Troy-Bilt TUFFY 643B, TUFFY 645A, TUFFY 643C, Tuffy/Bronco CRT 643C, Super Bronco 643B Operator's Manual

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Operator's Manual

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Rear-tine Tiller Models

643C m Tuffy¢ / Bronco CRT 643B, 645A -- Super BroncoTM

Mode1645A Shown

IMPORTANT: Read safety rules and instructions carefully before operating equipment.

Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-covered, brush-

covered or grass-covered land unless the engine's exhaust system is equipped with a spark attester meeting applicable local or state laws (if any). If a spark 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 through your nearest engine authorized service dealer or contact the service department, P.O. Box 361131

Cleveland, Ohio 44136-0019.

Troy-Bilt LLC, P.O.BOX361131CLEVELAND,OHIO44136-0019

PRINTEDINU.S.A. FORMNO. 769-00585E.

11/11/05

TABLEOFCONTENTS

Content Page Content Page Customer Support 2 Maintenance 17 Safety 3 Off-season Storage 21 Assembly 6 Troubleshooting 22

Features and Controls 10 Parts List 24 Operation 12 Warranty Back Cover

FINDINGMODELNUMBER

This Operator's Manual is an important part of your new tiller. Itwill 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 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 Department or an authorized service dealer.

Copy the model number here:

www.troybilt.com CLEVELAND,OH44136

P. O. BOX 361131

330-558-7220

866-840-6483_

CUSTOMERSUPPORT

PleasedoNOTreturnthe unit totheretailer without firstcontactingCustomerSupport.

If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenance of this unit, you can seek help from the experts. Choose from the options below:

Visit troy-bilt.com for many useful suggestions. Click on Customer Support button and you will get the four options reproduced here. Click on the appropriate button and help is

immediately available.

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Copy the serial number here:

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7%%%'7_-'.........................................

Iilo I1 II ff bl _ll i {_1 7 7fl ,

< ........ ,,,,,

If you prefer to reach a Customer Support Representative, please call 1(866) 840-6483.

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

performance, power-rating, specifications, warranty and service. Please refer to the engine manufacturer's Owner's/Operator's Manual, packed separately with your unit, for more

information.

SECTION1: SAFETY

This machine meets voluntary safety stan- dard B71.8-1996, which is sponsoredbythe Outdoor Power Equipment Institute, Inc., and is published bythe American National

Standards Institute.

WARNING

The engine exhaust from this productcontains chemicals known to the State of California to

cause cancer, birth defects or other reproduc- tive harm.

SafetyAlertSymbol

ForwardClutchBail

ReverseClutchControl

(Mode/s643B&645A)

DepthRegulator

TineHoodFlap

,_ This is a safety alert symbol. It is used

and any other literature you mayreceive. Bethoroughly familiar with the controls andthe proper useof the tiller and its en- gine. Knowhowto stop the unit and disen- gagethe controls quickly.

2. Neverallow childrento operatethetiller. Neverallow adults to operatethe tiller without proper instruction.

3. Keepthe area of operationclear of all persons, particularly children and pets.

4. Keepin mindthat the operatoror user is responsible for accidentsor hazardsoc- curring to otherpeople,their property,and

themselves.

in this manual and on the unit to alert you to potential hazards. When you see

this symbol, read and obey the message that follows it. Failure to obey

safety messages could result in personal injury or property damage.

3. Donot operatethetiller without wearing

1. Carefully readthis Own-

Training

er's Manual,the separate Engine Owner'sManual,

adequateouter garments. Avoid loose gar- ments or jewelry that could get caught in moving parts.

4. Donot operatethe tiller when barefoot or wearing sandals, sneakers,or light foot- wear.Wearprotective footwear that will improve footing on slippery surfaces.

5. Donottill nearunderground electricca- bles, telephone lines, pipes or hoses.If in doubt, contactyour telephoneor utility

company.

6. Warning: Handlefuel with care; it is highly flammableand its vaporsareexplo- sive.Takethe following precautions:

a. Storefuel in containers specifically

b. Thegascapshall neverberemovedor

Preparation

1. Thoroughly inspect the areawherethe

tiller is to be usedand removeall foreign

objects.

2. Be sure all tiller controls are released and both wheelsare inthe Wheel Drive po-

sition beforestarting the engine.

c. Keepmatches,cigarettes, cigars,

d. Fillfuel tank outdoors with extreme

Counter-Rotating-Tines

(CRT)

Drive Pin

Figure 1-1: Tiller featuresand contre/s.See separateEngineOwner'sManua/ to identifyenginecontre/s.

e. Replaceall fueltank andcontainer

caps securely.

f. Iffuel isspilled, do not attempt to

start the engine,but move the ma- chineawayfrom the areaof spillage and avoid creating any source of ig- nition until fuel vapors havedissi- pated.

7. Nevermakeadjustments when engineis running (unless recommendedby manu-

facturer).

Operation

1. Do not put hands or feetnear or under rotating parts.

designedfor this purpose.

fueladdedwhiletheengineisrunning. Allowthe engineto coolforseveral minutesbeforeaddingfuel.

pipes, openflamesandsparks away from thefuel tank and fuelcontainer.

care.Neverfill fueltank indoors. Use a funnel or spout to preventspillage.

2. Exerciseextremecaution when on or

crossing gravel drives, walks, or roads. Stay alert for hidden hazardsor traffic.

3. After striking a foreign object, stop the

engine, removethe wire from the spark plug wire andprevent it from touching the spark plug. Thoroughly inspect the ma- chine for any damageand repairthe dam- agebefore restarting and operatingthe

machine.

4.Exercisecautionto avoidslipping orfall-

ing.

5.Iftheunitshouldstarttovibrateabnor- mally,stoptheengine,disconnectthe

sparkplugwireandpreventitfromtouch- ingthesparkplug,andcheckimmediately

forthecause.Vibrationisgenerallya warningoftrouble.

6.Stoptheengine,disconnectthespark plugwireandpreventitfromtouchingthe sparkplug,wheneveryouleavetheoperat- ingposition,beforeuncloggingthetines, orwhenmakinganyrepairs,adjustments orinspections.

7.Takeallpossibleprecautionswhenleav- ingthemachineunattended.Stoptheen-

gine.Disconnectthesparkplugwireand moveitawayfromthesparkplug.Besure

thatbothwheelsareintheWheelDrivepo-

sition.

8.Beforecleaning,repairing,orinspect- ing,stoptheengineandmakecertainall

movingpartshavestopped.Disconnect

thesparkplugwireandpreventitfrom touchingthesparkplugtopreventacci-

dentalstarting.

9.Theflaponthetinehoodmustbedown whenoperatingthetiller.

10.Neverusethetillerunlessproper guards,plates,orothersafetyprotective devicesareinplace.

11.Donotruntheengineinanenclosed area.Engineexhaustcontainscarbon

monoxidegas,adeadlypoisonthatis odorless,colorless,andtasteless.

12.Keepchildrenandpetsaway.

13. Neveroperatethe tiller underengine powerif thewheels arein theFreewheel

position.Inthe Freewheelposition, the

wheelswill not hold the tiller back andthe revolvingtines could propel thetiller rapid-

ly,possibly causingloss of control. Always engagethe wheels with the wheel drive

pins in theWheel Drive position before starting the engine or engaging the

tines_vheelswith the Forward Clutch Bail

(all models)or the ReverseClutchcontrol (Models 643B& 645A only).

14. Be aware that the tiller may unex-

pectedlybounceupwardorjumpforward if thetines shouldstrikeextremelyhard packedsoil, frozenground,or buriedob- stacleslike largestones, roots,or stumps.

If indoubtaboutthe tilling conditions,al-

ways usethe following operating precau-

tionsto assistyouin maintainingcontrol of thetiller:

a. Walk behindandto one side of the

tiller, usingone handon thehandle barsRelax yourarm, but usea

securehandgrip.

b. Useshallowerdepthregulator

settings,working graduallydeeper

with each pass.

c. Useslowerenginespeeds.

d. Clearthetilling area of all large

stones,rootsor other debris.

e. Avoidusingdownwardpressureon

thehandlebars.If needbe, use slight upwardpressureto keep the

tinesfrom diggingtoodeeply.

f. Beforecontacting hard packedsoil

at the endof a row,reduceengine speedand lift the handlebarsto

raise the tines out of the soil.

g. In an emergency, stopthetinesand

wheels byreleasing whichever clutch controlis engaged.Do not

attemptto restrainthetiller.

15. Donot overloadthe tiller's capacityby attempting to till too deeply at too fast a

rate.

16. Neveroperate the tiller at high trans- port speeds onhard or slippery surfaces.

Look behind and usecarewhen backing up.

17. Donot operatethetiller on aslope that is too steep for safety.When on slopes,

slow down and makesure you have good footing. Neverpermit thetiller to freewheel

down slopes.

18. Neverallow bystandersnearthe unit.

19. Onlyuseattachmentsand accessories

that areapproved by the manufacturer of the tiller.

20. Usetiller attachmentsand accessories when recommended.

21. Neveroperatethe tiller without good visibility orlight.

22. Neveroperatethe tiller if you aretired; or underthe influence ofalcohol, drugs or

medication.

23. Operatorsshall not tamper with theen- gine-governor settings onthe machine;

the governor controls the maximum safe

operatingspeedto protect the engineand all movingparts from damagecaused by

overspeed.Authorized serviceshall be sought if a problem exists.

24. Do not touch engine parts which may

behot from operation.Let parts cool down sufficiently.

25. Pleaseremember:Youcan alwaysstop

the tines and wheels by releasingthe For-

ward Clutch Bailor on Models 643B & 645Athe ReverseClutchcontrol, (which-

evercontrol isengaged),or bymoving the ignition switch and/orthrottle control lever

on the engineto "OFF" or "STOP".

26. Toload or unloadthe tiller, seethe in-

structions in Section4 of this Manual.

27. Useextreme caution when reversing

or pullingthe machinetowards you.

28. Startthe enginecarefully accordingto

instructions and with feetwell away from

the tines.

29. Neverpick up or carry a machinewhile

the engineis running.

MaintenanceandStorage

1. Keepthe tiller, attachmentsand acces-

sories in safeworking condition.

2. Checkall nuts, bolts, and screws for

proper tightness to besurethe equipment is in safeworking condition.

3. Neverstore thetiller with fuel in thefuel

tank inside abuilding whereignition sourc- esare presentsuchashot waterandspace

heaters,furnaces, clothes dryers, stoves, electric motors, etc.). Allow the engine to cool beforestoring the unit in any enclo-

sure.

4. Toreducethe chancesof a fire hazard,

keepthe enginefreeofgrass, leaves,or ex- cessivegrease.

5. Storegasolinein acool, well-ventilated

area,safelyawayfrom anyspark- or flame-producing equipment. Store gaso- line in an approvedcontainer,safelyaway

from the reachof children.

6. Referto the Maintenancesections of

this Manualand the separateEngineOwn- er'sManualfor instructions ifthe unitis to

bestored for an extendedperiod.

7. Neverperform maintenancewhilethe

engineis running orthe sparkplug wire is connected,exceptwhen specifically in- structed to do so.

8. Ifthe fueltank hasto be drained,dothis

outdoors.

Decals

Foryour safety and the safetyof others, vari- ous safety andoperational decalsare located on your unit (seeFigure 1-2).

ForwardClutch Bail

ReverseClutch Control

OperatingInstruction

Keepthe decalsclean and legible atall times. Contactyour localservicedealeror thefactory

for replacementsif any decalsaredamagedor missing.

Referto the Parts List pagesin this Manualfor decallocations, descriptionsand part num-

bers.

_ (Models 643B& 645A

StartingStabilization

Message(on engine)

WarningMessages

Hot Surfaces Warning

Figure1-2: Locationof safety and operatingdeca/s.

OperatingSymbols

Varioussymbols(shownhere,_dthworddescrip'dons) maybeusedonte'dllerandengine.

NOTE:YourunihT_ynothaveallof_esymbols.

FAST SLOW STOP

* READTHEOWNER'SMANUAL. * KNOWLOCATIONSANDFUNCTIONSOFALLCONTROLS. * KEEPALLSAFETYDEVICESANDSHIELDSIN PLACEAND WORKING. . NEVERALLOWCHILDRENORUNINSTRUCTEDADULTSTOOPERATETILLER. ° SHUTOFFENGINEANDDISCONNECTSPARKPLUGWIRE BEFOREMANUALLYUN-

CLOGGINGTINESORMAKINGREPAIRS. ° KEEPBYSTANDERSAWAYFROMMACHINE. ° KEEPAWAYFROM ROTATINGPARTS. ° USEEXTREMECAUTIONWHENREVERSINGOR PULLINGTHE MACHINETOWARDS

YOU.

I"1 I*1 R

CHOKE CHOKE REVERSE

ON OFF ROTATINGTINES

<--o-->

TILLERDIRECTION

TO AVOID SERIOUS INJURY:

LEVERDIRECTION

BAIL

ENGAGED

BAIL

DISENGAGED

SECTION2: ASSEMBLY

WARNING: Toprevent

personalinjury or property damage,do notstart the engine

until all assemblysteps are completeandyou have read

and understandthesafety and operating instructions in this manual.

INTRODUCTION

Carefullyfollow theseassemblysteps to correctly prepareyour tiller for use. It is recommendedthatyou readthis Sectionin its entirety beforebeginning assembly.

NOTE: Various tiller models are

presented in this Manual. Use only the information appropriate for your tiller model. Enginestyles vary by model, Your engine may appear differently than those

illustrated in this manual.

INSPECTUNIT

Inspect the unitand carton for damageim- mediatelyafter delivery.Contactthe carrier

(trucking company) if you find or suspect damage.Inform them of the damageand

request instructions for filing a claim. To protect your rights, put your claim in writ-

ing and maila copyto the carrierwithin 15 days after the unit has beendelivered.

ContactTroy-Bilt LLCif you needassis-

tance inthis matter.

TOOLS/ MATERIALSNEEDED

(2) 1/2" open-end wrench* (2) 9/16" open-endwrench* (1) 3/8" open-endwrench*

(1) Largeadjustable wrench

(Models 643B & 645A only) (1) Scissors (totrim plasticties) (1) Ruler (for belttension check) (1) Block of wood (to support tiller when

removing wheels) (1) Tirepressure gauge(for models with

pneumatictires) (1) Cleanoil funnel (1) Motor oil. Refertothe EngineOwner's

Manualfor oilspecificationsand

quantityrequired.

* Adjustable wrenchesmay be used.

ASSEMBLYSTEPS

STEP 1: UNPACKING INSTRUCTIONS

NOTE:While unpacking, do not severely bend any control cables.

1.Thetiller weighs approximately 133 Ibs. Do notattempt to remove it from the ship-

ping platform until instructed to do so in

these Assembly steps.

2. Removeany packagingmaterial from

the carton. Removeany staples from the

bottom of the cartonand removethe car-

ton from the shipping platform.

3. Removeall unassembledparts andthe separatehardwarebag from the carton.

Checkthat you havethe items listed in the LooseParts List (contactyour localdealer or the factory itemsare missing or dam- aged).

NOTE: Use the screw length template

(Fig,2-1) to identify screws,

LooseParts List

Qty. Description 1 HandlebarSupport (seeA, Fig. 2-2)

1 HandlebarAssembly(seeK,Fig.2-2)

Hardwarebag contents:

4 Hexhd. screw, 5/16-18 x 1-1/2" 2 Hexhd. screw, 3/8-16 x 3/4" 2 FlatWasher,3/8"

4 Split lock washer,5/16" 4 Hex nut, 5/16"-18

2 HexIocknut,3_8"-16

*Models 643B & 645Aonly

IMPORTANT:Motor oil must beaddedto

the enginecrankcasebeforetheengine is

started. Followthe instructions inthis Sectionand in the separateEngine

Owner's Manual. NOTE: LEFTandRIGHTsides of thetiller

are as viewedfrom theoperator's position behind the handlebars.

STEP 2: ATTACHHANDLEBAR

1. Looselyattachthe legs of thehandlebar support (A, Fig. 2-2) to the innersides of

the tiller frame usingtwo 3/8"-16x3/4" hex

hd.screws (B),3/8" flat washers, and3/8"- 16 hexIocknuts.

_iiii

Figure2-1: Toidentifylengthofscrews,place

screwontemplateasshownandmeasuredis-

tancebetweenbottomofscrewheadandtipof

screw.

2. Usingtwo 5/16"-18x 1-1/2"screws (C), 5/16"split lock washers (D) and 5/16"-18 hexnuts (G), loosely attach the handlebar support (A)usingthe upperholes.Tighten

thetwo screws securely.

3. Therearethree height adjustment holes in the two handlebar support brackets (E

and F,Fig. 2-2). Usea setting that will po- sition the handlebarsat approximately waist levelwhenthetines are3"-4"intothe

soil. Looselyattachthe support bracketsto theoutsideof the handlebarassembly (I)

usingtwo 5/16"-18x 1-1/2" screws (G), 5/

16"split lockwashers(D)and5/16"-18 hex nuts (G). NOTE:If asupport bracketwill not move, loosenattaching screw (H) and

nut. IMPORTANT:The support bracketsmust

beassembledto theoutside ofthe handlebarassembly.

4. Tightenall handlebarmounting hard- waresecurely.

STEP 3: MOVE TILLER OFF CRATE

Toroll the tiller off the shipping platform, put the wheels in freewheel, asfollows:

1. Placeasturdy block underthetransmis- sion to raise one wheelabout 1" off the

ground.

2. Removethe Klik Pin (J, Fig. 2-3) from the wheelhub (K) and wheelshaft (L).

3. Slidethe wheelfully inwardonthewheel shaft (N,Fig. 2-3). Reinstallthe Klikpin (J)

The supportbracketsmust

be assembledto theoutside of the handlebarassembly.

Fig.2-3: WheelinFREEWHEELposition (wheeldrivepin throughwheelshaftonly).

STEP 4: INSTALL FORWARD CLUTCH CABLE

1. Carefullyunwrapthe forward clutch ca-

ble(cablewithout an attachedknob) from its shipping position andslide the thin ca-

blewire (M, Fig.2-4) intothe slot in the ca-

blebracket. Pushthe cableconnector (N, Fig.2-4) upthrough the holein thebracket

untilthe groove in the connector snaps into place.

2. Threadthe#10-24 hexnut (Z, Fig. 2-5) halfway ontothe screw (V)which runs through the spring (W,Fig. 2-5).

3. Threadthe screw (V) into the cablead- juster (X).

Fig. 2.2: Attachhandlebar.

through the wheel shaft (L) only (not through thewheelhub). Thewheelshould

now spin freely (freewheel)on the wheel shaft. Repeatwith the other wheel.

4. Usethe handlebarto roll the tiller to a flat area.

IMPORTANT:Beforestarting the engine,

the wheels must beplacedin theWHEEL

DRIVEposition (pinsthrough wheelhubs andwheelshaft). This procedureis described in WheelDrivePins on page 10.

Fig. 2-4:/nstal/ing forward clutchcable bracketand cable.

4. Checkfor correcttension ontheforward drive belt bytaking two measurementsof

the cablespring, as follows:

a.With the Forward Clutch Bail (Y,Fig. 2-

6) in an open (released)position, measure

the length ofthe cable spring (W) from the

outermost coil to the outermost coil. b. Squeezethe ForwardClutch Bailagainst

the handlebar(see Fig. 2-7) and re-mea-

surethe spring length. Thebelt tension is correct if this second measurementis be-

tween 1/16"to 3/16" longer thanthe first

measurement.If so,turn the hexnut (Z, Fig. 2-7) tightly against the cable adjuster (X) while preventing the cable adjuster

from turning. c. Ifthe spring length is incorrect, you

must adjustthe cabletension asdescribed in Checkingand Adjusting ForwardDrive

Belt Tensionin Section5. Incorrect cable

tension can result inbelt slippage (cable tension too loose), or unintentional tine

movement when the clutch bail is in Neu-

tral (cabletension too tight).

: v

iiiiiiiiiiiiiiii

Fig. 2-7: Tocheckforwardbelt tension, take twomeasurementsof thelengthofthe coilsin the spring-- first withthebah open, then withthe bah held against thehandlebar.

STEP 5: INSTALL REVERSECLUTCH

CABLE(MODELS643BAND 645A ONLY)

1. Unwrapthe reverseclutch cable (CC, Fig.2-8 and Fig.2-9) from itsshipping po- sition androute it up to the handlebar.Be

surethat the cableis routed beneaththe Forward Clutch Bail.

2. Insertthecable(CC,Fig.2-8)through the slot inthecablebracketandpositiontheflat sideof thethreadedassemblynextto the flat side of the hole.Slidethe hexnut (DD) up the cable andtighten it securely.

3. Fastenthe reverseclutch cable to the left side handlebarwith acabletie (EE,Fig.

2-9).

4. Testthefunction ofthe reverseclutch by pulling out and releasingthe cable knob. Theknob should return to its neutral posi-

tion (resting against bracket). If it doesn't,

contact your local dealeror Troy-Bilt LLC for technical assistance.

Fig. 2-8: Install reverse cable bracketand reverseclutchcable.

Flat Side

Fig.2-5: Cable springand adjuster.

Fig. 2-6: Attachforward clutchcable spring to

forwardclutch bail

Fig. 2-9: Routereverse clutchcable (CC)as

shown.Attachwithcable tie (EE).

5! =-P6:CHECKTRAHSMiSSiOH OILLEVEL

Thetransmission wasfilledwith gearoil at thefactory. However,you shouldcheckthe gear oil levelatthis time to makecertain it

is correct. IMPORTANT:Donot operatethe tiller ifthe

gear oil level is low. Doingso will result in severedamageto the transmission com- ponents.

1. With the tiller on levelground, pull the Depth RegulatorLever(FF,Fig. 2-10) back

andthen all theway up until the lowest notch inthe lever isengaged.

2. Removethe oil fill plug (GG,Fig. 2-11) from the transmission housing cover and

locatethe main drive shaft situated inside the housing.

3. Thegear oil leveliscorrect if the gearoil isapproximately halfway upthe sideofthe

main driveshaft.

4. Ifthe oil levelislow, addgear oil by re- ferring to A, ToCheckthe Transmission

GearOil Level in Section5.

I El."/: AUU IVlUI UH UIL

Thetiller isshipped withoutoil in the en- gine.

IMPORTANT:Donot start the engine with- out first adding motor oil. Severeengine

damagewill resultif the engineis run with- out oil.

1. Referto the separateEngineOwner's Manualfor engine oil specifications and

capacities.

2. With thetiller on levelground, movethe Depth RegulatorLever(FF,Fig.2-10) up or

down until the engine is level.

3. Addmotor oil as describedin the En- gine Owner's Manual.

4. Movethe DepthRegulator Leverall the way down untilthe highest notch is en- gaged.This placesthe tines in the"travel" position, which allows the tiller to be moved without thetines touching the ground.

_ I L:I."8: L;Ht:L;KHAHUWAHt: Checkall nuts and screws for tightness.

STEP 9: CHECKAIR PRESSURE IN TIRES (units with pneumatic tires)

Checkthe air pressurewith atire gauge.

Deflateor inflatethe tires equally to be- tween 15 PSiand 20 PSi (pounds per squareinch). Besurethat both tires arein- flated equally orthe unit will pull to one

side.

Fig. 2-10: AdjustDepth Regu/atorLever.

Fig. 2-11: Removegear oil fill plug.

IMPORTANT: This completesthe assembly steps. Be- fore operatingyour tiller, makesureyou readthefollow- ing sectionsin this Manual,as well as the separateEngineOwner'sManual:

• Section 1: Safety

• Section 3: Featuresand Controls

• Section 4: Operation

SECTION3: FEATURESANDCONTROLS

_ ARNING: Before

INTRODUCTION

This Section describesthe location and

function ofthecontrols onyourtiller. Refer to the following Section, Operationfor de- tailed operatinginstructions.

Practice usingthese controls, with the en-

gine shut off, untilyou understandthe op-

eration ofthe controls andfeelconfident

with eachof them.

ENGINE CONTROLS

Referto the enginemanufacturer'sEngine

Owner'sManual (included in the tiller liter-

aturepackage)to identify the controls on your engine.

IMPORTANT:Thecontrol for stopping the

engine is locatedonthe engine.

WHEEL DRIVE PINS

Eachwheel is equippedwith a wheel drive

Klik pin (A, Figures3-2 and 3-3) that se-

curesthe wheelto the wheel shaft (B).The

wheelscan be positioned in either a

WHEELDRIVEor a FREEWHEELmode.

_ WARNING: Neverallow

Beforestarting the engine,put both wheels

in the WHEELDRIVEposition byinserting the wheeldriveKlikpinsthrough the wheel

hubsandthewheelshaft. Doingso "locks" the wheels to the wheelshaft, causing the

wheelsto turn when eitherthe

operatingyour machine, carefully readand understand

all safety, controls and operating instructions in this

Manual,the separateEngine Owner's Manual,and on the decalson the machine.

Failureto follow these instructions can result in

serious personal injury.

either ofthewheelsto bein the FREEWHEELposition whenthe

engineis running. Alwaysput both wheelsin the WHEEL

DRIVEposition beforestarting

the engine.

Failureto comply could cause loss of tiller control, property damage,or personalinjury.

ForwardClutch

Wheel Drive Pin

Figure3-1: Tiller features and controls.See separateEngine Owner's Manual toidentify enginecontrols.

Forward Clutch Bail (all models) or the Re- verse Clutch Control (Models 643B & 645A) is engaged.

Usethe FREEWHEELmode only whenthe engineis not running. InFREEWHEEL,the

wheeldrive pinsare placedonly through

the holes in thewheelshaft (not the wheel

hubs), thus allowing the wheelsto turn freely when you manually movethe tiller.

Toplacethe wheels in WHEELDRIVEor FREEWHEEL:

1. Stopengine,disconnectsparkplug wire from sparkplug andallowengineto cool.

_ WARNING: Donotplace

2. Raiseone wheelabout one inch off the ground andplaceasturdy support under

the transmission.

3. RemoveKlick Pin (A, Figures3-2 and 3-

3) from wheel driveshaft (B).

4. FORWHEELDRIVEMODE(Figure3-2): Slide wheel outward andalign holes in

tiller on its sidewhen changing

wheeldrivepositions. Doingso could result ingasoline leaking from the fuel tank.

Failureto follow this instruction could result in personal injury

or propertydamage.

Figure3-2: WHEELDRIVEposition.

wheelhub (D,Figure 3-2) and wheel shaft (B). Insert Klik pin(A) through wheel hub (C)and wheelshaft (B). Repeatwith the other wheelandthen removethe sup- port from beneaththe transmission.

5. FORFREEWHEELMODE(Figure 3-3): Slide the wheelinward and insert the Klik

pin (A,Figure3-3) onlythrough thehole in the wheelshaft (B). Repeatfor the other wheeland then removethe support from

beneaththe transmission.

ReverseClutchControl (Models643B&645A)

Regulator

HeightAdjustment

(oneachwheel)

Figure3-3: FREEWHEELposition.

WARNING: Beforestarting

engine,besurethat both wheelsare in WHEELDRIVE

position. SeeWheelsDrivePins for instructions.

Engagingthe Forward Clutch Bail or ReverseClutchControl

(if equipped) whenthewheels arenot in WHEELDRIVEcould

allowthe tinesto rapidly propel

the tiller forward or backward.

Failureto comply could cause loss of tiller control, property damage,or personalinjury.

FORWARDCLUTCHBAIL

TheForward Clutch Bail(D, Figure3-4)

controls the engagementof forward drive to the wheelsand tines.

Tooperatethe ForwardClutchBail:

1. Put wheelsin WHEELDRIVEposition

(see"WARNING"statement above).

2. Lift and holdthe clutch bail (D,Figure 3-

4) againstthe handlebarto startthewheels

andtines rotating in a forward direction.

3. Releasethe clutch bail to disengage

(stop) the wheels andtines (theenginewill

continue to run).

REVERSECLUTCHCONTROL

(Models 643B & 645A only)

TheReverseClutchControl (E,Figure3-4)

controls the engagementof reversedrive to the wheelsandtines.The reversingfea-

ture is used for maneuvering the tiller

only-- never engage the tines in the

ground while operatingin reverse.

WARNING: Useextreme caution when reversing or

pulling the machinetowards

you. Look behindto avoid

obstacles. Neverattemptto till in reverse.

Failureto follow this warning could result in personal injury

or propertydamage.

Tooperatethe ReverseClutchControl:

1. Putwheels in WHEELDRIVEposition (see"WARNING"statement at the left).

2. Stopall tiller motion by releasingthe Forward Clutch Bail.

3. Lift the handlebar untilthe tines clear

the ground, look behindyou to avoid any

obstacles,and then pull the control knob (E, Figure3-4) out.The wheels andtines

will rotate in a reversedirection.

4. Releasethe control knobto disengage (stop) the wheels andtines (theenginewill continue to run).

Figure3-4:Allmodelshavea ForwardClutch Bail(E). OnlyModel634,4haveaReverse ClutchCentre/(F).

DEPTHREGULATORLEVER

Thislever(F,Figure3-5) controls thetilling depth of thetines. Pullthe lever backand slide it up or downto engagethe notched height settings.

The"travel position" (highestnotch) raises

the tines approximately1-1/2"off the

ground, allowingthe tiller to bemoved without the tines contacting the ground. This setting should also be usedwhen starting the engine.

Moving the lever upwardwill increasethe

tilling depth.The lowest notch allows a till-

ing depthof approximately6", depending on soil conditions.For best results,always

begintilling atavery shallow depthsetting

and gradually increasethe tilling depth.

to till too deeplytoo quickly.

WARNING: Donotattempt

Graduallywork downto deeper

tilling depths.

Placethe DepthRegulator Leverin the "travel" position

beforestarting theengine.This position prevents thetines from

touching the ground untilyou

are readyto begintilling. Failureto follow this warning

could result in personalinjury or propertydamage.

TravelPosition

Figure3-5: DepthRegulatorLever (G).

HANDLEBARHEIGHT ADJUSTMENT

Thehandlebarheight isadjustableto three different settings (Figure3-6). In general, adjust the handlebarsso they areat waist

levelwhenthe tines are3"-4" in the soil. Toadjust the handlebars:

1. Stopengine,disconnectspark plugwire from sparkplug and allow engineto cool.

2. Removehardware,reposition handle- bars,and reinstall hardwaresecurely.

High

Medium

Figure3-6: Handlebarheightadjustment.

SECTION4: OPERATION

_ ARNING: Before

operatingyour machine, carefully readand understand all safety (Section 1),controls (Section 3) and operating instructions (Section4) inthis

Manual,the separateEngine Owner's Manual,and on the

decalson the machine. Failureto follow these instructions can result in

serious personal injury.

INTRODUCTION

Readthis OperationSection andthe sepa- rate EngineOwner'sManualbeforeyou start the engine.Then,take the time to fa- miliarize yourself with the basic operation of thetiller before usingit in the garden. Findan open,levelareaand practice using

the tiller controls without thetines engag-

ing the soil (put tines in "travel" setting). Onlyafter you've becomecompletely fa-

miliar with thetiller shouldyou beginusing it in the garden.

BREAK-INOPERATION

Perform the following maintenanceafter

the first two (2) hours of new operation

(see MaintenanceSection in this manual and in the Engine Owner'sManual).

1. Changeengineoil.

2. Checkfor looseor missinghardwareon unit. Tightenor replaceas needed.

3. Checktension onforward drive belt.

4. Checktransmission gear oil level.

STARTINGANDSTOPPING

Pre-StartChecklist

With the spark plug wire disconnected from the sparkplug, perform the following

checksand services beforeeach use:

1. Readthe Safetyand Controls Sections in this manual. Readthe separateEngine

Owner's Manualprovidedwith the unit.

2. Putthe wheels inthe WHEELDRIVEpo- sition (wheel pins must be through holes in wheelhubs andwheel shaft).

3. Checkunit for loose or missing hard- ware. Serviceas required.

4. Checkengineoil level.SeeEngineOwn- er's Manual.

ReverseClutchControl

(Mode/s643B&

ClutchBail

Fig. 4-1

5. Checkthat all safety guards andcovers are in place.

6. Checkair cleanerand engine cooling system. SeeEngineOwner's Manual.

_ WARNING: GASOLINEIS

7. Fillthefueltank with gasoline according

to the directions inthe separate Engine

Owner's Manual.Follow all instructions and safety rules carefully.

8. Attachspark plug wire to spark plug. Startingthe Engine

Thefollowing steps describe how to start and stop the engine.

_ WARNING: Donotattempt

HIGHLYFLAMMABLEAND ITS VAPORSAREEXPLOSIVE.

Followgasolinesafety rules in

this Manual(seeSection 1)and

in the separateEngineOwner's Manual.

Failureto follow gasoline safety instructions can result in

serious personal injury and property damage.

to engagethetines or wheels

until you havereadall ofthe operatinginstructions in this Section.Also, reviewthe safety rules in Section1: Safety,and

the tiller and enginecontrols

information in Section3:

Featuresand Controls.

DepthRegulator

DrivePin

1. Completethe Pre-StartCheckliston this

page.

2. Putthe wheels inthe WHEELDRIVEpo-

sition (seeWheelDrivePinsin Section3 of

this manual).

,_ WARNING: Tohelp

• Before starting engine, put both

wheels in the WHEELDRIVEposition. Never have wheels in FREEWHEELpo- sition when engine is running.When thewheels are in FREEWHEEL,theydo

not hold back the tiller and the tines couldpropelthe tiller rapidly

forwardor backward.

• Before starting engine, put Forward

Clutch Bail (all models) and Reverse Clutch Control (Models 643B & 645A only)in neutral (disengaged)positions

by releasinglevers.

• Never run engine indoors or in en-

closed,poorlyventilatedareas. Engine exhaustcontainscarbonmonoxide,an

odorlessanddeadlygas.

• Avoidenginemufflerandnearbyareas.

Temperaturesin these areas may ex- ceed 150° F.

3. Movethe Depth RegulatorLeverall the

way down to the "travel" position, sothat thetines clearthe ground.

4. Releaseall controls on the tiller.

5. Onengine's with afuel shut-off valve,

turn valve to openposition, as instructed in the separateEngine Owner'sManual.

6. Put ignition switch and/or throttle con-

trol leverlocated on engine in the "ON", "RUN", "FAST"or "START"position, asin- structed inthe EngineOwner's Manual.

7. Chokeor prime engine,as instructed in

EngineOwner's Manual.

8. Put one hand onfuel tank to stabilize unitwhenpulling starter ropehandle.Then

userecoilstarter to start engine,as in-

structed inthe EngineOwner's Manual. Whenenginestarts, graduallymove choke lever (if so equipped) to "NO CHOKE", "CHOKEOFF"or "RUN" position.

9. Usethe "FAST"throttle speedsetting

whentilling.

preventserious personalinjury or damageto equipment:

Stopping the Engineand Tiller

1. Tostop the wheelsandtines, releasethe Forward Clutch Bail (all models) orthe Re-

verse Clutch Control (Models 643B & 645A) -- whichevercontrol is in use.

2. Tostop the engine,put the ignition switch and/or thethrottle control leverin

the "OFF"or "STOP"position.

OPERATINGTHETILLER

Thefollowing operating instructions pro- videguidelinesto using your tiller effec-

tively and safely. Besure to read Tilling

Tips & Techniquesinthis Section before

actually putting the tines into the soil. This is a"Counter-Rotating-Tine" (CRT)

tiller. It operatesdifferently from "Stan-

dard-Rotating-Tine" (SRT)tillers. Asthe wheels pull forward, the tines rotate back- ward, creating an "uppercut" action which

digs deeply, uprooting soil and weeds.

1. Followthe Pre-Start Checklistatthe be- ginning of this Section. Besurethat the

wheelsare in the WHEELDRIVEposition.

2. Movethe DepthRegulator Leverall the way down, so that thetines clearthe

ground. Usethis position when practicing with thetiller and when travelingbetween

tilling sites. Beforeactuallytilling, move the leverto the desireddepth setting (see

Tilling Tips & Techniques).

3. Start engineand allow it to warm up. Thenput throttle in "FAST"setting.

4. Forforwardmotion of the wheelsand powerto the tines:

(a) PullForward Clutch Bail (Fig.4-1) up against handlebar.Releasebail to stopfor- ward motion of wheels and tines.

(b) Whentilling, relaxand letthe wheels pull the unit while thetines dig.Walk be-

hind anda littleto onesideof the unit. Use one hand, yet keepa light--but secure--

grip onthe handlebar (while keepingyour arm loose). SeeFig.4-2. Letthe unit move at its own paceand donot pushdown on

the handlebarsto try and forcethe tines to

dig deeper-- this takes weight off the wheelsand reducestraction.

,_ WARNING: Donotpush

down onthe handlebarsto try

to makethe tiller till more

deeply.This prevents the wheelsfrom holding the tiller backand canallowthe tines to

rapidly propelthe tiller forward, which could resultin loss of

control, property damage,or personalinjury.

5. Forreverse motion ofthe wheelsand

tines (Models643B & 645A only):

(a) Look behindand exercisecautionwhen operating in reverse.Do not till while in

reverse. (b) Stopall forward motion. Lift handlebar

with one handuntil tines areoff the ground andthen pull ReverseClutchControl knob out (seeFig.4-3). Tostop reversing,letgo

of ReverseClutch Control knob.

(b) Swing the handlebarto theleft so the rightwheeltakes a "step" backward.Next

swing the handlebarto the rightso the left wheel"steps" backward.Repeatas needed.

in reverse,shut off the engine,then place thetwo wheels in FREEWHEEL.

7. ToTurnthe Tiller Around: (a) Practiceturning the tiller in a level,

openarea.Beverycarefulto keepyour feet and legs away from the tines.

(b) Tobeginaturn, lift the handlebarsuntil

thetinesareoutofthe groundandtheengine andtinesarebalancedoverthewheels(Fig. 4-4).

(c)With tiller balanced,push sideways on

handlebarto steer in directionof turn (Fig. 4-5). After turning, slowly lower tines into

soil to resumetilling.

Fig. 4-4: Tobegin turn,lift handlebarsuntil tinesare outof groundand unit is balanced.

Fig.4-2:Useonehandtoguidetiller when movingforward.

Fig.4-3:Raisetinesoffgreundandlook

behindwhenmovinginreverse.

6. Tomovethe Model643Cin reversefor short distances:

(a) Releaseforward ClutchBail.Thenlift handlebaruntiltines are off theground.

Fig. 4-5: With tines out of greund,push han- dlebarssidewaysto turn tiller.

StoppingtheTillerandEngine

1. Tostop the wheelsandtines, releasethe

Forward Clutch Bail (all models) orthe Re- verse Clutch Control (Models 643B & 645A) -- whichevercontrol is in use.

2. Tostop the engine,put the ignition

switch and/orthe throttle control leverin the "OFF"or "STOP"position.

TILLINGTIPS& TECHNIQUES

Tilling Depths

WAHNING: Before tilling, contactyour

telephoneor utilities companyand inquire if

undergroundequipment or

lines are usedon your property. Donottill near

buriedelectric cables,

telephonelines, pipes or hoses.

• Whencultivating(breakingupsurfacesoil aroundplantsto destroyweeds,seeFig.4-9), ajust thetinesto digonly 1"to 2" deep.Using shallowtilling depthshelpspreventinjury to plantswhoseroots often growclose to the surface.If needed,lift up onthe handlebars

slightlytopreventthetinesfrom diggingtoo deeply.(Cultivatingona regularbasisnot onlyeliminatesweeds,it alsoloosensandaerates thesoil for bettermoistureabsorptionandfaster plantgrowth.)Wateringthegardenareaafewdayspriorto tillingwill maketilling easier,

aswill lettingthe newlyworkedsoil setfor a dayor two beforemakinga final, deeptilling pass.

This is a CRT(counter-rotatingtine)tiller. Asthewheelspullforward,the tinesrotateback- ward. Thiscreatesan "uppercut" tine actionwhich digs deeply,uprootingsoil and weeds.

Don't overloadthe engine,but dig asdeeplyas possibleon eachpass.Onlaterpasses,the wheelsmaytendto spinin thesoft dirt. Helpthemalongbylifting upslightlyonthehandlebar

(onehand,palm up,works mosteasily).

Avoidthe temptationtopushdownon thehandlebarsinan attemptto force thetiller to dig deeper.Doingsotakesthe weightoff the poweredwheels,causingthemto lose traction.

Withoutthe wheelsto holdthetillerback,thetineswill attemptto propelthetiller backward, towardsthe operator.(Sometimes,slightdownwardpressureonthehandlebarswill helpget

througha particularlytoughsectionofsodor unbrokenground,butin mostcasesthiswon't benecessary.)

ChoosingCorrectWheel& TineSpeeds With experience,you will find the "just right" tilling depthandtilling speedcombination

that is bestfor yourgarden.

Setthe enginethrottle leverata speedto givetheengineadequatepowerandyetallowit tooperateattheslowestpossiblespeed...atleast until youhaveachievedthe maximumtilling depthyou desire.Fasterenginespeedsmaybe desirablewhenmakingfinal passesthrough

theseedbedor whencultivating.Selectionofthecorrectenginespeed,in relationto the tilling depth,will ensureasufficientpowerlevelto do the jobwithout causingtheengineto labor.

Letthe Tiller DotheWork

Whiletilling, relaxandletthe wheelspullthe tiller along while the tines do the digging.

Walkon thesidethat is notyet finished(to avoidmakingfootprints inthe freshly tilled

soil) and lightly,but securelygrip the han- dlebarwith just onehand.

AvoidMakingFootprints

Wheneverpossible, walk on the untilled

sideof the unit to avoidmakingfootprints in

your freshly tilled or cultivated soil. Foot-

prints causesoil compactionthat canham- per root penetrationand contributeto soil

erosion. They can also "plant" unwanted

weed seeds back into the freshly tilled

ground.

Preparing Seedbeds

•Whenpreparingaseedbed,go overthesamepathtwiceinthefirst row,thenover- lapone-halfthetiller width ontherest ofthe passes(seeFig.6).Whenfinishedin onedirection,makea secondpassat a right angle,as shownin Fig.4-7. Overlap

eachpassfor best results(invery hardground,it maytakethreeor four passesto

thoroughlypulverizethesoil.)

• If thegardensizewill not permitlengthwiseandthencrosswisetilling, then over- lapthefirst passesbyone-halfatiller

width,followedbysuccessivepasses ....................v .................................

at one-quarterwidth(seeFig.4-8). _ _

Fig. 4-8

AvoidTillingSoggy, WetSoil

Tilling wet soil often resultsin large,hard

clumpsof soil that caninterferewith plant-

ing.If time permits,wait aday or two after heavyrainsto allow the soil to dry before

tilling. Testsoil bysqueezingit intoa ball.If

itcompressestooeasily,it is too wetto till.

Fig. 4-6 Fig. 4-7

Cultivating

With planning, you can =,,_r,_, ..,'qr_ allow enoughroom _" _ (_

betweenrows to cultivate _ _ (seeFig.4-9). Leaveroom _ _

for the hood width,

plus enough extra _ _' roomfor future plant Fig.4-9

growth.

TillingOnSlopes

TILLINGTIPS& TECHNIQUES(CON'T)

Readthe followingrecommendationsbeforetilling onslopes:

Ifyou must gardenon a moderateslope,pleasefollowtwo veryimportantguidelines:

1.Tillonlyon moderateslopes,neveronsteepgroundwherefootingisdifficult (reviewsafe-

ty rulesin Section1:Safetyofthis manual).

2. We recommendtilling up and down slopes ratherthan terracing. Tilling vertically on a

slopeallows maximumplantingareaandalso leavesroomfor cultivating. IMPORTANT:Whentilling onslopes, besurethecorrectoil levelis maintainedintheengine

(checkeveryone-halfhour of operation).Theinclineof the slopewill causethe oil to slant

WAHNING: Do not operatetiller onaslopetoo

steepfor safe operation.Till slowly and besureyou have

good footing. Neverpermit tiller to freewheeldown

slopes.Failureto follow this warning could result in

personalinjury.

awayfrom its normallevelandthis canstarveenginepartsof requiredlubrication.Keepthe motor oil levelatthe full pointatall times!

Tilling Upand DownSlopes(Vertical Tilling)

• To keepsoil erosionto aminimum, besureto addenoughorganicmatterto thesoil sothat it hasgoodmoisture-holdingtextureandtry to avoidleavingfootprints or wheelmarks.

• Whentilling vertically,tryto makethefirst passuphillas thetillerdigsmoredeeplygoinguphillthanitdoesdownhill.Insoft soil or weeds, youmayhaveto lift the handlebarsslightlywhile going uphill.Whengoingdownhill, overlapthefirst passby about one-halfthewidth of

thetiller.

Clearingthe Tines

Thetines have a self-clearing action which eliminates most tangling of debris in the tines. However,occasionally dry grass, stringy stalks or tough vines maybecome tan- gled. Follow these proceduresto help avoid tangling and to cleanthe tines, if neces- sary.

•To reducetangling, setthe depth regulatordeep enoughto get maximum "chopping" action as the tines chop the material against the ground. Also, try to till under crop residues or covercrops while they are green, moist andtender.

• While tilling, try swaying the handlebars from side to side (about 6" to 12"). This "fishtailing" action often clearsthe tines of debris.

• Iftangling occurs, lift the tines out of the soil and run the tiller in reverse(if unit is equippedwith poweredreverse) for a few feet.This reversing action should unwind a good deal of debris.

• It may benecessaryto removethe debris by hand(a pocketknifewill helpyou to cut awaythe material). Be

sure to stop the engineand disconnect the sparkplug wire beforeclearing the tines by hand.

tines by hand,stop the engine,allow all

WARNING: Beforeclearing the

moving partsto stop and disconnect the spark plug wire. Removethe ignition key on electric start models.

Failureto follow this warning could result

in personalinjury.

LoadingandUnloadingtheTiller

_ ARNING: Loading and

• Beforeloading or unloading, stopthe engine, wait for all parts to stop moving,

disconnect the spark plug wire and let the en- gine and muffler cool.

• Thetiller is too heavy and bulky to lift safely by one person. Twoor morepeople should

sharethe load.

unloadingthe tiller into avehicle is potentially hazardousandwe don't

recommend doing so unless absolutelynecessary,as thiscould result in personal injury or property damage.

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

guidelines given next.

• Usesturdy ramps and manually (engine shut off) roll the tiller into and out ofthe vehicle. Two or more people areneededto do

this.

• Theramps mustbe strong enoughto support the combined weight of the tiller and any han-

dlers. Theramps should provide good traction to prevent slipping; they shouldhavesiderails

to guidethe tiller alongthe ramps; and they should havealocking deviceto securethem to

the vehicle.

• Thehandlersshouldwearsturdyfootwear that will helpto preventslipping.

• Positionthe loading vehicle so that the ramp angleis asflat as possible (the less inclineto the ramp, the better). Turn the vehicle'sengineoff and apply its parking brake.

• When going up ramps, stand in the normal operating position and push the tiller

ahead of you. Havea person at eachside to turn the wheels.

• When going down ramps, walk backward

with the tiller following you. Keep alert for any

obstaclesbehind you. Position a person at eachwheel to control the speedof the tiller.

Nevergo down ramps tiller-first, as the tiller could tip forward.

• Placewooden blocks on the downhill side of

the wheels if you needto stop the tiller from

rolling down the ramp. Also, use the blocks to

temporarily keep the tiller in place onthe

ramps (if necessary),and to chockthe wheels in place after the tiller is in the vehicle.

• After loading the tiller, prevent it from rolling byengaging the wheels in the WHEELDRIVE position. Chockthe wheelswith blocks and se- curelytie the tiller down.

TILLINGTIPS& TECHNIQUES(CON'T)

TerraceGardening(continued)

• Tocreateaterrace,startat the top of the slopeand work down. Gobackand

forth acrossthefirst rowas shownin Fig.4-10.

• Eachsucceedinglowerterraceis startedby walking belowthe terraceyou're 0 m_ preparing.Foraddedstabilityofthetiller,alwayskeeptheuphillwheelinthesoft,

newlytilled soil. Donottill the last 12" or moreof the downhill outsideedgeof

eachterrace.Thisuntilled strip helpspreventstheterracesfrom breakingapart andwashingdownhill. It alsoprovidesa walkingpathbetweenrows. _, REPEAT

Fig. 4-10

LOADINGAND UNLOADING THE TILLER

,_ WARNING: Loadingand

• Before loading or unloading,stop the en- gine,wait for all parts to stop moving,

disconnect the sparkplug wire and letthe engineand muffler cool.

•The tiller istoo heavyand bulky to lift safelyby one person. Twoor more people

should sharethe load.

unloading the tiller into a vehicleis potentially hazardous

andwedon't recommenddoing so unlessabsolutelynecessary,

asthis could result in personal injury or property damage.

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

guidelinesgivennext.

• Usesturdy ramps and manually (engine shut off) roll thetiller into and out of the vehicle.Twoor more peopleare neededto

do this.

• The ramps must bestrong enoughto support the combined weight of the tiller

and any handlers. The rampsshould pro- videgoodtraction to preventslipping; they

should haveside rails to guidethe tiller along the ramps; andthey should havea

locking deviceto securethem to the vehicle.

•The handlersshouldwearsturdy footwear

that will helpto preventslipping.

• Position the loading vehicle so that the ramp angle is asflat aspossible (the less incline to the ramp,the better). Turn the vehicle'sengine off and apply its parking

brake.

• When going up ramps,stand in the normal operating position and push the

tiller aheadof you. Havea person at each sideto turn the wheels.

•When going down ramps,walkbackward with thetiller following you. Keepalertfor

anyobstacles behind you. Position aper- son ateachwheelto control the speedof

thetiller. Nevergo down ramps tiller-first, asthe tiller could tip forward.

•Placewoodenblocksonthe downhill side of the wheels if you needto stop the tiller

from rolling down the ramp. Also, usethe

blocksto temporarily keepthe tiller in

placeon the ramps (if necessary),and to chockthe wheels in placeafter the tiller is

in the vehicle.

• After loading the tiller, prevent it from rolling byengagingthe wheels in the

WHEELDRIVEposition. Chockthewheels with blocksandsecurelytiethetiller down.

SECTION5: MAINTENANCE

WARNING: Before inspecting, cleaning or servicing

the machine,shut off engine,

wait for allmoving partsto come

to acomplete stop, disconnect

spark plug wire and movewire awayfrom spark plug. Remove

ignition keyon electricstart models.

Failureto follow these instructions can result in serious

personalinjury or property damage.

MAINTENANCESCHEDULE

PROCEDURE

Checkmotor oil level Cleanengine

Checkdrive belttension Checknuts and bolts

Changemotor oil Lubricate tiller

Serviceengine air cleaner system Checkgearoil levelin transmission

Checktines for wear Checkair pressure in tires

(if unit haspneumatic tires) Servicespark plug

NOTES

1 Checkafter first 2 hours of break-in operation.

2 Beforeeach use. 3 Every5 operating hours.

4 Every 10operating hours, 5 Every30 operating hours,

6 Changemore frequently in dusty conditions.

7 - See EngineOwner's Manual forservice

recommendations.

8 - Whichever time interval occurs firsL g - Changeafter first 2 hours of break-in

NOTES

2,3 2,7

1,4 1,4

4,6,9 4

1,5

5 5

TILLER LUBRICATION

After every10 operating hours, oil or greasethe lubrication points shownin

Figure5-1 and described below. Usecleanlubricating oil (#30weight motor

oil is suitable) and cleangeneralpurpose

grease(greasecontaininga metallubricant

is preferred, if available).

• Removethe wheels,cleanthe wheelshaft (A,Fig. 5-1) and applya thin coating of

greaseto the wheel shaft.

• Greasethe back,front and sides of the depthregulator lever (B, Fig.5-1).

• Removethetines andclean the tine shaft (C,Fig.5-1). Useafile or sandpaperto gen-

tly removeany rust, burrs or roughspots

(especiallyaround holes in shaft). Apply

greaseto ends of shaft beforeinstalling tines.

• Oil thethreads on the handlebar height

adjustment screwsand the handlebar attaching screws (D, Fig.5-1).

D B

Figure5-1

CHECKFOROILLEAKS

Beforeeachuse,checkthetiller for signsof

an oil leak-- usually a dirty, oily accumu-

lation eitheron the unit or on the floor.

A littleseepagearound acover or an oil sealis usually not a causefor alarm. How- ever,if the oil drips overnight, then imme-

diateattention is needed. Ignoring an off

leakcanresult in severetransmission damage!

If acover is leaking,check for loose

screws. If the screws are tight, anew gasket or oil seal may be required.

If the leakis from around a shaft andoil

seal, the oil seal probably needsto be

replaced.Seeyour authorized dealeror

contact the factoryfor serviceor advice.

IMPORTANT:Neveroperatethe tiller if

thetransmission islow on oil.Checkthe

oil levelafter every 30 hours of operationand wheneverthere is any oil

leakage.

CHECKHARDWARE

Checkfor looseor missing hardwareaf-

ter every 10operatinghoursandtighten

or replace(asneeded)before reusing

tiller

Besureto checkthe screws underneath

thetiller hoodthat securethe transmis- sioncoverandthe DepthRegulatorLever

to thetransmission.

CHECKTIRE PRESSURE (Modelswith pneumatictires)

Checkthe air pressurein bothtires. The

air pressureshould bebetween 15 PSi and 20PSi (pounds per squareinch).

Keepbothtires equally inflated to help prevent machinefrom pulling to one

side.

TRANSMISSION

GEAROILSERVICE

Checkthe transmission gear oil level after every30 hours of operation or wheneveryou notice any oil leak.Oper- ating thetiller when the transmission is

low on oil can result in severedamage. A. To ChecktheTransmission

GearOil Level:

1. Checkthe gear oil level when the

transmission is cool. Gearoil will expandin warm operatingtemperatures

and this expansionwill providean incor-

rect oil level reading.

2. With thetiller onlevelground, pull the

Depth Regulator Leverall the way up.

3. Removethe oil fill plug (A,Fig. 5-2) from thetransmission housingandlook

insidethe oil fill hole to locatethe main

driveshaft situated below the hole.

moving partsto come to a completestop, disconnectspark plug wireand move wireawayfrom

WARNING: Beforeinspecting, cleaningor servicing the machine,shut offengine,wait for all

spark plug. Failureto follow these instructions canresult in serious personalinjury orproperty damage.

4. Thegear oil leveliscorrect if the gearoil isapproximately halfway upthe sideofthe

main driveshaft.

5. Ifthe gearoil levelislow, addgear oilas described next. If the gearoil levelis okay, securely replacethe oil fill plug.

IMPORTANT:Donot operatethe tiller ifthe gear oil level is low. Doingso will result in severedamageto the transmission com- ponents.

Figure5-2:Removeofffi/I p/ug(tl) to check gearoff levelandtoaddgearoiL Remove fourcoverscrews(B)todraingearoil.

6. If adding only a few ounces of gear oil, useAPIratedGL-4or GL-5gearoil having a viscosity of SAE140, SAE85W-140 or SAE80W-90. If refilling an emptytrans- mission, useonly GL-4gear oil having a viscosity of SAE85W-140 or SAE140.

IMPORTANT:Donot use automatic trans- mission fluid or motor oil in the transmis- sion.

7. Whilecheckingfrequentlyto avoid over- filling, slowly add gear oil into the oil fill

hole until it reachesthe halfway point on

the driveshaft.

8. Securely replacethe oilfill plug.

B. ToDrain theTransmissionGearOil:

Thetransmission gearoil doesnot needto bechangedunless it hasbeencontaminat- ed with dirt, sand or metal particles.

1. Draingasolinefrom thefuel tank or run

the engine until thefuel tank is empty.See

"DANGER"statement below.

WARNING: Gasolineis highlyflammableandits vapors

areexplosive. Followthese safety practicesto prevent personalinjury or property damagefrom fire or explosion.

Allow the engine and muffler to cool for at least two minutesbefore drain-

ingthe tiller's gasolinetank.

Do not allow open flames, sparks,

matchesorsmokingin thearea.

Wipe away spills and pushtiller away

from spilledfuel.

Use only an approved fuel container

and store it safely out of the reach of

children.

Donotstoregasolinein anarea where

itsvaporscould reach an open flame or spark, orwhere ignitionsourcesare present(such as hot water and space heaters, furnaces, clothes dryers, stoves,electricmotors,etc.)

2. Drainthe oil from the engine.

3. Removefour screws(B,Figure5-2) and removetransmissioncoverandgasket.

4. Removethe left-side wheel.

5. Tilt the left-side wheelshaft into adrain panand allowthe gearoil to drainthrough

the top of thetransmission.

6. Reinstallthe wheel.

7. Install a newgasket (do not reuse old gasket)and reinstall thetransmission cov- er.

8. Refill thetransmission using GL-4gear oil (SAE85W-140 or SAE140).

g. Refill the enginewith motor oil and re- plenishthe fuel tank with gasoline.

BOLOTINES

Thebolo tines will wearwith useand should beinspected at the beginning of

eachtilling seasonandafterevery 30 oper- ating hours. Thetines can be replacedei- ther individually or as acomplete set. See the Parts List pagesfor tine identification and part numbers.

A. Tine Inspection:

With use,the tines will becomeshorter, narrower and pointed. Badlyworn tines will result in aloss of tilling depth,and re- ducedeffectivenesswhenchopping up andturning under organic matter.

B. Removing4nstalling a Single Tine:

1. With the engine shut off and the spark plug wire disconnected,remove the two

screws (A, Figure5-3) and nuts (B)that at- tachasingle tine to atine holder.If needed,

usepenetrating oil on the nuts.

2. When installing a singletine, besureto position it so that its cutting edge (sharp)

will enter the soft first asthe tiller moves forward.

C. Removing4nstallingaTineAssembly:

1. Atine assemblyconsists of eight tines mounted on atine holder.

2. If removing both tine assemblies,mark them "left" and "right" before removal. Re- move the screw (C, Figure5-3) and lock- nut (D)that securethetineassemblyto the tineshaft. If necessary,usea rubber mallet to tapthe tine assembly outward off the

shaft.

3. Beforereinstalling the tine assembly,in- spectthe tineshaft for rust, roughspots or

burrs. Lightly file or sand, asneeded.Ap-

ply a thin coat of greaseto the shaft.

4. Install each tine assemblyso that the

cutting (sharp) edge of thetines wifl enter thesoil first whenthefiller movesforward.

Securethe fine assemblyto the tine shaft

usingthe screwand Iocknut

,_ WARNING: Beforeinspecting, cleaningor servicing the machine,shut offengine,wait for all

moving partsto come to a completestop, disconnectspark plug wireand move wireawayfrom spark plug. Failureto follow these instructions canresult in serious personalinjury orproperty

damage.

FORWARD

Figure5-3: Install tinesso that cuttingedge oftines entersoftfirst when tiller movesforward.

CHECKINGAND ADJUSTING FORWARDDRIVE BELT TENSION

It is important to maintain correct tension on the forward drive belt.A loosebelt will

causethe tinesandwheelsto slow down-- or stop completely -- eventhough the en-

gine is running at full speed.A too tight belt can result in unintentionaltine move-

ment when the clutch bail isin the Neutral (released)position.

• Checkbelt tension after the first two hours ofbreak-inoperationandafter every

10 operatinghours.

• At the end of eachtilling season,check

the beltfor cracks,cuts or frayed edges

and replace it as soonas possible.

ToCheckForwardBeltTension:

1. Stopengine,wait for all parts to stop moving anddisconnect spark plug wire.

2. With the ForwardClutchBailinan open (released)position, measureand notethe overalllengthofthecablespring (A, Figure 5-4) by measuringfrom the outermost coil

to the outermost coil.

3. SqueezetheForwardClutchBailagainst

the handlebar(see Figure 5-4) and re-

measurethe length of the coils. Thebelt

tension is correct if this second measure-

ment is between1/6"-to- 3/16"longer than

the first measurement.

4. If the spring is too short (lessthan 1/16"),the tension is too loose. If the spring istoo long (more than 3/16"), the

tension is too tight.

5. Toadjust the length of the spring: a. Releasethe Forward Clutch Bail.

Figure5-4: Tocheckforwardbelt tension, taketwomeasurementsofthe overa//length of thecoilsin the spring-- first withthedutch bail open,

thenwith thedutch bail closedagainst the handlebar.

b. Unthreadthe hexnut (C,Figure5-4)

halfway up the adjustment screw (D).

c. Unhookthe top ofthe springfrom the

Forward Clutch Bail.

d. Usepliers to preventthe adjuster (B) from turning andturn the slotted screwlo- cated inside the spring clockwise (viewed from operator'sposition) to increaseten- sion onthe spring. Turnthescrewcounter-

clockwiseto decreasetension. Once adjusted, reattachthe spring to the For-

ward Clutch Bail.

e.RepeatSteps2and3to re-measurethe lengthofthespring.Whenthesecondmea-

surementis between1/16"-to-3/16"longer

thanthefirst measurement,retightenthe hex

nut (C)againstthetop oftheadjuster(B).

ReplacementBelt Information

If the drive belt needsto be replaced,see

your local authorizeddealeror referto the

Parts Listfor ordering information. Use only a factory-authorizedbelt as an"over-

the-counter" belt may not perform satis-

factorily. Theprocedure requires average mechanicalability andcommonly available

tools.

,_ WARNING: Beforeinspecting, cleaningor servicing the machine,shut offengine,wait for all

moving partsto come to a completestop, disconnectspark plug wireand move wireawayfrom spark plug. Failureto follow these instructions canresult in serious personalinjury orproperty

damage.

FORWARDCLUTCH BAIL ADJUSTMENT

If the Forward Clutch Baildoes not func-

tion properly,first checkthat the forward

drive belt is adjusted properly (see Check-

ing andAdjusting Forward Drive Belt Ten- sion). If this fails to correct the problem,

contact Troy-Bilt LLCor your authorized dealerfor service advice.

CHECKINGANDADJUSTINGRE- VERSEDRIVEBELTTENSION

(Models643B & 645A only)

It is important to maintain correct tension on the reversedrive belt. A loose belt will

causethetines andwheelsto slow down - or stopcompletely - eventhough the en- gine is running at full speed.

Whenchecking belttension, also checkthe belt for cracks, cuts or frayed edgesand replaceit as soon as possible.

• Checkbelt tension after the first two hours ofbreak-inoperationandafter every

10 operatinghours.

ToCheckReverseBeltTension:

1. Stopengine,wait for all parts to stop moving anddisconnect spark plug wire.

2. Removescrew in plastic beltcover and slide beltcover (which is attachedto for-

ward clutch cable) out of the way.

3. Haveanassistant pull the Reverse Clutch Control knob all the way out and hold it inthat position. Measurethelength

of the cablewire betweenthe end of the

threadedcableadjuster (A,Figure5-5) and the end of the Z-fitting (B)to which the ca-

ble wire is attached.

4. Thebelttension is idealif the cablewire lengthmeasuresbetween1/8"to 1/4".If it is

lessthan 1/8"(andif there isno reverseac- tion whenthe tiller is running),thenmake the following adjustments

NOTE:Ifthe lengthis morethan 1/4",noad- justment isneeded--as longasthe reverse

actionfunctions properly.

5. Releasethe ReverseClutchControl knob.andthen unthread the inner jam nut

(C, Figure 5-6) oneto two turns. Pull the threaded cableadjuster (A, Figure5-6) to the left untilthe innerjam nut (C) touches

the bracket.

6. Preventthe inner jam nut (C) from turn-

ing and tighten the outer jam nut (D)

againstthe bracket. Preventthe outer jam

nut (D)from turning and tighten the inner jam nut (C) againstthe bracket.

7. Measurethe gapby repeatingStep 3.

Readjustasneededby repeating Steps 5

and 6.

8. Reinstallthe belt cover.

Figure5-5: Measure cable wire lengthto checkfor correctreversebelt tension.

Figure5-6:Movethreadedadjuster(,4)toleft toincreasebelttension.

Replacement Belt Information If the drive belt needsto be replaced,see

your local authorizeddealeror referto the

Parts Listfor ordering information. Use only a factory-authorizedbelt as an "over-

the-counter" belt may not perform satis-

factorily. Theprocedure requires average mechanicalability andcommonly available

tools.

ENGINECLEANING

Keepingthe engineclean will helpto en-

sure smooth operation and prevent dam- agefrom overheating.Referto the Engine

Owner's Manualfor enginecleaning ser- vice intervals andinstructions. Besure

thatthe muffler iscool beforeservicingthe engine.

AIRCLEANERSERVICE

Theair cleaner filters dirt and dust out of the air before it enters the carburetor.Op-

eratingthe enginewith a dirty, cloggedair filter can causepoor performanceand damageto the engine. Neveroperatethe enginewithout the aircleanerinstalled. In- spectand service the air cleanermore of- ten if operating in very dusty or dirty conditions. Referto the engine Owner's

Manualfor air cleanerserviceintervalsand

instructions.

ENGINEOIL SERVICE

Checkthe engineoil level beforeeachuse and after every five hours of continuous operation. Runningthe engine when it is low on oil will quickly ruin theengine.

It is recommendedthat you changethe motor oilafter every 10hours of operation and even sooner when operating in ex- tremely dirty or dustyconditions. Referto the EngineOwner'sManualfor detailed

serviceinstructions.

A. ToChecktheEngineOil Level:

1. Parkthetiller ona levelareaandshut off the engine.

2. Leveltheengine (usethe Depth Regula- tor Leverto adjust the engineangle).

moving partsto come to a completestop, disconnectspark plug wireand move wireawayfrom

WARNING: Beforeinspecting, cleaningor servicing the machine,shut offengine,wait for all

spark plug. Failureto follow these instructions canresult in serious personalinjury orproperty damage.

3. Cleanaround the oil dipstick or oil fill

tube (whicheverapplies) to preventdirt

from failing into the crankcase.

4. Onengines with an oil fill tube, remove

the fill cap and add oil (if required) until it

reachesthetop ofthefill tube. Reinstallthe fill cap.

5. Onengines with a dipstick, remove it and wipe it clean. Reinsertthe dipstick,

tighten it securely,and removeit. Add oil

asneededto bring the levelupto theFULL mark. Wipe dipstick cleaneachtime oil levelis checked. Donot overfill. Tighten dipstick securely.

B. ToChangetheEngineOil: Changethe engine oil as instructed in the

EngineOwner's Manual.

SPARKPLUGSERVICE

Inspect andcleanor replacethespark plug after every 100 operating hours or annual- ly. Referto the EngineOwner'sManualfor spark plug serviceinstructions.

In some areas,local law requires using re- sistor spark plugsto suppress ignition sig- nals. If the enginewas originally equipped with a resistor spark plug, use the same

type for replacement.

SPARKARRESTERSCREEN SERVICE

If the engine muffler is equipped with a spark arresterscreen, removeand cleanit according to the service intervalsand in- structions in the EngineOwner'sManual.

THROTTLELEVERADJUSTMENT

If the engine does not respondto various

throttle leversettings, referto the Engine

Owner'sManual for serviceinformation or contact your localauthorized engine

dealer.

WARNING: Operators shallnottamper withtheengine

governorsettings onthe machine;the governor controls

the maximum safeoperating

speedto protect theengineand all moving parts from damage causedby overspeed.

Authorizedserviceshall be sought if aproblem exists.

CARBURETOR/GOVERNOR CONTROLADJUSTMENTS

Thecarburetor wasadjusted at the factory for best operatingspeed. Referto the En- gine Owner's Manualfor any adjustment information or seeyour authorizedengine

dealer. Thegovernor controls the maximumsafe

operatingspeedand protects the engine andall moving partsfrom damagecaused by overspeeding.Donot tamper with the enginegovernor settings.

OFF-SEASONSTORAGE

Whenthetiller won't be usedfor an extendedperiod, prepareit for storageas

follows:

1. Cleanthetiller and engine.

2. Do routine tiller lubrication andcheck for looseparts and hardware.

3. Protectthe engine and perform recom- mendedengine maintenanceby following the storage instructions found in the EngineOwner'sManual. Besureto protect the fuel lines, carburetor and fuel tank from gum deposits byremoving fuel or by

treating fuel with a fuel stabilizer (follow enginemanufacturer'srecommendations).

4. Store unit in a clean,dry area.

5. Neverstore thetiller with fuel in thefuel tank in an enclosedareawhere gasfumes

could reachan open flame or spark, or whereignition sourcesare present (space

heaters,hot water heaters,furnaces, etc.).

moving partsto come to a completestop, disconnectspark plug wireand move wireawayfrom

WARNING: Beforeinspecting, cleaningor servicing the machine,shut offengine,wait for all

spark plug. Failureto follow these instructions canresult in serious personalinjury orproperty damage.

TROUBLESHOOTING

PROBLEM

Enginedoes notstart

Enginerunspoorly.

Engineoverheats.

Enginedoesnotshotoff WheelsandTineswillnotturn

Tinesturn,butwheelsdon't,

WheelsTurn,butTinesDon't,

Poor tilling performance.

POSSIBLECAUSE

1. Spark plug wire disconnected.

2. Engine Throttle Control Lever incorrectly set.

3. Fueltank empty.

4. Choke control (if so equipped) in incorrect position.

5. Stale gasoline.

6. Dirty airfilter.

7. Defective or incorrectly gapped spark plug.

8. Carburetor out of adjustment.

9. Misadjusted throttle control.

10. Dirt or water in fuel tank.

1. Defective or incorrectly gapped spark plug.

2. Dirty airfilter(s).

3. Carburetor out of adjustment.

4. Stale gasoline.

5. Dirt or water in fuel tank.

6. Engine cooling system clogged.

1. Engine cooling system clogged.

2. Carburetor out of adjustment.

3. Oil level is low.

1. Misadjusted throttle control or ignition switch.

1. Improper useof controls.

2. Worn, broken, or misadjusted drive belt(s).

3. Internal transmission wear or damage.

4. Bolt loose in transmission pulley.

1. Wheel Drive Pins not in WHEELDRIVE.

2. Bolt loose in transmission pulley.

3. Internal transmission wear or damage.

1. Tine holder mounting hardware missing.

2. Bolt loose in transmission pulley.

3. Internal transmission wear or damage.

1. Worn tines.

2. Improper Depth Regulator setting.

3. Incorrectthrottle setting.

4. Forward Drive Beltslipping.

CORRECTION

Reconnectwire.

2. Put lever in STARTposition.

3. Add fuel.

4. See EngineOwner's Manual.

5. Drain fuel and addfresh fuel.

6. Clean or replace filter.

7. Inspect spark plug.

8. See EngineService Dealer.

9. See EngineService Dealer

10. See Engine Service Dealer. Inspectspark plug (see EngineOwner's Manual).

2. Clean or replace (see EngineOwner's Manual).

3. See EngineService Dealer.

4. Replacewith fresh gasoline.

5. See EngineService Dealer.

6. Cleanair cooling system (see EngineOwner's Manual).

Cleanair cooling area (see Engine Owner's Manual).

2. See EngineService Dealer.

3. Check oil level (see Engine Owner's Manual).

1. See EngineOwner's Manual or EngineService Dealer.

1. ReviewSections 3 and 4.

2. See "Checking Drive Belt Tension," Section 5.

3. Contact local dealer or the factory.

4. Tighten bolt.

1. See "Wheel Drive Pins" in Section 3.

2. Tighten bolt.

3. Contact local Dealer or the Factory.

1. Replacehardware.

2. Tighten bolt.

3. Contact local Dealer or the Factory.

1. See "Bolo Tines" (Section 5).

2. See "Tilling Tips & Techniques," Section 4.

3. See Section 4.

4. See "Checking Forward Drive Belt Tension," Section 5.

NOTES

Models643C,643B& 645A

MODELS643C,643B& 645A

REF NO.

1 686-04043

2 710-0395 3 710-0597 4 710-0599 5 710-0874 6 710-3008 7 712-04063 8 712-04064 9 715-0108

10 732-04320 11 736-0275 12 750-04149 13 750-04160 14 750-04556 15 786-04092 16 786-04098 17 786-04104 18 786-04191

19 786-04290 20 786-04291 21 786-04292 22 710-0106 23 710-04163 24 712-3009 25 712-0121 26 712-0291

PART NO.

686-04041

DESCRIPTION

TineHoodAssembly(A) TineHoodAssembly(B)(C}

HexScrew,5/16-18x2.25 HexHd.Screw,1/4-20x 1

Screw,Self-Tapping,I/4-20x 1/2 mexHd.Screw,5/16-18x 1-1/4 mexHd.Screw,5/16-18x .75 HexLockNut,Nylon,5/16-18 HexLockNut,Nylon,1/4-20 SpirolPin Spring,DepthRegulator FlatWasher,5/16 Spacer,.462x.328x 1.63 Bushing Spacer ReverseStopArm

ChannelSupportBracket

DragBar FlapStopBracket HoodBracket,LeftHand HoodBracket,RightHand

AdjustableDepthBar

HexHd.Screw,1/4-20x 1-1/4 Screw,#10-24x2

HexLockNut,5/16-18 mexNut,#10-24

HexLockNut,1/4-20

REF NO.

27 732-04185 28 746-04208

29 746-04058 30 747-04210 31 749-04084

32 749-04208 33 749-04106 34 732-04040

35 786-04188 36 786-04200 37 710-0216 38 710-0805

39 712-3000 40 736-0119 41 725-0157

42 736-3050 43 712-04065 44 710-0347 45 710-0514

46 710-04048 47 742-04117 48 742-04116

49 686-04066

PART NO.

686-04065 GW-1901

DESCRIPTION

Spring, ForwardClutch CableAssembly, ForwardClutch CableAssembly, ReverseClutch (B) (C)

Bail, ForwardClutch Upper Handlebar

Lower Handlebar Tab,Conduit Mount Bracket,ReverseClutch Cable(B) (g)

HandlebarSupport Panel

Screw,Hex,3/8-16 x 3/4 Screw, Hex,5/16-18 x 1-1/2 Hex Lock Nut,3/8-16 LockWasher, 5/16

CableTie FlatWasher, 3/8

FlangeLock Nut 3/8-16 Hex Hd. Screw, 3/8-16 x 1-3/4

Hex Hd. Screw,3/8-16 x 1,Grade5 FlangeScrew .312-18 x 1.00

Single BoloTine - LeftHand Single BoloTine - Right Hand TineHolder(A) TineHolder(B) (C) Bolo Tine ReplacementSet (IncL eight

right-hand tines,eight left-hand tines and required hardware). (A)(B)(C)

(A)ForModel643C (B)ForModel643B

(C)ForModel645A

MODELS643C,643B& 645A

REF NO.

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

-- GW-1325C

* Useas requiredto obtain between .005" and.015" allowable end-play.

PARTNO. DESCRIPTION

SnapRing Bearing,Tapered Roller(with race) Support Washer, Rear

DriveShaft Shim, RearBearingCap,.010"thick

GW-1224-2" GW-1224-3" GW-1224-4"

Shim, sameasabove,except .030" thick Shim, same asabove, except .005"thick Shim, sameasabove,except .062" thick Shim Set (Incl. the following shims:

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

REF NO.

1 GW-9727 2 710-04049 3 736-0119 4 1918377 5 1916641 6 GW-50032 7 721-04030 8 721-04031 9 619-04013 10 721-04036 11 736-3008* 12 718-04008 13 710-04048 14 710-3008

PARTNO. DESCRIPTION

Plug,TransmissionOilFill HexHd.FlangeScrew,5/16-18x5/8,Gr.5 LockWasher,5/16 RearCover,Transmission FrontCover,Transmission Gasket,HousingCover OilSeal,DriveShaft OilSeal,WheelShaft TransmissionRousingAssembly OilSeal,TineShaft

Washer,Flat,.344x.750x.120

RearBearingCap HexHd.FlangeScrew,5/16-18x 1 Hexmd.FlangeScrew,5/16-18x3/4

*Includedwithtransmissionwhenpurchasedasanassemblyonly.

Removeanddiscardwheninstallingthetransmissionontiller.

FRONT

MODELS643C,643B& 645A

(A) ForModel643C (B) ForModel643B (C)ForModel645A

REF NO.

2 3

4 5

6 7 8 9

* Useas

PARTNO. DESCRIPTION

1909950 GW-1166-1* GW-1166-2" GW-1166-3" GW-1166-4" GW-1166-5"

GW-1086 711-04512 711-04486

GW-9305

GW-1132-2

1904278 711-04078

GW-1104

1916542

requiredto obtain between .005" and .030" allowableend-play.

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

BronzeBushing WheelShaft(A) WheelShaft(B)(C)

Key,Hi-Pro,1/4x1

Spacer WormGear,WheelShaft

TillerShaft WoodruffKey

WormGear,TillerShaft

MODELS643C,643B& 645A

Model 643C

MODELS643C,643B& 645A

REF

NO.

1 2

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

19 20 21 22

23 24 25 26

PARTNO.

736-0159 756-04198 656-04023 656-04005 756-04169 786-04095 754-04090 754-04091 731-05268 732-04289 732-04081 732-04079 786-04068 786-04069 786-04070 748-04087 786-04276 786-04275 710-0672 710-0117 710-0237 710-0376 710-04049 710-0347 710-0520 710-0599 710-3103 712-3000 712-3009

DESCRIPTION

FlatWasher, 5/16 Pulley, EngineDrive Transmission Pulley(A) Transmission Pulley(B} (C) Pulley, ReverseIdler (B) (C) Guard,Belts/Pulleys

ForwardDriveBelt ReverseDrive Belt(B) (C)

BeltCover ReverseReturnSpring (B) (C)

BeltGuide (B) (C) BeltGuide

EngineBracket, Left EngineBracket, Right Bracket,BeltCover

Shoulder Washer ReverseIdler Arm (B) (C)

ForwardIdler Lever HexHd. Screw,5/16-24 x 1.25 (A)

HexHd. Screw,5/16-24 x 1 (B) (C) HexHd. Screw,5/16-24 x 543 HexHd. Screw,5/16-18 x 1 HexHd. Screw,5/16-18 x 5/8 HexHd. Screw,3/8-16 x 1-3/4 (A)

HexHd. Screw,3/8-16 x 1.50 (B)(C) Screw,Self-Tapping, 1/4-20x 1/2

HexHd. Screw,5/16-18 x 2 (B) (C) Lock Nut,3/8-16 Lock Nut,5/16-18 (B) (C)

REF

NO.

27 28

29 30 31 32 33 34 35 36 37 38 39

40 41 42

43 44

45 46 47 48

PARTNO.

736-0119 750-0535 736-3050 736-3090 736-0452 710-0459A 736-04181 732-04085 786-04107 756-04170 714-0105 736-3078 736-04193 710-0805 710-0395 712-04063 750-0258 736-0315 736-04192

736-0242 749-04193

726-0201 714-0143 734-04188 634-04232 634-04218

734-0255 734-04163

DESCRIPTION

LockWasher, 5/16 (A) Spacer,.380 IDx .625 ODx .21 (A) FlatWasher .406x .812 x .051 (B) (C)

FlatWasher BellWasher

HexHd.Screw, 3/8-24 x 1.50,GR5 Support Washer ForwardReturnSpring Bracket,Cable Mounting ForwardIdler Pulley Key,3/16" x 1"

FlatWasher BellevilleWasher

HexScrew,5/16-18 x 1.50 Gr5 (A) (B) HexScrew,5/16-18 x 2-1/4, Gr5(C) Nut, HexLock, 5/16-18 Spacer,Shoulder (A)

Washer, Flat,.75x 1.5x.125 (A)

FlatWasher .786x 1.000x .031 (B) (C) BellWasher

Bumper (C) Nut,Speed, 5/16-18 (C)

Klik Pin CompleteWheelAssembly 10x 2.75 (A)

CompleteWheelAssembly 13x 5x 6 (B} (C) Rim Assembly (B) (C) AirValve(B} (C) Tire(B)(C)

(A)ForModel643C (B)ForModel643B

(C)ForModel645A

NOTES

TROY-BILT TILLER LIFETIME LIMITED WARRANTY

WHAT PRODUCT IS COVERED

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 original 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-Bilt 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.troybilt.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

Troy-Bilt TUFFY 643B, TUFFY 645A, TUFFY 643C, Tuffy/Bronco CRT 643C, Super Bronco 643B Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual