MTD 830, 860 User Manual
For Discount White Outdoor Parts Call 606-678-9623 or 606-561-4983
Shop Handbook
NOTE: These materials are for use by trained technicians who are experienced in the service and repair of outdoor power
equipment of the kind described in this publication, and are not intended for use by untrained or inexperienced individuals.
These materials are intended to provid e su pp lem ental information to assist the trained technician. Untrained or inexperienced individuals should seek the assistance of an experienced and tr ained professional. Read, understand, a nd follow all
instructions and use common sense when working on power equipment. This includes the contents of the product’s Operators Manual, supplied with the equipment. No liability can be accepted for any inaccuracies or omission in this publication,
although care has been taken to make it as complete a nd accura te as possib le at the time of publica tion. However, due to
the variety of outdoor power equipment and continuing product changes that occur over time, updates will be made to these
instructions from time to time. Therefore, it may be necessary to obtain the latest materials before servicing or repairing a
product. The company reserves the right to make changes at any time to this publication without prior notice and without
incurring an obligation to make such changes to previously published versions. Instructions, photographs and illustrations
used in this publication are for reference use only and may not depict actual model and component parts.
© Copyright 2006 MTD Products Inc. All Rights Reserved
MTD Products Inc - Product Training and Education Department
www.mymowerparts.com
830-860 Series mowers
FORM NUMBER - 769-03727
12/2007
For Discount White Outdoor Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com
For Discount White Outdoor Parts Call 606-678-9623 or 606-561-4983
Chapter 1: Introduction ......................................................................................................1
830 series ............................................................................................................................ 1
860 series ............................................................................................................................2
Chapter 2: Front wheels and axle ...................................................................................... 3
Front wheels ........................................................................................................................3
Front axle............................................................................................................................ 3
Chapter 3: Cutting blade .................................................................................................... 5
Chapter 4: Drive belt and baffles .......................................................................................7
Chapter 5: Speed control system ......................................................................................10
How the speed control works............................................................................................ 10
Speed control cable and lever.......................................................................................... 11
Clutch cable replacement ..................................................................................................14
Chapter 6: Transmission and rear wheels .......................................................................16
Transmission replacement ................................................................................................ 16
Low wheel mower ............................................................................................................ 16
Large-wheel mowers......................................................................................................... 21
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830-860 SERIES SELF-PROPELLED MOWERS
CHAPTER 1: INTRODUCTION
The 830 and 860 Series lawn mowers are rear-wheel
drive self-propelled mowers with a unique variable
ground speed feature. They are both capa ble of mulching, bagging or side-discharging grass clippings . Both
mowers have a 21” (53cm) cutting swath.
NOTE: This manual was prepared using preproduction mowers. The information contained
in the manual is true at the time of writing, but
the equipment may change without notice .
NOTE: This manual is intended to help professional technicians become acquainted with
newly introduced equipment, so that they can do
their jobs faster, better, and more easily.
If the user of this manual lacks tools or expertise
necessary to safely perform the tasks described,
they should seek the assistance of a trained professional.
NOTE: As should be standard operating procedure for any professional, test the operation of
the mower after any repair work, before returning it to service.
CAUTION: Disconnect and ground the s park
plug wire whenever there is a risk of injury from
rotating parts. Working on the cutting blade or
drive system are two examples of situations that
could place a technician at risk.
CAUTION: Take measures to avoid the creation
of a fire hazard when working around equipment
that would normal contain fuel:
830 series
The 830 series is identified by and eleven digit model
number, e.g.: 12A-83X
“12” indicates that it is a self-propelled mower,
“A” identifies the first generation of the model series.
“A” may be followed by an engine identifier.
The “X”s will be style and retailer identifiers. Engines
from different manufacturers may be used on different
models. The models depicted here are in Troy- B ilt livery, but similar models may be produced in different
lines and for different retailers. See Figure 1.1.
-XXX.
Figure 1.1
• Drain and store fuel in safe containers.
• Clean any fuel spills immediately.
• Avoid exposing fuel to heat sources or open
flame.
NOTE: Replace any worn or damaged fasteners. If a lock washer or bellville washer has lost
its tension, replace it. If the locking feature of a
self-locking nut has worn, replace the nut, or
install it using releasable thread-locking com-
pound such as Loctite
TM
242 (blue).
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830-860 SERIES SELF-PROPELLED MOWERS
860 series
The 860 series is very similar to the 830 Series except
for large rear wheels and some engineering dif ferences
that are necessary to accommodate the large rear
wheels. See Figure 1.2.
Figure 1.2
Differences include:
• Lower handlebars are longer on the 860 Series
than they are on the 830 Series.
• The single-point height adjust lever is on the lefthand side on the 830 Series, but it is on the
rig ht-h and-side on the 860 Series.
• The handlebar brackets are different between
the two models.
• The 860 Series has different final-drive gears,
including an idler gear between the transmission
axle and the ring gear in the rear wheel.
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830-860 SERIES SELF-PROPELLED MOWERS
CHAPTER 2: FRONT WHEELS AND AXLE
Front wheels
The front wheels fit over the ends of the axle, and are
held to the axle by nuts. See Figure 2.1.
nut
Figure 2.1
To remove the front wheels:
1. Loosen the wheel nuts using a 9/16” wrench.
2. Tilt the mower up so that the weight of the
mower is not resting on the front wheels.
3. Remove the nuts, and pull the front wheels off of
the mower. See Figure 2.2.
Front axle
To remove the front axle:
1. Remove the front wheels.
2. Set the height adjuster lever to the highest position, relieving the load on the lift-assist torsion
spring on the front axle . See Figure 2.3.
Torsion spring
Figure 2.3
3. Remove the shoulder screw that holds the
height adjuster connecting link to the front axle.
Use a 3/8” wrench. See Figure 2.4.
Wheel removed
Figure 2.2
4. When reinstalling the front wheels, tighten the
nuts to a torque of 12 ft.-lb.(166.3 N-m).
Shoulder screw
Height adjuster
connecting link
Figure 2.4
CAUTION: The torsion spring on the front axle
will be under tension, even in the highest cutting
position.
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830-860 SERIES SELF-PROPELLED MOWERS
4. Just inside of the deck shell, near each end of
the axle is a white plastic “C” clip. Remove both
“C” clips. See Figure 2.5.
C clip
Front axle
Flanged hex bushing
Figure 2.5
5. The “C” clips hold flanged hex bushings into keyhole slots in the deck shell. Slide the hex bushings in to release them from the deck shell.
See Figure 2.6.
6. As the flanged hex bushings are released from
the deck shell, the axle will come free of the
shell. Maneuver the front axle to unhook the to rsion spring from the deck shell. See Figure 2.7.
Torsion
spring
Figure 2.7
7. The torsion spring is captive on the front axle. If
either is damaged, both must be replaced.
See Figure 2.8.
Flanged hex bushing
Figure 2.6
Front axle weldment
Torsion spring
Figure 2.8
8. Reinstall the front axle by reversing the steps
used to remove it.
• Replace the “C” clips if they have lost their tension.
• Replace the flanged hex bushings if they are
worn.
• Do not trim the flanged hex bushings to ease
installation. They should be tight.
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830-860 SERIES SELF-PROPELLED MOWERS
CHAPTER 3: CUTTING BLADE
To remove the cutting blade:
1. Disconnect and ground the spark plug wire.
2. If the level of gasoline in the fuel tank is great
enough that it will spill if the mower is tipped,
remove the fuel filler cap, place a plastic bag
over the neck of the fuel tank, and reinstall the
cap.
3. Tip the mower with the muffler side down, or tilt
the mower back on a work bench, with the front
wheels up. See Figure 3.1.
Blade
Bolt
Belville spring
6. Lift away the blade. See Figure 3.2.
Blade adaptor
Figure 3.2
7. Inspect the blade. If it is bent or worn beyond
proper sharpening, replace it with a new blade.
8. Sharpen and balance the blade if it is not badly
worn.
Figure 3.1
4. Block the blade form rotating using a block of
wood or a blade holder tool.
5. Remove the blade bolt and diamond-shaped
bellville blade spring using a 5/8” wrench.
NOTE: The 830 and 860 Series mowers have a
3-in-1 blade. The outer part of the leading edge
cuts the grass. A wing behind it lift s the grass for
the next blade and propels clippings toward the
bag or side discharge chute if the path to either
is open. A stepped-up cutting edge just in-board
of the outer cutting edge mulches clippings as
they fall, if the side discharge chute is closed
and the mulch plug is in place.
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