Troy-Bilt B809H, R809K User Manual

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Operator’s Manual

Pedal Drive Garden Tractor

Models B809H

R809K

Model R809K Shown

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 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.

770-10189D.fm (12/2001)

TABLE OF CONTENTS

Content Page

Important Safe Operation Practices................................................................... 3

Slope Gauge...................................................................................................... 7

Tractor Set-up.................................................................................................... 8

Know Your Garden Tractor ................................................................................10

Operating Your Garden Tractor ......................................................................... 13

Making Adjustments ..........................................................................................16

Maintaining Your Garden Tractor....................................................................... 18

Service...............................................................................................................19

Off-Season Storage ...........................................................................................24

Attachments & Accessories ...............................................................................24

Troubleshooting................................................................................................. 25

Models B809H and R809K Parts List.................................................................26

FINDING MODEL NUMBER

This Operator’s Manual is an important part of your new Garden Tractor. 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 information 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 beneath the seat. 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 the model number here:

TROY-BILT LLC

www.troybilt.com

P. O. BOX CLEVELAND, OH 44136 330-558-7220 866-840-6483

361131

Copy the serial number here:

ENGINE INFORMATION

The engine manufacturer is responsible for all engine-related issues with regards to performance, power-rating, specifications, warranty and service. Please refer to the engine manufacturer’s Owner’s/Operator’s Manual packed separately with your unit for more information.

CALLING CUSTOMER SUPPORT

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.

Call 1- (330) 558-7220 or 1- (866) 840-6483 to reach a Customer Support representative. Please have your unit’s model number and serial number ready when you call. See previous section to locate this information. You will be asked to enter the serial

For more details about your unit, visit our website at www.troybilt.com

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 symbol—heed its warning.

DANGER: This machine was built to be operated according to the rules for safe operation in this man-

ual. 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 instructions could result in serious injury or death.

California Proposition 65 Warning:

WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain

or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

GENERAL OPERATION

1. Read, understand, and follow all instructions on the machine and in the manual(s) before attempting to assemble and operate. Keep this manual in a safe place for future and regular reference and for ordering replacement parts.

2. Be familiar with all controls and their proper operation. Know how to stop the machine and disengage them quickly.

3. Never allow children under 14 years old to operate this machine. 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.

4. Never allow adults to operate this machine without proper instruction.

5. To help avoid blade contact or a thrown object injury, keep bystanders, helpers, children and pets at least 75 feet from the machine while it is in operation. Stop machine if anyone enters the area.

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 picked up and thrown by the blade(s). Thrown objects can cause serious personal injury.

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.

8. 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.

9. Wear sturdy, rough-soled work shoes and closefitting slacks and shirts. Loose fitting clothes and jewelry can be caught in movable parts. Never operate this machine in bare feet or sandals.

10. Be aware of the mower and attachment discharge direction and do not point it at anyone. Do not operate the mower without the discharge cover or entire grass catcher in its proper place.

11. Do not put hands or feet near rotating parts or under the cutting deck. Contact with the blade(s) can amputate hands and feet.

12. A missing or damaged discharge cover can cause blade contact or thrown object injuries.

13. Stop the blade(s) when crossing gravel drives, walks, or roads and while not cutting grass.

14. Watch for traffic when operating near or crossing roadways. This machine is not intended for use on any public roadway.

15. Do not operate the machine while under the influence of alcohol or drugs.

16. Mow only in daylight or good artificial light.

17. Never carry passengers.

18. Disengage blade(s) before shifting into reverse. Back up slowly. Always look down and behind before and while backing to avoid a back-over accident.

19. Slow down before turning. Operate the machine smoothly. Avoid erratic operation and excessive speed.

20. Disengage blade(s), set parking brake, stop engine and wait until the blade(s) come to a complete stop before removing grass catcher, emptying grass, unclogging chute, removing any grass or debris, or making any adjustments.

21. Never leave a running machine unattended. Always turn off blade(s), place transmission in neutral, set parking brake, stop engine and remove key before dismounting.

22. Use extra care when loading or unloading the machine into a trailer or truck. This unit should not be driven up or down ramp(s), because the unit could tip over, causing serious personal injury. The unit must be pushed manually on ramp(s) to load or unload properly.

23. Muffler and engine become hot and can cause a burn. Do not touch.

24. Check overhead clearances carefully before driving under low hanging tree branches, wires, door openings etc., where the operator may be struck or pulled from the unit, which could result in serious injury.

25. Disengage all attachment clutches, depress the brake pedal completely and shift into neutral before attempting to start engine.

26. Your machine is designed to cut normal residential grass of a height no more than 10”. Do not attempt to mow through unusually tall, dry grass (e.g., pasture) or piles of dry leaves. Dry grass or leaves may contact the engine exhaust and/or build up on the mower deck presenting a potential fire hazard.

27. Use only accessories and attachments approved for this machine by the machine manufacturer. Read, understand and follow all instructions provided with the approved accessory or attachment.

28. Data indicates that operators, age 60 years and above, are involved in a large percentage of riding mower-related injuries. These operators should evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury.

29. If situations occur which are not covered in this manual, use care and good judgment. Contact an authorized Service Dealer for assistance.

SLOPE OPERATION

Slopes are a major factor related to loss of control and tip-over accidents which can result in severe injury or death. All slopes require extra caution. If you cannot back up the slope or if you feel uneasy on it, do not mow it.

For your safety, use the slope gauge included as part of this manual to measure slopes before operating this unit on a sloped or hilly area. If the slope is greater than 15 degrees as shown on the slope gauge, do not operate this unit on that area or serious injury could result.

DO:

1. Mow up and down slopes, not across. Exercise extreme caution when changing direction on slopes.

2. Watch for holes, ruts, bumps, rocks, or other hidden objects. Uneven terrain could overturn the machine. Tall grass can hide obstacles.

3. Use slow speed. Choose a low enough speed setting so that you will not have to stop or shift while on the slope. Tires may lose traction on slopes even though the brakes are functioning properly. Always keep machine in gear when going down slopes to take advantage of engine braking action.

4. Follow the manufacturer’s recommendations for wheel weights or counterweights to improve stability.

5. Use extra care with grass catchers or other attachments. These can change the stability of the machine.

6. Keep all movement on the slopes slow and gradual. Do not make sudden changes in speed or direction. Rapid engagement or braking could cause the front of the machine to lift and rapidly flip over backwards which could cause serious injury.

7. Avoid starting or stopping on a slope. If tires lose traction, disengage the blade(s) and proceed slowly straight down the slope.

DO NOT:

1. Do not turn on slopes unless necessary; then, turn slowly and gradually downhill, if possible.

2. Do not mow near drop-offs, ditches or embankments. The mower could suddenly turn over if a wheel is over the edge of a cliff, ditch, or if an edge caves in.

3. Do not try to stabilize the machine by putting your foot on the ground.

4. Do not use a grass catcher on steep slopes.

5. Do not mow on wet grass. Reduced traction could cause sliding.

6. Do not shift to neutral and coast downhill. Overspeeding may cause the operator to lose control of the machine resulting in serious injury or death.

7. Do not tow heavy pull behind attachments (e.g. loaded dump cart, lawn roller, etc.) on slopes greater than 5 degrees. When going down hill, the extra weight tends to push the tractor and may cause you to loose control. (e.g. tractor may speed up, braking and steering ability are reduced, attachment may jack-knife and cause tractor to overturn).

CHILDREN

1. Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. They do not understand the dangers. Never assume that children will remain where you last saw them.

a. Keep children out of the mowing area and in

watchful care of a responsible adult other than the operator.

b. Be alert and turn machine off if a child enters

the area.

c. Before and while backing, look behind and

down for small children.

d. Never carry children, even with the blade(s)

shut off. They may fall off and be seriously injured or interfere with safe machine operation.

e. Use extreme care when approaching blind

corners, doorways, shrubs, trees or other objects that may block your vision of a child who may run into the machine.

f. Disengage the cutting blade(s) before

shifting in reverse. The “No-Cut-In Reverse” feature is a reminder not to cut in reverse and to help avoid back over accidents. Do not defeat it.

g. Keep children away from hot or running

engines. They can suffer burns from a hot muffler.

h. Remove key when machine is unattended to

prevent unauthorized operation.

9. Never allow children under 14 years old to operate the machine. 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.

TOWING

1. Tow only with a machine that has a hitch designed for towing. Do not attach towed equipment except at the hitch point.

2. Follow the manufacturers recommendation for weight limits for towed equipment and towing on slopes.

3. Never allow children or others in or on towed equipment.

4. On slopes, the weight of the towed equipment may cause loss of traction and loss of control.

5. Travel slowly and allow extra distance to stop.

6. Do not shift to neutral and coast downhill.

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.

a. Use only an approved gasoline container. b. 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.

c. When practical, 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.

d. 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.

e. Extinguish all cigarettes, cigars, pipes and

other sources of ignition. f. Never fuel machine indoors. g. Never remove gas cap or add fuel while the

engine is hot or running. Allow engine to cool

at least two minutes before refueling. h. Never over fill fuel tank. Fill tank to no more

than ½ inch below bottom of filler neck to

allow space for fuel expansion. i. Replace gasoline cap and tighten securely. j. If gasoline is spilled, wipe it off the engine

and equipment. Move unit to another area.

Wait 5 minutes before starting the engine. k. To reduce fire hazards, keep machine free of

grass, leaves, or other debris build-up. Clean

up oil or fuel spillage and remove any fuel

soaked debris. l. 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. m. Allow a machine to cool at least 5 minutes

before storing.

GENERAL SERVICE:

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(s) and all moving parts have stopped. Disconnect the spark plug wire and ground against the engine to prevent unintended starting.

3. Periodically check to make sure the blades come to complete stop within approximately (5) five seconds after operating the blade disengagement control. If the blades do not stop within the this time frame, your unit should be serviced professionally by an authorized Service Dealer.

4. Check brake operation frequently as it is subjected to wear during normal operation. Adjust and service as required.

5. Check the blade(s) and engine mounting bolts at frequent intervals for proper tightness. Also, visually inspect blade(s) for damage (e.g., excessive wear, bent, cracked). Replace the blade(s) with the original equipment manufacturer’s (O.E.M.) blade(s) 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. Mower blades are sharp. Wrap the blade or wear gloves, and use extra caution when servicing them.

7. Keep all nuts, bolts, and screws tight to be sure the equipment is in safe working condition.

8. Never tamper with the safety interlock system or other safety devices. Check their proper operation regularly.

9. After striking a foreign object, stop the engine, disconnect the spark plug wire(s) and ground against the engine. Thoroughly inspect the machine for any damage. Repair the damage before starting and operating.

10. Never attempt to make adjustments or repairs to the machine while the engine is running.

11. Grass catcher components and the discharge cover are subject to wear and damage which could expose moving parts or allow objects to be thrown.

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.

TO REDUCE THE RISK OF INJURY, DO NOT OPERATE UNLESS DISCHARGE COVER OR GRASS CATCHER IS IN ITS PROPER PLACE. IF DAMAGED, REPLACE IMMEDIATELY.

