Troy-Bilt D609G, U609H, G609G, X609G Operator's Manual

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Operator’s Manual

Pedal Drive Lawn Tractor

Models D609G

G609G

U609H X609G

IMPORTANT: Read safety rules and instructions carefully before operating equipment.

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

covered, brush-covered or grass-covered land unless the engine’s exhaust system is equipped with a spark arrester meeting applicable local or state laws (if any). If a spark arrester is used, it should be maintained in effective working order by the operator. In the State of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. A spark arrester for the muffler is available through your nearest engine authorized service dealer or contact the service department, P.O. Box 361131 Cleveland, Ohio 44136-0019.

TROY-BILT LLC. P.O. BOX 361131, CLEVELAND, OHIO 44136-0019

PRINTED IN U.S.A.

FORM NO.

770-10490A.fm

(12/2001)

TABLE OF CONTENTS

Content Page

Important Safe Operation Practices...................................................................3

Slope Gauge...................................................................................................... 7

Tractor Set-up.................................................................................................... 8

Know Your Lawn Tractor ................................................................................... 9

Operating Your Lawn Tractor ............................................................................ 12

Making Adjustments .......................................................................................... 15

Maintaining Your Lawn Tractor ..........................................................................17

Service .............................................................................................................. 18

Off-Season Storage...........................................................................................22

Troubleshooting................................................................................................. 23

Parts List............................................................................................................24

FINDING MODEL NUMBER

This Operator’s Manual is an important part of your new lawn tractor. It will help you assemble, prepare and maintain the unit for best performance. Please read and understand what it says.

Before you start assembling your new equipment, please locate the model plate on the equipment and copy the information from it in the space provided below. The information on the model plate is very important if you need help from our Customer Support Department or an authorized dealer.

• You can locate the model number by looking beneath the seat. A sample model plate is explained below. For future reference, please copy model number and serial number of the equipment in the space below.

(Model Number)

www.troybilt.com

(Serial Number)

TROY-BILT LLC P. O. BOX CLEVELAND, OH 44136

330-558-7220 866-840-6483

361131

Copy the model number here:

Copy the serial number here:

ENGINE INFORMATION

The engine manufacturer is responsible for all engine-related issues with regards to performance, powerrating, specifications, warranty and service. Please refer to the engine manufacturer’s Owner’s/Operator’s Manual packed separately with your unit for more information.

CALLING CUSTOMER SUPPORT

If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenance of this unit, please call the Customer Support Department.

Call 1-866-840-6483 or 1-330-558-7220 to reach a Customer Support representative. Please have your unit’s model number and serial number ready when you call. See previous section to locate this information. You will be asked to enter the serial number in order to process your call.

For more details about your unit, visit our website at www.troybilt.com

SECTION 1: 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 this machine. Failure to comply with these instructions may result in personal injury. When you see this symbol—heed its warning.

WARNING: The Battery and Engine Exhaust contains chemicals known to the State of California

to cause cancer, birth defects or other reproductive harm. The battery and posts contain lead; wash hands after handling

WARNING: This machine 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 machine is capable of amputating hands and feet and throwing objects. Failure to observe the following safety instructions could result in serious injury or death.

General Operation

1. Read, understand, and follow all instructions on the machine and in the manual(s) before attempting to assemble and operate. Keep this manual in a safe place for future and regular reference and for ordering replacement parts.

2. Be familiar with all controls and their proper operation. Know how to stop the machine and disengage them quickly.

3. Never allow children under 14 years old to operate this machine. Children 14 years old and over should read and understand the operation instructions and safety rules in this manual and should be trained and supervised by a parent.

4. Never allow adults to operate this machine without proper instruction.

5. To help avoid blade contact or a thrown object injury, keep bystanders, helpers, children and pets at least 75 feet from the machine while it is in operation. Stop machine if anyone enters the area.

6. Thoroughly inspect the area where the equipment is to be used. Remove all stones, sticks, wire, bones, toys, and other foreign objects which could be picked up and thrown by the blade(s). Thrown objects can cause serious personal injury.

7. Plan your mowing pattern to avoid discharge of material toward roads, sidewalks, bystanders and the like. Also, avoid discharging material against a wall or obstruction which may cause discharged material to ricochet back toward the operator.

8. Always wear safety glasses or safety goggles during operation and while performing an adjustment or repair to protect your eyes. Thrown objects which ricochet can cause serious injury to the eyes.

9. Wear sturdy, rough-soled work shoes and closefitting slacks and shirts. Loose fitting clothes and jewelry can be caught in movable parts. Never operate this machine in bare feet or sandals.

10. Be aware of the mower and attachment discharge direction and do not point it at anyone. Do not operate the mower without the discharge cover or entire grass catcher in its proper place.

11. Do not put hands or feet near rotating parts or under the cutting deck. Contact with the blade(s) can amputate hands and feet.

12. A missing or damaged discharge cover can cause blade contact or thrown object injuries.

13. Stop the blade(s) when crossing gravel drives, walks, or roads and while not cutting grass.

14. Watch for traffic when operating near or crossing roadways. This machine is not intended for use on any public roadway.

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

16. Mow only in daylight or good artificial light.

17. Never carry passengers.

18. Disengage blade(s) before shifting into reverse. Back up slowly. Always look down and behind before and while backing to avoid a back-over accident.

19. Slow down before turning. Operate the machine smoothly. Avoid erratic operation and excessive speed.

20. Disengage blade(s), set parking brake, stop engine and wait until the blade(s) come to a complete stop before removing grass catcher, emptying grass, unclogging chute, removing any grass or debris, or making any adjustments.

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

22. Use extra care when loading or unloading the machine into a trailer or truck. This unit should not be driven up or down ramp(s), because the unit could tip over, causing serious personal injury. The unit must be pushed manually on ramp(s) to load or unload properly.

23. Muffler and engine become hot and can cause a burn. Do not touch.

24. Check overhead clearances carefully before driving under low tree branches, wires, door openings etc., where the operator may be struck or pulled from the unit, which could result in serious injury.

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

26. Your machine 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. Dry grass or leaves may contact the engine exhaust and/or build up on the mower deck presenting a potential fire hazard.

27. Use only accessories and attachments approved for this machine by the machine manufacturer. Read, understand and follow all instructions provided with the accessory or attachment.

28. Data indicates that operators, age 60 years and above, are involved in a large percentage of tractorrelated injuries. These operators should evaluate their ability to operate the tractor safely enough to protect themselves and others from serious injury.

29. If situations occur which are not covered in this manual, use care and good judgment. Contact your dealer for assistance.

Slope Operation

Slopes are a major factor related to loss of control and tip-over 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, 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 degrees as shown on the slope gauge, do not operate this unit on that area.

Do:

1. Mow up and down slopes, not across. Exercise extreme caution when changing direction on slopes.

2. Watch for holes, ruts, bumps, rocks, or other hidden objects. Uneven terrain could overturn the machine. Tall grass can hide obstacles.

3. Use slow speed. Choose a low enough speed setting so that you will not have to stop or shift while on the slope. Tires may lose traction on slopes even though the brakes are functioning properly. Always keep machine in gear when going down slopes to take advantage of engine braking action.

4. Follow the manufacturer’s recommendations for wheel weights or counterweights to improve stability of the machine. Use extra care with grass catchers or other attachments. These can change stability of the machine.

5. 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.

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

Do Not:

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

2. 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, ditch, or if an edge caves in.

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

4. Do not use a grass catcher on steep slopes.

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

6. Do not shift to neutral and coast downhill. Overspeeding may cause the operator to lose control of the machine resulting in serious injury or death.

7. Do not tow heavy pull behind attachments (e.g. loaded dump cart, lawn roller, etc.) on slopes greater than 5 degrees. When going down hill, the extra weight tends to push the tractor and may cause you to loose control. (e.g. tractor may speed up, braking and steering ability are reduced, attachment may jack-knife and cause tractor to overturn).

Children

1. 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. They do not understand the dangers. Never assume that children will remain where you last saw them.

a. Keep children out of the mowing area and in

watchful care of a responsible adult other than the operator.

b. Be alert and turn machine off if a child enters

the area.

c. Before and while backing, look behind and

down for small children.

d. Never carry children, even with the blade(s)

shut off. They may fall off and be seriously injured or interfere with safe machine operation.

e. Use extreme care when approaching blind

corners, doorways, shrubs, trees or other objects that may block your vision of a child who may run into the machine.

f. Disengage the cutting blade(s) before

shifting in reverse. The “No-Cut-In Reverse”

feature emphasises not to cut in reverse and to avoid back-over accidents; do not defeat it.

g. Keep children away from hot or running

engines. They can suffer burns from a hot muffler.

h. Remove key when machine is unattended to

prevent unauthorized operation.

