Operator`s manual

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Safety • Assembly • Operation • Tips & Techniques • Maintenance • Troubleshooting • Parts Lists • Warranty

Warning: This unit 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. 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. BOX 361131 CLEVELAND, OHIO 44136-0019

PRINTED IN U.S.A

READ SAFETY RULES AND INSTRUCTIONS CAREFULLY BEFORE OPERATION

IMPORTANT

OPERATOR’S MANUAL

Transmatic Lawn Tractor — Model Series 77T

01/2006

FORM NO. 769-02243A

Summary of content (48 pages)

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Safety • Assembly • Operation • Tips & Techniques • Maintenance • Troubleshooting • Parts Lists • Warranty OPERATOR’S MANUAL Transmatic Lawn Tractor — Model Series 77T IMPORTANT READ SAFETY RULES AND INSTRUCTIONS CAREFULLY BEFORE OPERATION Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-covered, brushcovered or grass-covered land unless the engine’s exhaust system is equipped with a spark arrester meeting applicable local or state l
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This Operator’s Manual is an important part of your new lawn tractor. It will help you assemble, prepare and maintain the unit for best performance. Please read and understand what it says. Table of Contents Slope Gauge ....................................................... 3 Safe Operation Practices ................................... 4 Setting Up Your Lawn Tractor ............................ 8 Operating Your Lawn Tractor ........................... 10 Adjusting Your Lawn Tractor .......................
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Use this page as a guide to determine slopes where you may not operate safely. Do not operate your lawn mower on such slopes. 1 Slope Gauge �� 3 WARNING 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.
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2 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. When you see this symbol.
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General Operation: 14. Watch for traffic when operating near or crossing roadways. This machine is not intended for use on 1. Read, understand, and follow all instructions on the any public roadway. machine and in the manual(s) before attempting to 15. Do not operate the machine while under the influassemble and operate. Keep this manual in a safe ence of alcohol or drugs. place for future and regular reference and for ordering 16. Mow only in daylight or good artificial light. replacement parts. 2.
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2 Safe Operation Practices 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. When you see this symbol.
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Service 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Never attempt to make adjustments or repairs to the machine while the engine is running. Never run an engine indoors or in a poorly ventilated 11. Grass catcher components and the discharge area. Engine exhaust contains carbon monoxide, an cover are subject to wear and damage which could odorless, and deadly gas. expose moving parts or allow objects to be thrown.
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3 Setting Up Your Lawn Tractor Attaching the Battery Cables �� NOTE: This unit may have been shipped with the battery cables already connected. If not, follow the instructions below for attaching the battery cables. NOTE: The positive battery terminal is marked Pos. (+). The negative battery terminal is marked Neg. (–). • The positive cable (heavy red wire) is secured to the positive battery terminal (+) with a hex bolt and hex nut at the factory.
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3 Attaching The Steering Wheel If the steering wheel for your tractor did not come attached, the hardware for attaching it has been packed within the steering wheel, beneath the steering wheel cap. Carefully pry off the steering wheel cap and remove the hardware. Setting Up Your Lawn Tractor 1. With the wheels of the tractor pointing straight forward, place the steering wheel over the steering shaft. 2. Place the washer (with the cupped side down) over the steering shaft and secure with the hex bolt.
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4 Know Your Lawn Tractor � � Operating Your Lawn Tractor � � NOTE: Any reference in this manual to the RIGHT or LEFT side of the tractor is observed from operator’s position.
