Troy-Bilt 540 Series User's Manual
Contents
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18. SIU pue fis J9 Operate RIDING mowers up and down slopes never across the face of slopes e jo 490000 6 10 gt Operate WALK BEHIND mowers across the face of slopes never up and down slopes AIO TOT OTT OTT OTT OTT ORO TOT TT A y N 1500 e 10 gt Safe Operation Practices WARNING This symbol points out important safety instructions which if not followed could endanger the personal safety and or property of yourself and others Read and follow all instructions in this manual before at tempting to operate this machine Failure to comply with these instructions may result in personal injury When you see this symbol tive harm instructions could result in serious injury or death General Operation 1 Readthis operator s manual carefully in its entirety before attempting to assemble this machine Read understand and follow all instructions on the machine and in the manual s before operation Be completely familiar with the controls and the proper use of this machine before operating it Keep this manual in a safe place for future and regular reference and for ordering replacement parts 2 This machine is a precision piece of power equipment not a plaything Therefore exercise extreme caution at all times Your unit has been designed to perform one job to mow grass Do not use it for any other pur
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24. Carburetor out of adjustment Engine oil level low Dirty air filter Air flow restricted Carburetor not adjusted properly Spark plug gap too close Carburetor idle mixture adjustment improperly set Spark plug fouled faulty or gap too wide Carburetor improperly adjusted Dirty air cleaner Cutting Blade loose or unbalanced Bent cutting blade Wet grass Excessive high grass Dull blade Wheels not positioned correctly Dull blade Remedy Engage blade control handle Connect wire to spark plug Fill tank with clean fresh gasoline Refer to engine manual Clean adjust gap or replace Clean fuel line Wait a few minutes to restart but do not prime Connect and tighten spark plug wire Clean fuel line fill tank with clean fresh gasoline Clear vent Drain fuel tank and carburetor Refill with fresh fuel Refer to engine manual Refer to engine manual Fill crankcase with proper oil Refer to the engine manual packed with your unit Remove blower housing and clean Refer to engine manual Adjust gap to 030 Refer to engine manual Refer to engine manual Reset gap to 030 or replace spark plug Refer to engine manual Refer to engine manual Refer to engine manual Tighten blade and adapter Balance blade Replace blade Do not mow when grass is wet wa
25. clean area Do not store next to corrosive materials such as fertilizer NOTE 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 Maintenance 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 An unbalanced blade will cause excessive vibration when rotat ing at high speeds It may cause damage to mower and could break causing per sonal injury Cutting grass in sandy soil condition causes abrasive wear to the blade Trouble Shooting For repairs beyond the minor adjust ments listed here contact an authorized service dealer amm Problem Engine fails to start Engine runs erratic Engine overheats Occasional skip hesitates at high speed Idles poorly Excessive vibration Mower will not mulch grass Uneven cut Cause Blade control handle disengaged Spark plug wire disconnected Fuel tank empty or stale fuel Engine not primed Faulty spark plug Blocked fuel line Engine flooding Spark plug wire loose Blocked fuel line or stale fuel Gas cap vent plugged Water or dirt in fuel system Dirty air cleaner
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28. Ensemble de roue 8 x 2 0 S Wave 33 710 04371 Hex L Scr 1 4 15 x 1 5 Vis hex 1 4 15 x 1 50 34A 746 1137 Control Cable 53 0 Lg Snap on Cable de la commande 53 0 po de lg 34B 746 04104 Control Cable 40 0 Lg Cable de la commande 40 0 po de lg 36 731 04998 Rear Flap Abattant de protection arri re 37 732 0700 Wire Fil 38 712 0397 Wingnut 1 4 20 crou oreilles 39 747 0996 Pivot Rod Tige de pivotement 40 732 0866 Spring Lever SP w o knob Ressort de levier sans bouton 41 687 02039A Pivot Bar RH SP Barre de pivot Droit 687 02040A Pivot Bar LH SP not shown Barre de pivot Gauche non illustr e 42 710 1652 Hex HD TT Tap Scr 1 4 20 x 5 8 Vis TT rondelle frein hex 1 4 x 5 8 43 712 04065 Flange Locknut 3 8 16 crou de blocage 3 8 16 44 714 0104 Int Cotter Pin 5 16 DIA Goupille fendue 5 16 DIA 45 710 0654A Hex Wash HD Tap Scr 3 8 16 x 88 Vis autotaraud e 3 8 16 x 0 88 46 687 02075A Height Adj Ass y LH w 8 Front Wheels Ensemble de r glage de roue CG avec 8 po pneu 687 02074A Height Adj Ass y RH w 8 Front Wheels Ensemble de r glage de roue CD avec 8 po pneu 47 731 04859 Snap On Bail Cover Grey Couvercle de commande instantan Gris 731 04204 Snap On Bail Cover Red Couvercle de commande instantan rouge 48 687 02057 LH Rear Height Adj Ass y Complete Ensemble de r glage de roue CG complet 687 02056 RH Rear Height Adj Ass y Complete Ensemble de r glage de roue CD complet 49 687 02191 LH Height Adj Brkt Ense
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32. out of engine Position B c Slip starter rope into the rope guide Position C d Tighten rope guide wing nut star knobs Position D 4 Insert post on cable ties into holes provided on the lower handle Pull cable tie tight and trim excess See Figure 4 IMPORTANT This unit is shipped WITHOUT GASOLINE or OIL After assem bly service engine with gasoline and oil as instructed in the separate engine manual packed with your unit Figure 4 Figure 3 5 Each wheel has a height adjustment lever to change the cutting height of the mower To change the height of cut squeeze adjuster lever toward the wheel moving up or down to selected height See Figure 5 6 To assemble the grasscatcher a Place bag over frame black plastic side is the bottom of bag Insert the hooks on the frame through the holes in the side plastic channels of the bag See Figure 6 Setup and Adjustments b Secure bag to frame by working the plastic channels on bag over frame as shown in Figure 6 All of the plastic channels except center top of bag attach from the outside of bag Center top of bag attaches from the inside of bag 7 Attaching Grass Catcher to Mower NOTE Make certain a Liftthe rear discharge door on the mower and bag is turned right side place the grass catcher on the pivot rod Let go Figure 5 out before assembling of discharge door so that it rests on the grass warning label will be on catcher See F
33. the engine discon nect the spark plug wire and ground against the engine Thoroughly inspect the mower for any damage Repair the damage before starting and operating the mower Never attempt to make a wheel or cutting height adjust ment while the engine is running 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 re place immediately with original equipment manufacturer s O E M parts only listed in this manual Use of parts which do not meet the original equipment specifications may lead to improper performance and compromise safety 10 Do not change the engine governor setting or overspeed the engine The governor controls the maximum safe operating speed of the engine 11 Maintain or replace safety labels as necessary 12 Observe proper disposal laws and regulations Improper disposal of fluids and materials can harm the environment Safe Operation Practices WARNING This symbol points out important safety instructions which if not followed could endanger the personal safety and or property of yourself and others Read and follow all instructions in this manual before at tempting to operate this machine Failure to comply with these instructions may result in personal injury When you see this symbol HEED ITS WARNING Your Responsibili
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38. Safety Set Up Operation Adjustments Maintenance Troubleshooting Parts Lists Warranty OPERATOR S MANUAL OTROV BILT 21 Rotary Mower Model Series 540 IMPORTANT READ SAFETY RULES AND INSTRUCTIONS CAREFULLY BEFORE OPERATING EQUIPMENT 772C0835 PRINTED IN U S A MTD Products Ltd P O Box 1386 KITCHENER ONTARIO N2G 04 13 06 This Operator s Manual is an important part of your new equipment It will help you assemble prepare and maintain the unit for best performance Please read and understand what it says Table of Contents Slope 6 m ere 3 Maintenance amp Off Season Storage 10 Safe Operation Practices 4 Trouble Shooting 12 Set Up amp Adjustments 0 13 ODEN AN OM 8 illustrated Parts Lists mme 14 Finding and Recording Model Number BEFORE YOU START ASSEMBLING YOUR NEW EQUIPMENT Model Number Serial Number please locate the model plate on the equipment and copy the Num ro de mod le Num ro de s rie the model number and the serial number to the sample model XXX XXXXXX plate provided to the right You can locate the model plate by standing at the operating position and looking down at the rear of the machine OTROY BILT POB CANADA KITCHENER ON N2G 4J1 Customer Support Please do NOT return the unit to
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42. feel you are losing your balance release the blade control handle immediately and the blade will stop rotating within 3 seconds Do Not 1 Do not mow near drop offs ditches or embankments you could lose your footing or balance 2 Do not mow slopes greater than 15 degrees as shown on the slope gauge 3 Do not mow on wet grass Unstable footing could cause slipping Children Tragic accidents can occur if the operator is not alert to the presence of children Children are often attracted to the mower and the mowing activity They do not understand the dangers Never assume that children will remain where you last saw them 1 Keep children out of the mowing area and under the watch ful care of a responsible adult other than the operator 2 Bealert and turn mower off if a child enters the area 3 Before and while moving backwards look behind and down for small children 4 Use extreme care when approaching blind corners doorways shrubs trees or other objects that may obscure your vision of a child who may run into the mower 5 Keep children away from hot or running engines They can suffer burns from a hot muffler 6 Never allow children under 14 years old to operate a power mower Children 14 years old and over should read and understand the operation instructions and safety rules in this manual and should be trained and supervised by a parent Service Safe Handling Of Gasoline 1 To avoid personal in
43. flec tor under the hinge pin on the hinged mulching plug assembly Lower the hinged mulching plug NOTE Do not remove the hinged mulching plug at any time even when you are not mulching L A Figure 11 Optional Feature Operating Your Lawn Mower WARNING The operation of any lawn mower can result in foreign objects being thrown into the eyes which can damage your eyes severely Always wear safety glasses while operating the mower or while performing any adjustments or repairs on it Be sure no one other than the operator is standing near the lawn mower while starting engine or operating mower Never run engine indoors or in enclosed poorly ventilated areas En gine exhaust contains carbon monoxide an odorless and deadly gas Keep hands feet hair and loose clothing away from any moving parts on engine and lawn mower Maintenance WARNING Always stop engine disconnect spark plug and ground against engine before cleaning lubricating or doing any kind of maintenance on your machine We do not recommend the use of pressure washers or garden hose to clean your unit These may cause damage to electrical components spindles pulleys bearings or the engine The use of water will result in shortened life and reduce serviceability Lubricate these points before ressembly Figure 12 General Recommendations 1 Always observe safety rules when per
44. forming any maintenance 2 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 3 Changing of engine governed speed will void engine warranty 4 All adjustments should be checked at least once each season 5 Periodically check all fasteners and make sure these are tight Lubrication 1 Lubricate the pivot points on the blade control handle at least once a season with light oil The blade control must operate freely in both directions See Figure 12 2 If your mower is equipped with ball bearing wheels lubricate at least once a season with a light oil all other types require no lubrication However if the wheels are removed for any reason lubricate the surface of the axle bolt and the inner surface of the wheel with light automotive oil 3 Lubricate the torsion spring and pivot point on the rear door periodically with light oil to prevent rust See Figure 12 4 Follow the accompanying engine manual for lubrica tion schedule and instruction Engine 1 Refer to the separate engine manual for engine maintenance instructions 2 Maintain engine oil as instructed in the separate engine manual packed with your unit Read and follow instructions carefully 3 Under normal conditions service air cleaner as instructed in the separate engine manual packed with yo
45. gs on the machine and in this manual before operating This blade control mechanism is a safety device Never attempt to bypass its operations Use extreme care when handling gasoline Gasoline is extremely flammable and the vapors are explosive Never fuel the machine indoors or while the engine is hot or running Extinguish cigarettes cigars pipes and other sources of ignition Know Your Lawn Mower Catcher gt Side Deflector Blade Control Mulch Plug optional Cutting Height Adjustment Lever for each wheel Figure 9 Blade Control Handle The blade control handle is located on the upper handle of the mower See Figure 9 The blade control handle must be depressed in order to operate the unit Release the blade control handle to stop the engine and blade Recoil Starter The recoil starter is attached to the right upper handle Stand behind the unit and pull the recoil starter rope to start the unit Mulching Plug optional The mulching plug is used to close the side discharge chute opening when mulching or bagging grass Do not remove the hinged mulching plug at any time even when you are not mulching Cutting Height Adjustment Levers If so equipped One adjustment lever is located on each wheel and is used to adjust the cutting height All four levers have to be at the same relative position to ensure uniform cut Before Starting 1 Service the engine w
46. he steps below for blade service 1 Disconnect spark plug wire from spark plug 2 Tip mower as specified in separate engine manual If it does not specify turn mower on its side making sure that the air filter and the carburetor are up 3 Remove the bolt and the blade bell support which hold the blade and the blade adapter to the engine crankshaft See Figure 13 10 Figure 13 4 Remove blade and adapter from the crankshaft 5 The blade may be resharpened by removing it and either grinding or filing the cutting edge keeping as close to the original bevel as possible Do not attempt to sharpen the blade while it is still on the mower 6 Itis extremely important that each cutting edge receives an equal amount of grinding to prevent an unbalanced blade NOTE Improper blade balance will result in excessive vibration causing eventual damage to the engine and mower Be sure to carefully balance blade after sharpen ing Possible damage resulting from blade unbalance condition is not the responsibility of the manufacturer NOTE Always remove blade from the adapter for testing balance 7 The blade can be tested for balance by balancing it on a round shaft screwdriver Remove metal from the heavy side until it balances evenly 8 Before reassembling the blade and the blade adapter to the unit lubricate the engine crankshaft and the inner surface of the blade adapter with light oil 9 Install the blade adapter
47. igure 7 A N the outside WARNING Never operate mower DV hN A unless the hooks on the grass C N NOTE Make certain catcher are firmly seated on the NN EN cables are routed to the pivot rod and the rear discharge SN outside of the handle so door rests firmly against top of 5 N the grass catcher when attaching the grass catcher 8 To remove grass catcher and utilize the mulching feature a Lift rear discharge door on the mower as shown in Figure 7 Lift grass catcher up and out off of the pivot rod Release rear discharge door to allow it to close rear opening of mower 9 Attaching Rear Wheels If Not Already Attached Remove the hex flanged nut on the rear axle from WAR N each side and place the rear wheel on the axle Make sure the spring washer is on the inside of the wheel Never operate mower between the wheel and the lawnmower See Figure 8 unless the hooks on Reinsert the flanged nut into the axle as shown and the gr tcher ar tighten securely Repeat on other side grass caner are firmly seated on the pivot rod and the rear discharge door rests firmly against top of the grass catcher All mowers are equipped with a rear protective guard The guard helps eliminate projectiles thrown by the blade from injuring the operator Figure 7 DO NOT REMOVE THIS GUARD Figure 8 Operating Your Lawn Mower WARNING Read understand and follow all instruc tions and warnin
48. it until later to cut Mow once at a high cutting height then mow again at desired height or make a narrower cutting path Sharpen or replace blade Place all four wheels in same height position Sharpen or replace blade TWO YEAR SUPREME WARRANTY For two years from date of retail purchase within Canada MTD PRODUCTS LIMITED will at its option repair or replace for the original purchaser free of charge any part or parts found to be defective in material or workmanship This warranty covers units which have been operated and maintained in accordance with Warranty the owner s instructions furnished with the unit and which have not been subject to misuse abuse commercial use neglect accident improper maintenance or alteration Normal wear parts or components thereof are subject to special terms as noted below in the NO FAULT Ninety Day Consumer Warranty clause The engine starter motor or component parts thereof carry separate warranties from their manufacturers Please refer to the applicable manufacturer s warranty policy for these items NO FAULT Ninety Day Consumer Warranty on Normal Wear Parts All normal Failure to comply wear part failures will be covered on this product for a period of 90 days regardless with suggested of cause After 90 days but within the two year warranty period normal wear part maintenance failures will be covered if caused by defects in material or workmanship of other and
49. ith gasoline and oil as instructed in the separate engine manual 2 Attach spark plug wire to spark plug If unit is equipped with a rubber boot over the end of the spark plug wire make certain the metal loop on the end of the spark plug wire inside the rubber boot is fastened securely over the metal tip on the spark plug To Start Engine 1 If your unit is equipped with a primer prime engine as instructed in the separate engine manual packed with your unit 2 Standing behind the unit depress the blade control handle and hold it against the upper handle as shown in Figure 10 3 Grasp the starter handle as shown and pull slowly until resistance is felt then pull rapidly to start engine and avoid kickback Return it slowly to the rope guide To Stop Engine 1 Release the blade control handle to stop the engine and blade WARNING The blade continues A to rotate for a few seconds after the engine is shut off 2 Disconnect and ground the spark plug wire as instructed in the separate engine manual to prevent accidental starting while equipment is unattended Using Your Lawn Mower WARNING Never operate your mower without either the rear door or the entire grass catcher assembly firmly secured Be sure the lawn is clear of stones sticks wire or other objects which could damage the lawn mower or the engine Such objects could be accidently thrown by the mower in any direction and cause serious perso
50. jury or property damage use extreme care in handling gasoline Gasoline is extremely flammable and the vapors are explosive Serious personal injury can occur when gasoline is spilled on yourself or your clothes which can ignite 2 Wash your skin and change clothes immediately 3 Use only an approved gasoline container 4 Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner Always place containers on the ground away from your vehicle before filling 5 Remove gas powered equipment from the truck or trailer and refuel it on the ground If this is not possible then refuel such equipment on a trailer with a portable container rather than from a gasoline dispenser nozzle 6 Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete Do not use a nozzle lock open device 7 Extinguish all cigarettes cigars pipes and other sources of ignition Never fuel machine indoors because flammable vapors will accumulate in the area Never remove gas cap or add fuel while the engine is hot or running Allow engine to cool at least two minutes before refueling 10 Never over fill fuel tank Fill tank to no more than 12 inch below bottom of filler neck to provide for fuel expansion 11 Replace gasoline cap and tighten securely 12 If gasoline is spilled wipe it off the engine and equipment Move unit to another area Wait 5 minutes before s
51. lubrication _ specifications will void warranty component parts Normal wear parts are defined as batteries belts blades blade adaptors grass bags rider deck wheels seats tires and clutch parts friction wheels Full Ninety Day Warranty on Battery For ninety 90 days from the date of retail purchase if any battery included with this unit proves defective in material or workmanship and our testing determines the battery will not hold a charge MTD PRODUCTS LIMITED will replace the battery at no charge to the original purchaser Additional Limited Thirty Day Warranty on Battery After ninety 90 days but within one hundred twenty 120 days from the date of purchase MTD PRODUCTS LIMITED will replace the defective battery for the original purchaser for a cost of one half 7 of the current retail price of the battery in effect at the date of return How to Obtain Service Warranty service is available with proof of purchase through your local MTD Authorized Service Dealer If you do not know the dealer in your area please write to the Service Department of MTD PRODUCTS LIMITED P O BOX 1386 KITCHENER ONTARIO N2G 4J1 The return of a complete unit will not be accepted by the factory unless prior written permission has been extended by MTD PRODUCTS LIMITED Other Warranties All other warranties express or implied including any implied warranty of merchantability is limited in its duration to that set forth in this express limi
52. mble de r glage de roue CG 687 02192 RH Height Adj Brkt Ensemble de r glage de roue CD 50 736 0182 Spring Washer 50 ID x 1 0 OD x 022 Rondelle 0 51 DI x 1 0 DE x 0 022 51 687 02055 Complete Hinged Mulching Plug Ass y Plaque de d chiquetage de charni re 52 732 1014 Torsion Spring Ressort de torsion 53 747 0710 Hinge Pin Axe de charni re 54 731 04177 Chute Deflector D flecteur de la goulotte 55 17032A Chute Adapter Adaptateur de d flecteur 56 710 0599 Hex Wash S Tapp Scr 1 4 20 x 50 Vis autotaraudeuse a rondelle hex 1 4 20 x 0 50 57 736 0270 Cupped Washer 265 ID x 75 OD x 062 Rondelle creuse 0 265 DI 0 75 DE x 0 062 58 7510042823 Screw Vis 59 751A1466513 Shroud Capot 60 736 0504 Wave Washer 510 x 750 x 017 Rondelle ondul e 0 510 x 0 750 x 0 017 61 710 0216 Hex Hd Cap Screw 3 8 16 x 75 Vis a t te hex 3 8 16 x 0 7 62 720 0312 Knob Bouton 63 731 1426A Hub Cap Yellow Moyeu de chapeau jaune 64 731 04526 Shroud Capot 11A 54X 04 13 06 15 Parts List Pieces d tach es For parts and or accessories refer to customer support on page 2 Adressez vous au Service apres vente la page 2 pour ce qui concerne les pi ces et ou accessoires L lejuepiooe ep Iu ep ejqesuodsei sed 159 0 Q3 LIIWIT 51900006 Simpojd ses ep ejuen e ep 5100006 ALN se juejuesoJdeJ 913
53. nal injury to the operator and others WARNING If you strike a foreign A object stop the engine Remove wire from the spark plug thor oughly inspect the mower for any damage and repair the damage before restarting and operating the mower Extensive vibration of the mower during operation is an indication of damage The unit should be promptly inspected and repaired Operating Tips 1 For best results and effective mulching do not cut wet grass 2 New grass thick grass or wet grass may require a narrower cut 3 For a healthier lawn never cut off more than one third of the total length of the grass 4 Your lawn should be cut in the fall as long as there is growth 5 Adjust ground speed according to condition of lawn 6 If the grass has been allowed to grow in excess of 4 inches mulching is not recommended Mow using the grass catcher to reduce the grass height to 3 1 4 inches or less before mulching WARNING Wait for the blade to A stop completely before doing any work on the mower or to remove the grass catcher Figure 10 NOTE To operate your unit using the grass catcher mulcher or optional side discharge refer to page 7 The side discharge is an optional feature If converting to side discharge make sure grass catcher is off unit and rear discharge door is closed a Onthe side of the mower deck lift the hinged mulching plug See Figure 11 b Slide the two hooks on the side discharge de
54. nd certain vehicle components contain or emit chemicals known to State of California to cause cancer and birth defects or other reproduc DANGER This machine was built to be operated according to the rules for safe operation in this manual As with any type of power equipment carelessness or error on the part of the operator can result in serious injury This machine is capable of amputating hands and feet and throwing objects Failure to observe the following safety a Step back from the mower to fully extend your arms b Besure 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 not operate the mower while under the influence of alcohol or drugs Do not engage the self propelled mechanism on units so equipped while starting engine The blade control handle is a safety device Never attempt to bypass its operation Doing so makes the safety device inoperative and may result in personal injury through contact with the rotating blade The blade control handle must operate easily in both directions and automatically return to the disengaged position when released 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 M
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56. ng or damaged discharge cover can cause blade contact or thrown object injuries 10 Many injuries occur as a result of the mower being pulled over the foot during a fall caused by slipping or tripping Do not hold on to the mower if you are falling release the handle immediately 11 Never pull the mower back toward you while you are walking If you must back the mower away from a wall or the manufacturer Failure to do so can result in personal injury 22 situations occur which are not covered in this manual use care and good judgment Call customer assistance for the name of your nearest servicing dealer Slope Operation Slopes are a major factor related to slip and fall accidents which can result in severe injury Operation on slopes requires extra caution If you feel uneasy on a slope do not mow it For your safety use the slope gauge included as part of this manual to obstruction first look down and behind to avoid tripping and then follow these steps measure slopes before operating this unit on a sloped or hilly area If the slope is greater than 15 degrees do not mow it Do 1 Mow across the face of slopes never up and down Exercise extreme caution when changing direction on slopes 2 Watch for holes ruts rocks hidden objects or bumps which can cause you to slip or trip Tall grass can hide obstacles 3 Always be sure of your footing A slip and fall can cause serious personal injury If you
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59. on the crankshaft with the star away from the engine See Figure 13 Place the blade with the side marked bottom or with part number facing away from the adapter Align the blade bell support over the blade with the tabs in the holes of the blade and insert the hex bolt 10 Tighten the hex bolt to the torque listed below Blade Mounting Torque Center Bolt 450 in Ib min 600 in Ib max To insure safe operation of your unit ALL nuts and bolts must be checked periodically for correct tightness Rear Flap Replacement 1 The rear flap is attached to the back of the mower deck and is designed to minimize the possibility that objects will be thrown from the rear of the mower toward the operator If the rear flap becomes dam aged replace as follows 2 To remove the old rear flap cut off the flat end of the wire rod which secures it to the deck using a pair of side cutters Attach the new rear flap using the new rod provided with the rear flap bending the ends of the rod over to secure Off Season Storage The following steps should be taken to prepare your lawn mower for storage 1 Clean and lubricate mower thoroughly as described in the lubrication instructions 2 We do not recommend the use of a pressure washer or garden hose to clean your unit 3 Refer to engine manual for correct engine storage instructions 4 Coat mower s cutting blade with chassis grease to prevent rusting 5 Store mower in a dry
60. ow only in daylight or in good artificial light Walk never run Stop the blade when crossing gravel drives walks or roads If the equipment should start to vibrate abnormally stop the engine and check immediately for the cause Vibration is generally a warning of trouble Shut the engine off and wait until the blade comes to complete stop before removing the grass catcher or unclogging the chute The cutting blade continues to rotate for a few seconds after the engine is shut off Never place any part of the body in the blade area until you are sure the blade has stopped rotating Never operate mower without proper trail shield discharge cover grass catcher blade control handle or other safety protective devices in place and working Never operate mower with damaged safety devices Failure to do so can result in personal injury HEED ITS WARNING and legs and steel toed shoes are recommended Never operate this machine in bare feet sandals slippery or light engine become Can cause aburi Do weight e g canvas shoes 21 Only use parts and accessories made for this machine by 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 8 Do not put hands or feet near rotating parts or under the cutting deck Contact with the blade can amputate hands and feet 9 A missi
61. pose 3 Never allow children under 14 years old to operate this machine Children 14 years old and over should read and understand the instructions in this manual and should be trained and supervised by a parent Only responsible individuals who are familiar with these rules of safe operation should be allowed to use this machine 4 Thoroughly inspect the area where the equipment is to be used Remove all stones sticks wire bones toys and other foreign objects which could be tripped over or picked up and thrown by the blade Thrown objects can cause serious personal injury Plan your mowing pattern to avoid discharge of material toward roads sidewalks bystanders and the like Also avoid discharging material against a wall or obstruction which may cause discharged material to ricochet back toward the operator 5 To help avoid blade contact or a thrown object injury stay in the operator zone behind the handles and keep children bystanders helpers and pets at least 75 feet from the mower while it is in operation Stop machine if anyone enters the area 6 Always wear safety glasses or safety goggles during operation and while performing an adjustment or repair to protect your eyes Thrown objects which ricochet can cause serious injury to the eyes 7 Wear sturdy rough soled work shoes and close fitting slacks and shirts Shirts and pants that cover the arms 18 19 WARNING Engine Exhaust some of its constituents a
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65. tarting the engine 13 Never store the machine or fuel container near an open flame spark or pilot light as on a water heater space heater furnace clothes dryer or other gas appliances 14 To reduce fire hazard keep mower free of grass leaves or other debris build up Clean up oil or fuel spillage and remove any fuel soaked debris 15 Allow a mower to cool at least 5 minutes before storing General Service 1 Never run an engine indoors or in a poorly ventilated area Engine exhaust contains carbon monoxide an odorless and deadly gas 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 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 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 Never tamper with safety devices Check their proper operation regularly After striking a foreign object stop
66. ted warranty The provisions as set forth in this warranty provide the sole and exclusive remedy of MTD PRODUCTS LIMITED obligations arising from the sale of its products MTD PRODUCTS LIMITED will not be liable for incidental or consequential loss or damage 13 14 REF PART NO NO N DE DE REF PIECE DESCRIPTION DESCRIPTION 1 747 1161A Blade Control Handle Black Poign e de commande de la lame noir 2 749 1092A Upper Handle Black Guidon sup rieur noir 3 747 04080 Catcher Lower Frame Sac a herbe bati inf rieur 4 749 0928B Lower Handle Guidon inf rieur 5 720 0279 Knob 1 4 20 Bouton 1 4 20 6 710 1205 Rope Guide Bolt Boulon de guidage de cordon 7 710 1174 Curved Carriage Bolt 5 16 18 x 2 00 Boulon ordinaire courb 5 16 18 x 2 00 8 664 04007A Generic Grasscatcher Bag Black Sac a herbe noir 664 04027 Grasscatcher Bag YM Sac herbe YM 664 04011 Grasscatcher Bag Troy w label Sac herbe Troy avec tiquette 9 720 0284 Knob 5 16 18 Bouton 5 16 18 10 736 0451 Saddle Washer Rondelle selle 11 726 0240 Cable Tie Attache c ble 12 710 0703 Carriage Bolt 1 4 20 x 75 Gr 1 Boulon ordinaire 1 4 20 x 0 75 Qual 1 18 731 04727 RB Chute Door Porte de goulotte 14 750 04162 Spacer 390 x 810 x 950 Entretoise 0 390 x 0 810 x 0 950 15 732 04089A LH Torsion Spring Ressort de torsion CG 16 732 04090A RH Torsion Spring Ressort de torsion CD 17A 734
67. the retailer from which it was purchased without first contacting Customer Support If you have difficulty assembling this product or have any questions regarding the controls operation or maintenance of this unit You can seek help from the experts choose from the options below 1 Visit www troybilt ca for many useful suggestions click on Customer Support button 2 Call a Customer Support Representative at 1 800 668 1238 3 The engine manufacturer is responsible for all engine related issues with regards to performance power rating specifica tions warranty and service Please refer to the engine manufacturer s Owner s Operator s Manual packed separately with your unit for more information Please have your unit s model number and serial number ready when you call See previous section to locate this information You will be asked to enter the serial number in order to process your call Use this page as a guide to determine slopes where you may not operate safely Do not operate your lawn mower on such slopes 0 C4 WARNING Do not mow on inclines with a slope in excess of 15 degrees a rise of approximately 2 1 2 feet every 10 feet A riding mower could overturn and cause serious injury If operating a walk behind mower on such a slope it is extremely difficult to maintain your footing and you could slip resulting in serious injury
68. ty 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 NOTE The units illustrated may vary slightly from your unit 1 Remove loose parts and any packing material which may be between upper and lower handles Pull up and back on the upper handle to raise the handle from position A into the operating position Setup and BY B See Figure 1 Adjustments N b Tighten hand knobs star knobs securing upper handle to lower handle Make sure that each carriage bolt is seated properly in the handle NOTE On some models wing nuts have been replaced with star knobs Figures show wing nuts only 2 Locate hairpin clip in one hole on the weld pin on each side of lower handle a Remove hairpin clip from this hole Using a pair of pliers insert hairpin clip into the other hole on the WARN NG Figure 1 weld pin Repeat on other side b Place one carriage bolt found in the hardware pack included with your unit in the upper hole of the right handle mounting bracket from the inside outward See Figure 2 Secure with one wing nut star knobs Repeat process on the left side Disconnect and ground the spark plug wire as instruct ed in the separate engine manual 3 Rope guide Setup as follows see Figure 3 a Hold the blade control against the upper handle Position A b Slowly pull starter rope
69. ur unit Clean every few hours under extremely dusty conditions Poor engine performance and flooding usually indicates that the air cleaner should be serviced 4 The spark plug should be cleaned and the gap reset once a season Spark plug replacement is recom mended at the start of each mowing season check engine manual for correct plug type and gap specifica tions NOTE This spark ignition system meets all require ments of the Canadian Interference Causing Equipment Regulations 5 Clean the engine regularly with a cloth or brush Keep the cooling system blower housing area clean to permit proper air circulation which is essential to engine performance and life Be certain to remove all grass dirt and combustible debris from muffler area Deck The underside of the mower deck should be cleaned after each use to prevent a buildup of grass clippings leaves dirt or other matter If this debris is allowed to accumulate it will invite rust and corrosion and may prevent proper mulching The deck may be cleaned by tilting the mower and scrap ing clean with a suitable tool make certain the spark plug wire is disconnected Blade Care 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 Periodically inspect the blade adapter for cracks especial ly if you strike a foreign object Replace when necessary Follow t
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