Troy-Bilt 830 Lawn Mower User Manual
Contents
1. 15 Safety Labels WARNING DO NOT remove safety or any labels from mower for any reason Model Series 830 yO 6 meos Comrolcable 8 725 0157 CableTie 9 73204265 Torsion Spring LH to 710 0599 TT Screw 1 4 20x 500 __ 749 04206 Upper Hande __ 756 04273t Upper Engine Pulley __ 756 04272t Lower Engine Pulley _6_ 136 05141t Flat Wash 885x 1 850 060 748 040964 Blade Adapter a 7101044 Screw 824x150 9 796 05248 Blade Ben Supon Teoste S Spor 25mm x 1 375 x 376 750 1260tt Sleeve Spacer 1 Equipped with electric start units 11 Equipped on units with Briggs amp Stratton engine or Honda engine GCV160AS1H Equipped on units with Honda engine GCV160AS3H 17 Parts List To order replacement parts call 1 866 840 6483 1 330 558 7220 or log on to our Web site at www troybilt com Model Series 830 18 Rai ay 1 al 731 05470 Clip Spacer 10 741 04136B Split Hex Flange Bearing 734 04014B Front Wheel 712 04065 Flange Lock Nut 3 8 16 11 634 04207D Rear Wheel 710 04531 Screw 1 4 20 x 39 782 7551A Wheel Dust Cover 717 04192A Spur Gear 14T RH 748 04159 Transmission Bearing Support 736 3084 Flat Washer 5 12 13 14 15 16 17 18 19 0 22 23 24 25 26 27 28 29 30 Parts List MID le EN2. Safety Assembly Operation Tips amp Techniques Maintenance Troubleshooting Parts Lists e Warranty OPERATOR S MANUAL OTROY BILT Shown with Optional Electric Start 21 inch Rotary Mower Model Series 830 IMPORTANT READ SAFETY RULES AND INSTRUCTIONS CAREFULLY BEFORE OPERATION Warning This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest covered brush covered or grass covered land unless the engine s exhaust system is equipped with a spark arrester meeting applicable local or state laws if any If a spark arrester is used it should be maintained in effective working order by the operator In the State of California the above is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands A spark arrester for the muffler is available through your nearest engine authorized service dealer or contact the service department P O Box 361131 Cleveland Ohio 44136 0019 FORM NO 769 02163B PRINTED IN U S A TROY BILT LLC P O BOX 361131 CLEVELAND OHIO 44136 0019 4 26 2007 This Operator s Manual is an important part of your new lawn mower It will help you assemble prepare and maintain the unit for best performance Please read and understand what it says Table of Contents Slope GAUGE 3 Maintaining Your Lawn Mower 10 Safe Operation Pract
3. Damage resulting from the installation or use of any part accessory or attachment not approved by Troy Bilt for use with the product s covered by this manual will void your warranty as to any resulting damage Normal Wear Parts are warranted to be free from defects in material and workmanship for a period of thirty 30 days from the date of purchase Normal wear parts include but are not limited to items such as batteries belts blades blade adapters tines grass bags wheels rider deck wheels seats snow thrower skid shoes friction wheels shave plates auger spiral rubber and tires 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 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 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 1 330 558 7220 or log on to our Web site at www troybilt com In Canada Contact MTD Products Limited Kitchener ON N2G 4J1 or call 1 800 668 1238 or log on to our Web site at www mtdcanada com This limited warranty does not provide coverage in the following
4. 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 man ual before attempting to operate this machine Failure to comply with these instructions may result in personal injury When you see this symbol HEED IT S 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 Setup and Adjustment Handle Mounting Bracket e Y NOTE This Operator s Manual covers several models Lawn Mower features vary by model Not all features discussed or engines pictured in this manual are applicable to all Lawn Mower models NOTE Stand behind the mower as if you were going to operate it Your right hand cor responds to the right side of the mower your left hand corresponds to the left side of the mone Figure 3 2 Secure handle to handle mounting brackets NOTE For shipping purposes your mower is set with the wheels in a low cutting height position For best results raise the cutting position until it is deter mined which height is best for your lawn refer to Adjustment section for instructions IMPORTANT DO NOT crimp the cables when lifting the handle up Figure 3 3 Pull recoil starter through rope guide and tighten 1 Remove any packing materi
5. cases a The engine or component parts thereof These items may carry a separate manufacturer s warranty Refer to applicable manufactur er s warranty for terms and conditions b Log splitter pumps valves and cylinders have a separate one year warranty c Routine maintenance items such as lubricants filters blade sharpening tune ups brake adjustments clutch adjustments deck adjustments and normal deterioration of the exterior finish due to use or exposure d Service completed by someone other than an authorized service dealer e Troy Bilt does not extend any warranty for products sold or exported outside of the United States and or Canada and their respective possessions and territories except those sold through Troy Bilt s authorized channels of export distribution f Replacement parts that are not genuine Troy Bilt parts g Transportation charges and service calls h Troy Bilt does not warrant this product for commercial use No implied warranty including any implied warranty of merchantability of fitness for a particular purpose applies after the applicable period of express written warranty above as to the parts as identified No other express warranty whether written or oral except as mentioned above given by any person or entity including a dealer or retailer with respect to any product shall bind Troy Bilt During the period of the warranty the exclusive remedy is repair or replacement of the produc
6. rear left wheel See Figure 3 7 a Pull the lever out and away from the mower b Move the lever forward or back for desired cutting height c Release lever towards mower deck Figure 3 7 The cutting height adjustment lever Drive Control The adjustment wheel is located in the drive control handle housing and is used to tighten or loosen the drive belt You will need to adjust the drive control if the mower does not propel itself with the drive control engaged or if the mower s wheels hesitate with the drive control engaged If either of these conditions occur rotate the adjustment wheel clockwise to tighten the cable or counterclockwise to loosen the cable See Figure 3 8 Loosen Figure 3 8 The adjustment wheel on the drive control Setup and Adjustment WARNING Never operate mower unless the hooks on the grass catcher are firmly seated on the pivot rod and the rear discharge door rests firmly against top of the grass catcher CUTTING HEIGHT For rough or uneven lawns move the height adjustment lever to a higher position This will help prevent scalping of the grass DRIVE CONTROL For some people the drive control may not be in a comfortable position You can adjust the handle by tightening the adjustment wheel Operating Your Lawn Mower WARNING The blade control mechanism is a safety device Never attempt to bypass its operations Use extreme care when handling gasoli
7. Batteries contain sulfuric acid which 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 1 Loosen round handle knobs securing upper and lower handles and carefully fold the upper handle down toward the lower handle as shown in Figure 5 6 2 Remove the two screws securing battery cover to battery housing and place them to the side See Figure 5 6 3 Open battery cover remove positive and negative leads from battery remove and replace with new battery See Figure 5 7 Connect the positive lead to the positive side of the battery pack then connect the negative side NOTE The battery you have may differ slightly from the one shown in Figure 5 7 Refer to the Parts List IMPORTANT When replacing battery pack in handle panel battery pack must be positioned with the positive terminal to the left side and the negative terminal to the right side of panel Positive terminal is closest to the key switch Figure 5 7 Replacing battery pack incorrectly will cause serious damage 4 Reattach battery cover to battery housing by secur ing with the two screws removed earlier making sure to snap the wire conduit on the left into place on the housing 5 Fold handles back up and tighten handle knobs WARNING Do not remove the battery pack from the electric starter housing for any reason other than replacement Figur
8. Figure 5 9 When replacing fuse use a standard automotive 40 vented during charg 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 3 After charging disconnect charger plug from outlet first then disconnect charger lead from battery Replacing Fuse If Equipped Blown Fuse 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 3 A f i a starter perform the following steps to check the fuse dite Inger discharging inside the battery housing Use in a well venti 1 Open the battery cover as described in Replacing lated area away from Battery Refer to Figure 5 6 e Refer to engine manual for correct engine storage sources of ignition 2 Remove fuse from socket and inspect as shown in instructions Figure 5 9 If it is burned out replace with standard e Coat mower s cutting blade with chassis grease to Use only the battery automotive 40 ampere fuse prevent rusting charger supplied 3 Carefully place wiring back into housing close battery Store mower in a dry clean area Do not store next with this mower cover and fold upper handle back into place to corrosive materials such as fertilizer When storing any type of power equipmen
9. G 4J1 Phone 1 800 668 1238 GDOC 100020 REV A
10. UINE ame FACTORY PARTS To order replacement parts call 1 866 840 6483 1 330 558 7220 or log on to our Web site at www troybilt com IMPORTANT For a proper working machine use Factory Approved Parts V BELTS are specially designed to engage and disengage safely A substitute non OEM V Belt can be danger ous by not disengaging completely MANUFACTURER S LIMITED WARRANTY FOR OTROV BILT The limited warranty set forth below is given by Troy Bilt LLC with 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 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 two 2 years commencing on the date of original purchase and will at its option repair or replace free of charge any part found to be defective in materials or workmanship This limited warranty shall only apply if this product has been operated and maintained in accordance with the Operator s Manual furnished with the product and has not been subject to misuse abuse commercial use neglect accident improper maintenance alteration vandalism theft fire water or damage because of other peril or natural disaster
11. again at desired height or MO make a narrower cutting path 3 Sharpen or replace blade 1 Dull blade 1 Sharpen or replace blade 1 Belt not installed properly 1 Check belt for proper pulley instal 2 Debris clogging drive operation lation and movement 2 Stop engine disconnect spark plug 3 Damaged or worn belt wire and clean out debris 3 Inspect and replace belt O r ss5sc dg 14 Safety Labels Found On Your Lawn Mower TO REDUCE THE RISK OF INJURY DO NOT OPERATE UNLESS DISCHARGE COVER OR GRASS CATCHER IS IN ITS PROPER PLACE IF DAMAGED REPLACE IMMEDIATELY Y RR 2 624 DANCI _ KEEP HANDS and FEET AWAY NT DO NOT MOW WHEN CHILDREN OR OTHERS ARE AROUND AVOID SERIOUS INJURY OR DEATH USE EXTRA CAUTION ON SLOPES DO NOT e KEEP HANDS AND FEET AWAY FROM MOW SLOPES GREATER THAN 15 MOW ROTATING PARTS ACROSS NEVER UP AND DOWN NEVER e REMOVE OBJECTS THAT CAN BE THROWN PULL MOWER CLOSE TO YOUR FEET LOOK BY T ADE IN ANY DIRECTION DOWN AND BEHIND BEFORE AND WHILE WEAR SAFETY GLASSES MOVING BACKWARDS READ OPERATOR S MANUAL KEEP SAFETY DEVICES BLADE CONTROL TRAILING SHIELD DISCHARGE COVER ETC IN PLACE AND WORKING IF DAMAGED REPLACE IMMEDIATELY 532102 CD A WARNING Read and follow Operating Instructions before running engine ti Gasoline is flammable Allow engine to cool at least 2 minutes before refueling Engines emit carbon monoxide DO NOT run in enclosed A area
12. al which may be between upper and lower handles a Pull up and back on upper handle as shown in Figure 3 1 Do not crimp cable while lifting the handle up Remove star knobs from handle mount ing brackets and secure the lower handle onto the handle brackets by placing the lower hole of the lower handle onto the pins of the handle brackets b Tighten star knobs securing upper handle to lower handle See Figure 3 1 Make sure that each carriage bolt is seated properly in the handle 2 Tighten star knobs securing lower handle to handle brackets See Figure 3 2 Make certain the lower handle is seated securely into the handle mounting brackets 3 The rope guide is attached to the right side of the upper handle Loosen the wing nut which secures the rope guide See Figure 3 3 a Hold the blade control against upper handle b Pull starter rope out of the engine Release the blade control c Slip starter rope into rope guide d Tighten wing nut 4 Secure cables to the lower handle using the cable tie Pull cable tie tight and cut off excess 5 To assemble the grass catcher if needed place bag over frame with the black plastic side at the bottom Slip plastic channel over hooks on frame All channels except for center top of bag attach from the outside The center of bag attaches from the inside 6 Before attaching the grass catcher the mulching baffle must be removed Refer to Figure 3 5 a Lift rear disc
13. andle and pull rope out with a rapid continu ous full arm stroke Keeping a firm grip on the starter handle let the rope rewind slowly Repeat until engine cranks Let the rope rewind each time slowly WARNING Wait for the blade to stop completely before performing any work on the mower or to remove the grass catcher Stopping Engine 1 Release blade control to stop the engine and blade 2 Disconnect spark plug wire from spark plug and ground against the engine Figure 4 2 Starting the mower Using Your Lawn Mower WARNING Never operate your mower without either the rear door or the entire grass catcher assembly firmly secured Be sure lawn is clear of stones sticks wire or other objects which could damage lawn mower or engine Such objects could be accidently thrown by the mower in any direction and cause serious personal injury to the operator and others WARNING If you strike a foreign object stop the engine Remove wire from the spark plug thoroughly inspect mower for any damage and repair damage before restart ing and operating Extensive vibration of mower during operation is an indication of damage The unit should be promptly inspected and repaired Using as Mulcher For mulching grass remove the grass catcher and side discharge chute from the 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 recom mende
14. 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 Mow only in daylight or 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 19 Shut the engine off and wait until the blade comes to a complete stop before removing the grass catcher or unclog ging the chute 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 b
15. d Use the grass catcher to bag clippings instead Using Grass Catcher You can use the grass catcher to collect clippings while you are operating the mower Refer to setup section for instructions on attaching the grass catcher 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 in doors or in enclosed poorly ventilated areas Engine exhaust contains carbon monoxide an odor less and deadly gas Keep hands feet hair and loose clothing away from any moving parts on engine and lawn mower Maintaining Your Lawn Mower WARNING Always stop engine disconnect spark plug and ground against engine before clean ing lubricating or performing any kind of maintenance on your machine IMPORTANT The use of a pressure washer or garden hose to clean your unit is not recommended These may cause damage to electric components spindles pulleys bear ings or the engine The use of water will result in shortened life and reduce serviceability Figure 5 2 Replacing the rear flap General Recommendations Always observe safety rules when perform
16. d certain vehicle compo nents contain or emit chemicals known to State of California to cause cancer and birth defects or other reproductive harm DANGER This machine was built to be operated according to the rules for safe operation in this manual As with any type of power equipment carelessness or error on the part of the operator can result in serious injury This machine is capable of amputating hands and feet and throwing objects Failure to observe the following safety instructions could result in serious injury or death Children Tragic accidents can occur if operator is not alert to presence of children Children are often attracted to mower and mowing activity They do not understand the dangers Never assume that children will remain where you last saw them 1 Keep children out of the mowing area and under watchful care of a responsible adult other than the operator 2 Be alert and turn mower off if a child enters the area 3 Before and while moving backwards look behind and down for small children 4 Use extreme care when approaching blind corners doorways shrubs trees or other objects that may obscure your vision of a child who may run into the mower 5 Keep children away from hot or running engines They can suffer burns from a hot muffler 6 Never allow children under 14 years old to operate a power mower Children 14 years old and over should read and understand operation instructions and safety rules in thi
17. e 5 6 Fold down upper handle and remove two screws from back of housing al Positive Terminal Negative Terminal Figure 5 7 Open cover to view battery and wires 12 Charging Battery If Equipped WARNING The battery contains cor A rosive fluid 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 Maintaining Your Lawn Mower NOTE The special designed plug on the charger will only fit into the plug on the battery box WARNING Use only the battery charger supplied with this mower 1 Plug the battery charger into the port on the underside of the battery housing Figure 5 8 Figure 5 8 Plug charger into battery lead 1 and then plug charger pack into 120 volt standard household outlet 2 2 Insert the battery charger plug into a standard 120 volt household outlet See Figure 5 8 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 and after any other extended periods of non use WARNING The battery contains corrosive fluid and toxic material handle with care and keep away from children Do not puncture disassemble mutilate or incinerate the battery Explosive gases could be
18. e discharged material to ricochet back toward the operator 5 To help avoid blade contact or a thrown object injury stay in operator zone behind handles and keep children bystanders helpers and pets at least 75 feet from mower while itis in operation Stop machine if anyone enters area A 16 17 18 Always wear safety glasses or safety goggles during opera tion and while performing an adjustment or repair to protect your eyes Thrown objects which ricochet can cause serious injury to the eyes 7 Wear sturdy rough soled work shoes and close fitting slacks and shirts 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 Do not put hands or feet near rotating parts or under cutting deck Contact with blade can amputate hands and feet Amissing or damaged discharge cover can cause blade contact or thrown object injuries 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 Never pull the mower back toward you while you are walking If you must back the mower away from a wall or obstruction first look down and behind to avoid tripping and then follow these steps a Step back from mower to fully extend your arms b Be sure you
19. e 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 Push primer if equipped three times Wait about two seconds between each push See Figure 4 2 In temperature around 55 F or below prime five times Do not prime to restart a warm engine 2 Standing behind the mower squeeze the blade control against upper handle See Figure 4 2 3 Recoil Start Grasp recoil starter handle and pull rope out with a rapid continuous full arm stroke See Figure 4 2 Keeping a firm grip on the starter handle let the rope rewind slowly Repeat until engine cranks Let the rope rewind each time slowly Electric Start If Equipped Turn ignition key to the right to start the engine See Figure 4 2 Release the key after the engine starts Honda Engine If Equipped 1 Place the fuel valve lever found on the left side of the engine into the ON OPEN position 2 Move the choke lever If equipped all the way backward into the choke position See Figure 4 2 inset 3 Standing behind the mower squeeze the blade control against upper handle as shown in Figure 4 2 The choke will now begin to slowly return to the off choke position after activating the blade control Therefore quickly move onto step four below 4 Holding these two handles together firmly grasp recoil starter h
20. eplace hex bolt and tighten hex bolt to torque 450 in Ibs min 600 in Ibs max To ensure safe operation of your mower periodically check the blade bolt for correct torque Belt Care 1 Disconnect the spark plug wire and ground it against the engine 2 Drain the fuel tank or place a piece of plastic beneath the cap to prevent gasoline leakage 3 Tip mower on its side air cleaner side of engine up 4 Remove blade adapter and related hardware as instructed under Blade Care above See Figure 5 3 5 a Remove the self tapping screws that secures the engine baffle to the deck See Figure 5 4 Remove engine baffle b Loosen self tapping screw that secures deck baffle to the deck See Figure 5 4 Figure 5 3 Remove the bolt and blade bell support to access the blade and underside components Figure 5 4 A Remove the screws that hold the engine baffle onto the deck B Loosen the screw that holds deck baffle onto deck Figure 5 5 Remove belt from transmission and engine pulley 6 a Working from the rear of the mower carefully remove belt from transmission pulley b Once belt is off transmission pulley push down on deck baffle to access engine pulley and slide belt off this pulley and out from under the deck See Figure 5 5 11 Maintaining Your Lawn Mower WARNING When removing the cutting blade for sharpening or replacement or when sliding the belt around it protec
21. erformance and compromise safety 4 Mower blades are sharp and can cut Wrap the blade or wear gloves and use extra caution when servicing them 5 Keep all nuts bolts and screws tight to be sure the equip ment is in safe working condition 6 Never tamper with safety devices Check their proper operation regularly 7 After striking a foreign object stop the engine discon nect the spark plug wire and ground against the engine Thoroughly inspect the mower for any damage Repair the damage before starting and operating the mower 8 Never attempt to make a wheel or cutting height adjust ment while the engine is running 9 Grass catcher components discharge cover and trail shield are subject to wear and damage which could expose moving parts or allow objects to be thrown For safety protection frequently check components and 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 over rev 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
22. g Mulching Plug The mulching plug is used for mulching purpose Instead of collecting the grass clippings in the grass catcher your mower has the option of recirculating the clippings back to the lawn Make sure that the rear discharge door is closed and the grass catcher is removed from unit while mulching Electric Starter If Equipped The ignition switch is located on the left 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 information Gas and Oil Fill 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 See Engine manual for location of gas and oil fill WARNING Use extreme care when A 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 WARNING The operation of any lawn A 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 Starting Engine WARNING Be sure no one other than the A operator is standing near the lawn mower while starting engine or operating mower Never run engin
23. harge door b Remove mulching baffle 7 To attach grass catcher refer to Figure 3 4 a Lift rear discharge door Figure 3 4 Lift discharge door and place grass catcher on rod b Place grass catcher on the pivot rod Let go of discharge door so that it rests on the grass catcher WARNING Never operate mower unless the hooks on the grass catcher are firmly seated on the pivot rod and the rear discharge door rests firmly against top of the grass catcher 8 The battery pack within the Electric Starter must be charged 8 to 10 hours before use Refer to Charging Battery in the Maintenance section for instructions 9 Follow the steps below to install the mulching baffle Figure 3 5 The mulching baffle a Lift the rear discharge door and lift the grass catcher up and off of the pivot rod if installed b Insert the mulching baffle as shown in Figure 3 5 and release the rear discharge door 10 To convert to side discharge make sure grass catcher is off of the unit and rear discharge door is closed a On the side of the mower lift the mulching plug b Slide two hooks on side discharge chute under hinge pin on mulching plug assembly See Figure 3 6 Lower the mulching plug Do not remove side mulching plug at any time even when you are not mulching Figure 3 6 Installing the side discharge chute Adjustments Cutting Height The cutting height adjustment lever is located above the
24. ices 4 Troubieshooting urrrrrericemezinzieneazinasinizanzo 14 Setup and AdjustMent 6 Off Season Storage and Safety Labels 15 Operating Your Lawn Mower Y Parts EI octal 16 MTD LLC reserves the right to change product specifications designs and equipment without notice and without incurring obligation Finding and Recording Model Number BEFORE ASSEMBLING YOUR NEW EQUIPMENT please locate the model plate on the equipment and copy the information to the sample model plate pro vided to the right You can locate the model plate by standing at the operating position and looking down at the rear of the deck This information will be neces MTD LLC sary to use the manufacturer s web site to obtain MTD P O BOX 361131 assistance from the Customer Support Department EAA CLEVELAND OH 44136 l ZEA 330 220 4683 or when contacting an authorized service dealer www mtdproducts com 800 800 7310 Model Number Serial Number Customer Support Please do NOT return the unit to 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 e Visit www mtdproducts com e Phone a Customer Support Represe
25. ing any maintenance The warranty on this lawn mower does not cover items that have been subjected to operator abuse or negligence To receive full value from warranty operator must maintain the lawn mower as instructed here Changing of engine governed speed will void engine warranty All adjustments should be checked at least once each season Periodically check all fasteners and make sure these are tight WARNING Always stop engine discon nect spark plug and ground against engine before cleaning lubricating or doing any kind of maintenance on your machine Lubrication 1 Lubricate pivot points on the blade control at least once a season with light oil The blade control must operate freely in both directions See Figure 5 1 2 Lubricate the wheels at least once a season with light oil or motor oil If wheels are removed for any reason lubricate surface of the axle and inner surface of the wheel with light oil 3 Lubricate the torsion spring and pivot point on the rear discharge door and side mulch plug periodically with light oil to prevent rust See Figure 5 1 4 The transmission is pre lubricated and sealed at the factory and does not require lubrication 5 Follow the accompanying engine manual for lubrica tion schedule and instruction for engine lubrication Deck Care 1 Disconnect spark plug wire Drain gasoline from lawn mower or place a piece of plastic under the gas cap 2 Tip mower so
26. lade area until you are sure the blade has stopped rotating 20 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 21 Muffler and engine become hot and can cause a burn Do not touch 22 Only use parts and accessories made for this machine by manufacturer Failure to do so can result in personal injury 23 If situations occur which are not covered in this manual use care and good judgment Contact your dealer for assistance Slope Operation Slopes are a major factor related to slip and fall accidents which can result in severe injury Operation on slopes requires extra caution If you feel uneasy on a slope do not mow it For your safety use the slope gauge included as part of this manual to measure slopes before operating this unit on a sloped or hilly area If the slope is greater than 15 degrees do not mow it Do 1 Mow across the face of slopes never up and down Exercise extreme caution when changing direction on slopes 2 Watch for holes ruts rocks hidden objects or bumps which can cause you to slip or trip Tall grass can hide obstacles 3 Always be sure of your footing A slip and fall can cause serious personal injury If you feel you are losing your balance release the blade control handle immediate
27. ly 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 Service eae Handling Of Gasoline 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 2 Use only an approved gasoline container 3 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 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 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 6 Extinguish all cigarettes cigars pipes and other sources of ignition 7 Never fuel machine indoor because flammable vapors will accumulate in the area 8 Never remove gas cap or add fuel while engine is ho
28. ne 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 IMPORTANT This unit is shipped without gasoline or oil in the engine Fill up gasoline and oil as instructed in the accompanying engine manual BEFORE operating your mower Drive Control Now that you have setup your lawn mower for operation it s important to become aquainted with its controls and features Blade Control The blade control is attached to the upper handle of the mower Depress and squeeze it against the upper handle to operate unit Release it to stop engine and blade WARNING The blade control is a safety device Do not bypass its operation Drive Control The drive control is located on the upper handle Squeeze the drive control lever to engage the drive system Release it to disengage the drive system To slow down when approaching an obstacle making a turn or stopping release the lever Cutting Height Adjustment Lever The cutting height adjustment lever is located above the left rear wheel To adjust the cutting height refer to the Adjustment Section 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 Know Your Lawn Mower Figure 4 1 The major components on the mower Mulching Plu
29. ntative at 1 800 800 7310 Spanish speaking agents are available e 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 manufacturers Owner s Operator s Manual packed separately with your unit for more information Use this page as a guide to determine slopes where you may not operate safely Do not operate your lawn mower on such slopes 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 991 EOIU9A E YUM J A SIY Ploy pue 1ybis gt Operate WALK BEHIND mowers across the face of slopes never up and down slopes BUIpjing e jo 19u109 e 10 gt 1sod agua e 10 gt 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 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 WARNING Engine Exhaust some of its constituents an
30. s manual and should be trained and supervised by a parent General Operation 1 Read this operator s manual carefully in its entirety before attempting to assemble this machine Read understand and follow all instructions on the machine and in the manual s before operation Be completely familiar with the controls and the proper use of this machine before operating it Keep this manual in a safe place for future and regular reference and for ordering replacement parts 2 This machine is a precision piece of power equipment not a plaything Therefore exercise extreme caution at all times Your unit has been designed to perform one job to mow grass Do not use it for any other purpose 3 Never allow children under 14 years old to operate this machine Children 14 years old and over should read and understand the instructions in this manual and should be trained and supervised by a parent Only responsible individuals who are familiar with these rules of safe operation should be allowed to use this machine 4 Thoroughly inspect the area where the equipment is to be used Remove all stones sticks wire bones toys and other foreign objects which could be tripped over or picked up and thrown by the blade Thrown objects can cause serious personal injury Plan your mowing pattern to avoid discharge of material toward roads sidewalks bystanders and the like Also avoid discharging material against a wall or obstruction which may caus
31. st gap or replace 6 Clean fuel line Faulty spark plug Blocked fuel line 7 Wait a few minutes to restart but do not prime Engine flooded Burnt fuse Electric Start Only 8 Replace fuse see Maintenance Spark plug wire loose 1 Connect and tighten spark plug wire 2 Clean fuel line fill tank with clean fresh gasoline Blocked fuel line or stale fuel 3 Clear vent 4 Drain fuel tank Refill with fresh fuel Vent in gas cap plugged Water or dirt in fuel system Dirty air cleaner 5 Refer to engine manual Carburetor out of adjustment 6 Refer to engine manual Engine oil level low 1 Fill crankcase with proper oil Air flow restricted 2 Remove blower housing and clean Carburetor not adjusted properly 3 Refer to engine manual 1 Adjust gap to 030 2 Refer to engine manual Spark plug gap too close Carburetor idle mixture adjustment improperly set Spark plug fouled faulty or gap too wide 1 Reset gap to 030 or replace spark plug Carburetor improperly adjusted 2 Refer to engine manual Dirty air cleaner 3 Refer to engine manual Cutting blade loose or unbalanced 1 Tighten blade and adapter Balance blade Bent cutting blade 2 See an authorized service dealer Wet grass 1 Do notmow when grass is wet wait until later to cut Excessively high grass 2 Mow once at a high cutting height then mow
32. t your hands with a pair of heavy gloves or use a heavy rag to hold the blade An unbalanced blade will cause excessive vibration when rotating at high speeds It may cause damage to mower and could break causing personal injury Maintaining Your Lawn Mower WARNING Batteries contain sulfuric acid which 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 Do not remove the battery pack from the electric starter housing for any reason other than replacement NOTE Make certain that belt is seated correctly and that it is riding smoothly on the engine pulley and is not pinched between the lower and upper pulley halves 7 Replace with new belt working it between the deck and baffle first around the transmission pulley and then the engine pulley NOTE Make certain that belt is seated correctly and that it is riding smoothly on the engine pulley and is not pinched between the lower and upper pulley halves 8 Tighten self tapping screw securing deck baffle loosened earlier 9 Replace engine baffle and secure with self tapping SCrews 10 Replace blade blade adapter and associated hardware Follow instructions in Blade Care section for proper assembly 11 Tip mower back onto its wheels and remove piece of plastic from under gas cap if applicable Replacing Battery If Equipped WARNING
33. t as set forth above The provisions as set forth in this warranty provide the sole and exclusive remedy arising from the sale Troy Bilt shall not be liable for incidental or consequential loss or damage including without limitation expenses incurred for substitute or replacement lawn care services or for rental expenses to temporarily replace a warranted product Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts so the above exclusions or limitations may not apply to you In no event shall recovery of any kind be greater than the amount of the purchase price of the product sold Alteration of safety features of the product shall void this warranty You assume the risk and liability for loss damage or injury to you and your property and or to others and their property arising out of the misuse or inability to use the product This limited warranty shall not extend to anyone other than the original purchaser or to the person for whom it was purchased as a gift HOW STATE LAW RELATES TO THIS WARRANTY This limited warranty gives you specific legal rights and you may also have other rights which vary from state to state IMPORTANT Owner must present Original Proof of Purchase to obtain warranty coverage Troy Bilt LLC P O BOX 361131 CLEVELAND OHIO 44136 0019 Phone 1 866 840 6483 1 330 558 7220 MTD Canada Limited KITCHENER ON N2
34. t in a poorly NOTE The engine can be started manually if the fuse ventilated or metal storage shed care should be taken burns out to rust proof the equipment Using a light oil or silicone coat the equipment especially cables and all moving Off Season Storage parts of your lawn mower before storage The following steps should be taken to prepare your lawn Battery If Equipped NOTE The engine can mower for storage The battery must be stored with a full charge Extended ee Clean and lubricate mower thoroughly as described in storage of a discharged battery will reduce life and be started manually if the lubrication instructions capacity of the battery the fuse burns out e We do not recommend the use of a pressure washer or garden hose to clean your unit 13 Trouble Shooting Ta For repairs beyond the minor adjust ments listed here contact an authorized service dealer Engine fails to start Engine runs erratic Engine overheats Occasional skips hesitates at high speed Idles poorly Excessive Vibration Mower will not mulch grass Uneven cut Mower will not self propel Blade control disengaged 1 Engage blade control Spark plug wire disconnected 2 Connect wire to spark plug Fuel tank empty or stale fuel 3 Fill tank with clean fresh gasoline Engine not primed if equipped 4 Prime engine as instructed in Operating Your Lawn Mower 5 Clean adju
35. t or running Allow engine to cool at least two minutes before refueling 9 Never over fill fuel tank Fill tank to no more than Y inch below bottom of filler neck to provide for fuel expansion 10 Replace gasoline cap and tighten securely 11 If gasoline is spilled wipe it off the engine and equipment Move unit to another area Wait 5 minutes before starting engine 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 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 14 Allow a mower to cool at least 5 minutes before storing General Service 1 Never run an engine indoors or in a poorly ventilated area Engine exhaust contains carbon monoxide an odorless and deadly gas 2 Before cleaning repairing or inspecting make certain the blade and all moving parts have stopped Disconnect the spark plug wire and ground against the engine to prevent unintended starting 3 Check the blade and engine mounting bolts at frequent intervals for proper tightness Also visually inspect blade for damage e g bent cracked worn Replace blade with the original equipment manufacture s O E M blade only listed in this manual Use of parts which do not meet the original equipment specifications may lead to improper p
36. that it rests on the housing Keep the side with the air cleaner facing up Hold mower firmly WARNING Never tip the mower more than 90 degrees in any directions and do not leave the mower tipped for any length of time Oil can drain into the upper part of the engine causing a starting problem 3 Scrape and clean the underside of the deck with a suitable tool Do not spray with water 4 Put the mower back on its wheels on the ground If you had put plastic under the gas cap earlier make sure to remove it now Engine Care e Maintain oil level as instructed in engine manual Service air cleaner every 25 hours under normal conditions Clean every few hours under extremely dusty conditions Refer to engine manual e Clean spark plug and reset the gap once a season Check engine manual for correct plug type and gap specifications e Clean engine regularly with a cloth or brush Keep the cooling system blower housing area clean to permit proper air circulation Remove all grass dirt and combustible debris from muffler area Replacing Rear Flap 1 Lift up rear door 2 Bend bow the rear flap inward on each side to release tabs from the holes in the handle mounting brackets See Figure 5 2 Replace with new flap by bending the rear flap and sliding into place 10 Blade Care WARNING When removing cutting blade for sharpening or replacement protect your hands with a pair of heavy gloves or use a heav
37. y rag to hold blade 1 Disconnect spark plug wire from spark plug Turn mower on its side making sure that the air filter and the carburetor are up 2 Remove bolt blade bell support blade and adapter from the engine crankshaft See Figure 5 3 NOTE When removing the blade adapter etc be care ful not to remove or misplace parts above it associated with the engine pulley 3 The blade can be sharpened with a file or on a grind ing wheel Do not attempt to sharpen the blade while it is still on the mower When sharpening blade follow original angle of grind Grind cutting edges equally to keep blade balanced 4 Remove blade from the adapter for testing balance Balance the blade on a round shaft screwdriver to check Remove metal from the heavy side until it balances evenly WARNING An unbalanced blade will A cause excessive vibration when rotating at high speeds It may cause damage to mower and could break causing personal injury 5 Lubricate the engine crankshaft and the inner surface of the blade adapter with light oil Slide the blade adapter onto the engine crankshaft Place the blade on the adapter such that the side of the blade marked Bottom or with part number faces the ground when the mower is in the operating position Make sure that blade is aligned and seated on blade adapter flanges 6 Place blade bell support on the blade Align notches on the blade bell support with small holes in blade R
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