Troybilt 440, 12A-446A711 Owner’s Manual

Safety o Assembly o Operation oTips &Techniques oMaintenance *Troubleshooting o Parts Lists oWarranty

®

21" Rotary Mower -- Model Series 440

READ SAFETY RULES AND mNSTRUCTmONS CAREFULLY BEFORE OPERATION

Warning: Thisunitis equippedwithan internalcombustionengineandshouldnotbeusedonornearanyunimprovedforest-covered,brush=
coveredor grass=coveredlandunlesstheengine'sexhaustsystemisequippedwitha sparkarrestermeetingapplicablelocalorstatelaws(if any),

If a sparkarresterisused,it shouldbemaintainedineffectiveworkingorderbytheoperator,Inthe StateofCaliforniatheaboveis requiredbylaw
(Section4442ofthe CaliforniaPublicResourcesCode),Otherstatesmayhavesimilarlaws,Federallawsapplyonfederallands,A sparkarrester

forthe mufflerisavailablethroughyournearestengineauthorizedservicedealeror contacttheservicedepartment,RO,Box361131Cleveland,
Ohio44136=0019,

PRINTEDiN U,S,A Troy-Bilt LLC, P.O. BOX 381131 CLEVELAND, OHIO 44138-0019 FORMNO,769=02166

Phone: 1(888} 840-8483, 1-330-558-7220 10/2005

This Operator's Manua_ is an important part of your new lawn mower, mtwH_ he_p you assemble,

prepare and maintain the unit for best performance. Please read and understand what it says.

Table of Contents

Slope Gauge ....................................................... 3

Safe Operation Practices ................................... 4

Setup and Adjustment ....................................... 6

Operating Your Lawn Mower .............................. 8

Finding and Recording Model Number

BEFOREYOU STARTASSEMBLING
YOURNEW EQUIPMENT,
please locatethe modelplate onthe equipmentand copythe
informationto the sample model plate providedto the righL

Youcan locatethe modelplate by standing at the operating
positionand lookingdown at the rearof the deck. This

informationwill be necessaryto usethe manufacturer'sweb
site and/or obtainassistancefrom theCustomerSupport

Departmentoran authorizedservice dealer.

Maintaining Your Lawn Mower ......................... 10

Trouble Shooting .............................................. 12

Off-Season Storage and Safety Labe{s .......... 13

Parts List ........................................................... 14

Warranty ............................................ Back Cover

Modem Number Serial Number

0 TRDV BILT TROY-B LTLLc

www.troybiit.com CLEVELAND,ON44136

P. O. BOX 361131

338=558=7228

Customer Support

PIease do NOTreturn the unit to the retai{er from which it was

purchased, without first contacting Customer Support.

ifyou havedifficulty assemblingthis productor have any

questions regardingthe controls, operationor maintenanceof
this unit, you can seek help from the expert& Choose fromthe

options below:

1_VisittroybHt.com for manyuseful suggestions.Clickon

CustomerSupport button and you will get the four options
reproducedin this sampleto the righLClick on the appro-
priatebutton and help is immediatelyavailable.

2_Phonea Customer Support Representative

at 1(866)840-6483.

3. The engine manufacturer is responsiblefor all engine-
relatedissueswith regardsto performance,power-rating,
specifications,warrantyand service. Pleasereferto the

eng Need a manual and/or parts list? Download

separatelywithyour unit, for more information, literature from recent model years.

Click here to search our knowledge base°
Searchby product, keyword, or phrase.

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.

2

yourlawnmoweronsuchslopes.

/

t

/

/

/

/

/

o

WARNING

w_

Do not mowon inclines

with a dope in excess

of 15 degrees (a rise

of approximately

2-"

feet). A riding r
couldoverturnand

cause serious injury.

if operatinga walb
behindmoweron such

a dope, it isextremely

footing and you could

dip, resultingin serious
injury.

OperateRiDiNG
mowersupand down

dopes, neveracross

o

3

theface of dopes.

Operate
WALK-BEHIND

mowersacrossthe

face of dopes, never

up and down slopes.

\

manual.Aswithanytypeofpowerequipment,carelessnessorerroronthepartoftheoperatorcan

resultinseriousinjury.Thismachineiscapableofamputatinghandsandfeetandthrowingobjects.

! Failuretoobservethefollowingsafetyinstructionscouldresultinseriousinjuryordeath.

Children

Tragicaccidentscan occurifoperatorisnotalertto presence
ofchildren.Childrenare oftenattractedto mowerandmowing

activity.Theydonot understandthe dangers.Neverassume
thatchildrenwill remainwhereyoulastsawthem.

1. Keepchildrenoutofthe mowingareaandunderwatchful
careof aresponsibleadultotherthanthe operator.

2. Bealertandturnmoweroffifa childentersthearea.

3. Beforeand whilemovingbackwards,look behindanddown
forsmallchildren.

4. Useextremecarewhenapproachingblindcorners,
doorways,shrubs,trees,orotherobjectsthatmayobscure
yourvisionofa childwho mayrun intothemower.

