Troy-Bilt TUFFY CRT 640C, TUFFY CRT 644A Operator's Manual

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Operator's Manual

Rear-tine Tiller Models

640C-- Tuffy_ CRT 644A m Super Bronco TM CRT

Mode1644A Shown

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

Warning: This unit isequipped 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. 769-00585C

9/15/04

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 23 Operation 12 Warranty Back Cover

FINDINGMODELNUMBER

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 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:

OTRDV-BILT T,OV-BmLTLLC

www.troybilt.com CLEVELAND,OH44136

,. 1-800-520-552_

P. O. BOX 361131

330-558-7220

Copy the serial number here:

CUSTOMERSUPPORT

PleasedoNOTreh/m thel/nit totheretailer withoutfirstcontactingCustomerSupport.

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.

_ 7>,,,,

/;/ ,> ;'V }/ )

..... f ; @; t ;D

j;_ ?" #'s " 4t, ' F_ i/!s ,

* ;,, #FOX }_ j,"

,,, >,, rL;, " ¢j ,_ <# ft, *x J ,7;; _

'_,-., _tf';_'ivc ,l

,v yO, ,_;7f'_;:'

If you prefer to reach a Customer Support Representative, please call 1(800) 520-5520.

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 by the 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-

SafetyAlertSymbol

ForwardClutchBail

ReverseClutchControl

(Models644A)

DepthRegulator

TineHoodFlap

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

and any other literatureyou may receive. Bethoroughly familiar with the controls andthe proper use ofthe tiller and its en- gine. Knowhowto stopthe unit anddisen- gagethe controls quickly.

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

3. Keepthe area of operationclear of all persons, particularly children andpets.

4. Keepin mindthat theoperatoror useris responsible for accidentsor hazardsoc- curring to other people,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. Donotoperatethetiller without wearing

1. Carefully readthis Own-

Training

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

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

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

5. Donottill nearundergroundelectric ca- bles,telephone lines, pipes or hoses. If in doubt, contactyour telephone or utility

company.

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

a. Storefuel in containers specifically

b. Thegascapshall neverberemovedor

Preparation

1. Thoroughly inspect the areawhere the

tiller is to be usedand removeallforeign

objects.

2. Be sure all tiller controls are released and both wheels arein the Wheel Drive po-

sition beforestarting the engine.

c. Keepmatches,cigarettes, cigars,

d. Fill fuel tank outdoorswith extreme

Standard-Rotating-Tines

(CRT)

DrivePin

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

e. Replaceall fueltank andcontainer

caps securely.

f. If fuel isspilled, do not attempt to

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

7. Nevermakeadjustments when engineis running (unless recommendedby manu-

facturer).

Operation

1. Do not put hands or feet near or under rotating parts.

designedfor this purpose.

fueladdedwhiletheengineisrunning. Allowthe engineto coolforseveral minutesbeforeaddingfuel.

pipes, openflamesand sparksaway from thefueltankand fuelcontainer.

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

2. Exerciseextremecaution when on or

crossing gravel drives, walks, or roads. Stayalert for hiddenhazardsor traffic. Do

not carry passengers.

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 andoperatingthe

machine.

4.Exercisecautiontoavoidslippingorfall- ing.

5.Iftheunitshouldstarttovibrateabnor- mally,stoptheengine,disconnectthe

sparkplugwireandpreventitfromtouch- ingthesparkplug,andcheckimmediately forthecause.Vibrationisgenerallya warningoftrouble.

6. Stopthe engine, disconnectthe spark plug wire andprevent it from touching the

spark plug, wheneveryou leavethe operat- ing position, beforeunclogging thetines,

or whenmaking any repairs,adjustments or inspections.

7. Takeall possible precautionswhenleav- ing the machine unattended.Stopthe en-

gine. Disconnectthespark plug wire and move it awayfrom thespark plug. Besure

that both wheelsarein the Wheel Drive po-

sition.

8. Beforecleaning, repairing,or inspect- ing, stop the engine and make certain all

moving partshavestopped. Disconnect

the spark plug wire and preventit from touching thespark plugto preventacci-

dentalstarting.

9. Theflapon thefine hood must bedown when operatingthetiller.

10. Neveruse the tiller unless proper guards, plates, or other safetyprotective devicesare in place.

11. Donot run the enginein an enclosed area.Engineexhaust containscarbon

monoxide gas, a deadlypoison that is odorless, colorless, and tasteless.

12. Keepchildren and pets away.

13. Never operate the tiller underengine

powerif thewheels are in theFreewheel position.Inthe Freewheelposition,the

wheelswill not holdthe tiller back andthe revolvingtines could propel thetiller rapid-

ly,possibly causingloss ofcontrol. Always engagethe wheels with the wheel drive pins in theWheel Drive position before starting the engine or engaging the

tines4Nheelswith the ForwardClutch Bail

(all models)or the ReverseClutchcontrol (Model 644A only).

14. Beaware that the tiller may unex-

pectedlybounceupwardorjumpforward if the tines shouldstrikeextremelyhard packedsoil, frozenground,or buriedob- stacleslike large stones,roots,or stumps.

If indoubtaboutthetilling conditions, al-

ways usethe following operating precau-

tionsto assistyouin maintainingcontrol of the tiller:

a. Walk behindandto one side of the

tiller, usingone handonthehandle barsRelax yourarm, but usea

securehandgrip.

b. Useshallowerdepthregulator

settings,working graduallydeeper

with eachpass.

¢. Use slower enginespeeds.

d. Clearthetilling area of all large

stones,rootsor other debris.

e. Avoidusingdownwardpressureon

thehandlebars.If needbe, use slight upwardpressureto keep the

tinesfrom diggingtoodeeply.

f. Beforecontacting hardpackedsoil

at the endofa row,reduceengine speedand lift thehandlebarsto

raise the tines out of the soil.

g. In an emergency,stopthe tinesand

wheels byreleasingwhichever clutch controlis engaged.Do not

attemptto restrainthetiller.

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

rate.

16. Neveroperate the tiller at high trans- port speeds on hard orslippery surfaces.

Look behind and usecarewhen backing up.

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

slow down and makesure you havegood footing. Neverpermit thetille rto 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. Neveroperate the tiller without good visibility or light.

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 protectthe 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.Letparts cool down

sufficiently.