9. Never allow children under 14 years old to operate the machine. Children 14 years old and over should read and understand the operation instructions and safety rules in this manual and should be trained and supervised by a parent.

To win g

1. Tow only with a machine that has a hitch designed for towing. Do not attach towed equipment except at the hitch point.

2. Follow the manufacturers recommendation for weight limits for towed equipment and towing on slopes.

3. Never allow children or others in or on towed equipment.

4. On slopes, the weight of the towed equipment may cause loss of traction and loss of control.

5. Travel slowly and allow extra distance to stop.

6. Do not shift to neutral and coast downhill.

Service

Safe Handling Of Gasoline

1. To avoid personal injury or property damage use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive. Serious personal injury can occur when gasoline is spilled on yourself or your clothes which can ignite. Wash your skin and change clothes immediately.

a. Use only an approved gasoline container. b. Never fill containers inside a vehicle or on a

truck or trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before filling.

c. When practical, remove gas-powered

equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment on a trailer with a portable container, rather than from a gasoline dispenser nozzle.

d. Keep the nozzle in contact with the rim of the

fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device.

e. Extinguish all cigarettes, cigars, pipes and

other sources of ignition. f. Never fuel machine indoors. g. Never remove gas cap or add fuel while the

engine is hot or running. Allow engine to cool

at least two minutes before refueling.

h. Never over fill fuel tank. Fill tank to no more

than ½ inch below bottom of filler neck to

allow space for fuel expansion. i. Replace gasoline cap and tighten securely. j. If gasoline is spilled, wipe it off the engine

and equipment. Move unit to another area.

Wait 5 minutes before starting the engine. k. To reduce fire hazards, keep machine free of

grass, leaves, or other debris build-up. Clean

up oil or fuel spillage and remove any fuel

soaked debris. l. Never store the machine or fuel container

inside where there is an open flame, spark or

pilot light as on a water heater, space heater,

furnace, clothes dryer or other gas

appliances. m. Allow a machine to cool at least 5 minutes

before storing.

General Service

1. Never run an engine indoors or in a poorly ventilated area. Engine exhaust contains carbon monoxide, an odorless, and deadly gas.

2. Before cleaning, repairing, or inspecting, make certain the blade(s) and all moving parts have stopped. Disconnect the spark plug wire and ground against the engine to prevent unintended starting.

3. Periodically check to make sure the blades come to complete stop within approximately (5) five seconds after operating the blade disengagement control. If the blades do not stop within the this time frame, your unit should be serviced professionally by an authorized dealer.

4. Check brake operation frequently as it is subjected to wear during normal operation. Adjust and service as required.

5. Check the blade(s) and engine mounting bolts at frequent intervals for proper tightness. Also, visually inspect blade(s) for damage (e.g., excessive wear, bent, cracked). Replace the blade(s) with the original equipment manufacturer’s (O.E.M.) blade(s) only, listed in this manual. “Use of parts which do not meet the original equipment specifications may lead to improper performance and compromise safety!”

6. Mower blades are sharp. Wrap the blade or wear gloves, and use extra caution when servicing them.

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

8. Never tamper with the safety interlock system or other safety devices. Check their proper operation regularly.

9. After striking a foreign object, stop the engine, disconnect the spark plug wire(s) and ground against the engine. Thoroughly inspect the machine for any damage. Repair the damage before starting and operating.

10. Never attempt to make adjustments or repairs to the machine while the engine is running.

11. Grass catcher components and the discharge cover are subject to wear and damage which could expose moving parts or allow objects to be thrown. For safety protection, frequently check components and replace immediately with original equipment manufacturer’s (O.E.M.) parts only, listed in this manual. “Use of parts which do not meet the original equipment specifications may lead to improper performance and compromise safety!”

12. Do not change the engine governor settings or over-speed the engine. The governor controls the

TO REDUCE THE RISK OF INJURY, DO NOT OPERATE UNLESS DISCHARGE COVER OR GRASS CATCHER IS IN ITS PROPER PLACE. IF DAMAGED, REPLACE IMMEDIATELY.

AVOID SERIOUS INJURY OR DEATH

KEEP HAND S AND FEET AWAY FROM ROTATING PARTS. REMOVE OBJECTS THAT CAN BE THROWN BY THE

BLADE IN ANY DIRECTION. WEAR SAFETY GLASSES. DO NOT MOW WHEN CHILDREN OR OTHERS ARE AROUND.

NEVER CARRY CHILDREN EVEN WITH BLADES OFF. USE EXTRA CAUTION ON SLOPES. DO NOT MOW SLOPES

GREATER THAN 10° MOW UP AND DOWN, NOT ACROSS.

S30536

READ OPERATOR'S MANUAL. KEEP SAFETY DEVICES IN PLACE AND WORKING.

Label shape may vary by tractor model. Label contents do not vary.

AVOID SUDDEN TURNS, USE LOW GEAR.

maximum safe operating speed of the engine.

13. Maintain or replace safety and instruction labels, as necessary.

14. Observe proper disposal laws and regulations for gas, oil, etc. to protect the environment.

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.

WARNING

TO AVOID SERIOUS INJURY OR DEATH

• GO UP AND DOWN SLOPES, NOT ACROSS.

• AVOID SUDDEN TURNS.

• DO NOT OPERAT E THE UNIT WHERE IT

COULD SLIP OR TIP.

• IF MACHINE STOPS GOING UPHILL, STOP

BLADE(S) AND BACK DOWNHILL SLO WLY.

• DO NOT MOW WHEN CHILDREN OR OTHERS

ARE AROUND.

• NEVER CARRY CHILDREN EVEN WITH.

BLADES OFF.

• LOOK DOWN & BEHIND BEFORE AND WHILE

BACKING.

• KEEP SAFETY DEVICES (GUARDS, SHIELDS, AND

SWITCHES, ETC.) 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 PLACING HANDS OR FEET NEA R BLADE(S).

• BEFORE LEAVING OPERATOR'S POSITION,

DISENGAGE BLADE(S), PLACE THE SHIFT LEVER

IN NEUTRAL, ENGAGE PARKING BRAKE,

SHUT OFF AND REMOVE KEY.

READ OPERATOR'S MANUAL

SECTION 2: SLOPE GAUGE

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.

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

15°

WARNING

A CORNER OF A BUILDING

SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE

A POWER POLE

OR A FENCE POST

SECTION 3: SETTING UP YOUR TRACTOR

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

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 carriage screw and hex nut at the factory. Make certain that the rubber boot covers the terminal to help protect it from corrosion.

• Remove the shoulder bolt and wing nut from the negative cable.

• Remove the black plastic cover, if present, from the negative battery terminal and attach the negative cable (heavy black wire) to the negative battery terminal (–) with the bolt and the wing nut.

• Make certain the hold-down strap is in position over the battery, securing it in place. See Figure 1.

Rubber

Boot

WARNING: Use extreme care when

handling gasoline. Gasoline is extremely flammable and the vapors are explosive. Never fuel machine indoors or while the engine is hot or running. Extinguish cigarettes, cigars, pipes, and other sources of ignition.

• Your tractor is shipped with motor oil in the engine. However, you must check the oil level before operating. Be careful not to overfill.

Removing Shipping Brace

WARNING: Make sure the riding mower’s

engine is off, remove the ignition key, and set the parking brake before removing the shipping brace

IMPORTANT:

purposes only, must be removed and discarded before operating your lawn tractor.

• Locate the shipping brace and accompanying warning tag on the right side of the tractor, between the discharge chute and the cutting deck. See Figure 2.

The shipping brace, used for packaging

Wing

Nut

Shoulder Bolt

Figure 1

NOTE: If the battery is put into service after the date

shown on top of battery, charge the battery as instructed on page 21 of this manual prior to operating the tractor.

Gas and Oil Fill-Up

• The gasoline tank is located under the hood and has a capacity of either two or three gallons according to the respective model. Do not overfill.

