Troy-Bilt 836 series User manual

SafetyoAssembly oOperation oTips &Techniques oMaintenance *Troubleshooting oParts Lists oWarranty
®
21-inch Rotary Mower -- Model Series 836
READ SAFETY RULES AND mNSTRUCTmONS CAREFULLY BEFORE OPERATION
Warning: This unitisequippedwithan internalcombustionengineandshouldnotbeusedon or nearanyunimprovedforest-covered,brush=
coveredor grass=coveredlandunlesstheengine'sexhaustsystemis equippedwitha sparkarrestermeetingapplicablelocalorstatelaws(ifany),
If a sparkarresterisused,itshouldbemaintainedineffectiveworkingorderbytheoperator,Inthe StateofCaliforniatheaboveisrequiredbylaw
(Section4442oftheCaliforniaPublicResourcesCode),Otherstatesmayhavesimilarlaws,Federallawsapplyonfederallands,A sparkarrester
forthemufflerisavailablethroughyournearestengineauthorizedservicedealeror contacttheservicedepartment,RO,Box361131Cleveland,
Ohio44136=0019,
PRINTEDIN U,S,A MTD LLC, RO. BOX 361131 CLEVELAND, OHiO 44136-0019 FORMNO,769=01541B
11/29/2005

This Operator's Manua_ is an important part of your new lawn mower. JtwH_ he_p you assembJe,
prepare, and maintain the unit for best performance. P_ease read and understand what it says.
Table of Contents
SJope Gauge ....................................................... 3
Safe Operation Practices ................................... 4
Setup and Adjustment ....................................... 6
Operating Your Lawn Mower .............................. 8
Maintaining Your Lawn Mower ......................... 10
Troub{eshooting ................................................ 14
Safety Labels .................................................... 15
Parts List ........................................................... 16
Warranty ............................................ Back Cover
Finding and Recording Model Number
BEFOREASSEMBLINGYOUR NEWEQUIPMENT,please
locate the model plateon the equipmentand copythe
informationtothe samplemodel plate providedto the right.
Youcan locatethe modelplate by standing atthe operating
positionand lookingdown at the rearof the deck. This infor-
mation will be necessaryto use the manufacturer'sweb site,
obtainassistancefrom the CustomerSupport Department,or
when contactingan authorizedservice dealer.
Modet Number Serial Number
O TRI:IItf B#LT' TRO¥-BULTLLC
P. O. BOX 361131
www.troybimt.com CLEVELAND,OH44136
338-558-7228
Customer Support
P_ease DO NOT return the unit to the retai_er from which it was purchased without first
contacting Customer Support.
Ifyou havedifficulty assemblingthis productor have anyquestions regardingthe controls,operation,or maintenanceof this
unit,youcan seekhelp fromthe experts.Choose fromthe options below:
1. Visitwww.troybilt.com
2. Phonea CustomerSupport Representativeat 1o866o840o6483.
3. The enginemanufactureris responsiblefor all engine-relatedissues with regards to performance,power-rating,specifica-
tions, warranty,and service. Pleasereferto theengine manufacturer'sOwner's/Operator's Manual,packedseparatelywith
your unit, for more information.
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 downslopes.
\
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. Beforeand whilemovingbackwards,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 properuseofthismachinebefore
operatingit.Keepthis manualin asafeplaceforfuture
andregularreferenceandfor orderingreplacementparts.
2. Thismachineisa precisionpieceof powerequipment,
nota plaything.Therefore,exerciseextremecautionat all
times.Yourunithasbeendesignedto performonejob: to
mowgrass.Do notuseitfor anyotherpurpose.
3. Neverallowchildrenunder 14yearsoldto operatethis
machine.Children14yearsoldand overshouldreadand
understandthe instructionsinthismanualandshould
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 repairtoprotect
youreyes.Thrownobjectswhichricochetcancauseserious
injurytothe eyes.
7. Wearsturdy,rough-soledworkshoesandclose-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. Amissingor damageddischargecovercancauseblade
contactor thrownobject injuries.
10.Manyinjuriesoccurasa resultofthe mowerbeingpulled
overthefootduringa fall causedby slippingortripping.
Do notholdontothe mowerifyouarefalling;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 mowerinwet grass.Alwaysbesureof
yourfooting. Aslipandfallcan causeseriouspersonal
injury.If youfeelyouarelosingyourfooting,releasethe
bladecontrolhandleimmediatelyandthe bladewillstop
rotatingwithinthreeseconds.
16.Mowonlyindaylightor goodartificiallight.Walk,neverrun.
17.Stopthe bladewhencrossinggraveldrives,walksor roads.
18.Ifthe equipmentshouldstarttovibrateabnormally,stopthe
engineandcheckimmediatelyforthe cause.Vibrationis
and followthewarnings 5. Tohelpavoidbladecontactorathrownobjectinjury, ._ generallya'_arningof!rouble.........
]_ _nutthe engne errandwar unl: me Daaecomes-coa
and i..struction2stayinoperatorzone behindhandlesandkeepchildren, "
u _ competestop beforeremovngthe grasscatcheror uncog
, ,; bystanders,helpers,andpetsat least75feetfrommower .
un_nusmanuau glngthechute
whileit isin operation.Stopmachineifanyoneenters
and onthe machine, area.
..... ,J 4