25. Pleaseremember:Youcan alwaysstop

thetines andwheels by releasingthe For- ward ClutchBail or on Model644Athe Re-

verseClutchcontrol, (whichevercontrol is engaged),or bymoving the ignition switch and/orthrottle control leveron the engine

to "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 awayfrom thetines.

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 insidea building whereignition sourc- esare presentsuchashot waterandspace

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

sure.

4. Toreducethe chances of afire hazard,

keepthe enginefreeofgrass, leaves,or ex- cessivegrease.

5. Storegasolinein acool, well-ventilated

area,safelyawayfrom any spark- 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 spark plug wire is connected,exceptwhen specifically in- structed to do so.

8. Ifthe fueltank hasto be drained,dothis

outdoors.

Decals

Foryour safety and the safety of others, vari- ous safety and operationaldecalsare located on your unit (seeFigure 1-2).

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.

ForwardClutchBail

StartingStabilization

Message(on engine)

Figure 1-2: Locationofsafety and operatingdeca/s.

ReverseClutch Control

OperatingInstruction

(Models 644A)

WarningMessages

HotSurfacesWarning

OperatingSymbols

Varioussymbols(shownhere,withworddescriptions) mayheusedonte'dllerandengine.

NOTE:Yourunitmaynothaveallof_esymbds.

FAST SLOW STOP

* READTHEOWNER'SMANUAL. * KNOWLOCATIONSAND FUNCTIONSOFALLCONTROLS. * KEEPALLSAFETYDEVICESANDSHIELDSIN PLACEANDWORKING. ° NEVERALLOWCHILDRENORUNINSTRUCTEDADULTSTOOPERATETILLER. ° SHUTOFFENGINEANDDISCONNECTSPARKPLUGWIREBEFOREMANUALLYUN-

CLOGGINGTINESORMAKINGREPAIRS. ° KEEPBYSTANDERSAWAYFROM MACHINE. ° KEEPAWAYFROM ROTATINGPARTS. ° USEEXTREMECAUTIONWHENREVERSINGOR PULLINGTHEMACHINETOWARDS

YOU.

I"1 I*1 R

CHOKE CHOKE REVERSE

ON OFF ROTATINGTINES

<,-K,

TILLERDIRECTION

TO AVOID SERIOUS INJURY:

<--o-->

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 operatinginstructions in this manual.

INTRODUCTION

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

NOTE: Various rifler 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 644A only) (1) Scissors (totrim plasticties) (1) Ruler (for belttension check) (1) Block of wood (to support tiller when

removing wheels) (1) Tire pressure gauge (for models with

pneumatictires) (1) Cleanoil funnel (1) Motor oil. Referto the 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 staplesfrom 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 items are 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 lockwasher,5/16" 4 Hexnut, 5/16"-18

2 HexIocknut, 34}"-16

*Model 644Aonly

IMPORTANT:Motor oil must beaddedto

the enginecrankcasebeforetheengine is

started. Followthe instructions inthis Sectionand in the separateEngine

Owner's Manual.

NOTE: LEFTand RIGHTsides of the tiller are as viewedfrom theoperator's position

behind the handlebars.

STEP 2: ATTACHHANDLEBAR

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

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

hd. screws (B), 3/8" flat washers(C), and 3/8"-16 hex Iocknuts (D).

_iiii

Figure2-1: Toidentifylengthofscrews,place

screwontemplateasshownandmeasuredis-

tancebetweenbottomofscrewheadandtipof

screw.

2. Usingtwo 5/16"-18 x 1-1/2"screws (G), 5/16" split lockwashers (H) and 5/16"-18 hexnuts (I), looselyattach the handlebar support (A)usingthe upperholes.Tighten

thetwo screws securely.

3. Therearethree heightadjustment 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" into the

soil. Looselyattachthe support bracketsto theoutsideofthe handlebarassembly (K)

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

16"split lockwashers(H)and5/16"-18 hex nuts (I).NOTE:Ifa support bracketwill not move, loosenattaching screw (J) and nut.

IMPORTANT:The support bracketsmust

beassembledtotheoutsideofthe 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 wheel about 1"off the

ground. 2, Removethe hairpin cotter (L, Fig.2-3)

and wheel drive pin (M) from the wheel hub (0) and wheelshaft (N).

3. Slidethe wheelfully inwardonthe wheel shaft (N, Fig.2-3). Reinstall the wheel

°-! °

Fig. 2-3: Wheel in FREEWHEELposition

Fig. 2.2: Attachhandlebar.

drive pin (M) through thewheelshaft only (not through the wheelhub). Securethe

wheeldrive pin with the hairpin cotter (L), pushingthe hairpincotter in as far as it will

go. Thewheelshould now spin freely (freewheel) on the wheelshaft. Repeat

with the other wheel.

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

STEP 4: INSTALL FORWARD

CLUTCH CABLE

1. Carefullyunwrapthe forward clutch ca-

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

blewire (T,Fig. 2-4) into the slot in the ca-

blebracket. Pushthe cable connector (U, Fig.2-4) upthrough the holein thebracket

untilthe groove inthe 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).

IMPORTANT: Beforestartingthe engine,

the wheels must beplacedin the WHEEL

DRIVEposition (pinsthrough wheel hubs andwheelshaft). This procedureis

describedin WheelDrivePinsin Section3.

Fig. 2-4: Installingforward clutchcable bracketand cable.

4. Checkfor correcttension ontheforward drive belt by taking two measurements of

the cablespring, as follows:

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

6) in an open (released)position, measure

the length of thecablespring (W) fromthe

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

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

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

tween 1/16"to 3/16" longerthanthe first

measurement.If so,turn the hexnut (Z, Fig. 2-7) tightly against the cableadjuster (X) while preventingthe cableadjuster

from turning. c. Ifthe spring lengthis incorrect, you

must adjustthe cabletension asdescribed in Checkingand Adjusting ForwardDrive

Belt Tensionin Section5. Incorrect cable

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

movement when the clutch bail is in Neu-

tral (cabletension too tight).

iiiiiiiiiiiiiiii

Fig. 2-7: Tocheckforwardbelt tension,take two measurementsofthelengthof the coils inthe spring-- firstwiththebail open, then withthe bail held against thehandlebar.

STEP 5: INSTALL REVERSECLUTCH CABLE (MODEL 644A 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 ofthe hole.Slidethe hexnut (DD) up the cable andtighten it securely.

Flat Side

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

2-9).

