Troy Bilt Lawn Mower TB 38 User Manual

Safe Operation Practices • Set-Up • Operation • Maintenance • Service • Troubleshooting • Warranty  
OperatOrs Manual  
TB-38 Lawn Tractor  
WARNING  
READ AND FOLLOW ALL SAFETY RULES AND INSTRUCTIONS IN THIS MANUAL  
BEFORE ATTEMPTING TO OPERATE THIS MACHINE.  
FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.  
TROY-BILT LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019  
Printed In USA  
Form No. 769-10742  
(April 9, 2015)  
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Important Safe Operation Practices  
2
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!  
CALIFORNIA PROPOSITION 65  
WARNING! Engine Exhaust, some of its constituents, and certain vehicle components  
contain or emit chemicals known to State of California to cause cancer and birth defects  
or other reproductive harm.  
WARNING! Battery posts, terminals, and related accessories contain lead and lead  
compounds, chemicals known to the State of California to cause cancer and reproductive  
harm. Wash hands after handling  
DANGER! This machine was built to be operated according to the safe operation practices 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.  
6.  
Thoroughly inspect the area where the equipment is to be  
used. Remove all stones, sticks, wire, bones, toys, and other  
foreign objects which could be picked up and thrown by  
the blade(s). Thrown objects can cause serious personal  
injury.  
General Operation  
1.  
Read, understand, and follow all instructions on the  
machine and in the manual(s) before attempting to  
assemble and operate. Keep this manual in a safe place for  
future and regular reference and for ordering replacement  
parts.  
7.  
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.  
2.  
3.  
Be familiar with all controls and their proper operation.  
Know how to stop the machine and disengage them  
quickly.  
Never allow children under 14 years of age to operate this  
machine. Children 14 and over should read and understand  
the instructions and safe operation practices in this manual  
and on the machine and should be trained and supervised  
by an adult.  
8.  
9.  
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. Loose fitting clothes and jewelry can be  
caught in movable parts. Never operate this machine in  
bare feet or sandals.  
4.  
5.  
Never allow adults to operate this machine without proper  
instruction.  
To help avoid blade contact or a thrown object injury,  
keep bystanders, helpers, children and pets at least 75 feet  
from the machine while it is in operation. Stop machine if  
anyone enters the area.  
10. Be aware of the mower and attachment discharge direction  
and do not point it at anyone. Do not operate the mower  
without the discharge cover or entire grass catcher in its  
proper place.  
11. Do not put hands or feet near rotating parts or under the  
cutting deck. Contact with the blade(s) can amputate  
hands and feet.  
3
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12. A missing or damaged discharge cover can cause blade  
contact or thrown object injuries.  
Slope Operation  
Slopes are a major factor related to loss of control and tip-over  
accidents which can result in severe injury or death. All slopes  
require extra caution. If you cannot back up the slope or if you  
feel uneasy on it, do not mow it.  
13. Stop the blade(s) when crossing gravel drives, walks, or  
roads and while not cutting grass.  
14. Watch for traffic when operating near or crossing  
roadways. This machine is not intended for use on any  
public roadway.  
For your safety, use the slope gauge included as part of this  
manual to measure slopes before operating this machine on  
a sloped or hilly area. If the slope is greater than 15 degrees as  
shown on the slope gauge, do not operate this machine on that  
area or serious injury could result.  
15. Do not operate the machine while under the influence of  
alcohol or drugs.  
16. Mow only in daylight or good artificial light.  
17. Never carry passengers.  
Do:  
1.  
Mow up and down slopes, not across. Exercise extreme  
caution when changing direction on slopes.  
18. Disengage blade(s) before shifting into reverse. Back up  
slowly. Always look down and behind before and while  
backing to avoid a back-over accident.  
2.  
Watch for holes, ruts, bumps, rocks, or other hidden  
objects. Uneven terrain could overturn the machine. Tall  
grass can hide obstacles.  
19. Slow down before turning. Operate the machine smoothly.  
Avoid erratic operation and excessive speed.  
3.  
Use slow speed. Choose a low enough speed setting so  
that you will not have to stop or shift while on the slope.  
Tires may lose traction on slopes even though the brakes  
are functioning properly. Always keep machine in gear  
when going down slopes to take advantage of engine  
braking action.  
20. Disengage blade(s), set parking brake, stop engine and wait  
until the blade(s) come to a complete stop before removing  
grass catcher, emptying grass, unclogging chute, removing  
any grass or debris, or making any adjustments.  
21. Never leave a running machine unattended. Always turn  
off blade(s), place transmission in neutral, set parking  
brake, stop engine and remove key before dismounting.  
4.  
5.  
6.  
Follow the manufacturer’s recommendations for wheel  
weights or counterweights to improve stability.  
22. Use extra care when loading or unloading the machine into  
a trailer or truck. This machine should not be driven up or  
down ramp(s), because the machine could tip over, causing  
serious personal injury. The machine must be pushed  
manually on ramp(s) to load or unload properly.  
Use extra care with grass catchers or other attachments.  
These can change the stability of the machine.  
Keep all movement on the slopes slow and gradual. Do  
not make sudden changes in speed or direction. Rapid  
engagement or braking could cause the front of the  
machine to lift and rapidly flip over backwards which could  
cause serious injury.  
23. Muffler and engine become hot and can cause a burn. Do  
not touch.  
24. Check overhead clearances carefully before driving under  
low hanging tree branches, wires, door openings etc.,  
where the operator may be struck or pulled from the  
machine, which could result in serious injury.  
7.  
Avoid starting or stopping on a slope. If tires lose traction,  
disengage the blade(s) and proceed slowly straight down  
the slope.  
25. Disengage all attachment clutches, depress the brake  
pedal completely and shift into neutral before attempting  
to start engine.  
Do Not:  
1.  
Do not turn on slopes unless necessary; then, turn slowly  
and gradually downhill, if possible.  
26. Your machine is designed to cut normal residential grass of  
a height no more than 10”. Do not attempt to mow through  
unusually tall, dry grass (e.g., pasture) or piles of dry leaves.  
Dry grass or leaves may contact the engine exhaust and/  
or build up on the mower deck presenting a potential fire  
hazard.  
2.  
Do not mow near drop-offs, ditches or embankments. The  
mower could suddenly turn over if a wheel is over the edge  
of a cliff, ditch, or if an edge caves in.  
3.  
Do not try to stabilize the machine by putting your foot on  
the ground.  
4.  
5.  
Do not use a grass catcher on steep slopes.  
27. Use only accessories and attachments approved for this  
machine by the machine manufacturer. Read, understand  
and follow all instructions provided with the approved  
accessory or attachment.  
Do not mow on wet grass. Reduced traction could cause  
sliding.  
6.  
7.  
Do not shift to neutral and coast downhill. Over-speeding  
may cause the operator to lose control of the machine  
resulting in serious injury or death.  
28. Data indicates that operators, age 60 years and above, are  
involved in a large percentage of riding mower-related  
injuries. These operators should evaluate their ability  
to operate the riding mower safely enough to protect  
themselves and others from serious injury.  
Do not tow heavy pull behind attachments (e.g. loaded  
dump cart, lawn roller, etc.) on slopes greater than 5  
degrees. When going down hill, the extra weight tends  
to push the tractor and may cause you to loose control  
(e.g. tractor may speed up, braking and steering ability are  
reduced, attachment may jack-knife and cause tractor to  
overturn).  
29. If situations occur which are not covered in this manual, use  
care and good judgment. Contact your customer service  
representative for assistance.  
4
Section 2 — important Safe operation practiceS  
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Children  
Service  
1.  
Tragic accidents can occur if the operator is not alert to the  
Safe Handling of Gasoline:  
presence of children. Children are often attracted to the  
machine and the mowing activity. They do not understand  
the dangers. Never assume that children will remain where  
you last saw them.  
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. Wash your skin  
and change clothes immediately.  
a. Keep children out of the mowing area and in  
watchful care of a responsible adult other than the  
operator.  
a. Use only an approved gasoline container.  
b. Be alert and turn machine off if a child enters the  
area.  
b. 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.  
c. Before and while backing, look behind and down for  
small children.  
d. Never carry children, even with the blade(s) shut off.  
They may fall off and be seriously injured or interfere  
with safe machine operation.  
c. When practical, 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.  
e. Use extreme care when approaching blind corners,  
doorways, shrubs, trees or other objects that may  
block your vision of a child who may run into the  
path of the machine.  
d. 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.  
f.  
To avoid back-over accidents, always disengage  
the cutting blade(s) before shifting into Reverse.  
If equipped, the “Reverse Caution Mode” should  
not be used when children or others are around.  
e. Extinguish all cigarettes, cigars, pipes and other  
sources of ignition.  
f.  
Never fuel machine indoors.  
g. Keep children away from hot or running engines.  
They can suffer burns from a hot muffler.  
g. Never remove gas cap or add fuel while the engine  
is hot or running. Allow engine to cool at least two  
minutes before refueling.  
h. Remove key when machine is unattended to  
prevent unauthorized operation.  
h. Never over fill fuel tank. Fill tank to no more than ½  
inch below bottom of filler neck to allow space for  
fuel expansion.  
2.  
Never allow children under 14 years of age to operate this  
machine. Children 14 and over should read and understand  
the instructions and safe operation practices in this manual  
and on the machine and should be trained and supervised  
by an adult.  
i.  
j.  
Replace gasoline cap and tighten securely.  
If gasoline is spilled, wipe it off the engine and  
equipment. Move machine to another area. Wait 5  
minutes before starting the engine.  
Towing  
1.  
Tow only with a machine that has a hitch designed for  
towing. Do not attach towed equipment except at the  
hitch point.  
k. To reduce fire hazards, keep machine free of grass,  
leaves, or other debris build-up. Clean up oil or fuel  
spillage and remove any fuel soaked debris.  
2.  
Follow the manufacturers recommendation for weight  
limits for towed equipment and towing on slopes.  
l.  
Never store the machine or fuel container inside  
where there is an open flame, spark or pilot light  
as on a water heater, space heater, furnace, clothes  
dryer or other gas appliances.  
3.  
4.  
Never allow children or others in or on towed equipment.  
On slopes, the weight of the towed equipment may cause  
loss of traction and loss of control.  
m. Allow a machine to cool at least five minutes before  
storing.  
5.  
Always use extra caution when towing with a machine  
capable of making tight turns (e.g. “zero-turn” ride-on  
mower). Make wide turns to avoid jack-knifing.  
General Service  
1.  
Never run an engine indoors or in a poorly ventilated area.  
Engine exhaust contains carbon monoxide, an odorless,  
and deadly gas.  
6.  
7.  
Travel slowly and allow extra distance to stop.  
Do not shift to neutral and coast downhill.  
2.  
Before cleaning, repairing, or inspecting, make certain the  
blade(s) and all moving parts have stopped. Disconnect the  
spark plug wire and ground against the engine to prevent  
unintended starting.  
Section 2 — important Safe operation practiceS  
5
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3.  
Periodically check to make sure the blades come to  
complete stop within approximately (5) five seconds after  
operating the blade disengagement control. If the blades  
do not stop within the this time frame, your machine  
should be serviced professionally by an authorized MTD  
Service Dealer.  
Do not modify engine  
To avoid serious injury or death, do not modify engine in any  
way. Tampering with the governor setting can lead to a runaway  
engine and cause it to operate at unsafe speeds. Never tamper  
with factory setting of engine governor.  
4.  
5.  
Check brake operation frequently as it is subjected to wear  
during normal operation. Adjust and service as required.  
Notice Regarding Emissions  
Engines which are certified to comply with California and federal  
EPA emission regulations for SORE (Small Off Road Equipment)  
are certified to operate on regular unleaded gasoline, and  
may include the following emission control systems: Engine  
Modification (EM), Oxidizing Catalyst (OC), Secondary Air  
Injection (SAI) and Three Way Catalyst (TWC) if so equipped.  
Check the blade(s) and engine mounting bolts at frequent  
intervals for proper tightness. Also, visually inspect blade(s)  
for damage (e.g., excessive wear, bent, cracked). Replace  
the blade(s) with the original equipment manufacturer’s  
(O.E.M.) blade(s) only, listed in this manual. “Use of parts  
which do not meet the original equipment specifications  
may lead to improper performance and compromise  
safety!”  
When required, models are equipped with low permeation fuel  
lines and fuel tanks for evaporative emission control. California  
models may also include a carbon canister. Please contact  
Customer Support for information regarding the evaporative  
emission control configuration for your model.  
6.  
7.  
Mower blades are sharp. Wrap the blade or wear gloves,  
and use extra caution when servicing them.  
Keep all nuts, bolts, and screws tight to be sure the  
equipment is in safe working condition.  
Spark Arrestor  
8.  
9.  
Never tamper with the safety interlock system or other  
safety devices. Check their proper operation regularly.  
WARNING! This machine 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 arrestor  
meeting applicable local or state laws (if any).  
After striking a foreign object, stop the engine, disconnect  
the spark plug wire(s) and ground against the engine.  
Thoroughly inspect the machine for any damage. Repair  
the damage before starting and operating.  
If a spark arrestor 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 arrestor 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.  
10. Never attempt to make adjustments or repairs to the  
machine while the engine is running.  
11. Grass catcher components and the discharge cover are  
subject to wear and damage which could expose moving  
parts or allow objects to be thrown. For safety protection,  
frequently check components and replace immediately  
with original equipment manufacturer’s (O.E.M.) parts only,  
listed in this manual. “Use of parts which do not meet the  
original equipment specifications may lead to improper  
performance and compromise safety!”  
12. Do not change the engine governor settings or over-speed  
the engine. The governor controls the maximum safe  
operating speed of the engine.  
13. Maintain or replace safety and instruction labels, as  
necessary.  
14. Observe proper disposal laws and regulations for gas, oil,  
etc. to protect the environment.  
15. According to the Consumer Products Safety Commission  
(CPSC) and the U.S. Environmental Protection Agency (EPA),  
this product has an Average Useful Life of seven (7) years,  
or 270 hours of operation. At the end of the Average Useful  
Life have the machine inspected annually by an authorized  
service dealer to ensure that all mechanical and safety  
systems are working properly and not worn excessively.  
Failure to do so can result in accidents, injuries or death.  
WARNING! Your Responsibility—Restrict the use of this power machine to persons who read, understand and  
follow the warnings and instructions in this manual and on the machine.  
SAVE THESE INSTRUCTIONS!  
6
Section 2 — important Safe operation practiceS  
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Safety Symbols  
This page depicts and describes safety symbols that may appear on this product. Read, understand, and follow all instructions on the  
machine before attempting to assemble and operate.  
Symbol  
Description  
READ THE OPERATOR’S MANUAL(S)  
Read, understand, and follow all instructions in the manual(s) before attempting to  
assemble and operate  
DANGER — ROTATING BLADES  
Never carry passengers. Never carry children, even with the blades off.  
DANGER — ROTATING BLADES  
Always look down and behind before and while backing to avoid a back-over accident.  
DANGER — ROTATING BLADES  
Do not put hands or feet near rotating parts or under the cutting deck. Contact with  
the blade(s) can amputate hands and feet. Be sure blades and engine are stopped before  
placing hands or feet near blades.  
DANGER — BYSTANDERS  
Mowing in reverse is not recommended. Do not mow when children or others are around.  
Keep bystanders, helpers, children and pets at least 75 feet from the machine while it is in  
operation.  
DANGER — THROWN OBJECTS  
This machine may pick up and throw and objects which can cause serious personal injury.  
Remove objects which could be thrown by the blades.  
DANGER — SLOPE OPERATION  
Go up and down slopes, not across. Use extra caution on slopes. Do not mow slopes  
greater than 15 degrees. Avoid sudden turns. Use low speed. Do not operate machine  
where it could tip or slip. If machine stops going uphill, stop blades and back down slowly.  
DANGER — ROTATING BLADES  
Before leaving operator’s position, disengage blades, engage parking brake, shut off engine  
and remove key. Keep safety devices (guards, shields, switches, etc.) in place and in working  
order.  
DANGER — HOT SURFACES  
Allow machine to cool before fueling or storing.  
DANGER — HOT SURFACES  
Do not drive through piles of dry leaves or tall dry grass. Keep machine free of debris.  
max10"  
WARNING — HOT SURFACES  
Operation of this equipment may create sparks that can start fires around dry vegetation.  
A spark arrestor may be required. The operator should contact local fire agencies for laws  
or regulations relating to fire prevention requirements.  
Section 2 — important Safe operation practiceS  
7
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8
Section 2 — important Safe operation practiceS  
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Assembly & Set-Up  
3
NOTE: If the battery is put into service after the date shown  
Tractor Set-Up  
on top/side of battery, charge the battery as instructed in the  
Maintenance section your Operator’s Manual prior to operating  
the tractor.  
Tools Required:  
3/8-inch wrench (or adjustable wrench)  
Shipping Brace Removal  
7⁄16-inch wrench (or adjustable wrench)  
1/2-inch socket wrench  
WARNING! Never operate the mower deck  
without the chute deflector installed and in the  
down position.  
Connecting the Battery Cables  
CALIFORNIA PROPOSITION 65 WARNING:  
Battery posts, terminals, and related accessories  
contain lead and lead compounds, chemicals known  
to the State of California to cause cancer and  
reproductive harm. Wash hands after handling.  
1.  
Check the mower deck for a shipping brace that may be  
holding the chute deflector upward for shipment. If the  
brace is present, it must be removed before operating the  
tractor. Holding the chute deflector fully upward, remove  
the shipping brace. Lower the chute deflector and discard  
the shipping brace. See Figure 3-2.  
CAUTION: When attaching battery cables, always  
connect the POSITIVE (Red) wire to its terminal first,  
followed by the NEGATIVE (Black) wire.  
For shipping reasons, both battery cables on your equipment  
may have been left disconnected from the terminals at the  
factory. To connect the battery cables, proceed as follows:  
NOTE: The positive battery terminal is marked Pos. (+). The  
negative battery terminal is marked Neg. (–).  
1.  
Remove the plastic cover, if present, from the positive  
battery terminal and attach the red cable to the positive  
battery terminal (+) with the bolt and hex nut. See Figure 3-1.  
2.  
Remove the plastic cover, if present, from the negative  
battery terminal and attach the black cable to the negative  
battery terminal (–) with the bolt and hex nut. See Figure 3-1.  
Figure 3-2  
Figure 3-1  
3.  
Position the red rubber boot over the positive battery  
terminal to help protect it from corrosion.  
9
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Attaching The Steering Wheel  
If the steering wheel for your tractor did not come attached, the  
hardware for attaching it has been packed within the steering  
wheel, beneath the steering wheel cap. Carefully pry off the  
steering wheel cap and remove the hardware.  
1.  
With the wheels of the tractor pointing straight forward,  
place the steering wheel over the steering shaft.  
a
2.  
Place the washer (with the cupped side down) over the  
steering wheel and secure with the hex bolt. See Figure  
3-3.  
b
Figure 3-4  
5.  
To adjust the position of the seat, remove the adjustment  
knob on the bottom of the seat. Slide the seat forward or  
backward as desired. Reinstall the adjustment knob. See  
Figure 3-5.  
c
Figure 3-3  
3.  
Place the steering wheel cap over the center of the steering  
wheel and push downward until it “clicks” into place.  
Attaching The Seat  
If the seat for your tractor was not attached at the factory, refer  
to the following steps.  
d
NOTE: For shipping reasons, seats are either fastened to the  
tractor seat’s pivot bracket with a plastic tie, or mounted  
backward to the pivot bracket. In either case, free the seat from  
its shipping position and remove the adjustment knob from the  
bottom of seat before proceeding with the instructions below.  
1.  
As already instructed, remove the seat adjustment knob  
installed by the factory in the bottom of the seat. See “a” in  
Figure 3-4.  
Figure 3-5  
2.  
Align the seat over the seat pivot bracket as shown in  
Figure 3-4 and fit the seat onto the pivot bracket inserting  
the two tabs on the seat bottom into the slots on the pivot  
bracket.  
3.  
4.  
Slide the seat rearward in the seat pivot bracket (c),  
lining up the center rear slot in the pivot bracket with the  
remaining hole in the seat’s base. See Figure 3-5.  
Note: Be certain the two seat tabs engauge the pivot  
bracket as shown in the bottom inset of Figure 3-5.  
Select desired position for the seat, and secure with the  
adjustment knob removed earlier (d in Figure 3-5).  
10  
Section 3— ASSembly & Set-Up  
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Tire Pressure  
To Add Gasoline  
1.  
2.  
3.  
Turn the engine off and let engine cool at least 2 minutes  
WARNING! Maximum tire pressure under any  
before removing the fuel cap. The gasoline tank is located  
under the hood. Remove the fuel cap by turning it  
counterclockwise.  
circumstances is 30 psi. Equal tire pressure should be  
maintained at all times. Never exceed the maximum  
inflation pressure shown on the sidewall of the tire.  
Fill the fuel tank with gasoline. Use only clean, fresh (no  
more than 30 days old), unleaded gasoline. Fill tank to no  
more than 1/2 inch below bottom of filler neck to allow  
space for fuel expansion.  
The recommended operating tire pressure is:  
Approximately 10 psi for the rear tires  
Approximately 14 psi for the front tires  
Reinstall the fuel cap.  
IMPORTANT: Refer to the tire sidewall for exact tire  
manufacturer’s recommended or maximum psi. Do not  
overinflate. Uneven tire pressure could cause the cutting deck to  
mow unevenly.  
IMPORTANT: Do not overfill the tank. Fill tank to no more  
than 1/2 inch below bottom of filler neck to allow space for fuel  
expansion. See Figure 3-6.  
Gas and Oil Fill-up  
OIL  
IMPORTANT: Your tractor is shipped with motor oil in the  
engine. However, you MUST check the oil level before operating.  
Be careful not to overfill.  
Service and check the engine oil as instructed in the separate  
Engine Operator/Owner Manual packed with your tractor. Read  
the instructions carefully.  
GASOLINE  
The gasoline tank is located under the hood. Do not overfill.  
WARNING! Use extreme care when handling  
gasoline. Gasoline is extremely flammable and the  
vapors are explosive. Never fuel machine indoors or  
while the engine is hot or running. Extinguish  
cigarettes, cigars, pipes, and other sources of ignition.  
NOTE : Purchase gasoline in small quantities. Do not use gasoline  
left over from the previous season, to minimize gum deposits in  
the fuel system.  
Figure 3-6  
This engine is certified to operate on unleaded gasoline.  
For best results, fill the fuel tank with only clean, fresh,  
unleaded gasoline with a pump sticker octane rating of 87  
or higher.  
Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline  
by volume) is an approved fuel. Other gasoline/alcohol  
blends, such as E85, are not approved.  
Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline  
blends (up to a maximum of 15% MTBE by volume) are  
approved fuels. Other gasoline/ether blends are not  
approved.  
Fill fuel tank outdoors or in well-ventilated area.  
Do not overfill fuel tank. Fill tank to no more than 1/2  
inch below bottom of filler neck to allow space for fuel  
expansion.  
Never remove gas cap or add fuel while the engine is hot or  
running. Allow engine to cool at least two minutes before  
refueling.  
If gasoline is spilled, wipe it off the engine and equipment.  
Move machine to another area. Wait 5 minutes before  
starting the engine.  
Section 3 — ASSembly & Set-Up  
11  
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Controls & Features  
4
Throttle/Choke Lever  
Clutch/Brake Pedal  
Ignition Switch  
Speed Control &  
Parking Brake Lever  
Shift Lever  
Deck Lift Lever  
Cup Holder  
PTO (Blade Engage) Lever  
Figure 4-1  
NOTE: Steering wheel not shown for clarity  
Lawn Tractor controls and features are illustrated in Figure 4-1 and described on the following pages.  
WARNING! Read and follow all safety rules and instructions in this manual, including the entire Operation section,  
before attempting to operate this machine. Failure to comply with all safety rules and instructions may result in personal  
injury.  
12  
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Throttle / Choke Control  
Clutch-Brake Pedal  
The clutch-brake pedal is located on the left side of the lawn  
tractor, along the running board. Depress the clutch-brake pedal  
part way down when slowing the tractor by changing speeds  
(Refer to Speed Control Lever). Depress the pedal all the way down  
to engage the disc brake and bring the tractor to a complete stop.  
The throttle control lever is located on the left side  
of the tractor’s dash panel, see Figure 4-1. This lever  
controls the speed of the engine, as well as the  
choke when it is pushed all the way forward. When  
set in a given position, the throttle will maintain a  
uniform engine speed.  
NOTE: The clutch-brake pedal must be depressed to start the  
engine. Refer to Safety Interlock Switches in the Operation  
section of this manual.  
IMPORTANT: When operating the tractor with the  
cutting deck engaged, be certain that the throttle  
lever is always in the FAST (rabbit) position.  
Shift Lever  
Moving the throttle lever all the way forward  
activates the engine’s choke control. Activating  
the choke control closes the choke plate on the  
carburetor and aids in starting the engine.  
The shift lever is located on the left side of the fender and has  
three positions, FORWARD, NEUTRAL and REVERSE. The brake  
pedal must be depressed and the tractor must not be in motion  
when moving the shift lever. See Figure 4-3.  
Refer to Starting The Engine in the Operation  
section of this manual for detailed starting  
instructions.  
IMPORTANT: Never force the shift lever. Doing so may result in  
serious damage to the tractor’s transmission.  
Ignition Switch  
The ignition switch is activated to start the engine.  
Insert key into the ignition switch and turn clockwise to the  
START position. Release the key into the ON position once engine  
has fired. See Figure 4-2.  
WARNING! Never leave a running machine  
unattended. Always disengage PTO, move shift lever  
into neutral position, set parking brake, stop engine  
and remove key to prevent unintended starting.  
IMPORTANT: Prior to operating the tractor, refer to both Safety  
Interlock Switches and Starting The Engine in the Operation section  
of this manual for detailed instructions regarding the Ignition Switch  
Module.  
On/Lights  
Start  
Figure 4-3  
Speed Control Lever  
The speed control lever, located on the lower left  
side of the tractor’s dash console, allows you to  
regulate the ground speed of the lawn tractor.  
To use, depress the clutch-brake pedal and move  
the lever out of the parking brake notch and  
forward to increase the tractor’s ground speed.  
When a desired speed has been reached, release  
the lever into an appropriate notch to maintain  
that speed.  
To slow the tractor’s ground speed, depress the  
clutch-brake pedal and move the speed control  
lever rearward and release it into a notch.  
Figure 4-2  
Section 4 — controlS & FeatureS  
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Parking Brake  
Deck Lift Lever  
To set the parking brake, fully depress the clutch-  
brake pedal. Move the speed control lever all the  
way down and into the parking brake position.  
Release the clutch-brake pedal to allow the  
parking brake to engage.  
Found on your tractor’s right fender, the deck lift  
lever is used to change the height of the cutting deck.  
To use, move the lever to the left, then place in the  
notch best suited for your application.  
RUN  
PARK  
BRAKE  
OFF  
PTO (Blade Engage) Lever  
To release the parking brake, depress the clutch-  
brake pedal and move the speed control lever  
out of the parking brake position into the desired  
position. Release the clutch-brake pedal.  
Found on the tractor’s right fender, the PTO (blade  
engage) lever is used to engage power to the cutting  
deck. To operate, move the lever all the way forward.  
Moving the lever all the way rearward into the PTO  
OFF position disengages power to the cutting deck.  
NOTE: The parking brake must be set if the  
operator leaves the seat with the engine running  
or the engine will automatically shut off.  
NOTE: The PTO (blade engage) lever must be in the  
disengaged (PTO OFF) position when starting the  
engine.  
PARK  
BORANKE  
14  
Section 4— controlS & FeatureS  
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Operation  
5
Engaging the Parking Brake  
To engage the parking brake:  
1.  
2.  
3.  
Fully depress the clutch-brake pedal and hold it down with  
your foot.  
Move the speed control lever all the way down and into the  
parking brake position.  
Release the clutch-brake pedal to allow the parking brake  
to engage.  
To release the parking brake:  
1.  
Depress the clutch-brake pedal and move the speed  
control lever out of the parking brake position and into a  
desired speed.  
Setting the Cutting Height  
1.  
Select the height position of the cutting deck by placing  
the deck lift lever in any of the different cutting height  
notches on the right side of the fender.  
WARNING! Keep hands and feet away from the  
discharge opening of the cutting deck.  
Refer to Leveling the Deck in the Maintenance & Adjustments  
section of this manual for more detailed instructions regarding  
various deck adjustments.  
Starting the Engine  
WARNING! Do not operate the tractor if the  
interlock system is malfunctioning. This system was  
designed for your safety and protection.  
Safety Interlock Switches  
This tractor is equipped with a safety interlock system for the  
protection of the operator. If the interlock system should ever  
malfunction, do not operate the tractor. Contact an authorized  
Troy-Bilt service dealer.  
NOTE: Refer to the Assembly & Set-Up section of this manual for  
gasoline and oil fill-up instructions.  
The safety interlock system prevents the engine from  
cranking or starting unless the parking brake is engaged,  
and the PTO (Blade Engage) lever is in the disengaged (OFF)  
position.  
1.  
2.  
Insert the tractor key into the ignition switch.  
Place the PTO (Blade Engage) lever in the disengaged (OFF)  
position.  
3.  
4.  
5.  
Engage the tractor’s parking brake.  
Activate the choke control.  
The engine will automatically shut off if the operator leaves  
the seat before engaging the parking brake.  
Turn the ignition key clockwise to the START position. After  
the engine starts, release the key. It will return to the ON  
position.  
The engine will automatically shut off if the operator leaves  
the tractor’s seat with the PTO (Blade Engage) lever in the  
engaged (ON) position, regardless of whether the parking  
brake is engaged.  
IMPORTANT: Do NOT hold the key in the START position for  
longer than ten seconds at a time. Doing so may cause damage  
to your engine’s electric starter.  
The engine will automatically shut off if the PTO (Blade  
Engage) lever is moved into the engaged (ON) position with  
the shift lever in Reverse.  
6.  
Aftertheenginestarts,deactivatethechokecontrolandplace  
the throttle control in the FAST position.  
WARNING! Do not operate the tractor if the  
interlock system is malfunctioning. This system was  
designed for your safety and protection.  
NOTE: Do NOT leave the choke control on while operating the  
tractor. Doing so will result in a “rich” fuel mixture and cause the  
engine to run poorly.  
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3.  
Shut engine off and remove the key.  
Stopping the Engine  
Doing so will minimize the possibility of having your lawn  
‘‘browned’’ by hot exhaust from your tractor’s running  
engine.  
WARNING! If you strike a foreign object, stop the  
engine, disconnect the spark plug wire(s) and  
ground against the engine. Thoroughly inspect the  
machine for any damage. Repair the damage before  
restarting and operating.  
If unit stalls with speed control in high speed, or if unit will not  
operate with speed control lever in a low speed position, proceed  
as follows:  
1.  
If the blades are engaged, place the PTO (Blade Engage)  
lever in the disengaged (OFF) position.  
1.  
2.  
3.  
4.  
5.  
6.  
7.  
Place shift lever in NEUTRAL.  
Restart engine.  
2.  
3.  
Turn the ignition key counterclockwise to the STOP position.  
Place speed control lever in highest speed position.  
Release clutch-brake pedal fully.  
Depress clutch-brake pedal.  
Remove the key from the ignition switch to prevent  
unintended starting.  
Driving The Tractor  
Place speed control lever in desired position.  
WARNING! Avoid sudden starts, excessive speed  
and sudden stops.  
Place shift lever in either FORWARD or REVERSE, and follow  
normal operating procedures.  
WARNING! Do not leave the seat of the tractor  
without first placing the PTO (Blade Engage) lever in  
the disengaged (OFF) position, depressing the brake  
pedal and engaging the parking brake. If leaving  
the tractor unattended, also turn the ignition key off  
and remove the key.  
Driving On Slopes  
Refer to the SLOPE GAUGE in the Important Safe Operation  
Practices section in the front of this manual to help determine  
slopes where you may operate the tractor safely.  
WARNING! Do not mow on inclines with a slope in  
excess of 15 degrees (a rise of approximately 2-1/2 feet  
every 10 feet). The tractor could overturn and cause  
serious injury.  
WARNING! Always look down and behind before  
and while backing up to avoid a back-over accident.  
1.  
Depress the clutch-brake pedal to release the parking  
brake and let the pedal up.  
Mow up and down slopes, NEVER across.  
2.  
3.  
Move the throttle lever into the FAST (rabbit) position.  
Exercise extreme caution when changing direction on  
slopes.  
Place the shift lever in either the FORWARD or REVERSE  
position.  
Watch for holes, ruts, bumps, rocks, or other hidden  
objects. Uneven terrain could overturn the machine. Tall  
grass can hide obstacles.  
CAUTION: Do NOT use the shift lever to change  
the direction of travel when the tractor is in motion.  
Always use the clutch-brake pedal to bring the  
tractor to a complete stop before shifting.  
Avoid turns when driving on a slope. If a turn must be  
made, turn down the slope. Turning up a slope greatly  
increases the chance of a roll over.  
4.  
Release the parking brake by depressing the clutch-brake pedal  
and positioning the speed control lever in desired position.  
Avoid stopping when driving up a slope. If it is necessary  
to stop while driving up a slope, start up smoothly and  
carefully to reduce the possibility of flipping the tractor  
over backward.  
IMPORTANT: First-time operators should use speed positions 1  
or 2. Become completely familiar with the tractor’s operation and  
controls before operating the tractor in higher speed positions.  
5.  
6.  
Release clutch-brake pedal slowly to put unit into motion  
Engaging the Blades  
Engaging the PTO (Blade Engage) transfers power to the cutting  
The lawn tractor is brought to a stop by depressing the  
clutch-brake pedal.  
deck. To engage the blades, proceed as follows:  
NOTE: When operating the unit initially, there will be little  
difference between the highest two speeds until after the belts  
have seated themselves into the pulleys during the break-in  
period.  
1.  
2.  
3.  
Move the throttle control lever to the FAST (rabbit)  
position.  
Grasp the PTO (Blade Engage) lever and pivot it all the way  
forward into the engaged (ON) position.  
WARNING! Before leaving the operator’s position  
for any reason, disengage the blades, place the shift  
lever in neutral, engage the parking brake, shut  
engine off and remove the key.  
Keep the throttle lever in the FAST (rabbit) position for the  
most efficient use of the cutting deck.  
IMPORTANT: The PTO (Blade Engage) lever must be in the  
disengaged (OFF) position when starting the engine, when  
traveling in reverse, and if the operator leaves the seat. Refer to  
Safety Interlock Switches in the Operation section of this manual.  
IMPORTANT: When stopping the tractor for any reason while  
on a grass surface, always:  
1.  
2.  
Place the shift lever in neutral,  
Engage the parking brake,  
16  
Section 5— operation  
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Using the Deck Lift Lever  
To raise the cutting deck, move the deck lift lever to the left, then  
place it in the notch best suited for your application. Refer to  
Setting The Cutting Height earlier in this section.  
Headlights  
The Headlights are ON whenever the tractor’s engine is  
running.  
The lamps turn OFF when the ignition key is moved to the  
STOP position.  
Mowing  
WARNING! To help avoid blade contact or a  
thrown object injury, keep bystanders, helpers,  
children and pets at least 75 feet from the machine  
while it is in operation. Stop machine if anyone  
enters the area.  
The following information will be helpful when using the cutting  
deck with your tractor:  
WARNING! Plan your mowing pattern to avoid  
discharge of materials 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.  
Do not mow at high ground speed, especially if a mulch kit  
or grass collector is installed.  
For best results it is recommended that the first two laps be  
cut with the discharge thrown towards the center. After the  
first two laps, reverse the direction to throw the discharge  
to the outside for the balance of cutting. This will give a  
better appearance to the lawn.  
Do not cut the grass too short. Short grass invites weed  
growth and yellows quickly in dry weather.  
Mowing should always be done with the engine at full  
throttle.  
Under heavier conditions it may be necessary to go back  
over the cut area a second time to get a clean cut.  
Do NOT attempt to mow heavy brush and weeds and  
extremely tall grass. Your tractor is designed to mow lawns,  
NOT clear brush.  
Keep the blades sharp and replace the blades when worn.  
Refer to Cutting Blades in the Service section of this manual  
for proper blade sharpening instructions.  
Section 5 — operation  
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Maintenance & Adjustments  
6
6.  
4.  
Reinstall the oil drain plug securely. Be careful not to  
overtighten.  
Maintenance  
WARNING: Before performing any maintenance or  
repairs, disengage PTO, move shift lever into neutral  
position, set parking brake, stop engine and remove  
key to prevent unintended starting.  
Refill the engine with new motor oil as instructed in the  
Engine Owner’s Manual packed with your unit.  
IMPORTANT: Refer to the Engine Owner’s Manual packed with  
your unit for information regarding the quantity and proper  
viscosity of motor oil.  
Engine  
Refer to the Engine Owner’s Manual for engine maintenance  
instructions.  
Changing The Engine Oil on Kohler Engine Models  
To complete an oil change, proceed as follows:  
Check engine oil level before each use as instructed in the Engine  
Owner’s Manual packed with your unit. Follow the instructions  
carefully.  
1.  
Run the engine for a few minutes to allow the oil in the  
crankcase to warm up. Warm oil will flow more freely and  
carry away more of the engine sediment which may have  
settled at the bottom of the crankcase. Use care to avoid  
burns from hot oil.  
Changing Engine Oil On Briggs & Stratton Models  
For draining oil from the engine’s crankcase, a plastic oil drain  
sleeve is packed with this Operator’s Manual. To drain the oil,  
proceed as follows:  
2.  
3.  
Open the tractor’s hood and locate the oil drain port on the  
right side of the engine.  
Pop open the protective cap on the end of the oil drain  
valve to expose the drain port. Figure 6-2.  
1.  
Run the engine for a few minutes to allow the oil in the  
crankcase to warm up. Warm oil will flow more freely and  
carry away more of the engine sediment which may have  
settled at the bottom of the crankcase. Use care to avoid  
burns from hot oil.  
4.  
5.  
Remove the oil fill cap/ dipstick from the oil fill tube.  
Push the oil drain hose (packed with this manual) onto the  
oil drain port. Route the opposite end of the hose into an  
appropriate oil collection container with at least a 2.5 quart  
capacity, to collect the used oil.  
2.  
Open the tractor’s hood and locate the oil drain port on the  
right side of the engine and the oil fill cap on the topside of  
the engine.  
6.  
Rotate the drain valve counter-clockwise and release to  
drain the oil. See Figure 6-2.  
3.  
4.  
5.  
Unscrewtheoilfillcapandremovethedipstickfromtheoilfill  
tube.  
Snap the small end of oil drain sleeve onto the space  
provide around the oil drain plug. See Figure 6-1.  
Remove drain plug and drain oil into a suitable container  
with a capacity of no less than 64 oz.  
Figure 6-2  
7.  
After the oil has finished draining, push the end of the oil  
drain valve back in, until the tabs click into place. Re-cap  
the end of the oil drain valve to keep debris from entering  
the drain port.  
Figure 6-1  
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8.  
9.  
Replace the oil filter as instructed in the separate engine  
Owner’s Manual.  
IMPORTANT: If removing the battery for any reason,  
disconnect the NEGATIVE (Black) wire from it’s terminal first,  
followed by the POSITIVE (Red) wire. When re-installing the  
battery, always connect the POSITIVE (Red) wire its terminal  
first, followed by the NEGATIVE (Black) wire. Be certain that the  
wires are connected to the correct terminals; reversing them  
could change the polarity and result in damage to your engine’s  
alternating system.  
Refill the engine with new oil. Refer to the engine Owner’s  
Manual for information regarding the proper volume and  
weight of engine oil.  
IMPORTANT: Refer to the Engine Owner’s Manual packed with  
your unit for information regarding the quantity and proper  
viscosity of motor oil.  
Charging  
Air Cleaner  
IMPORTANT: When charging your tractor’s battery, use only a  
charger designed for 12V lead-acid batteries. Read your battery  
charger’s Owner’s Manual prior to charging your tractor’s battery.  
Always follow its instructions and heed its warnings.  
Service the pre-cleaner (if equipped) and cartridge/air cleaner  
element as instructed in the Engine Owner’s Manual packed with  
your unit.  
Spark Plug  
If your tractor has not been put into use for an extended period  
of time, charge the battery as follows:  
The spark plug should be cleaned and the gap reset once a  
season. Spark plug replacement is recommended at the start of  
each mowing season. Refer to the Engine Owner’s Manual for  
correct plug type and gap specifications.  
Set your battery charger to deliver a maximum of 10  
amperes. If your battery charger is automatic, charge  
the battery until the charger indicates that charging is  
complete.  
Lubrication  
NOTE: If the charger is not automatic, charge for no fewer than  
eight hours.  
WARNING: Before lubricating, repairing, or  
inspecting, always disengage PTO, move shift lever  
into neutral position, set parking brake, stop engine  
and remove key to prevent unintended starting.  
WARNING! Batteries give off an explosive gas  
while charging. Charge battery in a well ventilated  
area and keep away from an open flame or pilot  
light as on a water heater, space heater, furnace,  
clothes dryer or other gas appliances.  
Engine  
Lubricate the engine with motor oil as instructed in the Engine  
Owner Manual packed with your unit.  
Jump Starting  
WARNING! When removing or installing the  
battery, follow these instructions to prevent the  
screwdriver from shorting against the frame.  
Pivot Points & Linkage  
Lubricate all the pivot points on the drive system, parking brake  
and lift linkage at least once a season with light oil.  
IMPORTANT: Never jump your tractor’s dead battery with the  
battery of a running vehicle.  
Rear Wheels  
The rear wheels should be removed from the axles once a  
season. Lubricate the axles and the rims well with an all-purpose  
grease before re-installing them.  
1.  
2.  
3.  
Connect end of one jumper cable to the positive terminal  
of the good battery, then the other end to the positive  
terminal of the dead battery.  
Connect the other jumper cable to the negative terminal  
of the good battery, then to the frame of the unit with the  
dead battery.  
Cleaning the Engine And Deck  
Any fuel or oil spilled on the machine should be wiped off  
promptly. Do NOT allow debris to accumulate around the cooling  
fins of the engine or on any other part of the machine.  
Start the tractor as instructed in the Operation section.  
WARNING! Failure to use this procedure could  
cause sparking, and the gas in either battery could  
explode.  
IMPORTANT: The use of a pressure washer to clean your  
tractor is NOT recommended. It may cause damage to electrical  
components, spindles, pulleys, bearings or the engine.  
Cleaning Battery  
Battery  
Clean the battery by removing it from the tractor and washing  
with a baking soda and water solution. If necessary, scrape the  
battery terminals with a wire brush to remove deposits. Coat  
terminals and exposed wiring with grease or petroleum jelly to  
prevent corrosion.  
The battery is sealed and is maintenance-free. Acid levels cannot  
be checked.  
Always keep the battery cables and terminals clean and  
free of corrosive build-up.  
After cleaning the battery and terminals, apply a light coat  
of petroleum jelly or grease to both terminals.  
Always keep the rubber boot positioned over the positive  
terminal to prevent shorting.  
Section 6 — Maintenance & adjuStMentS  
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4.  
5.  
After loosening the jam nut:  
Battery Failures  
Some common causes for battery failure are:  
a. Tighten the lock nut to raise the front of the deck;  
b. Loosen the lock nut to lower the front of the deck.  
Incorrect initial activation  
Overcharging  
Retighten the jam nut loosened earlier when proper  
adjustment is achieved.  
Freezing  
Side-to-Side  
Undercharging  
If the cutting deck appears to be mowing unevenly, a side-to-  
side adjustment can be performed. Adjust if necessary as follows:  
Corroded connections  
These failures are NOT covered by your tractor’s warranty.  
1.  
2.  
3.  
With the tractor parked on a firm, level surface, place the  
deck lift lever in the second from the top notch (second  
highest position) and rotate both blades so that they are  
perpendicular with the tractor.  
Adjustments  
WARNING: Never attempt to make any  
adjustments while the engine is running, except  
where specified in the operator’s manual.  
Measure the distance from the outside of the left blade  
tip to the ground and the distance from the outside of the  
right blade tip to the ground. Both measurements taken  
should be equal. If they’re not, proceed to the next step.  
Leveling the Deck  
NOTE: Check the tractor’s tire pressure before performing any  
deck leveling adjustments. Refer to Tires in the Service section of  
this manual for information regarding tire pressure.  
Loosen, but do NOT remove, the hex cap screw on the left  
deck hanger bracket. See Figure 6-4.  
Front-to-Rear  
The front of the cutting deck is supported by a stabilizer bar that  
can be adjusted to level the deck from front-to-rear. The front of  
the deck should be between ¼-inch and 38-inch lower than the  
rear of the deck. Adjust if necessary as follows:  
1.  
With the tractor parked on a firm, level surface, place the  
lever for lifting the platform on the second to the top notch  
(second highest position) and rotate the blade as close to  
the discharge channel that is parallel to the tractor.  
2.  
Measure the distance from the front of the blade tip to  
the ground and the rear of the blade tip to the ground.  
The first measurement taken should be between ¼” and  
38” less than the second measurement. Determine the  
approximate distance necessary for proper adjustment and  
proceed, if necessary, to the next step.  
3.  
Locate the jam nut and lock nut on the front side of the  
stabilizer bracket. See Figure 6-4.  
Figure 6-4  
4.  
5.  
Balance the deck by using a wrench to turn the adjustment  
gear (found immediately behind the hex cap screw just  
loosened) clockwise/up or counterclockwise/down.  
The deck is properly balanced when both blade tip  
measurements taken earlier are equal.  
Retighten the hex cap screw on the left deck hanger  
bracket when proper adjustment is achieved.  
Figure 6-3  
20  
Section 6— Maintenance & adjuStMentS  
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Seat Adjustment  
Refer to the Set-Up and Assembly section of this manual for seat  
adjustment instructions.  
Parking Brake Adjustment  
WARNING: Never attempt to adjust the brakes  
while the engine is running. Always disengage PTO,  
move shift lever into neutral position, stop engine  
and remove key to prevent unintended starting.  
If the tractor does not come to a complete stop when the brake  
pedal is completely depressed, or if the tractor’s rear wheels  
can roll with the parking brake applied, the brake is in need of  
adjustment. See an authorized Troy-Bilt Service Dealer to have  
your brakes properly adjusted.  
Maintenance Schedule  
Before  
Every  
Every  
Every  
Every  
Prior  
Each use  
10 Hours  
25 Hours  
50 Hours  
100 Hours  
to Storing  
Clean Hood/Dash Louvers  
Check Engine Oil Level  
P
P
P P  
P
Check Air Filter for Dirty, Loose or Damaged Parts  
Clean and Re-oil Air Filter’s Foam Pre-cleaner  
(if Equipped)  
P
Replace Air Filter Element  
P
Change Engine Oil and Replace Oil Filter  
(if Equipped)  
P
Clean Battery Terminals  
Lube Front Axles and Rims  
Clean Engine Cooling Fins  
Lube Pedal Pivot Points  
Check Spark Plug Condition & Gap  
Replace Fuel Filter  
P
P
P
P
P
P
P
P
P P  
P
IMPORTANT: It is important to consult the specific engine operator’s manual included with this machine for detailed engine  
maintenance procedures and intervals.  
Section 6 — Maintenance & adjuStMentS  
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Service  
7
Cutting Deck Removal  
To remove the cutting deck, proceed as follows:  
1.  
2.  
3.  
Place the PTO (Blade Engage) lever in the disengaged (OFF)  
position and engage the parking brake.  
Lower the deck by moving the deck lift lever into the  
bottom notch on the right fender.  
Remove the belt-keeper rod, from around the tractor’s  
engine pulley, by removing the self-tapping screw (A) that  
secures it. See Figure 7-1.  
NOTE: Make a mental note what hole the other end of the belt-  
keeper rod is inserted in for reinstallation purposes.  
A
C
Figure 7-2  
7.  
Move the deck lift lever into the top notch on the right  
fender to raise the deck lift arms up and out of the way.  
8.  
Gently slide the cutting deck toward the front of the tractor  
carefully guiding the hooks on the deck off of the deck  
stabilizer rod. See Figure 7-3.  
B
Figure 7-1  
4.  
5.  
Remove the belt (C) from around the tractor’s engine  
pulley and idler pulley(s). See Figure 7-1.  
Looking at the cutting deck from the left side of the tractor,  
locate the bow-tie pin that secures the deck support rod  
on the rear left side of the deck. See Figure 7-2. Remove  
the bow-tie pin that secures the deck support rod, and  
carefully remove the deck support from the deck lift arm.  
6.  
Repeat the above steps on the tractor’s right side.  
Figure 7-3  
22  
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9.  
Carefully remove the PTO cable from the rear of the cutting  
deck by removing the hair pin clip which secures it. Remove  
the spring from the deck idler bracket. See Figure 7-4.  
1.  
2.  
3.  
4.  
Connect positive (+) cable to positive post (+) of your  
tractor’s discharged battery.  
Connect the other end of the cable to the (positive +) post  
of the jumper battery.  
Connect the second cable (negative ) to the other post of  
the jumper battery.  
Make the final connection on the engine block of the  
tractor, away from the battery. Attach to a unpainted part  
to assure a good connection.  
CAUTION: If the jumper battery is installed on a  
vehicle (i.e. car, truck), do NOT start the vehicle’s  
engine when jump starting your tractor.  
5.  
6.  
Start the tractor as instructed in the Operation section of  
this manual.  
Set the tractor’s parking brake before removing the jumper  
cables, in reverse order of connection.  
Charging  
WARNING! Batteries give off an explosive gas  
while charging. Charge the battery in a well  
ventilated area and keep away from an open flame  
or pilot light as on a water heater, space heater,  
furnace, clothes dryer or other gas appliances.  
Figure 7-4  
10. Gently slide the cutting deck (from the left side) out from  
CAUTION: When charging your tractor’s battery,  
use only a charger designed for 12V lead-acid  
batteries. Read your battery charger’s Owner’s  
Manual prior to charging your tractor’s battery.  
Always follow its instructions and heed its warnings.  
underneath the tractor.  
Tires  
WARNING! Never exceed the maximum inflation  
pressure shown on the sidewall of the tire.  
If your tractor has not been put into use for an extended period  
of time, charge the battery as follows:  
1.  
Set your battery charger to deliver a max of 10 amperes.  
The recommended operating tire pressure is:  
If your battery charger is automatic, charge the battery until the  
charger indicates that charging is complete. If the charger is not  
automatic, charge for no fewer than eight hours.  
Approximately 10 psi for the rear tires  
Approximately 14 psi for the front tires  
IMPORTANT: Refer to the tire sidewall for exact tire  
manufacturer’s recommended or maximum psi. Do not  
overinflate. Uneven tire pressure could cause the cutting deck to  
mow unevenly.  
Fuse  
One 20 AMP fuse is installed in your tractor’s wiring harness to  
protect the tractor’s electrical system from damage caused by  
excessive amperage.  
Battery  
If the electrical system does not function, or your tractor’s engine  
will not crank, first check to be certain that the fuse has not  
blown. It can be found at the rear of the unit, underneath the  
fender located by the battery.  
CALIFORNIA PROPOSITION 65 WARNING!  
Battery posts, terminals, and related accessories  
contain lead and lead compounds, chemicals known  
to the State of California to cause cancer and  
reproductive harm. Wash hands after handling.  
WARNING! Always use a fuse with the same  
amperage capacity for replacement.  
CAUTION: If removing the battery, disconnect the  
NEGATIVE (Black) wire from it’s terminal first,  
followed by the POSITIVE (Red) wire. When re-  
installing the battery, always connect the POSITIVE  
(Red) wire its terminal first, followed by the  
NEGATIVE (Black) wire.  
Cutting Blades  
WARNING! Shut the engine off and remove  
ignition key before removing the cutting blade(s) for  
sharpening or replacement. Protect your hands by  
using heavy gloves when grasping the blade.  
Jump Starting  
WARNING! Never jump start a damaged or frozen  
battery. Be certain the vehicles do not touch, and  
ignitions are off. Do not allow cable clamps to touch.  
WARNING! Periodically inspect the blade spindles  
for cracks or damage, especially if you strike a  
foreign object. Replace immediately if damaged.  
Section 7 — Service  
23  
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The blades may be removed as follows.  
IMPORTANT: If the cutting edge of the blade has already been  
sharpened to within 1 58” from the edge, or if any metal separation is  
present, replace the blades with new ones. See Figure 7-6.  
1.  
Remove the deck from beneath the tractor, (refer to Cutting  
Deck Removal earlier in this section) then gently flip the deck  
over to expose its underside.  
2.  
3.  
Place a block of wood between the center deck housing baffle  
and the cutting blade to act as a stabilizer. See Figure 7-5.  
Remove the hex flange nut that secures the blade to the  
spindle assembly. See Figure 7-5.  
Figure 7-6  
CAUTION: If the cutting edge of the blade has  
previously been sharpened, or if any metal  
separation is present, replace the blades with new  
ones.  
WARNING! A poorly balanced blade will cause  
excessive vibration, may cause damage to the  
tractor and/or result in personal injury.  
Figure 7-5  
4.  
To properly sharpen the cutting blades, remove equal amounts  
of metal from both ends of the blades along the cutting edges,  
parallel to the trailing edge, at a 25° to 30° angle.  
5.  
Test the blade’s balance using a blade balancer. Grind  
metal from the heavy side until it balances evenly.  
NOTE: When replacing the blade, be sure to install the blade with  
the side of the blade marked ‘‘Bottom’’ (or with a part number  
stamped in it) facing the ground when the mower is in the  
operating position.  
CAUTION: Use a torque wrench to tighten the  
blade spindle hex flange nut to between 70 lbs-ft  
and 90 lbs-ft.  
Section 7— Service  
24  
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3.  
5.  
Remove the belt keeper rod from around the engine pulley.  
Changing the Deck Belt  
WARNING! Avoid the possibility of a pinching  
injury. Do not place your fingers on the idler spring  
or between the belt and a pulley while removing the  
belt.  
WARNING! Be sure to shut the engine off, remove  
ignition key, disconnect the spark plug wire(s) and  
ground against the engine to prevent unintended  
starting before removing the belt.  
Remove the deck belt from around all pulleys, including  
the deck idler pulley.  
WARNING! All belts on your tractor are subject to  
wear and should be replaced if any signs of wear are  
present.  
6.  
7.  
Route the new belt as shown in and Figure 7-7.  
Remount the belt guards removed earlier.  
IMPORTANT: The V-belt found on your tractor is specially  
designed to engage and disengage safely. A substitute (non-  
OEM) V-belt can be dangerous by not disengaging completely.  
For a proper working machine, use factory approved belts.  
Changing the Transmission Drive Belt  
NOTE: Several components must be removed and special tools  
(i.e. air/impact wrench) in order to change the tractor’s drive belt.  
See an authorized MTD Service Dealer to have your drive belt  
replaced or phone Customer Support as instructed on page 2 for  
information on ordering a Service Manual.  
To change or replace the deck belt on your tractor, proceed as follows:  
1.  
Lower the deck by moving the deck lift lever into the  
bottom notch on the right fender.  
2.  
Remove the belt guards by removing the self-tapping  
screws that fasten them to the deck. See Figure 7-7.  
Engine Pulley  
Belt Guard  
Idler Bracket  
Deck Idler Pulley  
Figure 7-7  
Section 7 — Service  
25  
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Troubleshooting  
8
Problem  
Cause  
Remedy  
1. Place blade engage lever in disengaged  
(OFF) position.  
Engine fails to start  
1. PTO/Blade engaged.  
2. Spark plug wire disconnected.  
3. Fuel tank empty, or stale fuel.  
2. Connect wire to spark plug.  
3. Fill tank with clean, fresh (less than 30 days  
old) gas.  
4. Choke not activated.  
5. Faulty spark plug.  
6. Blown fuse(s).  
4. Place the throttle control in CHOKE position.  
5. Clean, adjust gap or replace plug.  
6. Replace fuse(s)  
7. Engine flooded.  
7. Crank engine with throttle in FAST position.  
8. Engage parking brake.  
8. Parking brake not engaged  
9. Throttle control lever not in correct starting  
position.  
9. Place throttle lever to FAST position.  
Engine runs erratic  
1. Unit running with CHOKE activated.  
1. Move the throttle contol out of the CHOKE  
position.  
2. Spark plug wires loose.  
2. Connect and tighten spark plug wire.  
3. Blocked fuel line or stale fuel.  
3. Clean fuel line; fill tank with clean, fresh  
gasoline and replace fuel filter  
4. Vent in gas cap plugged.  
5. Water or dirt in fuel system.  
4. Clear vent or replace cap if damaged.  
5. Drain fuel tank. Refill with clean, fresh  
gasoline.  
6. Dirty air cleaner.  
6. Replace air cleaner paper element or clean  
foam precleaner.  
Engine overheats  
1. Engine oil level low.  
1. Fill crankcase with proper amount and  
weight of oil.  
2. Air flow restricted.  
2. Clean grass clippings and debris from around  
the engine’s cooling fins and blower housing.  
Engine hesitates at high  
RPM  
1. Spark plug gap too close.  
1. Remove spark plug and reset the gap.  
Engine Idles rough  
1. Spark plug fouled, faulty or gap too wide.  
2. Dirty air cleaner.  
1. Replace spark plug. Set plug gap.  
2. Replace air cleaner element and/or clean  
pre-cleaner.  
Excessive vibration  
1. Cutting blade loose or unbalanced.  
1. Tighten blade and spindle. Balance blade.  
2. Damaged or bent cutting blade.  
1. Engine speed too low.  
2. Replace blade.  
Mower will not mulch grass  
1. Place throttle in FAST (rabbit) position.  
2. Wet grass.  
2. Do not mulch when grass is wet.  
3. Excessively high grass.  
3. Mow once at a high cutting height, then  
mow again at desired height or make a  
narrower cutting swath.  
4. Dull blade.  
4. Sharpen or replace blade.  
Uneven cut  
1. Deck not leveled properly.  
1. Perform side-to-side deck adjustment.  
2. Dull blade.  
2. Sharpen or replace blade.  
3. Uneven tire pressure.  
3. Check tire pressure in all four tires.  
26  
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Replacement Parts  
9
Component  
Part Number and Description  
954-04062  
Deck Belt  
918-04474B  
942-0610A  
Deck Spindle  
Blade  
925-1707D  
Battery  
751-0603A  
725-1744A  
Fuel Tank Cap  
Key  
634-05067  
634-0104  
Front Tire, 15 x 6 x 6  
Rear Tire, 20 x 8 x 8  
746-04367  
631-05229  
Throttle Control/Cable  
Chute Assembly  
Be sure to have your model number and serial number ready. These can be found on the model plate located under the seat. Refer to  
page 2 for more information regarding locating your model and serial numbers.  
27  
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Attachments & Accessories  
10  
The following attachments and accessories are compatible for the Troy-Bilt Lawn Tractor. See the retailer from which you  
purchased your tractor, an authorized Troy-Bilt Service Dealer or phone (800) 828-5500 for information regarding price  
and availability.  
CAUTION: This Troy-Bilt Lawn Tractor is NOT designed for use with any type of ground-engaging  
attachments (e.g. tiller or plow). Use of this type of equipment WILL void the tractor’s warranty.  
Model Number  
Description  
OEM-190-679  
Bumper  
38-inch Deck Mulch Kit  
Twin Bagger Grass Collector  
Deluxe Tractor Sunshade  
42-inch Two-stage Snow Thrower  
Rear Wheel Weight Kit  
Tire Chains, 20 x 8 Tires  
42-inch Front Snow Blade  
Blade Removal Tool  
OEM-190-116  
OEM-190-180A  
OEM-190-607  
OEM-190-032  
490-900-M060  
490-241-0023  
OEM-190-833  
490-850-0005  
490-850-0008  
Oil Siphon  
28  
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Notes  
11  
29  
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30  
Section 11— noteS  
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Section 11 — noteS  
31  
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Warranty Conditions — Australia (Not applicable to other Regions)  
The benefits given to you under this warranty are in addition to other rights and remedies that you have under  
Australian law in relation to the goods.  
MTD Products Australia Pty Ltd warrants that this machine is free from defects in material and workmanship. This  
warranty is limited to repairing or replacing any part which appears upon inspection by MTD Products Australia Pty  
Ltd or its agent to be defective in material or workmanship.  
A separate warranty is provided in respect of the engine for this machine. Refer to the engine warranty statement in  
the Engine Owner’s Manual which has been included with this machine.  
For domestic use, this warranty will apply for a period of 2 years from date of purchase. Warranty for commercial  
or industrial use is 90 days from the date of purchase. In the event of dispute, MTD Products Australia Pty Ltd will  
determine whether the machine was used for domestic, or commercial or industrial use.  
All costs associated with claiming under this warranty must be borne by you, including transport costs incurred in  
the repair or replacement of any defective part.  
This warranty excludes fair wear and tear and any damage caused by misuse or abuse. Parts such as Blades, Bump  
Knobs, Outer Spools, Cutting Line, Inner Reels, Starter Pulley, Starter Ropes, Drive Belts, Saw Blades, Guide Bars,  
Cultivator Tines, Spark Plugs, Carburettor Adjustments and Filters which can be subjected to use beyond their normal  
intended working capacity are also excluded.  
This warranty is void if alterations are made to the machine without MTD Products Australia Pty Ltd prior written  
authority.  
Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a  
replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage.  
You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the  
failure does not amount to a major failure.  
IN ORDER TO MAKE A CLAIM UNDER THIS WARRANTY YOU WILL NEED TO TAKE YOUR PRODUCT AND YOUR  
PROOF OF PURCHASE TO AN AUTHORISED MTD DEALER. YOUR NEAREST MTD DEALER CAN BE FOUND at  
WILL BE VOID.  
For your Record:  
Retailers Name: ........................................................................  
Phone No: ..................................................................................  
Serial No: ....................................................................................  
MTD Products Australia Pty Ltd.  
Address: ......................................................................................  
Model No: ..................................................................................  
Date of Purchase: ....................................................................  
Postal Address: PO. Box 376 Dandenong. Vic. 3175  
Business Address: 6 Zenith Road, Dandenong. Vic. 3175 and 97 Trade Street. Lytton.  
Qld. 4178  
Email Address: [email protected]  
Customer Service Phone: 1300 951 594  
© Copyright 2012  
04016921  
A.B.N. 96 004 873 572  
Revision 10.1. 2012  
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