Troy-Bilt PONY 664DM, PONY E666M Operator's Manual

'0 TRO BI£T°----

Operator's Manual

Rear-tine Tiller Model

664DmPony_

E666MmPony _

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 attester meeting applicable local or state laws (if any).

If a spark attester is used, it should be maintained in effective working order by the operator. In the State of California the above is required by law
(Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. A spark arrester

for the muffler is available by contacting the service 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)

TABLEOFCONTENTS

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

FINDINGMODELNUMBER

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

O]_II__IpD,m...]_. TROY-BILT LLC

P. O. BOX 361131

www.troybilt.com CLEVELAND, OH 44136

330-558-7220
866-840-6483

Copy Model Number Here

Copy Serial Number Here

ENGINEINFORMATION

The engine manufacturer is responsible for all engine-related issues with regards to performance, power-rating, speci-
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.

CALLINGCUSTOMERSUPPORT

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- [phone] or 1- [phone] 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.

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.

SafetyAlert Symbol

_ his isasafetyalert symbol. It is usedin this

manualand on the unit to alertyou to potential
hazards. Whenyou seethis symbol, readand
obeythe messagethat follows it. Failureto
obeysafety messagescould result in personal
injury or property damage.

WARNING

The engine exhaust from this product contains

chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm.

TRAINING

1. Carefullyreadthis

Owner's Manual,the sepa-

rateEngineOwner's
Manual,and anyother literatureyou may

receive.Bethoroughly familiar with the
controls andthe proper useofthe tiller
and itsengine. Knowhow to stop the unit
and disengagethe controls quickly.

2. Neverallow children to operatethe
tiller. Neverallow adultsto operatethe
tiller without proper instruction.

3. Keepthe areaof operation clear ofall

persons,particularly children and pets.

4. Keepin mind thatthe 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 usedand removeall foreign
objects.

2. Besure all controls are releasedand
the WheelGearLeveris in ENGAGE

beforestarting the engine.

3. Do not operatethetiller without
wearing adequateouter garments. Avoid

loosegarments or jewelry that could get
caught inmoving parts.

4. Donotoperatethetiller when barefoot
or wearing sandals,sneakers,or light
footwear.Wearprotectivefootwearthat will

improvefooting onslipperysurfaces.

e.

f.

5. Donottill nearundergroundelectric
cables,telephonelines, pipesor hoses.If in
doubt, contactyourtelephoneor utility

company.

6. Warning: Handlefuel with care; it is
highlyflammableand itsvaporsareexplo-
sive. Takethefollowing precautions:

a. Storefuel in containersspecifically

designedfor this purpose.

b. Thegascap shall neverbe removed

or fuel addedwhile the engine is
running. Allow the engineto cool

for several minutes beforeadding
fuel.

c. Keepmatches,cigarettes,cigars,

pipes, open flames, and sparks
awayfrom the fuel tankand fuel

container.

d. Fillfuel tank outdoors with extreme

care. Neverfill fuel tank indoors.
Usea funnel or spout to prevent

spillage.

Replaceall fuel tankand container

caps securely.
If fuel is spilled, do not attemptto

start the engine, but move the
machine awayfrom the area of
spillageand avoid creating any
source of ignition until fuel vapors
havedissipated.

OPERATION

1. Donot put handsor feet nearor 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 aforeign object, stop the
engine (andremovethe ignition key on
electric start models), disconnect the
spark plugwire and prevent it from
touching the spark plug,carefully inspect
the tiller for any damage,and repair the

damagebeforerestarting and operating

the tiller.

4. Exercisecaution to avoid slipping or
falling.

5. Ifthe unitshould startto vibrateabnor-
mally,stop the engine(andremovethe

ignition keyon electric start models). Dis-

connectthespark plugwire andpreventit
from touchingthe spark plug,and check

immediatelyfor thecause.Vibration is

generallya warning of trouble.

6. Stopthe engine(and removethe igni-

tion key on electric start models), discon-

nectthe spark plug wire and prevent it

from touching thespark plugwhenever
you leavethe operating position, before

7. Nevermakeadjustments when engine unclogging thetines, or when making any
is running (unless recommendedby repairs, adjustments or inspections.

manufacturer).

7. Takeall possible precautionswhen
leavingthe machineunattended.Stopthe

engine. Removeignition key on electric
start models. Disconnect sparkplug wire
and moveit awayfrom the spark plug.

MoveWheelGear Leverto ENGAGE.

8. Beforecleaning, repairing, or inspect-
ing,stop the engine,remove the ignition
keyon electric start models,and make

certain all moving parts havestopped.

Disconnectthe spark plug wire and
preventit from touchingthe spark plug to
preventaccidentalstarting. Onelectric

start models,always removethe cable
from the negativeside (-) of the battery.

9. Always keepthe tiller tine hood flap

down, unlessusing the hiller/furrower
attachment.

10. Never usethe tiller unless proper

guards, plates,or othersafetyprotective
devicesarein place.

11. Do not run enginein an enclosed

area.Engineexhaustcontains carbon

monoxide gas,a deadly poisonthat is

odorless, colorless, and tasteless.

