Troybilt 12AS5690063-2002 Owner’s Manual
Operator's Manual
21" Three-in-One
Self Starter
Self-Propelled
Mower
Model
560 Series
IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY
Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-
covered, brush*covered or grass-covered land unless the engine's exhaust system is equipped with a spark arrester meeting
applicable local or state laws (if any). If a spark arrester is used, it should be maintained in effective working order by the operator.
In the State of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have
similar laws. Federal laws apply on federal lands. A spark arrester for the muffler is available through your nearest engine authorized
service dealer or contact the service department, P.O. Box 361131 Cleveland, Ohio 44136-0019.
TROY-BILTLLC, P.O.BOX361131CLEVELAND,0HI0 44136-0019
PRINTED IN U.S.A. FORM NO. 769-00006B
ECO No.
(2/2002)
TABLEOFCONTENTS
Content Page
Important Safe Operation Practices ................................................................... 3
Slope Gauge ...................................................................................................... 6
Assembling Your Lawn Mower ........................................................................... 7
Know Your Lawn Mower .................................................................................... 9
Operating Your Lawn Mower ............................................................................. 10
Making Adjustments .......................................................................................... 12
Maintaining Your Lawn Mower ........................................................................... 13
Off-Season Storage ........................................................................................... 16
Troubleshooting ................................................................................................. 17
Parts List ............................................................................................................ 18
FINDINGMODELNUMBER
This Operator's Manual is an important part of your new lawn mower, It wilt help you assemble, prepare and
maintain the unit for best performance, Please read and understand what it says,
Before you start assembling your new equipment, please locate the model plate on the
equipment and copy the information from it in the space provided below. The information on
the model plate isvery important if you need help from our Customer Support Department or
an authorized Service dealer.
You can locate the model number by standing at the operating position and looking down at the rear
of the mower. A sample model plate is explained below. For future reference, please copy the model
number and the serial number of the equipment in the space below.
(Model Number) (Serial Number)
Copy the model number here:
3311_tttfi1!1_'1_I1_I
Copy the serial number here:
, inlu4,1e-_j
ENGINEINFORMATION
The engine manufacturer is responsible for all engine-related issues with regards to performance, power-
rating, specifications, warranty and service. Please refer to the engine manufacturer's Owner's/Operator's
Manual packed separately with your unit for more information.
CALLINGCUSTOMERSUPPORT
If you have difficulty assembling this product or have any questions regarding the controls, operation or
maintenance of this unit, please call the Customer Support Department,
Call 1- (330) 558-7220 or 1-(866)-840-6843 to reach a Customer Support representative.
Please have your unit's model number and serial number ready when you call. See previous
section to locate this information. You will be asked to enter the serial number in order to
process your call.
2
SECTION1: IMPORTANTSAFEOPERATIONPRACTICES
WARNING: This symbol points out important safety instructionswhich, ifnot followed, could endanger
the personal safety and/or property of yourself and others. Read and follow all instructions inthis manual
before attempting to operate this machine. Failure to comply with these instructions may result in personal
injury. When you see this symbol--HEED ITS WARNING.
WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain or emit
chemicals known to State of California to cause cancer and birth defects or other reproductive harm.
DANGER: This machine was built to be operated according to the rules for safe operation in this manual. As with
any type of power equipment, carelessness or error on the part of the operator can result in serious injury. This
machine is capable of amputating hands and feet and throwing objects. Failure to observe the following safety instruc-
tions could result in serious injury or death.
GeneralOperation
1. Read this operator's manual carefully in its entirety
before attempting to assemble this machine. Read,
understand, and follow all instructions on the machine
and in the manual(s) before operation. Be completely
familiar with the controls and the proper use of this
machine before operating it. Keep this manual in a safe
place for future and regular reference and for ordering
replacement parts.
2. This machine is a precision piece of power equipment,
not a plaything. Therefore, exercise extreme caution at all
times. Your unit has been designed to perform one job: to
mow grass. Do not use it for any other purpose.
3. Never allow children under 14 years old to operate this
machine. Children 14 years old and over should read and
understand the operation instructions and safety rules in
this manual and should be trained and supervised by a
parent. Only responsible individuals who are familiar with
these safe operation rules should use this machine.
4. Thoroughly inspect the area where the equipment is to
be used. Remove all stones, sticks, wire, bones, toys and
other foreign objects which could be tripped over or
picked up and thrown by the blade. Thrown objects can
cause serious personal injury. Plan your mowing pattern
to avoid discharge of material toward roads, sidewalks,
bystanders and the like. Also, avoid discharging material
against a wall or obstruction which may cause discharged
material to ricochet back toward the operator.
5. To help avoid blade contact or athrown object injury, stay
in the operator zone behind the handles and keep
bystanders, helpers, children and pets at least 75 feet
from the machine while it is in operation. Stop machine if
anyone enters the area.
6. Always wear safety glasses or safety goggles during
operation and while performing an adjustment or repair to
protect your eyes. Thrown objects which ricochet can
cause serious injury to the eyes.
7. Wear sturdy, rough-soled work shoes and dose-fitting
slacks and shirts. Shirts and pants that cover the arms
and legs and steel-toed shoes are recommended. Never
operate this machine in bare feet, sandals, slippery or
light weight (e.g. canvas) shoes.
8. Do not put hands or feet near rotating parts or under the
cutting deck. Contact with the blade can amputate hands
and feet.
9. A missing or damaged discharge cover can cause blade
contact or thrown object injuries.
10. Many injuries occur as a result of the mower being pulled
over the foot during a fall caused by slipping or tripping.
Do not hold on to the mower if you are failing; release the
handle immediately.
11. Never pub the mower back toward you while you are
walking. If you must back the mower away from a wall or
obstruction first look down and behind to avoid tripping
and then follow these steps:
a. Step back from the mower to fully extend your
arms.
b. Be sure you are web balanced with sure footing.
c. Pull the mower back slowly, no more than half way
toward you.
d. Repeat these steps as needed.
12. Do not operate the mower while under the influence of
alcohol or drugs.
13. Do not engage the self-propelled mechanism on units so
equipped while starting engine.
14. The blade control handle is a safety device. Never
attempt to bypass its operation. Doing so makes the
safety device inoperative and may result in personal
injurythrough contact with the rotating blade. The blade
control handle must operate easily in both directions and
automatically return to the disengaged position when
released.
15. Never operate the mower in wet grass. Always be sure of
your footing. A slip and fall can cause serious personal
injury. If you feel you are losing your footing, release the
blade control handle immediately and the blade will stop
rotating within three seconds.
16. Mowin daylightor good artificiallight. Walk, never run.
17. Stop the blade when crossing gravel drives, walkways
or roads.
18. If the equipment should start to vibrate abnormally, stop
the engine and check immediately for the cause.
Vibration is generally a warning of trouble.
19. Shut the engine off and wait until the blade comes to a
complete stop before removing the grass catcher or
unclogging the chute. The cutting blade continues to
rotate for a few seconds after the engine is shut off.
Never place any part of the body in the blade area until
you are sure the blade has stopped rotating.
20. Never operate mower without proper trail shield,
discharge cover, grass catcher, blade control handle or
3
othersafetyprotectivedevicesinplaceandworking.
Neveroperatemowerwithdamagedsafetydevices.
Failuretodeso,canresultinpersonalinjury.
21.Mufflerandenginebecomehotandcancauseaburn.Do
nottouch.
22.Only use parts and accessories made for this machine by
the original equipment manufacturer (O.EM). Failure to
do so can result in personal injury.
23. If situations occur which are net covered in this manual,
use care and good judgment. Contact your dealer for
assistance. Telephone 1-866-840-6483 for the name of
your nearest dealer.
SlopeOperation
Slopes are a major factor related to slip and fall accidents
which can result in severe injury. Operation on slopes
requires extra caution. If you feel uneasy on a slope, do not
mow it. Before operating this unit on a slope or hilly area, use
the slope gauge on page 6 to measure slopes. Ifthe slope is
greater than 15 degrees, do not mow it.
DO:
1. Mow across the face of slopes; never up and down.
Exercise extreme caution when changing direction on
slopes.
2. Watch for holes, ruts, rocks, hidden objects, or bumps
which can cause you to slip or trip. Tall grass can hide
obstacles.
3. Always be sure of your footing. A slip and fall can cause
serious personal injury. If you feel you are losing your
balance, release the blade control handle immediately,
and the blade will stop rotating within 3 seconds.
Do Not:
f. Do not mow near drop-offs, ditches or embankments,
you could lose your footing or balance.
2. Do not mow slopes greater than 15 degrees as shown on
the slope gauge.
3. De net mow on wet grass. Unstable footing could cause
slipping.
Children
Tragic accidents can occur if the operator is not alert to the
presence of children. Children are often attracted to the
mower and the mowing activity. They do not understand the
dangers. Never assume that children will remain where you
last saw them.
1. Keep children out of the mowing area and under the
watchful care of a responsible adult other than the
operator.
2. Be alert and turn mower off if a child enters the area.
3. Before and while moving backwards, look behind and
down for small children.
4. Use extreme care when approaching blind corners,
doorways, shrubs, trees, or other objects that may
obscure your vision of a child who may run into the
mower.
5. Keep children away from hot or running engines. They
can suffer burns from a hot muffler.
6. Never allow children under 14 years old to operate a
power mower. Children 14 years old and over should
read and understand the operation instructions and
safety rules in this manual and should be trained and
supervised by a parent.
Service
Safe Handling OfGasoline:
1. To avoid personal injury or property damage use extreme
care in handling gasoline. Gasoline is extremely
flammable and the vapors are explosive. Serious
personal injury can occur when gasoline is spilled on
yourself or your clothes which can ignite.
2. Wash your skin and change clothes immediately.
3. Use only an approved gasoline container.
4. Never fill containers inside a vehicle or on atruck or
trailer bed with a plastic liner. Always place containers on
the ground away from your vehicle before filling.
5. If possible, remove gas-powered equipment from the
truck or trailer and refuel it on the ground. If this is not
possible, then refuel such equipment on a trailer with a
portable container, rather than from a gasoline dispenser
nozzle.
6. Keep the nozzle in contact with the rim of the fuel tank or
container opening at all times until fueling is complete. Do
not use a nozzle lock-open device.
7. Extinguish all cigarettes, cigars, pipes and other sources
of ignition.
8. Never fuel machine indoors because flammable vapors
will accumulate in the area.
9. Never remove gas cap or add fuel while the engine is hot
or running. Allow engine to cool at least two minutes
before refueling.
10. Neveroverfillfueltank. Fill tank to no mere than ½ inch
below bottom of filler neck to provide space for fuel
expansion.
11. Replace gasoline cap and tighten securely.
12. If gasoline is spilled, wipe it off the engine and
equipment. Move unit to another area. Wait 5 minutes
before starting the engine.
13. Never store the machine or fuel container inside where
there is an open flame, spark or pilot light as on a water
heater, space heater, furnace, clothes dryer or other gas
appliances.
14. To reduce fire hazard, keep mower free of grass, leaves,
or other debris build-up. Clean up oil or fuel spillage and
remove any fuel soaked debris.
15. Allow a mower to cool at least 5 minutes before storing.
GeneralService:
1. Never run an engine indoors or in a poorly ventilated
area. Engine exhaust contains carbon monoxide, an
odorless and deadly gas.
2. Before cleaning, repairing, or inspecting, make certain
the blade and all moving parts have stopped. Disconnect
the spark plug wire and ground against the engine to
prevent unintended starting.
3. Check the blade and engine mounting bolts at frequent
intervals for proper tightness. Also, visually inspect blade
for damage (e.g., bent, cracked, worn) Replace blade
with the original equipment manufacture's (O.E.M) blade
only, listed in this manual. "Use of parts which do not
4
meettheoriginalequipmentspecificationsmayleadto
improperperformanceandcompromisesafety!"
4. Mowerbladesaresharpandcancut.Wrapthebladeor
weargloves,anduseextracautionwhenservicingthem.
5. Keepallnuts,bolts,andscrewstighttobesurethe
equipmentisinsafeworkingcondition.
6. Nevertamperwithsafetydevices.Checktheirproper
operationregularly.
7. Afterstrikingaforeignobject,stoptheengine,disconnect
thesparkplugwireandgroundagainsttheengine.
Thoroughlyinspectthemowerforanydamage.Repair
thedamagebeforestartingandoperatingthemower.
8. Neverattempttomakeawheelorcuttingheight
adjustmentwhiletheengineisrunning.
9. Grasscatchercomponents,dischargecover,andtrail
shieldaresubjecttowearanddamagewhichcould
exposemovingpartsorallowobjectstobethrown.For
replaceimmediatelywithoriginalequipment
manufacturer's(O.EM.)partsonly,listedinthismanual
"Useofpartswhichdonotmeettheoriginalequipment
specificationsmayleadtoimproperperformanceand
compromisesafety!"
10.Donotchangetheenginegovernorsettingoroverspeed
theengine.Thegovernorcontrolsthemaximumsafe
operatingspeedoftheengine.
11.Maintainorreplacesafetyandinstructionlabels,as
necessary.
12.Observeproperdisposallawsandregulations.Improper
disposaloffluidsandmaterialscanharmthe
environment.
13.ALWAYSde-energizeselfstarterpriortoperformingany
maintenanceorservicetotheengineandormower.
Followinstructionsbothinmanualandontheengineand
ormachinetode-energizestarter.
safetyprotection,frequentlycheckcomponentsand
YourResponsibility
Restrict the use of this power machine to persons who read, understand and follow the warnings and instructions in
this manual and on the machine.
DANGER
5
USE THIS PAGE AS A GUIDE TO DETERMINE SLOPES WHERE YOU MAY NOT OPERATE SAFELY.
SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE
A POWER POLE
A CORNER OF A BUILDING
ORA FENCE POST
|
I
¢0
15°
WARNING _
Do not mow on inclines with a slope in excess of 15 degrees (a rise of approximately 2-1/2 feet every 10 feet). A
riding mower could overturn and cause serious injury. If operating a walk-behind mower on such a slope, it is
extremely difficult to maintain your footing and you could slip, resulting in serious injury.
Operate RIDING mowers up and down slopes, never across the face of slopes.
Operate WALK-BEHIND mowers across the face of slopes, never up and down slopes.
SECTION3: ASSEMBLINGYOURLAWNMOWER
ToRemoveUnit FromCarton
Remove staples, break glue on top flaps, or cut tape
at carton end and peel along top flap to open carton.
Remove loose parts included with your unit (i.e.,
operator's manual, etc.).
Cut along corners and lay carton down flat.
Remove packing material.
Roll or slide unit out of carton.
HardwarePack
1. Carriage Bolt 1/4-20 x.75" (2)
2. Wing Nut with Bell Washer (2)
ToolsRequired
1. Pair of Pliers
2. Funnel
NOTE: Reference to right or left hand side of the mower
is observed from the operating position.
DisconnectingSparkPlug
Before setting up your lawn mower, disconnect the
spark plug wire from the spark plug, and ground it
against the engine. See Figure 1.
Raise the lower handle, as shown in Figure 2, till it
snaps into place.
Raise the upper handle as shown in Figure 2.
Tighten the two wing nuts which are already on the
handle. See Figure 3.
Assembly
Nuts
Figure 3
NOTE: Make sure to route the cables outside the lower
handle. Also de not crimp the cables while lifting the
handle up.
Place rear wheels in the highest height position
using the rear height adjustment lever.
Remove the hairpin clips from the outer hole in the
weld pins on the handle mounting brackets. Using a
pair of pliers, squeeze one leg of the lower handle
against the handle mounting bracket. Insert the
hairpin clip into the inner hole on the weld pin.
Repeat on the other side. See Figure 4.
_-Spark Plug
Figure I
AssemblingHandle
For shipping purposes, the grass bag was placed
on top of the unit. Remove it from the unit and set it
out of the way. See Figure 2.
2. Lift lower
handle 1.Move bag
3. Lift upper
handle
Figure 2
away
_, _, Handle Mounting
Hairpin \ \\ "ll\_
"_'_'J _© _'_ Weld
Insert post of cable ties that are on lower handle
intothe holes provided on the lower handle. The
holes may be on the inside oroutside. Pull cable
ties tight and cutoff the extra. See Figure 5.
NOTE: Holes can be on the inside or outside of the
handle.
Post on
F_----_/Bracket
\\'_'hk,_,_ Insert hairpin
"_ _ ((((e"_ clip here
_ Pin
Figure 4
Cable Tie
Figure 5
7
AttachingStarter Rope
The rope guide is already attached to the right side of
the lower handle of your mower.
The rope guide is attached to the right side of upper
handle. Loosen the wing nut which secures the
rope guide. See Figure 6.
With spark plug wire disconnected and grounded,
hold the blade control handle against the upper
handle, and pull the starter rope out of the engine.
Release blade control handle. Slip the rope into the
rope guide. Tighten the wing nut. See Figure 6.
To remove the mulching baffle, lift the rear
discharge door on the mower. Remove the
mulching baffle. See Figure 8.
Slip rope into
rope gu_/,_ jing Nut
Figure 6
Tighten all nuts and bolts securely.
After you have moved the hairpin clips as shown in
Figure 4, place one carriage bolt (found in the
hardware pack included with your unit) in the upper
hole of the right handle mounting bracket from the
inside outward. See Figure 7. Secure with one
plastic wing nut. Repeat process on the left side
Figure 8
IMPORTANT: Make sure cables are routed to the
outside ofthe handle so they are not in the way when
attaching the grass catcher.
Liftthe rear discharge door on the mower.
Place the hooks, found on both sides of the grass
catcher frame, over the chute door pivot rod at the
rear ofthe mower. See Figure 9. Release the rear
discharge door.
To remove the grass catcher, lift the rear
discharge door on the mower. Lift the grass catcher
up and off the pivot rod. Reinstall the mulching
baffle and release the rear discharge door. See
Figure 9.
WARNING: Never operate the mower
unless the hooks on the grass catcher are
firmly seated on the chute pivot rod, and the
rear discharge door rests firmly against the
top of the grass catcher.
Discharge Door
Figure 7
AttachingGrassCatcherToMower
NOTE: The mulching baffle is already in place on the
mower for shipping purposes. Your lawn mower is
equipped with both a mulching baffle and a mulching
plug. While the mulching baffle is located at the rear of
the mower, the mulching plug is located on the right
side of the cutting deck. De not remove the mulching
plug from the mower even when you are not mulching
the grass.
Figure 9
ConvertingTo SideDischarge
Lift the rear discharge door and install the mulching
baffle. See Figure 8.
On the side of the mower, lift the mulching plug.
See Figure 10.
Slide the two hooks of the side discharge chute
under the hinge pin on the mulching plug assembly
as shown in Figure 10. Lower the side mulching
plug.
8
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