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Troy-Bilt 644H Tiller User Manual

1. Avoid making footprints Whenever possible walk on the untilled side of the unit to avoid making foot prints in your freshly tilled or cultivated soil Footprints cause soil compaction that can hamper root penetration and contribute to soil erosion They can also plant unwanted weed seeds back into the freshly tilled ground Choosing correct wheel and tine speeds With experience you will find the just right tilling depth and tilling speed combination that is best for your garden Set the engine throttle lever at a high enough speed to give the engine adequate power and yet allow it to operate without overloading it Fastest engine speeds may be desirable when making final passes through the seedbed or when cultivating Selection of the correct engine speed in relation to the tilling depth will ensure a suffi cient power level to do the job without causing the engine to labor Suggested tilling patterns When preparing a seedbed go over the same path twice in the first row then make individual passes right next to each other see Figure 4 6 When finished in one direction make second passes at a right angle as shown in Figure 4 7 In very hard ground it may take three or four overlapping passes to thor oughly pulverize the soil See Figure 4 8 f the garden size will not permit lengthwise and then crosswise tilling then overlap the first passes by one half a tiller width followed by s
2. A To Check the Transmission Gear Oil Level 1 Check the gear oil level when the trans mission is cool Gear oil will expand in warm operating temperatures and this expansion will provide an incorrect oil level reading 2 With the tiller on level ground adjust the Depth Regulator Lever up or down to the notch that makes the tiller level 3 Remove the oil fill plug A Fig 5 2 from the transmission housing and look into the oil fill hole You will see the main drive shaft on one side of the hole 4 The gear oil level is correct if the gear oil is approximately half way up the side of the drive shaft 5 If the gear oil level is low add gear oil as described next If the gear oil level is okay securely replace the oil fill plug IMPORTANT Do not operate the tiller if the gear oil level is low Doing so will result in severe damage to the transmis sion components 6 If adding only a few ounces of gear oil use API rated GL 4 or GL 5 transmis sion gear oil having a viscosity of SAE 140 SAE 85W 140 or SAE 80W 90 If refilling an empty transmission use only GL 4 transmission gear oil having a viscosity of SAE 85W 140 or SAE 140 NOTE Do not use automatic transmission fluid or engine oil in the transmission 7 While checking frequently to avoid overfilling slowly add gear oil into the oil fill hole until it reaches the halfway point on the drive shaft 8 Securely replace the oil fill plug Section 5 Main
3. Forward Drive Bett slipping See Tines Section 5 See Tilling Tips amp Techniques Section 4 See Section 4 See Checking Forward Drive Belt Tension Section 5 25 6 Parts List Section 26 MODELS 644H amp 645A E PART NO DESCRIPTION 1185469 Spirol Pin 710 0597 Hex Hd Screw 1 4 20 x 1 710 0599 Screw Self Tapping 1 4 20 x 1 2 710 0874 Hex Hd Screw 5 16 18 x 1 1 4 1186331 Hex Hd Screw 5 16 18 x 1 0 712 0291 Hex Lock Nut 1 4 20 712 3004A Hex Flange Lock Nut 5 16 18 712 3009 Hex Nut 5 16 18 736 0119 Lock Washer 5 16 GW 55013 1 Hood Bracket Left Hand GW 55013 2 Hood Bracket Right Hand GW 55015 Drag Bar GW 55018 Depth Regulator Lever 686 04029 Tine Hood Assembly GW 55088 Bushing GW 9384 Spring Depth Regulator GW 9534 Spacer 710 04048 Hex Hd Flange Screw 5 16 18 x 1 618 04046 Transmission Assembly CRT 1916569 Flap Stop Bracket 1916570 Reverse Stop Arm 710 3073 Hex Screw 5 16 18 x 2 25 1916771 Spacer 462 x 328 x 1 63 1107382 Flat Washer 5 16 710 3025 Hex Screw 5 16 18 x 625 1916708 Hood Support Bracket 1916707 Channel Support Bracket On c C A GDM 27 MODELS 644H amp 645A 28 MODELS 644H amp 645A E PART NO DESCRIPTION 1916719 Cable Assembly Reverse Clutch 1916755 Upper Handlebar 1917479 Bail Forward Clutch 1918745 Cable Assembly Forward Clutch 710 0599 Screw Self Tapping 1 4 20 x 1 2 710 3008 Screw Hex 5 16 18 x 3 4 712 3
4. Reinstall the wheel drive pin and hairpin cotter through the wheel shaft only not through the wheel hub Repeat with the other wheel 3 Using the handlebar as a lever roll the tiller to a flat area IMPORTANT Before starting the engine the wheels must be placed in their WHEEL DRIVE position pins through wheel hubs and wheel shaft This procedure is described in Wheel Drive Pins in Section 3 Section 2 Assembly Fig 2 2 Attach handlebar Fig 2 3 Wheel in FREEWHEELING position wheel drive pin through wheel shaft only Section 2 Assembly STEP 4 Install Forward Clutch Cable 1 Place the forward clutch cable bracket P Fig 2 4 on the handlebar support A Attach the cable bracket using a 1 4 20 x 1 1 4 hex hd screw R Fig 2 4 and 1 4 20 hex locknut S Tighten securely 2 Carefully unwrap the forward clutch cable the cable without a knob attached to it from its shipping position and slide the thin cable wire T Fig 2 4 into the slot in the cable bracket Push the cable connector U Fig 2 4 up through the hole in the bracket until the groove in the connector snaps into place on the bracket 3 Insert the 210 24 x 2 slotted hd screw V Fig 2 5 down into the cable spring W The threaded end of the screw will extend from the bottom of the spring 4 Thread the 210 24 hex nut Z on the slotted head screw V Thread it halfway up 5 Thread screw V into cable adjuste
5. Section 5 Maintenance property damage J WARNING Before inspecting cleaning or servicing the unit shut off engine wait for all t parts to come to a complete stop disconnect spark plug wire and move wire away from spark plug Failure to follow these instructions can result in serious personal injury or en from turning by gripping the upper end of the threaded adjuster B with pliers 6 Repeat Step 3 to measure the length of the clutch bail spring Once the length is correct retighten the hex nut against the top of the adjuster Forward Belt Replacement Information If the drive belt needs to be replaced see your local authorized dealer or phone the factory as instructed on Page 2 Refer to the Parts List in the back of this manual for correct components Use only OEM Original Equipment Manufacturer fre placement belts A substitute belt may not perform satisfactorily The procedure requires average mechanical ability and commonly available tools FORWARD CLUTCH BAIL ADJUSTMENT If the Forward Clutch Bail does not function properly first check that the forward drive belt is adjusted properly see Checking and Adjusting Forward Drive Belt Tension If this fails to correct the problem contact the factory technical service department or your authorized dealer for service advice CHECKING AND ADJUSTING REVERSE DRIVE BELT TENSION Maintaining correct tension on the reverse drive belt is important t
6. 16 Never operate the tiller at high transport speeds on slippery surfaces Look behind and use great care when backing up 17 Do not operate the tiller on a slope that is too steep for safety When on slopes slow down and make sure you have good footing Never permit the tiller to freewheel down slopes 18 Never allow bystanders near the unit 19 Only use attachments and acces sories that are approved by the manufac turer of the tiller 20 Use tiller attachments and acces sories when recommended 21 Never operate the tiller without good visibility or light 22 Never operate the tiller if you are tired or under the influence of alcohol drugs or medication 23 Operators shall not tamper with the engine governor settings on the machine the governor controls the maximum safe operating speed to protect the engine and all moving parts from damage caused by overspeed Authorized service shall be sought if a problem exists 24 Do not touch engine parts which may be hot from operation Let parts cool down sufficiently 25 Please remember You can always stop the tines and wheels by releasing the Forward Clutch control or the Reverse Clutch control whichever control you have engaged or by moving the throttle control lever on the engine to OFF or STOP 26 To load or unload the tiller see the instructions in Section 4 of this Manual 27 Use extreme caution when reversing or pulling the machin
7. 3 8 16 x 1 1 2 Screw Self Tapping 1 4 20 x 1 2 Hex Hd Screw 5 16 18 x 2 Lock Nut 3 8 16 Lock Nut 5 16 18 Lock Washer 5 16 Flat Washer 3 8 Flat Washer Bell Washer Hex Hd Screw 3 8 24 x 2 0 GR5 A Hex Hd Screw 3 8 24 x 1 5 GR5 B Support Washer Forward Return Spring Bracket Cable Mounting Forward idler Pulley Key 3 16 x 1 Flat Washer Belleville Washer Hex Screw 5 16 18 x 2 25 Gr5 Shim 1 0 x 765 x 031 A Only 35 TROY BILT TILLER LIFETIME LIMITED WARRANTY WHAT PRODUCT IS COVERED WHAT IS COVERED BY THIS WARRANTY WHAT IS NOT COVERED BY THIS WARRANTY LIMITED COMMERCIAL USE WARRANTY HOW TO OBTAIN SERVICE 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 Troy Bilt LLC will at its option repair or replace any part found to be defective in material or workmanship without charge for parts and labor 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 This warranty does not apply to parts that have been damaged by accident alteration misuse abuse neglect improper maintenance vandalism theft fire water
8. GW 9380 Clevis Pin 312 x 1 3 4 712 3009 Hex Lock Nut 5 16 18 GW 9338 Hair Pin Cotter 710 3096 Hex Hd Screw 3 8 16 x 2 712 3000 Hex Lock Nut 3 8 16 1817059 Single Tine Left Hand 1817059 Replacement Tines Set Incl three LH tines 1916702 LH Tine Holder three RH tines and required hardware 1916703 RH Tine Holder 33 MODELS 644H amp 645A l REVERSE LUTCH CABLE 15 34 A For Model 644H B For Model 645A Fa PART NO 1107382 714 0139 1108841 1916531 619 04016 1916532 1916535 1916652 1916657 1916658 1916660 1916724 1916725 1916726 1916794 1916795 1917326 1917746 1918731 1918744 710 0117 710 0237 710 0376 710 04049 710 0520 710 0599 710 3103 712 3000 712 3009 736 0119 736 3050 736 3090 736 0452 710 0151 710 0459A GW 50027 GW 55034 GW 55049 GW 9090 GW 9301 GW 9929 GW 9944 710 0395 GW 1138 2 MODELS 644H amp 645A DESCRIPTION Flat Washer 5 16 Key 3 16 x 2 A Key 3 6 x 1 1 2 B Pulley Engine Drive A Pulley Engine Drive B Transmission Pulley Pulley Reverse Idler Guard Belts Pulleys Forward Drive Belt Reverse Drive Belt Belt Cover Reverse Return Spring Belt Guide Forward Belt Guide Engine Bracket Left Engine Bracket Right Bracket Belt Cover Shoulder Washer Reverse Idler Arm Forward idler Lever Hex Hd Screw 5 16 24 x 4 Hex Hd Screw 5 16 24 x 58 Hex Hd Screw 5 16 18 x 1 Hex Hd Screw 5 16 18 x 5 8 Hex Hd Screw
9. Owner s Manual Clean or replace see Engine Owner s Manual See Engine Service Dealer Replace with fresh gasoline See Engine Service Dealer Clean air cooling system see Engine Owner s Manual Engine overheats _ Engine cooling system clogged Carburetor out of adjustment e Oii level is low Clean air cooling area see Engine Owner s Manual See Engine Service Dealer Check oil level see Engine Owner s Manual Engine does not shut off Misadjusted throttie control or ignition switch L See Engine Owner s Manuai or Engine Service Dealer Wheels and Tines will not turn Improper use of controis Worn broken or misadjusted drive belt s Internal transmission wear or damage Bolt loose in transmission pulley 1 2 Review Sections 3 and 4 See Checking Drive Belt Tension Section 5 3 Contact focal dealer or the factory 4 Tighten bolt Tines turn but wheels don t Wheel Drive Pins not in WHEEL DRIVE Internal transmission wear or damage 1 2 See Wheel Drive Pins in Section 3 Contact local Dealer or the Factory Wheels Turn but Tines Don t Tine holder mounting hardware missing Internal transmission wear or damage Replace hardware 2 Contact local Dealer or the Factory Poor tilling performance Worn tines Improper Depth Regulator setting Incorrect throttle setting
10. 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 purchased for commercial or other non residential use Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts so the above exclusions or limitations may not apply to you This limited warranty gives you specific legal rights and you may also have other rights which vary from state to state 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
11. become shorter narrower and pointed Badly worn tines will result in a loss of tilling depth and reduced effectiveness in general and specifically when chopping up and turning under organic matter B Removing and Installing Tine Assemblies 1 Use a 9 16 socket 6 extension a ratchet and a 9 16 box end wrench to loosen the nut A Figure 5 3 and screw B that secure the tine holder to the tine shaft 2 Use a rubber mallet to tap the tine holder loose Slide tine assembly off 3 Repeat Steps 1 and 2 above to remove the other tine assembly 4 Installing the tine assembly is simply the reverse of its removal First be sure to remove any rust uneven spots or burrs from the tine shaft using fine sandpaper Then grease the tine shaft before rein stalling the tine assemblies Be sure all the cutting edges face so they will enter the soil first when the tiller is moving forward this means the cutting edge on the top of each tine faces toward the operator position Tighten hardware C Removing and Installing Individual Tines 1 Use two 9 16 box end wrenches to remove the two screws C Figure 5 3 and nuts D that secure the tine to its tine holder NOTE If the nuts are rusted apply pene trating oil then loosen the hardware 2 When installing individual tines do so in the reverse order from which they were removed The two sets of inboard tines are installed so one set faces toward the transmission an
12. components 1 Put the tiller on level ground Pull the Depth Regulator Lever FF Fig 2 10 back and then adjust it up or down to the notch that makes the tiller level 2 Remove the oil fill plug GG Fig 2 11 from the transmission housing and look into the oil fill hole You will see the main drive shaft on one side of the hole 3 The gear oil level is correct if the gear oil is approximately halfway up the side of the drive shaft 4 If the gear oil level is low add gear oil by referring to A To Check the Transmis sion Gear Oil Level in Section 5 STEP 7 Add Motor Oil to Engine The tiller is shipped without oil in the engine IMPORTANT Do not start the engine without first adding motor oil Severe engine damage will result if the engine is run without oil 1 Refer to the Engine Owner s Manual supplied with tiller for engine oil specifi cations and capacities 2 With the tiller on level ground pull the Depth Regulator Lever FF Fig 2 10 back and then slide it up or down as necessary until the engine is level 3 Add motor oil as described in the Engine Owner s Manual 4 Move the Depth Regulator Lever all the way down until the highest notch is engaged This places the tines in the travel position STEP 8 Check Hardware for Tightness Check all nuts and screws for tightness Section 2 Assembly b Fig 2 10 Adjust Depth Regulator Lever he gt o Fig 2 11 Remove
13. control knob toward you The wheels will rotate in a reverse direction 4 Release the reverse clutch control knob to disengage stop the wheels and tines All reverse motion will stop the engine will continue to run TRE WARNING Use extreme caution when reversing or pulling the machine towards you Look behind to avoid obstacles e Never attempt to till in reverse Failure to follow this warning _ could result in personal injury or property damage 11 Section 3 Features and Controls Depth Regulator Lever This lever G Figure 3 5 controls the tilling depth of the tines Pull the lever straight back and slide it up or down to engage the notched height settings The highest notch lever all the way down raises the tines approximately 1 1 2 off the ground This travel setting allows the tiller to be moved without the tines digging into the ground Also use this setting when starting the engine Move the lever upward to increase the tilling depth The lowest notch allows a tilling depth of approximately 6 8 depending on soil conditions For best results begin tilling at the deepest depth possible without causing the tiller to bog down Increase the tilling depth from one pass over the soil to the next Travel y Position Shallow Settings Place the Depth Regulator Lever in the travel position before starting the engine This position prevents the tines from tou
14. n n nh nn 24 Troubleshooting 2 ee Seine eee e gu IRAE LIAE 25 uci p e 26 Watrany Informationi x Leo qune euni eme dave tux exit baa wales edn aUe Rode eus Back Cover FINDING MODEL NUMBER This Operator s Manual is an important part of your new Rear tineTiller 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 infor mation from it in the space provided below This information is very important if you need help from our Customer Support Department or an authorized dealer You can locate the model number by looking at the rear surface of the tine shield A sample model plate is explained below For future reference please copy the model number and the serial number of the equipment in the space below Copy Model Number Here A TROY BILT LLC Copy Serial Number Here OTROY BILT FO tin did www troybilt com CLEVELAND OH 44136 330 558 7220 866 840 6483 ENGINE INFORMATION The engine manufacturer is responsible for all engine related issues with regards to performance power rating speci fications warranty and service Please refer to the engine manufacturer s Owner s Operator s Manual packed sepa rately with your unit for more information CALLING CUSTOMER SUPPORT if you have difficulty assembling this product or have any questions regar
15. present space heaters hot water heaters furnaces etc Section 5 Maintenance PROBLEM TROUBLESHOOTING Before performing any corrections refer to the appropriate information in this Manual or in the Engine Owner s Manual for the correct safety precautions and operating or maintenance procedures Contact your local authorized Engine Service Dealer for engine service Contact your local authorized equipment dealer or the factory for all other service problems POSSIBLE CAUSE CORRECTION Engine does not start 0076 0 0 4i 0 n Spark plug wire disconnected Engine Throttle Controi Lever incorrectly set Fuel tank empty Choke contro if so equipped in incorrect position Stale gasoline Dirty air filter s Defective or incorrectly gapped spark plug Carburetor out of adjustment Misadjusted throttle control cable Dirt or water in fuel tank 1 Reconnect wire 2 Put lever in START position 3 Add fuel 4 See Engine Owner s Manual 5 Drain fuel and add fresh fuel 6 Clean or replace filter s 7 Inspect spark plug 8 See Engine Service Dealer 9 See Engine Service Dealer 10 See Engine Service Dealer Engine runs poorly C5 Cc 4 ON Defective or incorrectly gapped spark piug Dirty air filter s Carburetor out of adjustment Stale gasoline Dirt or water in fuel tank Engine cooling system clogged Inspect spark plug see Engine
16. that you have the items listed below contact your local dealer or the factory if any items are missing or damaged NOTE Use the screw length template Fig 2 1 to identify screws Loose Parts List Qty Description 1 Handlebar Support see A Fig 2 2 page 7 1 Handlebar Assembly see K Fig 2 2 The following items are in the hardware bag 1 Slotted hd screw 10 24 x 2 Hex hd screw 1 4 20 x 1 1 4 Curved hd screw 5 16 18 x 1 1 2 Hex hd screw 3 8 16 x 3 4 Flat washer 3 8 Split lockwasher 5 16 Hex locknut 1 4 20 Hex nut 5 16 18 Hex locknut 3 8 16 Hex nut 210 24 Spring cable see W Fig 2 5 page 8 Bracket forward clutch cable see P Fig 2 5 page 8 Bracket reverse clutch cable see BB Fig 2 8 page 9 whe ND CD OD ND ho OD e IMPORTANT Motor oil must be added to the engine crankcase before the engine is started Follow the instructions in this Assembly section NOTE LEFT and RIGHT sides of the tiller are as viewed from the operator s position behind the handlebars Tools Materials Needed for Assemhly 1 3 8 open end wrench 2 7 16 open end wrench 1 1 2 open end wrench 2 9 16 open end wrench 1 Large adjustable wrench 1 Scissors to trim plastic ties 1 Ruler for belt tension check 1 Block of wood to support tiller when removing wheels 1 Automotive type air pressure gauge 1 Clean oil funnel 1 Clean high quality
17. wheels if you need to stop the tiller from rolling down the ramp Also use the blocks to temporar ily keep the tiller in place on the ramps if necessary and to chock the wheels in place after the tiller is in the vehicle When the tiller is in the vehicle prevent it from rolling by chocking the wheels with blocks and securely tie the tiller down Section inici shut off engine _ wait for all moving parts to come to a complete stop disconnect spark plug wire and move wire away from spark plug Failure to follow these instructions can result in REQUIRED MAINTENANCE SCHEDULE Before Every Every As PROCEDURE Each 10 30 Noted Use Hours Hours Check engine oil level And every 5 operating hours Clean engine e A Check drive belt tension t Check nuts and bolts t Change engine oil Lubricate tiller Service engine air cleaner system A Check gear oil level in t transmission Check tines for wear Check air pressure in tires if pneumatic Service spark plug A Check Anti Reverse Stake Change more frequently in dusty or dirty conditions Ghange after first 2 hours of break in operation t Check after first 2 hours of break in operation A See Engine Owner s Manual for service intervals and instructions 19 Section 5 Maintenance i property damage WARNING before inspecting cleaning or servicing the uni
18. will not hold the tiller back and the revolving tines could propel the tiller rapidly possibly causing loss of control Always engage the wheels with the wheel drive pins in the Wheel Drive position before starting the engine or engaging the tines wheels with the Forward Clutch Bail or the Reverse Clutch Control 14 Be aware that the tiller may unexpect edly bounce upward or jump backward and be propelled toward you if the tines should strike extremely hard packed soil frozen ground or buried obstacles like large stones roots or stumps If in doubt about the tilling conditions always use the following operating precautions to assist you in maintaining control of the tiller a Walk behind and to one side of the tiller using one hand on the han dlebars Relax your arm but use a secure hand grip b Use a deep depth regulator setting c Use slower engine speeds d Clear the tilling area of all large stones roots and other dehris e Avoid using downward pressure on handlebars If need be use slight upward pressure to keep the tines from digging too deeply f Before contacting hard packed soil at the end of a row reduce engine speed and lift handlebars to raise tines out of the soil g In an emergency stop tines and wheels by releasing whichever clutch control is engaged Do not attempt to restrain the tiller 15 Do not overload the tiller s capacity by attempting to till too deeply at too fast a rate
19. 009 Hex Lock Nut 5 16 18 GW 55042 Handlebar Support GW 55043 Lower Handlebar GW 55102 Panel GW 55044 Tab Conduit Mount GW 9855 Screw 10 24 x 2 725 0157 Cable Tie 736 3050 Flat Washer 3 8 1916674 Bracket Reverse Clutch Cable 1916712 Spring Forward Clutch 710 0106 Hex Hd Screw 1 4 20 x 1 1 4 710 0216 Screw Hex 3 8 16 x 3 4 710 0805 Screw Hex 5 16 18 x 1 1 2 712 0121 Hex Nut 10 24 712 0291 Hex Lock Nut 1 4 20 712 3000 Hex Nut 3 8 16 736 0119 Lock Washer 5 16 On Co C A GD MH E PART NO DESCRIPTION 1918749 Bumper 710 0395 Hex Screw 5 16 18 x 2 1 4 Gr5 712 0267 Nut Hex 5 16 18 736 0119 Lock Washer 5 16 29 MODELS 644H amp 645A Ei PART NO DESCRIPTION GW 9517 Snap Ring GW 1714 Bearing Tapered Roller with race GW 50043 Support Washer Rear 711 04110 Drive Shaft CRT GW 1224 1 Shim Rear Bearing Cap 010 thick GW 1224 2 Shim same as above except 030 thick GW 1224 3 Shim same as above except 005 thick GW 1224 4 Shim same as above except 062 thick GW 1325C Shim Set Incl the following shims two 1224 1 two 1224 2 amp one 1224 4 Use as required to obtain between 005 and 015 allowable end play 30 MODELS 644H amp 645A Fa PART NO DESCRIPTION GW 9512 Retainer Snap Ring E Type 1909950 Retainer Snap Ring GW 1166 1 Shim 0 062 thick GW 1166 2 Shim 0 030 thick GW 1166 3 Shim 0 015 thick GW 1166 4 Shim 0 010 thick GW 1166 5
20. E Pre Start Checklist Make the following checks and perform the following services before starting the engine 1 Read the Safety and Controls sections in this manual Read the separate Engine Owner s Manual provided by the engine manufacturer 2 Check that the wheels are in the WHEEL DRIVE position wheel pins must be through the wheel hubs and the wheel shaft holes 3 Check unit for loose or missing hardware Service as required 4 Check engine oil level See Engine Owner s Manual 5 Check that all safety guards and covers are in place 6 Check air cleaner and engine cooling System See Engine Owner s Manual 7 Attach spark plug wire to spark plug 8 Fill the fuel tank with gasoline according to the directions in the separate Engine Owner s Manual Follow all instructions and safety rules carefully Reverse Clutch Control knob on back of bracket Forward Clutch Bail Depth Regulator Lever 4 3 Anti Reverse Stake Wheel Drive Pin on each wheel QU DANGER GASOLINE IS HIGHLY FLAMMABLE AND ITS VAPORS ARE EXPLOSIVE Follow gasoline safety rules in this manual see Section 1 and in the separate Engine Owner s Manual Failure to follow gasoline safety instructions can result in serious personal injury and property damage 13 Section 4 Operation Starting the Engine The following steps describe how to start and stop the engine Do not attempt to engage
21. G statement 2 Lift and hold the bail against the handlebar The wheels and tines will rotate and the tiller will move in a forward direction 3 Release the bail to disengage stop the wheels and tines Forward tiller motion will stop the engine will continue to run Before starting the engine be sure that both wheels are in the WHEEL DRIVE position _ See Wheel Drive Pins for _ instructions Engaging the Forward Clutch Bail or the Reverse Clutch Control when the wheels are not in the WHEEL DRIVE _ position could allow the tines to rapidly propel the tiller forward or backward Failure to comply could cause loss of tiller control property damage or personal injury EN N Figure 3 4 Forward Clutch Bail E and Reverse Clutch Control F Reverse Clutch Control The Reverse Clutch Control F Figure 3 4 controls the engagement of reverse drive to the wheels and tines This powered reversing feature is used for maneuvering the tiller only never engage the tines in the ground while going in the reverse direction To Operate the Reverse Clutch Control 1 Operate only when the wheels are in the WHEEL DRIVE position see the WARNING statement at the left 2 Stop all tiller motion by releasing the Forward Clutch Bail 3 Lift up the handlebar until the tines clear the ground look behind you to avoid any obstacles and then pull the reverse clutch
22. OTROV BILT Operator s Manual bid ueniet Rear tine Tiller Models 644H Bronco 645A Bronco Model 644H Shown bumper syles vary IMPORTANT READ SAFETY RULES AND INSTRUCTIONS CAREFULLY Warning This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest covered brush Covered or grass covered land uniess the engine s exhaust system is equipped with a spark arrester meeting applicable local or state laws if any If a spark arrester is used it should be maintained in effective working order by the operator In the State of California the above is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands A spark arrester for the muffler is available by contacting the service department at Troy Bilt LLC P O Box 361131 Cleveland Ohio 44136 0019 TROY BILT LLC P O BOX 361131 CLEVELAND OH 44136 0019 PRINTED IN USA FROM NO 769 00585 12 2002 TABLE OF CONTENTS Content Page Calling Customer Support 0 2002 0202 ce eee 2 Safety woe ein hee eke his eut LRoididueiem etra aig as tieu 3 Assembly dde E ESA ee ee des REP dec VE ys 6 Features and Control i sso olera pedro ad ea eae eee RR Sake rd RR e OUR 10 Operation es doctiss E n Ie eere LERNEN ee ee ee ees 13 Maintenance ME MED 19 Off Season Storage lllllllllllelellllle ese
23. Refer to the separate parts catalog for various safety and operational decals are times Contact your local service dealer decal locations part numbers and located on your unit see Figure 1 below or the factory for replacements if any ordering instructions decals are damaged or missing Forward Clutch Control Reverse Clutch Control Operating Instruction 2 m n Operating Instruction Starting Stabilization Message on engine Warning Messages on tine hood Hot Surfaces Warning on belt cover Figure 1 Location of Safety and Operating Decals Model 644H shown Operating Symbols R Various symbols shown here with word REVERSE i K CHOKE CHOKE descriptions are used on the tiller and engine ON OFF ROTATING a y your unit may not have all of the symbols TINES BAIL BAIL B a a gt lt e lt o gt ENGAGED _DISENGAGED FAST SLOW STOP TILLER DIRECTION LEVER DIRECTION AX WARNING TO AVOID SERIOUS INJURY READ THE OWNER S MANUAL KNOW LOCATIONS AND FUNCTIONS OF ALL CONTROLS KEEP ALL SAFETY DEVICES AND SHIELDS IN PLACE AND WORKING NEVER ALLOW CHILDREN OR UNINSTRUCTED ADULTS TO OPERATE TILLER SHUT OFF ENGINE AND DISCONNECT SPARK PLUG WIRE BEFORE MANUALLY UNCLOG GING TINES OR MAKING REPAIRS KEEP BYSTANDERS AWAY FROM MACHINE KEEP AWAY FROM ROTATING PARTS USE EXTREME CAUTION WHEN REVERSING OR PULLING THE MACHINE TOWARDS YOU WARNING To prevent personal injury or
24. Shim 0 005 thick GW 1086 Bronze Bushing 711 04092 Wheel Shaft CRT GW 9305 Key Hi Pro 1 4 x 1 GW 1132 2 Spacer 1904278 Worm Gear Wheel Shaft 711 04078 Tiller Shaft GW 1104 Woodruff Key 1904279 Worm Gear Tiller Shaft wt ai O 00 OD C A Use as required to obtain between 005 and 030 allowable end play 31 MODELS 644H amp 645A included with transmission when purchased as an assembly only Remove and discard when installing the transmission on tiller Fa PART NO DESCRIPTION Ei PART NO DESCRIPTION GW 9727 Plug Transmission Oil Fill 721 04031 Oil Seal Wheel Shaft 710 04049 Hex Hd Flange Screw 5 16 18 x 5 8 Gr 5 619 04013 Transmission Housing Assembly 736 0119 Lock Washer 5 16 721 04036 Oil Seal Tine Shaft 1918377 Rear Cover Transmission 736 3008 Washer Flat 344 x 750 x 120 1916641 Front Cover Transmission 718 04008 Rear Bearing Cap GW 50032 Gasket Housing Cover 710 04048 Hex Hd Flange Screw 5 16 18 x 1 721 04030 Oil Seal Drive Shaft 710 3008 Hex Hd Flange Screw 5 16 18 x 3 4 32 Hold Tines With Cutting Edge at the TOP MODELS 644H amp 645A of each tine facing TOWARD You FRONT FORWARD 1 RIGHT HAND TINE LEFT HAN WHEEL SHAFT ENGINE 4r DENOTES CUTTING EDGE OF TINE Fa PART NO DESCRIPTION pa PART NO DESCRIPTION 710 3008 Hex Hd Screw 5 16 18 x 3 4 Grade 5 1917487 Wheel amp Tire Ass y Left Right Side 1817060 Single Tine Right Hand
25. ching the ground until you are ready to begin tilling 12 Handlebar Height Adjustment The handlebar height is adjustable to three different settings see Figure 3 6 As a general rule adjust the handlebars so they are at waist level when the tines are 3 4 into the soil To Adjust the Handlebars 1 Stop the engine disconnect the spark plug wire from the spark plug and allow the engine to cool 2 Remove the screws lockwashers and nuts reposition the handlebars and reinstall the hardware Figure 3 6 Handlebar height adjustment Anti Reverse Stake This stake is located at the rear of the transmission under the tine hood see H Figure 3 7 Its purpose is to automati cally help prevent the counter rotating tines from letting the tiller back up in the direction of the operator if the tiller wheels had been inadvertently left in the FREEWHEEL position In this situation the Anti Reverse Stake will be forced down into the ground lifting the tines upward out of the soil and helping prevent backward motion of the tiller The Anti Reverse Stake requires no adjust ment but should be inspected before each tiller use to verity that it swivels freely Remove any clogged materials dirt roots rocks etc that prevent the Anti Reverse Stake from swinging freely Figure 3 7 Anti Heverse Stake ENGINE CONTROLS Refer to the engine manufacturer s Engine Owner s Manual included in the till
26. d the other faces away from it The single outboard tine set faces toward the transmission housing Also be sure the cutting edge at the top of each tine faces toward the operator position See Figure 5 3 21 Section 5 Maintenance property damage A WARNING Before inspecting cleaning or servicing the unit shut off engine wait for all t parts to come to a complete stop disconnect spark plug wire and move wire away from spark plug Failure to follow these instructions can result in serious personal injury or s ENGINE ir DENOTES CUTTING EDGE OF TINE OPERATOR POSITION Figure 5 3 Tines tine holders and installation hardware Figure 5 4 Lift bail and check length of Clutch Bail Spring to check for correct belt tension 1 7 8 CHECKING AND ADJUSTING FORWARD DRIVE BELT TENSION Maintaining correct tension on the forward drive belt is important to good tilling performance and long belt life A loose belt will slip on the engine and 22 transmission pulleys and cause the tines and wheels to slow down or stop com pletely even though the engine is running at full speed A loose belt can also result in premature belt wear If you find you can not bring the Forward Clutch Bail all the way up to the bottom of the upper handlebars you will need to loosen the belt tension Also check the belt for cracks cuts or frayed edges and replace it as soon as p
27. d when moving in reverse Figure 4 4 To begin turn lift handlebars until engine and tines are balanced over wheels Be sure tines are out of ground Stopping the Tiller and Engine 1 To stop the wheels and tines release the Forward Clutch Bail or the Reverse Clutch Control whichever is engaged 2 To stop the engine move the throttle control lever on engine to OFF or STOP position WARNING Before tilling contact your telephone or utilities company and inquire if underground equipment or lines are used in your area Their representa tive will he giad to answer your questions and tell you if any of their equipment or lines are buried underground on your property t Figure 4 5 With tiller balanced over wheels and tines out of the ground push handlebars sideways to turn tiller 15 Section 4 Operation Tilling Tips amp Techniques Let the tiller do the work While tilling relax and let the wheels pull the tiller along while the tines do the digging Walk on the side that is not yet finished to avoid making foot prints in the freshly tilled soil and lightly but securely grip the handlebar with just one hand See Figure 4 2 Avoid the temptation to push down on the handlebars in an attempt to force the tiller to dig deeper Doing so takes the weight off the powered wheels causing them to lose traction With
28. ding the controls operation or maintenance of this unit please call the Customer Support Department your unit s model number and serial number ready when you call See previous section to locate this Call 1 330 558 7220 or 1 866 840 6483 to reach a Customer Support representative Please have information You will be asked to enter the serial number in order to process your call For more details about your unit visit our website at www troybilt com SPARK ARRESTER WARNING TO RESIDENTS OF CALIFORNIA AND SEVERAL OTHER STATES Under California law and under the laws of several other states you are not permitted to operate an internal combustion engine using hydrocarbon fuels on any forest brush hay grain or grass covered land or land covered by any flammable agricultural crop without an engine spark arrester in continuous effective working order The engine on the unit is an internal combustion engine which burns gasoline a hydrocarbon fuel and must be equipped with a spark arrester muffler in continuous effective working order The spark arrester must be attached to the engine exhaust system in such a manner that flames or heat from the system will not ignite flammable material Failure of the owner operator of the unit to comply with this regulation is a misdemeanor under California law and other states and may also be a violation of other state and or federal regulations laws ordinances or codes Contact your local f
29. e in ON RUN FAST or START position as instructed in the separate Engine Owner s Manual 7 Choke or prime engine as instructed in the separate Engine Owner s Manual 8 Place one hand on the fuel tank to stabilize the unit when you pull the starter handle Use the recoil starter rope to start the engine as instructed in the separate Engine Owner s Manual When engine starts gradually move choke lever on engines so equipped to NO CHOKE CHO Hot surfaces can cause severe burns Do not touch muffler or adjacent areas 9 Use the FAST throttle speed setting when tilling M WARNING Keep away from rotating tines Rotating tines will 4 cause injury Stopping the Engine and Tiller 1 To stop the wheels and tines release the Forward Clutch Bail or the Reverse Clutch Control whichever control is in use 2 To stop the engine put the throttle control lever on engine in OFF or STOP position OPERATING THE TILLER The following pages provide guidelines to using your tiller effectively and safely in various gardening applications Be sure to read Tilling Tips amp Techniques in this Section before you actually put the tines into the soil This is a CRT counter rotating tine tiller As the wheels pull forward the tines rotate backward This creates an uppercut tine action which digs deeply uprooting soil and weeds Don t overload the engine but dig as dee
30. e towards you 28 Start the engine carefully according to instructions and with feet well away from the tines 29 Never pick up or carry a machine while the engine is running Maintenance and Storage 1 Keep the tiller attachments and acces sories in safe working condition 2 Check all nuts bolts and screws at frequent intervals for proper tightness to be sure the equipment is in safe working condition 3 Never store the tiller with fuel in the fuel tank inside a building where ignition sources are present such as hot water and space heaters furnaces clothes dryers stoves electric motors etc Allow engine to cool before storing in any enclosure 4 To reduce the chances of a fire hazard keep the engine free of grass leaves or excessive grease 5 Store gasoline in a cool well ventilated area safely away from any spark or flame producing equipment Store gasoline in an approved container safely away from the reach of children 6 Refer to the Maintenance sections of this Manual and the separate Engine Owner s Manual for instructions if the tiller is to be stored for an extended period 7 Never perform maintenance while the engine is running or the spark plug wire is connected except when specifically instructed to do so 8 If the fuel tank has to be drained do this outdoors Section 1 Safety Decals For your safety and the safety of others Keep the decals clean and legible at all
31. eel shaft into a drain pan and allow the gear oil to drain through the top of the transmission 6 After draining oil reinstall the wheel install a new gasket do not reuse old gasket and screw on transmission cover 7 Refill transmission using GL 4 gear oil SAE 85W 140 or SAE 140 8 Refill the engine with motor oil and replenish the fuel tank with gasoline Figure 5 2 Remove oil fill plug A to check gear oil level and to add gear oil Remove four cover screws B io drain gear ail TINES The tines wear with use and they should be inspected at the beginning of each tilling season and after every 30 operating hours The tines can be replaced individ ually or as a complete set Refer to the Parts List Section of this manual for tine identification information _ WARNING This is a CRT counter rotating tine tiller and its tines must be mounted in the direction Shown in Figure 5 3 if mounted with curves in the opposite direction tiller will dig poorly and be more likely to run backward Failure to comply could result in personal injury or property damage NOTE You must first remove the tiller hood before removing either a single tine holder or individual tines Remove the two screws at the front of the hood and the two screws at the rear of the hood and lift off the hood Be sure to replace the hood securely after changing a tine or tine holders A Tine Inspection With use the tines will
32. engine oil Refer to the Engine Owner Manual for engine oil specifications and quantity required Do not overfill Adjustable wrenches may be used Figure 2 1 To identify length of screw place screw on template as shown and measure distance between bottom of screw head and tip of screw STEP 2 Attach Handlebar 1 Attach the two legs of the handlebar support A Fig 2 2 loosely to the inner sides of the tiller frame using two 3 8 16 X 3 4 hex hd screws B 3 8 flat washers C and 3 8 16 hex locknuts D 2 Using the middle holes in the handlebar support brackets E and F Fig 2 2 loosely attach the support brackets to the handlebar support A using two 5 16 18 x 1 1 2 curved hd screws G 5 16 split lockwashers H and 5 16 18 hex nuts I NOTE If a support bracket will not move loosen attaching screw J and nut 3 Attach the handlebar assembly K to the handlebar support A using four 5 16 18 x 1 1 2 curved hd screws G 5 16 split lockwashers H and 5 16 18 hex nuts 1 Tighten the four screws securely 4 Tighten all handlebar mounting hardware securely STEP 3 Move Tiller Off Shipping Platform To move the tiller without the engine running put the wheels in their FREEWHEEL position as described below 1 Use a sturdy block to raise one wheel off the ground 2 Remove the hairpin cotter L Fig 2 3 and wheel drive pin M Slide the wheel inward on the wheel shaft N
33. er lit erature package to identify the controls on your engine IMPORTANT The control for stopping the engine is located on the engine Before operating your machine carefully read and understand all safety Section 1 controls Section 3 and operating instructions Section 4 in this Manual in the separate Engine Owner s _ Manual and on the decals on the machine Failure to follow these instruc tions can result in serious personal injury INTRODUCTION Read this Section of the manual thor oughly before you start the engine Then take the time to familiarize yourself with the basic operation of the tiller before using it in the garden Find an open level area and practice using the tiller controls without the tines engaging the soil put tines in travel setting Only after you ve become completely familiar with the tiller should you begin using it in the garden INITIAL OPERATION Perform the following maintenance during the first hours of new operation see Maintenance section in this manual and in the Engine Owner s Manual 1 Change engine oil after first 2 hours of new engine operation 2 Check for loose or missing hardware on unit Tighten or replace as needed 3 Check tension on forward drive belt after first 2 hours of operation 4 Check transmission gear oil level after first 2 hours of operation Recoil Starter Figure 4 1 STARTING AND STOPPING THE ENGIN
34. follow the guidelines given next Before loading or unloading stop the engine wait for all parts to stop moving disconnect the spark plug wire and let the engine and muffler cool The tiller is too heavy and bulky to lift safely by one person Two or more people should share the load 18 Use sturdy ramps and manually engine shut off roll the tiller into and out of the vehicle Two or more people are needed to do this Ramps must be strong enough to support the combined weight of the tiller and any handlers The ramps should provide good traction to prevent slipping they should have side rails to guide the tiller along the ramps and they should have a locking device to secure them to the vehicle The handlers should wear sturdy footwear that will help to prevent slipping Position the loading vehicle so that the ramp angle is as flat as possible the less incline to the ramp the better Turn the vehicle s engine off and apply its parking brake When going up ramps stand in the normal operating position and push the tiller ahead of you Have a person at each side to turn the wheels When going down ramps walk backward with the tiller following you Keep alert for any obstacles behind you Position a person at each wheel to control the speed of the tiller Never go down ramps tiller first as the tiller could tip forward Use wooden blocks to place on the downhill side of the
35. gear oil fill plug STEP 9 Check Air Pressure in Tires Use a tire pressure gauge to check the air pressure in both tires Deflate or inflate both tires equally to 15 to 20 PSI pounds per square inch Be sure that both tires are inflated equally or the unit will pull to one side IMPORTANT This completes the assembly steps Before operating your tiller make sure you read the following Sections in this Manual as well as the separate Engine Owner s Manual Section 1 Safety Section 3 Features and Controls Section 4 Operation Before operating your _ machine carefully read and understand all safety controls Failure to follow these _ instructions can result in serious personal injury Introduction This section describes the locations and functions of the controls on your tiller Refer to the next section Operation for detailed operating instructions Practice using these controls with the engine shut off until you understand the operation of the controls and feel confident with each of them IMPORTANT Refer to the separate engine manufacturer s Engine Owner s Manual for information about the controls on the engine 10 BE i Forward Reverse Clutch j Clutch Bail Control j L Depth Regulator Figure 3 1 Features and controls Wheel Drive Pins WARNING Never allow either of the wheels to be in the FREEWHEEL position when
36. hine 4 Exercise caution to avoid slipping or falling 5 If the unit should start to vibrate abnor mally stop the engine disconnect the spark plug wire and prevent it from touching the spark plug and check immediately for the cause Vibration is generally a warning of trouble 6 Stop the engine disconnect the spark plug wire and prevent it from touching the spark plug whenever you leave the operating position before unclogging the tines or when making any repairs adjust ments or inspections Section 1 Safety 7 Take all possible precautions when leaving the machine unattended Stop the engine Disconnect spark plug wire and move it away from the spark plug Be sure both wheels are in the Wheel Drive position 8 Before cleaning repairing or inspect ing stop the engine and make certain all moving parts have stopped Disconnect the spark plug wire and prevent it from touching the spark plug to prevent acci dental starting 9 The flap on the tine hood must be down when operating the tiller 10 Never use the tiller unless proper guards plates or other safety protective devices are in place 11 Do not run engine in an enclosed area Engine exhaust contains carbon monoxide gas a deadly poison that is odorless colorless and tasteless 12 Keep children and pets away 13 Never operate the tiller under engine power if the wheels are in the Freewheel position In the Freewheel position the wheels
37. ighly flammable and its vapors are explosive Be sure to take the following precautions a Store fuel in containers specifically designed for this purpose b The gas cap shall never be removed or fuel added while the engine is running Allow the engine to cool for several minutes before adding fuel Keep matches cigarettes cigars pipes open flames and sparks away from the fuel tank and fuel container d Fill fuel tank outdoors with extreme care Never fill fuel tank indoors Use a funnel or spout to prevent spillage e Replace all fuel tank and container caps securely f If fuel is spilled do not attempt to start the engine but move the machine away from the area of spillage and avoid creating any source of ignition until fuel vapors have dissipated 7 Never make adjustments when engine is running unless recommended by manufacturer Operation 1 Do not put hands or feet near or under rotating parts The tines begin to rotate once the engine starts and the Forward Clutch Bail or Reverse Clutch Control is engaged 2 Exercise extreme caution when on or crossing gravel drives walks or roads Stay alert for hidden hazards or traffic Do not carry passengers 3 After striking a foreign object stop the engine remove the wire from the spark plug and prevent it from touching the spark plug thoroughly inspect the machine for any damage and repair the damage before restarting and operating the mac
38. ire marshal or forest service for specific information about which regulations apply in your area Training 1 Carefully read this E Owner s Manual the TS separate Engine Owner s Manual and any other literature you may receive Be thoroughly familiar with the controls and the proper use of the tiller and its engine Know how to stop the unit and disengage the controls quickly 2 Never allow children to operate the tiller Never allow adults to operate the tiller without proper instruction 3 Keep the area of operation clear of all persons particularly children and pets 4 Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people their property and themselves Preparation 1 Thoroughly inspect the area where the tiller is to be used and remove all foreign objects 2 Be sure all tiller controls are released and both wheels are in the Wheel Drive position before starting the engine 3 Do not operate the tiller without wearing adequate outer garments Avoid loose garments or jewelry that could get caught in moving parts 4 Do not operate the tiller when barefoot or wearing sandals sneakers or light footwear Wear protective footwear that will improve footing on slippery surfaces 5 Do not till near underground electric cables telephone lines pipes or hoses If in doubt contact your telephone or utility company 6 Warning Handle fuel with care it is h
39. l authorized engine service dealer CARBURETOR GOVERNOR CONTROL ADJUSTMENTS The carburetor was adjusted at the factory for best operating speed Refer to the separate Engine Owner s Manual for any adjustment information or see your autho rized engine service dealer The governor controls the maximum safe operating speed and protects the engine and all moving parts from damage caused by overspeeding Do not tamper with the engine governor settings WARNING Operators shall not tamper _ with the engine governor settings on the machine _ the governor controls the maximum safe operating speed to protect the parts from damage caused by overspeed Authorized OFF SEASON STORAGE When the tiller won t be used for extended periods prepare it for storage as follows 1 Clean the tiller and engine 2 Do routine tiller lubrication and check for loose parts and hardware 3 Protect the engine and perform rec ommended engine maintenance by following the engine storage instruc tions found in the separate Engine Owner s Manual NOTE Be sure to protect the fuel lines carburetor and fuel tank from gum deposits by removing fuel or by treating fuel with a fuel stabilizer follow engine manufac turer s recommendations 4 Store unit in a clean dry area 5 Never store the tiller with fuel in the fuel tank in an enclosed area where gas fumes could reach an open flame or spark or where ignition sources are
40. ller till more deeply This prevents the wheels from holding the tiller back and can allow the tines to rapidly propel the tiller backward toward the operator which could result in loss of control property damage or personal Let the tiller move at its own pace and do not push down on the handlebars to try to dig deeper this takes weight off the wheels cuts traction and causes the tines to try and propel the tiller 5 For reverse motion of the wheels and tines a Look behind and exercise caution when operating in reverse Do not till while in reverse b Stop all forward motion before reversing Lift the handlebars with one hand until the tines are off the ground and then pull the Reverse Clutch Control knob out to engage reverse motion see Figure 4 3 To stop reverse motion let go of the Reverse Clutch Control knob 6 To Turn the Tiller Around a Practice turning the tiller in a level open area Be very careful to keep your feet and legs away from the tines b To make a turn lift the handlebars until the engine and tines are balanced over the wheels Figure 4 4 Thetines must be out of the ground while turning the tiller c With the tiller balanced push sideways on the handlebar to move the tiller in the direction of the turn Figure 4 5 After completing the turn slowly lower the tines into the soil to resume tilling 2 Vs p yo Hes Figure 4 3 Raise tines off ground and look behin
41. lope allows maximum planting area and also leaves room for cultivating IMPORTANT When tilling on slopes be sure the correct oil level is maintained in the engine check every one half hour of operation The incline of the slope will cause the oil to slant away from its normal level and this can starve engine parts of required lubrication Keep the engine oil level at the full point at all times A Tilling up and down slopes To keep soil erosion to a minimum be sure to add enough organic matter to the soil so that it has good moisture holding texture and try to avoid leaving footprints or wheel marks When tilling vertically try to make the first pass uphill as the tiller digs more deeply going uphill than it does downhill In soft soil or weeds you may have to lift handlebars slightly while going uphill B Tilling across slopes without using terraces If previously described tilling methods aren t practical for you then you can till laterally across a slope However we don t really recommend this method as it can create unsure footing and invites soil erosion 17 Section 4 Operation LOADING AND UNLOADING THE TILLER M WARNING Loading and unloading the iller into or from a vehicle is potentially hazardous We don t recommend doing so unless absolutely necessary as this could result in person al injury or property damage However if you must load or unload the tiller
42. n 1 4 no adjustment is needed as long as the reverse action functions properly 5 Release the Reverse Clutch Control knob Unthread the inner jam nut C Figure 5 6 one to two turns and pull the threaded cable adjuster A Figure 5 6 to the left until the inner jam nut rests against the bracket B Prevent the inner jam nut C from turning and tighten the outer jam nut D against the bracket Prevent the outer jam nut D from turning and tighten the inner jam nut C against the bracket 7 Measure the gap by repeating Step 3 Readjust as needed by repeating Steps 5 and 6 8 Reinstall the belt cover Figure 5 5 Measure cable wire length to check for correct reverse belt tension ES Figure 5 6 Move threaded adjuster A to left to increase belt tension Reverse Belt Replacement Information If the drive belt needs to be replaced see your local authorized dealer or phone the factory as instructed on Page 2 Refer to the Parts List in the back of this manual for correct components Use only QEM Original Equipment Manufacturer fre placement belts A substitute belt may not perform satisfactorily The procedure requires average mechanical ability and commonly available tools 23 Section 5 Maintenance _ property damage WARNING Before inspecting cleaning or servicing the unit shut off engine wait for all t parts to come to a complete stop disconnect spark plug wire and move wire away f
43. nt damage from overheating Refer to the separate Engine Owner s Manual for specific repair and cleaning instructions All inspections and services must be done with the engine shut off and cool to the touch 24 AIR CLEANER SERVICE The engine air cleaner filters dirt and dust out of the air before it enters the carbure tor Operating the engine with a dirty clogged air filter can cause poor perfor mance and damage to the engine Never operate the engine without the air cleaner installed Inspect and service the air cleaner more often if operating in very dusty or dirty conditions Service the air cleaner as instructed in the separate Engine Owner s Manual SPARK PLUG SERVICE Inspect and clean or replace the spark plug after every 100 operating hours or annually Clean the plug and set the gap as described in the separate Engine Owner s Manual In some areas local law requires using resistor spark plugs to suppress ignition signals If the engine was originally equipped with a resistor spark plug use the same type for replacement SPARK ARRESTER SCREEN SERVICE If the engine muffler is equipped with a spark arrester screen remove and clean it according to the time intervals and instruc tions in the separate Engine Owner s Manual THROTTLE LEVER ADJUSTMENT If the engine does not respond to various throttle lever settings refer to the separate Engine Owner s Manual for service infor mation or contact your loca
44. o good performance and long belt life A loose belt will slip on the engine and transmis sion pulleys and cause the tines and wheels to slow down or stop com pletely even though the engine is running at full speed A loose belt can also result in premature belt wear If there is no reverse action when the Reverse Clutch Control knob is pulled out then the belt tension is too loose When checking belt tension also check the belt for cracks cuts or frayed edges and replace it as soon as possible Check belt tension after the first two hours of break in operation new belt Check belt tension after every 10 operating hours To Check Reverse Belt Tension 1 Be sure that the engine is stopped and the spark plug wire is disconnected and moved away from the spark plug 2 Remove the screw in the plastic belt cover and slide the cover which is attached to the forward clutch cable out of the way 3 Have an assistant pull the Reverse Clutch Control knob all the way out and hold it in that position Measure the length of the cable wire between the end of the threaded cable adjuster A Figure 5 5 and the end of the Z fitting B to which the cable wire is attached 4 The belt tension is ideal if the cable wire length measures between 1 8 to 1 4 If the length is less than 1 8 and if there is no reverse action when the tiller is running then make the following adjustments NOTE If the length is more tha
45. om the fuel tank Failure to follow this instruc tion could result in personal _ injury or property damage Figures 3 2 and 3 3 by removing the hairpin cotter C 4 FOR WHEEL DRIVE mode Figure 3 2 Slide the wheel outward and align the holes in the wheel hub D Figure 3 2 and the wheel shaft B Insert the wheel drive pin A through the wheel hub and the wheel shaft Secure the wheel drive pin with the hairpin cotter C by pushing the hairpin cotter in as far as it will go Repeat for the other wheel and then remove the support from beneath the transmission 5 FOR FREEWHEEL mode Figure 3 3 Slide the wheel inward and insert the wheel drive pin A Figure 3 3 only through the hole in the wheel shaft B Secure the wheel drive pin with the hairpin cotter C by pushing the hairpin cotter in as far as it will go Repeat for the other wheel and then remove the support from beneath the transmission Figure 3 2 WHEEL DRIVE position Figure 3 3 FREEWHEEL position Section 3 Features and Controls Forward Clutch Bail The Forward Clutch Bail E Figure 3 4 controls the engagement of forward drive to the wheels and power to the tines NOTE The wheels will rotate in a forward direction the tines will rotate counter clockwise backward toward the operator To Operate the Forward Clutch Bail 1 Put the wheels in the WHEEL DRIVE position see the following WARNIN
46. or damage because of peril or other natural disaster 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 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 noi apply to parts that have been damaged by accident alteration misuse abuse neglect improper maintenance vandalism theft fire water or damage because of peril or other natural disaster Warranty service is available with proof of purchase through your local authorized service dealer To locate a dealer in your area consult your Yellow Pages or contact Troy Bilt LLC at P O Box 361131 Cleveland Ohio 44136 0019 1 866 840 6483 or log on to our Web site at www troybilt com The provisions set forth in this warranty provide the sole
47. ossible Check belt tension after the first two hours of initial operation new belt Check belt tension after every 10 operating hours To Check Forward Belt Tension 1 Be sure that the engine is stopped and the spark plug wire is disconnected and moved away from the spark plug 2 Loosen nut C Figure 5 4 several turns so it is about halfway up the threaded adjustment screw 3 Lift the Forward Clutch Bail up and hold it to the bottom of the handlebars Measure the length of the clutch bail spring A Figure 5 4 with a ruler If the belt tension is correct the length of the coiled portion of the spring should be approximately 1 7 8 Nut C should then be snugged down against the top of the adjuster B 4 If the spring is too short the belt tension will be too loose 1f the spring is too long the belt tension will be too tight 5 To adjust the length of the spring release the Forward Clutch Bail Thread the hex nut C Fig 5 4 halfway up the adjustment screw Turn the screw inside the spring A Figure 5 4 counterclock wise as viewed from the operator s position while holding the adjuster B steady to increase the length of the spring or turn clockwise as viewed from the operator s position to decrease the length of the spring NOTE If you have difficulty holding the adjuster steady by hand use a pliers or wrench on the adjuster While you turn the screw keep the Forward Clutch Cable
48. out the wheels helping to hold the tiller back the tines will attempt to propel the tiller backward toward the operator often causing the tiller to skip rapidly across the ground Tilling depths When preparing the soil till a fresh path on each pass rather than overlap ping passes This gives the wheels maximum traction on undisturbed soil See Figure 4 6 Dig as deeply as possible on each pass without over loading the engine Later passes can be overlapped Watering the garden area a few days prior to tilling will make tilling easier as will letting the newly worked soil set for a day or two before making a final deep tilling pass When cultivating breaking up the surface soil around plants to help destroy weeds adjust the tines to dig only 1 1 2 to 2 deep Using shallow tilling depths helps prevent injury to plants whose roots often grow close to the surface f needed lift up on the handlebars slightly to prevent the tines from digging too deeply Cultivating on a regular basis not only eliminates weeds it also loosens and aerates the Soil for better moisture absorption and faster plant growth Avoid tilling soggy wet soil Tilling wet soil often results in large hard clumps of soil that can interfere with planting If time permits wait a day or two after heavy rains to allow the soil to dry before tilling Test soil by squeezing it into a ball If it compresses too easily it is too wet to till
49. ply as possible on each pass On later passes the wheels may tend to spin in the soft dirt Help them along by lifting up slightly on the handlebar palm facing up 1 Follow the Pre Start Checklist on the previous page Be sure that the wheels are in the WHEEL DRIVE position 2 Put the Depth Regulator Lever in the travel position lever all the way down so that the tines are clear of the ground Use this position when practicing with your tiller or when moving to or from the garden When you are ready to begin tilling you must move the Depth Regulator Lever to the desired depth setting see Tilling Tips amp Techniques Check that the Anti Reverse Stake swivels freely back and forth Remove any clogged material on or around the stake es 1092 CN ww Figure 4 2 Use one hand to guide tiller when moving forward 3 Start the engine and allow it to warm up When warm put throttle control in fast speed setting 4 For forward motion of wheels and power to the tines a Pull the Forward Clutch Bail up and hold it against the handlebar Release the bail to stop forward motion of the wheels and power to the tines b As the tiller moves forward relax and iet the wheels pull the unit along while the tines dig Walk behind and a little to one side of the tiller Use a light but secure grip with one hand on the handlebars keeping your arm loose See Figure 4 2 Section 4 Operation ti
50. property damage do not start the engine until all assembly steps are complete and you have read and understand the safety and operating instruc tions in this manual Introduction Carefully follow these assembly steps to correctly prepare your tiller for use It is recommended that you read this Section in its entirety before beginning assembly NOTE Engine syles vary by model The engine on your tiller may appear differ ently than those shown in illustrations and Figures throughout this manual inspect unit Inspect the unit and carton for damage immediately after delivery Contact the carrier trucking company if you find or suspect damage Inform them of the damage and request instructions for filing a claim To protect your rights put your claim in writing and mail a copy to the carrier within 15 days after the unit has been delivered STEP 1 Unpacking Instructions 1 Remove any cardboard inserts and packaging material from the carton Remove any staples from the bottom of the carton and then lift the carton up and off the unit 2 The tiller is heavy and you should not attempt to remove it from the shipping platform until the handlebars are installed The procedure for removing the tiller is explained in Step 3 of these assembly steps Assembly NOTE Be careful not to severely bend any of the control cables on the unit 3 Remove all unassembled parts and the separate hardware bag from the carton Check
51. r X 6 Hook cable spring W Fig 2 6 into V shaped bend in the forward clutch bail Y 7 Lift and hold the Forward Clutch bail against the handlebar See Fig 2 7 8 Measure the length of the cable spring between the ends of the coils Fig 2 7 The length should be approximately 1 7 8 If the length is correct turn the 210 24 hex nut Z down tightly against the cable adjuster X while holding the adjuster in place See Figure 2 7 If the length is incorrect you must make an adjustment to the cable tension as described in Checking and Adjusting Forward Drive Belt Tension in Section 5 When the spring length is correct tighten the hex nut Z against the cable adjuster X STEP 5 Install Reverse Clutch Cable 1 Remove the two pre installed self tapping screws AA Fig 2 8 from the handlebars 2 Position the reverse cable mounting bracket BB Fig 2 8 as shown and reinstall the two self tapping screws 3 Unwrap the reverse clutch cable the cable with a knob and a large hex nut attached to it from around its shipping position and route the cable CC Fig 2 8 and Fig 2 9 up to the cable bracket BB Fig 2 8 Be sure that the cable goes beneath the Forward Clutch Bail as it is routed up to the cable bracket Fig 2 4 in
52. rom spark plug Failure to follow these instructions can result in serious personal injury or m ENGINE OIL SERVICE Check the engine oil level before starting the engine each day and check it after each 5 hours of continuous operation Running the engine when it is low on oil will quickly ruin the engine It is recommended that you change the motor oil after every 10 hours of operation and even sooner when operating in extremely dirty or dusty conditions Refer to the separate Engine Owner s Manual for detailed service instructions A To Check the Engine Oil Level 1 Move the tiller to a level area and shut off the engine 2 Level the engine by adjusting the Depth Regulator Lever The tines must be in contact with the ground Move the Anti Reverse Stake back if necessary 3 Clean the area around the oil dipstick or oil fill tube to prevent dirt from falling into the crankcase 4 On engines with an oil fill tube remove the filler cap add oil if required until it reaches the top of the tube and reinstall the filler cap 5 On engines with a dipstick remove it wipe it clean and reinstall it finger tight Remove the dipstick and check the reading Add oil if required to bring the level to the FULL mark Do not overfill B To Change the Engine Oil Change the engine oil as instructed in the separate Engine Owner s Manual ENGINE CLEANING Keep the engine clean to assure smooth operation and to preve
53. stalling forward clutch cable bracket and cable Fig 2 5 Assemble Spring and adjuster Fig 2 6 Install forward clutch cable Hold bail against handlebar while measuring spring Fig 2 7 Measure cable spring 4 Insert the cable up through the slot in the cable bracket and position the threaded assembly as shown in Fig 2 8 Make sure that the flat side of the threaded assembly is aligned with the flat side of the mounting hole Slide the large hex nut DD up the cable and tighten it securely 5 Use a cable tie EE Fig 2 9 to fasten the reverse clutch cable to the left side handlebar 6 Test the function of the reverse clutch cable by pulling the knob out and releasing it The knob should return to its neutral position resting against bracket when it is released If it doesn t contact your local dealer or the factory for technical assistance l j a ie BB N DD cC Flat Side Fig 2 8 install reverse cable mounting bracket and the reverse clutch cable Fig 2 9 Route reverse cluich cable CC as shown Attach to handlebar with cable tie EE STEP 6 Check Level of Transmission Gear Oil The transmission was filled with gear oil at the factory However you should check the gear oil level to make certain it is correct IMPORTANT Do not operate the tiller if the gear oil level is low Doing so will result in severe damage to the transmis sion
54. t shut off engine wait for all parts to come to a complete stop disconnect spark plug wire and move wire away from spark plug Failure to follow these instructions can result in serious personal injury or t rh TILLER LUBRICATION Proper lubrication of the tiller is an essential part of maintenance After every 10 operating hours oil or grease the lubrication points shown in Figures 5 1 and 5 1A and described below Use a good quality lubricating oil 30 weight engine oil is suitable and a quality general purpose grease with a metal lubricant if available Remove wheels clean wheel shaft A Fig 5 1 and apply thin coating of grease to the shaft Grease back front and sides of depth regulator lever B Fig 5 1 Remove tines clean tine shafts C Fig 5 1 Inspect for rust rough spots or burrs look around holes File or sand smooth coat ends of shaft with grease Qil the threads on the handlebar height adjustment screws and the handlebar attaching screws D Fig 5 1 Shifting Mechanism Lightly oil pivot points for smooth operation E Fig 5 1A Figure 5 1 Figure 5 1A 20 CHECK FOR OIL LEAKS Before each use check your tiller for signs of an oil leak usually a dirty oily accumulation either on the unit or on the floor where it has been parked A little seepage around a cover or oil seal is usually not a cause for alarm However if the oil drips overnight then immedia
55. te attention is needed as ignoring a leak can result in severe transmission damage If a cover is leaking try tightening any loose screws If the screws are tight a new gasket or oil seal may be required If the leak is from around a shaft and oil seal the oil seal probably needs to be replaced See your authorized dealer or contact the factory for service or advice IMPORTANT Never operate the tiller if the transmission is low on oil Check the oil level after every 30 hours of operation and whenever there is any oil leakage CHECK HARDWARE Check for loose or missing hardware after every 10 operating hours Tighten or replace hardware before using the tiller Be sure to check the screws underneath the tiller hood lift the hood flap that secure the transmission cover and the depth regulator lever to the transmission CHECK TIRE PRESSURE on machines equipped with pneumatic tires Check the air pressure in both tires Deflate or inflate both tires evenly from 15 to 20 PSI pounds per square inch Be sure that both tires have the same air pressure or the unit will tend to pull to one side NOTE Your tiller may not be equipped with pneumatic tires eliminating the need for air pressure checks TRANSMISSION GEAR OIL SERVICE Check the transmission gear oil level after every 30 hours of operation or whenever you notice any oil leak Operating the tiller when the transmission is low on oil can result in severe damage
56. tenance D _ WARNING Before inspecting cleaning or servicing the unit shut off engine wait for all parts to come to a complete stop disconnect spark plug wire and move wire away from spark _ plug Failure to follow these instructions can result in serious personal injury or property damage 1 Ex A DANGER Gasoline is highly flammahle and its vapors explosive Fol low these safely practices to prevent injury or property damage from fire or explosion Allow the engine and muffler to cool before draining the tiller s gasoline tank Do not allow open flames sparks matches or smoking in the area Wipe away spills and push tiller away from spilled fuel Use only an approved fuel container and store it safely out of the reach of children Do not store gasoline where its vapors could reach an open flame or spark or where ignition sources are present such as hot water and space heaters furnaces clothes dryers stoves electric motors etc The transmission gear oil does not need to be changed unless it has been contam inated with dirt sand or metal particles 1 Drain gasoline from the fuel tank or run the engine until the fuel tank is empty See DANGER statement above 2 Drain the oil from the engine 3 Remove the four screws B Figure 5 2 and washers from the transmission cover and remove the cover and gasket 4 Remove the left side wheel 5 Tilt the left side wh
57. the engine is running Always put both wheels in the WHEEL DRIVE position before starting the engine ailure to comply could cause loss of tiller control property damage or personal injury Each wheel is equipped with a Wheel Drive Pin A Figures 3 2 and 3 3 that secures the wheel to the wheel shaft B The wheels can be positioned in either a WHEEL DRIVE or a FREEWHEEL mode Before starting the engine put both wheels in the WHEEL DRIVE position by inserting the Wheel Drive Pins through the wheel hubs and the wheel shaft This locks the wheels to the wheel shaft causing the wheels to turn when either the Forward Clutch Bail or the Reverse Clutch Control is engaged Use the FREEWHEEL mode only when the engine is not running In FREEWHEEL the Wheel Drive Pins are placed only Handlebar Height Adjustment LLL Anti Reverse Stake Wheel Drive Pin on each wheel through the holes in the wheel shaft not the wheel hubs thus allowing the wheels to turn freely when the tiller is pushed or pulled by hand To Place the Wheels in WHEEL DRIVE or FREEWHEEL 1 Stop the engine disconnect the spark plug wire from the spark plug and allow the engine to cool 2 Raise one wheel off the ground and place a sturdy support under the transmission 3 Remove the wheel drive pin A WARNING Do not place the tiller on its side when changing the wheel drive positions as doing so could result in gasoline leaking fr
58. tines or wheels until you have read all the operating instructions in this Section Also review the safety rules in Section 1 Safety and the tiller and engine controls information in Section 3 Features and Controls To help prevent serious personal injury or damage to Before starting engine put both wheels in the WHEEL DRIVE position Never have the wheels in the FREEWHEEL position when the engine is running When the wheels are in FREEWHEEL they do not hold back the tiller and the tines could propel the tiller rapidly backward Before starting engine put Forward Clutch Bail all Models and Reverse Clutch Control in neutral disen gaged positions by releasing levers Never run engine indoors or in enclosed poorly venti lated areas Engine exhaust contains carbon monoxide an odoriess and deadly gas Avoid engine muffler and nearby areas Temperatures in these areas may exceed 150 F 1 Complete the Pre Start Checklist on the previous page 2 Put the wheels in the WHEEL DRIVE position see Wheel Drive Pins in Section 3 3 Put the Depth Regulator Lever in the travel position lever all the way down so that the tines are clear of the ground 4 Release all controls on the tiller 5 If engine is equipped with a fuel valve Um valve to open position as instructed in the separate Engine Owner s Manual 6 Put ignition switch and or throttle control lever on engin
59. ucces sive passes at one quarter width see Figure 4 8 With planning you can allow enough room between rows to cultivate see Figure 4 9 Leave room for the hood width plus enough extra room for future plant growth Figure 4 6 Figure 4 7 Figure 4 8 n Lm HT Figure 4 9 7 R m Section 4 Operation Tilling Tips amp Techniques Clearing the tines Dry grass stringy stalks or tough vines may become tangled in the tines Follow these procedures to help avoid tangling and to clean the tines if necessary To reduce tangling set the depth regulator to maximum depth While tilling try swaying the handle bars from side to side about 6 to 12 This fishtailing action often clears the tines of debris If tangling occurs lift the tines out of the soil and run the tiller in reverse for a few feet This may unwind a good deal of debris t may be necessary to remove the debris by hand a pocket knife will help y un WARNING disconnect the spark plug wire Failure to follow this warning could result in personal injury Tilling on slopes If you must garden on a moderate slope please follow two very important guide lines 1 Till only on moderate slopes never on steep ground where footing is difficult review safety rules in the Safety section of this manual 2 We recommend tilling up and down Slopes rather than terracing Tilling vertically on a s

Troy-Bilt 644H Tiller User Manual

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