AVOID SERIOUS IN JURY OR DEATH

KEEP HAND S AND FEET AWAY FROM ROTATING PARTS. REMOVE OBJECTS THAT CAN BE THROWN BY THE

BLADE IN ANY DIRECTION. WEAR SAFETY GLASSES. DO NOT MOW WHEN CHILDREN OR OTHERS ARE AROUND.

NEVER CARRY CHILDREN EVEN WITH BLADES OFF. USE EXTRA CAUTION ON SLOPES. DO NOT MOW SLOPES

GREATER THAN 10° MOW UP AND DOWN, NOT ACROSS.

S30536

READ OPERATOR'S MANUAL. KEEP SAFETY DEVICES IN PLACE AND WORKING.

AVOID SUDDEN TURNS, USE LOW GEAR.

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!”

12. Do not change the engine governor settings or over-speed the engine. The governor controls the maximum safe operating speed of the engine.

13. Maintain or replace safety and instruction labels, as necessary.

14. Observe proper disposal laws and regulations for gas, oil, etc. to protect the environment.

WARNING

TO AVOID SERIOUS INJURY OR DEATH

• GO UP AND DOWN SLOPES, NOT ACROSS.

• AVOID SUDDEN TURNS.

• DO NOT OPERATE THE UNIT WHERE IT

COULD SLIP OR TIP.

• IF MACHINE STOPS GOING UPHILL, STOP

BLADE(S) AND BACK DOWNHILL SLOWLY.

• DO NOT MOW WHEN CHILDREN OR OTHERS

ARE AROUND.

• NEVER CARRY CHI LDREN EVEN WITH.

BLADES OFF.

• LOOK DOWN & BEHIND BEFORE AND WHILE

BACKING.

• KEEP SAFETY DEVICES (GUARDS, SHIELDS, AND

SWITCHES, ETC.) IN PLACE AND WORKING.

• REMOVE OBJECTS THAT COULD BE

THROWN BY THE BLADE(S).

• KNOW LOCATION AND FUNCTION OF ALL

CONTROLS.

• BE SURE BLADE(S) AND ENGINE ARE STOPPED

BEFORE PLACING HANDS OR FEET NEAR BLADE(S).

• BEFORE LEAVING OPERATOR'S POSITION,

DISENGAGE BLADE(S), PLACE THE SHIFT LEVER

IN NEUTRAL, ENGAGE PARKING BRAKE,

SHUT OFF AND REMOVE KEY.

READ OPERATOR'S MANUAL

SECTION 2: SLOPE GAUGE

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. If operating a walk-behind mower on such a slope, it is extremely difficult to maintain

your footing and you could slip, resulting in serious injury.

Operate RIDING mowers up and down slopes, never across the face of slopes.

15°

WARNING

A CORNER OF A BUILDING

SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE

A POWER POLE

OR A FENCE POST

SECTION 3: TRACTOR SET-UP

Attaching the Battery Cables

NOTE: The positive battery terminal is marked Pos.

(+). The negative battery terminal is marked Neg. (–).

• The positive cable (heavy red wire) is secured to the positive battery terminal (+) with a hex bolt and hex nut at the factory. Make certain that the rubber boot covers the terminal to help protect it from corrosion.

• Remove the hex bolt and wing nut from the negative cable.

• Remove the black plastic cover, if present, from the negative battery terminal and attach the negative cable (heavy black wire) to the negative battery terminal (–) with the bolt and wing nut.

• Make certain the hold-down strap is in position over the battery, securing it in place. See Figure 1.

Rubber

Boot

Service the engine with gasoline and oil as instructed in the separate Briggs & Stratton Operator/Owner Manual packed with your tractor. Read instructions carefully.

IMPORTANT:

engine. However, you MUST check the oil level before operating. Be careful not to overfill.

Your tractor is shipped with motor oil in the

Shipping Brace Removal

WARNING: Make sure the riding mower’s

engine is off, remove the ignition key, and set the parking brake before removing the shipping brace

• On model B809H, locate the shipping brace and accompanying warning tag found on the right side of the mower, between the discharge chute and the cutting deck. See Figure 2.

Wing

Nut

Hex Bolt

Figure 1

NOTE: If the battery is put into service after the date

shown on top of battery, charge the battery as instructed on page 24 of this manual prior to operating the tractor.

Gas and Oil Fill-up

The gasoline tank is located under the hood and has a capacity of either two or three gallons. Do not overfill.

WARNING: Use extreme care when

handling gasoline. Gasoline is extremely flammable and the vapors are explosive. Never fuel machine indoors or while the engine is hot or running. Extinguish cigarettes, cigars, pipes, and other sources of ignition.

Shipping Brace

Warning Tag

Figure 2

• While holding the discharge chute with your left hand, remove the shipping brace with your right hand by grasping it between your thumb and index finger and rotating it clockwise.

WARNING: The shipping brace, used for

packaging purposes only, must be removed and discarded before operating your riding mower.

WARNING: The mowing deck is capable of

throwing objects. Failure to operate the riding mower without the discharge cover in the proper operating position could result in serious personal injury and/or property damage.

Attaching The Cutting Deck (Model R809K)

Deck Lift Assembly

Fender

Lift Lever

Deck Support Pins

Belt Guard

Discharge Chute

NOTE:

Many tractor components not shown for clarity.

Notches

Lift Cables

Deck Lift Arms

Deck Idler Pulleys

Belt Guard

PTO / Deck Belt

Deck

Stabilizer

Bracket

Front of Tractor

Electric PTO Clutch

Deck Stabilizer Rod

Figure 3

WARNING: Before attaching the cutting deck, engage the parking brake, turn the ignition key to the

OFF position and remove the key from the switch to avoid accidental starting.

• Raise the deck lift arms up and out of the way by placing the lift lever in the top notch on the right fender.

• Gently slide the cutting deck beneath the tractor from the right side.

• Move the cutting deck into position so that the hooks found on the front end of the deck fit snugly around the

deck stabilizer rod as shown in Figure 3.

NOTE: The stabilizer rod may be secured to the tractor frame with a plastic cable tie for shipping reasons. If so,

carefully cut the cable tie before mounting the front of the cutting deck.

• Lower the deck lift arms by placing the lift lever in the bottom notch on the right fender.

• Raise the left side of the cutting deck by grasping the deck and lifting upward. Pull the deck support pin (on

the left side of the deck) outward and align it with the hole on the rear of the left deck lift arm before releasing the pin to lock it in place as shown in Figure 3. Repeat on the right side.

• Make certain that the PTO belt is routed around the spindle pulleys (found beneath the belt guards) and both idler pulleys as illustrated in Figure 3.

• Route the PTO belt around the electric PTO clutch as shown in Figure 3.

IMPORTANT:

Perform any adjustments, if necessary, prior to operating the tractor

Be certain that the FLAT side of the PTO belt is the side coming in contact with the deck idler pulleys.

After mounting the cutting deck, refer to Leveling the Deck in the ADJUSTMENTS section of this manual.

SECTION 4: KNOW YOUR GARDEN TRACTOR

NOTE: Steering Wheel not shown for clarity.

Figure 4

A PTO (Power Take-off) Knob H Ignition Switch B Choke Control I Brake Pedal C Parking Brake Button J Drive Pedal D Shift Lever K Cruise Control Button E Cup Holder L Seat Adjustment Lever F Systems Indicator Monitor/Hour Meter M Deck Lift Lever G Throttle Control Lever

NOTE: Any reference in this manual to the RIGHT or LEFT side of the tractor is observed from operator’s position.

Throttle Control Lever

The throttle control lever is located on the right side of the tractor’s dash panel. This lever controls the speed of the engine. When set in a given position, the throttle will maintain a uniform engine speed. See Figure 5.

Fast

Position

Slow

Position

Figure 5

Ignition Switch

WARNING: Never leave a running

machine unattended. Always disengage PTO, move shift lever into neutral position, set parking brake, stop engine and remove key to prevent unintended starting.

To start the engine, insert the key into the ignition switch and turn clockwise to the START position. Release the key into the ON position once engine has fired. See Figure 6.

On/Lights

Off

IMPORTANT:

deck engaged, be certain that the throttle lever is always in the FAST (rabbit) position.

When operating the tractor with the cutting

Choke Control

The choke control can be found on the left side of the dash panel and is activated by pulling the knob outward. Activating the choke control closes the choke plate on the carburetor and aids in starting the engine. Refer to Starting The Engine on page 14 of this manual for detailed starting instructions.

Brake Pedal

The brake pedal is located on the right front side of the tractor above the drive pedal along the running board. The brake pedal can be used for sudden stops or setting the parking brake.

NOTE: The brake pedal must

be fully depressed to activate the safety interlock switch when

starting the tractor

Start

Figure 6

Refer to Starting The Engine on page 14 of this manual for detailed starting instructions

The ignition switch is also used to operate the tractor’s headlights. Refer to Operating The Headlights on page 16 of this manual for detailed instructions.

Drive Pedal

The drive pedal is located below the brake pedal on the right front side of the tractor along the running board. Depress the drive pedal with your right foot when the tractor shift lever is in either FORWARD or REVERSE to cause the tractor to move. Ground speed is also controlled with the drive pedal. The further down the pedal is depressed, the faster the tractor will travel. The pedal will return to its original position when it’s not depressed.

IMPORTANT:

leaving the tractor unattended.

Always set the parking brake when

Systems Indicator Monitor / Hour Meter

Your tractor is equipped with four indicator lights and an hour meter located on the left side of the dash panel. See Figure 7.

Battery

Hour

Meter

1/10

PTO

Figure 7

If the Brake light or PTO light illuminates when attempting to start the unit, proceed as follows:

Brake — Engage the parking brake. PTO — Move the PTO knob into the disengaged

(OFF) position.

It is normal for the Oil light and the Battery light to illuminate while the engine is cranking, but if either illuminates while the engine is running, proceed as follows:

Oil— Stop the tractor immediately and check the

crankcase oil level as instructed in the Briggs & Stratton Operator/Owner Manual included. Add oil as required.

Battery— If this light illuminate’s while the engine is

running, it indicates that the battery is in need of a charge OR that the engine’s charging system is not generating sufficient amperage. Refer to Battery on page 20 of this manual for the proper battery charging procedure or have the engine’s charging system checked by an authorized Briggs & Stratton dealer.

The hour meter operates whenever the engine is running and records the actual hours of tractor operation.

Oil

Brake

Cup Holder

The tractor’s cup holder is located on the fender to the left of the seat, just to the rear of the parking brake lever.

Electric PTO (Power Take-off) Knob

To engage the power to the cutting deck or other (separately available) attachments, pull outward on the PTO knob. Push the PTO knob inward to disengage the power to the cutting deck.

NOTE: The PTO knob must be in the disengaged

(OFF) position when starting the engine, when traveling in reverse and if the operator leaves the seat.

Shift Lever

The shift lever is located on the front of the fender between the operator’s legs and has four positions, FORWARD—HI, FORWARD—LO, NEUTRAL and REVERSE. The brake pedal must be depressed and the tractor must not be in motion when moving the shift lever. Always bring the tractor to a complete stop prior to moving the shift lever from FORWARD—HI to FORWARD—LO or vice-versa. See Figure 8.