Thecuttingbladecontinuesto rotateforafewsecondsafter
the engineisshutoff. Neverplaceanypartofthe bodyin
the bladeareauntilyouaresurethe blade hasstopped
rotating.
20.Neveroperatemowerwithoutpropertrailshield,discharge
cover,grasscatcher,bladecontrolhandle,or othersafety
protectivedevicesin placeandworking.Neveroperate
mowerwithdamagedsafetydevices.Failuretodo socan
resultin personalinjury.
21.Mufflerandenginebecomehotandcancauseaburn.Do
nottouch.
22.Onlyusepartsandaccessoriesmadefor thismachineby
manufacturer.Failureto dosocanresultinpersonalinjury.
23.Ifsituationsoccurwhichare 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. Alwaysbesureofyourfooting.A slip andfall cancause
seriouspersonalinjury.If youfeelyouarelosingyour
balance,releasethe bladecontrolhandleimmediately,and
the bladewillstop rotatingwithin 3seconds.
Do Not:
1. Do notmowneardrop-offs,ditchesorembankments,where
you couldloseyourfootingorbalance.
2. Do notmowslopesgreaterthan15degreesasshownon
the slopegauge.
3. Do notmowon wetgrass.Unstablefootingcouldcause
slipping. Service
Safe HandlingOf Gaso%e:
1. To avoidpersonalinjury or propertydamageuseextreme
carein handlinggasoline.Gasolineisextremelyflammable
andthevaporsareexplosive.Seriouspersonalinjurycan
occurwhengasolineis spilledonyourselforyourclothes
whichcanignite.
2. Washyourskinandchangeclothesimmediately.
3. Useonlyanapprovedgasolinecontainer.
4. Neverfill containersinsideavehicleor ona truckor trailer
bedwith a plasticliner.Alwaysplacecontainersonthe
groundawayfromyourvehiclebeforefilling.
5. Removegas-poweredequipmentfromthe truckortrailer
andrefuelit onthe ground.Ifthisis notpossible,then refuel
suchequipmentonatrailerwitha 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 oraddfuelwhileengineishot or
running. Allowengineto coolatleasttwominutesbefore
refueling.
10.Neveroverfillfueltank. Filltankto nomorethan_ inch
belowbottomoffillerneckto providefor fuelexpansion.
11.Replacegasolinecapandtightensecurely.
12.Ifgasolineis spilled,wipeit 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. Afterstrikingaforeignobject,stopthe engine,discon-
nectthe sparkplugwireandgroundagainsttheengine.
Thoroughlyinspectthe mowerfor anydamage.Repairthe
damagebeforestartingandoperatingthe mower.
8. Neverattempttomakeawheelorcuttingheightadjustment
whilethe engineis running.
9. Grasscatchercomponents,dischargecover,andtrail
shieldaresubjecttowear anddamagewhichcould expose
movingpartsorallow objectsto bethrown.Forsafety
protection,frequentlycheckcomponentsand replaceim-
mediatelywithoriginalequipmentmanufacturer's(O.EM.)
partsonly,listedin this manual."Useof partswhichdo
not meettheoriginalequipmentspecificationsmayleadto
improperperformanceandcompromisesafety!"
10.Donot changetheenginegovernorsettingor overspeedthe
engine.Thegovernorcontrolsthe maximumsafeoperating
speedofthe engine.
11.Maintainor replacesafetylabels,asnecessary'.
12.Observeproperdisposallawsand regulations.Improper
disposaloffluidsandmaterialscanharmtheenvironment.
w o°,°o
ThisSymbolpoints
ua! before attemptingto
resuUt in personalinjury_
::When you see th s
_symbol
,EEDMTSWARNmNG
Responsibility
Restrictthe use
of this powermachine
to personswhoread
understand
5

