Troybilt 909J, 12A-909J063 Owner’s Manual

TRnV BILT

Operator's Manual

909J--Tuff-Cut e

Model

IMPORTANT:READ SAFETY RULES AND INSTRUCTIONS CAREFULLY

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 by contacting the service department at Troy-Bilt LLC, P.O. Box 361131 Cleveland, Ohio 44136-0019.

TROY-BILT LLC, P.O. BOX 361131, CLEVELAND, OH 44136-0019

PRINTED IN USA FORM NO. 770-10601A

(01/2002)

TABLE OF CONTENTS

Content Page

Calling Customer Support .................................................... 2

Safety ................................................................... 3

Assembly................................................................. 6

Features and Controls ....................................................... 8

Operation ................................................................ 10

Maintenance .............................................................. 15

Parts List................................................................. 22

Warrany Information ........................................................ Back Cover

FINDING MODEL NUMBER

This Operator's Manual is an important part of your new Mower. It will help you assemble, prepare and maintain the
unit for best performance. Please read and understand what it says.

Before you start assembling your new equipment, please locate the model plate on the equipment and copy the infor-
mation from it in the space provided below. This information is very important if you need help from our Customer
Support Department or an authorized dealer.

You can locate the model number by looking at the rear surface of the cutting deck. A sample model plate is
explained below. For future reference, please copy the model number and the serial number of the equipment

in the space below

Copy Model Number Here

O BILT. TROY-BILT LL(

www.troybilt.com CLEVELAND, OH 44136

• 866-840-5483

P. O. BOX 361131

330-558-7220

Copy Serial Number Here

ENGINEINFORMATION

The engine manufacturer is responsible for all engine-related issues with regards to performance, power-rating, speci-
fications, warranty and service. Please refer to the engine manufacturer's Owner's/Operator's Manual packed sepa-

rately with your unit for more information.

CALLINGCUSTOMERSUPPORT

If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenance
of this unit, please call the Customer Support Department.

your unit's model number and serial number ready when you call. See previous section to locate this infor-

Call 1- [phone] or 1- [phone] to reach a Customer Support representative. Please have
mation. You wilt be asked to enter the serial number in order to process your call.

2

Safety

SafetyAlert Symbol

This machine meets voluntary safety standard B71.1 -
1998, which is sponsored by the Outdoor Power
Equipment Institute, Inc.,andis published bythe American

National StandardsInstitute.

,_ This is a safety alertsymbol. It is used in this

safety messagescould result in personal injury or property
damage.

I. GENERALOPERATION

1. Read,understandand follow all

2. Do not put handsor feet nearor

3. Onlyallow responsible individuals,

4. Clearthe area of objects such as

5. Be surethe area isclear of other

6. Do not operatethe mower when 14.

7. Do not pull mower backwards unless

8. Do not operatemower without all

manualand on the unit to alert you to potential
hazards. Whenyou seethis symbol, readand

obey the messagethat follows it. Failureto obey

SafeOperationPracticesfor Walk-BehindMowers

Thiscuttingmachineis capableofamputatinghandsandfeet andthrowingobjects.

Failureto observethefollowingsafetyinstructionscouldresultinseriousinjuryordeath.

instructions on the machineand in
the manuals providedwith the unit.

Bethoroughly familiar with the 10.
controls andthe proper use of the

mower beforestarting. 11.

under rotating parts. Keepclear of
the mower bladeand discharge
opening at all times. 12.

who are familiar with the instruc-
tions, to operatethe mower.

rocks, toys, wire, bones, sticks, etc.,
which could be picked up and thrown
by the blade.

people before mowing. Stop mower if
anyoneenters thearea. Keep

bystanders at least 25 feetaway from 13.
the areaof operation.

barefoot or wearing open sandals.
Alwayswear substantial foot wear. 15.

absolutely necessary.Look down and
behind beforeandwhile moving
backwards. 16.

guards in placeand eitherthe entire 17.
Grass Catcher,the Mulching Plug or
the optional Side-DischargeChute

installed. ROTATINGBLADES-- Do
not open discharge guard while

engine is running.

.

Referto providedinstructions for 18.
proper operation andaccessory

installation. Useonly accessories
approved by GardenWay Inc. 19.
Shut off engine when crossing gravel

drives, walks, or roads. 20.
Stop engineand disconnectspark

plug wirefrom spark plug whenever
you leaveunit,beforecleaningmower
or uncloggingchute.