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

Shipping Brace

Warning Tag

Mulch Plug

• While holding the discharge chute with your left hand, remove the shipping brace with your right hand by grasping it between your thumb and index finger and rotating it clockwise.Do not discard the mulch plug, if already installed inside the chute

opening.

(If equipped)

Figure 2

WARNING: The mowing deck is capable of

throwing objects. Failure to operate the tractor without the discharge cover in the proper operating position could result in serious personal injury and/or property damage.

SECTION 4: KNOW YOUR LAWN TRACTOR

Compare the illustration below with the controls on your tractor; get familiar with these features before you start to operate the tractor. This manual covers two models. So follow the descriptions and instructions pertaining to your tractor model only.

IB*

NOTE: Steering Wheel not shown for clarity.

Figure 3

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

Throttle Control Lever

The throttle control lever is located on the right side of the tractor’s dash panel. This lever controls the speed of the engine. When set in a given position, the throttle will maintain a uniform engine speed. On model D609G, push this lever all the way forward for choke control also.

IMPORTANT:

operating the tractor with the cutting deck engaged, make sure that the throttle lever is always in the FAST (rabbit) position.

When

Choke*

Fast

Slow

*some models only

Choke Control

On model D609G, moving the throttle lever all the way forward activates the engine’s choke control. On model U609H, 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 on page 12 of this manual for detailed instructions.

Choke*

Brake Pedal

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

NOTE: Brake pedal must be fully depressed to activate the safety interlock switch when starting the tractor

Ignition Switch

To start the engine, insert the key into the ignition switch and turn clockwise to the START position. Once the engine starts, turn the key to ON position.

Refer to Starting The Engine on page 12 of this manual for more details.

The ignition switch is also used to operate the tractor’s headlights. Refer to Operating The Headlights on page 14 for details.

Off

On/Lights

Start

WARNING: Never leave a running machine

unattended. Always disengage PTO, move shift lever into neutral position, set parking brake, stop engine and remove key to prevent unintended starting.

Drive Pedal

The drive pedal is located below the brake pedal on the right front side of the tractor along the running board. Depress the drive pedal with your right foot (when the tractor shift lever is in either FORWARD or REVERSE) to move the tractor. Ground speed is also controlled with the drive pedal. Further down the pedal is depressed, faster the tractor will travel. The pedal will return to its original position when it is not depressed.

IMPORTANT:

leaving the tractor unattended.

Systems 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. These indicators are shown here.

The hour meter operates whenever the engine is running and records the actual hours of tractor operation.

It is normal for the oil light and the battery light to illuminate while the engine is cranking, but if either illuminates while the engine is running, follow the steps given below. If the brake light or PTO light illuminates while starting the tractor, proceed as follows.

Brake Light Engage the parking brake.

PTO Light Move the PTO lever into the OFF

Oil Light Stop the tractor immediately and

Battery Light Indicates that the battery needs to be

Always set the parking brake when

Battery Light

Hour Meter

PTO Light

(disengaged) position.

check the crankcase oil level as instructed in the engine manual. Add oil as required.

charged or that the engine’s charging system is not generating sufficient

Oil Light

1/10

Brake Light

amperage. Refer to Battery charging procedure on page 21 or have the engine’s charging system checked by an authorized dealer.

Cup Holder

The tractor’s cup holder is located on the fender to the left of the seat and rear of the parking brake lever.

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 power to the cutting deck or other (separately available) attachments; move the PTO lever backward (toward the rear of the tractor) to disengage power to the attachments.

Electric PTO Knob (If equipped)

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

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.

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:

leaving the tractor unattended.

Always set the parking brake when

Deck Lift Lever

Located on your tractor’s right fender, the deck lift lever is used to change the height of the cutting deck. To use, move the lever to the left, then place in the notch best suited for your application.

NOTE: The PTO lever/knob must be in the OFF position when (i) starting the engine, (ii) travelling in reverse or (iii) if the operator leaves the seat.

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 moving the shift lever.

IMPORTANT:

the shift lever. Doing so may result in serious damage to the transmission.

Never force

Shift

Knob

Seat Adjustment Lever

To adjust the seat forward or backward, slide the seat adjustment lever to the left and reposition the seat to the desired position. Once a comfortable position is found, release the seat adjustment lever to lock the seat in place. Refer to Seat Adjustment on page 16 for more detailed instructions.

Cruise Control Button

The cruise control button is located on the dash panel of the tractor to the left of the ignition switch. Push the cruise control button while the tractor is traveling forward at a desired speed. Holding the button in, release pressure from the drive pedal. This will engage cruise control and allow the tractor to maintain that speed without applying pressure to the drive pedal. Depress the brake pedal or the drive pedal to deactivate cruise control. Refer to OPERATING YOUR LAWN TRACTOR section on page 12 for detailed instructions.

NOTE: Cruise control cannot be engaged at the tractor’s fastest ground speed. If the operator should attempt to do so, the tractor will automatically decelerate to the fastest optimal mowing ground speed.

SECTION 5: OPERATING YOUR LAWN TRACTOR

• Insert the tractor key into the ignition switch.

WARNING: Read, understand, and follow all

instructions and warnings on the machine and in this manual before operating.

Safety Interlock Switches

This tractor is equipped with a safety interlock system for the protection of the operator. The safety interlock system prevents the engine from cranking or starting unless the parking brake is engaged and the PTO lever is in the disengaged (OFF) position.

The safety interlock system will automatically shut off the engine if:

1. the operator leaves the seat before engaging the parking brake;

2. the operator leaves the tractor’s seat with the PTO lever in the engaged (ON) position, regardless of whether the parking brake is engaged;

3. the PTO lever is moved to the engaged (ON) position with drive pedal placed for reverse travel.

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

• Engage the tractor’s parking brake.

• Pull the choke control outward (model U609H)or

move the throttle control lever into the CHOKE position (model D609G).

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

IMPORTANT:

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

• After the engine starts, de-activate choke control and place throttle control in the FAST position.

NOTE: Do not leave the choke control on while operating the tractor. Doing so will result in a "rich" fuel mixture and cause the engine to run poorly.

Do not hold the key in the START position

WARNING

IMPORTANT:

Tampering with or attempting to bypass

the tractor’s safety interlock switches in any way will void your tractor’s warranty.

WARNING: This safety interlock system

was designed for your safety and protection. If this system should ever malfunction, do not operate the tractor; contact an authorized Service Dealer.

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 fender.

• Adjust the deck wheels so that they are between ¼inch and ½-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 opening of the cutting deck.

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 Leveling the Deck on page 15 for more details regarding various deck adjustments.

Starting the Engine

NOTE: Refer to page 8 of this manual for Gasoline and Oil Fill-Up instructions.

AVOID SERIOUS INJURY OR DEATH

• 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, EVEN WITH BLADES OFF.

• LOOK DOWN AND BEHIND BEFORE AND WHILE BACKING.

• KEEP SA FETY 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 STOPPE D BEFORE PLAC-

ING HANDS OR FEET NEA R 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.

READ OPERATOR’S MANUAL

Stopping the Engine

• If the blades are engaged, place the PTO lever in the disengaged (OFF) position.

• Turn the ignition key counterclockwise to the OFF position.

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

WARNING: If you strike a foreign object,

stop the engine, disconnect the spark plug wire(s) and ground against the engine. Thoroughly inspect the machine for any damage. Repair the damage before restarting and operating

Driving the Tractor

IMPORTANT:

sudden stops.

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

IMPORTANT:

FORWARD to REVERSE or vice versa 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 drive pedal until the desired speed is achieved.

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

Avoid sudden starts, high speed and

WARNING: Do not leave the seat of the

tractor without first placing the PTO lever in the disengaged (OFF) position, depressing the brake pedal and engaging the parking brake. If leaving the tractor unattended, also turn the ignition key off and remove the key.

Do not move the shift lever from

Engaging the Parking Brake

To engage parking brake:

• Fully depress brake pedal and hold it there while gently pushing the parking brake button inward.

• Hold parking brake button in while removing your foot from the brake pedal.

• Once engaged, the parking brake button and the brake pedal will lock in the “down” position.

To disengage parking brake:

• Slightly depress the brake pedal.

NOTE: The parking brake must be engaged if the operator leaves the seat with the engine running or the engine will automatically shut off.

• 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.

Setting the Cruise Control

NOTE: The cruise control feature should only be utilized while traveling in the forward direction.

