Troy-Bilt 644H, 645A User Manual
Operator’s Manual
Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-covered, brushcovered 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.
IMPORTANT:READ SAFETY RULES AND INSTRUCTIONS CAREFULLY
TROY-BILT LLC, P.O. BOX 361131, CLEVELAND, OH 44136-0019
PRINTED IN USA FROM NO. 769-00585B
(11/2003)
Rear-tine Tiller Models
644H—Bronco
TM
645A—Bronco
TM
Model 644H Shown (bumper syles vary)
TABLE OF CONTENTS
Content Page
Customer Support 2
Safety 3
Assembly 6
Features and Controls 10
Operation 13
Content Page
Maintenance 19
Off-season Storage 24
Troubleshooting 25
Parts List 26
Warranty Back Cover
FINDING MODEL NUMBER
This Operator’s Manual is an important part of your new lawn tractor. It will 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 th e equipment and
copy the information from it in the space provided below. A sample model plate is also given below. You can
locate the model plate by looking at the rear of the tine shield. This information will be necessary to use the
manufacturer’s web site and/or help from the Customer Support Depa rtment or an authorized service dealer.
Copy the model number here:
Copy the serial number here:
www.troybilt.com
TROY-BILT LLC
P. O. BOX
CLEVELAND, OH 44136
330-558-7220
1-800-520-5520
361131
CUSTOMER SUPPORT
Please do NOT return the unit to the retailer without first contacting Customer Support.
If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenance of
this unit, you can seek help from the experts. Choose from the op tions below:
Visit troy-bilt.com for many useful suggestions. Click on Customer Support button and you
will get the four options reproduced here. Click on the appropriate button and help is
immediately available.
The answer you are
looking for could be just
a mouse click away!
If you prefer to reach a Customer Support Representative, please call 1( 800) 520-5520.
The answer you are
looking for could be just
a mouse click away!
Engine
Manual
The engine manufa cturer is responsible for all engine- related issues with regard to
performance, power-rating, specifications, warranty and service. Please refer to t he engine
manufacturer’s Owner’s/Operator’s Ma nual, packed separately wi th your unit, for more
information.
2
3
Training
1. Carefully read this
Owner’s Manual, the
separate Engine Owner’s
Manual, and any other literature you may
receive. Be thoroughly familiar with the
controls and the proper use of the tiller
and its engine. Know how to stop the unit
and disengage the controls quickly.
2. Never allow children to operate the
tiller. Never allow adults to operate the
tiller without proper instruction.
3. Keep the area of operation clear of all
persons, particularly children and pets.
4. Keep in mind that the operator or user
is responsible for accidents or hazards
occurring to other people, their property,
and themselves.
Preparation
1. Thoroughly inspect the area where the
tiller is to be used and remove all foreign
objects.
2. Be sure all tiller controls are released
and both wheels are in the Wheel Drive
position before starting the engine.
3. Do not operate the tiller without
wearing adequate outer garments. Avoid
loose garments or jewelry that could get
caught in moving parts.
4. Do not operate the tiller when barefoot
or wearing sandals, sneakers, or light
footwear. Wear protective footwear that
will improve footing on slippery surfaces.
5. Do not till near underground electric
cables, telephone lines, pipes or hoses. If
in doubt, contact your telephone or utility
company.
6. Warning: Handle fuel with care; it is
highly flammable and its vapors are
explosive. Be sure to take the following
precautions:
a. Store fuel in containers specifically
designed for this purpose.
b. The gas cap shall never be removed
or fuel added while the engine is
running. Allow the engine to cool
for several minutes before adding
fuel.
c. Keep matches, cigarettes, cigars,
pipes, open flames, and sparks
away from the fuel tank and fuel
container.
d. Fill fuel tank outdoors with extreme
care. Never fill fuel tank indoors.
Use a funnel or spout to prevent
spillage.
e. Replace all fuel tank and container
caps securely.
f. If fuel is spilled, do not attempt to
start the engine, but move the
machine away from the area of
spillage and avoid creating any
source of ignition until fuel vapors
have dissipated.
7. Never make adjustments when engine
is running (unless recommended by
manufacturer).
Operation
1. Do not put hands or feet near or under
rotating parts. The tines begin to rotate
once the engine starts and the Forward
Clutch Bail (or Reverse Clutch Control) is
engaged.
2. Exercise extreme caution when on or
crossing gravel drives, walks, or roads.
Stay alert for hidden hazards or traffic. Do
not carry passengers.
3. After striking a foreign object, stop the
engine, remove the wire from the spark
plug and prevent it from touching the
spark plug, thoroughly inspect the
machine for any damage, and repair the
damage before restarting and operating
the machine.
4. Exercise caution to avoid slipping or
falling.
5. If the unit should start to vibrate abnormally, stop the engine, disconnect the
spark plug wire and prevent it from
touching the spark plug, and check
immediately for the cause. Vibration is
generally a warning of trouble.
6. Stop the engine, disconnect the spark
plug wire and prevent it from touching
the spark plug whenever you leave the
operating position, before unclogging the
tines, or when making any repairs, adjustments or inspections.
Section
Safety
SPARK ARRESTER WARNING TO RESIDENTS OF CALIFORNIA AND SEVERAL OTHER STATES
Under California law, and under the laws of several other states, you are not permitted to operate an
internal combustion engine using hydrocarbon fuels on any forest, brush, hay, grain, or grass
covered land; or land covered by any flammable agricultural crop without an engine spark arrester in
continuous effective working order.
The engine on the unit is an internal combustion engine which burns gasoline, a hydrocarbon fuel, and must be equipped with a
spark arrester muffler in continuous effective working order. The spark arrester must be attached to the engine exhaust system in
such a manner that flames or heat from the system will not ignite flammable material. Failure of the owner/operator of the unit to
comply with this regulation is a misdemeanor under California law (and other states) and may also be a violation of other state
and/or federal regulations, laws, ordinances or codes. Contact your local fire marshal or forest service for specific information
about which regulations apply in your area.
1
7. Take all possible precautions when
leaving the machine unattended. Stop the
engine. Disconnect spark plug wire and
move it away from the spark plug. Be
sure both wheels are in the Wheel Drive
position.
8. Before cleaning, repairing, or inspecting, stop the engine and make certain all
moving parts have stopped. Disconnect
the spark plug wire and prevent it from
touching the spark plug to prevent accidental starting.
9. The flap on the tine hood must be
down when operating the tiller.
10. Never use the tiller unless proper
guards, plates, or other safety protective
devices are in place.
11. Do not run engine in an enclosed
area. Engine exhaust contains carbon
monoxide gas, a deadly poison that is
odorless, colorless, and tasteless.
12. Keep children and pets away.
13. Never operate the tiller under
engine power if the wheels are in the
Freewheel position. In the Freewheel
position, the wheels will not hold the
tiller back and the revolving tines could
propel the tiller rapidly, possibly
causing loss of control.
Always engage
the wheels with the wheel drive pins in
the Wheel Drive position before starting
the engine or engaging the tines/wheels
with the Forward Clutch Bail or the
Reverse Clutch Control .
14. Be aware that the tiller may unexpectedly bounce upward or jump backward
and be propelled toward you if the tines
should strike extremely hard packed soil,
frozen ground, or buried obstacles like
large stones, roots, or stumps. If in doubt
about the tilling conditions, always use
the following operating precautions to
assist you in maintaining control of the
tiller:
a. Walk behind and to one side of the
tiller, using one hand on the handlebars. Relax your arm, but use a
secure hand grip.
b. Use a deep depth regulator
setting.
c. Use slower engine speeds.
d. Clear the tilling area of all large
stones, roots and other debris.
e. Avoid using downward pressure
on handlebars. If need be, use
slight upward pressure to keep the
tines from digging too deeply.
f. Before contacting hard packed soil
at the end of a row, reduce engine
speed and lift handlebars to raise
tines out of the soil.
g. In an emergency, stop tines and
wheels by releasing whichever
clutch control is engaged. Do not
attempt to restrain the tiller.
15.
Do not overload the tiller’s capacity
by attempting to till too deeply at too fast
a rate.
16. Never operate the tiller at high
transport speeds on slippery surfaces.
Look behind and use great care when
backing up.
17. Do not operate the tiller on a slope
that is too steep for safety. When on
slopes, slow down and make sure you
have good footing. Never permit the tiller
to freewheel down slopes.
18. Never allow bystanders near the unit.
19. Only use attachments and acces-
sories that are approved by the manufacturer of the tiller.
20. Use tiller attachments and accessories when recommended.
21. Never operate the tiller without good
visibility or light.
22. Never operate the tiller if you are
tired, or under the influence of alcohol,
drugs or medication.
23. Operators shall not tamper with the
engine-governor settings on the machine;
the governor controls the maximum safe
operating speed to protect the engine and
all moving parts from damage caused by
overspeed. Authorized service shall be
sought if a problem exists.
24. Do not touch engine parts which may
be hot from operation. Let parts cool
down sufficiently.
25. Please remember: You can always
stop the tines and wheels by releasing the
Forward Clutch control or the Reverse
Clutch control (whichever control you
have engaged), or by moving the throttle
control lever on the engine to “OFF” or
“STOP”.
26. To load or unload the tiller, see the
instructions in Section 4 of this Manual.
27. Use extreme caution when reversing
or pulling the machine towards you.
28. Start the engine carefully according to
instructions and with feet well away from
the tines.
29. Never pick up or carry a machine
while the engine is running.
Maintenance and Storage
1. Keep the tiller, attachments and accessories in safe working condition.
2. Check all nuts, bolts, and screws at
frequent intervals for proper tightness to
be sure the equipment is in safe working
condition.
3. Never store the tiller with fuel in the
fuel tank inside a building where ignition
sources are present such as hot water
and space heaters, furnaces, clothes
dryers, stoves, electric motors, etc.).
Allow engine to cool before storing in any
enclosure.
4. To reduce the chances of a fire hazard,
keep the engine free of grass, leaves, or
excessive grease.
5. Store gasoline in a cool, well-ventilated
area, safely away from any spark- or
flame-producing equipment. Store
gasoline in an approved container, safely
away from the reach of children.
6. Refer to the Maintenance sections of
this Manual and the separate Engine
Owner’s Manual for instructions if the
tiller is to be stored for an extended
period.
7. Never perform maintenance while the
engine is running or the spark plug wire
is connected, except when specifically
instructed to do so.
8. If the fuel tank has to be drained, do
this outdoors.
4
Section 1: Safety
Section 1: Safety
5
Decals
For your safety and the safety of others,
various safety and operational decals are
located on your unit (see Figure 1 below).
Keep the decals clean and legible at all
times. Contact your local service dealer
or the factory for replacements if any
decals are damaged or missing.
Refer to the separate parts catalog for
decal locations, part numbers and
ordering instructions.
Forward Clutch Control
Operating Instruction
Reverse Clutch Control
Operating Instruction
Warning Messages
on tine hood
Hot Surfaces
Warning on belt cover
Starting Stabilization
Message on engine
Figure 1: Location of Safety and Operating Decals (Model 644H shown).
TO AVOID SERIOUS INJURY:
• READ THE OWNER’S MANUAL.
• KNOW LOCATIONS AND FUNCTIONS OF ALL CONTROLS.
• KEEP ALL SAFETY DEVICES AND SHIELDS IN PLACE AND WORKING.
• NEVER ALLOW CHILDREN OR UNINSTRUCTED ADULTS TO OPERATE TILLER.
• SHUT OFF ENGINE AND DISCONNECT SPARK PLUG WIRE BEFORE MANUALLY UNCLOGGING TINES OR MAKING REPAIRS.
• KEEP BYSTANDERS AWAY FROM MACHINE.
• KEEP AWAY FROM ROTATING PARTS.
• USE EXTREME CAUTION WHEN REVERSING OR PULLING THE MACHINE TOWARDS YOU.
WARNING
Operating Symbols
Various symbols (shown here, with word
descriptions) are used on the tiller and engine
(your unit may not have all of the symbols).
FAST
SLOW
CHOKE
ON
CHOKE
OFF
STOP
REVERSE
R
ROTATING
TINES
BAIL
ENGAGED
BAIL
DISENGAGED
TILLER DIRECTION
LEVER DIRECTION
STOP
6
WARNING
To prevent personal injury or
property damage, do not start
the engine until all assembly
steps are complete and you
have read and understand the
safety and operating instructions in this manual.
Introduction
Carefully follow these assembly steps to
correctly prepare your tiller for use. It is
recommended that you read this Section
in its entirety before beginning assembly.
NOTE: Engine syles vary by model. The
engine on your tiller may appear differently than those shown in illustrations
and Figures throughout this manual.
Inspect unit
Inspect the unit and carton for damage
immediately after delivery. Contact the
carrier (trucking company) if you find or
suspect damage. Inform them of the
damage and request instructions for filing
a claim. To protect your rights, put your
claim in writing and mail a copy to the
carrier within 15 days after the unit has
been delivered.
STEP 1: Unpacking Instructions
1. Remove any cardboard inserts and
packaging material from the carton.
Remove any staples from the bottom of
the carton and then lift the carton up and
off the unit.
2. The tiller is heavy and you should not
attempt to remove it from the shipping
platform until the handlebars are
installed. The procedure for removing the
tiller is explained in Step 3 of these
assembly steps.
NOTE: Be careful not to severely bend any
of the control cables on the unit.
3. Remove all unassembled parts and
the separate hardware bag from the
carton. Check that you have the items
listed below (contact your local dealer or
the factory if any items are missing or
damaged). NOTE: Use the screw length
template (Fig. 2-1) to identify screws.
Loose Parts List
Qty. Description
1 Handlebar Support (see A, Fig. 2-2,
page 7)
1 Handlebar Assembly
(see K, Fig. 2-2)
The following items are in the
hardware bag:
4 Hex hd. screw, 5/16-18 x 1-1/2"
2 Hex hd. screw, 3/8-16 x 3/4"
2 Flat washer, 3/8"
4 Split lockwasher, 5/16"
4 Hex nut, 5/16"-18
2 Hex locknut, 3/8"-16
IMPORTANT: Motor oil must be added to
the engine crankcase before the engine
is started. Follow the instructions in this
“Assembly” section.
NOTE: LEFT and RIGHT sides of the tiller
are as viewed from the operator’s
position behind the handlebars.
Tools/Materials Needed for
Assembly
(2) 1/2" open-end wrench*
(1) 3/8" open-end wrench*
(2) 9/16" open-end wrench*
(1) Large adjustable wrench
(1) Scissors (to trim plastic ties)
(1) Ruler (for belt tension check)
(1) Block of wood (to support tiller
when removing wheels)
(1) Automotive-type air pressure gauge
(1) Clean oil funnel
(1) Clean, high-quality engine oil. Refer
to the Engine Owner Manual for
engine oil specifications and quantity
required. Do not overfill.
* Adjustable wrenches may be used.
Section
Assembly
Figure 2-1: To identify length of screw,
place screw on template as shown and
measure distance between bottom of screw
head and tip of screw.
2
1
1
2
2
7
Section 2: Assembly
STEP 2: Attach Handlebar
1. Attach the two legs of the handlebar
support (A, Fig. 2-2) loosely to the inner
sides of the tiller frame using two 3/8"-16
x 3/4" hex hd. screws (B), two 3/8” flat
washers (C) and 3/8"-16 hex locknuts (D).
2. Using using two 5/16"-18 x 1-1/2" hex
hd. screws (G), 5/16" split lockwashers
(H) and 5/16"-18 hex nuts (I), loosely
attach the the handlebar support (A) using
the upper holes.
3. There are three height adjustment holes
in the two handlebar support brackets. E
& F, Fig. 2-2). Use a setting that will
position the handlebars at approximately
waist level when the tines are 3”-4” into
the soil. Loosely attach the handlebar
support brackets
to the outside of the
handlebar assembly (K) using two 5/16"18 x 1-1/2" screws (G), 5/16" split lockwashers (H) and 5/16"-18 hex nuts (I).
NOTE: If a support bracket will not move,
loosen attaching screw (J) and nut.
IMPORTANT: The support brackets must
be assembled
to the outside of the
handlebar assembly.
4. Tighten all handlebar mounting
hardware securely.
STEP 3: Move Tiller Off Shipping
Platform
To move the tiller without the engine
running, put the wheels in their
FREEWHEEL position, as described below.
1. Use a sturdy block to raise one wheel
off the ground.
2. Remove the hairpin cotter (L, Fig. 2-3)
and wheel drive pin (M). Slide the wheel
inward on the wheel shaft (N). Reinstall
the wheel drive pin and hairpin cotter
through the wheel shaft only (not through
the wheel hub). Repeat with the other
wheel.
3. Using the handlebar as a lever, roll the
tiller to a flat area.
IMPORTANT: Before starting the engine,
the wheels must be placed in their WHEEL
DRIVE position (pins through wheel hubs
and wheel shaft). This procedure is
described in “Wheel Drive Pins” in
Fig. 2-2: Attach handlebar.
G
H
A
F
E
I
B
C
G
K
J
D
Fig. 2-3: Wheel in FREEWHEELING
position (wheel drive pin through wheel
shaft only).
M
N
L
8
Section 2: Assembly
STEP 4: Install Forward Clutch Cable
1. Carefully unwrap the forward clutch
cable (the cable without a knob attached to
it) from its shipping position and slide the
thin cable wire (T, Fig. 2-4) into the slot in
the cable bracket. Push the cable connector
(U, Fig. 2-4) up through the hole in the
bracket until the groove in the connector
snaps into place on the bracket.
2. Thread the #10-24 hex nut (Z) halfway
onto the screw (V) which runs through the
spring (W, Fig. 2-5).
3. Thread screw (V) into cable adjuster (X).
4. Lift and hold the Forward Clutch bail
against the handlebar. See Fig. 2-7.
5. Measure the length of the cable spring
between the ends of the coils (Fig. 2-7).
The length should be approximately 1-7/8".
If the length is correct, turn the #10-24 hex
nut (Z) down tightly against the cable
adjuster (X) while holding the adjuster in
place. See Figure 2-7. If the length is
incorrect, you must make an adjustment to
the cable tension as described in
“Checking and Adjusting Forward Drive
Belt Tension” in Section 5. When the
spring length is correct, tighten the hex nut
(Z) against the cable adjuster (X).
STEP 5: Install Reverse Clutch
Cable
1. Unwrap the reverse clutch cable (the
cable with a knob and a large hex nut
attached to it) from around its shipping
position and route the cable (CC, Fig. 2-8
and Fig. 2-9) up to the cable bracket (BB,
Fig. 2-8). Be sure that the cable goes
beneath the Forward Clutch Bail as it is
routed up to the cable bracket.
2. Insert the cable up through the slot in
the cable bracket and position the threaded
assembly as shown in Fig. 2-8. Make sure
that the flat side of the threaded assembly
is aligned with the flat side of the mounting
hole. Slide the large hex nut (DD) up the
cable and tighten it securely.
Fig. 2-5: Assemble
spring and adjuster.
V
Z
X
W
Fig. 2-6: Install forward clutch cable.
Fig. 2-4: Installing forward clutch cable bracket and cable.
Fig. 2-7: Measure cable spring.
5
T
Y
W
U
Hold bail against handlebar
while measuring spring
Z
X
4
3
2
1
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