Troy-Bilt R809K manual

O per at or’ s Man ual PRI NTED IN U . S .A. 770-1 0189D.fm (12/2001) IMPOR T ANT : READ SAFETY RUL ES AND INST R UCTIONS CAREFUL L Y P e dal Dri v e G ard en T ractor Mo dels B8 09H Wa r n in g : Th is un it is eq ui pp ed wit h an int ern al co mb us ti on en gin e and shou ld no t be us ed on o r ne ar a ny un im pro ve d fore st - co ver e d,[...]

2 TABL E OF CO NT ENTS Conten t Page Import ant Safe Ope rati on Pr act ices ..... .. ... .. ..... .. .. ... .. ... .... ... .. .. ... .. ..... .. ... .. .. ... .... . 3 Slo pe Gau ge.... ... .. .. ... .. ..... .. ... .. .. ... .... ... .. ... .. .. ..... .. ... .. ... .. ..... .. .. ... .. .. ..... ... .. .. ... .. ... 7 Trac tor Se t -up ..... ..[...]

3 SECT I ON 1: I M POR TA NT SAF E OPE RAT I ON PRA C TICE S WARNING: This symbol points out important safety instructions which, if not followed, could enda nger the personal safety and/or property of yourself and others. Read and follow all instructions in t his manua l before attempting to operat e this m achine. Failure to com ply with these in[...]

4 23. Muf fler and engine becom e hot and c an cause a burn. Do not touch. 24. Chec k overhead clearances carefully before drivin g under low hangin g tree branches, wires, door openings etc., whe re the operator may be s truck or pulled from the unit, whic h could result in serious inj ury. 25. Disengage al l attachment clutches, depress th e brak[...]

5 e. Use extreme care when approa ching blind corners, doorways, shrubs, trees or other objects that m ay block your vision of a chil d who may run into the machine . f. Disengage the cutting blade (s) before shif tin g in r ev erse . Th e “ No-Cut-In Reverse ” feature is a rem inder no t to cut in reverse and to help avoid back over ac cidents[...]

6 8. Never tamper wi th t he sa fety inte rlock syst e m or other safety devices. Che ck their proper operation regularly. 9. After striking a foreign obj ect, stop the engi ne, disconne ct the spark plug wire(s) and ground against the engin e. Thoroughl y inspect the machine for any dama ge. Repair the dam age before starting and operating. 10. Ne[...]

7 SECTION 2: SLOPE GAUGE 15° SIGHT AND HOLD THIS LEVEL W ITH A VERTICAL TRE E A POWE R PO LE A CO R NER O F A BU ILDING OR A FENCE PO ST F O L D O N D O T T E D L I N E , R E P R E S E N T I N G A 1 5 ° S L O P E Do not mow on inclines with a slope i n excess of 15 degre es (a ri se of approximately 2-1/2 feet every 10 feet). A ri ding mower coul[...]

8 SECTION 3: TRACTOR SET-UP Attac h ing the B att er y Ca bles NOTE: The positive ba ttery terminal is marked P os. (+). The negative battery term inal is marked Neg. (–). • The positive ca ble (heavy red wire) is secured to the positive batte ry terminal (+) with a hex bolt and hex nu t at the factory. Make certain that the rubb er boot covers[...]

9 Attac h ing The Cu tting D eck ( Model R809K) Fi gure 3 WARNING: Before attaching the cutting deck, engage the parking brake, turn the ignition key to t h e OFF position an d remove the k ey from the switch to avoid accidental st arting. • Raise the deck lift arms up and out of the way by placing the lift lever in the top notch on the right fen[...]

10 SECTION 4: KNOW YOUR GARDEN TRACTOR Fi gure 4 NOTE: A ny reference in this manual to the RIGHT or LEFT side of the tractor is observed from operator ’ s position. A PTO (Power Take-off) Knob H Ignition Switc h B Choke Con trol I Brake P edal C Parking Brak e Button J Drive Peda l D Shift Lever K Cruise C ontrol Button E Cup Holder L Seat A dju[...]

11 Throttle C ontrol Lever T he th ro tt le co nt ro l l eve r is lo cat ed on t he ri ght si de of the tr a c to r ’ s dash panel. This lev er controls the speed of the engine. When s et in a given position , the throttle will maintain a uniform engine speed . See Figure 5. Fi gure 5 IMPORT ANT: When ope rating t he tractor with the cutt ing dec[...]