To engage cruise control:

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

• Lightly depress the cruise control button.

• Holding the cruise control button in, lift your foot

from the drive pedal (you should feel the cruise latch engage).

• Once engaged, the cruise control button and the drive pedal will lock in the “down” position, and the tractor will maintain the same forward speed.

To disengage cruise control: (Follow one of two methods described below.)

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

2. Lightly depress the drive pedal.

To change direction to reverse when operating with cruise control:

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

• Place shift lever in the REVERSE position and depress the drive pedal.

Driving on Slopes

Refer to the SLOPE GAUGE on page 7 to help determine slopes where you may operate tractor 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.

• Mow up and down slopes, never across.

• Exercise extreme caution when changing direction

on slopes.

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

Using the Deck Lift Lever

• To raise the cutting deck, move the deck lift lever to the left, then place it in the notch best suited for your application. Refer to Setting The Cutting Height earlier in this section.

Engaging the PTO

Engaging the PTO transfers power to the cutting deck or other (separately available) attachments. To engage the PTO, proceed as follows:

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

• Grasp the PTO lever and pivot it all the way forward to the engaged (ON) position.

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

NOTE: The operator must remain on the tractor seat at all times of operation. If the operator leaves the seat without moving the PTO lever into the disengaged (OFF) position, the tractor’s engine will automatically shut off, regardless of whether the parking brake is engaged or not

IMPORTANT:

the PTO lever is moved into the engaged (ON) position with the drive pedal in position for reverse travel. Refer to Safety Interlock Switches on page 12.

The engine will automatically shut off if

Mowing

WARNING: To help avoid blade contact or a

thrown object injury, keep by-standers, helpers, children and pets at least 75 feet from the tractor while it is in operation. Stop the tractor if anyone enters the area.

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

WARNING: Plan your mowing pattern to

avoid discharge of materials toward roads, sidewalks, by-standers and the like. Also, avoid discharging material against a wall or obstruction which may cause discharged material to ricochet back toward the operator.

grass clippings repeatedly beneath the cutting deck. The ultra-fine clippings are then forced back into the lawn where they act as a natural fertilizer. Observe the following points for best results in mulching:

• Never attempt to mulch if the lawn is damp. Wet grass tends to stick to the underside of the cutting deck preventing proper mulching of the clippings.

• Do not attempt to mulch more than 1/3 the total height of the grass or approximately 1-1/2 inches. Doing so will cause the clippings to clump up beneath the deck and not be mulched effectively.

• Maintain a slow ground speed to allow the grass clippings more time to effectively be mulched.

• Always position the throttle control lever in the FAST (rabbit) position and allow it to remain there while mowing. Failing to keep the engine at full throttle places strain on the tractor’s engine and does not allow the blades to properly mulch grass.

NOTE: It is not necessary to remove the discharge chute to operate the mower with the mulch kit installed.

• To operate the cutting deck without mulching, simply remove the mulch plug by unthreading the plastic wing nut which fastens it to the cutting deck. This will allow the clippings to discharge through the side-discharge opening. See Figure 4 .

Carriage Screw

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

• For best results it is recommended that the first two laps be cut with the discharge thrown towards the center. Then reverse the direction to throw rest of the discharge to the outside . 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.

• Under heavier conditions it may be necessary to go back over the cut area 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 Cutting Blades on page 21 for blade sharpening instructions.

Mulching

Lawn tractor models xxxxxxx come equipped with a mulch kit which incorporates special blades, already standard on your tractor, in a process of recirculating

Bell

Washer

Plastic Wing Nut

Figure 4

Mulch Plug

Operating the Headlights

To turn on the headlights:

• Start the engine .Turn the key one notch counterclockwise into the On/Lights position of the ignition switch. Refer to figure on page 10.

To turn off the headlights:

• 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 on page 10.

NOTE: Never move the key into the Start position while the engine is running. Doing so may cause damage to the tractor ‘s electric starter.

SECTION 6: MAKING ADJUSTMENTS

WARNING: Disconnect the spark plug

wire(s) and ground against the engine before performing any adjustments, repairs or maintenance.

WARNING: Do not make any adjustments

while the engine is running, except where specified in this or the engine manual.

Leveling the Deck

NOTE: Check the tractor’s tire pressure before performing any deck leveling adjustments. Refer to Tires on page 21 for information on tire pressure.

Front To Rear

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

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

• Measure the distance from front of the blade tip to the ground and 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.

Lock

Nuts

• Loosen the two jam nuts on the rear side of the deck stabilizer bracket. See Figure 5A.

• Locate the two lock nuts on the opposite side of the stabilizer bracket. See Figure 5A. 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:

• With the tractor parked on a firm, level surface, place the deck lift lever in the top notch (highest position) and rotate 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 5B.

• Balance the deck by using a wrench to turn the adjustment gear (found immediately behind the hex cap screw just loosened) clockwise/up or counterclockwise/down.

• The deck is properly balanced when both blade tip measurements taken earlier are equal.

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

Deck

Stabilizer

Bracket

Deck

FRONT TO REAR

Jam

Nuts

SIDE TO SIDE

Figure 5

Adjustment Gear

Hex Cap Screw

Seat Adjustment

WARNING: Before operating this machine,

make sure the seat is engaged in the seat stop, stand behind the machine and pull back on seat until fully engaged into stop.

• Move the seat adjustment lever to the left and slide the seat forward or rearward. Make sure seat is locked into position before operating the tractor.

Parking Brake Adjustment

WARNING: Never attempt to adjust the

brakes while the engine is running. Always disengage PTO, move shift lever into neutral position, stop engine and remove key to prevent unintended starting.

Adjust the brake if (i) the tractor does not come to a complete stop when the brake pedal is completely depressed, or (ii) the tractor’s rear wheels roll even with the parking brake applied. Locate the brake disc on the right side of the transmission in the rear of the tractor. Adjust as follows:

• Looking at the transmission from the right side of the tractor, locate the compression spring and brake disc. See Figure 6.

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.

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 7 .

• Remove the hex nut and lock washer on the top of ball joint. See Figure 7 .

• 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.

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

Hex Nut and Lock Washer

Axle

Grease Fitting

Pivot Bar

Hex Nut

Set Gap

at .011"

Brake Disc

NOTE: View shown from beneath tractor.

• Loosen, but do not remove, the hex nut found on the right side of the brake assembly. See Figure 6.

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

• Re-tighten the hex nut loosened earlier.

Compression

Spring

Transmission

Figure 6

Drag Link

Jam Nut

Ball Joint

Figure 7

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".

Front tire toe-in can be measured as follows:

• Place the steering wheel in position for straight ahead travel.

• 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.

SECTION 7: MAINTAINING YOUR LAWN TRACTOR

WARNING: Before performing any

maintenance or repairs, disengage PTO, move shift lever into neutral position, set parking brake, stop engine and remove key to prevent unintended starting.

Cleaning Engine and Deck

• Promptly wipe off any fuel or oil spilled on the machine. Do not allow debris to accumulate around the cooling fins of the engine or on any other part of the machine, especially on the belts, pulleys and other moving parts.

• Clean the underside of the deck with a wire broom, scraper or forced air after each mowing.

NOTE: The use of 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 shorten life of the tractor and reduce its serviceability.

Maintaining the Engine

Refer to the engine manual for maintenance instructions. also follow these steps to maintain the engine in good working order.

• Check engine oil level before each use as instructed in the engine manual. Read and follow instructions carefully.

Changing Engine Oil

• Unscrew oil fill cap and remove dipstick from the oil fill tube. See Figure 8 .

• Pop open the protective cap on the end of the oil drain valve to expose the drain port. See Figure 8 .

• Push the oil drain hose (packed with this manual) 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 (approximately 48 oz. in model D609G and 64 oz. in model U609H).

• Push the oil drain valve in slightly, then rotate counter-clockwise and pull outward to begin draining oil. See Figure 8 .

• Service the oil filter (if so equipped) as instructed in the engine manual.

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

• Refill the engine with new motor oil (approximately 48 oz.in model D609G and 64 oz. in model U609H).

Oil Fill Cap

Oil Fill Tube

Oil Drain

Hose

Figure 8

Protective Cap

Oil Drain Valve

Drain Port

Air Cleaner

• Service the pre-cleaner, if so equipped, and cartridge/air cleaner element as instructed in the engine manual.

