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Safety • Assembly • Operation • Adjustments • Maintenance • Troubleshooting • Parts Lists • Warranty
OPERATOR’S MANUAL
21-inch Self-Propelled Mulching Mower — Model 569
IMPORTANT
READ SAFETY RULES AND INSTRUCTIONS CAREFULLY BEFORE OPERATION
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.
PRINTED IN U.S.A
TROYBILT LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019
FORM NO. 769-02344
1/23/2006
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This Operator’s Manual is an important part of your new lawn mower. It will help you assemble,
www.troybilt.com
TROY-BILT LLC
P. O. BOX
36 1 13 1
CLEVELAND, OH 44136
866-840-6483
330-558-7220
prepare, and maintain the unit for best performance. Please read and understand what it says.
Table of Contents
3
Slope Gauge .......................................................
Safe Operation Practices ................................... 4
Setup and Adjustment ....................................... 6
Operating Your Lawn Mower .............................. 8
Maintaining Your Lawn Mower ......................... 10
Troubleshooting ................................................ 12
Off-Season Storage and Safety Labels .......... 13
Parts List ........................................................... 14
Warranty ............................................ Back Cover
Finding and Recording Model Number
BEFORE YOU BEGIN ASSEMBLING YOUR NEW EQUIPMENT, please locate the model plate on the equipment and
copy the information to the sample model plate provided to
the right. 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, to obtain assistance from the Customer Support
Department, or when contacting an authorized service dealer.
Model Number Serial Number
Customer Support
Please do
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.
• Visit www.troybilt.com for many useful suggestions. Click the Customer Support button.
• Phone a Customer Support Representative at 1-866-840-6483
• The engine manufacturer is responsible for all engine-related issues with regards to performance, power-rating, specifica
tions, warranty and service. Please refer to the engine manufacturer’s Owner’s/Operator’s Manual, packed separately with
your unit, for more information.
NOT
return the unit to the retailer from which it was purchased, without first
contacting Customer Support.
.
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Use this page as a guide to determine slopes where you may not operate safely. Do not operate
your lawn mower on such slopes.
1
Slope
Gauge
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 walkbehind 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.
3
Operate
WALK-BEHIND
mowers across the
face of slopes, never
up and down slopes.
Page 4
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.
2
Safe
Operation
Practices
WARNING
This symbol points
out important safety
instructions which, if
not followed, could
endanger 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
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.
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 instructions could result in serious injury or death.
Children
Tragic accidents can occur if operator is not alert to presence
of children. Children are often attracted to mower and 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 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 operation instructions and safety rules in this
manual and should be trained and supervised by a parent.
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 instructions in this manual and should
be trained and supervised by a parent. Only responsible
individuals who are familiar with these rules of safe
operation should be allowed to 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 a thrown object injury,
stay in operator zone behind handles and keep children,
bystanders, helpers, and pets at least 75 feet from mower
while it is in operation. Stop machine if anyone enters
area.
6. Always wear safety glasses or safety goggles during opera
tion 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 close-fitting
slacks and shirts. Shir ts 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 cutting
deck. Contact with 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 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.
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 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.
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. Mow only in daylight or good artificial light. Walk, never run.
17. Stop the blade when crossing gravel drives, walks 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 unclog
ging the chute.
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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 trailshield, 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.
21. Muffler and engine become hot and can cause a burn. Do
not touch.
22. Only use parts and accessories made for this machine by
manufacturer. Failure to do so can result in personal injury.
23. If situations occur which are not 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.
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. For your
safety, use the slope gauge included as part of this manual to
measure slopes before operating this unit on a sloped or hilly
area. 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 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:
1. Do not mow near drop-offs, ditches or embankments, where
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.
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. 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 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 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
engine.
13. Never store the machine or fuel container near 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 equip
ment is in safe working condition.
6. Never tamper with safety devices. Check their proper opera
tion regularly.
7. After striking a foreign object, stop the engine, discon
nect 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 im
mediately 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 labels, as necessary.
