BMW 635CSi Automobile User Manual
Contents
1. Figure 3 e Fasten the cable to the lower handle with the cable tie found on the lower handle Pull the cable tie tight and trim off the excess See Figure 4 Cable Tie Lower Je Handle Figure 4 Attaching Rope Guide e If not already attached to the upper handle insert rope guide into the first hole on the upper handle as indicated in Figure 5 Secure the rope guide to handle with wing nut but do not tighten Starter Upper Handle Rope Wing Nut Lower Handle Figure 5 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 wing nut Removing Chute Retainer For shipping purposes the chute deflector on your mower is held in an upright position by a retainer Remove the retainer by following the steps below before running the mower for the first time e Push the chute deflector up and towards the engine Holding the deflector in this position remove the retainer See Figure 6 e Lower the chute deflector carefully to its operating position keeping your fingers out of the way Retainer a Raise chute deflector Remove etainer Figure 6 Installing Mulching Baffle If your mower is equipped with the optional mulching baffle install it on the right side of the deck following these instruct2. 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 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 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 10 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
3. 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 exclusive 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
4. 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 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 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 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 orrunning Allow engine to cool at least two minutes b
5. 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
6. 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 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 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
7. Bolens SINCE 1850 Operators Manual 22 Rotary Mowers Model 084 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 O BOX 361131 CLEVELAND OHIO 44136 0019 PRINTED IN U S A FORM NO 769 00509 10 2002 TABLE OF CONTENTS Content Page Important Safe Operation Practices eee eeeeceeeeeeeeeneeeeeeeeaeeeeeeeaaeeeeeeeaeeeeeneaaa 3 SIO PS GAW GO oean ietch uazeneveadedive chante ced apatite staat a atigiia ae 6 Assembling Your Lawn MOWED cceeeeeeeeeeeenneeeeeeenaaeeeeeeeaeeeeseeaaeeeeseeeaeeeeeeeaaees 7 Know Your Lawn MOWED c ccceeecsceceeeeenneeeeeeeeaeeeeeeeeaaeeeeeeeaaeeeeeeeaaaeeeeeeeaeeeeeneaaa 9 Operating Your LAWN MOWE
8. D eecceeeeeeeeeeeeeeeeeeeee eee eeeeeaeeeeaaeeeeeeeeneeeeeeeneeeeeenes 9 Making AdjUStme nt snosi cs lt dvasunexyans wattexyshaseeeexsnesasexscaraanes 10 Maintaining Your Lawn MOWET cccceeeceeeeeeeeeee eee ecteee eee taeeeeeeeaaeeeeeeeaeeeeenenaa 11 Storing Your LAWN MOWE ccecceeeeeeeeneeceeeeeeceeeeeeeaeeeeeesaaeeeeeeeeeaeeeeeeeeeeeeees 13 Troubleshooting ee aaa cectivaneedes cts N veda et nested tdeedlane teen Anke ed 13 Pans Lisl 2 ccdeess owen ceshoccevtnenccowdbnen ccewmsetsiccaeedehiecestens deoetaneeeeeds See eed eee TEE 14 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 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 Model Number Serna Number Copy the model number here TROY BILT LLC Bolens 355 CLEVELAND OH 44136 www bolens com 330 558 7220 866 840 6483 C
9. arpen or replace blade NOTE For repairs beyond the minor adjustments listed above contact an authorized service dealer 13 SECTION 10 PARTS LIST FOR MODEL 084 Model 084 ae Part No Part Description A Part No Part Description 1 747 1161A Blade Control Handle 22 738 1173 Shoulder Screw 2 749 1092A Upper Handle 23 736 0741 Bell Washer 760 ID x 1 25 OD 3 720 0279 Wing Nut 24 734 1987 Rear Wheel 8 x 1 8 4 710 1205 Eye Bolt 25 710 0514 Hex Cap Screw 3 8 16 x 1 0 5 710 1174 Carriage Bolt 5 16 18 x 2 0 27 736 0270 Bell Washer 265 ID x 75 OD 6 720 0284 Wing Nut 28 738 1172 Shoulder Screw 7 736 0451 Shoulder Washer 320 ID x 93 OD 29 734 1988 Front Wheel 7 x 1 8 8 749 04037 Lower Handle 30 748 0376C Blade Adapter 9 725 0157 Cable Tie 31 742 0742A Mulching Blade 22 10 710 0599 TT Screw 1 4 20 x 0 5 32 736 0524A Blade Bell Support 11 17098 Hinge Clip 33 710 1044 Hex Cap Screw 3 8 24 x 1 5 12 731 04019 Trail Shield 34 747 0710 Hinge Pin 13 682 3065 Handle Bracket Assembly LH 35 732 1014 Torsion Spring 14 682 3064 Handle Bracket Assembly RH 36 731 1035B Chute Hinge 15 687 02048 Deck Assembly 22 37 731 1034B Hinged Chute Deflector 16 710 0654A TT Screw 3 8 16 x 1 0 39 746 0957 Blade Control Cable 37 25 17 741 0751 Height Adjuster Bearing 40 731 04197 Mulching Plug 18 720 0426 Height Adjuster Knob 42 736 0105 Washer Spacer 401 ID x 870 OD 19 687 02051 Lever Assembly inc
