Section 2: Assembly - Troy-Bilt TUFFY 643B Operator's Manual

SECTION 2: 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 instructions in this
manual.
INTRODUCTION
Carefully follow these assembly steps to
correctly prepare your tiller for use. It is
recommendedthat you readthis 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.
INSPECTUNIT
Inspect the unit and carton for damageim-
mediatelyafter delivery.Contactthe carrier
(trucking company) if you find or suspect
damage. Inform them of the damageand
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 LLCif you need assis-
tance in this matter.
TOOLS / MATERIALSNEEDED
(2) 1/2" open-end wrench*
(2) 9/16" open-end wrench*
(1) 3/8" open-end wrench*
(1) Large adjustable wrench
(Models 643B & 645A only)
(1) Scissors (to trim plastic ties)
(1) Ruler (for belt tension check)
(1) Block of wood (to support tiller when
removing wheels)
(1) Tire pressure gauge (for models with
pneumatic tires)
(1) Cleanoil funnel
(1) Motor oil. Refertothe EngineOwner's
Manualfor oil specificationsand
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 Ibs.
Do not attempt to remove it from the ship-
ping platform until instructed to do so in
these Assembly steps.
2. Removeany packaging material from
the carton. Removeany staples from the
bottom of the carton and remove the car-
ton from the shipping platform.
3. Removeall unassembled parts and the
separate hardware bag from the carton.
Checkthat you havethe 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 HandlebarSupport (seeA, Fig. 2-2)
1 HandlebarAssembly (seeK, Fig.2-2)
Hardware bag contents:
4 Hex hd. screw, 5/16-18 x 1-1/2"
2 Hex hd. screw, 3/8-16 x 3/4"
2 Flat Washer,3/8"
4 Split lock washer,5/16"
4 Hex nut, 5/16"-18
2 Hex Iocknut,3_8"-16
*Models 643B & 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 separateEngine
Owner's Manual.
NOTE: LEFTand RIGHTsides of the tiller
are as viewed from the operator's position
behind the handlebars.
STEP 2: ATTACH HANDLEBAR
1. Loosely attachthe legs of the handlebar
support (A, Fig. 2-2) to the inner sides of
the tiller frame usingtwo 3/8"-16 x 3/4" hex
hd. screws (B), 3/8" flat washers, and 3/8"-
16 hex Iocknuts.
_iiii
Figure 2-1: Toidentify length ofscrews,place
screwontemplate asshown andmeasure dis-
tance between bottom ofscrewheadandtipof
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. Thereare three height adjustment holes
in the two handlebar support brackets (E
and F,Fig. 2-2). Use a setting that will po-
sition the handlebarsat approximately
waist levelwhen the tines are 3"-4" into the
soil. Loosely attachthe support bracketsto
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
beassembled 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:
1. Placea sturdy block under the transmis-
sion to raise one wheel about 1" off the
ground.
2. Removethe Klik Pin (J, Fig. 2-3) from
the wheel hub (K) and wheel shaft (L).
3. Slidethe wheelfully inward on the wheel
shaft (N, Fig. 2-3). Reinstallthe Klik pin (J)