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To release the parking brake, depress the clutch-brake pedal and move the speed control lever out of the notches to the desired position. Release the speed control lever and the clutch-brake pedal. �� NOTE: The parking brake must be set if the operator leaves the seat with the engine running or the engine will automatically shut off. Clutch-Brake Pedal The clutch-brake pedal is located on the left side of the lawn tractor, along the running board.
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�� NOTE: The PTO (blade engage) lever must be in the disengaged (PTO OFF) position when starting the engine. �� Operating Your Lawn Tractor Found on the tractor’s right fender, the PTO (blade engage) lever is used to engage power to the cutting deck or other (separately available) attachments. To operate, move the lever all the way forward. Moving the lever all the way rearward into the PTO OFF position disengages power to the cutting deck/ attachment.
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Driving The Tractor WARNING: Avoid sudden starts, ex-cessive speed and sudden stops. WARNING: Do not leave the seat of the tractor without first placing the PTO (Blade Engage) lever in the disengaged (OFF) position, depressing the brake pedal and engaging the parking brake. If leaving the tractor unattended, also turn the ignition key off and remove the key. WARNING: Always look down and behind before and while backing up to avoid a back-over accident.
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4 Operating Your Lawn Tractor Engaging the Blades WARNING Engaging the PTO (Blade Engage) transfers power to the cutting deck or other (separately available) attachments. To engage the blades, proceed as follows: AVOID SERIOUS INJURY OR DEATH 1. Move the throttle control lever to the FAST (rabbit) position. 2. Grasp the PTO (Blade Engage) lever and pivot it all the way forward into the engaged (ON) position. 3.
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4 Mulching (If Equipped) A mulch kit is sold separately and incorporates special blades that incorporate a process of recirculating grass clippings repeatedly beneath the cutting deck. The ultrafine clippings are then forced back into the lawn where they act as a natural fertilizer. Operating Your Lawn Tractor Observe the following points for the best results when mulching: • Never attempt to mulch if the lawn is damp.
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5 3/8-inch lower than the rear of the deck. Adjust if necessary as follows: 1. With the tractor parked on a firm, level surface, place the deck lift lever in the top notch (highest position) and rotate the blade nearest the discharge chute so that it is parallel with the tractor. Adjusting Your Lawn Tractor 2. Measure the distance from the front of the blade tip to the ground and the rear of the blade tip to the ground.
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5 Parking Brake Adjustment WARNING: Never attempt to adjust the brakes while the engine is running. Always disengage PTO, move shift lever into neutral position, stop engine and remove key to prevent unintended starting. Adjusting Your Lawn Tractor If the tractor does not come to a complete stop when the brake pedal is completely depressed, or if the tractor’s rear wheels can roll with the parking brake applied, the brake is in need of adjustment.
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6 IMPORTANT: Refer to the Engine Operator/Owner’s Manual packed with your unit for information regarding the quantity and proper weight of motor oil. Air Cleaner Service the pre-cleaner, if so equipped, and cartridge/air cleaner element as instructed in the Engine Operator/ Owner’s Manual packed with your unit. Maintaining Your Lawn Tractor Spark Plug The spark plug should be cleaned and the gap reset once a season. Spark plug replacement is recommended at the start of each mowing season.
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6 Deck Wash System™ A hex plug can be found on your tractor’s deck surface. See Figure 15. This plug can be replaced with a water port to be used as part of a separately-available deck wash system. Use the Deck Wash System™ to rinse grass clippings from the deck’s underside and prevent the buildup of corrosive chemicals. Maintaining Your Lawn Tractor NOTE: Refer to page 24 for information regarding this and other separately-available attachments & accessories for your tractor.
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6 Maintaining Your Lawn Tractor Tires Jump Starting WARNING: Never exceed the maximum inflation pressure shown on the sidewall of tire. WARNING: When removing or installing the battery, follow these instructions to prevent the screwdriver from shorting against the frame. The recommended operating tire pressure is: • Approximately 10 psi for the rear tires • Approximately 14 psi for the front tires IMPORTANT: Refer to the tire sidewall for exact tire manufacturer’s recommended or maximum psi.
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6 Cutting Blades WARNING: Be sure to shut the engine off, remove ignition key, disconnect the spark plug wire(s) and ground against the engine to prevent unintended starting before removing the cutting blade(s) for sharpening or replacement. Protect your hands by using heavy gloves or a rag to grasp the cutting blade. Maintaining Your Lawn Tractor WARNING: Periodically inspect the blade spindles for cracks or damage, especially if you strike a foreign object. Replace immediately if damaged.
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6 IMPORTANT: Carefully allow the ratchet to pivot rearward before removing it from the square hole. �� WARNING: Avoid the possibility of a pinching injury. Do not place your fingers on the idler spring or between the belt and a pulley while removing the belt. Maintaining Your Lawn Tractor 7. Remove the deck belt from around all pulleys, including the deck idler pulley. 8. Route the new belt as shown in and Figure 21. 9. Remount the belt guards removed earlier.
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�� 6 Maintaining Your Lawn Tractor �� Figure 21 23
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7 Clean and lubricate the tractor as instructed in Section 6: MAINTAINING YOUR LAWN TRACTOR on page 18 of this manual before storing for an extended period. Follow the instructions in the Service, Storage & Specifications section of the Engine Operator/Owner’s Manual for proper engine care prior to storing your tractor. WARNING: Drain fuel only into an approved container outdoors, away from an open flame. Allow engine to cool.
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8 ��
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9 Problem Engine fails to start Cause 1. Place PTO knob (or lever) in disengaged (OFF) position. 1. PTO engaged. 2. Spark plug wire(s) disconnected. 3. Fuel tank empty or stale fuel. Trouble Shooting Remedy 4. Choke not activated. 2. Connect wire(s) to spark plug(s). 3. Fill tank with clean, fresh gasoline. 4. Pull out the CHOKE control (if so equipped) or place the throttle control in CHOKE position. 5. Faulty spark plug. 5. Clean, adjust gap, or replace. 6. Blocked fuel line. 6.
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Problem Engine overheats Engine hesitates at high RPM Idles poorly Excessive Vibration Mower will not mulch grass (If Equipped) Cause 1. Engine oil level low. 1. Fill crankcase with proper oil. 2. Air flow restricted. 2. Clean grass clippings and debris from around the engine’s cooling fins and blower housing. 1. Spark plug(s) gap too close. 1. Remove spark plug(s) and reset the gap. 1. Spark plug(s) fouled, faulty or gap too wide. 1. Replace spark plug(s). Set plug(s) gap. 2. Dirty air cleaner.
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Model 77T 11 16 1 6 6 5 12 8 14 21 7 1 18 17 26 25 17 24 4 10 23 19 20 16 1 27 13 9 22 28 2 2 2 15 3 28
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10 Illustrated Parts List Ref. No. Part No. Description Ref. No. Part No. Description 1 710-0599 Screw, 1/4-20, 0.500 15 783-05027 Front Pivot Support Bracket 2 710-0604A Screw, 5/16-18, 0.625 16 726-0230 Cable Tie, 34.75 3 710-1260A Screw, 5/16-18, 0.750 17 751-0555B Fuel Tank, 1.5 gal. 4 710-1611B Screw, 5/16-18, 0.750 18 751-0603 Fuel Tank Cap 5 712-0185 Nut, 1/4-20, Speed U-type 19 710-04483 Screw, 1/4-14, .
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Models 77T �� 30 ��
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10 Ref. No. Part No. Description 1 710-04483 Screw, 1/4-20 x .500 2 710-0599 Screw, 1/4-20, 0.500 3 710-0604A Screw, 5/16-18, 0.625 4 731-04591A Cup Holder 5 736-0607 6 783-04587A Fender 7 783-1489B Mounting Bracket, Seat 8 723-04025 Foot Pad, Abrasive, RH 9 723-04026 Foot Pad, Abrasive, LH 10 712-04063 Nut, Flange Lock, 5/16-18, GrF 11 720-04061 Knob, 3/8-16, .875 12 732-1184 Spring, Exten., .84 Dia x 4.6 Lg. 13 738-0296 Scr., Shlder, .437 x .
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Models 77T 37 3 11 38 14 8 13 15 22 26 17 16 36 1 6 21 5 11 2 10 18 19 33 20 4 8 27 7 40 30 12 34 41 42 43 31 23 25 39 29 24 35 32 9 28 32
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10 Ref. No. Part No. Description Ref. No. Part No. Description 1 617-04024 Gear Assembly, Steering 24 638-04008 Axle Assembly, RH 2 710-0376 Screw, 5/16-18, 1.00, Gr5 25 683-0128B Pivot Bar 3 710-0643 Screw, 5/16-18, 1.00, Gr5, Lock 26 710-0726 Screw, 5/16-12, 0.750 4 710-1309 Screw, Mach, 5/16-18, 0.750 27 712-04065 Nut, Flange Lock, 3/8-16, GrF 5 710-3180 Screw, 5/16-18, 1.75, Gr5 28 714-04039 Pin, Cotter, 5/32, 1.
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Models 77T �� IMPORTANT For a proper working machine, use Factory Approved Parts. V-belts are designed to engage and disengage safely. A substitute (non OEM) V-belt can be dangerous by not disengaging completely.
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Ref. No. Part No. Description Ref. No. Part No. Description 1 618-04034 Transmission Assembly 39 710-1008 Screw, 3/8-16, 1.875, Gr5 2 647-04035 Lever Assembly, Shift 40 731-05362 7 Speed Shift Lever 3 710-0176 Screw, 5/16-18, 2.75, Gr5 41 710-04483 Screw, 1/4-20, 0.500 4 710-0227 Screw, #8-18, 0.500 42 711-0736 Adjustment Ferrule 1/4-20 5 710-0726 Screw, 5/16-12, 0.750 43 712-04065 Nut, Flange Lock, 3/8-16, GrF 6 710-0809 Screw, 1/4-20, 1.
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Models 760-779 �� 36
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Ref. No. Part No. Description Ref. No. Part No. Description 1 17962 Plate, Switch 28 783-04548A Seat Bracket, Frame 2 647-04040 Handle Asswmbly, PTO 29 783-04637 Bracket, Runing Board 3 710-0224 Screw, #10-16, 0.500 30 725-1426A Solenoid 4 710-0599 Screw, 1/4-20, 0.500 31 683-04155 Shaft Assembly, Lift 5 710-3157 Screw, 7/16-20, 3.25, Gr5 32 712-04065 Nut, Flange Lock, 3/8-16, GrF 6 714-0104 Pin, Cotter, .072 Dia. x 1.13 33 714-04043 Pin, Cotter, .080 x 1.
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Models 760-779 � � � � � � � � � � �� 38 ��
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Ref. No. Part No. Description 1 732-0614 Ring, Wire 2 716-0231 Ring, E Type,.750 3 736-0336* Flat Washer, 5/8 x 1.0 x.030 736-0337* Flat Washer, 5/8 x 1.0 x.040 10 Illustrated Parts List 736-0349* Flat Washer, 5/8 x 1.0 x.020 4 736-0335 Washer, Thrust.635 x 1.26 x.06 5 710-1325 Self-tapping Screw, 1/4-20 x 1.625 6 719-04017 Upper Housing 7 711-1109 Input Shaft 8 741-0335 Needle Bearing,.625 x.813 x.495 9 717-1464 14-tooth Bevel Pinion 10 716-0108 Retaining Ring,.
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Models 77T (42” Deck) 9 9 44 47 19 32 1 28 12 45 32 35 37 45 4 11 2 43 39 40 13 11 23 46 19 26 43 27 9 5 24 29 8 15 14 3 36 31 34 25 30 19 17 41 42 18 33 20 6 22 10 7 38 16 40 21
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10 Ref. No. Part No. Description Ref. No. Part No. Description 1 618-0624 Spindle Assembly, Pul, 6.23” Dia 25 726-0233 Nut, Push, .25 ID x .50 OD 2 683-04138A Brake Assembly, Deck 26 732-04280A Spring, Exten. , .75 Dia. x 6.375 3 683-04165A Deck Shell, 42” (w/o Wheel Brkt) 27 732-04287 Spring, Exten. , .50 Dia. x 6.375 4 683-04167 Brake Assembly, Deck 28 710-0347 Screw, 3/8-16 x 1.75 5 683-04228 Brkt.
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Models 77T 13 20 7 16 11 10 12 18 22 8 21 14 15 6 23 17 19 5 4 2 9 1 3 42
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10 Ref. No. Part No. Description 1 683-04256 Muffler Shield Assembly 2 783-04576 Muffler Shield 3 783-05006 Lower Heat Shield 4 710-0227 Screw, #8-18 x .50 5 710-0599 Screw, 1/4-20, 0.500 6 710-0642 Screw, 1/4-20, 0.750 7 710-1237 Screw, #10-32, .625 8 710-1314A Socket Cap Screw, 5/16-18, .625 9 710-1315 Self-tapping Screw, 3/8-16, 1.25 10 712-0271 Hex Sems Nut, 1/4-20 11 721-0208 Exhaust Gasket 12 725-0157 Cable Tie, 7.4” 13 726-0205 Hose Clamp, .
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NOTES: Use this page to make notes and write down important information. For parts and/or accessories please call 1-866-840-6483, or 1-330-558-7220. www.troybilt.
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NOTES: Use this page to make notes and write down important information. For parts and/or accessories please call 1-866-840-6483, or 1-330-558-7220. www.troybilt.
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NOTES: Use this page to make notes and write down important information. For parts and/or accessories please call 1-866-840-6483, or 1-330-558-7220. www.troybilt.
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CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and MTD Consumer Group Inc are pleased to explain the evaporative emission control system warranty on your 2006 lawn mower. In California, new lawn mower must be designed, built and equipped to meet the State’s stringent anti-smog standards.
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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, its possessions and territories. “Troy-Bilt” warrants this product against defects in material and workmanship for a period of two (2) years commencing on the date of original purchase and will, at its option, repair or replace, free of charge, any part found to be defective in materials or workmanship.