Troy-Bilt J860 Series, Operator'S Manual

Page 1: ... Up Operation Maintenance Service Troubleshooting Warranty WARNING READ AND FOLLOW ALL SAFETY RULES AND INSTRUCTIONS IN THIS MANUAL BEFORE ATTEMPTING TO OPERATE THIS MACHINE FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY Form No 769 03842 January 28 2008 Self Propelled Mower Model Series J860 ...

Page 2: ...o all models Troy Bilt LLC reserves the right to change product specifications designs and equipment without notice and without incurring obligation This product has met the rigid safety standards of the Outdoor Power Equipment Institute and an independent testing laboratory If you have any problems or questions concerning the machine phone a authorized Troy Bilt service dealer or contact us direc...

Page 3: ...s and pets at least 75 feet from mower while it is in operation Stop machine if anyone enters area Always wear safety glasses or safety goggles during 9 operation and while performing an adjustment or repair to protect your eyes Thrown objects which ricochet can cause serious injury to the eyes Wear sturdy rough soled work shoes and close fitting 10 slacks and shirts Shirts and pants that cover th...

Page 4: ...t 25 adjustment while the engine is running Only use parts and accessories made for this machine by 26 the manufacturer Failure to do so can result in personal injury When starting engine pull cord slowly until resistance 27 is felt then pull rapidly Rapid retraction of starter cord kickback will pull hand and arm toward engine faster than you can let go Broken bones fractures bruises or sprains c...

Page 5: ...he blade and engine mounting bolts at frequent 3 intervals for proper tightness Also visually inspect blade for damage e g bent cracked worn Replace blade with the original equipment manufacture s O E M blade only listed in this manual Use of parts which do not meet the original equipment specifications may lead to improper performance and compromise safety Mower blades are sharp and can cut Wrap ...

Page 6: ... the muffler is available through your nearest engine authorized service dealer or contact the service department P O Box 361131 Cleveland Ohio 44136 0019 Average Useful Life According to the Consumer Products Safety Commission CPSC and the U S Environmental Protection Agency EPA this product has an Average Useful Life of seven 7 years or 140 hours of operation At the end of the Average Useful Lif...

Page 7: ... a guide to determine slopes where you may not operate safely WARNING Do not operate your lawn mower on such slopes Do not mow on inclines with a slope in excess of 15 degrees a rise of approximately 2 1 2 feet every 10 feet A riding mower could overturn and cause serious injury Operate riding mowers up and down slopes never across the face of slopes Operate walk behind mowers across the face of s...

Page 8: ...te the hairpin clip on the weld pin on each side of 2 lower handle Remove hairpin clip from this hole Using a pair of a pliers insert hairpin clip into the hole on pin closest to the bracket See Fig 3 2 Repeat on other side Insert a carriage bolt from the hardware pack into b the lower hole on the handle mounting bracket Secure with one plastic wing nut also included in the hardware pack Repeat on...

Page 9: ...on the pivot rod and the rear discharge door rests firmly against top of the grass catcher Hold blade control against upper handle a Pull starter rope out of the engine Release blade b control Slip starter rope into rope guide c Tighten wing nut d Grass Catcher Follow steps below to assemble the grass catcher Make 1 certain bag is turned right side out before assembling warning label will be on th...

Page 10: ...nstructed in the 2 separate engine owner s manual WARNING Use extreme care when handling gasoline Gasoline is extremely flammable and the vapors are explosive Never fuel the machine indoors or while the engine is hot or running Extinguish cigarettes cigars pipes and other sources of ignition Side Discharge Chute To convert to side discharge make sure grass catcher is off of the unit and rear disch...

Page 11: ...Electric start Ignition Switch Blade Control Drive Control Cutting Height Adjustment Lever Mulch Plug Speed Control Speed Control The speed control is located on the variable speed control housing on the upper handle This control is used to select the forward speed of the mower See Fig 4 1 inset IMPORTANT Move the speed control only when the engine is running Changing the speed control setting wit...

Page 12: ... and others WARNING The operation of any lawn mower can result in foreign objects being thrown into the eyes which can damage your eyes severely Always wear safety glasses while operating the mower or while performing any adjustments or repairs on it Once the engine is running squeeze the drive control 1 against the upper handle to propel mower To change speed move speed control to the desired spe...

Page 13: ...points on the rear 3 discharge door and side mulch plug periodically with light oil to prevent rust See Fig 6 1 The transmission is pre lubricated and sealed at the factory 4 and does not require lubrication Follow the accompanying engine manual for lubrication 5 schedule and instruction for engine lubrication Deck Care Clean underside of the mower deck after each use to prevent build up of grass ...

