Troy-Bilt 830 Series User manual

SafetyoAssembly oOperation oTips &Techniques oMaintenance *Troubleshooting oParts Lists oWarranty
®
21" Rotary Mower -- Model Series 830 ModelG839EShown
READ SAFETY RULES AND mNSTRUCTmONS CAREFULLY BEFORE OPERATION
Warning: This unitisequippedwithan internalcombustionengineandshouldnotbeusedon or nearanyuniiprovedforest=covered,brush=
coveredor grass=coveredlandunlesstheengine'sexhaustsystemisequippedwitha sparkattestermeetingapplicablelocalorstatelaws(ifany),
if a sparkattesterisused,itshouldbemaintainedineffectiveworkingorderbytheoperator,inthe StateofCaliforniatheaboveisrequiredbylaw
(Section4442oftheCaliforniaPublicResourcesCode),Otherstatesmayhavesimilarlaws,Federallawsapplyonfederallands,A sparkattester
forthemufflerisavailablethroughyournearestengineauthorizedservicedealeror contacttheservicedepartment,RO,Box361131Cleveland,
Ohio44136-0019,
FORMNO,769=01541
PRINTEDiN U,S,A MTD LLC, P.O. BOX 361131 CLEVELAND, OHiO 44136-0019 1/4/2005

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 .............................................. 14
Safety Labels .................................................... 15
Parts List ........................................................... 16
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
O TRO_X_--T° TBOY=BRLT LLC
P. O. BOX 361131
www.troybilt.com CLEVELAND, ON 44136
33e=558=7220
1 =800=52e=552e
% J
Customer Support
P{ease do NOTreturn the unit to the retailer 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 seekhelp fromthe experts.Choose fromthe
options below:
Click here to search our knowledge base.
Searchby product, keyword, or phrase.
1. Visit troybHt.com for manyuseful suggestions. Clickon
CustomerSupport button and youwill get the fouroptions
reproducedin this sampleto the right.Click on the appro-
priatebutton and help is immediatelyavailable.
2. Phonea Customer Support Representative
at 1(800)520-5520.
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.
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manual.As with any type of powerequipment,carelessnessor erroronthe partof the operatorcan
resultin seriousinjury.This machineis capable of amputatinghandsand feet and throwing objects.
! Failureto observethe followingsafetyinstructionscould resultin seriousinjury or death.
endangerthe personal
safetyand/or property
Children
Tragicaccidentscan occurifoperatorisnotalerttopresence
ofchildren.Childrenareoftenattractedto mowerandmowing
activity.Theydonot understandthe dangers.Neverassume
thatchildrenwill remainwhereyoulastsawthem.
1. Keepchildrenoutofthe mowingareaandunderwatchful
careof aresponsibleadultotherthanthe operator.
2. Bealertandturnmoweroffifachildentersthearea.
3. Beforeandwhilemovingbackwards,lookbehindanddown
forsmallchildren.
4. Useextremecarewhenapproachingblindcorners,
doorways,shrubs,trees,orotherobjectsthatmayobscure
yourvisionofachildwhomayrunintothemower.
5. Keepchildrenawayfromhot orrunningengines.Theycan
sufferburnsfroma hotmuffler.
6. Neverallowchildrenunder14yearsoldto operateapower
mower.Children14yearsold andovershouldreadand
understandoperationinstructionsandsafetyrulesinthis
manualandshouldbetrainedandsupervisedbyaparent.
General Operation
1. Readthis operator'smanual carefullyin 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.Children14yearsoldandovershouldreadand
understandthe instructionsinthis manualandshould
betrainedandsupervisedbya parent.Only responsible
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.Thrownobjectswhichricochetcancauseserious
injurytothe eyes.
7. Wearsturdy,rough-soledworkshoesand close-fitting
slacksandshirts. Shirtsand pantsthat coverthe armsand
legsandsteel-toedshoesarerecommended.Neveroperate
this machinein barefeet,sandals,slipperyor lightweight
(e.g.canvas)shoes.
8. Do notputhandsorfeet nearrotatingpartsor undercutting
deck.Contactwithbladecanamputatehandsandfeet.
9. Amissingor damageddischargecovercancauseblade
contactor thrownobject injuries.
10.Manyinjuriesoccurasa resultofthe mowerbeingpulled
overthefoot duringa fall causedby slippingortripping.
Do notholdonto the mowerifyouarefalling;releasethe
handleimmediately.
11.Neverpullthe mowerbacktowardyouwhileyouare
walking.If youmustbackthe mowerawayfroma wallor
obstructionfirstlookdownandbehindtoavoidtrippingand
thenfollowthesesteps:
a. Stepbackfrommowerto fully 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 a safetydevice.Neverattempt
tobypassits operation.Doingso makesthe safetydevice
inoperativeandmay resultinpersonalinjurythrough
contactwiththe rotatingblade.The bladecontrolhandle
mustoperateeasilyin bothdirectionsandautomatically
returntothe disengagedpositionwhenreleased.
15.Neveroperatethe mowerinwetgrass.Alwaysbesureof
yourfooting. A slipandfallcan causeseriouspersonal
injury.Ifyoufeelyouarelosingyourfooting,releasethe
bladecontrolhandleimmediatelyandthe bladewillstop
rotatingwithinthreeseconds.
16.Mowonlyindaylightor goodartificiallight.Walk,neverrun.
17.Stopthe bladewhencrossinggraveldrives,walksor roads.
18.Ifthe equipmentshouldstart tovibrateabnormally,stopthe
engineandcheckimmediatelyforthe cause.Vibrationis
and followthewarnings 5. Tohelpavoidbladecontactorathrownobjectinjury, ._ generallya_arning of!rouble.........
]_ _nuttheengne errandwar unl: me Daaecomes-coa
and i..struction2stayinoperatorzone behindhandlesandkeepchildren, "
u _ competestop beforeremovngthe grasscatcheror uncog
, ,i bystanders,helpersandpetsatleast75feetfrommower .
un_nusmanuau glngthechute
whileit isin operation.Stopmachineifanyoneenters
and onthe machine, area.
..... ,J 4