Shift Knob

Figure 8

IMPORTANT:

result in serious damage to the tractor’s transmission.

Seat Adjustment Lever

To adjust the seat forward or backward, slide the seat adjustment lever to the left and reposition the seat to the desired position. Once a comfortable position is found, release the seat adjustment lever to lock the seat in place. Refer to Seat Adjustment on page 17 of this manual for more detailed instructions.

Never force the shift lever. Doing so may

Deck Lift Lever

Found on your tractor’s right fender, the deck lift lever is used to change the height of the cutting deck. To use, move the lever to the left, then place in the notch best suited for your application.

Parking Brake Button

To set the parking brake, fully depress the brake pedal and push the parking brake button in. Hold the button in while taking your foot off the brake pedal. Both the parking button and the brake pedal will then stay depressed. To release the parking brake, depress the brake pedal slightly. The parking brake button will then return to its original position.

NOTE: The parking brake must be set if the operator

leaves the seat with the engine running or the engine will automatically shut off.

Cruise Control Button

The cruise control button is located on the tractor dash panel to the left of the ignition switch. Push the cruise control button while traveling forward at a desired speed. While holding the button in, release pressure from the drive pedal. This will engage the cruise control and allow the tractor to remain at that speed without applying pressure to the drive pedal. Depress the brake pedal or the drive pedal to deactivate cruise control. Refer to SECTION 5: OPERATING YOUR GARDEN TRACTOR in this manual for detailed instructions regarding the cruise control feature.

NOTE: Cruise control can not be engaged at the

tractor’s fastest ground speed. If the operator should attempt to do so, the tractor will automatically decelerate to the fastest optimal mowing ground speed.

IMPORTANT:

leaving the tractor unattended.

Always set the parking brake when

SECTION 5: OPERATING YOUR GARDEN TRACTOR

WARNING: Read, understand, and follow

all instructions and warnings on the machine and in this manual before operating.

AVOID SERIOUS INJURY OR DEATH

Safety Interlock Switches

This tractor is equipped with a safety interlock system for the protection of the operator. If the interlock system should ever malfunction, do not operate the tractor. Contact an authorized service dealer. The safety interlock system prevents the engine from cranking or starting unless the parking brake is engaged, and the PTO knob is in the disengaged (OFF) position.

• The engine will automatically shut off if the operator

leaves the seat before engaging the parking brake.

• The engine will automatically shut off if the operator

leaves the tractor’s seat with the PTO knob in the engaged (ON) position, regardless of whether the parking brake is engaged.

• The electric PTO clutch will automatically shut off if

the PTO knob is moved into the engaged (ON) position with the shift lever in position for reverse travel.

WARNING: Do not operate the tractor if the

interlock system is malfunctioning. This system was designed for your safety and protection.

• GO UP AND DOWN SLOPES, NOT ACROSS.

• AVOID SUDDEN TURNS.

• DO NOT OPERATE THE UNIT WHERE IT COULD SLIP OR TIP.

• IF MACHINE STOPS GOING UPHILL, STOP BLADE(S) AND BACK

DOWNHILL SLOWLY.

• DO NOT MOW WHEN CHILDREN OR OTHERS ARE AROUND.

• NEVER CARRY CHILDREN, EVEN WITH BLADES OFF.

• LOOK DOWN AND BEHIND BEFORE AND WHILE BACKING.

• KEEP SAFETY DEVICES (GUARDS, SHIELDS, AND SWITCHES) IN

PLACE AND WORKING.

• REMOVE OBJECTS THAT COULD BE THROWN BY THE BLADE(S).

• KNOW LOCATION AND FUNCTION OF ALL CONTROLS.

• BE SURE BLADE(S) AND ENGINE ARE S TOPPED BEFORE PLAC-

ING HANDS OR FEET NEAR BLADE(S).

• BEFORE LEAVING OPERATOR’S POSITION, DISENGAGE BLADE(S), PLACE THE SHIFT LEVER IN NEUTRAL, ENGAGE BRAKE LOCK, SHUT ENGINE OFF AND REMOVE KEY.

Setting the Cutting Height

Select the height position of the cutting deck by placing the deck lift lever in any of the six different cutting height notches on the right side of the fender. Then adjust the deck wheels so that they are between ¼-inch and ½- inch above the ground when the tractor is on a smooth, flat surface such as a driveway.

WARNING

READ OPERATOR’S MANUAL

WARNING: Keep hands and feet away

from the discharge opening of the cutting deck.

NOTE: The deck wheels are an anti-scalp feature of

the deck and are not designed to support the weight of the cutting deck.

Refer to Leveling the Deck on page 17 of this manual for more detailed instructions regarding various deck adjustments.

Starting the Engine

WARNING: Do not operate the tractor if the

interlock system is malfunctioning. This system was designed for your safety and protection.

NOTE: Refer to the TRACTOR SET-UP on page 8 of this

manual for Gasoline and Oil fill-up instructions.

• Insert the tractor key into the ignition switch.

• Place the PTO knob in the disengaged (OFF)

position.

• Engage the tractor’s parking brake.

• Place the throttle control in the FAST (rabbit)

position.

• Pull the choke control outward.

• Turn the ignition key clockwise to the START

position. After the engine starts, release the key. It will return to the ON position.

IMPORTANT:

position for longer than ten seconds at a time. Doing so may cause damage to your engine’s electric starter.

• After the engine starts, deactivate the choke control and place the throttle control in the FAST position.

Do NOT hold the key in the START

NOTE: Do NOT leave the choke control on while

operating the tractor. Doing so will result in a "rich" fuel mixture and cause the engine to run poorly.

Stopping the Engine

Driving The Tractor

WARNING: Avoid sudden starts, ex-

cessive speed and sudden stops.

WARNING: Do not leave the seat of the

tractor without first placing the PTO knob in the disengaged (OFF) position, depressing the brake pedal and engaging the parking brake. If leaving the tractor unattended, also turn the ignition key off and remove the key.

• Depress the brake pedal to release the parking brake and let the pedal up. Move the throttle lever into the FAST (rabbit) position.

IMPORTANT:

direction of travel when the tractor is in motion. Always use the brake pedal to bring the tractor to a complete stop before shifting.

• To move forward, place the shift lever in the FORWARD position, then slowly depress the drive pedal until the desired speed is achieved.

• To move in reverse, place the shift lever in the REVERSE position, check that the area behind is clear then slowly depress the drive pedal.

Do NOT use the shift lever to change the

Engaging the Parking Brake

To engage the parking brake:

• Fully depress the brake pedal and hold it there while gently pushing the parking brake button inward.

• Hold the parking brake button in while removing your foot from the brake pedal.

• Once engaged, the parking brake button and the brake pedal will lock in the “down” position.

To disengage the parking brake:

• Slightly depress the brake pedal.

NOTE: The parking brake must be engaged if the

operator leaves the seat with the engine running or the engine will automatically shut off.

WARNING: If you strike a foreign object,

stop the engine, disconnect the spark plug wire(s) and ground against the engine. Thoroughly inspect the machine for any damage. Repair the damage before restarting and operating

• If the blades are engaged, place the PTO knob in the disengaged (OFF) position.

• Turn the ignition key counterclockwise to the OFF position.

• Remove the key from the ignition switch to prevent unintended starting.

Driving On Slopes

Refer to the SLOPE GAUGE on page 7 to help determine slopes where you may operate the tractor safely.

WARNING: Do not mow on inclines with a

slope in excess of 15 degrees (a rise of approximately 2-1/2 feet every 10 feet). The tractor could overturn and cause serious injury.

• Mow up and down slopes, NEVER across.

• Exercise extreme caution when changing direction

on slopes.

• Watch for holes, ruts, bumps, rocks, or other hidden objects. Uneven terrain could overturn the machine. Tall grass can hide obstacles.

• Avoid turns when driving on a slope. If a turn must be made, turn down the slope. Turning up a slope greatly increases the chance of a roll over.

• Avoid stopping when driving up a slope. If it is necessary to stop while driving up a slope, start up smoothly and carefully to reduce the possibility of flipping the tractor over backward.

Front View

Pull Out

Push In

OFF

Setting The Cruise Control

NOTE: The cruise control feature should only be

utilized while traveling in the forward direction.

• Place the shift lever in the FORWARD position, then slowly depress the drive pedal until the desired speed is achieved.

• Lightly depress the cruise control button.

• While continuing to hold the cruise button in, lift

your foot from the drive pedal (you should feel the cruise latch engage).

• Once engaged, the cruise control button and the drive pedal will lock in the “down” position, and the tractor will maintain the same forward speed.

NOTE: Cruise control can not be engaged at the

tractor’s fastest ground speed. If the operator should attempt to do so, the tractor will automatically decelerate to the fastest optimal mowing ground speed.

Disengage the cruise control using one of the following methods:

• Depress the brake pedal to disengage the cruise control and stop the tractor.

• Lightly depress the drive pedal.

To change to the reverse direction when operating with cruise control, depress the brake pedal to disengage the cruise control and bring the tractor to a complete stop. Then place the shift lever in the REVERSE position and depress the drive pedal.

Using the Deck Lift Lever

To raise the cutting deck, move the deck lift lever to the left, then place it in the notch best suited for your application. Refer to Setting The Cutting Height earlier in this section.

Engaging the PTO

Engaging the PTO transfers power to the cutting deck or other (separately available) attachments. To engage the PTO, proceed as follows:

• Move the throttle control lever to the FAST (rabbit) position.

• Pull the PTO knob outward into the engaged (ON) position. See Figure 9.

Figure 9

• Keep the throttle lever in the FAST (rabbit) position for the most efficient use of the cutting deck or other (separately available) attachments

IMPORTANT:

shut off if the PTO is engaged with the shift lever in position for reverse travel. Refer to Safety Interlock Switches on page 13.

The electric PTO clutch will automatically

Mowing

WARNING: To help avoid blade contact or

a thrown object injury, keep bystanders, helpers, children and pets at least 75 feet from the machine while it is in operation. Stop machine if anyone enters the area.

The following information will be helpful when using the cutting deck with your tractor.

WARNING: Plan your mowing pattern to

avoid discharge of materials 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.

• Do not mow at high ground speed, especially if a mulch kit or grass collector is installed.

• For best results it is recommended that the first two laps be cut with the discharge thrown towards the center. After the first two laps, reverse the direction to throw the discharge to the outside for the balance of cutting. This will give a better appearance to the lawn.

• Do not cut the grass too short. Short grass invites weed growth and yellows quickly in dry weather.

• Mowing should always be done with the engine at full throttle.

• Under heavier conditions it may be necessary to go back over the cut area a second time to get a clean cut.

• Do NOT attempt to mow heavy brush and weeds and extremely tall grass. Your tractor is designed to mow lawns, NOT clear brush.

• Keep the blades sharp and replace the blades

when worn. Refer to Cutting Blades on page 23 of this manual for proper blade sharpening instructions.

Operating The Headlights

To turn the tractor’s headlights on:

• Start the engine following the instructions earlier in

this section.