12. Observe proper disposal laws and regulations. Improper
disposal of fluids and materials can harm the environment.
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2
Safe
Operation
Practices
WARNING
This symbol points
out important safety
instructions which, if
not followed, could
endanger 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
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.
5
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3
Setup and
Adjustment
NOTE: Stand behind
the mower as if you
were going to operate
it. Your right hand corresponds to the right
side of the mower; your
left hand corresponds
to the left side of the
mower.
IMPORTANT
DO NOT crimp the
cables when lifting the
handle up. Make sure
to route the cables
under the lower handle.
IMPORTANT
This unit is shipped
without gasoline or
oil in the engine. Fill
up gasoline and oil
as instructed in the
accompanying engine
manual BEFORE
operating your mower.
1. Remove any packing material which may be between
upper and lower handles.
a. Pull up and back on upper handle as shown in
A
B
Step 1
B
A
Step 2
A
Step 1. Make certain the lower handle is seated
securely into the handle mounting brackets.
b. Tighten star knobs securing upper handle to
lower handle. Make sure that each carriage bolt is
seated properly in the handle.
2. Locate hairpin clip on the weld pin on each side of
lower handle.
a. Remove hairpin clip from this hole. Using a pair of
pliers, insert hairpin clip into the other hole on the
weld pin. Repeat on other side.
b. Insert a carriage bolt from the hardware pack into
the upper hole on the handle mounting bracket.
Secure with one plastic wing nut, also included in
the hardware pack. Repeat on other side.
3. The rope guide is attached to the right side of the
upper handle. Loosen the wing nut which secures the
rope guide.
a. Hold the blade control against upper handle.
b. Pull starter rope out of the engine. Release the
blade control.
c. Slip starter rope into rope guide.
d. Tighten wing nut.
Insert post on cable ties into holes provided on the
lower handle. Pull cable tie tight around cables and
handle and trim excess.
4. Follow steps below to assemble the grass catcher:
a. Place bag over frame so that its black plastic side
is at the bottom.
b. Slip plastic channel of grass bag over hooks on the
frame. See Step 4. All the plastic channels except
center top of bag attach from outside of bag.
c. Attach center top of bag from inside of bag.
A
B
D
C
Step 3
B
Step 4
C
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5. Follow steps below to attach grass catcher:
a. Lift rear discharge door.
b. Place grass catcher on the pivot rod. Let go of discharge door so that it rests on the grass catcher, Step 5.
WARNING: Never operate mower unless the hooks on the grass catcher are firmly seated on the
pivot rod and the rear discharge door rests firmly against top of the grass catcher.
To remove grass catcher or convert to a mulcher (if equipped), lift rear discharge door on the mower. Lift grass
catcher up and off of the pivot rod. Release rear discharge door to allow it to close rear opening of mower.
6. If coverting to side discharge, make sure grass catcher is off unit and rear discharge door is closed.
a. Lift mulching plug on the right side of mower.
b. Slide two hooks of side discharge chute under the hinge pin on the mulching plug assembly and lower the
side mulching plug. See Step 6.
NOTE: Do not remove the side mulching plug at any time, even when you are not mulching.
B
A
3
Setup and
Adjustment
CUTTING HEIGHT
All wheels must be
placed in the same
position.
GRASS CATCHER
Make certain bag is
turned right side out
before assembling
(warning label will be
on the outside).
Step 5
Adjustments
Cutting Height
A cutting height adjustment lever is located at each
wheel, Step 7.
a. Pull the lever out and away from the mower.
b. Move the lever forward or back for desired cutting
height.
c. Release lever towards mower deck.
2
1
3
Step 6
Drive Control
The adjustment wheel is located in the drive control
handle housing and is used to tighten or loosen the
drive belt. You will need to adjust the drive control if
the mower does not propel itself with the drive control
engaged or if the mower’s wheels hesitate with the drive
control engaged. If either of these conditions occur,
rotate the adjustment wheel clockwise to tighten the
cable or counterclockwise to loosen the cable, Step 8.
