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20

Section 5:  Maintenance 

TILLER LUBRICATION

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 a metal
lubricant, if available).

• 

Remove wheels, clean wheel shaft (A,
Fig. 5-1) and apply thin coating of
grease to the shaft.

• 

Grease back, front and sides of depth
regulator lever (B, Fig. 5-1).

• 

Remove tines, clean tine shafts (C, Fig.
5-1). Inspect for rust, rough spots or
burrs (look around holes). File or sand
smooth, coat ends of shaft with grease.

• 

Oil the threads on the handlebar height
adjustment screws and the handlebar
attaching screws (D, Fig. 5-1).

• Shifting Mechanism.  Lightly oil pivot

points for smooth operation (E, Fig. 5-1A).

TRANSMISSION GEAR OIL SERVICE

Check the transmission gear oil level after
every 30 hours of operation or whenever
you notice any oil leak.  Operating the
tiller when the transmission is low on oil
can result in severe damage.

A. To Check the Transmission 
Gear Oil Level:

1. 

Check the gear oil level when the trans-

mission is cool.  Gear oil will expand in
warm operating temperatures and this
expansion will provide an incorrect oil
level reading.

2. 

With the tiller on level ground, adjust

the Depth Regulator Lever up or down to
the notch that makes the tiller level..

3.

Remove the oil fill plug (A, Fig. 5-2)

from the transmission housing and look
into the oil fill hole.  You will see the main
drive shaft  on one side of the hole.

4.

The gear oil level is correct if the gear

oil is approximately half way up the side
of the drive shaft.

5.

If the gear oil level is low, add gear oil

as described next.  If the gear oil level is
okay, securely replace the oil fill plug.

IMPORTANT:

Do not operate the tiller if

the gear oil level is low.  Doing so will
result in severe damage to the transmis-
sion components. 

6.

If adding only a few ounces of gear

oil, use API rated GL-4 or GL-5 transmis-
sion gear oil having a viscosity of SAE
140, SAE 85W-140 or SAE 80W-90.  If
refilling an empty  transmission, use only
GL-4 transmission gear oil having a
viscosity of SAE 85W-140 or SAE 140.

NOTE: Do not use automatic transmission
fluid or engine oil in the transmission.

7.  

While checking frequently to avoid

overfilling, slowly add gear oil into the oil
fill hole until it reaches the halfway point
on the drive shaft. 

8.  

Securely replace the oil fill plug.

CHECK FOR OIL LEAKS

Before each use, check your tiller for
signs of an oil leak – usually a dirty, oily
accumulation either on the unit or on the
floor where it has been parked.

A little seepage around a cover or oil seal
is usually not a cause for alarm. However,
if the oil drips overnight then immediate
attention is needed as ignoring a leak can
result in severe transmission damage. 

If a cover is leaking, try tightening any
loose screws. If the screws are tight, a
new gasket or oil seal may be required. If
the leak is from around a shaft and oil
seal, the oil seal probably needs to be
replaced.  See your authorized dealer or
contact the factory for service or advice.

IMPORTANT: 

Never operate the tiller if

the transmission is low on oil.  Check the
oil level after every 30 hours of operation
and whenever there is any oil leakage. 

CHECK HARDWARE

Check for loose or missing hardware after
every 10 operating hours.  Tighten or
replace hardware before using the tiller.
Be sure to check the screws underneath
the tiller hood (lift the hood flap) that
secure the transmission cover and the
depth regulator lever to the transmission.

CHECK TIRE PRESSURE (on
machines equipped with
pneumatic tires)

Check the air pressure in both tires.
Deflate or inflate both tires evenly from
15-to-20 PSI (pounds per square inch).
Be sure that both tires have the same air
pressure or the unit will tend to pull to
one side.

NOTE: Your tiller may not be equipped
with pneumatic tires, eliminating the need
for air pressure checks.

Figure 5-1

A

B

C

D

D

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.

E

Figure 5-1A

Summary of Contents for 644H-Bronco, 645A-Bronco

Page 1: ...er 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 IMPORTANT READ SAFETY RULES AND INSTRUCTIONS CAREFULLY TROY ...

Page 2: ...n seek help from the experts Choose from the options below Visit troy bilt com for many useful suggestions Click on Customer Support button and you will get the four options reproduced here Click on the appropriate button and help is immediately available If you prefer to reach a Customer Support Representative please call 1 800 520 5520 The engine manufacturer is responsible for all engine relate...

Page 3: ...dissipated 7 Never make adjustments when engine is running unless recommended by manufacturer Operation 1 Do not put hands or feet near or under rotating parts The tines begin to rotate once the engine starts and the Forward Clutch Bail or Reverse Clutch Control is engaged 2 Exercise extreme caution when on or crossing gravel drives walks or roads Stay alert for hidden hazards or traffic Do not ca...

Page 4: ...at care when backing up 17 Do not operate the tiller on a slope that is too steep for safety When on slopes slow down and make sure you have good footing Never permit the tiller to freewheel down slopes 18 Never allow bystanders near the unit 19 Only use attachments and acces sories that are approved by the manufac turer of the tiller 20 Use tiller attachments and acces sories when recommended 21 ...

Page 5: ...ngine Figure 1 Location of Safety and Operating Decals Model 644H shown TO AVOID SERIOUS INJURY READ THE OWNER S MANUAL KNOW LOCATIONS AND FUNCTIONS OF ALL CONTROLS KEEP ALL SAFETY DEVICES AND SHIELDS IN PLACE AND WORKING NEVER ALLOW CHILDREN OR UNINSTRUCTED ADULTS TO OPERATE TILLER SHUT OFF ENGINE AND DISCONNECT SPARK PLUG WIRE BEFORE MANUALLY UNCLOG GING TINES OR MAKING REPAIRS KEEP BYSTANDERS A...

Page 6: ...reful not to severely bend any of the control cables on the unit 3 Remove all unassembled parts and the separate hardware bag from the carton Check that you have the items listed below contact your local dealer or the factory if any items are missing or damaged NOTE Use the screw length template Fig 2 1 to identify screws Loose Parts List Qty Description 1 Handlebar Support see A Fig 2 2 page 7 1 ...

Page 7: ...ll not move loosen attaching screw J and nut IMPORTANT The support brackets must be assembled to the outside of the handlebar assembly 4 Tighten all handlebar mounting hardware securely STEP 3 Move Tiller Off Shipping Platform To move the tiller without the engine running put the wheels in their FREEWHEEL position as described below 1 Use a sturdy block to raise one wheel off the ground 2 Remove t...

Page 8: ...you must make an adjustment to the cable tension as described in Checking and Adjusting Forward Drive Belt Tension in Section 5 When the spring length is correct tighten the hex nut Z against the cable adjuster X STEP 5 Install Reverse Clutch Cable 1 Unwrap the reverse clutch cable the cable with a knob and a large hex nut attached to it from around its shipping position and route the cable CC Fig...

Page 9: ...mis sion Gear Oil Level in Section 5 STEP 7 Add Motor Oil to Engine The tiller is shipped without oil in the engine IMPORTANT Do not start the engine without first adding motor oil Severe engine damage will result if the engine is run without oil 1 Refer to the Engine Owner s Manual supplied with tiller for engine oil specifi cations and capacities 2 With the tiller on level ground pull the Depth ...

Page 10: ... the engine is running Always put both wheels in the WHEEL DRIVE position before starting the engine Failure to comply could cause loss of tiller control property damage or personal injury WARNING Do not place the tiller on its side when changing the wheel drive positions as doing so could result in gasoline leaking from the fuel tank Failure to follow this instruc tion could result in personal in...

Page 11: ...everse Clutch Control The Reverse Clutch Control F Figure 3 4 controls the engagement of reverse drive to the wheels and tines This powered reversing feature is used for maneuvering the tiller only never engage the tines in the ground while going in the reverse direction To Operate the Reverse Clutch Control 1 Operate only when the wheels are in the WHEEL DRIVE position see the WARNING statement a...

Page 12: ...i Reverse Stake This stake is located at the rear of the transmission under the tine hood see H Figure 3 7 Its purpose is to automati cally help prevent the counter rotating tines from letting the tiller back up in the direction of the operator if the tiller wheels had been inadvertently left in the FREEWHEEL position In this situation the Anti Reverse Stake will be forced down into the ground lif...

Page 13: ... operation 4 Check transmission gear oil level after first 2 hours of operation STARTING AND STOPPING THE ENGINE Pre Start Checklist Make the following checks and perform the following services before starting the engine 1 Read the Safety and Controls sections in this manual Read the separate Engine Owner s Manual provided by the engine manufacturer 2 Check that the wheels are in the WHEEL DRIVE p...

Page 14: ...WHEEL DRIVE position Never have the wheels in the FREEWHEEL position when the engine is running When the wheels are in FREEWHEEL they do not hold back the tiller and the tines could propel the tiller rapidly backward Before starting engine put Forward Clutch Bail all Models and Reverse Clutch Control in neutral disen gaged positions by releasing levers Never run engine indoors or in enclosed poorl...

Page 15: ...ure 4 5 After completing the turn slowly lower the tines into the soil to resume tilling Turning the Tiller Around Figure 4 3 Raise tines off ground and look behind when moving in reverse Figure 4 4 To begin turn lift handlebars until engine and tines are balanced over wheels Be sure tines are out of ground Figure 4 5 With tiller balanced over wheels and tines out of the ground push handlebars sid...

Page 16: ...large hard clumps of soil that can interfere with planting If time permits wait a day or two after heavy rains 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 Avoid making footprints Whenever possible walk on the untilled side of the unit to avoid making foot prints in your freshly tilled or cultivated soil Footprints ...

Page 17: ...also leaves room for cultivating IMPORTANT When tilling on slopes be sure the correct oil level is maintained in the engine check every one half hour of operation The incline of the slope will cause the oil to slant away from its normal level and this can starve engine parts of required lubrication Keep the engine oil level at the full point at all times A Tilling up and down slopes To keep soil e...

Page 18: ... the vehicle s engine off and apply its parking brake When going up ramps stand in the normal operating position and push the tiller ahead of you Have a person at each side to turn the wheels 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 How...

Page 19: ...essure in tires if pneumatic Service spark plug Check Anti Reverse Stake Change more frequently in dusty or dirty conditions Change after first 2 hours of break in operation Check after first 2 hours of break in operation See Engine Owner s Manual for service intervals and instructions WARNING Before inspecting cleaning or servicing the machine shut off engine wait for all moving parts to come to ...

Page 20: ...ing a viscosity of SAE 140 SAE 85W 140 or SAE 80W 90 If refilling an empty transmission use only GL 4 transmission gear oil having a viscosity of SAE 85W 140 or SAE 140 NOTE Do not use automatic transmission fluid or engine oil in the transmission 7 While checking frequently to avoid overfilling slowly add gear oil into the oil fill hole until it reaches the halfway point on the drive shaft 8 Secu...

Page 21: ...even spots or burrs from the tine shaft using fine sandpaper Then grease the tine shaft before rein stalling the tine assemblies Be sure all the cutting edges face so they will enter the soil first when the tiller is moving forward this means the cutting edge on the top of each tine faces toward the operator position Tighten hardware C Removing and Installing Individual Tines 1 Use two 9 16 box en...

Page 22: ...g A Figure 5 4 counterclock wise as viewed from the operator s position while holding the adjuster B steady to increase the length of the spring or turn clockwise as viewed from the operator s position to decrease the length of the spring NOTE If you have difficulty holding the adjuster steady by hand use a pliers or wrench on the adjuster While you turn the screw keep the Forward Clutch Cable Fig...

Page 23: ...possible Check belt tension after the first two hours of break in operation new belt Check belt tension after every 10 operating hours To Check Reverse Belt Tension 1 Be sure that the engine is stopped and the spark plug wire is disconnected and moved away from the spark plug 2 Remove the screw in the plastic belt cover and slide the cover which is attached to the forward clutch cable out of the w...

Page 24: ...y or dirty conditions Service the air cleaner as instructed in the separate Engine Owner s Manual SPARK PLUG SERVICE Inspect and clean or replace the spark plug after every 100 operating hours or annually Clean the plug and set the gap as described in the separate Engine Owner s Manual In some areas local law requires using resistor spark plugs to suppress ignition signals If the engine was origin...

Page 25: ...e Service Dealer 4 Stale gasoline 4 Replace with fresh gasoline 5 Dirt or water in fuel tank 5 See Engine Service Dealer 6 Engine cooling system clogged 6 Clean air cooling system see Engine Owner s Manual Engine overheats 1 Engine cooling system clogged 1 Clean air cooling area see Engine Owner s Manual 2 Carburetor out of adjustment 2 See Engine Service Dealer 3 Oil level is low 3 Check oil leve...

Page 26: ... commercial institutional industrial rental or demonstrator purposes the warranty COMMERCIAL on the tiller is limited in duration to 90 days from the date of purchase USE WARRANTY 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 ...

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