Bolens 135-688-000 User Manual
OUTDOOR POWER EQUIPMENT
for all seasons
.75
600 SERIES
TRANSMATIC
LAWN
TRACTORS
Model Numbers
135-618-000
135-620-000
135-638-000
135-668-000
135-688-000
135-698-000
Important:
Read Safety Rules and
Instructions Carefully
PRINTED IN U.S.A.
Thank you for purchasing
an American-built product.
J
FORM NO. 770-4066
INDEX
Safe Operation Practices
Assembly Instructions
Controls...............................................................10
Operation
Adjustments
Lubrication
Maintenance
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Instructions given with this symbol are for per
A
sonal safety . Be sure to follow them.
.3
12
13
15
16
Off-Season Storage
4
Troubleshooting Chart
Illustrated Parts for Rider
Illustrated Parts for Transaxle
Electrical System
Parts Information
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36, 37, 38,39
Back Cover
19
20, 21
22-33
34,35
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V
LIMITED WARRANTY
For one year from the date of orig nal retail purchase, MTD PRODUCTS INC will either
repair or replace, at its option, free charge, F.O.B. factory or authorized service firm, any
part or parts found to be defective i ^ material or workmanship. Transportation charges for
the movement of any power equipm ant unit or attachment are the responsibility of the pur
chaser. Transportation charges for iiny parts submitted for replacement under this warran
ty must be paid by the purchaser un ess such return is requested by MTD PRODUCTS INC.
This warranty will not apply to any ^art which has become inoperative due to misuse, ex
cessive use, accident, neglect, improper maintenance, alterations, or unless the unit has
been operated and maintained in accordance with the instructions furnished. This warran
ty does not apply to the engine, motor, battery, battery chargeror component parts thereof.
Please refer to the applicable manufacturer’s warranty on these items.
This warranty will not apply where the unit has been used commercially.
Warranty service is available throuch your local authorized service dealer or distributor. If
you do not know the dealer or distributor in your area, please write to the Customer Service
Department of MTD.
The return of a complete unit will not be accepted by the factory unless prior written per
mission has been extended by MTD.
This warranty gives you specific legal rights. You may also have other rights which vary
from state to state.
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WARNING
AC
This unit is equipped with an internal com justion engine and should not be used on or near any unim
proved forest-covered, brush-covered or (¡rass-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 muffler is
available at your nearest engine authorized: service center.
AC warnTng^J
To reduce the potential for any injury, comply with the following safety Instructions. Failure to comply
with the instructions may result in personal injury.
SAFE OPERATION PRACTICES FOR RIDING VEHICLES
1. Read this owner’s manual carefully in its en
tirety before attempting to assemble or
operate this unit. Keep this manual in a safe
place for future and regular reference and for
ordering replacement parts.
2. This unit is a precision piece of power equip
ment, not a plaything. Therefore exercise ex
treme caution at all times.
3. Know the controls and how to stop quickly—
READ THIS OWNER’S MANUAL.
4. Do not allow children to operate vehicle. Do
not allow adults to operate it without proper
instruction. Only persons well acquainted
with these rules of safe operation should be
allowed to use your mower.
5. No one should operate this unit while intox
icated or while taking medication that impairs
the senses or reactions.
6. Wear sturdy, rough-soled work shoes and
close-fitting slacks and shirts to avoid en
tanglement in the moving parts. Never operate
a unit in bare feet, sandals, or sneakers.
7. To prevent injury, do not carry passengers or
give rides. Keep children, pets and by
standers out of the area while mowing. Only
the operator should ride on the unit and only
ride in the seat.
8. Check overhead clearance carefully before
driving under power lines, guy wires, bridges
or low hanging tree branches, before entering
or leaving buildings, or in any other situation
where the operator may be struck or pulled
from the unit, which could result in serious in
jury.
9. To maintain control of the unit and reduce the
possibility of upset or collision, operate the
tractor smoothly. Avoid erratic operation and
excessive speed.
10. Keep the area of operation clear of all per
sons, particularly small children and pets.
Stop engine when they are in the vicinity of
your mower. Although the area of operation
should be completely cleared of foreign ob
jects, a small object may have been over
looked and could be accidently thrown by the
mower in any direction and cause injury.