4. Testthefunction ofthe reverseclutch by

Fig. 2-8:/nsta//reverse cablebracketand reverseclutchcable.

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.2-5: Cable springand adjuster.

Fig. 2-6: Attachforward clutchcable spring to

forwardclutch bail.

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

shown.Attachwithcable tie (EE).

5! 6: CHECKTRAHSMiSSiOH OILLEVEL

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

is correct. IMPORTANT:Donot operatethetiller ifthe

gear oil level islow. 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 level is correct ifthegear oil isapproximately halfway upthe sideofthe

main driveshaft.

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

dear 0il 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 result if the engineis runwith- 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) upor

down until the engineis 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.

_1 El-'8: I.;HEI.;K HAHUWAHE Checkall nuts and screws for tightness. STEP g: CHECK AIR PRESSURE IN

TIRES (unitswithpneumatictires)

Checkthe air pressurewith a tire gauge.

Deflateor inflatethe tires equally to be- tween 15 PSIand 20PSI (pounds per squareinch). Besurethat bothtires arein- flated equally or the unit will pull to one

side.

Fig. 2-10: AdjustDepth RegulatorLever.

Fig. 2-11: Removegear oil fill plug.

IMPORTANT: This completesthe assemblysteps. Be- fore operatingyour tiller, makesure you readthefollow- ing sectionsin this Manual,as well asthe separateEngineOwner'sManual:

• Section1: Safety

• Section3: Featuresand Controls

• Section4: Operation

SECTION3: FEATURESANDCONTROLS

_ ARNING: Before

operatingyour machine, carefully readand understand

all safety, controls and operatinginstructions in this

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

Failureto follow these instructions can result in

serious personal injury.

INTRODUCTION

This Section describesthe locationand

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

Practice usingthese controls, with the en-

gine shut off, until you understandthe op-

eration ofthe controls andfeel confident

with eachof them.

ENGINE CONTROLS

Referto the enginemanufacturer'sEngine

Owner'sManual (included inthe 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 awheel drive

pin (A, Figures3-2 and 3-3) that secures the wheelto the wheelshaft (B). The

wheelscan be positioned in either a

WHEELDRIVEor a FREEWHEELmode.

_ WARNING: Neverallow

either ofthewheelsto bein the FREEWHEELposition whenthe

engineis running. Alwaysput both wheelsin theWHEEL

DRIVEposition beforestarting

the engine.

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

Beforestarting the engine,put both wheels

in the WHEELDRIVEposition byinserting the wheel drive pins through the wheel

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

wheelsto turn when either the

ForwardClutch

Figure3-1: Tiller features and controls.See separateEngineOwner's Manual to identify enginecontrols.

Bail ReverseClutchControl

(Model 644A)

gulator

HandlebarHeight Adjustment

Wheel Drive Pin

(oneachwheel)

Forward Clutch Bail (all models) or the Re- verse Clutch Control (Model 644A)is en-

gaged. Usethe FREEWHEELmode only whenthe

engineis not running, in FREEWHEEL,the wheeldrive pins areplacedonly through

the holes in the wheel shaft (notthe wheel

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

Toplacethe wheels in WHEELDRIVEor FREEWHEEL:

1. Stopengine,disconnectsparkplug wire

Figure3-2: WHEELDRIVEposition.

from sparkplug andallowengineto cool.

wheelhub (D,Figure3-2) and wheel

_ WARNING: Donotplace

tiller on its sidewhen changing

wheeldrivepositions. Doingso could result in gasolineleaking from the fuel tank.

Failureto follow this instruction could result in personalinjury

or propertydamage.

2. Raiseone wheelabout oneinch off the ground andplaceasturdy support under

the transmission.

shaft (B). Insert wheel drive pin (A) through wheel hub (D)and wheel shaft (B). Securewheeldrive pinwith hair- pin cotter (C) by pushing hairpin cotter in asfar as it will go. Repeatwith the other wheeland then removethe support from

beneaththe transmission.

5. FORFREEWHEELMODE(Figure 3-3): Slidethewheelinwardandinsertthewheel

drive pin (A, Figure3-3) onlythrough the hole in the wheel shaft (B). Secure wheel

3. Removehairpin cotter (C,Figures3-2 and 3-3) from wheel drive pin (A).

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

drivepin with hairpincotter (C)bypushing hairpin cotter in asfar asit will go. Repeat

for the other wheeland then removethe support from beneath the transmission.

_--'i_ caution when reversing or

,,_- D you. Look behindto avoid

Figure3-3:FREEWHEELposition.

engine,besurethat both the ground, look behindyou to avoid any

WARNING: Beforestarting 3. Lift the handlebar until the tines clear

wheelsare inWHEELDRIVE obstacles,and then pull the control knob position. SeeWheelsDrivePins (F,Figure3-4) out. The wheels and tines

for instructions, will rotate in a reversedirection. Engagingthe Forward Clutch 4. Releasethe control knobto disengage

Bail or ReverseClutchControl (stop) thewheels andtines (theenginewill (if equipped) whenthewheels continue to run).

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(E, Figure3-4)

controls the engagementof forward drive F to the wheelsand tines. E

Tooperate the ForwardClutchBail:

1. Put wheelsin WHEELDRIVEposition Figure3-4:AII modelshavea ForwardClutch

(see"WARNING"statement above). Bail(E). OnlyMode1644AhaveaReverse

2. Lift and hold the clutch bail (E, Figure3-

4)againstthehandlebartostartthewheels DEPTH REGULATOR LEVER

andtines rotating in aforward direction.

3. Releasethe clutch bail to disengage ing depth of the tines. Pullthe leverback

(stop) the wheels andtines (theenginewill andslide it up or downto engagethe

continue to run). notched height settings.

REVERSECLUTCHCONTROL The"travel position" (highestnotch) raises

(Model 644A only) the tines approximately1-1/2"off the

TheReverseClutch Control (F,Figure 3-4) without the tines contacting the ground.

controls the engagementof reversedrive Thissetting should also be used when to the wheelsandtines. The reversingfea- starting the engine.

ture is usedfor maneuveringthe tiller

only-- neverengagethetines in the Moving the leverupward will increasethe

ground while operatingin reverse.

_ WARNING: Useextreme

pulling the machinetowards obstacles.

Neverattemptto till in reverse. Failureto follow this warning

could result in personalinjury or propertydamage.

Tooperatethe ReverseClutchControl:

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

2. Stopall tiller motion by releasing the Forward Clutch Bail.

ClutchControl(F).

