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Troy-Bilt 645AMBRONCO manual

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Table of contents for the manual

  • Page 1

    0 T RtllcBILT' - --- Operator's Manual Rear-tine Tiller Models 644HmBronco TM 645AmBronco TM 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-[...]

  • Page 2

    TABLE OF CONTENTS Content Page Content Page Customer Support 2 Maintenance 19 Safety 3 Off-season Storage 24 Assembly 6 Troubleshooting 25 Features and Controls 10 Operation 13 Warranty Back Cover FINDING MODEL NUMBER This Operator's Manual is an important part of your new lawn tractor. It will help you assemble, prepare and maintain the unit [...]

  • Page 3

    n Safety 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 witho[...]

  • Page 4

    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 [...]

  • Page 5

    Section 1: Safety Decals For your safety and the safety of others, various safety and operational decals are located on your unit (see Figure 1 below). Keepthe 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 separate parts catalog for decal l[...]

  • Page 6

    n Assembly WARNING 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 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 Sec[...]

  • Page 7

    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), two 3/8" flat washers (C) and 3/8"-16 hex Iocknuts (D). 2. Using using two 5/16"-18 x 1-1/2" hex hd. screws (G), 5/16" split Iockwashers[...]

  • Page 8

    Section 2: Assembly STEP4: Install Forward Clutch Cable 1. 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 co[...]

  • Page 9

    Section 2: Assembly 3. Use a cable tie (EE, Fig. 2-9) to fasten the reverse clutch cable to the left side handlebar. 4. 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[...]

  • Page 10

    n Features and Controls WARNING 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. Forward ReverseClutch Clutch Bail Control [...]

  • Page 11

    Section 3: Features andControls 4. FORWHEELDRIVE 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[...]

  • Page 12

    Section 3: Features andControls 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 a[...]

  • Page 13

    ......................... Operation WARNING 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 person[...]

  • Page 14

    Section 4: Operation Starting the Engine The following steps describe how to start and stop the engine. Do not attempt to engage tines or wheels until you have read all the operatinginstructions in this Section. Also review the salety rules in Section 1: "Safety" and the tiller and engine controls inlormation in Section 3: "Features [...]

  • Page 15

    Section 4: Operation WARNING 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 backward toward the operator, which could result in loss of control, property damage, or personal injury. Let the tiller move at its ow[...]

  • Page 16

    Section 4: Operation 16 Tilling Tips & 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 Figu[...]

  • Page 17

    Section 4: Operation Tilling Tips & Techniques Clearing the tines Dry grass, stringy stalks or tough vines may becometangled 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 sid[...]

  • Page 18

    Section 4: Operation LOADING AND UNLOADING THE TILLER WARNING Loading and unloading the tiller 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, follow the guidelines given next. [...]

  • Page 19

    Maintenance 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. REQUIRED MAINTENANCE SCHEDULE PROCEDURE Check e[...]

  • Page 20

    Section 5: Maintenance 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. TILLERLUBRICATION Proper lubrication of the ti[...]

  • Page 21

    Section 5: Maintenance 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. B. To Drain the Transmission Gear Oil: DANGER [...]

  • Page 22

    Section 5: Maintenance 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. TINED OPERATOR C POSITION A ENGINE ,'_ DE[...]

  • Page 23

    Section 5: Maintenance 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. from turning by gripping the upper end of the [...]

  • Page 24

    Section 5: Maintenance WARNING Before inspecting, cleaning or servicing the unit, shut off engine, wait for all partsto 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. ENGINE OIL SERVICE Check the engine oil level b[...]

  • Page 25

    Section 5: Maintenance 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 equipme[...]

  • Page 26

    n Parts List 7 _ 7 13 9 4 15 12 8 19 14 2 20 18 23 24 22 7 21 26[...]

  • Page 27

    MODELS 644H & 645A REF NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 PART NO. DESCRIPTION 1185469 710-0597 710-0599 710-0874 1186331 712-0291 712-3004A 712-3009 736-0119 GW-55013-1 GW-55013-2 GW-55015 GW-55018 686-04029 GW-55088 GW-9384 GW-9534 710-04048 618-04046 786-04191 1916570 710-3073 1916771 1107382 710-3025[...]

  • Page 28

    MODELS 644H & 645A 2 5 10 3 20 13 I 17 4 18 / 23 18 28[...]

  • Page 29

    MODELS 644H & 645A REF NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22 23 25 PART NO. DESCRIPTION 1916719 1916755 747-04210 1918745 710-0599 710-3008 712-3009 786-04188 GW-55043 786-04200 GW-55044 GW-9855 725-0157 736-3050 732-04040 732-04185 710-0106 710-0216 710-0805 712-0121 712-0291 712-3000 736-0119 Oable Assembly, Reverse Olutch[...]

  • Page 30

    MODELS 644H & 645A 1 2 3 / REF NO. 1 GW-9517 2 GW-1714 3 GW-50043 4 711-04110 5 GW-1224-1" GW-1224-2" GW-1224-3" GW-1224-4" -- GW-13250 PART NO. DESCRIPTION Snap Ring Bearing,Tapered Roller (with race) Support Washer, Rear Drive Shaft (ORT) Shim, Rear Bearing Oap, .010" thick Shim, same as above, except .030" thick[...]

  • Page 31

    MODELS 644H & 645A FRONT 4 7 J REF NO. 1 2 3 4 5 6 7 8 9 10 11 7 4 3 2 PART NO. DESCRIPTION GW-9512 1909950 GW-1166-1 * GW-1166-2" GW-1166-3" GW-1166-4" GW-1166-5" GW-1086 711-04092 GW-9305 GW-1132-2 1904278 711-04078 GW-1104 1916542 Retainer, Snap Ring, "E" Type Retainer, Snap Ring Shim, 0.062" thick Shim, 0.[...]

  • Page 32

    MODELS 644H & 645A 2 10 10 12 3 14 13 * Included with transmission when purchased as an assembly only. Removeand discard when installing the transmission on tiller. REF PART NO. NO. 1 GW-9727 2 710-04049 3 736-0119 4 1918377 5 1916641 6 GW-50032 7 721-04030 DESCRIPTION REF NO. Plug, Transmission Oil Fill 8 Hex Hd. Flange Screw, 5/16-18 x 5i8,Gr[...]

  • Page 33

    Hold Tines With Cutting Edgeat the TOP of each tine facing TOWARDYou 10 8 I MODELS 644H & 645A FRONT/ FORWARD 9 WHEEL SHAFT 11 REF NO. 1 2 3 4 5 6 7 8 ENGINE 1 11 6 '_ ENOTES CUTTING EDGE OF TINE PART NO. 710-3008 1817060 712-3009 710-3096 1817059 1916702 1916703 1917487 DESCRIPTION Hex Hd. Screw, 5/16-18 x 3/4, Grade 5 Single Tine - Right[...]

  • Page 34

    MODELS 644H & 645A I 16 17 ,3O 24 16 34[...]

  • Page 35

    MODELS 644H & 645A REF NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 PART NO. DESCRIPTION 736-0159 1108841 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[...]

  • Page 36

    TROY-BILT TILLER LIFETIME LIMITED WARRANTY WHAT PRODUCT IS COVERED WHAT IS COVERED BY THIS WARRANTY WHAT IS NOT 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 purchas[...]