Troy-Bilt TUFFY 645A - Manual (Page 6)

SECTION 2: ASSEMBLY
A
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
recommended thatyou read this 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.
INSPECT UNIT
Inspect the unit and carton for damage im­
mediately after delivery. Contact the carrier
(trucking company) if you find or suspect
damage. Inform them of the damage and
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 LLC if you need assis­
tance in this matter.
TOOLS / MATERIALS NEEDED
(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) Clean oil funnel
(1) Motor oil. Refer to the Engine Owner’s
Manual for oil specifications and
quantity required.
* Adjustable wrenches may be used.
ASSEMBLY STEPS
STEP1: UNPACKING INSTRUCTIONS
NOTE: While unpacking, do not severely
bend any control cables.
1. The tiller weighs approximately 133 lbs.
Do not attempt to remove it from the ship­
ping platform until instructed to do so in
these AssemWy steps.
2. Remove any packaging material from
the carton. Remove any staples from the
bottom of the cation and remove the car­
ton from the shipping platform.
3. Remove all unassembled parts and the
separate hardware bag from the carton.
Check that you have the 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 Handlebar Support (see A. Fig. 2-2)
1 Handlebar Assembly (see K, 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 locknut. 3^"-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 separate Engine
Owner’s Manual.
NOTE: LEFT and RIGHT sides of the tiller
are as viewed from the operator’s position
behind the handlebars.
STEP 2: ATTACH HANDLEBAR
1. Loosely attach the legs of the handlebar
support (A, Fig. 2-2) to the inner sides of
the tiller frame using two 3/8"-16 x 3/4" hex
hd. screws (B), 3/8" flat washers, and 3/8"-
16 hex locknuts.
Figure 2-1: To identify length of screws, piace
screw on template as shown and measure dis­
tance between bottom of screw head and tip of
screw.
2. Using two 5/16"-18x 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. There are three height adjustment holes
in the two handlebar support brackets (E
and F, Fig. 2-2). Use a setting that will po­
sition the handlebars at approximately
waist level when the tines are 3"-4" into the
soil. Loosely attach the support brackets to
the outside ot the handlebar assembly (I)
using two 5/16"-18x 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
be assembled 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. Place a sturdy block under the transmis­
sion to raise one wheel about 1" off the
ground.
2. Remove the Klik Pin (J, Fig. 2-3) from
the wheel hub (K) and wheel shaft (L).
3. Slide the wheel fully inward on the wheel
shaft (N, Fig. 2-3). Reinstall the Kllk pin (J)