Safe Operation Practices • Set-Up • Operation • Maintenance • Service • Troubleshooting • Warranty
OperatOr’s Manual
Self Propelled Mower — Model Series C3X/D3X
WARNING
READ AND FOLLOW ALL SAFETY RULES AND INSTRUCTIONS IN THIS MANUAL
BEFORE ATTEMPTING TO OPERATE THIS MACHINE.
FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
TROY-BILT LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019
Printed In USA
Form No. 769-08490
(January 2, 2013)
Download from Www.Somanuals.com. All Manuals Search And Download.
Important Safe Operation Practices
2
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!
CALIFORNIA PROPOSITION 65
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.
WARNING: Battery posts, terminals, and related accessories contain lead and lead
compounds, chemicals known to the State of California to cause cancer and reproductive
harm. Wash hands after handling.
DANGER: This machine was built to be operated according to the safe operation practices 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 fingers, hands,
toes and feet and throwing objects. Failure to observe the following safety instructions could
result in serious injury or death.
6.
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.
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. Keep this manual in a safe
place for future and regular reference and for ordering
replacement parts.
7.
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.
2.
3.
Be completely familiar with the controls and the proper use
of this machine before operating it.
This machine is a precision piece of power equipment,
not a plaything. Therefore, exercise extreme caution at all
times. This machine has been designed to perform one job:
to mow grass. Do not use it for any other purpose.
8.
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.
4.
Never allow children under 14 years of age to operate this
machine. Children 14 and over should read and understand
the instructions and safe operation practices in this manual
and on the machine and should be trained and supervised
by an adult.
9.
Always wear safety glasses or safety goggles during
operation and while performing an adjustment or repair
to protect your eyes. Thrown objects which ricochet can
cause serious injury to the eyes.
10. Wear sturdy, rough-soled work shoes and close-fitting
slacks and shirts. Shirts and pants that cover the arms
and legs and steel-toed shoes are recommended. Never
operate this machine in bare feet, sandals, slippery or light-
weight (e.g. canvas) shoes.
5.
Only responsible individuals who are familiar with these
rules of safe operation should be allowed to use this
machine.
11. Do not put hands or feet near rotating parts or under the
cutting deck. Contact with blade can amputate fingers,
hands, toes and feet.
3
Download from Www.Somanuals.com. All Manuals Search And Download.
12. A missing or damaged discharge cover can cause blade
27. When starting engine, pull cord slowly until resistance
is felt, then pull rapidly. Rapid retraction of starter cord
(kickback) will pull hand and arm toward engine faster than
you can let go. Broken bones, fractures, bruises or sprains
could result.
contact or thrown object injuries.
13. 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.
28. If situations occur which are not covered in this manual,
use care and good judgement. Contact Customer Support
for assistance or the name of the nearest service dealer.
14. 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:
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 machine on a sloped or
hilly area. If the slope is greater than 15 degrees, do not mow it.
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.
Do:
15. Do not operate the mower while under the influence of
1.
Mow across the face of slopes; never up and down. Exercise
extreme caution when changing direction on slopes.
alcohol or drugs.
16. Do not engage the self-propelled mechanism on machines
2.
Watch for holes, ruts, rocks, hidden objects, or bumps
which can cause you to slip or trip. Tall grass can hide
obstacles.
so equipped while starting engine.
17. The blade control 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 must
operate easily in both directions and automatically return
to the disengaged position when released.
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 three (3) seconds.
18. 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.
Do Not:
1.
2.
3.
Do not mow near drop-offs, ditches or embankments, you
could lose your footing or balance.
Do not mow slopes greater than 15 degrees as shown on
the slope gauge.
19. Mow only in daylight or good artificial light. Walk, never
run.
Do not mow on wet grass. Unstable footing could cause
slipping.
20. Stop the blade when crossing gravel drives, walks or roads.
21. If the equipment should start to vibrate abnormally, stop
the engine and check immediately for the cause. Vibration
is generally a warning of trouble.
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.
22. 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 blade control is released.
Never place any part of the body in the blade area until you
are sure the blade has stopped rotating.
1.
Keep children out of the mowing area and under watchful
care of a responsible adult other than the operator.
2.
3.
Be alert and turn mower off if a child enters the area.
Before and while moving backwards, look behind and
down for small children.
23. Never operate mower without proper trail shield,
discharge cover, grass catcher, blade control 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.
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.
24. Muffler and engine become hot and can cause a burn. Do
not touch.
6.
