MTD Series 830 Bedienungsanleitung

Shop Handbook

830-860 Series mowers

MTD Products Inc - Product Training and Education Department

FORM NUMBER - 769-03727

12/2007

NOTE: These materials are for use by trained technicians who are experienced in the service and repair of outdoor power

equipment of the kind described in this publication, and are not intended for use by untrained or inexperienced individuals.

These materials are intended to provide supplemental information to assist the trained technician. Untrained or inexperi-

enced individuals should seek the assistance of an experienced and trained professional. Read, understand, and follow all

instructions and use common sense when working on power equipment. This includes the contents of the product’s Oper-

ators Manual, supplied with the equipment. No liability can be accepted for any inaccuracies or omission in this publication,

although care has been taken to make it as complete and accurate as possible at the time of publication. However, due to

the variety of outdoor power equipment and continuing product changes that occur over time, updates will be made to these

instructions from time to time. Therefore, it may be necessary to obtain the latest materials before servicing or repairing a

product. The company reserves the right to make changes at any time to this publication without prior notice and without

incurring an obligation to make such changes to previously published versions. Instructions, photographs and illustrations

used in this publication are for reference use only and may not depict actual model and component parts.

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Chapter 1: Introduction ......................................................................................................1

830 series ............................................................................................................................ 1

860 series ............................................................................................................................2

Chapter 2: Front wheels and axle ...................................................................................... 3

Front wheels ........................................................................................................................3

Front axle............................................................................................................................ 3

Chapter 3: Cutting blade .................................................................................................... 5

Chapter 4: Drive belt and baffles .......................................................................................7

Chapter 5: Speed control system ......................................................................................10

How the speed control works............................................................................................ 10

Speed control cable and lever.......................................................................................... 11

Clutch cable replacement ..................................................................................................14

Chapter 6: Transmission and rear wheels .......................................................................16

Transmission replacement ................................................................................................ 16

Low wheel mower ............................................................................................................ 16

Large-wheel mowers......................................................................................................... 21

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830-860 SERIES SELF-PROPELLED MOWERS

The 830 and 860 Series lawn mowers are rear-wheel

drive self-propelled mowers with a unique variable

ground speed feature. They are both capable of mulch-

ing, bagging or side-discharging grass clippings. Both

mowers have a 21” (53cm) cutting swath.

NOTE: This manual was prepared using pre-

production mowers. The information contained

in the manual is true at the time of writing, but

the equipment may change without notice.

NOTE: This manual is intended to help profes-

sional technicians become acquainted with

newly introduced equipment, so that they can do

their jobs faster, better, and more easily.

If the user of this manual lacks tools or expertise

necessary to safely perform the tasks described,

they should seek the assistance of a trained pro-

fessional.

NOTE: As should be standard operating proce-

dure for any professional, test the operation of

the mower after any repair work, before return-

ing it to service.

CAUTION: Disconnect and ground the spark

plug wire whenever there is a risk of injury from

rotating parts. Working on the cutting blade or

drive system are two examples of situations that

could place a technician at risk.

CAUTION: Take measures to avoid the creation

of a fire hazard when working around equipment

that would normal contain fuel:

• Drain and store fuel in safe containers.

• Clean any fuel spills immediately.

• Avoid exposing fuel to heat sources or open

flame.

NOTE: Replace any worn or damaged fasten-

ers. If a lock washer or bellville washer has lost

its tension, replace it. If the locking feature of a

self-locking nut has worn, replace the nut, or

install it using releasable thread-locking com-

pound such as LoctiteTM 242 (blue).

830 series

The 830 series is identified by and eleven digit model

number, e.g.: 12A-83X-XXX.

“12” indicates that it is a self-propelled mower,

“A” identifies the first generation of the model series.

“A” may be followed by an engine identifier.

The “X”s will be style and retailer identifiers. Engines

from different manufacturers may be used on different

models. The models depicted here are in Troy-Bilt liv-

ery, but similar models may be produced in different

lines and for different retailers. See Figure 1.1.

Figure 1.1

CHAPTER 1: INTRODUCTION

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830-860 SERIES SELF-PROPELLED MOWERS

860 series

The 860 series is very similar to the 830 Series except

for large rear wheels and some engineering differences

that are necessary to accommodate the large rear

wheels. See Figure 1.2.

Differences include:

• Lower handlebars are longer on the 860 Series

than they are on the 830 Series.

• The single-point height adjust lever is on the left-

hand side on the 830 Series, but it is on the

right-hand-side on the 860 Series.

• The handlebar brackets are different between

the two models.

• The 860 Series has different final-drive gears,

including an idler gear between the transmission

axle and the ring gear in the rear wheel.

Figure 1.2

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830-860 SERIES SELF-PROPELLED MOWERS

Front wheels

The front wheels fit over the ends of the axle, and are

held to the axle by nuts. See Figure 2.1.

To remove the front wheels:

1. Loosen the wheel nuts using a 9/16” wrench.

2. Tilt the mower up so that the weight of the

mower is not resting on the front wheels.

3. Remove the nuts, and pull the front wheels off of

the mower. See Figure 2.2.

4. When reinstalling the front wheels, tighten the

nuts to a torque of 12 ft.-lb.(166.3 N-m).

Figure 2.1

nut

Figure 2.2

Wheel removed

Front axle

To remove the front axle:

1. Remove the front wheels.

2. Set the height adjuster lever to the highest posi-

tion, relieving the load on the lift-assist torsion

spring on the front axle . See Figure 2.3.

3. Remove the shoulder screw that holds the

height adjuster connecting link to the front axle.

Use a 3/8” wrench. See Figure 2.4.

CAUTION: The torsion spring on the front axle

will be under tension, even in the highest cutting

position.

Figure 2.3

Torsion spring

Figure 2.4

Shoulder screw

Height adjuster

connecting link

CHAPTER 2: FRONT WHEELS AND AXLE

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830-860 SERIES SELF-PROPELLED MOWERS

4. Just inside of the deck shell, near each end of

the axle is a white plastic “C” clip. Remove both

“C” clips. See Figure 2.5.

5. The “C” clips hold flanged hex bushings into key-

hole slots in the deck shell. Slide the hex bush-

ings in to release them from the deck shell.

See Figure 2.6.

6. As the flanged hex bushings are released from

the deck shell, the axle will come free of the

shell. Maneuver the front axle to unhook the tor-

sion spring from the deck shell. See Figure 2.7.

7. The torsion spring is captive on the front axle. If

either is damaged, both must be replaced.

See Figure 2.8.

8. Reinstall the front axle by reversing the steps

used to remove it.

• Replace the “C” clips if they have lost their ten-

sion.

• Replace the flanged hex bushings if they are

worn.

• Do not trim the flanged hex bushings to ease

installation. They should be tight.

Figure 2.5

C clip

Front axle

Flanged hex bushing

Figure 2.6

Flanged hex bushing

Figure 2.7

Torsion

spring

Figure 2.8

Front axle weldment

Torsion spring

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830-860 SERIES SELF-PROPELLED MOWERS

To remove the cutting blade:

1. Disconnect and ground the spark plug wire.

2. If the level of gasoline in the fuel tank is great

enough that it will spill if the mower is tipped,

remove the fuel filler cap, place a plastic bag

over the neck of the fuel tank, and reinstall the

cap.

3. Tip the mower with the muffler side down, or tilt

the mower back on a work bench, with the front

wheels up. See Figure 3.1.

4. Block the blade form rotating using a block of

wood or a blade holder tool.

5. Remove the blade bolt and diamond-shaped

bellville blade spring using a 5/8” wrench.

Figure 3.1

Blade

Bolt

Belville spring

6. Lift away the blade. See Figure 3.2.

7. Inspect the blade. If it is bent or worn beyond

proper sharpening, replace it with a new blade.

8. Sharpen and balance the blade if it is not badly

worn.

NOTE: The 830 and 860 Series mowers have a

3-in-1 blade. The outer part of the leading edge

cuts the grass. A wing behind it lifts the grass for

the next blade and propels clippings toward the

bag or side discharge chute if the path to either

is open. A stepped-upcutting edge just in-board

of the outer cutting edge mulches clippings as

they fall, if the side discharge chute is closed

and the mulch plug is in place.

Figure 3.2

Blade adaptor

CHAPTER 3: CUTTING BLADE

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830-860 SERIES SELF-PROPELLED MOWERS

9. Check the blade adaptor for damage. There is a

wave washer on the crankshaft, directly above

the wave washer. See Figure 3.3.

10. Install the blade with wave washer, blade adap-

tor, and bellville spring washer properly posi-

tioned. Tighten the blade bolt to a torque of 38-

50 ft.-lb. (51-68 N-m).

Figure 3.3

Crankshaft

Wave washer

Blade adaptor

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830-860 SERIES SELF-PROPELLED MOWERS

To remove the drive belt:

1. First remove the mulch plug. See Figure 4.1.

2. Remove the blade as described in Chapter 2:

Cutting blade..

3. Remove the baffle extension cover using a 3/8”

wrench. See Figure 4.2.

Figure 4.1

Mulch plug

Figure 4.2

Baffle

extension

4. Remove the rear baffle:

4a. Remove the two screws that hold the rear of

the baffle to the mower deck. The screws

are located just in front of the handlebar

brackets, and can be removed using a 3/

8” wrench. There is one on the left and

one on the right. See Figure 4.3.

4b. Remove the two nuts and bolts that hold the

right handlebarbracket to the mower deck

using a pair of 1/2” wrenches. They do

not hold the baffle in place, but they get in

the way of its removal. See Figure 4.4.

Figure 4.3

Baffle screw

Figure 4.4

Baffle (inset)

Bolts

Handlebar

bracket

Nuts on bolts that impede the

removal of the baffle

CHAPTER 4: DRIVE BELT AND BAFFLES

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