Thecuttingbladecontinuesto rotatefor afewsecondsafter
the engineisshutoff. Neverplaceanypartofthe bodyin
the bladeareauntilyouaresurethe bladehasstopped
rotating.
20.Neveroperatemowerwithoutpropertrail shield,discharge
cover,grasscatcher,bladecontrolhandleor othersafety
protectivedevicesin placeandworking.Neveroperate
mowerwithdamagedsafetydevices.Failuretodo so,can
resultin personalinjury.
21.Mufflerandenginebecomehotandcancausea burn.Do
nottouch.
22.Onlyusepartsandaccessoriesmadeforthismachineby
manufacturer.Failureto doso canresultinpersonalinjury.
23.Ifsituationsoccurwhichare not coveredin this manual,
usecareand goodjudgment.Contactyourdealerfor
assistance.Telephone[phone]forthe nameofyour
nearestdealer.
SJope Operation
Slopesareamajorfactorrelatedto slipandfallaccidentswhich
canresultinsevereinjury.Operationonslopesrequiresextra
caution.Ifyoufeeluneasyona slope,donotmowit.Foryour
safety,usethe slopegaugeincludedaspartofthis manualto
measureslopesbeforeoperatingthis unitona slopedor 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. Alwaysbesureofyourfooting.A slip andfall cancause
seriouspersonalinjury.Ifyoufeelyouarelosingyour
balance,releasethe bladecontrolhandleimmediately,and
the bladewillstop rotatingwithin3 seconds.
Do Not:
1. Do notmowneardrop-offs,ditchesorembankments,you
could loseyourfootingor balance.
2. Do notmowslopesgreaterthan 15degreesasshownon
the slopegauge.
3. Do notmowon wetgrass.Unstablefootingcouldcause
slipping. Service
Safe HandlingOf Gaso%e:
1. Toavoidpersonalinjury or propertydamageuseextreme
carein handlinggasoline.Gasolineisextremelyflammable
andthevaporsareexplosive.Seriouspersonalinjurycan
occurwhengasolineis spilledonyourselforyourclothes
whichcanignite.
2. Washyourskinandchangeclothesimmediately.
3. Useonlyanapprovedgasolinecontainer.
4. Neverfill containersinsidea vehicleor onatruckor trailer
bedwith a plasticliner.Alwaysplacecontainersonthe
groundawayfromyourvehiclebeforefilling.
5. Removegas-poweredequipmentfromthe truckortrailer
andrefuelit onthe ground.Ifthis is notpossible,then refuel
suchequipmentona trailerwitha portablecontainer,rather
thanfromagasolinedispensernozzle.
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.Ifgasolineis spilled,wipeit offthe engineand equipment.
Moveunitto anotherarea.Wait5minutesbeforestarting
engine.
13.Neverstorethe machineorfuel containernearanopen
flame,sparkorpilotlightas onawaterheater,space
heater,furnace,clothesdryeror othergasappliances.
14.Toreducefire hazard,keepmowerfreeofgrass,leaves,
or otherdebrisbuild-up.Cleanupoil orfuel spillageand
removeanyfuel soakeddebris.
15.Allowa mowertocoolat 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
inthis manual."Useofpartswhichdo notmeettheoriginal
equipmentspecificationsmayleadto improperperformance
andcompromisesafety!"
4. Mowerbladesaresharpandcancut.Wrapthebladeorwear
gloves,anduseextracautionwhenservicingthem.
5. Keepallnuts,bolts,andscrewstight tobesurethe equip-
mentisin safeworkingcondition.
6. Nevertamperwithsafetydevices.Checktheirproperopera-
tionregularly.
7. Afterstrikingaforeignobject,stopthe engine,discon-
nectthe sparkplugwireandgroundagainsttheengine.
Thoroughlyinspectthe mowerfor anydamage.Repairthe
damagebeforestartingandoperatingthe mower.
8. Neverattempttomakeawheelorcuttingheightadjustment
whilethe engineis running.
9. Grasscatchercomponents,dischargecover,andtrail
shieldaresubjecttowearanddamagewhichcould expose
movingpartsorallow objectsto bethrown.Forsafety
protection,frequentlycheckcomponentsand replaceim-
mediatelywithoriginalequipmentmanufacturer's(O.EM.)
partsonly,listedin thismanual."Useof partswhich do
not meettheoriginalequipmentspecificationsmayleadto
improperperformanceandcompromisesafety!"
10.Donot changetheenginegovernorsettingor overspeedthe
engine.Thegovernorcontrolsthe maximumsafeoperating
speedofthe engine.
11.Maintainor replacesafetylabels,asnecessary'.
12.Observeproperdisposallawsand regulations.Improper
disposaloffluidsandmaterialscanharmtheenvironment.
w o°,°o
ThisSymbQUpoints
ua! beforeattempting to
resuUt in personaUinjury_
::When you see th s
_symbol
,EEDMTSWARNmNG
Responsibility
Restd_tthe use
of this powermachine
to personswhoread
understand
5