Page 14: ...op of the engine clean to permit proper air circulation Remove all grass dirt and combustible debris from muffler area Replacing Rear Flap To remove rear flap lift rear door remove screw and press 1 flap in on either side to remove from hole See Fig 6 2 Remove screw and flap from opposite hole and replace 2 with new flap in the opposite order and manner of removal Adjustments Variable Speed Cable ...

Page 15: ...r of needle nose pliers or similar tool move 7 eyelet in cable only one slot to the left in housing as shown in Fig 6 5 NOTE Moving eyelet to the left speeds unit up moving it to the right slows it down Replace screw and washer removed earlier Reassemble 8 back of housing Reattach battery harness assembly to the speed control housing making sure to snap the tab on the harness into the slot on the ...

Page 16: ... assembly from the speed 3 control housing See Fig 7 2 Blade Care WARNING When removing the cutting blade for sharpening or replacement protect your hands with a pair of heavy gloves or use a heavy rag to hold the blade Periodically inspect the blade adapter for cracks especially if you strike a foreign object Replace when necessary Follow the steps below for blade service Disconnect spark plug bo...

Page 17: ...ep away from children Do not puncture disassemble mutilate or incinerate the battery Explosive gases could be vented during charging or discharging Use in a well ventilated area away from sources of ignition NOTE The special designed plug on the charger will only fit into the plug on the battery box Plug the battery charger into the port on the underside of 1 the battery housing See Fig 7 4 Insert...

Page 18: ... Blown Fuse Off Season Storage The following steps should be taken to prepare your lawn mower for storage Clean and lubricate mower thoroughly as described in the lubrication instructions Do not use a pressure washer or garden hose to clean your unit Coat mower s cutting blade with chassis grease to prevent rusting Refer to engine manual for correct engine storage instructions Store mower in a dry...

Page 19: ...ir cleaner 5 Unit running with CHOKE if equipped 6 applied Connect and tighten spark plug boot 1 Clean fuel line fill tank with clean fresh 2 gasoline Clear vent 3 Drain fuel tank Refill with fresh fuel 4 Refer to engine manual 5 Push CHOKE knob in 6 Engine overheats Engine oil level low 1 Air flow restricted 2 Fill crankcase with proper oil 1 Clean area around and on top of engine 2 Occasional sk...

Page 20: ...sition 1 if equipped with individual height adjusters Sharpen or replace blade 2 Mower will not self propel Belt not installed properly 1 Debris clogging drive operation 2 Damaged or worn belt 3 Check belt for proper pulley installation and 1 movement Stop engine disconnect spark plug boot 2 and clean out debris Inspect and replace belt 3 ...

Page 21: ...Notes 9 21 ...

Page 22: ...s J860 50 55 54 28 43 42 41 44 11 45 35 12 10 10 23 2 6 7 39 37 1 49 5 13 36 31 15 21 19 17 8 38 14 46 20 48 56 4 51 22 3 46 18 47 27 34 53 25 30 26 29 16 9 25 30 40 10 33 32 24 10 26 A B B A 52 46 59 57 58 46 60 61 ...

Page 23: ...18 27 731 05462A Trailshield 28 731 05157 Mulch Plug 29 731 05017A Rear Door 30 710 1241 Screw 1 4 15 x 1 00 Ref No Part Number Description 31 720 04072 Star Knob 32 732 04534 Torsion Spring RH 33 711 04374 Door Pivot Rod 34 647 04051 Grass Catcher Frame 35 664 04045 Grass Catcher 36 710 1174 Carriage Bolt 5 16 18 x 2 00 37 720 0279 Wing Nut 38 710 1205 Eye Bolt 39 749 04436 Upper Handle 40 736 02...

Page 24: ...24 Model Series J860 45 13 29 46 18 43 42 19 16 44 12 14 15 17 40 21 51 50 27 49 47 28 20 12 37 38 9 7 9 10 11 A A 12 10 5 5 8 48 33 32 34 35 36 39 1 30 26 6 4 2 3 28 12 23 25 31 22 24 41 ...

Page 25: ...r Pulley 26 687 02428 Handle Bracket Assembly LH Includes Ref s 18 46 47 Model Series J860 Ref No Part Number Description 27 715 0221 Dowel Pin 28 618 04581 Transmission Assembly 29 687 02429 Handle Bracket Assembly RH Includes Ref s 18 46 47 30 756 04311A Pulley Half 31 732 04313 Extension Spring 32 748 04096 Blade Adapter 33 710 1044 Screw 3 8 24 x 1 50 34 736 0524B Blade Bell Support 35 742 074...

Page 26: ...Notes 26 ...

Page 27: ...27 Notes ...

Page 28: ...anty Refer to applicable manufactur er s warranty for terms and conditions b Log splitter pumps valves and cylinders have a separate 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 Service completed by someone other than a...