light but secure grip with one hand
on the handiebars, but keep your
arm ioose. See Figure 4-2. Let the
tiiler move ahead at its own pace
and do not push down on the han
diebars to try and force the tiiier to
dig deeper - this takes weight off the
wheels, reduces traction, and causes
the tines to try and propei the tiiier.
A WARNING
Do not push down on 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 wheeis and
tines:
(a) Look behind and exercise caution
when operating in reverse.
till while in reverse.
(b) Stop aii forward motion before
reversing. Lift the handlebars with
one hand untii the tines are off the
ground and then puii the Reverse
Ciutch Controi knob out to engage
reverse motion (see Figure 4-3). To
stop reverse motion, let go of the
Reverse Clutch Control knob.
Do not
Figure 4-3: Raise tines off ground and iook
behind when moving in reverse.
6
. To Turn the Tiller Around:
(a) Practice turning the tiiier in a ievel,
open area. Be very carefui to keep
your feet and legs away from the
tines.
(b) To make a turn, reduce the engine
speed and then lift the handiebars
untii the engine and tines are baianced over the wheels (Figure 4-4).
(c) With the tiiier baianced, push side
ways on the handlebar to move the
tiller in the direction of the turn
(Figure 4-5). After completing the
turn, siowiy iower the tines into the
soii and increase the engine speed.
Stopping the Tiller and Engine
1. To stop the wheels and tines, release
the Forward Clutch Control levers or the
Reverse Clutch Control knob (whichever
is engaged).
2.
To stop the recoii start engine, move
the Engine Throttie Control Lever to
“STOP”. On electric start models, turn the
Ignition keyswitch to “OFF” to stop the
engine.
Turning the Tiller Around
speed and iift handiebars untii engine
and tines are haianced over wheeis.
Figure 4-5: With tiiier haianced over
wheeis (and tines out of the ground),
push handiebars sideways to turn tiiier.
Tilling Tips & 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 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
• 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 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 four passes to thoroughly
pulverize the soil).
• If 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).
• 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.
C
Figure 4-6
Figure 4-8
If fte
Figure 4-9
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