MTD Yard-Man AutoDrive 604, M3800S-BN, Yard-Man AutoDrive U604H Operator's Manual

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OPERATOR’S MANUAL

Model U604H Shown

AutoDrive

™

Lawn Tractor

Model 604

IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY

Warning:

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 368022 Cleveland, Ohio 44136-9722.

This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-

MTD PRODUCTS INC. P.O. BOX 368022 CLEVELAND, OHIO 44136-9722

PRINTED IN U.S.A. FORM NO. 770-10235B

(10/99)

SECTION 1: TABLE OF CONTENTS

PAGE

FINDING YOUR MODEL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

CALLING CUSTOMER SUPPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

IMPORTANT SAFE OPERATION PRACTICES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SAFETY LABLES FOUND ON YOUR UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

SLOPE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

ATTACHMENTS & ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

TRACTOR SET-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

WARRANY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover

SECTION 2: FINDING YOUR MODEL NUMBER

This Operator’s Manual is an important part of your new rider. It will help you assemble, prepare and maintain your rider. Please read and understand what it says. Before you start to prepare your tractor for its first use, please locate the model plate and copy the information from it in this Operator’s Manual. The information on the model plate is very important if you need help from your dealer or the MTD customer support department.

• Every tractor has a model plate. You can locate it by lifting the seat and looking at the seat bracket.

• An example of what the model plate will look like is shown below.

This is where your model number will be.

XXX-X-XXX-X-XXX XXXXXXXXXXX

This is where your serial number will be.

Copy the model number here:

MTD PRODUCTS INC

P.O. BOX 368022

CLEVELAND, OHIO 44136

Copy the serial number here:

SECTION 3: CALLING CUSTOMER SUPPORT

• LOCATE YOUR MODEL NUMBER AND SERIAL NUMBER — Record this information in the space

provided. To find your unit’s specific model number and serial number, see SECTION 2: FINDING YOUR MODEL NUMBER.

• If you are having difficulty assembling this product or if you have any questions regarding the controls,

operation or maintenance of this unit, please call the Customer Support Department.

• Customer Support can be reached by dialing: 1- (330) 220-4MTD

(4683)

1- (800)-800-7310

• Please have your model number and serial number ready when you call.

• Although both numbers are important, you will be asked to enter only your serial number before your

call can be processed.

SECTION 4: IMPORTANT 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 YOUR LAWN MOWER. FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WHEN YOU SEE THIS SYMBOL, HEED ITS WARNING.

WARNING: The Engine Exhaust from this product contains chemicals known to

the State of California to cause cancer, birth defects or other reproductive harm.

DANGER: Your lawn mower was built to be operated according to the rules for safe operation in

this manual. As with any type of power equipment, carelessness or error on the part of the operator can result in serious injury. This lawn mower is capable of amputating hands and feet and throwing objects. Failure to observe the following safety instructions could result in serious injury or death.

1. GENERAL OPERATION

• Read, understand, and follow all instructions in the

operator’s manual and on the machine before starting. Keep this manual in a safe place for future and regular reference and for ordering replacement parts.

• Only allow responsible individuals familiar with the

instructions to operate the machine. Know controls and how to stop the machine quickly.

• Do not put hands or feet under cutting deck or near

rotating parts.

• Clear the area of objects such as rocks, toys, wire,

etc., which could be picked up and thrown by the blade. A small object may have been overlooked and could be accidentally thrown by the mower in any direction and cause injury to you or a bystander. To help avoid a thrown objects injury, keep children, bystanders and helpers at least 75 feet from the mower while it is in operation. Always wear safety glasses or safety goggles during operation or while performing an adjustment or repair, to protect eyes from foreign objects. Stop the blade(s) when crossing gravel drives, walks or roads.

• Be sure the area is clear of other people before

mowing. Stop machine if anyone enters the area.

• Never carry passengers.

• Disengage blade(s) before shifting into reverse and

backing up. Always look down and behind before and while backing.

• Be aware of the mower and attachment discharge

direction and do not point it at anyone. Do not operate the mower without either the entire grass catcher or the chute guard in place.

• Slow down before turning. Operate the machine

smoothly. Avoid erratic operation and excessive speed.

• Never leave a running machine unattended. Always turn off blade(s), place transmission in neutral, set park brake, stop engine and remove key before dismounting.

• Turn off blade(s) when not mowing.

• Stop engine and wait until blade(s) comes to a complete stop before (a) removing grass catcher or unclogging chute, or (b) making any repairs, adjusting or removing any grass or debris.

• Mow only in daylight or good artificial light.

• Do not operate the machine while under the influence of alcohol or drugs.

• Watch for traffic when operating near or crossing roadways.

• Use extra care when loading or unloading the machine into a trailer or truck. This unit should not be driven up or down 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 on a ramp to load or unload properly.

• Never make a cutting height adjustment while engine is running if operator must dismount to do so.

• Wear sturdy, rough-soled work shoes and closefitting slacks and shirts. Do not wear loose fitting clothes or jewelry. They can be caught in moving parts. Never operate a unit in bare feet, sandals, or sneakers.

• Check overhead clearance carefully before driving under power lines, 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 injury.

• Disengage all attachment clutches, thoroughly depress the brake pedal, and shift into neutral before attempting to start engine.

• Your mower is designed to cut normal residential grass of a height no more than 10". Do not attempt to mow through unusually tall, dry grass (e.g., pasture) or piles of dry leaves. Debris may build up on the mower deck or contact the engine exhaust presenting a potential fire hazard.

2. SLOPE OPERATION

Slopes are a major factor related to loss of control and tipover accidents which can result in severe injury or death. All slopes require extra caution. If you cannot back up the slope or if you feel uneasy on it, do not mow it. For your safety, use the slope gauge included as part of this manual to measure slopes before operating this unit on a sloped or hilly area. If the slope is greater than 15° as shown on the slope gauge, do not operate this unit on that area or serious injury could result.

DO:

• Mow up and down slopes, not across.

• Remove obstacles such as rocks, limbs, etc.

• Watch for holes, ruts or bumps. Uneven terrain could overturn the machine. Tall grass can hide obstacles.

• Use slow speed. Always keep machine in gear when going down slopes to take advantage of engine braking action.

• Follow the manufacturer’s recommendations for wheel weights or counterweights to improve stability.

• Use extra care with grass catchers or other attachments. These can change the stability of the machine.

• Keep all movement on the slopes slow and gradual. Do not make sudden changes in speed or direction. Rapid engagement or braking could cause the front of the machine to lift and rapidly flip over backwards which could cause serious injury.

• Avoid starting or stopping on a slope. If tires lose traction, disengage the blade(s) and proceed slowly straight down the slope.

DO NOT:

• Do not turn on slopes unless necessary; then, turn slowly and gradually downhill, if possible.

• Do not mow near drop-offs, ditches or embankments. The mower could suddenly turn over if a wheel is over the edge of a cliff or ditch, or if an edge caves in.

• Do not mow on wet grass. Reduced traction could cause sliding.

• Do not try to stabilize the machine by putting your foot on the ground.

• Do not use grass catcher on steep slopes.

3. CHILDREN

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them.

• Keep children out of the mowing area and in watchful care of an adult other than the operator.

• Be alert and turn machine off if children enter the area.

• Before and when backing, look behind and down for small children.

• Never carry children, even with the blades off. They may fall off and be seriously injured or interfere with the safe machine operation.

• Never allow children under 14 years old to operate the machine. Children 14 years and over should only operate machine under close parental supervision and proper instruction.

• Remove key when machine is unattended to prevent unauthorized operation.

• Use extra care when approaching blind corners, shrubs, trees or other objects that may obscure your vision of a child or other hazard.

4. SERVICE

• Use extreme care in handling gasoline and other fuels. They are extremely flammable and the vapors are explosive.

• Use only an approved container.

• Never remove fuel cap or add fuel with the engine running. Allow engine to cool at least two minutes before refueling.

• Replace fuel cap securely and wipe off any spilled fuel before starting the engine as it may cause a fire or explosion.

• Extinguish all cigarettes, cigars, pipes and other sources of ignition.

• Never refuel the machine indoors because fuel vapors will accumulate in the area.

• Never store the fuel container or machine inside where there is an open flame or spark, such as a gas hot water heater, space heater or furnace.

• Never run a machine inside a closed area.

• To reduce fire hazard, keep the machine free of grass, leaves or other debris build-up. Clean up oil or fuel spillage. Allow machine to cool at least 5 minutes before storing.

• Before cleaning, repairing or inspecting, make certain the blade and all moving parts have stopped. Disconnect the spark plug wire, and keep the wire away from the spark plug to prevent accidental starting.

• Check the blade and engine mounting bolts at frequent intervals for proper tightness. Also, visually inspect blade for damage (e.g., excessive wear, bent, cracked). Replace with blade which meets original equipment specifications.

• Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition.

• Never tamper with safety devices. Check their proper operation regularly. Use all guards as instructed in this manual.

• After striking a foreign object, stop the engine, remove the wire from the spark plug and thoroughly inspect the mower for any damage. Repair the damage before restarting and operating the mower.

• Grass catcher components are subject to wear, damage and deterioration, which could expose moving parts or allow objects to be thrown. For your safety protection, frequently check components and replace with manufacturer’s recommended parts when necessary.

• Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves and use extra caution when servicing blade(s).

• Check brake operation frequently. Adjust and service as required.

• Muffler, engine and belt guards become hot during operation and can cause a burn. Allow to cool

• Do not change the engine governor settings or overspeed the engine. Excessive engine speeds are dangerous.

• Observe proper disposal laws and regulations. Improper disposal of fluids and materials can harm the environment and the ecology.

• Prior to disposal, determine the proper method to dispose of waste from your local Environmental Protection Agency. Recycling centers are established to properly dispose of materials in an environmentally safe fashion.

• Use proper containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Properly dispose of the containers immediately following the draining of fluids.

• DO NOT pour oil or other fluids into the ground, down a drain or into a stream, pond, lake or other body of water. Observe Environmental Protection Agency regulations when disposing of oil, fuel, coolant, brake fluid, filters, batteries, tires and other harmful waste.

down before touching.

WARNING - YOUR RESPONSIBILITY: Restrict the use of this power machine to persons

who read, understand and follow the warnings and instructions in this manual and on the machine.

Figure 1 Safety Labels found on your unit

WARNING

TO AVOID SERIOUS INJURY OR DEATH

• GO UP AND DOWN SLOPES, NOT ACROSS.

AVOID SUDDE N TURNS.

• DO NOT OPERATE THE UNIT WHERE IT

COULD SLIP OR TIP.

• IF MACHINE STOPS GOING UPHILL, ST OP

BLADE(S) AND BACK DOWNHILL SL OWLY.

• DO NOT MOW WHE N CHILDREN OR OTHERS

ARE AROUND.

• NEVER CAR RY CHILDREN.

• LOOK DOWN & BEHIND BEFORE AND WHILE

BACKING.

• KEEP SAFETY DEV ICES (GUARDS, SHIELDS,

AND SWITCHES, ETC.) IN PLACE AND WORKING.

• REMOVE OBJE CTS THAT COULD BE

THROWN BY THE BLADE(S).

• KNOW LOCATION AND FUNCTION OF ALL

CONTROLS.

• BE SURE BLA DE(S) AND ENGINE ARE STOPPED

BEFORE PLACI NG HANDS OR FEET NEAR BLADE(S).

• BEFORE LEAVING OPERATOR'S POSITION,

DISENGAGE BLADE( S), PLACE THE SHIFT

LEVER IN NEUTRAL, ENGAGE PARKING BRAKE,

SHUT OFF AND R EMOVE KEY.

