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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)

Summary of content (44 pages)

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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-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).
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TABLEOFCONTENTS Content Page Important Safe Operation Practices Tractor Set-Up Know Your Garden Tractor 3 Operating Your Garden Tractor Making Adjustments Maintaining Your Garden Tractor Content Page 7 10 Service Off-Season Storage Attachments&Accessories 13 Troubleshooting 26 18 Illustrated Parts List Warranty 27 44 16 19 24 25 FINDINGMODELNUMBER This Operator's Manual is an important part of your new lawn tractor.
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SECTION 1: IMPORTANT SAFEOPERATION PRACTICES ,_ WARNING: This and/or symbol property points out safety instructions which, notinstructions followed, could the personal safety of important yourself and others. Read and followif all in thisendanger manual before attempting to operate this machine. Failure to comply with these instructions may result in personal injury. When you see this symbol--heed its warning.
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through unusually tall,drygrass(e.g.,pasture) orpilesof dryleaves. Drygrassorleaves maycontact theengine exhaust and/or builduponthemower deckpresenting a potential firehazard. 27. Useonlyaccessories andattachments approved for this machine by the machine manufacturer. Read, understand and follow all instructions provided with the approved accessory or attachment. 28. Data indicates that operators, age 60 years and above, are involved in a large percentage of riding mowerrelated injuries.
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extremely flammable and the vapors are explosive. Serious personal injury can occur when gasoline is spilled on yourself or your clothes which can ignite. Wash your skin and change clothes immediately. a. Use only an approved gasoline container. b. Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before filling. c.
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SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE ,11 A POWER POLE A CORNER OF A BUILDING OR A FENCE POST I £O W ILl ..I i_ WARNING &i Z i I,LI 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. If operating a walk-behind mower on such a slope, it is extremely difficult to maintain your footing and you could slip, resulting in serious injury.
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SECTION3: SETTINGUPTHETRACTOR NOTE: Any reference here to the RIGHT or LEFT side of the tractor is observed from operator's position. Place the steering wheel cap over the center of the steering wheel and push downward until it "clicks" into place. ShippingBraceRemoval _ WARNING: Steering _ Make sure the tractor engine is _ Wheel Capri, off. Remove ignition key, and set the parking brake before removing the shipping brace.
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both the left-hand deck roller bracket and the righthand deck roller bracket. See Figure 6 or refer to DeckRollerHeightAdjustment on page 9 for more detailed instructions on adjusting the deck roller upward or downward. Raise the deck lift arms up and out of the way by placing the deck lift lever in the top notch on the right fender. Gently slide the cutting deck beneath the tractor from the right side.
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Installing the PT0/Deck Belt IMPORTANT: Be certain that the FLAT side of the PTO/ Make certain that the PTO!Deck belt is routed around the spindle pulleys (found beneath the belt guards) and both idler pulleys as illustrated in Figure 5 before proceeding. Relieve tension on the deck idler by inserting a 3/8" drive ratchet wrench (set to "loosen") in the hole found in the idler bracket and pivoting the wrench handle counterclockwise. See Figure 5.
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SECTION4: KNOWYOURGARDEN TRACTOR F \ G H B I A:PTOleverq J K C L D M Wheel not shown Figure7 A B PTO(Blade Engage) Knob/Lever Choke Control H I Ignition Switch Brake Pedal C D Parking Brake Button Shift Lever J Drive Pedal K Cruise ControtButton E Cup Holder F G Systems Indicator Monitor/HourMeter Throttle Control Lever L M Seat Adjustment Lever Deck Lift Lever 10
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Throttle ControlLever Drive Pedal The throttle control lever is located on the right side of the tractor's dash panel. This lever controls the speed of the engine. When set in a given position, the throttle will maintain a uniform The drive pedal is located below the brake pedal on the right front side of the tractor along the running board. Depress the drive pedal with your fight foot when the tractor shift lever is in either FORWARD or REVERSE to cause the tractor to move. Fas_ engine speed.
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seat in place. Refer to SeatAdjustmenton page 17 of this manual for more detailed instructions. Indication Deck Lift Lever Found on your tractor's right fender, the deck lift lever is used to change the height of the cutting deck. To use, move the lever to the left, then place in the notch best suited for your application. Brake light on Engage the parking brake. PTO light on Move PTO knob to the disengaged(OFF) position.
