Troy-Bilt Horse Z809K, Operator'S Manual

Page 1: ...g 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 ...

Page 2: ...s explained below For future reference please copy the model and the serial numbers of the equipment in the space below 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 infor...

Page 3: ...t 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 Avo...

Page 4: ...rop 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 It may cause sliding 6 Do not shift to neutral and coast downhill Over speeding may cause the operator to lose control of...

Page 5: ...requently 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 origina...

Page 6: ...P E 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 WARNING ...

Page 7: ...ns carefully IMPORTANT Your tractor is shipped with motor oil in the engine However you must check the oil level before operating Be careful not to overfill Shipping Brace Removal Locate the shipping brace and accompanying warning tag on the right side of the tractor between the discharge chute and the deck See Figure 2 Figure 2 While holding the discharge chute with your left hand remove the ship...

Page 8: ...rd 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 5 Repeat on the right side Installing the PTO Deck Belt Make certain that the PTO Deck belt is routed around the spindle pulleys found beneath the belt guards and both idler pulleys as illustrated in Figure 4 before proceeding Relieve tension on the deck idler by inse...

Page 9: ...ller 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 5 IMPORTANT Be certain that the left roller bracket and the right roller bracket are set in the same position IMPORTANT After mounting the cutting deck perform any adjustments on the deck if necessary prior to operating t...

Page 10: ... 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 I B A H C E M K J L G F D NOTE Steering Wheel not shown for clarity ...

Page 11: ... 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 is not depressed IMPORTANT Always set the parking brake when leaving the tractor unattended 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 Pow...

Page 12: ...tructions 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 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 If the brake light or PTO...

Page 13: ...e starts release the key It will return to the ON position IMPORTANT Do NOT hold the key in the START 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 NOTE Do NOT leave the choke control on while operating the tractor Doing so will resul...

Page 14: ...cks 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 downwards on the slope Turning upwards on 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 possi...

Page 15: ...t 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 In heavi...

Page 16: ...ts 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 hori...

Page 17: ...e 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 10B Balance the deck by using a wrench to turn the adjustment gear found immediately behind the hex cap screw just lo...

Page 18: ...e air cleaner element as instructed in the engine manual Spark Plugs Clean the spark plugs and reset the gap once a season Spark plug replacement is recommended at the start of each mowing season Refer to the engine manual for correct plug type and gap specifications Cleaning the Engine and Deck Promptly wipe off any fuel or oil spilled on the machine Do not allow grass leaves and dirt to accumula...

Page 19: ...th 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 Ref...

Page 20: ...d 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 According to your tractor model route the new belts as shown in Figure 16 or Figure 17 Remount the belt guards removed earlier Figure 16 Electric PTO Clutch Left Hand Double Pulley Right Hand Double Pulley Center Pulley Deck Idler Pulley Self Tapping Screws beneath bel...

Page 21: ...he 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 counter clockwise to roll the belt off it Remove the upper drive belt by pulling it up through the battery tray opening Reroute the new upper drive belt as shown in...

Page 22: ...igure 19 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 18 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 Remove the drive pedal re...

Page 23: ... not function or your tractor s engine will not crank first check to be certain that the fuse has not blown One fuse is located 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 Replace if necessary I...

Page 24: ...ain 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 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 MODEL DESCRIPTION OEM 190 118 Mulch Kit ...

Page 25: ...ap if damaged Drain fuel tank Refill with clean fresh less than 30 days old gasoline Replace air cleaner cartridge element or clean pre cleaner if so equipped Engine overheats Engine oil level low Air flow restricted Fill crankcase with proper capacity and weight of oil Clean grass clippings and debris from around the engine s cooling fins and blower housing Engine hesitates at high RPM Spark plug...

Page 26: ...26 SECTION 12 PARTS LIST FOR MODELS Z809H Z809K 9 7 11 for choke 13 4 12 6 9 22 18 19 20 8 10 14 10 5 10 5 16 15 1 17 5 24 3 2 21 23 ...

Page 27: ... 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...

Page 28: ...28 22 41 40 37 42 3 7 15 1 19 13 4 2 4 18 20 14 9 5 17 38 27 21 45 46 47 11 44 31 29 30 28 26 6 5 10 8 33 32 35 34 27 16 48 36 24 25 8 43 49 9 50 51 52 23 42 Models Z809H Z809K ...

Page 29: ...3213 Fuel Tank 3 gallon 26 725 1745 Ignition Key w plastic cover 725 1744 Ignition Key w o 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 04215 Cruise Control Button 33 731 04217 Parking Brake Button 34 736 0142 Flat Washer 9 32 x 1 ...

