Safe Operation Practices • Set-Up • Operation • Maintenance • Service • Troubleshooting • Warranty
Op e r a t O r ’s Ma n u a l
Self-Propelled Mower — Model Series J860
WARNING
READ AND FOLLOW ALL SAFETY RULES AND INSTRUCTIONS IN THIS MANUAL
BEFORE ATTEMPTING TO OPERATE THIS MACHINE.
FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
TROY-BILT LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019
Printed In USA
Form No. 769-03842
(January 28, 2008)
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Important Safe Operation Practices
2
WARNING: This symbol points out important safety instructions which, if not followed,
could endanger the personal safety and/or property of yourself and others. Read and follow
all instructions in this manual before attempting to operate this machine. Failure to comply
with these instructions may result in personal injury.
When you see this symbol. HEED ITS WARNING!
CALIfORNIA PROPOsITION 65
WARNING: Engine Exhaust, some of its constituents, and certain vehicle components
contain or emit chemicals known to State of California to cause cancer and birth defects
or other reproductive harm.
WARNING: Battery posts, terminals, and related accessories contain lead and lead
compounds, chemicals known to the State of California to cause cancer and reproductive
harm. Wash hands after handling.
DANGER: This machine was built to be operated according to the safe operation practices in
this manual. As with any type of power equipment, carelessness or error on the part of the
operator can result in serious injury. This machine is capable of amputating fingers, hands,
toes and feet and throwing objects. Failure to observe the following safety instructions could
result in serious injury or death.
6.
Thoroughly inspect the area where the equipment is to be
used. Remove all stones, sticks, wire, bones, toys and other
foreign objects, which could be tripped over or picked up
and thrown by the blade. Thrown objects can cause serious
personal injury.
General Operation
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
manuals) before operation. Keep this manual in a safe
place for future and regular reference and for ordering
replacement parts
7.
Plan your mowing pattern to avoid discharge of material
toward roads, sidewalks, bystanders and the like. Also,
avoid discharging material against a wall or obstruction,
which may cause discharged material to ricochet back
toward the operator.
2.
3.
Be completely familiar with the controls and the proper use
of this machine before operating it.
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.
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.
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.
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.
5.
Only responsible individuals who are familiar with these
rules of safe operation should be allowed to use this
machine.
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.
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12. A missing or damaged discharge cover can cause blade
27. When starting engine, pull cord slowly until resistance
is felt, then pull rapidly. Rapid retraction of starter cord
(kickback) will pull hand and arm toward engine faster than
you can let go. Broken bones, fractures, bruises or sprains
could result.
contact or thrown object injuries.
13. Many injuries occur as a result of the mower being pulled
over the foot during a fall caused by slipping or tripping.
Do not hold on to the mower if you are falling; release the
handle immediately.
28. If situations occur which are not covered in this manual,
use care and good judgement. Contact Customer Support
for assistance or the name of the nearest service dealer.
14. 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:
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. 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.
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.
Do:
15. Do not operate the mower while under the influence of
1.
Mow across the face of slopes; never up and down. Exercise
extreme caution when changing direction on slopes.
alcohol or drugs.
16. Do not engage the self-propelled mechanism on machines
2.
Watch for holes, ruts, rocks, hidden objects, or bumps
which can cause you to slip or trip. Tall grass can hide
obstacles.
so equipped while starting engine.
17. The blade control handle is a safety device. Never attempt
to bypass its operation. Doing so makes the safety device
inoperative and may result in personal injury through
contact with the rotating blade. The blade control handle
must operate easily in both directions and automatically
return to the disengaged position when released.
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.
18. Never operate the mower in wet grass. Always be sure of
your footing. A slip and fall can cause serious personal
injury. If you feel you are losing your footing, release the
blade control handle immediately and the blade will stop
rotating within three seconds.
Do Not:
1.
2.
3.
Do not mow near drop-offs, ditches or embankments, you
could lose your footing or balance.
Do not mow slopes greater than 15 degrees as shown on
the slope gauge.
19. Mow only in daylight or good artificial light. Walk, never
run.
Do not mow on wet grass. Unstable footing could cause
slipping.
20. Stop the blade when crossing gravel drives, walks or roads.
21. If the equipment should start to vibrate abnormally, stop
the engine and check immediately for the cause. Vibration
is generally a warning of trouble.
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.
22. Shut the engine off and wait until the blade comes to
a complete stop before removing the grass catcher or
unclogging the chute. The cutting blade continues to
rotate for a few seconds after the blade control is released.
Never place any part of the body in the blade area until you
are sure the blade has stopped rotating.
1.
Keep children out of the mowing area and under watchful
care of a responsible adult other than the operator.
2.
3.
Be alert and turn mower off if a child enters the area.
Before and while moving backwards, look behind and
down for small children.
23. Never operate mower without proper trail shield, discharge
cover, grass catcher, blade control handle or other safety
protective devices in place and working. Never operate
mower with damaged safety devices. Failure to do so can
result in personal injury.
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.
24. Muffler and engine become hot and can cause a burn. Do
not touch.
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.
25. Never attempt to make a wheel or cutting height
adjustment while the engine is running.
26. Only use parts and accessories made for this machine by
the manufacturer. Failure to do so can result in personal
injury.
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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 manufacture’s (O.E.M.) blade only,
listed in this manual. “Use of parts which do not meet the
original equipment specifications may lead to improper
performance and compromise safety!”
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. Wash your skin and change clothes
immediately.
4.
5.
6.
7.
Mower blades are sharp and can cut. Wrap the blade or
wear gloves, and use extra caution when servicing them.
Keep all nuts, bolts, and screws tight to be sure the
equipment is in safe working condition.
2.
3.
Use only an approved gasoline container.
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.
Never tamper with safety devices. Check their proper
operation regularly.
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.
4.
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.
8.
Never attempt to make a wheel or cutting height
adjustment while the engine is running.
5.
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.
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, listed in this manual. “Use of parts
which do not meet the original equipment specifications
may lead to improper performance and compromise
safety!”
6.
7.
Extinguish all cigarettes, cigars, pipes and other sources
of ignition.
Never fuel machine indoors because flammable vapors will
accumulate in the area.
8.
Never remove gas cap or add fuel while engine is hot or
running. Allow engine to cool at least two minutes before
refueling.
9.
Never over fill fuel tank. Fill tank to no more than 1 inch
below bottom of filler neck to provide for fuel expansion.
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.
10. Replace gasoline cap and tighten securely.
11. Check fuel line, tank, cap, and fittings frequently for cracks
11. If gasoline is spilled, wipe it off the engine and equipment.
Move machine to another area. Wait 5 minutes before
starting engine.
or leaks. Replace if necessary.
12. Do not crank engine with spark plug removed.
12. 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.
13. Maintain or replace safety and instruction labels, as
necessary.
14. Observe proper disposal laws and regulations. Improper
13. 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.
disposal of fluids and materials can harm the environment.
Do not modify engine
14. Allow machine to cool at least 5 minutes before storing.
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.
General Service:
1.
Never run an engine indoors or in a poorly ventilated area.
Engine exhaust contains carbon monoxide, an odorless
and deadly gas.
Notice Regarding Emissions
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.
Engines which are certified to comply with California and federal
EPA emission regulations for SORE (Small Off Road Equipment)
are certified to operate on regular unleaded gasoline, and
may include the following emission control systems: Engine
Modification (EM), Oxidizing Catalyst (OC), Secondary Air
Injection (SAI) and Three Way Catalyst (TWC) if so equipped.
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Spark Arrestor
Average Useful Life
According to the Consumer Products Safety Commission
(CPSC) and the U.S. Environmental Protection Agency (EPA),
this product has an Average Useful Life of seven (7) years, or 140
hours of operation. At the end of the Average Useful Life, buy
a new machine or have the machine inspected annually by an
authorized service dealer to ensure that all mechanical and
safety systems are working properly and not worn excessively.
Failure to do so can result in accidents, injuries or death.
WARNING: This machine is equipped with an
internal combustion engine and should not be used
on or near any unimproved forest-covered, brush
covered or grass-covered land unless the engine’s
exhaust system is equipped with a spark 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.
WARNING: Your Responsibility—Restrict the use of this power machine to persons who read, understand and
follow the warnings and instructions in this manual and on the machine.
SAVE THESE INSTRUCTIONS!
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7
Assembly & Set-Up
3
Contents of Carton
•
•
•
One Lawn Mower
•
•
One Lawn Mower Operator’s Manual
One Engine Operator’s Manual
•
•
One Bottle of Oil
One Grass Catcher
One Hardware Pack
One Side Discharge Chute
2.
Locate the hairpin clip on the weld pin on each side of
lower handle.
Assembly
NOTE: This unit is shipped without gasoline or oil in the engine.