12 Sys tems In dica tor Monit or / Ho ur Met er Your tractor is equipped with four indicator lights and an hour meter loca ted on the left side of the dash pa nel. See Figure 7. Fi gure 7 If the Brake light or PTO light illuminat es when attempting to start the unit, proceed as fo llows: Brake — E nga ge the parking brake. PTO — Move t he PTO k[...]

13 Deck L ift L ever Found on your t ractor ’ s right fender, th e deck lift lever is used to change th e height of the cutting dec k. To use, move the leve r to the left, then place in the notch best suited for your application. Parkin g Brak e Bu tt on To set the parking brake, fully depress the b rake p edal and push the parking brake but ton [...]

14 WARNING: Keep han ds an d feet away from the di scharge openi ng of t he cuttin g deck. NOTE: The d eck wheels are an anti-scalp f eature of the deck and are not desi gned to supp ort the w eight of the cut ting deck. Refer to Leveling th e Deck on page 17 of this ma nual for more d etailed instructions regarding vario us d eck adjustments. Star[...]

15 • Watch f o r holes, ruts, b umps, ro cks, or othe r hidden obj ects. Unev en terrain could overturn the machine . Tall grass can hide obst acles. • Avoid turns wh en driving on a s lope. If a t urn m ust be made , turn down the slope. Turni ng up a slope greatly increases t he chance of a roll over. • Avoid sto pping when driving up a slo[...]

16 • Keep the blad es sharp and re place the blade s when worn. Refer to Cutting B lades on pa ge 23 of t hi s manua l for proper blade sharpeni ng instructions. Oper ating The Headlights To t u r n th e tr ac t o r ’ s h eadlights on: • Start the engine following the instructions earlier in this se ction. • Turn the key one not ch count er[...]

17 • Replace hex nut and lock was her and retighten the jam nu t after proper adjustment is achieved. NOTE: Threa ding the ball joints too f ar onto the drag links will cause the fron t tires to "toe-in" too far. Proper toe-in is between 1/16" and 5/16". F ron t ti re t oe -i n can be me as ured as fol low s: • Place the s t[...]

18 Deck Roller Height Adjustme nt (Units with 54- inch Deck) To adjust the heig ht of the rollers on the rear of the mowing deck, proceed as follows: • Place the deck lift l ever in the bottom no tch (lowest position). • Remove th e clevis pins and hai rpin clips from the deck rol ler brackets on the left and right sides of the cutting deck . S[...]

19 Air Cl eaner Service the pre-cleaner, if so equipped, and cartridge/ air cleaner element as instruc ted in the Briggs & Str atton O perator/O wner Manual pa cked with your unit. Spar k Plugs The spark plugs should be cleaned and t he gap reset once a season. Spark plug replacem ent is recommend ed at the start of eac h mowing seas on. Refer [...]

20 Chan ging t he Deck Belt( s) WARNING: Be s ure to shut the e ngine of f, remove ignition key, disconne ct the spark plug wire(s) and ground against the engine to prevent unin tended st arting before re moving t he be lt ( s) . All belts on your tractor are subject to wear and shou ld be replaced if any signs of wear are pres ent. IMPORT ANT: The[...]

21 Figu re 17 Chan ging t he T ra nsmission Drive Belt WARNING: Be s ure to shut the e ngine of f, remove ignition key, disconne ct the spark plug wire(s) and ground against the engine to prevent unin tended st arting before re moving t he be lt ( s) All belts on your tractor are subject to wear and shou ld be replaced if any signs of c racking, sh[...]

22 • Reroute the new uppe r drive belt as shown in Figure 17. L ow er D ri ve B elt NOTE: P roper removal of the lower drive bel t requires the removal of several tractor component s. Read through the following proced ure prior to att e mpting it to determine if you feel you could successfu lly complete it. If you don ’ t, see an a uthorized Tr[...]

23 Cutting Bla des WARNING: Be s ure to shut the eng ine off, remove ignition key , disconnect the spark plug wire(s) and ground against the engine to prevent uni ntended starting before re movin g the cutting blade(s) for sharpening or replacement. Protect yo ur hands by us ing heavy gloves or a rag to grasp the cutti n g blade. WARNING: P eriodic[...]

24 Batte r y The battery is sealed and is m aintenan ce-free. Acid levels cannot be chec ked. • Always keep t he battery cables and terminals clean and free of c orrosive build-up. • After cleaning the battery and terminals, ap ply a light coat of petro leum jelly or grease to both terminals • Always keep th e rubber boot posit ioned over the[...]

25 SECTION 11: TROUBLESHOOTING T r o uble P o ssible Cause(s) Corrective Action Engine f ails to start PT O knob engaged. P arkin g brak e not engaged. Spark plug wire( s) disconnect ed. Thrott le cont rol le ver not in corr ect starting posit ion. Choke not activ ated Fuel t ank empt y , or sta l e f uel. Bloc ked fuel line . F aulty spark pl ug. [...]

26 SECTION 12: MODELS B809H & R809K PARTS LIST 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[...]

27 Models B809H & R809K REF . NO . P ART NO . DESCRIPTI ON 1 710-02 27 Self- tappin g Screw , # 8- 18 x .5 2 710-05 99 Self- t appin g Screw , 1 /4-20 x .5 3 710-06 04A Self- tappin g Screw , 5 / 16-18 x .6 25 4 710 -1237 Screw , #10- 32 x . 625 5 710-13 14A Sock et Cap Scre w , 5/16-18 x .62 5 6 710-13 15 Self- t appin g Screw , 3 /8-16 x 1.25[...]

28 Models B809H & R809K 31 33 27 16 35 9 23 23 5 32 28 30 29 43 23 24 36 25 42 12 34 22 26 6 11 41 40 37 42 3 7 15 1 19 13 4 2 4 18 20 10 8 14 9 5 17 38 27 21 44 45 46 47[...]

29 Models B809H & R809K REF . NO . P ART NO . DESCRIPTI ON 1 783-13 46 Gr il l Support Brack et (9-styl e) 2 710-05 99 Self- t appin g Screw , 1 /4-20 x .5 3 710-05 28 He x Cap Screw , 5/16-1 8 x 1.25 4 710-09 24 Phill i ps P an Scre w , 1/4- 20 x .75 5 710-10 17 T rus s Phill ips Scre w , 1/4-20 x .6 25 6 725-17 41 Ignit ion Swi tch 7 726-02 7[...]

30 50 14 8 52 17 21 10 20 12 23 21 2 2 24 6 2 52 14 18 25 19 5 3 4 1 16 9 7 17 15 6 26 Models B809H & R809K 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 53 58 29 59 60 29 61[...]

31 REF . NO . PA R T NO . DESCRIPTION 1 747- 1130B Dec k St abilizer Rod (M odel B809H) 747-132 4 Dec k St abilizer Rod ( Model R809K) 2 683- 0197A Li ft Shaft Ass emb ly (Model B809H) 683-064 2 Lif t Shaft Ass emb ly (Model R809K) 3 711- 0332 Cle vis Pi n, .5 x .78 4 712- 0206 He x Nut, 1 /2-13 5 712- 0431 Flang e Loc k Nut , 3/8-16 6 712- 3004A F[...]

32 Models B809H & R809K 24 23 43 31 29 2 1 2 5 3 9 6 38 7 10 12 1 3 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[...]

33 Models B809H & R809K REF . NO . P ART NO . DESCRIPTI ON 1 710-12 60A Self- tappin g Screw , 5 / 16-18 x .7 5 2 710-06 04A Self-tapp ing Scre w , 16-18 x . 625 3 783-07 26B R H Piv ot Support Brac ke t 4 783-07 27A LH Piv ot Support Bra ck et 5 7 8 3- 0 72 8 Pi vot Ba r B ra cke t 6 710-05 14 He x Cap Scr ew , 3/8 -16 x 1 (Grade 5) 7 711-14 0[...]

34 Models B809H & R809K 74 60 8 30 24 25 3 21 4 13 18 16 28 32 8 13 13 73 26 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 58 52 71 56 67 57 68 63 18 51 52 23 37 48 13 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 8 1 82 83 72 13 13 20 84 85 31 69 44 43 8[...]

35 REF . NO . PA R T NO . DESCRIPTION 1 618- 0375 V ariabl e-speed Brac ket Assem bly 2 618- 0376 T wo-spe ed T rans m iss i on Assemb ly 3 631- 0009A Shfter Knob 4 647- 0037 Shif t Lev er 5 656- 0050 V ariabl e-speed Pulle y Assemb ly 6 756- 0665 T ransmi ssion Pul ley , 8. 5 7 683- 0251 Doub le-idle r Brac ket 8 710- 0176 He x Cap Sc rew , 5 /16-[...]

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 3 6 2 9 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 B809H & R809K[...]

37 Models B809H & R809K NOTE: T rans mission has a greas e capacity of 32 oz. Order par t number 737-0148. NOTE: Upon reas sembling tr an smission input shaft f or any reason, refill its c avity with a pproximately 2/3 oz. of grease. Order par t number 737-0289. REF . NO . P ART NO . DESCRIPTI ON 1 618-02 25 Re verse Col l ar Assemb ly 2 618-02[...]

38 15 9 1 4a 3a 2* 28* 5 7* 12* 11* 8* 10* 13* 16* 17 18 14* Models B809H & R809K 29 31 34 25 24 35 32 36 32 23 32 33 30 6 27 9 9 26 20 21 22 19 37 38 4b 3b * F ound on Model B 809H only .[...]

39 REF . NO . P ART NO . DESCRIPTI ON 1 783-06 53E Steering Sup por t Brac ket 2 7 54 - 047 6 PTO B e lt 3a 717-17 09 El ectric PT O Clutch (Model B809H) 3b 717-17 74 El ectric PT O Clutch (Model R809K) 4a 783-10 03 PTO Clutch Anti-r ot ati on Brac ket (Model B809H) 4b 783-14 87 PTO Clutch Anti-r ot ati on Brac ket (Model R 809K) 5 710-08 59 He x C[...]

40 30 41 39 Model B809H 12 12 45 46 19 4 4 40 3 38 20 32 24 25 27 9 20 32 19 33 42 8 22 26 37 5 23 31 11 47 48 10 17 6 7 32 21 14 13 16 2 2 13 44 43 19 30 34 29 15 21 1 15 17 18 18 18 35 35 36 47 19[...]

41 Model B809H REF . NO . PA R T NO . DESCRIPTION 1 16606 Retain er Hook 2 17982 Spindl e Reinf orcement Pl ate 3 618-0 430A Spindle As sembl y , 5. 0 Dia. 756-1 187 Pulley Only 4 618-0 431 Doubl e Pulle y Spindl e Assemb ly 756-0 603 Doubl e Pulle y O n ly 5 683-0 254 Deck Adj ustm ent Br ack et Assemb ly 6 683-0 199C 46-inch Dec k Shell 7 710-0 1[...]

42 15 18 54 63 69 64 56 52 5 26 36 53 68 3 26 1 65 67 38 48 61 55 26 41 33 59 6 62 17 26 37 13 47 19 27 28 42 57 45 46 26 8 26 23 70 73 72 39 66 50 60 51 30 34 21 21 20 58 25 71 21 11 10 9 26 24 44 40 20 26 35 22 32 26 38 21 Model R809K 74[...]

43 REF . NO . PA R T NO . DESCRIPTION 1 1265 0 Brac ke t , Ad ju stment , Height 2 1660 6 Brac ke t , Ho ok, Retai ner 3 618- 0671 Spind le Assemb ly , Pul ley , 5.39 Di a x .5625 4 683- 0254 Brac ke t Assemb ly , Deck, Hanger LH 5 683- 0459 Idl r Assemb ly , 54" 6 683- 0608 Brac ke t Asse mbly , Lif t, 54" 7 683- 0609 Brac ke t Assemb ly[...]

44 MANUF A CTURER ’ S LIMITED W ARRANTY FOR: The l imited warr anty s et forth below i s give n by Troy -Bilt LL C with r espect to new merchandi se purchased and used i n the Unit ed States, i ts p ossessi ons and t errito ries. Troy- Bilt LLC wa r rant s this pr oduct again st def ects for a peri od of two ( 2) years co mmencing on t he dat e o[...]