TROY-BILT TB 240 (01) PDF MANUAL

Before setting up and operating your new equipment, please locate the model plate on the equipment and record the information. You can locate the model plate by standing at the operator’s position and looking down at the rear of the deck. This information will be necessary, should you seek technical support.

1. Read this operator’s manual carefully in its entirety before attempting to assemble this machine. Read, understand, and follow all instructions on the machine and in the manual(s) before operation. Keep this manual in a safe place for future and regular reference and for ordering replacement parts.

2. Be completely familiar with the controls and the proper use of this machine before operating it.

3. This machine is a precision piece of power equipment, not a plaything. Therefore, exercise extreme caution at all times. This machine has been designed to perform one job: to mow grass. Do not use it for any other purpose.

4. 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.

5. Only responsible individuals who are familiar with these rules of safe operation should be allowed to use this machine.

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 tripped over or picked up and thrown by the blade. Thrown objects can cause serious personal injury.

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.

8. To help avoid blade contact or a thrown object injury, stay in operator zone behind handles and keep children, bystanders, helpers and pets at least 75 feet from mower while it is in operation. Stop machine if anyone enters area.

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.

10. Wear sturdy, rough-soled work shoes and close-fitting slacks and shirts. Shirts and pants that cover the arms and legs and steel-toed shoes are recommended. Never operate this machine in bare feet, sandals, slippery or light-weight (e.g. canvas) shoes.

11. Do not put hands or feet near rotating parts or under the cutting deck. Contact with blade can amputate fingers, hands, toes and feet.

12. A missing or damaged discharge cover can cause blade contact or thrown object injuries.

13. Do not operate the mower while under the influence of alcohol or drugs.

14. The blade control is a safety device. Never attempt to bypass its operation. The blade control must operate easily in both directions and automatically return to the disengaged position when released.

Never pull the mower back toward you while you are walking. If you must back the mower away from a wall or obstruction first look down and behind to avoid tripping and then follow these steps:

a. Step back from mower to fully extend your arms.

b. Be sure you are well balanced with sure footing.

c. Pull the mower back slowly, no more than half way toward you.

d. Repeat these steps as needed.

Slopes are a major factor related to slip and fall accidents, which can result in severe injury. Operation on slopes requires extra caution. If you feel uneasy on a slope, do not mow it. For your safety, use the slope gauge included as part of this manual to measure slopes before operating this machine on a sloped or hilly area. If the slope is greater than 15 degrees, do not mow it.

Do:

1. Mow across the face of slopes; never up and down. Exercise extreme caution when changing direction on slopes.

2. Watch for holes, ruts, rocks, hidden objects, or bumps which can cause you to slip or trip. Tall grass can hide obstacles.

3. Always be sure of your footing. A slip and fall can cause serious personal injury. If you feel you are losing your balance, release the blade control handle immediately and the blade will stop rotating within three (3) seconds.

Do Not:

1. Do not mow near drop-offs, ditches or embankments, you could lose your footing or balance.

2. Do not mow slopes greater than 15 degrees as shown on the slope gauge.

3. Do not mow on wet grass. Unstable footing could cause slipping.

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the mower and the mowing activity. They do not understand the dangers. Never assume that children will remain where you last saw them.

1. Keep children out of the mowing area and under watchful care of a responsible adult other than the operator.

2. Be alert and turn mower off if a child enters the area.

3. Before and while moving backwards, look behind and down for small children.

4. Use extreme care when approaching blind corners, doorways, shrubs, trees, or other objects that may obscure your vision of a child who may run into the mower.

5. Keep children away from hot or running engines. They can suffer burns from a hot muffler.

6. 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 be trained and supervised by an adult.

7. After stopping engine, remove Electric Start Push Key (if equipped) and keep it in a safe place out of the reach of children.

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.

1. Use only an approved gasoline container.

2. 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.

3. 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.

4. 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.

5. Extinguish all cigarettes, cigars, pipes and other sources of ignition.

6. Never fuel machine indoors because flammable vapors will accumulate in the area.

7. Never remove gas cap or add fuel while engine is hot or running. Allow engine to cool at least two minutes before refueling.

8. Never over fill fuel tank. Fill tank to no more than 1 inch below bottom of filler neck to provide for fuel expansion.

9. Replace gasoline cap and tighten securely.

10. If gasoline is spilled, wipe it off the engine and equipment. Move machine to another area. Wait 5 minutes before starting engine.

11. Never store the machine or fuel container near an open flame, spark or pilot light as on a water heater, space heater, furnace, clothes dryer or other gas appliances.

12. To reduce fire hazard, keep machine free of grass, leaves, or other debris build-up. Clean up oil or fuel spillage and remove any fuel soaked debris.

13. Allow machine to cool at least 5 minutes before storing.

1. Never run an engine indoors or in a poorly ventilated area. Engine exhaust contains carbon monoxide, an odorless and deadly gas.

2. Before cleaning, repairing, or inspecting, make certain the blade and all moving parts have stopped. Disconnect the spark plug wire and ground against the engine and remove Electric Start Push Key (if equipped) to prevent unintended starting.

3. Check the blade and engine mounting bolts at frequent intervals for proper tightness. Also, visually inspect blade for damage (e.g., bent, cracked, worn) Replace blade with the original equipment manufacturer’s (O.E.M.) blade only.

4. Mower blades are sharp and can cut. Wrap the blade or wear gloves, and use extra caution when servicing them.

5. Keep all nuts, bolts, and screws tight to be sure the equipment is in safe working condition.

6. Never tamper with safety devices. Check their proper operation regularly.

7. After striking a foreign object, stop the engine, disconnect the spark plug wire and ground against the engine. Thoroughly inspect the mower for any damage. Repair the damage before starting and operating the mower.

8. Never attempt to make a wheel or cutting height adjustment while the engine is running.

9. Grass catcher components, discharge cover, and trail shield 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.

10. Do not change the engine’s governor setting or over-speed the engine. The governor controls the maximum safe operating speed of the engine.

11. Check fuel line, tank, cap, and fittings frequently for cracks or leaks. Replace if necessary.

12. Do not crank engine with spark plug removed.

13. Maintain or replace safety and instruction labels, as necessary.

14. Observe proper disposal laws and regulations. Improper disposal of fluids and materials can harm the environment.

15. 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.

To check the slope, proceed as follows:

1. Remove the slope gauge page from the manual and fold along the dashed line.

2. Locate a vertical object on or behind the slope (e.g. a pole, building, fence, tree, etc.).

3. Align either side of the slope gauge with the object.

4. Adjust the gauge up or down until the left corner touches the slope.

5. If there is a gap below the gauge, the slope is too steep for safe operation.

WARNING! Slopes are a major factor related to tip-over and roll-over accidents which can result in severe injury or death. Do not operate machine on slopes in excess of 15 degrees. All slopes require extra caution. Always mow across the face of slopes, never up and down slopes.

One Lawn Mower

One Grass Catcher

One Bottle of Oil

One Lawn Mower Operator’s Manual

One Engine Operator’s Manual

One Side Discharge Chute

Electric Start Push Key (If Equipped)

NOTE: This unit is shipped without gasoline or oil in the engine. Fill up with gasoline and oil as instructed in the accompanying engine manual BEFORE operating your mower.

1. Remove any packing material which may be between upper and lower handles.

2. Remove wing nuts and carriage bolts from the handle. Do not loosen or remove adjacent hex head screws.

3. While stabilizing the mower so it doesn’t move, pivot the upper handle up. Do not crimp the cable while lifting the handle up.

4. Remove the T-bolts from the handle brackets.

5. Pull upward on the handle until holes in the lower handle line up with holes in the handle bracket. NOTE: When pulling upward on the handle, make sure to not pull the handle all the way out.

6. Insert the T-bolts removed earlier through the handle brackets and lower handle and tighten securely to secure the handle in place.

7. Reattach the wing nuts and carriage bolts removed earlier into the lower holes of the handle.

8. The rope guide is attached to the right side of the upper handle. Loosen the wing knob which secures the rope guide.

9. Hold the blade control against the upper handle.

10. Slowly pull the starter rope handle from the engine and slip the starter rope into the rope guide.

11. Tighten the rope guide wing knob.

12. Use the cable tie(s) to secure the cable(s) to the lower handle.

Make certain the bag is turned right side out before assembling (the warning label will be on the outside).

1. Place the bag over the frame so that its black plastic side is at the bottom.

2. Slip the plastic channel of the grass bag over the hooks on the frame.

To Attach:

1. Lift the rear discharge door.

2. Place the grass catcher into the slots in the handle brackets. Let go of the discharge door so that it rests on the grass catcher.

To Remove:

1. Lift the rear discharge door on the mower.

2. Lift the grass catcher up and out of the slots in the handle brackets.

3. Release the rear discharge door to allow it to close the rear opening of the mower.

Your mower is shipped as a mulcher. To convert to side discharge, make sure the grass catcher is off of the unit and the rear discharge door is closed.

1. On the side of the mower, lift the side mulching plug.

2. Slide the two hooks of the side discharge chute under the hinge pin on the mulching plug assembly. Lower the mulching plug. Do not remove the side mulching plug at any time, even when you are not mulching.

There is a cutting height adjustment lever located above the front and rear right wheel. NOTE: For mowers with low wheels, the height adjustment levers move in the opposite direction to adjust; for those with high wheels, the levers move in the same direction.

1. Pull the height adjustment lever towards the wheel (the unit will tend to fall when the lever is moved outward).

2. Move the lever to the desired position for a change in cutting height.

IMPORTANT: Both the front and rear wheels must be placed in the same relative position. For rough or uneven lawns, move the height adjustment levers to a higher position. This will stop scalping of grass.

For convenience of operation, you may adjust the pitch of the handle as follows:

1. Remove the wing nuts and carriage bolts from the handle.

2. Position the handle in one of the three positions that is most comfortable.

3. Secure into position with the wing nuts and carriage bolts removed earlier.

The adjustment wheel is located in the drive control handle housing and is used to tighten or loosen the drive belt. You will need to adjust the drive control if the mower does not propel itself with the drive control engaged or if the mower’s wheels hesitate with the drive control engaged. If either of these conditions occur, rotate the adjustment wheel clockwise to tighten the cable or counterclockwise to loosen the cable.

Refer to the separate engine owner’s manual for additional engine information.

1. Add the provided oil before starting the unit for the first time out of the box.

2. Service the engine with gasoline as instructed in the separate engine owner’s manual.

WARNING: Use extreme care when handling gasoline. Gasoline is extremely flammable and the vapors are explosive. Never fuel the machine indoors or while the engine is hot or running. Extinguish cigarettes, cigars, pipes and other sources of ignition.

Blade Control: Attached to the upper handle. Depress and squeeze it against the upper handle to operate the unit. Release it to stop the engine and blade. WARNING: This blade control is a safety device. Never attempt to bypass its operations.

Drive Control: Located on top of the upper handle. Squeeze it against the upper handle to engage the drive; release it to slow down or stop the mower from propelling.

Electric Starter Push Key (If Equipped): Located on the right side of the upper handle. It is both a removable key and push button.

Recoil Starter: Attached to the right upper handle. Stand behind the unit and pull the recoil starter rope to start the unit.

Side Discharge Chute: Used to discharge grass clippings to the side. Follow instructions in the “Assembly & Set-Up” section to attach.

Deck Wash: A water port on the deck’s surface used to rinse grass clippings from the deck’s underside.

Cutting Height Adjustment Lever: One lever is located on the right rear wheel and one is on the right front wheel. Both levers must be in the same relative position to ensure a uniform cut.

WARNING: Be sure no one other than the operator is standing near the lawn mower while starting the engine or operating the mower. Never run the engine indoors or in enclosed, poorly ventilated areas. Engine exhaust contains carbon monoxide, an odorless and deadly gas. Keep hands, feet, hair and loose clothing away from any moving parts on the engine and lawn mower.

1. (Electric Start units only) Insert the plastic Electric Start Push Key into the starter housing located on the right side of the upper handle until it snaps in place.

2. Standing behind the mower, squeeze the blade control against the upper handle.

3. Recoil Start: Holding these two handles together firmly, grasp the recoil starter handle and pull the rope out with a rapid, continuous, full arm stroke. Keeping a firm grip on the starter handle, let the rope rewind slowly. Repeat until the engine cranks. Let the rope rewind each time slowly.

4. Electric Start (If Equipped): Push the electric starter push key to start the engine. NOTE: The electric starter is equipped with an internal circuit breaker. If the unit fails to start when the starter button is depressed, wait one minute for the breaker to reset, then attempt to start again.

WARNING: Be sure no one other than the operator is standing near the lawn mower while starting the engine or operating the mower. Never run the engine indoors or in enclosed, poorly ventilated areas. Engine exhaust contains carbon monoxide, an odorless and deadly gas. Keep hands, feet, hair and loose clothing away from any moving parts on the engine and lawn mower.

1. Place the fuel valve lever found on the left side of the engine into the ON (OPEN) position.

2. Standing behind the mower, squeeze the blade control against the upper handle.

3. Holding these two handles together firmly, grasp the recoil starter handle and pull the rope out with a rapid, continuous, full arm stroke. Keeping a firm grip on the starter handle let the rope rewind slowly. Repeat until the engine cranks. Let the rope rewind each time slowly.

1. Release the blade control to stop the engine and blade.

2. (Electric Start units only) Remove the Electric Start Push Key if the mower is to be left unattended, stored, or serviced. To remove the key, grasp the key’s top push button and pull it straight up and out. Keep the key in a safe place out of the reach of children.

WARNING: Wait for the blade to stop completely before performing any work on the mower or to remove the grass catcher.

For mulching grass, remove the grass catcher and allow the rear discharge door to close the rear opening of the mower. For effective mulching, do not cut wet grass. If the grass has been allowed to grow in excess of four inches, mulching is not recommended. Use the grass catcher to bag clippings instead.

You can use the grass catcher to collect clippings while you are operating the mower.

1. Attach the grass catcher following instructions in the “Assembly & Set-Up” section. Grass clippings will automatically collect in the bag as you run the mower. Operate the mower till the grass bag is full.

2. Stop the engine completely by releasing the blade control. Make sure that the unit has come to a complete stop.

3. Lift the discharge door and pull the grass bag up and away from the mower to remove the bag. Dispose of the grass clippings and reinstall the bag when complete.

WARNING: If you strike a foreign object, stop the engine. Remove the wire from the spark plug, thoroughly inspect the mower for any damage, and repair the damage before restarting and operating. Extensive vibration of the mower during operation is an indication of damage. The unit should be promptly inspected and repaired.

Always observe safety rules when performing any maintenance.

The warranty on this lawn mower does not cover items that have been subjected to operator abuse or negligence. To receive full value from warranty, operator must maintain the lawn mower as instructed here.

Changing of engine-governed speed will void engine warranty.

All adjustments should be checked at least once each season.

Periodically check all fasteners and make sure these are tight.

WARNING: Always stop the engine, remove the Electric Start Push Key (if equipped), allow the engine to cool, disconnect the spark plug and ground against the engine before performing any type of maintenance on your machine.

1. Lubricate pivot points on the blade control at least once a season with light oil. This control must operate freely in both directions.

2. The transmission is pre-lubricated and sealed at the factory and does not require lubrication.

3. Follow the accompanying engine manual for the lubrication schedule and instruction for engine lubrication.

Clean the underside of the mower deck after each use to prevent the build-up of grass clippings or other debris. Follow the steps below for this job.

1. Disconnect the spark plug wire. Drain gasoline from the lawn mower or place a piece of plastic under the gas cap.

2. Tip the mower so that it rests on the housing. Keep the side with the air cleaner facing up. Hold the mower firmly.

WARNING: Never tip the mower more than 90° in any direction and do not leave the mower tipped for any length of time. Oil can drain into the upper part of the engine causing a starting problem.

3. Scrape and clean the underside of the deck with a suitable tool.

4. Put the mower back on its wheels on the ground. If you had put plastic under the gas cap earlier, make sure to remove it now.

Use the deck wash to rinse grass clippings from the deck’s underside and prevent the buildup of corrosive chemicals. Complete the following steps AFTER EACH MOWING:

1. Push the mower to a level, clear spot on your lawn, near enough for your garden hose to reach. CAUTION: Make certain the mower’s discharge chute is directed AWAY from your house, garage, parked cars, etc.

2. Thread the hose coupler (packaged with your mower’s Operator’s Manual) onto the end of your garden hose.

3. Attach the hose coupler to the water port on your deck’s surface.

4. Turn the water on.

5. Start the engine as described in the Operation section.

6. Run the engine for a minimum of two minutes, allowing the underside of the cutting deck to thoroughly rinse.

7. Release the blade control to stop the engine and blade.

8. Turn the water off and detach the hose coupler from the water port on your deck’s surface.

After cleaning your deck, restart the mower. Keep the engine and blade running for a minimum of two minutes, allowing the underside of the cutting deck to thoroughly dry.

Follow the accompanying engine manual for a detailed list and instructions.

• Maintain oil level as instructed in the engine manual.

• Service the air cleaner every 25 hours under normal conditions. Clean every few hours under extremely dusty conditions. Poor engine performance and flooding usually indicates that the air cleaner should be serviced. To service the air cleaner, refer to the engine manual.

• Clean the spark plug and reset the gap once a season. Spark plug replacement is recommended at the start of each mowing season. Check the engine manual for the correct plug type and gap specifications.

• Clean the engine regularly with a cloth or brush. Keep the top of the engine clean to permit proper air circulation. Remove all grass, dirt, and combustible debris from the muffler area.

• Engines stored between 30 and 90 days need to be treated with a gasoline stabilizer such as STA-BIL® to prevent deterioration and gum from forming in the fuel system or on essential carburetor parts.

WARNING: When removing the cutting blade for sharpening or replacement, protect your hands with a pair of heavy gloves or use a heavy rag to hold the blade. Periodically inspect the blade adapter for cracks, especially if you strike a foreign object. Replace when necessary.

1. Disconnect the spark plug boot from the spark plug and remove the Electric Start Push Key (if equipped). Turn the mower on its side making sure that the air filter and the carburetor are facing up (not pointed toward the ground).

2. Remove the bolt and the blade bell support which hold the blade and the blade adapter to the engine crankshaft.

3. Remove the blade and adapter from the crankshaft.

4. Remove the blade from the adapter for testing balance. Balance the blade on a round shaft screwdriver to check. Remove metal from the heavy side until it balances evenly. When sharpening the blade, follow the original angle of grind. Grind each cutting edge equally to keep the blade balanced.

5. Lubricate the engine crankshaft and the inner surface of the blade adapter with light oil. Slide the blade adapter onto the engine crankshaft. Place the blade on the adapter such that the side of the blade marked “Bottom” (or with part number) faces the ground when the mower is in the operating position. Make sure that the blade is aligned and seated on the blade adapter flanges.

6. Place the blade bell support on the blade. Align notches on the blade bell support with small holes in the blade.

7. Replace the hex bolt and tighten the hex bolt to torque: 450 in. lbs. min., 600 in. lbs. max.

WARNING: An unbalanced blade will cause excessive vibration when rotating at high speeds. It may cause damage to the mower and could break causing personal injury.

To ensure safe operation of your mower, periodically check the blade bolt for correct torque.

NOTE: Several components must be removed in order to change the mower’s belt. See an authorized Service Dealer to have your belt replaced.

WARNING: Batteries contain sulfuric acid which may cause burns. Do not short circuit or mutilate batteries in any way. Do not put batteries in fire as these may burst or release toxic materials.

1. Unhinge the cover seal and lift off the battery cover.

2. Remove the positive (red) and negative (black) leads from the battery, and pull up on the battery to remove.

3. Replace with a new battery. Connect the positive lead (red) to the positive (+) terminal of the battery pack, then connect the negative lead (black) to the negative (-) terminal.

4. Reattach the battery cover and cover seal.

WARNING: The battery contains corrosive fluid and toxic material; handle with care and keep away from children. Do not puncture, disassemble, mutilate or incinerate the battery. Explosive gases could be vented during charging or discharging. Use in a well-ventilated area, away from sources of ignition.

NOTE: The special designed plug on the charger will only fit into the plug on the battery box.

1. Unhinge the cover seal and plug the battery charger into the port on the side of the battery housing.

2. Insert the battery charger plug into a standard 120 volt household outlet. Charge the battery for 8 to 10 hours before initial use. Do not charge longer than 12 hours. The battery should only need to be charged upon initial setup, at the end of the season, after any other extended periods of non-use, and as needed. NOTE: If you frequently stop and restart the mower during each cut throughout the season (for instance when bagging), more frequent charging may be necessary.

3. After charging, disconnect the charger plug from the outlet first, then disconnect the charger lead from the battery and reattach the cover seal.

IMPORTANT: Do not remove the battery pack from the electric starter housing for any reason other than replacement.

IMPORTANT: Always plug the charger lead into the battery pack lead first, and then insert the battery charger plug into a 120 volt standard household outlet. Follow this order of action every time you charge the battery.

The following steps should be taken to prepare your lawn mower for storage.

• Clean and lubricate the mower thoroughly as described in the lubrication instructions.

• Coat the mower’s cutting blade with chassis grease to prevent rusting.

• Refer to the engine manual for correct engine storage instructions.

• Secure the side discharge chute to the handle.

• Store the mower in a dry, clean area. Do not store next to corrosive materials, such as fertilizer.

• When storing any type of power equipment in a poorly ventilated or metal storage shed, care should be taken to rust-proof the equipment. Using a light oil or silicone, coat the equipment, especially cables and all moving parts of your lawn mower before storage.

For models with a battery: The battery must be stored with a full charge. Extended storage of a discharged battery will reduce the life and capacity of the battery. For optimal battery life, charge the battery once per month while in storage. Remove the Electric Start Push key and keep it in a safe place out of the reach of children.

† If Equipped