11. Clear work area of objects which might be
picked up and thrown by the mower in any
direction and cause injury.
12. Stop the blade(s) when crossing gravel drives,
walks or roads.
13. Disengage all attachment clutches and shift
into neutral before attempting to start engine.
14. Disengage power to attachment(s) and stop
engine before leaving operating position.
15. Do not put hands or feet near or under rotating
parts. Keep clear of the discharge opening at
all times as the rotating blade(s) can cause in
jury.
16. Disengage power to attachment(s) and stop
engine before making any repairs or ad
justments. Disconnect the spark plug wire
and keep the wire away from the plug to pre
vent accidental starting.
17. Before attempting to unclog the mower or
discharge chute, stop the engine. The mower
blade(s) may continue to rotate for a few
seconds after the engine is shut off.
Therefore, be sure the blade(s) have stopped
completely. Disconnect the spark plug wire
and keep the wire away from the plug to pre
vent accidental starting.
18. Disengage power to attachment(s) when
transporting or not in use.
19. Take all possible precautions when leaving
vehicle unattended such as disengaging
power-take-off, lowering attachments, shift
ing into neutral, setting parking brake, stop
ping engine and removing key.
20. Do not stop or start suddenly when going
uphill or downhill. Mow up and down face of
steep slopes; never across the face. Use ex
treme caution if it is necessary to drive the
tractor up an incline or back the tractor down
an incline because the front of the tractor
could lift and rapidly flip over backward which
could cause serious injury.
21. Reduce speed on slopes and in sharp turns to
prevent tipping or loss of control. Always
keep the tractor in gear when going down
steep hills to take advantage of engine brak
ing action.
22. Stay alert for holes in terrain and other hidden
hazards.
23. Use care when pulling loads or using heavy
equipment.
A. Use only approved drawbar hitch points.
B. Limit loads to those you can safely control.
C. Do not turn sharply. Use care when back
ing.
D. Use counterweight(s) or wheel weights
when suggested in owner’s manual.
24. Watch out for traffic when crossing or near
roadways.
25. When using any attachments, neverdirect dis
charge of material toward bystanders nor
allow anyone near vehicle while in operation.
26. Handle gasoline with care. It is highly flam
mable.
A. Use approved gasoline container.
B. Never remove cap or add gasoline to a run
ning or hot engine or fill fuel tank indoors.
Wipe up spilled gasoline.
C. Open doors if engine is run in garage. Ex
haust fumes are dangerous. Do not run
engine indoors.
27. Keep the vehicle and attachments in good
operating condition, and keep safety devices
in place. Use guards as instructed in
operator’s manuai.
28. Keep all nuts, bolts, and screws tight to be
sure the equipment is in safe working condi
tion.
29. Never store the equipment with gaso ine in
the tank inside a building where fumes may
reach an open fiame or spark. Ailow en<|ine to
cool before storing in any enciosure.
30. To reduce fire hazard, keep engine f^ee of
grass, ieaves or excessive grease.
31. The vehicle and attachments should be
stopped and inspected for damage afte ' strik
ing a foreign object. The damage shojid be
repaired before restarting and operating the
equipment.
32. Do not change the engine governor settings
or overspeed the engine.
33. When using the vehicle with mower, proceed
as follows;
(1) Mow only in daylight or in good ar ificial
light.
(2) Never make a cutting height adjustment
while engine is running if operator must
dismount to do so.
(3) Shut the engine off and wait untii the
blade comes to a complete stop before
removing the grass catcher.
(4) Check biade mounting bolts for proper
tightness at frequent intervals.
34. Check grass catcher bags frequently for wear
or deterioration. For safety protection, replace
only with new bag meeting originai equipment
specifications.
35. Look behind to make sure the area is clear
before placing the transmission in reverse
and continue looking behind while backing
up. Disengage blades before shifting into
reverse and backing up.
36. This unit should not be driven up a ramp onto
a trailer or truck under power, because the
unit could tip over, causing serious personal
injury. The unit must be pushed manually to
load properly.
This unit is shipped WITHOUT GAS
OLINE or OIL. After assembly, see
separate engine manual for proper
fuel and engine oil recommenda
tions.
FIGURE 1.
NOTE
ASSEMBLY
This owner’s manual covers various models of
lawn tractors. The units illustrated may vary slight
ly from your unit. Follow the instructions which
pertain to your unit.
NOTE
Reference to right hand or left hand
side of machine is from the driver’s
seat facing forward.
Contents of Hardware Pack:
(See Figure 1)
A (1) Steering Wheel Cap
B
(1) Belleville Washer
Hex Nut 5/16-18 Thread
C
(1)
Steering Bellow
D
(1)
Ignition Keys
E
(2)
■F
Hardware for Mounting the Seat (Not Shown)
Loose Parts in Carton:
Battery Strap
(1)
Battery Strap Hooks
G
(2)
Cable Tie
H
(1)
Clevis Pin
I
(1)
Hairpin Cotter
(1)
(2) Hex Bolts and Lock Washers
or
(1) Hex Nut and Lock Washer
(1) Battery Pack
(1) Steering Wheel
(1) Seat
BATTERY INFORMATION
Ac WARNING ^
A. Battery acid must be handled with great care
as contact with it can burn and blister the skin.
It is aiso advisable to wear protective clothing
(goggles, rubber gloves and apron) when work
ing with it.*
B. Should battery acid accidentally splatter into
the eyes or onto the face, rinse the affected
area immediately with clean cold water. If
there is any further discomfort, seek prompt
medical attention.
C. If acid spills on clothing, first dilute it with
clean water, then neutralize with a solution of
ammonia/water or baking soda/water.
Screwdriver
D. Since battery acid is corrosive, do not pour it
into any sink or drain. Before discarding empty
electrolyte containers, rinse them with a
neutralizing solution.
E. NEVER connect or disconnect charger clips to
battery while charger is turned on as it can
cause sparks.
F. Keep all lighted materials (cigarettes, match
es, lighters) away from the battery as the
hydrogen gas generated during charging can
be combustible.
G. As a further precaution, only charge the battery
in a well-ventilated area.
*Always shield eyes, protect skin and clothing
when working near batteries.
ACTIVATING AND INSTALLING THE BATTERY
1. Upon opening the battery pack, you should
receive acid pack, battery, drain tube, filling
adapter and hardware.
Manifold
on Battery
Clear Plastic
Drain Tube
FIGURE 2.
Large Tab
Filling
Adapter
FIGURE 3.
Fill Caps
^ WARNING I
A
BATTERIES CONTAIN SULFURIC
ACID AND MAY CONTAIN EXPLO
SIVE GASES (when electrolyte has
been added).
2. Place the battery on table or workbench to be
filled.
3. Place one end of clear plastic drain tube on
— manifold of battery. See figure 2.
NOTE
Some batteries may already have
the drain tube installed, in which
case it may be necessary to snip off
the sealed end.
4. Remove the six fill caps from the top of the
battery with a screwdriver. Care should be
taken not to damage the fill caps. See figure 2.
5. Lay acid package down, with “push in” facing
up. Using thumb, push in small perforated tab
at dot on front of package. Tear down large tab
to solid line, exposing hose. Do not use any
sharp object to open acid package.
6. Pull out hose from package and hold upright.
Squeeze hose forcing all acid back into
package. Cut off tip of hose and insert filling
— adapter. See figure 3.
7. Fill each cell to upper level marked on front of
battery. Replace fill caps on battery. See
figure 3.
Ac
DANGER
Battery contains sulfuric acid. Refer to warning on
page 5. Antidote: EXTERNAL—Flush with water.
INTERNAL—Drink large quantities of water or
milk. Follow with milk of magnesia, beaten egg or
vegetable oil. Seek prompt medical attantion.
EYES: Flush with cool water for at least 15
minutes, then seek immediate medical attention.
Since batteries produce explosive gases, keep all
lighted materials (cigarettes, lighters, matches,
etc.) away. Be sure to charge battery only n wellventilated areas.
KEEP BATTERIES
OUT OF THE REACH OF CHILDREN!
8.
Allow battery to sit for 20 to 30 minutes. Add
additional acid, if necessary, to bring it up to
the proper level.
9.
The battery can be charged after the 20
minutes sitting period. SLOW CHARGE THE
BATTERY (DO NOT FAST CHARGE) at a max
imum bench rate of 1.4 amperes until the
specific gravity reading is 1.260-1.280. Charge
for a minimum of 2 hours and a maximum of 8
hours.
NOTE
Charging rate after battery has been
put into operation: The battery is to
be charged for a period of 14-16
hours. NO LONGER THAN 30
HOURS.
After battery has been in service,
add only distilled water. Do not add
acid.
H^NOTE
This engine is equipped with an
alternator. The current for the bat
tery charger alternator is unregu
lated. During normal operation, it is
only necessary to charge the battery:
1. When it is activated for the first
time.
2. Before winter storage.
3. Before using the lawn tractor
after winter storage.
INSTALLING THE BATTERY
—1. Place gear shift lever in the “neutral” posi
tion. Unscrew the gear shift knob. See figure
4.
FIGURE 4.
2. Remove the two truss head screws which
— secure the transmission cover. See figure 5.
3. Lift the transmission cover. Unplug the green
safety wire from beneath the transmission
-cover.
See figure 6. Remove transmission
cover.
4. Assemble one hook (G) to each end of the bat-
-tery strap (G) as shown in figure 7. Adjust the
strap so there is about 2" of strap beyond the
hooks.
FIGURE 7.
Hole for
Drain Tube
FIGURE 8.
5. Hook one end of the battery strap into the
■hole provided in the frame. See figure 8. Lay
the strap over the side of the frame.
FIGURE 9.
Set the battery in the lawn tractor so that the
negative terminal is toward the front of the
-unit. See figure 9. Place the end of the drain
tube into the hole in the frame shown in figure
8.
7.
Slide the square nut (provided with battery
hardware) into the positive (-i-) terminal. Place
the positive (heavy red wire) cable on the
positive terminal. Secure with screw provided.
See figure 9.
8.
Slide the square nut (provided with battery
hardware) into the negative (-) terminal.
Place the negative (heavy black wire) cable on
the negative terminal. Secure with screw pro
vided.
Incline
Assistance
9. Slide the battery forward into position as
-----
shown in figure 10. Secure in place with the
battery strap, stretching strap over the battery
and hooking into hole in the frame.
10. Slide rubber boot over the positive terminal.
See figure 10.
11.--Route the battery drain tube toward the back
of the unit, over the shaft on the incline
assistance brake and inside the deck links.
-----
See figure 11.
12. Secure drain tube to hole in the side of frame
with cable tie (H) as shown in figure 11. Cut off
excess end of cable tie. Be certain tube is
routed away from wheel rim.
FIGURE 11.
13. Plug the green safety wire into the switch
beneath the transmission cover. Refer to
figure 6. Replace the transmission cover and
gear shift knob.
Plastic
Bushing
in Dash
Panel
Upper Steering
Clevis
Pin (I)
FIGURE 12.—Model 698 Shown
Shaft
Hairpin Cotter (J)
Lower Steering
Shaft
STEERING WHEEL INSTALLATION
1.-----For shipping purposes, the upper steering
shaft is pushed ail the way down over the
lower steering shaft. Pull the upper steering
shaft up. The four holes in the shaft provide
four steering wheel heights. Select desired
hole and secure with clevis pin (I) and hairpin
------
cotter (J). See figure 12.
NOTE
On model 668, the four adjustment
holes are located above the dash
panel.
Steering
Bellow (D)
FIGURE 13.
Belleville
Washer (B)
Hex Nut (C)
2. Attach steering bellow (D) to the steering
wheel as shown in figure 13.
NOTE
One end of the steering bellow is
slightly larger than the other. The
larger end must be assembled to the
steering wheel.
3. Place steering wheel and bellow on the steer
ing shaft, lining up the flats in the wheel with
the flats on the shaft.
4. Secure with belleville washer (B) (cupped side
against the steering wheel) and hex nut (C).
— See figure 14.
5. Press the steering wheel cap (A) on the steer
ing wheel by hand.
FIGURE 14.
Two
Lock Washers
Two
Hex Bolts
FIGURE 15.
Lock Washer
Hex ljut
SEAT INSTALLATION
Your seat mounts to the unit in one of two ways.
A. Two weld nuts in the bottom of the seat;
The seat may be adjusted to three different
positions. Select desired position and secure
to seat spring with two hex bolts and lock
------
washers. See figure 15.
B. Weld bolt in the bottom of the seat:
The seat may be adjusted to four different
positions. Select desired position and secure
to seat spring with one lock washer and hex
nut. See figure 15.
CONTROLS
THROTTLE CONTROL
The throttle control is used to regulate the engine
speed and to activate the choke on the engi ie. To
get maximum efficiency from cutting, the tf rottle
should be in the FAST position when operating
the mower. Pushing the throttle all the Wc.y for
ward past FAST, will choke the engine. See figure
16.
Clutch-Brake
Pedal
Throttle
Control
Ammeter
(Optional)
/
FIGURE 16.—Models 620, 638 and 698 Shovm
GEAR SHIFT LEVER
The shift lever is located on the left side sf the
console and has three positions, “FORWARD,”
“NEUTRAL” and “REVERSE.” See figure IT. The
clutch-brake pedal must be depressed ard the
lawn tractor must not be moving when shifting
gears. Do not force the shift lever. Releas e the
clutch-brake pedal slightly to line up the stiifting
collar in the transmission. Then try to shift jears.
Li it and
Disen<)agement
Lever
Ignition
Sv itch
Light S witch
(Optionai)
\
SPEED CONTROL LEVER
The speed control lever allows you to regulate the
ground speed of the lawn tractor. See figure 17. To
select the ground speed, depress clutch pedal.
Push speed control lever outward and move back
ward to slow lawn tractor, move forward to In
crease speed. When desired speed has been ob
tained, release lever in that position. Whenever
clutch is engaged, unit will automatically go to the
pre-set speed.
IGNITION SWITCH
Turn the key to the “START” position to start the
engine. When the engine is running, let the key
return to the “ON” position. To stop the engine,
turn the key to the left to the “OFF” position and
remove it to prevent accidental starting. See
figure 16.
LIGHT SWITCH (Optional)
Push the light switch to turn on the lights. The
lights will only operate when the engine is run
ning. See figure 16.
AMMETER (Optional)
The ammeter registers the rate of battery charge
or discharge. The ammeter will register on the
discharging side when starting the engine. It
should register on the opposite side (charging)
when the engine is running in the fast position untii the battery is completely charged. With a fully
charged battery or with the engine idling, the am
meter will not show a charge. See figure 16.
CLUTCH-BRAKE PEDAL
The clutch-brake pedal is located on the left side
of the lawn tractor. Depressing the clutch-brake
pedal part way disengages the clutch. Pressing
the pedal all the way down disengages the clutch
and engages the disc brake. See figure 16.
10
NOTE
The clutch-brake pedal must
be
depressed to start the engine.
PARKING BRAKE
The speed control lever is used to set the parking
brake. To set the parking brake, depress the
clutch-brake pedal. Press the speed control lever
outward and all the way to the rear of the unit.
Release the speed control lever and the clutchbrake pedal.
To release the parking brake, depress the clutch-
brake pedal, press the speed control lever outward
and move to desired position. Release the speed
control lever and the clutch-brake pedal.
Lift and
Disengagement
Lever
CUTTING CONTROLS
A. LIFT AND DISENGAGEMENT LEVER
The lift and disengagement lever is used to raise
and lower the cutting deck. Pulling it all the way
back and locking it disengages the blades. The lift
and disengagement lever must be in the disen
gaged position when starting the engine and
when shifting into reverse. See figure 17.
B. DECK LIFT INDICATOR
The deck lift indicator marks the position being
used for the lift lever. Select the lift lever position
desired, press the indicator lever outward, move it
to the position immediately below the lift lever
and release the indicator lever. See figure 17.
C. WHEEL HEIGHT ADJUSTER
Move the lever towards the wheel and set it in the
desired height. See figure 18.
Speed
Control
‘Lever
Deck.
Lift
Indicator
FIGURE 17.
INCLINE ASSISTANCE BRAKE
When stopping on a hill, hold the incline
assistance brake lever back while you release the
clutch-brake pedal until the lawn tractor begins to
move, then release the lever. This lever permits
smoother starts and clutch engagement by
holding the tractor during the brake release/clutch
engagement operation. See figure 17.
INTERLOCKS (Not Shown)
Interlock safety switches are located on the
clutch-brake pedal, and the lift and disengage
ment lever and gear shift lever.
Before the engine will start, the clutch-brake
pedal must be depressed all the way and the lift
and disengagement lever must be in the disen
gaged position.
Before the unit can be shifted into reverse, the lift
and disengagement must be in the disengaged
position.
Wheel Height
Adjuster
FIGURE 18.
3. SETTING THE CUTTING HEIGHT
1. Select the position for the lift lever which
gives the desired cutting height. Move the
deck lift indicator so that the lift lever can be
returned to the same position after it is raised.
2. Set the wheel height adjusters on the deck so
that the wheels are V4 to Vz inch above the
ground.
11
OPERATION
Ac WARNING \
CAUTION
Keep all shields in place.
Before leaving operator’s position:
a. Shift transmission to neutral
b. Set parking brake
c. Disengage attachment clutch
d. Shut off engine
e. Remove ignition key
Wait for all movement to stop befo
3.
servicing machine.
4.
Keep people and pets a safe distanc
away from machine.
Look to the rear before backing up.
5.
TIRE PRESSURE
For shipping purposes, the tires on your un
be over-inflated. Tire pressure should be re
before unit is put into operation. Recomm
operating tire pressure should be 10 p.s.i.
Check sidewall of tire for manufacturer’s max
imum tire pressure. If this information dotis not
appear on your tire, maximum tire pressure under
any circumstances is 30 p.s.i. Equal tire pr( ssure
should be maintained on all tires.
STARTiNG THE ENGINE
NOTE
t may
juced
inded
Do not operate the lawn tractor if
the interlock system is malfunction
ing because it is a safety device,
designed for protection.
4. Set the throttle control in the CHOKE posi
tion. See figure 16.
5. Turn the ignition key to the “START” position.
When the engine is running, let the key return
to the “ON” position. See figure 16.
6. Move the throttle control to desired engine
speed.
STOPPING THE ENGINE
Turn the ignition key to the left to the “OFF” posi
tion. Remove the key to prevent accidental start
ing.
NOTE
A brief break-in period is essential
to ensure maximum engine and
mower life. The break-in consists of
running the engine at half speed for
a period of time required to use one
tank of gasoline. It is also recom
mended to change crankcase oil
after the first 5 hours of operation.
To open "the hood, simply lift
up on both sides of the hood on
all models except 668.
1. Service the engine with oil and gasoline as
described in the engine manual.
2. Depress the clutch-brake pedal and set the
parking brake.
3. Place the lift and disengagement lever in the
DISENGAGED_^position. See figure 17.
NOTE
This unit is equipped with a safety
interlock system for your protec
tion. The purpose of the safety inter
lock system is to prevent the engine
from cranking or starting unless the
clutch-brake pedal is depressed
and the lift and disengagement
lever is in the disengaged position.
In addition, the lift and disen
gagement lever must be in the dis
engaged position when the unit is
put into reverse or the engine will
shut off.
Be sure that the lawn is clear of stones, sticks,
wire, or other objects which could damage lawn
tractor or engine. For best results and to insure
more even grass distribution, do not mow when
lawn is excessively wet.
IMPORTANT
If you strike a foreign object, stop
the engine. Remove wire from spark
plug, thoroughly inspect the unit
for any damage, and repair the dam
age before restarting and operating
the mower.
OPERATING THE LAWN TRACTOR
1. Set the desired cutting height.
2. Start the engine as instructed in previous col
umn.
3. Move throttle control to Va or full throttle to
prevent strain on the engine and to operate
the cutting blades.
4. Place the shift lever in either the “FORWARD”
or “REVERSE” position.
12
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