Shut the engine off andwait until the

bladecomesto a completestop

beforeinstalling or removingthe

Mulching Plug,optional Side-

DischargeChuteor the Grass
Catcher. Makecertain that an attach-

ment is installed before operatingthe

mower. Emptythe GrassCatcher
after eachuse- decomposing debris

could generateenough heatto catch
fire.

Mow only in daylight or ingood arti-
ficial light.

Do not operatemower while under
the influenceof alcohol or drugs.

Neveroperatemower in wet grass.
Always besure ofyour footing; keep

a firm hold onthe handleand walk;

neverrun.

Besure WheelDriveBailisdisen-
gaged beforestarting engine.

If the unit should start to vibrate
abnormally, stop the engineand dis-

connect the spark plug wire. Then
check immediately for the cause.
Vibration is generallyawarning of

trouble.

IMPORTANT

• lL WARNING

The engine exhaust from this product contains
chemicals known to the State of California to cause

cancer, birth defects or other reproductive harm.

Werecommend that you wear safety
gogglesor safety glasses when
operatingthe mower.

Watchfor traffic when operating
near,or whencrossing roadways.

Neverattempt to carry children or
other passengersonthe mower.
Theycould fall off and beseriously
injured, or they could interfere with
thesafe operation of the mower.

21.

Checkthe operation of the Operator
PresenceControl Bail (top bail,
mounted on handlebar) beforeeach
use.The OperatorPresenceControl
Bail is a safety devicethat is designed

to stopthe mower blade within three

secondsafter releasingthe bail. The
bail must operate freely when pulled
backagainst the handlebarand
return automatically to the disen-
gaged positionwhen released.If the
engine runs longer than three
secondsafter releasingthe bail, the
system is not working properly.
Immediately contact an authorized
servicedealeror the Factory
TechnicalServiceDepartmentfor

instructions. Donot usethe mower
until the mechanismis repaired.

22.

Neverrun the enginein an enclosed
area.Engineexhaustcontains carbon
monoxide,a deadlygasthat is

odorless,colorless andtasteless.
Alwaysrun the engine outdoors and

makesure there isadequate
ventilation.

Section1: Safety

II. OPERATING ON A SLOPE
Slopesare a majorfactorrelated to slip

and fail accidentswhichcanresultin
severeinjury. All slopesrequireextra

caution,if youfeel uneasyonaslope,
do notmow it.

DO:

Mow across thefaceof slopes;never
up anddown. Exerciseextreme

caution whenchanging direction on
slopes. Avoid slopesgreater than 15o.

Removeobjects such as rocks, tree
limbs, etc.

Watch for holes, ruts, or bumps. Tall
grass can hide obstacles.

DONOT:

Donot mow near drop-offs, ditches,
or embankments.Theoperator could

loosefooting or balance.

Donot mow excessivelysteep slopes.
Donot mow on wet grass. Reduced

footing could causeslipping.

III. CHILDREN

Tragic accidentscanoccurif the
operatoris notalert tothe presenceof
children.Childrenare oftenattractedto

the mowerandto the mowingactivity.

Neverassumethat childrenwill remain

whereyou lastsawthem.

1. Keepchildren out of the mowing area
and underthe watchful careof a

responsible adult.

2. Bealert and turn mower off if
children enter thearea.

3. Beforeand while moving backwards,
look behindand downfor small

children.

4. Neverallow children to operatethe 7.

mower.

5. Useextra carewhen approaching
blind corners, shrubs, trees, or other

objects that may obscure vision. 8.

IV.SERVICE

1. Useextra carein handling gasoline 9.

and other fuels. Theyare flammable
and their vapors areexplosive.

a) Useonly an approvedcontainer.

b) Neverremove gascapor add fuel

when theengine is running.
Allow engine to cool before

refueling. Do not smoke. 10.

c) Neverrefuelthe machine

indoors.

d) Neverstore the machine or fuel

container insidewhere there is an
open flame, such asa water 12.

heater,etc.

e) Move mower away from any

gasolinefumes beforestarting
the engine. 13.

2. Neverrun an engine

a_a.

3.

Nevermakeadjustments or repairs

with the engine running. Disconnect
the spark plug wire and movethe
wire awayfrom the plug to prevent
accidentalstarting.

.

Keepall nuts and screws, especially

the bladeattachment bolts, tight and

keepequipment in good condition.

.

Nevertamper with safety devices.

Checktheir operation regularly.

6.

Keepmower free of grass, leavesor

other debris build-up. Cleanup oil or
fuel spillage. Allow mowerto cool

beforestoring.

insidea closed

After striking anobject, stop the

engineand disconnectthe spark plug
wire. Inspect the mower and repair, if

necessary,before restarting.
Neverattempt to make mower cutting

height adjustmentswhile the engine
is running.

