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Safe Operation Practices • Set-Up • Operation • Maintenance • Service • Troubleshooting • Warranty
Otreap Or ’s Mlauna
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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To The Owner 1 Thank You Thank you for purchasing a Lawn Mower manufactured by This product has met the rigid safety standards of the Outdoor Troy-Bilt LLC. It was carefully engineered to provide excellent Power Equipment Institute and an independent testing performance when properly operated and maintained. laboratory. If you have any problems or questions concerning the machine, phone a authorized Troy-Bilt service dealer or contact Please read this entire manual prior to operating the eq
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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! CALIf ORNIA PROPOs ITION 65 WARNING: Engine Exhaust, some of its constituents, and certain
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12. A missing or damaged discharge cover can cause blade 27. When starting engine, pull cord slowly until resistance contact or thrown object injuries. is felt, then pull rapidly. Rapid retraction of starter cord (kickback) will pull hand and arm toward engine faster than 13. Many injuries occur as a result of the mower being pulled you can let go. Broken bones, fractures, bruises or sprains over the foot during a fall caused by slipping or tripping. could result. Do not hold on to the mow
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3. Check the blade and engine mounting bolts at frequent Service intervals for proper tightness. Also, visually inspect blade for damage (e.g., bent, cracked, worn) Replace blade with Safe Handling Of Gasoline: the original equipment manufacture’s (O.E.M.) blade only, 1. To avoid personal injury or property damage use extreme listed in this manual. “Use of parts which do not meet the care in handling gasoline. Gasoline is extremely flammable original equipment specifications may lead to i
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Spark Arrestor Average Useful Life According to the Consumer Products Safety Commission WARNING: This machine is equipped with an (CPSC) and the U.S. Environmental Protection Agency (EPA), internal combustion engine and should not be used this product has an Average Useful Life of seven (7) years, or 140 on or near any unimproved forest-covered, brush hours of operation. At the end of the Average Useful Life, buy covered or grass-covered land unless the engine’s a new machine or have the
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Fold along dotted line (represents a 15° slope) Sight and hold this level with a vertical tree... or a corner of a building... or a fence post 15° Use this page as a guide to determine slopes where you may not operate safely. WARNING: Do not operate your lawn mower on such slopes. Do not mow on inclines with a slope in excess of 15 degrees (a rise of approximately 2-1/2 feet every 10 feet). A riding mower could overturn and cause serious injury. Operate riding mowers up and down slopes, neve
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Assembly & Set-Up 3 Contents of Carton • One Lawn Mower • One Lawn Mower Operator’s Manual • One Bottle of Oil • One Grass Catcher • One Engine Operator’s Manual • One Hardware Pack • One Side Discharge Chute 2. Locate the hairpin clip on the weld pin on each side of Assembly lower handle. NOTE: This unit is shipped without gasoline or oil in the engine. a. Remove hairpin clip from this hole. Using a pair of Fill up gasoline and oil as instructed in the accompanying engine pliers, insert hai
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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. Figure 3-5 d. Tighten wing nut. Grass Catcher 3. Follow the steps below to attach the grass catcher: 1. Follow steps below to assembl
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Side Discharge Chute Adjustments To convert to side discharge, make sure grass catcher is off of the Cutting Height unit and rear discharge door is closed. The cutting height adjustment lever is located above the rear 1. On the side of the mower, lift the mulching plug. See Fig. right wheel. 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 und
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Controls and Features 4 Drive Control Blade Control Speed Control Electric star t 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 The blade control is attached to the upper handle of the mower. housing on the upper handle. This control is used to select the Depress and squeeze it against the upper handle to operate the forward speed of the mower. See Fig. 4-1 inset. u
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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
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Maintenance & Adjustments 6 2. Lubricate the wheels and rear wheel gears at least once a Maintenance season with light oil (or motor oil). If wheels are removed for any reason, lubricate surface of the pivot arm and inner General Recommendations surface of the wheel with light oil. See Fig. 6-1. • Always observe safety rules when performing any 3. Lubricate the torsion spring and pivot points on the rear maintenance. discharge door and side mulch plug periodically with light • The warranty
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Engine Care Adjustments A list of key engine maintenance jobs required for good Variable Speed Cable performance by the mower is given below. Follow the accompanying engine manual for a detailed list and instructions. Periodic adjustment of the variable speed cable may be necessary due to normal wear on the drive system. Adjustment is • Maintain oil level as instructed in engine manual. needed if unit begins to run too slow or too fast. • Service air cleaner every 25 hours under normal condi
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5. Remove back cover of speed control housing by removing 7. Using a pair of needle nose pliers or similar tool, move the three screws securing it to the housing. See Fig. 6-4. 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 NOTE: Make sure to take note of which slot in housing to the right slows it down. cable is in. 8. Repl
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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 WARNING: When removing the cutting blade for adapter (and wave washer, if applicable) onto the engine sharpening or replacement, protect your hands with crankshaft. Place the blade on the adapter such that the side of the blade marked “Bottom” (or with part number) a pair of heavy gloves or use a heavy rag to hold the faces the ground when the mower is in the o
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4. Carefully remove old battery and replace with new one. Charging Battery Connect the positive lead to the positive side of the battery pack, then connect the negative side. See Fig. 7-3. WARNING: The battery contains corrosive fluid and toxic material; handle with care and keep away IMPORTANT: When replacing battery pack in harness from children. Do not puncture, disassemble, assembly, battery pack must be positioned with the mutilate or incinerate the battery. Explosive gases positive
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Replacing Fuse Off-Season Storage The electric starter circuit and battery are protected by a 40 The following steps should be taken to prepare your lawn mower ampere fuse. If the fuse burns out, the electric starter will not for storage. operate. If the unit fails to start with the electric starter, perform • Clean and lubricate mower thoroughly as described in the the following steps to check the fuse inside the battery housing: lubrication instructions. 1. Open the battery cover as describ
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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. 2. Connect wire to spark boot. 3. Fuel tank empty or stale fuel. 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. 5. Clean, adjust gap, or replace. 6. Blocked fuel line. 6. Clean fuel line. 7. Engine flooded. 7. Wait a few minutes to
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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. 2. Stop engine, disconnect spark plug boot, and clean out debris. 3. Damaged or worn belt. 3. Inspect and replace b