Page 30: ... 8 52 17 21 10 20 12 23 21 22 24 6 2 52 14 18 25 19 5 3 4 1 16 9 7 17 15 6 26 Models Z809H Z809K 32 57 55 56 49 39 46 6 40 45 41 37 43 42 36 47 48 44 16 30 28 38 33 27 31 34 51 11 28 13 35 54 58 29 59 60 29 61 ...

Page 31: ... 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 31 731 1993 Cover w Cup Holder 32 736 3078 Flat Washer 349 x 1 0 x 063 33 783 0677 Lift Adjustment Bracket 34 783 12...

Page 32: ...32 24 23 43 31 29 2 1 2 5 3 9 6 38 7 10 12 13 11 13 14 15 16 17 18 19 21 20 22 20 25 26 27 28 32 30 29 34 30 36 33 37 39 40 11 8 22 4 41 11 Models Z809H Z809K ...

Page 33: ...31 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 ...

Page 34: ...6 9 80 55 52 60 50 66 65 22 59 52 57 70 22 30 20 75 22 57 63 46 64 49 53 61 54 52 71 56 67 57 68 63 18 51 52 23 37 48 24 47 64 7 40 36 33 18 45 29 19 14 80 43 17 5 41 6 10 42 34 1 15 20 13 35 20 18 13 11 27 20 2 76 77 78 12 12 81 82 83 72 25 13 20 84 85 31 69 44 43 86 ...

Page 35: ...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 59 736 0187 Flat Washer 64 x 1 24 x 06 60 736 0204 Flat Washer 344 x 062 x ...

Page 36: ...36 49 48 44 47 11 34 37 43 15 42 41 23 40 13 10 36 8 12 9 18 20 6 36 21 17 27 14 31 31 36 29 7 12 9 18 38 30 5 28 4 35 22 26 2 25 24 16 1 19 4 32 3 33 46 15 Models Z809H Z809K ...

Page 37: ...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 Shi...

Page 38: ...11 8 10 13 16 17 18 14 Models Z809H Z809K 31 6 27 20 21 22 19 37 38 4b 3b Found on Model Z809H only 39 32 33 26 34 32 36 35 32 29 24 25 23 30 30 36 35 41 42 41 42 For reference only Ground Wire 25 43 32 44 40 45 46 47 48 9 9 15 ...

Page 39: ...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...

Page 40: ...20 14 13 50 39 32 1 12 18 22 16 13 19 6 17 17 9 46 22 34 5 15 19 38 31 42 48 11 8 34 21 3 19 43 19 37 29 45 7 2 28 10 33 24 23 40 4 28 23 21 34 27 26 36 18 12 11 30 3 49 25 56 56 57 53 54 55 52 51 Model Z809H ...

Page 41: ...24 717 1553B Deck Adjustment Gear 25 721 04041 Nozzle Adapter 27 726 0233 Push Nut 25 x 5 28 732 0306 Compression Spring 406 x 531 x 1 75 29 732 0594A Extension Spring 91 x 7 3 30 732 0934 Extension Spring 31 734 0973 Deck Wheel 32 734 3058B Deck Wheel 33 736 0119 Lock Washer 5 16 34 736 0270 Bell Washer 265 x 75 x 062 35 736 0760 Lock Washer 36 737 04003 Nozzle Deck Wash Out System 37 738 0347 Sh...

Page 42: ... 22 27 29 74 23 16 64 53 44 53 64 37 29 72 25 20 57 68 56 29 73 29 69 5 68 60 57 20 29 36 46 63 4 15 51 40 29 66 6 17 17 75 3 67 3 7 14 16 29 47 58 32 14 30 54 31 29 24 71 1 35 39 59 38 52 65 43 52 65 52 39 23 27 38 10 23 27 29 19 A A 55 33 62 28 22 76 13 23 22 77 23 23 14 78 70 ...

Page 43: ...A Deflector Chute 46 732 0306 Spring Compression 406 x 531 x 1 75 47 732 0459 Spring Extension 94 Dia x 6 74 48 732 0934 Spring Extension 1 15 Dia x 5 99 49 732 3070 Torsion Spring 44 I d x 2 10 50 734 3058B Deck Wheel 5 Dia 51 736 0119 Lock Washer 52 736 0134 Flat Washer 812 ID x 1 38 OD x 1 53 736 0208 Flat Washer 51 ID x 1 5 OD x 07 54 736 0760 Lock Washer 55 736 0921 Washer Lock 1 2 Regular Du...

Page 44: ...h 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 Par...