WARNING
Never operate mower
unless the hooks on
the grass catcher are
firmly seated on the
pivot rod and the rear
discharge door rests
firmly against top of
the grass catcher.
Step 7
Step 8
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Know Your Lawn Mower
4
Operating
Your Lawn
Mower
WARNING
The blade control is a
safety device. Never
attempt to bypass its
operations.
Use extreme care
when 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.
Keep hands and feet
away from the chute
area on cutting deck.
Refer to warning
label on the unit.
Drive Control
Recoil Starter
Mulching Plug
Side Discharge Chute
Now that you have set up your lawn mower, it’s
important to become acquainted with its controls
and features.
Blade Control
Figure 1
Blade Control
The blade control is attached to the upper handle
of the mower. Depress and squeeze it against the
upper handle to operate the unit. Release it to stop
engine and blade.
WARNING: This blade control is a safety
device. Never attempt to bypass its
operations.
Drive Control
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; release it to slow down or stop mower from
propelling.
Mulching Plug
The mulching plug is used only for mulching
purposes. Instead of collecting the grass clippings
in the grass catcher, your mower has the option of
recirculating the clippings back to the lawn. Make
sure that the rear discharge door is closed and the
grass catcher is removed from unit while mulching.
Cutting Height
Adjustment
Levers (one at
each wheel)
Cutting Height Adjustment Levers
One adjustment lever is located at each wheel and is
used to adjust the cutting height. All four levers must
be set to the same position to ensure a uniform cut.
Side Discharge Chute
Instead of collecting grass clippings in the bag, you may
attach the side discharge chute to expel the clippings.
Recoil Starter
The recoil starter is attached to the right upper
handle. Stand behind the unit and pull the recoil
starter rope to start the unit.
Gas and Oil Fill-Up
Refer to engine manual for details.
1. Check oil level and add oil if necessary.
2. Service the engine with gasoline as instructed in the
engine manual.
WARNING: Use extreme care when
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. The operation of
any lawn mower can result in foreign objects being
thrown into the eyes, which can damage your eyes
severely. Always wear safety glasses while operating
or maintaining the mower.
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Starting Engine
WARNING: Be sure no one other than the
operator is standing near the lawn mower
while starting engine or operating mower.
Never run engine indoors or in enclosed, poorly
ventilated areas. Engine exhaust contains carbon
monoxide, an odorless and deadly gas. Keep hands,
feet, hair and loose clothing away from any moving
parts on engine and lawn mower.
4
Operating
Your Lawn
Refer to the engine manual for further details.
1. Place the fuel valve lever found on the left side of the
engine into the ON (OPEN) position, Figure 2.
2. Move the choke lever all the way backward into the
choke position.
3. Standing behind the mower, squeeze the blade control
against upper handle, Figure 2. The choke will now
begin to slowly return to the off choke position after
activating the blade control. Therefore, quickly move
onto step four below.
4. Holding these two handles together firmly, grasp recoil
starter handle and pull rope out with a rapid, continu
ous, full arm stroke, Figure 2. Keeping a firm grip on
the starter handle let the rope rewind slowly. Repeat
until engine cranks. Let the rope rewind each time
slowly.
-
Stopping Engine
1. Release blade control to stop the engine and blade.
2. Disconnect spark plug wire from spark plug and
ground against the engine.
WARNING: Wait for the blade to stop
completely before doing any work on the
mower or to remove the grass catcher.
Using Your Lawn Mower
WARNING: Never operate your mower
without either the rear door or the entire
grass catcher assembly firmly secured.
Be sure 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.
WARNING: If you strike a foreign object,
stop the engine. Remove wire from the
spark plug, thoroughly inspect mower for
any damage, and repair damage before restarting
and operating. Extensive vibration of mower during
operation is an indication of damage. The unit should
be promptly inspected and repaired.
