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Dodge 2005 Stratus Sedan Automobile User Manual

1. RUN FAST or START position as in structed in the Engine Owner s Manual 7 Choke or prime engine as instructed in Engine Owner s Manual 8 Put one hand on fuel tank to stabilize unit when pulling starter rope handle Then use recoil starter to start engine as in structed in the Engine Owner s Manual When engine starts gradually move choke lever if so equipped to NO CHOKE CHOKE OFF or RUN position 9 Use the FAST throttle speed setting when tilling A WARNING Mo 274 KEEP AWAY FROM ROTATING TINES ROTATING TINES WILL CAUSE INJURY Stopping the Engine and Tiller 1 To stop the wheels and tines release the Forward Clutch Bail all models or the Re verse Clutch Control Models 643B amp 645A whichever control is in use 2 To stop the engine put the ignition switch and or the throttle control lever in the OFF or STOP position OPERATING THE TILLER The following operating instructions pro vide guidelines to using your tiller effec tively and safely Be sure to read Tilling Tips amp Techniques in this Section before actually putting the tines into the soil This is a Counter Rotating Tine CRT tiller It operates differently from Stan dard Rotating Tine SRT tillers As the wheels pull forward the tines rotate back ward creating an uppercut action which digs deeply uprooting soil and weeds 1 Follow the Pr
2. NOTE LEFT and RIGHT sides of the tiller are as viewed from the operator s position behind the handlebars STEP 2 ATTACH HANDLEBAR 1 Loosely attach the legs of the handlebar support A Fig 2 2 to the inner sides of the tiller frame using two 3 8 16 x 3 4 hex hd screws B 3 8 flat washers and 3 8 16 hex locknuts P9 PNY P Figure 2 1 To identify length of screws place Screw on template as shown and measure dis tance between bottom of screw head and tip of screw 2 Using two 5 16 18 x 1 1 2 screws C 5 16 split lock washers D and 5 16 18 hex nuts G loosely attach the handlebar support A using the upper holes Tighten the two screws securely 3 There are three height adjustment holes in the two handlebar support brackets E and F Fig 2 2 Use a setting that will po sition the handlebars at approximately waist level when the tines are 3 4 into the soil Loosely attach the support brackets to the outside of the handlebar assembly I using two 5 16 18 x 1 1 2 screws G 5 16 split lock washers D and 5 16 18 hex nuts G NOTE If a support bracket will not move loosen attaching screw H and nut IMPORTANT The support brackets must be assembled to the outside of the handlebar assembly 4 Tighten all handlebar mounting hard ware securely STEP 3 MOVE TILLER OFF CRATE To roll the tiller off the shipping platform put the wheels in freewheel as follows
3. 1 Place a sturdy block under the transmis sion to raise one wheel about 1 off the ground 2 Remove the Klik Pin J Fig 2 3 from the wheel hub K and wheel shaft L 3 Slide the wheel fully inward on the wheel shaft N Fig 2 3 Reinstall the Klik pin J The support brackets must be assembled to the outside of the handlebar assembly Fig 2 2 Attach handlebar Fig 2 3 Wheel in FREEWHEEL position wheel drive pin through wheel shaft only STEP 4 INSTALL FORWARD CLUTCH CABLE 1 Carefully unwrap the forward clutch ca ble cable without an attached knob from its shipping position and slide the thin ca ble wire M Fig 2 4 into the slot in the ca ble bracket Push the cable connector N Fig 2 4 up through the hole in the bracket until the groove in the connector snaps into place 2 Thread the 10 24 hex nut Z Fig 2 5 halfway onto the screw V which runs through the spring W Fig 2 5 3 Thread the screw V into the cable ad juster X through the wheel shaft L only not through the wheel hub The wheel should now spin freely freewheel on the wheel shaft Repeat with the other wheel 4 Use the handlebar to roll the tiller to a flat area IMPORTANT Before starting the engine the wheels must be placed in the WHEEL DRIVE position pins through wheel hubs and wheel shaft This procedure is described in Wheel Drive Pins on page 10 Fig
4. 2 4 Installing forward clutch cable bracket and cable 4 Check for correct tension on the forward drive belt by taking two measurements of the cable spring as follows a With the Forward Clutch Bail Y Fig 2 6 in an open released position measure the length of the cable spring W from the outermost coil to the outermost coil b Squeeze the Forward Clutch Bail against the handlebar see Fig 2 7 and re mea sure the spring length The belt tension is correct if this second measurement is be tween 1 16 to 3 16 longer than the first measurement If so turn the hex nut Z Fig 2 7 tightly against the cable adjuster X while preventing the cable adjuster from turning c If the spring length is incorrect you must adjust the cable tension as described in Checking and Adjusting Forward Drive Belt Tension in Section 5 Incorrect cable tension can result in belt slippage cable tension too loose or unintentional tine movement when the clutch bail is in Neu tral cable tension too tight d Fig 2 6 Attach forward clutch cable spring to forward clutch bail Fig 2 5 Cable spring and adjuster Hold bail against handlebar while taking second measurement of spring Fig 2 7 To check forward belt tension take two measurements of the length of the coils in the Spring first with the bail open then with the bail held against the handlebar STEP 5 INSTALL
5. Sometimes slight downward pressure on the handlebars will help get through a particularly tough section of sod or unbroken ground but in most cases this won t be necessary When cultivating breaking up surface soil around plants to destroy weeds see Fig 4 9 a just the tines to dig only 1 to 2 deep Using shallow tilling depths helps prevent injury to plants whose roots often grow close to the surface If 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 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 Choosing Correct Wheel amp 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 speed to give the engine adequate power and yet allow it to operate at the slowest possible speed at least until you have achieved the maximum tilling depth you desire Faster 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 sufficient power level to do the job without causing the engine to labo
6. Test soil by squeezing it into a ball If it compresses too easily it is too wet to till Cultivating With planning you can AMV allow enough room between rows to cultivate see Fig 4 9 Leave room for the hood width plus enough extra room for future plant growth TILLING TIPS amp TECHNIQUES CON T A Tilling On Slopes Read the following recommendations before tilling on slopes WARNING Do not operate tiller on a slope too steep for safe operation Till slowly and be sure you have good footing Never permit tiller to freewheel down slopes Failure to follow this warning could result in personal injury If you must garden on a moderate slope please follow two very important guidelines 1 Till only on moderate slopes never on steep ground where footing is difficult review safe ty rules in Section 1 Safety of this manual 2 We recommend tilling up and down slopes rather than terracing Tilling vertically on a slope 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 motor oil level at the full point at all times Tilling Up and Down Slopes Vertical Tilling e To keep soil erosion to a minimum be sure to
7. 3 8 16 x 3 4 Screw Hex 5 16 18 x 1 1 2 Hex Lock Nut 3 8 16 Lock Washer 5 16 Cable Tie Flat Washer 3 8 Flange Lock Nut 3 8 16 Hex Hd Screw 3 8 16 x 1 3 4 Hex Hd Screw 3 8 16 x 1 Grade 5 Flange Screw 312 18 x 1 00 Single Bolo Tine Left Hand Single Bolo Tine Right Hand Tine Holder A Tine Holder B C Bolo Tine Replacement Set Incl eight right hand tines eight left hand tines and required hardware A B C A For Model 643C B For Model 643B C For Model 645A 25 MODELS 643C 643B amp 645A de PART NO DESCRIPTION 1 GW 9517 Snap Ring 2 GW 1714 Bearing Tapered Roller with race 3 GW 50043 Support Washer Rear 4 711 04110 Drive Shaft 5 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 Be PART NO DESCRIPTION 1 GW 9727 Plug Transmission Oil Fill 2 710 04049 Hex Hd Flange Screw 5 16 18 x 5 8 Gr 5 3 736 0119 Lock Washer 5 16 4 1918377 Rear Cover Transmission 5 1916641 Front Cover Transmission 6 GW 50032 Gasket Housing Cover 7 721 04030 Oil Seal Drive Shaft 8 721 04031 Oil Seal Wheel Shaft 9 619 04013
8. Transmission Housing Assembly 10 721 04036 Oil Seal Tine Shaft 11 736 3008 Washer Flat 344 x 750 x 120 12 718 04008 Rear Bearing Cap 13 710 04048 Hex Hd Flange Screw 5 16 18 x 1 14 710 3008 Hex Hd Flange Screw 5 16 18 x 3 4 Included with transmission when purchased as an assembly only Remove and discard when installing the transmission on tiller MODELS 643C 643B amp 645A FRONT 4 3 2 ic PART NO DESCRIPTION 2 1909950 Retainer Snap Ring 3 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 Shim 0 005 thick 4 GW 1086 Bronze Bushing 5 711 04512 Wheel Shaft A 711 04486 Wheel Shaft B C 6 GW 9305 Key Hi Pro 1 4 x 1 7 GW 1132 2 Spacer 8 1904278 Worm Gear Wheel Shaft 9 711 04078 Tiller Shaft 10 GW 1104 Woodruff Key 11 1916542 Worm Gear Tiller Shaft A For Model 643C B For Model 643B Use as required to obtain between 005 and 030 allowable end play C For Model 645A 27 MODELS 643C 643B amp 645A Model 643C Ch ch MODELS 643C 643B amp 645A Ae PART NO DESCRIPTION in PART NO DESCRIPTION 1 736 0159 Flat Washer 5 16 27 736 0119 Lock Washer 5 16 A 2 756 04198 Pulley Engine Drive 28 750 0535 Spacer 380 ID x 625 OD x 21 A 3 656 04023 Transmission Pulley A 736 3050 Flat Washer 406 x 812
9. add enough organic matter to the soil so that it has good moisture holding texture and try to avoid leaving footprints or wheel marks e 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 the handlebars slightly while going uphill When going downhill overlap the first pass by about one half the width of the tiller Clearing the Tines The tines have a self clearing action which eliminates most tangling of debris in the tines However occasionally dry grass stringy stalks or tough vines may become tan gled Follow these procedures to help avoid tangling and to clean the tines if neces sary e To reduce tangling set the depth regulator deep enough to get maximum chopping action as the tines chop the material against the ground Also try to till under crop residues or cover crops while they are green moist and tender e It may be necessary to remove the debris by hand a pocket knife will help you to cut away the material Be sure to stop the engine and disconnect the spark plug wire before clearing the tines by hand e While tilling try swaying the handlebars from side to side about 6 to 12 This fishtailing action often clears the tines of debris e If tangling occurs lift the tines out of the soil and run the tiller in reverse if unit is equipped with powered reverse for a few feet Thi
10. are out of ground and unit is balanced Fig 4 5 With tines out of ground push han dlebars sideways to turn tiller Stopping the Tiller and Engine 1 To stop the wheels and tines release the Forward Clutch Bail all models or the Re verse Clutch Control Models 643B amp 645A whichever control is in use 2 To stop the engine put the ignition switch andor the throttle control lever in the OFF or STOP position Tilling Depths VVARNING Before A tilling contact your telephone or utilities company and inquire if underground equipment or lines are used on your property Do not till near buried electric cables telephone lines pipes or hoses TILLING TIPS amp TECHNIQUES e This is a CRT counter rotating tine tiller As the wheels pull forward the tines rotate back ward This creates an uppercut tine action which digs deeply uprooting soil and weeds Don t overload the engine but dig as deeply 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 one hand palm up works most easily 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 Without the wheels to hold the tiller back the tines will attempt to propel the tiller backward towards the operator
11. 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 LIMITED COMMERCIAL USE WARRANTY If used for commercial institutional industrial rental or demonstrator purposes the warranty on the tiller is limited in duration to 90 days from the date of purchase This warranty does not apply to parts that have been damaged by accident alteration misuse abuse neglect improper maintenance vandalism theft fire water or damage because of peril or other natural disaster HOW TO OBTAIN SERVICE 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 troyb
12. engine is running or the spark plug wire is connected except when specifically in structed to do so 8 If the fuel tank has to be drained do this outdoors Decals For your safety and the safety of others vari ous safety and operational decals are located on your unit see Figure 1 2 Keep the decals clean and legible at all times Contact your local service dealer or the factory for replacements if any decals are damaged or missing Refer to the Parts List pages in this Manual for decal locations descriptions and part num bers Starting Stabilization Message on engine Forward Clutch Bail Reverse Clutch Control Operating Instruction Models 643B amp 645A Warning Messages Hot Surfaces Warning Figure 1 2 Location of safety and operating decals Operating Symbols is Various symbols shown here with word descriptions gt t R gt 9 NOTE Yourunit may not haveal of the symbos ON OFF ROTATING TINES BAIL BAIL deg MM SE er o ENGAGED DISENGAGED FAST SLOW STOP TILLER DIRECTION LEVER DIRECTION 4h WARNING TO AVOID SERIOUS INJURY READ THE OWNER S MANUAL KNOW LOCATIONS AND FUNCTIONS OF ALL CONTROLS e KEEP ALL SAFETY DEVICES AND SHIELDS IN PLACE AND WORKING e NEVER ALLOW CHILDREN OR UNINSTRUCTED ADULTS TO OPERATE TILLER e SHUT OFF ENGINE AND DISCONNECT SPARK PLUG WIRE BEFORE MANUALLY UN CLOGGING TINES OR MAKING REPAIRS e KEEP BYSTANDERS AWAY FROM M
13. ever control is engaged or by moving the ignition switch and or throttle control lever on the engine to OFF or STOP 26 To load or unload the tiller see the in structions in Section 4 of this Manual 27 Use extreme caution when reversing or pulling the machine towards you 28 Start the engine carefully according to instructions and with feet well away from the tines 29 Never pick up or carry a machine while the engine is running Maintenance and Storage 1 Keep the tiller attachments and acces sories in safe working condition 2 Check all nuts bolts and screws 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 sourc es are present such as hot water and space heaters furnaces clothes dryers stoves electric motors etc Allow the engine to cool before storing the unit in any enclo sure 4 To reduce the chances of a fire hazard keep the engine free of grass leaves or ex cessive grease 5 Store gasoline in a cool well ventilated area safely away from any spark or flame producing equipment Store gaso line in an approved container safely away from the reach of children 6 Refer to the Maintenance sections of this Manual and the separate Engine Own er s Manual for instructions if the unit is to be stored for an extended period 7 Never perform maintenance while the
14. oil leak usually a dirty oily accumu lation either on the unit or on the floor A little seepage around a cover or an oil seal is usually not a cause for alarm How ever if the oil drips overnight then imme diate attention is needed gnoring an oil leak can result in severe transmission damage 17 If a cover is leaking check for 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 af ter every 10 operating hours and tighten or replace as needed before reusing tiller Be sure to check the screws underneath the tiller hood that secure the transmis sion cover and the Depth Regulator Lever to the transmission CHECK TIRE PRESSURE Models with pneumatic tires Check the air pressure in both tires The air pressure should be between 15 PSI and 20 PSI pounds per square inch Keep both tires equally inflated to help prevent machine from pulling to one side TRANSMISSION GEAR OIL SERVICE Check the transmission gear oil level after every 30 hours of operation or whenever you notice any oil leak Op
15. the wheels and tines To operate the Forward Clutch Bail 1 Put wheels in WHEEL DRIVE position see WARNING statement above 2 Lift and hold the clutch bail D Figure 3 4 against the handlebar to start the wheels and tines rotating in a forward direction 3 Release the clutch bail to disengage stop the wheels and tines the engine will continue to run REVERSE CLUTCH CONTROL Models 643B amp 645A only The Reverse Clutch Control E Figure 3 4 controls the engagement of reverse drive to the wheels and tines The reversing fea ture is used for maneuvering the tiller only never engage the tines in the ground while operating in reverse WARNING Use extreme caution when reversing or pulling the machine towards you Look behind to avoid obstacles Never attempt to till in reverse Failure to follow this warning could result in personal injury or property damage A To operate the Reverse Clutch Control 1 Put wheels in WHEEL DRIVE position see WARNING statement at the left 2 Stop all tiller motion by releasing the Forward Clutch Bail 3 Lift the handlebar until the tines clear the ground look behind you to avoid any obstacles and then pull the control knob E Figure 3 4 out The wheels and tines will rotate in a reverse direction 4 Release the control knob to disengage stop the wheels and tines the engine will continue to run i Figure 3 4 All mod
16. to the For ward Clutch Bail e Repeat Steps 2 and 3 to re measure the length of the spring When the second mea surement is between 1 16 to 3 16 longer than the first measurement retighten the hex nut C against the top of the adjuster B Replacement Belt Information If the drive belt needs to be replaced see your local authorized dealer or refer to the FORWARD Figure 5 3 Install tines so that cutting edge of tines enter soil first when tiller moves forward CHECKING AND ADJUSTING tension is correct if this second measure daa eii eis dE Use ment is between 1 6 to 3 16 longerthan OMY a factory authorized belt as an over FORWARD DRIVE BELT TENSION the first measurement the counter belt may not perform satis It is important to maintain correct tension on the forward drive belt A loose belt will cause the tines and wheels to slow down WE i or stop completely even though the en e IS gt SETE than 3 16 the gine is running at full speed A too tight ension B ORUM belt can result in unintentional tine move 5 To adjust the length of the spring ment when the clutch bail is in the Neutral a Release the Forward Clutch Bail released position Check belt tension after the first two hours of break in operation and after every 10 operating hours e At the end of each tilling season check the belt for cracks cuts or frayed edges and replace it as soon as possible factorily The p
17. 0395 Hex Screw 5 16 18 x 2 25 29 3 710 0597 Hex Hd Screw 1 4 20 x 1 30 4 710 0599 Screw Self Tapping 1 4 20 x 1 2 31 5 710 0874 Hex Hd Screw 5 16 18 x 1 1 4 32 6 710 3008 Hex Hd Screw 5 16 18 x 75 33 7 712 04063 Hex Lock Nut Nylon 5 16 18 34 8 712 04064 Hex Lock Nut Nylon 1 4 20 35 9 715 0108 Spirol Pin 36 10 7382 04320 Spring Depth Regulator 37 11 736 0275 Flat Washer 5 16 38 12 750 04149 Spacer 462 x 328 x 1 63 39 13 750 04160 Bushing 40 14 750 04556 Spacer 41 15 786 04092 Reverse Stop Arm 42 16 786 04098 Channel Support Bracket 43 17 786 04104 Drag Bar 44 18 786 04191 Flap Stop Bracket 45 19 786 04290 Hood Bracket Left Hand 46 20 786 04291 Hood Bracket Right Hand 47 21 786 04292 Adjustable Depth Bar 48 22 710 0106 Hex Hd Screw 1 4 20 x 1 1 4 49 23 710 04163 Screw 10 24 x 2 24 712 3009 Hex Lock Nut 5 16 18 25 712 0121 Hex Nut 10 24 26 712 0291 Hex Lock Nut 1 4 20 PART NO 732 04185 746 04208 746 04058 747 04210 749 04084 749 04208 749 04106 732 04040 786 04188 786 04200 710 0216 710 0805 712 3000 736 0119 725 0157 736 3050 712 04065 710 0347 710 0514 710 04048 742 04117 742 04116 686 04066 686 04065 GW 1901 DESCRIPTION Spring Forward Clutch Cable Assembly Forward Clutch Cable Assembly Reverse Clutch B C Bail Forward Clutch Upper Handlebar Lower Handlebar Tab Conduit Mount Bracket Reverse Clutch Cable B C Handlebar Support Panel Screw Hex
18. 7 734 04188 Complete Wheel Assembly 10 x 2 75 A 710 0520 Hex Hd Screw 3 8 16 x 1 50 B C 48 634 04232 Complete Wheel Assembly 13 x 5 x 6 B C 23 710 0599 Screw Self Tapping 1 4 20 x 1 2 634 04218 Rim Assembly B C 24 710 3103 Hex Hd Screw 5 16 18 x 2 B C 734 0255 Air Valve B C 25 712 3000 Lock Nut 3 8 16 734 04163 Tire B C 26 712 3009 Lock Nut 5 16 18 B C A For Model 643C B For Model 643B C For Model 645A 29 NOTES 30 NOTES 31 TROY BILT TILLER LIFETIME LIMITED VARRANTY VVHAT PRODUCT IS COVERED VVHAT IS COVERED BY THIS WARRANTY 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 WHAT IS NOT COVERED BY THIS WARRANTY This warranty does not apply to parts that have been damaged by accident alteration misuse abuse neglect improper maintenance vandalism theft fire water or
19. ACHINE e KEEP AWAY FROM ROTATING PARTS e USE EXTREME CAUTION WHEN REVERSING OR PULLING THE MACHINE TOWARDS YOU SECTION 2 ASSEMBLY 1 VVARNING To prevent personal injury or property damage do not start the engine until all assembly steps are complete and you have read and understand the safety and operating instructions in this manual INTRODUCTION Carefully follow these assembly steps to correctly prepare your tiller for use It is recommended that you read this Section in its entirety before beginning assembly NOTE 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 INSPECT UNIT Inspect the unit and carton for damage im mediately 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 writ ing and mail a copy to the carrier within 15 days after the unit has been delivered Contact Troy Bilt LLC if you need assis tance in this matter TOOLS MATERIALS NEEDED 2 1 2 open end wrench 2 9 16 open end wrench 1 3 8 open end wrench 1 Large adjustable wrench Models 643B amp 645A only 1 Scissors to trim plastic ties 1 Ruler for belt tension check 1 Block of wood to su
20. D ob D REPEAT DOWNHILL a e 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 e When going down ramps walk backward with the tiller following you Keep alert for any obstacles behind you Position a per son at each wheel to control the speed of the tiller Never go down ramps tiller first as the tiller could tip forward e Place wooden blocks on the downhill side of the wheels if you need to stop the tiller from rolling down the ramp Also use the blocks to temporarily keep the tiller in place on the ramps if necessary and to chock the wheels in place after the tiller is in the vehicle e After loading the tiller prevent it from rolling by engaging the wheels in the WHEEL DRIVE position Chock the wheels with blocks and securely tie the tiller down SECTION 5 MAINTENANCE VVARNING Before inspecting cleaning or servicing the machine shut off engine vvait for all moving parts to come to a complete stop disconnect spark plug wire and move wire away from spark plug Remove ignition key on electric start models Failure to follow these instructions can result in serious personal injury or property A damage MAINTENANCE SCHEDULE PROCEDURE NOTES Check motor oil level 2 3 Clean engine 2 7 Check drive belt tension 1 4 Check nuts and bolts 1 4 Change motor oil 4 6 9 Lubricate tiller 4 Service engine air cleaner s
21. OTROY BILT Operator s Manual Rear tine Tiller Models 643C Tuffy Bronco CRT 643B 645A Super Bronco Model 645A Shown IMPORTANT READ SAFETY RULES AND INSTRUCTIONS CAREFULLY PRINTED IN U S A P O Box 1386 97 Kent Avenue Kitchener Ontario N2G 4J1 772C0845 12 05 TABLE OF CONTENTS 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 FINDING MODEL NUMBER This Operator s Manual is an important part of your new tiller It will help you assemble prepare and maintain the unit for best performance Please read and understand what it says Before you start assembling your new equipment please locate the model plate on the equipment and copy the information from it in the space provided below A sample model plate is also given below You can locate the model plate by looking at the rear of the tine shield This information will be necessary to use the manufacturer s web site and or help from the Customer Support Department or an authorized service dealer Model Number Serial Number Num ro de mod le Num ro de s rie Copy the model number here XXX XXXXXX XXXXXXXXXXX Copy the serial number here e TROYBILT CANADA OTROY BILT KITCHENER ON N2G 4J1 CUSTOMER SUPPORT Please do NOT return the unit to the retailer without first contacting Customer S
22. REVERSE CLUTCH CABLE MODELS 643B AND 645A ONLY 1 Unwrap the reverse clutch cable CC Fig 2 8 and Fig 2 9 from its shipping po sition and route it up to the handlebar Be sure that the cable is routed beneath the Forward Clutch Bail 2 Insertthe cable CC Fig 2 8 through the slot in the cable bracket and position the flat side of the threaded assembly next to the flat side of the hole Slide the hex nut DD up the cable and tighten it securely 3 Fasten the reverse clutch cable to the left side handlebar with a cable tie EE Fig 2 9 4 Test the function of the reverse clutch by pulling out and releasing the cable knob The knob should return to its neutral posi tion resting against bracket If it doesn t contact your local dealer or Troy Bilt LLC for technical assistance DD Flat Side Fig 2 8 Install reverse cable bracket and reverse clutch cable Fig 2 9 Route reverse clutch cable CC as shown Attach with cable tie EE STEP 6 CHECK TRANSMISSION OIL LEVEL The transmission was filled with gear oil at the factory However you should check the gear oil level at this time 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 transmission com ponents 1 With the tiller on level ground pull the Depth Regulator Lever FF Fig 2 10 back and then all the way up until the l
23. bey safety messages could result in Forward Clutch Bail Reverse Clutch Control Models 643B amp 645A Depth Regulator Tine Hood Flap Counter Rotating Tines CRT Wheel Drive Pin Figure 1 1 Tiller features and controls See separate Engine Owner s Manual to personal injury or property damage identify engine controls Training 1 Carefully read this Own ers Manual the separate Engine Owner s Manual and any other literature you may receive Be thoroughly familiar with the controls and the proper use of the tiller and its en gine Know how to stop the unit and disen gage 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 oc curring 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 po sition before starting the engine 3 Do not operate the tiller without wearing adequate outer garments Avoid loose gar ments or jewelry that could get caught in moving parts 4 Do not operate the tiller when barefoot or wearing sandals sneakers or li
24. e Start Checklist at the be ginning of this Section Be sure that the wheels are in the WHEEL DRIVE position 2 Move the Depth Regulator Lever all the way down so that the tines clear the ground Use this position when practicing with the tiller and when traveling between tilling sites Before actually tilling move the lever to the desired depth setting see Tilling Tips amp Techniques eg Moshe Fig 4 2 Use one hand to guide tiller when moving forward 3 Start engine and allow it to warm up Then put throttle in FAST setting 4 For forward motion of the wheels and power to the tines a Pull Forward Clutch Bail Fig 4 1 up against handlebar Release bail to stop for ward motion of wheels and tines b When tilling relax and let the wheels pull the unit while the tines dig Walk be hind and a little to one side of the unit Use one hand yet keep a light but secure grip on the handlebar while keeping your arm loose See Fig 4 2 Let the unit move at its own pace and do not push down on the handlebars to try and force the tines to dig deeper this takes weight off the wheels and reduces traction 1 VVARNING Do not push down on the handlebars to try to make the tiller till more deeply This prevents the wheels from holding the tiller back and can allow the tines to rapidly propel the tiller forward which could result in loss of control property damage or personal injury 5 For re
25. e oil from the engine 3 Remove four screws B Figure 5 2 and remove transmission cover and gasket 4 Remove the left side wheel 5 Tilt the left side wheel shaft into a drain pan and allow the gear oil to drain through the top of the transmission 6 Reinstall the wheel 7 Install a new gasket do not reuse old gasket and reinstall the transmission cov er 8 Refill the transmission using GL 4 gear oil SAE 85W 140 or SAE 140 9 Refill the engine with motor oil and re plenish the fuel tank with gasoline 18 BOLO TINES The bolo tines will wear with use and should be inspected at the beginning of each tilling season and after every 30 oper ating hours The tines can be replaced ei ther individually or as a complete set See the Parts List pages for tine identification and part numbers A Tine Inspection With use the tines will become shorter narrower and pointed Badly worn tines will result in a loss of tilling depth and re duced effectiveness when chopping up and turning under organic matter B Removing nstalling a Single Tine 1 With the engine shut off and the spark plug wire disconnected remove the two screws A Figure 5 3 and nuts B that at tach a single tine to a tine holder If needed use penetrating oil on the nuts 2 When installing a single tine be sure to position it so that its cutting edge sharp will enter the soil first as the tiller moves forward C RemovingAnstallin
26. een 15 PSI and 20 PSI pounds per square inch Be sure that both tires are in flated equally or the unit will pull to one side e Section 1 Safety IMPORTANT This completes the assembly steps Be fore operating your tiller make sure you read the follow ing sections in this Manual as well as the separate Engine Owner s Manual e Section 3 Features and Controls e Section 4 Operation SECTION 3 FEATURES AND CONTROLS VVARNING Before operating your machine carefully read and understand all safety controls and operating instructions in this Manual the separate Engine Owner s Manual and on the decals on the machine Failure to follow these instructions can result in serious personal injury INTRODUCTION This Section describes the location and function of the controls on your tiller Refer to the following Section Operation for de tailed operating instructions Practice using these controls with the en gine shut off until you understand the op eration of the controls and feel confident with each of them ENGINE CONTROLS Refer to the engine manufacturer s Engine Owner s Manual included in the tiller liter ature package to identify the controls on your engine IMPORTANT The control for stopping the engine is located on the engine WHEEL DRIVE PINS Each wheel is equipped with a wheel drive Klik pin A Figures 3 2 and 3 3 that se cures the wheel to the wheel shaft B The whe
27. els can be positioned in either a WHEEL DRIVE or a FREEWHEEL mode 1 WARNING Never allow A either of the wheels to be in the FREEWHEEL position when the engine is running Always put both wheels in the WHEEL DRIVE position before starting the engine Failure to comply could cause loss of tiller control property damage or personal injury Before starting the engine put both wheels in the WHEEL DRIVE position by inserting the wheel drive Klik pins through the wheel hubs and the wheel shaft Doing so locks the wheels to the wheel shaft causing the wheels to turn when either the Forward Clutch Bail Reverse Clutch Control Models 643B amp 645A Depth Regulator Handlebar Height Adjustment Wheel Drive Pin on each wheel Figure 3 1 Tiller features and controls See separate Engine Owner s Manual to identify engine controls Forward Clutch Bail all models or the Re verse Clutch Control Models 643B amp 645A is engaged Use the FREEWHEEL mode only when the engine is not running In FREEWHEEL the wheel drive pins are placed only through the holes in the wheel shaft not the wheel hubs thus allowing the wheels to turn freely when you manually move the tiller To place the wheels in WHEEL DRIVE or FREEWHEEL 1 Stop engine disconnect spark plug wire from spark plug and allow engine to cool 1 VVARNING Do not place tiller on its side when changing wheel drive positions Doi
28. els have a Forward Clutch Bail E Only Model 634A have a Reverse Clutch Control F DEPTH REGULATOR LEVER This lever F Figure 3 5 controls the tilling depth of the tines Pull the lever back and slide it up or down to engage the notched height settings The travel position highest notch raises the tines approximately 1 1 2 off the ground allowing the tiller to be moved without the tines contacting the ground This setting should also be used when starting the engine Moving the lever upward will increase the tilling depth The lowest notch allows a till ing depth of approximately 6 depending on soil conditions For best results always 11 begin tilling at a very shallow depth setting and gradually increase the tilling depth WARNING Do not attempt to till too deeply too quickly Gradually work down to deeper tilling depths Place the Depth Regulator Lever in the travel position before starting the engine This position prevents the tines from touching the ground until you are ready to begin tilling Failure to follow this warning could result in personal injury or property damage A Travel Position F Ca Shallow Settings Dee p gt a Settings Figure 3 5 Depth Regulator Lever G HANDLEBAR HEIGHT ADJUSTMENT The handlebar height is adjustable to three different settings Figure 3 6 In general adjust the handlebars so they are at waist level when the ti
29. en and pets away 13 Never operate the tiller under engine power if the wheels are in the Freewheel position In the Freewheel position the wheels will not hold the tiller back and the revolving tines could propel the tiller rapid ly 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 tines4wheels with the Forward Clutch Bail all models or the Reverse Clutch control Models 643B amp 645A only 14 Be aware that the tiller may unex pectedly bounce upward or jump forward if the tines should strike extremely hard packed soil frozen ground or buried ob stacles like large stones roots or stumps If in doubt about the tilling conditions al ways use the following operating precau tions to assist you in maintaining control of the tiller a Walk behind and to one side of the tiller using one hand on the handle bars Relax your arm but use a secure hand grip b Use shallower depth regulator settings working gradually deeper with each pass c Use slower engine speeds d Clear the tilling area of all large stones roots or other debris e Avoid using downward pressure on the 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 the handlebars to raise the tines out of the soil g I
30. ent it from touching the spark plug Thoroughly inspect the ma chine for any damage and repair the dam age before restarting and operating the machine 4 Exercise caution to avoid slipping or fall ing 5 If the unit should start to vibrate abnor mally stop the engine disconnect the spark plug wire and prevent it from touch ing 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 operat ing position before unclogging the tines or when making any repairs adjustments or inspections 7 Take all possible precautions when leav ing the machine unattended Stop the en gine Disconnect the spark plug wire and move it away from the spark plug Be sure that both wheels are in the Wheel Drive po sition 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 the engine in an enclosed area Engine exhaust contains carbon monoxide gas a deadly poison that is odorless colorless and tasteless 12 Keep childr
31. er ating the tiller when the transmission is low on oil can result in severe damage A To Check the Transmission Gear Oil Level 1 Check the gear oil level when the transmission is cool Gear oil will expand in warm operating temperatures and this expansion will provide an incor rect oil level reading 2 With the tiller on level ground pull the Depth Regulator Lever all the way up 3 Remove the oil fill plug A Fig 5 2 from the transmission housing and look inside the oil fill hole to locate the main drive shaft situated below the hole WARNING Before inspecting cleaning or servicing the machine 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 serious personal injury or property damage 4 The gear oil level is correct if the gear oil is approximately halfway up the side of the main 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 transmission com ponents Figure 5 2 Remove oil fill plug A to check gear oil level and to add gear oil Remove four cover screws B to drain gear oil 6 If adding only a few ounces of gear oil use API rated GL 4 or GL 5 gear oil havi
32. fill tube Reinstall the fill cap 5 On engines with a dipstick remove it and wipe it clean Reinsert the dipstick tighten it securely and remove it Add oil as needed to bring the level up to the FULL mark Wipe dipstick clean each time oil level is checked Do not overfill Tighten dipstick securely B To Change the Engine Oil Change the engine oil as instructed in the Engine Owner s Manual SPARK PLUG SERVICE Inspect and clean or replace the spark plug after every 100 operating hours or annual ly Refer to the Engine Owner s Manual for spark plug service instructions In some areas local law requires using re sistor spark plugs to suppress ignition sig nals 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 service intervals and in structions in the Engine Owner s Manual THROTTLE LEVER ADJUSTMENT If the engine does not respond to various throttle lever settings refer to the Engine Owner s Manual for service information or contact your local authorized engine dealer A WARNING 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 sou
33. g a Tine Assembly 1 A tine assembly consists of eight tines mounted on a tine holder 2 If removing both tine assemblies mark them left and right before removal Re move the screw C Figure 5 3 and lock nut D that secure the tine assembly to the tine shaft If necessary use a rubber mallet to tap the tine assembly outward off the shaft 3 Before reinstalling the tine assembly in spect the tine shaft for rust rough spots or burrs Lightly file or sand as needed Ap ply a thin coat of grease to the shaft 4 Install each tine assembly so that the cutting sharp edge of the tines will enter the soil first when the tiller moves forward Secure the tine assembly to the tine shaft using the screw and locknut WARNING Before inspecting cleaning or servicing the machine 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 serious personal injury or property damage b Unthread the hex nut C Figure 5 4 halfway up the adjustment screw D c Unhook the top of the spring from the Forward Clutch Bail d Use pliers to prevent the adjuster B from turning and turn the slotted screw lo cated inside the spring clockwise viewed from operator s position to increase ten sion on the spring Turn the screw counter clockwise to decrease tension Once adjusted reattach the spring
34. ght foot wear Wear protective footwear that will improve footing on slippery surfaces 5 Do not till near underground electric ca bles telephone lines pipes or hoses If in doubt contact your telephone or utility company 6 Warning Handle fuel with care it is highly flammable and its vapors are explo sive 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 Fill fuel tank outdoors with extreme care Never fill fuel tank indoors Use a funnel or spout to prevent spillage e e 3 e Replace all fuel tank and container caps securely f If fuel is spilled do not attempt to start the engine but move the ma chine away from the area of spillage and avoid creating any source of ig nition until fuel vapors have dissi pated 7 Never make adjustments when engine is running unless recommended by manu facturer Operation 1 Do not put hands or feet near or under rotating parts 2 Exercise extreme caution when on or crossing gravel drives walks or roads Stay alert for hidden hazards or traffic 3 After striking a foreign object stop the engine remove the wire from the spark plug wire and prev
35. ght if a problem exists CARBURETOR GOVERNOR CONTROL ADJUSTMENTS The carburetor was adjusted at the factory for best operating speed Refer to the En gine Owner s Manual for any adjustment information or see your authorized engine 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 21 OFF SEASON STORAGE When the tiller won t be used for an extended period 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 recom mended engine maintenance by following the storage instructions found in the Engine Owner s Manual 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 manufacturer 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 present Space heaters hot water heaters furnaces etc WARNING Before inspecting cleaning or servicing the machine 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 fol
36. h a dirty clogged air filter can cause poor performance and damage to the engine Never operate the engine without the air cleaner installed In spect and service the air cleaner more of ten if operating in very dusty or dirty conditions Refer to the engine Owner s Manual for air cleaner service intervals and instructions ENGINE OIL SERVICE Check the engine oil level before each use and after every five 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 ex tremely dirty or dusty conditions Refer to the Engine Owner s Manual for detailed service instructions A To Check the Engine Oil Level 1 Park the tiller on a level area and shut off the engine 2 Level the engine use the Depth Regula tor Lever to adjust the engine angle A WARNING Before inspecting cleaning or servicing the machine 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 serious personal injury or property damage 3 Clean around the oil dipstick or oil fill tube whichever applies to prevent dirt from falling into the crankcase 4 On engines with an oil fill tube remove the fill cap and add oil if required until it reaches the top of the
37. ilt com The provisions set forth in this warranty provide the sole and exclusive remedy arising from the sale Troy Bilt LLC shall not be liable for any incidental or consequential damage or expense of any kind including but not limited to cost of equipment rental loss of profits or costs of hiring services to perform tasks normally performed by the equipment Any implied warranties including any implied warranty of merchantability or fitness for a particular purpose shall be limited in duration to the period of ownership by the original purchaser and a maximum of 90 days from the date of sale if the tiller is 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
38. low these instructions can result in serious personal injury or property damage TROUBLESHOOTING PROBLEM POSSIBLE CAUSE CORRECTION Engine does not start 1 Spark plug wire disconnected 1 Reconnect wire 2 Engine Throttle Control Lever incorrectly set 2 Put lever in START position 3 Fuel tank empty 3 Add fuel 4 Choke control if so equipped in incorrect position 4 SeeEngine Owner s Manual 5 Stale gasoline 5 Drain fuel and add fresh fuel 6 Dirty air filter 6 Clean or replace filter 7 Defective or incorrectly gapped spark plug 7 Inspect spark plug 8 Carburetor out of adjustment 8 SeeEngine Service Dealer 9 Misadjusted throttle control 9 See Engine Service Dealer 10 Dirt or water in fuel tank 10 See Engine Service Dealer Engine runs poorly 1 Defective or incorrectly gapped spark plug 1 Inspect spark plug see Engine Owner s Manual 2 Dirty air filter s 2 Clean or replace see Engine Owner s Manual 3 Carburetor out of adjustment 3 See Engine Service Dealer 4 Stale gasoline 4 Replace with fresh gasoline 5 Dirt or water in fuel tank 5 See Engine Service Dealer 6 Engine cooling system clogged 6 Clean air cooling system see Engine Owner s Manual Engine overheats 1 Engine cooling system clogged 1 Clean air cooling area see Engine Owner s Manual 2 Carburetor out of adjustment 2 SeeEngine Service Dealer 3 Oil level is low 3 Check oil level see Engine Ow
39. lt LLC or your authorized dealer for service advice CHECKING AND ADJUSTING RE VERSE DRIVE BELT TENSION Models 643B amp 645A only It is important to maintain correct tension on the reverse drive belt A loose belt will cause the tines and wheels to slow down or stop completely even though the en gine is running at full speed When checking belt tension also check the belt for cracks cuts or frayed edges and replace it as soon as possible e Check belt tension after the first two hours of break in operation and after every 10 operating hours To Check Reverse Belt Tension 1 Stop engine wait for all parts to stop moving and disconnect spark plug wire 2 Remove screw in plastic belt cover and slide belt cover which is attached to for ward 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 ca ble wire is attached 4 The belt tension is ideal if the cable wire length measures between 1 8 to 1 4 If itis less than 1 8 and if there is no reverse ac tion when the tiller is running then make the following adjustments NOTE If the length is more than 1 4 no ad justment is needed as long as the reverse action functions properly 5 Release the Reverse Clutch Control k
40. nan emergency stop the tines and wheels by releasing whichever clutch control is engaged Do not attempt to restrain the tiller 15 Do not overload the tiller s capacity by attempting to till too deeply at too fast a rate 16 Never operate the tiller at high trans port speeds on hard or slippery surfaces Look behind and use 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 accessories that are approved by the manufacturer of the tiller 20 Use tiller attachments and accessories when recommended 21 Never operate the tiller without good visibility or light 22 Never operate the tiller if you are tired or under the influence of alcohol drugs or medication 23 Operators shall not tamper with the en gine 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 4 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 For ward Clutch Bail or on Models 643B amp 645A the Reverse Clutch control which
41. ner s Manual Engine does not shut off 1 Misadjusted throttle control or ignition switch 1 See Engine Owner s Manual or Engine Service Dealer Wheels and Tines will not turn 1 Improper use of controls 1 Review Sections 3 and 4 2 Worn broken or misadjusted drive belt s 2 See Checking Drive Belt Tension Section 5 3 Internal transmission wear or damage 3 Contact local dealer or the factory 4 Boltloose in transmission pulley 4 Tighten bolt Tines turn but wheels don t 1 Wheel Drive Pins not in WHEEL DRIVE 1 See Wheel Drive Pins in Section 3 2 Boltloose in transmission pulley 2 Tighten bolt 3 Internal transmission wear or damage 3 Contact local Dealer or the Factory Wheels Turn but Tines Don t 1 Tine holder mounting hardware missing 1 Replace hardware 2 Boltloose in transmission pulley 2 Tighten bolt 3 Internal transmission wear or damage 3 Contact local Dealer or the Factory Poor tilling performance 1 Worn tines 1 See Bolo Tines Section 5 2 Improper Depth Regulator setting 2 See Tilling Tips amp Techniques Section 4 3 Incorrect throttle setting 3 SeeSection 4 4 Forward Drive Belt slipping 4 See Checking Forward Drive Belt Tension Section 5 22 NOTES Models 643C 643B amp 645A MODELS 643C 643B amp 645A REF REF NO PART NO DESCRIPTION NO 1 686 04043 Tine Hood Assembly A 27 686 04041 Tine Hood Assembly B C 28 2 710
42. nes are 3 4 in the soil To adjust the handlebars 1 Stop engine disconnect spark plug wire from spark plug and allow engine to cool 2 Remove hardware reposition handle bars and reinstall hardware securely High Q Medium Low Figure 3 6 Handlebar height adjustment SECTION 4 OPERATION 1 WARNING Before Operating your machine carefully read and understand all safety Section 1 controls Section 3 and operating instructions Section 4 in this Manual the separate Engine Owner s Manual and on the decals on the machine Failure to follow these instructions can result in serious personal injury INTRODUCTION Read this Operation Section and the sepa rate Engine Owner s Manual before you start the engine Then take the time to fa miliarize 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 engag ing the soil put tines in travel setting Only after you ve become completely fa miliar with the tiller should you begin using it in the garden BREAK IN OPERATION Perform the following maintenance after the first two 2 hours of new operation see Maintenance Section in this manual and in the Engine Owner s Manual 1 Change engine oil 2 Check for loose or missing hardware on unit Tighten or replace as needed 3 Check tension on forward drive belt 4 Check
43. ng a viscosity of SAE 140 SAE 85W 140 or SAE 80W 90 If refilling an empty trans mission use only GL 4 gear oil having a viscosity of SAE 85W 140 or SAE 140 IMPORTANT Do not use automatic trans mission fluid or motor oil in the transmis sion 7 While checking frequently to avoid over filling 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 B To Drain the Transmission Gear Oil The transmission gear oil does not need to be changed unless it has been contaminat ed 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 below WARNING Gasoline is highly flammable and its vapors are explosive Follow these safety practices to prevent personal injury or property damage from fire or explosion e Allow the engine and muffler to cool for at least two minutes before drain ing 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 e Use only an approved fuel container and store it safely out of the reach of children Do not store gasoline in an area 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 2 Drain th
44. ng so could result in gasoline leaking from the fuel tank Failure to follow this instruction could result in personal injury or property damage 2 Raise one wheel about one inch off the ground and place a sturdy support under the transmission 3 Remove Klick Pin A Figures 3 2 and 3 3 from wheel drive shaft B 4 FOR WHEEL DRIVE MODE Figure 3 2 Slide wheel outward and align holes in 10 Figure 3 2 WHEEL DRIVE position wheel hub D Figure 3 2 and wheel shaft B Insert Klik pin A through wheel hub C and wheel shaft B Repeat with the other wheel and then remove the sup port from beneath the transmission 5 FOR FREEWHEEL MODE Figure 3 3 Slide the wheel inward and insert the Klik pin A Figure 3 3 only through the hole in the wheel shaft B Repeat for the other wheel and then remove the support from beneath the transmission Figure 3 3 FREEWHEEL position WARNING Before starting A engine be sure that both wheels are in WHEEL DRIVE position See Wheels Drive Pins for instructions Engaging the Forward Clutch Bail or Reverse Clutch Control if equipped when the wheels are not in WHEEL DRIVE 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 FORWARD CLUTCH BAIL The Forward Clutch Bail D Figure 3 4 controls the engagement of forward drive to
45. nnect the spark plug wire Remove the ignition key on electric start models Failure to follow this warning could result in personal injury e 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 e 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 e Place wooden blocks on the downhill side of the wheels if you need to stop the tiller from rolling down the ramp Also use the blocks to temporarily keep the tiller in place on the ramps if necessary and to chock the wheels in place after the tiller is in the vehicle e After loading the tiller prevent it from rolling by engaging the wheels in the WHEEL DRIVE position Chock the wheels with blocks and se curely tie the tiller down TILLING TIPS amp TECHNIQUES CON T Terrace Gardening continued e To create a terrace start at the top of the slope and work down Go back and forth across the first row as shown in Fig 4 10 e Each succeeding lower terrace is started by walking below the terrace you re oO Bs preparing For added stability of the tiller always keep the uphill wheel in the soft newly tilled soil Do not till the last 12 or more of the downhill outside edge of each terrace This u
46. nob and then unthread the inner jam nut C Figure 5 6 one to two turns Pull the threaded cable adjuster A Figure 5 6 to the left until the inner jam nut C touches the bracket 6 Prevent the inner jam nut C from turn ing 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 E E ZA Figure 5 5 Measure cable wire length to check for correct reverse belt tension x ITS Figure 5 6 Move threaded adjuster A to left to increase belt tension 20 Replacement Belt Information If the drive belt needs to be replaced see your local authorized dealer or refer to the Parts List for ordering information Use only a factory authorized belt as an over the counter belt may not perform satis factorily The procedure requires average mechanical ability and commonly available tools ENGINE CLEANING Keeping the engine clean will help to en sure smooth operation and prevent dam age from overheating Refer to the Engine Owner s Manual for engine cleaning ser vice intervals and instructions Be sure that the muffler is cool before servicing the engine AIR CLEANER SERVICE The air cleaner filters dirt and dust out of the air before it enters the carburetor Op erating the engine wit
47. ntilled strip helps prevents the terraces from breaking apart and washing downhill It also provides a walking path between rows LOADING AND UNLOADING THE TILLER 1 VVARNING Loading and unloading the tiller into a vehicle is potentially hazardous and we don t recommend doing so unless absolutely necessary as this could result in personal injury or property damage However if you must load or unload the tiller follow the guidelines given next e Before loading or unloading stop the en gine wait for all parts to stop moving disconnect the spark plug wire and let the engine and muffler cool e The tiller is too heavy and bulky to lift safely by one person Two or more people should share the load e 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 e The ramps must be strong enough to support the combined weight of the tiller and any handlers The ramps should pro vide 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 e The handlers should wear sturdy footwear that will help to prevent slipping e 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 16 uq tm o ger 12 UNTILLE
48. owest notch in the lever is engaged 2 Remove the oil fill plug GG Fig 2 11 from the transmission housing cover and locate the main drive shaft situated inside the housing 3 The gear oil level is correct if the gear oil is approximately halfway up the side of the main drive shaft 4 Ifthe oil level is low add gear oil by re ferring to A To Check the Transmission Gear Oil Level in Section 5 a Fig 2 10 Adjust Depth Regulator Lever Fig 2 11 Remove gear oil fill plug STEP 7 ADD MOTOR OIL The tiller is shipped without oil in the en gine IMPORTANT Do not start the engine with out first adding motor oil Severe engine damage will result if the engine is run with out oil 1 Refer to the separate Engine Owner s Manual for engine oil specifications and capacities 2 With the tiller on level ground move the Depth Regulator Lever FF Fig 2 10 up or down until the engine is level 3 Add motor oil as described in the En gine Owner s Manual 4 Move the Depth Regulator Lever all the way down until the highest notch is en gaged This places the tines in the travel position which allows the tiller to be moved without the tines touching the ground STEP 8 CHECK HARDWARE Check all nuts and screws for tightness STEP 9 CHECK AIR PRESSURE IN TIRES units with pneumatic tires Check the air pressure with a tire gauge Deflate or inflate the tires equally to be tw
49. perating 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 12 1 Complete the Pre Start Checklist on this page 2 Putthe wheels in the WHEEL DRIVE po sition see Wheel Drive Pins in Section 3 of this manual WARNING To help A prevent serious personal injury or damage to equipment e Before starting engine put both wheels in the WHEEL DRIVE position Never have wheels in FREEWHEEL po sition when engine is running When the wheels are in FREEWHEEL they do not hold back the tiller and the tines could propel the tiller rapidly forward or backward Before starting engine put Forward Clutch Bail all models and Reverse Clutch Control Models 643B amp 645A only in neutral disengaged positions by releasing levers Never run engine indoors or in en closed poorly ventilated areas Engine exhaust contains carbon monoxide an odorless and deadly gas Avoid engine muffler and nearby areas Temperatures in these areas may ex ceed 150 F 3 Move the Depth Regulator Lever all the way down to the travel position so that the tines clear the ground 4 Release all controls on the tiller 5 On engine s with a fuel shut off valve turn valve to open position as instructed in the separate Engine Owner s Manual 6 Put ignition switch and or throttle con trol lever located on engine in the ON
50. pport tiller when removing wheels 1 Tire pressure gauge for models with pneumatic tires 1 Clean oil funnel 1 Motor oil Refer to the Engine Owner s Manual for oil specifications and quantity required Adjustable wrenches may be used ASSEMBLY STEPS STEP 1 UNPACKING INSTRUCTIONS NOTE While unpacking do not severely bend any control cables 1 The tiller weighs approximately 133 lbs Do not attempt to remove it from the ship ping platform until instructed to do so in these Assembly steps 2 Remove any packaging material from the carton Remove any staples from the bottom of the carton and remove the car ton from the shipping platform 3 Remove all unassembled parts and the separate hardware bag from the carton Check that you have the items listed in the Loose Parts List contact your local dealer or the factory items are missing or dam aged 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 1 Handlebar Assembly see K Fig 2 2 Hardware bag contents Hex hd screw 5 16 18 x 1 1 2 Hex hd screw 3 8 16 x 3 4 Flat Washer 3 8 Split lock washer 5 16 Hex nut 5 16 18 Hex locknut 3 8 16 Models 643B amp 645A only IMPORTANT Motor oil must be added to the engine crankcase before the engine is started Follow the instructions in this Section and in the separate Engine Owner s Manual
51. r 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 footprints in the freshly tilled soil and lightly but securely grip the han dlebar with just one hand Preparing Seedbeds Avoid Making Footprints Whenever possible walk on the untilled side of the unit to avoid making footprints in your freshly tilled or cultivated soil Foot prints cause soil compaction that can ham per root penetration and contribute to soil erosion They can also plant unwanted weed seeds back into the freshly tilled ground e When preparing a seedbed go over the same path twice in the first row then over lap one half the tiller width on the rest of the passes see Fig 6 When finished in one direction make a second pass at a right angle as shown in Fig 4 7 Overlap each pass for best results in very hard ground it may take three or four passes to thoroughly pulverize the soil e f the garden size will not permit lengthwise and then crosswise tilling then over lap the first passes by one half a tiller width followed by successive passes at one quarter width see Fig 4 8 OS ege Avoid Tilling Soggy Wet Soil Tilling wet soil often results in large hard clumps of soil that can interfere with plant ing H time permits wait a day or two after heavy rains to allow the soil to dry before tilling
52. rocedure requires average mechanical ability and commonly available tools 4 If the spring is too short less than 1 16 the tension is too loose If the To Check Forward Belt Tension 1 Stop engine wait for all parts to stop moving and disconnect spark plug wire Hold bail against handlebar while 2 With the Forward Clutch Bail in an open taking second measurement of spring released position measure and note the overall length of the cable spring A Figure 5 4 by measuring from the outermost coil to the outermost coil Figure 5 4 To check forward belt tension take two measurements of the 3 Squeeze the Forward Clutch Bail against overall length of the coils in the spring first with the clutch bail open the handlebar see Figure 5 4 and me then with the clutch bail closed against the handlebar measure the length of the coils The belt 19 A WARNING Before inspecting cleaning or servicing the machine 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 serious personal injury or property damage FORWARD CLUTCH BAIL ADJUSTMENT If the Forward Clutch Bail does not func tion properly first check that the forward drive belt is adjusted properly see Check ing and Adjusting Forward Drive Belt Ten sion If this fails to correct the problem contact Troy Bi
53. s reversing action should unwind a good deal of debris Loading and Unloading the Tiller 1 VVARNING Loading and unloading the tiller into a vehicle is potentially hazardous and we don t recommend doing so unless absolutely necessary as this could result in personal injury or property damage However if you must load or unload the tiller follow the guidelines given next e Before loading or unloading stop the engine wait for all parts to stop moving disconnect the spark plug wire and let the en gine and muffler cool e The tiller is too heavy and bulky to lift safely by one person Two or more people should share the load e 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 e The ramps must be strong enough to support the combined weight of the tiller and any han dlers 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 e The handlers should wear sturdy footwear that will help to prevent slipping e 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 A WARNING Before clearing the tines by hand stop the engine allow all moving parts to stop and disco
54. transmission gear oil level STARTING AND STOPPING Pre Start Checklist With the spark plug wire disconnected from the spark plug perform the following checks and services before each use 1 Read the Safety and Controls Sections in this manual Read the separate Engine Owner s Manual provided with the unit 2 Put the wheels in the WHEEL DRIVE po sition wheel pins must be through holes in wheel hubs and wheel shaft 3 Check unit for loose or missing hard ware Service as required 4 Check engine oil level See Engine Own er s Manual Reverse Clutch Control Models 643B amp 645A Wheel Drive Pin Fig 4 1 5 Check that all safety guards and covers are in place 6 Check air cleaner and engine cooling system See Engine Owner s Manual WARNING 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 7 Fill the fuel tank with gasoline according to the directions in the separate Engine Owner s Manual Follow all instructions and safety rules carefully 8 Attach spark plug wire to spark plug Starting the Engine The following steps describe how to start and stop the engine WARNING Do not attempt to engage the tines or wheels until you have read all of the o
55. upport 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 www troybilt ca for many useful suggestions click on Customer Support button 2 Call a Customer Support Representative at 1 800 668 1238 3 The engine manufacturer is responsible for all engine related issues with regards to perfor mance power rating specifications warranty and service Please refer to the engine manufac turer s Owner s Operator s Manual packed separately with your unit for more information Please have your unit s model number and serial number ready when you call See previous section to locate this information You will be asked to enter the serial number in order to process your call SECTION 1 SAFETY This machine meets voluntary safety stan dard B71 8 1996 which is sponsored by the Outdoor Power Equipment Institute Inc and is published by the American National Standards Institute Ay WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm Safety Alert Symbol A 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 o
56. verse motion of the wheels and tines Models 643B amp 645A only a Look behind and exercise caution when Operating in reverse Do not till while in reverse b Stop all forward motion Lift handlebar with one hand until tines are off the ground and then pull Reverse Clutch Control knob out see Fig 4 3 To stop reversing let go of Reverse Clutch Control knob Fig 4 3 Raise tines off ground and look behind when moving in reverse 6 To move the Model 643C in reverse for short distances a Release forward Clutch Bail Then lift handlebar until tines are off the ground 13 b Swing the handlebar to the left so the right wheel takes a step backward Next swing the handlebar to the right so the left wheel steps backward Repeat as needed c If longer distances need to be covered in reverse shut off the engine then place the two wheels in FREEWHEEL 7 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 begin a turn lift the handlebars until the tines are out of the ground and the engine and tines are balanced over the wheels Fig 4 4 c With tiller balanced push sideways on handlebar to steer in direction of turn Fig 4 5 After turning slowly lower tines into soil to resume tilling oa S 3 n E n an Ti Fig 4 4 To begin turn lift handlebars until tines
57. x 051 B C 656 04005 Transmission Pulley B C 29 736 3090 Flat Washer 4 756 04169 Pulley Reverse Idler B C 30 736 0452 Bell Washer 5 786 04095 Guard Belts Pulleys 31 710 0459A Hex Hd Screw 3 8 24 x 1 50 GR5 6 754 04090 Forward Drive Belt 32 736 04181 Support Washer 7 754 04091 Reverse Drive Belt B C 33 732 04085 Forward Return Spring 8 731 05268 Belt Cover 34 786 04107 Bracket Cable Mounting 9 132 04289 Reverse Return Spring B C 35 756 04170 Forward Idler Pulley 10 732 04081 Belt Guide B C 36 714 0105 Key 3 16 x 1 11 732 04079 Belt Guide 37 736 3078 Flat Washer 12 786 04068 Engine Bracket Left 38 736 04193 Belleville Washer 13 786 04069 Engine Bracket Right 39 710 0805 Hex Screw 5 16 18 x 1 50 Gr5 A B 14 786 04070 Bracket Belt Cover 710 0395 Hex Screw 5 16 18 x 2 1 4 Grd C 15 748 04087 Shoulder Washer 40 712 04063 Nut Hex Lock 5 16 18 16 786 04276 Reverse Idler Arm B C 41 750 0258 Spacer Shoulder A 17 1786 04275 Forward Idler Lever 42 736 0315 Washer Flat 75 x 1 5 x 125 A 18 710 0672 Hex Hd Screw 5 16 24 x 1 25 A 736 04192 Flat Washer 786 x 1 000 x 031 B C 710 0117 Hex Hd Screw 5 16 24 x 1 B C 43 736 0242 Bell Washer 19 710 0237 Hex Hd Screw 5 16 24 x 5 8 44 749 04193 Bumper C 20 710 0376 Hex Hd Screw 5 16 18 x 1 45 726 0201 Nut Speed 5 16 18 C 21 710 04049 Hex Hd Screw 5 16 18 x 5 8 46 714 0143 Klik Pin 22 710 0347 Hex Hd Screw 3 8 16 x 1 3 4 A 4
58. ystem 7 Check gear oil level in transmission 1 5 Check tines for wear 5 Check air pressure in tires 5 if unit has pneumatic tires Service spark plug 7 NOTES 1 Check after first 2 hours of break in operation 2 Before each use 3 Every 5 operating hours 4 Every 10 operating hours 5 Every 30 operating hours B Change more frequently in dusty conditions 7 See Engine Owner s Manual for service recommendations 8 Whichever time interval occurs first 9 Change after first 2 hours of break in TILLER LUBRICATION After every 10 operating hours oil or grease the lubrication points shown in Figure 5 1 and described below Use clean lubricating oil 30 weight motor oil is suitable and clean general purpose grease grease containing a metal lubricant is preferred if available e Remove the wheels clean the wheel shaft A Fig 5 1 and apply a thin coating of grease to the wheel shaft e Grease the back front and sides of the depth regulator lever B Fig 5 1 e Remove the tines and clean the tine shaft C Fig 5 1 Use a file or sandpaper to gen tly remove any rust burrs or rough spots especially around holes in shaft Apply grease to ends of shaft before installing tines e Oil the threads on the handlebar height adjustment screws and the handlebar attaching screws D Fig 5 1 Figure 5 1 CHECK FOR OIL LEAKS Before each use check the tiller for signs of an

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