12. Keepchildren and pets away.

13. Never operatethe tiller under

engine powerif theWheel GearLeveris

in DISENGAGE(FREEWHEEL).In this

position,the wheelswill notholdthe
tiller backand therevolvingtines could

propelthe tiller rapidly, possibly
causinglossof control.Always movethe

WheelGearLeverto ENGAGEbefore
starting the engine or engagingthe

tines/wheelswith the ForwardClutch
Control orthe ReverseClutch Control.

14. Be aware that the tiller mayunex-

pectedlybounceupwardorjump
forwardif the tinesshouldstrike

extremelyhard packedsoil, frozen
ground,or buried obstacleslike large

stones,roots,or stumps.If in doubt
aboutthe tilling conditions,always use

thefollowingoperatingprecautionsto
assistyou in maintainingcontrolof the

tiller:

a.

Walk behindandto oneside of the
tiller, usingone handonthe han-
dlebars. Relaxyour arm, butusea

securehand grip.

b. Use shallowerdepth regulatorset-

tings, working graduallydeeper

with eachpass.
c. Useslowerenginespeeds.
d. Clearthe tilling area ofall large

stones,rootsandotherdebris.

e. Avoidusingdownwardpressure

on handlebars.If needbe, use
slightupwardpressureto keepthe

tines from diggingtoo deeply.
f. Beforecontactinghardpackedsoil

at the endof a row, reduceengine

speedand lift handlebarsto raise

tines out of the soil.

g. In an emergency,stoptinesand

wheels by releasing whichever

ClutchLever is engaged. Donot
attemptto restrainthetiller.

15. Do not overloadthetiller's capacity

by attempting to till too deeplyattoo fast
a rate.

16. Neveroperate thetiller at high trans-
port speeds on hardor slippery surfaces.
Look behind and use carewhen 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 freewheel down slopes.

18. Neverallow bystanders nearthe 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 undertheinfluenceof alcohol,drugs or

medication.

23. Operatorsshallnottamperwith the
engine-governorsettingsonthe machine;

the governorcontrolsthemaximumsafe

operatingspeedto protecttheengineand
all movingpartsfrom damagecausedby
overspeed.Authorizedserviceshallbe
soughtif a problemexists.

24. Donottouch enginepartswhich may
be hotfrom operation.Letpartscool down
sufficiently.

25. Thebatteryon electricstart modeltillers
containssulfuricacid.Avoidcontactwith

skin,eyes,or clothing.Keepoutof the

reachof children.

Antidote-External Contact:Flushimme-

diatelywith lotsof 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.
Ventilatewhencharging batteriesor when

usinga batteryinanenclosedspace.
ALWAYSwearsafetygoggleswhen
working nearbatteries.

27. Pleaseremember:Youcanalwaysstop
thetines andwheelsby releasingthe

ForwardClutchControlLeverorthe

ReverseClutchControlknob(whichever
control you haveengaged),or by moving
the EngineThrottleControlLever(located

onengine)to STOPon recoilstart models

or by turning the ignitionkeyto OFFon
electricstartmodels.

28. To loador unloadthetiller, seethe

instructionsinSection4 ofthis 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 insafe working condition.

2. Checkall nuts, bolts, andscrews at
frequent intervalsfor proper tightness to

besure the equipment is in safeworking
condition.

3. Neverstorethe tillerwith fuel inthefuel
tank insidea buildingwhere ignition

sourcesare presentsuchas hotwaterand
spaceheaters,furnaces,clothesdryers,
stoves,electric motors,etc. Allow engineto
cool beforestoring inanyenclosure.

4. To reducethe chancesof a fire
hazard,keeptheenginefree of grass,

leaves,orexcessivegrease.

5. Storegasolinein acool, well-venti-
latedarea, safelyawayfrom anyspark-

or flame-producingequipment. Store
gasolinein an approved container,
safelyawayfrom the reach of children.

6. Referto the Maintenancesectionof

this Manualand in the separateEngine
Owner's Manualfor instructions if the

tiller isto bestored for an extended

period.

7. Neverperform maintenancewhile

the engineis running orthe spark plug
wire is connected,exceptwhenspecifi-
cally instructed to do so.

8. If thefuel tankhasto bedrained,do

this outdoors.

DECALS

Foryour safetyand the safety of others, replacementsif any decalsare damagedor

various safety messagedecalsare on your missing.

unit (seeFigurebelow). Keepthe decals Referto the Parts List pagesfor decal

cleanand legibleat all times. Contactyour locations and partnumbers.

localservicedealer or the factoryfor

ControlDescri

TineWarning (onright

side of hoodflap)

StartingStabilization (on

top of engine or fuel tank)

OperatingInstructionsand

WarningMessages

OperatingSymbols

Various symbols (shown here, with
word descriptions)maybe usedonthe
tillerandengine.

FAST SLOW

STOP

6 I-'-I

CHOKE

STOP START

ON

I÷1

CHOKE ROTATING

OFF TINES

R

REVERSE

o--.>

LEVERDIRECTION

<--

TILLERDIRECTION

ENGAGED DISENGAGED

/MovingBelts

(ontopofbeltcover)

Figure 1:Locationof SafetyandOperatingDecals

TO AVOID SERIOUS INJURY:

• READTHEOWNER'S MANUAL.

• KNOWLOCATIONSAND FUNCTIONSOFALLCONTROLS.

• KEEPALLSAFETYDEVICESANDSHIELDSIN PLACEANDWORKING.

• NEVERALLOWCHILDRENORUNINSTRUCTEDADULTSTO OPERATETILLER.

• SHUTOFFENGINEANDDISCONNECTSPARKPLUGWIREBEFOREMANUALLYUNCLOG-

GINGTINESOR MAKINGREPAIRS.

• KEEPBYSTANDERSAWAYFROMMACHINE.

• KEEPAWAYFROMROTATINGPARTS.

• USEEXTREMECAUTIONWHEN REVERSINGORPULLINGTHEMACHINETOWARDSYOU.

2 Assembly

To prevent personal injury or property

damage,do notstartthe engine until all

assembly steps are complete and you

havereadand understandthe safetyand
operatinginstructionsin this Manual.

INTRODUCTION

Carefullyfollow theseassembly stepsto
correctly prepareyour tiller for use. It is

recommendedthat you readthis Section
in its entirety before beginningassembly.

INSPECTUNIT

Inspectthe unit andcarton for damage

immediatelyafter delivery. Contactthe
carrier (trucking company) ifyou find or
suspect damage. Inform them ofthe
damageand request instructions for filing
a claim. To protectyour rights, put your
claim inwriting and mail a copy to the
carrier within 15 days after the unit has

beendelivered.Contact us at the factory if
you needassistancein this matter.

UNPACKINGANDASSEMBLY
INSTRUCTIONS

STEP 1: UNPACKING INSTRUCTIONS

1. Removeanycardboard inserts and

packagingmaterialfrom the carton.

Removeany staples from the bottom of
the carton and removethe carton.

2. Cutthe large,plastictie strap that
securesthe transmission tubeto the ship-

ping pallet. Leavethe handlebarson top
of the tiller to avoid damaginganycables.

3. A bag with loose hardware is inside
the literature envelope. Checkthe con-
tents against thefollowing list and Figure
2-1. Contactyour local dealeror the
factory if any items aremissing or
damaged.

NOTE:Forelectric start units, a second

hardwarebag is located nearthe battery.

4. The tiller is heavy. You should not
attempt to remove it from theshipping

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 (SeeFigure 2-1A)

5 2 3/8" FlatWasher
6 2 #10 Lockwasher

7 2 3/8"-16 Nylock Lock Nut
8 2 #10-32 x 1/2" Round Hd.

Screw

9 2 #10-32 Nut
10 1 Cotter Pin (not used)

11 4 PlasticTie Strap (2 not used)

Tools/Materials Needed

for Assembly

(1) 3/8" open-endwrench*
(1) 7/16" open-endwrench* (electric

start unit only)

(2) 9/16" open-endwrench*
(1) 7/8" open-endwrench or 8" long

adjustable wrench
(1) Scissors(to trim plasticties)
(1) Ruler

(1) Small board (to tap plastic knob 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.

* Adjustablewrenches may be used.

IMPORTANT:Motor oil must beaddedto

the enginecrankcasebeforethe engine is

started. Followthe instructions in this
"Assembly" Sectionand inthe separate

EngineOwner's Manual.
NOTE:LEFTandRIGHTsides of thetiller

are as viewedfrom the operator's posi-

tion behindthe handlebars.

STEP 2: ATTACHHANDLEBARS

1. On electric start units, removeone
screw and Iockwasherfrom the curved

5@_, 60 o

8_ @©9

7_ 10_

11

Figure2-1:Loosehardware(shownin
reducedsize).

Figure2-1A Handlebarheightadjustment
usestheflangeheadscrew.

Figure2-2: Onelectric start units, move
heightadjustmentbracket aside.

heightadjustment bracket (A, Figure2-2),
loosenthe secondscrew, andswing the

bracketto one side.

2. Cutthe large, plastic cableties that
securethe handlebarendsto the handle-

bar mounting tabs on the transmission

top cover.

3. Gently lift handlebar (do not over-
stretch attached cable) and placehandle-
bar cross-brace (B, Figure2-3) in front of
curved height adjustment bracket (C).

Figure2-3: Forwardclutchcontrolcable not
shownforclarity.

4. With the forwardclutchcable (N,
Figure2-4) onthe inside of handlebar,

position the handlebarendson the
outside of thetwo mounting tabs (IVI,
Figure2-3) on the transmission top

cover.

NOTE:Thecurved handlebarheight

adjustment bracketappears asshown in

C,Figure2-3 for non-electricstart units.
Forelectricstart units, the bracket is loos-

ened and moved to one side.

5. Loosely attachthe handlebars to 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 (0, Figure2-4).

Figure 2-4: Attachhandlebars.