Grasscatchercomponents are
subject to wear, damageand deterio-

ration, which could expose moving
parts or allow objects to bethrown.

Frequentlycheck components and
replacewith factory recommended

parts,when necessary.
Themower bladeis sharp and can

cut. Wrapthe bladeor wear gloves,
and useextra caution when servicing.

11.

Do notchangethe engine governor
setting or overspeedthe engine.

Do nottouch engine parts which may
be hot from operation.Allow partsto
cool completely before inspecting,
cleaningor repairingthe mower.

Maintain or replacesafetyand
instructional decals. Refertothe

Parts List for replacementdecal
information.

Section1: Safety

SAFETY DECALS

Foryour safety andthe safety of others,various safetydecals are located on your unit (below - sizenot to scale).
Keepthe decalscleanand legibleat all times. Contactyour localservice dealeror the Factoryfor replacementsif any decalsare

damagedor missing. Referto the PartsList pagesinthis Manualfor decal part numbers.

Locatedonthebelt
cover. Thisdecal

providesa list of

warningsto help avoid

seriousinjury.

Locatedonthedischargeoutletguard. Thisdecalwarns
nottooperatethemowerwithoMthedischargeoutlet

guardinplaceandeithertheGrassCatcherorMulching
Pluginstalled.Thisdecalalsowarnsthatthereare
rotatingblades.Donotopenthedischargeoutletguard
whiletheengineis running.

Locatedontheleftsideofthe
mowerdeck. Thisdecalcautions

tokeephandsaway.

Before operating your machine,
carefully read and understand all

safety, controls and operating instruc-
tions in this Manual, the separate

Engine Owner's Manual, and on the
decals onthemachine.

Failure to follow these instructionscan
resultin seriouspersonalinjury.

INTRODUCTION

This Sectioncovers unboxing and assem-
bling your newmower. Pleasecarefully
read allthe instructions beforeyou

attempt to assemble the mower. After
you finish assembling the mower, read

Section 1: Safety,Section3: Featuresand

Controls,and Section4: Operation,before

using the mower.

INSPECTION

Inspectthe mower immediately after

delivery. Makesurethat neitherthe
carton nor the contents have been

damaged.

If you find orsuspectany damage,
contact the carrier (trucking company)
right away. Inform them ofthe specific
damageandthat you wish to file a claim.
To protect your rights, be sureto put this
in writing to the carrierwithin 15days
after your machinearrives. The carrier
will let you know how to proceed with
your claim.

LOOSE PARTS

Thefollowing items areshipped loose
within the container.

NOTE: Themower is
shipped with the

Mulching Plug
(B, Figure2-2)

installed in the
discharge outlet

(Figure 2-1).
,, The Grass

Catcherattachmer

(A,Figure 2-2).

A B

Figure2-2: Attachments

ASSEMBLING NEW UNITS

Themower bladeis sharpand can cause
serious personalinjury. When working

near the mower blade, wear heavy
leather gloves to protectyourself from

thesharp edges.

IMPORTANT:The mower isshipped

without motor oil inthe enginecrankcase.
Add motor oil to the engine before

starting. Follow instructionsin this
Section.

Step 1: Unpack Mower

1. The mower comesfullyassembled

with the handlebarsfolded compactly for
shipment. Removethe mowerfrom the

shipping container.

2. Thecontrol bails (P,Figure2-6) are
securedto the handlebar(Q) with a cable

tie. Cutthe cable tie off and removethe
protective packingmaterial.

3. Followsteps 2 through 8to complete
mower assembly.

Step 2: Unfold Handlebar Assembly

1. Loosenthe two lower handlebar

adjustment knobs (1, Figure 2-5).

2. Carefullyunfold lower section ofthe
handlebarassembly (2, Figure2-5).
Watchthe cableswhile unfolding and

makesure that they do not pinch, kink, or
over-stretch while unfolding.

3. Tighten thetwo lower handlebar
adjustment knobsjust enoughto allow

thetwo handlebarstruts (H, Figure 2-3)
to move in and out slightly.

4. Insertthe tab (F, Figure 2-3) on each
handlebarstrut into the slot (G) one each
side ofthe deck. Becertain to routethe
cables insidethe left sidestrut asshown

in Figure2-4.

5. Tighten both lower handlebaradjust-
ment knobssecurely.

6. Loosenthe two upper handlebar

adjustment knobs (3, Figure2-5).

7. Unfold the upper handlebarassembly
(4, Figure2-5) and align with the lower

handlebarassembly. Besure not to
pinch, kink, or over-stretch the cables

while unfolding.

8. Tighten both upper handlebaradjust-
ment knobssecurely.

9. Checkthe starter rope. Makesure

that it doesnot catch under thetop

handlebaradjustment knob (I, Figure
2-6). Thestarter rope should stretch

unobstructed to the engine.

Figure2-3: Assemblinghandlebar,(Right-

sidehandlebarstrutshown.)

Figure2-4: Cablescorrectlyroutedinside
handlebarstrut,

Section2: Assembly

Figure2-5: Unfoldingthehandlebar.

Step 3: Adjust Handlebar Height

1. Loosenone of the lower handlebar

adjustment knobs (K, Figure 2-6) and give
the knob a tap inwardto freethe square
shaft on the screw (N, Figure 2-7) from

the keyedslot (0) in the handlebarstrut.

Repeatthis step for the otherside.

2. Movethe handlebarstrut up or down
to align the squareshaft (N, Figure2-7)
with one ofthe three square keyedslots

(0). Themiddle slot is the medium
heightsetting.

3. Tighten the handlebar adjustment
knobs verysecurely.

NOTE:Make surethat the square shaft

seatssquarely into the slot beforetight-
ening the adjustment knobs.

Step 4: AddMotor Oil to Engine

1. Movethe mower to a levelarea.

2. Add motor oil according to the specifi-

cations and instructions providedin the
separateEngine Owner'sManual.

• Keepoil level atthe FULL mark on the

dipstick to avoid engine damage.

• Changeoilaccordingto scheduleand

instructions in EngineOwner's Manual.

Figure2-6: Fullyassembledhandlebar
assembly.

Step 5: Perform
Final AssemblyCheck

1. Checkall nuts, screws,and handlebar

adjustment knobs for tightness.

2. Besure to read Section 1: Safety,
Section3: Featuresand Controlsand

Section4: Operationbefore using the
mower.

Figure2-7:Adjustinghandlebarheight.

Step 6: Set Up Mowing Mode

Your mower canbesetup for either of
two mowing modes. Thesemowing

modes canbag clippings or mulch

clippings. SeeSetting UpMowing Modes

in Section4for detaileddescriptions and
instructions on how to set upeach mode.

NOTE:The mower is shipped in Mulching
Mode. This meansthat the Mulching

Plug is installed into the discharge outlet
(Figure2-1) and that the mower is ready

to mulchgrass clippings.

FeaturesandControls

H

G

A: OperatorPresenceControlBail
B: Wheel Speed Control

C:Wheel Drive Bail

D: RecoilRope Starter
E: UpperHandlebarAdjustmentKnob(2)

Figure3-1

Before operating your machine,
carefully read and understand all
safety, controls and operating instruc-
tions in this Manual, the separate
Engine Owner's Manual and on the

decals onthemachine.
Failure to follow these instructionscan

resultin seriouspersonalinjury.

INTRODUCTION

This Section introducesthe featuresand
controls found on the lawn mower.

Carefullyreview the information in this
Section,then readSection 4, Operation

beforeusing the mower.

/

/

/

F:SmartBagTM GrassFiBIndicator
G:GrassCatcher

H:DischargeOutletGuard
l:LowerHandlebarAdjustmentKnob(2)

J:HandlebarHeigMAdjuster(2)

MOWERATTACHMENTS

Themower is supplied with two easily
changedattachments --the Grass

Catcher(I, Figure 3-1) and the Mulching
Plug (M)-- which providetwo different
mowing modes. SeeSetting Up Mowing

Modes inSection4for detailedinforma-

tion onhow to installand use theattach-

ments.

A uniquefeature,the TROY-BILT®Rapid
AttachTM System, is incorporated into the
design of the attachments. This system
enablesyou to quickly and easily install
the attachments without using tools.

0

K:CuttingHeightAdjustmentLever
L:Belt Cover

M: MulchingPlug
N:DischargeOutlet
O:ClutchCableAdjuster

GrassCatcher Attachment

Usethe GrassCatcher(G, Figure3-1) to
collect clippings for disposal. The bag
can hold over two bushelsof clippings.

TheGrass Catcheris equippedwith the
Troy-Bilt@Smart BagTM feature (F, Figure
3-1). TheSmart Bagfeature is a grass fill

indicator that provides a visualalert when
the bagis full. SeeBaggingMode in

Section 4 for detailed information.

Mulching Plug Attachment

Usethe Mulching Plug (M, Figure 3-1) to

mulch lawn clippings. SeeMulching

Modein Section4.