Troy-Bilt 466 Lawn Mower User Manual
Contents
1. s Place the new blade on the blade adapter with the side marked bottom has a part number facing away from the adapter s Secure the blade to the assembly with two hex bolts and lock nuts Tighten the hex bolts to the 13 recommended torque Refer to Blade Mounting Torque information below Install the blade assembly on the engine crankshaft Secure with the hex bolt and bell washer cupped side of washer to blade and tighten to the recommended torque Refer to Blade Mounting Torque information below IMPORTANT The bolt used to secure the blade to the engine is specially heat treated Do not substitute To order replacement bolt refer te the parts list in the back of this manual WARNING To ensure safe operation of your unit all nuts and bolis must be checked periodically for correct tightness Blade Mounting Torque Blade adapter bolts 120 in lbs minimum 150 in Ibs maximum Center bolt 450 in lbs minimum 600 in Ibs maximum To Sharpen Blade s The blade can be sharpened with a file or on a grinding wheel Do not attempt to sharpen the blade while it is still on the mower s Follow the original angle of grind as a guide Make sure that each cutting edge receives an equal amount of grinding to prevent an unbalanced blade An unbalanced blade will cause excessive vibration when rotating at high speeds may cause damage to the mower and or personal injury Test the blade by balancing2. neglect accident improper maintenance alteration vandalism theft fire water or damage because of other peril or natural disaster Damage resulting from the installation or use of any accessory or attachment not approved by Troy Bilt LLC for use with the productis covered by this manual will void your warranty as to any resulting damage Normal wear parts or components therecf are subject to separate terms as follows All normal wear parts or component failures will be covered on the product for a period of 90 days regardless of cause After 90 days but within the two year period normal wear part failures will be covered ONLY IF caused by defects in materials or workmanship of OTHER component parts Normal wear parts and components include but are nat limited to batteries belts blades blade adapters grass bags rider deck wheels seats snow thrower skid shoes shave plates auger spiral rubber and tires HOW TO OBTAIN SERVICE Warranty service is available WITH PROOF OF PURCHASE through your local authorized service dealer To locate the dealer in your area check your Yellow Pages or contact Troy Bilt LLC at P O Box 361131 Cleveland Ohio 44136 0013 or call 1 866 840 6483 or 1 330 558 7220 or log on te cur Web sits at www troybilt com This limited warranty does not provide coverage in the following cases a The engine or component parts thereof These items carry a separate manufacturers warranty Refer to appl
3. servicing them Keep all nuts bolts and screws tight to be sure the equipment is in safe working condition Never tamper with safety devices Check their proper operation regularly After striking a foreign object stop the engine disconnect the spark plug wire and ground against the engine Thoroughly inspect the mower for any damage Repair the damage before starting and operating the mower Never attempt to make a wheel or cutting height adjustment while the engine is running Grass catcher components discharge cover and trail shield are subject to wear and damage which could expose moving parts or allow objecis to be thrown For safety protection frequenily check componenis and replace immediately with original equipment manufacturer s O E M parts only listed in this manual Use of parts which do not mest the original equipment specifications may lead to improper performance and compromise safety Do not change the engine governor setting or overspeed the engine The governor controls the maximum safe operating speed of the engine Maintain or replace safety and instruction labels as necessary Observe proper disposal laws and regulations Improper disposal of fluids and materials can harm the environment REED GAFENY D TORR MANUAL DISCHARGE COVER E TC SEL SLOPE GAUGE SECTION 2 AAA SGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE Mg A POWER POLE ron I Laa A CORNER OF A BUILDING T gd O
4. 25 hours of use and replace the paper filter component every 100 hours You may have to service the air filter more frequenily if you are operating the mower under extremely dusty conditions Clean engine periodically with a cloth or brush s Clean the spark plug and reset the gap to 030 at least once a season or every 50 hours of operation Spark plug replacement is recommended at the start of each season s Inspect muttler periodically and replace if necessary Damaged mufflers or spark arresters can create a fire hazard Make sure to avoid muffler and surrounding areas while the mower engine is hot because temperature of these areas of the engine may exceed 150 F Lubrication See Figure 12 Whesls Lubricate the wheels and bearings if so equipped at least once a season with light ofl or engine oil Also if the wheels are removed for any reason lubricate the surface of the axle bolt and the inner surface of the wheel with light oil Chute Deflector amp Rear Discharge Door Lubricate the torsion spring and the pivot point on each end of the chute deflector and the rear discharge door using a light oil This will prevent rusting and ensure that the deflector which is a safety device can always work properly Engine s Follow the engine manual instructions and recommended schedule for lubricating engine componenis Pivot Points s Lubricate the pivot points on the blade control handle lower bail hadle and th