Never allow children under 14 years of age to operate this
machine. Children 14 and over should read and understand
the instructions and safe operation practices in this manual
and on the machine and be trained and supervised by an
adult.
25. Never attempt to make a wheel or cutting height
adjustment while the engine is running.
26. Only use parts and accessories made for this machine by
the manufacturer. Failure to do so can result in personal
injury.
4
Section 2 — important Safe operation practiceS
Download from Www.Somanuals.com. All Manuals Search And Download.
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!”
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. Wash your skin and change clothes
immediately.
4.
5.
6.
7.
Mower blades are sharp and can cut. Wrap the blade or
wear gloves, and use extra caution when servicing them.
Keep all nuts, bolts, and screws tight to be sure the
equipment is in safe working condition.
2.
3.
Use only an approved gasoline container.
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.
Never tamper with safety devices. Check their proper
operation regularly.
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.
4.
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.
8.
Never attempt to make a wheel or cutting height
adjustment while the engine is running.
5.
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.
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!”
6.
7.
Extinguish all cigarettes, cigars, pipes and other sources
of ignition.
Never fuel machine indoors because flammable vapors will
accumulate in the area.
8.
Never remove gas cap or add fuel while engine is hot or
running. Allow engine to cool at least two minutes before
refueling.
9.
Never over fill fuel tank. Fill tank to no more than 1 inch
below bottom of filler neck to provide for fuel expansion.
10. Do not change the engine’s governor setting or over-speed
the engine. The governor controls the maximum safe
operating speed of the engine.
10. Replace gasoline cap and tighten securely.
11. Check fuel line, tank, cap, and fittings frequently for cracks
11. If gasoline is spilled, wipe it off the engine and equipment.
Move machine to another area. Wait 5 minutes before
starting engine.
or leaks. Replace if necessary.
12. Do not crank engine with spark plug removed.
12. 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.
13. Maintain or replace safety and instruction labels, as
necessary.
14. Observe proper disposal laws and regulations. Improper
13. To reduce fire hazard, keep machine free of grass, leaves,
or other debris build-up. Clean up oil or fuel spillage and
remove any fuel soaked debris.
disposal of fluids and materials can harm the environment.
15. According to the Consumer Products Safety Commission
(CPSC) and the U.S. Environmental Protection Agency (EPA),
this product has an Average Useful Life of seven (7) years,
or 140 hours of operation. At the end of the Average Useful
Life have the machine inspected annually by an authorized
service dealer to ensure that all mechanical and safety
systems are working properly and not worn excessively.
Failure to do so can result in accidents, injuries or death.
14. Allow machine 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.
Do not modify engine
To avoid serious injury or death, do not modify engine in any
way. Tampering with the governor setting can lead to a runaway
engine and cause it to operate at unsafe speeds. Never tamper
with factory setting of engine governor.
Section 2 — important Safe operation practiceS
5
Download from Www.Somanuals.com. All Manuals Search And Download.
Notice Regarding Emissions
Spark Arrestor
Engines which are certified to comply with California and federal
EPA emission regulations for SORE (Small Off Road Equipment)
are certified to operate on regular unleaded gasoline, and
may include the following emission control systems: Engine
Modification (EM), Oxidizing Catalyst (OC), Secondary Air
Injection (SAI) and Three Way Catalyst (TWC) if so equipped.
WARNING: This machine 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 arrestor
meeting applicable local or state laws (if any).
If a spark arrestor 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 arrestor 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.
6
Section 2 — important Safe operation practiceS
Download from Www.Somanuals.com. All Manuals Search And Download.
Safety Symbols
This page depicts and describes safety symbols that may appear on this product. Read, understand, and follow all instructions on the
machine before attempting to assemble and operate.
Symbol
Description
READ THE OPERATOR’S MANUAL(S)
Read, understand, and follow all instructions in the manual(s) before attempting to
assemble and operate
DANGER — ROTATING BLADES
To reduce the risk of injury, keep hands and feet away. Do not operate unless discharge cover
or grass catcher is in its proper place. If damaged, replace immediately.
DANGER — BYSTANDERS
Do not mow when children or others are around.
DANGER — HAND/ FOOT CUT
Keep hands and feet away from rotating parts.
DANGER — THROWN DEBRIS
Remove objects that can be thrown by the blade in any direction. Wear safety glasses.
DANGER — SLOPES
Use extra caution on slopes. Do not mow slopes greater than 15°.
WARNING—GASOLINE IS FLAMMABLE
Allow the engine to cool at least two minutes before refueling.
WARNING— CARBON MONOXIDE
Never run an engine indoors or in a poorly ventilated area. Engine exhaust contains carbon
monoxide, an odorless and deadly gas.
WARNING— HOT SURFACE
Engine parts, especially the muffler, become extremely hot during operation. Allow engine
and muffler to cool before touching.
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.
SAVE THESE INSTRUCTIONS!
Section 2 — important Safe operation practiceS
7
Download from Www.Somanuals.com. All Manuals Search And Download.
8
Section 2 — important Safe operation practiceS
Download from Www.Somanuals.com. All Manuals Search And Download.
Assembly & Set-Up
3
Contents of Carton
•
•
One Lawn Mower
•
•
One Grass Catcher
•
•
One Bottle of Oil
One Lawn Mower Operator’s Manual
One Engine Operator’s Manual
One Side Discharge Chute
NOTE: Please be aware that this Operator’s Manual covers both
the low and high wheel models of this mower. While this manual
illustrates the low wheel model, the instructions and features
are equally applicable to the high wheel model as well, unless
otherwise noted.
b. While stabilizing mower so it doesn’t move, pivot
upper handle up as shown in Figure 3-2. Do not
crimp cables while lifting the handle up and make
sure they go on the outside of the handle.
Assembly
NOTE: This unit is shipped without gasoline or oil in the engine.
Fill up with gasoline and oil as instructed in the accompanying
engine manual BEFORE operating your mower.
B
Handle
1.
Remove any packing material which may be between
upper and lower handles.
a. Remove wing nuts and carriage bolts from handle
as shown in Figure 3-1. Do not loosen or remove
adjacent hex head screws.
A
Figure 3-2
A
Figure 3-1
9
Download from Www.Somanuals.com. All Manuals Search And Download.
2.
Remove the T-bolts from the handle brackets as shown in
Figure 3-3.
C
C
Figure 3-5
4.
The rope guide is attached to the right side of the upper
handle. Loosen the wing knob which secures the rope
guide. See Figure 3-6.
Figure 3-3
3.
Follow the steps below to complete handle assembly:
a. Pull upward on the handle approximately 8 inches
until holes in lower handle (shown in Figure 3-3 deck
cutaway) line up with holes in handle bracket. See
Figure 3-4.
A
B
D
B
A
B
C
Figure 3-6
a. Hold blade control against upper handle.
b. Slowly pull starter rope handle from engine and slip
starter rope into the rope guide. See Figure 3-6.
Figure 3-4
c. Tighten rope guide wing knob.
NOTE: When pulling upward on handle, make sure to not
pull handle all the way out.
d. Use cable tie(s) to secure cable(s) to lower handle.
Grass Catcher
b. Insert the T-bolts removed earlier through the
handle brackets and lower handle and tighten
securely to secure the handle in place. See Figure
3-4.
1.
Follow steps below to assemble the grass catcher (if
needed). Make certain bag is turned right side out before
assembling (warning label will be on the outside).
a. Place bag over frame so that its black plastic side is
at the bottom.
c. Reattach wing nuts and carriage bolts removed
earlier into lower holes of handle as shown in Figure
3-5.
10
Section 3 — ASSembly & Set-Up
Download from Www.Somanuals.com. All Manuals Search And Download.
b. Slip plastic channel of grass bag over hooks on the
frame. See Figure 3-7.
1.
On the side of the mower, lift the side mulching plug. See
Figure 3-9.
Side Mulching
Plug
1
2
Figure 3-7
Follow steps below to attach grass catcher:
a. Lift rear discharge door.
Figure 3-9
2.
2.
Slide two hooks of side discharge chute under hinge pin on
mulching plug assembly. Lower the mulching plug. Do not
remove side mulching plug at any time, even when you are
not mulching.
b. Place grass catcher into the slots in the handle
brackets as shown in Figure 3-8. Let go of discharge
door so that it rests on the grass catcher.
Adjustments
Cutting Height
A
The cutting height adjustment lever is located above the rear left
wheel.
B
1.
2.
Depress height adjustment lever towards wheel.
Slide lever to desired position for a change in cutting
height. Refer to Figure 3-10 for low wheel adjustment and
Figure 3-11 for high wheel.
B
Lower
2
Higher
3
1
Figure 3-8
To remove grass catcher, lift rear discharge door on the mower.
Lift grass catcher up and off of the slots in the handle brackets.
Release rear discharge door to allow it to close rear opening of
mower.
Side Discharge Chute
Your mower is shipped as a mulcher. To convert to side discharge,
make sure grass catcher is off of the unit and rear discharge door
is closed.