5. Keepchildrenawayfromhot orrunningengines.Theycan
sufferburnsfroma hotmuffler.

6. Neverallowchildrenunder14yearsoldto operateapower
mower.Children14yearsold andovershouldreadand
understandoperationinstructionsandsafetyrulesinthis
manualandshouldbetrainedandsupervisedbyaparent.

endangerthepersonal
safetyand/orproperty

and followthewarnings 5. Tohelpavoidbladecontactora thrownobjectinjury, ._ generallya '_arningof!rouble.........

and i..struction2 stay inoperatorzonebehindhandlesandkeepchildren, "

u _ competestop beforeremovngthe grasscatcheror uncog

, ,; bystanders,helpers,andpetsat least75feet frommower .

un_nusmanuau glngthechute

1. Readthis operator'smanualcarefullyin its entiretybefore

2. Thismachineis aprecisionpieceof powerequipment,

3. Neverallowchildrenunder 14yearsoldto operatethis

4. Thoroughlyinspecttheareawherethe equipmentisto

General Operation

attemptingtoassemblethismachine.Read,understand,
andfollow allinstructionsonthe machineandin the

manual(s)beforeoperation.Becompletelyfamiliarwith
thecontrolsandthe properuseof thismachinebefore
operatingit.Keepthismanualin asafeplaceforfuture
andregularreferenceandfor orderingreplacementparts.

nota plaything.Therefore,exerciseextremecautionat all
times.Yourunithasbeendesignedto performonejob: to
mowgrass.Do notuseitfor anyotherpurpose.

machine.Children14yearsoldand overshouldreadand
understandthe instructionsinthis manualandshould

betrainedand supervisedbya parent.Onlyresponsible
individualswhoarefamiliarwiththese rulesof safe

operationshouldbeallowedtousethis machine.

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.

whileit isin operation.Stopmachineifanyoneenters

6. Alwayswearsafetyglassesorsafetygogglesduringopera-
tionandwhileperforminganadjustmentor repairtoprotect
youreyes.Thrownobjectswhich ricochetcancauseserious
injurytothe eyes.

7. Wearsturdy,rough-soledworkshoesand close-fitting
slacksandshirts. Shirtsand pantsthatcoverthe armsand
legsandsteel-toedshoesare recommended.Neveroperate
thismachinein barefeet,sandals, slipperyor lightweight
(e.g.canvas)shoes.

8. Donotputhandsorfeet nearrotatingpartsor undercutting
deck.Contactwithbladecanamputatehandsandfeet.

9. Amissingor damageddischargecovercancauseblade
contactor thrownobject injuries.

10.Manyinjuriesoccurasa resultofthe mowerbeingpulled
overthefoot duringafall causedby slippingortripping.
Do notholdonto the mowerifyouarefalling;releasethe
handleimmediately.

11.Neverpullthe mowerbacktowardyouwhileyouare
walking.Ifyou mustbackthe mowerawayfromawallor
obstructionfirstlookdownandbehindtoavoidtrippingand
thenfollow thesesteps:

a. Stepbackfrommowertofully extendyourarms.
b. Besureyou arewell balancedwithsurefooting.

c. Pullthe mowerbackslowly,no morethanhalfway

towardyou.

d. Repeatthese stepsasneeded.

12.Donotoperatethe mowerwhileunderthe influenceof
alcoholor drugs.

13.Donotengage theself-propelledmechanismon unitsso
equippedwhilestartingengine.

14.Thebladecontrolhandleis asafetydevice.Neverattempt
tobypassits operation.Doingso makesthesafetydevice
inoperativeandmay resultinpersonal injurythrough
contactwiththe rotatingblade.The bladecontrolhandle
mustoperateeasilyin bothdirectionsandautomatically
returntothe disengagedpositionwhenreleased.

15.Neveroperatethe mowerinwetgrass. Alwaysbesure of
yourfooting. A slipandfallcan causeseriouspersonal
injury.If youfeelyouare losingyourfooting,releasethe
bladecontrolhandleimmediatelyandthe bladewillstop
rotatingwithinthreeseconds.

16.Mowonlyindaylightor goodartificiallight.Walk,neverrun.

17.Stopthe bladewhencrossinggraveldrives,walksor roads.

18.Ifthe equipmentshouldstart tovibrateabnormally,stopthe
engineandcheck immediatelyforthecause.Vibrationis

]_ _nutthe engne errandwar unl: me Daaecomes-coa

and on the machine, area.

..... ,J

4

Thecuttingbladecontinuesto rotatefora fewsecondsafter
the engineisshutoff. Neverplaceanypartofthe bodyin
the bladeareauntilyou aresurethe blade hasstopped

rotating.

20.Neveroperatemowerwithoutpropertrailshield,discharge
cover,grasscatcher,bladecontrolhandle,or othersafety

protectivedevicesin placeandworking.Neveroperate
mowerwithdamagedsafetydevices.Failuretodo socan
resultin personalinjury.

21.Mufflerandenginebecomehotand cancauseaburn.Do

nottouch.

22.Onlyuseparts andaccessoriesmadefor thismachineby

manufacturer.Failureto doso canresultinpersonalinjury.

23.Ifsituationsoccurwhichare not coveredinthis manual,

usecareand goodjudgment.Contactyourdealerfor
assistance.Telephone[phone]forthe nameofyour

nearestdealer.

SJope Operation

Slopesareamajorfactorrelatedto slipandfallaccidentswhich
canresultinsevereinjury.Operationonslopesrequiresextra

caution.Ifyoufeel uneasyonaslope,donotmowit.Foryour
safety,usethe slopegaugeincludedas partofthis manualto
measureslopesbeforeoperatingthisunitona slopedor hilly
area.Iftheslopeis greaterthan15degrees,donotmowit.

Do:

1. Mowacrossthefaceof 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,releasetheblade controlhandleimmediately,and

the bladewillstop rotatingwithin3seconds.

Do Not:

1. Donotmowneardrop-offs, ditchesorembankments,where
you couldloseyour footingorbalance.

2. Donotmowslopesgreaterthan15degrees asshownon
the slopegauge.

3. Donotmowon wetgrass.Unstablefootingcouldcause

slipping.

Service

Safe HandlingOf Gasoline:

1. To avoidpersonalinjuryor propertydamageuseextreme
carein handlinggasoline.Gasolineisextremelyflammable

andthevaporsare explosive.Seriouspersonalinjurycan
occurwhengasolineis spilledonyourselforyourclothes

whichcanignite.

2. Washyourskinand changeclothesimmediately.

3. Useonly anapprovedgasolinecontainer.

4. Neverfill containersinsideavehicleoronatruckor trailer

bedwith a plasticliner.Alwaysplacecontainerson the
groundawayfromyourvehiclebeforefilling.

5. Removegas-poweredequipmentfromthe truck ortrailer

andrefuelit on theground.Ifthisis notpossible,then refuel
suchequipmentonatrailerwitha portablecontainer,rather

thanfroma gasolinedispensernozzle.

6. Keepthe nozzleincontactwiththerim of thefuel tankor
containeropeningat alltimesuntilfuelingis complete.Do

notusea nozzlelock-opendevice.

7. Extinguishallcigarettes,cigars,pipesandothersources
ofignition.

8. Neverfuelmachineindoorsbecauseflammablevaporswill
accumulatein the area.

9. Neverremovegascap oraddfuelwhileengineishot or
running. Allowengineto coolat leasttwominutesbefore
refueling.

10.Neveroverfillfueltank. Filltankto nomorethan_ inch
belowbottomof fillerneckto provideforfuelexpansion.

11.Replacegasolinecapandtightensecurely.

12.Ifgasolineis spilled,wipeit off theengineand equipment.
Moveunitto anotherarea.Wait5 minutesbeforestarting
engine.

13.Neverstorethemachineorfuel containernearanopen
flame,sparkorpilot lightas onawater heater,space
heater,furnace,clothesdryer,orothergas appliances.

14.Toreducefire hazard,keepmowerfreeofgrass,leaves,
or otherdebrisbuild-up.Cleanupoil orfuel spillageand
removeanyfuel soakeddebris.

15.Allowamowertocool at least5 minutesbeforestoring.

General Service:

1. Neverrunanengineindoorsorina poorlyventilatedarea.
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. Mowerbladesare sharpandcancut.Wrapthebladeorwear
gloves,anduseextracautionwhenservicingthem.

5. Keepallnuts,bolts,andscrewstighttobe surethe equip-
mentisin safeworkingcondition.

6. Nevertamperwithsafetydevices.Checktheirproperopera-
tionregularly.

7. Afterstrikinga foreignobject,stopthe engine,discon-
nectthe sparkplugwireandgroundagainsttheengine.
Thoroughlyinspectthemowerforanydamage.Repairthe
damagebeforestartingandoperatingthemower.

8. Neverattempttomakea wheelorcuttingheight adjustment
whiletheengineis running.

9. Grasscatchercomponents,dischargecover,andtrail
shieldaresubjecttowear anddamagewhichcould expose
movingpartsorallow objectsto bethrown.Forsafety
protection,frequentlycheckcomponentsand replaceim-
mediatelywithoriginal equipmentmanufacturer's(O.EM.)
partsonly,listedin this manual.'Use of partswhich do
not meettheoriginalequipmentspecificationsmayleadto
improperperformanceandcompromisesafety!"

10.Donot changetheenginegovernorsettingor overspeedthe
engine.Thegovernorcontrolsthe maximumsafeoperating
speedofthe engine.

11.Maintainorreplacesafetylabels,asnecessary'.

12.Observeproperdisposallawsand regulations.Improper
disposaloffluidsand materialscanharmtheenvironment.

ThisSymbolpoints

ua! before attemptingto

resuUt in personalinjury_
::When you see th s
_symbol

,EEDMTSWARNmNG

Responsibility

Restrictthe use

of this powermachine

to personswhoread

understand

5

NOTE:Stand behind
Ihemoweras if you

were going to operate

it,Your righthandcor-
respondsto the right

sideof the mower;your
left hand corresponds

to the left side d the

mower.

IMPORTANT

DO NOTcrimp the
cableswhen liftingthe

handleup.

Step 1

HardwarePack

Wing Nuts (2) CarriageBolts (2)

1, Removeanypackingmaterialwhichmaybebetween

upperand lowerhandles,
a, Pullupand backon upperhandleasshownin

Step1,Makecertainthelowerhandleisseated
securelyintothe handlemountingbrackets,

b, Tightenhandknobssecuringupperhandleto

lowerhandle,Makesurethateach carriageboltis
seatedproperlyinthe handle,

2, Locatehairpinclip in oneholeontheweldpinon each

sideof lowerhandle,
a, Removehairpinclipfromthis hole,Usinga pairof

pliers,inserthairpinclipintotheotherholeonthe
weldpin, Repeaton otherside,

b, inserta carriageboltfromthehardwarepackinto

theupperholeon thehandlemountingbracket,
Securewithoneplasticwingnut,also included
inthe hardwarepack,Repeatonothersidewith
remainingitemsfromhardwarepack,

3, The ropeguideisattachedtothe rightsideofthe

upperhandle,Loosenthewingnutwhichsecuresthe
ropeguide,

a, Holdthe bladecontrolagainstupperhandle,
b, Pullstarterropeoutofthe engine,Releasethe

bladecontrol,

c, Slipstarterropeintoropeguide,Tightenwingnut,

4, Insertpostoncane ties into holesprovidedon the

lowerhandle,Pullcane tie tightandtrimexcess,

IMPORTANT

This unit isshipped
without gasoline or

oilin the engine. Fill
upgasolineand oil

as instructedin the
accompanyingengine

manual BEFORE
operatingyour mower,

Step 2

Step 3 Step 4

6

positionprovidescuttingheightadiustment,

a, Depresslevertowardswheel,

b, Moveitto anyof theninepositionsfordesired

cuttingheight,SeeStep5,

c, Releaselevertowardsmowerdeck,

6, Followstepsbelowtoassemblethegrasscatcher:

a, Placebagoverframesothatitsblackplasticside

isat thebottom,

b, Slipplasticchannelofgrassbagover hooksonthe

frame,SeeStep6,All the plasticchannelsexcept
centertopof bagattachfromoutsideof bag,

c, Attachcentertopof bagfrominsideof bag,

7, Followstepsbelowtoattachgrasscatcher:

a, Liftreardischargedoor,

b, Placegrasscatcheron thepivotrod, Letgo

ofdischargedoorso that itrestson thegrass
catcher,SeeStep7,

Toremovegrasscatcherorconvertto a mulcher(if
equipped),liftreardischargedooronthe moweras
showninStep8, Liftgrasscatcherupand outofthe pivot
rod,Releasereardischargedoorto allowit tocloserear
openingofmower,

Step 5

_Make certain bagis

WARNING: Never operate mower
unless the hooks on the grass

catcher are firmlyseated on the
pivot rod, and the rear discharge

door rests firmJyagainst top of
the grass catcher.

\

Step 6

unless the hooks on

}

Step 7

7

Recoil

Grass Bag

,<-_ Blade Control

-- Drive Control

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 hands and feet

_way from the chute

tea on cutting deck.

Refer to warning

label on the unit.

Levers

Gasoline

Now that you have set up your lawn mower for op-
eration, get aquainted with its controls and features.

These are described below and illustrated on this
page. This knowledge will allow you to use your

new equipment to its fullest potential.

B_ade Control

The blade control is attached to the upper handle
of the mower. Depress and squeeze it against the
upper handle to operate the unit. Release it to stop

engine and blade.

WARNING:This bladecontrol mecha-
nism isa safety device. Neverattempt

to bypass its operations.

Drive Contro_

The drive control is located on the underside of
the upper handle and is used to engage the drive.

Squeeze it against the upper handle to engage the
drive; reIease it to slow down or stop mower from

propelling. See Figure 1=

Height

Levers

J

Figure 1

Cutting Height Adjustment Levers

One adjustment lever is located on each wheel and
is used to adjust the cutting height. All four levers
have to be at the same relative position to ensure a

uniform cut.

Recoi_ Starter

The recoiI starter is attached to the right upper
handle. Stand behind the unit and puII the recoil
starter rope to start the unit.

Gas and Oil Fil_-Up

1. Check oil level and add oil if necessary. Follow engine
manual for this. See Figure 1 above for location of the

oil fill.

2. Service the engine with gasoline as instructed in the
engine manual See Figure 1above for location of

gas fill

WARNING: Use extreme care when han-
dling gasoline. Gasoline is extremely

flammable and the vapors are explosive.
Never fuel the machine indoors or while

the engine is hot or running. Extinguish
cigarettes, cigars, pipes and other
sources of ignition.

8

WARNING:The operation of anylawn

mowercan result inforeign objects
being thrown into the eyes,wNch can
damageyour eyes severely.Always
wearsafety glasses while operating

the mower,or while performing any

adjustments or repairs on it.

Starting Engine

WARNING:Besure no one other than
the operator isstanding nearthe lawn

mowerwhile starting engine or operat-
ing mower.Neverrun engineindoors

or inenclosed, poorly ventilated areas.
Engine exhaustcontains carbon monox-

ide,an odorless and deadly gas. Keep
hands,feet, hair and loose clothing

awayfrom anymoving partsonengine
and lawn mower.

1, Pushprimerthreetimes,Waitabouttwoseconds

betweeneachpush,SeeFigure2,In temperature
around55° F or below,primefivetimes,Donotprime
to restarta warmengine,

2, Standingbehindthe mower,squeezethebladecontrol

againstupperhandle,SeeFigure2,

3, Holdingthesetwohandlestogetherfirmly,grasprecoil

starterhandleand pullropeout witha rapid,continu=
ous,fullarm stroke,SeeFigure2,Keepinga firm
gripon thestarterhandle,lettheroperewindslowly,

Repeatuntilenginecranks,Lettheroperewindeach
timeslowly,

Stopping Engine

1, Releasebladecontrolto stoptheengineandblade,

2, Disconnectsparkplugwire fromsparkplugand

groundagainsttheengine,

_k ARNING:Wait for the blade to stop

Using Your Lawn Mower

Be surelawnisclear ofstones,sticks,wire,or other
obiectswhichcoulddamagelawnmowerorengine,
Suchobiectscouldbe acddentlythrownbythemower
in anydirectionandcauseseriouspersonaliniuryto the
operatorandothers,

completely beforedoing anywork
on the moweror to removethe grass

catcher.

WARNING:Neveroperateyour mower

without either the rear door orthe entire
grass catcher assembly firmly secured.

J

Figure 2

_IL ARNING:If you strike aforeign

1, Oncetheengineis running,squeezethedrive

controlagainsttheupperhandleto propelmower,

2, For bestresults,do notcut wetgrass,
3, Fora healthierlawn,nevercutoff morethanone=

thirdof thetotallengthofthe grass,

object, stop the engine. Remove
wire from the spark plug, thoroughly

respect mowerfor anydamage,and
repair damagebefore restarting and
operating. Extensivevibration of
mower during operation isan indica-
tion of damage.Theunit should be
promptly inspected and repaired.

Using as Muncher

Formulchinggrass,removethegrasscatcherfromthe
mower,The reardischargedoorshouldbeclosed,

1, Foreffectivemulching,do notcut wetgrass,
2, Neworthickgrassmayrequirea narrowercut,

Adiustgroundspeedaccordingtoconditionoflawn,

3, If thegrasshasbeenallowedto growinexcessof

4 inches,mulchingisnotrecommended,Usethe
grasscatcherto bagclippingsinstead,

Using Grass Catcher

Youcanusethegrasscatchertocollectclippingswhile
youareoperatingthemower,

1, Attachgrasscatcherfollowinginstructionsonpage

7,Grassclippingswill automaticallycollectinbagas
yourun mower,Operatemowertillgrassbagisfull,

2, Stopenginecompletelybyreleasingtheblade

controlhandle,Makesurethattheunit hascometo
a completestop,

3, Liftdischargedoorand pullgrassbagup andaway

fromthemowertodisposeofthe grassclippings,

being thrown into

the eyes, which can
damage your eyes

severely. Always wear

safety glasses while

iioperating the mower,

_ngine or operating

_ower. Never tun

engine !ndoors or

in enclosed poorly

ventilated areas' En_

gine exhaust Contains

carbon monoxide, an

odorless and deadly

_gas, Keep hands, feet,

hair and loose Clothing

away from any mov ng

/

9

disconnectspark

plug,andground

oga n,teng n b fOrO

\

Figure 3

reassembiy,

mustoperatefreelyin bothdirections,SeeFigure3,

2, Lubricatethewheelsatleastoncea seasonwith

lightoil (or motoroil), If wheelsareremovedforany
reason,lubricatesurfaceof thepivotarm andinner
surfaceofthewheelwithlightoil SeeFigure3,

3, Lubricatethetorsionspringandpivotpointontherear

dischargedoorperiodicallywithlightoil to prevent
rust,SeeFigure3,

4, Thetransmissionis prequbricatedandsealedatthe

factoryanddoesnotrequirelubrication,

5, Followthe accompanyingenginemanualforlubrica-

tionscheduleandinstructionforenginelubrication,

Deck Care

1, Disconnectsparkplugwire,Draingasolinefromlawn

mower,or placea pieceof plasticunderthegascap,

2, Tip mowersothatitrestsonthe housing,Keepthe

sidewiththe aircleanerfacingup,Holdmowerfirmly,

WARNING:Nevertip the mowermore
than 90 degrees in anydirections and
do not leavethe mowertipped for any
length of time. Oil can drain into the
upper part of the enginecausing a
starting problem.

Figure 4

Genera[ Recommendations
1, Alwaysobservesafetyruleswhen performing

anymaintenance,

2, Thewarrantyonthislawnmowerdoesnotcover

itemsthathavebeensubiectedtooperatorabuse
or negligence,Toreceivefullvaluefromwarranty,
operatormustmaintainthe lawnmoweras

instructedhere,

3, Changingofengine-governedspeedwill void

enginewarranty,

4, Alladjustmentsshouldbecheckedat leastonce

eachseason,

5, Periodicallycheckall fastenersand makesurethese

aretight,

WARNING:Alwaysstop engine,
disconnect spark plug, andground

against engine beforecleaning,
lubricating or doing any kind of

maintenanceon your machine.

3, Scrapeanddean theundersideofthe deckwitha

suitabletool Do notspraywithwater,

4, Putthemowerbackonits wheelsonthe ground,If

youhadput plasticunderthe gascapearlier,make
sureto removeitnow,

Engine Care
1, Maintainoillevelasinstructedinenginemanual,

2, Serviceaircleanerevery25 hoursundernormal

conditions,Cleaneveryfewhoursunderextremely
dustyconditions,Refertoenginemanual

3, Cleansparkplugandresetthegap oncea season,

Checkenginemanualforcorrectplugtype andgap
specifications,

4, Cleanengineregularlywitha clothorbrush,Keepthe

coolingsystem(blowerhousingarea)dean topermit
properaircirculation,Removeallgrass,dirtand

combustibledebrisfrom mufflerarea,

Replacing Rear Flap

1, Toremoverearflap,cut offtheflatendof thewire rod

whichsecuresit tothe deck,SeeFigure4,

2, Attachthenewflapand newrodtodeck, bendingthe

endsof thenew rodoverto securetodeck,

10

B_ade Care f -_,

_ ARNING:When removing cutting

1, Disconnectsparkplugwirefromsparkplug,Turn

moweron itssidemakingsurethattheairfilterand
thecarburetorareup,

2, Removebolt,bladebell support,blade,andblade

adapterfromthe enginecrankshaft,SeeFigure5,

3, The bladecanbe sharpenedwitha fileoron agrind=

ingwheel Do notattemptto sharpenthebladewhile

itis stillon themower,Whensharpeningblade,follow
originalangleofgrind,Grindcuttingedgesequallyto

keepbladebalanced,

4, Removebladefromthe adapterfortestingbalance,

Balancethebladeona roundshaftscrewdriverto
check,Removemetalfromthe heavysideuntilit

balancesevenly,

bladefor sharpening or replacement,
protect your handswith apairof heavy
gloves or usea heavy rag to hold blade.

WARNING:An unbalanced bladewill

cause excessivevibration when rotating
at high speeds, it may causedamage

to mower,and could breakcausing

personalinjury.

i i i

Figure 5

WhenremOVing

the cutting blade

_for sharpening or

rep!aeement or

5, Lubricatetheenginecrankshaftandtheinnersurface

ofthe bladeadapterwithlightoil Slidethe blade
adapterontotheenginecrankshaft,Placetheblade

on theadaptersuchthat theside ofthe blademarked
"Bottom"(orwithpartnumber)facesthe groundwhen

themoweris intheoperatingposition,Makesurethat

bladeisalignedandseatedon bladeadapterflanges,

6, Placebladebellsupporton the blade,Alignnotches

on thebladebellsupportwithsmallholesinblade,

Replacehexbolt andtightenhexbolttotorque:450

in,Ibs,rain,,600 in,Ibs,max,

Toensuresafeoperationof yourmower,periodically
checkthe bladeboltfor correcttorque,

Belt Care
1, Removetwoshoulderscrewssecuringfrontdrive

coverto mowerdeck,SeeFigure6, Pressinwardon
sidesoffrontdrivecoverand releasetabsthatsecure

itto theheightadiusterbrackets,Removedrive cover
frommower,

2, Loosenscrewholdingbelttensionspringtotrans=

mission,SeeFigure6 inset,Donot removescrew
completely,As youloosenit, tensiononthebeltwillbe

released,

3, Pushtransmissionupa littleandslidebeltoffthe

transmissionpulley,Lift mowertoaccessbeltfrom

undersideof mower,Slidebeltoff ofenginepulleyand
aroundtheblade,SeeFigure7,

Figure 6

::, ,, /

Figure 7

4, Replacewithnewbelt,workingaroundblade,Make

surebelt isfirmlyseatedonenginepulleywhile
pullingfromtheothersideandslidingit aroundthe
transmissionpulley,Tightenscrewloosenedearlier
tosecurebelt tensionspringto thetransmission,

Reassemblefrontdrivecover,

pair of heavy g oves

or use a heavy rag to

hold the blade.

An unbalanced blade
will cause excessive

vibration when rotat-

ingat high speeds, it
may cause damage

to mower, and could
break causing per-

sonal injury.

11

Shoot og

For repairs beyond

theminoradjustments

listed here, contact

an authorized service

dealer.,

Enginefailsto Start 1, B!aclecontroidisengaged, i: Engagebladecent[eL

2. SparkPlugwh'edisc0nnected_ 2. C0nneciWgetoSparkplug,
Fue!tankempty0rStalefueL Filltankwith Clean,freshgaso)ine

Enginenotprirned, 4. Pdrneengineasinstructedin ©perat-

5. Eautysparkpug, 5, Cean, adustgap, orrepace.!ngYourLawnMowe[.

6. Blocked fuel line, 6. Clean fuel line,

7. Enginefl00ded. 7 Waitalewminutest0restart butdo

l

Engineruns erratic 1. Sparkplugwireloose. 1 Connectandtightensparkplugwire.

2. Blockedfuellineor stalefuel. 2. Cleanfuelline:fill tank withclean,
freshgasoline.

3. Vent ingas capplugged.

4. Wateror dirt infuel system.

5. Dirtyaircleaner.

6. Carburetorout of adjustment.

3. Clearvent.

4. Drainfueltank.Refill withfresh fuel.

5. Refertoenginemanual.

6. Refertoenginemanual.

Engineoverheats 1. Engineoi! levellow. 1. Fillcrankcasewithproperoi!.

2. Air flowrestricted. 2. Removeblowerhousing
andclean.

!

: 3. Carburetornot adjustedproperly, : 3. Refertoenginemanual.

il_ _ i i i

!i_ii_i_i_ii_i _ii iiilt t t t t t t t t t __i

Occasionalskips

(hesitates)at

highspeed

1. Sparkpluggaptooclose.

2. Carburetoridle mixtureadjustment
improperlyset.

3. Dirtyair cleaner. ! 3. Refertoenginemanual.

1. Adjustgap to .030".

2. Refertoenginemanual.

2. Refertoenginemanual.

Excessive 1. Cuttingbladelooseorunbalanced. 1. Tighten bladeand adapter.Balance

Vibration

2. Bentcutting blade.

I B

Uneven cut 1. Wheels notpositionedcorrectly. 1. Placeall fourwheelsin same

2. Dullblade. 2. Sharpenorreplaceblade.

blade.

2. Seean authorizedservicedealer.

heightposition.

Mowerw not 1 Betnot nsta edpropery 1 Checkbet for properpu ey nsta aton

se f re I 1 and movement.

p pe 2. Debriscloggingdriveoperation. 2. Stopengine,disconnectsparkplug

3. Damagedorworn belt. m & inspectandreplacebelt.

wireand cleanoutdebris.

14

Off-Season Storage 4, Coatmower'scutt,ngbladewithchass,sgreaseto
Thefollowingstepsshouldbetakento prepareyourlawn preventrusting,

mowerforstorage, S,Storemowerinadry,e_eanarea,Donotstorenext ,//

1, Cleanand lubricatemowerthoroughlyasdescribedin to corrosivematerials,suchas fertilizer, / /

the ubrcaton nstructons ..........

2, We donotrecommendtheuseofa pressurewasher ventilatedor metalstorageshed,careshouldbetaken

or gardenhoseto cleanyour unit, torust=prooftheequipment,Usinga lightoilorsilicone,

3, Referto enginemanualforcorrectengine coattheequipment,especiallycablesandall moving SOn

storageinstructions, partsofyourlawnmowerbeforestorage,

when storinganytypeOTpowerequipmentinapoorly

Safety Labels Found On Your Lawn Mower

PLACEANDWORKING.IF DAMAGEDREPLACEiMMEDiATELY.

WARNING

DONOTremove safety

(or any) labels from

mower for any reason,

13

\

Q

Q

@

Q

..//"

-@

@.

Q

o "_

14

1 747-1161A BladeControlHandle
2 749-1092A UpperHandle

3 747-04080 GrassCatcherFrame
4 749-0928A LowerHandle

5 720-0279 WingNut
6 710-1205 RopeGuide

7 710-1174 CarriageBolt,5/16-18x 2
8 664-04011 GrassBagAssembly

9 720-04072 StarKnob5/16-18
10 731-04204 DeluxeBaleCover
11 726-0240 CableTie

12 710-0703 CarriageBolt,I/4-20
13 731-04134A RearDischargeDoor

14 750-04162 Spacer
15 732-04089A TorsionSpring- LH
16 732-04090A TorsionSpring- RR

17 734-04014B RearWheel,8"x2,125"
18 731-04150C RearBaffle

20 787-01277 Deck- 21"
22 782-5002B FrontBaffle

23 748-04015A BladeAdapterw/Pulley
24 742-0741 21"StandardCut Blade

25 710-1257 HexBolt, 3/8-24x2,5
26 687-02044 PivotPlateAssembly
27 736-0524B BladeBelISupport

28 787-01298 HeightAdiustmentPlate- RH

787-01299 HeightAdiustmentPlate- LH

29 720-0426 AdiustmentLeverKnob
30 732-0706 FrontLever-RH

732-0707 FrontLever- LH
31 738-04136 ShoulderScrew
32 634-04018 FrontWheel,8" x2,125"
33 710-04371 Screw,1/4-15x 1,250

34 746-1132 ControICable-40,75"

36 731-04998 Trailshield

37 732-0700 TrailshieldWire

38 712-0397 WingNut,1/4-20
39 747-04035 RearDoorPivotRod

40 732-04175 SpringLever
41 687-02071A PivotArm Assembly- RH

687-02070A PivotArmAssembly-LH

42 710-1652 ABScrew
43 712-04065 FlangeLockNut,3/8-16

44 714-0104 HairpinClip
45 710-0654A TT SeresScrew,3/8-16x 1,00

46 687-02193 Ht, Adj,Assy,Front- LH

687-02194 Ht, Adi,Assy,Front- RH

47 687-02069 RearHandleBracketAssy,-LR

687-02068 RearHandleBracketAssy,- RH

48 747-1214 LowerBailHandle
49 710-1650 ShoulderScrew

50 746-04203 DriveCable51"
51 754-04101 V-Belt

52 618-04376 TransmissionAssembly
53 731-05020A FrontDriveCover

54 732-1043 BeltTensionSpring
55 682-0015 BearingAssembly

56 736-0447 WaveWasher
57 710-0216 HexScrew

58 715-0221 DowelPin
59 717-1762 Gear,14T-RH

717-1761 Gear,14T- LH

60 710-04531 Screw1/4-20
61 782-7551A WheeIDustCap

62 716-0102 SnapRing
63 736-0474 Washer,1,5"0D
64 750-04594 SleeveSpacer-LH
65 750-04595 SleeveSpacer-RR

66 715-04030 Roll Pin
67 756-04151A InputPulley

68 787-01292 HandleBracket-RH

787-01291 HandleBracket-LH

and disengage safely.
A substitute inon OEMt

oV-Beltcan bedanger-

us by notdisengaging

completely,

To order

replacement parts,

call 1=866=840-648S,

1-336=558-7220_
or log on to our

Web site at

www.troybiltocom

NOTE:Forpaintedparts,pleaserefertothe listof
colorcodesbelow, Pleaseaddtheapplicablecolor

code,whereverneeded,to thepart numbertoorder
a replacementpart, For instance,ifa part numbered

700-xxxxispaintedTroybiltRed,the partnumberto
orderwouldbe 700-xxxx-0638,

TroybiltRed:0638

PowderBlack:0637

\

15

MANUFACTURER'S LIMITED WARRANTY FOR

®

The limitedwarrantyset forthbelowis givenbyTroy_BiltLLCwithrespect

tonewmerchandisepurchasedandusedintheUnitedStates,itsposses_
sionsandterritories.

"Troy_Bilt"warrantsthis productagainstdefectsinmatedalandworkmam
shipfor a periodof two(2)yearscommencingon thedateoforiginal
purchaseandwill,atits option,repairorreplace,freeofcharge,anypart
foundto bedefectivein materialsor workmanship.This limitedwarranty
shallonly applyif this producthasbeenoperatedand maintainedin
accordancewiththe Operator'sManualfurnishedwiththeproduct,and
hasnotbeensubiectto misuse,abuse,commercialuse,neglect,accident,
impropermaintenance,alteration,vandalism,theft,fire,water,or damage
becauseofother perilor naturaldisaster.Damageresultingfromthe
installationor use ofany part,accessoryorattachmentnotapprovedby

Troy_Biltforuse withtheproduct(s)coveredbythis manualwillvoidyour

warrantyastoany resultingdamage.
Normalwearpartsarewarrantedtobefreefromdefectsinmaterialand

workmanshipfora periodofthirty (30)daysfromthedate ofpurchase.
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 your local authorizedservice
dealer.To locate the dealer inyourarea, 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 logon to our

Web site at www.troybilt.com.
This limitedwarrantydoesnot providecoverageinthefollowingcases:

a. Theengineorcomponentpartsthereof.Theseitemsmay

carrya separatemanufacturer'swarranty.Refertoapplicable
manufacturer'swarrantyfortermsandconditions.

b. Logsplitterpumps,valves,andcylindershaveaseparateone

yearwarranty.

c. Routinemaintenanceitemssuchas lubricants,filters,blade

sharpening,tune_ups,brakeadiustments,clutch adiustments,
deckadiustments,andnormaldeteriorationofthe exteriorfinish
duetouse orexposure.

d. Servicecompletedbysomeoneotherthananauthorizedservice

dealer.

e. Troy_Biltdoesnotextendanywarrantyforproductssoldor

exportedoutsideofthe UnitedStates,its possessionsand
territories,exceptthosesold throughTroy_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,whetherwritten 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 remedyis repair or replacement

of the product as setforth above.
The provisions as set forth inthis warranty provide the sole and

exclusive remedyarising from the sale. Troy-Bilt shall not be liable
for incidental orconsequential loss or damage including, without

limitation, expensesincurred for substitute or replacement lawncare

services or for rental expensesto temporarily replacea warranted

product.
Somestatesdonot allowtheexclusionorlimitationofincidentalor

consequentialdamages,or limitationson howlonganimpliedwarranty

lasts,sothe aboveexclusionsor limitationsmaynotapplytoyou.
Innoeventshall recoveryof anykindbegreaterthantheamountofthe

purchasepriceof theproductsold.Alteration of safety features of the
product shall void this warranty. Youassumetheriskandliabilityfor
loss,damage,oriniurytoyouand yourpropertyand/ortoothersandtheir
propertyarisingout ofthe misuseorinabilityto usethe product.

This limitedwarrantyshallnotextendto anyoneotherthanthe original

purchaseror to thepersonforwhomit waspurchasedasa gift.
HOWSTATELAWRELATESTOTHISWARRANTY:Thislimitedwar-

rantygh,'esyouspecificlegalrights,andyoumayalso haveotherrights

whichvaryfromstateto state.

IMPORTANT:OwnermustpresentOriginalProofofPurchasetoobtain

warrantycoverage.

TROYBILT LLC, P.O. BOX 361131 CLEVELAN D, OHIO 44136-0019; Phone: 1(866} 840-6483, 1-330-558-7220