Troy Bilt Lawn Mower TRU CUT 100 User Manual

Operator’s Manual  
20" Mulching  
Rotary Lawn Mower  
IMPORTANT: Read safety rules and instructions carefully before operating equipment.  
Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-covered, brush-  
covered or grass-covered land unless the engine’s exhaust system is equipped with a spark arrester meeting applicable local or state laws (if  
any). If a spark arrester is used, it should be maintained in effective working order by the operator. In the State of California the above is required  
by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. A spark  
arrester 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.  
TROY-BILT LLC., P.O. BOX 361131, CLEVELAND, OHIO 44136-0019  
PRINTED IN U.S.A.  
FORM NO. 770-10755D.
(3/2003)  
 
SECTION 1: IMPORTANT SAFE OPERATION PRACTICES  
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 symbolHEED ITS WARNING.  
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.  
DANGER: This machine was built to be operated according to the rules for safe operation 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 instruc-  
tions could result in serious injury or death.  
9. A missing or damaged discharge cover can cause blade  
General Operation  
contact or thrown object injuries.  
1. Read this operators manual carefully in its entirety  
10. Many injuries occur as a result of the mower being pulled  
before attempting to assemble this machine. Read,  
over the foot during a fall caused by slipping or tripping.  
understand, and follow all instructions on the machine  
Do not hold on to the mower if you are falling; release the  
and in the manual(s) before operation. Be completely  
familiar with the controls and the proper use of this  
handle immediately.  
11. Never pull the mower back toward you while you are  
machine before operating it. Keep this manual in a safe  
walking. If you must back the mower away from a wall or  
place for future and regular reference and for ordering  
obstruction first look down and behind to avoid tripping  
replacement parts.  
and then follow these steps:  
2. This machine is a precision piece of power equipment,  
a. Step back from the mower to fully extend your  
not a plaything. Therefore, exercise extreme caution at all  
arms.  
times. Your unit has been designed to perform one job: to  
b. Be sure you are well balanced with sure footing.  
mow grass. Do not use it for any other purpose.  
3. Never allow children under 14 years old to operate this  
c. Pull the mower back slowly, no more than half way  
toward you.  
machine. Children 14 years old and over should read and  
d. Repeat these steps as needed.  
understand the operation instructions and safety rules in  
12. Do not operate the mower while under the influence of  
this manual and should be trained and supervised by a  
alcohol or drugs.  
parent. Only responsible individuals who are familiar with  
13. Do not engage the self-propelled mechanism on units so  
these safe operation rules should use this machine.  
equipped while starting engine.  
4. Thoroughly inspect the area where the equipment is to  
14. The blade control handle is a safety device. Never  
be used. Remove all stones, sticks, wire, bones, toys and  
attempt to bypass its operation. Doing so makes the  
other foreign objects which could be tripped over or  
safety device inoperative and may result in personal  
picked up and thrown by the blade. Thrown objects can  
injury through contact with the rotating blade. The blade  
cause serious personal injury. Plan your mowing pattern  
control handle must operate easily in both directions and  
to avoid discharge of material toward roads, sidewalks,  
automatically return to the disengaged position when  
bystanders and the like. Also, avoid discharging material  
released.  
against a wall or obstruction which may cause discharged  
15. Never operate the mower in wet grass. Always be sure of  
material to ricochet back toward the operator.  
your footing. A slip and fall can cause serious personal  
5. To help avoid blade contact or a thrown object injury, stay  
injury. If you feel you are losing your footing, release the  
in the operator zone behind the handles and keep  
bystanders, helpers, children and pets at least 75 feet  
blade control handle immediately and the blade will stop  
rotating within three seconds.  
from the machine while it is in operation. Stop machine if  
16. Mow in daylight or good artificial light. Walk, never run.  
anyone enters the area.  
6. Always wear safety glasses or safety goggles during  
17. Stop the blade when crossing gravel drives, walkways  
or roads.  
operation and while performing an adjustment or repair to  
18. If the equipment should start to vibrate abnormally, stop  
protect your eyes. Thrown objects which ricochet can  
the engine and check immediately for the cause.  
cause serious injury to the eyes.  
Vibration is generally a warning of trouble.  
7. Wear sturdy, rough-soled work shoes and close-fitting  
19. Shut the engine off and wait until the blade comes to a  
slacks and shirts. Shirts and pants that cover the arms  
complete stop before removing the grass catcher or  
and legs and steel-toed shoes are recommended. Never  
unclogging the chute. The cutting blade continues to  
operate this machine in bare feet, sandals, slippery or  
rotate for a few seconds after the engine is shut off.  
light weight (e.g. canvas) shoes.  
Never place any part of the body in the blade area until  
8. Do not put hands or feet near rotating parts or under the  
you are sure the blade has stopped rotating.  
cutting deck. Contact with the blade can amputate hands  
20. Never operate mower without proper trail shield,  
and feet.  
discharge cover, grass catcher, blade control handle or  
3
 
other safety protective devices in place and working.  
Never operate mower with damaged safety devices.  
Failure to do so, can result in personal injury.  
21. Muffler and engine become hot and can cause a burn. Do  
not touch.  
power mower. Children 14 years old and over should  
read and understand the operation instructions and  
safety rules in this manual and should be trained and  
supervised by a parent.  
22. Only use parts and accessories made for this machine by  
the original equipment manufacturer (O.E.M). Failure to  
do so can result in personal injury.  
23. If situations occur which are not covered in this manual,  
use care and good judgment. Contact your dealer for  
assistance. Telephone 1-800-800-7310 for the name of  
your nearest dealer.  
Service  
Safe Handling Of Gasoline  
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.  
2. Wash your skin and change clothes immediately.  
3. Use only an approved gasoline container.  
4. 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.  
5. If possible, 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.  
6. 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.  
7. Extinguish all cigarettes, cigars, pipes and other sources  
of ignition.  
Slope Operation  
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. Before operating this unit on a slope or hilly area, use  
the slope gauge on page 6 to measure slopes. 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 3 seconds.  
8. Never fuel machine indoors because flammable vapors  
will accumulate in the area.  
9. Never remove gas cap or add fuel while the engine is hot  
or running. Allow engine to cool at least two minutes  
before refueling.  
10. Never over fill fuel tank. Fill tank to no more than ½ inch  
below bottom of filler neck to provide space for fuel  
expansion.  
11. Replace gasoline cap and tighten securely.  
12. If gasoline is spilled, wipe it off the engine and  
equipment. Move unit to another area. Wait 5 minutes  
before starting the engine.  
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.  
13. 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.  
14. To reduce fire hazard, keep mower free of grass, leaves,  
or other debris build-up. Clean up oil or fuel spillage and  
remove any fuel soaked debris.  
Children  
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.  
15. Allow a mower to cool at least 5 minutes before storing.  
General Service  
1. Keep children out of the mowing area and under the  
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.  
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 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 manufactures (O.E.M.) blade  
only, listed in this manual. Use of parts which do not  
6. Never allow children under 14 years old to operate a  
4
 
meet the original equipment specifications may lead to  
improper performance and compromise safety!”  
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.  
expose moving parts or allow objects to be thrown. For  
safety protection, frequently check components and  
replace immediately with original equipment  
manufacturers (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!”  
6. Never tamper with safety devices. Check their proper  
operation regularly.  
10. Do not change the engine governor setting or overspeed  
the engine. The governor controls the maximum safe  
operating speed of the engine.  
11. Maintain or replace safety and instruction labels, as  
necessary.  
12. Observe proper disposal laws and regulations. Improper  
disposal of fluids and materials can harm the  
environment.  
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  
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.  
5
 
SECTION 2: SLOPE GAUGE  
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SECTION 3: ASSEMBLING YOUR LAWN MOWER  
To Remove Unit From Carton  
Remove staples, break glue on top flaps, or cut tape  
at carton end and peel along top flap to open carton.  
Remove loose parts included with your unit (i.e.,  
operators manual, etc.).  
Carriage Bolt  
Saddle  
Washer  
Upper  
Handle  
Cut along corners and lay carton down flat.  
Remove packing material.  
Roll or slide unit out of carton.  
Lower  
Handle  
IMPORTANT: This unit is shipped WITHOUT  
GASOLINE. Make sure to service engine with gasoline  
and oil as instructed in the separate engine manual  
before operating your mower.  
Hand  
Knob  
Saddle Washer  
Figure 2  
NOTE: Reference to right or left side of the mower is  
observed from the operating position.  
Remove the hairpin clips from the outer holes in the  
weld pins on the handle mounting brackets.  
Using a pair of pliers, squeeze one leg of the lower  
handle against the handle mounting bracket. Insert  
the hairpin clip into the inner hole on the weld pin.  
See Figure 3. Repeat on other side.  
Tools Required  
Pair of pliers (not necessary, but helpful)  
Disconnect Spark Plug Wire  
Hairpin  
Clip in  
Disconnect spark plug wire from the spark plug and  
attach rubber boot to a bolt on the engine to  
ground. See Figure 1.  
Inner Hole  
Weld  
Pin  
Lower  
Handle  
Rubber Boot  
Handle  
Mounting  
Bracket  
Figure 3  
Attaching Starter Rope  
Spark Plug  
Figure 1  
The rope guide is attached to the right side of the  
upper handle. Loosen the wing nut which secures  
the rope guide. For location of the wing nut, see  
Figure 4.  
Attaching Handle  
Insert starter rope into  
rope guide  
Pull up and back on the upper handle to raise the  
handle into the operating position. Make certain the  
lower handle is seated securely into the handle  
mounting brackets. Tighten the hand knobs on  
each side of the handle (carriage bolts and saddle  
washers must be seated properly into the handle as  
shown). See Figure 2.  
Wing Nut  
Rope  
Guide  
NOTE: Your mower is shipped with the handle in the  
higher height position. If you wish to lower the height of  
the handle, refer to the instructions for handle height  
adjustment on page 10.  
Figure 4  
7
 
With the spark plug wire disconnected and  
grounded, hold the blade control handle against the  
upper handle, and pull the starter rope out of the  
engine. Release the blade control handle. Slip the  
starter rope into the rope guide. Tighten the wing  
nut. See Figure 4.  
Make certain all nuts and bolts are tightened  
securely.  
Attach cables to the lower handle with the two cable  
ties already on the lower handle, insert pegs on  
cable ties into the holes on the lower handle. Pull  
cable ties tight and cut off the extra. See Figure 5.  
Converting to Side Discharge  
Your mower has been shipped as a mulcher. To  
convert it to a side-discharge mower, lift the  
mulching plug. Slide the two hooks on the side-  
discharge deflector under the hinge pin on the  
mulching plug assembly. Lower the mulching plug.  
See Figure 6.  
Mulching  
Plug  
Cable Tie  
Hinge  
Pin  
Lower  
Handle  
Side  
Chute  
Deflector  
Figure 6  
Figure 5  
SECTION 4: KNOW YOUR LAWN MOWER  
Compare Figure 7 with your equipment to get familiar  
with the mower controls before operating it.  
Cutting Height Adjustment Lever  
This lever, located at each wheel, lets you adjust cutting  
height of the grass. Remember to put all four levers at  
the same height to avoid uneven cut.  
Blade Control Handle  
The blade control handle is located on the upper handle  
of the mower. The blade control handle must be  
depressed in order to operate the unit. Release the  
blade control handle to stop the engine and blade.  
Blade Control  
Handle  
WARNING: This control mechanism is a  
safety device. Never attempt to bypass its  
operations. The blade will be rotating  
whenever the engine is running.  
Throttle Control  
Your engine is equipped with a constant speed throttle,  
which is set at full throttle for best performance.  
Cutting Height  
Adjustment Lever  
Starter  
Starter Rope  
Rope  
The starter rope is attached to the handle. Stand behind  
the unit and pull the starter rope to start the unit.  
Primer  
The primer is used to pump gas into the carburetor. Use  
it to start a cold engine, but do not use it to restart a  
warm engine after a short shutdown.  
Mulching  
Mulching Plug  
Plug  
Spark Plug  
Wire  
The mulching plug is used only for mulching purposes.  
This process recirculates the clippings back to the lawn.  
Do not operate the mower if the mulching plug is not  
firmly situated on the unit.  
Figure 7  
8
 
SECTION 5: OPERATING YOUR LAWN MOWER  
Grasp starter handle and pull rope out slowly until  
WARNING: Keep hands and feet away  
from the chute area on cutting deck. The  
blade will be rotating whenever the engine is  
running.  
engine reaches start of compression cycle (rope  
will pull slightly harder at this point). Let the rope  
rewind slowly.  
Pull rope with a rapid, continuous, full arm stroke.  
Keep a firm grip on starter handle. Return it slowly  
to the rope guide. If you encounter any problems,  
refer to the Trouble Shooting Guide for helpful  
information.  
Be sure no one other than the operator is  
standing near the lawn mower while starting  
the engine or operating the mower.  
Never run engine indoors or in enclosed,  
poorly ventilated areas. Engine exhaust  
contains carbon monoxide, an odorless and  
deadly gas.  
Stopping Engine and Blade  
Release the blade control handle to stop the engine  
and the blade.  
Gas and Oil Fill-Up  
WARNING: The blade continues to rotate  
for a few seconds after the engine is shut off.  
Do not touch the blade in any way while it is  
still rotating.  
Service the mower engine with gasoline and oil  
following instructions in the engine manual. If your  
mower was shipped with oil in the engine, fill up the  
required amount of gasoline only. Always make  
sure there is adequate oil in the engine before  
starting the engine. Fill up as necessary.  
Disconnect spark plug wire and ground it against  
the engine to prevent accidental starting while  
equipment is unattended.  
WARNING: Never fill fuel tank indoors,  
with engine running or until the engine has  
been allowed to cool for at least two minutes  
after running.  
Using Your Rotary Mower  
Be sure that lawn is clear of stones, sticks, wire, or  
other objects which could damage lawn mower or  
engine. Such objects could be accidently thrown by  
the mower in any direction and cause serious  
personal injury to the operator and others.  
For best results, do not cut wet grass because it  
tends to stick to the underside of the mower,  
preventing proper discharge of grass clippings, and  
could cause you to slip and fall. New grass, thick  
grass or wet grass may require a narrower cut.  
Speed of the mower should be adjusted to the  
condition of the lawn.  
Adjusting Cutting Height  
Your mower was shipped at the highest cutting  
height. For best results in mowing, keep the cutting  
height position high until it is determined which  
height is best for your lawn.  
Refer to height adjustments section of this manual  
on page 10 for instruction on how to adjust the  
cutting height and the handle height.  
Before Starting  
For a healthier lawn, always cut off one-third or less  
of the total length of grass. Lawn should be mowed  
in the fall season as long as there is growth.  
Attach spark plug wire to spark plug. Make certain  
the metal cap on the end of the spark plug wire  
(inside the rubber boot) is fastened securely over  
the metal tip on the spark plug.  
WARNING: If your mower strikes a foreign  
object, stop the engine. Remove wire from  
spark plug, thoroughly inspect the mower for  
any damage, and repair the damage before  
restarting and operating the mower.  
Extensive vibration of the mower during  
operation is an indication of damage. The unit  
should be promptly inspected and repaired.  
To Start Engine and Engage Blade  
Prime engine as instructed in the engine manual.  
Standing behind the unit, depress the blade control  
handle and hold it against the upper handle.  
9
 
SECTION 6: MAKING ADJUSTMENTS  
WARNING: Do not at any time make any  
adjustment to your lawn mower without first  
stopping the engine and disconnecting the  
spark plug wire.  
Carburetor  
WARNING: If any adjustments are made to  
the engine while the engine is running (e.g.  
carburetor), keep clear of all moving parts and  
heated surfaces (e.g. muffler).  
Handle Height  
Your mower is shipped with the handle in the higher  
height position.To lower the handle height for your  
convenience, proceed as follows.  
Minor carburetor adjustments may be required to  
compensate for differences in fuel, temperature,  
altitude and load. To adjust carburetor, refer to the  
engine manual.  
NOTE: A dirty air cleaner will cause an engine to run  
rough. Make sure air cleaner is clean and attached to  
the carburetor before adjusting carburetor.  
Lower  
Handle  
Cutting Height  
Notch  
An adjusting plate and thumb lever at each wheel  
position provides cutting height adjustment. Each  
adjusting plate has nine height positions. Height of cut  
will be changed when the thumb lever is moved from  
one hole to another.  
Figure 8  
Simply depress the lever towards wheel and move  
wheel and lever assembly to desired position. All  
wheels must be placed in the same relative  
position. See Figure 9.  
Remove the starter rope from the rope guide.  
Remove the upper handle by removing the hand  
knobs and carriage bolts. Lay the upper handle out  
of the way, being careful not to bend or kink cables.  
Remove the hairpin clips from the weld pins on the  
handle brackets. Press outward on the legs of the  
lower handle, and remove it from the mower.  
Turn the lower handle around so the notches on the  
bottom of the lower handle are facing forward as  
shown in Figure 8. Reassemble, placing the bottom  
holes in the handle over the weld pins in the handle  
mounting bracket.  
Height  
Adjustment  
Lever  
Reassemble the upper handle.  
Place the hairpin clips in the inner holes in the weld  
pins. Reattach the starter rope.  
Figure 9  
SECTION 7: MAINTAINING YOUR LAWN MOWER  
with light oil. See Figure 10. The blade control must  
operate freely in both directions.  
Wheels  
WARNING: Always stop engine and  
disconnect spark plug wire before cleaning,  
lubricating or doing any kind of maintenance  
work on lawn mower.  
Lubricate the wheel bearings (if so equipped) at  
least once a season with light oil (or engine oil).  
Also, if the wheels are removed for any reason,  
lubricate the surface of the axle bolt and the inner  
surface of the wheel with light oil. See Figure 10.  
Lubrication  
Blade Control  
Lubricate the pivot points on the blade control  
handle and the brake cable at least once a season  
Engine  
Follow engine manual for lubrication instructions.  
10  
 
Blade  
Adapter  
Blade Bell Support  
Hex Bolt  
Lubricate  
Figure 11  
Before reinstalling the blade and the blade adapter  
to the unit, lubricate the engine crankshaft and the  
inner surface of the blade adapter with light oil (or  
engine oil).Also lubricate the bolt holes and bolts.  
Lubricate  
Bearings  
To Reinstall Blade  
Be sure to install the blade with the side of the  
blade marked Bottom(or with part number) facing  
the ground when the mower is in the operating  
position.  
Figure 10  
WARNING: Be sure to disconnect and  
ground the spark plug wire before performing  
any repairs or maintenance.  
Make sure the blade is aligned with and seated  
onto the blade adapter flanges.  
Place blade bell support on blade. Make sure the  
notches on the blade bell support are aligned with  
the small holes in the blade. See Figure 11.  
Replace hex bolt. Tighten to recommended torque.  
Blade Torque: 450 in. lbs. min., 600 in. lbs. max.  
NOTE: When tipping the unit, empty fuel tank and  
keep engine spark plug side up.  
Cutting Blade  
To ensure safe operation of mower, check all nuts  
and bolts periodically for correct torque.  
WARNING: When removing the cutting  
blade for sharpening or replacement, protect  
hands by using heavy gloves or a rag to grasp  
the cutting blade.  
Cutting Deck  
The underside of the mower deck should be  
cleaned after each use to prevent a build-up of  
grass clippings, leaves, dirt or other matter. If this  
debris is allowed to accumulate, it will invite rust  
and corrosion, and may prevent proper mulching.  
The deck may be cleaned by tilting the mower and  
scraping clean with a suitable tool (make certain the  
spark plug wire is disconnected).  
To remove blade  
Remove the bolt and blade bell support which hold  
the blade and adapter to the engine crankshaft.  
See Figure 11. Remove the blade and the adapter  
from the crankshaft.  
WARNING: Periodically inspect the blade  
adapter for cracks, especially if you strike a  
foreign object. Replace when necessary.  
NOTE: We do not recommend the use of pressure  
washers or garden hose to clean your unit. It may  
cause damage to electric components, spindles,  
pulleys, bearings or the engine. The use of water will  
shorten life and reduce serviceability of the equipment.  
When sharpening the blade, follow the original  
angle of grind as a guide. It is extremely important  
that each cutting edge receives an equal amount of  
grinding to prevent an unbalanced blade. An  
unbalanced blade will cause excessive vibration  
when rotating at high speeds, may damage the  
mower and/or cause personal injury.  
The blade can be tested by balancing it on a round  
shaft screwdriver. Remove metal from the heavy  
side until it balances evenly. It is recommended that  
the blade always be removed from the adapter for  
the best test of balance  
Engine  
Refer to the engine manual for all engine  
maintenance instructions.  
Maintain engine oil as instructed in the engine  
manual.  
Service air cleaner every 25 hours of operation  
under normal conditions. Clean every few hours  
under extremely dusty conditions. Poor engine  
11  
 
performance and flooding usually indicates that the  
air cleaner should be serviced. To service the air  
cleaner, refer to the engine manual.  
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;  
check engine manual for correct plug type and gap  
specifications.  
Clean engine regularly with a cloth or brush. Keep  
the cooling system (blower housing area) cleaned  
to permit proper air circulation which is essential to  
engine performance and life. Make sure to remove  
all grass, dirt and combustible debris from muffler  
area.  
SECTION 8: OFF-SEASON STORAGE  
The following steps should be taken to prepare lawn  
mower for storage.  
Refer to engine manual for correct engine storage  
instructions.  
Coat mowers cutting blade with chassis grease to  
prevent rusting.  
Store mower in a dry, clean area. Do not store next  
to corrosive materials, such as fertilizer.  
Clean and lubricate mower thoroughly as described  
in the lubrication instructions.  
NOTE: We do not recommend the use of pressure  
washers or garden hose to clean your unit. They may  
cause damage to electric components, spindles,  
pulleys, bearings or the engine. The use of water will  
result in shortened life and reduce serviceability.  
NOTE: When storing any type of power equipment in  
an unventilated or metal storage shed, care should be  
taken to rust-proof the equipment. Using a light oil or  
silicone, coat the lawn mower, especially cables and all  
moving parts, before storing it for the off-season.  
SECTION 9: TROUBLE SHOOTING GUIDE  
Trouble  
Possible Cause(s)  
Corrective Action  
Engine fails to start  
1. Blade control handle disengaged. 1. Engage blade control handle.  
2. Spark plug wire disconnected.  
3. Fuel tank empty, or stale fuel.  
4. Blocked fuel line.  
2. Connect wire to spark plug.  
3. Fill tank with clean, fresh gasoline.  
4. Clean fuel line.  
5. Faulty spark plug.  
6. Engine flooded.  
5. Clean, adjust gap or replace.  
6. Wait a few minutes to restart. Do not prime.  
Engine runs erratic  
Engine overheats  
1. Spark plug wire loose.  
1. Connect and tighten spark plug wire.  
2. Clean fuel line; fill tank with fresh gasoline.  
3. Clear vent.  
4. Drain fuel tank. Refill with fresh fuel.  
5. Clean air cleaner.  
2. Blocked fuel line or stale fuel.  
3. Vent in gas cap plugged.  
4. Water or dirt in fuel system.  
5. Dirty air cleaner.  
6. Carburetor out of adjustment.  
6. Adjust carburetor.  
1. Engine oil level low.  
2. Air flow restricted.  
1. Fill crankcase with proper oil.  
2. Remove blower housing and clean.  
3. Carburetor not adjusted properly. 3. Adjust carburetor.  
Hesitates at high  
speed  
1. Spark plug gap too close. 1. Adjust gap to .030.  
Idles poorly  
1. Spark plug fouled or gap too wide. 1. Reset gap to.030or replace spark plug.  
2. Carburetor improperly adjusted. 2. Adjust carburetor.  
3. Dirty air cleaner.  
3. Clean air cleaner.  
Excessive vibration  
1. Blade loose or unbalanced.  
2. Bent cutting blade.  
1. Tighten blade and adapter. Balance blade.  
2. Replace blade.  
Mower will not mulch 1. Wet grass.  
1. Wait until later to cut.  
grass  
2. Excessively high grass.  
3. Dull blade.  
2. Mow once at high, then mow again lower.  
3. Sharpen or replace blade.  
Uneven cut  
1. Wheels not positioned correctly. 1. Place all four wheels in same height position.  
2. Dull blade. 2. Sharpen or replace blade.  
12  
 
Safety & Decorative Labels Location  
(MODEL PLATE  
ON LEFT SIDE)  
777S30143  
R
E
ATO  
C
O
777S30118  
777S30108  
ON SIDE  
777D06000  
DISCHARGE DOOR  
TO REDUCE THE RISK OF INJURY,DO NOT  
OPERATE UNLESS THIS GUARD IS IN  
IT'S PROPER PLACE. IF DAMAGED,  
REPLACE IMMEDIATELY.  
20"  
CUT  
6
.
5
HP  
13  
 
SECTION 10: TRU CUT 100 PARTS LIST  
1
5
13  
2
4
3
6
46  
8
10  
7
15  
11  
8
46  
9
16  
12  
28  
29  
17  
27  
18  
35  
20  
21  
22  
23  
19  
32  
24  
45  
30  
36  
33  
26  
38  
33  
34  
20  
19  
22  
38  
37  
40  
39  
27  
24  
23  
26  
21  
41  
43  
44  
42  
14  
 
Tru Cut 100  
Ref. No.  
Part No.  
Description  
Ref. No.  
Part No.  
Description  
1.  
2.  
647-04014 Control Handle Assembly  
26.  
27.  
28.  
738-0507B Shoulder Bolt  
710-1270  
712-0324  
746-0883  
720-0295  
Oval C-Sunk Screw  
Hex Lock Nut  
15262B  
Pivot Bar  
3.  
682-3024  
682-3025  
738-0585  
732-0731  
14578  
Handle Bracket Assy. RH  
Handle Bracket Assy. LH*  
Stake Bolt  
4.  
Control Housing  
Foam Grip  
5.  
29.  
30.  
31.  
6.  
749-0705A Upper Handle  
Torsion Spring  
7.  
710-1205  
710-1174  
Rope Guide  
Carriage Bolt  
Height Adjust. Assembly RH  
Height Adjust. Assembly LH  
Mounting Bracket  
Bell Washer  
8.  
14579*  
9.  
749-0928A Lower Handle  
32.  
33.  
34.  
35.  
36.  
37.  
38.  
39.  
40.  
41.  
782-7006  
736-0270  
710-0599  
10.  
11.  
12.  
13.  
15.  
16.  
17.  
18.  
19.  
20.  
21.  
22.  
23.  
24.  
720-0279  
720-0284  
714-0104  
746-0554  
726-0240  
17098  
Wing Nut  
Hand Knob  
Hairpin Clip  
Control Cable 40.5”  
Cable Tie  
Self-tapping Screw  
710-0654A Self-tapping Sems Screw  
731-1409  
682-7002  
712-0431  
15261A  
Chute Deflector  
Mulching Plug Assembly  
Hex Lock Nut  
Hinge Clip  
731-04019 Trail Shield  
Height Adjustment Plate  
Cover: Front End  
682-0139  
736-0105  
720-0426  
732-0404  
Cutting Deck Assembly: 20”  
731-1949  
Bell Washer  
748-0376C Blade Adapter  
Knob: Height Adjustment  
Lever: Spring  
753-0588  
742-0740  
Blade Adapter Kit  
42.  
43.  
44.  
45.  
46.  
20Mulching Blade  
734-04033 Wheel Assembly  
736-0524A Blade Bell Support  
736-0504  
738-0102  
Wave Washer  
Axle Bolt  
710-1044  
747-0710  
736-0451  
Hex Bolt  
Hinge Pin  
Saddle Washer  
* Not shown in Illustration on previous page  
NOTE: For painted parts, please refer to the list of color  
codes below. Please add the applicable color code, wherever  
needed, to the part number to order a replacement part. For  
instance, if a part numbered 700-xxxx is painted Red, the part  
number to order would be 700-xxxx-0638.  
Red: 0638; Black: 0637  
15  
 
MANUFACTURERS LIMITED WARRANTY FOR:  
The limited warranty set forth below is given by Troy-Bilt LLC  
with respect to new merchandise purchased and used in the  
United States, its possessions and territories.  
d.  
Troy-Bilt LLC does not extend any warranty for  
products sold or exported outside of the United States,  
its possessions and territories, except those sold  
through Troy-Bilt LACs authorized channels of export  
distribution.  
Parts that are not genuine Troy-Bilt parts are not  
covered by this warranty.  
Service completed by someone other than an  
authorized service dealer is not covered by this  
warranty.  
Troy-Bilt LLC warrants this product against defects for a  
period of two (2) years commencing on the date of original  
purchase and will, at its option, repair or replace, free of  
charge, any part found to be defective in materials or  
workmanship. This limited warranty shall only apply if this  
product has been operated and maintained in accordance  
with the Operators Manual furnished with the product, and  
has not been subject to misuse, abuse, commercial use,  
neglect, accident, improper maintenance, alteration,  
vandalism, theft, fire, water, or damage because of other peril  
or natural disaster. Damage resulting from the installation or  
use of any accessory or attachment not approved by Troy-Bilt  
LLC for use with the product(s) covered by this manual will  
void your warranty as to any resulting damage.  
e.  
f.  
g.  
Transportation charges and service calls are not  
covered.  
No implied warranty, including any implied warranty of  
merchantability of fitness for a particular purpose,  
applies after the applicable period of express written  
warranty above as to the parts as identified. No other  
express warranty, whether written or oral, except as  
mentioned above, given by any person or entity,  
including a dealer or retailer, with respect to any product,  
shall bind Troy-Bilt LLC. During the period of the  
warranty, the exclusive remedy is repair or replacement  
of the product as set forth above.  
Normal wear parts or components thereof are subject to  
separate terms as follows: All normal wear parts or  
component failures will be covered on the product for a period  
of 90 days regardless of cause. After 90 days, but within the  
two year period, normal wear part failures will be covered  
ONLY IF caused by defects in materials or workmanship of  
OTHER component parts. Normal wear parts and  
components include, but are not limited to: batteries, belts,  
blades, blade adapters, grass bags, rider deck wheels, seats,  
snow thrower skid shoes, shave plates, auger spiral rubber,  
and tires.  
The provisions as set forth in this warranty provide the  
sole and exclusive remedy arising from the sale. Troy-Bilt  
LLC shall not be liable for incidental or consequential  
loss or damage including, without limitation, expenses  
incurred for substitute or replacement lawn care services  
or for rental expenses to temporarily replace a warranted  
product.  
HOW TO OBTAIN SERVICE: Warranty service is available,  
WITH PROOF OF PURCHASE, through your local authorized  
service dealer. To locate the dealer in your area, check your  
Yellow Pages, or contact Troy-Bilt LLC at P.O. Box 361131,  
Cleveland, Ohio 44136-0019, or call 1-866-840-6483 or 1-  
Some states do not allow the exclusion or limitation of  
incidental or consequential damages, or limitations on how  
long an implied warranty lasts, so the above exclusions or  
limitations may not apply to you.  
In no event shall recovery of any kind be greater than the  
amount of the purchase price of the product sold. Alteration  
of safety features of the product shall void this warranty.  
You assume the risk and liability for loss, damage, or injury to  
you and your property and/or to others and their property  
arising out of the misuse or inability to use the product.  
This limited warranty does not provide coverage in the  
following cases:  
a.  
The engine or component parts thereof. These items  
carry a separate manufacturers warranty. Refer to  
applicable manufacturers warranty for terms and  
conditions.  
This limited warranty shall not extend to anyone other than the  
original purchaser or to the person for whom it was purchased  
as a gift.  
b.  
c.  
Log splitter pumps, valves, and cylinders have a  
separate one year warranty.  
Routine maintenance items such as lubricants, filters,  
blade sharpening, tune-ups, brake adjustments, clutch  
adjustments, deck adjustments, and normal  
deterioration of the exterior finish due to use or  
exposure.  
HOW STATE LAW RELATES TO THIS WARRANTY: This  
limited warranty gives you specific legal rights, and you may  
also have other rights which vary from state to state.  
Troy-Bilt LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019; Phone: 1-866-840-6483, 1-330-558-7220  
 

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