• Turn the key one notch counterclockwise into the On/Lights position of the ignition switch. Refer to Figure 6.

SECTION 6: MAKING ADJUSTMENTS

To turn the tractor’s headlights off:

• Turn the key either into the On position (to leave the

engine running) or the Off position (to shut the engine off). Refer to Figure 6.

NOTE: Never move the key into the Start position

while the engine is running. Doing so may cause damage to your engine’s electric starter.

WARNING: Never attempt to make any

adjustments while the engine is running, except where specified in the operator’s manual.

WARNING: Disconnect the spark plug

wire(s) and ground against the engine before performing any adjustments, repairs or maintenance.

Parking Brake Adjustment

WARNING: Never attempt to adjust the

brakes while the engine is running. Always disengage PTO, move shift lever into neutral position, stop engine and remove key to prevent unintended starting.

If the tractor does not come to a complete stop when the brake pedal is completely depressed, or if the tractor’s rear wheels can roll with the parking brake applied, the brake is in need of adjustment. The brake disc can be found on the right side of the transmission in the rear of the tractor. Adjust if necessary as follows:

• Looking at the transmission from the right side of the tractor, locate the compression spring and brake disc.

• Loosen, but do NOT remove, the hex nut found on the right side of the brake assembly.

• Using a feeler gauge, set the gap between the brake disc and the brake puck at .011".

• Re-tighten the hex nut loosened earlier.

To adjust the position of the seat, move the seat adjustment lever to the left and slide the seat forward or rearward. Make sure seat is locked into position before operating the tractor.

Steering Adjustment

If the tractor turns tighter in one direction than the other, or if the ball joints are being replaced due to damage or wear, the steering drag links may need to be adjusted.

Adjust the drag links so that equal lengths are threaded into the ball joint on the left side and the ball joint on the right side:

• Loosen the jam nut found on the drag link at the rear of the ball joint. See Figure 10.

Hex Nut and Lock Washer

Axle

Jam Nut

Ball Joint

Pivot Bar

Drag Link

Seat Adjustment

WARNING: Before operating this machine,

make sure the seat is engaged in the seat stop, stand behind the machine and pull back on seat until fully engaged into stop.

Figure 10

• Remove the hex nut and lock washer on the top of ball joint. See Figure 10.

• Thread the ball joint toward the jam nut to shorten the drag link. Thread the ball joint away from the jam nut to lengthen the drag link.

• Replace hex nut and lock washer and retighten the jam nut after proper adjustment is achieved.

NOTE: Threading the ball joints too far onto the drag

links will cause the front tires to "toe-in" too far. Proper toe-in is between 1/16" and 5/16".

Front tire toe-in can be measured as follows:

• Place the steering wheel in position for straight ahead travel.

• In front of the axle, measure the distance horizontally from the inside of the left rim to the inside of the right rim. Note the distance.

• Behind the axle, measure the distance horizontally from the inside of the left rim to the inside of the right rim. Note the distance.

• The measurement taken in front of the axle should be between 1/16" and 5/16" less than the measurement taken behind the axle. Adjust if necessary.

Leveling the Deck

NOTE: Check the tractor’s tire pressure before

performing any deck leveling adjustments. Refer to

Tires on page 24 for information regarding tire pressure.

Front To Rear

The front of the cutting deck is supported by a stabilizer bar that can adjusted to level the deck from front to rear. The front of the deck should be between 1/4-inch and 3/8-inch lower than the rear of the deck. Adjust if necessary as follows:

• With the tractor parked on a firm, level surface, place the deck lift lever in the top notch (highest position) and rotate the blade nearest the discharge chute so that it is parallel with the tractor.

• Measure the distance from the front of the blade tip to the ground and the rear of the blade tip to the ground.

• The first measurement taken should be between 1/4" and 3/8" less than the second measurement. Determine the approximate distance necessary for proper adjustment and proceed, if necessary, to the next step.

• Loosen the two jam nuts on the rear side of the deck stabilizer bracket. See Figure 11Figure 11A.

• Locate the two lock nuts on the opposite side of the stabilizer bracket. See Figure 11Figure 11A. Tighten the lock nuts to raise the front of the deck; loosen the lock nuts to lower the front of the deck.

• Retighten the two jam nuts loosened earlier when proper adjustment is achieved.

Side to Side

If the cutting deck appears to be mowing unevenly, a side to side adjustment can be performed. Adjust if necessary as follows:

• With the tractor parked on a firm, level surface, place the deck lift lever in the top notch (highest position) and rotate both blades so that they are perpendicular with the tractor.

• Measure the distance from the outside of the left blade tip to the ground and the distance from the outside of the right blade tip to the ground. Both measurements taken should be equal. If they’re not, proceed to the next step.

• Loosen, but do NOT remove, the hex cap screw on the left deck hanger bracket. See Figure 11B.

• Balance the deck by using a wrench to turn the adjustment gear (found immediately behind the hex cap screw just loosened) clockwise/up or counterclockwise/down.

• The deck is properly balanced when both blade tip measurements taken earlier are equal.

• Retighten the hex cap screw on the left deck hanger bracket when proper adjustment is achieved.

Deck

Stabilizer

Bracket

eck

FRONT TO REAR

Lock

Nuts

Jam Nuts

SIDE TO SIDE

Figure 11

Adjustment Gear

Hex Cap Screw

Deck Roller Height Adjustment

(Units with 54-inch Deck)

To adjust the height of the rollers on the rear of the mowing deck, proceed as follows:

• Place the deck lift lever in the bottom notch (lowest position).

• Remove the clevis pins and hairpin clips from the deck roller brackets on the left and right sides of the cutting deck. See Figure 12.

• Position the deck roller brackets up or down through the slots on the rear of the deck until desired position is reached, then re-attach with the clevis pins and hairpin clips just removed. See Figure 12.

NOTE: Be certain that the left roller bracket and the

right roller bracket are set in the same position.

Hairpin Clip

SECTION 7: MAINTAINING YOUR GARDEN TRACTOR

WARNING: Before performing any

maintenance or repairs, disengage PTO, move shift lever into neutral position, set parking brake, stop engine and remove key to prevent unintended starting.

Oil Fill Cap

Oil Drain Hose

Deck Roller Bracket

Clevis pin

Figure 12

Protective Cap

Engine

Refer to the Briggs & Stratton Operator/Owner Manual for engine maintenance instructions.

Check engine oil level before each use as instructed in the Briggs & Stratton Operator/Owner Manual packed with your unit. Follow the instructions carefully.

Changing Engine Oil

NOTE: Depending on the engine model found on your

tractor, it may be necessary to remove the tractor’s side panel in order to replace the oil filter (if so equipped).

• Unscrew oil fill cap and remove dipstick from the oil fill tube. See Figure 13.

• Pop open the protective cap on the end of the oil drain valve to expose the drain port. See Figure 13.

• Push the oil drain hose (packed with this manual) onto the oil drain port. Route the opposite end of the hose into an appropriate oil collection container with a capacity great enough to collect the used oil (approximately 64 oz.).

• Push the oil drain valve in slightly, then rotate counterclockwise and pull outward to begin draining oil. See Figure 13.

Oil Fill Tube

Drain Port

Figure 13

• Service the oil filter (if so equipped) as instructed in the separate Briggs & Stratton Operator/Owner Manual packed with your unit.

Perform the above steps in the opposite order after oil has finished draining.

• Refill the engine with new motor oil.

IMPORTANT:

Owner Manual packed with your unit for information regarding the quantity and proper weight of motor oil.

Refer to the Briggs & Stratton Operator/

Oil Drain Valve

Air Cleaner

Service the pre-cleaner, if so equipped, and cartridge/ air cleaner element as instructed in the Briggs & Stratton Operator/Owner Manual packed with your unit.

Spark Plugs

The spark plugs should be cleaned and the gap reset once a season. Spark plug replacement is recommended at the start of each mowing season. Refer to the Briggs & Stratton Operator/Owner Manual for correct plug type and gap specifications.

Cleaning the Engine And Deck

Any fuel or oil spilled on the machine should be wiped off promptly. Do NOT allow debris to accumulate around the cooling fins of the engine or on any other part of the machine, especially the belts, pulleys and other moving parts. Clean the underside of the deck with a wisk broom, scraper or forced air after each mowing.

IMPORTANT:

hose to clean your tractor is NOT recommended. It may cause damage to electrical components, spindles, pulleys, bearings or the engine. The use of water will result in a shortened life of the tractor and reduce its serviceability.

The use of a pressure washer or garden

Lubrication

WARNING: Before lubricating, repairing, or

inspecting, always disengage PTO, move shift lever into neutral position, set parking brake, stop engine and remove key to prevent unintended starting.

Engine

Lubricate the engine with motor oil as instructed in the Briggs & Stratton Operator/Owner Manual packed with your unit.

Pivot Points & Linkage

Lubricate all the pivot points on the drive system, parking brake and lift linkage at least once a season with light oil.

Front Wheels

Each end of the tractor’s front pivot bar is equipped with a grease fitting. Lubricate with a grease gun after every 25 hours of tractor operation.

SECTION 8: SERVICE

Cutting Deck Removal

To remove the cutting deck, proceed as follows:

• Place the PTO knob in the disengaged (OFF) position and engage the parking brake.

• Lower the deck by moving the deck lift lever into the bottom notch on the right fender.

• Remove the PTO belt from around the electric PTO clutch. Refer to Figure 15.

• Looking at the cutting deck from the left side of the tractor, locate the deck support pin on the rear left side of the deck.

• Pull the deck support pin outward to release the deck from the deck lift arm. See Figure 14.

• Rotate the pin slightly toward the rear of the tractor and release the pin into the hole provided.

• Repeat the above steps on the tractor’s right side.

• Move the deck lift lever into the top notch on the

right fender to raise the deck lift arms up and out of the way.

• Gently slide the cutting deck toward the front of the tractor allowing the hooks on the deck to release themselves from the deck stabilizer rod.

Support Pin

• Gently slide the cutting deck (from the right side) out from underneath the tractor.

Figure 14

Changing the Deck Belt(s)

WARNING: Be sure to shut the engine off,

remove ignition key, disconnect the spark plug wire(s) and ground against the engine to prevent unintended starting before removing the belt(s).

All belts on your tractor are subject to wear and should be replaced if any signs of wear are present.

IMPORTANT:

specially designed to engage and disengage safely. A substitute (non-OEM) V-belt can be dangerous by not disengaging completely. For a proper working machine, use factory approved belts.

The V-belts found on your tractor are

To change or replace the deck belts on your tractor, proceed as follows:

• Lower the deck by moving the deck lift lever into the bottom notch on the right fender.

• Remove the belt guards by removing the selftapping screws that fasten them to the deck.

• Grasp the PTO idler bracket and pivot it toward the discharge chute to relieve tension on the PTO belt.

• Remove the PTO belt from the electric PTO clutch and from around the PTO idler pulley, if present.

• Grasp the deck idler pulley and pivot it toward the left side of the deck to relieve tension on the belt.

• Remove the belt from around all spindle pulleys, and deck idler pulley(s).

• Route the new belts as shown in Figure 15.

• Remount the belt guards removed earlier.