6. Onelectric start units, reattach the
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 threaded hole 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 height adjustment screw
(F, Figure2-3) into the hole in the handle-
bar cross-brace, makingsure that the
raisedkeyson the washer fit into theslot
on the height adjustment bracket.

Tighten the heightadjustment screw
securely. Next,securely tighten the two

screws andnuts in the endsof the han-

dlebar (M, Figure2-3).

9. To removethe tiller from its shipping
platform, first carefully unwrap the wheel

gear cable (with attachedlever - see

Figure2-5) from around the chassis.
Movethe Wheel GearLever (G)to the
DISENGAGEposition--this allows the

wheels to rotatefreely. Usethe handle-

STEP 4: ATTACHFORWARD
CLUTCH CONTROL CABLE

1. Removeanyfasteners (rubber bands,

tape, etc.) that maysecurethe Forward

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

Figure2-5: CarefullyunwrapWheelGear
LeverandmovelevertoDISENGAGE.

barsto roll thetiller off the platform.
NOTE:TheWheelGearLever will be

installed later inthis procedure.
IMPORTANT: Usethe DISENGAGEposi-

tion only when the engine is not running.

Beforestarting the engine,the Wheel Gear
Levermust be placed inthe ENGAGE
position (seeSection 3 for details).

STEP3: ATTACH REVERSE
CLUTCH CONTROL CABLE

1. Carefullyunwrapthe reverseclutch
control cable(H, Figure2-6) from its
shipping position and route it up along
the insideedge ofthe left side handlebar.
A knoband large hexnut (I) is installed

on the cable.

I

LeftSide ReverseClutch]

Handlebar ControlKnob

I

Figure2-7: ForwardClutchControllevers
(J). Forwardclutchcontrollinkage(K).

2. Theforward clutch control cable(with
attachedspring) is hanging loosely near

the right-side wheel. Being careful not to

kink orstretch the cable, insert thez-con-
nector (L, Figure2-8 - end of the spring)

into the hole at the end of the forward
clutch control linkage(K, Figure2-7).

Figure2-6: Attachreverse clutch control
assemblyto slottedhole in handlebarpanel.

2. Insertthe cable into the slot in the
control paneland fit the threadedassem-

bly into the holein theslot (see Figure2-

6). Besure that theflat side of the
threadedassembly is aligned with the flat
side of the hole. Slide the hex nut (I) up
the cableand tighten it securely.

3. Testthefunction of the reverseclutch
control cableby pulling the knob out and

releasingit. Theknob should return to its
neutral position against the tapered
bushing. If it doesn't, contact your local
dealeror the factory for technical

assistance.

Figure2-8

3. Attachthe cableadjuster (A, Figure
2-9) to the bracket onthe right-side han-

dlebar. Usetwo 1/2"wrenchesto loosen

the two jam nuts (B) just enoughto slide
the cableadjuster onto the bracket. Then

hand tighten the jam nuts.

Figure2-9

Incorrectcable adjustment could cause
the wheels andtines to rotate unexpect-
edly. Follow adjustment procedures
carefully. Failure to do so could result

in personalinjury orpropertydamage.

4. Checkfor correct spring/cable tension

as instructed in Section5, Checkingand
Adjusting ForwardClutch Belt Tension.

5. Whentension is correct, tighten the
two jam nuts (B) securely.

STEP5: CHECKTRANSMISSION

GEAROIL LEVEL

Thetransmission was filled with gear oil
at the factory. However,be sureto check

the oil levelat this time to makecertain it

iscorrect.

IMPORTANT:Do not operatethe tiller if
the gear oil level is low. Doingso will

result inseveredamageto the transmis-
sion components.

1. With the tiller on levelground, pull the

Depth Regulator Lever(R, Figure2-13)

backand then slide it to the second notch
from the top. NOTE:If the lever does not

move,lift the tine hoodflap and look for a

plastictie securing the lever in place. Cut
and removethe tie.

2. Removethe oil levelcheck plug (M,

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

mission. (Dueto dried painton the plug
threads, it may require some force to

removethe plug the first time.) The gear

oil levelis correct if oil starts to flow out

ofthe hole asthe plug is removed. If so,
securely reinstall the plug.

Figure2-10: Gearoil level checkplug.

3. If oil does notflow from the check

hole,add oil as follows:

NOTE:Donot use automatic transmission
fluid or motor oil inthe transmission.

(a) Cleanareaaround the fill hole (N,

Figure2-11) and unscrewgear oil fill

plug.

Figure2-11: Addinggearoil.

(b) If adding only a few ouncesof gear
oil, useAPI ratedGL-4 or GL-5 gear oil
havinga viscosity of SAE140, SAE85W-
140 or SAE80W-90. If refilling anempty

transmission, useonly GL-4 gear oil

havinga viscosity of SAE85W-140 or
SAE140.

(c) Usinga cleanfunnel, slowly add gear
oil until itflows from the gearoil level

check hole (N, Figure2-11).

(d) Reinstalland tighten securelythe gear
oil fill plug (M, Figure2-10).

STEP 6: ATTACHWHEEL GEAR
LEVER

1. Insert the Wheel GearLever(P, Figure

2-12) up through theslot in the control

panelthat is labeled"WHEELGEAR."

2. Insert two #10-32 x 1/2" round head
screws down through the "+" marks on

the control paneldecal and securely
attach thewheel gear mounting bracket

usingtwo #10 Iockwashersand #10-32
nuts.

3. Usea small board to tap the Wheel
GearLeverknobsecurely onto the lever.

4. Securethe wheelgear cableand the
reverseclutch control cableto the left-

side handlebarwith two plastic ties (S,

Figure2-13) locatedabout two feet apart.
Snip off anyexcesstie lengthwith

scissors.

STEP7 ATTACHINGTHE BATTERY
CABLES(MODEL E666M)

The positive battery terminal is marked

Pos. (+). The negativebattery terminal is
marked Neg.(-).

1. Removethe hex bolt and hex nut from
the positive cable (heavy red wire).

2. Removethe plastic cover from the
positive batteryterminal and attachthe
positive cableto the positive batteryter-
minal (+) with the bolt and hex nut. Make

certain that the rubber boot coversthe

Figure2-12: AttachWheel GearLever.

Figure2-13: Attach wheel gear cable and
reverseclutchcable with cable ties (S).

positive terminal to help protect it from
corrosion.

3. Removethe hexbolt and hex nut from
the negativecable (heavyblackwire).

4. Removethe black plastic cover from
the negativebattery terminal andattach
the negativecableto the negativebattery
terminal (-) with the bolt and hex nut.

IMPORTANT:

• If the battery is put into serviceafter the

dateshown ontop of battery, chargethe
batteryas instructed in the Maintenence
sectionof this manualprior to operating

the tiller.

STEP 8: CHECKAIR
PRESSURE IN TIRES

Usea tire pressuregaugeto check the air
pressure in bothtires. Deflateor inflate
both tires equallyto between15 PSI and
20 PSI). Besure that both tires are
inflated equally orthe unit will pull to one

side.

STEP 9: CHECK HARDWARE
FOR TIGHTNESS

Inspect the hardwareon the unit and
tighten anyloose screws, bolts and nuts.

3 Featuresand Controls

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

resultin seriouspersonalinjury.

INTRODUCTION

This Sectiondescribesthe location and
function of the controls on your tiller.

Referto thefollowing section "Operation"

for detailedoperating instructions.

Practiceusingthese controls, with the
engine shut off, until you understandthe
operation of the controls and feel confi-

dent with them.

IMPORTANT:Referto the separateengine

manufacturer'sEngineOwner's Manual
for information about the controls on the

engine.

WHEEL GEAR LEVER

This lever(A, Figure3-1) has two posi-
tions: ENGAGEand DISENGAGE.

Inthe ENGAGEposition, the wheels will
start turning when eitherthe Forward

Clutch Control or the ReverseClutch
Control is engaged(the tines will also

start turning when eitherclutch is
engaged).

Figure3-1: Controlslocatedon handlebar.

The DISENGAGEposition placesthe
wheels inthefreewheeling modeto allow
the unitto be moved without the engine

running. Usethe DISENGAGEposition
only whenthe engineis not running. See

"DANGER"statementthat follows.

To shift to ENGAGE,gently (do not force)

movethe 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),

movethe lever rearward, without rolling
the tiller. Thewheels will roll freely
when the lever is properly set in the

DISENGAGEposition.

FORWARD CLUTCH CONTROL

The two interconnected levers (B, Figure

3-1) control the engagementof forward
drive to the wheelsand tines.

To Operatethe ForwardClutchControl:

1. Beforeengagingthe ForwardClutch

Control, put the WheelGearLeverin the
ENGAGEposition (see"WARNING"
below).

2. Pull up and hold one or both of the
levers againstthe handlebar grips to
engagethe wheels 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
thetiller rapidlyforwardor backward.

Failure to follow this instruction could
result in personal injury or property

damage.

Never engagethe wheels andtines 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 rapidlypropelthe tiller forward

or backward.
Failure to follow this warning could

result in personal injury or property
damage.

REVERSE CLUTCH CONTROL

The ReverseClutchControl (C, Figure

3-1) controls the engagementof reverse
driveto thewheels and tines. The revers-

ingfeature is usedfor maneuveringthe

tiller only- neverengagethe tines in
the groundwhile goingin the reverse

direction.

• Use extreme caution when reversing
or pulling the machine towards you.

Lookbehindto avoid obstacles.

• Neverattemptto till in reverse.

Failure to follow this warning could
result in personal injury or property
damage.

To Operatethe ReverseClutchControl:

1. Putthe WheelGearLeverin the

ENGAGEposition (seethe "WARNING"
statementon previouspage).

2. Stopall tiller motion by releasingthe

ForwardClutch Control levers.

3. Lift upthe handlebarsuntil thetines

clearthe ground, look behindyou to avoid
anyobstacles,and then pull the Reverse

ClutchControl knob out. Thetines and
wheelswill rotate in a reverse direction.

4. Releasethe ReverseClutch Control

knobto 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 inthe
"travel" position before starting the
engine. This position prevents the
tines from touching the ground until
youare readytobegintilling.

Failure to follow this warning could
result in personal injury or property
damage.

DEPTH REGULATOR

The Depth Regulator lever(D, Figure3-2)

controls the tilling depth of the tines. Pull

the leverstraight backand slide it upor

downto engagethe notched height set-

tings.

Figure3-2: DepthRegulatorLever.

The highest notch (leverall the way
down) raisesthe tines approximately

1-1/2 inches off the ground. This "travel"
position allowsthetiller to be moved

without the tines digging into the ground.

Moving the lever up increasesthe tilling
depth. Thelowest notch allows a tilling
depth of approximately six to eight

inches,depending on soil conditions.

Forbest results,always begintilling at
a very shallowdepthsettingand gradu-
ally increasethe tilling depth. Complete

details onusing the Depth Regulatorare
found in the "Operation" Section of this

manual.

HANDLEBAR HEIGHT ADJUSTMENT
The handlebarheight is adjustableto four

different settings. Setthe handlebar

heightto a comfortable setting, but keep

in mindthat the handlebarswill be lower
when thetines are engagedin the soil.

ToAdjusttheHandlebarHeight:

F

Figure3-3: Handlebarheightadjustment.

1. Stopthe engine, wait for all partsto
stop moving and then disconnectthe
spark plugwire. Removethe ignition key

on electric start models.

2. Loosenthetwo screws atthe lower
ends of the handlebar.

3. Loosenthe height adjustment screw

(E,Figure3-3) and pull the keyedwasher

(F)free ofthe slots in the curved height
adjustment bracket.

4. Movethe handlebarsto the newslot

setting and insert the raisedkeyson the
keyedwasher into the slot. Tighten the
height adjustment screw securely.

5. Retightenthe two screws at the ends
of the handlebar.

ENGINECONTROLS

Referto the engine manufacturer'sEngine
Owner's Manual(included in thetiller lit-
erature package)to identify the controls
on your engine. The following two con-
trols areusedwhen stopping or starting
the engine.

IMPORTANT:The control for stopping
the recoil start engineis locatedon the
engine.

ENGINE THROTTLE CONTROLLEVER
TheEngineThrottleControlLever(located

on engine--see Figure 4-1) is usedto reg-
ulatethe engine speed. Onthe recoil start
model only, it is also usedto stop the
engine (on the electric start model,the
electric start keyswitch is usedto stop the
engine). The throttle settings are shown

below.
IMPORTANT:See"Starting and Stopping

the Engine" inthe "Operation" Sectionfor
detailedenginestarting andstopping

instructions.

FAST- Usefor most tilling and

cultivating projects.

-l_ SLOW- Usewhen idling engineor
when slower tilling and cultivating

speeds are needed.

_) TOP- Stops the engine (on

recoil start models only).

ELECTRIC START KEYSWITCH
(MODEL E666M)

Theignition keyswitch on the electric start
model is used to start and stop the
engine. The keyswitch settings are

described below.
IMPORTANT:See"Starting and Stopping

the Engine" inthe "Operation" Sectionfor
detailedinstructions.

OFF- Stops engine.
RUN- After starting, keyreturns to run

position.
START- Startsengine. Releasekeywhen

engine starts (avoidcranking engine for
longer than 15 secondsfor eachattempt)

Operation

ReverseClutch

ForwardClutch

ControlLever

Wheel GearLever

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.

Failureto follow these instructionscan

resultin seriouspersonalinjury.

INTRODUCTION

Readthis Section ofthe manual thor-

oughly beforeyou start the engine. Then,
takethe time 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
engagingthe soil (put tines in "travel"
setting). Only after you've becomecom-

pletelyfamiliar with the tiller should you

begin using it in the garden.

BREAK-IN OPERATION

Perform the following maintenanceafter
thefirst two hours of newoperation (see

"Maintenance" in this manualand the

EngineOwner's Manual).

1. Changeengineoil.

2. Checkfor looseor missing hardware
on unit. Tighten or replace as needed.

3. Checktransmission gear oil level.

4. Checktension on forward clutch belt.

HandlebarHeight

AdjustmentScrew

,ill!iih,

\

ForwardClutch
ControlLever

DepthRegulatorLever

EngineThrottle
ControlLever

Figure4-1: Locationof main tiller controls.

STARTINGANDSTOPPING

THE ENGINE

To help preventserious personal injury

or damageto equipment:

*Before starting engine, put Wheel

GearLever in ENGAGEposition.

* Before starting engine, put Forward

Clutch Control levers and Reverse
ClutchControl in 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

the following services beforestarting the

engine.

1. ReadSections1 and 3 in this Manual.
Readthe separateEngineOwner's

Manual.

2. Checkunit for looseor missing hard-
ware. Serviceas required.

3. Checkengine oil level. SeeEngine
Owner's Manual.

4. Checkthat all safety guards and
coversare in place.

5. Checkair cleanerand enginecooling
system. SeeEngineOwner's Manual.

8. Attachspark plugwire to spark plug.

GASOLINEIS HIGHLYFLAMMABLEAND
ITSVAPORSAREEXPLOSIVE.

Follow gasoline safety rules in this
manual(see Section1) andin the sepa-
rateEngineOwner'sManual.

Failureto follow gasolinesafety instruc-

tions can result in serious personal

injuryand propertydamage.

7. Fillthe fueltank with gasolineaccord-

ing to the directions in the separate
EngineOwner's Manual. Follow all
instructions and safety rules carefully.

STARTINGTHE ENGINE

Thefollowing steps describe howto start
and stop the engine, go notattempt to

engagethe tines orwheels untilyou
haveread all ofthe operatinginstruc-

tionsin this Section. Alsoreview
the safetyrules in Section1: "Safety"

and the tiller and enginecontrols

informationin Section3: "Features and
Controls."

1. Completethe "Pre-Start Checklist" on

the previous page.

2. Put the WheelGearLever(Figure4-1)
in the ENGAGEposition.

3. Putthe DepthRegulator Lever inthe
"travel" position (leverall the way down)

so that the tines are clearof the ground.

4. Releaseall controls on the tiller.

5. Putthe EngineThrottle Control Lever
(Figure4-1) inthe "FAST"setting.

6. On enginesequippedwith afuel valve,

turn valveto open position as instructed

in the separateengine manual.

7. Chokeor prime engineas instructed in

the separateEngineOwner's Manual.

8. Forrecoil (non-electric) starting
models:

(a) Placeone hand onfuel tankto stabi-

lizeunit whenyou pull the starter
handle.

(b) Usethe recoil starter ropeto start

the engineas instructed inthe sepa-
rate EngineOwner's Manual. When
the enginestarts, graduallymove

the choke lever(on enginesso
equipped) to the "NO CHOKE",

"CHOKEOFF"or "RUN" position.

(c) Leavethe EngineThrottle Control

Leverinthe "FAST"setting.

9. Forelectric starting models (E666M):

(a) Turn the engine ignition keyto the

"START"setting andallow the
starter motor to crank the enginefor
several seconds. Avoid cranking the
engine longer than 15seconds at a
time as doing so could damage the

starter motor. NOTE: Referto the

EngineOwner's Manualfor detailed
starting instructions.

(b) When the engine starts, releasethe

keyand it will returnto the "RUN"

setting.

(c) Graduallymovechoke lever(on

enginesso equipped)to "NO
CHOKE","CHOKEOFF"or "RUN"
position.

(d) Leavethe EngineThrottle Control

Leverinthe "FAST"setting.

To Start the ElectricStart EngineWith
the Recoil StarterRope

If necessary,the electric start engine can
be started with the recoilstarter rope by

following the steps below:

1. If the battery is not "dead" or
damaged,leaveit connectedto the tiller
so it will be rechargedduring engine
operation. Makesure the battery cells are

filled to the UPPERLEVELline with elec-
trolyte.

2. If the battery is "dead" or damaged,
remove it (referto "Battery Removal and

Installation" in Section 5) and have it

tested. Beforestarting engine, coverthe
terminal on the looseend of the positive

(+) cable with the insulatedboot and
secure it in placewith electricaltape to

prevent electrical sparks.

3. Put the ignition key in the "RUN"
position andthenfollow Steps 1-8 of
"Starting the Engine."

STOPPING THE ENGINE

1. Tostop the wheels andtines, release

the ForwardClutch Control levers or the

ReverseClutch Controlknob (whichever
control is engaged).

2. Tostop the engine on the recoil start
model, move the EngineThrottle Control
Leverto the "STOP" position.

3. Tostop theengine on an electricstart
model, move the ignition keyto "OFF".

IMPORTANT:Afterstopping anelectric
start engine, removethe ignition keyfrom

the switch to reduce the possibility of

unauthorizedstarting of the engine.

OPERATINGTHETILLER

Thefollowing pagesprovideguidelines to

usingyour tiller effectively and safely in
various gardening applications. Besure
to read"Tilling Tips &Techniques" in this
Section before you actually put the tines

intothe soil.
This isa traditional "standard rotating

tine" tiller with forward rotating tines. It
operatescompletely differently from CRT

(CounterRotating Tines)tillers or from

low-cost front tine tillers.

1. Followthe "Pre-Start Checklist" on the

previous page. Besure thatthe Wheel
GearLeveris in the ENGAGEposition.

2. Putthe Depth Regulator Leverin the
"travel" position (lever all the way down)
so that the tines areclear of the ground.

Usethis position when practicingwith
your tiller or when movingto orfrom the
garden. When you are readyto begin
tilling, you must movethe Depth Regula-
tor Leverto the desireddepth setting (see
"Tilling Tips & Techniques").

3. Start theengine and allow it to warm

up. When warm, put EngineThrottle
Control Leverin "FAST"speedsetting.

Keepawayfrom rotatingtines. Rotating

tines will causeinjury.

4. For forward motion of the wheelsand
tines:

(a) Pull one or both of the Forward

Clutch Control Levers upand hold
them against the handlebars.To
stop forward motion of the wheels

and tines, releasethe levers.

Figure4-2: Useone handtoguide tiller

whenmovingforward.

(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

on the handlebars,but keepyour
arm loose. SeeFigure4-2. Letthe
tiller move aheadat its own pace
and do not push down on the han-
dlebarsto try andforce the tiller to
dig deeper- this takesweight off the
wheels, reducestraction, and causes
the tines to try and propel the tiller.

Do not push down on the
handlebars to 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
of control,propertydamage, or personal

injury.

5. Forreverse motion of the wheelsand
tines:

(a) Look behind andexercisecaution

when operating in reverse. Do not

till while in reverse.

(b) Stop all forward motion before

reversing. Lift the handlebarswith
one hand until the tines areoff the

ground andthen pull the Reverse
Clutch Control knob out to engage
reverse motion (seeFigure 4-3). To
stop reversemotion, let go ofthe

ReverseClutch Control knob.

Figure4-3: Raise tinesoffgroundand look
behindwhen movingin reverse.

6. To Turn the Tiller Around:
(a) Practiceturning the tiller in a level,

open area. Bevery careful to keep
your feet and legsawayfrom the

tines.

(b) To makea turn, reducethe engine

speedandthen lift the handlebars
until the engine and tines are bal-
ancedoverthe wheels (Figure4-4).

(c) With the tiller balanced,pushside-

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 and Engine

1. To stop the wheelsandtines, release

the Forward ClutchControl levers or the

ReverseClutch Control knob whichever
isengaged).

2. To stop the recoil start engine, move
the EngineThrottle Control Leverto
"STOP". Onelectric start models,turn the

ignition keyswitchto "OFF"to stop the

engine.

Beforetilling, contactyour telephoneor
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 oftheir equipmentor

lines are buried underground on your

property.

Turningthe Tiller Around

Figure4-4: Tobegin turn,reduce engine
speedand lift handlebars until engine

and tines are balancedover wheels.

Figure4-5: Withtiller balanced over

wheels(and tines outof the ground),

pushhandlebarssidewaysto turn tiller.

TillingTips& Techniques

Letthetiller dothe work

• While tilling, relaxand let the wheels
pull the tiller along while thetines do

the digging. Walk on the sidethat is

notyet finished (to avoid making foot-
prints inthe freshly tilled soil) and

lightly, butsecurely gripthe handlebar

with just one hand.

• Avoid pushing down on the handlebars
in an attempt to force the tiller to dig

deeper. Doing so takesthe weight off
the poweredwheels,causing them to

losetraction. Without the wheels
helpingto 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 pressureon the handlebarswill

helpget through a particularly tough

section of sod or unbrokenground, but

in mostcases this 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. Useshallow depth reg-

ulator settings (only an inch or two

deep) for the first passesthrough the
garden area. With eachsucceeding

pass,adjust the depth regulatorto dig

another inch or two deeper. (Watering
the garden areaa few days prior to
tilling will maketilling easier,as will

letting the newlyworked soil set for a

day or two beforemaking a final, deep
tilling pass.)

• When cultivating (breaking up the

surfacesoil around plantsto help
destroyweeds),usevery shallow depth
settingsto preventinjury to plantswhose

rootsoftengrow closetothesurface. If
needed,lift uponthe handlebarsslightly

to preventthetinesfrom diggingtoo
deeply. (Cultivatingona regularbasis

notonlyeliminatesweeds,it also loosens

andaeratesthesoil for bettermoisture
absorptionandfaster plantgrowth.)

Avoidtillingsoggy,wetsoil

Tilling wet soil often results in large,

hardclumps of soil that can interfere
with planting. Iftime permits, wait aday
or two after heavyrainsto 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 untilledside
of the unit to avoid makingfootprints in
thefreshly tilled soil. Footprintscause
soil compaction that canhamperroot

penetrationandcontribute to soil
erosion. They can also"plant" unwanted
weedseedsback intothe freshly tilled
ground.

Choosing correctwheel

and tine speeds

With experience,you will find the "just

right" tilling depth andtilling speed com-

binationthat is best for your garden.
Setthe EngineThrottle Control Lever to

a speed to give the engineadequate

powerand yet allow it to operate at the
slowest possiblespeed...atleast until
you haveachievedthe maximum tilling
depth you desire. Fasterengine speeds

may bedesirablewhen making final

passesthrough the seedbedor when
cultivating. Selectionof the correct
engine speed, in relationto the tilling
depth, will ensurea sufficient power

levelto do the job without causingthe
engine to labor.

Suggestedtilling patterns

• When preparinga seedbed,go overthe

same path twice in thefirst row, then
overlapone-half thetiller width on the
rest ofthe passes(see Figure4-6).
Whenfinished in onedirection, make a
second pass ata right angle asshown
in Figure4-7. Overlapeach passfor
best results (in very hardground it may
takethree or four passesto thoroughly
pulverizethe soil).

• Ifthe gardensizewill not permit
lengthwiseand then crosswisetilling,

then overlapthe first passesby one-

halfa tiller width, followed by succes-

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, plus enough extra room for
future plantgrowth.

Figure4-6

r y V

Figure4-7

Figure4-8

Figure4-9