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TRnV BILTOperator's Manual

Model909J--Tuff-Cut e

IMPORTANT:READ SAFETY RULES AND INSTRUCTIONS CAREFULLY

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 arresterfor the muffler is available by contacting the service department at Troy-Bilt LLC, P.O. Box 361131 Cleveland, Ohio 44136-0019.

TROY-BILT LLC, P.O. BOX 361131, CLEVELAND, OH 44136-0019

PRINTED IN USA FORM NO. 770-10601A

(01/2002)

TABLE OF CONTENTS

Content Page

Calling Customer Support .................................................... 2

Safety ................................................................... 3

Assembly ................................................................. 6

Features and Controls ....................................................... 8

Operation ................................................................ 10

Maintenance .............................................................. 15

Parts List ................................................................. 22

Warrany Information ........................................................ Back Cover

FINDING MODEL NUMBER

This Operator's Manual is an important part of your new Mower. It will help you assemble, prepare and maintain theunit 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 infor-mation from it in the space provided below. This information is very important if you need help from our CustomerSupport Department or an authorized dealer.

You can locate the model number by looking at the rear surface of the cutting deck. A sample model plate isexplained below. For future reference, please copy the model number and the serial number of the equipmentin the space below

O BILT. TROY-BILT LL(P. O. BOX 361131www.troybilt.com CLEVELAND, OH 44136

330-558-7220• 866-840-5483

Copy Model Number Here

Copy Serial Number Here

ENGINEINFORMATION

The engine manufacturer is responsible for all engine-related issues with regards to performance, power-rating, speci-fications, warranty and service. Please refer to the engine manufacturer's Owner's/Operator's Manual packed sepa-rately with your unit for more information.

CALLINGCUSTOMERSUPPORT

If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenanceof this unit, please call the Customer Support Department.

Call 1- (336) 558-7220 or 1- (866) 840-6483 to reach a Customer Support representative. Please haveyour unit's model number and serial number ready when you call. See previous section to locate this infor-mation. You wilt be asked to enter the serial number in order to process your call.

2

SafetySafetyAlert Symbol

,_ This is a safety alert symbol. It is used in thismanual and on the unit to alert you to potentialhazards. When you seethis symbol, readandobey the messagethat follows it. Failureto obey

safety messagescould result in personal injury or propertydamage.

This machine meets voluntary safety standard B71.1 -1998, which is sponsored by the Outdoor PowerEquipment Institute, Inc., and is published by the AmericanNational StandardsInstitute.

• lL WARNINGThe engine exhaust from this product containschemicals known to the State of California to cause

cancer, birth defects or other reproductive harm.

IMPORTANT

SafeOperationPracticesfor Walk-BehindMowersThiscuttingmachineis capableofamputatinghandsandfeet andthrowingobjects.

Failureto observethe followingsafetyinstructionscouldresult inseriousinjuryordeath.

I. GENERALOPERATION .

1. Read,understandand follow allinstructions on the machineand inthe manuals provided with the unit.Bethoroughly familiar with the 10.controls andthe proper use of themower before starting. 11.

2. Do not put hands or feet nearorunder rotating parts. Keepclear ofthe mower bladeand dischargeopening at all times. 12.

3. Only allow responsible individuals,who are familiar with the instruc-tions, to operate the mower.

4. Clearthe area of objects such asrocks, toys, wire, bones, sticks, etc.,which could be picked up and thrownby the blade.

5. Be sure the area is clear of otherpeople before mowing. Stop mower ifanyone enters the area. Keepbystanders at least 25 feetaway from 13.the areaof operation.

6. Do not operatethe mower when 14.barefoot or wearing open sandals.Always wear substantial foot wear. 15.

7. Do not pull mower backwards unlessabsolutely necessary.Look down andbehind before andwhile movingbackwards. 16.

8. Do not operate mower without allguards in placeand either the entire 17.Grass Catcher,the Mulching Plug orthe optional Side-Discharge Chuteinstalled. ROTATINGBLADES-- Donot open discharge guard whileengine is running.

Refer to provided instructions for 18.proper operation andaccessoryinstallation. Useonly accessoriesapproved by GardenWay Inc. 19.Shut off engine when crossing gravel

drives, walks, or roads. 20.

Stop engineand disconnectsparkplug wire from spark plug wheneveryou leaveunit, before cleaning moweror unclogging chute.

Shut the engine off andwait until thebladecomes to a complete stopbefore installing or removing theMulching Plug, optional Side-Discharge Chuteor the GrassCatcher. Makecertain that an attach-ment is installed before operating themower. Empty the GrassCatcherafter each use- decomposing debriscould generateenough heat to catchfire.

Mow only in daylight or in good arti-ficial light.

Do not operate mower while underthe influenceof alcohol or drugs.

Neveroperatemower in wet grass.Always besure of your footing; keepa firm hold on the handleand walk;never run.

Besure Wheel Drive Bail is disen-gaged before starting engine.

If the unit should start to vibrateabnormally, stop the engineand dis-connect the spark plug wire. Thencheck immediately for the cause.Vibration is generallya warning oftrouble.

21.

22.

We recommend that you wear safetygoggles or safety glasses whenoperating the mower.

Watch for traffic when operatingnear, or when crossing roadways.

Neverattempt to carry children orother passengers onthe mower.Theycould fall off and beseriouslyinjured, or they could interfere withthe safe operation of the mower.

Checkthe operation of the OperatorPresenceControl Bail (top bail,mounted on handlebar) before eachuse.The Operator PresenceControlBail is a safety devicethat is designedto stop the mower blade within threeseconds after releasingthe bail. Thebail must operate freely when pulledbackagainst the handlebarandreturn automatically to the disen-gaged position when released. If theengine runs longer than threeseconds after releasingthe bail, thesystem is not working properly.Immediately contact an authorizedservice dealeror the FactoryTechnical ServiceDepartment forinstructions. Do not usethe moweruntil the mechanismis repaired.

Neverrun the enginein an enclosedarea. Engineexhaustcontains carbonmonoxide, a deadly gas that isodorless, colorless andtasteless.Always run the engine outdoors andmakesure there is adequateventilation.

Section1: Safety

II. OPERATING ON A SLOPE

Slopes are a major factorrelated to slipand fail accidentswhich can resultinsevere injury. All slopesrequire extracaution, if youfeel uneasyona slope,do notmow it.

DO:

Mow across the face of slopes; neverup and down. Exerciseextremecaution when changing direction onslopes. Avoid slopesgreater than 15o.

Removeobjects such as rocks, treelimbs, etc.

Watch for holes, ruts, or bumps. Tallgrass can hide obstacles.

DONOT:

Do not mow near drop-offs, ditches,or embankments. The operator couldloose footing or balance.

Do not mow excessivelysteep slopes.

Do not mow on wet grass. Reducedfooting could causeslipping.

III. CHILDREN

Tragic accidentscan occurif theoperator is notalert to the presenceofchildren. Childrenare oftenattractedto

the mowerandto the mowingactivity.Neverassumethat childrenwill remain

whereyou last sawthem.1. Keepchildren out of the mowing area

and under the watchful care of a

responsible adult.

2. Bealert and turn mower off ifchildren enter the area.

3. Before and while moving backwards,look behindand down for smallchildren.

4. Neverallow children to operate the 7.mower.

5. Useextra care when approachingblind corners, shrubs, trees, or otherobjects that may obscure vision. 8.

IV. SERVICE

1. Useextra care in handling gasoline 9.and other fuels. Theyare flammableand their vapors areexplosive.

a) Useonly an approved container.

b) Neverremove gas cap or add fuelwhen the engine is running.Allow engine to cool beforerefueling. Do not smoke. 10.

c) Neverrefuelthe machineindoors.

11.d) Neverstore the machine or fuel

container inside where there is anopen flame, such as a water 12.heater,etc.

e) Move mower away from anygasoline fumes before startingthe engine. 13.

inside a closed2. Neverrun an enginea_a.

3.

.

.

6.

Nevermakeadjustments or repairswith the engine running. Disconnectthe spark plug wire and movethewire awayfrom the plug to preventaccidental starting.

