Troy-Bilt J860 Series Operator's Manual
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Troy-Bilt J860 Series Operator's Manual

Troy-Bilt J860 Series Operator's Manual

Self-propelled mower
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Safe Operation Practices • Set-Up • Operation • Maintenance • Service • Troubleshooting • Warranty
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Self-Propelled Mower — Model Series J860
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.
TROY-BILT LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019
Printed In USA
Form No. 769-03842
(January 28, 2008)

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Summary of Contents for Troy-Bilt J860 Series

  • Page 1 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. TROY-BILT LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019 Printed In USA Form No. 769-03842...

  • Page 2: Table Of Contents

    Call a Customer Support Representative at (800) 828-5500 or (330) 558-7220 ◊ Write us at Troy-Bilt LLC • P.O. Box 361131 • Cleveland, OH • 44136-0019 This product has met the rigid safety standards of the Outdoor Power Equipment Institute and an independent testing laboratory.

  • Page 3: Safe Operation Practices

    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.
  • Page 4 A missing or damaged discharge cover can cause blade contact or thrown object injuries. Many injuries occur as a result of the mower being pulled over the foot during a fall caused by slipping or tripping. Do not hold on to the mower if you are falling; release the handle immediately.
  • Page 5 Service Safe Handling Of Gasoline: 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.

  • Page 6: Spark Arrestor

    Spark Arrestor WARNING: This machine 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.
  • Page 7 2 — i ectiOn MpOrtant peratiOn ractices...

  • Page 8: Assembly & Set-Up

    Assembly & Set-Up Contents of Carton • One Lawn Mower • One Grass Catcher • One Side Discharge Chute Assembly NOTE: This unit is shipped without gasoline or oil in the engine. Fill up gasoline and oil as instructed in the accompanying engine manual BEFORE operating your mower.
  • Page 9 Figure 3-3 Hold blade control against upper handle. Pull starter rope out of the engine. Release blade control. Slip starter rope into rope guide. Tighten wing nut. Grass Catcher Follow steps below to assemble the grass catcher. Make certain bag is turned right side out before assembling (warning label will be on the outside).
  • Page 10 Side Discharge Chute To convert to side discharge, make sure grass catcher is off of the unit and rear discharge door is closed. On the side of the mower, lift the mulching plug. See Fig. 3-7. Figure 3-7 Slide two hooks of side discharge chute under hinge pin on mulching plug assembly.

  • Page 11: Controls & Features

    Controls and Features Electric start Ignition Switch Recoil Starter Blade Control The blade control is attached to the upper handle of the mower. Depress and squeeze it against the upper handle to operate the unit. Release it to stop engine and blade. WARNING: This blade control is a safety device.

  • Page 12: Operation

    Operation Starting Engine WARNING: Be sure no one other than the operator is standing near the lawn mower while starting engine or operating mower. Never run engine indoors or in enclosed, poorly ventilated areas. Engine exhaust contains carbon monoxide, an odorless and deadly gas.

  • Page 13: Maintenance & Adjustments

    Maintenance & Adjustments Maintenance General Recommendations • Always observe safety rules when performing any maintenance. • The warranty on this lawn mower does not cover items that have been subjected to operator abuse or negligence. To receive full value from warranty, operator must maintain the lawn mower as instructed here.
  • Page 14 Engine Care A list of key engine maintenance jobs required for good performance by the mower is given below. Follow the accompanying engine manual for a detailed list and instructions. • Maintain oil level as instructed in engine manual. • Service air cleaner every 25 hours under normal conditions.
  • Page 15 Remove back cover of speed control housing by removing the three screws securing it to the housing. See Fig. 6-4. Figure 6-4 Remove screw and flat washer securing cable. See Fig. 6-4. NOTE: Make sure to take note of which slot in housing cable is in.

  • Page 16: Service

    To ensure safe operation of your mower, periodically check the blade bolt for correct torque. Belt Care NOTE: Several components must be removed in order to change the mower’s belt. See an authorized Troy-Bilt Service Dealer to have your belt replaced. Replacing Battery WARNING: may cause burns.

  • Page 17: Charging Battery

    Carefully remove old battery and replace with new one. Connect the positive lead to the positive side of the battery pack, then connect the negative side. See Fig. 7-3. IMPORTANT: When replacing battery pack in harness assembly, battery pack must be positioned with the positive terminal to the left side and the negative terminal to the right side of panel (Positive terminal is closest to the key switch).
  • Page 18 Replacing Fuse The electric starter circuit and battery are protected by a 40 ampere fuse. If the fuse burns out, the electric starter will not operate. If the unit fails to start with the electric starter, perform the following steps to check the fuse inside the battery housing: Open the battery cover as described in Replacing Battery.

  • Page 19: Troubleshooting

    Troubleshooting Problem Engine Fails to start Engine runs erratic Engine overheats Occasional skips (hesitates) at high speed Idles poorly Excessive Vibration Mower will not mulch grass Cause Blade control disengaged. Spark plug boot disconnected. Fuel tank empty or stale fuel. Engine not primed (if equipped with primer).
  • Page 20 Troubleshooting Problem Uneven cut Wheels not positioned correctly. Dull blade. Mower will not self propel Belt not installed properly. Debris clogging drive operation. Damaged or worn belt. Cause Place all four wheels in same height position (if equipped with individual height adjusters). Sharpen or replace blade.
  • Page 21 Notes...

  • Page 22: Parts List

    Model Series J860...
  • Page 23 Screw, 5/16-18 x .625 712-04063 Flange Lock Nut, 5/16-18 731-05462A Trailshield 731-05157 Mulch Plug 731-05017A Rear Door 710-1241 Screw, 1/4-15 x 1.00 Model Series J860 Part Number Description 720-04072 Star Knob 732-04534 Torsion Spring, RH 711-04374 Door Pivot Rod 647-04051 Grass Catcher Frame...
  • Page 24 Model Series J860...
  • Page 25 Upper Pulley 736-0406 Flat Washer, .442 x 1.38 x .060 756-04317 Lower Pulley 687-02428 Handle Bracket Assembly LH (Includes Ref. #’s 18, 46, & 47) Model Series J860 Part Number Description 715-0221 Dowel Pin 618-04581 Transmission Assembly 687-02429 Handle Bracket Assembly RH (Includes Ref.
  • Page 26 Notes...
  • Page 27 Otes...

  • Page 28: Warranty

    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 and/or its territories and possessions, and by MTD Products Limited with respect to new merchandise purchased and used in Canada and/or its territories and possessions (either entity respectively, “Troy-Bilt”).

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