NOTE:Standbehind
Ihemoweras ifyou
Jveregoingto operate
it,Your righthandcor-
espondsto the right
sideof the mower;your
left handcorresponds
to the left sidedthe
mower.
NOTE: Forshipping
purposesyour mower
is setwith the wheels
in a lowcutting
heightposition, For
bestresults raisethe
cutting positionuntil il
is determinedwhich
heightis best for your
lawn.See Step 8 for
details.
IMPORTANT
DO NOTcrimpthe
cableswhenliftingthe
handleup.
IMPORTANT
This unit isshipped
without gasolineor
oil inthe engine. Fill
upgasoline and oil
manual BEFORE
Figure 1
zJ'i .........
Figure 2
1. Removegrasscatcherand anypackingmaterial
whichmaybe betweenupperandlowerhandles.
a. Removehandknobsfromhandlebracketsand
pullupand backon upperhandleasshownin
Figure1.Makecertainthelowerhandb isseated
securelyintothe handb mountingbrackets,
b. Tightenhandknobssecuringupperhandb to
lowerhandb.Makesurethateachcarriageboltis
seatedproperlyin thehandb.
2. Replaceandtightenhandknobsremovedearlbr
securinglowerhandb to handlebrackets,SeeFigure
2.
3. Theropeguideisattachedtotherightsideofthe
upperhandb. Loosenthewingnutwhichsecuresthe
ropeguide,SeeFigure3.
a. Holdthebladecontrolagainstupperhandle.
b. Pullstarterropeoutoftheengine,Releasethe
bladecontrol.
c. Slipstarterropeintoropeguide,Tightenwingnut,
4. Attachcanes tothelowerhandb withthecane ties
alreadyonthe lowerhandle.Insertpegson cane ties
intothehobs on thelowerhandle.Pullcane tiestight
andcutoff theextra,
5, Followstepsbelowtoattachgrasscatcher:
a. Lift reardischargedoorand removemulching
baffle.
b, Placegrasscatcheronthepivotrod,Letgo
ofdischargedoorsothatit restsonthegrass
catcher,SeeFigure4.
WARNING: Never operate mower
unless the hooks on the grass
catcher are firmly seated in the
slots on the handle bracket as°
semblies, and the rear discharge
door rests firmly against top of
the grass catcher.
Figure 3 Figure 4
operating your mower.
6