Low Wheel
Figure 3-10
Section 3 — ASSembly & Set-Up
11
Download from Www.Somanuals.com. All Manuals Search And Download.
Drive Control
2
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 adjustment wheel clockwise to tighten
cable or counterclockwise to loosen the cable. See Figure 3-13.
Higher
3
Lower
1
High Wheel
Loosen
Tighten
Figure 3-11
3.
Release lever towards deck and place lever on one of the
six height adjustment teeth.
Handle Pitch
For convenience of operation, you may adjust the pitch of the
handle as follows:
1.
Remove wing nuts and carriage bolts from handle. See
Figure 3-12.
Figure 3-13
NOTE: For ease of adjustment, the speed control should be in the
second or third speed.
Set-Up
Gas and Oil Fill-Up
Refer to the separate engine owner’s manual for additional
engine information.
1.
Add oil provided before starting unit for the first time out
of the box.
2.
Service the engine with gasoline as instructed in the
separate engine owner’s 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.
Figure 3-12
2.
3.
Position the handle in one of the three positions that is
most comfortable. See Figure 3-12 inset.
Secure into position with wing nuts and carriage bolts
removed earlier.
12
Section 3 — ASSembly & Set-Up
Download from Www.Somanuals.com. All Manuals Search And Download.
Controls and Features
4
Drive Control
Blade Control
Speed Control
Drive Control
Electric Start
Ignition Switch
Cutting Height
Adjustment
Lever
Recoil Starter
Deck Wash
Side Discharge
Chute
Figure 4-1
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.
Cutting Height Adjustment Lever
The cutting height adjustment lever is located above the left
rear wheel. To adjust the cutting height, refer to the “Assembly &
Set-Up” Section.
WARNING: This blade control is a safety device.
Never attempt to bypass its operations.
Deck Wash (If Equipped)
Your mower’s deck is equipped with a water port on its surface
as part of its deck wash system. Use the deck wash to rinse grass
clippings from the deck’s underside.
Drive Controls
The drive controls are located on top of the upper handle and are
used to engage the drive. Squeeze the right, left, or both right
and left controls against the upper handle to engage the drive;
release it/them to slow down or stop mower from propelling.
Side Discharge Chute
Your mower is shipped as a mulcher. To discharge the grass
clippings to the side instead, follow the instructions in the
“Assembly & Set-Up” section to attach the side discharge chute.
Speed Control
The speed control is located on the variable speed control
housing on the upper handle. This control is used to select the
forward speed of the mower. See Figure 4-1 inset.
WARNING: Keep hands and feet away from the
chute area on cutting deck. Refer to warning label
on the unit.
Electric Start Ignition Switch (If Equipped)
The electric start ignition switch is located on the right side of
the upper handle. It is used only for the electric starter.
IMPORTANT: Move the speed control only when the engine is
running. Changing the speed control setting with the engine off
can damage the mower.
13
Download from Www.Somanuals.com. All Manuals Search And Download.
Operation
5
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.
1
2
Refer to engine manual for help with the engine.
2
1.
Standing behind the mower, squeeze the blade control
against upper handle. See Figure 5-1.
2.
Recoil Start: Holding these two handles together firmly,
grasp recoil starter handle and pull rope out with a rapid,
continuous, full arm stroke. See Figure 5-1. Keeping a firm
grip on the starter handle, let the rope rewind slowly.
Repeat until engine cranks. Let the rope rewind each time
slowly.
Electric Start (If Equipped): Turn ignition key to the right
to start the engine. Release the key after the engine starts.
Figure 5-1
Stopping Engine
1.
Release blade control to stop the engine and blade.
WARNING: Wait for the blade to stop completely
before performing any work on the mower or to
remove the grass catcher.
Using Your Lawn Mower
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.
1.
Once the engine is running and while continuing to hold
the blade control down, squeeze either (or both) drive
controls against the upper handle to propel mower. See
Figure 5-2.
Engage the right, the left, or
2.
To change speed, move speed control to the desired speed.
both the right and left control
levers to propel the mower.
NOTE: When selecting a drive speed, use the first speed
until you are comfortable and familiar with the operation
of the mower.
IMPORTANT: If you are shifting speeds while the mower
is stationary it may be difficult to shift into first speed
under certain conditions. This is easily remedied by briefly
engaging the drive lever.
Figure 5-2
NOTE: Your mower is equipped with an advanced internal
drive system for ease of use and smooth shifting. When
turning or pulling the unit rearward, you may notice higher
than normal resistance in the rear wheels under certain
conditions. This is perfectly normal and can be remedied
by allowing the unit to roll forward slightly without the
drive lever(s) engaged before pulling backwards.
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.
14
Download from Www.Somanuals.com. All Manuals Search And Download.
Using as Mulcher
Using Grass Catcher
You can use the grass catcher to collect clippings while you are
operating the mower.
For mulching grass, remove the grass catcher and allow the rear
discharge door to close the rear opening of mower. For effective
mulching, do not cut wet grass. 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.
1.
Attachgrasscatcherfollowinginstructionsinthe“Assembly&
Set-Up” section. Grass clippings will automatically collect in
bag as you run mower. Operate mower till grass bag is full.
2.
3.
Stop engine completely by releasing the blade control. Make
sure that the unit has come to a complete stop.
Lift discharge door and pull grass bag up and away from the
mower to remove the bag. Dispose of the grass clippings
and reinstall the bag when complete.
NOTE: Make sure to clean any excess grass from around
the rear opening of the mower, especially between the
transmission cover and sidewall on the left hand side and
along the bottom, to ensure tight fit of bag onto mower.
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.
Section 5 — operation
15
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance & Adjustments
6
2.
3.
The transmission is pre-lubricated and sealed at the factory
and does not require lubrication.
Maintenance
General Recommendations
Follow the accompanying engine manual for lubrication
schedule and instruction for engine lubrication.
•
Always observe safety rules when performing any
maintenance.
Deck Care
•
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.
Clean underside of the mower deck after each use to prevent
build-up of grass clippings or other debris. Follow steps below
for this job.
1.
Disconnect spark plug wire. Drain gasoline from lawn
mower or place a piece of plastic under the gas cap.
•
•
•
Changing of engine-governed speed will void engine
warranty.
2.
Tip mower so that it rests on the housing. Keep the side
with the air cleaner facing up. Hold mower firmly.
All adjustments should be checked at least once each
season.
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.
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.
3.
Scrape and clean the underside of the deck with a suitable
tool.
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.
Lubrication
1.
Lubricate pivot points on the blade control at least once
a season with light oil. This control must operate freely in
both directions. See Figure 6-1.
Figure 6-1
16
Download from Www.Somanuals.com. All Manuals Search And Download.
Deck Wash (If Equipped)
Engine Care
Your mower’s deck may be equipped with a water port on its
surface as part of its deck wash system.
A list of key engine maintenance jobs required for good
performance by the mower is given below. Follow the
accompanying engine manual for a detailed list and instructions.
Use the deck wash to rinse grass clippings from the deck’s
underside and prevent the buildup of corrosive chemicals.
Complete the following steps AFTER EACH MOWING:
•
•
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.
Poor engine performance and flooding usually indicates
that the air cleaner should be serviced. To service the air
cleaner, refer to the engine manual.
1.
Push the mower to a level, clear spot on your lawn, near
enough for your garden hose to reach.
CAUTION: Make certain the mower’s discharge
chute is directed AWAY from your house, garage,
parked cars, etc.
•
•
•
Clean spark plug and reset the gap once a season. Spark
plug replacement is recommended at the start of each
mowing season. Check engine manual for correct plug
type and gap specifications.
2.
3.
Thread the hose coupler (packaged with your mower’s
Operator’s Manual) onto the end of your garden hose.
Clean engine regularly with a cloth or brush. Keep the
top of the engine clean to permit proper air circulation.
Remove all grass, dirt, and combustible debris from muffler
area.
Attach the hose coupler to the water port on your deck’s
surface. See Figure 6-2.
Engines stored between 30 and 90 days need to be treated
with a gasoline stabilizer such as STA-BIL® to prevent
deterioration and gum from forming in fuel system or on
essential carburetor parts.
Figure 6-2
Turn the water on.
4.
5.
6.
Start the engine as described in the Operation section.
Run the engine for a minimum of two minutes, allowing
the underside of the cutting deck to thoroughly rinse.
7.
Release blade control to stop the engine and blade.
8.
Turn the water off and detach the hose coupler from the
water port on your deck’s surface.
After cleaning your deck, restart the mower. Keep the engine
and blade running for a minimum of two minutes, allowing the
underside of the cutting deck to thoroughly dry.
Section 6 — Maintenance & adjuStMentS
17
Download from Www.Somanuals.com. All Manuals Search And Download.
Service
7
5.
Place the blade on the adapter such that the side of the
Blade Care
blade marked “Bottom” (or with part number) faces the
ground when the mower is in the operating position. Make
sure that the blade is aligned and seated on the blade
adapter flanges. See Figure 7-1 inset.
WARNING: When removing the cutting blade for
sharpening or replacement, protect your hands with
a pair of heavy gloves or use a heavy rag to hold the
blade.
6.
Place blade bell support on the blade. Align notches on the
blade bell support with small holes in blade.
Periodically inspect the blade adapter for cracks, especially if you
strike a foreign object. Replace when necessary. Follow the steps
below for blade service.
7.
Replace hex bolt and tighten hex bolt to torque: 450 in. lbs.
min., 600 in. lbs. max.
1.
Disconnect spark plug boot from spark plug. Turn mower
on its side making sure that the air filter and the carburetor
are facing up.
To ensure safe operation of your mower, periodically check the
blade bolt for correct torque.
Belt Care
2.
Remove the bolt and the blade bell support which hold the
blade and the blade adapter to the engine crankshaft. See
Figure 7-1.
NOTE: Several components must be removed in order to change
the mower’s belt. See an authorized Service Dealer to have your
belt replaced.
Blade
Adapter
Blade
Blade Bell
Support
Bolt
Figure 7-1
3.
Remove blade from the adapter for testing balance.
4.
Balance the blade on a round shaft screwdriver to check.
Remove metal from the heavy side until it balances evenly.
When sharpening the blade, follow the original angle of
grind. Grind each cutting edge equally to keep the blade
balanced.
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.
18
Download from Www.Somanuals.com. All Manuals Search And Download.
Replacing Battery (If Equipped)
Charging Battery (If Equipped)
WARNING: Batteries contain sulfuric acid which
WARNING: The battery contains corrosive fluid
may cause burns. Do not short circuit or mutilate
batteries in any way. Do not put batteries in fire as
these may burst or release toxic materials.
and toxic material; handle with care and keep away
from children. Do not puncture, disassemble,
mutilate or incinerate the battery. Explosive gases
could be vented during charging or discharging. Use
in a well ventilated area, away from sources of
ignition.
1.
Unhinge cover seal and lift off battery cover.
2.
Remove positive and negative leads from battery, and pull
up on battery to remove. See Figure 7-2.
NOTE: The special designed plug on the charger will only fit into
the plug on the battery box.
1.
Unhinge the cover seal and plug the battery charger into
the port on the side of the battery housing. See Figure 7-4.
2
1
Figure 7-2
3.
Replace with new battery. Connect the positive lead (red)
to the positive side of the battery pack, then connect the
negative lead (black) to the negative side. See Figure 7-3.
Figure 7-4
2.
Insert the battery charger plug into a standard 120 volt
household outlet. Charge battery for 8 to 10 hours before
initial use. Do not charge longer than 12 hours. The battery
should only need to be charged upon initial setup, at the
end of the season, after any other extended periods of
non-use, and as needed.
(+) Positive
Terminal
(-) Negative
Terminal
NOTE: If you frequently stop and restart the mower
during each cut throughout the season (for instance when
bagging), more frequent charging may be necessary.
3.
After charging, disconnect charger plug from outlet first,
then disconnect charger lead from battery and reattach
cover seal.
IMPORTANT: Do not remove the battery pack from
the electric starter housing for any reason other than
replacement.
IMPORTANT: Always plug charger lead into battery pack
lead first, and then insert battery charger plug into 120
volt standard household outlet. Follow this order of action
every time you charge the battery.
Figure 7-3
4.
Reattach battery cover and cover seal.
Section 7 — Service
19
Download from Www.Somanuals.com. All Manuals Search And Download.
Replacing Fuse (If Equipped)
Off-Season Storage
The following steps should be taken to prepare your lawn mower
for storage.
The electric starter circuit and battery are protected by a 40
ampere fuse. If the fuse burns out, the electric starter will not
operate. If the unit fails to start with the electric starter, perform
the following steps to check the fuse inside the battery housing:
•
•
•
•
Clean and lubricate mower thoroughly as described in the
lubrication instructions.
1.
Open the battery cover as described in Replacing Battery.
Coat mower’s cutting blade with chassis grease to prevent
rusting.
2.
Remove fuse from socket and inspect as shown in Figure
7-5. If it is burned out, replace with standard automotive 40
ampere fuse.
Refer to engine manual for correct engine storage
instructions.
Secure side discharge chute to handle as shown in Figure
7-6.
Figure 7-5
3.
Carefully place wiring back into housing, and reattach
battery cover.
Figure 7-6
NOTE: The engine can be started manually if the fuse burns
out.
•
Store mower in a dry, clean area. Do not store next to
corrosive materials, such as fertilizer.
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.
Battery (If Equipped)
The battery must be stored with a full charge. Extended storage
of a discharged battery will reduce life and capacity of the
battery.
20
Section 7— Service
Download from Www.Somanuals.com. All Manuals Search And Download.
Notes
21
Download from Www.Somanuals.com. All Manuals Search And Download.
Troubleshooting
8
Problem
Cause
Remedy
Engine Fails to start
1. Blade control disengaged.
1. Engage blade control.
2. Spark plug boot disconnected.
3. Fuel tank empty or stale fuel.
2. Connect wire to spark boot.
3. Fill tank with clean, fresh gasoline.
4. Engine not primed (if equipped with primer).
4. Prime engine as instructed in the Operation
section.
5. Faulty spark plug.
6. Blocked fuel line.
7. Engine flooded.
5. Clean, adjust gap, or replace.
6. Clean fuel line.
7. Wait a few minutes to restart, but do not
prime.
8. Fuel valve (if equipped) closed.
8. Open fuel valve. See engine manual.
9. Choke engine. See engine manual.
9. Engine not choked (if equipped with choke).
10. Burnt fuse. (Electric Start only)
1. Spark plug boot loose.
10. Replace fuse (see Service Section).
1. Connect and tighten spark plug boot.
Engine runs erratic
2. Blocked fuel line or stale fuel.
2. Clean fuel line; fill tank with clean, fresh
gasoline.
3. Vent in gas cap plugged.
4. Water or dirt in fuel system.
5. Dirty air cleaner.
3. Clear vent.
4. Drain fuel tank. Refill with fresh fuel.
5. Refer to engine manual.
6. Push CHOKE knob in.
6. Unit running with CHOKE (if equipped)
applied.
Engine overheats
1. Engine oil level low.
2. Air flow restricted.
1. Fill crankcase with proper oil.
2. Clean area around and on top of engine.
1. Adjust gap to .030”.
Occasional skips
(hesitates) at
high speed
1. Spark plug gap too close.
Idles poorly
1. Spark plug fouled, faulty, or gap too wide.
2. Dirty air cleaner.
1. Reset gap to .030” or replace spark plug.
2. Refer to engine manual.
Excessive Vibration
1. Cutting blade loose or unbalanced.
2. Bent cutting blade.
1. Tighten blade and adapter. Balance blade.
2. See an authorized service dealer.
Mower will not
mulch grass
1. Wet grass.
1. Do not mow when grass is wet; wait until
later to cut.
2. Excessively high grass.
3. Dull blade.
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.
Continued on next page
22
Download from Www.Somanuals.com. All Manuals Search And Download.
Problem
Cause
Remedy
Uneven cut
1. Wheels not positioned correctly.
1. Place front and rear wheels in same height
position. (Dual Height Adjusters)
2. Dull blade.
2. Sharpen or replace blade.
Mower will not self propel
1. Belt not installed properly.
1. Check belt for proper pulley installation and
movement.
2. Debris clogging drive operation.
2. Stop engine, disconnect spark plug boot,
and clean out debris.
3. Damaged or worn belt.
3. Inspect and replace belt.
4. Drive control out of adjustment.
4. Adjust drive control. (See Assembly & Set-up
section).
High pullback effort
1. Pulling mower backwards before
1. Allow the unit to roll forward slightly without
the drive lever(s) engaged before pulling
backwards.
transmission disengages.
Section 8 — troubleShooting
23
Download from Www.Somanuals.com. All Manuals Search And Download.
Replacement Parts
9
Component
Part Number and Description
BS-591868
Spark Plug
BS-491588S
BS-493537S
Air Filter Cartridge
Pre-Cleaner
BS-799585
BS-796577
Fuel Tank Cap
Fuel Tank Cap
634-04660
Wheel (Front)
634-05042
634-04666
Wheel (Rear - Low)
Wheel (Rear - High)
731-07131
Discharge Chute
942-0741A
942-0741-X
Mulching Blade
Xtreme Mulching Blade
Phone (800) 828-5500 or (330) 558-7220 to order replacement parts or a complete Parts Manual (have your full model number and
24
Download from Www.Somanuals.com. All Manuals Search And Download.
Component
Part Number and Description
964-04150B
Grass Bag
954-04282
725-04329†
Belt
Battery Charger
725-04903†
925-0201†
Battery
Key
† If Equipped
Section 9 — Replacement paRtS
Download from Www.Somanuals.com. All Manuals Search And Download.
25
Attachments & Accessories
10
Model Number and Description
Component
490-850-0005 Blade Removal Tool —
Holds blade in place for faster, safer
removal.
SPW-134
Spark Plug Wrench —
Duel ended wrench to serve multiple
uses. Fits ¾” or 13⁄16” hex plug.
490-850-0008 Oil Siphon —
Makes it easy to transfer gas, oil and
liquids from tank to container.
490-850-0016 Side Discharge Blower —
Blows leaves, grass clippings and
debris. Eliminates need for separate
blower. Easy installation with no tools.
490-850-0015 Cargo Carrier —
Conveniently holds drinks, tools and
more. Simple installation. Attaches in
less than two minutes with no tools.
490-241-0034
Garage Floor Mat —
Anti-skid mat, measures 24” x 36”.
Projects garage floor form stains.
490-850-0012 Mower Kick Stand —
Keeps mower stable for changing/
sharpening blade and cleaning
underside of deck.
Phone (800) 800-7310 or (330) 220-4683 to order attachments and accessories. Have your mower’s full model number and serial
26
Download from Www.Somanuals.com. All Manuals Search And Download.
Component
Model Number and Description
22216
STA-BIL® fuel Stabilizer, 32 oz —
Treats 80 gallons of fuel. Keeps stored
fuel fresh for quick, easy starts.
Prevents corrosion from moisture and
ethanol-induced attraction. Prevents
gum and varnish.
490-290-0012 Mower Cover —
Protects your mower against sun, rain
and dust damage. Coated for maximum
water resistance and repellency. U.V.
and milddew resistant
490-900-0062 Non-Stick Mower Deck Spray —
Long-Lasting anti-stick graphite spray.
Prevents grass clippings buildup in
mowing deck.
Section 10 — AttAchmentS & AcceSSorieS
27
Download from Www.Somanuals.com. All Manuals Search And Download.
MANUFACTURER’S LIMITED WARRANTY FOR
The limited warranty set forth below is given by Troy-Bilt LLC with
c.
Routine maintenance items such as lubricants, filters, blade
respect to new merchandise purchased and used in the United States
and/or its territories and possessions, and by MTD Products Limited
with respect to new merchandise purchased and used in Canada and/
or its territories and possessions (either entity respectively, “Troy-Bilt”).
sharpening, tune-ups, brake adjustments, clutch adjustments,
deck adjustments, and normal deterioration of the exterior finish
due to use or exposure.
d.
e.
Service completed by someone other than an authorized service
dealer.
This warranty is in addition to any applicable emissions warranty
provided with your product.
Troy-Bilt does not extend any warranty for products sold or
exported outside of the United States and/or Canada, and their
respective possessions and territories, except those sold through
Troy-Bilt’s authorized channels of export distribution.
“Troy-Bilt” warrants this product (excluding its Normal Wear Parts
and Attachments as described below) against defects in material and
workmanship for a period of three (3) 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.
f.
Replacement parts that are not genuine Troy-Bilt parts.
Transportation charges and service calls.
g.
h.
Troy-Bilt does not warrant this product for commercial use.
No implied warranty, including any implied warranty of
merchantability or 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.
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, tines, grass bags, wheels, rider
deck wheels, seats, snow thrower skid shoes, friction wheels, shave
plates, auger spiral rubber and tires.
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.
Attachments — Troy-Bilt warrants attachments for this product against
defects in material and workmanship for a period of one (1) year,
commencing on the date of the attachment’s original purchase or
lease. Attachments include, but are not limited to items such as: grass
collectors and mulch kits.
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.
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:
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.
In the U.S.A.
Check your Yellow Pages, or contact Troy-Bilt LLC at P.O. Box 361131,
Cleveland, Ohio 44136-0019, or call 1-866-840-6483,
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.
In Canada
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.
Contact MTD Products Limited, Kitchener, ON N2G 4J1, or call 1-800-
This limited warranty does not provide coverage in the following cases:
IMPORTANT: Owner must present Original Proof of Purchase to obtain
warranty coverage.
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.
Troy-Bilt LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019; Phone: 1-866-840-6483, 1-330-558-7220
MTD Canada Limited - KITCHENER, ON N2G 4J1; Phone 1-800-668-1238
GDOC-100242 REV. A
Download from Www.Somanuals.com. All Manuals Search And Download.
|