This lever (G,Figure 3-5) controls the till-

ground, allowingthe tiller to be moved

tilling depth.Thelowest notch allows a till-

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

begintilling atavery shallow depthsetting

and gradually increasethe tilling depth.

_b ARNING: Donotattempt

TravelPosition

Figure3-5: DepthRegulator Lever (G).

HANDLEBARHEIGHT ADJUSTMENT

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

levelwhenthe tines are3"-4" in the soil.

Toadjustthe handlebars:

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

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

Figure3-6: Handlebarheightadjustment.

to till too deeplytoo quickly.

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.

High

Medium

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'sManual before you start the engine. Then,take thetime to fa- miliarize yourself with the basic operation of thetiller before using it 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 should you 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 EngineOwner'sManual).

1. Changeengineoil.

2. Checkfor looseor missinghardwareon unit. Tightenor replaceas needed.

3. Checktension onforward drive belt.

4. Checktransmission gear oil level.

STARTING AND STOPPING

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 bethrough holes in wheelhubs andwheelshaft).

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

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

ReverseClutchControl

(Model644A)

ClutchBail

,epthRegulator

DrivePin

Fig. 4-1

5. Checkthat all safety guards andcovers are in place.

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

,_ WARNING: GASOLINEIS

7. Fillthefuel tank with gasolineaccording

to the directions inthe separateEngine

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 rulesin

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 have readall ofthe operatinginstructions in this Section.Also, reviewthe safety rules in Section 1:Safety,and

the tiller and enginecontrols

information in Section3:

Featuresand Controls.

1. Completethe Pre-StartChecklistonthis

page.

2. Putthe wheels inthe WHEELDRIVEpo-

sition (seeWheelDrivePinsin Section3 of this manual).

,_ WARNING: Tohelp

• Before starting engine, put both

wheels inthe WHEELDRIVEposition. Never have wheels in FREEWHEELpo- sition when engine is running. When thewheels are in FREEWHEEL,they do

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(Model 644A only) in neutral (disengaged)positionsby re-

leasinglevers.

• Never run engine indoors or in en-

closed,poorlyventilatedareas. Engine exhaustcontainscarbonmonoxide,an

odorlessanddeadlygas.

• Avoidenginemuffler andnearbyareas.

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 a fuel shut-off valve,

turn valve to openposition, asinstructed 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, as in- structed inthe EngineOwner's Manual.

7. Chokeor prime engine,as instructed in

EngineOwner's Manual.

8. Put one hand on fueltank to stabilize unitwhen pullingstarter 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 (Model 644A)-- whichevercontrol is in use.

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

the "OFF"or "STOP"position.

OPERATINGTHETILLER

Thefollowing operatinginstructions pro- videguidelinesto usingyour 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. As the wheels pull forward, the tines rotateback- ward, creating an "uppercut" action which

digs deeply, uprooting soil andweeds.

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

wheelsare in the WHEELDRIVEposition.

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

ground. Usethis position when practicing with thetiller and when traveling between

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 ofthe wheelsand powerto thetines:

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

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

hind anda little to 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 do not push down on

the handlebarsto try and forcethe tines to

dig deeper-- this takesweight offthe wheels and 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 (Model644A 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) Swingthe handlebarto theleft so the right wheeltakesa "step" backward.Next

swing the handlebarto the rightso theleft wheel"steps" backward.Repeatasneeded.

the two wheels inFREEWHEEL.

7. ToTurnthe Tiller Around:

(a) Practiceturning the tiller in alevel, openarea.Beverycarefulto keepyour feet and legs away from the tines.

(b) Tobeginaturn, liftthe handlebarsuntil

thetinesareoutofthegroundandtheengine

andtinesarebalancedoverthewheels(Fig. 4-4).

(c) With tiller balanced,push sideways on handlebarto steer in direction of turn (Fig. 4-5). After turning, slowly lower tines into

soil to resumetilling.

Fig. 4-4: Tobegin turn, lift handlebars until tines are out of groundand unit is balanced.

Fig.4-2:Useonehandtoguidetillerwhen movingforward.

Fig.4-3:Raisetinesoffgreundandlook

behindwhenmovinginreverse.

6. Tomovethe Model640Cin reversefor short distances:

(a) Releaseforward ClutchBail.Thenlift handlebaruntiltines are off the ground.

Fig.4-5: Withtinesoutofgreund,pushhan- dlebarssidewaysto turntiller.

StoppingtheTillerandEngine

1. Tostop the wheelsandtines, releasethe

Forward Clutch Bail (all models) orthe Re- verse Clutch Control (Model 644A)--

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(breakingupsurfacesoilaroundplantsto destroyweeds,seeFig.4-9), ajust the tinesto dig only 1"to 2"deep.Using shallowtilling depthshelpspreventinjury to plantswhoseroots often growclose to the surface.If needed,lift up on the handlebars

slightlytopreventthetinesfrom diggingtoo deeply.(Cultivatingona regularbasisnotonlyeliminatesweeds,it alsoloosensandaerates thesoil for bettermoistureabsorptionandfaster plantgrowth.)Wateringthegardenareaafewdayspriorto tillingwill maketillingeasier,

aswill lettingthenewlyworkedsoil setfor a dayor two beforemakinga final, deeptilling pass.

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

Don't overloadthe engine,but dig asdeeplyaspossibleon eachpass.Onlaterpasses,the wheelsmaytendto spinin thesoft dirt. Helpthemalongby lifting upslightly onthehandlebar

(onehand,palm up,works most easily).

Avoidthe temptationto pushdownon thehandlebarsinan attemptto forcethetiller to dig deeper.Doingsotakesthe weightoff the poweredwheels,causingthemto losetraction.

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

througha particularlytoughsectionofsodor unbrokenground, but in mostcasesthiswon't benecessary.)

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

that is bestfor your garden.

Setthe enginethrottle leverata speedto givethe engineadequatepowerandyetallowit to operateattheslowestpossiblespeed...atleast until youhaveachievedthe maximumtilling depthyou desire.Fasterenginespeedsmaybe desirablewhenmakingfinal passesthrough

theseedbedor whencultivating. Selectionofthecorrectenginespeed,in relationtothetilling depth,will ensureasufficientpowerlevelto do the jobwithout causingthe enginetolabor.

Letthe Tiller DotheWork

Whiletilling, relaxandletthe wheelspullthe tiller along while the tinesdo the digging.