Fill up gasoline and oil as instructed in the accompanying engine
manual BEFORE operating your mower.
a. Remove hairpin clip from this hole. Using a pair of
pliers, insert hairpin clip into the hole on pin closest
to the bracket. See Fig. 3-2. Repeat on other side.
Handle
1.
Remove any packing material which may be between
upper and lower handles.
Hardware Pack
Carriage
Bolts (2)
a. Pull up and back on upper handle as shown in Fig.
3-1. Make certain the lower handle is seated securely
into the handle mounting brackets. Do not crimp
cables while lifting the handle up.
Wing Nuts (2)
A
B
A
B
Figure 3-2
B
b. Insert a carriage bolt from the hardware pack into
the lower hole on the handle mounting bracket.
Secure with one plastic wing nut, also included
in the hardware pack. Repeat on other side with
remaining items from hardware pack.
3.
The rope guide is attached to the right side of the upper
handle. See Fig. 3-3. Loosen the wing nut which secures the
rope guide.
Figure 3-1
b. Tighten star knobs to secure upper handle to lower
handle. Make sure that each carriage bolt is seated
properly in the handle.
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c. Attach center top of bag from inside of frame.
A
2.
Before attaching the grass catcher, the mulching baffle
must be removed.
a. Lift rear discharge door.
b. Remove mulching baffle. See Fig. 3-5.
A
B
D
C
B
Figure 3-3
a. Hold blade control against upper handle.
b. Pull starter rope out of the engine. Release blade
control.
c. Slip starter rope into rope guide.
d. Tighten wing nut.
Figure 3-5
Grass Catcher
3.
Follow the steps below to attach the grass catcher:
1.
Follow steps below to assemble the grass catcher. Make
certain bag is turned right side out before assembling
(warning label will be on the outside).
a. Lift rear discharge door. See Fig. 3-6.
a. Place bag over frame so that its black plastic side is
at the bottom. See Fig. 3-4.
A
C
B
Figure 3-6
b. Place grass catcher on the pivot rod. Let go of
discharge door so that it rests on the grass catcher.
Figure 3-4
WARNING: Never operate mower unless the hooks
on the grass catcher are firmly seated on the pivot
rod and the rear discharge door rests firmly against
top of the grass catcher.
b. Slip plastic channel of grass bag over hooks on the
frame. All the plastic channels except center top of
bag attach from outside of frame.
se c t i O n 3 — as s e M b l y & se t -up
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Side Discharge Chute
To convert to side discharge, make sure grass catcher is off of the
unit and rear discharge door is closed.
Adjustments
Cutting Height
The cutting height adjustment lever is located above the rear
right wheel.
1.
On the side of the mower, lift the mulching plug. See Fig.
3-7.
1.
Depress height adjustment lever towards wheel.
2.
Slide lever to desired position for a change in cutting
height. See Fig. 3-8.
1
2
2
1
3
Figure 3-7
2.
Slide two hooks of side discharge chute under hinge pin on
mulching plug assembly. Lower the mulching plug.
Figure 3-8
NOTE: Do not remove side mulching plug at any time, even
when you are not mulching.
3.
Release lever towards deck.
Set-Up
Gas and Oil Fill-Up
Refer to the separate engine owner’s manual for additional
engine information.
1.
Add oil provided before starting 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.
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Controls and Features
4
Drive Control
Blade Control
Speed Control
Electric start
Ignition Switch
Recoil Starter
Cutting Height
Adjustment Lever
Mulch Plug
Figure 4-1
Speed Control
Blade Control
The speed control is located on the variable speed control
housing on the upper handle. This control is used to select the
forward speed of the mower. See Fig. 4-1 inset.
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.
IMPORTANT: Move the speed control only when the engine is
running. Changing the speed control setting with the engine off
can damage the mower.
WARNING: This blade control is a safety device.
Never attempt to bypass its operations.
NOTE: The speeds noted on the speed control are not exact.
Speed will vary depending on belt wear, cable wear, and mowing
conditions.
Drive Control
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; release it to stop mower from
propelling. See Fig. 4-1.
Electric Start Ignition Switch
The electric start ignition switch is located on the right side of
the variable speed control housing on the upper handle. It is
used only for the electric starter.
Cutting Height Adjustment Lever
The cutting height adjustment lever is located above the right
rear wheel. To adjust the cutting height, refer to the “Assembly &
Set-Up” Section.
Mulch Plug
The mulch plug is used for mulching purpose. Instead of
collecting the grass clippings in the grass catcher, your mower
has the option of recirculating the clippings back to the lawn.
