Troy-Bilt 31/2 HP- Manuals

SECTION 1: SAFETY IMPORTANT—Safe Operation Practices for Sickle Bar Mowers W hen operating o r servicing the mower a lways follow the safe operating practices described in this Section. If you should e ver lend this mower to another person, m ake sure that he or she understands the safe operation o ...

SAFETY 8. Stop both the cutter bar blade and the wheel drive when you are approached by any child, inattentive person, or pet.9. Before inspecting, cleaning, adjusting, or repairing the m ower or cutter bar: stop the engine, disconnect the spark plug wire and prevent it from touching the spark plug,...

SECTION 2: EASY ASSEMBLY Please follow the assem bly steps given in this Sec­ tion to properly assem ble your m ower. These steps will not take very long and they will assure you of having assembled your m ower correctly. Before you begin assem bly, please read this Sec­ tion all the way through to ...

EASY ASSEMBLY Open the hardware p ackages. Com pare their con­ tents with Photo 2-2 and the following list. If any pieces are m issing, call us for replacem ents. 1. Two handlebar lock clamps. 2. Two handlebar knobs. 3. Two handlebar star washers.4. Tie straps (four for electric start m odels; two f...

EASY ASSEMBLY Step 3: Installing the Throttle Lever 1. The throttle cable is already a ttached to the Throt­ tle Lever and the carburetor. U nwrap the throttle cable and lever from the m ower. 2. From underneath the control panel, insert the Throttle Lever’s handle up, through the sm all rectan­ gul...

EASY ASSEMBLY this for the rem aining three holes. Then tighten ail four nuts. DRIVE Photo 2-7: Installing the cutter bar assembly 8. Place the forward (shorter) half of one of the height adjusters beneath the rear of the cutter bar. M ake sure that the “hum p” on the height adjuster faces u p. A li...

Step 6: Add Oil to the Engine 1. Push the m ower to a level area. 2. Unscrew the dipstick from the engine. W ipe the dipstick clean. 3. Insert a clean funnel into the oil fill tube as shown in Photo 2-11. 4. Pour the oil into the engine. The engine will hold approxim ately Vk pints. See Photo 2-11. ...

EASY ASSEMBLY Step 9: Connecting the Wiring Harness 1. Unwrap the wiring harness from the mower. 2. Route the wiring harness beneath the left-hand handlebar tube. Plug the connector at the top of the wiring harness into the back of the keyswitch. (You can attach the connector to the two keyswitch te...

SECTION 3: ENGINE AND MOWER CONTROLS This Section shows the location and describes the function of the various mower and engine controls you will need to use when operating the mower. After reading this Section and familiarizing yourself with the various controls, please refer to “Section 4: Operati...

MOWER CONTROLS Cutting Height Adjusters There are two cutting height adjusters, one on each side of the rear end of the cutter bar. These adjusters are used to raise or lower the blade’s cutting height. You can adjust the blade’s cutting height from approx­ imately 1 1 / 4 -inch to 5-inches. To prev...

Engine Throttle Lever The Engine Throttle Lever is attached to the right- hand side of the handlebar control panel. This lever controls the speed of the engine (which in turn con­ trols the speed of both the cutter bar and the wheels when you have those handlebar levers engaged). Moving the Engine T...

SECTION 4i MOWER OPERATION This Section of the Manual provides step-by-step starting and operating procedures. Before you start your mower’s engine, please review all of the Safety Instructions given in “Section 1: Safety”. When first operating the mower, it is a good idea to practice using it on a ...

OPERATION ENGINE THROTTLE LEVER BLADE DRIVE LEVER RECOIL STARTER ROPE WHEEL DRIVE LEVER ELECTRIC START KEYSWITCH Photo 4-1: Mower Controls. Starting the Mower ^WARNING Do not operate the mower when children or others are around. Failure to follow this instruction could result in personal injury or p...

OPERATION Mowing 1. Stand behind the mower in the operator’s position and place both hands on the handlebar grips. 2. To engage the cutter bar drive, squeeze the right- hand handlebar lever (the Blade Drive Lever). The cutter bar blade should begin to oscillate (move from side to side) rapidly. 3. T...

SECTIONS: MAINTENANCE Engine Maintenance Checking the Engine Oil Level and Adding Oil to the Engine Before starting the mower’s engine, check its oil level. If you run the engine while it’s low on oil, you risk causing damage to the engine. While mowing, frequently stop the engine and check its oil ...

MAINTENANCE Changing the Engine Oii After the very first five hours that you operate your new mower, change the engine oil. Thereafter, change the engine oii every twenty-five hours of operation. If you operate your mower in very dusty or dirty condi­tions, change the engine oil even more frequently...

MAINTENANCE To service the 4-horsepower engine air cleaner: 1. Clean any excess dirt, dust, or chaff from the air cleaner and carburetor. 2. Unscrew the knob from the top of the air cleaner and lift the cover off. 3. Remove the foam pre-cleaner by sliding it upward, off the paper cartridge. 4. Unscr...

Air Cooling System Maintenance As you mow, dry grass or chaff can clog the engine’s cooling fins and shrouds. Clean any debris from the engine as often as needed to avoid engine over­heating and damage. If the accumulation of debris and dirt is especially heavy, it may be necessary to remove the eng...

Mower Maintenance Lubrication Please refer to Photo 5-7 and the list of items that follow it to see which items on your mower should be lubricated. Keeping these items lubricated helps your mower to perform better. Photo 5-7: Mower lubrication points. NOTES • Use fresh automotive grease when grease ...

MAINTENANCE Removing and Reinstaliing the Wheels The mower’s wheels are secured to the wheel shaft by a clevis pin and a clinch pin. Removing the wheels is a simple matter. Occasionally, especially when you’re mowing taller vegetation, you might find that this vegetation tends to wrap around the whe...

MAINTENANCE 12. Align the holes in the hub of the small sprocket with the hole through the left-hand side of the jack- shaft. Insert the spirol pin into these holes and use the V 4 -inch straight punch and hammer to drive the spirol pin back into these holes. Photo 5-20: DrMng the spirol pin back in...

MAINTENANCE Wheel Drive Initial Setting 1. Using two %-inch open-end wrenches, loosen the jam nut on the wheel drive cable upper adjuster. Turn the jam nut all the way up the threaded barrel on the main adjuster. Then turn the barrel up the threaded barrel until it is approximately Vs-inch away from...

MAINTENANCE Cutter Bar Drive Belt Removal and Installation A CAUTION Before removing or installing the cutter bar drive belt, shut the engine off, allow it to cool, discon­nect the spark plug wire and prevent it from touch­ing the spark plug, and reinstall the plastic blade protector on the front of...

MAINTENANCE 4. Lift the washer off the upper end of the pivot bolt. 5. Lift the drive arm off the mower. When you lift the drive socket off the drive pin (on the cutter bar), the drive socket is free to slip out of the end of the drive arm. TE- . . SOCKEf^ V-.. AND CUTTER BAR NOT SHOWN. Photo 5-26; ...

MAINTENANCE 2. Place the wire-form belt guide over the cutter bar belt as shown in Photo 5-30. Secure the wire-form belt guide in place with the previously removed bolts. EQUAL DISTANCE WHEN J’USHiNG IDLER,.oULLEY d-O RIGHT - Photo 5-30: Reinstalling the wire-form belt guide. 3. Push the idler pulle...

MAINTENANCE Cutter Bar Drive Adjustment (General) If you have replaced any of the cutter bar drive system components (belt, control cable, control lever, idler arm spring, etc.) you will need to perform the Initial Setting prior to performing the Cutter Bar Drive Check. If you have not replaced any ...

MAINTENANCE 4. Turn the rear jam nut on the adjuster until you get a dimension of approximately 1V4-inch between the rear of the jam nut and the top of the adjuster as shown in Photo 5-34. Photo 5-34: Setting the Lower Adjuster. 5. Use a Vz-inch open-end wrench to hold the rear jam nut in place whil...

MAINTENANCE Cutter Bar Maintenance Removal and Installation of the Cutter Bar Assembly A CAUTION Before removing or installing the cutter bar assem­bly, shut the engine off, allo\w it to cool, discon­nect the spark plug wire and prevent it from touch­ing the spark plug, and reinstall the plastic bla...

MAINTENANCE DRIVE ARM IS ABOVE AND PARALLEL TO CUTTER BAR HOLDER DRIVE SOCKET SHAFT IS ABOVE AND PARALLEL TO CUTTER BAR MOUNTING! SHAFT Photo 5-37: Positions for instaiiing cutter bar. 6. Slide the cutter bar sideways until the shaft on the drive socket is above and parallel to the cutter bar mounti...

MAINTENANCE Blade Guide Adjustment The object of adjusting the cutter bar assembly’s four blade guides is to make the cutter blade assem­ bly as snug as possible in the blade guides without having it bind when it moves from side to side. A CAUTION • Before adjusting the blade guides, shut the engine...

MAINTENANCE Photo 5-42: Removing the drive pin retaining bolts. 2. Slide the cutter blade assembly sideways through the blade guides and out of the cutter bar. Photo 5-43: Removing the cutter bar. To install the cutter blade assembly: 1. From either side, slide the cutter blade assembly into the cut...

MAINTENANCE A ,• To remove a damaged blade: 1. If you’re replacing a ledger plate, remove the cut­ ter bar assembly from the mower. If you’re replacing a blade section, proceed to Step 2. 2. Remove the cutter blade assembly from the cutter bar assembly. 3. File, grind, or saw off the rounded heads o...

MAINTENANCE Electric Starting System Maintenance Battery Charging The engine on the electric start mower is equipped with an alternator to provide continuous battery charging whenever the engine is running. However, to extend the battery life and to ensure that the battery is always ready for use, w...

MAINTENANCE Battery Removal and Installation A CAUTION • Before working on, or near, the electrical sys­ tem, shut the engine off, allow it to cool, dis­ connect the spark plug wire and prevent it from touching the spark plug. Remove the Engine Ignition key from the keyswitch. • Remove all rings or ...

MAINTENANCE Storage Whenever the mower will not be used for more than 90 days, you should perform the following steps to ensure that the mower will be ready the next time you use it.1. Install the plastic blade protector on the blade. 2. Remove all fuel from the tank.3. Change the engine oil. See Pa...

MAINTENANCE TROUBLESHOOTING CHART ENGINE PROBLEMS TROUBLE POSSIBLE PROBLEM SOLUTION E n g in e d o e s n o t s ta rt. S p a rk p lu g w ire d is c o n n e c te d . R e c o n n e c t s p a rk p lu g w ire to s p a rk p lu g . E n g in e T h ro ttle L e v e r in S T O P p o s itio n . M o v e le v e r...

MAINTENANCE TROUBLESHOOTING CHART (continued) MOWER PROBLEMS (continued) TROUBLE POSSIBLE PROBLEM SOLUTION W h e e ls d o n o t ro ta te w h e n le ft-h a n d h a n d le b a r le v e r Is e n g a g e d (s q u e e z e d ). N o t e n o u g h te n s io n o n w h e e l d riv e c a b le . W o rn o r b ro...

INDEX MAINTENANCE Air Filter...................................................19Air Pressure, Tires............. inside rear coverArrester, Spark........................................ 20Assembly Steps......................................... 6 B Battery, Removal & Inst...........................