Walkon thesidethat is notyet finished(to avoidmakingfootprints inthefreshly 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,gooverthesamepathtwice inthefirst row,thenover- lapone-halfthetiller width ontherest ofthepasses(seeFig.6).Whenfinishedin onedirection,makea secondpassata rightangle,as shownin Fig.4-7. Overlap

eachpassfor best results(invery hardground, it maytakethreeor four passesto

thoroughlypulverizethesoil.)

• Ifthegardensizewill not permitlengthwiseandthencrosswisetilling, thenover- lapthefirst passesbyone-halfatiller

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

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

Fig. 4-8

AvoidTilling Soggy,WetSoil

Tilling wet soil often resultsin large,hard

clumpsof soil thatcaninterferewith plant-

ing.If time permits,wait a day or twoafter heavyrainsto allow the soil to dry before

tilling. Testsoil bysqueezingit into a ball.If

itcompressestoo easily,it is toowet to till.

Fig. 4-6 Fig.4-7

Cultivating

With planning, you can ==.._vp. ==_._v_ 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 on slopes:

Ifyou must gardenon a moderateslope,pleasefollowtwo very importantguidelines:

1.Tillonlyon moderateslopes,neveronsteepgroundwherefootingis difficult (reviewsafe-

ty rulesin Section1:Safetyof this manual).

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

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

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

WAHNING: Donot operatetiller on aslopetoo

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(VerticalTilling)

• Tokeepsoil erosionto aminimum, besureto addenoughorganicmatterto thesoil sothat it has goodmoisture-holdingtextureandtry to avoidleavingfootprints or wheelmarks.

• Whentilling vertically,tryto makethefirst passuphillasthetiller digsmoredeeplygoing uphillthan it doesdownhill.Insoftsoilor weeds, youmayhaveto lift the handlebarsslightlywhile going uphill. Whengoingdownhill, overlapthefirst passby aboutone-halfthewidth of

thetiller.

Clearingthe Tines

Thetineshavea self-clearingactionwhicheliminatesmosttanglingofdebrisinthe tines.However,occasionallydrygrass,stringystalksortoughvinesmaybecometan- gled.Followtheseproceduresto helpavoidtanglingandto cleanthetines,if neces- sary.

•Toreducetangling,setthedepthregulatordeepenoughtogetmaximum"chopping" actionasthetines chopthe materialagainstthe ground.Also,try to till undercrop residuesor covercropswhiletheyaregreen,moistandtender.

• Whiletilling,try swayingthehandlebarsfrom sideto side(about6"to 12").This "fishtailing"actionoftenclearsthetinesof debris.

• Iftanglingoccurs,lift thetinesoutofthesoilandrunthetiller inreverse(if unit is equippedwith poweredreverse)forafewfeet.Thisreversingactionshouldunwinda gooddealofdebris.

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

sure to stop the engineanddisconnect thespark plug wire beforeclearing the tines by hand.

tines byhand,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.

Loading andUnloadingtheTiller

,_ WARNING: Loadingand

•Beforeloadingor unloading,stoptheengine, waitfor allpartsto stopmoving,

disconnectthesparkplugwireandlettheen- gineandmufflercool.

•Thetilleristooheavyandbulkytolift safely byoneperson.Twoor morepeopleshould

sharetheload.

unloadingthetillerintoavehicleis potentiallyhazardousandwedon't

recommenddoingso unless absolutelynecessary,asthiscould resultinpersonalinjuryor propertydamage.

However,ifyoumustloador unloadthetiller,followthe

guidelinesgivennext.

• Use sturdy ramps andmanually (engineshut off) roll the tiller into and out of the vehicle. Two or morepeople areneededto do

this.

• Theramps must bestrong enoughto support the combined weight of the tiller and any han-

dlers. Theramps should provide good traction to prevent slipping; they shouldhave side rails

to guidethe tiller along the ramps; andthey should havea locking deviceto securethemto

the vehicle.

• Thehandlersshouldwearsturdyfootwearthat 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 personat eachsideto turn the wheels.

• When going down ramps, walk backward

with the tiller following you. Keepalert for any

obstacles behindyou. Position a personat eachwheel to control the speedof thetiller.

Nevergo down ramps tiller-first, asthe 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,startatthe top of the slopeand work down. Gobackand forth acrossthefirst rowasshown in Fig.4-10.

• Eachsucceedinglowerterraceis startedby walking belowthe terraceyou're O m_ preparing.Foraddedstabilityofthetiller,alwayskeeptheuphillwheel inthesoft,

newlytilled soil. Donottill the last12"or moreof the downhill outsideedgeof

eachterrace.Thisuntilled strip helpspreventsthe terracesfrom breakingapart andwashingdownhill. It alsoprovidesawalkingpathbetweenrows. _, REPEAT

Fig. 4-10

LOADINGAND UNLOADING THE TILLER

,_ WARNING: Loadingand

• Beforeloading 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.

• Theramps must bestrong enoughto support the combined weight of thetiller

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

should haveside railsto guide the tiller along the ramps; andthey should have a

locking deviceto secure them to the vehicle.

•The handlersshouldwearsturdy footwear

that will helpto preventslipping.

• Positionthe loading vehicle so that the ramp angle is as flat aspossible (the less incline to the ramp,the better). Turnthe vehicle'sengine off and apply its parking

brake.

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

tiller aheadof you. Havea person ateach sideto turn the wheels.

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

anyobstacles behind you. Position a per- son ateachwheel to 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 downthe ramp. Also, use the

blocksto temporarily keepthe tiller in

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

in the vehicle.

• Afterloading 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 parts to come

to acomplete stop, disconnect

spark plug wire andmovewire 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 Lubricatetiller

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 - SeeEngineOwner'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

7 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 clean generalpurpose

grease(greasecontaininga metallubricant

is preferred, if available).

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

greaseto the wheelshaft.

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

• Removethetines andcleanthetine shaft (C,Fig.5-1). Useafile orsandpaperto gen-

tly removeany rust, burrs or rough spots

(especiallyaround holes in shaft). Apply

greaseto ends of shaft beforeinstalling tines.

• Oilthethreads on the handlebarheight

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

Figure5-1

CHECKFOR OIL LEAKS

Beforeeachuse,checkthetiller for signs of

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

lation eitheron the unit or on the floor.