Keepall nuts and screws, especiallythe bladeattachment bolts, tight andkeepequipment in good condition.

Nevertamper with safety devices.Checktheir operation regularly.

Keepmower free of grass, leavesorother debris build-up. Clean up oil orfuel spillage. Allow mower to coolbefore storing.

After striking an object, stop theengineand disconnect the spark plugwire. Inspect the mower and repair, ifnecessary, before restarting.

Neverattempt to make mower cuttingheight adjustments while the engineis running.

Grasscatcher components aresubject to wear, damageand deterio-ration, which could expose movingparts or allow objects to bethrown.Frequentlycheck components andreplacewith factory recommendedparts, when necessary.

The mower bladeis sharp and cancut. Wrap the bladeor wear gloves,and use extra caution when servicing.

Do not change the engine governorsetting or overspeedthe engine.

Do not touch engine parts which maybe hot from operation.Allow parts tocool completely before inspecting,cleaning or repairing the mower.

Maintain or replace safetyandinstructional decals. Refer tothe

Parts List for replacementdecalinformation.

Section1: Safety

SAFETY DECALS

Foryour safety andthe safety of others, various safetydecals are located on your unit (below - sizenot to scale).

Keepthe decalsclean and legibleat all times. Contactyour local service dealeror the Factoryfor replacements if any decals aredamaged or missing. Refer to the PartsList pages in this Manualfor decal part numbers.

Locatedon thebeltcover. Thisdecal

providesa list ofwarningsto help avoidserious injury.

Locatedonthedischargeoutletguard. ThisdecalwarnsnottooperatethemowerwithoMthedischargeoutletguardinplaceandeithertheGrassCatcherorMulchingPluginstalled.Thisdecalalsowarnsthattherearerotatingblades.Donotopenthedischargeoutletguardwhiletheengineis running.

Locatedontheleftsideof themowerdeck. Thisdecalcautionstokeephandsaway.

Before operating your machine,carefully read and understand allsafety, controls and operating instruc-tions in this Manual, the separateEngine Owner's Manual, and on thedecals onthe machine.

Failure to follow these instructionscanresult in seriouspersonalinjury.

INTRODUCTIONThis Sectioncovers unboxing and assem-bling your new mower. Pleasecarefullyread all the instructions before youattempt to assemble the mower. Afteryou finish assembling the mower, readSection 1: Safety,Section3: FeaturesandControls,and Section4: Operation,beforeusing the mower.

INSPECTION

Inspect the mower immediately afterdelivery. Makesure that neither thecarton nor the contents have beendamaged.

If you find or suspect any damage,contact the carrier (trucking company)right away. Inform them ofthe specificdamage andthat you wish to file a claim.To protect your rights, be sure to put thisin writing to the carrier within 15 daysafter your machinearrives. The carrierwill let you know how to proceed withyour claim.

LOOSE PARTS

The following items areshipped loosewithin the container.

NOTE: The mower isshipped with theMulching Plug(B, Figure 2-2)installed in thedischarge outlet(Figure 2-1).

,, The GrassCatcherattachmer(A, Figure 2-2).

A B

Figure2-2: Attachments

ASSEMBLING NEW UNITS

Themower blade is sharpand can causeserious personal injury. When workingnear the mower blade, wear heavyleather gloves to protect yourself fromthe sharp edges.

IMPORTANT: The mower isshippedwithout motor oil in the enginecrankcase.Add motor oil to the engine beforestarting. Follow instructionsin thisSection.

Step 1: Unpack Mower1. The mower comes fullyassembledwith the handlebarsfolded compactly forshipment. Removethe mower from theshipping container.

2. The control bails (P, Figure 2-6) aresecuredto the handlebar(Q) with a cabletie. Cut the cable tie off and removetheprotective packingmaterial.

3. Followsteps 2 through 8to completemower assembly.

Step 2: Unfold Handlebar Assembly1. Loosenthe two lower handlebar

adjustment knobs (1, Figure 2-5).

2. Carefully unfold lower section of thehandlebarassembly (2, Figure2-5).Watch the cableswhile unfolding andmakesure that they do not pinch, kink, orover-stretch while unfolding.

3. Tighten the two lower handlebaradjustment knobsjust enoughto allowthe two handlebarstruts (H, Figure 2-3)to move in and out slightly.

4. Insert the tab (F, Figure 2-3) on eachhandlebarstrut into the slot (G) one eachside of the deck. Becertain to route thecables inside the left side strut as shownin Figure 2-4.

5. Tighten both lower handlebaradjust-ment knobs securely.

6. Loosen the two upper handlebaradjustment knobs (3, Figure 2-5).

7. Unfold the upper handlebarassembly(4, Figure 2-5) and align with the lowerhandlebarassembly. Besure not topinch, kink, or over-stretch the cableswhile unfolding.

8. Tighten both upper handlebaradjust-ment knobs securely.

9. Checkthe starter rope. Makesurethat it does not catch under the tophandlebaradjustment knob (I, Figure2-6). The starter rope should stretchunobstructed to the engine.

Figure2-3: Assemblinghandlebar,(Right-sidehandlebarstrutshown.)

Figure2-4: Cablescorrectlyroutedinsidehandlebarstrut,

Section2: Assembly

Figure2-5: Unfoldingthehandlebar.

Step 3: Adjust Handlebar Height1. Loosen one of the lower handlebar

adjustment knobs (K, Figure 2-6) and givethe knob a tap inward to free the squareshaft on the screw (N, Figure 2-7) fromthe keyedslot (0) in the handlebarstrut.Repeatthis step for the other side.

2. Movethe handlebarstrut up or downto align the square shaft (N, Figure2-7)with one of the three square keyedslots(0). The middle slot is the mediumheight setting.

3. Tighten the handlebar adjustmentknobs very securely.

NOTE: Make sure that the square shaftseats squarely into the slot beforetight-ening the adjustment knobs.

Step 4: Add Motor Oil to Engine1. Movethe mower to a level area.

2. Add motor oil according to the specifi-cations and instructions provided in theseparateEngine Owner's Manual.

• Keepoil level at the FULL mark on thedipstick to avoid engine damage.

• Changeoil according to scheduleandinstructions in EngineOwner's Manual.

Figure2-6: Fullyassembledhandlebarassembly.

Step 5: PerformFinal Assembly Check1. Checkall nuts, screws, and handlebaradjustment knobs for tightness.

2. Besure to read Section 1: Safety,Section3: Featuresand Controls andSection4: Operationbefore using themower.

Figure2-7:Adjustinghandlebarheight.

Step 6: Set Up Mowing ModeYour mower can be set up for either oftwo mowing modes. These mowingmodes can bag clippings or mulchclippings. SeeSetting Up Mowing Modesin Section 4 for detailed descriptions andinstructions on how to set up each mode.

NOTE: The mower is shipped in MulchingMode. This meansthat the MulchingPlug is installed into the discharge outlet(Figure 2-1) and that the mower is readyto mulch grass clippings.

FeaturesandControls

//

/

0

H

G

A: OperatorPresenceControlBail

B: Wheel Speed Control

C: Wheel Drive Bail

D: RecoilRope Starter

E: UpperHandlebarAdjustmentKnob(2)

Figure3-1

Before operating your machine,carefully read and understand allsafety, controls and operating instruc-tions in this Manual, the separateEngine Owner's Manual and on thedecals onthe machine.

Failure to follow these instructionscan

result in seriouspersonalinjury.

INTRODUCTIONThis Section introduces the features andcontrols found on the lawn mower.Carefully review the information in thisSection, then readSection 4, Operation

before using the mower.

F:SmartBagTM GrassFiBIndicatorG:GrassCatcher

H:DischargeOutletGuardl: LowerHandlebarAdjustmentKnob(2)J:HandlebarHeigMAdjuster(2)

MOWERATTACHMENTSThe mower is supplied with two easilychanged attachments --the GrassCatcher(I, Figure 3-1) and the MulchingPlug (M)-- which provide two differentmowing modes. SeeSetting Up MowingModes in Section 4 for detailed informa-tion on how to install and use the attach-ments.

A uniquefeature, the TROY-BILT®RapidAttachTM System, is incorporated into thedesign of the attachments. This systemenables you to quickly and easily installthe attachments without using tools.

K: CuttingHeightAdjustmentLever

L: Belt Cover

M: Mulching Plug

N: DischargeOutlet

O:ClutchCable Adjuster

Grass Catcher Attachment

Usethe GrassCatcher(G, Figure3-1) tocollect clippings for disposal. The bagcan hold over two bushels of clippings.

The Grass Catcheris equippedwith theTroy-Bilt@Smart BagTM feature (F, Figure3-1). The Smart Bagfeature is a grass fillindicator that provides a visual alert whenthe bagis full. SeeBagging Mode inSection 4 for detailed information.

Mulching Plug AttachmentUsethe Mulching Plug (M, Figure 3-1) tomulch lawn clippings. SeeMulchingMode in Section 4.

Section3: FeaturesandControls

MOWER CONTROLS

Thefollowinginformationidentifiesanddescribesthecontrolsforall mowermodels.

Operator Presence Control BailThe Operator PresenceControl Bail(A, Figure 3-1) must be pulled backagainst the handlebarand held therewhile starting the engineand operatingthe unit. Releasingthe bail will shut offthe engine andstop the mower blade.The engine will not restart unless the bailis pulled back against the handlebar.

NOTE: This control disengagesan enginebrakewhen pulled backagainst thehandlebarand engagesthe engine brakewhen released. The mower blade is

bolted directly to the engineshaft,therefore it stops when the engine stops.The engine will not restart unless the bailis pulled back against the handlebar. SeeStopping the Engineand Mower Blade inSection 4 for more information.

Wheel Drive BailThe Wheel Drive Bail (C,Figure 3-1)engagesthe powered rearwheels when itis pulled up against the handlebar, anddisengagesthe wheelswhen released.See Mowingand Turning the MowerinSection 4 for more information.

To move the mower without enginepower, releasethe controls and push orpull the mower.

NOTE: The pinion gears inside the rearwheels may produce an occasionalknocking sound when pushing or pullingthe mower manually. This sound isharmless. Do not lubricate the drivewheels. Servicethe drive assembly onlyas instructed in Section 5.

Wheel Speed Control

The Wheel SpeedControl (B, Figure3-1)provides three different wheel speeds.Selectionsare:

• 1 for low speed• 2 for medium speed• 3 for high speed

SeeMowing in Section 4 for more infor-mation.

Cutting Height Adjustment LeverThis control (K, Figure 3-1) provides eightcutting heights, enabling you to choosethe most appropriate height for the lawncondition. Cutting heights rangefrom3/4-inches to 4-1/4-inches. See Prepara-tion forMowing in Section 4 for morenforrnation.

NOTE: Actual cutting height w_llvaryaccording to turf conditions..

ENGINECONTROLS

Throttle

Models 909J has an enginethat isequipped with a fixed throttle speed forthe most efficient engine performanceundervarying loads.

Primer BulbThe Primer Bulb is used to start a coldengine. Seethe EngineOwner's Manualfor information specific to your engine.

Fuel Shut-Off Valve

The FuelShut-Off Valve (if so equipped)opens and closes the fuel line. SeetheEngineOwner's Manual for informationspecific to your engine.

Recoil Rope StartThe recoil rope start (D. Figure3-1) Esusedto pull-start the engine. SeetheEngineOwner's Manualfor starting infor-matEonspecific to your engine. Also seeStarting the Engine in Section4

Adjustable Handlebar HeightThe mower provides three handlebarheight settings (J, Figure 3-1). SeeStep5: Adjust Handlebar Height in Section 2.

Operation

Before operating the mower, carefullyread and understandall safety, controland operating instructions in thisManual, the separate Engine Owner'sManual andthe decalson the machine.

Failure to follow these instructionscan

result in seriouspersonalinjury.

• Never operate the mower with thedischarge outlet guard removed orproppedopen.

• Do not operate mower without theGrass Catcher, Mulching Plug oroptional Side-Discharge Chute inplace.

• Never change mowing modes orempty the Grass Catcher while theengine is running.

• Check the condition of the GrassCatcherfor excessivewear or deterio-

ration. If damaged, contactan autho-rized dealer or the factory for areplacement.

The Grass Catcherand the optional Side-Discharge Chute both use the samesystem. This system consists of anelongated tab (A, Figure 4-1) on the top ofthe discharge outlet and a receptacle(B)built into the top of the GrassCatcherdoor and the optional Side-DischargeChute.

Figure4-1: TROY-BIL7_RapidAttachTM

System,

bagwhen emptying.

The Grass Catcheralso has a Smart BagTM

grass-fill indicator (Figure4-3) whichmakes it easyto tell when the bag is full.The indicator is a rectangularpiece ofcloth sewn to the top of the bag. Theindicator lays flat against the bagwhenthe bagis full (F, Figure4-3) and billows(G) when the bag is not full.

NOTE: Windy conditions mayaffect theindicator's ability to provide an accuratebagfill reading.

SettingUp BaggingMode

1. With the engineand bladestopped,removethe Mulching Plug or optionalSide-Discharge Chute.

10

INTRODUCTIONReadthis Section thoroughly before youstart the engine. Then takethe time tofamiliarize yourself with the mower'sbasicoperation.

Findan open, level areaand practiceusingthe mower controls. Onlyafter youbecomefamiliar with the mower shouldyou use it in smaller areas or on uneventerrain.

TROY-BILT®RAPIDATTACHTM SYSTEMThe RapidAttach System (Figure 4-1) is afeature designed into the mower deckwhich enablesyou to install and removethe GrassCatcher, the (optional) Side-DischargeChuteand the Mulching Plugquickly and easily.

Attaching the Mulching Plug is just aseasy. Hold openthe discharge outletguard (K, Figure4-1) and insert the plug(L), with the word "TOP" facing up, intothe discharge outlet.

SETTINGUPMOWINGMODESThe lawn mower has two mowing modes:bagging mode and mulching mode. Thefollowing provides descriptions of the twomodes and how to implement them.

Bagging ModeThemower is set up for bagging modewhen the GrassCatcher is attached to thedischarge outlet.

The Grass Catcheris equipped with twohandles and a swing-open door thatmakes emptying easy. Usethe wire-formed handle to help attach, remove,transport and empty the bag. Usetherear cloth handle to lift the bottom of the

Figure4-2: AttachingGrassCatcher.

2. Graspthe Grass Catcherby the wire-formed handle. With the other hand, holdopen the discharge outlet guard (C, Figure4-2).

3. Lower (at an angle) the bagdoor (D,Figure4-2) onto the tab (E) onthedischarge outlet. Makesure the bag doorseats squarely onto the tab and coversthe tab completely.

Removingthe GrassCatcher

1. When mowing, the Grass Catcherisfull when the grass fill indicator laysflatagainst the bag (F, Figure4-3).

An alternative method for judging bagfullness is to nudgethe bagwith yourfoot. The bagwill give easily when notfull, and will resist when full.

Section4: Operation

Figure4-3: SmartBagTM indicateswhenbagis full(F)andnotfull(G),

2. With the engineand blade stopped,hold open the discharge outlet guard (C,Figure 4-2). With the other hand, graspthe wire-formed handleand guide the bagup and off the discharge outlet.

Mulching ModeThe mulching mode cuts and recuts grassclippings within the mower housingbefore recycling the finely cut clippingsinto the lawn. Mulching makes it easierfor the the lawn to absorb the grassnutrients back into the soil.

Setting UpMulchingMode

1. With the engineand blade stopped,removethe Grass Catcheror the optionalSide-Dischargeattachment.

2. Lift open the discharge outlet guard(K, Figure4-1).

3. Position the plug with the word "TOP"facing up and push the Mulching Plugfirmly into the discharge outlet (Figure4-4).

4. The plug's flange (rim) must fit snuglyagainst the edge of the discharge outlet toensure efficient mulching (Figure 4-4).

Figure4-4: Installed MulchingPlug,

2. Graspthe Mulching Plug's hand-gripwith one handand pull back until the plugclears the discharge outlet.

PREPARATION FOR MOWING

ReviewSection 1: Safetyand Section 3:Featuresand Controls. Then readthisSection completely before starting themower.

1. Move lawn mowerto a clear, levelarea - If on a grassy area, make sure thegrass is low enough as to not interferewith blade rotation when starting.

2. Inspectarea to be cut - Checkfor andremove debris such as rocks, toys, wire,bones, sticks, etc., which could be pickedup and thrown by the blade. Also inspectthe terrain for holes or other obstacles.

3. Checkmower-

• Checkthe mower for loose or missinghardware. Tighten or replace beforestarting the mower.

• Checkthe Operator PresenceControlBail for freedom of movement.

• Checkthe Wheel Drive Control Bail forfreedom of movement.

• Checkbladefor excessivewear ordamage. Do not operatethe mowerwith a damagedblade.

• Securelyconnect the spark plug wire tothe spark plug.

4. Adjusthandlebarheight- The mowerhas three handlebarheights which can beadjusted as follows:

a. Loosen one ofthe lower handlebaradjustment knobs (H, Figure 4-5) andgive the knob atap to free thehandlebarstrut (K) for adjustment.Repeatfor the other side.

Removingthe MulchingPlug

1. With the engineand blade stopped, liftopenthe discharge outlet guard.

Figure 4-5: Adjustinghandlebarheight.

b. Adjust the handlebarsto thedesired height and then tighten thehandlebaradjustment knobs. Makesure that the square shank onthescrew (J, Figure4-5) seats squarelyinto one of the square slots (I).

5. Set cuttingheight - You can set themower to any of eight cutting heights.Cutting heights rangefrom 3/4" to 4-1/4".

To avoid personal injury, never adjustcutting height while engine is running.Release all handlebar controlsand waitfor all motion to stop before adjustingcuttingheight.

NOTE: Actual cutting height will varyaccording to grass, terrain, and soil con-ditions.

a. To adjust cutting height, pull theCutting Height Lever (A, Figure4-6)away from the mower to releasethetab from the slot. Besure to grip thelever firmly to prevent the mower deckfrom dropping down rapidly.

Figure4-6: CuMngheightadjustmenL

11

Section4: Operation

12

b. While pulling the leveraway fromthe mower, move the lever towards thebackof the mower (B, Figure 4-6) for ahigher cut or towards the front of themower (C) for a lower cut.

c. Seatthe lever's tab squarely intothe slot.

IMPORTANT: The mower is equippedwith a safety flap located on the rear ofthe mower deck. After setting the cuttingheight, be certain that the flap hangsfreely and is not caught under the deck.

6. Prepare Engine-

• Checkoil level - If this is a new mower,add motor oil as described in the EngineOwner's Manual; otherwise, check oillevel and add as recommended in theEngineOwner's Manual.

GASOLINEIS HIGHLYFLAMMABLEANDITSVAPORSAREEXPLOSIVE.

Follow the gasoline safety rules in thisManual (Section 1) and in the separateEngineOwner'sManual.

Failure to follow gasolinesafetyinstruc-tions can result in serious personalinjuryand propertydamage.

• Add fuel - Fill the fuel tank with gasolineaccording to the directions in theseparateEngineOwner's Manual.Follow all instructions and Safety rulescarefully.

• Checkair filter - The engine is equippedwith an air filtration system. Whenclogged, it causes starting difficultiesand operates inefficiently. SeetheEngineOwner's Manual for informationon how to maintain the air filter system.

OPERATINGTHEMOWERThe following procedures explain how tostart, stop and operatethe mower.

Do not operate the engine in anenclosedarea. Engineexhaustcontainscarbon monoxide, a deadly gas that isodorless, colorless and tasteless.Always run the engine outdoors andmake surethere is adequateventilation.

Starting the Engine1. Openthe fuel shut-off valve, if soequipped.

2. Prime the engine by pushing theprimer bulb firmly 3 times.

NOTE: Priming may not be necessarywhen restarting a warm engine.However,cool weather may requirepriming again. Seethe EngineOwner'sManual for priming information.

To avoid injury or property damage,thoroughlyinspectarea where mower isto be used and remove all stones,sticks, wires, bones, nails and otherforeign objects.

3. Stand behind the mower handlebarand pull the Operator PresenceControlBail (A, Figure3-1) backagainst thehandlebarand hold.

4. Checkbehind you for obstacles, thenslowly pull the recoil rope (E, Figure3-1)until resistance is felt. Pull the rope outrapidly to start engine. Let the ropereturn slowly. If the enginefails to startafter three pulls, repeat steps 2-4.

Stopping theEngine and Mower Blade

To avoid personal injury, keep handsand feet clear of mower blade or other

rotatingparts.

1. Releasethe Operator PresenceControlBail (A, Figure3-1) to stop the engineandblade.

EmergencyStopping

Releaseall controls. This stops theengine, wheel movement and the blade.

IMPORTANT:The mower is equippedwith a BladeControl System which isdesigned to stop the mower bladewithinthree (3) seconds after releasingtheOperator PresenceControl Bail. Thissystem also stops the engine.

If the Blade Control System does notoperate properly, the blade couldcontinue to rotate for longer than three(3) secondsafter releasing the OperatorPresence Control Bail. If this occurs,discontinueusingthe mowerand imme-diately contact your local authorizeddealer or the factory for instructions.Do not operate the mower until theBlade ControlSystemis repaired.

Failure to do this could result inpersonal injuryor propertydamage.

Mowing1. Start the engine. SeeStarting theEngine in this Section.

2. Usethe Wheel SpeedControl to selecta wheel speed. The mower has threewheel speeds. Selecta slower speedwhen first starting out (or when learninghow to use the mower), then move intofaster speedsif needed.

• Low Speed(1) - is engagedwhen thelever is pulled all the way back. Lowspeed provides the most efficient cut.

• Medium Speed(2)- is engagedwhenthe lever is movedto the middle detent

position (the control lever will click intoplace). This speed is a good compro-mise for speed and cutting perfor-mance.

• High Speed(3) - is engagedwhen thelever is pushed all the way forward.High speed enablesyou to cover thecutting areamore quickly, but mayresult in a less efficient cut. This speedis most effective on short, thin grass.

3. Pull the Wheel Drive Bail (B, Figure4-7) up against the handlebarto powerthe rearwheels and move forward.

NOTE: Releasethe Wheel Drive Bailandcontinue to hold the Operator PresenceControl Bail (A, Figure4-7) to pauseduring mowing with the enginerunning,or to maneuver in tight conditions.

TurningtheMower

1. For short turns, releasethe WheelDrive Bail (B, Figure 4-7) but continue tohold the Operator PresenceControl Bail(A). This disengagesthe wheel drive, butthe engine continues to run.

Section4: Operation

Figure4-7: Disengagingthewheelswithengine running,

2. Pressdown on the handlebar to raisethe front end slightly.

3. Push the handlebar opposite thedirection to which you want to turn.

4. For longer, wider turns, there is noneedto disengagethe poweredwheels.

MOWINGTIPSANDHINTS

Mow When Lawn Is DryDo not mow grass when it is wet. Wetgrass isdifficult to mow andclumpstogether insidethe mower housing. Thiscauses inefficient operation and anunevencut. Additionally, wet clippingsstick together inunsightly clumps on topof the lawn which causes inefficientabsorption of nutrients back into the soil.

Avoid Midday MowingIf possible, mow in the late afternoon orearly eveningto avoid exposing newly cutgrass to the drying effects of directsunlight.

Never Cut Lower Than One-Third Grass

Height In One PassIf possible, mow 1often enough or _high enough toavoid cutting offmore than 1/3 ofthe grass height.Forexample, if youare maintaining your lawn at 2", mowbefore it reaches3".

Removing more than 1/3 of total grassbladelength may exposetender, shadedstems to the drying effects of the sun andwind and produce a dull, brown-lookinglawn. Cutting off too much leaf area isalso a shock to the root system and itmaytake weeksto repair the damage.

Clean Mower FrequentlyCleanthe mowing housing frequently toremoveany grass build-up. Referto thecleaning instructions in Section5.

Vary Cutting PatternVary the cuttingpatternfrom week __]]P_to week. Oneweekmow horizontally.Mow vertically the following week. Thishelps prevent wear patterns and soil com-paction.

AvoidSharp TurnsSharpturns may produce an uneven cut.If possible, follow natural groundcontours or use gentle, sweepingturnsfor a better looking lawn.

Mow LongGrass TwiceIf the grassis 5" long ormore, cut it __onceat thehighest setting andthen mow it againatthe desired height. This method mayproduce too manyclippings to use themulcher effectively. Usethe GrassCatcherto remove the grass clippings.

Use Extreme Caution on SlopesWhen operating onsloping ground,exercise extremecaution and use goodcommon sensetoavoid possiblepersonal injury or property damage.

Do not mow steep slopes! Avoid slopesgreater than 15 degrees,or whereverfooting is unsure. If a slope is difficult tostand on, it is probably too steep to mow(in such a case, it may be best toestablish a ground cover that doesn'trequire mowing).

Do not mow on slopes when the groundis wet. Mow across the face of slopes,never up and down. Slow down andexercise extreme caution when changingdirection on slopes. Keepthe WheelDrive Bailengagedto ensure easieroperation and better control of the mower

To avoid injuryor propertydamage:

• Maximum safe operatingangle is t5 o.

• Exceeding maximum safe operatingangle may cause tipping or loss offooting.

• Do notmowwet slopes.

• Mow acrossslopes,not upand down.

*Exercise extreme caution whenchangingdirectionon slopes.

Empty Grass Catcher When FullEmptying the GrassCatcherwhen it is fullresults in bettercollection and mowerperformance. Empty the bag as soon asthe bagis filled. SeeBagging Modeformore information on the Smart Bagfeature.

Match SpeedTo Terrain and Conditions

Adjust the speedto grass conditions andterrain. UseLow and Medium speedsfornormal mowing conditions. You'll getbetter results at slower speeds, especiallyif the grass is tall or lush. Use Highspeed to transport the mower or whengrass conditions are light and appearanceis not as important.

Keep Mower Blade SharpA sharp bladecuts the grass cleanly,resulting in a smooth, evenlycut lawn. Adull bladetears at the grass and will fraythe tips so that they dry out quicklyresulting in a dull, brown-looking lawn.

See BladeSharpeningand Balancing inSection 5 of this manual for more infor-mation.

Mulching Leaves

A light covering of leavescan be effec-tively mulched into the turf. As the leavesdecompose, they provide valuable organicmatter and minerals to the soil.

To ensure effective mulching, be sure theleavesare dry. Useaslow travel speedand don't try to mulch a deeplayer ofleaves.

13

Maintenance

Before inspecting,cleaning orservicingthe machine,shot off engine, wait for movingpartsto stop, dis-connectsparkplugwire andmove wire away fromsparkplug.

Failureto followthese instructionscan result inseriouspersonalinjury or propertydamage.

REQUIRED MAINTENANCE SCHEDULE

PROCEDURE

Checkengine oil level

Changeengine oil

Service spark plug

Checknutsandscrews

Servicefoampre-cleanerair filter(if soequipped)

Servicepaperair filter(if soequipped)

Inspectsparkarrester(if so equipped)

Cleanengine

Cleanmowerhousing

Cleanunderbeltcover

Checkclutchspringextension

Cleandrive-wheelpiniongears

Before Every10 Every25Using Hours Hours

AsNoted

Aftereach5operatinghours

41,A


1"

Annually

Aftereachuse

€


• Changemorefrequentlyin dustyor dirtyconditions.Changeafterfirst 2 hoursofbreak-inoperation,

i" Checkafter first 2 hoursof break-inoperation.• SeeEngineOwner'sManualfor servicerecommendations.• Beforeandafterstoringunit for 3 weeksor more,

REMOVING AND

REPLACING THE BELT COVER

Removing the Belt Cover1. Usea 3/8" wrench to remove both

screws (D, E, Figure 5-1).

Figure5-1: Beltcover

2. Lift the backend of the cover then

carefully pull out.

Do not operate the mower without thebelt cover in place. Doing so couldresult in personal injury or damage tocomponents.

When working near the blade, wearheavy leather gloves to protectyourselffromthe sharpedgesonthe blade.

ENGINEOILSERVICE

Check the engine oil level before startingthe engine eachday and after each 5hours of continuous operation. Runningthe engine when the oil level is low willquickly ruin the engine.

Changeengine oil after the first 2 hoursof break-in operation, thereafter, in accor-dance with your EngineOwnersManual.Changemore often in extremely dirty ordusty conditions. Refertothe Engine

Owner's Manual for detailed informationon changing oil.

SERVICING THE AIR CLEANER

The engine air cleaner filters dirt and dustout of the air before it enters the carbure-tor. Operatingthe engine with a dirty,clogged air cleaner can cause poor per-formance and damageto the engine.Neveroperatethe engine without the aircleaner installed. Inspectand service theair cleaner more often if operating in verydusty or dirty conditions.

Servicethe air cleaneras instructed in theseparate EngineOwner's Manual.

Replacing the Belt Cover1. Seatthe rear end of the cover. Makesore that both control cablesare routed

through the cutout in the rear of thecover. This will help prevent damagecaused by pinching the cablesunder thecover or contact with the transmission

pulley or belt.

2. Tighten screws snugly. Do not over-tighten (D, E, Figure5-1).

TIPPINGTHEMOWERFORSERVICE1. Beforetipping the mower, make surethat the fuel tank is empty to prevent thepossibility of gasoline spillage. See"DANGER"statement that follows.

14

Section5: Maintenance

_ efore inspecting,cleaning orservicingthe machine, shutoff engine, wait for movingpartsto stop, dis-

connectsparkplugwire andmove wire awayfrom sparkplug.


2. When servicing the underside of themower, the mower should betipped onlyin the direction of the muffler. Tippingthe mower awayfrom the muffler couldresult in enginedamage or difficultstarting.

SPARKPLUGSERVICEInspectand clean or replacethe sparkplug after every 100 operating hours orannually. Setthe gapas described in theseparateEngine Owner's Manual.

In some areas, local law requires usingresistor spark plugs to suppress ignitionsignals. If the engine was originallyequipped with a resistor spark plug,replacewith the sametype.

CLEANINGTHE ENGINE

The engine must be keptclean to insuresmooth operation and to prevent damagefrom overheating. Refer tothe EngineOwner's Manual for more information.

CLEANINGUNDERTHE MOWER HOUSING

Checkthe mower regularly for grassbuild-up. Cleaningunder the mowerdeckshould bedone after (rather than before)operating the mower, as grass is moistand removedmore easily.

1. Tip mower towards the muffler ontoits side. See Tipping the Mower forService in this Section.

2. Brushorscrapeoff grassbuild-up.

CLEANINGTHE GRASSCATCHER

Bagcleanlinessaffects collection perfor-manceas a dirty bagwill restrict air flow.Cleanthe GrassCatcher bag annually,more often in dusty environments.

IMPORTANT: Do not wash or dry theGrass Catcherin a washing machine ordryer.

1. To clean the bag, remove it from themower and hand wash the fabric with

mild detergent.

Before servicing the underside of themower:

• MOVINGPARTSHAZARD!

Stop engine, wait for all partsto stopmoving, and disconnect spark plugwire.

• FIRE- EXPLOSIONHAZARD!Gasolineis highly flammable and itsvaporsare explosive.1. Drain fuel into an approved con-tainer outdoors, away from openflame.

2. Be sure engine and muffler arecool beforedraining gasoline.3. Do notsmoke.

Failure to comply with the above canresult in serious personal injury andpropertydamage.

2. Rinsethe bag thoroughly with cleanwater and allow to dry completely beforeusing. Do not usea damp bag.

CLEANINGUNDERBELTCOVERCheckunderside of belt cover for grassclippings every 10 hours of use.

1. Removethe belt cover. SeeRemoving the Belt Cover in this Section.

2. Removeany grass clippings or debris.

3. Replacebelt cover. See ReplacingtheBelt Coverin this Section.

SPARKARRESTERSCREENSERVICE

If the engine muffler is equippedwith aspark arrester screen, removeand clean itaccording to the time intervals andinstructions in the separateEngineOwner's Manual.

CARBURETOR/GOVERNOR

CONTROL ADJUSTMENTS

The carburetor was adjustedat thefactory for best operating speed. Refer tothe separateEngineOwner's Manual forany adjustment information or seeyourauthorized engine service dealer.

The governor controls the maximum safeoperating speed and protects the engineand all moving parts from damage causedby overspeeding. Do not tamper with theengine governor settings. Seekautho-rized service if a problem exists.

MOWER BLADEMAINTENANCE

Blade Inspection1. Tip mower towards the muffler ontoits side. See Tipping the Mower forService in this Section.

Never reach under mower deck whilethe engine is running. Mower bladerotates at all times while engine isrunning and up to 3 secondsafter it isshutoff.

2. Inspect periodically for a dull orslightly nicked blade. Sharpenif needed.Also check for a deformed, cracked, orexcessivelyworn blade (Figure 5-2). Donot use the mower if any of these condi-tions exist. Replacethe bladeimmedi-ately.

3. Checkthe bladescrew for tightness.If loose, tighten to 35 ft-lbs with a 3/4"torque wrench.

NewBlade

Replaceblade immediately if cracked,deformed or badly nicked.

Figure 5-2: Mower blade inspection,

15


Before inspecting,cleaning orservicingthe machine,shot off engine, wait for movingpartsto stop, dis-connectsparkplugwire andmove wire away fromsparkplug.


Mower blade is sharp.

*Wear heavy leather gloves whenworking near or with blade for protec-tion fromsharp edges.

, Wear safety approved eye protectionwhensharpeningblade to protecteyesfromflying metal debris.

Removing Mower Blade

IMPORTANT: Theblade coupler(D, Figure 5-5) may come off the engineshaft when removing the blade. If it does,do not lose the square key (C). The keyfits into a square slot inside the bladecoupler. Without it, the bladewill notrotate.

1. Removethe spark plug wire from thespark plug and move it away.


3. Usea 3/4" wrench to loosen the blade

screw (A, Figure 5-5). Hold the bladewith a gloved hand to prevent the bladefrom rotating.

Figure5-3: Removingorinstallingblade.

4. Remove bladescrew and Bellevillewasher (A, B, Figure5-5).

5. Remove blade.You may haveto givethe blade atap to jar it loose from themounting tabs.

16

Curved end downCurved end down

/ Mower Deck

Figure5-4: Correctbladeinstallation.

Lawn

Figure5-5: Mower bladeassembly.

Installing Mower Blade1. Removethe spark plug wire from thespark plug and move it away.


3. If the bladecoupler (D, Figure5-5)and/or square key (C) came off the engineshaft during bladeremoval, reinstall thoseparts back onto the engineshaft.

4. Position the bladewith the curved

ends facing downward (Figure 5-4).

5. Slip the Belleville washer (B, Figure5-5) onto the screw (A). Facethe dished-in side to the blade.

6. Mount the bladeonto the two tabs of

the blade coupler. Makesure that youseat the bladecompletely onto thecoupler.

7. Insert the screw and washer throughthe bladeand into the bladecoupler.Tighten with a torque wrench to 35 ft-lbs.

Sharpening andBalancing Mower Blade

IMPORTANT: We recommend that thebladebe sharpened by a professionalsharpening service. Replacea cracked orseverely worn bladewith a new one.

1. Remove bladefrom the mower. SeeRemoving Mower Blade.

2. Clampthe blade in a vise. Usea metalfile or grinder to sharpen the bladewhilemaintaining the original cutting angle. Itis very important to maintain the originalcutting bevel to insure the most effectivecut.

3. To retain blade balance,removethesame amount of material from both endsof the blade.

4. To check bladebalance,place thebladeon a rounded pivot such as a pencilor penunder the center hole. Hold bladeparallel to ground then release. SeeFigure5-6. If bladeis unbalanced, theheavierside will leandownward.

5. Usea file to lightly remove materialfrom the heavierside of the blade.

6. See Installing Mower Blade for infor-mation on how to re-install the blade.

REMOVING AND

REPLACING DRIVE BELT

This procedure can bemade easierbyremoving the blade (see RemovingMower Blade);however, bladeremoval isnot absolutely necessary.

I

Figure5-6: Balancebladeonpivottocheckbladebalance.





Figure5-7:Pressdownonpoint"A"toremoveorinstallbelt.

1. Remove the belt cover. SeeRemoving the Belt Cover in this Section.

2. Pressfirmly downward on the cablemounting bracket (A, Figure 5-7) until ittilts and the belt slackens.

3. Remove belt (B, Figure5-7) fromtransaxle pulley.

4. Tip the mower onto its side (towardsthe muffler) and pull the belt through thecutout in the housing.

5. Do this step only if you did notremovethe mower blade-- otherwise, goonto step 6.

a. Make sure the spark plug wire isremoved from the sparkplug andmoved away from the plug. Rotate thebladeso that one end is somewhere

within the front of the mower housing.b. Work the belt around and over that

end of the blade(Figure 5-8).c. Rotate the bladeso that the otherend is somewhere within the front of

the mower housing and work the beltaround and off the mower.d. Work the new belt around and overthe same end of the blade.e. Rotate the bladeso that the otherend of the bladeis somewhere within

the front area of the mower housingand work the new belt around and overthe same end.

6. Seatthe new belt into the groove onthe engine pulley that is locatedon thebladedrive shaft.

7. Grasp one end of the new belt andinsert it in and through the cutout in thehousing.

Figure5-8: Removeor installbeltaroundblade.

8. Tip the mower backdown to itsnormal position.

9. Apply firm pressureagainst the cablemounting bracket on the transaxleassembly (A, Figure 5-7) until it tiltsforward.

18. Pullthe belt over thetransaxle pulleyand into the groove.

11. Releasepressure on the transaxlebracket slowly. Makesure that the beltseats properly into the pulley groove.

12. Checkthe other end of the belt

(engine pulley) to insure that it is seatedproperly into the groove.

13. Reinstallthe belt cover. SeeReplacing the Belt Cover in this Section.

ADJUSTINGWHEELDRIVECONTROLLoss of wheel drive indicates that the

Wheel Drive Control may needadjust-ment. This condition could also be the

result of not completely engaginga wheelspeed gear setting. Beforeyou adjust thewheel drive control cable, move the WheelSpeedControl Lever to 1 (all the wayback) or to 3 (all the way forward). If thewheels still do not engage, adjust thewheel drive clutch spring.

1. Removethe belt cover (SeeRemovingand Replacing the Belt cover) and locatethe wheel drive clutch spring.

2. Measurethe length of the body of thewheel drive clutch spring (Figure 5-9).

Figure5-9: Firstmeasurementwithdriveclutchspringdisengaged.

3. Engagethe Wheel DriveControl Bailand measurethe extendedlength of thespring body again (Figure 5-10).

Figure5-10: Secondmeasurementwithdriveclutchspringengaged,

4. The difference betweenthe two mea-

surements should be approximately 1/4".Adjust if the result does not meet thisspecification. Spring extension isadjusted with a cable adjuster (R, Figure3-1) on the wheel drive cable. To adjust,hold the turnbuckle (A, Figure5-11) whileturning each adjuster (B, Figure5-11)awayfrom the turnbuckle 1/2 turn each.

Figure5-11: Drivecable adjustment.

17





5. Measureagain, as in steps 2, 3 and4 2. Removethe Grass Catcherdoor. Seeto determine if you needto continue Replacing the Grass CatcherDoor.

adjusting. Adjust until the two spring 3. The bag is mounted over the wiremeasurementsdiffer in length by approxi- frame and under the door, and is held inmately 1/4". place with four plastic clips (E, Figure6. Reinstall the belt cover. See 5-13). Remove eachof the clips by

Replacingthe Belt Cover. pulling from an end and off the frame (F).

GRASS CATCHER

PARTS REPLACEMENT

The GrassCatcher is made up of threeparts: the door, the frame, and the clothbag. The following procedure explainshow to removeand replace each of theparts.

Replacing the Grass Catcher Door1. Remove the GrassCatcherfrom themower.

2. The door is mounted onto rods at bothends of the wire-formed handle. Squeezethe handlewith one hand while pulling thetop-side of the door (C,Figure 5-12) outand off the end of the rod (D).

Figure5-12: Replacingbag door,

Figure5-13

4. Pull the bagoff the frame.

5. To replacethe frame or bag, positionthe top of the bag (long side) up.Position the top of the frame (wire-formed handleside) up. Pull the openend of the bag over the rear end of theframe and under the handle.

6. Presseach of the bag's four plasticclips (E, Figure 5-13) onto the frameopening (F).

7. Install the door. Seestep 3,Replacing the Grass CatcherDoor.

3. To replacethe door, insert one of theends of the wire-formed handle (D, Figure5-12) into the hole in the top-side of thedoor (C).

4. Squeezethe handlewith one handwhile you pull the other side of the door(C, Figure5-12) up and over the endofthe other rod (D). The door should swingfreely when done.

Replacing the Cloth Bag or Frame1. Remove the GrassCatcherfrom themower.

EXTENDED STORAGE

Usethe following suggestions whenstoring the mower for extendedperiods oftime.

• Store mower in a level position.• Thoroughly inspect the

mower for any loose,broken, or missing parts.Repair or replaceasnecessary.

• Removeall fuel from fueltank or use a fuel stabilizeradditive as directed inEngineOwner's Manual.

• Never store mower with fuel in fueltank inside a building where fumes canreach an open flame or spark, or whereignitionsourcesare presentsuchas hotwater and space heaters, furnaces,clothes dryers, stoves, electric motors,etc. Make sure engine is cool beforestoring.

• Drain gasoline outdoors into anapprovedcontainer.

• Do not smoke and keep away fromopen flame.

Failure to follow these instructionswill

result in serious personal injury orpropertydamage.

• Perform engine maintenanceasdescribed in the Storage instructions ofthe EngineOwner's Manual.

• Checkall nuts andscrews for tightness.• On electric start models remove key

from keyswitch.• Chargethe battery for 24 to 48 hours

before and after seasonalstorage.• Disconnectspark plug wire from spark

plug.

Folding the Handlebar Assembly

IMPORTANT: To avoid damageto thecablesand wiring, always fold the topsection of the handlebarassemblybackward. Cablescan be severely bent iffolded incorrectly.

1. Loosenthe top two handlebaradjust-ment knobs (1, Figure5-16) while sup-porting the assembly with one hand.

[]

18 Figure5-16:Foldingthemowerforstorage.





Figure 5-17: Dislodginghand/ebarstruts.

2. Foldthe top section of the assemblybackward (2, Figure 5-16). Guidethecables carefully while folding. Besurenot to bend, pinch, or stretch the cables.

IMPORTANT: To avoid damageto cables,always fold the top section of thehandlebarassembly backwardand thebottom section forward.

3. Still supporting the handlebarassembly with one hand, loosen the twolower handlebaradjustment knobs(3, Figure 5-16) just enoughto dislodgeboth handlebarstruts (L, Figure5-17)from the slots (K) in the wheel bracketassembly.

NOTE: The handlebar height could inad-vertently change if the lower adjustmentknobs are loosenedexcessivelyduringthis step.

4. Carefullyfold the bottom section ofthe handlebarassembly forward over theengine (4, Figure 5-16). Guidethe cablescarefully while folding. Besure not tobend, pinch, or stretch the cables;also,keepcablesaway from muffler-- theouter cable covering can be burned if theengine is still hot.

5. To unfold handlebarassembly,perform folding steps in reverseorder.

PINIONGEARSERVICEThe mower drive wheels (rear wheels)each contain a pinion gear. This geartransfers drive power to the wheels whichpropels the mower forward. It is veryimportant to keepthese internal partsclean. The following procedure explainshow to disassemble, clean and reassem-blethe mower drive wheels. Conductthismaintenanceon the pinion gears afterevery 50 operating hours.

Figure5-18: Drive wheel assembly.

Tools and Materials• 9/16" Socket and Ratchet

• Small Snap-Ring Pliers

• Cleaning Rags

Procedure

NOTE: This procedure is done only onthe drive wheels (rear wheels).

1. Placea sturdy, stable block under themower to elevatea rear wheel off the

ground.2. Usea 9/16" wrench to removewheel

assembly (A, B, C,D, E,Figure 5-18).

3. Removesnap-ring (J, Figure5-18)from axle.

4. Removeshim(s) (I, Figure 5-18). Thenumber of shims vary from mower tomower. Put them next to the snap-ring.

5. Pull off pinion gear (H, Figure5-18).

6. Removedrive pin (G, Figure5-18).

7. Remove plastic washer/seal(F, Figure5-18).

8. Thoroughly clean off debris from thedrive pin, axle, hole in axle (for drive pin)and the washer/seal.

9. Reinstall washer/seal (F,Figure 5-18).Besure to install flat side of washeragainst bearing(mower deck).

10. Insert the drive pin (G, Figures5-18)into the hole in the axle.

NOTE: The pin should slide freely withinthe hole.

11. Thoroughly clean pinion gear,including surface areaand cavity.

12. Slidethe pinion gear (H, Figure5-18)onto the axle with the cavity toward themower. Pressthe gear firmly against thewasher/seal (F, Figure5-18). Be certainthat the gear is flush against the surfaceof the washer/sealand that the

washer/seal is flush against the wheelmounting bracket.

18. Slidethe shims (I, Figure 5-18) ontothe axle and against the pinion gear. Besure to install the same number of shimsas were removedfrom the unit.

14. Install the snap-ring onto the axle(J, Figures 5-18) and into the groove inthe axle. Pull the pinion gear outward tobesure that the snap-ring seats properly.

NOTE: If you can't get the snap-ring intothe slot in the axle, press the pinion gearmore firmly against the washer/seaL Donot leaveoff shims.

15. Insert wheel screw (A, Figure5-18) through wheel (B), flat washer (C),center hole in wheel shield (D), andspacer (E). The wheel shield has a doubleedge on the rim. Position this sidetoward the wheel.

16. Align pinion gear with the hole in thewheel shield. At the same time, align thewheel screw with the welded nut on thewheel bracket and tighten securely.

19

PartsList Modo_909J

23

22

I

21

24

62

I

16

55

41

39 35f

18

/54

56/ 63

/

59

52/

36 F 49

48_ J_48

i

tJ 45I 34

/

/56

59

2O

Mode 909J PartsList

Ref. # Part # Description Qty.

! 1917000 Mower Deck........................................... 1

2 Engine .................................................... 13 1917072 Support Bracket ..................................... 14 1917045 Torsion Spring ....................................... 15 19!7044 Discharge Outlet Cover........................... 16 777S30145 Decal - Warning...................................... 17 19! 7086 Pin.......................................................... 1

8 1727342 FlangePush Nut, 5/!6 dia ...................... 19 1754128 Hex Hd. FlangeScrew, 1/4-20 x 3/4,

Self-Thrd .............................................. 10

10 1918076 Hex Hd. Screw, 3/8-16 x 1-1/4,Self-Thrd .............................................. 3

11 777D06222 Decal - Logo ........................................... 112 1918339 SpacerTube, Plastic............................... 113 777S32021 Decal - Warning, Belt Cover ................... 114 1918223 Belt Cover............................................... 1

15 1917088 Hex Hd. FlangeScrew, 1/4-20 x 2-1/4,Self-Thrd .............................................. 1

16 1917002 Discharge Outlet Baffle........................... 117 1917071 Safety Flap.............................................. 118 1917073 Flap Rod................................................. 119 777S32022 Decal - Danger, BBCOpening................. 120 1918284 Rubber Extrusion ................................... 12! 1917029 GrassCatcher Door ................................ 122 1917030 GrassCatcher Frame.............................. 1

23 1918182 GrassCatcher Bag.................................. 124 1917084 Mulching Plug ........................................ I25 1917056 Side-Discharge Deflector**. ................... 126 1917054 Mower Blade.......................................... 1

27 1917017 EnginePulley/Blade CouplerAssy.......... 128 GW-9928 Belleville Washer, 1/2". ........................... 129 1917060 Shoulder Screw, 3/8-24 x 1.65............... 130 1917005 V-Belt ..................................................... I31 GW-9302 Square Key, .188 x 1-1/4 ........................ 1

32 1746425 Rope Stop .............................................. 133 1917004 Transaxle................................................ I

34 1917038 HandleSupport Bracket, Lett-Hand........ I

Ref. #

35 191701836 1723037

Part # Description Qty.

37 191701438 191707939 191832340 1909380

190938241 GW-951642 191832243 77712201244 190904445 191700346 118630947 191700948 GW-9552

49 191703250 191703751 171512752 1767754

53 720-031354 191701155 191707456 190931157 191708358 176575059 190341660 191701261 118525762 191701063 176574064 191701565 1917068

HandleSupport Bracket, Right-Hand...... 1Hex Hd. FlangeScrew, 3/8-16 x 3/4,Self-Thrd .............................................. 4

RearAxle Bearing................................... 2Washer/Seal, Nylon................................ 2Pinion Gear, Right-Hand......................... !Shim, .016'L............................................ A/RShim, .062"............................................. A!R

Snap-Ring .............................................. 2Pinion Gear, Lett-Hand........................... IDecal- BladeCutting Height ................... 1Round Pin .............................................. 2

Transaxle Pulley ..................................... IHex Hd. Screw, 114-2Ox 5/8, GR. 5 ....... ICableMounting Bracket ......................... IHex FlangeHd. Screw, I14-20 x I/2,Self-Thrd .............................................. 2

Drive Control Cable................................ I

SpeedControl Cable/Lever..................... ICableClamp ........................................... IHexWasher Hd. FlangeScrew,#10-24 x 112......................................... I

LeverGrip ............................................... 1RearAxle Assembly................................ 1Spacer.................................................... 4FlatWasher, .406" ID.............................. 4Wheel Shield .......................................... 2

RearWheel/Tire Assembly ..................... 2Shoulder Screw, 3/8-16 x 2.42 ............... 4Deck HeightAdjust Linkage.................... 1E-Clip ..................................................... 2Front Axle Assembly............................... IFront Wheel/Tire Assembly .................... 2Front Axle Bearing.................................. 2Compression Spring............................... !

Order parts from your local authorized engine dealer. Refer to engine/model type nameplate on engine.

** Optional Equipment

A/R As Required.

21

PartsList Mode 9o9J

22 19

4

10

22

Ref. # Part # Description Qty.

!23456789

1011

19170211917026191703617637671177038173102519170871110108110006817636821917050

Lower Handlebar .................................... 1

Upper Handlebar .................................... 1HandlebarSupport Strut ........................ 2

HandlebarAdjustment Knob................... 4Ext. Tooth Lock Washer, 5/!6 ................ 4

Curved HeadScrew, 5/16-18 x 1-3/4 ..... 2Carriage Bolt, 5/16-18 x 1-3/4, Special... 2Hex Lock Nut, 3/8-16 ............................. 2Hex Hd. Screw, 3/8-16 x 3/4, GR.5 ....... 2CableTie................................................. 2

Bail Grip ................................................. 1

Ref. # Part# Description Qty.

!2 1917053!3 191708514 191708115 191816116 710-1205!7 720-0279!8 191703719 191703210 190867721 191709122 1917092

Operator PresenceControl Bail .............. 1Wheel Drive Bail..................................... 1Operator PresenceControl Cable ........... 1

Decal- Bail Operating Instructions ......... 1RopeGuide............................................. 1

Wing Knob, 1/4-20 ................................ 1Speed Control Lever/Cable..................... 1Drive Control Cable ................................ 1

Bushing, Nyliner ..................................... 4Hex Hd. Screw, M6................................. 1Hex Nut, M6 ........................................... 1

Mod_909J Notes

MANUFACTURER'S LIMITED WARRANTY FOR:

0 TRIIKBILT°The limited warranty set forth below is given by Troy-Bilt LLCwith respect to new merchandise purchased and used in theUnited States, its possessions and territories.

Troy-Bilt LLC warrants this product against defects for a periodof two (2) years commencing on the date of original purchaseand will, at its option, repair or replace, free of charge, any partfound to be defective in materials or workmanship. This limitedwarranty shall only apply if this product has been operated andmaintained in accordance with the Operator's Manual furnishedwith the product, and has not been subject to misuse, abuse,commercial use, neglect, accident, improper maintenance, alter-ation, vandalism, theft, fire, water, or damage because of otherperil or natural disaster. Damage resulting from the installationor use of any accesson/or attachment not approved by Troy-BiltLLC for use with the product(s) covered by this manual will voidyour warranty as to any resulting damage.

Normal wear parts or components thereof are subject toseparate terms as follows: All normal wear parts or componentfailures will be covered on the product for a period of 90 daysregardless of cause. After 90 days, but within the two yearperiod, normal wear part failures will be covered ONLY IFcaused by defects in materials or workmanship of OTHERcomponent 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, tires.

HOW TO OBTAIN SERVICE: Warranty service is available,WITH PROOF OF PURCHASE, through your local authorizedservice dealer. To locate the dealer in your area, check yourYellow Pages, or contact Troy-Bilt LLC at P.O. Box 361131,Cleveland, Ohio 44136-0019, 1-866-840-6483, or log on to ourWeb site at www.troybilt.com.

This limited warranty does not provide coverage in the followingcases:

a. The engine or component parts thereof. These itemscarry a separate manufacturer's warranty. Refer to theapplicable manufacturer's warranty for terms and condtions.

b. Log splitter pumps, valves, and cylinders have a separateone year warranty.

c. Routine maintenance items such as lubricants, filters,

blade sharpening, tune-ups, brake adjustments, clutchadjustments, deck adjustments, and normal deterioration ofthe exterior finish due to use or exposure.

d. Troy-Bilt LLC does not extend any warranty for productssold or exported outside of the United States, its pos-sessions 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 bythis warranty.

f. Service completed by someone other than an authorizedservice dealer is not covered by this warranty.

g. Transportation charges and service calls are not covered.

No implied warranty, including any implied warranty of mer-chantability of fitness for a particular purpose, applies afterthe applicable period of express written warranty above asto the parts as identified. No other express warranty,whether written or oral, except as mentioned above, givenby any person or entity, including a dealer or retailer, withrespect to any product, shall bind Troy-Bilt LLC. During theperiod of the warranty, the exclusive remedy is repair orreplacement of the product as set forth above.

The provisions as set forth in this warranty provide the soleand exclusive remedy arising from the sale. Troy-Bilt LLCshall not be liable for incidental or consequential loss ordamage including, without limitation, expenses incurred forsubstitute or replacement lawn care services or for rentalexpenses 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 impliedwarranty lasts, so the above exclusions or limitations may notapply to you.

In no event shall recovery of any kind be greater than theamount of the purchase price of the product sold. Alteration ofthe safety features of the product shall void this warranty.You assume the risk and liability for loss, damage, or injury toyou and your property and/or to others and their property arisingout of the misuse or inability to use the product.

This limited warranty shall not extend to anyone other than theoriginal purchaser or to the person for whom it was purchasedas a gift.

HOW STATE LAW RELATES TO THIS WARRANTY: This

limited warranty gives you specific legal rights, and youmay also have other rights which vary from state to state.

TROY-BILT LLC, P.O. BOX 361131, CLEVELAND, OHIO 44136-0019, 1-866-840-6483

trnv bilt - c.searspartsdirect.com · mow only in daylight or in good arti-ficial light. do not...

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