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SECTION5: OPERATING YOURGARDEN TRACTOR NOTE: The deck wheels are an anti-scalp feature of the deck and are not designed to support the weight of the cutting deck. WARNING AVOIDSERIOUS INJURYORDEATH • • • • • • • • • • • • Refer to LevelingtheDeckon page 16 of this manual for more detailed instructions regarding various deck adjustments. GO UP AND DOWN SLOPES, NOT ACROSS. AVOID SUDDEN TURNS. DO NOT OPERATE THE UNiT WHERE iT COULD SLiP OR TIP.
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DrivingOnSlopes _ Refer to the SlopeGaugeon page 6 to help determine slopes where you may operate the tractor safely. WARNING: Do not leavethe thePTO seatknob of thein the tractor without first placing 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. ,i_ Depress the brake pedal to release the parking brake and let the pedal up.
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To disengage the PTO, move the PTO lever to the "Blade Stop" position. This will cut off power to deck or other attachments. UsingtheDeckLiftLever To raise the cutting deck, move the deck lift lever to the left, then place it in the notch best suited for your application. Refer to SettingTheCuttingHeightearlier in this section.
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SECTION6: MAKINGADJUSTMENTS ,_ WARNING: Hex Nut and Lock Washer Never attempt to make any Pivot Bar 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. / ParkingBrake _'_ WARNING: Never attempt to adjust the brakes while the engine is running.
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Withthetractorparkedonafirm,levelsurface, placethedeckliftleverinthetopnotch(highest position)androtatethebladenearest thedischarge chutesothatitis parallelwiththetractor. Measurethedistancefromfrontofthebladetipto thegroundandrearofthebladetiptotheground. Thefirstmeasurement takenshouldbebetween 1/4"and3/8"lessthanthesecondmeasurement. Determine theapproximate distancenecessary for properadjustment andproceedtothenextstep. Locatethetwolocknutsontheoppositesideofthe stabilizerbracket.SeeFigure11A.
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SECTION7: MAINTAINING YOURGARDEN TRACTOR any _ Air Cleaner WARNING: maintenance orBefore repairs,performing disengage PTO, move Service the pre-cleaner, if so equipped, and cartridge!air cleaner element as instructed in the engine manual. shift lever into neutral position, set parking brake, stop engine and remove key to prevent unintended starting. Spark Plugs Engine Clean the spark plugs and reset the gap once a season. Spark plug replacement is recommended at the start of each mowing season.
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Lubrication Disengage PTO,moveshiftleverintotheneutral position,settheparkingbrake,andstopengine. Threadthehosecoupler(packaged withthis manual)ontotheendofyourgardenhose. Attachthehosecouplertothewaterportonyour deckssurface.SeeFigure14. Turnthewateron. Whilesittingintheoperator'spositiononthe tractor,re-starttheengineandplacethethrottle leverintheFAST(rabbit)position. Engagethetractor'sPTO.
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Model T809H Engine Pulley PTO Idler Bracket (mounted on tractor) _Deck Belt (Bottom) _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, proceed as fallows: Model Z809K only: Remove the PTO belt from the electric PTO clutch and from around the PTO idler pulley, if present. Grasp the deck idler pulley and pivot it toward the left side of the deck to relieve tension on the belt.
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Upper DriveBelt ChangingtheTransmission DriveBelt ,_ Locate the transmission idler pulley on the upper drive belt by looking through the battery tray opening. See Figure 18. Grasp the bracket and pivot the transmission idler pulley toward the rear of the tractor to release tension on the upper drive belt.
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IMPORTANT: Note the routing of the lower drive belt around both the pulleys and the belt keepers before performing the following steps. not to lose the small flat washers found on the pin). See Figure 20. Remove the drive pedal return spring. Using two 9/16" wrenches, remove the pin from the speed control assembly. See Figure 20. Thread the idler adjustment rod inward or outward to lengthen or shorten the travel of the double-idler bracket until proper adjustment is achieved.
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Remove the deck from beneath the tractor, (refer to CtrttingDeckRemovalon page 19) then gently flip the deck over to expose its underside. Place a block of wood between the center deck Blade Separation housing baffle and the cutting blade to act as a stabilizer. See Figure 21.
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5. Charging If the tractor has not been used for an extended 6. period of time, use a voltmeter or load tester to measure the charge. The voltmeter should read 12.6 V or higher for adequate charge. Otherwise, charge the battery with an automotive-type 12-volt charger for a minimum of one hour at six amps. Follow the chart below to charge: Voltmeter Reading ,_ State of Charge (percentage) 8. 9. Charging Time (minutes) 12.7 100 0 12.4 75 9O 12.2 5O 180 12 25 280 WARNING: 7.
