Troybilt PRO LINE Bronco 645A Owner's manual

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Operator's Manual

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

PRINTEDIN U.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.

P. O. BOX 361131

www.troybilt.com CLEVELAND,OH44136

330-558-7220

866-840-6483_

Copy the model number here:

Copy the serial number here:

CUSTOMERSUPPORT

PleasedoNOTreturntheunit 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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;J< / I+ 1_,7_ .............. ......

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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

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

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.

ForwardClutchBail

ReverseClutchControl

(Mode/s643B&645A)

DepthRegulator

TineHoodFlap

Counter-Rotating-Tines

(CRT)

Drive Pin

Figure 1-1: Tiller featuresandcontre/s. See separateEngineOwner'sManua/ to

identifyenginecontre/s.

Training

1. Carefully readthis Own-

er's Manual,the separate

Engine Owner'sManual,

and anyother literature you may receive.

Bethoroughly familiar with the controls

andthe proper useofthe tiller and its en-

gine. Knowhowto stop the 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 and pets.

4. Keepin mindthat theoperatoror useris

responsible for accidents or hazardsoc-

curring to otherpeople,their property,and

themselves.

Preparation

1. Thoroughly inspect the areawherethe

tiller is to be usedand removeall foreign

objects.

2. Be sure all tiller controls are released

and bothwheelsare in theWheelDrive po-

sition beforestarting the engine.

3. Donot operatethetiller without wearing

adequateoutergarments. Avoid loosegar-

ments or jewelry that could get caught in

moving parts.

4. Donot operatethe tiller when barefoot

or wearingsandals,sneakers,or light foot-

wear.Wearprotective footwear thatwill

improve footing onslippery surfaces.

5. Donottill nearundergroundelectricca-

bles, telephonelines, pipes or hoses.If in

doubt, contactyour telephoneor utility

company.

6. Warning: Handlefuel with care; it is

highly flammableand its vapors areexplo-

sive.Takethe following precautions:

a. Storefuel in containers specifically

designedfor this purpose.

b. Thegascapshallneverberemovedor

fueladdedwhiletheengineisrunning.

Allowthe engineto coolforseveral

minutesbeforeaddingfuel.

c. Keepmatches,cigarettes, cigars,

pipes, openflamesandsparks away

from thefueltank andfuelcontainer.

d. Fillfuel tank outdoors with extreme

care.Neverfill fueltank indoors. Use

a funnelor spout to preventspillage.

e. Replaceall fueltank and container

caps securely.

f. Iffuel isspilled, do not attemptto

start the engine,but move the ma-

chineawayfrom the areaof spillage

and avoidcreating any source of ig-

nition until fuel vapors havedissi-

pated.

7. Nevermakeadjustmentswhenengineis

running (unless recommendedby manu-

facturer).

Operation

1. Do not put hands or feet near or under

rotating parts.

2. Exerciseextremecaution when on or

crossing gravel drives, walks, or roads.

Stay alertfor hidden hazardsor traffic.

3. After striking a foreign object, stop the

engine, removethe wirefrom the spark

plug wire and prevent it from touching the

spark plug. Thoroughly inspectthe 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. Neveroperatethetiller underengine

powerif thewheels arein theFreewheel

position.Inthe Freewheelposition, the

wheelswill not hold the 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

tines_vheelswith the Forward Clutch Bail

(all models) or the ReverseClutchcontrol

(Models 643B & 645A only).

14. Beaware thatthe tiller may unex-

pectedlybounceupwardor jumpforward

if thetines shouldstrike extremelyhard

packedsoil, frozen ground,or buriedob-

stacleslike largestones,roots,or

stumps.

If indoubtaboutthe tilling conditions,al-

ways usethefollowing operating precau-

tionstoassistyouin 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 upwardpressuretokeepthe

tinesfrom diggingtoodeeply.

f. Beforecontacting hardpackedsoil

at the endof a row,reduceengine

speedand lift thehandlebarsto

raise thetines out of the soil.

g. In anemergency, stopthetinesand

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. Neveroperatethetiller at high trans-

port speeds on hard or slippery surfaces.

Look behind and usecarewhen backing

up.

17. Donot operatethetiller on aslopethat

is too steep for safety.When on slopes,

slow down and makesure you havegood

footing. Neverpermit thetiller to freewheel

down slopes.

18. Neverallow bystanders nearthe unit.

19. Onlyuseattachmentsand accessories

that are approved bythe manufacturer of

the tiller.

20. Usetiller attachmentsand accessories

when recommended.

21. Neveroperatethe tiller without good

visibility orlight.

22. Neveroperatethe tiller ifyou aretired;

or underthe influence ofalcohol, drugs or

medication.

23. Operatorsshallnottamper with theen-

gine-governor settings onthe machine;

the governor controls the maximum safe

operatingspeedto protectthe engineand

all moving parts from damagecaused by

overspeed.Authorized serviceshall be

sought if a problem exists.

24. Do nottouch engine parts which may

behot from operation.Letparts cool down

sufficiently.

25. Pleaseremember:Youcanalwaysstop

the tines and wheels by releasingthe For-

ward Clutch Bailor on Models643B &

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. Useextremecaution when reversing

or pulling the 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 screwsfor

proper tightness to besurethe equipment

is in safeworking condition.

3. Neverstore thetiller with fuel in thefuel

tank insideabuilding whereignition sourc-

esare presentsuchashot waterandspace

heaters,furnaces, clothes dryers, stoves,

electric motors, etc.). Allow the engine to

cool beforestoring the unit in anyenclo-

sure.

4. Toreducethe chancesof a fire hazard,

keeptheenginefreeofgrass, 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 andthe safety of others, vari-

ous safety and operationaldecalsare located

on your unit (seeFigure 1-2).

Keepthe decalscleanand legible atall times.

Contactyour localservicedealeror thefactory

for replacementsif anydecalsaredamagedor

missing.

Referto the Parts List pagesin this Manualfor

decallocations, descriptions and part num-

bers.

ForwardClutch Bail

StartingStabilization

Message(on engine)

ReverseClutch Control

OperatingInstruction

_ (Models 643B& 645A

WarningMessages

Hot Surfaces Warning

Figure1-2: Locationofsafety and operatingdeca/s.

OperatingSymbols

Varioussymbols(shownhere,_dthworddescrip'dons)

maybeusedonte'dllerandengine.

NOTE:YourunihT_ynothaveallof_esymbols.

FAST SLOW STOP

I"1 I*1 R

CHOKE CHOKE REVERSE

ON OFF ROTATINGTINES

TILLERDIRECTION

<--o-->

LEVERDIRECTION

BAIL

ENGAGED

BAIL

DISENGAGED

TO AVOID SERIOUS INJURY:

* READTHEOWNER'SMANUAL.

* KNOWLOCATIONSAND FUNCTIONSOFALLCONTROLS.

* KEEPALLSAFETYDEVICESANDSHIELDSIN PLACEANDWORKING.

. NEVERALLOWCHILDRENORUNINSTRUCTEDADULTSTO OPERATETILLER.

° SHUTOFFENGINEAND DISCONNECTSPARKPLUGWIREBEFOREMANUALLYUN-

CLOGGINGTINESORMAKINGREPAIRS.

° KEEPBYSTANDERSAWAYFROMMACHINE.

° KEEPAWAYFROMROTATINGPARTS.

° USEEXTREMECAUTIONWHEN REVERSINGOR PULLINGTHE MACHINETOWARDS

YOU.

SECTION2: ASSEMBLY

WARNING: Toprevent

personalinjury or property

damage,do notstartthe engine

until all assemblysteps are

completeandyou haveread

and understandthesafety and

operating instructions in this

manual.

INTRODUCTION

Carefullyfollow these assemblysteps 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. Engine styles 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 in this 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 oil specificationsand

quantityrequired.

* Adjustable wrenchesmay beused.

ASSEMBLYSTEPS

STEP 1: UNPACKING INSTRUCTIONS

NOTE:While unpacking,do not severely

bend anycontrol cables.

1.Thetiller weighs approximately133 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 carton and 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,

LoosePartsList

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: LEFTand RIGHTsides of thetiller

are as viewedfrom theoperator's position

behind thehandlebars.

STEP 2: ATTACHHANDLEBAR

1. Looselyattachthe legsof thehandlebar

support (A, Fig. 2-2) to the inner sidesof

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

hd.screws (B),3/8" flatwashers, 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) and5/16"-18

hexnuts (G), loosely attachthe 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"intothe

soil. Looselyattachthesupport bracketsto

theoutsideofthe 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, loosenattachingscrew (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 raiseone 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: Wheelin FREEWHEELposition

(wheeldrivepin throughwheelshaftonly).

STEP 4: INSTALL FORWARD

CLUTCH CABLE

1. Carefullyunwrapthe forward clutch ca-

ble(cablewithout an attachedknob) from

its shipping position andslide thethin 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 wheelshaft (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:Beforestartingthe engine,

the wheels must beplacedin theWHEEL

DRIVEposition (pinsthrough wheelhubs

andwheelshaft). This procedureis

described in WheelDrivePinson page 10.

Fig. 2-4:/nstal/ing forward clutchcablebracketand 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 ofthecablespring (W) from the

outermost coil to the outermost coil.

b. Squeezethe ForwardClutch Bailagainst

the handlebar(seeFig. 2-7) and re-mea-

surethe spring length. Thebelt 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 preventing thecable adjuster

from turning.

c. If the spring length is incorrect, you

must adjustthe cabletension asdescribed

in Checkingand Adjusting Forward Drive

Belt Tensionin Section 5. Incorrect cable

tension can result inbelt slippage (cable

tension too loose), or unintentional tine

movement whenthe clutch bail is in Neu-

tral (cabletensiontoo tight).

: v

Fig.2-5: Cable

springand

adjuster.

Fig. 2-6: Attachforward

clutchcablespring to

forwardclutch bail

iiiiiiiiiiiiiiii

Fig. 2-7: Tocheckforwardbelttension,take twomeasurementsofthelengthofthe coilsin the

spring-- first withthebah open, then withthe bah held against thehandlebar.

STEP 5: INSTALL REVERSECLUTCH

CABLE(MODELS643BAND645A ONLY)

1. Unwrapthe reverseclutch cable (CC,

Fig.2-8 and Fig.2-9) from its shipping po-

sition and route it up to the handlebar.Be

surethat the cableis routedbeneaththe

Forward Clutch Bail.

