Bolens 416 Lawn Mower User Manual
Contents
1. e Coat mower s cutting blade with chassis grease to prevent rusting e 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 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 e Store mower in a dry clean area Do not store next to corrosive materials such as fertilizer NOTE When storing any type of power equipment in an unventilated 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 SECTION 9 TROUBLE SHOOTING GUIDE Trouble Possible Cause s Corrective Actions Engine failsto 1 Blade control handle disengaged 1 Engage blade control handle start 2 Spark plug wire disconnected 2 Connect wire to spark plug 3 Dirty aircleaner 3 Refer to the engine manual 4 Primer button not depressed 4 Refer to the engine manual 5 Throttle control lever if so equipped notin 5 Move throttle lever to FAST or START position correct starting position 6 Fueltank empty or stale fuel 6 Filltank with clean fresh gasoline 7 Blocked fuel line 7 Cleanfuel line 8 Faulty spark plug 8 Clean adju2. ASN SECTION 3 ASSEMBLING YOUR LAWN MOWER Unpacking e Remove staples break glue on top flaps or cut tape at carton end and peel along top flap to open carton Remove loose parts if included with unit i e owner s manual etc e Cut along corners and lay carton down flat Remove packing material e Roll or slide unit out of carton Check carton thoroughly for loose parts Tools Required 1 Pair of Pliers 2 Funnel Disconnect Spark Plug Wire Al ps Spark Plug Wire Spark Plug Figure 1 e Before setting up your lawn mower disconnect spark plug wire from the spark plug and ground it against the engine See Figure 1 e Inthe case of lawn mowers where engine is equipped with a rubber boot attach rubber boot to a bolt on the engine to ground See Figure 1 Hardware Pack Please identify each piece of the hardware pack as shown in Figure 2 here Nut Carriage Bolt 2 Figure 2 Assembling Handle NOTE Reference to right or left side of the mower is observed from the operating position Remove any packing material which may be between the upper and lower handles for shipping purposes e Pull up and back on the upper handle to raise the handle into the operating position Make certain the lower handle is seated securely into the handle mounting brackets Tighten hand knob Tighten hand knob Figure 3 e Tighten the hand knobs securing uppe
3. Attach spark plug wire to spark plug If the mower is equipped with a rubber boot over the end of the spark plug wire ensure that the metal cap at the end of the spark plug wire inside the rubber boot is fastened securely over the spark plug s metal tip To Start Engine amp Engage Blade Prime engine as instructed in the engine manual e Standing behind the unit depress the blade control handle and hold it against the upper handle e Grasp starter handle and pull rope out slowly until engine reaches start of compression cycle rope will pull slightly harder at this point Let the rope rewind slowly Repeat till the engine starts WARNING The blade will be rotating whenever the engine is running Keep your hands and feet away from a rotating blade To Stop Engine amp Blade e Release the blade control handle to stop the engine and the cutting blade e Disconnect the spark plug wire and ground it against the engine WARNING Wait for the blade to stop completely before doing any work on the mower or to remove the grass catcher Using Rotary Mower N WARNING Never operate your mower without either the rear door or the entire grass catcher assembly firmly secured e Be sure that lawn is clear of stones sticks wire or other objects which could damage lawn mower or engine Such objects could be accidentally thrown by the mower in any direction and cause serious personal injury to the operator and others WARNING If
4. certain bag is turned right side out before assembling warning label will be on the outside Parts for Grass Bag 1 Frame Assembly 2 Grass bag Assemble grass bag as follows e Place bag over frame black plastic side is the bottom of bag Slip the openings in the side of the plastic channel on bag over the hooks on the frame e Secure bag to frame by working the plastic channels on bag over frame as shown in Figure 7B All of the plastic channels except center top of bag Rear Discharge Door attach from the outside of bag Center top of bag attaches from the inside of bag Plastic Channels Figure 7 Attaching Grass Catcher To Mower Lift the rear discharge door and place the grass catcher on the pivot rod Let go of discharge door so that it rests on the grass catcher See Figure 8 Catcher 9 Figure 8 To remove the grass catcher Lift the rear discharge door on the mower as shown in Figure 8 Lift the grass catcher up out of the slots in the handle bracket assemblies Release the rear discharge door Converting To Mulcher Lift the rear discharge door on the mower and remove the grass catcher Release the discharge door to allow it to close the rear opening of the mower Now it is ready to mulch the hooks on the grass catcher are firmly seated in the slots on the handle bracket assemblies and the rear discharge door rests firmly against top of the grass catcher N WARNING Never ope
5. Bolens SINCE 1850 Operator s Manual 21 Rear Discharge Push Mower Model 416 IMPORTANT Read safety rules and instructions carefully before operating equipment 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 TROY BILT LLC P 0 BOX 361131 CLEVELAND OHIO 44136 0019 PRINTED IN U S A FORM NO 769 00590 12 2002 TABLE OF CONTENTS Content Page Important Safe Operation Practices 24444400nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 3 Slope Gauge eriein ninaa ean aa E ANENE AE ERa EA EROE rn anar nr enn ranas 6 Assembling Your Lawn Mower uussssssnnnnnennennnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnn nn 7 Know Your Lawn MOWO sae esitin anaa ea a Ea ASEE ER a aN a KARESE 9 Operating Your Lawn MOWED uuunssssensssnnnnsnnnnnnnnn
6. acturer s warranty Refer to applicable manufacturer s warranty for terms and conditions b Log splitter pumps valves and cylinders have a sepa rate 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 Troy Bilt LLC does not extend any warranty for products sold or exported outside of the United States its possessions and territories except those sold through Troy Bilt LLC s authorized channels of export distribution e Parts that are not genuine Troy Bilt parts are not covered by this warranty f Service completed by someone other than an authorized service dealer is not covered by this warranty g Transportation charges and service calls are not covered 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 LLC During the period of the warranty the exclusive remedy is repair or replacement of the product as set forth above The provisions as set forth in this warranty provide the sole and exclu
7. and the brake cable at least once a season with light oil See Figure 14 The blade control must operate freely in both directions Rear Discharge Door The torsion springs and pivot points should be lubricated periodically with light oil to prevent any rust or binding Door must work freely Wheels The wheels 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 oil Engine oil may also be used Engine Follow engine manual for lubrication instructions Figure 14 Engine A list of key engine maintenance jobs required for good performance by the mower is given in the next page Follow the accompanying engine manual for detailed list and instructions e Maintain engine oil level as instructed in engine manual e 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 SECTION 8 OFF SEASON STORAGE If the lawn mower is not going to be used for 30 days or longer prepare the unit for storage Follow the steps below for proper storage of the mower e Clean and lubricate mower thoroughly as described in the lubrication instructions e Refer to engine manual for correct engine storage instructions
8. arge 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 To help avoid blade contact or a thrown object injury stay in the operator zone behind the handles and keep bystanders helpers children and pets at least 75 feet from the machine while it is in operation Stop machine if anyone enters the area 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 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 8 10 11 11 Do not put hands or feet near rotating parts or under the cutting deck Contact with the blade can amputate hands and feet A missing 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 fi
9. cles 3 Always be sure of your footing A slip and fall can cause serious personal injury If you feel you are losing your balance release the blade control handle immediately and the blade will stop rotating within 3 seconds Do Not 1 Do not mow near drop offs ditches or embankments you could lose your footing or balance 2 Donotmow slopes greater than 15 degrees as shown on the slope gauge 3 Donotmow 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 Keepchildren out of the mowing area and under the watchful 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 Keepchildren 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 a
10. d pins in the handle mounting bracket Reattach hardware P d Lower Handle QD G Figure 10 Notch lt e Reassemble the upper handle e Place the hairpin clips in the inner holes of the weld pins and replace the carriage bolts and wing nuts on the handle brackets Attach the starter rope as instructed in the Assembly section Cutting Height An adjusting plate and thumb lever at each wheel position provides cutting height adjustment Each adjusting plate has nine height positions e Simply depress the lever towards wheel and move it to any of the nine positions for the desired cutting height See Figure 11 All four levers on the four wheels must be placed in the same relative position for uniform cutting height Height Adjustment Lever Figure 11 Carburetor Minor carburetor adjustments may be required to compensate for differences in fuel temperature altitude and load To adjust carburetor refer to the engine manual NOTE A dirty air cleaner will cause an engine to run rough Be certain air cleaner is clean and attached to the carburetor before adjusting carburetor the engine while the engine is running e g carburetor keep clear of all moving parts Be careful of heated surfaces and muffler T WARNING If any adjustments are made to SECTION 7 MAINTAINING YOUR LAWN MOWER WARNING Be sure to disconnect and ground the spark plug wire before performing any repairs or maintenance Maintaini
11. de 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 13 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 14 Muffler and engine become hot and can cause a burn Do not touch 15 Only use parts and accessories made for this machine by the original equipment manufacturer O E M Failure to do so can result in personal injury 16 If situations occur which are not covered in this manual use care and good judgment Contact your dealer for assistance Call 1 866 840 6483 or 1 330 558 7220 for the name of your nearest dealer Slope Operation Slopes are a major factor related to slip and fall accidents which can result in severe injury Operation on slopes requires extra caution If you feel uneasy on a slope do not mow it Before operating this unit on a slope or hilly area use the slope gauge on page 6 to measure slopes 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 obsta
12. e is spilled wipe it off the engine and equipment Move unit to another area Wait 5 minutes before starting the engine 13 Never store the machine or fuel container inside where there is an open flame spark or pilot light as on a water heater space heater furnace clothes dryer or other gas appliances 14 To reduce fire hazard keep mower free of grass leaves or other debris build up Clean up oil or fuel spillage and remove any fuel soaked debris 15 Allow a mower to cool at least 5 minutes before storing General Service 1 Never run an engine indoors or in a poorly ventilated area Engine exhaust contains carbon monoxide an odorless and deadly gas 2 Before cleaning repairing or inspecting make certain the blade and all moving parts have stopped Disconnect the spark plug wire and ground against the engine to prevent unintended starting ABO 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 condi
13. er disposal laws and regulations Improper disposal of fluids and materials can harm the environment 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 Some of the safety labels are reproduced below for information purposes Maintain safety by following these labels A WARNING TO REDUCE THE RISK OF INJURY DO NOT OPERATE MOWER UNLESS THIS GUARD OR ENTIRE GRASS CATCHER IS IN ITS PROPER PLACE TO REDUCE THE RISK OF INJURY DO NOT OPERATE MOWER UNLESS DISCHARGE CHUTE COVER OR GRASS CATCHER IS IN ITS PROPER PLACE DANGER KEEP HANDS and FEET AWAY n SLOPE GAUGE SECTION 2 CUT ALONG DOTTED LINE 9 sedojs Jo ese eui ssoJoe 1eAeu sedo s umop pue dn sjewoui ONIGIY ere1edo funfui snoues ul Buninsej dijs pjnoo noA pue Bunoo 4no urejureuJ oj jnoyjrp jeweanxe si y adojs e uons uo Jamou purueq yyem e Bunejedo y Anfu snoues esneo pue uinje o pjnoo 1ewouu Buipu e saupu Jadea s UD 199 O lana 1991 Z L z Ajeyeuurxoadde jo esu e seeJ6ep G jo sseoxe ul edojs e ui seuipoui uo mow jou oj ONINHVM W 1SOd 3J9N34 V HO I ONIGTING V AO H3NHOO V TT a l r a F10d U3MOd YW gt 33481 WOILYSA V HLIM 13441 SIHL QTOH ANY LHOIS A133VS 31V43d0 LON AVIN NOA SYSHM S3dO lS ANINYALAG OL 301N9 V SV 39Vd SIHL
14. hould be closed e For effective mulching do not cut wet grass because it tends to stick to the underside of the deck preventing proper mulching New or thick grass may require a narrower cut The ground speed should be adjusted to the condition of the lawn If mowing has been delayed and the grass has been allowed to grow in excess of 4 mulching is not recommended Mow using the grass bag to reduce the grass height to 3 1 4 maximum before mulching Bagging Grass Clippings You can use the grass catcher bag to collect clippings while you are operating the mower e Attach grass catcher following instructions on page 8 Grass clippings will automatically collect in the bag as you run the mower Operate the mower till the grass bag is full e Stop engine completely by releasing the blade control handle Make sure that the unit has come to a complete stop e Lift discharge door and pull grass bag up and away from the mower to dispose of the grass clippings Remove the hairpin clips from the weld pins on the handle brackets Press outward on the legs of the lower handle and remove it from the mower Remove the carriage bolts and wing nuts from the handle brackets Press out on the legs of the lower handle Remove lower handle from the mower Turn the lower handle around so the notches on the bottom of the lower handle are facing forward as shown in Figure 10 Reassemble placing the bottom holes in the handle over the wel
15. ith 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 Tighten the hex bolt to the torque listed here Blade Mounting Torque Center Bolt 450 in lbs min 600 in lbs max e To ensure safe operation of your unit all nuts and bolts must be checked periodically for correct tightness Replacing Rear Flap e Toremove rear flap cut off the flat end of the wire rod which secures it to the deck See Figure 13 e Attach the new flap and new rod to deck bending the ends of the new rod over to secure to deck Handle Bracket Handle Bracket Figure 13 Deck Care NOTE We do not recommend the use of pressure washers or garden hose to clean your unit These may cause damage to electric components spindles pulleys bearings or the engine The use of water will shorten life of the mower and reduce its serviceability e The underside of the mower deck should be cleaned after each use to prevent a build up of grass clippings leaves dirt or other matter If this debris is allowed to accumulate it will invite rust and corrosion and may cause an uneven discharge of grass clippings at the next cutting e The deck may be cleaned by tilting the mower and scraping clean with a suitable tool make certain the spark plug wire is disconnected Lubrication Blade Control Lubricate the pivot points on the blade control handle
16. nd supervised by a parent Service Safe Handling Of Gasoline 1 Toavoid personal injury or property damage use extreme care in handling gasoline Gasoline is extremely flammable and the vapors are explosive Serious personal injury can occur when gasoline is spilled on yourself or your clothes which can ignite 2 Wash your skin and change clothes immediately 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 5 If possible remove gas powered equipment from the truck or trailer and refuel it on the ground If this is not possible then refuel such equipment on a trailer with a portable container rather than from a gasoline dispenser nozzle 6 Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete Do not use a nozzle lock open device 7 Extinguish all cigarettes cigars pipes and other sources of ignition 8 Never fuel machine indoors because flammable vapors will accumulate in the area 9 Never remove gas cap or add fuel while 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 inch below bottom of filler neck to provide space for fuel expansion 11 Replace gasoline cap and tighten securely 12 If gasolin
17. ng the Blade e Periodically inspect the blade adapter for cracks especially if you strike a foreign object Replace when necessary WARNING When removing the cutting A blade for sharpening or replacement protect hands by using heavy gloves or a rag to grasp the cutting blade Remove the bolt and bell support which hold the blade and adapter to the engine crankshaft See Figure 12 Remove the blade and adapter from the crankshaft Crankshaft Support 4 Hex Bolt Figure 12 When sharpening the blade follow the original angle of grind as a guide It is extremely important that each cutting edge receive an equal amount of grinding to prevent an unbalanced blade An unbalanced blade will cause excessive vibration when rotating at high speeds and may cause damage to the mower and or personal injury The blade can be tested by balancing it on a round shaft screwdriver Remove metal from the heavy side until it balances evenly It is recommended that the blade always be removed from the adapter for the best test of balance 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 or engine oil Lubricating the bolt holes bolts and inner surface of the nuts is also recommended e Install the blade adapter on the crankshaft with the star away from the engine Place the blade with the side marked bottom or w
18. nnnnnnnnnnnnnnnnnnnnnnnnnnnnn mann 9 Making Adjustments encena ooann AEEA NE nnne nennen 10 Maintaining Your Lawn Mower sesseeeeeeeeenneem eene nnne 11 Off S ason StOarge iot te ended rd c ea E RE Rua Leda xu x ERR 13 Troubleshooting uus coo i ee 14 g ucaEc m 15 FINDING MODEL NUMBER 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 Before you start assembling your new equipment please locate the model plate on the equipment and copy the information from it in the space provided below The information on the model plate is very important if you need help from our Customer Support Department or an authorized dealer You can locate the model number by standing at the operating position and looking down at the rear of the deck A sample model plate is explained below For future reference please copy the model number and the serial number of the equipment in the space below Copy the model number here B 7 NS TROY BILT LLC Copy the serial number here T e CLEVELAND on 44136 www bolens com 330 558 7220 866 840 6483 ENGINE INFORMATION The engine manufacturer is responsible for all engine related issues with regards to performance power rating specifications warranty and service Please refer to the engine manufacture
19. r handle to lower handle carriage bolts must be seated properly into the handle See Figure 3 For shipping purposes the hairpin clip is placed in the outer hole of the weld pin on the lower handle Remove the hairpin clip from the outer hole of the weld pin See Figure 4 Using a pair of pliers insert the hairpin clip into the inner hole on the weld pin Repeat on other side See Figure 4 Carriage Bolt Figure Insert the carriage bolt included in the hardware pack in the upper hole on the handle mounting bracket carriage bolt must go to the inside of handle Secure with one plastic wing nut also included in the hardware pack Repeat on the other side with remaining items from the hardware pack e The rope guide is attached to the right side of upper handle Loosen the wing nut which secures the rope guide e With the spark plug wire disconnected and grounded hold the blade control handle against the upper handle and pull the starter rope out of the engine Release the blade control handle Slip the starter rope into the rope guide Tighten the wing nut See Figure 5 e Tighten all nuts and bolts securely Slip rope into rope guide Wing Nut oa ON Rope Guide c Figure 5 e Insert post on cable ties into holes provided on the lower handle Pull the cable tie tight and trim the excess See Figure 6 Cable Tie Hole on Lower Handle Figure 6 Assembling Grass Catcher NOTE Make
20. r s Owner s Operator s Manual packed separately with your unit for more information CALLING CUSTOMER SUPPORT If you have difficulty assembling this product or have any questions regarding the controls operation or maintenance of this unit please call the Customer Support Department Call 1 866 840 6483 or 1 330 558 7220 to reach a Customer Support representative 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 For more details about your unit visit our website at www bolens com SECTION 1 IMPORTANT SAFE OPERATION PRACTICES A 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 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 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 opera
21. rate mower unless SECTION 4 KNOW YOUR LAWN MOWER Compare the illustrations in Figure 9 with your lawn mower to familiarize yourself with the location of various controls and adjustments aa Cf Upper Handle Recoil diii Grass cue Height Adjustment Lever Blade Control Handle Figure 9 Blade Control Handle The blade control handle is located on the upper handle of the mower The blade control handle must be depressed in order to operate the unit Release the blade control handle to stop the engine and blade a safety device Never attempt to bypass it T WARNING The blade control mechanism is Recoil Starter The recoil starter handle is attached to the handle and is used to start the engine Cutting Height Adjustment Lever These levers are located on each wheel and they are used to adjust the cutting height All four levers have to be at the same relative position to ensure uniform cut SECTION 5 OPERATING YOUR LAWN MOWER WARNING Keep hands and feet away from the chute area on cutting deck Refer to A warning label on the unit Gas and Oil Fill Up e Service the engine with gasoline and oil as instructed in the engine manual packed with your mower Read instructions carefully WARNING Never fill fuel tank 1 indoors A 2 with engine running or 3 until the engine has been allowed to cool for at least two minutes after running Before Starting e
22. rst look down and behind to avoid tripping and then follow these steps a Step back from the 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 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 in daylight or good artificial light Walk never run Stop the blade when crossing gravel drives walkways 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 a complete stop before removing the grass catcher or unclogging the chute The cutting bla
23. sembly Rear Height Adj 732 04072 Torsion Spring RH 47 14765 Pivot Bar 9 Position RH 19 787 01016 Handle Bracket RH 14766 Pivot Bar 9 Position LH 787 01015 Handle Bracket LH 48 710 0896 AB Screw 1 4 14 x 625 20 1734 1987 Wheel 49 712 0431 Flange Lock Nut 3 8 16 21 782 5003 Rear Baffle LH 50 714 0104 Hairpin Clip 23 787 01103 Cutting Deck Rear Discharge 51 710 0654A TT Sems Screw 3 8 16 x 1 0 24 710 1017 AB Screw 1 4 14 x 625 52 14578 Handle Bracket Assy Front LH 25 782 5002 Front Baffle 14579 Handle Bracket Assy Front RH 26 748 0376C Blade Adapter 53 687 02037 Handle Bracket Assy Rear LH 27 742 0741 Mulching Blade 687 02036 Handle Bracket Assy Rear RH 28 710 1044 Hex Bolt 3 8 24 x 1 5 16 YOUR NOTES Date Comments 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 its possessions and territories Troy Bilt LLC warrants this product against defects 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
24. sive remedy arising from the sale Troy Bilt LLC 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 Troy Bilt LLC P 0 BOX 361131 CLEVELAND OHIO 44136 0019 Phone 1 866 840 6483 1 330 558 7220
25. st gap or replace 9 Engine flooded 9 Referto the engine manual Engine runs 1 Spark plug wire loose 1 Connectand tighten spark plug wire erratic 2 Blocked fuel line if equipped or stale fuel 2 Clean fuel line fill tank with clean fresh gasoline 3 Ventin gas cap plugged 3 Clear vent or threads or replace 4 Water or dirt in fuel system 4 Drain fuel tank Refill with fresh fuel 5 Dirty air cleaner 5 Referto the engine manual 6 Carburetor out of adjustment 6 Refer to the engine manual Engine 1 Engine oil level low 1 Fill crankcase with proper oil overheats 2 Dirty aircleaner 2 Refer to the engine manual 3 Airflow restricted Stop engine and disconnect spark plug wire Remove blower housing and clean 4 Carburetor not adjusted properly 4 Refer to the engine manual Occasionally 1 Spark plug gap too close 1 Adjust gap to 030 skips at high 2 Carburetor idle mixture adjustment 2 Referto the engine manual packed with your unit speed improperly set Idles poorly 1 Spark plug fouled faulty or gap too wide 1 Reset gap to 030 or replace spark plug 2 Carburetor improperly adjusted 2 Refer to the engine manual 3 Dirty air cleaner 3 Refer to the engine manual Excessive 1 Cutting blade loose or unbalanced 1 Tighten blade and adapter Balance blade vibration 2 Bent cutting blade 2 See an authorized service dealer Mowerwillnot 1 Wet grass 1 Do not mow when grass is wet wait until later to cu
26. t mulch grass 2 Excessively high grass 2 Mowonce at a high cutting height then mow again at desired height or make a narrower cutting swath 1 2 width Uneven cut 1 Wheels not positioned correctly 1 Place all four wheels in same height position 2 Dull blade 2 Sharpen or replace blade NOTE For repairs beyond those listed above contact a Bolens authorized service dealer 14 SECTION 10 PARTS LIST FOR MODEL 416 15 Model 416 Ref Part No Description Ref Part No Description No No 1 747 1161A Control Handle 29 736 0524A Blade Bell Support 2 749 1092A Upper Handle 30 15261A Front Adjustment Plate 3 747 04080 Grass Catcher Frame 31 15262B Pivot Bar 7 749 0928A Lower Handle 32 720 0426 Knob Adjustment Lever 8 720 0279 Wing Nut 33 732 0404 Spring Lever Assembly 9 710 1205 Rope Guide 34 738 0507B Shoulder Screw 10 710 1174 Carriage Bolt 5 16 18 x 2 35 736 0105 Bell Washer 375 x 870 11 664 04005 Grass Bag Assembly 37 738 0102 Shoulder Screw 498 x 1 4 12 720 0284 Hand Knob 38 782 5004A Rear Baffle RH 13 736 0451 Saddle Washer 39 746 1130 Control Cable 40 14 726 0240 Cable Tie 41 731 1236 Trailshield 15 710 0703 Carriage Bolt 1 4 20 42 732 0700 Trailshield Wire 16 731 04134 Rear Discharge Door 44 712 0397 Wing Nut 1 4 20 17 750 04162 Spacer 45 710 0654A Hex L Washer Hd Screw 3 8 16 x 1 0 18 732 04071 Torsion Spring LH 46 687 02020 Lever As
27. the mower strikes a foreign A object stop the engine Remove wire from spark plug thoroughly 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 e For best results do not cut wet grass because it tends to stick to the underside of the mower preventing proper discharge of grass clippings SECTION 6 MAKING ADJUSTMENTS WARNING Do not at any time make any adjustment to lawn mower without first stopping the engine and disconnecting the spark plug wire Handle Height The mower is shipped with the handle at a higher height position To lower the height proceed as follows Remove the starter rope from the rope guide Remove the hand knobs washers and carriage bolts securing the upper handle to the lower handle Lay the upper handle out of the way being careful not to bend or kink the cables e Fora healthy lawn never cut more than one third of the total length of the grass at any one cutting e This mower is set at full throttle for best performance NOTE For shipping purposes your mower is set with the wheels in a low cutting height position For best results raise the cutting position to the height which is best suited for your lawn See cutting height adjustment section on next page Using as Mulcher For mulching grass remove the grass catcher from the mower The rear discharge opening s
28. tion 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 Never attempt to make a wheel or cutting height adjustment 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 AVOID SERIOUS INJURY OR DEATH KEEP HANDS AND FEET AWAY FROM iin BY THE REMOVE OBJECTS THAT CAN BE THR BLADE IN ANY DIRECTION WEAR SAFETY CLASES DO NOT MOW WHEN CHILDREN OR OTHERS ARE AROS USE EXTRA CAUTION ON SLOPES DO NOT MOM SU GREATER THAN 15 MOW ACROSS NEVER UP p NEVER PULL MOWER CLOSE TO YOUR FET LOOK DON Sr ry E O BEFORE AND WHILE MOV a ZUNG SHIELD DIANUAL KEEP PATET N PLACE 10 11 12 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 Do not change the engine governor setting or overspeed the engine The governor controls the maximum safe operating speed of the engine Maintain or replace safety and instruction labels as necessary Observe prop
29. 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 accessory or attachment not approved by Troy Bilt LLC for use with the product s covered by this manual will void your warranty as to any resulting damage Normal wear parts or components thereof are subject to separate terms as follows All normal wear parts or component failures will be covered on the product for a period of 90 days regardless of cause After 90 days but within the two year period normal wear part failures will be covered ONLY IF caused by defects in materials or workmanship of OTHER component parts Normal wear parts and components include but are not limited to batteries belts blades blade adapters grass bags rider deck wheels seats snow thrower skid shoes shave plates auger spiral rubber and tires HOW TO OBTAIN SERVICE Warranty service is available WITH PROOF OF PURCHASE through your local authorized service dealer To locate the dealer in your area check your Yellow Pages or contact Troy Bilt LLC at P O Box 361131 Cleveland Ohio 44136 0019 or call 1 866 840 6483 or 1 330 558 7220 or log on to our Web site at www troybilt com This limited warranty does not provide coverage in the following cases a The engine or component parts thereof These items carry a separate manuf
30. tor 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 General Operation 1 Read this operators 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 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 Never allow children under 14 years old to operate this machine 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 Only responsible individuals who are familiar with these safe operation rules should use this machine 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 disch
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