Electric PTO Clutch

Deck Idler Pulley

Left Hand

Double Pulley

NOTE:

Left hand belt cover not shown for clarity. 46-inch deck shown.

Electric PTO Clutch

Center Pulley

Figure 15

PTO Idler Bracket

(mounted on tractor)

Self-Tapping Screws

Deck Idler Pulleys

Deck belt (Bottom)

PTO belt (Top)

Right Hand

Double Pulley

(beneath belt guard)

Deck / PTO belt

Left Hand

Pulley

NOTE:

Center Pulley

Belt covers not shown f or clarity. 54-inch deck shown.

Right Hand

Pulley

Figure 16

Variable-Speed

Pulley

Battery Tray

Opening

Shift Lever

Rear Idler Pulley

Belt Keeper

Front Idler Pulley

Keeper Pins

Drive belt (Lower)

Drive belt (Upper)

Engine Pulley

Double Idler Bracket

Transmission Idler Pulley

Idler Bracket

Two-speed

Transmission

NOTE: View shown from above tractor.

Transmission Pulley

Front of Tractor

Figure 17

Changing the Transmission Drive Belt

WARNING: Be sure to shut the engine off,

remove ignition key, disconnect the spark plug wire(s) and ground against the engine to prevent unintended starting before removing the belt(s)

All belts on your tractor are subject to wear and should be replaced if any signs of cracking, shredding or rotting are present.

IMPORTANT:

specially designed to engage and disengage safely. A substitute (non-OEM) V-belt can be dangerous by not disengaging completely. For a proper working machine, use factory approved belts.

To change or replace the drive belt on your tractor, proceed as follows:

NOTE: It’s recommended that both drive belts be

replaced at the same time.

• Remove the cutting deck as instructed earlier in this section.

The V-belts found on your tractor are

Electric PTO Clutch

Belt Keeper

• After disconnecting the battery cables, remove the battery and battery tray from beneath the seat.

IMPORTANT:

When removing the battery, disconnect

the NEGATIVE (Black) wire from it’s terminal first, followed by the POSITIVE (Red) wire. Re-install in reverse order.

Upper Drive Belt

• Locate the transmission idler pulley on the upper drive belt by looking through the battery tray opening. See Figure 17.

• Grasp the bracket and pivot the transmission idler pulley toward the rear of the tractor to release tension on the upper drive belt.

• Remove the belt from around the transmission idler pulley.

• Remove the upper drive belt from around the transmission pulley and the variable-speed pulley.

NOTE: Slowly rotate the pulley counterclockwise to

roll the belt off of it.

• Remove the upper drive belt by pulling it up through the battery tray opening.

• Reroute the new upper drive belt as shown in Figure 17.

Lower Drive Belt

Idler Adj. Rod

Place Wrenches Here

NOTE: Proper removal of the lower drive belt requires

the removal of several tractor components. Read through the following procedure prior to attempting it to determine if you feel you could successfully complete it. If you don’t, see an authorized Troy-Bilt Service Dealer to have the belt changed.

IMPORTANT:

around both the pulleys and the belt keepers BEFORE performing the following steps.

• Locate the variable-speed pulley through the battery tray opening. See Figure 17.

• Remove the variable-speed pulley by loosening the hex bolt that secures it to the transmission. Use a second wrench to hold the hex nut on the bottom side of the pulley.

• Slide the belt off of the variable-speed pulley as you lift the pulley up and out through the battery tray opening.

• Remove the rear idler pulley from the double- idler bracket while unrouting the belt from around both the rear and the front idler pulley. Refer to Figure

17.

• Remove the hex bolt from the center of the electric PTO clutch and gently lower it off of the engine crankshaft. Be careful not to lose any washers or which may be found on top of the PTO clutch.

IMPORTANT:

the center hex bolt to between 38 foot-pounds and 50 foot-pounds.

• Remove the drive belt by feeding it from both ends toward the front idler pulley on the double-idler bracket. See Figure 17.

• Reassemble by following the above steps in reverse order.

• Reroute the new belt around the pulleys, belt keepers and keeper pins EXACTLY as the old one was routed. Refer to Figure 17.

The drive pedal is properly adjusted when the hole found in the double-idler bracket has approximately 1-3/8" of travel with ten pounds of pressure applied to the drive pedal. See Figure 19.

Adjust the drive pedal after replacing the drive belts on your tractor, if necessary, as follows:

• Locate the speed control assembly on the underside of the steering support bracket. See Figure 19.

• Remove both hairpin clips from the pin which is fastened to the speed control assembly (be careful not to lose the small flat washers found on the pin). See Figure 18.

Note the routing of the lower drive belt

When remounting the PTO clutch, torque

Neutral

Return

Bracket

Hairpin

Clips

Drive Pedal

Return Spring

Speed Control

Assembly

Figure 18

Double-idler Bracket

Hole

”

Front of Tractor

Idler

Adjuster Rod

NOTE: View shown from above tractor.

Figure 19

• Remove the drive pedal return spring.

• Using two 9/16" wrenches, remove the pin from the

speed control assembly. See Figure 18.

• Thread the idler adjustment rod inward or outward to lengthen or shorten the travel of the double-idler bracket until proper adjustment is achieved.

• Reassemble by following the above steps in reverse order.

Tires

WARNING: Never exceed the maximum

inflation pressure shown on the sidewall of the tire.

Refer to the tire sidewall for exact tire manufacturer’s recommended or maximum psi. Do not overinflate. Uneven tire pressure could cause the cutting deck to mow unevenly.

Cutting Blades

WARNING: Be sure to shut the engine off,

remove ignition key, disconnect the spark plug wire(s) and ground against the engine to prevent unintended starting before removing the cutting blade(s) for sharpening or replacement. Protect your hands by using heavy gloves or a rag to grasp the cutting blade.

WARNING: Periodically inspect the blade

adapter and/or spindle for cracks or damage, especially if you strike a foreign object. Replace immediately if damaged

Blade Separation

Worn Blade Edge

Wind Wing

The blades may be removed as follows.

• Remove the deck from beneath the tractor, (refer to

Cutting Deck Removal on page 19) then gently flip the deck over to expose its underside.

• Place a block of wood between the center deck housing baffle and the cutting blade to act as a stabilizer. See Figure 20.

Hex Flange Nut

Wood Block

Spindle Assembly

Figure 20

Sharpen Edge Evenly

Figure 21

It is important that each cutting blade edge be ground equally to maintain proper blade balance. A poorly balanced blade will cause excessive vibration and may cause damage to the tractor and result in personal injury.

The blade can be tested by balancing it on a round shaft screwdriver. Grind metal from the heavy side until it balances evenly.

When replacing the blade, be sure to install the blade with the side of the blade marked ‘‘Bottom’’ (or with a part number stamped in it) facing the ground when the mower is in the operating position.

IMPORTANT:

Use a torque wrench to tighten the blade spindle hex flange nut to between 70 foot-pounds and 90 foot-pounds.

WARNING: Before servicing, repairing, or

inspecting, always disengage PTO, move shift lever into neutral position, set parking brake, stop engine and remove key to prevent unintended starting.

• Use a 15/16" wrench to remove the hex flange nut that secures the blade to the spindle assembly. See Figure 20.

To properly sharpen the cutting blades, remove equal amounts of metal from both ends of the blades along the cutting edges, parallel to the trailing edge, at a 25° to 30° angle. See Figure 21.

IMPORTANT:

If the cutting edge of the blade has already been sharpened to within 5/8" of the wind wing radius, or if any metal separation is present, replace the blades with new ones. See Figure 21.

Fuses

Two fuses are installed in your tractor’s wiring harness to protect the tractor’s electrical system from damage caused by excessive amperage.

If the electrical system does not function, or your tractor’s engine will not crank, first check to be certain that the fuse has not blown.

One can be found under the hood mounted behind the top of the dash panel on the support bar. The other can be found under the seat mounted to the inside of the tractor frame next to the battery tray. Pull the fuse out and inspect it to determine if it is good or blown.

IMPORTANT:

amperage capacity for replacement.

Always use a fuse with the same

Battery

The battery is sealed and is maintenance-free. Acid levels cannot be checked.

• Always keep the battery cables and terminals clean

and free of corrosive build-up.

• After cleaning the battery and terminals, apply a

light coat of petroleum jelly or grease to both terminals

• Always keep the rubber boot positioned over the

positive terminal to prevent shorting.

IMPORTANT:

disconnect the NEGATIVE (Black) wire from it’s terminal first, followed by the POSITIVE (Red) wire. When re-installing the battery, always connect the POSITIVE (Red) wire its terminal first, followed by the

If removing the battery for any reason,

SECTION 9: OFF-SEASON STORAGE

Clean and lubricate the tractor as instructed in Section 7: MAINTAINING YOUR GARDEN TRACTOR on page 18 of this

manual before storing for an extended period.

WARNING: Drain fuel only into an

approved container outdoors, away from an open flame. Allow engine to cool. Extinguish cigarettes, cigars, pipes, and other sources of ignition prior to draining fuel.

NEGATIVE (Black) wire. Be certain that the wires are connected to the correct terminals; reversing them could change the polarity and cause damage to your engine’s alternating system.

Charging

If the tractor has not been put into use for an extended period of time, charge the battery with an automotivetype 12-volt charger for a minimum of one hour at six amps.

WARNING: Batteries give off an explosive

gas while charging. Charge battery in a well ventilated area and keep away from an open flame or pilot light as on a water heater, space heater, furnace, clothes dryer or other gas appliances.

Follow the instructions in the Service, Storage & Specifications section of the Briggs & Stratton Operator/Owner Manual for proper engine care prior to storing your tractor.

WARNING: Never store the machine or

fuel container indoors where there is an open flame, spark or pilot light such as on water heater, furnace, clothes dryer or other gas appliance.

SECTION 10: ATTACHMENTS & ACCESSORIES

The following attachments and accessories are compatible for tractor Models B809H & R809K. See the retailer from which you purchased your tractor or phone (866) 840-6483 for information regarding price and availability.

MODEL DESCRIPTION

OEM-190-118 Mulch Kit (For 46-inch Decks Only) OEM-190-603 FastAttach™ Grille Guard (mounts on front of tractor) OEM-190-604 FastAttach™ Yard-Mate™ Storage Container/Toolbox (mounts on rear of tractor) OEM-190-607 FastAttach™ Deluxe Tractor Sunshade OEM-190-608 FastAttach™ Sleeve Hitch, Manual Lift OEM-190-821 FastAttach™ Triple Bagger Grass Collector (For 46-inch Decks Only) OEM-190-822 FastAttach™ 46-inch Front Dozer Blade OEM-190-823 42-inch Two-stage Snowthrower OEM-190-824 Sleeve Hitch with Electric Lift OEM-190-841 Mulch Kit (For 54-inch Decks Only) OEM-190-842 FastAttach™ Triple Bagger Grass Collector (For 54-inch Decks Only)

SLEEVE HITCH ATTACHMENTS (For use with OEM-190-824 or OEM-190-608 )

OEM-190-825 30-inch Hydraulic Tiller† OEM-190-984 Row Crop Cultivator OEM-190-980 Single-disc Harrow OEM-190-978 10-inch Mulboard Plow OEM-190-804 42-inch Heavy Duty Rear Blade

† OEM-190-824 is required for use of this attachment. OEM-190-608 can NOT be used in it’s place.