READ OPERATOR'S MANUAL

Slope Gauge

USE THIS PAGE AS A GUIDE TO DETERMINE SLOPES WHERE YOU MAY NOT OPERATE SAFELY.

Operate RIDING mowers up and down slopes, never across the face of slopes.

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.

A CORNER OF A BUILDING

SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE

A POWER POLE

WARNING

15°

OR A FENCE POST

SECTION 5: ATTACHMENTS & ACCESSORIES

MODEL NUMBER DESCRIPTION

OEM-190-601 FastAttach OEM-190-602 FastAttach OEM-190-112 Mulch Kit (For 42-inch Decks Only) OEM-190-118 Mulch Kit (For 46-inch Decks Only) OEM-190-603 FastAttach OEM-190-604 TracPac OEM-190-822 FastAttach OEM-190-823 42-inch Two-stage Snow Thrower

™

Twin Bagger Grass Collector (For 42-inch Decks Only)

™

Twin Bagger Grass Collector (For 46-inch Decks Only)

™

Grille Guard (mounts on front of tractor)

™

Storage Container (mounts on rear of tractor)

™

46-inch Front Dozer Blade

SECTION 6: TRACTOR SET-UP

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. Make certain that the rubber boot covers the terminal to help protect it from corrosion.

• Remove the hex bolt and wing nut from the negative cable. Attach the negative cable (heavy black wire) to the negative battery terminal (–) with the bolt and wing nut.

• Place the hold-down strap in position over the battery to secure it in place. See Figure 2.

Positive

Terminal

Rubber

Boot

GAS AND OIL FILL-UP

Service the engine with gasoline and oil as instructed in the separate engine manual packed with your tractor. Read instructions carefully.

IMPORTANT: Your tractor is shipped with oil;

however, you MUST check the oil level before operating. Be careful not to overfill. Overfilling with oil may cause the engine to smoke. This will result in poor engine performance and could cause permanent engine damage.

The gasoline tank is located under the hood and has a capacity of approximately two gallons. Do not overfill.

WARNING: Gasoline produces noxious

fumes. Never fill fuel tank indoors. Always fill the fuel tank in a well ventilated area to avoid inhalation of gasoline fumes.

Battery

Wing

Nut

Negative

Terminal

Hold-down Strap

Bolt

Tray

Figure 2

NOTE: If battery is put into service after date

shown on top of battery, charge for minimum of one hour at 6-10 amps. Refer to the MAINTENANCE section of this manual for more detailed instructions regarding proper battery charging procedure.

WARNING: Never smoke while fueling

your tractor or fill the fuel tank while engine is running or while engine is hot.

WARNING: Do not fill closer than 1/2

inch from the top of the fuel tank to prevent spills and to allow for fuel expansion. If gasoline is accidently spilled, move tractor away from area of spill. Avoid creating any source of ignition until gasoline vapors have disappeared.

INSTALLING THE MULCH KIT

On units equipped with a 42-inch deck, the mulch kit is installed at the factory. To remove it, unfasten the wing knob found on the top of the cutting deck and carefully pull the mulch plug out from the discharge area of the deck. On units equipped with a 46-inch deck, the mulch kit is packaged separately within the crate.

SECTION 7: CONTROLS

NOTE: Steering Wheel not shown for clarity.

Figure 3

A Ignition Switch H Brake Pedal B Throttle Control Lever I Parking Brake Button C Choke Control (if so equipped) J Shift Lever D Indicator Monitor/Hour Meter K Seat Adjustment Lever E Lift Lever L Cup Holder F PTO (Power Take-Off) Lever* M Cruise Control Button

™

G AutoDrive

Pedal N PTO (Power Take-Off) Knob*

*Tractors vary by model and are equipped with either a PTO lever or a PTO knob, NEVER both.

NOTE: Any reference in this manual to the RIGHT or LEFT side of the tractor is observed from operator’s position.

IGNITION SWITCH

To start the engine, insert key into the ignition switch and turn clockwise to the START position. Release key to the ON position once engine has fired. See Figure 4. Refer to STARTING THE ENGINE in the OPERATION section of this manual for detailed starting instructions. The ignition switch is also used to operate the headlights. Refer to OPERATING THE HEADLIGHTS in the OPERATION section of this manual for detailed instructions

WARNING: Remove the key from the

tractor when the tractor is not in use to prevent accidental starting.

Off

On/Lights

IMPORTANT: When using PTO operated

equipment such as the cutting deck or other attachments, always operate the tractor with the throttle lever in the FAST (rabbit) position.

CHOKE CONTROL

On some units, moving the throttle lever all the way forward activates the engine’s choke control. On all other units, the choke control can be found on the left side of the dash panel and is activated by pulling the knob outward. Activating the choke control closes the choke plate on the carburetor and aids in starting the engine. Refer to STARTING THE ENGINE in the OPERATION section of this manual for detailed starting instructions.

Start

Figure 4

THROTTLE CONTROL LEVER

The throttle lever is located on the right side of the tractor’s dash panel. This lever controls the speed of the engine, and on some units the choke control also. When set in a given position, the throttle will maintain a uniform engine speed. See Figure 5.

Throttle

Symbol

Choke

Position

Fast

Position

Slow

Position

Throttle

Symbol

Fast

Position

Slow

Position

INDICATOR MONITOR / HOUR METER

Your tractor is equipped with four indicator lights and an hour meter located on the left side of the dash panel. See Figure 6.

Battery

Hour

Meter

1/10

PTO

Figure 6

If a light illuminates when attempting to start the unit, proceed as follows: BRAKE — Depress the brake pedal. PTO — Move PTO lever, or PTO knob into the

disengaged (OFF) position.

OIL— Check the crankcase oil level, and add

oil as required.

BATTERY—If this light illuminate’s while the engine

is running, it indicates that the battery is in need of a charge. Refer to the MAINTENANCE section of this manual for the proper battery charging procedure.

Oil

Brake

Figure 5

The hour meter operates whenever the ignition key is in the On or On/Lights position and records the actual hours of tractor operation.

ELECTRIC PTO (POWER TAKE-OFF) KNOB

To engage the power to the cutting deck or other attachments, pull outward on the PTO knob. Push the PTO knob inward to disengage the power to the attachments.

NOTE: The PTO knob must be in the disengaged

(OFF) position when starting the engine, when shifting into reverse and if the operator leaves the seat.

PTO (POWER TAKE-OFF) LEVER

The PTO lever is located on the left side of the dashboard next to the steering wheel. Move the PTO lever forward to engage the power to the cutting deck or other attachments; move the PTO lever backward (toward the rear of the tractor) to disengage the power to the attachments.

NOTE: The PTO lever must be in the disengaged

(OFF) position when starting the engine, when shifting into reverse and if the operator leaves the seat.

AUTODRIVE™ PEDAL

BRAKE PEDAL

BRAKE

The brake pedal is located on the right front side of the tractor above the AutoDrive running board. The brake pedal can be used for sudden stops or setting the parking brake.

™

pedal along the

NOTE: The brake pedal must be fully depressed to

activate the safety interlock switch when starting the

tractor

LIFT LEVER

The lift lever is used to change the operating position (height) of the cutting deck. To operate, move the lever to the left, then place in the notch best suited for your application.

PARKING BRAKE BUTTON

To set the parking brake, fully depress the brake pedal and push the parking brake button in. Hold the button in while taking your foot off the brake pedal. Both the parking button and the brake pedal will then stay depressed. To release the parking brake, depress the brake pedal slightly. The parking brake button will then return to its original position.

The AutoDrive™ pedal is located below the brake pedal on the right front side of the tractor along the running board. Depress the AutoDrive your right foot when the tractor shift lever is in either forward or reverse to cause the tractor to move. Ground speed is also controlled with the AutoDrive pedal. The further down the pedal is depressed, the faster the tractor will travel. The pedal will return to its original position when it’s not depressed.

IMPORTANT: Always set the parking brake

when leaving the tractor unattended.

™

pedal with

NOTE: The parking brake must be set if the

operator leaves the seat with the engine running or the engine will automatically shut off.

IMPORTANT: Always set the parking brake

when leaving the tractor unattended.

™

SHIFT LEVER

The shift lever is located on the left side of the fender and has three positions, FORWARD, NEUTRAL and REVERSE. The brake pedal must be depressed and the tractor must not be in motion when the moving shift lever.

IMPORTANT: Never

force the shift lever. Doing so may result in serious damage to the tractor’s transmission.

Shift

Knob

SECTION 8: OPERATION

SAFETY INTERLOCK SWITCHES

This tractor is equipped with a safety interlock system for the protection of the operator. If the interlock system should ever malfunction, do not operate the tractor. Contact an authorized MTD Service Dealer in your area. The safety interlock system prevents the engine from cranking or starting unless the brake pedal is fully depressed, and the PTO lever, or PTO knob is in the disengaged (OFF) position.

• The safety interlock system will automatically shut off the engine if the operator leaves the seat before engaging the brake lock.

• The safety interlock system will automatically shut off the engine if the operator leaves the seat with the PTO lever, or PTO knob in the engaged (ON) position, regardless of whether the brake lock is engaged. The PTO lever, or PTO knob must be in the disengaged (OFF) position to restart the engine.

• On units equipped with an electric PTO, the safety interlock system will automatically shut off the PTO if the PTO knob is moved into the engaged (ON) position with the shift lever in the REVERSE position.

• On units equipped with a manual PTO, the safety interlock system will automatically shut off the tractor’s engine if the PTO lever is moved into the engaged (ON) position with the shift lever in the REVERSE position.

CRUISE CONTROL BUTTON

The cruise control button is located on the tractor dash panel to the left of the ignition switch. Push the cruise control button while traveling forward at a desired speed. While holding the button in, release pressure from the

™

AutoDrive

pedal. This will engage the cruise control and allow the tractor to remain at that speed without applying

™

pressure to the AutoDrive

pedal.

Depress the brake pedal or the

™

AutoDrive

pedal to deactivate cruise control. Refer to the OPERATION section of this manual for detailed instructions regarding the cruise control feature.

WARNING: Do NOT attempt to bypass

or disconnect the tractor’s safety interlock. Doing so could result in serious personal injury or death.

IMPORTANT: Tampering with or attempting to

bypass the tractors Safety Interlock Switches in any way WILL void your warranty.

WARNING

• GO UP AND DOWN SLOPES, NOT ACROSS.

• AVOID SUDDEN TURNS.

• DO NOT OPERATE THE UNIT WHERE IT COULD SLIP OR TIP.

• IF MACHINE STOPS GOING UPHILL, STOP BLADE(S) AND BACK

DOWNHILL SLOWLY.

• DO NOT MOW WHEN CHILDREN OR OTHERS ARE AROUND.

• NEVER CARRY CHILDREN.

• LOOK DOWN AND BEHIND BEFORE AND WHILE BACKING.

• KEEP SAFETY DEVICES (GUARDS, SHIELDS, AND SWITCHES) IN

PLACE AND WORKING.

• REMOVE OBJECTS THAT COULD BE THROWN BY THE BLADE(S).

• KNOW LOCATION AND FUNCTION OF ALL CONTROLS.

• BE SURE BLADE(S) AND ENGINE ARE STOPPED BEFORE PLAC-

ING HANDS OR FEET NEAR BLADE(S).

• BEFORE LEAVING OPERATOR’S POSITION, DISENGAGE BLADE(S), PLACE THE SHIFT LEVER IN NEUTRAL, ENGAGE BRAKE LOCK, SHUT ENGINE OFF AND REMOVE KEY.

AVOID SERIOUS INJURY OR DEATH

READ OPERATOR’S MANUAL

SETTING THE CUTTING HEIGHT

Select the height position of the cutting deck by placing the deck lift lever in any of the six different cutting height notches on the right side of the fender. Then adjust the deck wheels so that they are at least 1/4 inch to 1/2 inch above the ground when the tractor is on a smooth, flat surface such as a driveway.