Standbehindthe
moweras ifyouwere
goingto operate it,
respondsto the right
sideof the mower;your
eft handcorresponds
to the left side ofthe
mower.
Forshipping purposes
yourmoweris setwith
the wheels in a low
cutting heightposition.
Forbest resultsrase
thetutti ngposition
until itisdetermined
which heiahtis best
for your lawn,referto
instructions,
IMPORTANT
DO NOTcrimpthe
canes when liftingthe
handb up.
iMPORTANT
without gasoline or
up gasolineand oil
as instructedin the
accompanyingengine
manual BEFORE
operating your mower,
HandleMounting
Figure3-1:Unfoldhandleandtightenhardware,
f
Figure3-2:Securehandleto handlemountingbrackets,
asshownin Figure34. Makecertainthelower
handleisseatedsecurelyintothehandlemounting
brackets.
b. Tightenhandknobssecuringupperhandleto
lowerhandle.Makesurethateachcarriageboltis
seatedproperlyin thehandb.
2. Replaceandtightenhandknobsremovedearlbr
securinglowerhandb to handlebrackets,Figure3-2.
3. Theropeguideisattachedtotherightsideofthe
upperhandle.Loosenthewingnutwhichsecuresthe
ropeguide,Figure3-3.
a. Holdthebladecontrolagainstupperhandle.
b. Pullstarterropeoutoftheengine.Releasethe
bladecontrol.
c. Slipstarterropeintoropeguide.
d. Tightenwingnut.
4. Securecanes tothelowerhandb usingthecane tie.
Pullcane tietightandcutoff excess.
5. Toassembbthegrasscatcher(ifneeded),placebag
overframewiththeblackplastb sideatthebottom.
Slipplastb channeloverhooksonframe.All channels
exceptforcentertopofbagattachfromtheoutside.
Thecenterofbagattachesfromtheinside.
6. Beforeattachingthegrasscatcher,themulching
bafflemustberemoved,Figure3-5.
a. Lift reardischargedoor.
b. Removemulchingbaffle.
7. Toattachgrasscatcher,Figure3-4.
a. Lift reardischargedoor.
b. Placegrasscatcheronthepivotrod.Letgo
ofdischargedoorsothatit restsonthegrass
catcher.
Figure3-3:Pullrecoilstarterthroughropeguideandtighten. Figure3-4:Liftdischargedoorandplacegrasscatcheronrod.
6

8. ThebatterypackwithintheElectricStartermustbecharged8 to 10hoursbeforeuse.Referto"Charging
Battery"in theMaintenancesectionforinstructions.
9. Followthestepsbelowtoinstallthemulchingbaffle:
a. Liftthereardischargedoorandliftthegrasscatcherupandoff ofthe pivotrod,ifinstalled.
b. InsertthemulchingbaffleasshowninFigure3-5and releasethereardischargedoor.
10.Toconverttosidedischarge,makesuregrasscatcherisoffof theunitandreardischargedoorisclosed.
a. On thesideofthemower,liftthemulchingplug.
b. Slidetwo hooksonsidedischargechuteunderhingepin onmulchingplugassembly,Figure3-6. Lowerthe
mulchingplug.Donotremovesidemulchingplugatanytimeevenwhenyouarenotmulching.
J
Figure3-5:Themulchingbaffle Figure3-6:Installingthesidedischargechute.
Adjustments
Cutting Height
Thecuttingheightadiustmentleverislocatedabovetherearleftwheel,Figure3-7.
a. Pulltheleveroutandawayfromthe mower.
b. Movethe leverforwardor backfordesiredcuttingheight.
c. Releaselevertowardsmowerdeck.
Drive Control
Theadiustmentwheelislocatedinthedrivecontrolhandlehousingandisusedtotightenor loosenthedrivebelt.
Youwillneedtoadiustthedrivecontrolifthemowerdoesnotpropelitselfwiththedrivecontrolengagedor ifthe
mower'swheelshesitatewiththedrivecontrolengaged.If eitheroftheseconditionsoccur,rotatetheadiustment
wheelclockwisetotightenthecableor counterclockwisetoloosenthecable,Figure3-8.
,,%
f
/'
the grass.
drive controlmay not
post on You can adjust
the handlebytightening
theadjustment wheeL
i
Figure3-8:Theadjustmentwheelonthedrivecontrol.
7