5. Bell Washer 0 265 x 0 75 Front Baffle Transmission Assembly Compl Screw 12 x 0 497 Front Drive Cover Rall Pin Bell Washer Bearing Support Wave Washer Height Adj Plate LH Height Adj Plate RH Pivot Plate Assembly Drive Pulley Blade Adapter Mulching Blade w Star 21 Hex Lock Nut Hex Screw Dowel Pin Gear 14T RH Gear 14T LH Hairpin Clip Flat Washer Snap Ring Wheel Dust Cap Snap Ring Washer DD 1 5 O D Input Pulley Hex Bolt Bell Washer Grass Bag Rear Baffle RH Slev Spacer LH Slev Spacer RH Height Adj Assembly RH Compl Height Adj Assembly LH Compl RD Chute Door Torsion Spring Cable Tie not shown TT Screw Height Adj Assembly RH Compl Height Adj Assembly LH Compl Weld Pin Wheel Front Spring Lever MANUFACTURER S LIMITED WARRANTY FOR The limited warranty set forth below is given by Trey Bilt LLC with respect to new merchandise purchased and used in the United States its possessions and territories Troy Bilt LLC warrants this product against defects for a period of two 2 years commencing on the date of original purchase and will atits option repair or replace free of charge any part found to be defective in materials or workmanship This limited warranty shall only apply if this product has been operated and maintained in accordance with the Operator s Manual furnished with the product and has net keen subject te misuse abuse commercial use
6. than 15 degrees as shown on the slope gauge 3 Donot mow on wet grass Unstable footing could cause slipping Children Tragic accidents can occur if the operator is not alert to the presence of children Children are often attracted to the mower and the mowing activity They do not understand the dangers Never assume that children will remain where you last saw them 1 Keep children out of the mowing area and under the watchful care of a responsible adult other than the operator 2 Be alert and turn mower off if a child enters the area 3 Before and while moving backwards look behind and down for small children 4 Use extreme care near blind corners doorways shrubs trees or other objects that may obscure your vision of a child who may run inte the mower 5 Keep children away from hot or running engines They can suffer burns from a hot muffler 6 Never allow children under 14 years old to operate a power mower Children 14 years old and over should read and understand the operation instructions and safety rules in this manual and should be trained and supervised by a parent Service Safe Handling of Gasoline 1 Te avoid personal injury or property damage use extreme care in handling gasoline Gasoline is extremely flammable and the vapors are explosive Serious personal injury can occur when gasoline is spilled on yourself or your clothes which can ignite Wash your skin and change clothes immediately U
7. your lawn mower Cleaning the Mower s Clean the underside of the mower deck after sach use to prevent any build up of grass clippings If this debris is allowed to accumulate it will result in rust and corrosion NOTE We do not recommend the use of pressure washers or garden hose to clean your unit These may cause damage to electric components spindies pulleys bearings or the engine The use of water will result in shortened life and reduced serviceability Disconneci spark plug wire Drain the gasoline from the lawn mower or place a piece of plastic under the gas cap s Tilt the mower so that the side with the air cleaner is facing up Hold the mower firmly Scrape and clean the underside of the deck with a suitable tool Do not spray with water s Putthe mower back on its wheels If you had put plastic under the gas cap remove it now WARNING Never tip the mower more than A 90 degrees in any direction and do not leave the mower tipped for any length of time Oil can drain into the upper part of the engine causing a starting problem Engine Maintenance A list of key maintenance jobs required for good performance by the mower ls given below Follow the accompanying engine manual for detailed list and instructions Change engine oil after the first two operating hours and every 25 operating hours thereatier Check oil level before starting engine every time Service foam filter in the air cleaner every
8. 4 0637 Part Description Lower Bail Handle Blade Control Handle Upper Handle Oval C Sunk Ser 1 4 20 x 1 31 Control Housing Hex Lock Nut 1 4 20 Control Cable 43 Lower Handle Drive Cable Hex Screw 1 4 20 x 1 5 Carriage Bolt Handle Knob Saddle Washer Wing Nut Hope Guide Grass Catcher Frame Rear Grass Catcher Frame Front Engine Spacer Assembly Hairpin Clip Fear Trail Shield Wire Trail Shield Knob Ser Tr Mach 110 24 x 0 380 Torsion Spring LH Rear Baffle LH Ser AB 1 4 14 x 0 625 Torsion Spring RH Hex Ser w Wash 1 4 14 x 0 62 Knob Bell Washer 375 x 870 Wheel Rear Shoulder Screw Hubcap Handle Bracket Assembly LH Handle Bracket Assembly RH Pivot Bar LH Pivot Bar RH Front Lever RH Front Lever LH Shoulder Screw Hinge Pin Mounting Bracket Hex Nut Flat Washer Belt Tension Spring 3 in 1 Deck 21 V Belt ES 731 1404A 731 1409 710 0999 736 0270 782 5002 618 0657 7910042824 731 2601 715 6169 736 0331 748 0355 736 0447 782 0511A 782 0512B 682 0509 756 1146A 748 0411 742 0741 712 0324 710 0216 719 0221 717 1762 717 1761 714 0101 736 3013 716 0865 782 7991 716 9102 736 0474 796 1231 710 1257 736 0492 664 0176 782 5004 750 1166 750 1165 682 0516A 682 0515A 782 7000 732 0731 726 0240 710 1008 682 0512A 682 0511A 719 1248 734 2042 732 0417A 19 Part Description Muleh Plug Discharge Deflector SD TT Screw 1 4 20 x 0 5
9. 5 Figure 18 Carburetor WARNING I any adjustments are made to the engine g carburetor while the engine is running keep clear of all moving paris Be careful of heated surfaces like the muffler NOTE A dirty air cleaner may cause an engine to run rough too Make sure that the air cleaner is clean and attached to the carburetor before deciding to adjust the carburetor To adjust carburetor please follow the engine manual Gasoline s Be not store gasoline from one season to another NOTE Gasoline stored for more than one month may affect engine performance So use fresh gasoline Replace your gasoline can t it starts to rust Rust and or dirt in the gascline will cause problems Engine Clean engine and remove any grass clippings dirt and debris from the cooling fins air intake screen levers linkage and the exterior of the engine s Follow recommendations in engine manual for off season storage of the engins Change oil as stated in the engine manual Storage s Store unitin a clean dry area Do not store next to corrosive materials such as fertilizer or rocksalt s If storing the mower in an unventilated or metal storage shed make sure to rustproof the equipment with a light oil or silicone SECTION 10 TROUBLE SHOOTING GUIDE Engine fails to start 1 Blade control handle disengaged 1 Engage blade control handle 2 Spark plug wire disconnected 2 Gonnect wire to spark plug 3 Fuelt
10. ING MODEL NUMBER This Operator s Manual is an important part of your new Lawn Mower It will help you assemble prepare and maintain the unit for best performance Please read and understand what it says Before you start assembling your new equipment please locate the model plate on the equipment and copy the information from it in the space provided below The information on the model plate is very important if you need help from our Customer Support Department or an authorized dealer You can locate the model number by standing behind the unit in the operating position and looking down ai the rear of the deck 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 Model Number Serial Number Copy the model number here the serial number here OTROYBIT meyers 0 P 0 BOX 351131 MNNM troy DITE COT CLEVELAND DH 44136 330 556 7220 666 640 6463 ENGINE INFORMATION The engine manufacturer is responsible for all engine related issues with regards to performance power rating specifications warranty and service Please refer to the engine manufacturer s Owner s Operator s Manual packed separately with your unit for more information CALLING CUSTOMER SUPPORT If you have difficulty assembling this product or have any questions regarding the controls operation or maintenance of this unit please call the Customer Support D
11. Make sure that the cables are routed to the outside of the handie when attaching the grass catcher s Lift the rear discharge door s Place the hooks of the grass catcher into the slots in the handle bracket assemblies on both sides See Figure 9 Release the rear discharge door Rear Discharge Deor Y o nn Figure 3 Removing Grass Catcher Lift the rear discharge door on the mower Lift the grass catcher up cut of the slots in the handle bracket assemblies Reinstall the plastic rear baffle Release the rear discharge door U WARNING Never operate the mower unless the hooks on the grass catcher are seated in the slots on the handle bracket assemblies and the rear discharge door rests tirmly against the top of the grass catcher Converting to Side Discharge Your mower has been shipped as a mulcher To convert it to a side discharge mower lift the mulching plug Slide the two hacks on the side discharge deflector under the hinge pin on the mulching plug assembly Lower the mulching plug See Figure 10 Do not remove the side mulching plug at any time even when you are not mulching Mulching Plug Figure 10 SECTION 4 KNOW YOUR LAWN MOWER Read this owner s manual and safety rules before operating your lawn mower Compare the illustrations in Figure 11 with your lawn mower to familiarize yourself with the location of various controls and adjustments Blade Control Handle L
12. OTROV BILT Operators Manual 21 Three in One Lawn Mower Model 466 IMPORTANT Read safety rules and instructions carefully before operating equipment 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 cquipped with a spark arrester meeting applicable local or state laws if any If a spark arrestor is used n should be maintained in effective working order by the operator Inthe State of Califomia the above is required by law Section 4442 of the California Public Resources Code Other statos may have similar laws Federal laws apply on federal lands A spark arrester Tor the mutiler is available through your nearest engine authorized service dealer or contact the service department P O Box 361131 Cleveland Ohio 44136 001 9 TROY BILT LLC P O BOX 361131 CLEVELAND OHIO 44136 0019 FORM NO 7629 00005 PRINTED IN U S A 12 2001 TABLE OF CONTENTS Content Page Important Safe Operation Practices cece neee eee Gd Slope Gauge I hI Assembling aur pe Mower slana eat Stat E agrio ati vanat T Know Your Lawn a adi 10 Operating Your Lawn NM OWSr see eee ee eee eee 11 Maintaining Your Lawn Mower sss sees eee cece eee eee eee 12 Service AA SE T A TETE E Making Zaue A la Off Season A MR D Troubleshooting ic piratas td ac 1G Pans Liet our ln data ici 18 FIND
13. R AFENCE POST Aero Do not mow on inclines with a slope in excess of 15 degrees a rise of approximately 2 1 2 feet every 10 feet A riding mower could overturn and causs serious injury If opsrating a walk bshind mower on such a slops it is extremely difficult to maintain your footing and you could slip resulting in serious injury Operate RIDING mowers up and down slopes never across the face of slopes Operate WALK BEHIND mowers across the face of slopes never up and down slopes SECTION 3 ASSEMBLING YOUR LAWN MOWER Removing Unit From Carton s Remove staples break glue on top flaps or cut tape ai carton end and peel along top flap to open carton Remove loose parts if included with unit e operator s manual hardware pack etc Cut comers and lay carion down flat Remove packing material s Rell or slide unit out of carton Check carton thoroughly for loose parts NOTE Make sure not to crimp cables while removing foose parts or the entire unit from the carton Tools Required s Pair of Pliers Funnel s Setof adjustable wrenches Disconnecting Spark Plug Before setting up your lawn mower disconnect the spark plug wire from the spark plug and attach rubber boot to a bolt on the engine to ground Ses Figure 1 Spark Plug Figure 1 NOTE Heference to right or left hand side of the mower is observed from the operating position IMPORTANT This unit is shipped without gasoline or cil in the en
14. ade NOTE For repairs beyond the minor adjusimenis listed above contact your nearest authorized service dealer Refer to separate engine manual packed with your mower for more engine related information 16 Safety amp Decorative Labels MODEL PLATE ON LEFT SIDE 777830145 MA 477530110 FACING OPE ST e RATOR il 777D06018 77708002 777D06010 77 D06012 XR NOTE FRONT B amp S LOGO S1B274040 PROVIDED BY MANUFACTURER 17 SECTION 11 PARTS LIST FOR MODEL 466 IMPORTANT Fer a proper working machine use Factory Approved Parts V BELTS are specially designed te engage and disengage safely A substitute non OEM V Belt can be dangerous by not disengaging completely Model 466 Binal m W K MM 5 5 5 5 5 5 5 5 KM KM BG BM K NGG BO 28 OO WWW WO ww M B J WO MAMM k DADARLNZO 747 2136 647 0004 749 1501 710 1270 746 0883 712 0324 746 0551 749 0928A 746 1146 710 0606 710 1174 720 0284 736 0451 720 0279 710 1209 764 0310 764 0311 6831 0075B 714 0104 731 1236 732 0700 720 0275 710 0192 732 0677 782 5003 710 1017 732 0678 710 0896 720 0426 736 0105 7734 20044 738 0102 731 0981A 682 0513 682 0514 14766 14769 732 0706 732 0707 739 0507B 747 0710 782 7006 712 0798 736 0356 732 1043 782 0082A 79
15. ank empty or stale fuel 3 Fill up tank with fresh gasoline 4 Blocked fuel line 4 Clean fuel line 5 Faulty spark plug 5 Clean adjust gap or replace 6 Engine flooded 6 Wait afew minutes and start again Engine runs erratic 1 Spark plug wire loose 1 Connect and tighten spark plug wire 2 Blocked fuel line or stale fuel 2 Clean fuel line fill tank with fresh gas 3 Ventin gas cap plugged 3 Clear vent 4 Water or dirt in fuel system 4 Drain fuel tank Refill with fresh fuel 5 Dirty air cleaner 5 Clean air cleaner Refer to engine manual Engine overheats 1 Engine oil level low 1 Fill crankcase with proper oll 2 Air flow restricted 2 Clean lawn mower engine Occasional skip at 1 Spark plug gap too close 1 Adjust gap to 030 inches high speed Idles poorly 1 Spark plug fouled faulty or gap too wide 1 Reset gap to 030 inches or replace spark plug 2 Dirty air cleaner 2 Clean air cleaner Excessive vibration 1 Cutting blade loose or unbalanced 4 Tighten blade and adapter balance blade 2 Bent cutting blade 2 Replace blade 3 Bent engine crankshaft 3 Contact your nearest service center Mower will not 1 Wet grass 1 Wait until grass is dry to cut mulch grass 2 Excessively high grass 2 Mow once ata high cutting height 3 Dull blade then mow again at desired height 3 Sharpen or replace blade Uneven cut 1 Wheels not in same height position 1 Reposition all wheels at same height 2 Dullblade 2 Sharpen or replace bl
16. by slipping or tripping Do not hold on to the mower if you are falling release the handle immediately Never pull the mower back toward you while you are walking If you must back the mower away from a wall or obstruction first look down and behind to avoid tripping and then follow these steps a Step back from the mower to fully extend our arms 4 Thoroughly inspect the area where equipment is to b Aa sure you are well balanced with sure be used Remove all stones sticks wire bones j footing toys and other foreign objects which could be c Pull the mower back slowly no more than tripped over or picked up and thrown by the blade hal way toward you Thrown objects can cause serious personal injury d Repeat these steps a needed Pan Jou mewing patom to avoid discharge of 12 Do not operate the mower while under the influence material toward roads sidewalks bystanders and ot alcohol or drugs the like Also avoid discharging material against a 3 Da nat engage the selt propelled mechanism on wall or obstruction which may cause discharged units so equipped while starting engine material to ricochet back toward the operator 14 The blade control handle is a safety device Never 5 To help avoid blade contact or a thrown object injury stay in the operator zone behind the handles and keep bystanders helpers children and pets at least 75 feet from the machine while itis in operation Stop machine if anyone enters the area 6 Alwa
17. e cutting height adjustment lever at least once a season with light oil The blade control handle and the lower bail handle must operate freely in both directions The cutting height adjustment levers should be able to move easily Lubricate N Lubricate Lubricate Lubricate Lubricate Figure 12 SECTION 7 SERVICING YOUR MOWER Blade Care Periodically inspect the blade adapter and pulley for cracks especially if you strike a foreign object Replace when necessary WARNING When removing the cutting blade for sharpening or replacement protect hands by using heavy gloves or a thick rag to grasp the cutting blade Disconnect spark plug wire from spark plug Turn mower on its side making sure that the air filter and the carburetor are up To Remove Blade Remove the bolt and the bell washer that hold the blade pulley assembly to ihe engine crankshaft See Figure 13 Remove the assembly from the crankshaft Remove the two bolts and lock nuts from the blade assembly s Remove the blade from blade adapter and pulley To Replace Blade Before reinstalling the blade pulley assembly to the unit lubricate the engine crankshaft and the inner surface of the blade adapter with light oil s Also lubricate the bolt holes bolt and the inner surface of the nuts Installthe blade adapter on the pulley with the star away from the pulley See Figure 13 Lock Nut Figure 13 Hex Bolt
18. epartment Call 1 866 840 6483 or 1 330 558 7220 to reach a Customer Support representative Please have your unit s model number and serial number ready when you call See previous section to locate this information You will be asked to enter the serial number in order to process your call SECTION 1 IMPORTANT SAFE OPERATION PRACTICES T WARNING This symbol points out important safety instructions which if not followed could endanger the personal safety and or property of yourself and others Read and follow all instructions in this manual before attempting to operates this machine Failure to comply with these instructions may result in personal injury When you ses this symbol HEED ITS WARNING T WARNING Engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known to State of California to cause cancer and birth defects or other reproductive harm any type of power equipment carelessness or error on the part of the operator can result in serious injury This machine ig capable of amputating hands and feet and throwing objects Failure to cbserve the following safety instructions could result in serious injury or death T WARNING This machine was built to be operated according to the rules for safe operation in this manual As with General Operation ricochet can cause serious injury to the eyes 7 Wear sturdy rough soled work shoes and close fitting slacks and s
19. free of grass leaves or other debris build up Clean up oil or fuel spillage and remove any fuel soaked debris Allow a mower to cool at least 5 minutes before storing General Service T Never run an engine indoors or in a poorly ventilated area Engine exhaust contains carbon monoxide an odorless and deadly gas Betore cleaning repairing or inspecting make certain the blade and all moving parts have stopped Disconnect the spark plug wire and ground against the engine te prevent unintended starting Check the blade and engine mounting bolts at frequent intervals for proper tightness Also visually inspect blade for damage e g bent cracked worn Replace blade with the original equipment manutacture s O E M blade only listed in this manual Use of parts which do not meet the original equipment specifications may Your Responsibility Restrict the use of this power machine to persons who read understand and follow the warnings and instructions in this manual and on the machine TO REDUCE THE RISK OF INJURY NOT OPERATE MOWER UNLESS VER OR GRASS DO NS DISCHARGE CHUTE C CATCHER 15 IN ITS F DAN T A WARNING TO REDUCE THE REISK OF INJURY DD ROT OPERATE MOWER UNLESS THIS GUARD OR ERTIRE GRASS CATCHER IS IN ITS PROPER PLACE 10 11 12 lead to improper pertormance and compromise safety Mower blades are sharp and can cut Wrap the blade or wear gloves and use extra caution when
20. gine Be certain to service engine with gasoline and oil before operating your mower Assembling Handle s For shipping purposes the grass bag was placed on top of the unit Remove it from the unit and set it out of the way See Figure 2 Figure 2 s Raise the lower handle as shown in Figure 2 till it snaps into place s Raise the upper handle as shown in Figure 2 Tighten the two wing nuts which are already on the handle Ses Figure 3 Tighten these wing nuts Figure 3 NOTE Make sure io route the cables outside the lower handle Also do not crimp the cables while lifting the handle up s Forshipping purposes the hairpin clip is placed in the outer hole of the weld pin on the lower handle Remove the hairpin clip from the outer hole of the weld pin Using a pair of pliers insert the hairpin clip into the inner hole in the weld pin Repeat on the other side See Figure 4 we Lower Handle Hairpin Cli Inner Hole Insert post of cable ties that are on lower handle into the holes provided on the lower handle The holes may be on the inside or outside Pull cable ties tight and cut off the extra See Figure 5 below Cable Tie Figure Attaching Starter Rope The rope guide is already attached to the right side of the lower handle of your mower See Figure 6 s With the spark plug wire disconnected and grounded hold the blade contro handle against the upper handle and pull
21. hirts Shirts and panis that cover the arms and legs and steel toed shoes are recommended Never operate this machine in bare feet sandals slippery or light weight e g canvas shoes Do not put hands or feet near rotating paris or under the cutting deck Contact with the blade can amputaie hands and fest 1 Read this operators manual carefully in its entirety before attempting to assemble this machine Read understand and follow all instructions on the machine and in the manual s before operation Be completely familiar with the controls and the proper use of this machine before operating it Keep this 8 manual in a safe place for future and regular l reterence and tor ordering replacement parts 2 This machine is a precision piece of power 9 A missing or damaged discharge cover can cause equipment nat gt plaything U INICIAN blade contact or thrown object injuries extreme caution at al times Your unit has been 0 Many injuries occur as a result of the mower being designed to perform one job to mow grass Do not use it for any other purpose 3 Never allow children under 14 years old to operate this machine Children 14 years old and over 41 should read and understand the operation instructions and safety rules in this manual and should be trained and supervised by a parent Only responsible individuals who are familiar with these sate operation rules should use this machine pulled over the foot during a fall caused
22. icable manufacturer s warranty far terms and conditions b Log splitter pumps valves and cylinders have a sepa rate one year warranty G Routine maintenance items such as lubricants filters blade sharpening tune ups brake adjustments clutch adjustments deck adjustments and normal deterioration of the exterior finish due to use or exposure OTROY BILT d Troy Bilt LLC does not extend any warranty for products sold or exported outside of the United States its possesions and territories except those sold through Troy Bilt LLC s authorized channels of export distribution e Parts that are net genuine Troy Bilt parts are not covered by this warranty f Service completed by someone other than an authorized service dealer is not covered by this warranty g Transportation charges and service calls are not covered No implied warranty including any implied warranty of merchantability of fitness for a particular purpose applies after the applicable period of express written warranty above as to the parts as identified No other express warranty whether written or oral except as mentioned above given by any person or entity including a dealer or retailer with respect to any product shall bind Troy Bilt LLC During the period of the warranty the exclusive remedy is repair or replacement of the product as set forth above The provisions as set forth in this warranty provide the sole and exclusive remedy arising fr
23. in the same relative position For rough or uneven lawns move the height adjustment lever tc a higher position This will help stop scalping of the grass An adjusting plate and thumb lever at sach wheel position provides cutting height adjustment Each adjusting plate has nine height positions Height cf cut will change when you move the thumb lever from ons position to another Simply depress the lever towards the wheel and move the lever assembly te desired position Ses Figure 18 SECTION 9 OFF SEASON STORAGE Prepare your lawn mower for storage at the end of the season or if it will not be used for 30 days or more Mower Clean underside of the mower following instructions on page 12 NOTE We do not recommend the use of pressure washers or garden hose to clean your unit They may cause damage to electric components spindies pulleys bearings or the engine The use of water will result in shortened life and reduce serviceability Lubricate the mower as instructed on page 12 You can fold your mower s handle for convenience of storage Remove the starter rope from the rope guide loosen the two hand knobs on the sides of the handle and let the upper handle told down to the rear Move the hairpin clips to the outer hole in the weld pins on the handle mount ing brackets Spread sides of the lower handle and push it forward and down Inspect and replace sharpen blade if required Refer to page 13 1
24. it on a round shaft screwdriver or a blade balancer s ifthe blade is not balanced remove metal from the heavy side until it balances evenly Replacing Drive Belt Remove two shoulder screws securing the front drive cover to the mower deck See Figure 14 Press inward on the sides of the front drive cover and release the tabs that secure the front drive cover to the height adjusier brackets Remove drive cover from the mower Using a torx wrench loosen the screw holding the belt tension spring to the transmission See Figure 14 De not remove the screw completely As you loosen the screw the tension on the belt will be released Push the transmission up a little and slide the belt off the transmission pulley s Liftihe mower to access the belt from the underside of the mower Loosen this screw Shoulder Screw 4 ES CP Shoulder Screw Front Drive Transmission Cover Figure 14 s Slide the belt off the engine pulley and around the blade Ses Figure 15 WARNING As always use a thick piece of A rag to handle the blade while sliding the belt around it Make sure the spark plug is disconnected and grounded for this job s Replace with the new belt working around the blade Make sure the belt is firmly seated on the engine pulley while pulling from the other side and sliding it around the transmission pulley s Putthe mower down with all four wheels firmly placed on one leve
25. l s Tighten the screw loosened earlier to secure the belt tension spring to the transmission and reassemble the front drive cover SECTION 8 MAKING ADJUSTMENTS Handle Height Your mower is shipped with the handle in the higher height position To lower height proceed as follows s Remove the starter rope from the rope guide s Remove the upper handle by removing the hand knobs and carriage bolis Lay the upper handle out of the way being careful not to bend or kink cables s Remove the hairpin clips from the weld pins on the handle brackets Refer to Figure 4 Press out on the Pulley Figure 18 Replacing Rear Flap To remove rear flap cut off the flat end of the wire rod which secures it to the deck See Figure 16 Attach the new flap and new rod to deck bending the ends of the new rod over to secure to deck Rear Discharge Door Handle Bracket Figure 16 legs of the lower handle Remove lower handle from the mower Turn lower handie around so the notch is facing forward as shown in Figure 17 Reassemble placing the bottom holes in the handle over the weld pins in the handle mounting bracket s Reassemble the upper handle to the lower handle Insert hairpin clips in the inner holes of the weld pins and attach the starter rope as instructed in Assembling Your Lawn Mower section Lower Handle Q Figure 17 Cutting Height IMPORTANT All wheels must be placed
26. om the sale Troy Bilt LLC shall not be liable for incidental or consequential loss or damage including without limitation expenses incurred for substitute or replacement lawn care services or for rental expenses to temporarily replace a warranted product Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts so the above exclusions or limitations may not apply to you In no event shall recovery of any kind be greater than the amount of the purchase price of the product sold Alteration of safety features of the product shall void this warranty You assume the risk and liability for loss damage or injury te you and your property and or to others and their property arising cut of the misuse or inability to use the product This limited warranty shall not extend to anyone other than the original purchaser orto the person for whem it was purchased as a gift HOW STATE LAW RELATES TO THIS WARRANTY This limited warranty gives you specific legal rights and you may also have other rights which vary from state to state Troy Bilt LLC P O BOX 361131 CLEVELAND OHIO 44136 0019 Phone 1 866 840 6483 1 330 558 7220
27. ower Bail Handle Starter Rope Cutting Height p Oil Plug N gt AA Gasoline Fill SS NY Na n R f Spark Plug NK Hf Bag Fill A Indicator V Mulch A Plug Cutting Height Side Discharge Adjustment Lever Fourth lover nat shown Chute Deflector Figure 11 Recoil Starter Lower Bail Handle The recoil starter is attached to the handle Stand The lower bail handle is located on the upper handle behind the unit and pull the starter rope to start the unit and is used to engage the drive Squeeze the bail Primer handle against the upper handle to engage the drive The primer is used to pump gas into the carburetor Use release Vic Sow doewn OL Sop The mower ran it to assist in starting a cold engine but do not use it propelling when restarting a warm engine after a short shutdown Throttle Control Refer to engine manual for location of the primer The engine is equipped with a constant speed throttle Blade Control Handle which is set at full throttle for maximum engine and The blade control handle is located on the upper handle cutting performance of the mower The blade control handle must be Grass Bag Bag Fill Indicator depressed in order to operate the unit Release the The grass bag is equipped with a bag fill indicator to blade control handle to stop the engine and the blade add convenience to your work While the mower is running air will flow through the bag and into the sail WARNING The blade control handle i
28. r operate mower with damaged safety devices Failure to do so can result in personal injury 20 Muffler and engine become hot and can cause a burn Do not touch 21 Only use parts and accessories made by the original equipment manufacturer O E M Failure to do so can result in personal injury 22 If situations occur which are not covered in this manual use care and good judgment Contact your dealer for assistance Telephone 1 866 840 6483 for the name of your nearest dealer Slope Operation Slopes are a major factor related to slip and fall accidents which can result in severe injury Operation on slopes requires extra caution If you feel uneasy on a slopes do not mow it Before operating this unit on a slope or hilly area use the slope gauge on page to measure slopes If the slope is greater than 15 degrees do not mow it Do 1 Mow across the face of slopes never up and down Exercise extreme caution when changing direction on slopes 2 Watch for holes ruts rocks hidden objects or bumps which can cause you to slip or trip Tall grass can hide obstacles 3 Always be sure of your footing A slip and fall can cause serious personal injury If you feel you are losing your balance release the blade control handle immediately and the blade will stop rotating within 3 seconds Do Not 1 Do not mow near drop offs ditches or embankments you may lose your footing or balance 2 Donot mow slopes greater
29. s a If the grass catcher is empty air flows through easily safety device Never attempt to bypass its pushing the sail up If the grass catcher Is full air does operations The blade will be rotating whenever nottlow through It allowing the sail to fall So the the engine is running position of the sail acts as a bag fill indicator signifying when to empty the grass bag 10 SECTION 5 OPERATING YOUR LAWN MOWER Gas and Oil Fill Up T WARNING Never fill fuel tank indoors or when engine is running or hot Do not smoke when filling up the fuel tank Service the engine with gasoline and oil as instructed in the separate engine manual packed with your mower Read the instructions carefully Before Starting Mower s Attach spark plug wire to spark plug Make certain the metal cap on the end of the spark plug wire inside the rubber boot is fastened securely over the metal tip on the spark plug Starting Engine T WARNING Be sure no one other than the operator is standing near the lawn mower while starting engine or operating mower WARNING Never run engine indoors or in enclosed poorly ventilated areas Engine exhaust contains carbon monoxide an odorless and deadly gas WARNING Keep hands fest hair and loose clothing away from any moving paris on engine and lawn mower Push the primer three times Wait two seconds between each push In temperatures below 55 F prime five times Do not prime to restart a
30. se only an approved gasoline container Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner Always place containers on the ground away from your vehicle before filling 5 If possible remove gas powered equipment from the truck or trailer and refuel it on the ground If this is not possible then refuel such equipment on a trailer with a portable container rather than from a gasoline dispenser nozzle 6 Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete Do not use a nozzle lock open device 7 Extinguish all cigarettes cigars pipes and other sources of ignition 8 Never fuel machine indoors because flammable vapors will accumulate in the area 9 Never remove gas cap or add fuel while the engine AUN 14 15 is hot or running Allow engine to cool at least two minutes before refusling Never over fill fuel tank Fill tank te no more than Y inch below bottom of filler neck to provide space for fuel expansion Replace gasoline cap and tighten securely 2 If gasoline is spilled wipe it off the engine and equipment Move unit to anciher area Wait 5 minutes before starting the engine Never store the machine or fuel container inside where there is an open flame spark or pilot light as on a water heater space heater furnace clothes dryer or other gas appliances To reduce fire hazard keep mower
31. ss of the total length of the grass Lawn should be trimmed in fall as long as there is growth WARNING If you strike a foreign object stop the engine Remove spark plug wire from spark plug thoroughly inspect the mower for any damage Repair the damage before restarting and operating the mower Extensive vibration of the mower during operation is an indication of damage The unit should be promptly inspected and repaired Adjusting Cutting Height Reter to pages 14 and 15 for instruction on how to adjust the cutting height and the hancle height s For best results in mowing keep the cutting height position high until you have determined which cutting height is preferred Bagging Grass Clippings You can use the grass catcher bag to collect clippings while you are operating the mower s Attach ihe grass catcher following instructions on page 8 of this manual The grass clippings will automatically collect in the bag as you run the mower Operate the mower till the grass bag is full Refer to page 10 for description of bag fill indicator s Stop the engine completely by releasing the control handle s Make sure that the unit has come to a complete stop s Lift discharge deer and pull grass bag up and away from the mower to dispose of the grass clippings SECTION 6 MAINTAINING YOUR LAWN MOWER WARNING Always stop the engine and A disconnect the spark plug wire before performing any maintenance work or adjustments on
32. the starter rope up to the rope guide See Figure 6 s Slip the rope through the rope guide as shown below Tighten the wing nut holding the rope guide to the lower handle Lower Handle Starter Rope Rope aa ing Figure Grass Catcher Assembly If the grass catcher is not already assembled follow the steps below to assemble it Otherwise go to the next sub section on Attaching Grass Catcher NOTE Make ceriain the grass bag is turned right side out before assembling warning label will be on the outside Parts for Grass Bag 1 Front Frame 2 Rear Frame 3 Bag Assembling Grass Bag Join the rear frame and front frame assembly as shown in Figure 7A Place the bag over the frame black plastic side is the bottom of bag Slip the openings in the side of the plastic channels on the bag over the hooks on the grass catcher frame Secure bag to frame by working the plastic channels on bag over frame as shown in Figure 7B All of the plastic channels except the center top of the bag attach from the outside of bag The center top of the bag atiaches from inside the bag A B Frame Front Hook Frame Assembly Rear Frame Bag Plastic Channels Figure 7 Attaching Grass Catcher s If your mower is equipped with a rear baffle and it is in place on the mower lift the rear discharge door and remove it from the mower See Figure 8 Rear Baffle Figure 8 NOTE
33. warm engine after a short shutdown s Standing behind the mower depress the blade control handle and hold it against the upper handle Grasp starter handle and pull rope cut slowly until engine reaches start of compression cycle rope will pull slightly harder at this point Let the rope rewind slowly Pull rope with a rapid continuous full arm stroke Keeping a firm grip on the starter handle let the rope rewind slowly Once the engine has started squeeze the lower bail handle and the blade control handle against the upper handle to run the mower Stopping Engine Release blade control handle to stop the engine and the blade s Disconneci spark plug wire and move away from spark plug to prevent accidental starting Using Your Lawn Mower s Do not operate the mower without the mulching cover the grass catcher bag or the discharge chute properly installed s Be sure thatthe lawn is clear of stones sticks wire or other objects which could damage lawn mower or engine Such objects could be accidently thrown by the mower in any direction and cause serious personal injury to the operator and others s For best results do not cut wet grass because it tends to stick to the underside of the mower preventing proper discharge of grass clippings poor mulching conditions and could cause you to slip and fall New grass thick grass or wet grass may require a narrower cut s Fora healthy lawn always cut off one third or le
34. ys wear safety glasses to protect your eyes during equipment operation and while performing 415 an adjustment or repair Thrown objects which atiempt to bypass its operation Doing so makes the safety device inoperative and may result in personal injury through contact with the rotating blade The blade control handle must operate easily in both directions and automatically return to the disengaged position when released Never operate the mower in wet grass Always be sure of your footing A slip and fall can cause serious personal injury If you feel you are losing your footing release the blade control handle immediately and the blade will stop rotating within three seconds 16 Mow in daylight or good artificial light Walk never run Step the blade when crossing gravel drives walkways or roads 17 ihe equipment should start to vibrate abnormally stop the engine and check immediately for the causs Vibration is generally a warning of trouble 18 Shut the engine off and wait until the blade comes to a complete stop before removing the grass catcher or unclogging the chute The cutting blade continues to rotate for a few seconds after the engine is shut off Never place any part of the body in the blade area until you are sure the blade has stopped rotating 19 Never operate mower without proper trail shield discharge cover grass catcher blade control handle or other safety protective devices in place and working Neve
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