Make sure that the rear discharge door is closed and the grass
catcher is removed from unit while mulching.
Recoil Starter
The recoil starter is attached to the right upper handle. Stand
behind the unit and pull the recoil starter rope to start the unit.
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Operation
5
Starting Engine
WARNING: Be sure no one other than the operator
is standing near the lawn mower while starting
engine or operating mower. Never run 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
engine and lawn mower.
1.
Push primer (if equipped) three times. Wait about two
seconds between each push. In temperature around 55°F
or below, prime five times. Do not prime to restart a warm
engine.
2.
Standing behind the mower, squeeze the blade control
against upper handle. See Fig. 5-1.
3.
Electric Start: Turn ignition key to the right to start the
engine. Release the key after the engine starts. See Fig. 5-1.
Recoil Start: Grasp starter handle and pull rope out slowly
until 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.
Keeping a firm grip on the starter handle, let the rope
rewind slowly.
Figure 5-1
WARNING: If you strike a foreign object, stop the
engine. Remove wire from the spark plug,
thoroughly inspect mower for any damage, and
repair damage before restarting and operating.
Extensive vibration of mower during operation is an
indication of damage. The unit should be promptly
inspected and repaired.
Stopping Engine
1.
Release blade control to stop the engine and blade.
WARNING: Wait for the blade to stop completely
before performing any work on the mower or to
remove the grass catcher.
Using as Mulcher
For mulching grass, remove the grass catcher, insert rear mulch
plug, and remove side discharge chute from 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.
Using Your Lawn Mower
Be sure 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.
Using Grass Catcher
You can use the grass catcher to collect clippings while you are
operating the mower.
WARNING: The operation of any lawn mower can
result in foreign objects being thrown into the eyes,
which can damage your eyes severely. Always wear
safety glasses while operating the mower, or while
performing any adjustments or repairs on it.
1.
Attach grass catcher following instructions in the
“Assembly & Set-Up” section. Grass clippings will
automatically collect in bag as you run mower. Operate
mower till grass bag is full.
1.
Once the engine is running, squeeze the drive control
against the upper handle to propel mower.
2.
3.
Stop engine completely by releasing the blade control.
Make sure that the unit has come to a complete stop.
2.
To change speed, move speed control to the desired speed.
Lift discharge door and pull grass bag up and away from
the mower to remove the bag. Dispose of the grass
clippings and reinstall the bag when complete.
NOTE: When selecting a drive speed, use the first speed
until you are comfortable and familiar with the operation
of the mower.
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Maintenance & Adjustments
6
2.
3.
Lubricate the wheels and rear wheel gears at least once a
season with light oil (or motor oil). If wheels are removed
for any reason, lubricate surface of the pivot arm and inner
surface of the wheel with light oil. See Fig. 6-1.
Maintenance
General Recommendations
•
Always observe safety rules when performing any
maintenance.
Lubricate the torsion spring and pivot points on the rear
discharge door and side mulch plug periodically with light
oil to prevent rust. See Fig. 6-1.
•
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.
4.
The transmission is pre-lubricated and sealed at the factory
and does not require lubrication.
5.
Follow the accompanying engine manual for lubrication
schedule and instruction for engine lubrication.
•
•
•
Changing of engine-governed speed will void engine
warranty.
All adjustments should be checked at least once each
season.
Deck Care
Clean underside of the mower deck after each use to prevent
build-up of grass clippings or other debris. Follow steps below
for this job.
Periodically check all fasteners and make sure these are
tight.
1.
Disconnect spark plug wire. Drain gasoline from lawn
mower or place a piece of plastic under the gas cap.
WARNING: Always stop engine, disconnect spark
plug, and ground against engine before performing
any type of maintenance on your machine.
2.
Tip mower so that it rests on the housing. Keep the side
with the air cleaner facing up. Hold mower firmly.
Lubrication
WARNING: Never tip the mower more than 90º 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.
1.
Lubricate pivot points on the blade and drive controls
at least once a season with light oil. These controls must
operate freely in both directions. See Fig. 6-1.
3.
Scrape and clean the underside of the deck with a suitable
tool. Do not spray with water.
IMPORTANT: Do not use a pressure washer or garden hose
to clean your unit. These may cause damage to bearings,
or the engine. The use of water will result in shortened life
and reduce serviceability.
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.
Figure 6-1
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Engine Care
Adjustments
A list of key engine maintenance jobs required for good
performance by the mower is given below. Follow the
accompanying engine manual for a detailed list and instructions.