Know Your Lawn Mower
Drive Control
WARNING
The blade control
mechanism is a
safety device. Never
attempt to bypass its
operations.
Use extreme care
when handling
gasoline.Gasoline is
extremely flammabb
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
Jabelon the unit.
Oil Fill
Figure4-1:Themajorcomponentsonthe mower.
Now that you have setup your lawn mower for op-
eration, it's important to become aquainted with its
controls and features.
B_ade Contro_
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: The blade control is a safety
device. Do not bypass its operation.
Drive Contro_
The drive controi is Iocated on the upper handIe.
Squeeze the drive control Iever to engage the drive
system. ReIease it to disengage the drive system.
To slow down when approaching an obstacle, mak-
ing a turn, or stopping, release the lever.
Cutting Height Adjustment Lever
The cutting height adiustment lever is located
above the left rear wheel To adjust the cutting
height, refer to the Adiustment Section.
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_ectrie Starter
The ignition switch is located on the Ieft side of
the electric starter handle panel. It is necessary to
charge the battery for 8 to 10 hours before initial use.
Refer to the Maintenance section for more informa-
tion.
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 service deaIer.
Gas and Oi_ Fii{-Up
1, Check oil level and add oil if necessary, Follow engine
manual for this,
2, Service the engine with gasoline as instructed in the
engine manual
Mu_ching P_ug
The mulching plug is used for mulching purpose,
Instead of colbcting the grass clippings in the grass
catcher, your mower has the option of recirculating
the clippings back to the lawn, Make sure that the
rear discharge door is closed and the grass catcher is
removed from unit while mulching,
WARNING:Usee×trernecarewhen
handling gasoline. Gasoline ise×tremely
flammable andthe vapors are explosive.
Neverfuel the machine indoors or while the engine is
hot or running. Extinguish cigarettes, cigars, pipes
and other sources of ignition.
8

WARNING:Theoperation of any lawn f l
mower canresult inforeign objects being
thrown intothe eyes,which can damage
your eyes severely.Alwayswear safety glasses
while operating the moweror while performing any
adjustments or repairs on it.
1. Pushprimerthreetimes.Waitabouttwoseconds
betweeneachpush,Figure4=2.Intemperature
around55°For below,primefivetimes.Donotprime
to restarta warmengine.
2. Standingbehindthe mower,squeezethebladecontrol
againstupperhandle,Figure4=2.
3. RecoilStart: Grasprecoilstarterhandleandpullrope
outwitha rapid,continuous,fullarmstroke,Figure
4=2.Keepinga firmgripon thestarterhandle,let the
roperewindslowly.Repeatuntilenginecranks.Letthe
roperewindeachtimeslowly.
Electric Start: Turnignitionkeytotherightto startthe
engine,Figure4=2.Releasethekeyaftertheengine
starts.
Stopping Engine
1. Releasebladecontroltostoptheengineandblade.
2. Disconnectsparkplugwirefromsparkplugand
groundagainsttheengine.
WARNING:Wait for the bladeto stop
completely beforedoing anywork on the
mower or to removethe grass catcher.
Using Your Lawn Mower
WARNING:Neveroperateyour mower
without eitherthe rear door or the entire
grass catcher assembly firmly secured.
Be surelawnisdear ofstones,sticks,wire,or other
obiectswhichcoulddamagelawnmowerorengine.
Suchobiectscouldbe accidentlythrownbythemower
in anydirectionandcauseseriouspersonaliniurytothe
operatorandothers.
Figure4-2:Startingthe mower.
_ ARNING:If you strike aforeign object,
stop the engine. Removewirefrom the
spark plug,thoroughly inspectmower
for anydamage,and repair damagebefore restart-
ingand operating. Extensive vibration of mower
during operation isan indicationof damage.The
unit should be promptly inspectedand repaired.
1. Oncetheengineisrunning,squeezethedrive
controlagainsttheupperhandleto propelmower.
• Forbestresults,do notcut wetgrass.
. Fora healthierlawn,nevercutoff morethanone=
thirdofthetotallengthofthegrass.
Using as Mulcher
Formulchinggrass,removethegrasscatcherfrom
themowerand installthemulchingbaffle.Therear
dischargedoorshouldbeclosed.
• Foreffectivemulching,do notcut wetgrass.
• Neworthickgrassmayrequirea narrowercut.
Adiustgroundspeedaccordingtoconditionoflawn.
• if thegrasshasbeenallowedto growinexcessof
4 inches,mulchingisnotrecommended.Usethe
grasscatchertobagclippingsinstead.
Using Grass Catcher
Youcanusethegrasscatchertocollectclippingswhile
youareoperatingthemower.RefertoSetupsectionfor
installationinstructions.
Grassclippingswillautomaticallycollectinbagas
yourun mower.Operatemowertillgrassbagisfull.
. Stopenginecompletelybyreleasingtheblade
control Makesurethattheunithascometo a
moving partsoneng!ne
and awn mower.
comp otestopd schargodoorandgrassbagupandaway
fromthemowertodisposeofthegrassclippings.
9

f "_ Lubrication
i ii
IMPORTANT: The use
of a pressure washer
eUectricComponents,
\
Figure5-1:Lubricationareasonthemower.
f
Figure5-2:Replacingthe rearflap.
General Recommendations
• Alwaysobservesafetyruleswhenperforming
anymaintenance,
Thewarrantyon thislawnmowerdoesnotcover
itemsthathavebeensubjectedtooperatorabuse
or negligence,Toreceivefullvaluefromwarranty,
operatormustmaintainthe lawnmoweras
instructedhere,
, Changingofengine-governedspeedwillvoid
enginewarranty,
, Alladiustmentsshouldbecheckedat leastonce
eachseason,
• Periodicallycheckall fastenersand makesurethese
aretight,
WARNING:Always stop engine, discon-
nect spark plug, and ground against
engine beforecleaning, lubricating or
doing any kind of maintenanceon your machine.
1, Lubricatepivotpointson thebladecontrolat least
oncea seasonwithlightoil Thebladecontrolmust
operatefreelyinbothdirections,Figure54,
2, Lubricatethewheelsatleastoncea seasonwith
lightoil (or motoroil), Ifwheelsare removedforany
reason,lubricatesurfaceoftheaxleand innersurface
ofthewheelwith lightoiL
3, Lubricatethetorsionspringandpivotpointontherear
dischargedoorandsidemulchplugperiodicallywith
lightoil topreventrust,
4, Thetransmissionispre-lubricatedandsealedatthe
factoryanddoesnotrequirelubrication,
5, Followtheaccompanyingenginemanualforlubrica-
tionscheduleandinstructionforenginelubrication,
Deck Care
1, Disconnectsparkplugwire,Draingasolinefromlawn
mowerorplacea pieceof plasticunderthegascap,
2, Tipmowersothat itrestson thehousing,Keepthe
sidewiththeaircleanerfacingup,Holdmowerfirmly,
WARNING:Nevertip the mower more
than 90degrees inany directions and do
not leavethe mowertipped for any length
oftime. Oil candrain intothe upper partofthe engine
causing a starting problem.
3, Scrapeandcleantheundersideofthedeckwitha
suitabletool,Donotspraywithwater,
4, Putthemowerbackonits wheelsontheground,If
youhadputplasticunderthegascapearlier,make
suretoremoveitnow,
Engine Care
, Maintainoil levelasinstructedin enginemanual,
, Serviceaircleanerevery25 hoursundernormal
conditions,Cleaneveryfewhoursunderextremely
dustyconditions,Refertoenginemanual
, Cleansparkplugandresetthegap oncea season,
Checkenginemanualfor correctplugtype andgap
specifications,
• Cleanengineregularlywitha clothorbrush,Keepthe
coolingsystem(Newerhousingarea)cleantopermit
properaircirculation,Removeallgrass,dirtand
combustibledebrisfrom mufflerarea,
Replacing Rear F_ap
1, Lift upreardoor,
2, Bend(bow)therearflapinwardon eachsideto
releasetabsfromtheholesinthe handlemounting
brackets,Figure5-2,
3, Replacewith newflapbybendingtherearflapand
slidingintoplace,
10

thecarburetorareup,
2, Removebolt,bladebellsupport,blade,andadapter
fromtheenginecrankshaft,Figure5=3,
NOTE:Whenremovingtheblade,adapter,etc,,becare=
ful nottoremoveor misplacepartsaboveitassociated
withtheenginepulley,
3, Thebladecanbe sharpenedwitha fileoron agrind=
ingwheel Donotattempttosharpenthebladewhile
itisstillon themower,Whensharpeningblade,follow
originalangleofgrind,Grindcuttingedgesequallyto
keepbladebalanced,
4, Removebladefromtheadapterfortestingbalance,
Balancethebladeona roundshaftscrewdriverto
check,Removemetalfromtheheavysideuntilit
balancesevenly,
WARNING:An unbalanced blade will
cause excessivevibration when rotating
at high speeds. It maycause damageto
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,min,,600 in,Ibs,max,
Toensuresafeoperationof yourmower,periodically
checkthebladeboltforcorrecttorque,
Belt Care
1, Disconnectsparkplugwireandgroundagainst
engine,
2, Drainthefueltankorplacea pieceof plasticbeneath
thecaptopreventgasolineleakage,
3, Tipmoweron itsside(aircleanersideofengineup),
4, Removeblade,bladeadapter,and relatedhardware,
Figure5=3,
5, Loosenself=tappingscrewthat securesdeckbaffleto
thedeck,Figure5=4,
6, Workingfromtherearofthemower,carefullyremove
beltfromtransmissionpulley,
J
Figure5-3:Removethebolt,support,blade,andadapterto
accessthebladeandundersidecomponents.
j J/
Figure5-4:Removescrewholdingbaffletodeck.
f
/.........;_:;_........... "
.........i ¸¸
Figure5-5:Removebeltfromtransmissionthenengine.
7, Oncebeltisofftransmissionpulley,pushdownon
deckbaffletoaccessenginepulleyandslidebeltoff
thispulleyandoutfromunderthedeck,Figure5=5,
8, Replacewith newbelt,workingitbetweenthedeck
andbaffle,firstaroundthetransmissionpulleyand
thentheenginepulley,Tightenscrewloosened
earlierandreplacebladeandhardware,
9, Tipmowerbackontoitswheelsand removepieceof
plasticfromundergascap (ifapplicable),
11
WARNING ;
When removing
the cutting blade
for sharpening or
replacement or
when sliding the belt
around it, protect
your hands with a
pair of heavy gloves
or use a heavy ragto
hold the blade.
An unbalanced
blade will cause
excessive vibration
when rotating at high
speeds, it may cause
damage to mower and
could breakcausing
personaJ injury.
Make certain that bert
isseated correctly
and that it is riding
smoothJy on the en-
gine pulley and is
not pinched between
the lowerand upper
pulley halves.

WARNING
Batteries contain
sulfuric acid which may
cause burns. Donot
short circuit or mutilate
batteries in anyway.Do
not put batteries in fire
asthese may buret or
releasetoxic materials.
Useonlythe battery
charger supplied with
this mower,
Donot removethe
battery packfrom the
electric starter housing
for any reason other
than replacement.
releasetoxic materials.
1. Loosenroundhandleknobssecuringupperand
lowerhandlesandcarefullyfoldtheupperhandle
downtowardthe lowerhandleas showninFigure
5=3.
2. Removethetwoscrewssecuringbatterycoverto
batteryhousingandplacethemtotheside,Figure
5=3.
3. Openbatterycover,removepositiveandnegathfe
leadsfrombattery,removeandreplacewith new
battery,Figure5-4.Connectthepositiveleadtothe
positivesideofthebatterypack,thenconnectthe
negativeside.
NOTE:Thebatteryyouhavemaydifferslightlyfromthe
oneshownin Figure5-4.Refertothe PartsList.
IMPORTANT:When replacing battery pack inhandle
panel, battery pack must be positioned with the
positive terminal tothe left sideand the negative
terminal to the right sideof panel (Positiveterminal
isclosest to the key switch}, Figure 5°4.Replacing
battery pack incorrectly will causeserious damage.
4. Reattachbatterycoverto batteryhousingbysecur-
ingwiththetwoscrewsremovedearlier,makingsure
tosnapthewireconduiton theleft intoplaceonthe
housing.
5. Foldhandlesbackupand tightenhandleknobs.
Charging Battery
WARNING:The battery contains corroo
sire fluid and toxic material; handle with
care and keepawayfrom children. Do
not puncture, disassemble, mutilate or incinerate
the battery. Explosive gases could be vented during
charging or discharging. Use ina well ventilated
area,awayfrom sources of ignition.
NOTE:Thespecialdesignedplugon thechargerwill
onlyfit intothe plugon thebatterybox.
1. Plugthebatterychargerintotheportonthe
undersideofthebatteryhousing,Figure5=5.
2. Insertthebatterychargerplugintoa standard120
volthouseholdoutlet,Figure5-5.Chargebattery
for8 to10hoursbeforeinitialuse.Donotcharge
longer than 12hours. Thebatteryshouldonlyneed
tobechargeduponinitialsetupandafteranyother
extendedperiodsofnon=use.
3. Aftercharging,disconnectchargerplugfromoutlet
first,thendisconnectchargerleadfrombattery.
Figure5-3:Folddownupperhandleandremovetwoscrews
frombackofhousing.
f
Figure5-4:Opencovertoviewbatteryandwires.
f
J
Figure5-5:Plugchargerintobatterylead(1)andthenplug
chargerpackinto120voltstandardhouseholdoutlet(2),
IMPORTANT:Alwaysplugchargerleadintobattery
packleadfirst,andtheninsertbatterychargerpluginto
120volt standardhouseholdoutlet.Followthis orderof
actioneverytimeyouchargethebattery.
12

Replacing Fuse "_
Theelectricstartercircuitandbatteryareprotectedbya
40 amperefuse,If thefuseburnsout, theelectricstarter
willnotoperate,If theunitfailsto startwiththeelectric
starter,performthefollowingstepstocheckthefuse
insidethebatteryhousing:
1. OpenthebatterycoverasdescribedinReplacing
Battery,seeFigure5-3.
2. Removefusefromsocketandinspectasshownin _-
Figure5-6.If itis burnedout, replacewithstandard
automotive40amperefuse.
3. Carefullyplacewiringbackintohousing,closebattery
cover,andfoldupperhandlebackintoplace.
NOTE:Theengine canbe started manually ifthe fuse
burns out.
Off-Season Storage
Thefollowingstepsshouldbetakentoprepareyourlawn
mowerforstorage.
Cleanand lubricatemowerthoroughlyasdescribedin
thelubricationinstructions.
Wedonotrecommendtheuseofa pressurewasher
or gardenhosetodean yourunit.
Referto enginemanualforcorrectenginestorage
instructions.
Coatmower'scuttingbladewithchassisgreaseto
preventrusting.
. Storemowerin adry,cleanarea.Donotstorenextto
corrosivematerials,suchasfertilizer.
Whenstoringanytypeofpowerequipmentina poorly
ventilatedor metalstorageshed,careshouldbetakento
rust-prooftheequipment.Usingalightoilor silicone,coat
theequipment,especiallycablesandall movingpartsof
yourlawnmowerbeforestorage.
Battery
Thebatterymustbestoredwith afullcharge.Extended
storageofa dischargedbatterywillreducelifeand
capacityofthebattery.
J
Figure5-6:Whenreplacingfuse,useastandardautomotive
7_f2ampfuse.
The engine can be
started manuaity ifthe
fuse burns out,
\
13

For repairs beyond
the minoradjust-
mentslisted here,
eentact an authorize d
serviee dealer, I
Engineruns erratic 1. Sparkplugwireloose.
2. Blockedfuellineor stalefuel
3. Ventingascapplugged.
4. Waterordirtin fuelsystem.
1. Connectandtightensparkplug
wire.
2. Cleanfuelline;filltankwithclean,
freshgasoline.
3. Clearvent.
4. Drainfueltank.Refillwithfresh
fuel
5. Dirtyair cleaner. 5. Refertoenginemanual
6. Carburetoroutofadiustment. 6. Refertoenginemanual
Engneoverheats 1. Engineoil levellow. 1. Fil crankcasewthproperoil.
l
2. Airflow restricted. 2. RemoveNowerhousing
and clean.
'3. Carburetornotadjustedproperly. 3. Refertoenginemanual
Occasional skips 1. Sparkpluggap tooclose. 1. Adiustgapto.030inch.
(hesitates)at 2. Carburetoridlemixtureadiustment 2. Refertoenginemanual
highspeed improperlyset.
Idlespoorly
3. Refertoenginemanual
Excessive 1. Cuttingbladelooseor unbalanced. 1. Tightenbladeandadapter.Balance
Vibration blade.
2. Bentcuttingblade. 2. Seean authorizedservicedealer.
Mowerwill not 1 Wetgrass 1. Donotmowwhengrassiswet wait
mulchy-rass unt aterto cut
2. Excessivelyhighgrass. 2 Mowonceat a highcuttingheight,
j thenmowagainatdesiredheightor
Imakea narrowercuttingpath.
3. Dullblade. 3 Sharpenor replaceblade.
Unevencut 1. Dullblade. 1. Sharpenor replaceblade.
1. Checkbeltforproperpulleyinstaila-
3. Damagedorwornbelt. ' 3. inspectandreplacebelt.
14

Safety Labels Found On Your Lawn Mower
mower fet any reasen,
\
15

Shown fo_rde_el_ce _ Q
Q
Shownfor
relerence
16

1 75&04093 WBelt
2 73b04338 SpringLever
3 720-0230 FoamGrip
4 717-04184A SpurGear,14T-LH
5 710-0599 TT Screw,1/&20x 0.50
6 750-04305A Spacer
7 749-04267 CrossBracket
8 687_02204 FrontBracketAssembly
9 731-05470 C@Spacer
10 741-04136B SplitHexFlangeBearing
11 73&O4014B FrontWheel
12 71b04065 FlangeLockNut,3/8d6
13 63&04207C RearWheel
14 710-04531 Screw,1/&20x.39
15 717-04192A SpurGear,14T-RH
16 736-3084 FlatWasher
17 7867551A WheeIDustCover
18 74&04073C TransmissionBearingSupport
19 750-04317 ClipSpacer
20 716-0198 RetainingRing.875
21 687_02199 RearBracketAssembly
22 73b0320 ExtensionSpring
23 756-04151A Pulley,3.36OD
24 736-0105 BellWasher,.375x .870x.063
25 71b0411 HexLockNut,5/16_24
26 687_02205 HandleBracketAssemblyLH
27 715-0221 DowelPin
28 61&04378 TransmissionAssembly
29 687_02206 HandleBracketAssemblyRH
To order replacement
parts, call
1o800o648-6776
or visit
www.troybiff.eom
MPORTANT:For
a proper working
machine, use Factory
@proved Parts,
V-BELTSare speciaJJy
designed to engage
and disengage
safely.A substitute
(non=OEM)V-Belt
can be dangerous
by not disengaging
completely.
17

\\
\
18

1 746-04265A
2 735-04059
3 753-05096A
4 731-04204
5 747d161A
6 746_04213
7 749-04037
8 725-0157
9 73b04265
10 710-0599
11 787-01341
12 710-0654A
13 787-01346
14 756-04157B
15 756-04156B
16 736-0514
17 748-0376C
18 710=1044
19 736_0524B
20 74b0741
21 736-0513
22 750=1071
23 710_0653
24 731-05463
25 710-0260A
26 71b04063
27 731-05462
28 731-05157
DriveCable 29 731-05017A
RubberGrommet 30 710=1241
DriveControlAssembly 31 720_04072
BailCover 32 73b04264
BladeControl 33 711_04374
ControlCable 34 647_04051
LowerHandle 35 664-04045
CableTie 36 710=1174
TorsionSpring,LH 37 720_0279
TT Screw,1/4-20x,500 38 710q205
21dnchDeck 39 749-04209
TTScrew,3/8=16x 1,00 40 736-0270
DeckBaffle 41 7361014
UpperEnginePulley 42 17032A
LowerEnginePulley 43 747_0710
FlatWasher,,885x 1,850x ,060 44 987-02055
BladeAdapter 45 731-04177
Screw,3/8-24x 1,50 46a 725=1276
BladeBell Support 46b 725_04323
21"MulchingBlade 47 725-04329
SpringWasher,,890x 1,70x,048 48 725-04293
SleeveSpacer 49 728-0199
TT Screw,1/4-20x ,375 50 725-04347
DeckBaffle 51 725-0201
CarriageBolt,5/16-18x,62 52 731_05505
FlangeLockNut,5/16q8 731-05459
Trailshield 53 710q667A
MulchPlug
RearDoor
Screw,1/4=15x 1,00
StarKnob
TorsionSpring,RH
DoorPivotRod
GrassCatcherFrame
GrassCatcher
CarriageBolt,5/16=18x2,00
WingNut
EyeBolt
UpperHandle
BellWasher,,265x ,75x,062
TorsionSpring
ChuteDeflectorAdapter
HingePin
MulchPlugAssembly
SideDischargeChute
12VoltBattery
12VoltBattery
BatteryCharger
ElectricStarterHarness
Rivet
KeySwitch
Key
BatteryHsg,(usedw/ref,#46a)
BatteryHsg,(usedw/ref,#46b)
Screw,#10q6 x ,750
To order replacement
parts, ca[[
1-800-648-6776
or visit
www.troybiJt.eom
\
19

MANUFACTURER'S LIMITED WARRANTY FOR
®
The limitedwarrantyset forthbelowisgivenbyTroy_BiltLLCwithrespect
tonewmerchandisepurchasedandusedin theUnitedStates,itsposses_
sionsandterritories.
"Troy_Bilt"warrantsthis productagainstdefectsinmaterialandworkmam
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
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-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, includinga 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 providethe 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 injurytoyouand yourpropertyand/ortoothersandtheir
propertyarisingoutofthemisuseor inabilitytousetheproduct.
This limitedwarrantyshallnotextendto anyoneotherthantheoriginal
purchaseror tothepersonforwhomitwaspurchasedasa gift.
HOWSTATELAWRELATESTOTHiSWARRANTY:This limitedwar-
rantygh,'esyouspecificlegalrights,andyoumayalsohaveotherrights
whichvaryfromstatetostate.
IMPORTANT:OwnermustpresentOriginalProofofPurchasetoobtain
warrantycoverage.
TROYBILT LLC, P.O. BOX 361131 CLEVELAM D, OHIO 44136-0019; Phone: 1(866} 840-6483, 1-330-558-7220