Troy-Bilt 645A Super Bronco Operator'S Manual Download | Manualshive

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Summary of Contents for 645A Super Bronco

Page 1: ...ipped 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 co...

Page 2: ...future reference please copy the model number and the serial number of the equipment in the space below OTRII BILT TROY BILT LLC P O BOX 361131 www troybilt com CLEVELAND OH44136 330 558 7220 866 840 6483j Copy Model Number Here Copy Serial Number Here ENGINE INFORMATION The engine manufacturer is responsible for all engine related issues with regards to performance power rating speci fications wa...

Page 3: ...in moving parts 4 Do not operatethe tiller when barefoot or wearing sandals sneakers or light footwear Wear protectivefootwear that will improve footing on slippery surfaces 5 Do not till near underground electric cables telephone lines pipes or hoses If in doubt contact your telephone or utility company 6 Warning Handlefuel with care it is highly flammable and its vapors are explosive Besure to t...

Page 4: ...d use great care when backing up 17 Do not operatethe tiller on a slope that is too steepfor safety When on slopes slow down and makesure you have good footing Never permit the tiller to freewheeldown slopes 18 Neverallow bystanders nearthe unit 19 Only use attachments and acces sories that areapproved by the manufac turer of the tiller 20 Usetiller attachments and acces sories when recommended 21...

Page 5: ...ing onbeltcover Figure1 Locationof SafetyandOperatingDecals Model 644Hshown OperatingSymbols Various symbols shown here with word descdptions are used on the tiller and engine your unit may not haveall of the symbols FAST SLOW STOP I l I 1 CHOKE CHOKE ON OFF 411 TILLERDIRECTION R REVERSE ROTATING TINES o LEVERDIRECTION BAIL ENGAGED BAIL DISENGAGED TO AVOID SERIOUS INJURY READTHE OWNER SMANUAL KNOW...

Page 6: ... and the separatehardware bag from the carton Checkthat you havethe items listed below contact your local dealer or the factory if any items are missing or damaged NOTE Usethe screw length template Fig 2 1 to identify screws LooseParts List Qty Description 1 HandlebarSupport seeA Fig 2 2 page7 1 HandlebarAssembly see K Fig 2 2 Thefollowing items are in the hardware bag 1 Slotted hd screw 10 24 x 2...

Page 7: ...r screws securely 4 Tighten all handlebar mounting hardware securely STEP3 MoveTiller OffShipping Platform To movethe tiller without the engine running put the wheels in their FREEWHEEL position as described below 1 Usea sturdy block to raise onewheel off the ground 2 Removethe hairpin cotter L Fig 2 3 and wheel drive pin M Slide the wheel inward on the wheel shaft N Reinstall the wheel drive pin ...

Page 8: ...8 Measurethe length of the cable spring betweenthe ends of the coils Fig 2 7 The length should be approximately 1 7 8 If the length is correct turn the 10 24 hex nut Z down tightly againstthe cable adjuster X while holding the adjuster in place See Figure2 7 If the length is incorrect you must makean adjustment to the cabletension as described in Checking andAdjusting ForwardDrive Belt Tension in ...

Page 9: ... level is correct if the gear oil is approximately halfway up the side of the drive shaft 4 If the gear oil level is low add gear oil by referring to A To Checkthe Transmis sion GearOil Level in Section 5 STEP 7 Add Motor Oil to Engine The tiller is shipped withoutoil in the engine IMPORTANT Do not start the engine without first adding motor oil Severe engine damagewill result if the engine is run...

Page 10: ...ontrol property damage or personal injury through the holes in the wheel shaft not the wheel hubs thus allowing the wheels to turn freely when the tiller is pushed or pulled by hand To Place the Wheels in WHEELDRIVEor FREEWHEEL 1 Stop the engine disconnect the spark plug wire from the spark plug and allow the engineto cool 2 Raiseonewheel off the ground and place a sturdy support under the transmi...

Page 11: ...ines Forwardtiller motion will stop the engine will continue to run WARNING Before starting the engine be sure that both wheels are in the WHEEL DRIVE position See Wheel Drive Pins for instructions Engaging the Forward Clutch Bail or the Reverse Clutch Control when the wheels are not in the WHEEL DRIVE position could allow the tines to rapidly propel the tiller forward or backward Failure to compl...

Page 12: ...lebars so they areat waist level when the tines are3 4 into the soil ToAdjustthe Handlebars 1 Stop the engine disconnect the spark plug wire from the spark plug and allow the engineto cool 2 Removethe screws Iockwashersand nuts reposition the handlebars and reinstall the hardware Figure3 6 Handlebar heightadjustment Anti ReverseStake This stake is locatedat the rear of the transmission under the t...

Page 13: ...fter first 2 hours of operation 4 Checktransmission gear oil levelafter first 2 hours of operation Reverse ClutchControl ForwardClutchBail ulatorLever Recoil Starter Figure 4 1 Wheel Drive Pin on eachwheel STARTINGANDSTOPPINGTHE ENGINE Pre StartChecklist Makethe following checksand perform the following services before starting the engine 1 Readthe Safety and Controls sections in this manual Readt...

Page 14: ...vere burns Do not touch muffler or adjacent areas 9 Usethe FAST throttle speed setting when tilling WARNING Keep away from rotating tines Rotating tines will cause injury Stoppingthe EngineandTiller 1 To stop the wheelsand tines release the ForwardClutch Bail or the Reverse Clutch Control whichever control is in use 2 To stop the engine put the throttle control lever on engine in OFF or STOP posit...

Page 15: ...tand legs awayfrom the tines b To makea turn lift the handlebars until the engine andtines are balanced over the wheels Figure 4 4 Thetines must be out of the ground while turning the tiller c With the tiller balanced push sideways on the handlebarto move the tiller in the direction of the turn Figure 4 5 After completing the turn slowly lower the tines into the soil to resumetilling Figure 4 3 Ra...

Page 16: ...n large hard clumps of soil that can interfere with planting If time permits wait a day or two after heavyrains to allow the soil to dry before tilling Test soil by squeezing it into a ball If it compresses too easily it is too wet to till Avoidmakingfootprints Wheneverpossible walk on the untilled side of the unit to avoid making foot prints in your freshly tilled or cultivated soil Footprintscau...

Page 17: ...t review safety rules in the Safety section of this manual 2 We recommend tilling up and down slopes rather than terracing Tilling vertically on a slope allows maximum planting areaand also leavesroom for cultivating IMPORTANT When tilling on slopes be sure the correct oil level is maintained in the engine check everyone half hour of operation The incline of the slope will causethe oil to slant aw...

Page 18: ...r along the ramps and they should havea locking device to securethem to the vehicle The handlers should wear sturdy footwear that will helpto prevent slipping 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 When going up ramps stand in the normal operating position and push ...

Page 19: ...E Each 10 30 Noted Use Hours Hours Check engineoil level Cleanengine Check drive belt tension Check nuts and bolts Changeengine oil Lubricate tiller Service engineair cleaner system Checkgearoil levelin transmission Checktines for wear Checkair pressure in tires if pneumatic Service spark plug CheckAnti ReverseStake And every 5 operating hours t t t Changemore frequently in dusty or dirty conditio...

Page 20: ...dware after every 10 operating hours Tighten or replace hardware before using the tiller Besure to check the screws underneath the tiller hood lift the hood flap that securethe transmission cover andthe depth regulator lever to the transmission CHECKTIREPRESSURE on machines equipped with pneumatictires Checkthe air pressure in both tires Deflateor inflate both tires evenlyfrom 15 to 20 PSi pounds ...

Page 21: ...st Section of this manualfor tine identification information WARNING This is a CRT counter rotating tine tiller and its tines must be mounted in the direction shown in Figure 5 3 If mounted with curves in the opposite direction tiller will dig poorly and be more likely to run backward Failure to comply could result in personal injury or property damage NOTE You must first remove the tiller hood be...

Page 22: ...the first two hours of initial operation new belt Checkbelt tension after every 10 operating hours To CheckForwardBeltTension 1 Besure that the engine is stopped and the spark plug wire is disconnectedand moved awayfrom the spark plug 2 Loosen nut C Figure 5 4 several turns so it is about halfway up the threaded adjustment screw 3 Lift the Forward Clutch Bail upand hold it to the bottom of the han...

Page 23: ... it as soon as possible Checkbelt tension after the first two hours of break in operation new belt Checkbelt tension after every 10 operating hours ToCheckReverseBeltTension 1 Besure that the engineis stopped and the spark plug wire is disconnectedand moved awayfrom the spark plug 2 Removethe screw in the plastic belt cover and slide the cover which is attachedto the forward clutch cable out of th...

Page 24: ...y conditions Servicethe air cleaner as instructed in the separateEngineOwner s Manual SPARK PLUG SERVICE Inspect and clean or replacethe spark plug after every 100 operating hours or annually Cleanthe plug and set the gap as described in the separateEngineOwner s Manual In some areas local law requires using resistor spark plugs to suppress ignition signals If the engine was originally equippedwit...

Page 25: ...ent 3 SeeEngine ServiceDealer 4 Stalegasoline 4 Replacewith fresh gasoline 5 Dirt or water in fueltank 5 SeeEngine ServiceDealer 6 Engine coolingsystemclogged 6 Cleanair cooling system seeEngineOwner sManual Engine overheats 1 Engine coolingsystemclogged f Cteanair cooling area seeEngine Owner sManual 2 Carburetorout of adjustment 2 SeeEngine ServiceDealer 3 Oil levelis low 3 Checkoil level seeEng...

Page 26: ...List 1 18 9 24 23 22 26 ...

Page 27: ...6708 1916707 SpirolPin HexHd Screw 1 4 20x 1 Screw Self Tapping I 4 20 x 1 2 HexHd Screw 5 16 18x 1 1 4 HexHd Screw 5 16 18x 1 0 HexLockNut 1 4 20 HexFlange LockNut 5 16 18 HexNut 5 16 18 LockWasher 5 16 HoodBracket LeftHand HoodBracket RightHand DragBar DepthRegulator Lever TineHoodAssembly Bushing Spring DepthRegulator Spacer HexHd Flange Screw 5 16 18x 1 Transmission Assembly CRT FlapStopBracke...

Page 28: ...MODELS 644H 645A 2 16 12 2O 17 22 1 ji 18 25 7 20 14 J 18 23 28 ...

Page 29: ...bar Bail Forward Clutch Cable Assembly Forward Clutch Screw Self Tapping I 4 20 x 1 2 Screw Hex 5 16 18x 3 4 HexLockNut 5 16 18 Handlebar Support LowerHandlebar Panel Tab ConduitMount Screw 10 24x 2 Cable Tie FlatWasher 3 8 Bracket Reverse ClutchCable Spring Forward Clutch HexHd Screw 1 4 20x 1 1 4 Screw Hex 3 8 16x 3 4 Screw Hex 5 16 18x 1 1 2 HexNut 10 24 HexLockNut 1 4 20 HexNut 3 8 16 LockWash...

Page 30: ...ON SnapRing Bearing Tapered Roller withrace SupportWasher Rear DriveShaft ORT Shim RearBearing Cap 010 thick Shim sameasabove except 030 thick Shim sameasabove except 005 thick Shim sameasabove except 062 thick ShimSet IncLthefollowingshims two 1224 1 two 1224 2 one 1224 4 Useas requiredto obtainbetween 005 and 015 allowable end play 3O ...

Page 31: ...78 GW 1104 1904279 4 5 6 7 8 9 10 11 7 4 3 DESCRIPTION Retainer SnapRing E Type Retainer Snap Ring Shim 0 062 thick Shim 0 030 thick Shim 0 015 thick Shim 0 010 thick Shim 0 005 thick Bronze Bushing WheelShaft CRT Key Hi Pro 1 4x 1 Spacer WormGear WheelShaft TillerShaft WoodruffKey WormGear TillerShaft Useas required to obtain between 005 and 030 allowable end play 31 ...

Page 32: ...smission OilFill HexHd Flange Screw 5 16 18x 5 8 G r 5 LockWasher 5 16 Rear Cover Transmission FrontCover Transmission Gasket Housing Cover OilSeal DriveShaft REF PARTNO NO 8 721 04031 9 619 04013 10 721 04036 11 736 3008 12 718 04008 13 710 04048 14 710 3008 DESCRIPTION Oil Seal Wheel Shaft Transmission HousingAssembly Oil Seal Tine Shaft Washer Flat 344 x 750 x 120 Rear Bearing Cap Hex Hd Flange...

Page 33: ...0 712 3009 710 3096 1817059 1916702 1916703 DESCRIPTION Hex Hd Screw 5 16 18 x 3 4 Grade5 Single Tine Right Hand Hex Lock Nut 5 16 18 Hex Hd Screw 3 8 16 x 2 Single Tine Left Hand LH Tine Holder RH Tine Holder REF PARTNO NO 8 1917487 9 GW 9380 10 GW 9338 11 712 3000 1817059 DESCRIPTION Wheel TireAss y Left Right Side ClevisPin 312 x 1 3 4 HairPinCotter HexLockNut 3 8 16 Replacement TinesSet Incl t...

Page 34: ...MODELS 644H 645A I_i_ccLREVERSE UTCH CABLE 1_o j 2 41 _3 25 4 FORWARD CLUTCH CABLE 38 24 84 ...

Page 35: ...ngineDrive A Pulley EngineDrive B Transmission Pulley Pulley ReverseIdler Guard Belts Pulleys Forward Drive Belt ReverseDrive Belt Belt Cover ReverseReturn Spring Belt Guide Forward Belt Guide EngineBracket Left EngineBracket Right Bracket Belt Cover Shoulder Washer Reverse Idler Arm Forward idler Lever Hex Hd Screw 5 16 24 x 1 Hex Hd Screw 5 16 24 x 5 8 Hex Hd Screw 5 16 18 x 1 Hex Hd Screw 5 16 ...

Page 36: ...E 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 SE...

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