WARNING: Keep hands and feet away

from the discharge chute opening of the cutting deck.

STOPPING THE ENGINE

• Place the PTO lever, or PTO knob in the disengaged (OFF) position

• Move the throttle control into the SLOW (turtle) position and allow the engine to "idle down" for ten seconds. Failure to do so may result in an engine afterfire.

• Turn the ignition key counterclockwise to the OFF position.

• Remove the key from the ignition switch to prevent accidental starting.

NOTE: The deck wheels are an anti-scalp feature

of the deck and are not designed to support the weight of the cutting deck.

Refer to the ADJUSTMENTS section of this manual for more detailed instructions regarding various deck adjustments.

STARTING THE ENGINE

NOTE: Refer to the TRACTOR SET-UP section of

this manual for Gasoline and Oil fill-up instructions.

• Insert the tractor key into the ignition switch.

• Place the PTO lever, or PTO knob in the

disengaged (OFF) position.

• Depress the brake pedal and set the parking brake.

• Place the shift lever in the NEUTRAL position.

• Move the throttle control lever into the FAST

(or CHOKE, if so equipped) position.

• Pull out the choke control knob, if so equipped (a warm engine may not require choking).

• Turn the ignition key clockwise to the START position. After the engine starts, release the key. It will return to the ON position.

IMPORTANT: Do NOT hold the key in the START

position for longer than ten seconds at a time. Doing so may cause damage to your engine’s starter.

NOTE: If starting problems are encountered, refer

to the TROUBLESHOOTING section of this manual.

After the engine starts, slowly release the brake pedal. As the engine warms up, gradually push the choke control knob inward (or move the throttle control lever out of the CHOKE position into the FAST position) to open up the choke plate on the engine’s carburetor.

NOTE: Do NOT leave the choke control out while

operating the tractor. Doing so will result in a "rich" fuel mixture and cause the engine to run poorly.

IMPORTANT: If you think you’ve struck a foreign

object, stop the engine immediately. Remove the wire(s) from the spark plug(s), thoroughly inspect the unit for any damage, and repair the damage before restarting and operating the tractor.

DRIVING THE TRACTOR

WARNING: Avoid sudden starts,

excessive speed and sudden stops.

WARNING: Do not leave the seat of the

tractor without first placing the PTO lever, or PTO knob 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.

• Depress the brake pedal to release the parking brake and let the pedal up. Move the throttle lever into the FAST (rabbit) position.

IMPORTANT: Do NOT use the shift lever to

change the direction of travel when the tractor is in motion. Always use the brake pedal to bring the tractor to a complete stop before shifting.

• To move forward, place the shift lever in the FORWARD position, then slowly depress the AutoDrive achieved.

• To move in reverse, place the shift lever in the REVERSE position, check that the area behind is clear then slowly depress the AutoDrive

™

pedal until the desired speed is

™

pedal.

SETTING THE CRUISE CONTROL

NOTE:

utilized in the forward direction.

The cruise control feature should only be

• Place the shift lever in the FORWARD position, then slowly depress the AutoDrive pedal until the desired speed is achieved.

• Lightly depress the cruise control button.

™

• While continuing to hold the cruise button in,

™

lift your foot from the AutoDrive

pedal (you

should feel the cruise latch engage).

• If properly engaged, the cruise control button

™

and the AutoDrive

pedal should lock in the down position, and the tractor will maintain the same forward speed.

• Disengage the cruise control using one of the following methods:

• Depress the brake pedal to disengage the cruise control and stop the tractor.

• Lightly depress the

AutoDrive

™

pedal.

To change to the reverse direction when operating with cruise control, depress the brake pedal to disengage the cruise control and bring the tractor to a complete stop. Then place the shift lever in the REVERSE position and depress the AutoDrive pedal.

To turn the tractor’s headlights off:

• Turn the key either into the On position (to leave the engine running) or the Off position (to shut the engine off). Refer to Figure 4.

IMPORTANT: Never move the key into the Start

position while the engine is running. Doing so may cause damage to your engine’s starter.

STOPPING THE ENGINE

• Place the PTO lever, or PTO knob in the disengaged (OFF) position.

• Move the throttle control into the SLOW position and allow the engine to "idle down" for ten seconds, then turn the ignition key counterclockwise to the OFF position.

™

• Remove the key from the ignition switch to

prevent accidental starting.

DRIVING ON SLOPES

Refer to the SLOPE GAUGE on page 6 to help determine slopes where you may not operate safely.

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). The tractor could overturn and cause serious injury.

Operate the tractor up and down slopes, never across slopes. Do not drive so that the tractor may tip over sideways. Before operating the tractor on any slope, walk the slope to look for possible hazards such as rocks. mounds, ruts, stumps or other surface irregularities which could cause the tractor to be upset. Avoid turns when driving on a slope. If a turn must be made, turn down the slope. Turning up a slope greatly increases the chance of a roll over. Avoid stopping when driving up a slope. If it is necessary to stop while driving up a slope, start up smoothly and carefully to reduce the possibility of flipping the tractor over backward.

IMPORTANT: If you think you’ve struck a foreign

object, stop the engine immediately. Remove the wire(s) from the spark plug(s), thoroughly inspect the unit for any damage, and repair the damage before restarting and operating the mower.

USING THE LIFT LEVER

To raise the cutting deck, move the lift lever to the left, then place it in the notch best suited for your application. Refer to SETTING THE CUTTING HEIGHT earlier in this section.

ENGAGING THE ELECTRIC PTO (POWER TAKE-OFF) KNOB (if so equipped)

Front View

Pull Out

Push In

OFF

OPERATING THE HEADLIGHTS

To turn the tractor’s headlights on:

• Start the engine following the instructions

earlier in this section.

• Turn the key one notch counterclockwise into the On/Lights position of the ignition switch. Refer to Figure 4.

Figure 7

• Move the throttle control lever to the FAST (rabbit) position.

• Pull the PTO knob outward into the engaged (ON) position. See Figure 7.

• Keep the throttle lever in the FAST (rabbit) position for the most efficient use of the cutting deck and other attachments.

• The operator must remain in the tractor seat at all times. If the operator should leave the seat without pushing the PTO knob inward into the disengaged (OFF) position, the tractor’s engine will shut off.

IMPORTANT: The PTO knob cannot be in the

engaged (ON) position when the tractor is driving in the reverse direction. The PTO knob must be in the disengaged (OFF) position when the shift lever is in REVERSE or the PTO will automatically shut off. Refer to SAFETY INTERLOCK SWITCHES in this section.

ENGAGING THE PTO (POWER TAKE-OFF) LEVER

• Move the throttle control lever to the FAST (rabbit) position.

• Move the PTO lever forward into the engaged (ON) position.

• Keep the throttle lever in the FAST (rabbit) position for the most efficient use of the cutting deck and other attachments.

• The operator must remain in the tractor seat at all times. If the operator should leave the seat without moving the PTO lever into the disengaged (OFF) position and setting the parking brake, the engine will shut off.

(if so equipped)

IMPORTANT: The PTO lever cannot be in the

engaged (ON) position when the tractor is driving in the reverse direction. The safety interlock system will automatically shut off the engine if the PTO lever is moved into the engaged (ON) position with the shift lever in the REVERSE position. Refer to SAFETY INTERLOCK SWITCHES earlier in this section.

MOWING

This tractor is equipped with one of MTD’s high quality cutting decks. The following information will be helpful when using the cutting deck with your tractor.

WARNING: To avoid possible injury, do

not allow anyone in the area of the tractor while mowing. Even if the area to be mowed has been cleared of foreign objects, small objects may be picked up and discharged by the mower.

WARNING: Never direct the discharge

of material toward bystanders or allow anyone near the machine while in operation.

• For best results it is recommended that the first two laps be cut with the discharge thrown towards the center. After the first two laps, reverse the direction to throw the discharge to the outside for the balance of cutting. This will give a better appearance to the lawn.

• Do not cut the grass too short. Short grass invites weed growth and yellows quickly in dry weather.

• Mowing should always be done with the engine at full throttle.

• Do not mow at high ground speed, especially if a mulch kit or grass collector is installed.

• Under heavier conditions it may be necessary to go back over the cut area a second time to get a clean cut.

• Do NOT attempt to mow heavy brush and weeds and extremely tall grass. Your tractor is designed to mow lawns, NOT clear brush.

• Keep the blades sharp and replace the blades when worn. Refer to the MAINTENANCE section of this manual for proper blade sharpening instructions.

SECTION 9: ADJUSTMENTS

LEVELING THE DECK

WARNING: Cutting blades are sharp.

Always protect hands by wearing heavy leather work gloves to grasp blades.

NOTE: Check the tractor’s tire pressure before

performing any deck leveling adjustments. Refer to TIRES in the maintenance section of this manual for further information regarding tire pressure.

Front to Rear

The front of the cutting deck is supported by a stabilizer bar that can adjusted to level the deck from front to rear. The front of the deck should be 1/4" to 3/8" lower than the rear of the deck. Adjust if necessary as follows:

WARNING: Turn the tractor’s engine

off, remove the key from the ignition switch and apply the tractor’s parking brake before making any adjustments to the deck.

• With the tractor parked on a firm, level surface, place the lift lever in the top notch (highest position) and rotate the blade nearest the discharge chute so that it is parallel with the tractor.

• Measure the distance from the front of the blade tip to the ground and the rear of the blade tip to the ground. The first measurement taken should be between 1/4" and 3/8" less than the second measurement. Determine the approximate distance necessary for proper

adjustment and proceed, if necessary, to the next step.

• Loosen the two jam nuts on the rear side of the deck stabilizer bracket. See Figure 8A.

• Locate the two lock nuts on the opposite side of the stabilizer bracket. See Figure 8A. Tighten the lock nuts to raise the front of the deck; loosen the lock nuts to lower the front of the deck.

• Retighten the two jam nuts loosened earlier when proper adjustment is achieved.

Side to Side

If the cutting deck appears to be mowing unevenly, a side to side adjustment can be performed. Adjust if necessary as follows:

WARNING: Turn the tractor’s engine off, remove the key from the ignition switch and apply the

tractor’s parking brake before making any adjustments.

• With the tractor parked on a firm, level surface, place the lift lever in the top notch (highest position) and

rotate the both blades so that they are perpendicular with the tractor.

• Measure the distance from the outside of the left blade tip to the ground and the distance from the outside of the right blade tip to the ground. Both measurements taken should be equal. If they’re not, proceed to the next step.

• Loosen, but do NOT remove, the hex cap screw on the left deck hanger bracket. See Figure 8B.

• Balance the deck so that both blade tip measurements taken earlier are equal.

• Retighten the hex cap screw on the left deck hanger bracket when proper adjustment is achieved.

Lock

Deck

Stabilizer

Bracket

Deck

ront to Rear

Nuts

Jam Nuts

CARBURETOR ADJUSTMENT

WARNING: If any adjustments are

made to the engine while the engine is running (e.g. carburetor), disengage all clutches and blades. Keep clear of all moving parts. Be careful of heated surfaces and muffler.

Hex Cap Screw

Deck Hanger Bracket

Side to Side

Figure 8

NOTE: A dirty air cleaner will cause an engine to

run rough. Be certain it is clean and properly attached before adjusting carburetor. Refer to separate engine manual packed with your unit for information regarding air cleaner maintenance.

Refer to separate engine manual packed with your unit for carburetor adjustment information or see an authorized engine service dealer.

SEAT ADJUSTMENT

To adjust the position of the seat, move the seat adjustment lever (located under the seat) to the left and slide the seat forward or backwards. See Figure

9. Make sure seat is locked into one of the six adjustment positions before operating the tractor.

• Replace hex nut and lock washer and retighten the jam nut after proper adjustment is achieved.

NOTE: Threading the ball joints too far onto the

drag links will cause the front tires to "toe-in" too far. Proper toe-in is between 1/16" and 5/16".

Seat

Seat Adjustment Lever

Figure 9

STEERING ADJUSTMENT

If the tractor turns tighter in one direction than the other, or if the ball joints are being replaced due to damage or wear, the steering drag links may need to be adjusted.

Hex Nut and Lock Washer

Axle

Zerk Fittting

(if so equipped)

Ball Joint

Pivot Bar

Drag Link

Jam Nut

Front tire toe-in can be measured as follows:

• Place the steering wheel in position for straight ahead travel. Insert a 1/4" dowel up through aligning holes in both the steering gear and support plate. See Figure 11.

Drag Links

Insert Dowel

Here

Support Plate

NOTE: View shown from beneath tractor.

Steering Gear

Steering

Shaft

Figure 11

• In front of the axle, measure the distance horizontally from the inside of the left rim to the inside of the right rim. Note the distance.

• Behind the axle, measure the distance horizontally from the inside of the left rim to the inside of the right rim. Note the distance.

• The measurement taken in front of the axle should be between 1/16" and 5/16" less than the measurement taken behind the axle.

• Adjust if necessary.

• Remove the dowel inserted earlier before

attempting to operate the tractor.

Figure 10

Adjust the drag links so that equal lengths are threaded into the ball joint on the left side and the ball joint on the right side:

• Loosen the jam nut found on the drag link at the rear of the ball joint. See Figure 10.

• Remove the hex nut and lock washer on the top of ball joint. See Figure 10.

• Thread the ball joint toward the jam nut to shorten the drag link. Thread the ball joint away from the jam nut to lengthen the drag link.

BRAKE ADJUSTMENT

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. The brake disc can be found on the right side of the transmission in the rear of the tractor. Adjust if necessary as follows:

• Looking at the transmission from the right side of the tractor, locate the compression spring and brake disc. See Figure 12.

• Loosen, but do NOT remove, the hex nut found on the right side of the brake assembly. See Figure 12.

• Using a feeler gauge, set the gap between the brake disc and the brake puck at .011".

• Re-tighten the hex nut loosened earlier.

Hex Nut

Set Gap

at .011"

SECTION 10: MAINTENANCE

WARNING: Disconnect the spark plug

wire(s) and ground against the engine before performing any maintenance.

ENGINE

Refer to the separate engine manual for engine maintenance instructions.

Check engine oil level before each use as instructed in the separate engine manual packed with your unit. Read and follow instructions

carefully.

Changing Engine Oil

• Unscrew oil fill cap and remove dipstick from the oil fill tube. See Figure 13.

Oil Fill Cap

Oil Drain Hose

Protective Cap

Brake Disc

NOTE: View shown from beneath tractor.

Compression

Spring

Transmission

Figure 12

• Pop open the protective cap on the end of the oil drain valve to expose the oil drain port. See Figure 13.

• Push oil drain hose (packed with unit) onto the oil drain port. Route the opposite end of the hose into an appropriate oil collection container with a capacity great enough to collect the used oil.

• Push the oil drain valve in slightly, then rotate counterclockwise and pull outward to begin draining oil. See Figure 13.

• Service the oil filter (if so equipped) as instructed in the separate engine manual packed with your unit.

Perform the above steps in the opposite order after oil has finished draining.

• Refill the engine with new motor oil.

Oil Fill Tube

Oil Drain Port

NOTE:

Single-cylinder engine shown. Valve location will vary with engine style.

Figure 13

Oil Drain Valve

IMPORTANT: Refill the engine with the proper

capacity and weight of motor oil as instructed in the separate engine manual.

Service air cleaner every 25 hours under normal conditions. Clean every few hours under extremely dusty condition. To service the air cleaner, refer to the separate engine manual packed with your unit.

The spark plug(s) should be cleaned and the gap reset once a season. Spark plug replacement is recommended at the start of each mowing season; check engine manual for correct plug type and gap specifications.

CLEANING THE ENGINE AND DECK

Any fuel or oil spilled on the machine should be wiped off promptly. Do NOT allow grass, leaves, and dirt to accumulate around the cooling fins of the engine or on any other part of the machine, especially the pulleys and other moving parts. Clean the underside of the deck with a wisk broom, putty knife or forced air after each mowing.

IMPORTANT: The use a pressure washer or

garden hose to clean your tractor is NOT recommended. It may cause damage to electrical components, spindles, pulleys, bearings or the engine. The use of water will result in a shortened life of the tractor and reduce its serviceability.

CUTTING DECK REMOVAL

WARNING: Before performing any

maintenance, move the PTO lever, or PTO knob into the disengaged (OFF) position, engage the parking brake, turn the ignition key to the OFF position and remove the

key from the switch

Several attachments are available for your tractor. To mount some of these attachments and in order to perform certain maintenance procedures, the deck must be removed from the tractor. To properly remove the cutting deck, proceed as follows:

WARNING: Do NOT remove deck

immediately after operating the tractor. Allow the engine and other moving parts ample time to cool down.

• Move the PTO lever, or PTO knob into the disengaged (OFF) position and engage the parking brake.

• Lower the deck by moving the lift lever into the bottom notch on the right fender.

• Grasp the PTO idler pulley bracket (PTO engagement plate on manual PTO units) and pivot it toward the discharge chute to relieve tension on the belt.

• Remove the deck belt from around the electric PTO clutch (the bottom portion of the engine pulley on manual PTO units) and from around the PTO idler pulley(s).

NOTE: On units equipped with a 46-inch deck, the

bottommost belt on the deck does NOT need to be removed in order to remove the deck.

• Looking at the cutting deck from the right side of the tractor, locate the deck support pin on the rear right side of the deck.

• Pull the deck support pin outward to release the deck from the deck lift arm. See Figure 14.

• Rotate the pin slightly toward the rear of the tractor and release the pin into the hole provided.

• Repeat the above steps on the left side of the tractor.

• Move the lift lever into the top notch on the right fender to raise the deck lift arms out of the way.

• Gently slide the cutting deck toward the front of the tractor allowing the hooks on the deck to release themselves from the deck stabilizer rod. Do NOT let the deck fall to the ground.

• Gently slide the cutting deck (from the right side) out from underneath the tractor.

Deck Support Pins

PTO Idler Pulley Bracket

(PTO engagement plate will be located here on units equipped w/ a manual PTO)

NOTE:

Belt covers and other tractor components not shown for clarity. 42-inch deck shown

To Lift Assembly

Deck Stabilizer Rod

Figure 14

Deck Lift Arms

PTO Idler Pulley

PTO Belt

Hooks

Front of Tractor

Electric PTO Clutch

(Engine Pulley will be located here on units equipped w/ a manual PTO)

Deck

Stabilizer

Bracket

CHANGING THE DECK BELT(S)

All belts on your tractor are subject to wear and should be replaced if any signs of cracking, shredding or rotting are present.

IMPORTANT: The V-belts found on your tractor are specially designed to engage and disengage safely. A

substitute (non-OEM) V-belt can be dangerous by not disengaging completely. For a proper working machine, use factory approved belts.

To change or replace the deck belt(s) on your tractor, proceed as follows:

NOTE: Removing the deck from the tractor as instructed earlier in this section will ease the following steps.

Decks w/ Electric PTO

• Lower the deck by moving the lift lever into the bottom notch on the right fender.

• Remove the belt guards by removing the self-tapping screws that fasten them to the deck surface.

• Grasp the PTO idler pulley bracket and pivot it toward the discharge chute to relieve tension on the belt.

• Remove the PTO belt from the electric PTO clutch and from around the PTO idler pulley.

• Grasp the deck idler pulley and pivot it toward the left side of the deck to relieve tension on the deck

belt. Remove the belt from around all three spindle pulleys and the deck idler pulley.

• Route the new belts as shown in Figure 15. OEM belt part numbers are listed in the table on the following page.

NOTE: 42-inch decks engaged with an electric PTO do NOT have a bottom belt or a center pulley.

Disregard these items in Figure 15 when routing a replacement PTO belt on tractor’s so equipped.

• Remount the belt guards removed earlier.

Electric PTO Clutch

Deck Idler Pulley

Left Hand

Double Pulley

Center Pulley

PTO Idler Pulley

(mounted on tractor)

Self-Tapping Screws

Deck belt (Bottom)

PTO belt (Top)

Right Hand

Double Pulley

(beneath belt guard)

NOTE: Left hand belt cover not shown for clarity. 46-inch deck shown.

Figure 15

42-inch decks w/ manual PTO

• Lower the deck by moving the lift lever into the bottom notch on the right fender.

• Remove the belt guards by removing the self-tapping screws that fasten them to the deck surface.

• Move the PTO lever into the disengaged (OFF) position to relieve tension on the belt.

• Remove the PTO belt from around the bottom portion of the engine pulley and from around the two

idler pulleys found on the PTO engagement plate. See Figure 16.

• Route the new belt as shown in Figure 16, around the deck pulleys, idler pulleys and engine pulley. OEM belt part numbers are listed in the table on the following page

• Remount the belt guards removed earlier..

Engine Pulley

Belt Guard

Deck Stop (mounted on tractor)

PTO belt

Idler Pulleys

Left Hand Pulley

PTO Engagement Plate (mounted on tractor)

Right Hand Pulley

NOTE: Belt covers not shown for clarity.

Figure 16

42-Inch Deck

(Electric PTO) PTO (Top) Belt 754-0472 742-0485 754-0474 Bottom Belt N/A N/A 754-0349

42-Inch Deck

(Manual PTO)

46-Inch Deck

(Electric PTO)

CHANGING THE TRANSMISSION DRIVE BELT(S)

All belts on your tractor are subject to wear and should be replaced if any signs of cracking, shredding or rotting are present.

IMPORTANT: The V-belts found on your tractor are specially designed to engage and disengage safely. A

substitute (non-OEM) V-belt can be dangerous by not disengaging completely. For a proper working machine, use factory approved belts.

To change or replace the drive belt(s) on your tractor, proceed as follows:

NOTE: It’s recommended that both drive belts be replaced at the same time.

• Remove the cutting deck as instructed earlier in this section.

• After disconnecting the battery cables, remove the battery and battery tray from beneath the seat.

IMPORTANT: When removing the battery, disconnect the NEGATIVE (Black) wire from it’s terminal first,

followed by the POSITIVE (Red) wire. Re-install in reverse order.

Upper Drive Belt

• Locate the transmission idler pulley on the upper drive belt by looking through the battery tray opening. See Figure 17.

• Grasp the bracket and pivot the transmission idler pulley toward the rear of the tractor to release tension on the upper drive belt.

• Remove the belt from around the transmission idler pulley.

• Remove the upper drive belt from around the transmission pulley and the variable-speed pulley.

NOTE: Slowly rotate the pulley counterclockwise to roll the belt off of it.

• Remove the upper drive belt by pulling it up through the battery tray opening.

• Reroute the new upper drive belt as shown in Figure 17.

Variable-speed

Pulley

Battery Tray

Opening

Shift Lever

Rear Idler Pulley

Drive belt (Lower)

Drive belt (Upper)

Belt Keeper

Idler Bracket

Transmission Idler Pulley

Single-speed

Transmission

Transmission Pulley

NOTE: View shown from above tractor.

Figure 17

Lower Drive Belt

NOTE: Proper removal of the lower drive belt

requires the removal of several tractor components. Read through the following procedure prior to attempting it to determine if you feel you could successfully complete it. If you don’t, see an authorized MTD service dealer to have the belt changed.

IMPORTANT: Note the routing of the lower drive

belt around both the pulleys and the belt keepers BEFORE performing the following steps.

• Locate the variable-speed pulley through the battery tray opening. See Figure 16.

• Remove the variable-speed pulley by loosening the hex bolt that affixes it to the transmission. Use a second wrench to hold the hex nut on the bottom side of the pulley.

• Slide the belt off of the variable-speed pulley as you lift the pulley up and out through the battery tray opening.

NOTE: Jacking the rear of the tractor up off the

ground and securing it with jackstands at this point in the procedure will ease the following steps, but is not necessary.

Front Idler Pulley

Keeper Pins

to AutoDrive™ pedal

Double-Idler Bracket

Front of Tractor

• Remove the rear idler pulley from the doubleidler bracket while unrouting the belt from around both the rear and the front idler pulley. Refer to Figure 16.

• On units equipped with an electric PTO, carefully unplug the tractor’s wire harness from the connector on the electric PTO clutch. See Figure 17.

Hex Bolt

Electric

PTO Clutch

(if so equipped)

Connector

NOTE: View shown from beneath tractor.

Figure 18

Electric PTO Clutch (if so equipped)

Engine Pulley (Upper Portion)

• Remove the hex bolt from the center of the engine pulley (or the electric PTO clutch on units so equipped) and gently lower it off of the engine crankshaft. Be careful not to lose any washers or spacers which may be found on top of the engine pulley or the electric PTO clutch. See Figure 18.

• On units equipped with an electric PTO, the engine pulley is located directly above the electric PTO clutch. Lower the engine pulley far enough to be able to remove the upper drive belt from around it.

IMPORTANT: When remounting the engine

pulley or electric PTO clutch, torque the center hex bolt to between 38 foot-pounds and 50 foot-pounds.

• Remove the drive belt by feeding it from both ends toward the front idler pulley on the double-idler bracket. See Figure 16.

• Reassemble by following the above steps in reverse order.

• Reroute the new belt around the pulleys, belt keepers and keeper pins EXACTLY as the old one was routed. Refer to Figure 16.

™

The AutoDrive hole found in the double-idler bracket has approximately 1-3/8" of travel with ten pounds of pressure applied to the AutoDrive Figure 19.

Hole

NOTE: View shown from above tractor.

pedal is properly adjusted when the

™

pedal. See

Double-idler

Bracket

Idler

Adj. Rod

Front of Tractor

Using two 9/16" wrenches, remove the pin from the speed control assembly. See Figure 20.

Idler

Adj. Rod

Neutral

Return

Bracket

Hairpin

Clips

AutoDrive™ Pedal

Return Spring

Place Wrenches Here

Speed Control

Assembly

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.

• Reassemble by following the above steps in reverse order.

CUTTING BLADES

WARNING: Cutting blades are sharp.

Always protect hands by wearing heavy

leather work gloves to grasp blades. The blades may be removed for sharpening or replacement as follows.

• Remove the deck from beneath the tractor, (refer to DECK REMOVAL earlier in this section for detailed instructions) 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 stabilizer. See Figure 21.

Figure 19

Adjust the AutoDrive

™

pedal after replacing the drive

belts on your tractor, if necessary, as follows:

• Locate the speed control assembly on the underside of the steering support bracket. See Figure 20.

• Remove both hairpin clips from the pin which is fastened to the speed control assembly (be careful not to lose the small flat washers found on the pin). See Figure 20.

™

• Remove the AutoDrive

pedal return spring.

Hex Flange Nut

Spindle

Assembly

Cutting Blade

Block of Wood

Figure 21

• Use a 15/16" wrench to remove the hex flange nut that secures the blade to the spindle assembly. See Figure 21.

NOTE: The hex flange nut has a right-handed

(normal) thread pattern. Do NOT attempt to force the nut in the incorrect direction. Doing so may damage the nut and create a safety hazard.

To properly sharpen the cutting blades, remove equal amounts of metal from both ends of the blades along the cutting edges. See Figure 22. Sharpen the cutting edge straight across, parallel to the trailing edge, at a 25° to 30° angle. See Figure

22.

IMPORTANT: If the cutting edge of the blade has

already been sharpened to within 5/8" of the wind wing radius, or if any metal separation is present, replace the blades with new ones. See Figure 22.

Worn Blade Edge

Blade Separation

Sharpen Edge Evenly

Wind Wing

Figure 22

It is extremely important that each cutting blade edge be ground equally to maintain proper blade balance. An unbalanced blade will cause excessive vibration when rotating at high speeds, may cause damage to the tractor and result in personal injury. The blade can be tested by balancing it on a round shaft screwdriver. Grind metal from the heavy side until it balances evenly.

When replacing the blade, be sure to install the blade with the side of the blade marked ‘‘Bottom’’ (or with a part number stamped in it) facing the ground when the mower is in the operating position.

IMPORTANT: Use a torque wrench to tighten the

blade spindle hex flange nut to between 70 footpounds and 90 foot-pounds.

• After cleaning the battery and terminals, apply a light coat of petroleum jelly or grease to the terminals and over the positive terminal boot.

• Always keep the boot positioned over the positive terminal to prevent shorting.

IMPORTANT: If removing the battery for any

reason, disconnect the NEGATIVE (Black) wire from it’s terminal first, followed by the POSITIVE (Red) wire. When re-installing the battery, always connect the POSITIVE (Red) wire its terminal first, followed by the NEGATIVE (Black) wire. Be certain that the wires are connected to the correct terminals. reversing them could change the polarity and cause damage to your engine’s alternating system.

Charging

If the unit has not been put into use for an extended period of time, charge the battery with an automotive-type 12-volt charger for a minimum of one hour at six amps.

WARNING: Batteries give off an

explosive gas during and for some time after charging. Charge battery in a well ventilated area and do not allow a spark or an open flame near the battery.

TIRES

The recommended operating tire pressure is approximately 10 psi for the rear tires and 14 psi for the front tires. Refer to the tire sidewall for exact tire manufacturer’s recommended psi. Do not overinflate. Uneven tire pressure could cause the cutting deck to mow unevenly.

FUSE

A fuse is installed in your tractor’s wiring harness to protect the tractor’s electrical system from damage caused by excessive amperage. Always use the same capacity fuse for replacement. If the electrical system does not function, or your tractor’s engine will not crank, first check to be certain that the fuse has not blown. It can be found under the hood mounted behind the top of dash panel on the support bar. Pull the fuse out and compare it with Figure 23 to determine if it is good or bad.

BATTERY

The battery is sealed and is maintenance-free. Acid levels cannot be checked.

• Always keep the battery cables and terminals clean and free of corrosive build-up.

GOOD

BAD

Figure 23

SECTION 11: LUBRICATION

WARNING: Always stop the engine and disconnect the spark plug wire(s) and ground against the

engine before performing any maintenance.

ENGINE

Lubricate the engine with motor oil as instructed in the separate engine manual packed with your unit.

PIVOT POINTS

Lubricate all pivot points (AutoDrive™ pedal, brake pedal, etc.) at least once a season with light oil.

LINKAGE

Lubricate all the pivot points on the drive, brake and lift linkage at least once a season with SAE 30 engine oil.

STEERING GEAR

Lubricate the teeth of the steering gear with an all-purpose automotive grease every 25 hours of operation or once a season.

WHEELS

Both the front wheels and the rear wheels should be removed from the axles once a season. Lubricate the axles and the rims well with an all-purpose automotive grease before re-installing them.

FRONT AXLES

Your tractor may be equipped with grease fittings on the ends of the front pivot bar. Refer Figure 10. Lubricate both the left and the right front axles with a grease gun at least once a season.

SECTION 12: TROUBLESHOOTING GUIDE

Trouble

Engine will not crank

Engine cranks but will not start

Possible Cause(s)

Safety switch button not depressed.

Battery installed incorrectly.

Battery is dead or weak. Blown fuse

Throttle or choke not in starting position. No fuel to the carburetor.

No spark to spark plug(s).

Corrective Action

There are three safety switches in the starting circuit of your unit: the brake pedal switch, the seat switch and the PTO switch. Make certain the actuator found on the brake control assembly is fully depressing the button on the brake switch. The PTO must be in the disengaged (OFF) position and the operator must be seated on the tractor in order to start the engine, also. The battery must be installed with negative terminal attached to black ground wire. Negative terminal is identified at the post by “NEG”, “N” or “-”. The positive terminal, identified by “POS”, “P” or “+”, must be attached to the thick red wire which goes to the solenoid. Charge at six amps with a 12-volt automotive-type battery charger for one hour or until fully charged. Refer to operator’s manual for fuse location. Replace fuse with automotive type fuse of the proper amperage. Fuses seldom fail without a reason. The problem must be corrected. Check for loose connections in the fuse holder. Replace fuse holder if necessary. A dead short may be in the cranking or charging circuit where the insulation may have rubbed through and exposed the bare wire. Replace the wire or repair with electrician's tape if the wire strands have not been damaged. Note: Look for a wire pinched between body panels, burned by the exhaust pipe or muffler or rubbed against a moving part. Refer to the OPERATION section of this manual for the correct position of the throttle control and choke for starting.

Gasoline tank empty. Fill. Fuel line or in-line fuel filter plugged. Remove and clean fuel line. Replace fuel filter (if so equipped) if necessary. Spark plug lead disconnected. Connect lead. Using a spark tester, check for spark. If no spark is present, have engine’s magneto serviced by an authorized engine dealer.

Engine smokes

Excessive vibration

Mower won’t discharge grass or leaves uncut strips

Dirty aircleaner.

Engine oil has been overfilled. Engine loses crankcase vacuum. Bent blade or damaged pulley.

Engine speed low. Speed selection. Cutting height set too low. Blades dull.

If the air cleaner is dirty, the engine may not start. Refer to the engine manual packed with your unit. Check oil level.

Dipstick not seated or broken. Replace defective part. Engine breather defective. Replace.

Stop engine immediately. Check all pulleys, blade adapters, keys and bolts for tightness and spindle damage. Tighten or replace any loose or damaged parts. Always replace damaged blade. Only use original equipment blades. Throttle must be set at full throttle.

Use lower ground speed. The slower your ground speed, the better the quality of cut. Raise deck.

Sharpen or replace blades (uncut strip problem only).

Model 604

28 24

40 41

39 42

Tractor Body

REF.

NO.

1 710-3015 Hex Cap Screw, 1/4-20 x .75 2 710-0599 Self-tapping Screw, 1/4-20 x .5 3 712-3006 Hex Nut, 1/4-20 4 710-0895 Self-tapping Screw, 1/4-15 x .75 5 710-0924 Pan Phillips Screw, 1/4-20 x .75 6 710-0528 Hex Cap Screw, 5/16-18 x 1.25 7 712-0292 U-type Speed Nut, 1/4-20 8 712-3004A Flange Lock Nut, 5/16-18

9 726-0201 Speed Nut 10 725-1649 Head Lamp Socket 11 731-1978 RH Head Light Lens 12 731-1979 LH Head Light Lens 13 731-1980 Hood, 4-style (Yellow) 14 731-1981A LH Side Panel, 4-style (Yellow) 15 731-1982A RH Side Panel, 4-style (Yellow) 16 731-1995 LH Head Light Reflector 17 731-1996 RH Head Light Reflector 18 736-0173 Flat Washer, .28 x .74 x .063 19 736-3078 Flat Washer, .349 x 1.0 x .063 20 747-1132A Hood Support Rod 21 783-0808 Heat Shield, 4-style 22 710-0604A Self-tapping Screw, 5/16-18 x .625 23 710-1017 Torx Self-tapping Screw, 1/4-14 x .625 24 710-3217 Torx Screw, #8-32 x .375 25 712-0142 Hex Nut, 8-32 26 731-0071 Dash Panel, 4-style 27 731-0072 Parking Brake Button 28 731-1857 Throttle Control Lever 29 731-2106 Cruise Control Button 30 747-1155 Brake/Cruise Pivot Rod 31 749-1087 Dash Support Tube 32 731-2232 Intake Bellow (Kohler and Intek Single)

33 751-0658A Fuel Tank (3-gallon)

34 751-0603 Fuel Cap (fits either tank) 35 725-1745 Ignition Key w/ plastic cover

36 746-1084 Choke/Throttle Cable (Intek Single)

37 725-1752 Electric PTO Switch (if so equipped) 38 731-2272 Heat Shield 39 783-1000 Grille Support Bracket 40 710-0809 Self-tapping Screw, 1/4-20 x 1.25 41 736-0342 Flat Washer, .283 x .75 x .030 42 736-0329 Lock Washer, 1/4

PART

NO. DESCRIPTION

731-2234 Intake Bellow (Intek Twin)

751-0659 Fuel Tank (2-gallon, shown)

725-1744 Ignition Key w/o plastic cover

746-1085 Choke Cable (Intek Twin) 746-1088 Choke Cable (Kohler)

Model 604

43 42

45 41

37 48

44 30

40 36 47 16

38 28

35 32

13 52

17 21

10 20

21 22

25 19

28 53

9 7

Lift Assembly

REF.

NO.

1 747-1130 Deck Stabilizer Rod 2 683-0197 Lift Shaft Assembly 3 711-0332 Clevis Pin, .5 x .78 4 712-0206 Hex Nut, 1/2-13 5 712-0431 Flange Lock Nut, 3/8-16 6 712-3004A Flange Lock Nut, 5/16-18 7 712-3083 Hex Nut, 1/2-13 8 714-0104 Internal Cotter Pin

9 714-0145 Internal Cotter Pin 10 716-0106 E-ring 11 720-0311 Handle Grip 12 732-0874 Torsion Spring 13 732-0934 Lift-assist Spring, 1.15 x 5.99

14 736-0275 Flat Washer, 5/16 15 736-0921 Lock Washer, 1/2 16 736-3019 Flat Washer, .31 x 1.062 x .134 17 736-3084 Flat Washer, .51 x 1.12 x .06 18 738-0138 Hex Cap Screw, 5/16-18 x .62 19 738-0143 Shoulder Screw, 3/8-16 20 741-0225 Hex Flange Bearing 21 741-0715 Snap Flange Bearing 22 746-0968 Lift Cable, 16.16 23 747-1111 Lift Handle 24 756-1154 Roller Pulley 25 783-0678 Arm Lift 26 783-0720A Deck Stabilizer Bracket 27 710-0260 Carriage Bolt, 5/16 x .62

PA RT

NO. DESCRIPTION

(Found on Units w/ 46-inch Decks Only)

REF.

NO.

28 710-0604A Self-tapping Screw, 5/16-18 x .625 29 710-0895 Self-tapping Screw, 1/4-15 x .75 30 731-1990 Lift Lever Cover 31 731-2104A Shift Lever Cover w/ Cup Holder 32 738-0155 Shoulder Screw, .437 x 1.62 33 783-0677 Lift Adjustment Bracket 34 783-0685A Fender 35 783-0715 Seat Mounting Bracket 36 710-1268 Screw, #10-16 x .375 37 712-3027 Hex Flange Lock Nut, 1/4-20 38 720-0309A Seat Adjuster Grip 39 731-1989 Spacer 40 732-0499 Compression Spring, .41 x 1.5 41 736-0175 Spring Washer, .265 x .562 x .025 42 736-0204 Flat Washer, .344 x .62 x .03 43 738-0137A Shoulder Screw, .340 x .285,1/4-20 44 738-1007 Shoulder Screw, .50 x .50, 3/8-16 45 783-0611 Seat Stop 46 783-0738 Seat Pivot Bracket 47 783-0739 Seat Adjustment lever 48 783-0753 Seat Adjustment Selector 49 757-0365A Seat, Radiant Yellow, Medium Back

50 735-0657 LH Foot Pad 51 735-0656 RH Foot Pad

52 714-0111 Cotter Pin 53 783-0891A Deck Stop

PART

NO. DESCRIPTION

757-0372 Seat, Radiant Yellow, High Back w/ Holes

726-3046 Foot Pad Clips (Not Shown)

NOTE: For painted parts, please refer to the list of color codes below. Please add the applicable color code, wherever needed, to the part number to order a replacement part. For instance, if a part numbered 700-xxxx is painted Yard-Man Green, the part number to order would be 700-xxxx-0665.

Yard-Man Green: 0665

Yard-Man Yellow: 0674

Powder Black: 0637

Model 604

20 13

13 22

42 41

15 12

32 35

35 32

32 10 17

29 33 3

Steering Assembly

REF.

NO.

1 683-0304 Lower Frame Assembly

2 710-0604A Self-tapping Screw, 16-18 x .625

3 783-0726A RH Pivot Support Bracket

4 783-0727 LH Pivot Support Bracket

5 783-0728 Pivot Bar Bracket

6 710-0514 Hex Cap Screw, 3/8-16 x 1 (Grade 5)

7 711-1409A LH Drag Link

8 711-1408 RH Drag Link

9 712-0240 Jam Nut, 7/16-20 (Grade 2) 10 712-0241 Hex Nut, 3/8-24 (Grade 2) 11 712-0431 Flange Lock Nut, 3/8-16 12 712-0459 Flange Lock Nut, 7/16-20 13 712-3004A Flange Lock Nut, 5/16-18 14 717-1550A Steering Gear, 11/90 Ratio 15 717-1554 Steering Pinion Gear 16 723-0448A Ball Joint, 7/16-20 17 736-0169 Lock Washer, 3/8 18 736-3084 Flat Washer, .51 x 1.12 x .06 19 738-1001 Steering Shaft, .625 OD x 24.4 20 741-0475 Plastic Bushing, .38 ID 21 741-0656 Hex Flange Bearing, 5/8 22 738-0372 Shoulder Spacer, .38 ID 23 731-1869 Steering Wheel 24 731-1904 Steering Wheel Cap w/ Icon 25 638-0019 LH Axle Assembly, .625 Diameter

26 638-0020 RH Axle Assembly, .625 Diameter

27 683-0128A Pivot Bar

PA RT

NO. DESCRIPTION

638-0021 LH Axle Assembly, .625 / .750 Diameter

638-0022 RH Axle Assembly, .625 / .750 Diameter

REF.

NO.

28 712-0431 Flange Lock Nut, 3/8-16 29 714-0470 Cotter Pin 30 726-0214 Push Cap, .625

31 736-0162 Flat Washer, .64 x 1.0 x .12 32 736-0187 Flat Washer, .64 x 1.24 x .06

33 736-0285 Flat Washer, .635 x 1.589 x .06 34 738-1011 Shoulder Screw, .5 x 2.2, 3/8-16 35 741-0659 Flange Bearing, .632 ID x .937 OD

36 634-0105A Wheel Assembly Complete, 15 x 6 x 6

37 734-2290 Hub Cap 38 783-0653C Steering Support Bracket 39 738-0143 Shoulder Screw, 3/8-16 40 736-0331 Bell Washer, .39 x 1.13 x .062 41 738-0140 Shoulder Screw, .435 x .178, 5/16 x .56 42 736-0242 Bell Washer, .34 x .872 43 710-0643 Hex Bolt, 5/16-18 X 1 44 731-1291A Pivot Bar End Cap 45 719-0525B Cast Iron Pivot Bar (if so equipped) 46 737-3000 Lube Fitting, 3/16 (if so equipped) 47 710-1260A Self-tapping Screw, 5/16-18 x .750

PART

NO. DESCRIPTION

726-0341 Push Cap, .750

736-0316 Flat Washer, .78 x 1.59 x .06

741-0660 Flange Bearing, .760 ID x .937 OD

634-0172 Rim Only 734-0255 Air Valve (Not Shown) 734-1731 Tire Only, Square Shoulder 741-0487A Plastic Flange (Not Shown) 741-0706 Plastic Flange w/ Fitting (Not Shown)

NOTE: Units equipped with a 42-inch deck have axles with a .625 diameter.

Units equipped with a 46-inch deck have axles with a .625 / .750 diameter.

Yard-Man Green: 0665

Yard-Man Yellow: 0674

Powder Black: 0637

Model 604

22 13

5 29

11 18

56 71

55 73

66 59

32 20

10 1

35 88

47 34

17 49

Drive System

REF.

NO.

PA RT

NO. DESCRIPTION

1 783-1015 Shift Lever Support

2 17840 Transaxle Mounting Bracket

3 618-0307C Single-speed Transmission Assembly

4 631-0009 Shifter Knob

5 647-0045 Shift Lever

6 656-0048 Variable-speed Pulley Assembly

7 656-0051A Transmission Pulley, 8.5 x .5-36

8 683-0251 Double-idler Bracket

9 710-0189 Hex Cap Screw, 5/16-18 x 3 10 710-0227 Self-tapping Screw, #8-18 x .5 11 710-0347 Hex Cap Screw, 3/8-16 x 1.75 12 736-0272 Flat Washer, .51 x 1.0 x .060 13 710-0604A Self-tapping Screw, 5/16-18 x .625 14 710-0642 Self-tapping Screw, 1/4-20 x .75 15 710-3011 Hex Cap Screw, 3/8-16 x 2.25 16 711-0677 Ferrule, 5/16-18 17 712-0241 Hex Nut, 3/8-24 18 712-0378 Hex Nut, 7/16-20 19 712-0431 Flange Lock Nut, 3/8-16 20 712-0798 Hex Nut, 3/8-16 21 712-3004A Flange Lock Nut, 5/16-18 22 712-3008 Jam Nut, 3/8-16 23 714-0111 Cotter Pin 24 714-0149B Internal Cotter Pin 25 723-3018 Ball Joint 26 725-1644 Short Spring Switch 27 726-0320 Insulator Nut Plate 28 732-0384 Extension Spring, .62 Dia. x 6.12 29 732-0525 Compression Spring Clip 30 732-0716 Extension Spring, .59 OD x 4 31 732-0963 Extension Spring, .50 Dia. x 6.37

(hooks to flange, 783-0650, in frame) 32 736-0105 Bell Washer, .401 x .87 x .063 33 736-0140 Flat Washer, .385 x .62 x .063 34 736-0169 Lock Washer, 3/8 35 736-0275 Flat Washer, 5/16 36 736-0407 Bell Washer, .45 x 1.0 x .602 37 736-3010 Flat Washer, .407 x .812 x .135 38 738-0322 Shoulder Screw, .625 x .217 39 747-1122 Brake Rod 40 747-1123A Belt Guard 41 747-1127 Idler Adjustment Rod, 3/8 42 747-1156 Shift Rod 43 711-0736 Adjustment Ferrule, 1/4-20 x 1.0 44 748-0372 Shoulder Spacer, .38 ID 45 754-0467 Variable-speed Belt 46 754-0468 Drive Belt 47 756-0981 Flat Idler, 2.75 OD 48 783-0637 Shift Lever Support

REF.

NO.

PART

NO. DESCRIPTION

49 783-0667A Transmission Torque Bracket 50 783-0669 Idler Bracket 51 783-0714 Adjustable Shift Bracket 52 647-0031 Brake Control Assembly 53 647-0032 Speed Control Assembly

™

54 683-0266 AutoDrive

Pedal Assembly 55 712-0431 Flange Lock Nut, 3/8-16 56 711-0736 Ferrule, 1/4-20 57 711-1363 Pin, 3/8-16 x 2.43 58 714-0104 Cotter Pin 59 732-0437 Compression Spring, .34 OD x 1.0 60 732-0955 Extension Spring, .50 OD x 1.41

™

61 735-0662 AutoDrive

Pedal Pad 62 735-3049 Brake Pedal Pad 63 736-0140 Flat Washer, .281 x .5 x .0625 64 736-0187 Flat Washer, .64 x 1.24 x .06 65 736-0204 Flat Washer, .344 x .062 x .03 66 738-0155 Shoulder Screw, .437 x 1.62 67 738-0507B Shoulder Screw, .5 x .434 68 741-0225 Hex Flange Bearing 69 741-3065A Split Hex Flange Bearing 70 747-1137 Cruise Control Rod 71 747-1138 Brake Lock Control Rod 72 748-0413 Cruise Latch 73 748-0415A Spacer, 5/16 x 1.54 74 783-0653B Stearing Support Bracket

™

75 783-0732 AutoDrive

Lockout Bracket 76 783-0773 Brake Pedal 77 783-0780 Neutral Return Bracket 78 683-0304 Lower Frame Assembly 79 783-1031 Hitch Plate 80 736-0242 Bell Washer, .34 x .872 81 710-0627 Hex Cap Screw, 5/16-24 x .75 82 634-0177 Wheel Assembly Complete, 20 x 10 x 8

634-0104 Wheel Assembly Complete, 20 x 8 x 8 634-0077 Rim Only 734-0255 Air Valve (Not Shown) 734-1873 Tire Only, 20 x 10 x 8, Square Shoulder

734-1730 Tire Only, 20 x 8 x 8, Square Shoulder 83 734-2290 Hub Cap 84 710-0778 Self-tapping Screw, 1/4-20 x 1.5 85 750-0556 Spacer 86 710-1026 Self-tapping Screw, 1/4-20 x 1.75 87 750-0768 Spacer 88 710-1260A Self-tapping Screw, 5/16-18 x .75 89 710-1650 Self-tapping Screw, 5/16-18 x .875 90 710-0859 Hex Cap Screw, 3/8-16 x 2.5 91 736-0430 Flat Washer, .350 x 1.59 x .062

Model 604

Units with 618-0307C

Transmission ONLY

14 12*

12*

31 30

12c

12*

Single-speed Transmission

REF.

NO.

1 618-0318 Clutch Collar† 2 710-0788 Self-tapping Screw, 1/4-20 x 1.0 3 711-1274 Drive Shaft 4 711-1280 Counter Shaft 5 713-0474 22-link Chain, #420 6 713-0478 14-tooth Sprocket 7 717-1422 Sprocket Bevel Gear, 42/10 8 717-1565 29-tooth Spur Gear

9 717-1569 20-tooth Spur Gear 10 718-0652 Counter Shaft Coupling 11 719-0394 Lower Housing

12a 736-0336 Flat Washer, 5/8 x 1.0 x .030* 12b 736-0337 Flat Washer, 5/8 x 1.0 x .040* 12c 736-0349 Flat Washer, 5/8 x 1.0 x .020*

13 736-0519 Flat Washer, .70 x 1.125 x .031 14 741-0336 Flange Bearing, 5/8 x 3/4 x 3/4 15 741-0337 Flange Bearing, 5/8 x 3/4 x 15/16 16 750-1238 Spacer, .635 x 1.0 x .27 17 611-0112 Detent Shaft Assembly†

18 618-0369 Differential Assembly†

19 661-0006 Brake Assembly 20 710-1325 Self-tapping Screw, 1/4-20 x 1.625 21 710-1206 Self-tapping Screw, 1/4-20 x 2.375 22 717-0678 Brake Pad 23 732-0863 Compression Spring 24 741-0862 Detent Ball 25 761-0202 Brake Disc 26 711-1331 Input Shaft†

27 716-0385 Retaining Ring, .394†

28 717-1571 12-tooth Bevel Pinion†

29 719-0391A Upper Housing 30 736-0335 Thrust Washer, .63 x 1.24 x .062†

31 741-0525 Needle Bearing, .625 x .875 32 718-0228 Clutch Collar‡ 33 711-1431 Drive Shaft‡ 34 750-1234 Spacer, .633 x 1.0 x .513 35 717-1362 42-tooth Bevel Gear‡ 36 717-1363 42-tooth Bevel Gear‡ 37 736-0495 Thrust Washer, 1.0 x .632 x .0 38 741-0340 Sleeve Bearing, .75 x .1.0 x 1.0 39 721-0338 Seal, .75 x 1.0 x .125 40 716-0231 E-ring, .75

PA RT

NO. DESCRIPTION

611-0133 Detent Shaft Assembly‡

618-0424 Differential Assembly‡

711-1430 Input Shaft‡

716-0108 Retaining Ring, .437‡

717-1464 14-tooth Bevel Pinion‡

736-0723 Thrust Washer, .635 x 1.25 x .042‡

*If rebuilding transmission for any reason, use applicable flat washer (12a, 12b, or 12c) in this application allowing proper end play as instructed in MTD ’s Service Manual.

IMPORTANT: One of two different transmissions may be found on your lawn tractor (618-0307B & 618-0307C). Refer to the model plate found on the rear right portion of the transmission’s lower housing before ordering replacement service parts.

†Used on Single-speed transmission 618-0307B ONLY. ‡Used on Single-speed transmission 618-0307C ONLY.

Model 604

2 3

62 1

7 8

43 50

23 24 25

72*

Units Equipped w/ Electric PTO

31 38

73* 34

65 64

70 (PTO belt for

42" deck shown)

27 47

Power Take-off System

REF.

NO.

1 712-0431 Flange Lock Nut, 3/8-16 2 732-0996 Compression Spring, 1.31 x 3.0 3 783-0733 Spacer Cup, 1.5 OD 4 732-0997 Compression Spring, .66 OD x 1.5 5 710-0604A Self-tapping Screw, 5/16-18 x .625 6 710-0751 Hex Cap Screw, 1/4-20 x .62 7 712-0271 Hex Sems Nut, 1/4-20 8 712-3044 Wing Nut, 1/4-20

9 725-1706 12-volt Battery, 270 CCA 10 738-1014 Shoulder Screw, .5 x 1.25, 3/8-16 11 738-1020 Shoulder Screw, .625 x .5, 7/16-20 12 736-0407 Bell Washer, .45 x 1.0 x .062 13 723-0444 Battery Strap 14 783-1031 Hitch Plate 15 725-1747 Safety Interlock Plunger Switch 16 736-0222 Lock Washer, 1/4 17 725-1426 Solenoid, 12-Volt, 100 Amp 18 710-0599 Self-tapping Screw, 1/4-20 x .5 19 712-0459 Flange Lock Nut, 7/16-20 20 683-0304 Lower Frame Assembly 21 756-0639A Engine Pulley, 3.56 OD 22 783-1003 Electric Clutch Anti-rotation bracket 23 712-3010 Hex Nut, 5/16-18 24 710-3180 Hex Cap Screw, 5/16-18 x 1.75 (Grade 5) 25 732-0978 Extension Spring, 1.2 OD x 3.638 26 710-0642 Self-tapping Screw, 1/4-20 x .750 27 736-0322 Flat Washer, .45 x 1.25 x .164 28 712-3004A Flange Lock Nut, 5/16-18 29 783-0653C Steering Support Bracket 30 683-0301 Idler Bracket Assembly (42-inch decks)

31 738-3056 Shoulder Screw, 1/2 Diameter x 2.5 32 717-1708 Electric PTO Clutch 33 738--0785 Shoulder Spacer, 1.38 x .445 x .36 34 736-0171 Lock Washer, 7/16 35 710-3157 Hex Cap Screw, 7/16-20 x 3.25 (Grade 5) 36 710-3011 Hex Cap Screw, 3/8-16 x 2.25 (Grade 5) 37 756-0627 Flat Idler Pulley, 3.5 OD 38 754-0472 PTO Belt (42-inch Decks w/ Electric PTO)

PA RT

NO. DESCRIPTION

683-0297 Idler Bracket Assembly (46-inch decks)

754-0474 PTO Belt (46-inch Decks w/ Electric PTO)

REF.

NO.

39 783-0349 Battery Tray 40 783-0891A Deck Stop 41 710-3025 Hex Cap Screw, 5/16-18 x .625 42 736-0105 Bell Washer, .401 x .870 x .063 43 710-0376 Hex Cap Screw, 5/16-18 x 1.0 44 712-3006 Hex Nut, 1/4-20 45 736-0119 Lock Washer, 5/16 46 710-0757 Hex Cap Screw, 7/16-20 x 1.5 47 736-0171 Lock Washer, 7/16 48 750-0956 Spacer 49 756-0982A Engine Pulley 50 712-3004A Flange Lock Nut, 5/16-18 51 747-1204 Belt Guard 52 711-1004 Keeper Pin 53 731-2111 PTO Knob 54 736-0108 Flat Washer, .510 x .750 x .033 55 747-1112A PTO Handle 56 647-0046 PTO Lever 57 710-0528 Hex Cap Screw, 5/16-18 x 1.25 58 732-0995 Extension Spring, .5 x 6.0 59 712-0229 Push Nut, 3/8 60 783-0744A Engagement Stop Bracket 61 748-0415A Spacer, 3/8 x 1.54 62 738-0372 Shoulder Spacer 63 683-0302 PTO Engagement Plate 64 714-0145 Internal Cotter Pin 65 736-0140 Flat Washer, .385 x .62 x .063 66 732-0991 Belt Guard 67 732-0990 Belt Guard 68 732-0994 Extension Spring, .75 x 5.39 69 714-0111 Cotter Pin, 3/32 x 1.0 70 754-0485 PTO Belt (42-inch Decks w/ Manual PTO)

71 710-0615A Hex Cap Screw, 3/8-16 x 5.0 72 736-0277 Flat Washer, 1.031 x 1.62 x .095* 73 736-0322 Flat Washer, .45 x 1.25 x .17* 74 736-0267 Flat Washer. 3/8 x .87 x .06 75 736-0280 Falt Washer, .395 x 1.12 x .10

PART

NO. DESCRIPTION

754-0486 PTO Belt (46-inch Decks w/ Manual PTO)

*Found on units equipped with a Kohler engine ONLY.

Yard-Man Green: 0665

Yard-Man Yellow: 0674

Powder Black: 0637

Model 604

46-inch Deck

See PTO breakdown

†46-inch Deck Brake Assembly

‡

A double-pulley spindle is found in this location on 46-inch decks

engaged by electric PTOs only. Use 618-0240 on manual PTO decks.

44 78

80 17

81/83

51‡

19 57

31 22

51 15

55 32

73 54

35 29 30

42-inch Deck

44 45

35 29

30 42

†

82/84

17 11

†

38 27 21

†

12 36

Cutting Decks

REF.

NO.

1 16606 Retainer Hook

2 618-0324 Spindle Assembly, 5.75 Dia.

3 683-0198C 42-inch Deck Shell

4 683-0254 Deck Adjustment Bracket w/ Weld Nut

5 683-0303 Deck Brake Assembly, 42-inch Decks†

6 710-0520 Hex Cap Screw, 3/8-16 x 1.5

7 710-0528 Hex Cap Screw, 5/16-18 x 1.25

8 710-0604A Self-tapping Screw, 5/16-18 x .625

9 710-0751 Hex Cap Screw, 1/4-20 x .62 10 710-0817 Self-tapping Screw, 5/16-18 x 1.25 11 710-1122 Hex Cap Screw, 1/4-20 x 2.5 12 710-1260A Self-tapping Screw, 5/16-18 x .75 13 711-0677 Ferrule, 5/16-18† 14 712-0417A Hex Flange Nut, 5/8-18 15 712-0431 Flange Lock Nut, 3/8-16 16 712-3004A Flange Lock Nut, 5/16-18 17 712-3006 Hex Nut, 1/4-20 18 712-3009 Hex Lock Nut, 5/16-18 19 712-3027 Hex Flange Lock Nut, 1/4-20 20 714-0104 Internal Cotter Pin, .072 x 1.12† 21 714-0111 Cotter Pin, 3/32 x 1.0 22 717-1553A Deck Adjustment Gear 23 710-0578 Screw, 1/4-20 x 1.5 24 726-0233 Push Nut. .25 x .5 25 731-1032B Side Discharge Chute Assembly 26 731-2231A Belt Cover 27 732-0306 Compression Spring, .406 x .531 x 1.75 28 732-0428A Compression Spring, .50 x 4.35† 29 734-0973 Deck Wheel, 5 x 1.38 30 736-0105 Bell Washer, .401 x .87 x .063 31 736-0119 Lock Washer, 5/16 32 736-0270 Bell Washer, .265 x .75 x .062 33 736-0275 Flat Washer, .344 x .688 x .065† 34 736-0416 Flat Washer, .320 x 3.0 x .125 35 738-0373 Shoulder Screw, .498 x 1.53 36 742-0616 Three-in-one Blade, Star Center, 21.23" 37 746-0970 Bracket Cable, 5.35"† 38 747-1116 Deck Release Pin 39 747-1202 Deck Brake Rod† 40 748-0324 Shoulder Spacer† 41 783-1026 RH Belt Guard Bracket 42 783-1027 LH Belt Guard Bracket 43 731-1643A Mulch Plug, 42-inch Decks 44 712-3087 Wing Nut, 1/4-20

† Found on decks engaged by manual PTOs only.

PA RT

NO. DESCRIPTION

REF.

NO.

45 712-3006 Hex Nut, 1/4-20 46 710-0597 Hex Cap Screw, 1/4-20 x 1.0 47 736-0173 Flat Washer, .28 x .74 x .063 48 17258A RH Belt Cover Bracket 49 17928 Reinforcement Spindle Plate 50 618-0240 Spindle Assembly, 5.0 Dia. 51 618-0241

52 683-0265C 46-inch Deck Shell 53 710-0167 Carriage Screw, 1/4-20 x .50 54 710-0347 Hex Cap Screw, 3/8-16 x 1.75 55 710-0501 Hex Cap Screw, 1/4-20 x 2.0 56 710-0514 Hex Cap Screw, 3/8-16 x 1.0 57 710-0599 Self-tapping Screw,1/4-20 x .5 58 710-0650 Self-tapping Screw,15/16-18 x .875 59 710-0703 Hex Screw, 1/4-20 x .75 60 710-0805 Hex Cap Screw, 5/16-18 x 1.5 61 711-0993 Belt Keeper Pin 62 712-0271 Hex Sems Nut, 1/4-20 63 732-0429A Extension Spring, .5 x 3.97 64 732-0594A Extension Spring, .91 x 7.33 65 738-0347 Shoulder Spacer, .625 x 1.16 66 738-0572 Shoulder Screw, .374 x 1.16 67 742-0611 Three-in-one Blade, Star Center, 16.28" 68 742-0612 Three-in-one Blade, Star Center, 14.88" 69 746-1107 Bracket Cable, 12" 70 750-0807 Spacer, .385 x .625 x .70 71 754-0349 Deck Belt 72 756-0627 Flat Idler Pulley, 3.5 OD 73 783-0139 Idler Bracket 74 783-0141 Center Deck Skirt 75 783-0142 RH Deck Skirt 76 783-0747 LH Belt Cover 77 731-1636 Mulch Plug, 46-inch Decks 78 712-0291 Hex Lock Nut, 1/4-20 79 17116 Deck Brake Assembly, 46-inch Decks 80 783-0805A RH Belt Cover 81 753-0874 46-inch Deck Assembly Complete

82 753-0873 42-inch Deck Assembly Complete

83 753-0872 46-inch Deck Assembly Complete

84 753-0871 42-inch Deck Assembly Complete

PART

NO. DESCRIPTION

Double Pulley Spindle Assembly

(Electric PTO activated, w/o mulch kit)

(Manual PTO activated, w/o mulch kit)

‡

Model 604

Briggs & Stratton

Intek Twin

(for choke)

(for throttle)

Kohler

Single-cylinder

(for choke)

(deflector must

face forward)

24 27

(deflector must

face forward)

Engine Accessories

Briggs & Stratton

Intek Single

4 32

REF.

NO.

1 710-0148 Self-tapping Screw, #8-32 x .375 2 710-0599 Self-tapping Screw, 1/4-20 x .5 3 710-0604A Self-tapping Screw, 5/16-18 x .625 4 710-1237 Screw, #10-32 x .625 5 710-1314 Socket Cap Screw, 5/16-18 x .625 6 710-1315 Self-tapping Screw, 3/8-16 x 1.25 7 712-3017 Hex Nut, 3/8-16 8 721-0460 Exhaust Gasket (Intek Twin)

9 726-0205 Hose Clamp 10 736-0119 Lock Washer, 5/16 11 736-0300 Flat Washer, .406 x ..875 x .059 12 751B221535 Casing Clamp 13 751-0535 Fuel Line Hose 14 751-0564 Muffler Deflector 15 751-0616 Muffler, Twin Inlet 16 751-0650 RH Exhaust Pipe (Intek Twin) 17 751-0651 LH Exhaust Pipe (Intek Twin) 18 751-3140 Oil Drain Valve 19 751-3141 Oil Drain Hose

PA RT

NO. DESCRIPTION

(deflector must

face forward)

REF.

NO.

20 751-3142 Oil Drain Cap 21 783-0615 Muffler Heat Shield 22 783-0625B Engine Heat Shield 23 710-3206A Hex Cap Screw, M8-1.25 x 25 24 712-3086 Flange Nut, M8-1.25 25 721-0375 Exhaust Gasket (Kohler) 26 736-0607 External Lock Washer, 5/16 27 751-0621 Exhaust Pipe (Kohler) 28 751-0617 Muffler, Single Inlet 29 712-0271 Hex Sems Nut, 1/4-20 (for starter cable) 30 721-0208 Exhaust Gasket (Intek Single) 31 732-0966 Extension Spring, .275 x 1.25 32 751B213146 Casing Clamp 33 751-0619 Exhaust Pipe (Intek Single) 34 746-1084 Throttle/Choke Cable (Intek Single) 35 746-1086 Throttle Cable (Intek Twin) 36 746-1087 Throttle Cable (Kohler) 37 722-0263 Foam (fits over fuel line) 38 736-0300 Flat Washer, .406 x .875 x .059

PART

NO. DESCRIPTION

Model 604

Electrical System

Electric PTO harness shown. Manual PTO harness will vary slightly

18/1

REF.

NO.

1 625-0051 Bulb/Socket Headlight Assembly 2 629-0939 Wiring Harness w/o Ref. 14 (units w/ Electric PTO)

3 629-0126 Harness Adapter, #18 x 5 4 710-0599 Self Tapping Screw, 1/4-20 x .5 5 712-3006 Hex Nut, 1/4-20 6 725-1426 Solenoid, 12-volt, 100 Amp 7 725-1657A Snap Mount Safety Interlock Switch (Brake) 8 725-1741 Ignition Switch

9 725-1743 Indicator Monitor / Hour Meter 10 725-1745 Ignition Key 11 725-1747 Safety Plunger Switch (Seat) 12 736-0222 External Lock Washer, 1/4 13 736-0329 Lock Washer, 1/4 14 629-0309 Headlight Harness 15 725-1752 Electric PTO Switch† 16 783-0462 Retainer Bracket† 17 725-3007A Positive Terminal Cover (Boot) 18 729-0357 Fuse Holder 19 725-1381 20-amp Fuse 20 629-0924 Harness Adapter (for Kohler Engines)

PART

NO. DESCRIPTION

629-0944 Wiring Harness w/o Ref. 14 (units w/ Manual PTO)

16 15

† Found on tractors engaged by an electric PTO only.

Notes

MANUFACTURER’S LIMITED WARRANTY FOR:

The limited warranty set forth below is given by MTD PRODUCTS INC (“MTD”) with respect to new merchandise purchased and used in the United States, its possessions and territories.

MTD 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 material or workmanship. This limited warranty shall only apply if this product has been operated and maintained in accordance with the Operator’s Manual furnished with the product, and has not been subject to misuse, abuse, commercial use, neglect, accident, improper maintenance, alteration, vandalism, theft, fire, water or damage because of other peril or natural disaster. Damage resulting from the installation or use of any accessory or attachment not approved by MTD Products Inc. for use with the product(s) covered by this manual will void your warranty as to any resulting damages.

Normal wear parts or components thereof are subject to separate terms as follows: All normal wear part or component failures will be covered on the product for a period of 90 days regardless of cause. After 90 days, but within the two year period, normal wear part failures will be covered ONLY IF caused by defects in material or workmanship of OTHER component parts. Normal wear parts and components include, but are not limited to, belts, blades, blade adapters, grass bags, rider deck wheels, seats, snow thrower skid shoes, shave plates and tires. Batteries are covered by a 90-day limited replacement warranty.

HOW TO OBTAIN SERVICE: Warranty service is available, WITH PROOF OF PURCHASE THROUGH YOUR LOCAL AUTHORIZED SERVICE DEALER. To locate the dealer in your area, please check for a listing in the Yellow Pages or contact the Customer Service Department of MTD PRODUCTS INC by calling 1-800-800-7310 or writing to P.O. Box 368022, Cleveland, Ohio 44136-9722.

This limited warranty does not provide coverage in the following cases:

a. The engine or component parts thereof. These items

carry a separate manufacturer’s warranty. Please refer to the applicable manufacturer’s warranty on these items.

b. Log splitter pumps, valves and cylinders have a sepa-

rate one year warranty.

c. Routine maintenance items such as lubricants, filters,

blade sharpening and tune-ups, or adjustments such as brake adjustments, clutch adjustments or deck adjustments; and normal deterioration of the exterior finish due to use or exposure.

d. MTD does not extend any warranty for products sold

or exported outside of the United States of America, its possessions and territories, except those sold through MTD’s authorized channels of export distribu- tion.

No implied warranty, including any implied warranty of merchantability or fitness for a particular purpose, applies after the applicable period of express written warranty above as to the parts as identified. No other express warranty or guaranty, whether written or oral, except as mentioned above, given by any person or entity, including a dealer or retailer, with respect to any product shall bind MTD. During the period of the Warranty, the exclusive remedy is repair or replacement of the product as set forth above. (Some states do not

allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.)

The provisions as set forth in this Warranty provide the sole and exclusive remedy arising from the sales. MTD shall not be liable for incidental or consequential loss or damages including, without limitation, expenses incurred for substitute or replacement lawn care services, for transportation or for related expenses, or for rental expenses to temporarily replace a warranted product. (Some states do not allow the exclusion or limita-

tion of incidental or consequential damages, so the above exclusion or limitation may not apply to you.)

In no event shall recovery of any kind be greater than the amount of the purchase price of the product sold. Alteration of the safety features of the product shall void this Warranty. You assume the risk and liability for loss, damage, or injury to you and your property and/or to others and their property arising out of the use or misuse or inability to use the product.

This limited warranty shall not extend to anyone other than the original purchaser, original lessee or the person for whom it was purchased as a gift.

How State Law Relates to this Warranty: This limited warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

MTD Yard-Man AutoDrive 604, M3800S-BN, Yard-Man AutoDrive U604H Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual