Troybilt 440 Owner's manual

Brand: Troybilt

Model: 440

Category: Lawnmowers

Type: Owner's manual

This manual is also suitable for

12A-446A711

Safety o Assembly o Operation oTips &Techniques oMaintenance *Troubleshooting o Parts Lists oWarranty

21" Rotary Mower -- Model Series 440

READ SAFETY RULES AND mNSTRUCTmONS CAREFULLY BEFORE OPERATION

Warning: Thisunitisequippedwithan internalcombustionengineandshouldnotbeusedon or nearanyunimprovedforest-covered,brush=

coveredor grass=coveredlandunlesstheengine'sexhaustsystemisequippedwithasparkarrestermeetingapplicablelocalorstatelaws(ifany),

If a sparkarresterisused,itshouldbemaintainedineffectiveworkingorderbytheoperator,Inthe StateofCaliforniatheaboveisrequiredbylaw

(Section4442oftheCaliforniaPublicResourcesCode),Otherstatesmayhavesimilarlaws,Federallawsapplyonfederallands,A sparkarrester

forthemufflerisavailablethroughyournearestengineauthorizedservicedealeror contacttheservicedepartment,RO,Box361131Cleveland,

Ohio44136=0019,

PRINTEDiN U,S,A Troy-Bilt LLC, P.O. BOX 381131 CLEVELAND, OHIO 44138-0019 FORMNO,769=02166

Phone: 1(888} 840-8483, 1-330-558-7220 10/2005

This Operator's Manua_ is an important part of your new lawn mower, mtwH_ he_p you assemble,

prepare and maintain the unit for best performance. Please read and understand what it says.

Table of Contents

Slope Gauge ....................................................... 3

Safe Operation Practices ................................... 4

Setup and Adjustment ....................................... 6

Operating Your Lawn Mower .............................. 8

Maintaining Your Lawn Mower ......................... 10

Trouble Shooting .............................................. 12

Off-Season Storage and Safety Labe{s .......... 13

Parts List ........................................................... 14

Warranty ............................................ Back Cover

Finding and Recording Model Number

BEFOREYOU STARTASSEMBLING

YOURNEW EQUIPMENT,

please locatethe modelplate onthe equipmentand copythe

informationtothe samplemodel plateprovidedto the righL

Youcan locatethe modelplate by standing atthe operating

positionand lookingdownat the rearof the deck. This

informationwill be necessaryto usethe manufacturer'sweb

site and/or obtainassistancefrom the CustomerSupport

Departmentoran authorizedservicedealer.

Modem Number Serial Number

0 TRDV BILT TROY-B LTLLc

P. O. BOX 361131

www.troybiit.com CLEVELAND,ON44136

338=558=7228

Customer Support

PIease do NOTreturn the unit to the retai{er from which it was

purchased, without first contacting Customer Support.

ifyou havedifficulty assemblingthis productor have any

questions regardingthe controls, operationor maintenanceof

this unit, you can seekhelp from the expert& Choose fromthe

options below:

Click here to search our knowledge base°

Searchby product, keyword, or phrase.

1_VisittroybHt.com for manyuseful suggestions.Clickon

CustomerSupport button and youwillget the fouroptions

reproducedin this sampleto the righLClick on the appro-

priatebutton and help is immediatelyavailable.

2_Phonea Customer Support Representative

at 1(866)840-6483.

3. The engine manufacturer is responsiblefor all engine-

relatedissueswith regardsto performance,power-rating,

your inquiries, or update your personal profile.

Need local assistance? Click here to find authorized

service centers in your area.

specifications,warrantyand service. Pleasereferto the

eng Need a manual and/or parts list? Download

separatelywith your unit,for more information, literature from recent model years.

yourlawnmoweronsuchslopes.

WARNING

Do not mowon inclines

with a dope in excess

of 15degrees(a rise

of approximately

2-"

feet). A riding r

couldoverturnand

cause seriousinjury.

if operatinga walb

behindmoweron such

a dope, it isextremely

footing and you could

dip, resultingin serious

injury.

OperateRiDiNG

mowersupand down

dopes, neveracross

theface of dopes.

Operate

WALK-BEHIND

mowersacrossthe

face of dopes, never

up and down slopes.

manual.Aswithanytypeofpowerequipment,carelessnessorerroronthepartoftheoperatorcan

resultinseriousinjury.Thismachineiscapableofamputatinghandsandfeetandthrowingobjects.

! Failuretoobservethefollowingsafetyinstructionscouldresultinseriousinjuryordeath.

endangerthepersonal

safetyand/orproperty

Children

Tragicaccidentscan occurifoperatorisnotalerttopresence

ofchildren.Childrenareoftenattractedto mowerandmowing

activity.Theydonot understandthe dangers.Neverassume

thatchildrenwill remainwhereyoulastsawthem.

1. Keepchildrenoutofthe mowingareaandunderwatchful

careof aresponsibleadultotherthanthe operator.

2. Bealertandturnmoweroffifachildentersthearea.

3. Beforeandwhilemovingbackwards,lookbehindanddown

forsmallchildren.

4. Useextremecarewhenapproachingblindcorners,

doorways,shrubs,trees,orotherobjectsthatmayobscure

yourvisionofachildwhomayrunintothemower.

5. Keepchildrenawayfromhot orrunningengines.Theycan

sufferburnsfroma hotmuffler.

6. Neverallowchildrenunder14yearsoldto operateapower

mower.Children14yearsold andovershouldreadand

understandoperationinstructionsandsafetyrulesinthis

manualandshouldbetrainedandsupervisedbya parent.

General Operation

1. Readthis operator'smanualcarefullyin its entiretybefore

attemptingtoassemblethismachine.Read,understand,

andfollow allinstructionsonthe machineandin the

manual(s)beforeoperation.Becompletelyfamiliarwith

thecontrolsandthe properuseofthismachinebefore

operatingit.Keepthismanualin asafeplaceforfuture

andregularreferenceandfor orderingreplacementparts.

2. Thismachineisa precisionpieceof powerequipment,

nota plaything.Therefore,exerciseextremecautionat all

times.Yourunithasbeendesignedto performonejob: to

mowgrass.Donotuseitfor anyotherpurpose.

3. Neverallowchildrenunder14yearsoldto operatethis

machine.Children14yearsoldand overshouldreadand

understandthe instructionsinthismanualandshould

betrainedand supervisedbya parent.Onlyresponsible

individualswhoarefamiliarwiththeserulesofsafe

operationshouldbeallowedtousethismachine.

4. Thoroughlyinspectthe areawherethe equipmentisto

beused.Removeall stones,sticks,wire,bones,toysand

otherforeignobjectswhichcould betrippedoveror picked

upand thrownbytheblade.Thrownobjectscancause

seriouspersonalinjury.Planyourmowingpatternto avoid

dischargeofmaterialtowardroads,sidewalks,bystanders

andthe like.Also,avoiddischargingmaterialagainsta

wallorobstructionwhichmaycausedischargedmaterial

toricochetbacktowardtheoperator.

6. Alwayswearsafetyglassesor safetygogglesduringopera-

tionandwhile performinganadjustmentor repairtoprotect

youreyes.Thrownobjectswhichricochetcancauseserious

injurytothe eyes.

7. Wearsturdy,rough-soledworkshoesand close-fitting

slacksandshirts. Shirtsandpantsthat coverthe armsand

legsandsteel-toedshoesarerecommended.Neveroperate

thismachineinbarefeet,sandals,slipperyor lightweight

(e.g.canvas)shoes.

8. Donotputhandsorfeet nearrotatingpartsor undercutting

deck.Contactwithbladecanamputatehandsandfeet.

9. Amissingor damageddischargecovercancauseblade

contactor thrownobjectinjuries.

10.Manyinjuriesoccurasa resultofthe mowerbeingpulled

overthefoot duringafall causedbyslippingortripping.

Do notholdontothe mowerifyouarefalling;releasethe

handleimmediately.

11.Neverpullthe mowerbacktowardyouwhileyouare

walking.Ifyoumustbackthe mowerawayfromawallor

obstructionfirstlookdownandbehindtoavoidtrippingand

thenfollowthesesteps:

a. Stepbackfrommowertofully extendyourarms.

b. Besureyou arewellbalancedwithsurefooting.

c. Pullthe mowerbackslowly,no morethanhalfway

towardyou.

d. Repeatthesestepsasneeded.

12.Do notoperatethe mowerwhileunderthe influenceof

alcoholor drugs.

13.Do notengage theself-propelledmechanismon unitsso

equippedwhilestartingengine.

14.Thebladecontrolhandleis asafetydevice.Neverattempt

tobypassits operation.Doingsomakesthe safetydevice

inoperativeandmay resultinpersonalinjurythrough

contactwiththe rotatingblade.The bladecontrolhandle

mustoperateeasilyin bothdirectionsandautomatically

returntothe disengagedpositionwhenreleased.

15.Neveroperatethe mowerinwetgrass.Alwaysbesureof

yourfooting. Aslipand fallcan causeseriouspersonal

injury.If youfeelyouarelosingyourfooting,releasethe

bladecontrolhandleimmediatelyandthe bladewillstop

rotatingwithinthreeseconds.

16.Mowonlyindaylightor goodartificiallight.Walk,neverrun.

17.Stopthe bladewhencrossinggraveldrives,walksor roads.

18.Ifthe equipmentshouldstarttovibrateabnormally,stopthe

engineandcheckimmediatelyforthe cause.Vibrationis

and followthe warnings 5. Tohelpavoidbladecontactorathrownobjectinjury, ._ generallya'_arningof!rouble.........

]_ _nutthe engne errandwar unl: me Daaecomes-coa

and i..struction2 stayinoperatorzonebehindhandlesandkeepchildren, "

u _ competestop beforeremovngthe grasscatcheror uncog

, ,; bystanders,helpers,andpetsat least75feet frommower .

un_nusmanuau glngthechute

whileit isin operation.Stopmachineifanyoneenters

and onthe machine, area.

..... ,J

Thecuttingbladecontinuesto rotatefor a fewsecondsafter

the engineisshutoff. Neverplaceanypartofthe bodyin

the bladeareauntilyouaresurethe bladehasstopped

rotating.

20.Neveroperatemowerwithoutpropertrailshield,discharge

cover,grasscatcher,bladecontrolhandle,or othersafety

protectivedevicesin placeandworking.Neveroperate

mowerwithdamagedsafetydevices.Failuretodo socan

resultin personalinjury.

21.Mufflerandenginebecomehotand cancauseaburn.Do

nottouch.

22.Onlyusepartsandaccessoriesmadeforthismachineby

manufacturer.Failureto doso canresultinpersonalinjury.

23.Ifsituationsoccurwhicharenot coveredin thismanual,

usecareand goodjudgment.Contactyourdealerfor

assistance.Telephone1-866-840-6483forthe nameofyour

nearestdealer.

SJope Operation

Slopesarea majorfactorrelatedto slipandfallaccidentswhich

canresultinsevereinjury.Operationonslopesrequiresextra

caution.Ifyoufeeluneasyonaslope,donotmowit.Foryour

safety,usethe slopegaugeincludedaspartofthis manualto

measureslopesbeforeoperatingthisunitonaslopedor hilly

area.Iftheslopeis greaterthan15degrees,do notmowit.

Do:

1. Mowacrossthe faceof slopes;neverup anddown.

Exerciseextremecautionwhenchangingdirectionon

slopes.

2. Watchfor holes,ruts,rocks,hiddenobjects,or bumpswhich

can causeyou toslipor trip.Tallgrasscan hideobstacles.

3. Alwaysbesureofyourfooting.A slip andfall cancause

seriouspersonalinjury.If youfeelyouarelosingyour

balance,releasethe bladecontrolhandleimmediately,and

the bladewillstop rotatingwithin 3seconds.

Do Not:

1. Donotmowneardrop-offs,ditchesorembankments,where

you couldloseyourfootingor balance.

2. Donotmowslopesgreaterthan15degreesasshownon

the slopegauge.

3. Donotmowon wetgrass.Unstablefootingcouldcause

slipping.

Service

Safe HandlingOf Gasoline:

1. Toavoidpersonalinjury orpropertydamageuseextreme

carein handlinggasoline.Gasolineisextremelyflammable

andthevaporsareexplosive.Seriouspersonalinjurycan

occurwhengasolineis spilledonyourselforyourclothes

whichcanignite.

2. Washyourskinand changeclothesimmediately.

3. Useonlyanapprovedgasolinecontainer.

4. Neverfill containersinsideavehicleor onatruckor trailer

bedwith aplasticliner.Alwaysplacecontainersonthe

groundawayfromyourvehiclebeforefilling.

5. Removegas-poweredequipmentfromthe truckortrailer

andrefuelit onthe ground.Ifthis is notpossible,then refuel

suchequipmentonatrailerwitha portablecontainer,rather

thanfroma gasolinedispensernozzle.

6. Keepthe nozzlein contactwith therim ofthefueltank or

containeropeningat alltimesuntilfuelingis complete.Do

notusea nozzlelock-opendevice.

7. Extinguishallcigarettes,cigars,pipesandothersources

ofignition.

8. Neverfuel machineindoorsbecauseflammablevaporswill

accumulatein the area.

9. Neverremovegascap oradd fuelwhileengineishot or

running. Allowengineto coolatleasttwominutesbefore

refueling.

10.Neveroverfillfueltank. Filltankto nomorethan_ inch

belowbottomoffillerneckto provideforfuelexpansion.

11.Replacegasolinecapandtightensecurely.

12.Ifgasolineis spilled,wipeit offthe engineandequipment.

Moveunitto anotherarea.Wait5minutesbeforestarting

engine.

13.Neverstorethe machineorfuel containernearanopen

flame,sparkorpilotlightas onawaterheater,space

heater,furnace,clothesdryer,orothergas appliances.

14.Toreducefire hazard,keepmowerfreeofgrass,leaves,

or otherdebrisbuild-up.Cleanupoil orfuel spillageand

removeanyfuel soakeddebris.

15.Allowamowertocoolat least5 minutesbeforestoring.

General Service:

1. Neverrunanengineindoorsor ina poorlyventilatedarea.

Engineexhaustcontainscarbonmonoxide,an odorlessand

deadlygas.

2. Beforecleaning,repairing,or inspecting,makecertainthe

bladeandall movingpartshavestopped.Disconnectthe

sparkplugwireandgroundagainsttheengineto prevent

unintendedstarting.

3. Checkthe bladeandenginemountingboltsatfrequent

intervalsforpropertightness.Also,visuallyinspectbladefor

damage(e.g.,bent,cracked,worn)Replacebladewiththe

originalequipmentmanufacture's(O.EM.) bladeonly,listed

inthismanual."Useofpartswhichdo notmeettheoriginal

equipmentspecificationsmayleadto improperperformance

andcompromisesafety!"

4. Mowerbladesaresharpandcancut.Wrapthebladeorwear

gloves,anduseextracautionwhenservicingthem.

5. Keepallnuts,bolts,andscrewstight tobesurethe equip-

mentisin safeworkingcondition.

6. Nevertamperwithsafetydevices.Checktheirproperopera-

tionregularly.

7. Afterstrikingaforeignobject,stopthe engine,discon-

nectthe sparkplugwireandgroundagainsttheengine.

Thoroughlyinspectthe mowerforanydamage.Repairthe

damagebeforestartingandoperatingthemower.

8. Neverattempttomakeawheelorcuttingheightadjustment

whilethe engineis running.

9. Grasscatchercomponents,dischargecover,andtrail

shieldaresubjecttowear anddamagewhichcould expose

movingpartsorallow objectsto bethrown.Forsafety

protection,frequentlycheckcomponentsand replaceim-

mediatelywithoriginalequipmentmanufacturer's(O.EM.)

partsonly,listedin thismanual.'Use of partswhichdo

not meettheoriginalequipmentspecificationsmayleadto

improperperformanceandcompromisesafety!"

10.Donot changetheenginegovernorsettingor overspeedthe

engine.Thegovernorcontrolsthe maximumsafeoperating

speedofthe engine.

11.Maintainor replacesafetylabels,asnecessary'.

12.Observeproperdisposallawsandregulations.Improper

disposaloffluidsand materialscanharmtheenvironment.

ThisSymbolpoints

ua! before attemptingto

resuUt in personalinjury_

::When you see th s

_symbol

,EEDMTSWARNmNG

Responsibility

Restrictthe use

of this powermachine

to personswhoread

understand

NOTE:Stand behind

Ihemoweras ifyou

were going to operate

it,Your righthandcor-

respondsto the right

sideof the mower;your

left handcorresponds

to the left sided the

mower.

IMPORTANT

DO NOTcrimp the

cableswhen liftingthe

handleup.

IMPORTANT

This unit isshipped

without gasoline or

oilin the engine. Fill

upgasolineand oil

as instructedinthe

accompanyingengine

manual BEFORE

operatingyour mower,

Step 1

HardwarePack

Wing Nuts (2) CarriageBolts (2)

Step 2

1, Removeanypackingmaterialwhichmaybebetween

upperand lowerhandles,

a, Pullupand backon upperhandleasshownin

Step1,Makecertainthelowerhandleisseated

securelyintothe handlemountingbrackets,

b, Tightenhandknobssecuringupperhandleto

lowerhandle,Makesurethateachcarriageboltis

seatedproperlyin thehandle,

2, Locatehairpinclipin oneholeontheweldpinon each

sideof lowerhandle,

a, Removehairpinclipfromthis hole,Usinga pairof

pliers,inserthairpinclipintotheotherholeon the

weldpin,Repeaton otherside,

b, inserta carriageboltfromthehardwarepackinto

theupperholeon thehandlemountingbracket,

Securewithoneplasticwingnut,alsoincluded

inthe hardwarepack,Repeatonothersidewith

remainingitemsfromhardwarepack,

3, Theropeguideisattachedtotherightsideofthe

upperhandle,Loosenthewingnutwhichsecuresthe

ropeguide,

a, Holdthebladecontrolagainstupperhandle,

b, Pullstarterropeoutoftheengine,Releasethe

bladecontrol,

c, Slipstarterropeintoropeguide,Tightenwingnut,

4, Insertpostoncane ties intoholesprovidedon the

lowerhandle,Pullcane tietightandtrimexcess,

Step 3 Step 4

positionprovidescuttingheightadiustment,

a, Depresslevertowardswheel,

b, Moveittoanyoftheninepositionsfordesired

cuttingheight,SeeStep5,

c, Releaselevertowardsmowerdeck,

6, Followstepsbelowtoassemblethegrasscatcher:

a, Placebagoverframesothatitsblackplasticside

isatthebottom,

b, Slipplasticchannelofgrassbagoverhooksonthe

frame,SeeStep6,All theplasticchannelsexcept

centertopof bagattachfromoutsideof bag,

c, Attachcentertopof bagfrominsideofbag,

7, Followstepsbelowtoattachgrasscatcher:

a, Liftreardischargedoor,

b, Placegrasscatcheron thepivotrod,Letgo

ofdischargedoorsothat itrestson thegrass

catcher,SeeStep7,

Toremovegrasscatcherorconverttoa mulcher(if

equipped),liftreardischargedooronthe moweras

showninStep8, Liftgrasscatcherupand outofthepivot

rod,Releasereardischargedoorto allowittocloserear

openingofmower,

WARNING: Never operate mower

unless the hooks on the grass

catcher are firmlyseated on the

pivot rod, and the rear discharge

door rests firmJyagainst top of

the grass catcher.

Step 5

Step 6

_Make certain bagis

Step 7

unless the hooks on

}

WARNING

The blade control

mechanism is a

safety device. Never

attempt to bypassits

operations.

Use extreme care

when handling

gasoline. Gasoline is

extremely flammable

and the vapors are

explosive. Neverfuel

the machine indoors

or while the engine

is hot or running.

Extinguish cigarettes,

cigars, pipes and

other sources of

ignition.

Keep handsand feet

_way from the chute

tea on cutting deck.

Refer to warning

label on the unit.

,<-_ Blade Control

-- Drive Control

Recoil

Grass Bag

Levers

Gasoline

Height

Levers

Figure 1

Now that you have set up your lawn mower for op-

eration, get aquainted with its controls and features.

These are described below and illustrated on this

page. This knowledge will allow you to use your

new equipment to its fullest potential.

B_ade Control

The blade control is attached to the upper handle

of the mower. Depress and squeeze it against the

upper handle to operate the unit. Release it to stop

engine and blade.

WARNING:This bladecontrol mecha-

nism isa safety device. Neverattempt

to bypass its operations.

Drive Contro_

The drive control is located on the underside of

the upper handle and is used to engage the drive.

Squeeze it against the upper handle to engage the

drive; reIease it to slow down or stop mower from

propelling. See Figure 1=

Cutting Height Adjustment Levers

One adjustment lever is located on each wheel and

is used to adjust the cutting height. All four levers

have to be at the same relative position to ensure a

uniform cut.

Recoi_ Starter

The recoiI starter is attached to the right upper

handle. Stand behind the unit and puII the recoil

starter rope to start the unit.

Gas and Oil Fil_-Up

1. Check oil level and add oil if necessary. Follow engine

manual for this. See Figure 1above for location of the

oil fill.

2. Service the engine with gasoline as instructed in the

engine manual See Figure 1above for location of

gas fill

WARNING: Use extreme care when han-

dling gasoline. Gasoline is extremely

flammable and the vapors are explosive.

Never fuel the machine indoors or while

the engine is hot or running. Extinguish

cigarettes, cigars, pipes and other

sources of ignition.

WARNING:The operation of anylawn

mowercan result inforeign objects

being thrown into the eyes,wNch can

damageyour eyes severely.Always

wearsafety glasses while operating

the mower,or while performing any

adjustments or repairson it.

Starting Engine

WARNING:Besure no one otherthan

the operator isstanding nearthe lawn

mowerwhile starting engine or operat-

ing mower.Neverrun engine indoors

or inenclosed, poorly ventilated areas.

Engine exhaustcontains carbon monox-

ide,an odorless and deadly gas. Keep

hands,feet, hair and loose clothing

awayfrom anymoving parts on engine

and lawn mower.

1, Pushprimerthreetimes,Waitabouttwoseconds

betweeneachpush,SeeFigure2,Intemperature

around55° For below,primefivetimes,Donotprime

to restarta warmengine,

2, Standingbehindthe mower,squeezethebladecontrol

againstupperhandle,SeeFigure2,

3, Holdingthesetwo handlestogetherfirmly,grasprecoil

starterhandleand pullropeoutwitha rapid,continu=

ous,fullarmstroke,SeeFigure2,Keepinga firm

gripon thestarterhandle,lettheroperewindslowly,

Repeatuntilenginecranks,Lettheroperewindeach

timeslowly,

Stopping Engine

1, Releasebladecontroltostoptheengineandblade,

2, Disconnectsparkplugwirefromsparkplugand

groundagainsttheengine,

_k ARNING:Wait for the blade to stop

completely beforedoing anywork

on the moweror to removethe grass

catcher.

Using Your Lawn Mower

WARNING:Neveroperateyour mower

without either the rear door or the entire

grass catcher assembly firmly secured.

Be surelawnisclearofstones,sticks,wire,or other

obiectswhichcoulddamagelawnmowerorengine,

Suchobiectscouldbe acddentlythrownbythemower

in anydirectionandcauseseriouspersonaliniurytothe

operatorandothers,

Figure 2

_IL ARNING:If you strike aforeign

object, stop the engine. Remove

wire from the spark plug, thoroughly

respect mowerfor anydamage,and

repair damagebeforerestarting and

operating. Extensivevibration of

mower during operation isan indica-

tion of damage.Theunit should be

promptly inspected and repaired.

1, Oncetheengineisrunning,squeezethedrive

controlagainsttheupperhandleto propelmower,

2, Forbestresults,do notcut wetgrass,

3, Fora healthierlawn,nevercutoff morethanone=

thirdofthetotallengthofthegrass,

Using as Muncher

Formulchinggrass,removethegrasscatcherfromthe

mower,Thereardischargedoorshouldbeclosed,

1, Foreffectivemulching,do notcut wetgrass,

2, Neworthickgrassmayrequirea narrowercut,

Adiustgroundspeedaccordingtoconditionoflawn,

3, If thegrasshasbeenallowedto growinexcessof

4 inches,mulchingisnotrecommended,Usethe

grasscatchertobagclippingsinstead,

Using Grass Catcher

Youcanusethegrasscatchertocollectclippingswhile

youareoperatingthemower,

1, Attachgrasscatcherfollowinginstructionsonpage

7,Grassclippingswillautomaticallycollectinbagas

yourun mower,Operatemowertillgrassbagisfull,

2, Stopenginecompletelybyreleasingtheblade

controlhandle,Makesurethattheunithascometo

a completestop,

3, Liftdischargedoorand pullgrassbagup andaway

fromthemowertodisposeofthegrassclippings,

being thrown into

the eyes, which can

damage your eyes

severely. Always wear

safety glasses while

iioperating the mower,

_ngine or operating

_ower. Never tun

engine !ndoors or

in enclosed poorly

ventilated areas' En_

gine exhaust Contains

carbon monoxide, an

odorless and deadly

_gas, Keep hands, feet,

hair and loose Clothing

away from any mov ng

disconnectspark

plug,andground

oga n,teng n b fOrO

reassembiy,

Figure 3

Figure 4

Genera[ Recommendations

1, Alwaysobservesafetyruleswhenperforming

anymaintenance,

2, Thewarrantyon thislawnmowerdoesnotcover

itemsthathavebeensubiectedtooperatorabuse

or negligence,Toreceivefullvaluefromwarranty,

operatormustmaintainthe lawnmoweras

instructedhere,

3, Changingofengine-governedspeedwillvoid

enginewarranty,

4, Alladjustmentsshouldbecheckedat leastonce

eachseason,

5, Periodicallycheckall fastenersand makesurethese

aretight,

WARNING:Alwaysstop engine,

disconnect spark plug, and ground

against engine beforecleaning,

lubricating or doing any kind of

maintenanceon your machine.

mustoperatefreelyin bothdirections,SeeFigure3,

2, Lubricatethewheelsatleastoncea seasonwith

lightoil (or motoroil), If wheelsareremovedforany

reason,lubricatesurfaceofthepivotarmandinner

surfaceofthewheelwithlightoil SeeFigure3,

3, Lubricatethetorsionspringandpivotpointontherear

dischargedoorperiodicallywithlightoil toprevent

rust,SeeFigure3,

4, Thetransmissionis prequbricatedandsealedatthe

factoryanddoesnotrequirelubrication,

5, Followtheaccompanyingenginemanualforlubrica-

tionscheduleandinstructionforenginelubrication,

Deck Care

1, Disconnectsparkplugwire,Draingasolinefromlawn

mower,or placea pieceof plasticunderthegascap,

2, Tipmowersothat itrestson thehousing,Keepthe

sidewiththeaircleanerfacingup,Holdmowerfirmly,

WARNING:Nevertip the mowermore

than 90 degreesin anydirections and

do not leavethe mowertipped for any

length of time. Oil can drain into the

upper part ofthe enginecausing a

starting problem.

3, Scrapeanddean theundersideofthedeckwitha

suitabletool Donotspraywithwater,

4, Putthemowerbackonits wheelsontheground,If

youhadputplasticunderthegascapearlier,make

suretoremoveitnow,

Engine Care

1, Maintainoil levelasinstructedin enginemanual,

2, Serviceaircleanerevery25 hoursundernormal

conditions,Cleaneveryfewhoursunderextremely

dustyconditions,Refertoenginemanual

3, Cleansparkplugandresetthegap oncea season,

Checkenginemanualforcorrectplugtype andgap

specifications,

4, Cleanengineregularlywitha clothorbrush,Keepthe

coolingsystem(blowerhousingarea)dean topermit

properaircirculation,Removeallgrass,dirtand

combustibledebrisfrom mufflerarea,

Replacing Rear Flap

1, Toremoverearflap,cut offtheflatendofthewirerod

whichsecuresittothedeck,SeeFigure4,

2, Attachthenewflapand newrodtodeck,bendingthe

endsofthenewrodovertosecuretodeck,

B_ade Care f -_,

_ ARNING:When removing cutting

bladefor sharpening or replacement,

protect your handswith a pair of heavy

gloves or usea heavy rag to hold blade.

1, Disconnectsparkplugwirefromsparkplug,Turn

moweron itssidemakingsurethattheairfilterand

thecarburetorareup,

2, Removebolt,bladebell support,blade,andblade

adapterfromtheenginecrankshaft,SeeFigure5,

3, Thebladecanbe sharpenedwitha fileoron agrind=

ingwheel Donotattempttosharpenthebladewhile

itisstillon themower,Whensharpeningblade,follow

originalangleofgrind,Grindcuttingedgesequallyto

keepbladebalanced,

4, Removebladefromtheadapterfortestingbalance,

Balancethebladeona roundshaftscrewdriverto

check,Removemetalfromtheheavysideuntilit

balancesevenly,

i i i

Figure 5

WARNING:An unbalanced bladewill

cause excessivevibration when rotating

at high speeds, it may causedamage

to mower,and could breakcausing

personalinjury.

5, Lubricatetheenginecrankshaftandtheinnersurface

ofthe bladeadapterwithlightoil Slidetheblade

adapterontotheenginecrankshaft,Placetheblade

on theadaptersuchthat thesideoftheblademarked

"Bottom"(orwithpartnumber)facesthegroundwhen

themoweris intheoperatingposition,Makesurethat

bladeisalignedandseatedon bladeadapterflanges,

6, Placebladebellsupporton theblade,Alignnotches

on thebladebellsupportwithsmallholesin blade,

Replacehexboltandtightenhexbolttotorque:450

in,Ibs,rain,,600 in,Ibs,max,

Toensuresafeoperationof yourmower,periodically

checkthebladeboltforcorrecttorque,

Belt Care

1, Removetwoshoulderscrewssecuringfrontdrive

coverto mowerdeck,SeeFigure6, Pressinwardon

sidesoffrontdrivecoverand releasetabsthatsecure

ittotheheightadiusterbrackets,Removedrivecover

frommower,

2, Loosenscrewholdingbelttensionspringtotrans=

mission,SeeFigure6 inset,Donotremovescrew

completely,Asyouloosenit, tensiononthebeltwillbe

released,

Figure 6

::, ,, /

Figure 7

4, Replacewith newbelt,workingaroundblade,Make

surebeltisfirmlyseatedonenginepulleywhile

pullingfromtheothersideandslidingit aroundthe

transmissionpulley,Tightenscrewloosenedearlier

tosecurebelttensionspringtothetransmission,

Reassemblefrontdrivecover,

3, Pushtransmissionupa littleandslidebeltoffthe

transmissionpulley,Lift mowertoaccessbeltfrom

undersideofmower,Slidebeltoff ofenginepulleyand

aroundtheblade,SeeFigure7,

WhenremOVing

the cutting blade

_for sharpening or

rep!aeement or

pair of heavy g oves

or use a heavy rag to

hold the blade.

An unbalanced blade

will cause excessive

vibration when rotat-

ingat high speeds, it

may cause damage

to mower, and could

break causing per-

sonal injury.

Enginefails to Start 1, B!aclecontroidisengaged, i: Engagebladecent[eL

2. SparkPlugwh'edisc0nnected_ 2. C0nneciWgetoSparkplug,

Fue!tankempty0rStalefueL Filltankwith Clean,freshgaso)ine

5. Eautysparkpug, 5, Cean, adustgap, orrepace.!ngYourLawnMowe[.

Shoot og

For repairs beyond

theminoradjustments

listed here, contact

an authorized service

dealer.,

il_ _ i i i

!i_ii_i_i_ii_i _ii iiilt t t t t t t t t t __i

6. Blockedfuel line, 6. Clean fuelline,

7. Enginefl00ded. 7 Waitalewminutest0restart butdo

Engineruns erratic 1. Sparkplugwireloose. 1 Connectandtightensparkplugwire.

2. Blockedfuel lineor stalefuel. 2. Cleanfuelline:filltank withclean,

freshgasoline.

3. Ventingas capplugged.

4. Wateror dirt infuel system.

5. Dirtyaircleaner.

6. Carburetorout ofadjustment.

3. Clearvent.

4. Drainfueltank. Refillwithfreshfuel.

5. Refertoenginemanual.

6. Refertoenginemanual.

Engineoverheats 1. Engineoi!levellow. 1. Fillcrankcasewith properoi!.

2. Air flowrestricted. 2. Removeblowerhousing

andclean.

: 3. Carburetornot adjustedproperly, : 3. Referto enginemanual.

Occasionalskips

(hesitates)at

highspeed

1. Sparkpluggap tooclose.

2. Carburetoridlemixtureadjustment

improperlyset.

1. Adjustgapto .030".

2. Refertoenginemanual.

Vibration

3. Dirtyair cleaner. ! 3. Refertoenginemanual.

Excessive 1. Cuttingbladelooseor unbalanced. 1. Tightenbladeandadapter.Balance

blade.

2. Bentcuttingblade.

2. Seeanauthorizedservicedealer.

I B

Uneven cut 1. Wheelsnotpositionedcorrectly. 1. Placeall fourwheelsin same

heightposition.

2. Dullblade. 2. Sharpenor replaceblade.

Mowerw not 1 Betnot nsta edpropery 1 Checkbet forproperpu ey nsta aton

se f re I 1 andmovement.

p pe 2. Debriscloggingdriveoperation. 2. Stopengine,disconnectsparkplug

wireand cleanoutdebris.

3. Damagedorworn belt. m & inspectandreplacebelt.

Off-Season Storage 4, Coatmower'scutt,ngbladewithchass,sgreaseto

Thefollowingstepsshouldbetakentoprepareyourlawn preventrusting,

mowerforstorage, S,Storemowerinadry,e_eanarea,Donotstorenext ,//

1, Cleanand lubricatemowerthoroughlyasdescribedin tocorrosivematerials,suchasfertilizer, / /

the ubrcaton nstructons ..........

when storinganytypeOTpowerequipmentin apoorly

2, Wedonotrecommendtheuseofa pressurewasher ventilatedor metalstorageshed,careshouldbetaken

or gardenhosetocleanyourunit, torust=prooftheequipment,Usinga lightoil orsilicone,

3, Referto enginemanualforcorrectengine coattheequipment,especiallycablesandall moving SOn

storageinstructions, partsofyourlawnmowerbeforestorage,

Safety Labels Found On Your Lawn Mower

PLACEANDWORKING.IF DAMAGED REPLACEiMMEDiATELY.

WARNING

DONOTremove safety

(or any) labels from

mower for any reason,

..//"

o "_

1 747-1161A BladeControlHandle

2 749-1092A UpperHandle

3 747-04080 GrassCatcherFrame

4 749-0928A LowerHandle

5 720-0279 WingNut

6 710-1205 RopeGuide

7 710-1174 CarriageBolt,5/16-18x 2

8 664-04011 GrassBagAssembly

9 720-04072 StarKnob5/16-18

10 731-04204 DeluxeBaleCover

11 726-0240 CableTie

12 710-0703 CarriageBolt,I/4-20

13 731-04134A RearDischargeDoor

14 750-04162 Spacer

15 732-04089A TorsionSpring- LH

16 732-04090A TorsionSpring- RR

17 734-04014B RearWheel,8"x2,125"

18 731-04150C RearBaffle

20 787-01277 Deck- 21"

22 782-5002B FrontBaffle

23 748-04015A BladeAdapterw/Pulley

24 742-0741 21"StandardCut Blade

25 710-1257 HexBolt, 3/8-24x2,5

26 687-02044 PivotPlateAssembly

27 736-0524B BladeBelISupport

28 787-01298 HeightAdiustmentPlate- RH

787-01299 HeightAdiustmentPlate- LH

29 720-0426 AdiustmentLeverKnob

30 732-0706 FrontLever-RH

732-0707 FrontLever- LH

31 738-04136 ShoulderScrew

32 634-04018 FrontWheel,8"x2,125"

33 710-04371 Screw,1/4-15x 1,250

34 746-1132 ControICable-40,75"

36 731-04998 Trailshield

37 732-0700 TrailshieldWire

NOTE:Forpaintedparts,pleaserefertothelistof

colorcodesbelow, Pleaseaddtheapplicablecolor

code,whereverneeded,to thepartnumbertoorder

a replacementpart, Forinstance,ifa partnumbered

700-xxxxispaintedTroybiltRed,thepartnumberto

orderwouldbe 700-xxxx-0638,

TroybiltRed:0638

PowderBlack:0637

38 712-0397 WingNut,1/4-20

39 747-04035 RearDoorPivotRod

40 732-04175 SpringLever

41 687-02071A PivotArmAssembly- RH

687-02070A PivotArmAssembly-LH

42 710-1652 ABScrew

43 712-04065 FlangeLockNut,3/8-16

44 714-0104 HairpinClip

45 710-0654A TT SeresScrew,3/8-16x 1,00

46 687-02193 Ht,Adj,Assy,Front- LH

687-02194 Ht,Adi,Assy,Front- RH

47 687-02069 RearHandleBracketAssy,-LR

687-02068 RearHandleBracketAssy,-RH

48 747-1214 LowerBailHandle

49 710-1650 ShoulderScrew

50 746-04203 DriveCable51"

51 754-04101 V-Belt

52 618-04376 TransmissionAssembly

53 731-05020A FrontDriveCover

54 732-1043 BeltTensionSpring

55 682-0015 BearingAssembly

56 736-0447 WaveWasher

57 710-0216 HexScrew

58 715-0221 DowelPin

59 717-1762 Gear,14T-RH

717-1761 Gear,14T-LH

60 710-04531 Screw1/4-20

61 782-7551A WheeIDustCap

62 716-0102 SnapRing

63 736-0474 Washer,1,5"0D

64 750-04594 SleeveSpacer-LH

65 750-04595 SleeveSpacer-RR

66 715-04030 RollPin

67 756-04151A InputPulley

68 787-01292 HandleBracket-RH

787-01291 HandleBracket-LH

and disengagesafely.

A substitute inon OEMt

oV-Beltcan bedanger-

us by notdisengaging

completely,

To order

replacement parts,

call 1=866=840-648S,

1-336=558-7220_

or log on to our

Web site at

www.troybiltocom

MANUFACTURER'S LIMITED WARRANTY FOR

The limitedwarrantyset forthbelowisgivenbyTroy_BiltLLCwithrespect

tonewmerchandisepurchasedandusedin theUnitedStates,itsposses_

sionsandterritories.

"Troy_Bilt"warrantsthis productagainstdefectsinmatedalandworkmam

shipfora periodof two(2)yearscommencingon thedateoforiginal

purchaseandwill,atits option,repairorreplace,freeofcharge,anypart

foundtobedefectivein materialsor workmanship.This limitedwarranty

shallonlyapplyifthis producthasbeenoperatedand maintainedin

accordancewiththeOperator'sManualfurnishedwiththeproduct,and

hasnotbeensubiectto misuse,abuse,commercialuse,neglect,accident,

impropermaintenance,alteration,vandalism,theft,fire,water,or damage

becauseofotherperilor naturaldisaster.Damageresultingfromthe

installationor useofanypart,accessoryor attachmentnotapprovedby

Troy_Biltforusewiththeproduct(s)coveredbythis manualwillvoidyour

warrantyastoanyresultingdamage.

Normalwearpartsarewarrantedtobefreefromdefectsinmaterialand

workmanshipfora periodofthirty(30)daysfromthedateofpurchase.

Normalwearpartsinclude,butare notlimitedto itemssuchas: batteries,

belts,blades,bladeadapters,grassbags,riderdeckwheels,seats,snow

throwerskidshoes,shaveplates,augerspiralrubberandtires.

NOWTO OBTAIN SERVICE: Warranty service is available, WITH

PROOFOF PURCHASE,through yourlocal authorizedservice

dealer.To locate the dealer in yourarea, check your YellowPages,

or contact Troy-Bilt LLC at RO. Box 361131,Cleveland,Ohio 44136-

0019,or can 1-866-840-6483 or 1-330-558-7220,or log on to our

Web site at www.troybilt.com.

This limitedwarrantydoesnot providecoverageinthefollowingcases:

a. Theengineor componentpartsthereof.Theseitemsmay

carrya separatemanufacturer'swarranty.Refertoapplicable

manufacturer'swarrantyfortermsandconditions.

b. Logsplitterpumps,valves,andcylindershaveaseparateone

yearwarranty.

c. Routinemaintenanceitemssuchaslubricants,filters,blade

sharpening,tune_ups,brakeadiustments,clutch adiustments,

deckadiustments,andnormaldeteriorationoftheexteriorfinish

duetouseorexposure.

d. Servicecompletedbysomeoneotherthananauthorizedservice

dealer.

e. Troy_Biltdoesnotextendanywarrantyforproductssoldor

exportedoutsideoftheUnitedStates,its possessionsand

territories,exceptthosesoldthroughTroy_Bilt'sauthorized

channelsofexportdistribution.

f. Replacementpartsthatare notgenuineTroy_Biltparts.

g. Transportationchargesandservicecalls.

Noimpliedwarranty, includinganyimpliedwarrantyof merchant°

ability offitness for a particular purpose, applies after the applicable

period of express written warranty aboveasto the parts as identi-

fied. Noother express warranty, whether written or oral, exceptas

mentioned above,given by anyperson or entity, including a dealer or

retailer,with respectto any product, shall bind Troy-Bilt. Duringthe

period of the warranty,the exclusive remedy is repair or replacement

of the product as set forth above.

The provisions as set forth inthis warranty provide the sole and

exclusive remedyarising from the sale. Troy-Bilt shall not be liable

for incidental or consequential loss or damageincluding, without

limitation, expensesincurred for substitute or replacementlawncare

services or for rental expensesto temporarily replacea warranted

product.

Somestatesdo notallowtheexclusionor limitationofincidentalor

consequentialdamages,or limitationson howlonganimpliedwarranty

lasts,sotheaboveexclusionsor limitationsmaynotapplytoyou.

Innoeventshallrecoveryofanykindbegreaterthantheamountofthe

purchasepriceoftheproductsold.Alteration of safety features of the

product shall void this warranty. Youassumetheriskandliabilityfor

loss,damage,or iniurytoyouand yourpropertyand/ortoothersandtheir

propertyarisingoutofthemisuseor inabilitytousetheproduct.

This limitedwarrantyshallnotextendto anyoneotherthantheoriginal

purchaseror tothepersonforwhomitwaspurchasedasa gift.

HOWSTATELAWRELATESTOTHISWARRANTY:Thislimitedwar-

rantygh,'esyouspecificlegalrights,andyoumayalsohaveotherrights

whichvaryfromstatetostate.

IMPORTANT:OwnermustpresentOriginalProofofPurchasetoobtain

warrantycoverage.

TROYBILT LLC, P.O. BOX 361131 CLEVELAN D, OHIO 44136-0019; Phone: 1(866} 840-6483, 1-330-558-7220

Troybilt 440 Owner's manual

Brand: Troybilt

Model: 440

Category: Lawnmowers

Type: Owner's manual

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Troybilt 440 Owner's manual

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