2. Insertthecable(CC,Fig.2-8)through the

slot inthecablebracketandpositiontheflat

sideof thethreadedassemblynextto the

flat sideof the hole.Slidethe hexnut (DD)

up thecableandtighten it securely.

3. Fastenthe reverseclutch cableto the

left side handlebarwith acabletie (EE,Fig.

2-9).

4. Testthefunction ofthe reverseclutch by

pulling out and releasingthe cableknob.

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.

Flat Side

Fig. 2-8: Install reversecablebracketand

reverseclutchcable.

Fig. 2-9: Routereverseclutchcable (CC)as

shown.Attachwithcable tie (EE).

5! =-P6: CHECKTRAHSMiSSiOH

OILLEVEL

Thetransmission was filledwith gearoil at

thefactory. However,you shouldcheckthe

gear oil levelatthis time to makecertain it

is correct.

IMPORTANT:Donot operatethe tiller ifthe

gear oil level islow. Doingso will resultin

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 in the lever isengaged.

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

from the transmission housing cover and

locatethe maindrive shaft situated inside

the housing.

3. Thegear oil leveliscorrect ifthegear oil

isapproximately halfwayupthe sideofthe

main driveshaft.

4. Ifthe oil levelislow, add gear oil by re-

ferring to A, ToCheckthe Transmission

GearOil Levelin Section5.

I El."/: AUU IVlUI UH UIL

Thetiller isshipped withoutoil inthe en-

gine.

IMPORTANT:Donot start the engine with-

out first adding motor oil. Severeengine

damagewill result ifthe 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. Add motor 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 inthe"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 equallyto be-

tween 15 PSiand 20 PSi (pounds per

squareinch). Besurethat bothtires arein-

flated equally or the unit will pull to one

side.

Fig. 2-10: AdjustDepthRegu/atorLever.

Fig. 2-11: Removegear oil fill plug.

IMPORTANT: This completesthe assembly steps. Be-

fore operatingyour tiller, makesureyou readthefollow-

ing sections in this Manual,as well asthe

separateEngineOwner'sManual:

• Section 1: Safety

• Section 3: Featuresand Controls

• Section 4: Operation

SECTION3: FEATURESANDCONTROLS

_ ARNING: Before

operatingyour machine,

carefully readand understand

all safety,controls and

operating instructions in this

Manual,the separateEngine

Owner's Manual,andon the

decalson the machine.

Failureto follow these

instructions can result in

serious personalinjury.

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 and feelconfident

with eachof them.

ForwardClutch

ReverseClutchControl

(Models643B&645A)

Regulator

HeightAdjustment

Wheel Drive Pin

(oneachwheel)

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 located onthe engine.

WHEEL DRIVE PINS

Eachwheelis equippedwith a wheeldrive

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

curesthe wheelto thewheelshaft (B).The

wheelscan be positioned in either a

WHEELDRIVEor a FREEWHEELmode.

_ WARNING: Neverallow

either ofthewheelsto beinthe

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.

Beforestartingthe engine,put bothwheels

in the WHEELDRIVEposition byinserting

the wheeldriveKlikpinsthrough thewheel

hubsandthewheelshaft. Doingso "locks"

the wheels to the wheelshaft, causing the

wheelsto turn when eitherthe

Figure3-1: Tiller features and controls.See separateEngine Owner's Manual to identify

enginecontrols.

Forward ClutchBail (all models) or the Re-

verse ClutchControl (Models 643B &

645A) is engaged.

Usethe FREEWHEELmode only whenthe

engineis not running. InFREEWHEEL,the

wheeldrive pinsare placedonly through

the holes in thewheelshaft (notthe wheel

hubs), thus allowing the wheels to turn

freely whenyou manually movethe tiller.

Toplacethewheels in WHEELDRIVEor

FREEWHEEL:

1. Stopengine,disconnectsparkplug wire

from sparkplug andallowengineto cool.

_ WARNING: Donotplace

tiller on its sidewhenchanging

wheeldrivepositions. Doingso

could result in gasolineleaking

from the fuel tank.

Failureto follow this instruction

could result in personalinjury

or property damage.

2. Raiseone wheelabout one inch off the

ground and placeasturdy support under

the transmission.

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

3) from wheel driveshaft (B).

4. FORWHEELDRIVEMODE(Figure3-2):

Slide wheeloutward andalign holes in

Figure3-2: WHEELDRIVEposition.

wheelhub (D, Figure3-2) and wheel

shaft (B). Insert Klikpin (A)through wheel

hub (C)and wheelshaft (B). Repeatwith

the other wheelandthen removethe sup-

port from beneaththe transmission.

5. FORFREEWHEELMODE(Figure3-3):

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.

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 ClutchBail(D, Figure3-4)

controls the engagementof forward drive

to the wheelsand tines.

Tooperatethe ForwardClutchBail:

1. Put wheelsin WHEELDRIVEposition

(see"WARNING"statementabove).

2. Lift and holdthe clutch bail (D,Figure3-

4) againstthe handlebarto startthewheels

andtines rotatingin a forward direction.

3. Releasethe clutch bail to disengage

(stop) thewheels 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 usedfor maneuvering the tiller

only-- never engage the tines in the

ground while operatingin reverse.

WARNING: Useextreme

caution whenreversing or

pulling the machinetowards

you. Look behindto avoid

obstacles.

Neverattemptto till in reverse.

Failureto follow this warning

could result in personalinjury

or property damage.

Tooperatethe ReverseClutchControl:

1. Putwheels in WHEELDRIVEposition

(see"WARNING"statementat the left).

2. Stopall tiller motion by releasingthe

Forward Clutch Bail.

3. Lift the handlebar untilthe tines clear

the ground, look behind you to avoid any

obstacles,and then pullthe control knob

(E, Figure3-4) out.Thewheels andtines

will rotate in a reversedirection.

4. Releasethe control knobto disengage

(stop) thewheels andtines (theenginewill

continue to run).

Figure3-4:Allmodelshavea ForwardClutch

Bail(E).OnlyModel634,4havea Reverse

ClutchCentre/(F).

DEPTHREGULATORLEVER

Thislever(F,Figure3-5) controls thetilling

depth of thetines. Pull the leverback and

slide it up or downto engagethe notched

height settings.

The"travelposition" (highestnotch) raises

the tines approximately1-1/2"off the

ground, allowingthe tiller to bemoved

without the tines contactingthe ground.

This setting should also be usedwhen

starting the engine.

Moving the lever upwardwill increasethe

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.

WARNING: Donotattempt

to till too deeplytoo quickly.

Graduallywork downto deeper

tilling depths.

Placethe DepthRegulator

Leverin the "travel" position

beforestarting theengine.This

position preventsthetines from

touching the ground untilyou

are readyto begintilling.

Failureto follow this warning

could result in personalinjury

or property damage.

TravelPosition

Figure3-5: DepthRegulatorLever (G).

HANDLEBARHEIGHT ADJUSTMENT

Thehandlebarheight isadjustableto three

different settings (Figure3-6). In general,

adjust the handlebarssothey areat waist

levelwhenthe tines are3"-4"in the soil.

Toadjust the handlebars:

1. Stopengine,disconnectspark plugwire

from spark plug 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,andon the

decalson the machine.

Failureto follow these

instructions can result in

serious personalinjury.

INTRODUCTION

Readthis OperationSectionandthe sepa-

rate EngineOwner'sManualbeforeyou

start the engine.Then,take thetime 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. Changeengine oil.

2. Checkfor looseor missinghardwareon

unit. Tighten or replaceas needed.

3. Checktension on forward drive belt.

4. Checktransmission gear oil level.

STARTINGANDSTOPPING

Pre-StartChecklist

With the spark plug wire disconnected

from the sparkplug, perform the following

checksand services beforeeachuse:

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 and wheelshaft).

3. Checkunit for loose or missing hard-

ware. Serviceas required.

4. Checkengineoil level.SeeEngineOwn-

er's Manual.

ReverseClutchControl

(Mode/s643B&

ClutchBail

DepthRegulator

DrivePin

Fig. 4-1

5. Checkthat all safetyguards andcovers

are in place.

6. Checkair cleanerand enginecooling

system. SeeEngineOwner's Manual.

_ WARNING: GASOLINEIS

HIGHLYFLAMMABLEAND ITS

VAPORSAREEXPLOSIVE.

Followgasolinesafety rules in

this Manual(seeSection 1)and

in theseparateEngineOwner's

Manual.

Failureto follow gasolinesafety

instructions can result in

serious personalinjury and

property damage.

7. Fillthefueltank with gasolineaccording

to the directions inthe separate Engine

Owner's Manual.Followall 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

to engagethetines or wheels

until you havereadall 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

preventserious personalinjury

or damageto equipment:

• Before starting engine, put both

wheels in the WHEELDRIVEposition.

Never havewheels in FREEWHEELpo-

sition when engine is running. When

thewheels arein FREEWHEEL,theydo

not hold back the tiller and the tines

couldpropelthetiller 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 onthe tiller.

5. Onengine's with a fuel shut-off valve,

turn valve to openposition, as instructed

in the separateEngine Owner'sManual.

6. Put ignition switch and/or throttle con-

trol leverlocatedon enginein the "ON",

"RUN", "FAST"or "START"position, asin-

structed in the EngineOwner's Manual.

7. Chokeor prime engine,as instructed in

EngineOwner's Manual.

8. Put one hand on fueltank to stabilize

unitwhenpulling starter ropehandle.Then

userecoilstarter to start engine,as in-

structed in the EngineOwner's Manual.

Whenenginestarts, graduallymove choke

lever (if so equipped) to "NO CHOKE",

"CHOKEOFF"or "RUN" position.

9. Usethe "FAST"throttle speedsetting

whentilling.

Stopping the Engineand Tiller

1. Tostop thewheelsandtines, releasethe

Forward ClutchBail (all models) orthe Re-

verse ClutchControl (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 operatinginstructions pro-

videguidelinesto usingyour tiller effec-

tively and safely. Besure to read Tilling

Tips & Techniquesin this Sectionbefore

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, thetines 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 traveling between

tilling sites. Beforeactuallytilling, move

the leverto the desireddepth setting (see

Tilling Tips & Techniques).

Fig.4-2:Useonehandtoguidetiller when

movingforward.

3. Start engineand allow it to warm up.

Thenput throttle in "FAST"setting.

4. Forforwardmotion ofthe wheels and

powerto the tines:

(a) Pull Forward 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 keepalight--but secure--

grip on the handlebar (while keepingyour

arm loose). SeeFig.4-2. Letthe unit move

at its own paceand donot pushdown on

the handlebarsto try andforcethe tines to

dig deeper-- this takesweight off the

wheelsand reducestraction.

,_ WARNING: Donotpush

down onthe handlebarsto try

to makethetiller till more

deeply.This preventsthe

wheelsfrom holding the tiller

backand canallowthe tines to

rapidly propelthetiller forward,

which could resultin loss of

control, property damage,or

personalinjury.

5. Forreverse motion ofthe wheelsand

tines (Models643B & 645A only):

(a) Lookbehindand exercisecaution when

operating in reverse.Do not till while in

reverse.

(b) Stopall forward motion. Lifthandlebar

with one handuntiltines areoffthe ground

andthen pull ReverseClutchControl knob

out (seeFig.4-3). Tostop reversing,letgo

of ReverseClutch Control knob.

(b) Swingthe handlebarto theleft so the

rightwheeltakesa "step" backward.Next

swing the handlebarto the rightso theleft

wheel"steps" backward.Repeatasneeded.

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 legsaway from the tines.

(b) Tobeginaturn, lift thehandlebarsuntil

thetinesareoutofthegroundandtheengine

andtinesarebalancedoverthewheels(Fig.

4-4).

(c)With tiller balanced,pushsideways on

handlebarto steer in direction of turn (Fig.

4-5). After turning, slowly lower tines into

soil to resumetilling.

Fig.4-3:Raisetinesoffgreundandlook

behindwhenmovinginreverse.

6. Tomovethe Model643Cin reversefor

short distances:

(a) Releaseforward ClutchBail.Thenlift

handlebaruntiltines areoff theground.

Fig. 4-4: Tobeginturn,lift handlebarsuntil

tinesare outofgroundand unit is balanced.

Fig. 4-5: With tinesoutofgreund,push han-

dlebarssidewaystoturntiller.

StoppingtheTillerandEngine

1. Tostop thewheelsandtines, releasethe

Forward ClutchBail (all models) orthe Re-

verse ClutchControl (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, contact your

telephoneor utilities

companyand inquire if

undergroundequipment or

lines are usedon your

property. Donottill near

buriedelectric cables,

telephonelines, pipesor

hoses.

This isa CRT(counter-rotatingtine)tiller. Asthewheelspullforward,the tinesrotateback-

ward. Thiscreatesan "uppercut"tine actionwhich digs deeply,uprootingsoil and weeds.

Don't overloadthe engine,but dig asdeeplyaspossibleon eachpass.Onlaterpasses,the

wheelsmaytendto spinin thesoftdirt. Helpthemalongbylifting upslightlyonthehandlebar

(onehand,palm up,works mosteasily).

Avoidthetemptationtopushdownon thehandlebarsinan attemptto force thetiller to dig

deeper.Doingsotakestheweightoff the poweredwheels,causingthemto losetraction.

Withoutthewheelsto holdthetillerback,thetineswill attemptto propelthetiller backward,

towardstheoperator.(Sometimes,slightdownwardpressureonthehandlebarswill helpget

througha particularlytoughsectionofsodor unbrokenground,butin mostcasesthiswon't

benecessary.)

• Whencultivating(breakingup surfacesoilaroundplantsto destroyweeds,seeFig.4-9), ajust thetinesto 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

thesoilfor bettermoistureabsorptionandfasterplantgrowth.)Wateringthegardenareaafewdayspriorto tillingwill maketillingeasier,

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

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

that is bestfor yourgarden.

Settheenginethrottleleverata speedto givetheengineadequatepowerandyetallowit tooperateattheslowestpossiblespeed...atleast

until youhaveachievedthe maximumtilling depthyoudesire.Fasterenginespeedsmay bedesirablewhenmakingfinal passesthrough

theseedbedor whencultivating.Selectionofthecorrectenginespeed,in relationtothetilling depth,will ensurea sufficientpowerlevelto

do thejobwithout causingtheengineto labor.

Letthe Tiller DotheWork

Whiletilling, relaxandletthewheelspullthe

tiller along while the tines do the digging.

Walkon thesidethat is notyetfinished(to

avoidmakingfootprints in thefreshlytilled

soil) and lightly,but securelygrip the han-

dlebarwith just onehand.

AvoidMakingFootprints

Wheneverpossible, walk on the untilled

sideoftheunitto 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.

AvoidTillingSoggy,WetSoil

Tilling wet soil often resultsin large,hard

clumpsof soil that caninterferewith plant-

ing.If time permits,wait a dayor two after

heavyrainsto allow the soil to dry before

tilling. Testsoil bysqueezingit intoa ball.If

itcompressestooeasily,it is toowetto till.

Preparing Seedbeds

•Whenpreparingaseedbed,go overthesamepathtwiceinthefirst 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.)

Fig. 4-6 Fig. 4-7

• If thegardensizewill not permitlengthwiseandthencrosswisetilling, thenover-

lapthefirst passesbyone-halfatiller

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

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

Fig. 4-8

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.

TILLINGTIPS&TECHNIQUES(CON'T)

TillingOnSlopes

Readthe followingrecommendationsbeforetilling onslopes:

Ifyou mustgardenon amoderateslope,pleasefollow two very importantguidelines:

1.Tillonlyon moderateslopes,neveronsteepgroundwherefootingisdifficult (reviewsafe-

ty rulesin Section1:Safetyofthis manual).

2. We recommendtilling up and down slopesratherthan terracing.Tillingvertically on a

slopeallows maximumplantingareaandalsoleavesroomfor cultivating.

IMPORTANT:Whentilling onslopes,besurethecorrectoil levelis maintainedin theengine

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

awayfrom its normallevelandthis canstarveenginepartsof requiredlubrication.Keepthe

motor oil levelatthefull pointatall times!

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.

Tilling Upand DownSlopes(VerticalTilling)

• Tokeepsoil erosionto aminimum, besureto addenoughorganicmatterto thesoil sothat it hasgoodmoisture-holdingtextureandtry

to avoidleavingfootprints or wheelmarks.

• Whentilling vertically,tryto makethefirst passuphillasthetillerdigsmoredeeplygoing uphillthanitdoesdownhill.Insoftsoilor weeds,

youmayhaveto lift the handlebarsslightlywhilegoing uphill.Whengoingdownhill,overlapthefirst passbyaboutone-halfthewidth of

thetiller.

Clearingthe Tines

Thetines havea self-clearing action which eliminates most tangling of debris in the

tines. However,occasionally dry grass, stringy stalksor tough vines maybecometan-

gled. Follow these proceduresto help avoid tangling andto cleanthe tines, if neces-

sary.

•To reducetangling, setthe depth regulatordeepenoughto get maximum "chopping"

action as the tines chop the materialagainst the ground. Also, try to till under crop

residues or covercrops while they aregreen, moist and tender.

• While tilling, try swaying the handlebars from side to side (about 6" to 12"). This

"fishtailing" actionoften clearsthe tines of debris.

• If tangling occurs, lift the tines out of the soil and run the tiller in reverse(if unit is

equippedwith poweredreverse) for afew 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.

WARNING: Beforeclearing the

tines by hand,stop the engine,allowall

moving partsto stop anddisconnect the

spark plug wire. Removethe ignition key

on electric start models.

Failureto follow this warning could result

in personalinjury.

LoadingandUnloadingtheTiller

_ ARNING: Loadingand

unloadingthe tiller into avehicle is

potentially hazardousandwe don't

recommend doing so unless

absolutelynecessary,asthiscould

result in personal injury or

property damage.

However,if you must load or

unloadthe tiller, follow the

guidelines givennext.

• Beforeloadingor unloading, stopthe engine,

wait for all parts to stop moving,

disconnect the spark plug wire and letthe en-

gine and muffler cool.

• Thetiller is too heavy andbulky to lift safely

by oneperson. Twoor morepeople should

sharethe load.

• Use sturdy ramps andmanually (engineshut

off) roll the tiller into and out ofthe

vehicle. Two or more people areneededto do

this.

• Theramps mustbe strongenoughto 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; andthey

should havealocking deviceto securethemto

the

vehicle.

• Thehandlersshouldwearsturdyfootwearthat

will helpto preventslipping.

• Position the loading vehicle sothat the ramp

angleis as flat as possible(the less inclineto

the ramp, the better).Turnthe

vehicle'sengineoff andapply its parking brake.

• When going up ramps, stand in the

normal operating position and push the tiller

ahead of you. Havea personat eachside to

turn the wheels.

• When going down ramps,walk backward

with the tiller following you. Keepalertfor any

obstaclesbehind you. Position a personat

eachwheel to control the speedof the tiller.

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 andse-

curelytie the tiller down.

TILLINGTIPS&TECHNIQUES(CON'T)

TerraceGardening(continued)

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

forth acrossthefirst rowasshownin Fig.4-10.

• Eachsucceedinglowerterraceis startedby walking belowthe terraceyou're 0 m_

preparing.Foraddedstability ofthetiller,alwayskeeptheuphillwheelinthesoft,

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

eachterrace.Thisuntilledstrip helpspreventstheterracesfrom breakingapart

andwashingdownhill. It alsoprovidesa walkingpathbetweenrows. _, REPEAT

Fig. 4-10

LOADINGAND UNLOADING

THE TILLER

,_ WARNING: Loadingand

unloading thetiller into a

vehicleis potentially hazardous

andwedon't recommenddoing

so unlessabsolutelynecessary,

asthis could result inpersonal

injury or property damage.

However,if you must load or

unloadthe tiller, follow the

guidelinesgivennext.

• Beforeloading or unloading,stop the en-

gine,wait for all parts to stop moving,

disconnect the spark plug wire and letthe

engineand muffler cool.

•Thetiller istoo heavyandbulky to lift

safelyby one person.Twoor more people

should sharethe load.

• Usesturdy ramps and manually (engine

shut off) roll thetiller into andout of the

vehicle.Twoor more peopleareneededto

do this.

• Theramps must bestrong enoughto

support the combined weight of thetiller

and anyhandlers. The rampsshould pro-

videgoodtraction to preventslipping; they

should haveside railsto guidethetiller

along the ramps; andthey should havea

locking deviceto securethem to the

vehicle.

•Thehandlersshouldwearsturdyfootwear

that will helpto preventslipping.

• Position the loading vehicle so that the

ramp angle is asflat aspossible (the less

incline to the ramp,the better). Turnthe

vehicle'sengine off and apply its parking

brake.

• Whengoing up ramps,stand in the

normal operating position andpush the

tiller aheadofyou. Havea person ateach

sideto turn the wheels.

•Whengoing down ramps,walkbackward

with thetiller following you. Keepalertfor

anyobstacles behindyou. Position a per-

son ateachwheelto control the speedof

thetiller. Nevergo down rampstiller-first,

asthe tiller could tip forward.

•Placewoodenblocksonthedownhill side

of the wheels if you needto stop the tiller

from rolling downthe 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. Chockthe wheels

with blocksandsecurelytiethetiller down.

SECTION5: MAINTENANCE

WARNING: Before

inspecting, cleaningor servicing

the machine,shut off engine,

wait for all moving partsto come

to acompletestop, 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 level in transmission

Checktines for wear

Checkair pressurein tires

(if unit haspneumatic tires)

Servicespark plug

NOTES

2,3

2,7

1,4

4,6,9

1,5

1 Checkafter first 2 hours of break-in operation.

2 Before each 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

TILLER LUBRICATION

After every 10 operating hours, oilor

greasethe lubrication points shown in

Figure5-1 and described below.

Usecleanlubricating oil (#30weight motor

oil is suitable) and cleangeneralpurpose

grease(greasecontaining ametallubricant

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). Usea file or sandpaperto gen-

tly removeany rust, burrs or rough spots

(especiallyaround holes in shaft). Apply

greaseto ends of shaft beforeinstalling

tines.

• Oil thethreads on the handlebar height

adjustment screws and the handlebar

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

D B

Figure5-1

CHECKFOROILLEAKS

Beforeeachuse,checkthetiller for signs of

an oil leak-- usually adirty, oily accumu-

lation eitheron the unit or on the floor.

A little seepagearound a cover or anoil

sealis usuallynot 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, a new

gasket or oil seal may be required.

If the leakisfrom around a shaft andoil

seal, the oil sealprobably needsto be

replaced.Seeyour authorized dealeror

contact the factory for serviceor advice.

IMPORTANT:Neveroperatethe tiller if

thetransmission islow on oil.Checkthe

oil levelafter every30 hours of

operationand wheneverthere is anyoil

leakage.

CHECKHARDWARE

Checkfor looseor missing hardwareaf-

ter every 10 operatinghoursandtighten

or replace(asneeded)beforereusing

tiller

Besureto checkthe screws underneath

thetiller hoodthat securethe transmis-

sioncoverandtheDepthRegulatorLever

to thetransmission.

CHECKTIRE PRESSURE

(Modelswith pneumatictires)

Checkthe air pressurein bothtires. The

air pressure should bebetween 15 PSi

and 20 PSi (pounds per squareinch).

Keepbothtires equally inflated to help

prevent machinefrom pulling to one

side.

TRANSMISSION

GEAROIL SERVICE

Checkthe transmission gear oil level

after every 30 hours of operationor

wheneveryou notice any oil leak.Oper-

ating thetiller whenthe transmission is

low on oil can result in severedamage.

A. To ChecktheTransmission

GearOil Level:

1. Checkthe gear oil levelwhenthe

transmission is cool. Gearoil will

expandin warmoperatingtemperatures

and this expansionwill providean incor-

rect oil level reading.

2. With thetiller onlevelground, pull the

Depth Regulator Leverall the way up.

3. Removethe oilfill plug (A,Fig. 5-2)

from thetransmission housingandlook

insidethe oil fill hole to locatethe main

driveshaft situated belowthe hole.

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

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

spark plug. Failureto follow these instructions canresult in serious personalinjury or property

damage.

4. Thegear oil leveliscorrect ifthegear oil

isapproximately halfwayupthe sideofthe

main driveshaft.

5. Ifthe gearoil levelislow, addgearoil as

described next.If the gearoil levelis okay,

securely replacethe oil fill plug.

IMPORTANT:Donot operatethe tiller ifthe

gear oil level islow. Doingso will resultin

severedamageto the transmission com-

ponents.

Figure5-2:Removeofffi/I p/ug(tl) tocheck

gearoff levelandtoaddgearoiL Remove

fourcoverscrews(B)todraingearoil.

6. If adding only afew ouncesof 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 useautomatic trans-

mission fluid or motor oil in thetransmis-

sion.

7. Whilecheckingfrequentlyto avoidover-

filling, slowly addgear oil into the oil fill

hole until it reachesthe halfway point on

the driveshaft.

8. Securely replacethe oil fill plug.

B. ToDrain theTransmissionGearOil:

Thetransmission gear oil doesnot needto

bechangedunless it hasbeencontaminat-

ed with dirt, sand or metal particles.

1. Draingasolinefrom thefuel tank or run

the engine until thefuel 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 minutesbefore drain-

ingthetiller's gasolinetank.

Do not allow open flames, sparks,

matchesor smokingin thearea.

Wipe away spills and pushtiller away

from spilledfuel.

Use only an approvedfuel container

and store it safelyout 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 a drain

panand allowthe gearoil to drainthrough

the top of thetransmission.

6. Reinstallthe wheel.

7. Install a newgasket (do not reuseold

gasket)and reinstallthetransmission 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 beinspectedat the beginning of

eachtilling seasonand afterevery30 oper-

ating hours. Thetines can bereplacedei-

ther individually or as a completeset. 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 underorganic matter.

B. Removing4nstalling 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-

tachasingletineto 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 softfirst asthe tiller moves

forward.

C. Removing4nstallinga TineAssembly:

1. Atine assemblyconsists of eight tines

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 securethetineassemblytothe

tineshaft. Ifnecessary,usea rubbermallet

to tapthe tine assembly outward off the

shaft.

3. Beforereinstalling thetine assembly,in-

spectthe tineshaftfor rust, roughspots or

burrs. Lightly file or sand, asneeded.Ap-

ply a thin coat of greaseto the shaft.

4. Install eachtine 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 off engine,wait for all

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

spark plug. Failureto follow these instructions canresult in serious personalinjury or property

damage.

FORWARD

Figure5-3: Install tinesso thatcuttingedge oftines entersoftfirst whentiller movesforward.

CHECKINGAND ADJUSTING

FORWARDDRIVE BELT TENSION

It is important to maintain correct tension

on the forward drive belt. A loosebelt will

causethetinesandwheelsto slow down--

or stop completely -- eventhough the en-

gine is running at full speed.A too tight

belt can result in unintentional tine move-

ment whenthe clutch bail isin the Neutral

(released)position.

• Checkbelt tension after the first two

hours ofbreak-inoperationandafter every

10 operatinghours.

• Atthe end of eachtilling season,check

the beltfor cracks,cuts orfrayed edges

and replaceit as soonas possible.

tension is correct if this second measure-

ment isbetween1/6"-to- 3/16"longerthan

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 thespring:

a. Releasethe Forward Clutch Bail.

b. Unthreadthe hexnut (C,Figure5-4)

halfway up the adjustment screw (D).

c. Unhookthetop ofthe springfrom the

Forward Clutch Bail.

d. Usepliersto preventthe adjuster (B)

from turning andturn the slotted screwlo-

cated insidethe spring clockwise (viewed

from operator'sposition) to increaseten-

sion onthespring. 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,retightenthehex

nut (C)againstthetop oftheadjuster(B).

ReplacementBelt Information

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.

ToCheckForwardBeltTension:

1. Stopengine,wait for all partsto stop

moving and disconnect 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(seeFigure5-4) and re-

measurethe length of the coils. Thebelt

Figure5-4: Tocheckforwardbelt tension,taketwomeasurementsofthe

overa//length ofthecoilsin thespring-- first withthedutch bail open,

thenwith thedutch bail closedagainstthe handlebar.

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

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

spark plug. Failureto follow these instructions canresult in serious personalinjury or property

damage.

FORWARDCLUTCH

BAIL ADJUSTMENT

If the Forward Clutch Baildoes not func-

tion properly,first checkthat the forward

drive belt is adjusted properly (seeCheck-

ing andAdjusting Forward Drive Belt Ten-

sion). If this failsto correct the problem,

contact Troy-Bilt LLCor your authorized

dealerfor serviceadvice.

CHECKINGANDADJUSTINGRE-

VERSEDRIVEBELTTENSION

(Models643B & 645A only)

It is important to maintain correct tension

on the reversedrive belt. A loosebeltwill

causethetines andwheelsto slow down-

or stop completely - eventhough the en-

gine is running at full speed.

Whencheckingbelttension, alsocheckthe

belt for cracks, cuts or frayed edgesand

replaceit as soonas possible.

• Checkbelt tension after the first two

hours ofbreak-inoperationandafter every

10 operatinghours.

ToCheckReverseBeltTension:

1. Stopengine,wait for all parts to stop

moving and disconnect 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 long asthe reverse

actionfunctions properly.

5. Releasethe ReverseClutchControl

knob.andthen unthreadthe inner jam nut

(C, Figure5-6) 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 tightenthe inner

jam nut (C)againstthe bracket.

7. Measurethe gap by repeatingStep3.

Readjustasneededby repeatingSteps 5

and 6.

8. Reinstallthe belt cover.

Figure5-5: Measure cable wire lengthto

checkforcorrectreversebelt tension.

Figure5-6:Movethreadedadjuster(,4)toleft

toincreasebelttension.

Replacement Belt Information

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 enginecleanwill help to en-

sure smooth operation and prevent dam-

agefrom overheating.Referto the Engine

Owner's Manualfor enginecleaning ser-

vice intervals and instructions. Besure

thatthe muffler iscool beforeservicingthe

engine.

AIRCLEANERSERVICE

Theair cleanerfilters 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 air cleanerinstalled. In-

spectand service the aircleanermore of-

ten if operating in very dusty or dirty

conditions. Referto the engineOwner's

Manualfor air cleanerserviceintervalsand

instructions.

ENGINEOIL SERVICE

Checkthe engine oil level beforeeachuse

and after every five hours of continuous

operation. Runningthe enginewhen it is

low on oil will quickly ruin theengine.

It is recommendedthat you changethe

motor oil after every 10hours of operation

and evensoonerwhen 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).

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Troybilt PRO LINE Bronco 645A Owner's manual

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