Variable Speed Cable
Periodic adjustment of the variable speed cable may be
necessary due to normal wear on the drive system. Adjustment is
needed if unit begins to run too slow or too fast.
•
•
Maintain oil level as instructed in engine manual.
Service 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.
1.
2.
3.
4.
Start engine and place shift lever in the third speed
position.
Stop engine, remove ignition key, and disconnect spark
plug wire and ground it against engine.
•
•
Clean spark plug and reset the gap 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.
With engine off, shift back to first speed. This will provide
slack in the cable.
Carefully remove the harness assembly from the speed
control housing by removing the three screws securing it
to the housing. See Fig. 6-3.
Clean 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 muffler
area.
Slot
Replacing Rear Flap
1.
To remove rear flap, lift rear door, remove screw, and press
flap in on either side to remove from hole. See Fig. 6-2.
Tab
Figure 6-3
Figure 6-2
2.
Remove screw and flap from opposite hole and replace
with new flap in the opposite order and manner of
removal.
14
se c t i O n 6— Ma i n t e n a n c e & ad j u s t M e n t s
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5.
Remove back cover of speed control housing by removing
the three screws securing it to the housing. See Fig. 6-4.
7.
Using a pair of needle nose pliers or similar tool, move
eyelet in cable only one slot to the left in housing as shown
in Fig. 6-5.
Figure 6-4
Figure 6-5
6.
Remove screw and flat washer securing cable. See Fig. 6-4.
NOTE: Moving eyelet to the left speeds unit up; moving it
to the right slows it down.
NOTE: Make sure to take note of which slot in housing
cable is in.
8.
Replace screw and washer removed earlier. Reassemble
back of housing. Reattach battery harness assembly to the
speed control housing, making sure to snap the tab on the
harness into the slot on the housing. See Fig. 6-3. Secure
with the three screws removed earlier.
se c t i O n 6 — Ma i n t e n a n c e & ad j u s t M e n t s
15
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Service
7
5.
Lubricate the engine crankshaft and the inner surface
Blade Care
of the blade adapter with light oil. Slide the blade
adapter (and wave washer, if applicable) 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.
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. Follow the steps
below for blade service.
6.
7.
Place blade bell support on the blade. Align notches on the
blade bell support with small holes in blade.
1.
2.
3.
Disconnect spark plug boot from spark plug. Turn mower
on its side making sure that the air filter and the carburetor
are facing up.
Replace hex bolt and tighten hex bolt to torque: 450 in. lbs.
min., 600 in. lbs. max.
To ensure safe operation of your mower, periodically check the
blade bolt for correct torque.
Remove the bolt and the blade bell support which hold the
blade and the blade adapter to the engine crankshaft. See
Fig. 7-1.
Belt Care
Remove blade and adapter from the crankshaft. See Fig.
7-1.
NOTE: Several components must be removed in order to change
the mower’s belt. See an authorized Troy-Bilt Service Dealer to
have your belt replaced.
Replacing Battery
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.
Remove the ignition key.
Blade
2.
Remove the three screws securing battery harness
assembly to the speed control housing and place them to
the side.
Blade
Adapter
3.
Carefully remove the harness assembly from the speed
control housing. See Fig. 7-2.
Blade Bell
Support
Bolt
Slot
Figure 7-1
Tab
IMPORTANT: When removing these items, a wave washer
may also come off with the adapter. Be sure to include this
washer when reassembling the blade adapter. Failure to do
so will result in the unit not being able to change speeds.
4.
Remove 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.
WARNING: An unbalanced blade will cause
excessive vibration when rotating at high speeds. It
may cause damage to mower and could break
causing personal injury.
Figure 7-2
16
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4.
Carefully remove old battery and replace with new one.
Connect the positive lead to the positive side of the battery
pack, then connect the negative side. See Fig. 7-3.
Charging Battery
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.
IMPORTANT: When replacing battery pack in harness
assembly, battery pack must be positioned with the
positive terminal to the left side and the negative terminal
to the right side of panel (Positive terminal is closest to the
key switch). See Fig. 7-3. Replacing battery pack incorrectly
will cause serious damage.
NOTE: The special designed plug on the charger will only
fit into the plug on the battery box.
1.
Plug the battery charger into the port on the underside of
the battery housing. See Fig. 7-4.
Positive
Terminal
Negative
Terminal
Key
Switch
1
2
Figure 7-3
5.
Reattach battery harness assembly to the speed control
housing, making sure to snap the tab on the harness into
the slot on the housing. See Fig. 7-2. Secure with the three
screws removed earlier.
Figure 7-4
2.
3.
Insert the battery charger plug into a standard 120 volt
household outlet. Charge 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
and after any other extended periods of non-use.
WARNING: Do not remove the battery pack from
the electric starter housing for any reason other
than replacement.
After charging, disconnect charger plug from outlet first,
then disconnect charger lead from battery.
IMPORTANT: Always plug charger lead into battery pack
lead first, and then insert battery charger plug into 120
volt standard household outlet. Follow this order of action
every time you charge the battery.
WARNING: Use only the battery charger supplied
with this mower.
se c t i O n 7 — se r v i c e
17
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Replacing Fuse
Off-Season Storage
The following steps should be taken to prepare your lawn mower
for storage.
The electric starter circuit and battery are protected by a 40
ampere fuse. If the fuse burns out, the electric starter will not
operate. If the unit fails to start with the electric starter, perform
the following steps to check the fuse inside the battery housing:
•
•
•
•
•
Clean and lubricate mower thoroughly as described in the
lubrication instructions.
1.
Open the battery cover as described in Replacing Battery.
See Fig. 7-2.
Do not use a pressure washer or garden hose to clean your
unit.
2.
Remove fuse from socket and inspect as shown in Fig. 7-5.
If it is burned out, replace with standard automotive 40
ampere fuse.
Coat mower’s cutting blade with chassis grease to prevent
rusting.
Refer to engine manual for correct engine storage
instructions.
Store 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.
Battery
The battery must be stored with a full charge. Extended storage
of a discharged battery will reduce life and capacity of the
battery.
Blown Fuse
Figure 7-5
3.
Carefully place wiring back into housing, close battery
cover, and fold upper handle back into place.
NOTE: The engine can be started manually if the fuse burns
out.
18
se c t i O n 7— se r v i c e
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Troubleshooting
8
Problem
Cause
Remedy
Engine Fails to start
1. Blade control disengaged.
1. Engage blade control.
2. Spark plug boot disconnected.
3. Fuel tank empty or stale fuel.
2. Connect wire to spark boot.
3. Fill tank with clean, fresh gasoline.
4. Engine not primed (if equipped with primer).
4. Prime engine as instructed in the Operation
section.
5. Faulty spark plug.
6. Blocked fuel line.
7. Engine flooded.
5. Clean, adjust gap, or replace.
6. Clean fuel line.
7. Wait a few minutes to restart, but do not
prime.
8. Fuel valve (if equipped) closed.
8. Open fuel valve. See engine manual.
9. Engine not choked (if equipped with choke).
9. Choke engine. See engine manual.
10. Burnt fuse. (Electric Start only)
10. Replace fuse (see Service Section).
Engine runs erratic
1. Spark plug boot loose.
1. Connect and tighten spark plug boot.
2. Blocked fuel line or stale fuel.
2. Clean fuel line; fill tank with clean, fresh
gasoline.
3. Vent in gas cap plugged.
4. Water or dirt in fuel system.
5. Dirty air cleaner.
3. Clear vent.
4. Drain fuel tank. Refill with fresh fuel.
5. Refer to engine manual.
6. Push CHOKE knob in.
6. Unit running with CHOKE (if equipped)
applied.
Engine overheats
1. Engine oil level low.
2. Air flow restricted.
1. Fill crankcase with proper oil.
2. Clean area around and on top of engine.
1. Adjust gap to .030”.
Occasional skips
(hesitates) at
high speed
1. Spark plug gap too close.
Idles poorly
1. Spark plug fouled, faulty, or gap too wide.
2. Dirty air cleaner.
1. Reset gap to .030” or replace spark plug.
2. Refer to engine manual.
Excessive Vibration
1. Cutting blade loose or unbalanced.
2. Bent cutting blade.
1. Tighten blade and adapter. Balance blade.
2. See an authorized service dealer.
Mower will not
mulch grass
1. Wet grass.
1. Do not mow when grass is wet; wait until
later to cut.
2. Excessively high grass.
2. Mow once at a high cutting height, then
mow again at desired height or make a
narrower cutting path.
3. Dull blade.
3. Sharpen or replace blade.
Continued on next page
19
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Troubleshooting
8
Problem
Cause
Remedy
Uneven cut
1. Wheels not positioned correctly.
1. Place all four wheels in same height position
(if equipped with individual height adjusters).
2. Dull blade.
2. Sharpen or replace blade.
Mower will not self propel
1. Belt not installed properly.
1. Check belt for proper pulley installation and
movement.
2. Debris clogging drive operation.
3. Damaged or worn belt.
2. Stop engine, disconnect spark plug boot,
and clean out debris.
3. Inspect and replace belt.
20
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Notes
9
21
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Model Series J860
57
15
3
59
5
58
49
39
60
61
23
46
46
1
19
52
17
4
22
46
51
18
56
46
21
37
2
48
6
20
47
50
14
43
38
41
31
7
36
8
42
B
44
55
10
28
54
53
A
A
34
11
35
12
10
30
9
25
B
30
40
25
26
10
33
32
16
27
29
13
26
45
24
10
22
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Model Series J860
Ref
No.
Ref
No.
Part Number
Description
Part Number
Description
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
720-04072
732-04534
711- 04374
647-04051
664-04045
710 -1174
Star Knob
1
746-04515
735-04059
687-02417
732-04516
747-04917A
746-04465
749-04435
725-0157
Drive Cable
Torsion Spring, RH
Door Pivot Rod
2
Rubber Grommet
Drive Control
3
Grass Catcher Frame
Grass Catcher
4
Shift Spring
5
Blade Control
Carriage Bolt, 5/16-18 x 2.00
Wing Nut
6
Control Cable
720-0279
710-1205
749-04436
736-0270
732-1014
7
Lower Handle
Eye Bolt
8
Cable Tie
Upper Handle
9
732-04535
710-0599
Torsion Spring, LH
TT Screw, 1/4-20 x .500
21-inch Deck
Bell Washer, .265 x .75 x .062
Torsion Spring
10
11
12
13
14
15
16
17
18
19
20
21
22
787-01618
710-0654A
787-01346
731-06304
731-06305
710-0779A
736-0451
736-0329
712-04064
710-0606
631-04276
747-04718
747-04719
746-04439
731-06173
710-3025
17032A
Chute Deflector Adapter
Hinge Pin
TT Screw, 3/8-16 x 1.00
Front Deck Baffle
Variable Speed Cont. Panel Cover
Variable Speed Cont. Panel Cover
Screw, #10-16 x .500
Saddle Washer
747-0710
687-02055
731-04177
710-04373A
728-0199
731-06189
731-06193
715-04073
736-0275
736-3000
714-0104
712-0397
710-0703
710-0895
725-04329
625-04050
725-04323
725-0201
725-04347
Mulch Plug Assembly
Side Discharge Chute
Screw, #12-16 x .75
Rivet, Plastic
4 Speed Actuator
Speed Selector Level
Dowel Pin
Washer, Lock, 1/4
Nut, Flange Lock, 1/4-20
Screw, 1/4-20 x 1.50
Variable Speed Control Panel
Bail Pivot Rod - RH
Bail Pivot Rod - LH
Variable Speed Cable
Rear Baffle
Washer, Flat, .344 x .688 x .065
Washer, Flat, .250 x .750 x .119
Cotter Pin
Wing Nut
23
24
25
26
27
28
29
30
Carriage Bolt, 1/4-20
Screw, 1/4-15 x .750
Battery Charger
Harness Assembly
Battery, 12V
Screw, 5/16-18 x .625
Flange Lock Nut, 5/16-18
Trailshield
712-04063
731-05462A
731-05157
731-05017A
710-1241
Mulch Plug
Ignition Key
Rear Door
Key Switch
Screw, 1/4-15 x 1.00
23
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Model Series J860
4
5
49
3
2
51
7
21
47
26
27
6
28
50
5
40
30
10
1
48
18
17
10
29
46
9
43
42
19
8
A
11
9
15
16
44
A
14
12
39
12
38
37
12
20
13
45
28
12
24
22
41
32
36
34
23
25
35
31
33
24
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Model Series J860
Ref
No.
Ref
No.
Part Number
Description
Part Number
Description
27
28
29
715-0221
618-04581
687-02429
Dowel Pin
1
754-04176
732-04480A
720-04092
717-04452
738-04278
710-04762
749-04414
687-02367
731-05470
741-04136B
734-04014B
712-04065
634-04404
710-04770
717-04457
717-04575
731-06145
741-0604A
787-01645
731-06146
687-02390
732-04482
756-04316
736-0406
756-04317
687-02428
V-Belt
Transmission Assembly
Handle Bracket Assembly RH
(Includes Ref. #’s 18, 46, & 47)
Pulley, Half
2
Spring Lever
3
Height Adjuster Knob
Spur Gear, 16T - LH
Shldr. Screw, 1/4-20 x 0.50
Screw, #12-16
4
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
756 - 04311A
732-04313
748-04096
710-1044
5
Extension Spring
6
Blade Adapter
7
Cross Bracket
Screw, 3/8-24 x 1.50
8
Front Bracket Assembly
Clip Spacer
736-0524B
742-0741
Blade Bell Support
9
21” Mulching Blade
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Split Hex Flange Bearing
Front Wheel
736-0447
710-0599
731- 06112
656-04046
710-0653
710-04774
736-0504
736-3068
711- 04822A
731-06284
748-04177
732-0708
736-3012A
750-05029
750-05031
736-0314
Washer, Wave, 1.5 x 1.0 x .029
TT Screw, 1/4-20 x .500
Engine Baffle
Flange Lock Nut, 3/8-16
Rear Wheel
Lower Pulley Assembly
Screw, TT, 1/4-20 x .375
Screw, 1/4-15 x 1.25
Screw, 1/4-20 x .39
Spur Gear, 16T - RH
Gear, Spur, 23T
Washer, Wave, .510 x .750 x .017
Washer, Flat, .531 x .875 x .060
Shf., .500 Dia. X 2.456
Baffle
Wheel Dust Cover
Bearing Sleeve
Dust Cover Seal Plate
Hub Cap
Bearing Support
Rear Bracket Assembly
Compression Spring
Upper Pulley
Bearing Retainer
Washer, Wave, .390 x .625 x .016
Spacer, .499 x .685 x .380
Spacer, .499 x .860 x .380
Washer, Thrust, .375 x .70 x .030
Flat Washer, .442 x 1.38 x .060
Lower Pulley
Handle Bracket Assembly LH
(Includes Ref. #’s 18, 46, & 47)
25
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Notes
26
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nO t e s
27
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MANUFACTURER’S LIMITED WARRANTY FOR
The limited warranty set forth below is given by Troy-Bilt LLC with
c. 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.
respect to new merchandise purchased and used in the United States
and/or its territories and possessions, and by MTD Products Limited
with respect to new merchandise purchased and used in Canada
and/or its territories and possessions (either entity respectively,
“Troy-Bilt”).
d. Service completed by someone other than an authorized service
dealer.
“Troy-Bilt” warrants this product (excluding its Normal Wear Parts
and Attachments as described below) against defects in material and
workmanship 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 Operator’s 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 part, accessory or attachment not approved by Troy-Bilt
for use with the product(s) covered by this manual will void your
warranty as to any resulting damage.
e. Troy-Bilt does not extend any warranty for products sold or
exported outside of the United States and/or Canada, and their
respective possessions and territories, except those sold through
Troy-Bilt’s authorized channels of export distribution.
f. Replacement parts that are not genuine Troy-Bilt parts.
g. Transportation charges and service calls.
h. Troy-Bilt does not warrant this product for commercial use.
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. During the period of the warranty, the exclusive
remedy is repair or replacement of the product as set forth above.
Normal Wear Parts are warranted to be free from defects in material
and workmanship for a period of thirty (30) days from the date of
purchase. Normal wear parts include, but are not limited to items
such as: batteries, belts, blades, blade adapters, tines, grass bags,
wheels, rider deck wheels, seats, snow thrower skid shoes, friction
wheels, 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 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.
Attachments — Troy-Bilt warrants attachments for this product
against defects in material and workmanship for a period of one (1)
year, commencing on the date of the attachment’s original purchase
or lease. Attachments include, but are not limited to items such as:
grass collectors and mulch kits.
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.
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:
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.
In the U.S.A.
Check your Yellow Pages, or contact Troy-Bilt LLC at P.O. Box 361131,
Cleveland, Ohio 44136-0019, or call 1-866-840-6483,
In Canada
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.
Contact MTD Products Limited, Kitchener, ON N2G 4J1, or call 1-800-
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.
This limited warranty does not provide coverage in the following
cases:
a. The engine or component parts thereof. These items may carry a
separate manufacturer’s warranty. Refer to applicable manufactur-
er’s warranty for terms and conditions.
IMPORTANT: Owner must present Original Proof of Purchase to
obtain warranty coverage.
b. Log splitter pumps, valves, and cylinders have a separate one-
year warranty.
Troy-Bilt LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019; Phone: 1-866-840-6483, 1-330-558-7220
MTD Canada Limited - KITCHENER, ON N2G 4J1; Phone 1-800-668-1238
GDOC-100020 REV. A
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