Troy-Bilt 836 series Operator's Manual

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

®

21-inch Rotary Mower -- Model Series 836

READ SAFETY RULES AND mNSTRUCTmONS CAREFULLY BEFORE OPERATION

Warning: This unitis equippedwithan internalcombustionengineandshouldnotbeusedonornearanyunimprovedforest-covered,brush=
coveredor grass=coveredlandunlesstheengine'sexhaustsystemisequippedwithasparkarrestermeetingapplicablelocalorstatelaws(ifany),

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

forthe mufflerisavailablethroughyournearestengineauthorizedservicedealerorcontacttheservicedepartment,RO,Box361131Cleveland,
Ohio44136=0019,

PRINTEDIN U,S,A

MTD LLC, RO. BOX 361131 CLEVELAND, OHiO 44136-0019 FORMNO,769=01541B

11/29/2005

This Operator's Manua_ is an important part of your new lawn mower. JtwH_ he_p you assembJe,

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

Table of Contents

SJope Gauge ....................................................... 3

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

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

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

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

Finding and Recording Model Number

BEFOREASSEMBLINGYOUR NEWEQUIPMENT,please
locate the model plateon theequipmentand copythe

informationto the sample model plate providedto the right.
Youcan locatethe modelplate by standing atthe operating

positionand lookingdown at the rearof the deck. This infor-
mationwillbe necessaryto usethe manufacturer'sweb site,

obtainassistancefrom the CustomerSupportDepartment,or
whencontactingan authorizedservice dealer.

Troub{eshooting ................................................ 14

Safety Labels .................................................... 15

Parts List ........................................................... 16

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

Modet Number Serial Number

O TRI:IItf B#LT' TRO¥-BULTLLC

www.troybimt.com CLEVELAND,OH44136

P. O. BOX 361131
338-558-7228

Customer Support

P_ease DO NOT return the unit to the retai_er from which it was purchased without first

contacting Customer Support.

Ifyou havedifficulty assemblingthis product or have anyquestionsregardingthe controls,operation,or maintenanceof this
unit,youcan seekhelpfromthe experts.Choose from the options below:

1. Visit www.troybilt.com

2. Phonea CustomerSupport Representativeat 1o866o840o6483.

3. The enginemanufactureris responsiblefor all engine-relatedissues with regards to performance,power-rating,specifica-
tions,warranty,and service. Pleasereferto the engine manufacturer'sOwner's/Operator's Manual,packedseparatelywith
your unit, for more information.

2

yourlawnmoweronsuchslopes.

/

t

/

/

/

/

/

o

WARNING

w_

Do not mowon inclines

with a dope in excess

of 15 degrees (a rise

of approximately

2-"

feet). A riding r
couldoverturnand

cause serious injury.

if operatinga walb
behindmoweron such

a dope, it isextremely

footing and you could

dip, resultingin serious
injury.

OperateRiDiNG
mowersupand down

dopes, neveracross

o

3

theface of dopes.

Operate
WALK-BEHIND

mowersacrossthe

face of dopes, never

up and down slopes.

\

manual.Aswithanytypeofpowerequipment,carelessnessorerroronthepartoftheoperatorcan

resultinseriousinjury.Thismachineiscapableofamputatinghandsandfeetandthrowingobjects.

! Failuretoobservethefollowingsafetyinstructionscouldresultinseriousinjuryordeath.

Children

Tragicaccidentscan occurifoperatorisnotalertto presence
ofchildren.Childrenare oftenattractedto mowerandmowing

activity.Theydonot understandthe dangers.Neverassume
thatchildrenwill remainwhereyoulastsawthem.

1. Keepchildrenoutofthe mowingareaandunderwatchful
careof aresponsibleadultotherthanthe operator.

2. Bealertandturnmoweroffifa childentersthearea.

3. Beforeand whilemovingbackwards,look behindanddown
forsmallchildren.

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

5. Keepchildrenawayfromhot orrunningengines.Theycan
sufferburnsfroma hotmuffler.

6. Neverallowchildrenunder14yearsoldto operateapower
mower.Children14yearsold andovershouldreadand
understandoperationinstructionsandsafetyrulesinthis
manualandshouldbetrainedandsupervisedbyaparent.

endangerthepersonal
safetyand/orproperty

and followthewarnings 5. Tohelpavoidbladecontact orathrownobjectinjury, ._ generallya'_arningof!rouble.........

and i..struction2 stayinoperatorzone behindhandlesandkeepchildren, "

u _ competestop beforeremovngthe grasscatcheror uncog

, ,; bystanders,helpers,andpetsat least75feet frommower .

un_nusmanuau glngthechute

1. Readthis operator'smanualcarefullyin its entiretybefore

2. Thismachineisaprecisionpieceof powerequipment,

3. Neverallowchildrenunder 14yearsoldto operatethis

4. Thoroughlyinspecttheareawherethe equipmentisto

General Operation

attemptingtoassemblethismachine.Read,understand,
andfollow allinstructionsonthe machineandin the

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

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

machine.Children14yearsoldand overshouldreadand
understandthe instructionsinthis manualandshould

betrainedand supervisedbya parent.Onlyresponsible
individualswhoarefamiliarwiththese rulesof safe

operationshouldbeallowedtousethis machine.

beused.Removeall stones,sticks,wire,bones,toysand
otherforeignobjectswhichcould betripped overor picked
upand thrownbythe blade.Thrownobjectscancause
seriouspersonalinjury.Planyourmowingpatternto avoid
dischargeofmaterialtowardroads,sidewalks,bystanders
andthe like.Also,avoiddischargingmaterialagainsta
wallorobstructionwhichmaycausedischargedmaterial
toricochetbacktowardtheoperator.

whileit isin operation.Stopmachineifanyoneenters

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

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

8. Donotputhandsorfeet nearrotatingpartsor undercutting
deck.Contactwithbladecanamputatehandsandfeet.

9. Amissingor damageddischargecovercancauseblade
contactor thrownobject injuries.

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

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

a. Stepbackfrommowertofully extendyourarms.
b. Besureyou arewellbalancedwithsurefooting.

c. Pullthe mowerbackslowly,no morethanhalfway

towardyou.

d. Repeatthesestepsasneeded.

12.Donotoperatethe mowerwhileunderthe influenceof
alcoholor drugs.

13.Donotengage theself-propelledmechanismon unitsso
equippedwhilestartingengine.

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

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

16.Mowonlyindaylightor goodartificiallight.Walk,neverrun.

17.Stopthe bladewhencrossinggraveldrives,walksor roads.

18.Ifthe equipmentshouldstart tovibrateabnormally,stopthe
engineandcheck immediatelyforthecause.Vibrationis

]_ _nutthe engne errandwar unl: me Daaecomes-coa

and on the machine, area.

..... ,J

4

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

rotating.

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

protectivedevicesin placeandworking.Neveroperate
mowerwithdamagedsafetydevices.Failuretodo socan
resultin personalinjury.

21.Mufflerandenginebecomehotand cancauseaburn.Do

nottouch.

22.Onlyuseparts andaccessoriesmadefor thismachineby

manufacturer.Failureto dosocanresult inpersonalinjury.

23.Ifsituationsoccurwhichare not coveredinthis manual,

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

nearestdealer.

SJope Operation

Slopesareamajorfactorrelatedto slipandfallaccidentswhich
canresultinsevereinjury.Operationonslopesrequiresextra

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

Do:

1. Mowacrossthefaceof slopes;neverup anddown.

Exerciseextremecautionwhenchangingdirectionon
slopes.

2. Watchfor holes,ruts, rocks,hiddenobjects,or bumpswhich
can causeyou toslipor trip.Tallgrasscan hideobstacles.

3. Alwaysbesure ofyourfooting.A slip andfallcan cause

seriouspersonalinjury.If youfeelyouarelosingyour
balance,releasetheblade controlhandleimmediately,and

the bladewillstop rotatingwithin3seconds.

Do Not:

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

2. Donotmowslopesgreaterthan15degrees asshownon
the slopegauge.

3. Donotmowon wetgrass.Unstablefootingcouldcause

slipping.

Service

Safe HandlingOf Gaso%e:

1. Toavoidpersonalinjuryor propertydamageuseextreme
carein handlinggasoline.Gasolineisextremelyflammable

andthevaporsare explosive.Seriouspersonalinjurycan
occurwhengasolineis spilledonyourselforyourclothes

whichcanignite.

2. Washyour skinand changeclothesimmediately.

3. Useonly anapprovedgasolinecontainer.

4. Neverfill containersinsideavehicleoronatruckor trailer

bedwith a plasticliner.Alwaysplacecontainerson the
groundawayfromyourvehiclebeforefilling.

5. Removegas-poweredequipmentfromthe truck ortrailer

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

thanfroma gasolinedispensernozzle.

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

notusea nozzlelock-opendevice.

7. Extinguishallcigarettes,cigars,pipesandothersources
ofignition.

8. Neverfuelmachineindoorsbecauseflammablevaporswill
accumulatein the area.

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

10.Neveroverfillfueltank. Filltankto nomorethan_ inch
belowbottomof fillerneckto provideforfuelexpansion.

11.Replacegasolinecapandtightensecurely.

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

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

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

15.Allowamowertocool at least5 minutesbeforestoring.

General Service:

1. Neverrunanengineindoorsorina poorlyventilatedarea.
Engineexhaustcontainscarbonmonoxide,an odorlessand
deadlygas.

2. Beforecleaning,repairing,or inspecting,makecertainthe
bladeandall movingpartshavestopped.Disconnectthe
sparkplugwireandgroundagainsttheengineto prevent

unintendedstarting.

3. Checkthe bladeandenginemountingboltsatfrequent
intervalsfor propertightness.Also,visuallyinspectbladefor
damage(e.g.,bent,cracked,worn)Replacebladewiththe
originalequipmentmanufacture's(O.EM.) bladeonly,listed
inthismanual."Useofpartswhichdo notmeettheoriginal
equipmentspecificationsmayleadto improperperformance
andcompromisesafety!"

4. Mowerbladesare sharpandcancut.Wrapthebladeorwear
gloves,anduseextracautionwhenservicingthem.

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

6. Nevertamperwithsafetydevices.Checktheirproperopera-
tionregularly.

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

8. Neverattempttomakea wheelorcuttingheight adjustment
whiletheengineis running.

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

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

11.Maintainorreplacesafetylabels,asnecessary'.

12.Observeproperdisposallawsand regulations.Improper
disposaloffluidsand materialscanharmtheenvironment.

w o°,°o

ThisSymbolpoints

ua! before attemptingto

resuUt in personal injury_
::When you see th s
_symbol

,EEDMTSWARNmNG

Responsibility

Restrictthe use

of this powermachine

to personswhoread

understand

5

Standbehindthe
moweras if you were

goingto operate it,

respondsto the right
sideof the mower;your

eft handcorresponds

to the left side ofthe

mower.

Forshipping purposes
yourmower is set with

thewheels in a low

cutting heightposition.

Forbest resultsrase
thetutti ngposition

until it isdetermined
which heiaht is best

for your lawn,referto

instructions,

HandleMounting

Figure3-1:Unfoldhandleandtightenhardware,

f

Figure3-2:Securehandleto handlemountingbrackets,

asshownin Figure34. Makecertainthe lower
handleisseatedsecurelyintothe handlemounting

brackets.

b. Tightenhandknobssecuringupperhandleto

lowerhandle.Makesurethateach carriageboltis
seatedproperlyinthe handb.

2. Replaceandtightenhandknobsremovedearlbr
securinglowerhandbto handlebrackets,Figure3-2.

3. Theropeguideis attachedtotherightsideofthe
upperhandle.Loosenthewingnutwhichsecuresthe
ropeguide,Figure3-3.

a. Holdthe bladecontrolagainstupperhandle.
b. Pullstarterropeoutofthe engine.Releasethe

bladecontrol.

c. Slipstarterropeintoropeguide.
d. Tightenwingnut.

4. Securecanes to thelowerhandb usingthecane tie.
Pullcane tie tightandcutoff excess.

5. Toassembb thegrasscatcher(ifneeded),placebag
overframewiththe blackplastb sideat thebottom.
Slipplastb channeloverhooksonframe.Allchannels
exceptforcentertopof bagattachfromtheoutside.
Thecenterof bagattachesfromtheinside.

6. Beforeattachingthegrasscatcher,themulching
bafflemustberemoved,Figure3-5.

a. Lift reardischargedoor.
b. Removemulchingbaffle.

7. Toattachgrasscatcher,Figure3-4.
a. Lift reardischargedoor.
b. Placegrasscatcheronthepivotrod.Letgo

ofdischargedoorso thatit restsonthegrass
catcher.

IMPORTANT

DO NOTcrimpthe
canes when liftingthe

handb up.

iMPORTANT

without gasoline or

up gasolineandoil
as instructedin the

accompanyingengine
manual BEFORE

operating your mower,

Figure3-3:Pullrecoilstarterthroughropeguideandtighten. Figure3-4:Liftdischargedoorandplacegrasscatcheronrod.

6

8. ThebatterypackwithintheElectricStartermustbecharged8to 10hoursbeforeuse.Referto"Charging
Battery"in theMaintenancesectionforinstructions.

9. Followthestepsbelowto installthemulchingbaffle:

a. Liftthereardischargedoorandliftthe grasscatcherupandoff ofthe pivotrod,ifinstalled.

b. InsertthemulchingbaffleasshowninFigure3-5andreleasethereardischargedoor.

10.Toconverttosidedischarge,makesuregrasscatcherisoffof theunitandreardischargedoorisclosed.
a. On theside ofthe mower,liftthe mulchingplug.

b. Slidetwo hooksonsidedischargechuteunderhingepin onmulchingplugassembly,Figure3-6.Lowerthe

mulchingplug.Do notremovesidemulchingplugatany timeevenwhenyouarenotmulching.

the grass.

J

Figure3-5:Themulchingbaffle Figure3-6:Installingthesidedischargechute.

Adjustments

Cutting Height

Thecuttingheightadiustmentleverislocatedabovetherearleftwheel,Figure3-7.

a. Pulltheleveroutandawayfromthe mower.

b. Movethe leverforwardor backfordesiredcuttingheight.

c. Releaselevertowardsmowerdeck.

Drive Control

Theadiustmentwheelislocatedinthe drivecontrolhandlehousingandisusedtotightenor loosenthedrivebelt.
Youwillneedto adiustthedrivecontrolifthemowerdoesnotpropelitselfwiththedrivecontrolengagedor ifthe
mower'swheelshesitatewiththedrivecontrolengaged.Ifeitheroftheseconditionsoccur,rotatetheadiustment
wheelclockwisetotightenthe cableor counterclockwisetoloosenthecable,Figure3-8.

f

/'

,,%

drive control may not

poston You canadjust

the handle bytightening

theadjustment wheeL

i

Figure3-8:Theadjustmentwheelonthedrivecontrol.

7

Know Your Lawn Mower

Drive Control

Oil Fill

WARNING

The blade control
mechanism is a

safety device. Never
attempt to bypass its

operations.

Use extreme care
when handling

gasoline.Gasoline is
extremely flammabb

and the vapors are

explosive. Neverfuel

the machine indoors
or while the engine

is hot or running.

Extinguish cigarettes,

cigars, pipes and
other sources of

ignition.

Keep hands and feet

:way from the chute

tea on cutting deck.

Refer to warning

Jabelon the unit.

Figure4-1:The majorcomponentsonthe mower.

Now that you have setup your lawn mower for op-
eration, it's important to become aquainted with its

controls and features.

B_ade Contro_

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

WARNING: The blade control is a safety

device. Do not bypass itsoperation.

Drive Contro_

The drive controi is Iocated on the upper handIe.
Squeeze the drive control Iever to engage the drive

system. ReIease it to disengage the drive system.
To slow down when approaching an obstacle, mak-
ing a turn, or stopping, release the lever.

Cutting Height Adjustment Lever

The cutting height adiustment lever is located
above the left rear wheel To adjust the cutting
height, refer to the Adiustment Section.

Recoi_ Starter

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

starter rope to start the unit.

Mu_ching P_ug

The mulching plug is used for mulching purpose,

Instead of colbcting the grass clippings in the grass
catcher, your mower has the option of recirculating
the clippings back to the lawn, Make sure that the
rear discharge door is closed and the grass catcher is
removed from unit while mulching,

E_ectrie Starter

The ignition switch is located on the Ieft side of
the electric starter handle panel. It is necessary to
charge the battery for 8 to 10 hours before initial use.

Refer to the Maintenance section for more informa-
tion.

FreshStart TM Gas Cap (if Equipped)

This unit may be equipped with a FreshStart TM con-
tinuous fuel preserver gas cap which automatically

drips continuous fuel preserver into your fuel tank for
up to six months depending on conditions, such as
temperature, usage patterns, fuel type and blend. To
activate the gas cap, follow the instructions below:

1, Snap the fuel preserver cartridge that comes with your

unit into the fuel cap,

2, Peel off the white tab from the cartridge,
3, Twist the FreshStartTM cap onto the fuel tank,

When you visually see that the fuei preserver car-
tridge is empty, replacement cartridges are available
through your local service deaIer.

Gas and Oi_ Fii{-Up

1, Check oil level and add oil if necessary, Follow engine

manual for this,

2, Service the engine with gasoline as instructed in the

engine manual

WARNING:Usee×trernecarewhen

handling gasoline. Gasoline is e×tremely

flammable andthe vapors are explosive.
Neverfuel the machine indoors or while the engine is
hot or running. Extinguish cigarettes, cigars, pipes
and other sources of ignition.

8

WARNING:Theoperation of any lawn f
mower canresult inforeign objects being

thrown intothe eyes,whichcan damage
your eyes severely.Always wear safety glasses
while operating the moweror while performing any
adjustments or repairs on it.

l

1. Pushprimerthreetimes.Waitabouttwoseconds
betweeneachpush,Figure4=2.Intemperature

around55°Forbelow,primefivetimes.Donotprime
to restarta warmengine.

2. Standingbehindthe mower,squeezethebladecontrol
againstupperhandle,Figure4=2.

3. RecoilStart: Grasprecoilstarterhandleandpullrope
outwitha rapid,continuous,fullarm stroke,Figure
4=2.Keepinga firmgripon thestarterhandle,letthe

roperewindslowly.Repeatuntil enginecranks.Letthe
roperewindeachtimeslowly.

Electric Start: Turnignitionkeytothe rightto startthe

engine,Figure4=2.Releasethekeyaftertheengine
starts.

Stopping Engine

1. Releasebladecontroltostopthe engineandblade.

2. Disconnectsparkplugwire fromsparkplugand
groundagainsttheengine.

WARNING:Wait for the bladeto stop
completely beforedoing anywork on the

mower or to removethe grass catcher.

Figure4-2:Startingthe mower.

_ ARNING:If you strike aforeign object,
for any damage,and repair damagebefore restart-

ingand operating. Extensive vibration of mower
during operation is an indicationof damage.The
unit should be promptly inspectedand repaired.

1. Oncethe engineisrunning,squeezethedrive
controlagainsttheupperhandleto propelmower.

• For bestresults,do notcut wetgrass.
. Fora healthierlawn,nevercutoff morethanone=

thirdof thetotallengthofthe grass.

stop the engine. Removewirefrom the
spark plug,thoroughly inspectmower

Using as Mulcher

Formulchinggrass,removethegrasscatcherfrom
themowerandinstallthe mulchingbaffle.Therear
dischargedoorshouldbeclosed.

• Foreffectivemulching,do notcut wetgrass.

• Neworthickgrassmayrequirea narrowercut.
Adiustgroundspeedaccordingtoconditionoflawn.

• if thegrasshasbeenallowedto growinexcessof
4 inches,mulchingisnotrecommended.Usethe
grasscatcherto bagclippingsinstead.

Using Your Lawn Mower

WARNING:Neveroperateyour mower
without either the rear door or the entire

grass catcher assembly firmly secured.
Be surelawnisdear of stones,sticks,wire,or other
obiectswhichcoulddamagelawnmowerorengine.

Suchobiectscouldbe accidentlythrownbythemower
in anydirectionandcauseseriouspersonaliniuryto the

operatorandothers.

Using Grass Catcher

Youcanusethegrasscatchertocollectclippingswhile
youareoperatingthemower.RefertoSetupsectionfor

installationinstructions.

Grassclippingswillautomaticallycollectinbagas
yourun mower.Operatemowertillgrassbagisfull.

. Stopenginecompletelybyreleasingtheblade

control Makesurethatthe unithascometo a

comp otestopd schargodoorandgrassbagupandaway

fromthemowertodisposeofthe grassclippings.

9

moving partsoneng!ne

and awn mower.

f "_ Lubrication

1, Lubricatepivotpointson the bladecontrolat least

oncea seasonwithlightoil The bladecontrolmust
operatefreelyinboth directions,Figure54,

2, Lubricatethewheelsat leastoncea seasonwith

lightoil (or motoroil), Ifwheelsare removedforany
reason,lubricatesurfaceof theaxleand innersurface
ofthe wheelwithlightoiL

3, Lubricatethetorsionspringandpivotpointontherear

dischargedoorandsidemulchplugperiodicallywith
lightoil to preventrust,

4, Thetransmissionispre-lubricatedandsealedatthe

factoryanddoesnotrequirelubrication,

5, Followtheaccompanyingenginemanualforlubrica-

tionscheduleandinstructionforenginelubrication,

\

Figure5-1:Lubricationareasonthemower.

f

Deck Care

1, Disconnectsparkplugwire,Draingasolinefromlawn

mowerorplacea pieceof plasticunderthegas cap,

2, Tipmowersothat itrestson thehousing,Keepthe

sidewiththe aircleanerfacingup,Holdmowerfirmly,

oftime. Oil candrain intothe upper partofthe engine
causing a starting problem.

3, Scrapeandclean theundersideofthe deckwitha

suitabletool,Donotspraywithwater,

4, Putthe mowerbackonits wheelsontheground,If

youhadput plasticunderthe gascapearlier,make
sureto removeitnow,

WARNING:Nevertip the mower more
than 90degrees inany directions and do

not leavethe mowertipped for any length

i ii

IMPORTANT: The use

of a pressure washer

eUectricComponents,

Figure5-2:Replacingthe rearflap.

General Recommendations

• Alwaysobservesafetyruleswhen performing
anymaintenance,

Thewarrantyon thislawnmowerdoes notcover
itemsthathavebeensubjectedtooperatorabuse
or negligence,Toreceivefull valuefromwarranty,
operatormustmaintainthe lawnmoweras

instructedhere,

, Changingofengine-governedspeedwill void

enginewarranty,

, Alladiustmentsshouldbecheckedat leastonce

eachseason,

• Periodicallycheckall fastenersand makesurethese
aretight,

WARNING:Always stop engine, discon-

nect spark plug, and ground against

engine beforecleaning, lubricating or

doing any kind of maintenanceon your machine.

Engine Care

, Maintainoillevelasinstructedinenginemanual,
, Serviceaircleanerevery25 hoursundernormal

conditions,Cleaneveryfewhoursunderextremely
dustyconditions,Refertoenginemanual

, Cleansparkplugandresetthegap onceaseason,

Checkenginemanualforcorrectplugtype andgap
specifications,

• Cleanengineregularlywitha clothorbrush,Keepthe
coolingsystem(Newerhousingarea)cleantopermit
properaircirculation,Removeallgrass,dirtand

combustibledebrisfrom mufflerarea,

Replacing Rear F_ap

1, Lift upreardoor,
2, Bend(bow)the rearflapinwardon eachside to

releasetabsfromthe holesinthe handlemounting
brackets,Figure5-2,

3, Replacewith newflap bybendingthe rearflapand

slidinginto place,

10

thecarburetorareup,

2, Removebolt,bladebellsupport,blade,andadapter

fromtheenginecrankshaft,Figure5=3,

NOTE:Whenremovingtheblade,adapter,etc,,becare=
ful nottoremoveor misplacepartsaboveit associated
withtheenginepulley,

3, Thebladecan be sharpenedwitha file oron agrind=

ingwheel Do notattemptto sharpenthebladewhile
itis stillon themower,Whensharpeningblade,follow

originalangleofgrind,Grindcuttingedgesequallyto

keepbladebalanced,

4, Removebladefromthe adapterfortestingbalance,

Balancethebladeona roundshaftscrewdriverto

check,Removemetalfromthe heavysideuntilit

balancesevenly,

WARNING:An unbalanced blade will
cause excessivevibration when rotating

at high speeds. It maycause damageto

mower,and could breakcausing personalinjury.
5, Lubricatetheenginecrankshaftandtheinnersurface

ofthe bladeadapterwithlightoil Slidethe blade
adapterontotheenginecrankshaft.Placetheblade
on theadaptersuchthat theside ofthe blademarked
"Bottom"(orwithpartnumber)facesthe groundwhen
themoweris intheoperatingposition,Makesurethat

bladeisalignedandseatedon bladeadapterflanges,

6, Placebladebellsupporton the blade,Alignnotches

on thebladebellsupportwithsmallholesinblade,

Replacehexbolt andtightenhexbolttotorque:450
in,Ibs,min,,600in, Ibs,max,

Toensuresafeoperationof yourmower,periodically
checkthe bladeboltfor correcttorque,

Belt Care
1, Disconnectsparkplugwire andgroundagainst

engine,

2, Drainthefueltankorplacea pieceof plasticbeneath

thecap topreventgasolineleakage,

3, Tipmoweron itsside (aircleanersideofengineup),
4, Removeblade,bladeadapter,and relatedhardware,

Figure5=3,

5, Loosenself=tappingscrewthat securesdeckbaffleto

thedeck, Figure5=4,

6, Workingfromtherearof themower,carefullyremove

beltfromtransmissionpulley,

J

Figure5-3:Removethebolt,support,blade,andadapterto
accessthebladeandundersidecomponents.

j J/

Figure5-4:Removescrewholdingbaffletodeck.

f

/ .........;_:;_........... "

.........i ¸¸

Figure5-5:Removebeltfromtransmissionthenengine.
7, Oncebelt isofftransmissionpulley,pushdownon

deckbaffletoaccessenginepulleyandslidebeltoff
thispulleyandout fromunderthedeck,Figure5=5,

8, Replacewith newbelt,workingit betweenthedeck

andbaffle,firstaroundthetransmissionpulleyand
thenthe enginepulley,Tightenscrewloosened
earlierandreplacebladeandhardware,

9, Tipmowerbackonto itswheelsand removepieceof

plasticfromundergascap (ifapplicable),

WARNING ;

When removing
the cutting blade

for sharpening or

replacement or
when sliding the belt
around it, protect

your hands with a

pair of heavy gloves

or use a heavy ragto

hold the blade.

An unbalanced

blade will cause
excessive vibration

when rotating at high
speeds, it may cause

damage to mower and
could breakcausing

personaJ injury.

Make certain that bert

isseated correctly
and that it is riding
smoothJy on the en-

gine pulley and is

not pinched between

the lower and upper

pulley halves.

11

WARNING

Batteries contain
sulfuric acid which may

cause burns. Donot
short circuit or mutilate

batteries in any way.Do
not put batteries in fire

asthese may buret or

releasetoxic materials.

Useonlythe battery

charger supplied with
this mower,

Donot removethe

battery packfrom the
electric starter housing
for any reason other
than replacement.

releasetoxic materials.

1. Loosenroundhandleknobssecuringupperand
lowerhandlesandcarefullyfoldtheupperhandle

downtowardthe lowerhandleas showninFigure
5=3.

2. Removethetwoscrewssecuringbatterycoverto
batteryhousingandplacethemto theside,Figure

5=3.

3. Openbatterycover,removepositiveandnegathfe
leadsfrombattery,removeandreplacewith new
battery,Figure5-4.Connectthepositiveleadtothe
positivesideofthe batterypack,thenconnectthe
negativeside.

NOTE:Thebatteryyou havemaydifferslightlyfromthe
oneshownin Figure5-4.Refertothe PartsList.

IMPORTANT:When replacing battery pack inhandle
panel, battery pack must be positioned with the
positive terminal to the left sideandthe negative

terminal to the right sideof panel (Positiveterminal

isclosest to the key switch}, Figure 5°4.Replacing
battery pack incorrectly will causeserious damage.

4. Reattachbatterycoverto batteryhousingbysecur-
ingwiththetwoscrewsremovedearlier,makingsure
tosnapthewireconduiton theleft intoplaceonthe
housing.

5. Foldhandlesbackupand tightenhandleknobs.

Charging Battery

WARNING:The battery contains corroo
sire fluid and toxic material; handle with
care and keep awayfrom children. Do

not puncture, disassemble, mutilate or incinerate

the battery. Explosive gases could beventedduring

charging or discharging. Use ina well ventilated
area,awayfrom sources of ignition.

NOTE:Thespecialdesignedplugon thechargerwill
onlyfit intothe plugon the batterybox.

Figure5-3:Folddownupperhandleand removetwoscrews
frombackofhousing.

f

Figure5-4:Opencovertoviewbatteryandwires.

f

1. Plugthebatterychargerintotheportonthe
undersideofthebatteryhousing,Figure5=5.

2. Insertthe batterychargerplugintoa standard120
volthouseholdoutlet,Figure5-5. Chargebattery

for8 to 10hoursbeforeinitialuse.Do notcharge
longer than 12hours. The batteryshouldonlyneed
tobechargeduponinitialsetupandafteranyother
extendedperiodsof non=use.

3. Aftercharging,disconnectchargerplugfromoutlet
first,thendisconnectchargerleadfrombattery.

J

Figure5-5:Plugchargerintobatterylead(1)andthenplug
chargerpackinto120voltstandardhouseholdoutlet(2),

IMPORTANT:Alwaysplugchargerleadinto battery
packleadfirst,andtheninsertbatterychargerpluginto

120volt standardhouseholdoutlet. Followthis orderof
actioneverytimeyouchargethebattery.

12

Replacing Fuse "_

Theelectricstartercircuitandbatteryareprotectedbya
40 amperefuse,If thefuseburnsout, theelectricstarter
willnot operate,If theunitfailsto startwiththeelectric
starter,performthefollowingstepstocheckthefuse
insidethe batteryhousing:

1. Openthe batterycoveras describedinReplacing
Battery,seeFigure5-3.

2. Removefusefromsocketandinspectasshownin _-
Figure5-6.If itis burnedout, replacewithstandard

automotive40amperefuse.

3. Carefullyplacewiringbackinto housing,closebattery

cover,andfold upperhandlebackintoplace.

NOTE:The engine canbe started manually if the fuse
burns out.

Off-Season Storage
Thefollowingstepsshouldbetakento prepareyourlawn
mowerforstorage.

Cleanand lubricatemowerthoroughlyas describedin
thelubricationinstructions.

Wedonot recommendthe useof a pressurewasher
or gardenhoseto dean yourunit.

Referto enginemanualforcorrectenginestorage
instructions.

Coatmower'scuttingbladewithchassisgreaseto

preventrusting.

. Storemowerin adry,cleanarea.Donotstorenextto

corrosivematerials,suchas fertilizer.

Whenstoringany typeofpowerequipmentina poorly
ventilatedormetalstorageshed,careshouldbetakento
rust-prooftheequipment.Usingalight oilor silicone,coat
theequipment,especiallycablesandall movingpartsof
yourlawnmowerbeforestorage.

Battery
Thebatterymustbestoredwith afull charge.Extended
storageofa dischargedbatterywillreducelifeand
capacityofthe battery.

Figure5-6:Whenreplacingfuse,useastandardautomotive
7_f2ampfuse.

J

The engine can be

started manuaity ifthe

fuse burns out,

\

13

For repairs beyond

the minoradjust-
mentslisted here,

eentact an authorize d
serviee dealer,

Engineruns erratic

Engneoverheats 1. Engineoil levellow. 1. Fil crankcasewthproperoil.

I

Occasional skips 1. Sparkpluggaptooclose. 1. Adiustgapto .030inch.

1. Sparkplugwire loose.

2. Blockedfuellineor stalefuel

3. Ventingas capplugged.

4. Waterordirt in fuelsystem.

5. Dirtyair cleaner. 5. Referto enginemanual

6. Carburetoroutof adiustment. 6. Referto enginemanual

2. Airflow restricted. 2. RemoveNowerhousing

' 3. Carburetornot adjustedproperly. 3. Refertoenginemanual

1. Connectandtightensparkplug
wire.

2. Cleanfuelline; filltankwithclean,
freshgasoline.

3. Clearvent.

4. Drainfueltank.Refillwithfresh
fuel

l

and clean.

(hesitates)at 2. Carburetoridle mixtureadiustment 2. Refertoenginemanual

highspeed improperlyset.

Idlespoorly

3. Refertoenginemanual

Excessive 1. Cuttingbladelooseor unbalanced. 1. Tightenbladeandadapter.Balance

Vibration blade.

Mowerwill not 1 Wetgrass 1. Donotmowwhengrassis wet wait

mulchy-rass unt aterto cut

Unevencut 1. Dullblade. 1. Sharpenor replaceblade.

2. Bentcuttingblade. 2. Seean authorizedservicedealer.

2. Excessivelyhighgrass. 2 Mowonceat a highcutting height,
j thenmowagainatdesiredheightor

I makea narrowercuttingpath.

3. Dullblade. 3 Sharpenor replaceblade.

1. Checkbeltfor properpulleyinstaila-

3. Damagedorwornbelt. ' 3. inspectandreplacebelt.

14

Safety Labels Found On Your Lawn Mower

mower fet any reasen,

\

15

Shown fo_rde_el_ce_

Q

Shownfor
relerence

Q

16

1 75&04093 WBelt
2 73b04338 SpringLever

3 720-0230 FoamGrip
4 717-04184A SpurGear,14T-LH

5 710-0599 TT Screw,1/&20x 0.50
6 750-04305A Spacer

7 749-04267 CrossBracket
8 687_02204 FrontBracketAssembly

9 731-05470 C@Spacer
10 741-04136B SplitHexFlangeBearing

11 73&O4014B FrontWheel
12 71b04065 FlangeLockNut,3/8d6

13 63&04207C RearWheel
14 710-04531 Screw,1/&20x.39

15 717-04192A SpurGear,14T-RH
16 736-3084 FlatWasher

17 7867551A WheeIDustCover
18 74&04073C TransmissionBearingSupport

19 750-04317 ClipSpacer
20 716-0198 RetainingRing.875

21 687_02199 RearBracketAssembly
22 73b0320 ExtensionSpring
23 756-04151A Pulley,3.36OD

24 736-0105 BellWasher,.375x .870x .063
25 71b0411 HexLockNut,5/16_24
26 687_02205 HandleBracketAssemblyLH

27 715-0221 DowelPin
28 61&04378 TransmissionAssembly

29 687_02206 HandleBracketAssemblyRH

To order replacement

parts, call

1o800o648-6776

or visit

www.troybiff.eom

MPORTANT:For

a proper working

machine, use Factory
@proved Parts,

V-BELTSare speciaJJy

designed to engage

and disengage
safely.A substitute

(non=OEM)V-Belt
can be dangerous

by not disengaging

completely.

17

\

\

\

18

1 746-04265A

2 735-04059
3 753-05096A

4 731-04204
5 747d161A
6 746_04213
7 749-04037

8 725-0157
9 73b04265

10 710-0599
11 787-01341
12 710-0654A

13 787-01346
14 756-04157B
15 756-04156B
16 736-0514
17 748-0376C

18 710=1044

19 736_0524B
20 74b0741
21 736-0513
22 750=1071
23 710_0653

24 731-05463
25 710-0260A
26 71b04063
27 731-05462

28 731-05157

DriveCable 29 731-05017A
RubberGrommet 30 710=1241

DriveControlAssembly 31 720_04072
BailCover 32 73b04264
BladeControl 33 711_04374

ControlCable 34 647_04051
LowerHandle 35 664-04045
CableTie 36 710=1174

TorsionSpring,LH 37 720_0279
TT Screw,1/4-20x,500 38 710q205

21dnchDeck 39 749-04209

TTScrew,3/8=16x 1,00 40 736-0270

DeckBaffle 41 7361014
UpperEnginePulley 42 17032A

LowerEnginePulley 43 747_0710
FlatWasher,,885x 1,850x ,060 44 987-02055
BladeAdapter 45 731-04177

Screw,3/8-24x 1,50 46a 725=1276
BladeBell Support 46b 725_04323
21"MulchingBlade 47 725-04329
SpringWasher,,890x 1,70x,048 48 725-04293
SleeveSpacer 49 728-0199

TT Screw,1/4-20x ,375 50 725-04347

DeckBaffle 51 725-0201
CarriageBolt,5/16-18x,62 52 731_05505

FlangeLockNut,5/16q8 731-05459

Trailshield 53 710q667A

MulchPlug

RearDoor
Screw,1/4=15x 1,00

StarKnob
TorsionSpring,RH

DoorPivotRod
GrassCatcherFrame
GrassCatcher

CarriageBolt,5/16=18x2,00
WingNut
EyeBolt

UpperHandle
BellWasher,,265x ,75x,062
TorsionSpring

ChuteDeflectorAdapter
HingePin
MulchPlugAssembly
SideDischargeChute

12VoltBattery
12VoltBattery

BatteryCharger
ElectricStarterHarness

Rivet
KeySwitch

Key
BatteryHsg, (usedw/ref,#46a)
BatteryHsg, (usedw/ref,#46b)

Screw,#10q6x ,750

To order replacement

parts, ca[[

1-800-648-6776

or visit

www.troybiJt.eom

\

19

MANUFACTURER'S LIMITED WARRANTY FOR

®

The limitedwarrantyset forthbelowis givenbyTroy_BiltLLCwithrespect

tonewmerchandisepurchasedandusedin theUnitedStates,itsposses_
sionsandterritories.

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

Troy_Biltforusewiththeproduct(s)coveredbythis manualwillvoidyour

warrantyastoany resultingdamage.
Normalwearpartsarewarrantedtobefreefromdefectsinmaterialand

workmanshipforaperiodof thirty(30)daysfromthedateofpurchase.
Normalwearpartsinclude,butare notlimitedto itemssuchas: batteries,
belts,blades,bladeadapters,grassbags,riderdeckwheels,seats,snow
throwerskidshoes,shaveplates,augerspiralrubberandtires.

NOWTO OBTAIN SERVICE: Warranty service is available,WITH
PROOFOF PURCHASE,through your local authorizedservice
dealer.To locate the dealer in yourarea, check your YellowPages,
or contact Troy-Bilt LLC at RO. Box 361131,Cleveland,Ohio 44136-
0019,or can 1-866-840-6483 or 1-330-558-7220,or log on to our

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

a. The engineor componentpartsthereof.Theseitemsmay

carrya separatemanufacturer'swarranty.Refertoapplicable
manufacturer'swarrantyfortermsandconditions.

b. Logsplitterpumps,valves,andcylindershaveaseparateone

yearwarranty.

c. Routinemaintenanceitemssuchaslubricants,filters,blade

sharpening,tune_ups,brakeadiustments,clutch adiustments,
deckadiustments,andnormaldeteriorationof theexteriorfinish
duetouse orexposure.

d. Servicecompletedbysomeoneotherthananauthorizedservice

dealer.

e. Troy_Biltdoesnotextendanywarrantyforproductssoldor

exportedoutsideofthe UnitedStates,its possessionsand
territories,exceptthosesold throughTroy_Bilt'sauthorized

channelsofexportdistribution.
f. Replacementpartsthatare notgenuineTroy_Biltparts.
g. Transportationchargesandservicecalls.

Noimpliedwarranty, includinganyimpliedwarrantyof merchant°

ability of fitness for a particular purpose, applies after the applicable

period of express written warranty aboveasto the parts as identi-

fied. Noother express warranty,whetherwritten or oral, exceptas

mentioned above,given by anyperson or entity, includinga 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 setforth above.
The provisions as set forth inthis warranty providethesole and

exclusive remedyarising from the sale. Troy-Bilt shall not be liable
for incidental or consequential loss or damageincluding, without

limitation, expensesincurred for substitute or replacementlawncare

services or for rental expenses to temporarily replace a warranted

product.
Somestatesdonot allowtheexclusionorlimitationofincidentalor

consequentialdamages,or limitationson howlonganimpliedwarranty

lasts,sothe aboveexclusionsor limitationsmaynotapplyto you.
Innoeventshall recoveryof anykind begreaterthantheamountofthe

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

This limitedwarrantyshallnotextendto anyoneotherthanthe original

purchaseror tothe personforwhomitwaspurchasedasagift.
HOWSTATELAWRELATESTOTHiSWARRANTY:This limitedwar-

rantygh,'esyouspecificlegalrights,andyoumayalsohaveotherrights

whichvaryfromstateto state.

IMPORTANT:OwnermustpresentOriginalProofofPurchasetoobtain

warrantycoverage.

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