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SECTION9: 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.
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SECTION 10: TROUBLESHOOTING Trouble Possible Engine fails to start PTO knob engaged. Parking brake not engaged. Spark plug wire(s) disconnected. Throttle control lever not in correct starting position. Choke not activated Fuel tank empty, or stale fuel. Blocked fuel line. Faulty spark plug. Engine flooded. Unit running with CHOKE applied. Spark plug wire(s) loose. Blocked fuel line or stale fuel. Engine runs erratic Corrective Cause(s) Vent in gas cap plugged. Water or dirt in fuel system.
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SECTION11: PARTSLISTFORT809H & Z809K REF. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 2O 21 22 23 24 10 \ I I 27 PART NO. 710-0227 710-0599 710-0726 710-1237 710-1314A 710-1315 712-3017 721-0460 726-0205 712-0271 736-0300 751B221535 751-0535 751-0564A 751-0616A 751-0650A 751-0651A 751-3140 751-3141 751-3142 783-0615C 783-0625C 746-1086 725-0157 DESCRIPTION Self-tapping Screw, #8-18 x .5 Self-tapping Screw, 1/4-20 x .5 AB Screw, 5/16-12 x .75 Screw, #10-32 x .625 Socket Cap Screw, 5/16-18 x .
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ModelsZ809H & Z809K 17 26 \ 24 54 21 2 28
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ModelsT809H & Z809K REF. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 2O 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 PART NO.
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ModelsT809H & Z809K 46 38 27 14 .
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ModelsT809H & Z809K REE PART NO. NO. 1 747-1130B 747-1324 2 683-0197B 683-0462 3 711-0332 4 712-0206 5 712-0431 6 712-0429 7 712-3083 8 714-0104 9 714-0145 10 716-0106A 11 720-0311 12 732-0874 13 732-1184 14 736-0275 15 736-0921 16 736-3019 17 736-3084 18 738-0138A 19 738-0143 20 741-0225 21 741-0715 22 746-0968 23 747-1111A 24 756-1154 25 783-0678A 26 783-0720A 27 710-0260A 28 710-0726 29 710-0895 30 731-1990 REF. NO.
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ModelsT809H & Z809K 11 /38 / 14 / .
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ModelsT809H & Z809K REF. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 29 30 31 32 33 34 35 36 37 38 39 40 41 PART NO.
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ModelsT809H & Z809K 12 35 46 / 44 / 43./ 41 / 78 74 71 57. 59 53 * Refer to pages 36 and 37 for break-down of this assembly.
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ModelsT809H & Z809K RER NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. PART NO.
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ModelsT809H & Z809K 9 38 .
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ModelsT809H & Z809K REE NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 30 31 33 34 35 36 37 38 40 41 42 43 44 46 47 48 49 PART NO.
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ModelT809H .,,--32 ',--33 \ ( only) Ref.No. 1. 2. 3. 4. 5. 6. 7. 8. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. Part No.
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ModelZ809K REF. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 2O 21 22 23 24 25 26 27 28 29 3O 31 32 33 34 35 36 37 38 39 4O 41 42 43 44 45 46 47 48 49 _41 29 ( Ground Wire I 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. 12 ® i....--18 39 PART NO.
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ModelT809H 24 \ 12 54 7oS °-.
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ModelT809H Re_ No. 1, 2, 3, 4, 5, 6, 7. 8, 9, 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. Part No. 17116 17258D 17982 618-0430A 618-0595 683-0254 683-04121 710-0344 710-0501 710-0514 710-0528 710-0599 710-0650 710-0751 710-0805 710-1260A 710-3180 711-04069 711-0993 711-1554 712-0324 712-0417A 712-0429 712-0431 712-0641 712-3006 712-3010 712-3083 714-0470 717-04074 726-0233 732-0306A 732-0429A 732-0594A 732-1165 734-04039 Description Ref. No.
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ModelZ809K 72 5 47 44 14 40 39 l 26 77 76 42
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ModelZ809K RER NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 13. 14. 15. 16. 17. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 35. 36. 37. 38. 39. 40. 41. PART NO.
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MANUFACTURER'S LIMITED WARRANTY O 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.