Spark Plug

• The spark plug should be cleaned and the gap reset once a season. Spark plug replacement is recommended at the start of each mowing season. Refer to the engine manual for correct plug type and gap specifications.

Lubrication

Engine

Lubricate the engine with motor oil as instructed in the engine manual.

Pivot Points & Linkage

Lubricate all the pivot points on the drive system, parking brake and lift linkage at least once a season with light oil.

Rear Wheels

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

Front Wheels

Each of the front wheel axles is equipped with a grease fitting (Figure 7 ). Lubricate with a grease gun after every 25 hours of tractor operation.

IMPORTANT:

weight of motor oil to be used.

Refer to the engine manual for the proper

SECTION 8: SERVICE

WARNING: Before performing any

maintenance or repairs, disengage PTO, move shift lever into neutral position, set parking brake, stop engine and remove key to prevent unintended starting.

Cutting Blades

• Periodically inspect the blade adapter and/or spindle for cracks or damage, especially if you strike a foreign object. Replace immediately if damaged

To remove blade:

• Remove the deck from beneath the tractor, (refer to Cutting Deck Removal on page 18). 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 9 .

WARNING: Protect your hands by using

heavy gloves or a rag to grasp the blade.

if any metal separation is present, replace the blades with new ones. See Figure 10 .

• Grind each blade edge equally to maintain proper blade balance.

• Test the blade by balancing it on a round shaft screwdriver. Grind metal from the heavy side until it balances evenly.

IMPORTANT:

excessive vibration and may cause damage to the tractor and/or personal injury.

To replace blade:

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

• Use a torque wrench to tighten the blade spindle hex flange nut to between 70 foot-pounds and 90 foot-pounds.

A poorly balanced blade will cause

Blade Separation

Hex Flange Nut

Wood Block

Spindle Assembly

Figure 9

• Use a 15/16" wrench to remove the hex flange nut that secures blade to the spindle assembly. See Figure 9 .

To sharpen blades:

• Remove equal amounts of metal from both ends of the blades along the cutting edges, parallel to the trailing edge, at a 25° to 30° angle. See Figure 10 .

• If the cutting edge of the blade has already been sharpened to within 5/8" of the wind wing radius, or

Wor n Blade Edg e

Wind Wing

Sharpen edge evenly

Figure 10

Removing Cutting Deck

• Place the PTO lever in the disengaged (OFF) position and engage the parking brake.

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

• Remove the PTO belt from around the cutting deck’s center pulley. Refer to .

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

• Pull the deck support pin outward to release the deck from the deck lift arm. See Figure 11.

• Rotate the pin slightly toward the rear of the tractor and release the pin into the hole provided. Repeat on the right side.

Support Pin

Figure 11

• Move the deck lift lever into the top notch on the right fender to raise the deck lift arms up and 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.

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

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

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

To change or replace the deck belts on your tractor, proceed as follows:

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

• Remove the belt guards by removing the selftapping screws that fasten them to the deck.

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

• Remove the PTO belt from the engine pulley and from around the PTO idler pulleys.

• Grasp 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 pulleys, including the deck idler pulley.

• Route the new belts as shown in .

• Remount the belt guards removed earlier.

Changing Transmission Drive Belt

Changing Deck Belts

WARNING: Be sure to shut engine off,

remove ignition key, disconnect spark plug wire(s) and ground against engine before starting this job.

IMPORTANT:

specially designed to engage and disengage safely. A

The V-belts, found on your tractor, are

Engine Pulley

Left Hand Pulley

WARNING: Be sure to shut the engine off,

remove ignition key, disconnect the spark plug wire(s) and ground against the engine to prevent unintended starting before removing the 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.

PTO Idler Bracket

(mounted on tractor)

Deck belt (Bottom)

PTO belt (Top)

Right Hand Pulley

(beneath belt guard)

Deck Idler Pulley

NOTE:

Left hand belt cover not shown for clarity.

Center Pulley

Figure 12

Self-Tapping Screws

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 on your tractor, proceed as follows:

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

• Remove the cutting deck as instructed earlier.

• 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 13.

• Grasp the bracket and pivot the transmission idler

pulley toward the rear of the tractor to release tension on the upper drive belt.

• Remove belt from around the transmission idler

pulley.

Variable Speed

Pulley

Battery Tray Opening

Shift Lever

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

NOTE: Slowly rotate the pulley counter-clockwise to roll the belt off it.

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

• Re-route the new upper drive belt as shown in Figure 13.

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 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 13.

• Remove the variable-speed pulley by loosening the

hex bolt that secures it to the transmission. Use a second wrench to hold the hex nut on the bottom side of the pulley.

Drive Belt (Lower)

Rear Idler Pulley

Drive Belt (Upper)

Transmission

NOTE: View shown from above tractor.

Idler Bracket

Transmission Idler Pulley

Transmission Pulley

Belt Keeper

Double-Idler Bracket

Front of Tractor

Front Idler Pulley

Figure 13

Keeper Pins

to drive pedal

Engine Pulley

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

• Remove the rear idler pulley from the double- idler bracket while unrouting the belt from around both the rear and the front idler pulley. See Figure 13.

• Remove the hex bolt from the center of the engine pulley and gently lower it off of the engine crankshaft. Be careful not to lose any washers or spacers which may be on top of the engine pulley.

• When remounting the engine pulley, 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 14.

• 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 13.

The drive pedal is properly adjusted when the hole found in the double-idler bracket has approximately 1-3/8" of travel with ten pounds of pressure applied to the drive pedal. See Figure 14.

Double Idler

Bracket

Hole

Idler

Adjuster Rod

• Reassemble by following the above steps in reverse order.

Idler Adj. Rod

Neutral Return Bracket

Hairpin

Clips

Drive Pedal

Return Spring

Place wrenches here

Speed Control

Assembly

Figure 15

Tires

WARNING: Never exceed maximum

inflation pressure shown on sidewall of the tire.

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

”

Front of Tractor

NOTE: View shown from above tractor.

Figure 14

Adjust the drive 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 15•.

• 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 15•.

• Remove the drive pedal return spring.

• Using two 9/16" wrenches, remove the pin from the speed control assembly. See •Figure 15.

• Thread the idler adjustment rod inward or outward

to lengthen or shorten the travel of the double-idler bracket until proper adjustment is achieved.

Battery

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

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

• After cleaning, apply a light coat of petroleum jelly or grease to both terminals.

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

• If removing the battery for any reason, disconnect the NEGATIVE (black) wire from its terminal first, followed by the POSITIVE (red) wire. When reinstalling the battery, always connect the POSITIVE (red) wire to its terminal first, followed by the NEGATIVE (black) wire.

IMPORTANT:

correct terminals; reversing them could change polarity and cause damage to the engine’s alternating system.

Charging

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

Be certain that wires are connected to the

WARNING: Batteries give off an explosive

gas while charging. Charge battery in a well ventilated area and keep away from an open flame or pilot light as on a water heater, space heater, furnace, clothes dryer or other gas appliances.

• 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 the dash panel on the support bar. Pull the fuse out and inspect it to determine if it is good or blown.

Fuse

A fuse is installed in your tractor’s wiring harness to protect the tractor’s electrical system from damage caused by excessive amperage.

SECTION 9: OFF-SEASON STORAGE

Clean and lubricate the tractor as instructed on page 17 before storing for an extended period.

WARNING: Drain fuel only into an approved

container outdoors, away from an open flame. Allow engine to cool. Extinguish cigarettes, cigars, pipes, and other sources of ignition prior to draining fuel.

WARNING: Never store the machine or fuel

container indoors where there is an open flame, spark or pilot light such as on water heater, furnace, clothes dryer or other gas appliance.

IMPORTANT:

amperage capacity for replacement.

Follow the instructions in the Service, Storage & Specifications section of the Briggs & Stratton Operator/Owner Manual (or Kohler engines Owner’s Manual) for proper engine care prior to storing your tractor.

Always use a fuse with the same

SECTION 10: TROUBLESHOOTING

Trouble Possible Cause(s) Corrective Action

Engine fails to start PTO lever engaged.

Parking brake not engaged. Spark plug wire(s) disconnected. Throttle control lever not in correct starting position. Choke not activated

Fuel tank empty, or stale fuel. Blocked fuel line. Faulty spark plug. Engine flooded.

Engine runs erratic Unit running with CHOKE applied.

Spark plug wire loose. Blocked fuel line or stale fuel.

Vent in gas cap plugged. Water or dirt in fuel system.

Dirty air cleaner.

Engine overheats Engine oil level low.

Air flow restricted.

Engine hesitates at high RPM Spark plug gap too close. Remove spark plug and reset the gap to .030”. Idles poorly Spark plug fouled, faulty or gap too

wide. Dirty air cleaner.

Excessive vibration Cutting blade loose or unbalanced.

Damaged or bent cutting blade.

Mower will not mulch grass Engine speed too low.

Wet grass. Excessively high grass.

Dull blade.

Uneven cut Deck not balanced properly.

Dull blade. Uneven tire pressure.

Place PTO lever in disengaged (OFF) position. Engage parking brake. Connect wire(s) to spark plug. Place throttle lever to FAST or CHOKE (if so equipped) position. Place throttle lever to CHOKE (if so equipped) position or pull out the CHOKE control (if so equipped). Fill tank with clean, fresh (less than 30 days old) gas. Clean fuel line or replace fuel filter, if so equipped. Clean, adjust gap or replace plug. Crank engine with throttle in FAST position. Place throttle lever in FAST position or push CHOKE control (if so equipped) in. Connect and tighten spark plug wire. Clean fuel line; fill tank with clean, fresh (less than 30 days old) gasoline. Replace fuel filter, if so equipped. Clear vent or replace cap if damaged. Drain fuel tank. Refill with clean, fresh (less than 30 days old) gasoline. Replace air cleaner cartridge/element or clean precleaner, if so equipped. Fill crankcase with proper capacity and weight of oil. Clean grass clippings and debris from around the engine’s cooling fins and blower housing.

Replace spark plug. Set plug gap to .030”. Replace air cleaner cartridge/element or clean precleaner, if so equipped. Tighten blade and spindle. Balance blade. Replace blade. Place throttle in FAST (rabbit) position. Do not mow when grass is wet; wait until later to cut. Mow once at a high cutting height, then mow again at desired height or make a narrower cutting swath. Sharpen or replace blade. Perform side-to-side deck adjustment. Sharpen or replace blade. Check tire pressure in all four tires.

SECTION 11: PARTS LIST FOR MODELS D609, G609, U609 & X609

30 28

23 42

40 37

Models D609, G609, U609 & X609

REF. NO.

PART NO. DESCRIPTION

1 783-1346 Grill Support Bracket (9-style) 2 710-0599 Self-tapping Screw, 1/4-20 x .5 3 710-0528 Hex Cap Screw, 5/16-18 x 1.25

4 710-0924 Phillips Pan Screw, 1/4-20 x .75 5 710-1017 Truss Phillips Screw, 1/4-20 x .625 6 725-1741 Ignition Switch 7 726-0272 Clamp, 9/16 8 710-0642 Self-tapping Screw, 1/4-20 x .75 9 712-0292 U-type Speed Nut, 1/4-20

10 736-0270 Bell Washer, .265 x .75 x .062 11 725-1976 Systems Indicator Monitor 12 712-3004A Hex Nut, 5/16-18 13 731-2119A Grille (9-style) 14 731-0511 Trim Strip, 4 15 725-0175 Cable Tie, 3/16 x .05 x 7.4

16 746-1085 Choke Knob/Cable (Model G609G) 17 783-0783 Hood (9-style) 18 783-0784 RH Side Panel (9-style) 19 783-0785 LH Side Panel (9-style) 20 731-2637 Headlight Lens (9-style) 21 747-1162A Hood Hinge Rod

22 625-0051 Headlight Assembly 23 710-0604A Self-tapping Screw, 5/16-18 x .625 24 751-0603 Fuel Cap 25 751-0658C Fuel Tank, Three-gallon

REF. NO.

PART NO. DESCRIPTION

751-0659A Fuel Tank, Two-gallon (Model

D609G)

26 725-1745 Ignition Key w/ plastic cover

725-1744 Ignition Key w/o plastic cover 27 710-0895 Self-tapping Screw, 1/4-15 x .75

28 710-3217 Truss Phillips Screw, #8-32 x .375 29 712-0142 Hex Nut, #8-32 30 731-1857 Throttle Control Knob 31 731-2122C Dash Panel, 8/9-style, Manual PTO 32 731-2226 Cruise Control Button 33 731-2227 Parking Brake Button

34 736-0142 Flat Washer, 9/32 x 1/2 x 1/16 35 747-1196 Brake/Cruise Pivot Rod 36 749-1087A Dash Support Tube 37 712-3010 Hex Nut, 5/16-18 38 731-2270 Hood Plenum (Model G609G)

N/A Hood Plenum (Model D609G)

39 726-3046 Ratchet Clip 40 736-0119 Lock Washer, 5/16 41 726-0201 Speed Nut, .3125 42 736-3078 Flat Washer, .349 x 1.0 x .063 43 710-1238 Screw, 5/16-18 x .875 (Grade 5)

629-0469A Headlight Wire Harness (Not Shown)

629-1071 Tractor Wire Harness (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 Powder Black, the part number to order would be 700-xxxx-0637.

Red: 0638

Oyster Gray: 0662

Powder Black: 0637

Models D609, G609, U609 & X609

40 36

38 28

35 54

17 2

21 22

Models D609, G609, U609 & X609

REF.

NO.

1 747-1130A 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 13 732-1184 Extension Spring, .872 x 3.4 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 18 738-0138A 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 25 783-0678A Arm Lift 26 783-0720A Deck Stabilizer Bracket 27 710-0260A Carriage Bolt, 5/16 x .62 28 710-0604A Self-tapping Screw, 5/16-18 x .625

PA RT

NO.

DESCRIPTION

REF.

NO.

29 710-0895 Self-tapping Screw, 1/4-15 x .75 30 731-1990 Lift Lever Cover 31 731-2104B Shift Lever Cover w/ Cup Holder 32 736-3078 Flat Washer, .349 x 1.0 x .063 33 783-0677 Lift Adjustment Bracket 34 783-0685B Fender 35 783-1489 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 49 757-0348A High Back Seat, Black 50 735-0656 RH Foot Pad 51 735-0657 LH Foot Pad

52 714-0111 Cotter Pin 53 731-0511 Trim Strip 54 783-0209A Seat Lift Bracket 55 726-0201 Speed Nut

PA RT

NO.

726-3046 Foot Pad Clips (Not Shown)

DESCRIPTION

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 Powder Black, the part number to order would be 700-xxxx-0637.

Red: 0638

Oyster Gray: 0662

Powder Black: 0637

Models D609, G609, U609 & X609

17 45

Models D609, G609, U609 & X609

REF.

NO.

1 731-1291A Pivot Bar End Cap

2 710-1238 Self-tapping Screw, 16-18 x .625

3 783-0726B RH Pivot Support Bracket

4 783-0727A LH Pivot Support Bracket

5 783-0728 Pivot Bar Bracket

6 710-0723 Hex Cap Screw, 3/8-16 x 1

7 711-1408 RH Drag Link

8 711-1655 LH Drag Link

9 712-0240 Jam Nut, 7/16-20 10 712-0241 Hex Nut, 3/8-24 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 14 717-1550D 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 19 738-1001A Steering Shaft, .625 OD x 24.4 20 741-0475 Plastic Bushing, .38 ID 21 741-0656 Hex Flange Bearing, 5/8 22 738-0372B Shoulder Spacer, .38 ID 23 731-2624 Steering Wheel, 13.25 24 731-2625 Steering Wheel Cap

PA RT

NO.

DESCRIPTION

REF.

NO.

25 638-0019A LH Axle Assembly, .625 Diameter 26 638-0020A RH Axle Assembly, .625 Diameter 27 683-0128A Pivot Bar 28 712-0431 Flange Lock Nut, 3/8-16 29 714-0162 Cotter Pin 30 726-0214 Push Cap, .625 31 736-0162 Flat Washer, .64 x 1.0 x .12 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

37 734-2290A Hub Cap 38 783-0653D Steering Support Bracket 39 738-0143 Shoulder Screw, 3/8-16 40 736-0331 Bell Washer, .39 x 1.13 x .062 41 710-1260A Self-tapping Screw, 5/16-18 x .75 42 736-0242 Bell Washer, .34 x .872 43 710-0643 Hex Bolt, 5/16-18 X 1 44 783-0656A Axle Bracket RH 45 783-0657A Axle Bracket LH 46 736-3004 Flat Washer

PA RT

NO.

634-0172 Rim Only w/ Plastic Bearing 734-0255 Air Valve (Not Shown) 734-1731 Tire Only, Square Shoulder

DESCRIPTION

NOTE: For painted parts, please refer to the list of color codes below.

Red: 0638

Oyster Gray: 0662

Powder Black: 0637

Models D609, G609, U609 & X609

85 84

Models D609, G609, U609 & X609

REF.

NO.

1 783-1015 Shift Lever Support 2 17840 Transaxle Mounting Bracket 3 618-0551 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

9 710-0176 Hex Cap Screw, 5/16-18 x 2.75 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 20 712-3017 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

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 35 736-3008 Flat Washer, .344 x .750 x .120 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 42 747-0047A Shift Rod 43 711-0736 Adjustment Ferrule, 1/4-20 x 1.0 44 738-0372B Shoulder Spacer, .38 ID 45 754-0467 Lower Drive Belt 46 754-0468 Upper Drive Belt

PART

NO.

DESCRIPTION

(hooks to flange, 783-0650, in frame)

REF.

NO.

47 756-0981 Flat Idler, 2.75 OD 48 783-1016B Speed Control Rod Bracket 49 783-0667B Transmission Torque Bracket 50 783-0669 Idler Bracket 51 736-0430 Flat Washer, .350 x 1.59 x .062 52 647-0031 Brake Control Assembly 53 647-0032 Speed Control Assembly 54 683-0266 Drive Pedal Assembly 55 714-0470 Cotter Pin, 1/8 x 1.25 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 Drive Pedal Pad 62 735-3049 Brake Pedal Pad 63 736-0142 Flat Washer, .281 x .5 x .063 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 73 736-0275 Flat Washer, .344 x .688 x .065 74 783-0653D Stearing Support Bracket 75 783-0732 Drive Lock-out Bracket 76 783-0773 Brake Pedal 77 783-0780A Neutral Return Bracket 78 683-0304 Lower Frame Assembly 79 783-1031A Hitch Plate 80 736-0242 Bell Washer, .34 x .872 81 710-0627 Hex Cap Screw, 5/16-24 x .75 82 634-0105A Wheel Assembly (Model D609G)

83 734-2290A Hub Cap 84 710-0809 Self-tapping Screw, 1/4-20 x 1.25 85 750-0556 Spacer 86 710-0650 Self-tapping Screw, 5/16-18 x .875 87 710-1260A Self-tapping Screw, 5/16-18 x .75 88 747-1285 Shift Rod 89 748-0415B Spacer

PART

NO.

634-0177 Wheel Assembly (Model U609H) 634-0070 Rim Only 734-0255 Air Valve (Not Shown) 734-1730 Tire Only, 20 x 8 x 8, Square Shoulder

DESCRIPTION

NOTE: For painted parts, please refer to the list of color codes below.

Red: 0638

Oyster Gray: 0662

Powder Black: 0637

Models D609, G609, U609 & X609

REF.

12*

10 30 28

2 4

4 2

12*

NO.

1 716-0231 E-Ring, .75 2 721-0338 Seal, .75 x 1.0 x .125 3 711-1431 Drive Shaft 4 741-0340 Sleeve Bearing, .75 x .1.0 x 1.0 5 736-0495 Thrust Washer, 1.0 x .632 x .0 6 717-1362 42-Tooth Bevel Gear 7 717-1363 42-Tooth Bevel Gear 8 750-1234 Spacer, .633 x 1.0 x .513

9 718-0228 Clutch Collar 10 741-0525 Needle Bearing, .625 x .875 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 17 611-0133 Detent Shaft Assembly 18 618-0424 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 26 711-1430 Input Shaft 27 716-0108 Retaining Ring, .437 28 717-1464 14-Tooth Bevel Pinion 29 719-0391A Upper Housing 30 736-0723 Thrust Washer, .635 x 1.25 x .042

PART

NO.

DESCRIPTION

*Use applicable flat washer (12a, 12b or 12c) in this application allowing proper end-play as instructed in Service Manual.

Models D609, G609, U609 & X609

(for choke)

4 27

NOTE: Engine accessory parts are applicable to all models except otherwise noted.

REF.

NO.

1 710-0227 Self-tapping Screw, #8-18 x .5 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 5 710-1314A 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 (Model G609G) 8 721-0460 Exhaust Gasket (Model G609G)

9 726-0205 Hose Clamp 10 736-0119 Lock Washer, 5/16 11 736-0300 Flat Washer (Model G609G) 12 751B221535 Casing Clamp (Model G609G) 13 751-0535 Fuel Line Hose 14 751-0564 Muffler Deflector 15 751-0616 Muffler, Twin Inlet (Model G609G)

PART

NO. DESCRIPTION

REF.

NO.

16 751-0650 RH Exhaust Pipe (Model G609G) 17 751-0651 LH Exhaust Pipe (Model G609G) 18 751-3140 Oil Drain Valve 19 751-3141 Oil Drain Hose 20 751-3142 Oil Drain Cap 21 783-0615B Muffler Heat Shield 22 783-0625C Engine Heat Shield (Model G609G) 23 722-0263 Foam (fits over fuel line) 24 746-1086 Throttle Cable (Model G609G) 25 746-1084 Throttle Cable (Model D609G) 26 751-0619 Exhaust Pipe (Model D609G) 27 751B213146 Casing Clamp (Model D609G) 28 751-0617 Muffler, Single Inlet (Model D609G) 29 712-0271 Hex Sems Nut, 1/4-20 (for starter cable) 30 721-0208 Exhaust Gasket (Model D609G)

PA RT

NO. DESCRIPTION

Models D609, G609, U609 & X609

46 47

18 11

11 18

8 43

Models D609, G609, U609 & X609

REF.

NO.

1 647-0064 PTO Engage Lever Assembly

2 683-0450 PTO Engage Plate Assembly

3 710-0276 Carriage Screw, 5/16-18 x 1.00

4 710-0520 Hex Cap Screw, 3/8-16 x 1.5

5 710-0831 Hex Cap Screw, 3/8-16 x 5.5

6 710-1238 Hex Head Washer Screw, 5/16-18 x .875

7 712-0229 Push Nut, 3/8

8 712-0431 Flange Lock Nut, 3/8-16

9 712-3004A Flange Lock Nut, 5/16-18 10 712-3010 Hex Nut, 5/16-18 11 714-0470 Cotter Pin, 1/8 x 1.25 12 726-0201 Speed Nut, .3125 13 731-2111A PTO Knob 14 732-1170 Extension Spring, .75 x 6.75 15 732-0991A Belt Guard 16 736-0108 Flat Washer, .510 x .750 x .033 17 736-0119 Lock Washer, 5/16 18 736-0140 Flat Washer, .385 x .62 x .063 19 736-0275 Flat Washer, 5/16 20 736-3000 Flat Washer, .406 x .875 x .059 21 736-0331 Bell Washer, .39 x 1.13 x .062 22 736-3039 Flat Washer, .407 x .812 x .135 23 738-0372B Shoulder Spacer, .380 24 741-0708 Hex Split Flange Bearing 25 747-1112D PTO Engagement Handle 26 747-1286A Belt Keeper Rod 27 748-0415B Spacer, 3/8 x 1.54 28 756-0627B Idler Pulley, 3.5 29 756-1208 Idler Pulley, 4.0

PART

NO.

DESCRIPTION

REF.

NO.

30 783-0744A Engagement Stop 31 783-0891B Deck Stop 32 710-0604A Self-tapping Screw, 5/16-18 x .625 33 732-3080A Compression Spring, 1.28 x 3.5 34 723-0444 Battery Strap 35 738-1020 Shoulder Screw, .625 x .5, 7/16-20 36 736-0407 Bell Washer, .45 x 1.0 x .062 37 712-0459 Flange Lock Nut, 7/16-20 38 783-1031A Hitch Plate 39 783-0349 Battery Tray 40 725-1426 Solenoid, 12-Volt, 100 Amp 41 710-0599 Self-tapping Screw, 1/4-20 x .5 42 736-0222 Lock Washer, 1/4 43 683-0304 Lower Frame Assembly 44 725-1706 12-Volt Battery, 270 CCA 45 710-0703 Carriage Screw 1/4-20 x 0.75 46 712-0271 Hex Sems Nut, 1/4-20 47 712-3087 Wing Nut, 1/4-20 48 732-1165 Extension Spring, .50 x 5.0 49 710-3180 Hex Cap Screw, 5/16-18 x 1.75 50 750-0956 Spacer Cup 51 710-3029 Hex Head Cap Screw, 7/16-20 x 1.25 52 736-0171 Lock Washer, 7/16 53 736-0322 Flat Washer, .450 x 1.25 54 756-0982B Engine Pulley, 3.56 OD x 5.56 55 754-0497 PTO Belt 56 783-0653D Steering Support Bracket 57 711-1044 Keeper Pin, 5/16 x 4.75 58 738-1132 Shoulder Screw 1/4-20

PA RT

NO.

DESCRIPTION

NOTE: For painted parts, please refer to the list of color codes below.

Red: 0638

Oyster Gray: 0662

Powder Black: 0637

Models D609G, G609G & X609G

39 24

Models D609G, G609G & X609G

REF.

NO.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

PART NO. DESCRIPTION

16606 Bracket: Retainer Hook

618-0565 Spindle Assembly: Pulley

683-0198E Deck Assembly

683-0254 Deck Hanger Bracket LH

683-0440 Brake Assembly: deck

710-0520 Hex Screw 3/8-16 x 1.5

710-0528 Hex Screw 5/16-18 x 1.25

710-0604A TT Screw 5/16-18 x 0.625

710-0650 TT Screw 5/16-18 x 0.875

710-0751 Hex Screw 1/4-20 x 0.620

710-1238 Hex Washer Head Screw

710-1830 TT Screw 1/4-20 x 4.0

710-3151 Hex Screw 5/8-18 x 4.25

710-3180 Hex Screw 5/16-18 x 1.75

711-1534 Pin

712-0337 Hex Nut 5/8-18

712-0417A Flange Nut 5/8-18

712-0431 Flange Lock Nut

712-3004A Flange Lock Nut

712-3006 Hex Nut 1/4-20

712-3010 Hex Nut 5/16-18

712-3027 Lock Nut 1/4-20

714-0470 Cotter Pin

716-3020 Snap Ring

717-1553A Gear: Deck Adjustment

726-0233 Push Nut

731-2486 Belt Cover

REF.

NO.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.

51.

52.

53.

PART NO. DESCRIPTION

732-0306 Compression Spring

732-0470A Extension Spring

732-1165 Extension Spring

734-0973 Deck Wheel

736-0105 Bell Washer

736-0119 Lock Washer

736-0140 Flat Washer

736-0158 Lock Washer

736-0162 Flat Washer

736-0270 Bell Washer

738-0373 Sholder Spacer

741-0524 Bearing

742-0616 Blade

746-0970 Brake Cable

747-1116 Deck Release Rod

748-0331 Shoulder Spacer

750-0932A Spacer

754-0497 V-Belt

754-0498 V-Belt

756-0627B Idler Pulley

756-1202 Double Pulley

783-1025 Chute Stop

783-1291 Idler Bracket

712-3087 Wing Nut

710-0134 Carriage Screw

731-2363 Mulch Plug

Red: 0638

Oyster Gray: 0662

Powder Black: 0637

Model U609H

29 43

Model U609H

REF. NO.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

PART NO. DESCRIPTION

16606 Retainer hook: bracket

17116 Deck Brake Assembly

17258C Belt Cover RH

17982 Spindle Plate

618-0240A Spindle Assembly

618-0594 Spindle Assembly: Double Pulley

683-0254 Deck Hanger Bracket LH

683-0265C Deck Assembly

710-0167 Carriage Screw 1/4-20 x 0.5

710-0344 Hex Screw, Special 3/8-16 x 1.5

710-0501 Hex Screw 1/4-20 x 2.0

710-0514 Hex Bolt 3/8-16 x 1.0

710-0528 Hex Bolt 5/16-18 x 1.25

710-0599 TT Screw 1/4-20 x 0.5

710-0650 TT Screw 5/16-18 x 0.875

710-0703 Carriage Screw 1/4-20 x 0.75

710-0751 Hex Bolt 1/4-20 x 0.620

710-0805 Hex Screw 5/16-18 x 1.5

710-1260A LD Screw 5/16-18 x 0.75

710-3180 Hex Screw 5/16-18 x 1.75

711-0993 Belt Guard Pin

711-1554 Pin

712-0271 Sems Nut

712-0417A Hex Flange Nut

712-0431 Lock Nut

712-3004A Lock Nut

712-3006 Hex Nut 1/4-20

712-3010 Hex Nut 5/16-18

712-3027 Lock Nut 1/4-20

714-0470 Cotter Pin

717-1553A Gear: Deck Adjustment

REF. NO.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.

51.

52.

53.

54.

55.

56.

57.

58.

59.

60.

61.

62.

PART NO. DESCRIPTION

726-0233 Push Nut

732-0306 Compression Spring

732-0429A Extension Spring

732-594A Extension Spring

732-0934 Extension Spring

732-1165 Extension Spring

734-0973 Deck Wheel

736-0105 Bell Washer .375 x .870 x .063

736-0119 Lock Washer

736-0140 Flat Washer

736-0270 Bell Washer

736-0418A Flat Washer

738-0347 Shoulder Spacer

738-0373 Shoulder Screw

746-1107 Cable: Bracket

747-1116 Rod: Deck Release Handle

748-0234 Spacer

750-1320 Spacer

754-0349 V Belt

754-0486A V Belt

756-0627B Idler Pulley

783-0139A Idler Bracket

783-0141 Deck Skirt: Center

783-0142 Deck Skirt RH

783-1025 Chute Stop

783-1348 Belt Cover LH

710-0578 Machine Screw

736-0173 Flat Washer

712-3006 Hex Nut

712-3087 Wing Nut

731-1636 Mulch Plug

Red: 0638

Oyster Gray: 0662

Powder Black: 0637

MANUFACTURER’S LIMITED WARRANTY FOR:

The limited warranty set forth below is given by Troy-Bilt LLC with respect to new merchandise purchased and used in the United States, its possessions and territories.

Troy-Bilt LLC warrants this product against defects for a period of two (2) years commencing on the date of original purchase and will, at its option, repair or replace, free of charge, any part found to be defective in materials or workmanship. 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 Troy-Bilt LLC for use with the product(s) covered by this manual will void your warranty as to any resulting damage.

Normal wear parts or components thereof are subject to separate terms as follows: All normal wear parts 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 materials or workmanship of OTHER component parts. Normal wear parts and components include, but are not limited to: batteries, belts, blades, blade adapters, grass bags, rider deck wheels, seats, snow thrower skid shoes, shave plates, auger spiral rubber, and tires.

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, check your Yellow Pages, or contact Troy-Bilt LLC at P.O. Box 361131, Cleveland, Ohio 44136-0019, or call 1-866-840-6483 or 1330-558-7220, or log on to our Web site at www.troybilt.com.

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. Refer to applicable manufacturer’s warranty for terms and conditions.

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

rate one year warranty.

c. Routine maintenance items such as lubricants, filters,

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

d. Troy-Bilt LLC does not extend any warranty for

products sold or exported outside of the United States, its possesions and territories, except those sold through Troy-Bilt LLC’s authorized channels of export distribution.

e. Parts that are not genuine Troy-Bilt parts are not

covered by this warranty.

f. Service completed by someone other than an

authorized service dealer is not covered by this warranty.

g. Transportation charges and service calls are not

covered.

No implied warranty, including any implied warranty of merchantability of 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, 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 Troy-Bilt LLC. During the period of the warranty, the exclusive remedy is repair or replacement of the product as set forth above.

The provisions as set forth in this warranty provide the sole and exclusive remedy arising from the sale. TroyBilt LLC shall not be liable for incidental or consequential loss or damage including, without limitation, expenses incurred for substitute or replacement lawn care services or for rental expenses to temporarily replace a warranted product.

Some states do not allow the exclusion or limitation of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions or limitations 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 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 misuse or inability to use the product.

This limited warranty shall not extend to anyone other than the original purchaser or to 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.

Troy-Bilt LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019; Phone: 1-866-840-6483, 1-330-558-7220

Troy-Bilt D609G, U609H, G609G, X609G Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual