Troy-Bilt 645A-Bronco Operator's Manual
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Troy-Bilt 645A-Bronco Operator's Manual

Troy-bilt real-tine tiller operator's manual
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Model 644H Shown (bumper syles vary)
IMPORTANT:READ SAFETY RULES AND INSTRUCTIONS CAREFULLY
Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-covered, brush-
covered or grass-covered land 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 should be maintained in effective working order by the operator. In the State of California the above is required by law
(Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. A spark arrester
for the muffler is available by contacting the service department at Troy-Bilt LLC, P.O. Box 361131 Cleveland, Ohio 44136-0019.
TROY-BILT LLC, P.O. BOX 361131, CLEVELAND, OH 44136-0019
PRINTED IN USA
Operator's Manual
Rear-tine Tiller Models
644H—Bronco
645A—Bronco
FROM NO. 769-00585A
TM
TM
(01/2003)

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Summary of Contents for Troy-Bilt 645A-Bronco

  • Page 1 (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. A spark arrester for the muffler is available by contacting the service department at Troy-Bilt LLC, P.O. Box 361131 Cleveland, Ohio 44136-0019.

  • Page 2: Table Of Contents

    You can locate the model number by looking at the rear surface of the tine shield. A sample model plate is explained below. For future reference, please copy the model number and the serial number of the equipment in the space below TROY-BILT LLC P. O. BOX 3 6 1 1 3 1 www.troybilt.com...

  • Page 3: Safety

    Section 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;...

  • Page 4: Maintenance And Storage

    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.

  • Page 5: Operating Symbols

    Decals For your safety and the safety of others, various safety and operational decals are located on your unit (see Figure 1 below). Forward Clutch Control Operating Instruction Starting Stabilization Message on engine Figure 1: Location of Safety and Operating Decals (Model 644H shown). Operating Symbols Various symbols (shown here, with word descriptions) are used on the tiller and engine...

  • Page 6: Assembly

    Section 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.

  • Page 7: Step 2: Attach Handlebar

    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.

  • Page 8: Step 5: Install Reverse Clutch Cable

    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).

  • Page 9: Transmission Gear Oil

    4. Insert the cable up through the slot in the cable bracket and position the threaded assembly as shown in Fig. 2-8. Make sure that the flat side of the threaded assembly is aligned with the flat side of the mounting hole. Slide the large hex nut (DD) up the cable and tighten it securely.

  • Page 10: Features And Controls

    Section 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.

  • Page 11: Forward Clutch Bail

    4. FOR WHEEL DRIVE mode (Figure 3-2): Slide the wheel outward and align the holes in the wheel hub (D, Figure 3-2)) and the wheel shaft (B). Insert the wheel drive pin (A) through the wheel hub and the wheel shaft. Secure the wheel drive pin with the hairpin cotter (C) by pushing the hairpin cotter in as far as it will go.

  • Page 12: Handlebar Height Adjustment

    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"...

  • Page 13: Operation

    Section Operation WARNING Before operating machine, carefully read and understand all safety (Section 1), controls (Section 3) and operating instructions (Section 4) in this Manual, in the separate Engine Owner’s Manual, and on the decals on the machine. Failure to follow these instruc- tions can result in serious personal injury.

  • Page 14: Operating The Tiller

    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 operating instructions in this Section. Also review the safety rules in Section 1: “Safety”...
  • Page 15 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.

  • Page 16: Tilling Depths

    Section 4: Operation 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.

  • Page 17: Clearing The Tines

    Tilling Tips 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. •...
  • 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

    Section 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.

  • Page 20: Tiller Lubrication

    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.
  • Page 21 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.
  • 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.
  • Page 23 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.

  • Page 24: Off-Season Storage

    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.

  • Page 25: Troubleshooting

    Before performing any corrections, refer to the appropriate information in this Manual, or in the Engine Owner’s Manual, for the correct safety precautions and operating or maintenance procedures. Contact your local authorized Engine Service Dealer for engine service. Contact your local authorized equipment dealer or the factory for all other service problems. PROBLEM POSSIBLE CAUSE Engine does...

  • Page 26: Parts List

    Section Parts List...
  • Page 27 PART NO. 1185469 Spirol Pin 710-0597 Hex Hd. Screw, 1/4-20 x 1 710-0599 Screw, Self-Tapping,1/4-20 x 1/2 710-0874 Hex Hd. Screw, 5/16-18 x 1-1/4 1186331 Hex Hd. Screw, 5/16-18 x 1.0 712-0291 Hex Lock Nut, 1/4-20 712-3004A Hex Flange Lock Nut, 5/16-18 712-3009 Hex Nut, 5/16-18 736-0119...
  • Page 28 MODELS 644H & 645A...
  • Page 29 PART NO. 1918749 Bumper 710-0395 Hex Screw, 5/16-18 x 2-1/4, Gr5 712-0267 Nut, Hex, 5/16-18 736-0119 Lock Washer, 5/16 PART NO. DESCRIPTION 1916719 Cable Assembly, Reverse Clutch 1916755 Upper Handlebar 1917479 Bail, Forward Clutch 1918745 Cable Assembly, Forward Clutch 710-0599 Screw, Self-Tapping,1/4-20 x 1/2 710-3008 Screw, Hex, 5/16-18 x 3/4...
  • Page 30 MODELS 644H & 645A — * Use as required to obtain between .005” and .015” allowable end-play. PART NO. DESCRIPTION GW-9517 Snap Ring GW-1714 Bearing, Tapered Roller (with race) GW-50043 Support Washer, Rear 711-04110 Drive Shaft (CRT) GW-1224-1* Shim, Rear Bearing Cap, .010" thick GW-1224-2* Shim, same as above, except .030"...
  • Page 31 FRONT PART NO. 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 1904279 * Use as required to obtain between .005” and .030” allowable end-play. DESCRIPTION Retainer, Snap Ring, “E” Type Retainer, Snap Ring Shim, 0.062" thick Shim, 0.030"...
  • Page 32 MODELS 644H & 645A PART NO. GW-9727 Plug, Transmission Oil Fill 710-04049 Hex Hd. Flange Screw, 5/16-18 x 5/8,Gr. 5 736-0119 Lock Washer, 5/16 1918377 Rear Cover, Transmission 1916641 Front Cover, Transmission GW-50032 Gasket, Housing Cover 721-04030 Oil Seal, Drive Shaft * Included with transmission when purchased as an assembly only.
  • Page 33 Hold Tines With Cutting Edge at the TOP of each tine facing TOWARD You RIGHT-HAND TINE LEFT-HAND TINE DENOTES CUTTING EDGE OF TINE PART NO. 710-3008 Hex Hd. Screw, 5/16-18 x 3/4, Grade 5 1817060 Single Tine - Right Hand 712-3009 Hex Lock Nut, 5/16-18 710-3096...
  • Page 34 MODELS 644H & 645A FORWARD CLUTCH CABLE REVERSE CLUTCH CABLE...
  • Page 35 PART NO. 1107382 Flat Washer, 5/16 1108841 Key, 3/16" x 1-1/2" 619-04016 Pulley, Engine Drive 1916532 Transmission Pulley 1916535 Pulley, Reverse Idler 1916652 Guard, Belts/Pulleys 1916657 Forward Drive Belt 1916658 Reverse Drive Belt 1916660 Belt Cover 1916724 Reverse Return Spring 1916725 Belt Guide 1916726...
  • Page 36 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.

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