10. bell support are aligned with small holes in the blade e Replace hex bolt and tighten hex bolt to torque 450 in lbs min 600 in lbs max NOTE To ensure safe operation of your mower periodically check the blade bolt for correct torque SECTION 8 STORING YOUR LAWN MOWER The following steps should be taken to prepare your lawn mower for storage e Clean and lubricate mower thoroughly as described in the lubrication instructions IMPORTANT We do not recommend the use of a pressure washer or garden hose to clean your unit e Refer to engine manual for correct engine storage instructions Coat mower s cutting blade with chassis grease to prevent rusting 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 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 SECTION 9 TROUBLESHOOTING Problem Cause Remedy Engine fails to start 1 Blade control handle disengaged 1 Engage blade control handle 2 Spark plug wire disconnected 2 Connect wire to spark plug 3 Fuel tank empty or stale fuel 3 Fill tank with clean fresh gasoline 4 Blocked fuel line 4 Clean fuel line 5 Faulty spark plug 5 Clean adjust gap or replace 6 Engine flooded 6 Wait afew
11. ch can damage your eyes severely Always wear safety glasses while operating the mower or while performing any adjustments or repairs on it Blade Control Handle The blade control handle is attached to the upper handle of the mower Depress the blade control handle to operate the unit Release blade control handle to stop engine and blade WARNING This blade control mechanism is a safety device Never attempt to bypass its operations Cutting Height Adjustment Levers 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 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 Baffle The mulching baffle is used to recirculate the grass clippings back to the lawn Attach it as instructed on page 8 of this manual NOTE The shroud shown here may not resemble the shroud on your mower Recoil Cutting Height Starter Mulching Baffle Deflector Figure 8 Chute Deflector Discharge Chute The discharge chute when installed on the unit will allow for discharge of grass clippings beside each cutting lap If the grass has grown too tall and is not fit for mulching cut the grass using this chute first and then use the mulching baffle to mulch Stopping Engine e Release blade control ha
12. e WALK BEHIND mowers across the face of slopes never up and down slopes SECTION 3 ASSEMBLING YOUR LAWN MOWER Removing Unit From Carton e Remove staples break glue or cut tape at carton end and peel along top flap to open carton e Remove loose parts if included with unit i e operator s manual etc e Carefully cut along corners lay carton down flat and remove packing material e Roll or slide unit out of carton and check carton thoroughly for loose parts Before Assembly NOTE Reference to right or left hand side of the mower is observed from the operating position e Before setting up your lawn mower disconnect the spark plug wire from the spark plug and ground against the engine See Figure 1 Spark Plug Wire Plug Wire Spark Plug Figure 1 Setting Up Your Lawn Mower e Lift up and pull back on the upper handle to raise the handle into the operating position Make certain the lower handle is seated securely into the handle bracket assemblies e Tighten the two wing nuts on two sides to secure the upper handle to the lower handle carriage bolts must be seated properly into the handle See Figure 2 for location of wing nuts lt _ Upper Handle Lower Handle Ke es Wing Nut Figure 2 e Tighten the wing nuts at the end of the lower handle to secure the handle to handle bracket assemblies See Figure 3 Lower Handle Handle Bracket Assemblies
13. e 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 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 Donot 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 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
14. efore refueling 10 Never over fill fuel tank Fill tank to no more than 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 starting 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 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 o for damage e g bent cracked worn Replace blade replace immediately with original equipment with the original equipment manufacture s O E M blade manufacturer s O E M parts only listed in this manual only listed in this manual Use of parts which do not Use o
15. er 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 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 This machine is a precision piece of power equipment nota 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 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 Thoroughly inspect the area where the equipment is to be used
16. f parts which do not meet the original equipment meet the original equipment specifications may lead to specifications may lead to improper performance and improper performance and compromise safety compromise safety Mower blades are sharp and can cut Wrap the blade or 10 Do not change the engine governor setting or overspeed wear gloves and use extra caution when servicing them the engine The governor controls the maximum safe Keep all nuts bolts and screws tight to be sure the operating speed of the engine equipment is in safe working condition 11 Maintain or replace safety labels as necessary Never tamper with safety devices Check their proper 12 Observe proper disposal laws and regulations Improper operation regularly disposal of fluids and materials can harm the After striking a foreign object stop the engine disconnect environment the spark plug wire and ground against the engine Thoroughly inspect the mower for any damage Repair Your Responsibility the damage before starting and operating the mower Never attempt to make a wheel or cutting height s Restrict the use of this power machine to persons adjustment while the engine is running who read understand and follow the warnings and Grass catcher components discharge cover and trail instructions in this manual and on the machine shield are subject to wear and damage which could Some safety labels are reproduced below for your expose moving parts or allow objec
17. f the axle bolt and inner surface of the wheel with light oil Chute Deflector e Lubricate the torsion spring and pivot point periodically with light oil to prevent rust Engine Follow the accompanying engine manual for lubrication schedule and instruction Lubricate Figure 11 Cleaning Mower The underside of the mower deck should be cleaned after each use to prevent any build up of grass clippings leaves dirt or other debris 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 result in shortened life and reduce serviceability e Disconnect spark plug wire e Drain the gasoline from the lawn mower or place a piece of plastic under the gas cap e Tip the mower so that it rests on the housing Keep the side with the air cleaner facing up Hold the mower firmly e Scrape and clean the underside of the deck with a suitable tool Do not spray with water e Putthe mower back on its wheels on the ground If you had put plastic under the gas cap make sure to remove it now WARNING Never tip the mower more than A 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 Engine Care A list of key maintenance jobs required for good performance by the mower i
18. ide an odorless and deadly gas WARNING Keep hands feet hair and loose clothing away from any moving parts on engine and lawn mower e Push primer three times Wait about two seconds between each push In cold weather around 55 F or below prime five times Do not prime to restart a warm engine after a short shutdown e Standing behind the mower depress the blade control handle and hold it against the upper handle e Grasp starter handle and pull rope out slowly until engine reaches the start of compression cycle rope will pull slightly harder at this point Let the rope rewind slowly Pull rope with a rapid continuous full arm stroke Keeping a firm grip on the starter handle let the rope rewind slowly SECTION 6 MAKING ADJUSTMENTS Cutting Height WARNING Always stop engine disconnect spark plug and ground against engine before performing adjustments Each wheel has a height adjustment lever When this lever is moved from one slot to another the height of cut will be changed e Simply depress the lever towards the wheel and slide the lever assembly to desired position for a change in cutting height See Figure 9 IMPORTANT All wheels must be placed in the same relative position For rough or uneven lawns move the height adjustment lever to a higher position This will help stop scalping of the grass Using Your Lawn Mower 1 WARNING If you strike a foreign object stop the engine Remove wire fr
19. immediately for the cause Vibration is generally a warning of trouble 12 Shut the engine off and wait until the blade comes toa 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 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 manufacturer 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 Telephone 1 866 840 6483 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 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 th
20. ions Make sure to follow the correct sequence as indicated here e Lift up and hold the side discharge chute deflector e Insert bottom lip of the mulching baffle inside the chute opening See Figure 7 e Snap hooks of the mulching baffle over the hinge pin of the chute deflector See Figure 7 The hooks must snap into place on the hinge pin locking the mulching baffle firmly onto the mower For a close up of the hinge pin location see Figure 7 inset e Release the chute deflector NOTE nstall bottom lip inside chute opening indicated by 1 in the figure below before placing hooks over the hinge pin indicated by 2 in the figure below a Chute Deflector AS ZE Chute Opening Lip of Mulching Baffle install inside chute opening Figure 7 IMPORTANT This unit is shipped without gasoline or oil in the engine Be certain to service engine with gasoline and oil as instructed in the separate engine manual before operating your mower SECTION 4 KNOW YOUR LAWN MOWER Read this operator s manual and safety rules before operating your lawn mower Compare the illustration in Figure 8 with your lawn mower to familiarize yourself with the location of various controls and adjustments Save this manual for future reference WARNING The operation of any lawn A mower can result in foreign objects being thrown into the eyes whi
21. ludes Ref 18 43 712 0130 Hex Lock Nut 3 8 16 20 710 0216 Hex Cap Screw 3 8 16 x 75 44 712 0431 Lock Nut 3 8 16 21 682 0113 Pivot Arm 15 MANUFACTURER S LIMITED WARRANTY FOR OTROY 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 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 wea
22. minutes to restart but do not prime Engine runs erratic 1 Spark plug wire loose 1 Connect and tighten spark plug wire 2 Blocked fuel line or stale fuel 2 Clean fuel line fill tank with clean fresh gasoline 3 Ventin gas plugged 3 Clear vent 4 Water or dirt in fuel system 4 Drain fuel tank Refill with fresh fuel 5 Dirty air cleaner 5 Clean air cleaner 6 Carburetor out of adjustment 6 Adjust carburetor Engine overheats 1 Engine oil level low 1 Fill crankcase with proper oil 2 Air flow restricted 2 Remove blower housing and clean 3 Carburetor not adjusted properly 3 Adjust carburetor Occasional skip hesitates 1 Spark plug gap too close 1 Adjust gap to 030 at high speed Idles poorly 1 Spark plug fouled faulty or gap too 1 Reset gap to 030 or replace spark wide plug 2 Carburetor improperly adjusted 2 Adjust carburetor 3 Dirty air cleaner 3 Clean air cleaner Excessive vibration 1 Cutting blade loose or unbalanced 1 Tighten blade and adapter Balance blade 2 Bent cutting blade 2 Replace blade Mower will not mulch grass 1 Wet grass 1 Do not mow when grass is wet wait until later to cut 2 Excessively high grass 2 Mow once ata high cutting height then mow again at desired height or make a narrower cutting path 3 Dull blade 3 Sharpen or replace blade Uneven cut 1 Wheels not positioned correctly 1 Place all four wheels in same height position 2 Dull blade 2 Sh
23. ndle to stop the engine and the blade e Disconnect spark plug wire from spark plug and ground against the engine SECTION 5 OPERATING YOUR LAWN MOWER Starting Engine 1 WARNING Read understand and follow all instructions and warnings on the machine and in this manual before operating 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 determined which height is best for your lawn See the Adjustment Section for details Gas amp Oil Fill Up e Check oil level and add oil if necessary Follow relevant instructions in the engine manual for this e Service the engine with gasoline as instructed in the engine manual 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 Before Starting Mower e Attach spark plug wire to spark plug Make certain the metal cap on the end of the spark plug wire inside the rubber boot is fastened securely over the metal tip on the spark plug Starting Engine 1 WARNING Be sure no one other than the operator is standing near the lawn mower while starting engine or operating mower WARNING Never run engine indoors or in enclosed poorly ventilated areas Engine exhaust contains carbon monox
24. ne crankshaft See Figure 12 e Remove blade and adapter from the crankshaft Blade Adapter Blade Bell Support Hex Bolt Figure 12 Sharpening the Blade e The blade can be sharpened with a file or ona grinding wheel Do not attempt to sharpen the blade while it is still on the mower e Follow the original angle of grind as a guide Make sure that each cutting edge receives an equal amount of grinding to prevent an unbalanced blade WARNING An unbalanced blade will cause A excessive vibration when rotating at high speeds It may cause damage to the mower and could break causing personal injury Balancing the Blade e 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 when testing for balance Installing the Blade e Before reinstalling the blade and the blade adapter to the unit lubricate the engine crankshaft and the inner surface of the blade adapter with light oil e Be sure to install the blade with the side of the blade marked Bottom or with part number facing the ground when the mower is in the operating position e Slide the blade adapter onto the engine crankshaft e Place the blade on the adapter Be certain the blade is aligned and seated on the blade adapter flanges e Place blade bell support on blade Make sure the notches on the blade
25. om the 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 The unit should be promptly inspected and repaired IMPORTANT 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 personal injury to the operator and others 1 For best results do not cut wet grass 2 Newgrass thick grass or wet grass may require a narrower cut 3 Fora 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 Mulching 1 For effective mulching do not cut wet grass 2 Adjust ground speed according to the condition of the lawn NOTE f the grass has been allowed to grow in excess of 4 mulching is not recommended Mow using the side discharge to reduce the grass height to 3 1 4 or less before mulching Height Adjustment Lever Figure 9 Handle Height Your mower is shipped with the handle in the higher height position For convenience of operating you may lower the handle height as follows e Remove the starter rope from the rope guide e Disconnect the lower handle from the handle bracket assemblies by removing the wing nu
26. opy the serial number here 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 manufacturer 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 vj have your unit s model number and serial number ready when you call See previous section A 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 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 canc
27. r 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 manufacturer 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
28. s given below Follow the accompanying engine manual for details e Change engine oil regularly as instructed in the engine manual Check oil level before starting engine every time e Service foam filter in the air cleaner every 25 hours of use and replace the paper filter component every 100 hours You may have to service the air filter more frequently if you are operating the mower under extremely dusty conditions e Clean the engine periodically Remove dirt and debris with a cloth or brush e Clean the spark plug and reset the gap to 030 at least once a season Refer to the engine manual for correct spark plug type e Inspect muffler periodically and replace if necessary WARNING Damaged mufflers or spark A arresters can create a fire hazard Make sure to avoid muffler and surrounding areas while the mower engine is hot because temperature of these areas of the engine may exceed 150 F Blade Care WARNING When removing the cutting blade for sharpening or replacement protect your hands with a pair of heavy gloves or usea heavy rag to hold the blade Periodically inspect the blade adapter for cracks especially if you strike a foreign object Replace when necessary Removing the Blade e Disconnect spark plug wire from spark plug e Turn mower on its side making sure that the air filter and the carburetor are up e Remove the bolt and the blade bell support which hold the blade and the blade adapter to the engi
29. ts See Figure 10 e Position each handle bracket assembly stud into the top hole in the lower handle NOTE Each end of the lower handle must be placed in same relative position e Re attach the lower handle to the handle bracket on each side and tighten the wing nuts Re insert the starter rope into the rope guide Lower Handle Handle Bracket Assemblies Figure 10 SECTION 7 MAINTAINING YOUR LAWN MOWER General Recommendations e Always observe safety rules when performing any maintenance e The warranty on this lawn mower does not cover items that have been subjected to operator abuse or negligence To receive full value from the warranty operator must maintain the lawn mower as instructed in this manual e Changing of engine governed speed will void engine warranty e All adjustments should be checked at least once each season e Periodically check all fasteners and make sure these are tight Lubrication WARNING Always stop engine disconnect spark plug and ground against engine before cleaning lubricating or doing any kind of maintenance on your machine Blade Control Handle e 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 11 Wheels e Lubricate the wheels at least once a season with light oil or motor oil If the wheels are removed for any reason lubricate the surface o
30. ts to be thrown For information safety protection frequently check components and TO REDUCE THE RISK OF INJURY DO NOT OPERATE MOWER UNLESS DISCHARGE CHUTE COVER OR GRASS CATCHER IS IN ITS PROPER PLACE AVOID SERIOUS INJURY OR D KEEP HANDS and FEET AWAY KEEP HANDS AND FEET AWAY FROM ROTATING PAF e REMOVE OBJECTS THAT CAN BE THROWN BY SF BLADE IN ANY DIRECTION WEAR SAFET on DO NOT MOW WHEN CHILDREN OR OTHERS ARE ape USE EXTRA CAUTION ON SLOPES DO NOT MOW SiN os GREATER THAN 15 MOW ACROSS NEVER UP WN AND NEVER PULL MOWER CLOSE TO YOUR FEET LOOK DOY ARDS BEHIND BEFORE AND WHILE MOVING BA AWARNING TO REDUCE THE RISK OF INJURY DO NOT OPERATE MOWER UNLESS THIS GUARD IS IN IT S PROPER PLACE SLOPE GAUGE SECTION 2 Use this page as a guide to determine slopes where you may not operate safely Do not operate your lawn mower on such slopes es SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE i Ia POWER POLE l 1 og A CORNER OF A BUILDING a OR A FENCE POST 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 Operate RIDING mowers up and down slopes never across the face of slopes Operat
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