Troy-Bilt 436 User manual

0TRoKRILT
Operator's Manual
21" Rear& Side Discharge
Mulching Lawn Mower
Model 436
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 equipped with a spark attester 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 through your nearest engine authorized
service dealer or contact the service department, P.O. Box 361131 Cleveland, Ohio 44136-0019.
TROY-BILT LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019
PRINTED IN U.S.A. FORM NO. 769-00010C
(9/2003)

TABLEOFCONTENTS
Content
Important Safe Operation Practices
Slope Gauge
Assembling Your Lawn Mower
Know Your Lawn Mower
Operating Your Lawn Mower
Maintaining Your Lawn Mower
Page Content Page
3 Servicing Your Lawn Mower 13
6 Making Adjustments 14
7 Off Season Storage 15
9 Trouble Shooting 15
10 Illustrated Parts List 16
12 Warranty 20
FINDINGMODELNUMBER
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 informationfrom it in the space provided below. A sample model plate is
also given below. You can locate the model plate by standing at the operating position and
looking down at the rear of the deck. This information will be necessary to use the
manufacturer's web site and/or help from the Customer Support Department or an authorized
service dealer.
[wO : T.o.o,L.
O_BOX 36_131
CLEVE_D,OH44136
330=558=7220
1_800=520-552
Copy the model number here:
Copy the serial number here:
CUSTOMERSUPPORT
PleasedoNOTretumtheunittotheretailer from whereit waspurchased,withoutfirst contactingCustomerSupport.
If you have difficulty assembling this product or have any questions regarding the controls, operation or
maintenance of this unit, you can seek help from the experts. Choose from the options below:
Visit troybilt.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 isimmediately
available.
aY_swer you aye
looking for could be just
amouse click away!
L otJiEI_ chec_ lh÷ s__ll_s (_ y_lH /I,_eS_iOEhS,
llIofii_,
_nual$ O_ir,_
The answer you are
amouse click away!
If you prefer to reach a Customer Support Representative, please call 1-880-528-5528.
The engine manufacturer is responsible for all engine-related issues with regards to
)erformance, 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.

SECTION1: IMPORTANTSAFEOPERATIONPRACTICES
WARNING: This symbol points out importantsafety instructions which, if not followed, could endanger
the personal safety and/or property of yourself and others. Read and follow all instructionsin this manual
before attempting to operate this machine. Failure to comply with these instructionsmay result in personal
injury. When you see this symbol--HEED ITS WARNING
WARNING: This machine was built to be operated according to the rules for safe operation in this
manual. As with any type of power equipment, carelessness or error on the part of the operator can result in
serious injury. This machine iscapable of amputating hands and feet and throwing objects. Failure to
observe the following safety instructionscould result in serious injury or death.
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.
GeneralOperation
1. Read this operator's manual carefully in its entirety
before attempting to assemble this machine. Read,
understand, and follow all instructionson 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
manual in a safe place for future and regular
reference and for ordering replacement parts.
2. This machine is a precision piece of power
equipment, not a plaything. Therefore, exercise
extreme caution at all times. Your unit has been
designed to perform one job: to mow grass. Do not
use itfor any other purpose.
3. Never allow children under 14 years old to operate
this machine. Children 14 years old and over
should read and understand the operation
instructionsand safety rules in this manual and
should be trained and supervised by a parent. Only
responsible individuals who are familiar with these
safe operation rules should use this machine.
4. Thoroughly inspect the area where the equipment
isto be used. Remove all stones, sticks, wire,
bones, toys and other foreign objects which could
be tripped over or picked up and thrown by the
blade. Thrown objects can cause serious personal
injury. Plan your mowing pattern to avoid discharge
of material toward roads, sidewalks, bystanders
and the like. Also, avoid discharging material
against a wall or obstruction which may cause
discharged material to ricochet toward operator.
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 ifanyone enters the area.
6. Always wear safety glasses or safety goggles
during operation and while performing an
adjustment or repair to protect your eyes. Thrown
objects which ricochet can cause serious injury to
the eyes.
7. Wear sturdy, rough-soled work shoes and close-
fitting slacks and shirts. Shirts and pants 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.
8. Do not put hands or feet near rotating parts or
under the cutting deck. Contact with the blade can
amputate hands and feet.
9. A missing or damaged discharge cover can cause
blade contact or thrown object injuries.
10. Many injuries occur as a result of the mower being
pulled over the foot during a fall caused by slipping
or tripping. Do not hold on to the mower ifyou are
falling; release the handle immediately.
11. 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
your arms.
b. Be sure you are well balanced with sure
footing.
c. Pull the mower back slowly, no more than
half way toward you.
d. Repeat these steps as needed.
5. Do not operate the mower while under the influence
of alcohol or drugs.
6. Do not engage the self-propelled mechanism on
units so equipped while starting engine.
7. The blade control handle is a safety device. Never
attempt 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.

8. Neveroperatethemowerin wet grass. Always be
sure of your footing. A slip and fall can cause
serious personal injury. Ifyou feel you are losing
your footing, release the blade control handle
immediately and the blade will stop rotating within
three seconds.
9. Mow in daylight or good artificial light. Walk, never
run. Stop the blade when crossing gravel drives,
walkways or roads.
10. If the equipment should start to vibrate abnormally,
stop the engine and check immediately for the
cause. Vibration is generally a warning of trouble.
11. 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 isshut off. Never place any part of the body
in the blade area until you are sure the blade has
stopped rotating.
12. Never operate mower without proper trail shield,
discharge cover, grass catcher, blade control
handle or other safety protective devices in place
and working. Never operate mower with damaged
safety devices. Failure to do so, can result in
personal injury.
13. Muffler and engine become hot and can cause a
burn. Do not touch.
14. Only use parts and accessories made for this
machine by the original equipment manufacturer
(O.E.M). Failure to do so can cause personal injury.
15. If situations occur which are not covered in this
manual, use care and good judgment. Contact your
dealer for assistance. Telephone [phone]for
the name of your nearest dealer.
SlopeOperation
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
slope, do not mow it. Before operating this unit on a
slope or hilly area, use the slope gauge on page 6 to
measure slopes. Ifthe 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. Ifyou feel you are
losing your balance, release the blade control
handle immediately, and the blade will stop rotating
within 3 seconds.
DoNot:
1. Do not mow near drop-offs, ditches or
embankments, you could lose your footing or
balance.
2. Do not mow slopes greater than 15 degrees as
shown on the slope gauge.
3. Do not 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 when approaching blind corners,
doorways, shrubs, trees, or other objects that may
obscure your vision of a child who may run into 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
instructionsand safety rules in this manual and
should be trained and supervised by a parent.
Service
Safe Handling of Gasoline
1. To 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.
2. Wash yourskin and change clothes immediately.
3. Use only an approved gasoline container.
4. 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
is hot or running. Allow engine to cool at least two
minutes before refueling.
10. Never over fill fuel tank. Fill tank to no more than ½
inch below bottom of filler neck to provide space for
fuel expansion.
11. Replace gasoline cap and tighten securely.
12. If gasoline is spilled, wipe it offthe engine and
equipment. Move unit to another area. Wait 5
minutes before starting the engine.
13. 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.
14. To reduce fire hazard, keep mower free of grass,
leaves, or other debris build-up. Clean up oil or fuel
spillage and remove any fuel soaked debris.
15. Allow a mower to cool at least 5 minutes before
storing.
GeneralService
1. Never run an engine indoors or ina poorly
ventilated area. Engine exhaust contains carbon
monoxide, an odorless and deadly gas.
2. Before cleaning, repairing, or inspecting, make
certain the blade and all moving parts have
stopped. Disconnect the spark plug wire and
ground against the engine to prevent unintended
starting.
3. Check the blade and engine mounting bolts at
frequent intervals for proper tightness. Also,
visually inspectblade for damage (e.g., bent,
cracked, worn) Replace blade with the original
equipment manufacture's (O.E.M.) blade only,
listed in this manual. "Use of parts which do not
meet the original equipment specifications may
lead to improper performance and compromise
safety!"
4. Mower blades are sharp and can cut. Wrap the
blade or wear gloves, and use extra caution when
servicing them.
5. Keep all nuts, bolts, and screws tight to be sure the
equipment isin safe working condition.
6. Never tamper with safety devices. Check their
proper operation regularly.
7. After striking a foreign object, stop the engine,
disconnect the spark plug wire and ground against
the engine. Thoroughly inspectthe mower for any
damage. Repair the damage before starting and
operating the mower.
8. Never attempt to make a wheel or cutting height
adjustment while the engine is running.
9. Grass catcher components, discharge cover, and
trail shield are subject to wear and damage which
could expose moving parts or allow objects to be
thrown. For safety protection, frequently check
components and replace immediately with original
equipment manufacturer's (O.E.M.) parts only,
listed inthis manual. "Use of parts which do not
meet the original equipment specifications may
lead to improper performance and compromise
safety!"
10. Do not change the engine governor setting or
overspeed the engine. The governor controls the
maximum safe operating speed of the engine.
11. Maintain or replace safety and instruction labels, as
necessary.
12. Observe proper disposal laws and regulations.
Improper disposal of fluids and materials can harm
the environment.
YourResponsibility
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.
/ WARNING

USE THIS PAGE AS A GUIDE TO DETERMINE SLOPES WHERE YOU MAY NOT OPERATE SAFELY.
k--
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gJo
..4
d_hb WARNING
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 cause serious injury. If operating a walk-behind mower on such a slope, 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.
£O

SECTION3: ASSEMBLINGYOURLAWNMOWER
RemovingUnitFromCarton
Remove staples, break glue on top flaps or cut tape
at carton end and peel top flap to open carton.
Remove loose parts if included with unit.
Cut corners and lay carton down flat. Remove
packing material.
Roll or slide unit out of carton. Check carton
thoroughly for loose parts.
NOTE: Make sure not to crimp cables while removing
the loose parts or the entire unit from the carton.
HardwarePack
Please identify each piece
of the hardware pack as
shown here. Wing Carriage
Nut Bolt
1/4-20 (2) 1/4-20 (2)
ToolsRequired
Pair of Pliers
Funnel
NOTE: Reference to right or left hand side of the mower
is observed from the operating position.
DisconnectingSparkPlug
Before setting up your lawn mower, disconnect the
spark plug wire from the spark plug. See Figure 1.
Spa Spark Plug
Figure 1
AssemblingHandle
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
Raise the lower handle, as shown in Figure 2, until
it snaps into place.
Raise the upper handle as shown in Figure 2.
Tighten the two wing nuts which are already on the
handle. See Figure 3.
hten these
wing nuts
Upper
Handle
Lower
Handle
Figure 3
NOTE: Make sure to route the cables outside the lower
handle. Also do not crimp the cables while lifting the
handle up.
Remove the hairpin clips from the outer hole in the
weld pins on the handle bracket assemblies. Using
a pair of pliers, squeeze one leg of the lower handle
against the handle bracket assemblies. Insert the
hairpin clip into the inner hole on the weld pin.
Repeat on other side. See Figure 4.
After you have moved the hairpin clip, install the
carriage bolt, (carriage bolt must go to the inside of
handle) included in the hardware pack, in the upper
hole on the handle mounting bracket. Secure with
one plastic wing nut, also included in the hardware
pack. See Figure 4. Repeat process on other side.

Carriage Bolt
t\
Handle
Mounting
3rkt.
Wing
Move Hairpin Clip
Figure 4
Fasten the cable to the lower handle with the two
cable ties found on the lower handle. Pull the cable
ties tight and trim off the excess. See Figure 5.
Cable Tie
,os,o°
Cable Ti_
AttachingStarterRope
The rope guide is attached to the right side of upper
handle. Loosen the wing nut which secures the rope
guide. See Figure 6.
With the spark plug wire disconnected and
grounded, hold the blade control handle against the
upper handle, and pull the starter rope out of the
engine. Release the blade control handle. Slip the
starter rope into the rope guide. Tighten wing nut.
Slip rope into
rope gq_i_R
ing Nut
AssemblingGrassCatcher
NOTE: If your mower's grass catcher has been already
assembled before shipping, proceed to the next
section. If ff is unassembled, foflow the steps below.
Insert frame into grass bag with the black plastic
side on the bottom of bag. See Figure 7.
Insertframe
into
Grass
Frame
Figure 7
Slip the side openings of the plastic channel on the
bag over the hooks on the grass catcher frame.
Secure bag to the frame by working the six plastic
channels on bag over frame.
All the plastic channels attach from the outside of
bag. See Figure 8.
ijcrass#acr
Figure 8
AttachingGrassCatcher
Lift the rear discharge door and place the grass
catcher on the pivot rod. Let go of discharge door so
that it rests on the grass catcher. See Figure 9.
Figure 6Figure 9

RemovingGrassCatcher
Lift the rear discharge door on the mower, and lift
the grass catcher up.
Release the rear discharge door.
ConvertingtoSide-Discharge
Your mower has been shipped as a mulcher. To
convert it to a side-discharge mower, lift the
mulching plug. Slide the two hooks on the side-
discharge deflector under the hinge pin on the
mulching plug assembly. Lower the mulching plug.
See Figure 10.
Mulching
Plug
ge
Pin
(Side
Chute
Deflector
Figure 10
Do not remove the side mulching plug at any time,
even when you are not mulching.
_WARNING: Never operate the mower
without the mulching cover, the grass catcher
bag, or the discharge chute properly installed.
SECTION4: KNOWYOURLAWNMOWER
Read this owner's manual and safety rules before operating your lawn mower. Compare the illustrationsin Figure
11 with your lawn mower to familiarize yourself with the location of various controls and adjustments.
Blade Control
Handle
Grass Catcher_
Chute Height Adjustment
Lever
Figure 11
BladeControlHandle
The blade control handle is located on the upper handle
of the mower. The blade control handle must be
depressed in order to operate the unit. Release the
blade control handle to stop the engine and the blade.
_1 ARNING: The blade control handle isasafety device. Never attempt to bypass its
operations. The blade will be rotating whenever
the engine is running.

Cuffing Height Adjustment Lever
This lever, located at each wheel, lets you adjust cutting
height of the grass. Remember to put all four levers at
the same height to avoid uneven cut.
Throttle Control
The engine is equipped with a constant speed throttle
for maximum engine and cutting performance.
Recoil Starter
The recoil starter is attached to the handle. Stand
behind the unit and pull the recoil starter to start engine.
Primer
The primer is used to pump gas into the carburetor. Use
it to assist in starting a cold engine, but do not use it
when restarting a warm engine after a short shutdown.
Mulching Plug
The mulching plug is used only for mulching purposes.
Instead of collecting the grass clippings in a grass
catcher, some mower models have the option of
recirculating the clippings back to the lawn. This is
called mulching.
SECTION5: OPERATINGYOURLAWNMOWER
GasandOilFill-Up
,_ 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 instructions carefully.
BeforeStartingMower
Attach spark plug wire to spark plug. Make certain
the metal cap on the end of the spark plug wire is
fastened securely over the metal tip on the spark
plug.
StartingEngine
_ARNING: 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, feet, hair and
loose clothing away from any moving parts 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 warm
engine after a short shutdown.
Standing behind the mower, depress the blade
control handle and hold it against the upper handle.
Grasp starter handle and pull rope out 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.
NOTE: See your engine manual packed with your unit
for more detailed instructions.
StoppingEngine
Release blade control handle to stop the engine
and the blade.
Disconnect spark plug wire and move away from
spark plug to prevent accidental starting.
10