Page 1
Operator’s Manual
Models 566 & 569
Variable Speed
21” Self Propelled
Mulching Mower
IMPORTANT:
Warning:
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.
PRINTED IN U.S.A.
This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-covered, brush-
Read safety rules and instructions carefully before operating equipment.
Troy-Bilt LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019
FORM NO.
769-01542.fm
(12/2004)
Page 2
TABLE OF CONTENTS
Content Page
Important Safe Operation Practices 3
Slope Gauge 6
Assembling Your Lawn Mower 7
Know Your Lawn Mower 10
Operating Your Lawn Mower 11
Content Page
Service and Adjustments 14
Off Season Storage 15
Trouble Shooting 16
Illustrated Parts List 18
Warranty 20
Maintaining Your Lawn Mower 12
FINDING MODEL NUMBER
This Operator’s Manual is an important part of your new lawn mower. It will 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. A sample model plate is
also given below. You can locate the model plate by standing at the operating position and
looking down at the rear of the deck . This information will be necessary to use the
manufacturer’s web site and/or help from the Customer Support Department or an authorized
service dealer.
Copy the model number here:
www.troybilt.com
TROY-BILT LLC
P. O. BOX
361131
CLEVELAND, OH 44136
330-558-7220
1-800-520-5520
Copy the serial number here:
CUSTOMER SUPPORT
Please do NOT return the unit to the retailer from where it was purchased, without first contacting Customer Support.
If you have difficulty assembling this product or have any questions regarding the controls, operation or
maintenance of this unit, you can seek help from the experts. Choose from the options below:
Visit www.troybilt.com for many useful suggestions. Click on Customer Support button and
you will get the four options reproduced here. Click on the appropriate button and help is
immediately available.
The answer you are
looking for could be just
a mouse click away!
If you prefer to reach a Customer Support Representative, please call 1-800-520-5520.
The answer you are
looking for could be just
a mouse click away!
Engine
Manual
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.
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SECTION 1: IMPORTANT SAFE OPERATION PRACTICES
WARNING:
the personal safety and/or property of yourself and others. Read and follow all instructions in this 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:
chemicals known to State of California to cause cancer and birth defects or other reproductive harm.
WARNING:
manual. As with any type of power equipment, carelessness or error on the part of the operator can result in
serious injury. This machine is capable of amputating hands and feet and throwing objects. Failure to
observe the following safety instructions could result in serious injury or death.
This symbol points out important safety instructions which, if not followed, could endanger
Engine exhaust, some of its constituents, and certain vehicle components contain or emit
This machine was built to be operated according to the rules for safe operation in this
General Operation
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 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 a thrown 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 to protect your eyes
during equipment operation and while performing
an adjustment or repair. Thrown objects which
ricochet can cause serious injury to the eyes.
7. Wear sturdy, rough-soled work shoes and closefitting 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
falling; release the handle immediately.
11. Never pull 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 well balanced with sure
footing.
c. Pull the mower back slowly, no more than
half way toward you.
d. Repeat these steps as needed.
5. Do not operate the mower while under the influence
of alcohol or drugs.
6. Do not engage the self-propelled mechanism on
units so equipped while starting engine.
7. 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 injury through contact with the rotating
blade. The blade control handle must operate
easily in both directions and automatically return to
the disengaged position when released.
8. 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
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your footing, release the blade control handle
immediately and the blade will stop rotating within
three seconds.
9. Mow in daylight or good artificial light; walk, not run.
10. Stop the blade when crossing gravel drives,
walkways or roads.
11. If the equipment should start to vibrate abnormally,
stop the engine and check immediately for the
cause. Vibration is generally a warning of trouble.
12. 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.
13. Never operate mower without proper trail shield,
discharge cover, grass catcher, blade control
handle or other safety protective devices in place
and working. Never operate mower with damaged
safety devices. Failure to do so can result in
personal injury.
14. Muffler and engine become hot and can cause a
burn. Do not touch.
15. Only use parts and accessories made by the
original equipment manufacturer (O.E.M). Failure
to do so can result in personal injury.
16. If situations occur which are not covered in this
manual, use care and good judgment. Contact your
dealer for assistance. Call1-800-520-5520 for the
name of your nearest dealer.
Slope Operation
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 . If the slope is greater than 15
degrees, do not mow it.
Do:
1. Mow across the face of slopes; never up and down.
Exercise caution when changing direction.
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:
1. 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. Do not 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 of Gasoline:
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 a truck 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.
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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. Never over fill fuel tank. Fill tank to no more 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.
General Service:
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
meet the original equipment specifications may
lead to improper performance and compromise
safety!”
4. Mower blades are sharp and can cut. Wrap the
blade or wear gloves, and use extra caution when
servicing them.
5. Keep all nuts, bolts, and screws tight to be sure the
equipment is in safe working condition.
6. Never tamper with safety devices. Check their
proper operation regularly.
7. After striking a foreign object, stop the engine,
disconnect the spark plug wire and ground against
the engine. Thoroughly inspect the mower for any
damage. Repair the damage before starting and
operating the mower.
8. Never attempt to make a wheel or cutting height
adjustment while the engine is running.
9. Grass catcher components, discharge cover, and
trail shield are subject to wear and damage which
could expose moving parts or allow objects to be
thrown. For safety protection, frequently check
components and replace immediately with original
equipment manufacturer’s (O.E.M.) parts only,
listed in this manual. “Use of parts which do not
meet the original equipment specifications may
lead to improper performance and compromise
safety!”
10. Do not change the engine governor setting or
overspeed the engine. The governor controls the
maximum safe operating speed of the engine.
11. Maintain or replace safety and instruction labels, as
necessary.
12. Observe proper disposal laws and regulations.
Improper disposal of fluids and materials can harm
the environment.
Your Responsibility
• 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.
1299 AC
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SECTION 2: SLOPE GAUGE
p
p
,
p
p
Use this page as a guide to determine slopes where you may not operate safely.
your footing and you could slip, resulting in serious injury.
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
F
O
L
D
ON
D
R
P
E
R
I
N
E,
O
T
T
E
D
L
SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE
A POWER POLE
A CORNER OF A BUILDING
OR A FENCE POST
WARNING
15
o
E
S
E
N
T
I
N
Operate RIDING mowers up and down slopes, never across the face of slopes.
O
erate WALK-BEHIND mowers across the face of slo
es
never u
and down slo
es.
G
A
1
5
o
S
L
OP
E
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SECTION 3: ASSEMBLING YOUR LAWN MOWER
Removing Unit From Carton
• Remove staples, break glue on top flaps, or cut
tape at carton end and peel along top flap to open.
• Remove loose parts included with unit (i.e.,
operator’s manual, oil, etc.).
• Cut corners and lay carton down flat. Remove
packing material.
• Roll or slide unit out of carton. Check carton
thoroughly for loose parts.
NOTE: Make sure not to crimp cables while removing
loose parts or the entire unit from the carton.
Tools R e q uired
• Pair of Pliers
• Funnel
NOTE: Reference to right or left hand side of the mower
and/or front or behind the mower is observed from the
operating position.
Hardware Pack
Please identify each piece of the
hardware pack as shown in
figure here.
Wing
Nut (2)
Carriage
Bolt (2)
Assembling Handle
• Remove grass bag from the unit and set it out of the
way. See Figure 1 (step 1).
• Remove any packing material which may be
between the upper and lower handles for shipping
purposes.
2. Lift lower
handle
3. Lift upper
handle
Figure 1
• Raise the lower handle in the direction shown in
Figure 1 (step 2) till it snaps into place.
• Raise the upper handle in the direction shown in
Figure 1 (step 3). Tighten the wing nuts which are
already on the handle. See Figure 2 .
1. Move bag
away
Fresh Start
Cartridge
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:
• Snap the fuel preserver cartridge that comes with
your unit into the fuel cap.
• Peel off the white tab from the cartridge.
• Twist the FreshStart™ cap onto the fuel tank.
When you visually see that the fuel preserver cartridge
is empty, replacement cartridges you may purchase
through your local Troybilt service dealer
FreshStart™ Gas Cap
™
(Available on Model 569)
This unit is equipped with a
FreshStart™ continuous fuel
Disconnecting Spark Plug
• Before setting up your lawn mower, disconnect the
spark plug wire from the spark plug, and ground it
against the engine.
Upper Handle
Lower Handle
Tighten this
wing nut
Figure 2
NOTE: Make sure to route the cables inside the lower
handle. Also do not crimp the cables while lifting the
handle up.
• For shipping purposes, the hairpin clip is placed in
the outer hole of the weld pin on the lower handle.
Remove the hairpin clip from the outer hole of the
weld pin. See Figure 3.
• Using a pair of pliers, insert the hairpin clip into the
inner hole on the weld pin. Repeat on other side.
See Figure 3 .
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Carriage Bolt
Wing Nut
Hairpin Clip
Handle
Mounting Bracket
Weld Pin
Figure 3
• Insert the carriage bolt, included in the hardware
pack, in the upper hole on the handle mounting
bracket (carriage bolt must go to the inside of
handle). Secure with one plastic wing nut, also
included in the hardware pack. Repeat on the other
side with remaining items from the hardware pack.
• Attach cables to the lower handle with the two cable
ties already on the lower handle. Pull cable ties tight
and cut off the extra.
Attaching Starter Rope
The rope guide is already attached to the right side of
the upper handle of your mower. See Figure 4 .
• 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.
• Slip the rope through the rope guide as shown
below. Tighten the wing nut holding the rope guide
to the upper handle.
Wing Nut
Starter
Rope
Upper
Handle
Assembling Grass Catcher
NOTE: If the grass catcher came pre-assembled,
proceed to the next section. If not, follow the steps
below to assemble it before attaching to the mower.
• Insert frame into grass bag with the black plastic
side on the bottom of bag. See Figure 5.
Grass Catcher
Frame
Grass
Bag
Plastic
Channel
Figure 5
• Slip the openings in the side of the plastic channel
on bag over the hooks on the grass catcher frame.
Secure bag to the frame by working the six plastic
channels on bag over frame. All of the plastic
channels except the center top of the bag attach
from the outside of bag. The center top of the bag
attaches from inside the bag. See Figure 5.
WARNING:
When using the mower to bag
grass clippings, make sure 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.
Insert frame
into bag
Grass Catcher
Assembly
Complete
Rope Guide
Figure 4
Lower
Handle
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Attaching Grass Catcher
• Lift the rear discharge door and place the grass
catcher on the pivot rod. Let go of discharge door
so that it rests on the grass catcher. See Figure 6.
Rear Discharge
Door
Grass
Catcher
Converting To Side Discharge
• Make sure the grass catcher is off the unit and the
rear discharge door is closed. Refer to Figure 7.
• On the side of the mower, lift the mulching plug.
See Figure 7.
• Slide the two hooks of the side-discharge chute
under the hinge pin on the mulching plug assembly.
Lower the side mulching plug.
• Do not remove the side mulching plug at any time,
even when you are not mulching.
Mulching Plug
Hinge Pin
Deflector
Figure 6
Converting To Mulcher
• Lift the rear discharge door on the mower and lift
the grass catcher up. Release the discharge door
to allow it to close the rear opening of the mower.
Hooks
(Slide hooks under the two
sides of hinge pin)
Figure 7
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SECTION 4: KNOW YOUR LAWN MOWER
Read this owner’s manual and safety rules before
operating your lawn mower. Compare the illustrations
in Figure 8 with your lawn mower to familiarize yourself
with the location of various controls and adjustments.
Save this manual for future reference.
Blade Control Handle
The blade control handle is located on the upper handle
of the mower. The blade control handle must be
depressed in order to operate the unit. Release the
blade control handle to stop the engine and the blade.
Drive Clutch Control
Blade Control Handle
Upper Handle
Lower Handle
Cutting Height
Adjustment Levers
Starter
Rope
Grass Catcher
Bag
Side-Discharge
Chute
For engine controls, please refer to
NOTE:
the engine manual.
Mulching
Plug
Figure 8
Drive Clutch Control
The drive clutch control is located on the upper handle.
Squeeze the drive control to engage the drive system.
Release the clutch control to disengage the drive
system. Release the clutch control to slow down when
approaching an obstacle, making a turn, or stopping.
Starter Rope
The starter rope is attached to the handle. Stand behind
the unit and pull the starter rope to start the unit.
WARNING:
safety device. Never attempt to bypass its
operations or alter it in any way.
The blade control handle is a
Grass Catcher Bag
The grass bag is used for collecting grass clippings.
Attach it to the mower for this purpose, but remove it
when the intention is to mulch the grass.
Mulching Plug
The mulching plug is used only for mulching purposes.
Instead of collecting the grass clippings in a 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 the unit while mulching.
Cutting Height Adjustment Lever
These levers are located on each wheel and they are
used to adjust the cutting height. All four levers have to
be at the same relative position to ensure uniform cut.
WARNING:
mower can result in foreign objects being
thrown into the operator’s eyes thus causing
severe eye damage. Always wear safety
glasses while operating the mower, or while
performing any adjustments or repairs on it.
The operation of any lawn
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SECTION 5: OPERATING YOUR LAWN MOWER
WARNING:
instructions and warnings on the machine and
in this manual before operating.
Read and understand all
Gas & Oil Fill-Up
• Check oil level and add oil if necessary. Follow
relevant instructions in the engine manual for this.
• Service the engine with gasoline as instructed in
the engine manual.
WARNING:
handling 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.
Use extreme care when
Before Starting Mower
• Attach spark plug wire to spark plug. Make certain
the metal cap on the end of the spark plug wire
(inside the rubber boot) is fastened securely over
the metal tip on the spark plug.
• Check for proper drive clutch operation using the
neutral adjustment test described below:
Neutral Adjustment Test
To perform the neutral adjustment test answer the
following questions:
• With the drive clutch control released, push mower
forward and pull it backward. Does it move freely?
• Squeeze the drive clutch control and pull the
mower backward. Do the rear wheels lock?
• Is the drive clutch control cable free of kinks or
sharp bends?
• If you answered “yes” to all three questions, your
mower passed the test and you can start it.
• If you answered “no” to any of the three questions,
you will have to adjust the drive clutch control as
instructed in the adjustment section.
Throttle Speed
Your lawn mower engine is equipped with a constant
speed throttle, which is set at full throttle for best
performance.
Starting Engine
•On model 569, push the primer three times. Wait
about two seconds between each push. In cold
weather around 55
Do not prime to restart a warm engine after a short
shutdown. Model 566 has no primer and requires
no priming.
o
F or below, prime five times.
WARNING:
operator is standing near the lawn mower while
starting engine or operating mower.
WARNING:
enclosed, poorly ventilated areas. Engine
exhaust contains carbon monoxide, an
odorless and deadly gas.
WARNING:
loose clothing away from any moving parts on
engine and lawn mower.
WARNING:
first time, face the mower against a wall or a
fence. Start the unit and if it shows any signs of
motion while the drive clutch control is still
disengaged, shut engine off immediately.
• Standing behind the mower, depress the blade
control handle and hold it against the upper handle.
• Grasp starter handle and pull rope out slowly until
engine reaches the start of compression cycle
(rope will pull slightly harder at this point). Keeping
a firm grip on the starter handle, let the rope rewind
slowly.
NOTE: See your engine manual packed with your unit
for more detailed instructions.
Be sure no one other than the
Never run engine indoors or in
Keep hands, feet, hair and
When starting the unit for the
To Stop Engine
• Release the blade control handle to stop the engine
and blade.
• Disconnect spark plug wire and ground it against
the engine to prevent accidental starting while
equipment is unattended.
Using Your Lawn Mower
• You can use your mower as a mulcher or a rear
bagger or for side discharge of grass.
• Be sure that the lawn is clear of stones, sticks, wire,
or other objects which could damage lawn mower
or engine. Such objects could be accidently thrown
by the mower in any direction and cause serious
personal injury to the operator and others.
• For best results, do not cut wet grass because it
tends to stick to the underside of the mower.
•For a healthy lawn, always cut off one-third or less
of the total length of the grass. Lawn should be
trimmed in fall as long as there is growth.
WARNING:
object, stop the engine. Remove spark plug
wire from the spark plug and thoroughly inspect
for any damage. Repair the damage promptly
before restarting and operating the mower.
If the mower strikes a foreign
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Mulching
For effective mulching, do not cut wet grass because it
tends to stick to the underside of the deck, preventing
proper mulching of grass clippings. New or thick grass
may require a narrower cut. The ground speed should
be adjusted to the condition of the lawn. If mowing has
been delayed and the grass has been allowed to grow
in excess of 4”, mulching is not recommended. Mow
using the grass bag to reduce the grass height to 3 1/4”
maximum before mulching.
Adjusting Cutting Height
Refer to height adjustments section of this manual on
page 14 for instruction on how to adjust the cutting
height and the handle height.
For best results in mowing, keep the cutting height
position high until you can determine a suitable height.
Bagging Grass Clippings
You can use the grass catcher bag to collect clippings
while you are operating the mower.
• Attach grass catcher following instructions on page
9. Grass clippings will automatically collect in the
bag as you run the mower. Operate the mower till
the grass bag is full.
• Once the bag is full, stop the engine and the mower
completely. Lift discharge door and pull grass bag
up and away from the mower to dispose of the
grass clippings.
SECTION 6: MAINTAINING YOUR LAWN MOWER
WARNING:
disconnect the spark plug wire before
performing any maintenance work or
adjustments on your lawn mower.
Always stop the engine and
Cleaning Mower
The underside of the mower deck should be cleaned
after each use to prevent any build-up of grass
clippings, leaves, dirt, or other debris. If this debris is
allowed to accumulate, it will result in rust and
corrosion.
NOTE: We do not recommend the use of pressure
washers or garden hose to clean your unit. These may
cause damage to electric components, spindles,
pulleys, bearings, or the engine. The use of water will
result in shortened life and reduce serviceability.
• Disconnect spark plug wire.
• Drain the gasoline from the lawn mower, or place a
piece of plastic under the gas cap.
• Tip the mower so that it rests on the housing. Keep
the side with the air cleaner facing up. Hold the
mower firmly.
• Scrape and clean the underside of the deck with a
suitable tool. Do not spray with water.
• Put the mower back on its wheels on the ground. If
you had put plastic under the gas cap, make sure to
remove it now.
WARNING:
90 degrees in any directions and do not leave
the mower tipped for any length of time. Oil can
drain into the upper part of the engine causing
a starting problem.
Never tip the mower more than
Engine Care
A list of key maintenance jobs required for good
performance by the mower is given below. Follow the
accompanying engine manual for detailed list and
instructions.
• Change engine oil regularly, as instructed in the
engine manual. Check oil level before starting
engine every time.
• Service air cleaner regularly. You may have to
service this more frequently if you are operating the
mower under extremely dusty conditions.
• Clean the engine periodically. Remove dirt and
debris with a cloth or brush.
• Clean the spark plug and reset the gap to .030” at
least once a season. Refer to the engine manual for
correct spark plug type.
• Inspect muffler periodically, and replace if
necessary. Damaged mufflers or spark arresters
can create a fire hazard.
WARNING:
areas while the mower engine is hot because
temperature of these areas of the engine may
exceed 150
Avoid muffler and surrounding
o
F.
12
Page 13
Lubrication
Lube
Lube
Lube
Lube
Figure 9: Lubrication Chart
Wheels
• Lubricate the wheels and bearings, if so equipped, at
least once a season with light oil or engine oil. Also, if the
wheels are removed for any reason, lubricate the surface
of the axle and the inner surface of the wheel with light oil.
Mulch Plug & Rear Discharge Door
• Lubricate the torsion spring and the pivot point on each
end of the rear discharge door using a light oil.
Transmission
• The transmission is pre-lubricated and sealed at the
factory and does not require lubrication on a regular basis
as part of maintenance.
Blade Control
• Lubricate the pivot points on the blade control handle and
the brake cable at least once a season with a light oil. It
needs to move in both directions.
Engine
• Follow the engine manual instructions and recommended
schedule for lubricating engine components.
Blade Care
• Periodically inspect the blade adapter and pulley for
cracks, especially if you strike a foreign object. Replace
when necessary.
WARNING:
blade for sharpening or replacement, protect
hands by using heavy gloves or a thick rag to
grasp the cutting blade.
• Disconnect spark plug wire from spark plug.
When removing the cutting
• Turn mower on its side making sure that the air filter and
the carburetor are up.
To Remove Blade:
• Remove the hex bolt which holds the blade adapterpulley assembly to the engine crankshaft. See Figure 10 .
Remove the pulley assembly and the bell support from
the crankshaft.
• Remove blade from the blade adapter and pulley.
Adapter-Pulley
Assembly
Blade
Blade Bell
Support
Hex Bolt
Figure 10
To Replace Blade:
• Before reinstalling the blade-pulley assembly to the unit,
lubricate the engine crankshaft and the inner surface of
the blade adapter with light oil.
• Also lubricate the bolt hole and the hex bolt.
• Insert the hex bolt, earlier removed, through the center
holes on the blade bell support and the blade adapterpulley assembly respectively.
• Install the blade assembly on the crankshaft. Tighten the
hex bolt to the recommended torque.
Blade Mounting Torque:
Center bolt: 450 in.lbs. minimum, 600 in.lbs. maximum.
IMPORTANT:
is specially heat-treated.
replacement bolt, refer to the parts list in the back of this
manual.
The bolt used to secure the blade to the engine
Do not substitute.
WARNING:
your unit, all nuts and bolts must be checked
periodically for correct tightness.
To ensure safe operation of
To order
To Sharpen Blade:
• The blade can be sharpened with a file or on a grinding
wheel. Do not attempt to sharpen the blade while it is still
on the mower.
• Follow the original angle of grind as a guide. Make sure
that each cutting edge receives an equal amount of
grinding to prevent an unbalanced blade.
NOTE:
when rotating at high speeds, may cause damage to the
mower and could break, causing personal injury. Test the
blade by balancing it on a round shaft screwdriver or a blade
balancer.
• If the blade is not balanced, remove metal from the heavy
13
An unbalanced blade will cause excessive vibration
side until it balances evenly.
Page 14
SECTION 7: SERVICE & ADJUSTMENTS
Replacing Drive Belt
• Remove two shoulder screws securing the front
drive cover to the mower deck. See Figure 11.
Loosen this screw
Belt
Shoulder
Screw
Shoulder
Transmission
Screw
Figure 11
• Press inward on the sides of the front drive cover
and release the tabs that secure the front drive
cover to the height adjuster brackets. Remove drive
cover from the mower.
• Using a torx wrench, loosen the screw holding the
belt tension spring to the transmission. See Figure
11. Do not remove the screw completely. As you
loosen the screw, tension on the belt will release.
• Push the transmission up a little and slide the belt
off the transmission pulley.
• Lift the mower to access the belt from the underside
of the mower.
WARNING:
Use a thick piece of rag to
handle the blade while sliding the belt in the
next step. Make sure the engine does not start
at all while doing this job.
• Slide the belt off the engine pulley and around the
blade. See Figure 12 .
• Replace with the new belt, working around the
blade. Make sure the belt is firmly seated on the
engine pulley while pulling from the other side and
sliding it around the transmission pulley.
• Put the mower down with all four wheels firmly
placed on one level.
Front Drive
Cover
• Tighten the screw, loosened earlier, to secure the
belt tension spring to the transmission, and
reassemble the front drive cover.
Right Front
Wheel
Engine Pulley
Left Front
Wheel
Figure 12
Replacing Rear Flap
• To remove rear flap, cut off the flat end of the wire
rod which secures it to the deck. See Figure 13 .
• Attach the new flap and new rod to deck, bending
the ends of the new rod over to secure to deck.
Rear Discharge
Door
Handle
Bracket
W
d
o
R
e
r
i
Handle
Bracket
Rear
Flap
Figure 13
Adjusting Cutting Height
IMPORTANT:
relative position. For rough or uneven lawns, move the
height adjustment lever to a higher position. This will
help stop scalping of the grass.
An adjusting plate and thumb lever at each wheel
provides cutting height adjustment. Each adjusting
plate has nine height positions. Height of cut will be
changed when you move the thumb lever from one
position to another.
• Simply depress the lever towards the wheel and
move the lever assembly to desired position. See
Figure 14 .
• For rough or uneven lawns, move the height
adjustment handles to higher cutting height position
All wheels must be placed in the same
14
Page 15
.
Height Adjustment
Lever
.
Bottom View
Figure 14
Drive Clutch Control
The adjustment wheel is located in the drive clutch
control handle housing and is used to tighten or loosen
the drive belt. You will have to adjust the drive clutch
control if any of the following happens:
1. The mower does not propel itself with the drive
clutch engaged;
2. The mower’s drive wheels hesitate with the drive
clutch engaged.
To resolve the above problems, rotate the adjustment
wheel clockwise to tighten the cable and
counterclockwise to loosen the cable. See Figure 15.
Adjustment
Wheel
Figure 15
NOTE: For some people the drive clutch control may
not be in a comfortable position. You can adjust the
handle by tightening the adjustment wheel.
Upper
Handle
Drive Clutch
Control
Engine Adjustments
See the engine manual for adjustments to the engine.
Adjusting Carburetor
If the engine is running rough, minor adjustments to the
carburetor may be required to compensate for
differences in fuel, temperature, altitude and load.
NOTE: Dirty air cleaner may cause an engine to run
rough.Before adjusting carburetor, check air cleaner.
To adjust the carburetor, please follow the
recommendations and instructions on carburetor
adjustment in the engine manual.
SECTION 8: OFF-SEASON STORAGE
Prepare your lawn mower for storage at the end of the
season or if the unit will not be used for 30 days or
more. Store the mower in a clean, dry area.
Mower
• Clean underside of the mower following
instructions in the Maintain Your Lawn Mower
section of this manual.
• Lubricate mower as instructed on page 11.
• You can fold your mower’s handle for convenient
storage: Remove the starter rope from the rope
guide; loosen the two hand knobs on the sides of
the handle, and let the upper handle fold down to
the rear. Move the hairpin clips to the outer hole in
WARNING:
the engine (e.g. carburetor) while the engine is
running, keep clear of all moving parts. Be
careful of heated surfaces like the muffler.
the weld pins on the handle mounting brackets.
Spread the sides of the lower handle, and push it
forward and down.
• Inspect and replace/sharpen blade, if required.
If any adjustments are made to
Engine
IMPORTANT:
from forming in essential fuel system parts such as the
carburetor, fuel filter, fuel hose, or tank during storage.
Also, alcohol blended fuels (called gasohol or using
ethanol or methanol) can attract moisture which leads
to separation and formation of acids during storage.
Acidic gas can damage the fuel system of an engine
while in storage.
It is important to prevent gum deposits
15
Page 16
NOTE:
emptying the tank of fuel in minimizing the formation of
fuel gum deposits during storage.
• Add stabilizer to gasoline in fuel tank (on model 569
• Do not drain the gas tank and carburetor if using
In all cases, drain all the oil from the crankcase (this
should be done after the engine has been operated and
is still warm) and refill the crankcase with fresh oil.
When you visually see that the fuel preserver cartridge
is empty(model 569), replacement cartridges are
available through your local Troybilt Service Dealer.
If you do not use FreshStart™ or other fuel stabilizer,
follow these instructions:
Fuel stabilizer is an acceptable alternative to
if FreshStart™ fuel preserver cartridge is empty) or
storage container.
fuel stabilizer.
SECTION 9: TROUBLE-SHOOTING
• Drain the fuel from the tank by running the engine
until the fuel tank is empty.
• Remove spark plug, pour approximately 1/2 ounce
(approximately one tablespoon) of engine oil into
cylinder and crank slowly to distribute oil.
• Replace spark plug.
• Follow recommendations in the engine manual for
off-season storage of the engine.
• Clean engine and remove any grass clippings.
Other
• Do not store gasoline from one season to another.
• Replace your gasoline can if it starts to rust. Rust
and/or dirt in the gasoline will cause problems.
Store unit in a clean, dry area. Do not store next to
corrosive materials, such as fertilizer.
NOTE: If storing in an unventilated or metal storage
shed, be certain to rustproof the equipment by coating
with a light oil or silicone.
Problem Possible Cause Corrective Action
Engine fails to start 1. Blade control handle disengaged
2. Spark plug wire disconnected
3. Fuel tank empty, or stale fuel
4. Blocked fuel line
5. Faulty spark plug
6. Engine flooded
Engine runs erratic 1. Spark plug wire loose
2. Blocked fuel line or stale fuel
3. Vent in gas cap plugged
4. Water or dirt in fuel system
5. Dirty air cleaner
Engine overheats 1. Engine oil level low
2. Air flow restricted
Occasional skip
(hesitates) at high
speed
Idles poorly 1. Spark plug faulty, or gap too wide
Excessive vibration 1. Blade loose or unbalanced
Mower will not
mulch grass
Uneven cut 1. Wheels not at same height
1. Spark plug gap too close 1. Adjust gap to.030 inches.
2. Dirty air cleaner
2. Bent cutting blade
3. Bent engine crankshaft
1. Wet grass
2. Excessively high grass
3. Dull blade
2. Dull blade
1. Engage blade control handle.
2. Connect wire to spark plug.
3. Fill up tank with fresh gasoline.
4. Clean fuel line.
5. Clean, adjust gap, or replace.
6. Wait a few minutes to restart, Do not prime.
1. Connect and tighten spark plug wire.
2. Clean fuel line, fill tank with fresh gasoline.
3. Clear vent.
4. Drain fuel tank. Refill with fresh fuel.
5. Clean air cleaner. Refer to engine manual.
1. Fill crankcase with proper oil.
2. Clean lawn mower engine.
1. Reset gap to.030 inches or replace spark plug.
2. Clean air cleaner.
1. Tighten blade and adapter, balance blade.
2. Replace blade.
3. Contact the nearest service center
1. Wait until grass is dry to cut.
2. Mow once at a high cutting height, then mow.
again at desired height.
3. Sharpen or replace blade.
1. Reposition all wheels at same height.
2. Sharpen or replace blade.
NOTE: For repairs beyond the minor adjustments listed above, contact your local authorized service dealer.
16
Page 17
NOTES
17
Page 18
SECTION 10: PARTS LIST FOR MODEL SERIES 566 & 569
35
36
37
50
54
56
63
43
55
57
40
49
53
52
11
42
26
7
48
27
28
29
8
32
9
33
30
31
5
2
1
59
62
6
58
60
59
39
61
51
41
42
45
38
59
44
62
12
13
4
3
46
47
8
20
19
18
17
16
15
14
34
22
21
23
24
25
10
9
18
Page 19
Model Series 566 & 569
Ref.
No
1. 710-0599 TT Screw 1/4-20 x 0.5
2. 736-0270 Bell Washer.265 x 0.75
3. 17032A Deflector Chute Adapter
4. 732-1014 Torsion Spring
5. 747-0710 Hinge Pin
6. 710-0654A Self-Tapping Sems Screw
7. 787-01222 21” Deck
8. 710-0216 Hex Screw 3/8-16 x.75
9. 712-0431 Hex Nut 3/8-16
10. 782-5002B Front Baffle
11. 750-04404 Sleeve Spacer 9.10” Lg.
12. 750-04405 Slev. Spacer 1.5” Lg.
13. 734-04018A Wheel 8 x 2.125 Gear
14. 716-0865 Snap Ring
15. 717-1762 Gear 14T RH FWD
16. 782-7551A Wheel Dust Cap
17. 716-0102 Snap Ring
18. 736-0474 Washer
19. 687-02018 Lever Assembly RH
20. 687-02044 Pivot Plate Assembly
21. 782-0512B Height Adjuster Plate - RH
22. 736-0447 Wave Washer
23. 748-0355 Bearing Support
24. 741-0604A Bearing Sleeve
25. 732-0708 Bearing Retainer
26. 687-02057 Handle Bracket Assembly - LH
27. 687-02033 Handle Bracket - RH
28. 687-02039 Pivot Bar RH
29. 732-0866 Height Adjustment Lever
30. 720-0312 Foam Grip
*Not Pictured in Illustration
Part No. Description
717-1761 Gear 14T LH FWD *
782-0511A Height Adjuster Plate - LH*
687-02056 Handle Bracket Assembly - RH*
687-02031 Handle Bracket - LH*
687-02040 Pivot Bar LH*
Ref.
No
31. 738-0507B Shoulder Scr.500 Dia. x.434
32. 710-1652 Tt Screw 1/4-20 x.625”
33. 734-04127 Wheel, 12 x 2.125
34. 715-0221 Dowel Pin
35. 712-0116 Hex Jam Nut 5/16-24
36. 736-0105 Bell Washer.325 x.930 x.45
37. 756-04132 Pulley, 3.82 x.313 x.68
38. 732-04273 Compression Spring
39. 711-04317 Pinion Shaft
40. 731-05099 Upper Housing
41. 731-04883 Lower Housing
42. 710-04329 Torx Screw
43. 711-04304 Output Shaft
44. 682-0511A Height Adjustment Assembly LH
45. 618-04274 Transmission Assembly Comp.*
46. 720-0426 Adjustment Knob
47. 732-0706 Front Lever RH
48. 712-3005 Hex Flange Lock Nut 3/8-16
49. 707-04409 Shifter Fork
50. 707-04567 Transmission Bracket
51. 717-04194 28 Tooth Gear
52. 715-0129 Spirol Pin
53. 415-04030 Dowel Pin
54. 726-04043 Push Nut
55. 731-05187 Clutch Lever
56. 736-04178 Slotted Washer
57. 721-04110 O-ring
58.‘ 736-04170 Flat Washer
59. 721-04107 Oil Seal
60. 741-04116 Ball Bearing
61. 710-04374 Hex Screw
62. 741-04106 Plastic Bushing
63. 436-0572 Flat Washer
Part No. Description
682-0512A Height Adjustment Assembly RH*
732-0707 Front Lever LH*
19
Page 20
Model Series 566 & 569
4
3
15
13
7
10
2
42
8
43
12
17
27
1
11
16
9
6
18
21
20
24
22
19
25
23
29
32
26
34
30
33
28
31
39
44
40
41
38
14
47
37
5
45
46
35
14
36
20
Page 21
Model Series 566 & 569
Ref. No Part No. Description
1. 731-04204 Deluxe Bail Cover
2. 731-1059 Cable Mounting Cap
3. 731-1058 Control Cover Lower Half
4. 731-1057 Control Cover Upper Half
5. 787-01258 Cable Mount Bracket
6. 747-1161A Blade Control Handle
7. 749-04206 Upper Handle
8. 720-0279 Handle Knob
9. 720-0284 Handle Knob
10. 710-1205 Eye Bolt
11. 746-0957 Control Cable 37.25"
12. 710-1174 Carriage Bolt 5/16-18 x 2.0
13. 731-0620 Drive Control Lever
14. 710-0599 TT Screw 1/4-20 x 0.5
15. 746-04206
Drive Cable
16. 726-0240 Cable Tie
17. 749-0928A Lower Handle
18. 664-04011 Grassbag Assembly
19. 747-04080 Grass Bag Frame
20. 731-04998 Rear Trailing Shield
21. 732-0700 Wire
22. 731-04134A Rear Discharge Door
23. 747-0996 Pivot Rod
24. 750-04162 Spacer.375 x.50 x 1.02
Ref. No Part No. Description
25. 732-04089A Torsion Spring LH
732-04090A Torsion Spring RH
26. 714-0104 Cotter Pin
27. 712-0397 Wing Nut
28. 710-0703 Carriage Bolt 1/4-20
29. 710-0286 Machine Screw 1/4-20
30. 712-04064 Flange Lock Nut 1/4-20
31. 710-04371 HL Screw 1/4-15
32. 731-04150 Rear Baffle 21” Rd.
33. 731-04177 Chute Deflector
34. 687-02055 Mulch Plug Comp.
35. 710-1650 Shoulder Screw # 12 -24
36. 731-05020 Transmission Cover
37. 754-04082 V-Belt
38. 748-04015A Blade Adapter w/ Pulley
39. 742-0741 21” Mulching Blade
40. 736-0524B Blade Bell Support
41. 710-1257 Hex Screw 3/8-24 x 2.50
42. 710-1667A HL Screw #10-16
43. 736-0451 Saddle Washer
44. 687-02150 Belt Keeper Engine Bracket
45. 711-0993 Belt Guard Pin 1/4 x 1.43
46. 712-3055 Hex Lock Nut 1/4 x 20
47. 732-04286 Extension Spring
IMPORTANT: For a proper working machine, use
Factory Approved Parts. V-BELTS are specially
designed to engage and disengage safely. A
substitute (non OEM) V-Belt can be dangerous by
not disengaging completely.
21
Page 22
NOTES
22
Page 23
NOTES;
23
Page 24
MANUFACTURER’S LIMITED WARRANTY FOR:
The limited warranty set forth below is given by Troy-Bilt LLC
with respect to new merchandise purchased and used in the
United States, its possessions and territories.
“Troy-Bilt” warrants this product against defects in material
and workmanship for a period of two (2) years commencing
on the date of original purchase and will, at its option, repair or
replace, free of charge, any part found to be defective in
materials or workmanship. This limited warranty shall only
apply if this product has been operated and maintained in
accordance with the Operator’s Manual furnished with the
product, and has not been subject to misuse, abuse,
commercial use, neglect, accident, improper maintenance,
alteration, vandalism, theft, fire, water, or damage because of
other peril or natural disaster. Damage resulting from the
installation or use of any part, accessory or attachment not
approved by Troy-Bilt for use with the product(s) covered by
this manual will void your warranty as to any resulting
damage.
Normal wear parts are warranted to be free from defects in
material and workmanship for a period of thirty (30) days from
the date of purchase. Normal wear parts include, but not
limited to items such as: batteries, belts, blades, blade
adapters, grass bags, rider deck wheels, seats, snow thrower
skid shoes, shave plates, auger spiral rubber and tires.
HOW TO OBTAIN SERVICE: Warranty service is available,
WITH PROOF OF PURCHASE, through your local authorized
service dealer. To locate the dealer in your area, check your
Yellow Pages, or contact Troy-Bilt LLC at P.O. Box 361131,
Cleveland, Ohio 44136-0019, or call 1-866-840-6483 or 1330-558-7220, or log on to our Web site at www.troybilt.com.
This limited warranty does not provide coverage in the
following cases:
a. The engine or component parts thereof. These items
may carry a separate manufacturer’s warranty. Refer
to applicable manufacturer’s warranty for terms and
conditions.
b. Log splitter pumps, valves, and cylinders have a
separate one year warranty.
c. Routine maintenance items such as lubricants, filters,
blade sharpening, tune-ups, brake adjustments, clutch
adjustments, deck adjustments, and normal
deterioration of the exterior finish due to use or
exposure.
d. Service completed by someone other than an
authorized service dealer.
e. Troy-Bilt does not extend any warranty for products
sold or exported outside of the United States, its
possessions and territories, except those sold through
Troy-Bilt’s authorized channels of export distribution.
f. Replacement parts that are not genuine Troy-Bilt parts.
g. Transportation charges and service calls.
No implied warranty, including any implied warranty of
merchantability of fitness for a particular purpose,
applies after the applicable period of express written
warranty above as to the parts as identified. No other
express warranty, whether written or oral, except as
mentioned above, given by any person or entity,
including a dealer or retailer, with respect to any product,
shall bind Troy-Bilt. During the period of the warranty, the
exclusive remedy is repair or replacement of the product
as set forth above.
The provisions as set forth in this warranty provide the
sole and exclusive remedy arising from the sale. Troy-Bilt
shall not be liable for incidental or consequential loss or
damage including, without limitation, expenses incurred
for substitute or replacement lawn care services or for
rental expenses to temporarily replace a warranted
product.
Some states do not allow the exclusion or limitation of
incidental or consequential damages, or limitations on how
long an implied warranty lasts, so the above exclusions or
limitations may not apply to you.
In no event shall recovery of any kind be greater than the
amount of the purchase price of the product sold. Alteration
of safety features of the product shall void this warranty.
You assume the risk and liability for loss, damage, or injury to
you and your property and/or to others and their property
arising out of the misuse or inability to use the product.
This limited warranty shall not extend to anyone other than
the original purchaser or to the person for whom it was
purchased as a gift.
HOW STATE LAW RELATES TO THIS WARRANTY: This
limited warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.
IMPORTANT:
Owner must present Original Proof of
Purchase to obtain warranty coverage.
Troy-Bilt LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019; Phone: 1-866-840-6483, 1-330-558-7220
24
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