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TRilY RILT
Operator's Manual
Pedal Drive Garden Tractor
Horse
TM
(Models T809H & Z809K)
IMPORTANT:
Read safety rules and instructions
carefully
before operating
equipment.
Warning:
This unit is equipped with an internal combustion engine and should not be used on or near any unimproved
forest-cov-
ered, 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. BOX361131CLEVELAND,OHIO44136-0019
PRINTED IN U.S.A.
FORM NO. 770-10189F
(11/2003)
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Summary of Contents for Troy-Bilt Horse Z809K
- Page 1 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. BOX361131CLEVELAND,OHIO44136-0019 PRINTED IN U.S.A. FORM NO. 770-10189F...
- Page 2 This information will be necessary to use the manufacturer's web site and/or help from the Customer Support Department or an authorized service dealer. Copy the model number here: Copy the serial number here: • TROY-BILT 361131 www.trovbilt.com CL_E_NO,OH 4413_ 330-558-7220 •...
- Page 3 SECTION 1: IMPORTANT SAFEOPERATION P RACTICES 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 29. If situations occur which are not covered in this manual, the presence of children. Children are often attracted to use care and good judgment. Contact Troy-Bilt Customer the machine and the mowing activity. They do not Support Line at 1-866-840-6483 for assistance.
- Page 5 extremely flammable and the vapors are explosive. operating the blade disengagement control. If the blades Serious personal injury can occur when gasoline is do not stop within the this time frame, your unit should be spilled on yourself or your clothes which can ignite. Wash serviced professionally by an authorized Service Dealer.
- Page 6 SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE A POWER POLE A CORNER OF A BUILDING OR A FENCE POST £O WARNING &i 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.
- Page 7 SECTION 3: SETTING UPTHETRACTOR NOTE: Any reference here to the RIGHT or LEFT side Place the steering wheel cap over the center of the of the tractor is observed from operator's position. steering wheel and push downward until it "clicks" into place.
- Page 8 both the left-hand deck roller bracket and the right- GasandOilFill-Up hand deck roller bracket. See Figure 6 or refer to The gasoline tank is located under the hood and has a DeckRollerHeight Adjustment on page 9 for more capacity of either two or three gallons. Do not overfill. detailed instructions on adjusting the deck roller upward or downward.
- Page 9 Installing IMPORTANT: Be certain that the FLAT side of the PTO/ the PT0/Deck Belt Make certain that the PTO!Deck belt is routed Deck belt is the side coming in contact with the deck idler pulleys. around the spindle pulleys (found beneath the belt guards) and both idler pulleys as illustrated in With the tension relieved, carefully route the belt Figure 5 before proceeding.
- Page 10 SECTION 4: KNOW YOUR GARDEN TRACTOR A:PTOleverq Wheel not shown Figure7 PTO(Blade Engage) Knob/Lever Ignition Switch Choke Control Brake Pedal Drive Pedal Parking Brake Button Shift Lever Cruise ControtButton Cup Holder Seat Adjustment Lever Deck Lift Lever Systems Indicator Monitor/HourMeter Throttle Control Lever...
- Page 11 Throttle ControlLever Drive Pedal The throttle control lever is The drive pedal is located below j_..._j) located on the right side of the Fas_ the brake pedal on the right front tractor's dash panel. This lever side of the tractor along the controls the speed of the engine.
- Page 12 seat in place. Refer to SeatAdjustment on page 17 of this Indication Remedy manual for more detailed instructions. Deck Lift Lever Brake light on Engage the parking brake. Found on your tractor's right fender, the deck lift lever is PTO light on Move PTO knob to the used to change the height of the cutting deck.
- Page 13 SECTION 5: OPERATING Y OUR GARDEN TRACTOR NOTE: The deck wheels are an anti-scalp feature of the deck and are not designed to support the weight of the WARNING cutting deck. AVOID SERIOUS INJURY ORDEATH Refer to Leveling theDeckon page 16 of this manual for more detailed instructions regarding various deck •...
- Page 14 DrivingOnSlopes Refer to the Slope Gauge on page 6 to help determine WARNING: Do not leave the seat of the tractor without first placing the PTO knob in the slopes where you may operate the tractor safely. disengaged (OFF) position, depressing the brake pedal and engaging the parking brake.
- Page 15 To disengage the PTO, move the PTO lever to the Using theDeckLiftLever "Blade Stop" position. This will cut off power to deck To raise the cutting deck, move the deck lift lever to the or other attachments. left, then place it in the notch best suited for your application.
- Page 16 SECTION 6: MAKING ADJUSTMENTS Hex Nut and Pivot Bar WARNING: Never attempt to make any Lock Washer adjustments while the engine is running, except where specified in the manual. WARNING: Disconnect the spark plug wire(s) and ground against the engine before performing any adjustments, repairs or maintenance.
- Page 17 Withthetractor p arked onafirm,level s urface, position) and rotate both blades so that they are place thedeckliftleverinthetopnotch(highest perpendicular with the tractor. position) androtate thebladenearest thedischarge Measure the distance from the outside of the left chutesothatitis parallel withthetractor. blade tip to the ground and the distance from the Measure t hedistance f romfrontoftheblade tipto outside of the right blade tip to the ground.
- Page 18 SECTION 7: MAINTAINING YOUR GARDEN TRACTOR Air Cleaner WARNING: Before performing maintenance or repairs, disengage PTO, move Service the pre-cleaner, if so equipped, and shift lever into neutral position, set parking cartridge!air cleaner element as instructed in the brake, stop engine and remove key to prevent engine manual.
- Page 19 Lubrication Disengage P TO, m oveshiftleverintotheneutral position, settheparking brake, a ndstopengine. Thread thehosecoupler ( packaged withthis WARNING: Before lubricating, repairing, or manual) o ntotheendofyourgarden hose. inspecting, always disengage PTO, move Attach thehosecoupler t othewaterportonyour shift lever into neutral position, set parking decks surface.
- Page 20 Model T809H Engine Pulley PTO Idler Bracket _Deck Belt (Bottom) (mounted on tractor) _PTO Belt (Top) Right Hand Pulley guard) Left Hand Double Pulley Center Pulley Figure 16 To change or replace the deck belts on your tractor, Model Z809K only: Remove the PTO belt from the electric PTO clutch and from around the PTO idler proceed as fallows: pulley, if present.
- Page 21 IMPORTANT: When removing the battery, disconnect Otherwise, see an authorized Troy-Bilt Service Dealer the negative (black) wire from its terminal first, followed for the job. by the positive (red) wire. Re-install in reverse order.
- Page 22 IMPORTANT: Note the routing of the lower drive belt not to lose the small flat washers found on the pin). around both the pulleys and the belt keepers before See Figure 20. performing the following steps. Remove the drive pedal return spring. Using two 9/16"...
- Page 23 Remove the deck from beneath the tractor, (refer to Blade Separation Ctrtting DeckRemoval 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 Worn I_lade Edge stabilizer.
- Page 24 Start the stalled tractor and leave it running to Charging charge the battery. If the tractor has not been used for an extended Disconnect the negative (-) jumper cable from the period of time, use a voltmeter or load tester to tractor.
- Page 25 SECTION 9: ATTACHMENTS & ACCESSORIES The following attachments and accessories are compatible for tractor Models Z809H & Z809K. 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...
- Page 26 SECTION 10: TROUBLESHOOTING Trouble Corrective Action Possible Cause(s) Engine fails to start PTO knob engaged. Place PTO knob in disengaged (OFF) position. Parking brake not engaged. Engage parking brake. Spark plug wire(s) disconnected. Connect wire(s) to spark plug. Throttle control lever not in correct Place throttle lever to FAST position.
- Page 27 SECTION 11: PARTS LISTFORT809H & Z809K REF. PART DESCRIPTION 710-0227 Self-tapping Screw, #8-18 x .5 710-0599 Self-tapping Screw, 1/4-20 x .5 710-0726 AB Screw, 5/16-12 x .75 710-1237 Screw, #10-32 x .625 710-1314A Socket Cap Screw, 5/16-18 x .625 710-1315 Self-tapping Screw, 3/8-16 x 1.25 712-3017 Hex Nut, 3/8-16...
- Page 28 Models Z809H & Z809K...
- Page 29 Models T809H & Z809K REF. PART DESCRIPTION 783-1346 Grill Support Bracket (9-style) 710-0599 Self-tapping Screw, 1/4-20 x .5 710-0528 Hex Cap Screw, 5/16-18 x 1.25 710-0924 Phillips Pan Screw, 1/4-20 x .75 710-1017 Truss Phillips Screw, 1/4-20 x .625 725-1741 Ignition Switch 726-0272 Clamp, 9/16...
- Page 30 ModelsT809H & Z809K...
- Page 31 Models T809H & Z809K PART REF. PART DESCRIPTION DESCRIPTION 747-1130B 731-1993 Deck Stabilizer Rod (Model T809H) Cover w/Cup Holder 747-1324 736-3078 Deck Stabilizer Rod (Model ZS09K) Flat Washer, .349 x 1.0 x .063 683-0197B 783-0677 Lift Shaft Assembly (Model T809H) Lift Adjustment Bracket 683-0462 Lift Shaft Assembly (Model Z809K)
- Page 32 ModelsT809H & Z809K 34 / "26 "29...
- Page 33 Models T809H & Z809K REF. PART DESCRIPTION 710-1260A Self-tapping Screw, 5/16-18 x .75 710-0604A Self-tapping Screw, 16-18 x .625 783-0726B RH Pivot Support Bracket 783-0727A LH Pivot Support Bracket 783-0728 Pivot Bar Bracket 710-0514 Hex Cap Screw, 3/8-16 x 1 711-1408 RH Drag Link 711-1409A...
- Page 34 Models T809H & Z809K 46 / 44 / 43./ 41 / * Refer to pages 36 and 37 for break-down of this assembly.
- Page 35 Models T809H & Z809K REF. PART PART DESCRIPTION DESCRIPTION 618-0376A 712-3027 Transmission Assembly: Two Speed Flanged Lock Nut 618-04148 718-04012 Variable Speed Pulley Assembly Cup: Bearing 647-04023 736-0362 Flat Washer Shift Rod Assembly 710-0176 Hex Bolt 5/16-18 x 2.75 741-0600 Ball Bearing 710-0347 Hex Bolt 3/8-16 x 1.75...
- Page 36 ModelsT809H & Z809K...
- Page 37 Models T809H & Z809K PART DESCRIPTION 618-0225 Reverse Collar Assembly 618-0226 Hi-Lo Collar Assembly 618-0227A Shift Fork Assembly 710-0642 Self-tapping Screw, 1/4-20 x .75 718-04053 Shft. Cover 736-0227 Flat Washer 710-3119 Lock bolt 3/8-16 x 0.75 741-0681 Ball Bearing 618-0365 Wheel Hub Assembly 618-0368 Differential Axle Assembly...
- Page 38 ModelT809H .,,--32 ',--33 only) Re&No.I PaN No. Ref.No. Part No. Description Description 1736-0407 783-0653_ Bell Washer, .45 x 1.Ox .062 Steering Support Bracket 1738-1132 Shoulder Screw 647-0064_ PTO Lever Engagement Assembly PTO Belt 1754-0228 683-04060 Engagement Plate Assembly 1783-0693 Axle Bracket 710-1002 Hex Bolt 7/16-20 x 2.0 1712-3006...
- Page 39 ModelZ809K REF. PART DESCRIPTION 783-0653E Steering Support Bracket 754-0476 PTO Belt 717-1774 Elec. PTO Clutch (Mod. Z809K) 783-1487 PTO Clutch Anti-rot. Brakt. 710-0859 Hex Cap Screw, 3/8-16 x 2.5 710-0726 Hex Hd Wash. Screw, 5/16-18 x .875 712-0431 Flange Lock Nut, 3/8-16 732-0978 Extension Spring, .62 x 5.62 712-3004A...
- Page 40 ModelT809H 7oS °-.,7 -:LL */2_ */62...
- Page 41 ModelT809H Part No. Description Ref. Part No. Description 17116 Deck Wheel 5.0 x 1.38 Deck Brake Assembly 734-0973 17258D Belt Cover 736-0119 Lock Washer 17982 Bell Washer Spindle Plate 736-0270 618-0430A Flat Washer Spindle Assembly: Pulley w/fig, 736-0418A 618-0595 Lock Washer Spindle Assembly: Double Pulley 736-0760 683-0254...
- Page 42 ModelZ809K...
- Page 43 ModelZ809K PART PART DESCRIPTION DESCRIPTION 12650 731-0335 Roller, Deck Bracket, Adjustment, Height 16606 Bracket, Hook, Retainer 731-3005 Front Roller 618-0671 731-3131A Deflector, Chute Spindle Assembly, Pulley, 5.39 Dia x .5625 683-0254 732-0306 Bracket Assembly, Deck, Hanger LH Spring, Compression, .406 x .531 x 1.75 683-0459 732-0459 Idlr Assembly, 54"...
- Page 44 MANUFACTURER'S LIMITED WARRANTY FOR: ® The limited warranty set forth below is given by Troy-Bilt LLC Troy-Bilt does not extend any warranty for products sold or exported outside of the United States, its with respect to new merchandise purchased and used in the United States, its possessions and territories.