Troy-Bilt 645A-Bronco manual

Operator ’ s Manual Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-covered, brush - covered or grass-covered land unless the engine ’ s exhaust system is equipped with a spark arrester meeting applicable local or state laws (if any). If a spark arrester is used, it shoul[...]

2 For more details about your unit, visit our website at www .troybilt.com T ABLE OF CONTENTS Content Page Calling Customer Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

3 T raining 1. Carefully read this Owner’s 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 engine. Know how to stop the unit and disengage the controls quickly. 2. Never allow children to operate the tiller. Never allow adults[...]

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 an[...]

Section 1: Safety 5 Decals For your safety and the safety of others, various safety and operational decals are located on your unit (see Figure 1 below). 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 separate parts catalog for deca[...]

6 W ARNING T o 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 Section in[...]

7 Section 2: Assembly 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-[...]

8 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[...]

9 Section 2: Assembly Fig. 2-8: Install reverse cable mounting bracket and the reverse clutch cable. 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 ([...]

Wheel Drive Pins 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 whee[...]

11 Section 3: Features and Controls 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 i[...]

12 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 a[...]

13 Figure 4-1 Section 4 Operation W ARNING 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[...]

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 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. ” 1. Compl[...]

Section 4: Operation 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 [...]

16 Section 4: Operation T illing Tips & T echniques 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 [...]

17 Section 4: Operation T illing Tips & T echniques 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 fr[...]

18 Section 4: Operation LOADING AND UNLOADING THE TILLER • 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. • Use sturdy ramps and manua[...]

19 Section 5 Maintenance 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 • ▲ Check drive belt tension • ✝ Check nuts and bolts • ✝ Change engine oil • * Lubricate tiller • Service engine air cleaner system ▲ Check gea[...]

20 Section 5: Maintenance TILLER LUBRICA TION 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 [...]

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

22 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 possible. • Check belt tension after the first two hours of initial operation (new belt). • Check belt tension after every 10 operating hours. To Check Forw[...]

Section 5: Maintenance W ARNING 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[...]

24 Section 5: Maintenance W ARNING 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. ENGINE OIL SERVICE Check the engine oil le[...]

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 equip[...]

26 Section 6 Parts List 5 1 3 14 2 11 18 17 16 10 9 8 4 15 12 6 4 15 1 7 9 8 19 20 13 7 21 22 24 23 25 7 26 27[...]

27 MODELS 644H & 645A REF NO. P ART NO. DESCRIPTION 1 1 185469 S pirol Pin 2 710 -0 597 Hex Hd. Screw, 1/4-20 x 1 3 7 10-0599 Screw, Self-Tappi ng,1/4-20 x 1/ 2 4 710 -0 874 Hex Hd. Screw, 5/16-18 x 1-1/4 5 1 186331 H ex Hd. S crew, 5/1 6-18 x 1.0 6 7 12-0291 Hex Loc k Nut, 1/4-2 0 7 7 12-3004A Hex Fla nge Lock Nut , 5/16-18 8 712-300 9 He x Nu[...]

28 MODELS 644H & 645A 5 10 2 5 15 1 12 16 21 3 13 20 4 17 11 25 7 22 7 25 20 6 8 20 6 23 14 18 18 7 9[...]

29 MODELS 644H & 645A REF NO. P ART NO. DESCRIPTION 1 1 916719 Cab le Assembly, Reve rse Clutch 2 1 916755 U pper Handl ebar 3 1917479 Bail, Forward Clutch 4 1918745 Cable As sembly, Forward Clutch 5 7 10-0599 Screw, Self-Tappi ng,1/4-20 x 1/ 2 6 7 10-3008 Screw, H ex, 5/16-18 x 3/ 4 7 7 12-3009 Hex Loc k Nut, 5/16 -18 8 G W-55042 Han dlebar Su[...]

30 MODELS 644H & 645A * Use as req uire d to obtain be twee n .005” an d .015” allo wable en d-pla y . REF NO. P ART NO. DESCRIPTION 1 GW-9517 Snap Ri ng 2 GW-1714 Bearing , Taper ed Rol ler (wit h race) 3 G W-50043 Support Washer, Rear 4 7 11-04110 D rive Shaft (CRT) 5 GW-1224 -1* Sh im, Rea r Bearin g Cap, . 010" t hick GW-122 4-2* S[...]

31 MODELS 644H & 645A * Use as req uire d to obtain be twee n .005” an d .030” allo wable en d-pla y . REF NO. P ART NO. DESCRIPTION 1 GW-9512 Retainer, Snap Ri ng, “E” T ype 2 1 909950 R etainer, S nap Ring 3 G W-1166-1 * Shim, 0.062" thick GW-1 166-2* Shim, 0.030" thi ck GW-1 166-3* Shim, 0.015" thi ck GW-1 166-4* Shim,[...]

32 MODELS 644H & 645A REF NO. PAR T NO. DESCRIPTION 1 G W -972 7 Plug, T ransmis sion Oil Fil l 2 71 0-04049 Hex Hd. Fl ange Screw, 5/16-18 x 5/8,Gr. 5 3 73 6-0119 Lock W asher, 5/16 4 19 18377 Rear Cove r, Transmission 5 19 16641 Front Co ver, Transmission 6 G W-50032 Gaske t, Housing Cov er 7 7 21-0403 0 O il Seal, D rive S haft 8 72 1-04031 [...]

33 ENGINE TINE SHAFT DENO TES CUTTING EDGE OF TINE MODELS 644H & 645A REF NO. PAR T NO. DESCRIPTION 1 71 0-3008 Hex Hd. Screw , 5/16 -18 x 3/4, Grad e 5 2 18 17060 Si ngle Tine - Ri ght Hand 3 71 2-3009 Hex Lock N ut, 5/16-18 4 71 0-3096 Hex Hd. Screw, 3/8- 16 x 2 5 18 17059 Singl e Tine - Le ft Hand 6 19 16702 LH Tine Hold er 7 191670 3 RH Tin[...]

34 MODELS 644H & 645A 9 24 28 20 30 25 27 1 1 11 5 17 19 28 1 12 10 14 16 38 32 31 3 2 7 8 37 19 39 33 4 38 34 FORWAR D CLUTCH CABLE 35 42 28 24 22 22 24 6 13 21 28 16 29 18 36 23 40 REVERS E CLUTCH CABLE 15 28 26[...]

35 MODELS 644H & 645A REF NO. P ART NO. DESCRIPTION 1 1 107382 F lat Washer, 5 /16 2 1 108841 K ey, 3/16" x 1- 1/2" 3 6 19-04016 P ulley, Engi ne Drive 4 1 916532 T ransmissi on Pulley 5 1 916535 Pul ley, Reverse I dler 6 1 916652 G uard, Belts/ Pulleys 7 1 916657 F orward Dr ive Belt 8 1 916658 Rev erse Drive B elt 9 1 916660 B elt C[...]

TR O Y -BIL T TILLER LIFETIME LIMITED W ARRANTY WHAT PRO DUCT All Troy- Bilt bra nded rear t ine walk-b ehind til lers with g ear drive transmissi ons. IS COVERED This warra nty begi ns on the da te of purc hase and is warranted by Troy-Bil t LLC for th e life of the tiller, t o the or iginal purc haser onl y. WHAT IS COVERED Troy-Bilt LLC will , a[...]