6 Followstepsbelowtoinstallthemulchingbaffle:
a Liftthereardischargedoorandliftthegrass
catcherupandoff ofthepivotrod,if installed
b InsertthemulchingbaffleasshowninFigure5
and releasethereardischargedoor
7 Toconverttosidedischarge,makesuregrasscatcher
isofftheunitandreardischargedoorisclosed
a On thesideofthemower,liftthemulchingplug
b Slidetwo hooksofside-dischargechuteunder
hingepinon mulchingplugassemblyLowerside
mulchingplug SeeFigure6 Donotremovethe
sidemulchingplugatanytime,evenwhenyouare
notmulching
8 Thecuttingheightadiustmentleveris locatedabove
therearbft wheel SeeFigure7
a Pulltheleveroutandawayfromthe mower
b Movethe leverforwardor backfordesiredcutting
height
c Rebaselevertowardsmowerdeck
9 Theadiustmentwheelislocatedinthedrivecontrol
handlehousingandisusedtotightenor loosenthe
drivebelt Youwillhavetoadiustthedrivecontrolif
anyofthefollowinghappens:
a Themowerdoesnotpropelitselfwiththedrive
controlengaged
b Themower'sdrivewheelshesitatewiththedrive
controlengaged
If eitheroftheseconditionsoccur,rotatetheadiustment
wheelclockwisetotightenthecabb and counter-clocb
wisetoloosenthecabb toadjustthedrivecontrol See
Figure8
\Figure 8
Figure 5
Figure 6
/
/
Figure 7
/1
For rough or uneven
Never operate mower
unless the hooks on
the grass Catcher are
firmly seated in the
f rmly against top of
the grass catcher,
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.
Recoil Control
__ Electric Start
Ignition Switcht
HeightLAedjeustment
Fill
GasolineFiII
Figure 9
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=
Blade 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 itsoperations.
Drive Contro_
The drive control is Iocated on the upper handIe=
Squeeze the drive control to engage the drive
system= Release it to disengage the drive system=
Release the drive controI to slow down when ap-
proaching an obstacle, making a turn, or stopping=
See Figure 9=
Cutting Height Adjustment Lever
The cutting height adjustment lever is located
above the left rear wheeI. To adjust the cutting
height, refer to the Adjustment Section on page 7=
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=
E_ectric Start Ignition Switch (if
equipped)
If your mower is equipped with an electric starter,
the ignition switch is located on the left side of the
handle panel= It is used only for the electric starter=
FreshStart TM Gas Cap (if Equipped}
This unit may be equipped with a FreshStart TM con-
tinuous fuel preserver gas cap which automatically
drips continuous fuel preserver into your fuel tank for
up to six months depending on conditions, such as
temperature, usage patterns, fuel type and blend= To
activate the gas cap, follow the instructions below:
1, Snap the fuel preserver cartridge that comes with your
unit into the fuel cap,
2, Peel off the white tab from the cartridge,
3, Twist the FreshStartTM cap onto the fuel tank,
When you visually see that the fueI preserver car-
tridge is empty, replacement cartridges are available
through your local Troy-Bilt service dealer=
Gas and Oi_ Fill-Up
1, Check oil level and add oil if necessary, Follow engine
manual for this, See Figure 9 above for location of the
oil fill
2, Service the engine with gasoline as instructed in the
engine manual See Figure 9 above for location of
gas fill
WARNING:Useextreme carewhen han-
dling gasoline. Gasoline isextremely
flammable andthe vapors areexplosive.
Neverfuel the machine indoors or while
the engine ishotor running. Extinguish
cigarettes, cigars, pipesand other
sources of ignition.
Electric Start Units Only
Charge battery for 16 hours before initial use=Follow
instructions on page 11 in Maintenance section=
8

adjustments or repairson it.
Starting Engine
_k ARNING:Besure no one otherthan
the operator isstanding nearthe lawn
mowerwhile starting engine or operato
ing mower.Neverrun engine indoors
or in enclosed, poorly ventilated areas.
Engine exhaustcontains carbon monox-
ide,an odorless and deadly gas. Keep
hands,feet, hair and loose clothing
awayfrom anymoving parts onengine
and lawn mower.
1, Pushprimerthreetimes,Waitabouttwoseconds
betweeneachpush,SeeFigure10,Intemperature
around55° For below,primefivetimes,Donotprime
to restarta warmengine,
2, Standingbehindthe mower,squeezethebladecontrol
againstupperhandle,SeeFigure10,
3, Recoil Start: Grasprecoilstarterhandleandpull
ropeoutwitha rapid,continuous,fullarmstroke,See
Figure2,Keepingafirmgrip onthestarterhandle,let
theroperewindslowly,Repeatuntilenginecranks,Let
theroperewindeachtimeslowly,
Electric Start: Turnignitionkeytothe righttostart
theengine,Releasethekeyaftertheenginestarts,
Stopping Engine
1, Releasebladecontroltostoptheengineandblade,
2, Disconnectsparkplugwirefromsparkplugand
groundagainsttheengine,
WARNING: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 accidentlythrownbythemower
in anydirectionandcauseseriouspersonaliniurytothe
operatorandothers,
Figure 10
WARNING:If you strike aforeign
object, stop the engine. Remove
wire from the spark plug, thoroughly
inspect 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
control Makesurethattheunithascometo a
completestop,
3, Liftdischargedoorand pullgrassbagup andaway
fromthemowertodisposeofthegrassclippings,
y
can result
being thrown into
the eyes Which can ;
damage your eyes
severe!y. Nways wear
safety glasses while
iioperating the mower,
-_ngineor 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

f====== Lubrication
/_-J _ 1, Lubricatepivotpointson thebladecontrolat least
"_ _--'_ oncea seasonwithlightoil Thebladecontrolmust
r===_) ) _ ... . operatefreelyinbothdirections,SeeFigurell,
\ v /_ _. LuDrlca[e-[nose
- _ pc nts before 2, Lubricatethewheelsatleastoncea seasonwith
-- reassembI' lightoil (or motoroil). Ifwheelsare removedforany
,, ,, ,, y= ..
M _ | ['1t_ ! r'_ | r'_ C reason,lubricatesurfaceoftheaxleand innersurface
_= ='3_ == ........ ofthewheelwith hghtoff,SeeFigure11,
.......... ..............
Figure 12
General Recommendations
1, Alwaysobservesafetyruleswhenperforming
anymaintenance,
2, Thewarrantyon thislawnmowerdoesnotcover
itemsthathavebeensubjectedtooperatorabuse
or negfigence,Toreceivefullvaluefromwarranty,
operatormustmaintainthe lawnmoweras
instructedhere,
3, Changingofengine=governedspeedwillvoid
enginewarranty,
4, Alladiustmentsshouldbecheckedat leastonce
eachseason,
5, Periodicallycheckall fastenersand makesurethese
aretight,
_ ARNING:Alwaysstop engine,
disconnect spark plug, and ground
against engine beforecleaning,
lubricating or doing any kind of
maintenanceon your machine.
Ionot reCommend
3, Lubricatethetorsionspringandpivotpointontherear
dischargedoorandsidemulchplugperiodicallywith
lightoil topreventrust,SeeFigure11,
4, Thetransmissionis pro=lubricatedandsealedatthe
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 intothe
upper part ofthe enginecausing a
starting problem.
3, Scrapeandcleantheundersideofthedeckwitha
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,
Checkenginemanualforcorrectplugtype andgap
specifications,
4, Cleanengineregularlywitha clothorbrush,Keepthe
coolingsystem(blowerhousingarea)cleantopermit
properaircirculation,Removeallgrass,dirtand
combustibledebrisfrom mufflerarea,
Replacing Rear Flap
1, Toreplacerearflap,lift upreardoor,
2, Removetwoself=tappingscrewswhichsecurerear
flapto thedeck,SeeFigure12,
3, Replacewith newflapandsecureto deckwiththetwo
self=tappingscrewsremovedearlier,
10

Replacing Battery (Electric Start Units f -- "_
Only)
Removethebatterypackfromthehandlepanelfor ........
replacementonly.Donotseparatethebatteriesforany
reason.Disposeof batterbsproperly. _i
WARNING:Batteriescontain sulfuric
acid whichmaycause burns. Donot
short circuit or mutilate batteries inany
way.Do not put batteries infire asthese
may buretor releasetoxic materials.
Thepositivebad onthewireharnesshasthesmalbr
connector.Connectthepositivebad tothepositiveside
ofthebatterypack,thenconnectthenegativeside.
NOTE:Whenreplacingbatterypackin handb panel,bat-
tery packmustbepositionedwiththepositiveterminalto
therightsideandthenegativeterminaltotheleftsideof
panel SeeFigure13.Replacingbatterypackincorrectly
willcauseserious damage,
Charging Battery
WARNING:The battery contains cor-
rosive fluid and toxic material; handle
with careand keepawayfrom children.
Donot puncture, disassemble, mutilate
or incineratethe battery. Explosive
gases could be vented during charging
or discharging. Use ina wellventilated
area,awayfrom sources of ignition.
1. Removetheprotectivecapfromtheendofthebattery
packbad. Alwaysplugchargerbad intobatterypack
bad first,andtheninsertbatterychargerpluginto120
voltstandardhouseholdoutlet.Followthisorderof
actioneverytimeyouchargethebattery.
2. Chargebatteryfor16hoursbeforeinitialuse.Donot
charge longer than 20 hours.
3. Aftercharging,disconnectbatterychargerplugfrom
householdoutbt first,thendisconnectchargerbad
frombatterypackbad.
WARNING:Donot removethe battery
pack from the handle panelfor any
reasonother than replacement.
mnqine Fuse (EJectric Start Units Only)
Theunitisequippedwithan in=linefuse.Iftheunitfailsto
start,checkthefuseinsidethebatterycoverbypushing
in andturningtheend ofthefuseholdercounter=clock=
wiseandremovingfromthebatterycover.SeeFigure
14.Replacewithstandardautomotive7=1/2ampfuse.
Reinsertintobatterycoverbypushingfuseholderinand
turningclockwise.
+ Terminal ......:::::.........
a
Figure 13
Figure 14
_Use only the battery
iiiii_ _ i_ i _f_iiiii_ /
ii i . /
When removing
"Jiithe cutting blade
Figure 15 _for sharpen ng Or
B_ade Care
_ WARNING:Whenremovingcutting replacement or
blade for sharpening or replacement, when sliding the belt
i /
protect your handswith a pair of around it, protect
heavy gbves or usea heavy ragto your hands with a
hold blade, pair of heavy glOVes
1. Disconnectsparkplug'direfromsparkplug.Turn or use a heavy rag to
moweronits sidemakingsurethattheair filterand
thecarburetorareup, he d the bade.
2. Removebolt,bladebellsupport,blade,andblade
adapterfromtheenginecrankshaft.SeeFigure15.
11

Maintaining
Figure 8
f
Toensuresafeoperationofyourmower,periodically
checkthebladeboltforcorrecttorque,
Be_t Care
1, Disconnectthesparkplugwireandgrounditagainst
theengine,
2, Drainthefueltankor placea pieceofplasticbeneath
thecapto preventgasolineleakage,
3, Tipmoweron its side(aircleanersideofengineup),
4, Removeblade,bladeadapter,andrelatedhardware
asinstructedin BladeCareon Page11,
5, Loosenself-tappingscrewthatsecuresdeckbaffleto
thedeck,SeeFigure8,
6, Workingfromtherearofthemower,carefullyremove
beltfromtransmissionpulley,
7, Oncebeltisofftransmissionpulley,pushdownon
deckbaffletoaccessenginepulleyandslidebeltoff
thispulleyandoutfromunderdeck,SeeFigure9,
8, Replacewith newbelt,workingitbetweenthedeck
andbaffle,firstaroundthetransmissionpulleyand
thentheenginepulley,
NOTE: Makecertainthat beltisseatedcorrectlyand
thatitis ridingsmoothlyontheenginepulleyandisnot
pinchedbetweenthelowerand upperpulleyhalves,
\
An unbalanced blade
wil! cause excessive
vibrationwhen rotat-
ing at high speeds, it
may cause damage
to mower, and could
break causing per-
sonal injury.
All batteriesdischarge
during storage,Re-
charge batteryevery
two months and before
returningto service.
Figure 9
NOTE:Whenremovingtheblade,bladeadpter,etc,,be
carefulnottoremoveor losepartsaboveitassociated
withtheenginepulley,
3, Thebladecanbesharpenedwitha fileor ona
grindingwheel Donotattempttosharpentheblade
whileit isstillonthe mower,Whensharpeningblade,
followoriginalangleofgrind,Grindcuttingedges
equallyto keepbladebalanced,
4, Removebladefromtheadapterfortestingbalance,
Balancethebladeon a roundshaftscrewdriverto
check,Removemetalfromtheheavysideuntilit
balancesevenly,
_IL ARNING:An unbalanced blade
will causeexcessivevibration when
rotating at high speeds.It maycause
damageto mower,and could break
causing personalinjury.
5, Lubricatetheenginecrankshaftandtheinner
surfaceofthe bladeadapterwithlightoil, Slidethe
bladeadapterontotheenginecrankshaft,Placethe
bladeon theadaptersuchthat thesideoftheblade
marked"Bottom"(orwith partnumber)facesthe
groundwhenthemowerisintheoperatingposition,
Makesurethat bladeisalignedandseatedon blade
adapterflanges,
6, Placebladebellsupportontheblade,Alignnotches
onthebladebellsupportwithsmallholesin blade,
Replacehexboltand tightenhexbolttotorque:450
in,Ibs,rain,,600in,Ibs,max,
9, Tightenself-tappingscrewsecuringdeckbaffle
loosenedearlier,
10,Replaceblade,bladeadapter,andassociated
hardware,Followinstructionsin BladeCaresection
forproperassembly,
11,Tipmowerbackontoitswheelsandremovepieceof
plasticfromundergascap(ifapplicable),
OffoSeason Storage
Thefollowingstepsshouldbetakento prepareyourlawn
mowerforstorage,
1, Cleanandlubricatemowerthoroughlyasdescribedin
thelubricationinstructions,
2, Wedo notrecommendtheuseofa pressurewasher
orgardenhosetocleanyourunit,
3, Refertoenginemanualforcorrectengine
storageinstructions,
4, Coatmower'scuttingbladewithchassisgreaseto
preventrusting,
5, Storemowerina dry,cleanarea,Donotstorenextto
corrosivematerials,suchasfertilizer,
Whenstoringanytypeof powerequipmentin a poorly
ventilatedor metalstorageshed,careshouldbetakento
rust-prooftheequipment,Usinga lightoil orsilicone,coat
theequipment,especiallycablesandall movingpartsof
yourlawnmowerbeforestorage,
Battery (If equipped)
The batterymustbestoredwitha fullcharge,A dis_
chargedbatterywillfreeze,
12

Notes
Mower
\
13

ble
Shooting
For repairs beyond
the minoradjust-
ments listed here,
eentact an authorized
serviee dealer, I
il_ _ i i i
Problem Cause Remedy
EnginefaiUsto start !_ BladecontroEdisengaged, i !. EngageNadeeontrol,
spa[k PlugwiredisconneCte& 2: connect wiretoSparkpiug:
3. Filltankwithclean,freshgasoline.
8. Replacefusefollowinginstructions
on page11.
Engineruns erratic 1. Sparkplugwireloose. 1. Connectandtightenspark
plugwire.
2. Blockedfuellineor stalefuel 2. Cleanfuelline;filltankwithclean,
freshgasoline.
3. Ventingascapplugged. 3. Clearvent.
4. Waterordirt infuelsystem. 4. Drainfueltank.Refillwith
freshfuel.
5. Dirtyaircleaner. 5. Refertoenginemanual.
6. Carburetoroutofadjustment. 6. Refertoenginemanual
Engne overheats 1. Engineoil levellow. I. Fillcrankcasewithproperoil
2. Airflow restricted. 2. Removeblowerhousng
I andclean.
3. Carburetornotadjustedproperly. 3. Referto enginemanual.
Occasional skips 1. Sparkpluggaptooclose. 1. Adjustgapto.030".
(hesitates)at 2. Carburetoridlemixtureadjustment 2. Refertoenginemanual
highspeed improperlyset.
2. Carburetorimproperlyadjusted.
Excessive 1. Cuttingbladelooseor unbalanced.
Vibration
2. Bentcuttingblade.
Mower will not 1, Wetgrass.
mulchgrass
2. Excessivelyhighgrass.
3. Dullblade.
Uneven cut 1. Dullblade.
Damagedorworn
3. belt.
3. Referto enginemanual
1. Tightenbladeandadapter.
Balanceblade.
2. Seean authorizedservicedealer.
2. Mowonceata highcuttingheight,
thenmowagainatdesiredheight
or makea narrowercuttingpath.
3. Sharpenor replaceblade.
1. Sharpenor replaceblade.
wireandcleanoutdebris.
14

DONOTtemeve safety
(or any) labels frem
mewer fet any reasen,
\
15

Q
Q
Shown For Reference
/............Shown For Reference
@
1 618-04229 TransmissionAssembly
2 710-04223 Screw,M6x 1,0
3 715-0221 DowelPin
4 717-04184 SpurGear,14T-LH
5 717-04192 SpurGear,14T-RH
6 732-0611 ExtensionSpring,,38ODx3,6
7 736-0414 FlatWasher,,570x 1,120x ,062
8 741-0710 SleeveBearing,,502x,627x 1,00
9 748-04073 TransmissionBearingSupport
10 750-04317 ClipSpacer
11 754-04078A WBelt,3Lx35,5
12 7867551A WheeIDustCover
13 787-01262 TransmissionCableBracket
14 634-04207 RearWheel
15 734-04033 FrontWheel
16 687-02133 FrontBracketAssembly
17 687-02134 RearBracketAssembly
18 687-02148 HandleBracketAssembly-RH
19 687-02149 HandleBracketAssembly-LH
20 710-0599 TT Screw,1/4-20x ,500
21 71b0431 RangeLockNut,3/8q6
22 714-0174 CotterPin
23 720-0223 Grip
24 732-04261 SpringLever
25 73b04271 ExtensionSpring,,500IDx 6,85Lg
26 741-04136 SplitHexFlangeBearing
27 750-04305 Spacer
28 787-01235 CrossBracket
29 787-01251 StopBracket
30 736-0504 WaveWasher,,510x ,750x,017
31 731-05237 SpringBracketCover
16

1 721-04107 OilSeal
2 741-04106 PlasticBushing
3 707-04409 ShiftFork
4 707-04540 TransmissionBracket
5 710-04329 Screw,,1590Dx,610
6 710-04374 HexScrew,,159ODx,43
7 711-04386 OutputShaft
8 711-04394 [nputShaft
9 712-0411 HexLockNut,5/16-24
10 715-0129 SpirolPin
11 715-04030 DowelPin
12 717-04194 PlasticGear,28T
13 756-04151 Pulley,3,360D
14 721-04110 O-Ring
15 726-04043 PushNut,3/8 [Dx3/40D
16 731-04883 LowerHousing
17 731-05099 UpperHousing
18 731-05100 ClutchLever
19 732-04278 CompressionSpring,,5251Dx,588
20 736-0105 BellWasher,,375x ,870x,063
21 736-04170 FlatWasher,,508[D x 1,00OD
22 736-04178 FeltSIottedWasher
23 736-0572 FlatWasher,,510x 1,00x ,060
24 736-0864 ThrustWasher,,375x,812x ,060
25 741-04116 BallBearing
1!IIIII iiiiiiii!i IIIIII
Z i i i
i i
Z
i_ ill _ i£i£i ii£i ii ii£i ii£i£i ii£i ii£i_
17

18

1 747_1161A BladeControl
2 746_04195 DriveCable
3 746_1130 ControlCable
4 710_1667 Screw,#10_16x,625
5 731-0620 DriveControlLever
6 731q057 UpperControICover
7 731q058 LowerControlCov'er
8 731_1059 MountingCap
9 710q174 CarriageBolt,5/16_18x 2,0
10 710-1205 EyeBolt
11 720-0279 WingNut
12 720_0284 HandleKnob
13 725_0157 CableTie
14 736_0451 SaddleWasher,,320x,93x,060
15 749_04202 LowerHandle
16 749-04209 UpperHandle
17 787_01213 21"Deck
18 647_04048 GrassCatcherFrame
19 664_04042 GrassCatcher
20 731_05017 RearDoor
21 710_0260A CarriageBolt,5/16_18x,62
22 710q241 Screw,1/4_15x 1,00
23 710_0599 TT Screw,1/4_20x ,500
24 710_0653 TT Screw,1/4_20x ,375
25 710_0654A Screw,3/8_16x1,00
26 710_0703 CarriageScrew,1/4_20x ,75
27 710q044 Screw,3/8_24x1,50
28 710q802 Screw,1/4_20x2,00
29 711_04374 DoorPivotRod
30 711_0993 BeltGuardPin
31 712_04064 FlangeLockNut,1/4_20
32 712_3004A FlangeLockNut,5/16-18
33 712_3027 FlangeLockNut,1/4_20
34 731_05154 DeckBaffle
35 731_05157 MulchRug
36 731_05185 Trailshield
37 732_04264 DoorTorsionSpring- RR
39 736_0463 FlatWasher,,25x ,630x,0515
40 736_0513 SpringWasher,,890x 1,70x ,048
41 736_0514 FlatWasher,,885x 1,850x,060
42 736-0524B BladeBelISupport
43 742_0741 21"MulchingBlade
44 748_0358 EngineSpacer
45 748-0376C BladeAdapter
46 756_04156 LowerEnginePulley
47 756_04157 UpperEnginePulley
48 787-01224 FrontDeckBaffle
49 736_0270 BellWasher,,265x ,75x ,062
50 687-02055 MulchingBaffle
51 17032A DeflectorChuteAdapter
52 732q014 TorsionSpring
53 747_0710 HingePin
54 731-04177 SideDischargeChute
55 725_1442t ElectricStarterHarnessAssembly
56 710_01111 Screw,1/4_20x 1,25
57 710_01361 Screw,1/4_20x 1,75
58 710_09691 Screw,#12_16x 1,00
59 710_12501 CurvedCarriageBolt,5/16x 1,5
60 712_0324t HexLockNut,1/4_20
61 712-30061 HexNut,1/4-20
62 712_30101 HexNut,5/16_18
63 725_02981 7,5AmpFuse
64 725_0873t KeySwitch
65 725_12061 Plug
66 725_12761 12VoltBattery
67 725_1428t FuseHolder
68 725q5381 ExtHarness
69 731_0891A1-UpperBatteryTray
70 736_02421 BellWasher,,340x ,872x ,060
71 736_02701 BellWasher,,265x ,75x ,062
72 782_9012t LowerBatteryTray
73 725_0727t BatteryCharger(NotShown)
74 735-0226 RubberGromet
tIf equipped
parts, centact 1,800,
e48L6776or visit www.
machine,use Factory
Approved Parts.
V-BELTS are specially
designed to engage
and disengagesafely.
A substitute non OEMI
V-Belt canbe danger-
ous by not disengaging
completely.
\
19

MANUFACTURER'S LIMITED WARRANTY FOR
®
The limitedwarrantyset forthbelowisgivenbyTroy=BiltLLCwithrespect
tonewmerchandisepurchasedandusedin theUnitedStates,itsposses=
sionsandterritories.
"Troy=Bilt"warrantsthis productagainstdefectsinmaterialandworkman=
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,commerdaluse,neglect,accident,
impropermaintenance,alteration,vandalism,theft,fire,water,or damage
becauseofotherperilor naturaldisaster.Damageresultingfromthe
installationor useofanypart,accessoryor attachmentnotapprovedby
Troy=Biltforusewiththeproduct(s)coveredbythis manualwillvoidyour
warrantyastoanyresultingdamage.
Normalwearpartsarewarrantedtobefreefromdefectsinmaterialand
workmanshipforaperiodofthirty(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=BiltLLC at RO, Box 361131,Cleveland,Ohio 44136=
0019,or can 1=800=520=5520or 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.
Noimplied warranty, including anyimplied warrantyof 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 incidentalor consequential loss or damageincluding,without
limitation, expensesincurredfor substitute orreplacementlawncare
services or for rental expensesto temporarily replacea warranted
product.
Somestatesdo notallowtheexclusionor limitationofinddentalor
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:This limitedwar-
rantygh,'esyouspecificlegalrights,andyoumayalsohaveotherrights
whichvaryfromstatetostate,
IMPORTANT:OwnermustpresentOriginalProofofPurchasetoobtain
warrantycoverage,
Troy-Bilt LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019; Phone: [phone]