Figure 2
1. Once the engine is running, squeeze the drive
control to propel mower. For best results, do not cut
wet grass and never cut off more than one-third of
the total length of the grass.
Using as Mulcher
For mulching grass, remove the grass catcher from the
mower. The rear discharge door should be closed.
• For effective mulching, do not cut wet grass.
• New or thick grass may require a narrower cut.
Adjust ground speed according to condition of lawn.
• If the grass has been allowed to grow in excess of
four inches, mulching is not recommended. Use the
grass catcher to bag clippings instead.
Using Grass Catcher
You can use the grass catcher to collect clippings while
you are operating the mower.
1. Attach grass catcher following instructions in Setup
section. Grass clippings will automatically collect in
bag as you run mower. Operate mower till grass bag
is full.
2. Stop engine completely by releasing the blade
control handle. Make sure that the unit has come to
a complete stop.
3. Lift discharge door and pull grass bag up and away
from the mower to dispose of the grass clippings.
Mower
WARNING
The operation of any
lawn mower can result
in foreign objects being
thrown into the eyes,
which can damage
your eyes severely.
Always wear safety
glasses while operating
the mower, or while
performing any adjustments or repairs on it.
Be sure no one other
than the operator is
standing near the
lawn mower while
starting engine or
operating mower. Never
run engine indoors 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 moving
parts on engine and
lawn mower.
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5
Maintaining
Your Lawn
Mower
WARNING
Always stop engine,
disconnect spark
plug, and ground
against engine before
cleaning, lubricating
or doing any kind of
maintenance on your
machine.
Figure 3
Lubrication
• Lubricate pivot points on the blade control handle at
least once a season with light oil. The blade control
must operate freely in both directions. See Figure 3.
• Lubricate the wheels at least once a season with
light oil (or motor oil). If wheels are removed for any
reason, lubricate surface of the pivot arm and inner
surface of the wheel with light oil. See Figure 3.
• Lubricate the torsion spring and pivot point on the rear
discharge door periodically with light oil to prevent
rust. See Figure 3
• The transmission is pre-lubricated and sealed at the
factory and does not require lubrication.
• Follow the accompanying engine manual for engine
lubrication instructions.
.
Deck Care
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.
1. Disconnect spark plug wire. Drain gasoline from lawn
mower, or place a piece of plastic under the gas cap.
2. Tip mower so that it rests on the housing. Keep the
side with the air cleaner facing up. Hold mower firmly.
WARNING: Never tip the mower more than
90º in any direction 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.
3. Scrape and clean the underside of the deck with a
suitable tool. Do not spray with water.
4. Put the mower back on its wheels on the ground. If
you had put plastic under the gas cap earlier, make
sure to remove it now.
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.
Figure 4
General Recommendations
• Always observe safety rules when performing
any type of maintenance.
• The warranty on this lawn mower does not cover
items that have been subjected to operator abuse
or negligence. To receive full value from warranty,
operator must maintain the lawn mower as
instructed here.
• Changing of engine-governed speed will void
engine warranty.
• All adjustments should be checked at least once
each season.
• Periodically check all fasteners and make sure these
are tight.
WARNING: Always stop engine,
disconnect spark plug, and ground
against engine before performing any
type of maintenance on your machine.
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.
• Maintain oil level as instructed in engine manual.
• Service air cleaner every 25 hours under normal
conditions. Clean every few hours under extremely
dusty conditions. Refer to engine manual.
• Clean spark plug and reset the gap once a season.
Check engine manual for correct plug type and gap
specifications.
• Clean engine regularly with a cloth or brush. Keep the
cooling system (blower housing area) clean to permit
proper air circulation. Remove all grass, dirt and
combustible debris from muffler area.
Replacing Rear Flap
1. To remove rear flap, cut off the flat end of the wire rod
which secures it to the deck. See Figure 4.
2. Attach the new flap and new rod to deck, bending the
ends of the new rod over to secure to deck.
10
Page 11
Blade Care
WARNING: When removing cutting
blade for sharpening or replacement,
protect your hands with a pair of heavy
gloves or use a heavy rag to hold blade.
1. Disconnect spark plug wire from spark plug. Turn
mower on its side making sure that the air filter and
the carburetor are up.
2. Remove bolt, blade bell support, blade, and blade
adapter from the engine crankshaft. See Figure 5.
3. 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. When sharpening blade, follow
original angle of grind. Grind cutting edges equally to
keep blade balanced.
4. Remove blade from the adapter for testing balance.
Balance the blade on a round shaft screwdriver to
check. Remove metal from the heavy side until it
balances evenly.
WARNING: An unbalanced blade will
cause excessive vibration when rotating
at high speeds. It may cause damage
to mower, and could break causing
personal injury.
5. Lubricate the engine crankshaft and the inner surface
of the blade adapter with light oil. Slide the blade
adapter onto the engine crankshaft. Place the blade
on the adapter such that the side of the blade marked
“Bottom” (or with part number) faces the ground when
the mower is in the operating position. Make sure that
blade is aligned and seated on blade adapter flanges.
6. Place blade bell support on the blade. Align notches
on the blade bell support with small holes in blade.
Replace hex bolt and tighten hex bolt to torque: 450
in. lbs. min., 600 in. lbs. max.
To ensure safe operation of your mower, periodically
check the blade bolt for correct torque.
Belt Care
1. Remove two shoulder screws securing front drive
cover to mower deck. See Figure 6. Press inward on
sides of front drive cover and release tabs that secure
it to the height adjuster brackets. Remove drive cover
from mower.
2. Pull up on the belt keeper wire and pivot it out away
from the drive pulley. See Figure 6 inset.
3. Roll the belt off the transmission pulley. Tip mower
on its side with the air filter up to access belt from
underside of mower. Slide belt off of engine pulley and
thread through the opening in the belt keeper bracket.
Then remove the belt from around the blade by removing over one end at a time. See Figure 7.
Figure 5
1
2
3
Figure 6
Figure 7
4. Replace with new belt, working around blade and
up through the belt keeper bracket. Make sure belt
is firmly seated on engine pulley while pulling from
the other side and sliding it around the transmission pulley. Pivot the belt keeper wire back into its
operating position and snap into the slot provided.
Reassemble front drive cover.
5
Maintaining
Your Lawn
Mower
WARNING
When removing
the cutting blade
for sharpening or
replacement or
when sliding the belt
around it, protect
your hands with a
pair of heavy gloves
or use a heavy rag to
hold the blade.
An unbalanced blade
will cause excessive
vibration when rotating at high speeds. It
may cause damage
to mower, and could
break causing personal injury.
11
Page 12
Problem
Cause
Remedy
6
Trouble
Shooting
For repairs beyond
the minor adjustments
listed here, contact
an authorized service
dealer.
Engine fails to start
Engine runs erratic
Engine overheats
1. Blade control disengaged.
2. Spark plug wire disconnected.
3. Fuel tank empty or stale fuel.
4. Fuel valve closed.
5. Faulty spark plug.
6. Blocked fuel line.
7. Engine flooded.
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.
6. Carburetor out of adjustment.
1. Engine oil level low.
2. Air flow restricted.
3. Carburetor not adjusted properly.
1. Engage blade control.
2. Connect wire to spark plug.
3. Fill tank with clean, fresh gasoline.
4. Open fuel valve. See engine manual.
5. Clean, adjust gap, or replace.
6. Clean fuel line.
7. Wait a few minutes to restart.
1. Connect and tighten spark plug wire.
2. Clean fuel line; fill tank with clean,
fresh gasoline.
3. Clear vent.
4. Drain fuel tank. Refill with fresh fuel.
5. Refer to engine manual.
6. Refer to engine manual.
1. Fill crankcase with proper oil.
2. Remove blower housing
and clean.
3. Refer to engine manual.
Occasional skips
(hesitates) at
high speed
Idles poorly
Excessive
Vibration
Mower will not
mulch grass (If
Equipped)
Uneven cut
Mower will not
self propel
1. Spark plug gap too close.
2. Carburetor idle mixture adjustment
improperly set.
1. Spark plug fouled, faulty, or gap
too wide.
2. Carburetor improperly adjusted.
3. Dirty air cleaner.
1. Cutting blade loose or unbalanced.
2. Bent cutting blade.
1. Wet grass.
2. Excessively high grass.
3. Dull blade.
1. Wheels not positioned correctly.
2. Dull blade.
1. Belt not installed properly.
2. Debris clogging drive operation.
3. Damaged or worn belt.
1. Adjust gap to .030”.
2. Refer to engine manual.
1. Reset gap to .030” or replace
spark plug.
2. Refer to engine manual.
3. Refer to engine manual.
1. Tighten blade and adapter. Balance
blade.
2. See an authorized service dealer.
1. Do not mow when grass is wet; wait
until later to cut.
2. Mow once at a high cutting height,
then mow again at desired height or
make a narrower cutting path.
3. Sharpen or replace blade.
1. Place all four wheels in same
height position.
2. Sharpen or replace blade.
1. Check belt for proper pulley installation
and movement.
2. Stop engine, disconnect spark plug
wire, and clean out debris.
3. Inspect and replace belt.
12
Page 13
Off-Season Storage
The following steps should be taken to prepare your lawn mower for storage.
1. Clean and lubricate mower thoroughly as described in
the lubrication instructions.
2. We do not recommend the use of a pressure washer
or garden hose to clean your unit.
3. Refer to engine manual for correct engine
storage instructions.
4. Coat mower’s cutting blade with chassis grease to
prevent rusting.
5. Store mower in a dry, clean area. Do not store next to
corrosive materials, such as fertilizer.
Safety Labels Found On Your Lawn Mower
When storing any type of power equipment in a poorly
ventilated or metal storage shed, care should be taken
to rust-proof the equipment. Using a light oil or silicone,
coat the equipment, especially cables and all moving
parts of your lawn mower before storage.
7
Off-Season
Storage
&
Safety
Labels
WARNING
DO NOT remove safety
(or any) labels from
mower for any reason.
13
Page 14
14
Page 15
Ref. Part No. Description
1 687-02193 Height Adj. Assembly - LH
687-02194 Height Adj. Assembly - RH
2 750-04405 Sleeve Spacer 1.8” Long
3 618-04377 Transmission
4 750-04404 Sleeve Spacer 9.10” Long
5 782-5002B Front Baffle
6 712-04065 Flange Lock Nut, 3 /8-16
7 732-0708 Bearing Retainer
8 741-0604A Sleeve Bearing
9 748-0355 Bearing Support
10 736-0447 Wave Washer
11 787-01298 Front Height Adj. Plate - RH
787-01299 Front Height Adj. Plate - LH
12 687-02044 Pivot Plate Assembly
13 732-0706 Front Lever - RH
732-0707 Front Lever - LH
14 736-0474 Flat Washer
15 716-0102 Snap Ring
16 782-7551A Wheel Dust Cap
17 717-1762 Gear 14T RH FWD RH
717-1761 Gear 14T LH FWD LH
18 710-04531 Screw 1/4-20 x .390
19 734-04018A Front Wheel 8 x 2.125
Ref. Part No. Description
20 715-0221 Dowel Pin
21 710-0216 Hex Screw, 3/8-16 x .75
22 720-0426 Adjustment Knob
23 710-0599 TT Screw 1/4-20 x .5
24 736-0270 Bell Washer
25 710-1652 TT Screw 1/4-20 x .625
26 720-0312 Foam Grip
27 738-0507B Shoulder Screw .500 Dia. x .434
28 734-04127 Rear Wheel, 12 x 2.125
29 732-0866 Rear Spring Lever
30 687-02039A Pivot Arm Assembly - RH
687-02040A Pivot Arm Assembly - LH
31 687-02192 Handle Bracket - RH
687-02191 Handle Bracket - LH
32 787-01278 21” Deck
33 710-0654A TT Screw 3/8-16 x 1
34 687-02057 Handle Bracket Assembly - LH
687-02056 Handle Bracket Assembly - RH
35 747-0710 Hinge Pin
36 732-1014 Torsion Spring
37 17032A Chute Deflector Adapter
38 987-02055 Hinged Mulch Plug Assembly
8
Parts List
To order replacement
parts, call
1-800-648-6776
or visit
www.troybilt.com
15
Page 16
4
8
1
12
6
9
5
18
17
11
13
14
19
20
10
28
16
15
2
45
3
21
44
40
23
22
24
7
46
42
41
26
39
16
38
27
34
30
31
35
37
32
36
33
43
25
29
Page 17
Ref. Part No. Description
1 746-04206A Variable Speed Cable
2 731-04150C Rear Baffle 21” Rd.
3 710-04371 Screw 1/4-15
4 731-04204 Deluxe Bail Cover
5 747-1161A Blade Control
6 749-04206 Upper Handle
7 787-01258A Cable Mount Bracket
8 753-05096A Control Lever Assembly
9 720-0279 Handle Knob
10 720-04072 Star Knob
11 710-1205 Eye Bolt
12 746-0957 Control Cable - 37.25”
13 710-1174 Carriage Bolt 5/16-18 x 2.0
14 726-0240 Cable Tie
15 714-0104 Cotter Pin
16 712-0397 Wing Nut
17 664-04011 Grassbag Assembly
18 747-04080 Grass Bag Frame
19 732-0700 Wire
20 731-04998 Trailshield
21 731-04134A Rear Discharge Door
22 750-04162 Spacer
23 732-04089A Torsion Spring - LH
732-04090A Torsion Spring - RH
Ref. Part No. Description
24 747-0996 Pivot Rod
25 731-05020A Transmission Cover (Black)
26 710-1650 Shoulder Screw # 12 -24
27 787-01265A Belt Keeper Bracket
28 749-0928A Lower Handle
29 754-04082A V-Belt
30 756-04161 Upper Pulley Half 25mm x 2.62
31 756-04160 Lower Pulley Half 25mm x 2.62
32 750-04438A Sleeve Spacer 25mm x 1.375 x .62
33 748-04082 Blade Adapter
34 736-0524B Bell Blade Support
35 736-04173 Space Washer
36 736-0250 Flat Washer
37 710-1257 Hex Screw 3/8-24 x 2.50
38 742-0741 21” Mulching Blade
39 731-04177 Side Discharge Chute
40 732-04317 Extension Spring
41 732-04294 Belt Keeper Wire
42 710-04329 Torx Screw
43 710-0896 AB Screw 1/4-14 x .625
44 710-0599 TT Screw 1/4-20 x 0.5
45 710-0703 Carriage Bolt 1/4-20
46 738-1002 Shoulder Screw .375 x .25
8
Parts List
To order replacement
parts, call
1-800-648-6776
or visit
www.troybilt.com
17
IMPORTANT: For
a proper working
machine, use Factory
Approved Parts. VBELTS are specially
designed to engage
and disengage
safely. A substitute
(non OEM) V-Belt
can be dangerous
by not disengaging
completely.
Page 18
NOTES
18
Page 19
NOTES
19
Page 20
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 are 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 ser vice
dealer. To locate the dealer in your area, check your Yellow Pages,
or contac t Troy-Bilt LLC at P.O. Box 361131, Cleveland, Ohio 44136 0019, or call 1- 866 -840 -6483 or 1-330-558-7220, 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 merchant
ability 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.
-
TROYBILT LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019; Phone: 1(866) 840-6483, 1-330-558-7220
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