SECTION 11: TROUBLESHOOTING

Trouble Possible Cause(s) Corrective Action

Engine fails to start PTO knob engaged.

Parking brake not engaged. Spark plug wire(s) disconnected. Throttle control lever not in correct starting position. Choke not activated Fuel tank empty, or stale fuel. Blocked fuel line. Faulty spark plug. Engine flooded.

Engine runs erratic Unit running with CHOKE applied.

Spark plug wire(s) loose. Blocked fuel line or stale fuel.

Vent in gas cap plugged. Water or dirt in fuel system.

Dirty air cleaner.

Engine overheats Engine oil level low.

Air flow restricted.

Engine hesitates at high RPM Spark plug(s) gap too close. Remove spark plug(s) and reset the gap to .030” . Idles poorly Spark plug(s) fouled, faulty or gap too

wide. Dirty air cleaner.

Excessive vibration Cutting blade loose or unbalanced.

Damaged or bent cutting blade.

Mower will not mulch grass Engine speed too low.

Wet grass. Excessively high grass.

Dull blade.

Uneven cut Deck not balanced properly.

Dull blade. Uneven tire pressure.

Place PTO knob in disengaged (OFF) position. Engage parking brake. Connect wire(s) to spark plug. Place throttle lever to FAST position.

Pull out the CHOKE control (if so equipped). Fill tank with clean, fresh (less than 30 days old) gas. Clean fuel line or replace fuel filter, if so equipped. Clean, adjust gap or replace plug. Crank engine with throttle in FAST position. Push CHOKE control (if so equipped) in. Connect and tighten spark plug wire(s). Clean fuel line; fill tank with clean, fresh (less than 30 days old) gasoline. Replace fuel filter, if so equipped. Clear vent or replace cap if damaged. Drain fuel tank. Refill with clean, fresh (less than 30 days old) gasoline. Replace air cleaner cartridge/element or clean precleaner, if so equipped. Fill crankcase with proper capacity and weight of oil. Clean grass clippings and debris from around the engine’s cooling fins and blower housing.

Replace spark plug(s). Set plug(s) gap to .030” .

Replace air cleaner cartridge/element or clean precleaner, if so equipped. Tighten blade and spindle. Balance blade. Replace blade. Place throttle in FAST (rabbit) position. Do not mow when grass is wet; wait until later to cut. Mow once at a high cutting height, then mow again at desired height or make a narrower cutting swath. Sharpen or replace blade. Perform side-to-side deck adjustment. Sharpen or replace blade. Check tire pressure in all four tires.

SECTION 12: MODELS B809H & R809K PARTS LIST

(for choke)

Models B809H & R809K

REF.

NO.

1 710-0227 Self-tapping Screw, #8-18 x .5 2 710-0599 Self-tapping Screw, 1/4-20 x .5 3 710-0604A Self-tapping Screw, 5/16-18 x .625 4 710-1237 Screw, #10-32 x .625 5 710-1314A Socket Cap Screw, 5/16-18 x .625 6 710-1315 Self-tapping Screw, 3/8-16 x 1.25 7 712-3017 Hex Nut, 3/8-16 8 721-0460 Exhaust Gasket

9 726-0205 Hose Clamp 10 736-0119 Lock Washer, 5/16 11 736-0300 Flat Washer 12 751B221535 Casing Clamp 13 751-0535 Fuel Line Hose 14 751-0564 Muffler Deflector 15 751-0616 Muffler, Twin Inlet 16 751-0650 RH Exhaust Pipe 17 751-0651 LH Exhaust Pipe 18 751-3140 Oil Drain Valve 19 751-3141 Oil Drain Hose 20 751-3142 Oil Drain Cap 21 783-0615B Muffler Heat Shield 22 783-0625C Engine Heat Shield 23 722-0263 Foam (fits over fuel line) 24 746-1086 Throttle Cable

PART

NO. DESCRIPTION

Models B809H & R809K

23 42

Models B809H & R809K

REF.

NO.

1 783-1346 Grill Support Bracket (9-style)

2 710-0599 Self-tapping Screw, 1/4-20 x .5

3 710-0528 Hex Cap Screw, 5/16-18 x 1.25

4 710-0924 Phillips Pan Screw, 1/4-20 x .75

5 710-1017 Truss Phillips Screw, 1/4-20 x .625

6 725-1741 Ignition Switch

7 726-0272 Clamp, 9/16

8 710-0642 Self-tapping Screw, 1/4-20 x .75

9 712-0292 U-type Speed Nut, 1/4-20 10 736-0270 Bell Washer, .265 x .75 x .062 11 725-1976 Systems Indicator Monitor 12 712-3004A Hex Nut, 5/16-18 13 731-2119A Grille (9-style) 14 731-0511 Trim Strip, 4 15 725-0175 Cable Tie, 3/16 x .05 x 7.4 16 746-1085 Choke Knob/Cable 17 783-0783 Hood (9-style) 18 783-0784 RH Side Panel (9-style) 19 783-0785 LH Side Panel (9-style) 20 731-2119 Headlight Lens (9-style) 21 747-1162A Hood Hinge Rod 22 625-0051 Headlight Assembly 23 710-0604A Self-tapping Screw, 5/16-18 x .625 24 751-0603 Fuel Cap 25 751-0658B Fuel Tank, Three-gallon 26 725-1745 Ignition Key w/ plastic cover

27 710-0895 Self-tapping Screw, 1/4-15 x .75 28 710-3217 Truss Phillips Screw, #8-32 x .375 29 712-0142 Hex Nut, #8-32 30 731-1857 Throttle Control Knob 31 731-2225C Dash Panel, 8/9-style, Electric PTO 32 731-2226 Cruise Control Button 33 731-2227 Parking Brake Button 34 736-0142 Flat Washer, 9/32 x 1/2 x 1/16 35 747-1196 Brake/Cruise Pivot Rod 36 749-1087A Dash Support Tube 37 712-3010 Hex Nut, 5/16-18 38 731-2270 Hood Plenum* 39 726-3046 Ratchet Clip 40 736-0119 Lock Washer, 5/16 41 726-0201 Speed Nut, .3125 42 736-3078 Flat Washer, .349 x 1.0 x .063 43 710-1238 Screw, 5/16-18 x .875 (Grade 5) 44 725-1752 Electric PTO Switch 45 711-0332 Clevis Pin, .50 x .78 46 768-0010 Bumper Assembly 47 714-0145 Internal Cotter Pin

— 629-0469A Headlight Wire Harness — 629-1067 Tractor Wire Harness

PART

NO. DESCRIPTION

725-1744 Ignition Key w/o plastic cover

*Not standard on all tractors.

Models B809H & R809K

43 42

45 41

37 48

44 30

40 36 47 16

38 28 35

17 21

10 20

2 24

14 52

25 19

9 7

REF.

NO.

1 747-1130B Deck Stabilizer Rod (Model B809H)

2 683-0197A Lift Shaft Assembly (Model B809H)

3 711-0332 Clevis Pin, .5 x .78 4 712-0206 Hex Nut, 1/2-13 5 712-0431 Flange Lock Nut, 3/8-16 6 712-3004A Flange Lock Nut, 5/16-18 7 712-3083 Hex Nut, 1/2-13 8 714-0104 Internal Cotter Pin

9 714-0145 Internal Cotter Pin 10 716-0106 E-ring 11 720-0311 Handle Grip 12 732-0874 Torsion Spring 13 732-1184 Extension Spring, .84 x 4.6 14 736-0275 Flat Washer, 5/16 15 736-0921 Lock Washer, 1/2 16 736-3019 Flat Washer, .31 x 1.062 x .134 17 736-3084 Flat Washer, .51 x 1.12 x .06 18 738-0138A Hex Cap Screw, 5/16-18 x .62 19 738-0143 Shoulder Screw, 3/8-16 20 741-0225 Hex Flange Bearing 21 741-0715 Snap Flange Bearing 22 746-0968 Lift Cable, 16.16 23 747-1111A Lift Handle 24 756-1154 Roller Pulley 25 783-0678A Arm Lift 26 783-0720A Deck Stabilizer Bracket 27 710-0260A Carriage Bolt, 5/16 x .62 28 710-0604A Self-tapping Screw, 5/16-18 x .625 29 710-0895 Self-tapping Screw, 1/4-15 x .75 30 731-1990 Lift Lever Cover 31 731-1993 Cover w/ Cup Holder

PART

NO. DESCRIPTION

747-1324 Deck Stabilizer Rod (Model R809K)

683-0642 Lift Shaft Assembly (Model R809K)

Models B809H & R809K

REF.

NO.

32 736-3078 Flat Washer, .349 x 1.0 x .063 33 783-0677 Lift Adjustment Bracket 34 783-1280 Fender 35 783-1489 Seat Mounting Bracket 36 710-1268 Screw, #10-16 x .375 37 712-3027 Hex Flange Lock Nut, 1/4-20 38 720-0309A Seat Adjuster Grip 39 731-1989 Spacer 40 732-0499 Compression Spring, .41 x 1.5 41 736-0175 Spring Washer, .265 x .562 x .025 42 736-0204 Flat Washer, .344 x .62 x .03 43 738-0137A Shoulder Screw, .340 x .285,1/4-20 44 738-1007 Shoulder Screw, .50 x .50, 3/8-16 45 783-0611 Seat Stop 46 783-0738 Seat Pivot Bracket 47 783-0739 Seat Adjustment Lever 48 783-0753 Seat Adjustment Selector 49 757-0350 High Back Seat w/ Drain Holes, Black 50 735-0656 RH Foot Pad 51 735-0657 LH Foot Pad

— 726-3046 Foot Pad Clips 52 714-0111 Cotter Pin 53 731-0511 Trim Strip 54 783-0209A LH Seat Lift Bracket

— 17239A RH Seat Lift Bracket 55 710-0924 Phillips Pan Screw, 1/4-20 x .75 56 712-0292 U-type Speed Nut, 1/4-20 57 731-2480 Shift Lever Cover 58 738-0296 Shoulder Screw, .437 x .286 59 731-2618 RH Fender Flare 60 731-2619 LH Fender Flare 61 783-1478 Fender Clips

PA RT

NO. DESCRIPTION

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 Powder Black, the part number to order would be 700-xxxx-0637.

Red: 0638

Oyster Gray: 0662

Powder Black: 0637

Models B809H & R809K

20 1

13 22

15 12

10 17

Models B809H & R809K

REF.

NO.

1 710-1260A Self-tapping Screw, 5/16-18 x .75 2 710-0604A Self-tapping Screw, 16-18 x .625 3 783-0726B RH Pivot Support Bracket 4 783-0727A LH Pivot Support Bracket 5 783-0728 Pivot Bar Bracket 6 710-0514 Hex Cap Screw, 3/8-16 x 1 (Grade 5) 7 711-1408 RH Drag Link 8 711-1655 LH Drag Link

9 712-0240 Jam Nut, 7/16-20 (Grade 2) 10 712-0241 Hex Nut, 3/8-24 (Grade 2) 11 712-0431 Flange Lock Nut, 3/8-16 12 712-0459 Flange Lock Nut, 7/16-20 13 712-3004A Flange Lock Nut, 5/16-18 14 717-1550D Steering Gear, 11/90 Ratio 15 717-1554 Steering Pinion Gear 16 723-0448A Ball Joint, 7/16-20 17 736-0169 Lock Washer, 3/8 18 736-3084 Flat Washer, .51 x 1.12 x .06 19 738-1001A Steering Shaft, .625 OD x 24.4 20 741-0475 Plastic Bushing, .38 ID 21 741-0656 Hex Flange Bearing, 5/8 22 738-0372B Shoulder Spacer, .38 ID 23 731-2624 Steering Wheel, Soft Grip, Three Spoke 24 731-2625 Steering Wheel Cap, Round 25 638-0017 LH Axle Assembly, .75 Diameter 26 638-0018 RH Axle Assembly, .75 Diameter 27 719-0525B Cast Iron Pivot Bar w/ Fittings, .75 28 712-0431 Flange Lock Nut, 3/8-16 29 714-0162 Cotter Pin 30 726-0341 Push Cap, .750 31 736-0242 Bell Washer, .34 x .872 32 736-0316 Flat Washer, .78 x 1.59 x .06 33 736-0285 Flat Washer, .635 x 1.589 x .06 34 738-1011 Shoulder Screw, .5 x 2.2, 3/8-16 35 710-0643 Hex Bolt, 5/16-18 X 1 36 634-0183 Wheel Assembly Complete, 16 x 6.5 x 8

37 734-2290 Hub Cap 38 783-0653E Steering Support Bracket 39 738-0143 Shoulder Screw, 3/8-16 40 736-0331 Bell Washer, .39 x 1.13 x .062 41

PART

NO. DESCRIPTION

634-0182 Rim Only w/ Plastic Bearing 734-0255 Air Valve (Not Shown) 734-1727 Tire Only, Square Shoulder

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 Powder Black, the part number to order would be 700-xxxx-0637.

Red: 0638

Oyster Gray: 0662

Powder Black: 0637

Models B809H & R809K

16 28

61 53

50 66

20 46

18 29

42 43

40 36

33 43

52 51

1127

REF.

NO.

1 618-0375 Variable-speed Bracket Assembly 2 618-0376 Two-speed Transmission Assembly 3 631-0009A Shfter Knob 4 647-0037 Shift Lever 5 656-0050 Variable-speed Pulley Assembly 6 756-0665 Transmission Pulley, 8.5 7 683-0251 Double-idler Bracket 8 710-0176 Hex Cap Screw, 5/16-18 x 2.75

9 710-0227 Self Tapping Screw, #8-18 x .5 10 710-0347 Hex Cap Screw, 3/8-16 x 1.75 11 710-0805 Hex Cap Screw, 5/16-18 x 1.5 12 710-0809 Self-tapping Screw, 1/4-20 x 1.25 13 710-0604A Self Tapping Screw, 5/16-18 x .625 14 710-3011 Hex Cap Screw, 3/8-16 x 2.25 15 711-0677 Ferrule, 5/16 x .312 Dia. 16 712-0181 Hex Jam Nut, 3/8-16 17 712-0702 Hex Flange Nut, 7/16-20 18 712-0431 Flange Lock Nut, 3/8-16 19 712-0798 Hex Nut, 3/8-16 20 712-3004A Flange Lock Nut, 5/16-18 21 712-3008 Hex Jam Nut, 3/8-16 22 714-0111 Cotter Pin 23 723-3018 Ball Joint, 3/8-24 24 725-1713 Spring Switch 25 726-0320 Insulator Nut Plate 26 732-0384 Extension Spring, .62 Dia. x 6.12 27 732-0716 Extension Spring, .59 OD x 4.0 28 736-0105 Bell Washer, .401 x .870 x .063 29 736-0169 Lock Washer, 3/8 30 736-0275 Flat Washer, 5/16 31 718-0771 Pulley Hub, 1/2 Spline 32 736-0642 Flat Washer, .44 x .75 x .06 33 736-3010 Flat Washer, .407 x .812 x .135 34 738-0322 Shoulder Screw, .625 Dia. x .21 35 747-1122 Brake Rod 36 747-1123A Belt Guard 37 747-1127 Idler Adjustment Rod, 3/8 38 710-1026 Self-tapping Screw, 1/4-20 x 1.75 39 747-1185 Transmission Belt Guard Rod 40 738-0372B Shoulder Spacer, .380 ID 41 754-0468 Variable-speed Belt 42 754-0467 Drive Belt 43 756-0981A Flat Idler, 2.75 OD 44 783-0667A Transmission Torque Bracket 45 783-0669 Idler Bracket

PART

NO. DESCRIPTION

Models B809H & R809K

REF.

NO.

46 647-0031 Brake Control Shaft Assembly 47 647-0032 Speed Control Shaft Assembly 48 683-0266 Drive Pedal Assembly 49 710-1135 Self Tapping Screw, 5/16-18 x 2.5 50 711-0736 Ferrule, 1/4-20 51 711-1363 Pin, 3/8-16 x 2.43 52 714-0104 Cotter Pin 53 732-0437 Compression Spring, .34 OD x 1.0 54 732-0955 Extension Spring, .5 OD x 1.41 55 735-0662 Drive Pedal Pad 56 735-3049 Brake Pedal Pad 57 736-0140 Flat Washer, .281 x .5 x .0625 58 736-0142 Flat Washer, 9/32 x 1/2 x 1/16 59 736-0187 Flat Washer, .64 x 1.24 x .06 60 736-0204 Flat Washer, .344 x .062 x .03 61 738-0155 Shoulder Screw, .437 x 1.62 62 738-0507B Shoulder Screw, .5 x .434 63 741-0225 Hex Flange Bearing 64 741-3065B Split Hex Flange Bearing 65 747-1137 Cruise Control Rod 66 747-1138 Brake Lock Control Rod 67 748-0413 Cruise Latch 68 748-0415B Spacer, 5/16 x 1.54 69 783-0653E Steering Support Bracket 70 783-0732 Drive Lockout Bracket 71 783-0773 Brake Pedal 72 736-3008 Flat Washer, .344 x .750 x .120 73 783-0693 Axle Bracket 74 683-0304A Lower Frame Assembly 75 732-0963 Extension Spring, .5 OD x 6.37 76 731-2290 Hub Cap 77 712-3050 Lug Nut, 7/16-14 78 634-0132 Wheel Assembly Complete, 23 x 9.5 x 12

79 750-0768 Split Spacer, .25 x .37 x 1.32 80 750-0566A Spacer, .372 x .26 x 1.03 81 712-3026 Jam Nut, 3/4-16 82 736-0316 Flat Washer, .78 x 1.59 x .06 83 710-1260A Hex Screw, 5/16-18 x .75 84 747-1185 Transmission Belt Guard Rod 85 710-0599 Self Tapping Screw,1/4-20 x .5 86 756-0639A Engine Pulley, 3.56”

PA RT

NO. DESCRIPTION

634-0182 Rim Only 734-0255 Air Valve 734-1728 Tire Only, Square Shoulder

IMPORTANT:

For a proper working machine, use Factory Approved Parts. V-belts are designed to engage and disengage safely. A substitute (non OEM) V-belt can be dangerous by not disengaging completely.

Red: 0638

Oyster Gray: 0662

Powder Black: 0637

Models B809H & R809K

44*

43 42

Models B809H & R809K

REF.

NO.

1 618-0225 Reverse Collar Assembly 2 618-0226 Hi-Lo Collar Assembly 3 618-0227A Shift Fork Assembly 4 618-0284 Detent Block Assembly 5 618-0285 Output Bearing Block Assembly 6 618-0286 Output Seal Bearing Block Assembly 7 618-0287 Inboard Sealed Axle Block Assembly 8 618-0302 Inboard Sealed Axle Block Assembly

9 618-0365 Wheel Hub Assembly 10 618-0368 Differential Axle Assembly 11 719-0379A Upper Housing 12 641-0002A Axle Bearing Block Assembly 13 661-0012 Brake Assembly 14 710-0642 Self-tapping Screw, 1/4-20 x .75 15 710-0788 Self-tapping Screw, 1/4-20 x 1.0 16 711-1051A Drive Shaft 17 711-1216 Output Shaft 18 712-1329 Nut, 3/4-16 19 713-0446 9-tooth Sprocket 20 713-0447 16-tooth Sprocket 21 713-0448 22-link Chain, .625 22 716-0131 External Snap Ring 23 717-0678 Brake Pad 24 717-1438 41-tooth Bevel Gear 25 717-1439 20-tooth Spur Gear 26 717-1440 10-tooth Spur Gear 27 717-1441 27-tooth Spur Gear 28 717-1442 37-tooth Spur Gear 29 718-0500 Inner Axle Bearing Block 30 718-0504 Shifter Insert 31 718-0505 Shifter Cover 32 718-0537 Shifter Bearing Block 33 719-0385 Lower Housing 34 718-0540 Lockout Plate 35 736-0337 Flat Washer, 5/8 x 1.0 36 736-3046A Flat Washer, 1.01 x 1.86 x .060 37 711-1235 Input Shaft 38 747-1140 Shift Lever 39 750-1033A Spacer, 1.13 x 1.38 x 1.968 40 761-0215 Disc Brake 41 716-0114 Retaining Ring, .56 42 717-1463 13-tooth Bevel Gear 43 736-0335 Flat Washer 44 736-0336 Flat Washer, 5/8 x 1.0 x .030*

46 741-0335 Needle Bearing 47 741-0696 Needle Bearing 48 716-0231 E-ring, .75 49 618-0376 Transmisssion Assembly Complete

PART

NO. DESCRIPTION

736-0337 Flat Washer, 5/8 x 1.0 x ..040* 736-0349 Falt Washer,5/8 x 1.0 x .020*

NOTE: Transmission has a grease capacity of 32 oz. Order part number 737-0148.

NOTE: Upon reassembling transmission input shaft for any reason, refill its cavity with approximately 2/3 oz. of grease.

Order part number 737-0289.

*Use applicable flat washer (12a, 12b or 12c) in this application allowing proper end-play as instructed in Tr oy- Bi lt’s Service Manual.

Models B809H & R809K

21 22

11*

10*

* Found on Model B809H only.

12*

28*

14*

13*

16*

Models B809H & R809K

REF.

NO.

1 783-0653E Steering Support Bracket

2 754-0476 PTO Belt 3a 717-1709 Electric PTO Clutch (Model B809H) 3b 717-1774 Electric PTO Clutch (Model R809K) 4a 783-1003 PTO Clutch Anti-rotation Bracket (Model B809H) 4b 783-1487 PTO Clutch Anti-rotation Bracket (Model R809K)

5 710-0859 Hex Cap Screw, 3/8-16 x 2.5

6 710-1238 Hex Head Washer Screw, 5/16-18 x .875

7 712-0431 Flange Lock Nut, 3/8-16

8 732-0978 Extension Spring, .62 x 5.62

9 712-3004A Flange Lock Nut, 5/16-18 10 710-3180 Hex Cap Screw, 5/16-18 x 1.75 11 712-3010 Hex Nut, 5/16-18 12 683-0294 Idler Bracket Assembly 13 738-3056 Shoulder Screw, 1/2 x 2.5 14 710-3144 Hex Cap Screw, 3/8-16 x 2.0 15 710-3025 Hex Cap Screw, 5/16-18 x .625 16 738-0785 Shoulder Spacer, 1.38 x .445 x .36 17 736-0171 Lock Washer, 7/16 18 710-3157 Hex Cap Screw, 7/16-20 x 3.25 (Grade 5) 19 725-1706 12-volt Battery, 270 CCA 20 710-0751 Hex Cap Screw, 1/4-20 x .62 21 712-0271 Hex Sems Nut, 1/4-20 22 712-3087 Wing Nut, 1/4-20 23 725-1426 Solenoid, 12-Volt, 100 Amp 24 710-0599 Self Tapping Screw, 1/4-20 x .5 25 736-0222 Lock Washer, 1/4 26 783-1033A Hitch Plate 27 748-0415B Spacer, 3/8 x 1.54 28 756-0627B Idler Pulley, 3.5 29 783-0349 Battery Tray 30 712-0459 Flange Lock Nut, 7/16-20 31 783-0891B Deck Stop 32 710-0604A Self Tapping Screw, 5/16-18 x .625 33 732-3080 Compression Spring, 1.28 x 3.5 34 723-0444 Battery Strap 35 738-1020 Shoulder Screw, .625 x .5, 7/16-20 36 736-0407 Bell Washer, .45 x 1.0 x .062 37 738-1132 Shoulder Screw, 1/4-20, .25 x .15 38 736-0322 Flat Washer, .45 x 1.25 x .164

PART

NO. DESCRIPTION

IMPORTANT:

For a proper working machine, use Factory Approved Parts. V-belts are designed to engage and disengage safely. A substitute (non OEM) V-belt can be dangerous by not disengaging completely.

Red: 0638

Oyster Gray: 0662

Powder Black: 0637

Model B809H

22 26

Model B809H

IMPORTANT:

For a proper working machine, use Factory Approved Parts. V-belts are designed to engage and disengage safely. A substitute (non OEM) V-belt can be dangerous by not disengaging completely.

REF.

NO.

1 16606 Retainer Hook 2 17982 Spindle Reinforcement Plate 3 618-0430A Spindle Assembly, 5.0 Dia.

4 618-0431 Double Pulley Spindle Assembly

5 683-0254 Deck Adjustment Bracket Assembly 6 683-0199C 46-inch Deck Shell 7 710-0167 Carriage Screw, 1/4-20 x .50 8 710-0344 Hex Cap Screw, 3/8-16 x 1.5

9 710-0501 Hex Cap Screw, 1/4-20 x 2.0 10 710-0514 Hex Cap Screw, 3/8-16 x 1.0 11 710-0528 Hex Cap Screw, 5/8-18 x 1.25 12 710-0599 Self-tapping Screw,1/4-20 x .5 13 710-0650 Self-tapping Screw,15/16-18 x .875 14 710-0703 Hex Screw, 1/4-20 x .75 15 710-0751 Hex Cap Screw, 1/4-20 x .62 16 710-1260A Self-tapping Screw, 5/16-18 x .75 17 712-0271 Hex Sems Nut, 1/4-20 18 712-0417A Hex Flange Nut, 5/8-18 19 712-0431 Flange Lock Nut, 3/8-16 20 712-3006 Hex Nut, 1/4-20 21 712-3027 Hex Flange Lock Nut, 1/4-20 22 714-0470 Cotter Pin, 1/8 x 1.25 23 717-1553A Deck Adjustment Gear 24 726-0233 Push Nut. .25 x .5 25 731-1032B Side Discharge Chute Assembly 26 732-0306 Compression Spring, .406 x .531 x 1.75 27 732-0594A Extension Spring, .91 x 7.3 28 710-0578 Screw, 1/4-20 x 1.5 29 734-0973 Deck Wheel, 5 x 1.38 30 736-0105 Bell Washer, .401 x .87 x .063 31 736-0119 Lock Washer, 5/16 32 736-0270 Bell Washer, .265 x .75 x .062 33 738-0347 Shoulder Spacer, .625 x 1.16 34 738-0373 Shoulder Screw 35 742-0611 Three-in-one Blade, Star Center, 16.28" 36 742-0612 Three-in-one Blade, Star Center, 14.88" 37 747-1116 Deck Release Pin 38 754-0349 Deck Belt, Poly 39 738-3056 Shoulder Screw, 1/2-2.5 40 756-0627B Idler Pulley, 3.5 41 734-3058B Deck Wheel, 5.0 42 783-0139A Idler Bracket 43 783-0141 Center Deck Skirt 44 783-0142 RH Deck Skirt 45 783-0747 LH Belt Cover 46 783-0805A RH Belt Cover 47 753-0875 46-inch Deck Assembly Complete

PA RT

NO. DESCRIPTION

756-1187 Pulley Only

756-0603 Double Pulley Only

Model R809K

REF.

NO.

1 12650 Bracket, Adjustment, Height 2 16606 Bracket, Hook, Retainer 3 618-0671 Spindle Assembly, Pulley, 5.39 Dia x .5625 4 683-0254 Bracket Assembly, Deck, Hanger LH 5 683-0459 Idlr Assembly, 54" 6 683-0608 Bracket Assembly, Lift, 54" 7 683-0609 Bracket Assembly, LH-Front 8 683-0610 Bracket Assembly, RH-Front

9 683-0617 Stop Assembly, Chute 10 703-2093 Baffle, RR, Inner 11 703-2392 Bracket 12 703-3511 Guard, Finger 13 710-0528 Hex Screw, 5/16-18, 1.25, Gr5, 14 710-0602 Screw, Self-tapping, 5/16-18, 1.000 15 710-0604A Screw, Self-tapping, 5/16-18, 0.625 16 710-0751 Hex Screw, 1/4-20, .620, Gr5, 17 710-1644 Screw, Carriage, 3/8-16, Gr5, 5.00 18 710-3011 Hex Screw, 3/8-16, 2.25, Gr5, 19 710-3073 Hex Screw, 5/16-18, 2.25, Gr5, 20 710-3168 Bolt, Carriage, 3/8-16 x 1.0 21 710-3178 Short Neck Carriage Bolt 3/8-16 x .75 22 711-0332 Pin, Clevis, .50 Dia x .78 23 711-1737 Pin, Roller, .5" Dia x 10.06 . 24 711-1762 Pin, Hinge, Dia .375 x 14.06 25 712-0417A Nut, Hex Flange, 5/8-18 26 712-0431 Nut, Flange Lock, 3/8-16 27 712-3004A Nut, Flange Lock, 5/16-18, Gr5 28 712-3010 Nut, Hex, 5/16-18, Gr5 29 712-3019 Nut, Hex, 7/16-14, Gr2 30 712-3022 Nut, Hex Lock, 1/2-13 31 712-3027 Nut, 1/4-20, Hexflg, Lock 32 714-0145 Pin, Click, .092 x 1.64 33 714-0470 Pin, Cotter, 1/8 x 1.25 34 714-3004 Pin, Cotter, 3/32 x 1.25 35 715-0108 Pin, Sprg, 1/4 Dia x 1.00 36 715-0246 Pin, Spring, 3/16 x 1.25 37 717-1553A Adjustment, Deck, Gear

PART

NO. DESCRIPTION

Model R809K

REF.

NO.

38 731-0335 Roller, Deck 39 731-3005 Front Roller 40 731-3131A Deflector, Chute 41 732-0306 Spring, Compression, .406 x .531 x 1.75 42 732-0459 Spring, Extension, .94 Dia x 6.74 43 732-0934 Spring, Extension, 1.15 Dia x 5.99 44 732-3070 Torsion Spring .44 I.d. x 2.10 45 734-3058B Deck Wheel, 5" Dia. 46 736-0105 Washer, Bell, .375 x .870 x .063 47 736-0119 Washer, Lock, 5/16, Regular Duty 48 736-0134 Flat Washer, .812 ID x 1.38 OD x .1 49 736-0171 Washer, Lock, 7/16 , Regular Duty 50 736-0208 Flat Washer, .51 ID x 1.5 OD x .07 51 736-0921 Washer, Lock, 1/2 , Regular Duty 52 736-3027 Flat Washer, .531 x 1.75 x .090 53 736-3039 Flat Washer .406 ID X 1.5 x 11ga 54 736-3072 Washer, Flat .38 ID x.93 OD x.110 55 738-0295 Shoulder Screw, .750 x .47.12 56 738-1229 Shoulder Screw, 5/8 Dia x 2.50 . 57 738-3056 Shoulder Screw, 1/2 Dia x 2.50 . 58 742-0677 Blade, 18.50" 59 747-1116 Deck Release Handle Rod, .375 Dia 60 750-0151 Spacer .550 ID x .755 OD x 1.1 61 750-0212 Spacer, .82 ID x 1.00 OD x .53 62 750-3213 Spacer, .405 x .75 x 3.875 63 754-0642 Belt, V-Type, B Section 64 756-3105 Pulley, Idler, 5.0 Dia. 65 783-1453 Bracket, Mounting, 54" Roller 66 783-1454 Bracket, Roller, Front 67 783-1455 Bracket, Idler 68 783-1470 Cover, Spindle RH 69 783-1471 Cover, Spindle LH 70 783-1479 Deck Shell Assembly, 54" 71 783-1482 RH Skirt 72 783-1483 LH Skirt 73 783-1484 LH Extension Skirt 74 753-04000 54-inch Deck Assembly Complete

PA RT

NO. DESCRIPTION

IMPORTANT:

For a proper working machine, use Factory Approved Parts. V-belts are designed to engage and disengage safely. A substitute (non OEM) V-belt can be dangerous by not disengaging completely.

Red: 0638

Oyster Gray: 0662

Powder Black: 0637

MANUFACTURER’S 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.

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 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 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.

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.

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 1330-558-7220, or log on to our Web site at www.troybilt.com.

This limited warranty does not provide coverage in the following cases:

a. The engine or component parts thereof. These items

carry a separate manufacturer’s warranty. Refer to applicable manufacturer’s warranty for terms and conditions.

b. Log splitter pumps, valves, and cylinders have a sepa

rate one year warranty.

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.

d. Troy-Bilt LLC does not extend any warranty for

products sold or exported outside of the United States, its possesions and territories, except those sold through Troy-Bilt LLC’s authorized channels of export distribution.

e. Parts that are not genuine Troy-Bilt parts are not

covered by this warranty.

f. Service completed by someone other than an

authorized service dealer is not covered by this warranty.

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.

The provisions as set forth in this warranty provide the sole and exclusive remedy arising from the sale. TroyBilt 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.

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 shall not extend to anyone other than the original purchaser or to the person for whom it was purchased as a gift.

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

Troy-Bilt B809H, R809K User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual