Troybilt 21A-645A063, 21A-644H063 Owner’s Manual

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Page 1

0 TRtlI BILT°

Operator's Manual

Rear-tine Tiller Models

644H--Bronco TM 645A--Bronco TM

Model 644H Shown (bumper syles vary)

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. 769-00585A

(01/2003)

Page 2

TABLE OF CONTENTS

Content Page

Calling Customer Support .................................................... 2

Safety ................................................................... 3

Assembly................................................................. 6

Features and Controls ....................................................... 10

Operation ................................................................ 13

Maintenance .............................................................. 19

Off-Season Storage ........................................................ 24

Troubleshooting ........................................................... 25

Parts List................................................................. 26

Warrany Information ........................................................ Back Cover

FINDINGMODELNUMBER

This Operator's Manual is an important part of your new Rear-tineTiller. It wilt help you assemble, prepare and maintain 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

OTRII BILT" TROY-BILT LLC

www.troybilt.com CLEVELAND,OH44136

• 866-840-6483j

P. O. BOX 361131

330-558-7220

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.

CALLING 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.

your unit's model number and serial number ready when you call. See previous section to locate this

Call 1- (330) 558-7220 or 1- (866) 840-6483 to reach a Customer Support representative. Please have information. You will be asked to enter the serial number in order to process your call ..

Page 3

Safety

SPARKARRESTERWARNINGTORESIDENTSOFCALIFORNIAANDSEVERALOTHERSTATES

UnderCalifornia law, and under the laws of severalother states,you are not permitted to operatean internalcombustion engineusing hydrocarbon fuels on any forest, brush, hay, grain, or grass covered land;or land covered byany flammable agricultural crop without anenginesparkarresterin

continuous effective working order. Theengineon the unit is an internal combustion engine whichburns gasoline,a hydrocarbon fuel, and must be equippedwith a

spark arrester muffler incontinuous effective working order. Thespark arrester must be attachedto the engine exhaust system in such a manner that flames or heatfrom the system will not ignite flammablematerial. Failureof the owner/operator of the unit to comply with this regulation is a misdemeanor under California law (and other states) and may also bea violation of other state

and/or federal regulations, laws, ordinancesor codes, Contactyour localfire marshalor forest service for specificinformation aboutwhich regulations applyin your area,

Training

1. Carefully readthis Owner's Manual,the

separateEngineOwner's Manual, andany other literature you may

receive,Bethoroughly familiar with the controls and the proper use of the tiller

and its engine. Know howto stop theunit and disengagethe controls quickly.

2. Neverallow children to operatethe tiller,Neverallow adults to operatethe

tiller without proper instruction, 3, Keepthe area of operationclear of all

persons, particularly children andpets.

4. Keepin mindthat theoperator or user is responsible for accidents or hazards occurring to other people, their property,

and themselves.

Preparation

1. Thoroughly inspect theareawhere the tilleris to be usedandremoveallforeign objects.

2. Besure all tiller controls are released and both wheels arein the Wheel Drive

position beforestarting the engine,

3. Do not operatethe tiller without wearingadequateouter garments. Avoid loosegarments orjewelry that could get caught in moving parts.

4. Do not operatethe tillerwhen barefoot or wearing sandals, sneakers,or light footwear. Wearprotective footwearthat will improvefooting on slippery surfaces,

5. Donot till near underground electric

cables,telephone lines, pipes or hoses. If

in doubt, contact your telephoneor utility

company,

6. Warning: Handlefuel with care; it is highly flammable and its vapors are

explosive. Besureto take thefollowing

precautions:

a, Storefuel in containers specifically

designedfor this purpose.

b, Thegascap shall neverberemoved

or fuel addedwhile the engine is

running, Allow theengine to cool

for severalminutes beforeadding fuel.

Keepmatches,cigarettes, cigars, pipes, open flames,and sparks

away from the fuel tank and fuel container.

d, Fillfuel tank outdoors with extreme

care. Neverfill fuel tank indoors,

Usea funnel or spout to prevent

spillage.

e, Replaceall fuel tank and container

caps securely,

f. Iffuel is spilled, do not attempt to

start the engine, but move the

machineaway from the areaof spillage and avoid creating any source of ignition until fuel vapors

havedissipated,

7. Never makeadjustments when engine is running (unlessrecommendedby

manufacturer).

Operation

1. Do not put hands or feet nearor under

rotating parts. Thetines begin to rotate oncethe engine starts and the Forward Clutch Bail (or ReverseClutchControl) is engaged.

2. Exerciseextremecaution whenon or crossing gravel drives,walks, or roads,

Stay alert for hidden hazardsor traffic. Do not carry passengers,

3. After striking a foreign object, stop the engine,remove the wire from the spark

plug and prevent it from touching the spark plug, thoroughly inspectthe

machine for any damage,and repair the damagebefore restarting and operating

the machine.

4. Exercisecaution to avoid slipping or falling.

5. Ifthe unit should start to vibrate abnor- mally, stop theengine, disconnect the

spark plug wire and prevent it from touching the spark plug, and check

immediately for thecause. Vibration is generallya warning of trouble.

6. Stop theengine, disconnect the spark plug wire and prevent it from touching

the spark plug wheneveryou leavethe operating position, beforeunclogging the

tines, or when making anyrepairs,adJust- ments or inspections,

Page 4

Section1: Safety

7. Takeall possible precautionswhen

leavingthe machineunattended, Stop the

engine. Disconnectspark plug wire and

move it away from the spark plug. Be

sure both wheels are in the WheelDrive

position,

8. Beforecleaning, repairing, or inspect- ing,stop the engineand makecertainall

moving parts havestopped, Disconnect

the spark plug wire and prevent it from touching the spark plug to prevent acci- dentalstarting.

9. Theflap on the tine hood must be

down whenoperating the tiller.

10. Neverusethe tiller unless proper

guards, plates,orother safety protective devicesare in place.

11. Do not run enginein an enclosed

area,Engineexhaustcontains carbon

monoxide gas,a deadly poisonthat is

odorless, colorless, and tasteless,

12. Keepchildren andpetsaway.

13. Never operatethe tiller under

enginepowerifthe wheels are in the Freewheelposition.In the Freewheel position,the wheels will not holdthe

tiller backandthe revolvingtinescould

propelthe tiller rapidly, possibly causinglossofcontrol.Always engage

thewheelswith thewheel drive pinsin theWheelDrive positionbefore starting theengineor engagingthetines/wheels

with the ForwardClutch Bailor the

ReverseClutchControl.

14. Beawarethat the tiller may unexpect-

edly bounce upward orjump backward and be propelled toward you if the tines should strike extremely hard packedsoil, frozen ground, orburied obstacles like

largestones, roots, or stumps, If in doubt

about the tilling conditions, alwaysuse the following operating precautions to assist you inmaintaining control of the

tiller:

a. Walk behindand toone sideofthe

tiller, usingone handon the han- dlebars. Relaxyour arm, butuse a securehandgrip.

b. Use a deepdepth regulator

setting.

c. Useslowerengine speeds. d. Clear thetilling area of all large

stones,rootsandother debris.

e. Avoidusingdownwardpressure

on handlebars.If needbe, use slightupwardpressureto keepthe

tinesfrom diggingtoodeeply.

f. Beforecontactinghardpackedsoil

at the endof a row, reduceengine speedand lift handlebarstoraise tinesout ofthesoil.

In an emergency,stoptinesand

wheelsbyreleasingwhichever clutchcontrolisengaged. Donot

attemptto restrainthe tiller.

15. Do not overloadthetiller's capacity

by attempting to till too deeply at too fast

a rate.

16. Neveroperatethe tiller at high transport speedson slippery surfaces, Look behind and use great care when backing up,

17. Do not operatethe tiller on a slope that istoo steepfor safety,When on slopes, slow down and makesure you havegood footing, Never permit the tiller

to freewheeldown slopes,

18. Neverallow bystanders nearthe unit,

19. Onlyuse attachments and acces-

sories that areapproved bythe manufac- turer of the tiller,

20. Usetiller attachmentsandacces- sories when recommended.

21. Neveroperatethe tiller withoutgood visibility or light.

22. Neveroperatethe tiller if youare tired, or under the influenceof alcohol,

drugs or medication.

23. Operatorsshall not tamper with the engine-governorsettings on the machine; the governor controls the maximum safe operating speedto protect the engineand all moving parts from damagecausedby overspeed, Authorizedserviceshall be sought if a problem exists.

24. Do nottouch engine parts whichmay be hot from operation. Let parts cool down sufficiently.

25. Pleaseremember:Youcan always stop the tines and wheels by releasingthe

ForwardClutchcontrol or the Reverse Clutchcontrol (whichevercontrol you

haveengaged),or by moving the throttle control lever on the engineto "OFF"or

"STOP".

26. To load or unload the tiller, seethe instructions in Section4 of this Manual.

27. Useextremecaution whenreversing or pulling the machinetowards you.

28. Starttheengine carefullyaccordingto instructions and with feet well awayfrom

thetines.

29. Neverpick upor carry a machine while the engine is running.

MaintenanceandStorage

1. Keepthe tiller, attachments and acces- sories in safeworking condition.

2. Check all nuts, bolts, and screws at frequent intervalsfor proper tightness to

besure the equipment is in safeworking condition.

3. Neverstore the tiller with fuel in the fueltank insidea building whereignition

sourcesare present such as hot water andspace heaters,furnaces,clothes

dryers, stoves, electric motors, etc.). Allow engineto cool beforestoring in any

enclosure.

4. To reducethechances of a fire hazard, keepthe engine freeof grass, leaves,or

excessivegrease.

5. Storegasoline in a cool, well-ventilated area,safely away from any spark- or flame-producing equipment, Store gasolinein anapproved container, safely awayfrom the reachof children.

6. Referto the Maintenancesections of this Manualandtheseparate Engine

Owner'sManual for instructions if the tiller isto be stored for an extended

period.

7. Neverperform maintenancewhile the engineis running or the spark plug wire is connected,except when specifically

instructed to doso.

8. Ifthe fuel tank hasto be drained,do this outdoors,

Page 5

Decals

Foryour safety andthe safety of others, various safetyand operational decalsare located on your unit (see Figure1below).

Keepthe decals clean and legible atall times, Contactyour localservice dealer or the factory for replacementsif any decalsare damagedormissing,

Section1: Safety

Referto the separateparts catalog for decallocations, part numbers and

ordering instructions.

ForwardClutchControl

OperatingInstruction

StartingStabilization

Messageonengine

_ OperaUngInstruction

WarningMessages

ontinehood

HotSurfaces

Warningonbeltcover

ReverseClutchControl

Figure1:LocationofSafetyandOperatingDecals(Model 644Hshown).

OperatingSymbols

Various symbols (shown here, with word

descript'_ns)are usedon the tiller and engine

(your unit may not haveallof thesymbols).

FAST SLOW STOP

READTHEOWNER'SMANUAL. KNOWLOCATIONSANDFUNCTIONSOFALLCONTROLS. KEEPALLSAFETYDEVICESAND SHIELDSIN PLACEANDWORKING.

NEVERALLOWCHILDRENOR UNINSTRUCTEDADULTSTO OPERATETILLER. SHUTOFFENGINEANDDISCONNECTSPARKPLUGWIRE BEFOREMANUALLYUNCLOG-

GINGTINES ORMAKINGREPAIRS. KEEPBYSTANDERSAWAYFROMMACHINE. KEEPAWAYFROM ROTATINGPARTS. USEEXTREMECAUTIONWHENREVERSINGORPULLINGTHEMACHINETOWARDSYOU.

H I÷1

CHOKE CHOKE

ON OFF

(--411

TILLERDIRECTION

TO AVOID SERIOUS INJURY:

REVERSE

ROTATING

TINES

(-- o--->

LEVERDIRECTION

BAIL

ENGAGED

BAIL

DISENGAGED

Page 6

Assembly

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 instruc-

tions in this manual.

Introduction

Carefullyfollow theseassembly steps to correctly prepareyour tiller for use, It is recommendedthat you readthis Section in its entirety before beginning assembly, NOTE: Enginesyles vary by model, The engineon your tiller may appeardiffer- ently than those shown inillustrations and Figuresthroughout this manual,

Inspect unit

Inspect the unit and carton for damage immediately after delivery. Contactthe carrier (trucking company) if you find or suspect damage, Inform them of the damageand request instructions for filing aclaim. To protect your rights, put your claim in writing and mail acopy to the carrierwithin 15 daysafter the unit has

beendelivered,

STEP1: UnpackingInstructions

1. Removeanycardboard inserts and packagingmaterial from the carton.

Removeany staplesfrom the bottom of thecarton and then lift thecarton up and off theunit.

2,Thetiller is heavyandyou should not attempt to remove it from the shipping

platform until the handlebarsare installed, Theprocedurefor removing the

tiller is explainedin Step3 of these assemblysteps.

NOTE:Becareful not to severely bendany of the control cables on the unit.

3. Removeall unassembledpartsand the separatehardware bag from the carton, Checkthat you havethe items listed below (contact your localdealer or the factory if any items are missing or damaged), NOTE: Usethe screw length template (Fig, 2-1) to identify screws,

LooseParts List

Qty. Description

1 HandlebarSupport (seeA, Fig,2-2,

page7)

1 HandlebarAssembly

(seeK, Fig,2-2)

Thefollowing itemsarein the

hardwarebag:

1 Slotted hd. screw, #10-24 x 2" 1 Hexhd, screw, 1/4-20 x 1-1/4" 6 Curvedhd. screw, 5/16-18 x 1-1/2"

2 Hexhd, screw, 3/8-16 x 3/4" 2 Flatwasher, 3/8"

6 Split Iockwasher,5/16" 1 HexIocknut, 1/4"-20

6 Hexnut, 5/16"-18 2 HexIocknut, 3/8"-16

1 Hexnut,#10-24 1 Spring, cable(seeW, Fig. 2-5,

page8)

1 Bracket,forward clutch cable (see

P,Fig,2-5, page8)

1 Bracket,reverseclutch cable (see

BB,Fig, 2-8, page9).

IMPORTANT:Motoroil mustbeaddedto

the enginecrankcasebeforethe engine

isstarted. Followthe instructionsinthis "Assembly"section.

NOTE:LEFTand RIGHTsides of the tiller are asviewed from the operator's

position behindthe handlebars.

Tools]MaterialsNeededfor Assembly

(1) 3/8" open-endwrench* (2) 7/16" open-endwrench* (1) l/2" open-endwrench* (2) 9/16" open-endwrench* (1) Large adjustablewrench (1) Scissors (to trim plastic ties)

(1) Ruler (for belt tension check) (1) Block of wood (to support tiller

whenremoving wheels)

(1) Automotive-type air pressure gauge (1) Cleanoil funnel

(1) Clean,high-quality engine oil Refer

to the EngineOwner Manualfor engineoil specifications andquantity required, Do not overfill,

* Adjustablewrenches may be used.

Figure2-1:Toidentifylengthofscrew, placescrewontemplateasshownand measuredistancebetweenbottomofscrew

headandtipofscrew.

Page 7

STEP2: Attach Handlebar

1. Attach the two legs ofthe handlebar support (A, Fig.2-2) loosely to the inner sides of the tiller frame using two 3/8"-16

x 3/4" hexhd. screws (B), 3/8" flat washers(C) and 3/8"-16 hexIocknuts (D).

2. Usingthe middle holesin the handlebar support brackets (Eand F,Fig. 2-2), loosely attachthe support bracketsto the handlebarsupport (A) using two 5/16"-18 x 1-1/2" curved hd. screws (G),5/16" split Iockwashers (H)and 5/16"-18 hexnuts (I). NOTE:If a support bracketwill not move, loosenattaching screw (J) and nut.

3. Attach the handlebarassembly (K) to thehandlebarsupport (A) using four

5/16"-18 x 1-1/2" curved hd. screws (G), 5/16" split Iockwashers(H) and 5/16"-18 hexnuts (1).Tighten the four screws securely.

4. Tighten allhandlebarmounting hardwaresecurely.

Section2: Assembly

STEP3: MoveTiller OffShipping

Platform

Tomovethe tiller withouttheengine running, put the wheelsin their FREEWHEELposition, as described below.

1. Usea sturdy blockto raise onewheel off theground.

2. Removethe hairpin cotter (L, Fig.2-3) and wheeldrive pin (M). Slide the wheel

inward on the wheelshaft (N). Reinstall thewheel drive pin and hairpin cotter

through the wheelshaft only (not through thewheel hub). Repeatwith the other

wheel.

3. Using the handlebaras a lever, roll the tiller to aflat area.

IMPORTANT:Beforestarting the engine, thewheels must be placedintheirWHEEL DRIVEposition (pins through wheel hubs and wheelshaft). This procedureis

described in "Wheel Drive Pins" in Section 3.

Fig. 2-2: Attach handlebar.

Fig. 2-3: Wheel in FREEWHEELING position(wheel drivepin throughwheel

shaRonly).

Page 8

Section2: Assembly

STEP4: Install ForwardClutch Cable

1. Placethe forward clutch cablebracket (P,Fig.2-4) on the handlebarsupport (A).

Attach the cable bracket using a 1/4"-20 x

1-1/4" hexhd, screw (R, Fig. 2-4) and 1/4"-20 hexIocknut (S).Tightensecurely.

2. Carefullyunwrap the forward clutch

cable (the cablewithout a knob attachedto it) from its shipping position and slide the thin cablewire (T, Fig. 2-4) into the slot in

thecable bracket. Pushthecableconnector

(U, Fig,2-4) up through the hole in the

bracket until the groove in the connector snaps into placeonthe bracket.

3. Insertthe #10-24 x 2" slotted hd. screw (V,Fig.2-5) down into the cablespring

(W). The threadedend of thescrew will

extend from the bottom of the spring.

4. Threadthe #10-24 hex nut (Z) on the

slottedheadscrew(V).Threadit halfwayup,

5. Threadscrew (V) into cableadjuster (X),

6. Hookcablespring (W, Fig. 2-6) into "V"-

shapedbend in theforward clutch bail (Y).

7. Lift and hold the ForwardClutch bail

against the handlebar. SeeFig, 2-7,

8. Measurethe length of the cable spring

betweenthe ends of the coils (Fig. 2-7). Thelength should be approximately 1-7/8".

If the length is correct, turn the #10-24 hex

nut (Z) down tightly againstthe cable adjuster (X) while holding the adjuster in place. SeeFigure2-7, If the length is incorrect, you must makean adjustment to

the cable tension as described in "Checking andAdjusting ForwardDrive

Belt Tension" in Section 5. When the spring length is correct, tighten the hex nut

(Z)againstthe cable adjuster (X).

Fig. 2-4: Installing forwardclutchcable bracketand cable.

W-- Fig.2-5:Assemble

springandadjuster.

V-- --Z

X--

Fig,2-6:Installforwardclutchcable,

STEP5: Install ReverseClutch Cable

1. Removethetwo pre-installedself-tapping

screws (AA,Fig,2-8) from the handlebars.

2. Position the reversecablemounting

bracket (BB, Fig, 2-8) asshown and reinstall thetwo self-tapping screws.

3. Unwrapthe reverseclutch cable (the

cablewith a knobandalargehex nut attachedto it) from around its shipping positionand routethe cable(CC,Fig.2-8 and Fig,2-9) up to thecable bracket(BB, Fig, 2-8), Be surethat thecable goes

beneaththe ForwardClutch Bailas it is routed up to the cablebracket.

Fig.2-7:Measurecablespring.

Page 9

Section2: Assembly

4. Insertthe cableupthrough the slot in

the cable bracketand position the threadedassembly as shown in Fig,2-8,

Makesurethat the flat sideof the

threadedassembly is aligned with the fiat side of the mounting hole, Slidethe large

hexnut (DD) up thecable and tighten it

securely,

5. Usea cabletie (EE,Fig,2-9) to fasten the reverseclutch cable to the left side

handlebar,

6. Testthe function of the reverseclutch cable by pulling the knob out and

releasingit. Theknob should return to its neutralposition(resting against bracket)

when it is released. If it doesn't, contact your localdealer or the factory for

technical assistance,

AA_

STEP6: CheckLevelof TransmissionGearOil

Thetransmission was filled with gearoil

at the factory. However,you should check the gear oil levelto make certain it is

correct. IMPORTANT:Do not operate the tiller if

the gear oil levelis low. Doingso will result in severedamageto the transmis-

sion components,

1. Putthe tiller on level ground. Pullthe DepthRegulator Lever (FF,Fig. 2-10)

back and then adjust it up or down to the notch that makesthe tiller level.

2. Removethe oil fill plug (GG,Fig, 2-11)

from the transmission housing and look into theoil fill hole. Youwill see the main

drive shaft on one side of the hole,

3. The gearoil level is correct if the gear

oil is approximately halfway up the side of the drive shaft,

4. If the gear oil level is low,addgearoil

by referring to "A. To Checkthe Transmis- sion GearOil Level"in Section 5,

Fig, 2-10: AdjustDepthRegulator Lever.

Fig.2-11:Removegearoil fillplug.

FlatSide

Fig.2-8:Installreversecablemounting bracketandthereverseclutchcable.

Fig. 2-9: Route reverseclutch cable(CC)as shown. Attachtohandlebarwith cable tie

(EE).

STEP7: Add Motor Oil to Engine

The tiller is shippedwithoutoil in the engine.

IMPORTANT: Do not start the engine without first adding motor oil.Severe

engine damagewill result if the engine is run without oil,

1. Referto the EngineOwner'sManual (suppliedwith tiller) for engineoilspecifi-

cations and capacities,

2. With the tiller on levelground, pullthe DepthRegulator Lever (FF,Fig. 2-10)

back and then slide it up or down as necessaryuntil theengine is level.

3. Add motor oil asdescribedin the EngineOwner's Manual.

4. Move the Depth Regulator Leverall the

way down until the highest notch is engaged, This placesthetines in the

"travel" position,

STEP8: CheckHardwarefor Tightness

Checkall nuts and screws for tightness,

STEP9: CheckAir Pressurein Tires)

Usea tire pressuregauge to checktheair pressurein both tires, Deflateor inflate

both tires equallyto 15-to-20 PSI (pounds per square inch), Be surethat both tires areinflatedequallyor the unit

will pullto oneside.

IMPORTANT: This completes the assembly steps, Beforeoperating your tiller, make sureyou readthe following

Sectionsin this Manual, aswell as the separateEngineOwner's Manual:

• Section 1: "Safety"

• Section 3: "Featuresand Controls"

• Section 4: "Operation"

Page 10

FeaturesandControls

WARNING

Before operating your machine, carefully read and

understand all safety, controls and operating instructions in

this Manual, the separate Engine Owner's Manual, and

on the decals on the machine. Failure to follow these

instructions can result in serious personal injury.

Forward ReverseClutch

ClutchBail Control

ulator

ight

Adjustment

Anti-ReverseStake

DrivePin

(on eachwheel)

Figure3-1: Featuresandcontrols.

Introduction

Thissectiondescribes the locationsand

functions of thecontrols on your tiller. Referto the next section ("Operation") for detailed operating instructions.

Practiceusing thesecontrols, with the

engine shut off, until you understand the

operationof the controls and feel

confident with eachof them,

IMPORTANT:Referto theseparate

engine manufacturer's EngineOwner's

Manualfor informationabout the

controls on theengine.

WheelDrivePins

WARNING

Never allow either of the wheels to be in the FREEWHEEL position when the engine is running. Always

put both wheels in the WHEEL DRIVE position before starting the engine.

Failure to comply could cause loss of tiller control, property

damage, or personal injury.

Eachwheel isequippedwith aWheel

Drive Pin (A,Figures3-2and 3-3) that securesthe wheel to the wheelshaft (B).

Thewheelscan be positioned in either a WHEELDRIVEor aFREEWHEELmode.

Beforestarting the engine,put both wheels inthe WHEELDRIVEposition by inserting theWheel Drive Pinsthrough

the wheel hubs and the wheel shaft, This "locks" the wheels to the wheel shaft, causing the wheelsto turn when either

the ForwardClutch Bailor the Reverse ClutchControl is engaged.

Usethe FREEWHEELmode only whenthe engineis not running, In FREEWHEEL,

theWheel Drive Pins are placedonly

through the holesinthe wheel shaft (not thewheel hubs), thus allowingthe wheels

to turn freely whenthe tiller is pushed or pulled by hand,

To Place the Wheelsin WHEELDRIVEor FREEWHEEL:

1. Stop the engine, disconnect the spark

plug wire from the spark plug and allow theengine to cool,

2. Raiseonewheeloff the ground and placea sturdy supportunder the transmission.

3. Removethe wheel drive pin (A,

WARNING

Do not place the tiller on its side when changing the wheel

drive positions as doing so could result in gasoline leaking from the fuel tank.

Failure to follow this instruc- tion could result in personal

injury or propertydamage.

Figures 3-2 and 3-3) by removing the hairpin cotter (C).

Page 11

Section3: FeaturesandControls

4. FORWHEELDRIVEmode (Figure 3-2):

Slidethe wheel outward and align the holesin the wheel hub (D, Figure 3-2))

and the wheel shaft (B). Insertthe wheel drive pin (A)through the wheel hub and

the wheel shaft, Securethe wheel drive

pin with the hairpin cotter (C) by pushing

the hairpin cotter in as far as it will go.

Repeatfor the other wheelandthen removethe support from beneaththe

transmission,

5. FORFREEWHEELmode (Figure 3-3): Slidethe wheel inward and insert the

wheeldrive pin (A, Figure3-3) only through the hole in the wheel shaft (B).

Securethe wheel drive pin with the hairpin cotter (C)by pushing the hairpin

cotter inas far asit will go, Repeatfor the other wheel and then remove the support

from beneaththe transmission.

ForwardClutchBail

TheForward Clutch Bail (E, Figure 3-4) controls theengagementof forward drive to the wheels and powerto the tines,

NOTE: Thewheelswill rotate in aforward direction; the tines will rotatecounter- clockwise(backwardtoward the operator),

To OperatetheForwardClutchBail:

1. Putthe wheels in theWHEELDRIVE position(seethe following "WARNING"

statement).

2. Lift and hold the bail againstthe handlebar. Thewheels and tines will

rotate- and the tiller will moveina forward direction.

3. Releasethe bail to disengage(stop) thewheelsandtines. Forwardtiller motion

will stop (theenginewill continue to run).

WARNING

Before starting the engine, be sure that both wheels are in

the WHEEL DRIVE position.

See "Wheel Drive Pins" for instructions.

ReverseClutchControl

The ReverseClutchControl (F,Figure3-4) controls the engagementof reversedrive to thewheels and tines, Thispowered

reversing feature is used for maneuvering the tiller only - neverengagethetines in the ground while going in thereverse

direction.

To Operatethe ReverseClutchControl:

1. Operate onlywhen the wheels arein

the WHEELDRIVEposition (seethe

"WARNING"statement atthe left).

2. Stopall tiller motion by releasingthe

ForwardClutch Bail.

3. Lift up thehandlebar until the tines clear the ground, look behind you to avoid

anyobstacles, and then pull the reverse clutch control knobtoward you. The

wheels will rotate in a reversedirection.

4. Releasethe reverseclutch control

knobto disengage (stop) the wheels and tines, All reversemotion will stop (the engine will continueto run),

Figure3-2: WHEELDRIVEposition,

Figure3-3: FREEWHEELposition.

Engaging the Forward Clutch Bail or the Reverse Clutch

Control when the wheels are not in the WHEEL DRIVE

position could allow the tines to rapidly propel the tiller forward or backward.

Failure to comply could cause

loss of tiller control, property

damage, or personal injury.

Figure3-4:ForwardClutchBail(E)andReverse ClutchControl(F).

WARNING

• Use extreme cautionwhen

reversing or pulling the machine towards you. Look

behind to avoid obstacles.

• Never attempt to till in reverse.

Failure to follow this warning

could result in personal injury or property damage.

Page 12

Section3: FeaturesandControls

DepthRegulatorLever

Thislever (G,Figure3-5) controls the

tilling depthof the tines, Pullthe lever straight backand slideit up or down to engagethe notched height settings.

Thehighest notch (lever all the way down) raisesthe tines approximately 1-

1/2"off the ground. This "travel" setting

allows the tiller to be movedwithout the tines digging into the ground. Also use

this setting when starting the engine. Move the lever upwardto increasethe

tilling depth, Thelowest notch allowsa tilling depthof approximately 6"-8",

dependingon soil conditions, Forbestresults, begin tilling at the

deepestdepthpossiblewithout causing

the tiller to bog down. Increasethe tilling

depthfrom one passover the soil to the next.

Travel

Position

HandlebarHeightAdjustment

Thehandlebarheight is adjustableto

threedifferent settings (seeFigure 3-6). Asageneral rule, adjust the handlebars sothey areat waist levelwhen thetines

are3"-4"into the soil.

ToAdjustthe Handlebars:

1. Stopthe engine, disconnect the spark

plug wire from thespark plug and allow theengine to cool,

2. Removethe screws, Iockwashersand nuts, reposition the handlebars,and

reinstall the hardware.

Anti-ReverseStake

Thisstake is locatedat the rear of the transmission,under the tine hood (see H,

Figure3-7). Its purposeis to automati- cally help preventthe counter-rotating tines from letting the tiller back up in the direction of the operator if the tiller wheels had beeninadvertently left in the FREEWHEELposition. In this situation,

the Anti-ReverseStakewill be forced down into theground, lifting the tines

upward out of the soil and helping prevent backwardmotion of the tiller.

TheAnti-ReverseStakerequires no adjust- ment, but should be inspectedbefore eachtiller use to verify that it swivels

freely. Removeanyclogged materials (dirt, roots, rocks, etc.) that preventthe

Anti-ReverseStakefrom swinging freely.

Figure3-5."Depthregulatorlever,

WARNING

• 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 Referto the engine manufacturer's Engine

or propertydamage. Owner'sManual(includedin thetiller lit-

Figure3-6."Handlebarheightadjustment.

Figure3-7:Anti-ReverseStake.

ENGINECONTROLS

eraturepackage)to identify thecontrols onyour engine.

IMPORTANT:Thecontrol for stopping the

engine is located on the engine.

Page 13

Operation

WARNING

Before operating your machine, carefully 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 instruc- tions can result in serious personal injury.

,Reverse ClutchControl

ForwardClutchBail

ulatorLever

INTRODUCTION

Readthis Sectionof the manualthor-

oughly beforeyou start the engine, Then, take thetime to familiarizeyourself with the basic operation of thetiller before using it in the garden, Findanopen, level areaand practice using the tiller controls

without the tines engaging the soil (put tines in "travel" setting), Onlyafter

you've become completely familiar with the tiller should you begin using it in the

garden.

INITIAL OPERATION

Perform the following maintenanceduring

thefirst hours of newoperation (see

"Maintenance"section in this manualand in the EngineOwner's Manual).

1. Changeengineoil after first 2 hours of newengineoperation.

2. Checkfor looseor missing hardware

on unit, Tighten or replaceasneeded.

3. Checktension on forward drive belt

after first 2 hours of operation,

4. Checktransmission gear oil levelafter

first 2 hours of operation,

Recoil Starter

Figure4-1

STARTINGANDSTOPPINGTHE ENGINE

Pre-StartChecklist

Makethefollowing checksand perform the following servicesbeforestarting the engine,

1. Readthe"Safety" and "Controls" sections in this manual. Readthe

separateEngineOwner's Manual provided by the engine manufacturer,

2. Checkthat the wheelsare in the WHEELDRIVEposition (wheel pins must

bethrough the wheel hubsandthe wheel shaft holes).

3. Checkunit for loose or missing hardware. Serviceas required,

4. Checkengine oil level. See Engine Owner's Manual,

5. Checkthatall safety guards and coversarein place,

6. Checkair cleanerandenginecooling system, SeeEngineOwner's Manual.

7. Attach spark plug wire to spark plug.

8. Fill thefuel tank with gasoline according to the directions in the separateEngineOwner's Manual. Follow all instructions andsafetyrules carefully.

Wheel Drive Pin

(on eachwheel)

DANGER

GASOLINE IS HIGHLY FLAMMABLE AND ITS VAPORSARE EXPLOSIVE.

Followgasolinesafetyrulesin this manual (see Section 1)

and in the separate Engine Owner'sManual.

Failure to follow gasoline safety instructionscan result

in serious personal injury and property damage.

Page 14

Section4: Operation

Startingthe Engine Thefollowing steps describe how to start

and stop the engine. DOnotattempt to engagetines or wheels untilyouhave

read all the operatinginstructionsinthis Section. Also review thesafetyrules in Section1: "Safety" andthetiller and engine controlsinformationin Section

3: "Features andControls."

CAUTION

To help prevent serious

personal injury or damage to equipment:

• Before starting engine, put both wheels in the WHEEL

DRIVE position. Never have the wheels in the

FREEWHEEL position when the engine is running. When the wheels are in

FREEWHEEL, they do not hold back the tiller and the

tines could propel the tiller rapidly backward.

• Before starting engine, put Forward Clutch Bail (all

Models) and Reverse Clutch Control in neutral (disen-

gaged) positionsby releasing levers.

• Never run engine indoors or in enclosed, poorly venti-

lated areas. Engine exhaust contains carbon monoxide, an odorless and deadly gas.

*Avoid engine muffler and

nearby areas. Temperatures in these areas may exceed

150OF.

1. Completethe"Pre-Start Checklist" on theprevious page.

2. PutthewheelsintheWHEELDRIVE

position (see"Wheel DrivePins"in Section 3)+

3. Putthe DepthRegulatorLeverinthe "travel" position (leverallthe waydown) so that thetines areclear of the ground.

4. Releaseall controls on the tiller.

5. If engineis equipped witha fuel valve,

turn valveto openposition asinstructed

intheseparateEngineOwner's Manual.

6. Put ignitionswitch and/or throttle

control leveron enginein "ON," "RUN," "FAST"or"START"positionas instructed in the separateEngineOwner'sManual.

7. Chokeor primeengineas instructed in theseparateEngineOwner's Manual.

8. Placeonehandonthe fueltank to stabilizethe unit whenyou pullthe starter

handle. Usethe recoil starter ropeto start theengine as instructed in the separate EngineOwner's Manual. When engine starts,gradually movechoke lever (on enginesso equipped)to "NOCHOKE," "CHOKEOFF"or "RUN" position.

WARNING

Hot surfaces can cause severe burns. Do not touch muffler or adjacent areas.

9. Usethe "FAST"throttlespeedsetting whentilling.

WARNING

Keep away from rotating

tines. Rotating tines will

cause injury.

Stoppingthe EngineandTiller

1. To stop the wheelsandtines, release theForward Clutch Bail or the Reverse ClutchControl-- whichever control is in

use.

2. To stop the engine, put the throttle

control leveron enginein "OFF"or "STOP"position.

OPERATINGTHETILLER

Thefollowing pages provide guidelines to

using your tiller effectivelyand safely in various gardening applications. Besure to read "Tilling Tips & Techniques" in this Section beforeyou actually putthe tines

into the soil. This is a CRT(counter-rotating tine) tiller.

Asthe wheels pull forward, thetines rotate backward.

Thiscreates an "uppercut" tine action which digs deeply,uprooting soil and

weeds. Don't overloadthe engine,but dig asdeeplyas possible on each pass. On

later passes,the wheels may tend to spin in thesoft dirt. Help them along by lifting

up slightly on the handlebar(palm facing

up).

1. Followthe"Pre-Start Checklist" on the previous page. Besure that the wheels

are in the WHEELDRIVEposition.

2. Put theDepthRegulatorLeverinthe "travel" position (leverall the way down)

so that the tines are clear of the ground. Usethis position when practicing with

your tiller or when moving to or from the garden. When you are readyto begin

tilling, you must move the Depth Regulator Leverto the desireddepth

setting (see "Tilling Tips & Techniques"). Checkthat theAnti-Reverse Stakeswivels

freelybackand forth. Removeanyclogged material on or around the stake.

Figure4-2: Useonehandtoguidetiller

whenmovingforward.

3. Start theengineandallow it to warm up. When warm, putthrottle control in

fast speed setting.

4. Forforward motion of wheelsand powerto the tines:

(a) Pull the Forward Clutch Bail up and

hold it againstthe handlebar. Release the bail to stop forward motion of

thewheels and powerto the tines.

(b) Asthe tiller moves forward, relaxand

letthewheelspulltheunit alongwhile

the tines dig. Walk behindand a

little to oneside of thetiller. Usea light but securegrip with one hand

on the handlebars,keepingyour arm

loose. SeeFigure4-2.

Page 15

Section4: Operation

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 backward

toward the operator, which could result in loss of control,

property damage, or personal

injury.

Letthe tiller move at its own paceand do not push down on the handlebarsto tryto

dig deeper- this takesweight off the wheels,cuts traction, andcausesthetines

to try and propel the tiller.

5. Forreversemotion of thewheelsand tines:

(a) Lookbehindandexercisecaution

when operating in reverse. DOnet

till while in reverse.

(b) Stop all forward motion before

reversing, Lift the handlebarswith one hand until the tines are off the

ground and thenpull the Reverse ClutchControl knob out to engage reversemotion (see Figure4-3). To stop reversemotion, let go of the

ReverseClutch Control knob.

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

open area. Beverycarefulto keep your feetand legsawayfrom the

tines,

(b) To makea turn, lift the handlebars

until theengine and tines are balancedover the wheels (Figure

4-4). Thetinesmust be out of the ground while turning the tiller.

sideways on the handlebarto move the tiller in the direction of the turn

(Figure4-5). After completing the turn, slowly lower the tines into the soil to resume tilling.

Figure4-3: Raise tines offgroundand look behind whenmovingin reverse.

Turningthe TillerAround

Figure4-4: Tobeginturn,lift handlebars untilengineandtinesarebalancedover

wheels.Besuretinesareoutofground.

StoppingtheTiller andEngine

1. To stop thewheelsandtines, release

the ForwardClutch Bailor the Reverse Clutch Control - whichever is engaged.

2. To stop theengine, movethe throttle control leveron engineto "OFFIIor

"STOP"position.

WARNING

Before tilling, contact your telephone or utilities company and inquire if underground

equipment or lines are used in your area. Their representa-

tive will be glad to answer your questions and tell you if any of their equipment or lines

are buried underground on yourproperty.

Figure4-5: With tiller balancedover

wheels(and tines outof theground), push

handlebarssidewaystoturntiller.

Page 16

Section4: Operation

TillingTips& Techniques

Letthetiller dothe work

• Whiletilling, relaxandlet thewheels

pull the tiller along whilethe tines do the digging. Walkonthe side that is

not yetfinished (to avoid making foot- printsin the freshly tilled soil) and

lightly, but securely grip the handlebar with just one hand, SeeFigure4-2.

•Avoid the temptation to push 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 backwardtoward the

operator- often causing thetiller to skip rapidly acrossthe ground,

Tilling depths

•When preparing the soil, till a fresh pathon each pass ratherthan overlap- ping passes, This gives the wheels

maximum traction on undisturbed soil. SeeFigure4-6. Digas deeplyas

possible on eachpasswithout over- loading theengine, Later passescan be overlapped, (Watering the garden area afew 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, deeptilling pass.)

•Whencultivating (breaking up the surfacesoil around plantsto help destroyweeds),adjust the tines to dig only 1-1/2"to 2"deep, Usingshallow tilling depthshelpspreventinjury to plantswhoseroots often growcloseto the surface, ff needed,lift uponthe

handlebarsslightly to preventthetines from digging toodeeply. Cultivatingon

a regularbasisnotonlyeliminates weeds,it alsoloosensandaeratesthe

soil for bettermoistureabsorptionand fasterplantgrowth,

Avoidtillingsoggy,wetsoil

Tilling wet soil often results in large, hard clumps of soil that can interfere

with planting. If time permits, wait a day or two after heavyrainsto allow the soil

to dry beforetilling, Test soil by squeezing it into a ball, If it compresses

too easily,it is too wet to till.

Avoidmaking footprints

Wheneverpossible,walkonthe untilled side of theunit to avoid making foot- prints in your freshly tilled or cultivated soil. Footprintscausesoil compaction that can hamper root penetrationand contribute to soil erosion. Theycanalso "plant" unwantedweed seedsback into the freshly tilled ground,

Choosingcorrectwheel andtine speeds

With experience,you will find the'_just right" tilling depth and tilling speed combination thatis best for your garden,

Set the engine throttle leverat a high enough speedto give the engine adequatepower and yet allow it to operatewithout overloading it. Fastest engine speedsmay bedesirable when making final passesthrough the seedbedor when cultivating. Selection of thecorrect enginespeed, in relation to thetilling depth, will ensurea suffi-

cient power levelto do thejob without causing the engineto labor.

Suggestedtilling patterns

• Whenpreparinga seedbed,go over the same path twice in the first row, then makeindividual passes right next to each other (seeFigure4-6), When

finished in one direction, makesecond passesat a right angle asshown in

Figure4-7,

In very hard groundit may takethree or four overlapping passesto thor- oughly pulverizethe soil, (SeeFigure 4-8.)

• If thegardensizewill not permit lengthwiseand then crosswise tilling,

then overlap the first passesby one-

halfa tiller width, followed by succes- sive passesat one-quarterwidth (see Figure4-8).

•With planning, you can allow enough room between rows to cultivate (see Figure4-9). Leaveroom for the hood

width, plus enough extra room for

future plant growth.

Figure4-6

Figure4-7

Figure4-8

Figure4-9

Page 17

Section4: Operation

TillingTips& Techniques

Clearingthetines

Dry grass, stringy stalks or tough vines may become tangledin thetines. Follow these proceduresto help avoidtangling and to clean the tines, if necessary.

• Toreducetangling, set the depth regulator to maximum depth.

• Whiletilling, try swaying the handle- barsfrom sideto side (about6"to 12").

This "fishtailing" action oftenclearsthe tines of debris.

• If tangling occurs, lift the tines out of thesoil and runthe tiller in reversefor

a few feet, This may unwind a good dealof debris.

• It may be necessaryto remove the debris by hand (a pocket knifewill help youto cut awaythe material).

WARNING

Before clearing the tines by hand, stop the engine, allow all moving parts to stop and

disconnect the spark plug wire.

Failure to follow this warning could result in personal

injury.

Tilling onslopes

If you must garden on a moderate slope, pleasefollow two very important guide-

lines:

1.Tillonly on moderate slopes, neveron steepground where footing is difficult (review safety rules in the "Safety" sectionof this manual).

2.We recommend tillingup and down slopes ratherthan terracing, Tilling

vertically on a slope allows maximum

planting areaand also leavesroom for

cultivating,

IMPORTANT:Whentilling on slopes, be surethe correct oil levelis maintained in

the engine (check every one-haff hour of

operation). The incline of the slopewill

cause the oil to slant awayfrom its

normal level and this canstarve engine parts of required lubrication. Keepthe

engine oil levelat the full point at all times!

A. Tilling upand downslopes:

•To keepsoil erosion to a minimum, be

sure to add enough organicmatter to the soil so that it has good moisture- holding texture and try to avoid leaving footprints or wheel marks.

•When tillingvertically, try to makethe

first passuphill as thetiller digs more deeplygoing uphill than it does downhill, In soft soil or weeds,you may haveto lift handlebarsslightly while going uphill.

B. Tilling acrossslopeswithout usingterraces:

If previouslydescribedtilling methods

aren't practicalfor you, thenyou cantill

laterallyacross a slope. However,we don't reallyrecommendthis method as it can create unsurefooting and invites

soilerosion.

Page 18

Section4: Operation

LOADINGANDUNLOADINGTHE TILLER

WARNING

Loading and unloading the

tiller into or from a vehicle is

potentially hazardous. We don't recommend doing so

unless absolutely necessary,

as this couldresult in person- al injury or properly damage.

However, if you must load or unload the tiller, follow the

guidelines given next.

• Beforeloadingor unloading, stop the

engine,wait for all parts to stop moving, disconnect thespark plug wire and letthe engine and muffler cool,

• Thetiller istoo heavyandbulky tolift safelyby one person. Two or more

peopleshould sharethe load,

• Usesturdy ramps and manually (engine shut off) roll the tiller into and out of the

vehicle. Two or more people areneeded to dothis.

• Rampsmust be strong enough to support the combined weight of the tiller and any handlers.The ramps should

providegood traction to prevent slipping; they should haveside rails to guide the tiller along the ramps;and they should havea locking device to

secure them to thevehicle.

•The handlersshould wearsturdy footwear that willhelp to prevent slipping.

• Position the loading vehicleso that the

rampangleis as flat as possible (the less inclineto the ramp, the better).

Turn the vehicle's engine off and apply

its parkingbrake.

•When going up ramps, stand in the

normal operating position and push the

tiller aheadofyou. Havea person at eachside to turn the wheels,

• Whengoing down ramps, walk backwardwith thetillerfollowing you, Keepalertfor any obstacles behind you. Position a personat eachwheel to control the speedof the tiller, Nevergo

down ramps tiller-first, as thetiller could tip forward.

• Usewooden blocks to place on the downhill sideof the wheels if you need to stop the tiller from rolling down the ramp, Also, use the blocks to temporar- ily keep thetiller in placeon theramps (if necessary),and to chock the wheels in placeafter the tiller is in the vehicle,

• Whenthe tiller is in the vehicle,prevent it from rolling by chocking the wheels with blocks and securelytie the tiller

down.

Page 19

Maintenance

WARNING

Before inspecting, cleaning or servicing the machine, shut off engine,

wait for all moving parts to come to a complete stop,

disconnectspark plug wire and move wire away from spark plug.

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

REQUIRED MAINTENANCE SCHEDULE

PROCEDURE Each 10 30 Noted

Checkengine oil level

Cleanengine Checkdrive belttension Checknutsand bolts

Before Every Every As

Use Hours Hours

And every 5

operating hours

Changeengine oil Lubricate tiller

Serviceengine air cleanersystem

Checkgearoil levelin transmission

Checktines for wear Checkairpressure in tires

(if pneumatic)

Service spark plug CheckAnti-ReverseStake

* Changemore frequently in dusty or dirty conditions. Changeafter first 2 hours of

break-in operation.

t Checkafter first2 hours of break-inoperation.

• SeeEngineOwner'sManualforserviceintervalsandinstructions.

Page 20

Section5: Maintenance

WARNINGBefore inspecting,cleaning or servicingthe unit, shutoff engine, wait for all i_

partsto cometo a complete stop,disconnectspark plugwire and movewire away from spark ..,Lol plug. Failure to follow these instructions can result in serious personal injury or

propertydamage.

TILLERLUBRICATION

Proper lubrication of the tiller is an essentialpart of maintenance. After every 10 operating hours, oil or grease

the lubrication points shown in Figures 5-1 and 5-1A and described below.

Usea good quality lubricatingoil (#30 weight engineoil is suitable) and aquality

generalpurposegrease(with a metal lubricant, ifavailable).

• Removewheels,clean wheel shaft (A, Fig, 5-1) and apply thin coating of

greaseto the shaft.

• Greaseback,front and sides of depth regulator lever(B, Fig.5-1).

• Removetines, cleantine shafts (C,Fig. 5-1)+Inspectfor rust, rough spots or

burrs (lookaround holes). File or sand smooth, coat ends of shaft with grease.

• Oil the threads on the handlebarheight adjustment screws and the handlebar

attaching screws (D,Fig.5-1).

• ShiftingMechanism,Lightlyoilpivot pointsforsmoothoperation(E,Fig.5-1A).

A C

Figure5-1

Figure5-1A

CHECKFOROILLEAKS

Beforeeach use,checkyour tiller for signs of an oil leak- usually a dirty, oily

accumulation either on the unit or on the floor where it hasbeenparked,

A little seepagearound a cover or oil seal is usually not a cause for alarm. However, if the oil drips overnight then immediate attention is neededas ignoring a leakcan result in severetransmission damage.

If a cover is leaking, try tightening any loosescrews. If the screws are tight, a newgasketor oil sealmay berequired. If

the leak is from aroundashaft and oil seal,the oil sealprobablyneedsto be

replaced. Seeyour authorizeddealer or contact the factory for serviceor advice.

IMPORTANT:Neveroperatethetiller if thetransmissionis low on oil. Checkthe

oil levelafterevery30 hours of operation and wheneverthere is any oil leakage.

CHECKHARDWARE

Checkfor looseor missing hardwareafter every 10 operating hours, Tighten or replacehardware beforeusing the tiller.

Besure to check the screws underneath thetiller hood (lift the hood flap) that

securethe transmission cover andthe depth regulator leverto the transmission.

CHECKTIREPRESSURE(on machines equipped with pneumatic tires)

Checkthe air pressurein both tires. Deflateor inflate both tires evenlyfrom

15-to-20 PSI (pounds per squareinch). Besure that bothtires havethe sameair

pressure or the unit will tend to pullto one side.

NOTE:Yourtillermaynot beequipped with pneumatictires, eliminating the need for air pressurechecks,

TRANSMISSIONGEAROILSERVICE

Checkthe transmission gear oil level after every30 hours of operation or whenever

you notice any oil leak. Operating the tiller when the transmission is low on oil

canresult in severedamage.

A. To Checkthe Transmission GearOil Level:

1. Checkthe gearoil level when the trans-

mission is cool, Gearoil will expandin warm operating temperatures and this expansionwill provide an incorrect oil

levelreading.

2. With thetilleronlevel ground, adjust theDepthRegulatorLeverup or down to

the notch that makesthe tiller level,.

3. Removethe oilfill plug (A,Fig. 5-2) from the transmission housingand look

into the oil fill hole. You will seethe main drive shaft on onesideof the hole.

4. Thegear oil levelis correct ifthe gear oil is approximately half way up the side of the drive shaft.

5. If the gearoil level is low, add gearoil asdescribednext. If the gearoil levelis okay,securely replacethe oil fill plug.

IMPORTANT:Do not operate thetiller if thegear oil level is low. Doing so will

result in severedamage to the transmis- sion components.

6. If adding only a few ouncesof gear oil, use APIratedGL-4 or GL-5transmis-

sion gearoil havingaviscosity of SAE 140, SAE85W-140 or SAE80W-90. If

refilling anempty transmission, useonly GL-4 transmission gear oil havinga viscosity of SAE85W-140 or SAE140.

NOTE:Do not use automatic transmission fluid or engineoil in the transmission.

7. Whilechecking frequently to avoid overfilling, slowly add gear oil intothe oil fill holeuntil it reachesthe halfway point

on the drive shaft.

8. Securely replacethe oil fill plug,

Page 21

Section5: Maintenance

WARNINGBeforeinspecting,cleaning or servicingthe unit, shut off engine, wait for all I"

partsto cometo a completestop, disconnectspark plugwire and movewire away from spark ....t....[

plug. Failure to follow these instructions can result in serious personal injury or propertydamage.

B. To Drain theTransmissionGearOil:

DANGER

Gasoline is highly flammable and its vaporsexplosive. Fol-

low these safety practices to prevent injury or property damage from fire orexplosion.

• Allow the engine and

muffler to cool before draining the tiller's gasoline

tank.

• Do not allow open flames, sparks, matches or smoking

in the area.

• Wipe away spills and push tiller away from spilled fuel.

• Use only an approved fuel container and store it safely

out of the reach of children.

• Do notstoregasoline where

its vapors could reach an open flame or spark, or where ignition sources are present (such as hot water and space heaters, furnaces, clothes dryers, stoves, electric motors, etc.)

Thetransmission gearoil does not need to bechanged unless it hasbeencontam-

inatedwith dirt, sand or metal particles.

1. Drain gasolinefrom the fuel tank or run the engineuntil the fuel tank is empty.

See"DANGER"statement above.

2. Draintheoil from the engine.

3. Removethe four screws (B, Figure 5-2)

and washersfrom thetransmission cover and remove the cover and gasket,

4. Removethe left-side wheel.

5. Tiltthe left-sidewheel shaft intoa

drain panand allow thegearoil to drain through the top of the transmission,

6. Afterdraining oil, reinstall the wheel, install a newgasket (do not reuseold gasket)and screwon transmission cover.

7. Refill transmission using GL-4 gearoil (SAE85W-140 or SAE140).

8. Refill theenginewith motor oil and replenishthe fuel tank with gasoline.

Figure5-2: Removeoilfillplug(A)tocheck

gearoillevelandtoaddgearoil. Remove

fourcoverscrews(B)to draingearoil.

TINES

Thetines wear with useand they should

be inspectedat the beginning of each tilling seasonand after every30 operating hours, The tines canbereplacedindivid- ually or as a complete set, Referto the

Parts List Section of this manualfor tine

identification information.

WARNING

This is a CRT (counter-rotating tine) tiller and its tines must

be mounted in the direction shown in Figure 5-3. If

mounted with curves in the opposite direction, tiller will

dig poorly and be more likely to run backward.

Failure to comply could result in personal injury or property damage.

NOTE:You must first remove thetiller hood beforeremovingeither asingle tine

holder or individual tines, Removethe two screws at the front of the hood and

the two screwsatthe rear of the hood and lift off the hood, Besureto replace

the hood securely after changingatine or tine holders.

A. Tine Inspection:

With use, thetines will becomeshorter, narrower and pointed, Badly worn tines

will result in a loss of tilling depth and

reducedeffectiveness in general,and specifically when chopping upand turning under organic matter,

B. Removingand Installing Tine Assemblies

1. Usea 9/16" socket,6"extension, a

ratchet, and a 9/16"box end wrench to loosen the nut (A, Figure 5-3) and screw

(B) that secure the tine holder to the tine

shaft.

2. Usea rubber malletto tap thetine holder loose. Slidetine assembly off,

3. RepeatSteps1 and 2 aboveto remove the other tine assembly.

4. Installing the tine assembly is simply the reverseof its removal, Firstbesure

to remove any rust, uneven spots or burrs from thetine shaft using fine sandpaper, Thengrease thetine shaft before rein- stalling the tine assemblies, Be sure all the cutting edgesfaceso they will enter the soil first when the tiller is moving forward- this meansthecutting edge on

the top of eachtine faces toward the operator position, Tightenhardware.

C. Removingand Installing Individual Tines

1. Usetwo 9/16" boxendwrenches to

remove the two screws(C,Figure5-3) and nuts (D) that securethe tine to its tine holder,

NOTE:If the nuts are rusted, apply pene- trating oil, then loosenthe hardware.

2. When installing individual tines, do so in the reverseorder from which they were

removed, Thetwo sets of inboardtines are installed so one set faces toward the

transmission andtheother facesaway from it, Thesingle outboardtine set facestoward the transmission housing.

Also besure the cutting edge at the top

of each tine faces toward the operator

position. (SeeFigure 5-3.)

Page 22

Section5: Maintenance

WARNINGBeforeinspecting,cleaning or servicingthe unit, shut off engine, wait for all t

partsto cometo a completestop, disconnectsparkplugwire and move wire awayfrom spark ..£..I plug. Failure to foilow these instructions can resuit in serious personai injury or

propertydamage.

OPERATOR

POSITION

TINE

jl: "_

ENGINE

Figure5-3: Tines,tineholdersandinstallationhardware.

Figure5-4:LiftbailandchecklengthofClutchBailSpringtocheckforcorrectbelttension

(1-7/8").

CHECKINGANDADJUSTING FORWARDDRIVEBELTTENSION

Maintaining correct tension on the forward drivebelt is important to good tilling performanceandlong belt life. A loose belt will slip on the engine and

transmission pulleys and cause the tines and wheelsto slow down - or stop com- pletely- eventhough the engine is running at full speed, A loose belt can alsoresult in prematurebeltwear,

If you find you can not bring the Forward

ClutchBailall the way up to the bottom of

the upper handlebars,you will needto

loosenthe belt tension,

Also chock the belt for cracks,cutsor frayed edgesand replaceit as soon as

possible.

• Checkbelttension afterthe first two hours of initial operation (new belt),

• Checkbelttension afterevery10 operatinghours,

To CheckForwardBeltTension:

1. Besure that the engine isstoppedand

the spark plugwire is disconnectedand

moved awayfrom the spark plug,

2. Loosennut "C" (Figure5-4) several

turns so it is about halfway up the threaded adjustment screw.

3. Lift the ForwardClutchBail up and hold it to the bottom of the handlebars.

Measurethe length of theclutch bail spring (A,Figure 5-4) with a ruler. If the belttension is correct, the length of the

coiled portion of the spring should be approximately 1-7/8", Nut"C" should then besnuggeddown against the top of

the adjuster (B),

4. If the spring istoo short, the belt

tension will betoo loose. If thespring is too long, the belt tension will be too tight.

5. Toadjust the length of the spring, releasethe ForwardClutch Bail, Thread

the hexnut (C, Fig, 5-4) halfway up the adjustment screw, Turn the screw inside the spring (A, Figure5-4) counterclock-

wise (asviewedfrom the operator's

position) while holding the adjuster (B) steadyto increasethe length of the spring, or turn clockwise (as viewed from

the operator's position) to decreasethe

lengthof the spring, NOTE:If you havedifficulty holding the

adjuster steadyby hand,use a pliers or wrench on the adjuster, While you turn the screw, keepthe Forward Clutch Cable

Page 23

Section5: Maintenance

WARNINGBefore inspecting,cleaning or servicingthe unit, shutoff engine, wait for all i

partsto cometo a complete stop,disconnectsparkplugwire and movewire awayfrom spark ..L.I plug. Failure to follow these instructions can result in serious personal injury or

propertydamage.

from turning by gripping the upper end of thethreaded adjuster (B) with pliers.

6. RepeatStep 3 to measurethe length of the clutch bail spring. Oncethe length is correct, retightenthe hexnut against

thetop of theadjuster.

ForwardBeltReplacementInformation

If thedrive belt needsto be replaced,see your local authorizeddealer or phonethe factory as instructed on Page2, Referto

the Parts List in the back of this manual for correct components Useonly OEM

(Original Equipment Manufacturer) fre- placementbelts. A substitute belt may not perform satisfactorily, Theprocedure requiresaverage mechanicalability and commonly availabletools.

FORWARDCLUTCH BAILADJUSTMENT

If the ForwardClutch Bail does not function properly,first check that the

forward drive belt is adjusted properly (see"Checkingand Adjusting Forward

Drive BeltTension"), Ifthis fails to correct the problem, contact the factory

technicalservice department or your authorizeddealer for service advice,

CHECKINGANDADJUSTING REVERSEDRIVEBELTTENSION

Maintaining correct tensiononthe reversedrive belt is important to good performanceand long belt life. A loose belt will slip on the engine andtransmis- sion pulleys and causethe tines and wheelsto slow down - or stop com- pletely- eventhough the engine is running at full speed, A loose belt can alsoresult in prematurebeltwear,

If thereis no reverseaction when the ReverseClutch Control knob is pulled

out, then the belt tension is too loose. Whenchecking belt tension,also check

thebeltfor cracks,cuts or frayed edges and replaceit as soon as possible.

• Checkbelttension afterthe first two hours of break-in operation (new belt),

• Checkbelttension afterevery10 operatinghours,

ToCheckReverseBeltTension:

1. Besure thattheengine is stopped and

the spark plug wire is disconnectedand moved awayfrom the spark plug,

2. Removethe screw in the plastic belt

cover and slidethe cover (which is attachedto the forward clutch cable)out

of the way,

3. Havean assistant pull the Reverse

ClutchControl knob all theway out and hold it in that position. Measurethe length of thecablewire betweenthe end of the threadedcableadjuster (A, Figure 5-5) and theend of the Z-fitting (B) to

which the cable wire isattached,

4. The belttension is ideal if the cable

wire length measuresbetween1/8" to 1/4", If the length is lessthan 1/8" (and if

there is no reverseaction when the tiller is running), then makethe following

adjustments. NOTE:If the length is more than 114",noadjustment is needed,as

long as the reverseaction functions properly.

5. Releasethe ReverseClutch Control

knob. Unthreadthe innerjam nut (C, Figure5-6) one to two turns and pull the

threadedcable adjuster (A, Figure 5-6) to the left until the innerjam nut rests

againstthe bracket,

6. Preventtheinnerjam nut (C)from

turning and tighten the outerjam nut (D) againstthe bracket, Preventthe outer

jam nut (D) from turning and tighten the

innerjam nut (C)against the bracket,

7. Measurethe gap by repeatingStep3.

ReadJustas neededby repeating Steps 5 and 6.

8. Reinstallthe beltcover.

Figure55: Measurecablewirelengthto checkforcorrectreversebelttension.

Figure5-6: Movethreaded adjuster(A)toleftto

increasebelttension.

ReverseBeltReplacementInformation

If the drive belt needsto be replaced,see

your local authorized dealeror phonethe

factory as instructed on Page2, Referto the Parts List inthe back of this manual

for correct components Useonly OEM (Original Equipment Manufacturer) fre- placementbelts, A substitute belt may not perform satisfactorily, Theprocedure requiresaverage mechanicalability and commonly availabletools.

Page 24

Section5: Maintenance

WARNINGBefore inspecting,cleaning or servicingthe unit, shutoff engine, wait for all i"

partsto cometo a complete stop,disconnectsparkplugwire and movewire awayfrom spark ._L,.I plug. Failure to follow these instructions can result in serious personal injury or

propertydamage.

ENGINEOILSERVICE

Checkthe engineoil levelbeforestarting theengine each dayand check it after each 5 hours of continuous operation, Running theengine when it is low on oil will quickly ruin theengine.

It is recommendedthat you changethe motor oil after every 10 hours of operation and evensooner when operating in extremely dirty or dusty conditions. Refer to the separateEngineOwner's Manualfor

detailedservice instructions.

A. To Checkthe Engine0il Level:

1. Movethetiller to a levelareaand shut

off theengine.

2. Levelthe engine by adjusting the Depth Regulator Lever. Thetinesmust be in contact with the ground. Move the Anti- ReverseStakeback if necessary.

3. Cleantheareaaround the oil dipstick or oil fill tubeto prevent dirt from falling into

thecrankcase.

4. Onengineswith an oil fill tube, remove the fillercap, add oil (if required) until it reachesthe top of the tubeand reinstall the filler cap.

5. Onengineswith a dipstick, remove it, wipe it clean, and reinstall it finger-tight, Removethe dipstick and check the reading. Add oil (if required) to bring the level to the

FULLmark, Do not overfill.

B. To ChangetheEngine0il:

Changetheengine oil as instructedin the separateEngineOwner's Manual.

ENGINECLEANING

Keeptheenginecleanto assure smooth operationand to preventdamagefrom overheating. Referto the separateEngine

Owner's Manualfor specific repair and cleaninginstructions,All inspectionsand

services must be done with the engineshut off and cool to the touch.

AIR CLEANERSERVICE

Theengineair cleaner filters dirt and dust

out of the air before itenters the carbure- tor. Operating the enginewith a dirty,

cloggedair filter cancausepoor perfor- manceand damageto the engine. Never operatethe engine without theair cleaner installed, Inspect and service the air cleanermore often if operating in very dusty or dirty conditions.

Servicethe air cleaner as instructed in the separateEngineOwner'sManual,

SPARKPLUGSERVICE

Inspect and cleanor replacethe spark plug after every 100 operating hours or annually, Cleanthe plugand setthegap as described in the separateEngineOwner's

Manual, In some areas, local law requires using

resistor spark plugsto suppress ignition signals, If the engine was originally equippedwith a resistor spark plug, use thesame type for replacement.

SPARKARRESTERSCREENSERVICE

If theenginemuffler is equipped with a spark arrester screen,remove and clean it according to the time intervals and instruc- tions in the separateEngineOwner's

Manual.

THROTTLELEVERADJUSTMENT

If theenginedoes not respondto various throttleleversettings, refer to the separate

EngineOwner's Manual for service infor- mation or contact your localauthorized

engine servicedealer.

CARBURETOR/GOVERNORCONTROL

ADJUSTMENTS

Thecarburetor was adjusted at the factory

for best operating speed, Referto the separateEngineOwner'sManual for any adjustment information or seeyour autho- rizedengineservice dealer,

Thegovernorcontrols the maximum safe operatingspeed and protects the engineand all moving partsfrom damagecaused by overspeeding, Do not tamper with theenginegovernor settings.

WARNING

Operators shall not tamper with the engine governor

settings on the machine; the governor controls the

maximum safe operating speed to protect the engine and all moving

parts from damage caused by overspeed. Authorized

service shall be soughtif a problem exists.

OFFSEASONSTORAGE

Whenthe tiller won't be usedfor extendedperiods, prepareit for storage

asfollows:

1. Cleanthetiller and engine.

2. Do routine tiller lubrication and check for looseparts andhardware.

3. Protect theengine and perform rec- ommended engine maintenanceby following the engine storage instruc- tions found in the separate Engine

Owner's Manual. NOTE:Be sureto protect the fuel lines, carburetor and

fuel tank from gum deposits by removing fuel orby treating fuel with a fuel stabilizer (follow engine manufac- turer's recommendations).

4. Storeunit in a clean, dry area,

5. Neverstore thetiller with fuel in the

fuel tank in anenclosed areawhere gas fumes could reachanopenflameor spark,or where ignition sourcesare present (space heaters,hot water

heaters,furnaces, etc.).

Page 25

Section5: Maintenance

TROUBLESHOOTING

Beforeperforming anycorrections, refer to the appropriateinformation in this Manual, or in the EngineOwner's Manual, for the correct safety precautions and operating or maintenanceprocedures, Contact your local authorized EngineServiceDealerfor engineservice. Contact your local authorizedequipment dealeror the factory for all other service problems.

PROBLEM

Enginedoes n_ad.

Enginerunspoorly. 1. Defectiveorincorrectlygappedspark plug. 1. Inspectsparkplug (seeEngineOwner'sManual).

Engineoverheats. 1. Enginecoolingsystemclogged. 1. Cleanair cooling area(seeEngineOwner'sManual).

Enginedoesnot shutoff. 1. Misadjustadthrottle controlor ignitionswitch. 1. SeeEngineOwner'sManualor EngineServiceDealer.

WheelsandTines 1. Improperuseof controls. 1. ReviewSections3 and4. will notturn. 2.Worn, broken,or misadjusteddrivebelt(s). 2. See"CheckingDriveBeltTension,"Section5.

POSSIBLECAUSE CORRECTION

1. Sparkplug wiredisconnected.

2. EngineThrottleControlLeverincorrectlyset.

3. Fueltankempty.

4. Chokecontrol (if so equipped)in incorrectposition.

5. Stalegasoline.

6. Dirty airfiltar(s).

7. Defectiveor incorrectlygappedsparkplug.

8. Carburetorout ofadjustment.

9. Misadjustedthrottle controlcable.

10.Dirtor water in fueltank.

2. Dirty airfilter(s). 2. Cleanor replace(seeEngineOwner'sManual).

3. Carburetorout ofadjustment. 3. SeeEngineServiceDealer.

4. Stalegasoline. 4. Replacewith fresh gasoline.

5. Dirt or waterin fueltank. 5. SeeEngineServiceDealer.

6. Enginecoolingsystemclogged. 6. Cleanaircoolingsystem(seeEngineOwner'sManual).

2. Carburetorout ofadjustment. 2. SeeEngineServiceDealer.

3. Oillevelis low. 3. Checkoil level(seeEngineOwner'sManual).

3. Internaltransmission wearor damage. 3 Contactlocaldealeror thefactory.

4. Bolt loosein transmissionpulley. 4. Tightenbolt.

1. Reconnectwire.

2. Put leverin STARTposition.

3. Addfuel.

4. SeeEngineOwner'sManual.

5. Drainfueland addfreshfuel.

6. Cleanor replacefilter(s).

7. Inspectsparkplug.

8. SeeEngineServiceDealer.

9. SeeEngineServiceDealer

10. SeeEngineServiceDealer.

Tinesturn, but 1. WheelDrivePinsnot in WHEELDRIVE. 1. See"WheelDrivePins"in Section3. wheelsdon't. 2. Internaltransmissionwearor damage. 2. ContactlocalDealeror theFactory.

WheelsTurn,but 1. Tineholdermounting hardwaremissing. 1. Replacehardware. TinesDon't. 2. Internaltransmissionwearor damage. 2. ContactlocalDealerortheFactory.

Poortilling 1.Worntines. 1. See"Tines" (Section5). performance. 2. ImproperDepthRegulatorsetting. 2. See"Tilling Tips & Techniques,"Section4.

3. Incorrectthrottle setting. 3. SeeSection4.

4. ForwardDriveBeltslipping. 4. See"CheckingForwardDrive BeltTension,"Section 5.

Page 26

List

8 _ .o

Page 27

MODELS644H & 645A

REF

NO.

2 3

4 5

7 8

9 10

11 12

13 14 15 18 17 18 19

20 21

22 23

24 25 28 27

PARTNO. DESCRIPTION

1185469

710-0597 710-0599 710-0874

1186331

712-0291

712-3004A 712-3009 736-0119 GW-55013-1 GW-55013-2 GW-55015 GW-55018 686-04029 GW-55088 GW-9384 GW-9534 710-04048 618-04046 1916569 1916570 710-3073 1916771 1107382 710-3025 1916708 1916707

Spirol Pin HexHal.Screw, 1/4-20 x 1

Screw,Self-Tapping,1/4-20x 1/2 HexHal.Screw, 5/16-18 x 1-1/4

HexHal.Screw, 5/16-18 x 1.0 Hex LockNut, 1/4-20

HexFlangeLock Nut, 5/16-18 HexNut, 5/16-18

Lock Washer,5/16 Hood Bracket,LeftHand

Hood Bracket,RightHand DragBar DepthRegulatorLever

Tine HoodAssembly

Bushing Spring, Depth Regulator Spacer HexHal.FlangeScrew,5/16-18 x 1

Transmission Assembly (CRT)

FlapStop Bracket ReverseStop Arm

HexScrew, 5/16-18 x 2.25 Spacer,.462 x .328 x 1.63

FlatWasher, 5/16 HexScrew, 5/16-18 x .625

Hood Support Bracket ChannelSupport Bracket

Page 28

MODELS644H & 645A

7 20

Page 29

MODELS644H & 645A

REF

NO.

1 1916719 2 1916755 3 1917479 4 1918745 5 710-0599 6 710-3008 7 712-3009 8 GW-55042 9 GW-55043 10 GW-55102 11 GW-55044 12 GW-9855 13 725-0157 14 736-3050 15 1916674 16 1916712 17 710-0106 18 710-0216 20 710-0805 21 712-0121 22 712-0291 23 712-3000 25 736-0119

PARTNO. DESCRIPTION

CableAssembly, ReverseClutch UpperHandlebar

Bail,ForwardClutch CableAssembly, Forward Clutch

Screw,Self-Tapping,1/4-20x 1/2 Screw,Hex,5/16-18 x 3/4

Hex LockNut, 5/16-18 HandlebarSupport

Lower Handlebar Panel

Tab, Conduit Mount

Screw,#10-24x2 CableTie FlatWasher, 3/8 Bracket,ReverseClutchCable

Spring, ForwardClutch HexHal.Screw, 1/4-20 x 1-1/4

Screw,Hex,3/8-16 x 3/4 Screw,Hex,5/16-18 x 1-1/2 HexNut,#10-24 Hex LockNut, 1/4-20 HexNut, 3/8-16 Lock Washer,5/16

REF

NO.

PARTNO. DESCRIPTION

1 1918749 Bumper 2 710-0395 HexScrew,_16-18 x2-114,Gr5

3 712-0267 Nut,Hex,5116-18 4 736-0119 LockWasher,5/16

Page 30

MODELS644H & 645A

REF

NO.

1 GW-9517 2 GW-1714 3 GW-50043 4 711-04110 5 GW-1224-1_

-- GW-1325C

Useas required to obtain between .005" and.015" allowable end-play.

PARTNO. DESCRIPTION

SnapRing Bearing,TaperedRoller(with race) Support Washer, Rear DriveShaft (CRT) Shim, RearBearing Cap,.010"thick

GW-1224-2_ GW-1224-3_

GW-1224-4_

Shim,sameas above,except .030" thick Shim,sameas above,except.005" thick

Shim,sameas above,except .062" thick Shim Set (Incl.the following shims:

two #1224-1, two 1224-2 & one #1224-4)

Page 31

MODELS644H & 645A

FRONT

REF NO.

1 GW-9512 2 1909950 3 GW-1166-1_

4 5 6 7 8 9 10 11

PART NO.

GW-1166-2_ GW-1166-3'_ GW-1166-4'_ GW-1166-5'_ GW-1086 711-04092 GW-9305 GW-1132-2 1904278 711-04078 GW-1104 1904279

DESCRIPTION

Retainer,Snap Ring, "E" Type Retainer,Snap Ring

Shim,0.062"thick Shim,0.030"thick Shim,0.015"thick Shim,0.010"thick Shim,0.005"thick

BronzeBushing

Wheel Shaft(CRT)

Key,Hi-Pro, 1/4 x 1

Spacer Worm Gear,WheelShaft Tiller Shaft

Woodruff Key Worm Gear,Tiller Shaft

Useas required to obtain between .005" and.030" allowable end-play.

Page 32

MODELS644H & 645A

REF NO.

3 4 5 6 7

PART NO.

GW-9727

710-04049

736-0119 1918377 1916641 GW-50032 721-04030

DESCRIPTION

Plug, Transmission OilFill Hex Hd.FlangeScrew, 5/16-18 x 5/8,Gr. 5

Lock Washer, 5/16

RearCover,Transmission

Front Cover,Transmission Gasket,Housing Cover

Oil Seal,DriveShaft

10 3

* Includedwith transmission when purchasedas an assemblyonly.

Removeand discard when installing the transmission on tiller.

REF

NO.

8 721-04031 9 619-04013 10 721-04036 11 736-3008* 12 718-04008 13 710-04048 14 710-3008

PARTNO.

DESCRIPTION

Oil Seal,WheelShaft Transmission Housing Assembly

Oil Seal,TineShaft Washer,Flat, .344 x .750x.120

RearBearingCap Hex Hd.FlangeScrew, 5/16-18 x 1 Hex Hd.FlangeScrew, 5/16-18 x 3/4

Page 33

Hold TinesWith Cutting Edgeat theTOP

of each tine facing TOWARDYou

RIGHT-HANDTINE LEFT-HANDTINE

MODELS644H & 645A

FRONT/

=ORWARD

WHEELSHAFT

TINE SHAFT

ENGINE

5 5

OFTINE

-_DENOTES CUTTING EDGE

REF NO.

3 4 5 6 7

PART NO.

710-3008

1817060 712-3009 710-3096 1817059 1916702 1916703

DESCRIPTION

Hex Hd.Screw, 5/16-18 x 3/4, Grade5 Single Tine- Right Hand

Hex Lock Nut,5/16-18 Hex Hd.Screw, 3/8-16 x 2

Single Tine- Left Hand LH TineHolder

RHTine Holder

REF

NO.

8 1917487 9 GW-9380 10 GW-9338 11 712-3000

-- 1916783

PARTNO.

DESCRIPTION

Wheel& TireAss'y -- Left/Right Side ClevisPin, .312" x 1-3/4"

Hair Pin Cotter Hex Lock Nut,3/8-16

ReplacementTines Set(Incl. three LHtine_ three RHtines and required hardware)

Page 34

MODELS644H & 645A

I_i_ccLREVERSE

UTCHCABLE

_3 , 25

FORWARD

CLUTCHCABLE

Page 35

MODELS644H & 645A

REF

NO.

2 3

4 5

7 8

9 10

11 12

13 14 15 18 17 18 19

20 21

22 23

24 25 28 27 28 29 30 31 32 33 34 35 38 37 38 39

PARTNO. DESCRIPTION

1107382 1108841 619-04016 1916532 1916535 1916652 1916657 1916658 1916660 1916724 1916725 1916726 1916794 1916795 1917326 1917746 1918731 1918744 710-0117 710-0237 710-0376 710-04049 710-0520 710-0599 710-3103 712-3000 712-3009 736-0119 736-3050 736-3090 736-0452 710-0459A GW-50027 GW-55034 GW-55049 GW-9090 GW-9301 GW-9929 GW-9944 710-0395

FlatWasher, 5/16

Key,3/16" x1-1/2"

Pulley, EngineDrive Transmission Pulley

Pulley, ReverseIdler

Guard,Belts/Pulleys

ForwardDriveBelt

ReverseDrive Belt

BeltCover

ReverseReturn Spring

BeltGuide

ForwardBeltGuide

EngineBracket, Left

EngineBracket, Right

Bracket,Belt Cover

Shoulder Washer

ReverseIdler Arm

ForwardIdler Lever

HexHd.Screw, 5/16-24 x 1

HexHd.Screw, 5/16-24 x 5*8

HexHd.Screw, 5/16-18 x 1

HexHd.Screw, 5/16-18 x 5/8

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

Screw,Self-Tapping,1/4-20 x 1/2

HexHd.Screw, 5/16-18 x 2

Lock Nut,3/8-16

Lock Nut,5/16-18

Lock Washer,5/16

FlatWasher, 3/8

FlatWasher

BellWasher

HexHd.Screw, 3/8-24 x 1.5,GR5

Support Washer

ForwardReturnSpring

Bracket,Cable Mounting

ForwardIdler Pulley

Key,3/16" x 1"

FlatWasher

BellevilleWasher

HexScrew, 5/16-18 x 2.25 Gr5

Page 36

TROY-BILT TILLER LIFETIME LIMITED WARRANTY

WHATPRODUCT

ISCOVERED

WHAT IS COVERED Troy-Bilt LLC will, at its option, repair or replace any part found to be defective in material or BY THIS WARRANTY workmanship without charge for parts and labor

WHAT IS NOT This warranty does not apply to parts that have been damaged by accident, alteration, misuse, COVERED BY THIS abuse, neglect, improper maintenance, vandalism, theft, fire, water, or damage because of peril

WARRANTY or other natural disaster.

All Troy-Bilt branded rear tine walk-behind tillers with gear drive transmissions. This warranty begins on the date of purchase and is warranted by Troy-Bilt LLC for the life of the tiller, to the odgina] purchaser only.

This limited lifetime warranty also applies to non-powered attachments and accessories.

Powered attachments and accessories are warranted separately by their manufacturers. Refer

to the applicable manufacturer's warranty on these items for terms and conditions.

The following items are not covered after the first year of this residential use limited warranty: belts, batteries, bushings, seals, tines, tires, wheels, paint, appearance items, and similar items that are normally replaced through periodic maintenance.

Charges for pick-up, delivery, and service calls are not covered by this warranty.

Service completed by someone other than an authorized service dealer is not covered by this warranty.

Parts that are not genuine Troy-Bilt LLC service parts are not covered by this warranty.

The engine is warranted separately by the engine manufacturer. Refer to the engine manufacturer's warranty for terms and conditions.

LIMITED COMMERCIAL

USE WARRANTY

HOW TO OBTAIN

SERVICE

The provisions set forth in this warranty provide the sole and exclusive remedy arising from the sale. Troy-BUt LLC shall

not be liable for any incidental or consequential damage or expense of any kind, including but not limited to cost of

equipment rental, loss of profits, or costs of hiring services to perform tasks normally performed by the equipment.

Any implied warranties, including any implied warranty of merchantability or fitness for a particular purpose, shall be limited

in duration to the period of ownership by the original purchaser (and a maximum of 90 days from the date of sale if the tiller is

Some states do not allow the exclusion or limitation of incidental or consequential damages, or limitations on how long an

This limited warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

If used for commercial, institutional, industrial, rental, or demonstrator purposes, the warranty

on the tiller is limited in duration to 90 days from the date of purchase.

This warranty does not apply to parts that have been damaged by accident, alteration, misuse, abuse, neglect, improper maintenance, vandalism, theft, fire, water, or damage because of peril or other natural disaster.

Warranty service is available, with proof of purchase, through your local authorized service dealer. To locate a dealer in your area, consult your Yellow Pages, or contact Troy-Bilt LLC at

P.O. Box 361131, Cleveland, Ohio 44136-0019, 1-866-840-6483, or log on to our Web site at

www.t roybilt.com.

purchased for commercial or other non-residential use).

implied warranty lasts, so the above exclusions or limitations may not apply to you.

For customer assistance, contact your nearest authorized dealer, or contact us at:

TROY-BILT LLC, P.O. Box 361131, Cleveland, Ohio 44136-0019, 1-866-840-6483

Troybilt 21A-645A063, 21A-644H063 Owner’s Manual

Specifications and Main Features

Frequently Asked Questions

User Manual