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

diateattention is needed.Ignoring an oil

leakcanresult in severetransmission damage!

If acover is leaking,check for loose

screws. If the screws aretight, a new gasket or oil seal may be required.

If the leakis from arounda shaftand oil

seal, the oil seal probably needsto be

replaced.Seeyour authorized dealeror

contact the factoryfor serviceor advice.

IMPORTANT:Neveroperatethe tiller if

thetransmission islow onoil.Checkthe

oil levelafter every 30 hours of operationand wheneverthere is anyoil

leakage.

CHECKHARDWARE

Checkfor looseor missing hardwareaf-

ter every 10 operatinghours andtighten

or replace(asneeded)beforereusing

tiller

Besureto checkthe screwsunderneath

thetiller hoodthat securethe transmis- sioncoverandthe DepthRegulatorLever

to thetransmission.

CHECKTIRE PRESSURE

(Models with pneumatictires)

Checkthe air pressurein both tires. The

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

Keepbothtires equally inflated to help prevent machinefrom pulling to one

side.

TRANSMISSION

GEAROIL SERVICE

Checkthe transmission gear oil level after every30 hours of operationor wheneveryou notice anyoil leak.Oper- ating thetiller when thetransmission is

low on oil can result inseveredamage.

A. To Checkthe Transmission

GearOil Level:

1. Checkthe gear oil levelwhenthe

transmission is cool. Gearoil will expandin warm operatingtemperatures

and this expansionwill providean incor-

rect oil level reading.

2. With thetiller onlevelground, pullthe

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 belowthe hole.

moving partsto come to a completestop, disconnectspark plug wire and move wireawayfrom

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

spark plug. Failureto follow these instructions canresult in serious personal injury or property damage.

4. Thegear oil level is correct ifthegear oil isapproximately halfway upthe sideofthe

main driveshaft.

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

IMPORTANT:Donot operatethetiller ifthe gear oil level islow. Doingso will result in severedamageto the transmission com- ponents.

Figure5-2: Remove oil fill p/ug (,4)to check gear oil level and to addgear oil. Remove fourcoverscrews(B) to draingear oil.

6. If adding only afew 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 inthe transmis- sion.

7. Whilecheckingfrequently to avoidover- 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 doesnotneedto bechangedunless it has beencontaminat- ed with dirt, sand or metal particles.

1. Draingasolinefrom thefuel tank or run

the engine until the fuel tankis 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 minutesbeforedrain-

ingtheUller's gasolinetank.

Do not allow open flames, sparks,

matchesorsmokingin thearea.

Wipe away spills and pushtiller away

fromspilledfuel.

Use only an approvedfuel container

and store it safely out of the reach of children.

Do notstoregasoline in an area where

its vaporscould reach an openflame orspark,orwhere ignitionsourcesare present(suchas 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 a drain panand allowthe gearoil to drainthrough

the top of thetransmission.

6. Reinstallthe wheel.

7. Install a newgasket (do not reuseold gasket)and reinstall the transmission cov- er.

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

9. Refill the enginewith motor oil and re- plenishthe fuel tankwith gasoline.

BOLOTINES

Thebolo tines will wearwith useand should be inspectedatthe beginning of

eachtilling seasonand after every30 oper- ating hours. Thetines can be replacedei- ther individually or as a complete 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 a loss of tilling depth, and re- ducedeffectivenesswhenchopping up andturning under organic matter.

B. Removin_nstalling a Single Tine:

1. With the engine shut off andthe spark plug wire disconnected,remove thetwo

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 soil first as the tiller moves forward.

C. Removin_nstalling a Tine Assembly:

1. Atine assemblyconsists of eighttines mounted on atine holder.

2. If removing both tine assemblies,mark them "left" and "right" beforeremoval. 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. Beforereinstallingthe 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 whenthetiflermoves forward.

Securethe tine assemblyto the tine shaft

usingthe screwand Iocknut

,_ WARNING: Beforeinspecting, cleaning or servicing the machine,shut off engine,wait for all

moving partsto come to a completestop, disconnectspark plug wireand move wire awayfrom spark plug. Failureto follow these instructions canresult in serious personal injury or property

damage.

FORWARD

Figure5-3: Instafl tinesso that cutting edge of tines enter soft first when tiller movesforward.

CHECKINGAND ADJUSTING FORWARDDRIVE BELT TENSION

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

causethe tinesandwheelsto slowdown-- or stop completely -- eventhough the en-

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

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

• Checkbelt tension after the first two hours ofbreak-inoperation andafter every

10 operatinghours.

• Atthe endof each tilling season,check

the beltfor cracks, cuts or frayededges

and replace it assoon as 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. Ifthe spring istoo long (morethan 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///engthofthecoils inthespring-- first withthedutch bail open,

thenwith thedutch bail closedagainstthe handlebar.

b. Unthreadthe hexnut (C,Figure 5-4)

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. Turn the screw counter-

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,retightenthehex nut (C)againstthetop of the adjuster(B).

ReplacementBelt Information

If the drive belt needsto be replaced,see

your local authorizeddealeror referto the

Parts List for ordering information. Use only afactory-authorized belt as an "over- the-counter" belt may not perform satis-

factorily. Theprocedure requiresaverage mechanicalability andcommonly available

tools.

,_ WARNING: Beforeinspecting, cleaning or servicing the machine,shut off engine,wait for all

moving partsto come to a completestop, disconnectspark plug wireand move wire awayfrom spark plug. Failureto follow these instructions canresult in serious personal injury or property

damage.

FORWARDCLUTCH BAIL ADJUSTMENT

If the Forward Clutch Baildoes notfunc-

tion properly,first checkthat the forward

drive belt is adjustedproperly (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

(Model644A only)

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

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 soonas possible.

• Checkbelt tension after the first two hours ofbreak-inoperation andafter every

10 operatinghours.

ToCheckReverseBeltTension:

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

2. Removescrew in plastic belt cover 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. Measurethe length

of the cable wire betweenthe endof 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 is no 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 innerjam nut

(C, Figure 5-6) oneto two turns. Pull the threaded cableadjuster (A, Figure 5-6) 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 repeatingSteps 5

and 6.

8. Reinstallthe belt cover.

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

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

Replacement BeltInformation

If the drive belt needsto be replaced,see

your local authorizeddealeror referto the

Parts List for ordering information. Use

only a factory-authorized belt asan "over- the-counter" belt may not perform satis-

factorily. Theprocedure requiresaverage mechanicalability andcommonly available

tools.

ENGINECLEANING

Keepingthe engineclean will help to en-

sure smooth operation andprevent 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 entersthe carburetor. Op-

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

Manualfor air cleanerserviceintervalsand

instructions.

ENGINEOIL SERVICE

Checkthe engineoil level before each use 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'sManual for detailed

serviceinstructions.

A. ToChecktheEngineOil Level:

1. Parkthetiller ona levelareaandshut off the engine.

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

,_ WARNING: Beforeinspecting, cleaning or servicing the machine,shut off engine,wait for all

moving partsto come to a completestop, disconnectspark plug wireand move wire awayfrom spark plug. Failureto follow these instructions canresult in serious personal injury or property

damage.

3. Cleanaround the oil dipstick or oil fill

tube (whicheverapplies) to preventdirt

from falling into the crankcase.

4. Onengines with an oil fill tube, remove

the fill capand add oil (if required) until it

reachesthetop ofthe fill tube.Reinstallthe fill cap.

5. Onengineswith a dipstick, remove it and wipe it clean. Reinsertthe dipstick,

tighten it securely,and removeit. Addoil

asneededto bring the level upto the FULL mark.Wipe dipstick cleaneachtime oil levelis checked. Donot overfill. Tighten dipstick securely.

B. ToChangetheEngineOil: Changethe engine oil as instructed inthe

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 requiresusing re- sistor spark plugsto suppress ignition sig- nals. If the enginewas originally equipped with a resistor spark plug, usethe same

type for replacement.

SPARKARRESTERSCREEN SERVICE

If the engine muffler is equipped with a spark arresterscreen, removeand clean it according to the service intervals and in- structions in the EngineOwner'sManual.

THROTTLELEVERADJUSTMENT

If the engine does not respondto various

throttle lever settings, referto the Engine

Owner'sManual for serviceinformation or contact your localauthorized engine deal-

er.

WARNING: Operators

shallnottamper with the engine governorsettings onthe machine;the governor controls

the maximum safeoperating

speedto protect theengineand all moving partsfrom damage causedby overspeed.

Authorizedserviceshall be sought if aproblem exists.

CARBURETOR/GOVERNOR CONTROLADJUSTMENTS

Thecarburetor wasadjusted atthefactory for best operatingspeed. Referto the En- gine Owner's Manual for anyadjustment information or seeyour authorizedengine

dealer. Thegovernor controls the maximum safe

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

OFF-SEASONSTORAGE

Whenthetiller won't be used for an ex- tendedperiod,prepareit for storageasfol-

lows:

1. Cleanthetiller and engine.

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

3. Protectthe engine and perform recom- mendedengine maintenanceby following the storage instructions found inthe En- gine Owner's Manual. Besure to 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 aclean, 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 wire awayfrom

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

spark plug. Failureto follow these instructions canresult in serious personal injury or property damage.

TROUBLESHOOTING

PROBLEM

Enginedoes notstart

Enginerunspoorly.

Engineoverheats.

Enginedoesnotshotoff WheelsandTineswillnotturn

Tinesturn,butwheelsdon't,

WheelsTurn,butTinesDon't,

Poortillingperformance.

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 air filter.

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 air filter(s).

3. Carburetor out of adjustment.

4. Stale gasoline.

5. Dirt or water infuel tank.

6. Engine cooling system clogged.

1. Engine cooling system clogged.

2. Carburetor out of adjustment.

3. Oil levelis 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 WHEEL DRIVE.

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 Regulatorsetting.

3. Incorrectthrottle setting.

4. Forward Drive Beltslipping.

CORRECTION

Reconnectwire.

2. Put lever in STARTposition.

3. Add fuel.

4. See Engine Owner's Manual.

5. Drain fuel and add fresh fuel.

6. Clean or replace filter.

7. Inspect spark plug.

8. See Engine Service Dealer.

9. See Engine Service Dealer

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

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

3. See Engine Service Dealer.

4. Replacewith fresh gasoline.

5. See Engine Service Dealer.

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

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

2. See Engine Service Dealer.

3. Check oil level (see EngineOwner's Manual).

1. See Engine Owner's Manualor EngineService Dealer.

1. ReviewSections 3 and 4.

2. See "Checking DriveBelt 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.

PartsList

1 :::3

m13

(A)ForModel640C (B)ForModel644A

REF NO.

1 715-0108 2 710-0597 3 710-0599 4 710-0874 5 710-3008 6 712-04064 7 712-04063 8 1916707 9 736-0119 10 GW-55013-1 11 GW-55013-2 12 GW-55015 13 GW-55018

PART NO.

DESCRIPTION

Spirol Pin Hex Hd. Screw, 1/4-20 x 1

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

HexHd. Screw,5/16-18 x .75 HexLock Nut,Nylon, 1/4-20

HexLock Nut,Nylon, 5/16-18 ChannelSupport Bracket

Lock Washer,5/16 Hood Bracket, LeftHand

Hood Bracket, RightHand DragBar DepthRegulatorLever

REF

NO.

15 16 17 18 19

20 21 22 23 24

PARTNO.

686-04043 686-04041 GW-55088 GW-9384 GW-9534 710-04048 618-04254 618-04046 786-04191 1916570 710-0395 1916771 736-0275

DESCRIPTION

TineHoodAssembly (A} TineHoodAssembly (B)

Bushing Spring, Depth Regulator Spacer

HexHd. FlangeScrew,5/16-18 x 1 Transmission Assembly(A} Transmission Assembly(B)

FlapStop Bracket ReverseStop Arm

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

FlatWasher, 5/16

MODELS640C& 644A

14 18

MODELS640C & 644A

REF

NO.

1 2 3 4 5

8 9

18 20 21 22 23 25

PARTNO. DESCRIPTION

1916719 1916755

747-04210

1918745 710-0599 710-3008 712-3009 786-04188

GW-55043 786-04200

GW-55044

GW-9855 725-0157 736-3050 732-04040 732-04185 710-0106 710-0216 710-0805 712-0121 712-0291 712-3000 736-0119

CableAssembly,ReverseClutch (B)

UpperHandlebar Bail,ForwardClutch

CableAssembly,Forward Clutch

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

Lower Handlebar Panel

Tab, Conduit Mount

Screw,#10-24 x 2

CableTie

FlatWasher, 3/8 Bracket,ReverseClutch Cable(B) Spring,Forward Clutch HexHd.Screw, 1/4-20 x 1-1/4

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

HexNut,#10-24 HexLock Nut, 1/4-20 HexNut,3/8-16 LockWasher,5/16

REF

NO.

