Troy-Bilt 466 User manual

Operator's Manual
21" Three-in-One
Lawn Mower
Model 466
IMPORTANT: Read safety rules and instructions carefully before operating equipment.
Warning: This unit isequipped with an internal combustion engine and should net 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 an'ester meeting
applicable local or state laws {if any). If a spark arrestor is used, it should be maintained in effeutive werFdngorder by the oper_ttor.
In the State of California the above rsrequired by law {Sestron 4442 of the Califernra Publiu ResourCes Code). Other states may have
similar laws. Feder_tl laws apply on federal lands. A spark arrestor for the muffler isavailable through your nearest engine authorized
serviue dealer or conta_ the service department, P.O. Box 361131 Cleveland, Ohio 44136-001g.
TBOY-BILTLLC,P,O,BOX361131,CLEVELAND,OEIIO44136-0019
PRINTED IN U.S.A. FORM NO. 769-00005
(12,,"2001)

TABLEOFCONTENTS
Content Page
Important Safe Operation Practices ................................................................... 3
Slope Gauge ...................................................................................................... 6
Assembling Your Lawn Mower .......................................................................... 7
Know Your Lawn Mower .................................................................................... 10
Operating Your Lawn Mower ............................................................................. 11
Maintaining Your Lawn Mower .......................................................................... 12
Service .............................................................................................................. "13
Making Adiustments.......................................................................................... 14
Off_ Season Storage.......................................................................................... "15
Troubleshooting ................................................................................................ 16
Parts List ........................................................................................................... 18
FINDINGMODELNUMBER
This Operator's Manual isan important part of your new Lawn Mower. It willhelp you assemble, prepare
and maintain the unit for best performance. Please read and understand what itsays.
Before you start assembling your new equipment, please locate the model plate on the
equipment and copy the informationfrom itin the space provided below. The information on
the model plate isvery important ifyou need help from ourCustomer Support Department or
an authorized dealer.
•You can locate the model number by standing behind the unit inthe operating position and looking
down at the rear ofthe 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.
Copy the model number here:
Copy the serial number here:
ENGINEINFORMATION
The engine manufacturer is responsible for al]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.
CALLINGCUSTOMERSUPPORT
Ifyou have difficulty assembling this product or have any questions regarding the controls, operation or
maintenance of this unit, please call the Customer Support Department.
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.

SECTION1: IMPORTANTSAFEOPERATIONPRACTICES
WARNING: This symbol points out important safety instructionswhich, if net fol]owed, could endanger
the personal safety and/or property ofyourself and others. Read and fel]ew all instructiens inthis manual
before attempting te eperate this machine. Fai]ure to comply with these instructionsmay result in personal
iniury. When yeu see this symbol--HEED ITS WARNING.
WARNING: Engine exhaust, some ef itscenstituents, and certain vehicle cempenents centain or emit
chemicals knewn to State ofCalifornia to cause cancer and birth defects er other repreducttve harm.
WARNING: "-his 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
is capable of amputating hands and feet and throwing objects, Failure to observe the following safety instructions could
result in serious injury or death,
GeneralOperation
"1. Read this operater's manual caretul]y 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 ofthis machine before operating it. Keep this
manual in a safe place for future and regular
reference and for ordering replacement parts.
2. This machine isa precision piece of power
equipment, not a plaything. Therefore, exercise
extreme caution at al] times. Your unit has been
designed to perform one ieb: to mew grass. De net
use itfor any ether purpose.
3. Never allow children under "14years old to operate
this machine. Children "14years oldand over
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
safe operation rules should use this machine.
4. Thoroughly inspectthe area where equipment isto
be used. Remove all stones, sticks, wire, bones,
toys and ether foreign objects which could be
tripped over or picked up and thrown by the blade.
Thrown ebiects can cause serious personal iniury.
Plan your mewing pattern to avoid discharge of
material toward roads, sidewalks, bystanders and
the like. Also, avoid discharging material against a
wal]or obstruction which may cause discharged
material to ricochet back toward the operator.
5. To help avoid blade contact or a thrown object
injury, stay in the operator zone behind the hand]es
and keep bystanders, helpers, children and pets at
least 75 feet from the machine while it is in
operation. Stop machine it anyone enters the area.
6. Always wear safety g]asses to protect your eyes
during equipment operation and while performing
an adiustment or repair. Thrown ebiects which
ricochet can cause serious injuryto 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 eperate 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 iniuries.
"10. Many injuries occur as a result of the mower being
pulled over the foot during a fal] 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 whi]e you
are walking. If you must back the mower away from
a wal] or obstruction first look down and behind to
avoid tripping and then follow these steps:
a. Step back from the mower to ful]y extend
your arms.
b. Be sure you are well balanced with sure
footing.
c. Pull the mewer back slewly, ne more than
half way toward you.
d. Repeat these steps as needed.
"12. Do not eperate the mower while under the influence
ef alcohol or drugs.
"13. Do not engage the self-propelled mechanism en
units so equipped while starting engine.
"14. The blade centrol handle is a safety device. Never
attempt to bypass its operation. Deing so makes
the safety device ineperative and may result in
personal injurythreugh contact with the rotating
blade. The blade control handle must operate
easily in both directtens and automatically return te
the disengaged positien when released.
"15. Never operate the mower in wet grass. Always be
sure of yeur footing. A slip and fall can cause

seriouspersonalinjury. Ifyou feel you are losing
yeur feeting, release the blade control handle
immediately and the blade will step rotating within
three seconds.
"16. Mew in daylight or geod artificial light. Walk, never
run. Step the blade when crossing gravel drives,
walkways er reads.
"17. If the equipment should start to vibrate abnormally,
stop the engine and check immediately for the
cause. Vibration isgenerally 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 unclegging the chute. The cutting blade
centinues to retate fer a few seconds after the
engine is shut off. Never place any part of the bedy
in the blade area until you are sure the blade has
stopped rotating.
"19. Never operate mower witheut proper trail shield,
discharge cover, grass catcher, blade control
handle er ether safety pretective devices in place
and working. Never operate mower with damaged
safety devices. Failure te do so can result in
personal injury.
20. Muffler and engine beceme her and can cause a
burn. De net touch.
21. Only use parts and accessories made by the
eriginal 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 goed judgment. Contact your
dealer for assistance. Telephone 1_866_840-6483
for the name ef your nearest dealer.
SlopeOperation
Slopes are a major factor related te slip and faT]
accidents which can result in severe injury.Operatien
on slopes requires extra cautien. It you feel uneasy on a
slope, do net mow it. Before operating this unit on a
slope or hilly area, use the slepe gauge en page 6 te
measure slepes. It the slope is greater than 15
degrees, do net mew it.
gO:
"1. Mew acress the face ofslepes; never up and down.
Exercise extreme caution when changing diractien
en slopes.
2. Watch ter holes, ruts, recks, hidden obiects, or
bumps which can cause you te slip or trip. Tall
grass can hide obstacles.
3. Always be sure ef yeur footing. A slip and fall can
cause serious personal injury. Ityeu feel you are
lesing your balance, release the blade centrel
handle immediately, and the blade will stop rotating
within 3 seconds.
go Net:
"1. Do not mow near drop_offs, ditches or embankments;
you may lose your footing or balance.
2. Do not mew slepes greater than 15 degrees as
shown on the slepe gauge.
3. Do not mew en wet grass. Unstable footing could
cause slipping.
Children
Tragic accidents can occur if the operator is not alert to
the presence ef children. Children are often attracted to
the mower and the mowing activity. They do net
understand the dangers. Never assume that children
will remain where yeu last saw them.
"1. Keep children eut ofthe mowing area and under
the watchful care of a respensible adult other than
the operator.
2. Be alert and turn mower eft ifa child enters the
area.
3. Before and while reeving backwards, leek behind
and dewn for small children.
4. Use extreme care near blind corners, doorways,
shrubs, trees, or other obiectsthat may obscure
yeur vision efa child who may run inte the mewer.
5. Keep children away from hot or running engines.
They can suffer burns from a hot muffler.
6. Never allew children under "14years oldte eperate
a power mewer. Chi]dran 14 years eld and ever
should read and understand the eperation
instructions and safety rules in this manual and
should be trained and supervised by a parent.
Service
SafeHandlingel Gasellne:
"1. To avoid personal injury or property damage use
extreme care in handling gasoline. Gasoline is
extremely flammable and the vapors are explesive.
Serieus personal injurycan occur when gasoline is
spilled on yourself er your clethes which can ignite.
2. Wash your skin and change clethes immediately.
3. Use only an appreved gasoline centainer.
4. Never fill centainers inside a vehicle or en a truck or
trailer bed with a plastic liner. Always place
centainers on the greund away from yeur vehicle
before filling.
5. If possible, remove gas_powered equipment from
the truck er trailer and refuel iten the ground. If this
isnet possible, then refuel such equipment en a
trailer with a pertable container, rather than frem a
gasoline dispenser nezzle.
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

fshotorrunning. Allow engfne to cool at least two
minutes before refueling.
"10. Never over fill fuel tank. Ff]ltank to no more than ½
fnch below bottom of ffller neck to provfde space for
fuel expansion.
"11. Replace gasolfne cap and tighten securely.
"12. If gasoline is spilled, wipe ft off the engine and
equfpment. Move unit to another area. Waft 5
minutes before starting the engine.
"13. Never store the machine or fuel container fnsfde
where there fs an open flame, spark or pflot lfght as
on a water heater, space heater, furnace, clothes
dryer or other gas appliances.
"14.To reduce fire hazard, keep mower tree 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 in a poorly
ventilated area. Engine exhaust contains carbon
monoxide, an odorless and dead]y gas.
2. Before cleaning, repairing, or inspecting, make
certain the blade and al] 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 inspect blade 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 originalequipment 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 al] nuts, bolts, and screws tight to be sure the
equipment is in 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 inspect the 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 subiect 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.) pads only,
listed inthis manual. "Use of parts which do not
meet the originalequipment 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 envfronment.
YourResponsibility
•Restrict the use of this power machine to persons who read, understand and follow the warnings and
instructionsin this manual and on the machine.
WARNING,

4SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE
A POWER POLE
A CORNER OF A BUILDING
OR A FENCE POST
I
I
¢,D
15o
WARN,NG
Do not mow on inclines with a slope in excess of "I5 degrees (a rise of approximately 2-'I12 feet every "I0 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.

SECTION3: ASSEMBLINGYOURLAWNMOWER
RemovingUnitFromCarton
• Remove staples, break g]ue on top flaps or cut tape
at carton end and peel along top flap to open Lower Han,,_"_
carton.
• Remove loose parts ifincluded with unit (i.e.,
operator's manual, hardware pack etc.).
• Cut corners and lay carton down flat. Remove
packing material. Lift u
• Rel] or slide unit out ef carton. Check carton
thoroughly for loose parts.
NOTE: Make sure not to crimp cables while removing
loose parts orthe entire unit from the carton.
ToolsRequired
•Pair of Pliers
• Funnel
• Set of adjustable wrenches
DisconnectingSparkPlug
• 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. See
Figure 1 .
Spar g Wire Spark Plug
Figure 1
NOTE: Reference to right or left hand side of the mower
is observed from the operating position.
IMPORTANT:This unit is shipped without gasoline or oil
in the engine. Be certain to service engine with gasoline
and oil before operating your mower.
AssemblingHandle
• For shipping purposes, the grass bag was placed
on top ef the unit. Remove it from the unit and set it
out of the way. See Ffgure 2.
Lift lower handle
Figure 2
Raise the lower handle, as shown in Figure 2, tiff it
snaps into place.
Raise the upper hand]e as shown in Figure 2.
Tighten the two wing nuts which are already on the
handle. See Figure 3.
_ghten these
wing nuts
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.
• For shipping 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 clipinto the
inner hole tn the weld pin. Repeat on the other side.
See Figure 4.
Hairpin Clip
Inner Hole
Figure 4

Insert post ofcable 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 offthe extra. See Figure 5 below.
Cable "lle
\
'\\
Po_t on
Cable "lle
\
Figure 5
AttachingStarterRope
The rope guide isalready attached to the rightside of
the lower hand]e ofyour mower. 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 up to the
rope guide. See Figure 6.
• Slip the rope through the rope guide as shown
below. Tighten the wing nut holding the rope guide
to the lower handle.
Figure 6
GrassCatcherAssembly
Itthe grass catcher is not already assembled, foT]owthe
steps below to assemble it. Otherwise go to the next
sub-section on Attaching Grass Catcher.
NOTE: Make certain the grass bag is turned right side
out before assembling (waming label wi# be on the
outside).
Partsfor GrassBag
1. Front Frame
2. Rear Frame
3. Bag
AssemblingGrassBag
•Jointhe 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 ofthe plastic channels except the center top of
the bag attach from the outside ofbag. The center
top ofthe bag attaches from inside the bag.
[]
Assembly
Rear
Frart_
Plastic
Channels
Figure 7
AttachingGrassCatcher
• If your mower isequipped with arear baffle, and it
isin place on the mower, lift the rear discharge doer
and remove itfrom the mower. See Figure 8.
Figure 8
NOTE: Make sure that the cables are routed to the
outside of the handle when attaching the grass catcher.
Liftthe rear discharge door.
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 doer.

Figure 9
RemovingGrassCatcher
• Liftthe rear discharge door on the mower.
•Liftthe grass catcher up, out of the slots in the
handle bracket assemblies.
• Reinstall the plastic rear baffle.
• Release the rear discharge deer.
WARNING: Never operate the mower
Jnless the hooks on the grass catcher are
_eated in the slots on the handle bracket
assemblies, and the rear discharge deer rests
firmly against the top ef the grass catcher.
ConvertingtoSideDischarge
• Your mower has been shipped as a mulcher. Te
convert itto a side-discharge mower, lift the
mulching plug. Slide the two hooks en the side_
discharge deflscter under the hinge pin en the
mulching plug assembly. Lower the mulching plug.
See Figure "10.
• De net remove the side mulching plug at any time,
even when you are not mulching.
Mulching
Plug
Pin
(Side
"-Chute
Deflector
Figure 10

SECTION4: KNOWYOURLAWNMOWER
Read this owner's manual and safety rules befere operating your lawn mower. Compare the illustrations tn Figure
"11 with your lawn mewer te familiarize yourself with the location ofvarious contrels and adiustments.
Lower Bail Handle
Starter Rope
Oil Plug
Gasoline Fill
_-- Spark Plug
Bag*Fili
Indicator
* Fourth I_._r not shown
MulCh _
Plug
Side Discharge
Chute Deflector
Figure 11
RecoilStarter
The recoil starter ls attached to the handle. Stand
behind the unit and pull the starter rope to start the unit.
Primer
The primer isused te pump gas inte the carburetor. Use
itto assist in starting acold engine, but do not use it
when restarting a warm engine after a short shutdown.
Refer to engine manual for location of the primer.
BladeControlHandle
The blade control handle ls located on the upper handle
ofthe 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.
l'L WARNING: The blade control handle isa
Asafety'=== device. Never attempt to bypass its
............ operations. The blade wl]] be rotating whenever
the engine is running.
=gHeight
Adjustment Lever*
LnwerBallHandle
The lower bail handle ls located on the upper hand]e
and is used to engage the drive. Squeeze the bail
hand]e against the upper handle to engage the drive;
release tt to slow down or stop the mower from
prepelfing.
Throttle Cnntr01
The engine is equipped with a constant speed throttle
which ts set at ful] throttle for maximum engine and
cutting performance.
GrassBag!Bag-FillIndicator
The grass bag ls equipped with a bag-fill indicator to
add convenience to your work. While the mower ls
running, air will flow through the bag and trite the "sail."
If the grass catcher ls empty, air flows through easily
pushing the sail up. If the grass catcher ls full, air does
net flow through tt allowing the sat] to fall So the
position ofthe sail acts as a bag-fill indicator signifying
when to empty the grass bag.
10