Troy-Bilt 440 Series User manual

Safety oAssembly oOperation oTips &Techniques oMaintenance *Troubleshooting oParts Lists oWarranty
®
21" Rotary Mower -- Model Series 440
READ SAFETY RULES AND mNSTRUCTmONS CAREFULLY BEFORE OPERATION
Warning: Thisunitisequippedwithan internalcombustionengineandshouldnotbeusedon or nearanyunimprovedforest-covered,brush=
coveredor grass=coveredlandunlesstheengine'sexhaustsystemisequippedwitha sparkarrestermeetingapplicablelocalorstatelaws(ifany),
If a sparkarresterisused,itshouldbemaintainedineffectiveworkingorderbytheoperator,Inthe StateofCaliforniatheaboveisrequiredbylaw
(Section4442oftheCaliforniaPublicResourcesCode),Otherstatesmayhavesimilarlaws,Federallawsapplyonfederallands,A sparkarrester
forthemufflerisavailablethroughyournearestengineauthorizedservicedealeror contacttheservicedepartment,RO,Box361131Cleveland,
Ohio44136=0019,
PRINTEDiN U,S,A Troy-Bilt LLC, P.O. BOX 381131 CLEVELAND, OHIO 44138-0019 FORMNO,769=02166
Phone: 1(888} 840-8483, 1-330-558-7220 10/2005

This Operator's Manua_ is an important part of your new lawn mower, mtwH_ he_p you assemble,
prepare and maintain the unit for best performance. Please read and understand what it says.
Table of Contents
Slope Gauge ....................................................... 3
Safe Operation Practices ................................... 4
Setup and Adjustment ....................................... 6
Operating Your Lawn Mower .............................. 8
Maintaining Your Lawn Mower ......................... 10
Trouble Shooting .............................................. 12
Off-Season Storage and Safety Labe{s .......... 13
Parts List ........................................................... 14
Warranty ............................................ Back Cover
Finding and Recording Model Number
BEFOREYOU STARTASSEMBLING
YOURNEW EQUIPMENT,
please locatethe modelplate onthe equipmentand copythe
informationtothe samplemodel plate providedto the righL
Youcan locatethe modelplate by standing atthe operating
positionand lookingdown at the rearof the deck. This
informationwill be necessaryto use the manufacturer'sweb
site and/or obtainassistancefrom the CustomerSupport
Departmentor an authorizedservice dealer.
Modem Number Serial Number
0 TRDV BILT TROY-B LTLLc
P. O. BOX 361131
www.troybiit.com CLEVELAND,ON44136
338=558=7228
Customer Support
PIease do NOTreturn the unit to the retai{er from which it was
purchased, without first contacting Customer Support.
ifyou havedifficulty assemblingthis productor have any
questions regardingthe controls, operationor maintenanceof
this unit,you can seek helpfromthe expert& Choose from the
options below:
Click here to search our knowledge base°
Searchby product, keyword, or phrase.
1_VisittroybHt.com for manyuseful suggestions.Clickon
CustomerSupport button and youwill get the fouroptions
reproducedin this sampleto the righLClick on the appro-
priatebutton and help is immediatelyavailable.
2_Phonea Customer Support Representative
at 1(866)840-6483.
3. The engine manufacturer is responsiblefor all engine-
relatedissueswith regardsto performance,power-rating,
Login to check the status of your questions, modify
your inquiries, or update your personal profile.
Need local assistance? Click here to find authorized
service centers in your area.
specifications,warrantyand service. Pleasereferto the
eng Need a manual and/or parts list? Download
separatelywith your unit, for more information, literature from recent model years.
2

yourlawnmoweronsuchslopes.
/
/
/
/
o
/
/
t
o
w_ WARNING
Do not mowon inclines
with a dope in excess
of 15degrees(a rise
of approximately
2-"
feet). A riding r
couldoverturnand
cause seriousinjury.
if operatinga walb
behindmower on such
a dope, it isextremely
footing and youcould
dip, resultingin serious
injury.
OperateRiDiNG
mowersup and down
dopes, neveracross
thefaceof dopes.
Operate
WALK-BEHIND
mowersacrossthe
face of dopes, never
up and down slopes.
\
3

manual.Aswithanytypeofpowerequipment,carelessnessorerroronthepartoftheoperatorcan
resultinseriousinjury.Thismachineiscapableofamputatinghandsandfeetandthrowingobjects.
! Failuretoobservethefollowingsafetyinstructionscouldresultinseriousinjuryordeath.
endangerthepersonal
safetyand/orproperty
Children
Tragicaccidentscan occurifoperatorisnotalerttopresence
ofchildren.Childrenareoftenattractedto mowerandmowing
activity.Theydonot understandthe dangers.Neverassume
thatchildrenwill remainwhereyoulastsawthem.
1. Keepchildrenoutofthe mowingareaandunderwatchful
careof a responsibleadultotherthanthe operator.
2. Bealertandturnmoweroffifachildentersthearea.
3. Beforeandwhilemovingbackwards,lookbehindanddown
forsmallchildren.
4. Useextremecarewhenapproachingblindcorners,
doorways,shrubs,trees,orotherobjectsthat mayobscure
yourvisionofachildwhomayrunintothemower.
5. Keepchildrenawayfromhot orrunningengines.Theycan
sufferburnsfroma hotmuffler.
6. Neverallowchildrenunder14yearsoldto operateapower
mower.Children14yearsold andovershouldreadand
understandoperationinstructionsandsafetyrulesinthis
manualandshouldbetrainedandsupervisedbyaparent.
General Operation
1. Readthis operator'smanualcarefullyin its entiretybefore
attemptingtoassemblethismachine.Read,understand,
andfollow allinstructionsonthe machineandin the
manual(s)beforeoperation.Becompletelyfamiliarwith
thecontrolsandthe properuseofthis machinebefore
operatingit.Keepthis manualin a safeplaceforfuture
andregularreferenceandfor orderingreplacementparts.
2. Thismachineisaprecisionpieceof powerequipment,
nota plaything.Therefore,exerciseextremecautionat all
times.Yourunithasbeendesignedto performonejob: to
mowgrass.Do notuseitfor anyotherpurpose.
3. Neverallowchildrenunder14yearsoldto operatethis
machine.Children14yearsoldand overshouldreadand
understandthe instructionsinthis manualandshould
betrainedand supervisedbya parent.Onlyresponsible
individualswhoarefamiliarwiththeserulesofsafe
operationshouldbeallowedtousethismachine.
4. Thoroughlyinspectthe areawherethe equipmentisto
beused.Removeall stones,sticks,wire,bones,toysand
otherforeignobjectswhichcould betripped overor picked
upand thrownbythe blade.Thrownobjectscancause
seriouspersonalinjury.Planyourmowingpatternto avoid
dischargeofmaterialtowardroads,sidewalks,bystanders
andthe like.Also,avoiddischargingmaterialagainsta
wallorobstructionwhichmaycausedischargedmaterial
toricochetbacktowardtheoperator.
6. Alwayswear safetyglassesor safetygogglesduringopera-
tionandwhile performinganadjustmentor repairto protect
youreyes.Thrownobjectswhich ricochetcancauseserious
injurytothe eyes.
7. Wearsturdy,rough-soledworkshoesand close-fitting
slacksandshirts. Shirtsand pantsthatcoverthe armsand
legsandsteel-toedshoesarerecommended.Neveroperate
this machinein barefeet,sandals,slipperyor lightweight
(e.g.canvas)shoes.
8. Do notputhandsorfeet nearrotatingpartsor undercutting
deck.Contactwithbladecanamputatehandsandfeet.
9. A missingor damageddischargecovercancauseblade
contactor thrownobject injuries.
10.Manyinjuriesoccurasa resultofthe mowerbeingpulled
overthefoot duringa fall causedby slippingortripping.
Do notholdontothe mowerifyouare falling;releasethe
handleimmediately.
11.Neverpullthe mowerbacktowardyouwhileyouare
walking.If youmustbackthe mowerawayfromawallor
obstructionfirstlookdownandbehindtoavoidtrippingand
thenfollowthesesteps:
a. Stepbackfrommowertofully extendyourarms.
b. Besureyou arewellbalancedwithsurefooting.
c. Pullthe mowerbackslowly,no morethanhalfway
towardyou.
d. Repeatthesestepsasneeded.
12.Do notoperatethe mowerwhileunderthe influenceof
alcoholor drugs.
13.Do notengage theself-propelledmechanismon unitsso
equippedwhilestartingengine.
14.Thebladecontrolhandleis asafetydevice.Neverattempt
tobypassits operation.Doingso makesthe safetydevice
inoperativeandmay resultinpersonalinjurythrough
contactwiththe rotatingblade.The bladecontrolhandle
mustoperateeasilyin bothdirectionsandautomatically
returntothe disengagedpositionwhenreleased.
15.Neveroperatethe mowerinwetgrass.Alwaysbesureof
yourfooting. A slipand fallcan causeseriouspersonal
injury.If youfeelyouarelosingyourfooting,releasethe
bladecontrolhandleimmediatelyandthe bladewillstop
rotatingwithinthreeseconds.
16.Mowonlyindaylightor goodartificiallight.Walk,neverrun.
17.Stopthe bladewhencrossinggraveldrives,walksor roads.
18.If the equipmentshouldstart tovibrateabnormally,stopthe
engineandcheckimmediatelyforthe cause.Vibrationis
and followthewarnings 5. Tohelpavoidbladecontactorathrownobjectinjury, ._ generallya'_arningof!rouble.........
]_ _nutthe engne errandwar unl: me Daaecomes-coa
and i..struction2stayinoperatorzonebehindhandlesandkeepchildren, "
u _ competestop beforeremovngthe grasscatcheror uncog
, ,; bystanders,helpers,andpetsat least75feet frommower .
un_nusmanuau glngthechute
whileit isin operation.Stopmachineifanyoneenters
and onthe machine, area.
..... ,J 4

Thecuttingbladecontinuesto rotateforafewsecondsafter
the engineisshutoff. Neverplaceanypartofthe bodyin
the bladeareauntilyouaresurethe bladehasstopped
rotating.
20.Neveroperatemowerwithoutpropertrailshield,discharge
cover,grasscatcher,bladecontrolhandle,or othersafety
protectivedevicesin placeandworking.Neveroperate
mowerwithdamagedsafetydevices.Failuretodo socan
resultin personalinjury.
21.Mufflerandenginebecomehotand cancauseaburn.Do
nottouch.
22.Onlyusepartsand accessoriesmadeforthismachineby
manufacturer.Failureto dosocanresultinpersonalinjury.
23.If situationsoccurwhichare not coveredin this manual,
usecareand goodjudgment.Contactyourdealerfor
assistance.Telephone[phone]forthe nameofyour
nearestdealer.
SJope Operation
Slopesareamajorfactorrelatedto slipandfallaccidentswhich
canresultinsevereinjury.Operationonslopesrequiresextra
caution.Ifyoufeeluneasyonaslope,donotmowit.Foryour
safety,usethe slopegaugeincludedas partofthismanualto
measureslopesbeforeoperatingthisunitonaslopedor hilly
area.Iftheslopeis greaterthan15degrees,do notmowit.
Do:
1. Mowacrossthe faceof slopes;neverup anddown.
Exerciseextremecautionwhenchangingdirectionon
slopes.
2. Watchfor holes,ruts, rocks,hiddenobjects,or bumpswhich
can causeyou toslipor trip.Tallgrasscan hideobstacles.
3. Alwaysbesure ofyourfooting.A slip andfall cancause
seriouspersonalinjury.Ifyoufeelyouarelosingyour
balance,releasethe bladecontrolhandleimmediately,and
the bladewillstop rotatingwithin 3seconds.
Do Not:
1. Do notmowneardrop-offs,ditchesorembankments,where
you couldloseyourfootingor balance.
2. Do notmowslopesgreaterthan 15degreesas shownon
the slopegauge.
3. Do notmowon wetgrass.Unstablefootingcouldcause
slipping. Service
Safe HandlingOf Gasoline:
1. Toavoidpersonalinjury or propertydamageuseextreme
carein handlinggasoline.Gasolineisextremelyflammable
andthevaporsareexplosive.Seriouspersonalinjurycan
occurwhengasolineis spilledonyourselforyourclothes
whichcanignite.
2. Washyourskinand changeclothesimmediately.
3. Useonlyanapprovedgasolinecontainer.
4. Neverfill containersinsideavehicleor ona truckor trailer
bedwith a plasticliner.Alwaysplacecontainersonthe
groundawayfromyourvehiclebeforefilling.
5. Removegas-poweredequipmentfromthe truck ortrailer
andrefuelit onthe ground.Ifthis is notpossible,then refuel
suchequipmentonatrailerwitha portablecontainer,rather
thanfroma gasolinedispensernozzle.
6. Keepthe nozzlein contactwith therim ofthefueltank or
containeropeningat alltimesuntilfuelingis complete.Do
notusea nozzlelock-opendevice.
7. Extinguishallcigarettes,cigars,pipesandothersources
ofignition.
8. Neverfuel machineindoorsbecauseflammablevaporswill
accumulatein the area.
9. Neverremovegascap oradd fuelwhileengineishot or
running. Allowengineto coolatleasttwo minutesbefore
refueling.
10.Neveroverfillfueltank.Filltankto nomorethan_ inch
belowbottomoffillerneckto providefor fuelexpansion.
11.Replacegasolinecapandtightensecurely.
12.If gasolineis spilled,wipe it offthe engineand equipment.
Moveunitto anotherarea.Wait5 minutesbeforestarting
engine.
13.Neverstorethe machineorfuel containernearanopen
flame,sparkorpilotlightas onawaterheater,space
heater,furnace,clothesdryer,orothergas appliances.
14.Toreducefire hazard,keepmowerfreeofgrass,leaves,
or otherdebrisbuild-up.Cleanupoil orfuel spillageand
removeanyfuel soakeddebris.
15.Allowamowertocoolat least5 minutesbeforestoring.
General Service:
1. Neverrunanengineindoorsor inapoorlyventilatedarea.
Engineexhaustcontainscarbonmonoxide,an odorlessand
deadlygas.
2. Beforecleaning,repairing,or inspecting,makecertainthe
bladeandall movingpartshavestopped.Disconnectthe
sparkplugwireandgroundagainsttheengineto prevent
unintendedstarting.
3. Checkthe bladeandenginemountingboltsatfrequent
intervalsfor propertightness.Also,visuallyinspectbladefor
damage(e.g.,bent,cracked,worn)Replacebladewiththe
originalequipmentmanufacture's(O.EM.) bladeonly,listed
inthismanual."Useofpartswhichdo notmeettheoriginal
equipmentspecificationsmayleadto improperperformance
andcompromisesafety!"
4. Mowerbladesaresharpandcancut.Wrapthebladeorwear
gloves,anduseextracautionwhenservicingthem.
5. Keepallnuts,bolts,andscrewstight tobesurethe equip-
mentisin safeworkingcondition.
6. Nevertamperwithsafetydevices.Checktheirproperopera-
tionregularly.
7. Afterstrikinga foreignobject,stopthe engine,discon-
nectthe sparkplugwireandgroundagainsttheengine.
Thoroughlyinspectthe mowerfor anydamage.Repairthe
damagebeforestartingandoperatingthe mower.
8. Neverattempttomakeawheelorcuttingheightadjustment
whilethe engineis running.
9. Grasscatchercomponents,dischargecover,and trail
shieldaresubjecttowear anddamagewhichcould expose
movingpartsorallow objectsto bethrown.Forsafety
protection,frequentlycheckcomponentsand replaceim-
mediatelywithoriginalequipmentmanufacturer's(O.EM.)
partsonly,listedin this manual.'Use of partswhich do
not meettheoriginalequipmentspecificationsmayleadto
improperperformanceandcompromisesafety!"
10.Donot changetheenginegovernorsettingor overspeedthe
engine.Thegovernorcontrolsthe maximumsafeoperating
speedofthe engine.
11.Maintainor replacesafetylabels,as necessary'.
12.Observeproperdisposallawsandregulations.Improper
disposaloffluidsandmaterialscanharmtheenvironment.
ThisSymbolpoints
ua! before attemptingto
resuUt in personalinjury_
::When you see th s
_symbol
,EEDMTSWARNmNG
Responsibility
Restrictthe use
of this powermachine
to personswhoread
understand
5

NOTE:Stand behind
Ihemoweras if you
were going to operate
it,Your righthandcor-
respondsto the right
sideof the mower;your
left handcorresponds
to the left sidedthe
mower.
IMPORTANT
DO NOTcrimp the
cableswhenliftingthe
handleup.
IMPORTANT
This unit isshipped
without gasoline or
oil in the engine. Fill
upgasolineand oil
as instructedin the
accompanyingengine
manual BEFORE
operatingyour mower,
Step 1
HardwarePack
Wing Nuts (2) CarriageBolts (2)
Step 2
1, Removeanypackingmaterialwhichmaybebetween
upperand lowerhandles,
a, Pullupand backon upperhandleasshownin
Step1,Makecertainthelowerhandleisseated
securelyintothe handlemountingbrackets,
b, Tightenhandknobssecuringupperhandleto
lowerhandle,Makesurethateachcarriageboltis
seatedproperlyin thehandle,
2, Locatehairpinclipin oneholeontheweldpinon each
sideof lowerhandle,
a, Removehairpinclipfromthis hole,Usinga pairof
pliers,inserthairpinclipintotheotherholeon the
weldpin,Repeaton otherside,
b, inserta carriageboltfromthehardwarepackinto
theupperholeon thehandlemountingbracket,
Securewithoneplasticwingnut,alsoincluded
inthe hardwarepack,Repeatonothersidewith
remainingitemsfromhardwarepack,
3, Theropeguideisattachedtotherightsideofthe
upperhandle,Loosenthewingnutwhichsecuresthe
ropeguide,
a, Holdthebladecontrolagainstupperhandle,
b, Pullstarterropeoutoftheengine,Releasethe
bladecontrol,
c, Slipstarterropeintoropeguide,Tightenwingnut,
4, Insertpostoncane ties intoholesprovidedon the
lowerhandle,Pullcane tietightandtrimexcess,
Step 3 Step 4
6

positionprovidescuttingheightadiustment,
a, Depresslevertowardswheel,
b, Moveittoanyoftheninepositionsfordesired
cuttingheight,SeeStep5,
c, Releaselevertowardsmowerdeck,
6, Followstepsbelowtoassemblethegrasscatcher:
a, Placebagoverframesothatitsblackplasticside
isatthebottom,
b, Slipplasticchannelofgrassbagoverhooksonthe
frame,SeeStep6,All theplasticchannelsexcept
centertopof bagattachfromoutsideof bag,
c, Attachcentertopof bagfrominsideofbag,
7, Followstepsbelowtoattachgrasscatcher:
a, Liftreardischargedoor,
b, Placegrasscatcheron thepivotrod,Letgo
ofdischargedoorsothat itrestson thegrass
catcher,SeeStep7,
Toremovegrasscatcherorconverttoa mulcher(if
equipped),liftreardischargedooronthe moweras
showninStep8, Liftgrasscatcherupand outofthepivot
rod,Releasereardischargedoorto allowittocloserear
openingofmower,
WARNING: Never operate mower
unless the hooks on the grass
catcher are firmly seated on the
pivot rod, and the rear discharge
door rests firmJyagainst top of
the grass catcher.
Step 5
\
Step 6
_Make certain bagis
Step 7
unless the hooks on
}
7

WARNING
The blade control
mechanism is a
safety device. Never
attempt to bypassits
operations.
Use extreme care
when handling
gasoline. Gasoline is
extremely flammable
and the vapors are
explosive. Neverfuel
the machine indoors
or while the engine
is hot or running.
Extinguish cigarettes,
cigars, pipes and
other sources of
ignition.
Keep handsand feet
_way from the chute
tea on cutting deck.
Refer to warning
label on the unit.
,<-_ Blade Control
-- Drive Control
Recoil
Grass Bag
Levers
Gasoline
Height
Levers J
Figure 1
Now that you have set up your lawn mower for op-
eration, get aquainted with its controls and features.
These are described below and illustrated on this
page. This knowledge will allow you to use your
new equipment to its fullest potential.
B_ade Control
The blade control is attached to the upper handle
of the mower. Depress and squeeze it against the
upper handle to operate the unit. Release it to stop
engine and blade.
WARNING:This bladecontrol mecha-
nism isa safety device. Neverattempt
to bypass its operations.
Drive Contro_
The drive control is located on the underside of
the upper handle and is used to engage the drive.
Squeeze it against the upper handle to engage the
drive; reIease it to slow down or stop mower from
propelling. See Figure 1=
Cutting Height Adjustment Levers
One adjustment lever is located on each wheel and
is used to adjust the cutting height. All four levers
have to be at the same relative position to ensure a
uniform cut.
Recoi_ Starter
The recoiI starter is attached to the right upper
handle. Stand behind the unit and puII the recoil
starter rope to start the unit.
Gas and Oil Fil_-Up
1. Check oil level and add oil if necessary. Follow engine
manual for this. See Figure 1 above for location of the
oil fill.
2. Service the engine with gasoline as instructed in the
engine manual See Figure 1above for location of
gas fill
WARNING: Use extreme care when han-
dling gasoline. Gasoline is extremely
flammable and the vapors are explosive.
Never fuel the machine indoors or while
the engine is hot or running. Extinguish
cigarettes, cigars, pipes and other
sources of ignition.
8

WARNING:The operation of anylawn
mowercan result inforeign objects
being thrown into the eyes,wNch can
damageyour eyes severely.Always
wearsafety glasses while operating
the mower,or while performing any
adjustments or repairson it.
Starting Engine
WARNING:Besure no one otherthan
the operator isstanding nearthe lawn
mowerwhile starting engine or operat-
ing mower.Neverrun engine indoors
or inenclosed, poorly ventilated areas.
Engine exhaustcontains carbon monox-
ide,an odorless and deadly gas. Keep
hands,feet, hair and loose clothing
awayfrom anymoving parts on engine
and lawn mower.
1, Pushprimerthreetimes,Waitabouttwoseconds
betweeneachpush,SeeFigure2,Intemperature
around55° For below,primefivetimes,Donotprime
to restarta warmengine,
2, Standingbehindthe mower,squeezethebladecontrol
againstupperhandle,SeeFigure2,
3, Holdingthesetwo handlestogetherfirmly,grasprecoil
starterhandleand pullropeoutwitha rapid,continu=
ous,fullarmstroke,SeeFigure2,Keepinga firm
gripon thestarterhandle,lettheroperewindslowly,
Repeatuntilenginecranks,Lettheroperewindeach
timeslowly,
Stopping Engine
1, Releasebladecontroltostoptheengineandblade,
2, Disconnectsparkplugwirefromsparkplugand
groundagainsttheengine,
_k ARNING:Wait for the blade to stop
completely beforedoing anywork
on the moweror to removethe grass
catcher.
Using Your Lawn Mower
WARNING:Neveroperateyour mower
without either the rear door or the entire
grass catcher assembly firmly secured.
Be surelawnisclearofstones,sticks,wire,or other
obiectswhichcoulddamagelawnmowerorengine,
Suchobiectscouldbe acddentlythrownbythemower
in anydirectionandcauseseriouspersonaliniurytothe
operatorandothers,
Figure 2 J
_IL ARNING:If you strike aforeign
object, stop the engine. Remove
wire from the spark plug, thoroughly
respect mowerfor anydamage,and
repair damagebeforerestarting and
operating. Extensivevibration of
mower during operation isan indica-
tion of damage.Theunit should be
promptly inspected and repaired.
1, Oncetheengineisrunning,squeezethedrive
controlagainsttheupperhandleto propelmower,
2, Forbestresults,do notcut wetgrass,
3, Fora healthierlawn,nevercutoff morethanone=
thirdofthetotallengthofthegrass,
Using as Muncher
Formulchinggrass,removethegrasscatcherfromthe
mower,Thereardischargedoorshouldbeclosed,
1, Foreffectivemulching,do notcut wetgrass,
2, Neworthickgrassmayrequirea narrowercut,
Adiustgroundspeedaccordingtoconditionoflawn,
3, If thegrasshasbeenallowedto growinexcessof
4 inches,mulchingisnotrecommended,Usethe
grasscatchertobagclippingsinstead,
Using Grass Catcher
Youcanusethegrasscatchertocollectclippingswhile
youareoperatingthemower,
1, Attachgrasscatcherfollowinginstructionsonpage
7,Grassclippingswillautomaticallycollectinbagas
yourun mower,Operatemowertillgrassbagisfull,
2, Stopenginecompletelybyreleasingtheblade
controlhandle,Makesurethattheunithascometo
a completestop,
3, Liftdischargedoorand pullgrassbagup andaway
fromthemowertodisposeofthegrassclippings,
being thrown into
the eyes, which can
damage your eyes
severely. Always wear
safety glasses while
iioperating the mower,
_ngine or operating
_ower. Never tun
engine !ndoors or
in enclosed poorly
ventilated areas' En_
gine exhaust Contains
carbon monoxide, an /
odorless and deadly
_gas, Keep hands, feet,
hair and loose Clothing
away from any mov ng
9

disconnectspark
plug,andground
oga n,teng nb fOrO
\
reassembiy,
Figure 3
Figure 4
Genera[ Recommendations
1, Alwaysobservesafetyruleswhenperforming
anymaintenance,
2, Thewarrantyon thislawnmowerdoesnotcover
itemsthathavebeensubiectedtooperatorabuse
or negligence,Toreceivefullvaluefromwarranty,
operatormustmaintainthe lawnmoweras
instructedhere,
3, Changingofengine-governedspeedwillvoid
enginewarranty,
4, Alladjustmentsshouldbecheckedat leastonce
eachseason,
5, Periodicallycheckall fastenersand makesurethese
aretight, WARNING:Alwaysstop engine,
disconnect spark plug, and ground
against engine beforecleaning,
lubricating or doing any kind of
maintenanceon your machine.
mustoperatefreelyin bothdirections,SeeFigure3,
2, Lubricatethewheelsatleastoncea seasonwith
lightoil (or motoroil), If wheelsareremovedforany
reason,lubricatesurfaceofthepivotarmandinner
surfaceofthewheelwithlightoil SeeFigure3,
3, Lubricatethetorsionspringandpivotpointontherear
dischargedoorperiodicallywithlightoil toprevent
rust,SeeFigure3,
4, Thetransmissionis prequbricatedandsealedatthe
factoryanddoesnotrequirelubrication,
5, Followtheaccompanyingenginemanualforlubrica-
tionscheduleandinstructionforenginelubrication,
Deck Care
1, Disconnectsparkplugwire,Draingasolinefromlawn
mower,or placea pieceof plasticunderthegascap,
2, Tipmowersothat itrestson thehousing,Keepthe
sidewiththeaircleanerfacingup,Holdmowerfirmly,
WARNING:Nevertip the mowermore
than 90 degreesin anydirections and
do not leavethe mowertipped for any
length of time. Oil can drain into the
upper part ofthe enginecausing a
starting problem.
3, Scrapeanddean theundersideofthedeckwitha
suitabletool Donotspraywithwater,
4, Putthemowerbackonits wheelsontheground,If
youhadputplasticunderthegascapearlier,make
suretoremoveitnow,
Engine Care
1, Maintainoil levelasinstructedin enginemanual,
2, Serviceaircleanerevery25 hoursundernormal
conditions,Cleaneveryfewhoursunderextremely
dustyconditions,Refertoenginemanual
3, Cleansparkplugandresetthegap oncea season,
Checkenginemanualfor correctplugtype andgap
specifications,
4, Cleanengineregularlywitha clothorbrush,Keepthe
coolingsystem(blowerhousingarea)dean topermit
properaircirculation,Removeallgrass,dirtand
combustibledebrisfrom mufflerarea,
Replacing Rear Flap
1, Toremoverearflap,cut offtheflatendofthewirerod
whichsecuresittothedeck,SeeFigure4,
2, Attachthenewflapand newrodtodeck,bendingthe
endsofthenewrodovertosecuretodeck,
10

B_ade Care f -_,
_ ARNING:When removing cutting
bladefor sharpening or replacement,
protect your handswith a pair of heavy
gloves or usea heavy rag to hold blade.
1, Disconnectsparkplugwirefromsparkplug,Turn
moweron itssidemakingsurethattheairfilterand
thecarburetorareup,
2, Removebolt,bladebell support,blade,andblade
adapterfromtheenginecrankshaft,SeeFigure5,
3, Thebladecanbe sharpenedwitha fileoron agrind=
ingwheel Donotattempttosharpenthebladewhile
itisstillon themower,Whensharpeningblade,follow
originalangleofgrind,Grindcuttingedgesequallyto
keepbladebalanced,
4, Removebladefromtheadapterfortestingbalance,
Balancethebladeona roundshaftscrewdriverto
check,Removemetalfromtheheavysideuntilit
balancesevenly,
i i i
Figure 5
WARNING:An unbalanced bladewill
cause excessivevibration when rotating
at high speeds, it may causedamage
to mower,and could breakcausing
personalinjury.
5, Lubricatetheenginecrankshaftandtheinnersurface
ofthe bladeadapterwithlightoil Slidetheblade
adapterontotheenginecrankshaft,Placetheblade
on theadaptersuchthat thesideoftheblademarked
"Bottom"(orwithpartnumber)facesthegroundwhen
themoweris intheoperatingposition,Makesurethat
bladeisalignedandseatedon bladeadapterflanges,
6, Placebladebellsupporton theblade,Alignnotches
on thebladebellsupportwithsmallholesin blade,
Replacehexboltandtightenhexbolttotorque:450
in,Ibs,rain,,600 in,Ibs,max,
Toensuresafeoperationof yourmower,periodically
checkthebladeboltforcorrecttorque,
Belt Care
1, Removetwoshoulderscrewssecuringfrontdrive
coverto mowerdeck,SeeFigure6, Pressinwardon
sidesoffrontdrivecoverand releasetabsthatsecure
ittotheheightadiusterbrackets,Removedrivecover
frommower,
2, Loosenscrewholdingbelttensionspringtotrans=
mission,SeeFigure6 inset,Donotremovescrew
completely,Asyouloosenit, tensiononthebeltwillbe
released,
Figure 6
::, ,, /
Figure 7
4, Replacewith newbelt,workingaroundblade,Make
surebeltisfirmlyseatedonenginepulleywhile
pullingfromtheothersideandslidingit aroundthe
transmissionpulley,Tightenscrewloosenedearlier
tosecurebelttensionspringtothetransmission,
Reassemblefrontdrivecover,
3, Pushtransmissionupa littleandslidebeltoffthe
transmissionpulley,Lift mowertoaccessbeltfrom
undersideofmower,Slidebeltoff ofenginepulleyand
aroundtheblade,SeeFigure7,
11
WhenremOVing
the cutting blade
_for sharpening or
rep!aeement or
pair of heavy g oves
or use a heavy rag to
hold the blade.
An unbalanced blade
will cause excessive
vibration when rotat-
ingat high speeds, it
may cause damage
to mower, and could
break causing per-
sonal injury.

Enginefails to Start 1, B!aclecontroidisengaged, i: Engagebladecent[eL
2. SparkPlugwh'edisc0nnected_ 2. C0nneciWgetoSparkplug,
Fue!tankempty0rStalefueL Filltankwith Clean,freshgaso)ine
Enginenotprirned, 4. Pdrneengineas instructedin ©perat-
5. Eautysparkpug, 5, Cean, adustgap, orrepace.!ngYourLawnMowe[.
Shoot og
l
For repairs beyond
theminoradjustments
listed here, contact
an authorized service
dealer.,
!
il_ _ i i i
!i_ii_i_i_ii_i _ii iiilt t t t t t t t t t __i
6. Blocked fuel line, 6. Clean fuelline,
7. Enginefl00ded. 7 Waitalewminutest0restart butdo
Engineruns erratic 1. Sparkplugwireloose. 1 Connectandtightensparkplugwire.
2. Blockedfuel lineor stalefuel. 2. Cleanfuelline:filltank withclean,
freshgasoline.
3. Ventingas capplugged.
4. Wateror dirt infuel system.
5. Dirtyaircleaner.
6. Carburetorout ofadjustment.
3. Clearvent.
4. Drainfueltank.Refillwithfreshfuel.
5. Refertoenginemanual.
6. Refertoenginemanual.
Engineoverheats 1. Engineoi! levellow. 1. Fillcrankcasewith properoi!.
2. Air flowrestricted. 2. Removeblowerhousing
andclean.
: 3. Carburetornot adjustedproperly, : 3. Referto enginemanual.
Occasionalskips
(hesitates)at
highspeed
1. Sparkpluggaptooclose.
2. Carburetoridlemixtureadjustment
improperlyset.
1. Adjustgap to .030".
2. Refertoenginemanual.
2. Refertoenginemanual.
Vibration
3. Dirtyair cleaner. ! 3. Refertoenginemanual.
Excessive 1. Cuttingbladelooseor unbalanced. 1. Tightenbladeand adapter.Balance
blade.
2. Bentcuttingblade. 2. Seeanauthorizedservicedealer.
I B
Uneven cut 1. Wheelsnotpositionedcorrectly. 1. Placeall fourwheelsin same
heightposition.
2. Dullblade. 2. Sharpenor replaceblade.
Mowerw not 1 Betnot nsta edpropery 1 Checkbet for properpu ey nsta aton
se f re I 1 andmovement.
p pe 2. Debriscloggingdriveoperation. 2. Stopengine,disconnectsparkplug
wireandcleanoutdebris.
3. Damagedorworn belt. m & inspectand replacebelt.
14

Off-Season Storage 4, Coatmower'scutt,ngbladewithchass,sgreaseto
Thefollowingstepsshouldbetakentoprepareyourlawn preventrusting,
mowerforstorage, S,Storemowerinadry,e_eanarea,Donotstorenext ,//
1, Cleanand lubricatemowerthoroughlyasdescribedin tocorrosivematerials,suchasfertilizer, / /
the ubrcaton nstructons ..........
when storinganytypeOTpowerequipmentin apoorly
2, Wedonotrecommendtheuseofa pressurewasher ventilatedor metalstorageshed,careshouldbetaken
or gardenhosetocleanyourunit, torust=prooftheequipment,Usinga lightoil orsilicone,
3, Referto enginemanualforcorrectengine coattheequipment,especiallycablesandall moving SOn
storageinstructions, partsofyourlawnmowerbeforestorage,
Safety Labels Found On Your Lawn Mower
PLACEANDWORKING.IF DAMAGED REPLACEiMMEDiATELY.
WARNING
DONOT remove safety
(or any) labels from
mower for any reason,
\
13

Q
Q
..//"
@Q
Q
@. -@
o "_
14

1 747-1161A BladeControlHandle
2 749-1092A UpperHandle
3 747-04080 GrassCatcherFrame
4 749-0928A LowerHandle
5 720-0279 WingNut
6 710-1205 RopeGuide
7 710-1174 CarriageBolt,5/16-18x 2
8 664-04011 GrassBagAssembly
9 720-04072 StarKnob5/16-18
10 731-04204 DeluxeBaleCover
11 726-0240 CableTie
12 710-0703 CarriageBolt,I/4-20
13 731-04134A RearDischargeDoor
14 750-04162 Spacer
15 732-04089A TorsionSpring- LH
16 732-04090A TorsionSpring- RR
17 734-04014B RearWheel,8"x2,125"
18 731-04150C RearBaffle
20 787-01277 Deck- 21"
22 782-5002B FrontBaffle
23 748-04015A BladeAdapterw/Pulley
24 742-0741 21"StandardCut Blade
25 710-1257 HexBolt, 3/8-24x2,5
26 687-02044 PivotPlateAssembly
27 736-0524B BladeBelISupport
28 787-01298 HeightAdiustmentPlate- RH
787-01299 HeightAdiustmentPlate- LH
29 720-0426 AdiustmentLeverKnob
30 732-0706 FrontLever-RH
732-0707 FrontLever- LH
31 738-04136 ShoulderScrew
32 634-04018 FrontWheel,8"x2,125"
33 710-04371 Screw,1/4-15x 1,250
34 746-1132 ControICable-40,75"
36 731-04998 Trailshield
37 732-0700 TrailshieldWire
NOTE:Forpaintedparts,pleaserefertothelistof
colorcodesbelow, Pleaseaddtheapplicablecolor
code,whereverneeded,to thepartnumbertoorder
a replacementpart, Forinstance,ifa partnumbered
700-xxxxispaintedTroybiltRed,thepartnumberto
orderwouldbe 700-xxxx-0638,
TroybiltRed:0638
PowderBlack:0637
38 712-0397 WingNut,1/4-20
39 747-04035 RearDoorPivotRod
40 732-04175 SpringLever
41 687-02071A PivotArmAssembly- RH
687-02070A PivotArmAssembly-LH
42 710-1652 ABScrew
43 712-04065 FlangeLockNut,3/8-16
44 714-0104 HairpinClip
45 710-0654A TT SeresScrew,3/8-16x 1,00
46 687-02193 Ht,Adj,Assy,Front- LH
687-02194 Ht,Adi,Assy,Front- RH
47 687-02069 RearHandleBracketAssy,-LR
687-02068 RearHandleBracketAssy,-RH
48 747-1214 LowerBailHandle
49 710-1650 ShoulderScrew
50 746-04203 DriveCable51"
51 754-04101 V-Belt
52 618-04376 TransmissionAssembly
53 731-05020A FrontDriveCover
54 732-1043 BeltTensionSpring
55 682-0015 BearingAssembly
56 736-0447 WaveWasher
57 710-0216 HexScrew
58 715-0221 DowelPin
59 717-1762 Gear,14T-RH
717-1761 Gear,14T-LH
60 710-04531 Screw1/4-20
61 782-7551A WheeIDustCap
62 716-0102 SnapRing
63 736-0474 Washer,1,5"0D
64 750-04594 SleeveSpacer-LH
65 750-04595 SleeveSpacer-RR
66 715-04030 RollPin
67 756-04151A InputPulley
68 787-01292 HandleBracket-RH
787-01291 HandleBracket-LH
and disengagesafely.
A substitute inon OEMt
oV-Beltcan bedanger-
us by notdisengaging
completely,
To order
replacement parts,
call 1=866=840-648S,
1-336=558-7220_
or log on to our
Web site at
www.troybiltocom
\
15

MANUFACTURER'S LIMITED WARRANTY FOR
®
The limitedwarrantyset forthbelowisgivenbyTroy_BiltLLCwithrespect
tonewmerchandisepurchasedandusedin theUnitedStates,itsposses_
sionsandterritories.
"Troy_Bilt"warrantsthis productagainstdefectsinmatedalandworkmam
shipfora periodof two(2)yearscommencingon thedateoforiginal
purchaseandwill,atits option,repairorreplace,freeofcharge,anypart
foundtobedefectivein materialsor workmanship.This limitedwarranty
shallonlyapplyifthis producthasbeenoperatedand maintainedin
accordancewiththeOperator'sManualfurnishedwiththeproduct,and
hasnotbeensubiectto misuse,abuse,commercialuse,neglect,accident,
impropermaintenance,alteration,vandalism,theft,fire,water,or damage
becauseofotherperilor naturaldisaster.Damageresultingfromthe
installationor useofanypart,accessoryor attachmentnotapprovedby
Troy_Biltforusewiththeproduct(s)coveredbythis manualwillvoidyour
warrantyastoanyresultingdamage.
Normalwearpartsarewarrantedtobefreefromdefectsinmaterialand
workmanshipfora periodofthirty(30)daysfromthedateofpurchase.
Normalwearpartsinclude,butare notlimitedto itemssuchas: batteries,
belts,blades,bladeadapters,grassbags,riderdeckwheels,seats,snow
throwerskidshoes,shaveplates,augerspiralrubberandtires.
NOWTO OBTAIN SERVICE: Warranty service is available, WITH
PROOFOF PURCHASE,through yourlocal authorizedservice
dealer.To locate the dealer in yourarea, check your YellowPages,
or contact Troy-Bilt LLC at RO. Box 361131,Cleveland,Ohio 44136-
0019,or can 1-866-840-6483 or 1-330-558-7220,or log on to our
Web site at www.troybilt.com.
This limitedwarrantydoesnot providecoverageinthefollowingcases:
a. Theengineor componentpartsthereof.Theseitemsmay
carrya separatemanufacturer'swarranty.Refertoapplicable
manufacturer'swarrantyfortermsandconditions.
b. Logsplitterpumps,valves,andcylindershaveaseparateone
yearwarranty.
c. Routinemaintenanceitemssuchaslubricants,filters,blade
sharpening,tune_ups,brakeadiustments,clutch adiustments,
deckadiustments,andnormaldeteriorationoftheexteriorfinish
duetouseorexposure.
d. Servicecompletedbysomeoneotherthananauthorizedservice
dealer.
e. Troy_Biltdoesnotextendanywarrantyforproductssoldor
exportedoutsideoftheUnitedStates,its possessionsand
territories,exceptthosesoldthroughTroy_Bilt'sauthorized
channelsofexportdistribution.
f. Replacementpartsthatare notgenuineTroy_Biltparts.
g. Transportationchargesandservicecalls.
Noimpliedwarranty, includinganyimpliedwarrantyof merchant°
ability offitness for a particular purpose, applies after the applicable
period of express written warranty aboveasto the parts as identi-
fied. Noother express warranty, whether written or oral, exceptas
mentioned above,given by anyperson or entity, including a dealer or
retailer,with respectto any product, shall bind Troy-Bilt. Duringthe
period of the warranty,the exclusive remedy is repair or replacement
of the product as set forth above.
The provisions as set forth inthis warranty provide the sole and
exclusive remedyarising from the sale. Troy-Bilt shall not be liable
for incidental or consequential loss or damageincluding, without
limitation, expensesincurred for substitute or replacementlawncare
services or for rental expensesto temporarily replacea warranted
product.
Somestatesdo notallowtheexclusionor limitationofincidentalor
consequentialdamages,or limitationson howlonganimpliedwarranty
lasts,sotheaboveexclusionsor limitationsmaynotapplytoyou.
Innoeventshallrecoveryofanykindbegreaterthantheamountofthe
purchasepriceoftheproductsold.Alteration of safety features of the
product shall void this warranty. Youassumetheriskandliabilityfor
loss,damage,or iniurytoyouand yourpropertyand/ortoothersandtheir
propertyarisingoutofthemisuseor inabilitytousetheproduct.
This limitedwarrantyshallnotextendto anyoneotherthantheoriginal
purchaseror tothepersonforwhomitwaspurchasedasa gift.
HOWSTATELAWRELATESTOTHISWARRANTY:Thislimitedwar-
rantygh,'esyouspecificlegalrights,andyoumayalsohaveotherrights
whichvaryfromstatetostate.
IMPORTANT:OwnermustpresentOriginalProofofPurchasetoobtain
warrantycoverage.
TROYBILT LLC, P.O. BOX 361131 CLEVELAN D, OHIO 44136-0019; Phone: 1(866} 840-6483, 1-330-558-7220