PARTNO. DESCRIPTION

1 749-04193 Bumper(B) 2 710-0395 HexScrew,5/16-18x2-1/4,Gr5(B) 3 726-0201 Nut,Speed,5/16-18(B) 4 712-04063 HexLockNut,Nylon,5/16-18(B)

(A)ForModel640C (B)ForModel644A

MODELS640C& 644A

REF

NO.

1 2 3 4 5

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

PARTNO. DESCRIPTION

GW-9517 GW-1714 GW-50043 711-04110 GW-1224-1* GW-1224-2" GW-1224-3" GW-1224-4" GW-1325C

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

DriveShaft Shim, RearBearing Cap,.010"thick

Shim, same asabove, except .030" thick Shim, same asabove, except.O05"thick Shim, same asabove, except .062" thick Shim Set (Incl. thefollowing shims:

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

REF

NO.

PARTNO. DESCRIPTION

2 3 4 5 6 7 8 9 10 11 12 13 14

GW-9727 710-04049 736-0119 1918377 1916641 GW-50032 721-04030 721-04031 619-04013 721-04036 736-3008* 718-04008 710-04048 710-3008

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

*Includedwithtransmissionwhenpurchasedasanassemblyonly.

Removeanddiscardwheninstallingthetransmissionontiller.

MODELS640C & 644A

FRONT

(A)ForModel640C (B)ForModel644A

REF

NO.

1 2 3

4 5

7 8 9

PARTNO. DESCRIPTION

GW-9512 1909950 GW-1166-1* GW-1166-2" GW-1166-3" GW-1166-4* GW-1166-5"

GW-1086 711-04088 711-04092

GW-9305

GW-1132-2

1904278 711-04078

GW-1104

1916542

Retainer,Snap Ring, "E" Type Retainer,Snap Ring Shim,0.062"thick Shim,0.030"thick Shim,0.015"thick Shim,0.010"thick Shim,0.005"thick

BronzeBushing WheelShaft (A) WheelShaft (B)

Key,Hi-Pro, 1/4 x 1

Spacer Worm Gear,WheelShaft

Tiller Shaft Woodruff Key

Worm Gear,Tiller Shaft

.,J

* Useas

requiredto obtain between .005" and .030" allowable end-play.

MODELS640C& 644A

9 ! I11_ 7 1 19

, FORWARD

MODELS640C & 640A

REF

NO.

1 736-0159 2 714-0139

3 1916351 4 656-04023

5 1916535 6 1916652 7 1916657 8 1916658 9 1916660 10 1916724 11 1916725 12 1916726 13 1916794 14 1916795 15 1917326 16 1917746 17 1918731 18 1918744 19 710-0627

20 710-0237 21 710-0376

PART NO.

1108841

656-04005

710-0117

DESCRIPTION

FlatWasher, 5/16 Key,3/16"x 2" (A) Key,3/16" x 1-1/2" (B) Pulley, EngineDrive Transmission Pulley(A) Transmission Pulley(B) Pulley, ReverseIdler (B) Guard,Belts/Pulleys

ForwardDriveBelt ReverseDrive Belt(B)

BeltCover ReverseReturn Spring (B)

BeltGuide (B) ForwardBeltGuide

EngineBracket, Left EngineBracket, Right Bracket,BeltCover

Shoulder Washer ReverseIdler Arm (B)

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

HexHd. Screw,5/16-24 x 1(B} HexHd. Screw,5/16-24 x 5/8 HexHd. Screw,5/16-18 x 1

REF NO.

22 23

24 25 26 27 28

29 30

31 32 33 34 35 36

37 38

39 40 41 42 43

PART NO.

710-04049 710-0347

710-0599 710-3103 712-3000 712-3009 736-0119

750-0535 736-3090

736-0452 710-0151 GW-50027 GW-55034 GW-55049 GW-9090

GW-9301 736-3078

GW-9944 710-0395 712-3010 750-0258 736-0315 GW-1138-2

DESCRIPTION

Hex Hd.Screw, 5/16-18 x 5/8 Hex Hd.Screw, 3/8-16 x1-3/4

Screw,Self-Tapping, 1/4-20x 1/2 Hex Hd.Screw, 5/16-18 x 2 (B)

Lock Nut,3/8-16 Lock Nut,5/16-18 LockWasher, 5/16

Spacer,.380 IDx .625 ODx .21 FlatWasher

BellWasher Hex Hd.Screw, 3/8-24 x 2.0,GR5

Support Washer ForwardReturnSpring Bracket,CableMounting ForwardIdler Pulley Key,3/16" x 1"

FlatWasher BellevilleWasher

HexScrew,5/16-18 x 2.25 Gr5(A} Nut, HexLock, 5/16-18 (A) Spacer,Shoulder (A) Washer,Flat, .75 x 1.5 x.125 (A} Shim, 1.0x .765 x .031 (B}

(A)ForModel640C (B)ForModel644A

MODELS640C& 644A

TINE SHAFT

REF

NO.

1 2 3 4 5 6

8 9 10

7 "

FORWARD

PARTNO. DESCRIPTION

710-0514 GW-50049-02 712-3000 710-0347 GW-50049-01 1915075 1916747 1917486 734-04162 734-04161 GW-9380 GW-9338 GW-1901

HexHd.Screw, 3/8-16 x 1,Grade5 Single Bolo Tine- Left Hand

HexLock Nut, 3/8-16 HexHd. Screw,3/8-16 x 1-3/4 Single Bolo Tine- Right Hand TineHolder(A)

TineHolder(B} Wheel& TireAss'y -- Left/Right Side(B) Wheel& TireAss'y -- LeftSide Only (A)

Wheel& TireAss'y-- Right SideOnly(A) ClevisPin, .312"x 1-3/4"

Hair PinCotter Bolo Tine ReplacementSet (Incl. eight

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

HoldTinesWith Blunt EndTowardYou

RIGHT-HANDTINE LEFT-HANDTINE

NOTE:Identify Left and Right sides of tiller by standing in operator position and facing direction of forward travel.

(A)ForModel640C (B)ForModel644A

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, 1-866-520-5220, 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 CRT 640C, TUFFY CRT 644A Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual