Troy-Bilt 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 net 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-BILTLLC.P.O.BOX361131,CLEVELAND,OHIO44136-0019

PRINTED IN U.S.A. FORM NO. 770-10490A

(12/2001)

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TABLEOFCONTENTS

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

FINDINGMODELNUMBER

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 Numbe D (Serial Number)

Www.troybiIt.comCLEVELAND, OH44136

330-558-7220 866-840-6483

Copy the model number here:

Copy the serial number here:

ENGINEINFORMATION

The engine manufacturer is responsible for all engine-related issues with regards to performance, power-

rating, specifications, warranty and service. Please refer to the engine manufacturer's Owner's/Operator's Manual packed separately with your unit for more information.

CALLINGCUSTOMERSUPPORT

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.

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SECTION1: IMPORTANTSAFEOPERATIONPRACTICES

_ 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.

GeneralOperation

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 close- fitting 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.

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23.Mufflerandenginebecomehotandcancausea burn.Donottouch.

24.Checkoverheadclearancescarefullybeforedriving underlowtreebranches,wires,dooropeningsetc., wheretheoperatormaybestruckorpulledfromthe unit,whichcouldresultinseriousinjury.

25.Disengageallattachmentclutches,depressthe brakepedalcompletelyandshiftintoneutralbefore attemptingtostartengine.

26.Yourmachineisdesignedtocutnormalresidential grassofaheightnomorethan10".Donotattempt tomowthroughunusuallytall,drygrass(e.g., pasture)orpilesofdryleaves.Drygrassorleaves maycontacttheengineexhaustand/orbuildupon themowerdeckpresentingapotentialfirehazard.

27.Useonlyaccessoriesandattachmentsapproved forthismachinebythemachinemanufacturer.

Read,understandandfollowallinstructions providedwiththeaccessoryorattachment.

28.Dataindicatesthatoperators,age60yearsand above,areinvolvedinalargepercentageoftractor- relatedinjuries.Theseoperatorsshouldevaluate theirabilitytooperatethetractorsafelyenoughto protectthemselvesandothersfromseriousinjury.

29.Ifsituationsoccurwhicharenotcoveredinthis manual,usecareandgoodjudgment.Contactyour

dealerforassistance.

SlopeOperation

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. De:

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.

DoNot

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. Over- speeding 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"

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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.

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.

Towing

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 HandlingOfGasoline

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 andtighten securely.

j. If gasoline is spilled, wipe itoff 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.

I. 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.

GeneralService

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 issubjected 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 safetyF

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 interlocksystem 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.

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10.Neverattempttomakeadjustmentsorrepairsto themachinewhiletheengineisrunning.

11.Grasscatchercomponentsandthedischarge coveraresubjecttowearanddamagewhichcould exposemovingpartsorallowobjectstobethrown. Forsafetyprotection,frequentlycheckcomponents andreplaceimmediatelywithoriginalequipment manufacturer's(O.E.M.)partsonly,listedinthis manual."Useofpartswhichdonotmeetthe originalequipmentspecificationsmayleadto improperperformanceandcompromisesafetyF

12.Donotchangetheenginegovernorsettingsor over-speedtheengine.Thegovernorcontrolsthe

Label shape may vary by tractor model. Label contentsdo notvary.

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.

YourResponsibility

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.

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I,LI

..I

I.LI

SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE

A POWER POLE

A CORNER OFA BUILDING

OR A FENCE POST

_IL 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). 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.

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SECTION3: SETTINGUPYOURTRACTOR

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

position.

AttachingtheBatteryCables

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.

4_b 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.

RemovingShippingBrace

,_ 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:The shipping brace, used for packaging 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.

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.

GasandOilFill-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 inthe separate engine operator/owner manual packed with your tractor. Read instructions carefully.

Mulch Plug (if equipped)

Figure 2

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.

,_ 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.

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SECTION4: KNOWYOURLAWNTRACTOR

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.

A Systemslndicator Monitor/Hour Meter B PTO (Power Take-off) Lever

C Choke Control D Shift Lever

E Cup Holder F Throttle Control Lever

G Parking Brake Button

_ NOTE: Steering Wheel not shown for clarity.

Figure 3

H Cruise Control Button

I Ignition Switch J Brake Pedal

K Drive Pedal L Deck Lift Lever

M Seat Adjustment Lever

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ThrottleControlLever

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.

/ Choke*

*some models only

IMPORTANT:When operating the tractor with the cutting deck engaged,

make sure that the throttle lever is always in the FAST

(rabbit) position.

ChokeControl

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

Choke*

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.

BrakePedal

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.

I(o)

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 On/Lights switch and turn clockwise Off

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 ignitionswitch is also

used to operate the tractor's headlights. Refer to Operating The Headlights on page 14 for details.

WARNING: Never leave a running machineunattended. 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: Always set the parking brake when leaving the tractor unattended.

SystemsIndicator Monitor/ HourMeter Your tractor isequipped

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 runningand records the

actual hours oftractor operation.

It is normal for the oil light and the battery light to

illuminate whilethe engine is cranking, but ifeither

illuminates while the

engine is running, follow the steps given below. If the brake lightor 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

(disengaged) position.

Oil Light Stop the tractor immediately and

check the crankcase oil level as

instructed in the engine manual. Add

oilas required.

Battery Light Indicates that the battery needs to be

charged or that the engine's charging

system is notgenerating sufficient

B= ery Light Oil Light

Hour Meter

PTO Light Brake Light

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amperage. Refer to Battery charging procedure on page 21 or have the engine's charging system checked by

an authorized dealer.

CupHolder The tractor's cup holder is located on the fender to the

left of the seat and rear of the parking brake lever.

PTO(PowerTake-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. ElectricPT0 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.

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.

_,F

Knob

IMPORTANT: Never force the shift lever. Doing so

may result in serious damage to the transmission.

SeatAdjustmentLever

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.

ParkingBrakeButton

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 wilt 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: Always set the parking brake when leaving the tractor unattended.

DeckLift 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.

CruiseControlButton

The cruise control button is located on the dash panel

of the tractor to the left of

the ignition switch. Push ;i;

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.

Page 12

SECTION5: OPERATINGYOURLAWNTRACTOR

_ WARNING: Read, understand, and follow all

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

SafetyInterlockSwitches

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.

IMPORTAWI': 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.

Settingthe CuttingHeight

• 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 _A- inch and I/2-inch above the ground when the tractor is on a smooth, flat surface such as a driveway.

_ll 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.

StartingtheEngine

NOTE: Refer to page 8 of this manual for Gasoline and

Oil Fill-Up instructions.

• Insert the tractor key into the ignition switch.

• 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.

IMPORTAWI': 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 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.

WARNING

AV010SERIOUSINJURYORDEATH

• GO UP AND DOWN SLOPES, NOT ACROSS.

• AVOIDSUDDEN 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 OFE

• LOOK DOWN AND BEHIND BEFORE AND WHILE BACKING.

• KEEP SAFETY DEVICES (GUARDS, SHIELDS, AND SWITCHES) tN 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* tNG HANDS OR FEET NEAR BLADE(S).

• BEFORE LEAVING OPERATOR'S POSmON, DISENGAGE BLADE(S), PLACE THE SHIFT LEVER IN NEUTRAL, ENGAGE

BRAKE LOCK, SHUT ENGINE OFF AND REMOVE KEY.

READOPERATOR'SMANUAL

Stoppingthe Engine

• Ifthe 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.

_ll WARNING: Ifyou 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

Page 13

DrivingtheTractor

IMPORTANT:Avoid sudden starts, high speed and

sudden stops.

,_ 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.

• 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 move the shift lever from

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.

EngagingtheParkingBrake

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 inthe "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.

DrivingonSlopes

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.

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.

Settingthe CruiseControl

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 untilthe desired

speed isachieved.

• Lightlydepress the cruise control button.

• Holding the cruise control button in, liftyour foot from the drive pedal (you should feel the cruise

latch engage).

• Once engaged, the cruise control button and the

drive pedal will lockin the "down" position, and the

tractor will maintain the same forward speed.

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.

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

1. Depress the brake pedal to disengage the cruise controland 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 acomplete stop.

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

UsingtheDeckLiftLever

• To raise the cutting deck, move the deck lift lever to

the left, then place it in the notch best suited for your application. Refer to Setting The Cutting

Height earlier in this section.

EngagingthePTO

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.

Page 14

• 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, ff 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 engine wilt automatically shut off if 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.

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.

• 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

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 itto 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.

Plastic Wing Nut Mulch Plug

Figure 4

OperatingtheHeadlights

To turn on the headlights:

• Start the engine .Turn the key one notch counter-

clockwise 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.

Page 15

SECTION6: MAKINGADJUSTMENTS

_ 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.

• 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.

Sidetn Side

LevelingtheDeck

NOTE: Check the tractor's tire pressure before

performing any deck leveling adjustments. Refer to Tires on page 21 for information on tire pressure.

FrnntTn Bear

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.

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.

At Lock

Nuts

Stabilizer

Bracket

Deck

FRONTTO REAR SIDE TO SIDE

Figure 5

Page 16

SeatAdjustment

,_ 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.

ParkingBrakeAdjustment

,_ 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.

Hex Nut --___

Set Gap

at .011"

Brake Disc Compression

Spring

NOTE: View shown from beneath tractor.

Transmission

Figure 6

• 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.

SteeringAdjustment

If the tractor turns tighter in one direction than the other, or ifthe 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 Grease Fitting Pivot Bar Lock Washer

Dr_g 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 tiretoe-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.

Page 17

SECTION7: MAINTAININGYOURLAWNTRACTOR

_ 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.

CleaningEngineandDeck

• 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.

Maintainingthe 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 inthe engine manual. Read and follow instructions carefully.

ChangingEngineOil

• 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).

IMPORTANT: Refer to the engine manual for the proper weight of motor oil to be used.

Oil RII

Cap

Oil Drain

Hose

Protective Cap

Oil Fill Tube

Oil Drain Valve

Drain Port

Figure 8

AirCleaner

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

engine manual.

SparkPlug

• 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.

PivotPoints& Linkage

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

RearWheels

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.

FrontWheels

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.

Page 18

SECTION8: SERVICE

_lb 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.

CuttingBlades

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

,_ WARNING: Protect your hands by using

heavy gloves or a rag to grasp the blade.

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.

Hex Flange Nut

Spindle Assembly

Figure 9

• Use a 15/16" wrench toremove 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 within5/8" ofthe wind wing radius, or

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:A poorly balanced blade will cause 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.

Blade Separation

Worn Blade Edge

Wind Wing

Figure 10

RemovingCuttingDeck

• 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.

Page 19

Figure 11

• Move the deck lift lever intothe 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 self-

tapping 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.

ChangingTransmissionDriveBelt

ChangingDeckBelts

,_ WARNING: Be sure to shut engine off,

remove ignition key, disconnect spark plug

wire(s) and ground against engine before starting this job.

IMPORTANT:The V-belts, found on your tractor, are

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)

specially designed to engage and disengage safely. A

Engine Pulley

Left Hand Pulley

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

Deck belt (Bottom)

m PTO belt (Top)

rotting are present.

PTO Idler Bracket

Right Hand Pulley

(beneath belt guard)

Deck Idler Pulley

Center Pulley

NOTE: Left hand belt cover not shown for clarity.

Self-Tapping Screws

Figure 12

Page 20

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 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

• 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 firsL

followed by the POSITIVE (red) wire. Re-install in

reverse order.

UpperDrive 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.

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.

Battery Tray

Variable Speed Opening Shift Lever

Pulley Rear Idler Pulley

Drive Belt (Lower)

Drive Belt (Upper)

Keeper PinsI

I I

Engine Pulley

Transmissio_

Transmission Pulley

Front of Tractor

NOTE: V_ewshownfrom above tractor.

Figure 13

Page 21

• 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

Frontof 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.

• Reassemble by following the above steps in reverse order.

Idler Adj. Rod Place wrenches here

Drive Pedal Speed Control

Return Spring 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.

Battery

The battery is sealed and ismaintenance-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.

• Ifremoving the battery for any reason, disconnect

the NEGATIVE (black) wire from its terminal first, followed by the POSITIVE (red) wire. When re-

installing the battery, always connect the POSITIVE (red) wire to its terminal first, followed by the

NEGATIVE (black) wire.

IMPORTANT: Be certain that wires are connected to the 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 12-

volt charger for a minimum of one hour at six amps.

Page 22

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.

Fuse

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

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.

IMPORTANT: Always use a fuse with the same amperage capacity for replacement.

SECTION9: OFF-SEASONSTORAGE

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

_b 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.

4_ 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.

Follow the instructions in the Service, Storage & Specifications section ofthe Briggs & Sfratton Operator/Owner Manual (or Koh/erengines Owner's

Manual) for proper engine care prior to storing your tractor.

Page 23

SECTION10: TROUBLESHOOTING

Trouble

Engine fails to start

Engine runs erratic

Possible Cause(s) 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. 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. 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.

Corrective Action 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 pre- cleaner, 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. Remove spark plug and reset the gap to .030". Replace spark plug. Set plug gap to .030". Replace air cleaner cartridge/element or clean pre- cleaner, 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.

Page 24

SECTION11:PARTSLISTFORMODELSD609,G609,U609& X609

28. 5_- 11

6 '

Page 25

ModelsD609,G609,U609&X609

REF. PART NO. NO.

1 783-1346 2 710-0599 3 710-0528 4 710-0924 5 710-1017 6 725-1741 7 726-0272 8 710-0642

9 712-0292 10 736-0270 11 725-1976 12 712-3004A 13 731-2119A 14 731-0511 15 725-0175 16 746-1085 17 783-0783 18 783-0784 19 783-0785

20 731-2637 21 747-1162A 22 625-0051 23 710-0604A 24 751-0603 25 751-0658C

DESCRIPTION REF. PART NO.

NO.

Grill Support Bracket (9-style) 751-0659A

Self-tapping Screw, 1/4-20 x .5 Hex Cap Screw, 5/16-18 x 1.25 26 725-1745

Phillips Pan Screw, 1/4-20 x .75 725-1744

Truss Phillips Screw, 1/4-20 x .625 27 710-0895

Ignition Switch 28 710-3217

Clamp, 9/16 29 712-0142

Self-tapping Screw, 1/4-20 x .75 30 731-1857 U4ype Speed Nut, 1/4-20 31 731-2122C

Bell Washer, .265 x .75 x .062 32 731-2226 Systems Indicator Monitor 33 731-2227

Hex Nut, 5/16-18 34 736-0142 Grille (9-style) 35 747-1196 Trim Strip, 4 36 749-1087A Cable Tie, 3/16 x .05 x 7.4 37 712-3010 Choke Knob/Cable (Model G609G) 38 731-2270

Hood (9-style) N/A

RH Side Panel (9-style) 39 726-3046

LH Side Panel (9-style) 40 736-0119

Headlight Lens (9-style) 41 726-0201

Hood Hinge Rod 42 736-3078

Headlight Assembly 43 710-1238

Self-tapping Screw, 5/16-18 x .625 629-0469A

Fuel Cap 629-1071

Fuel Tank, Three-gallon

DESCRIPTION

Fuel Tank, Two-gallon (Model D609G)

Ignition Key w/plastic cover Ignition Key w/o plastic cover Self-tapping Screw, 1/4-15 x .75

Truss Phillips Screw, #8-32 x .375

Hex Nut, #8-32

Throttle Control Knob

Dash Panel, 8/9-style, Manual PTO Cruise Control Button

Parking Brake Button Flat Washer, 9/32 x 1/2 x 1/16

Brake/Cruise Pivot Rod Dash Support Tube

Hex Nut, 5/16-18 Hood Plenum (Model G609G) Hood Plenum (Model D609G) Ratchet Clip

Lock Washer, 5/16 Speed Nut, .3125

Flat Washer, .349 x 1.0 x .063 Screw, 5/16-18 x .875 (Grade 5) Headlight Wire Harness (Not Shown

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

Page 26

ModelsD609,G609,U609&X609

48. 37 44

-6

Page 27

ModelsD609,G609,U609&X609

REE PART

NO. NO.

1 747-1130A

2 683-0197

3 711-0332 4 712-0206 5 712-0431 6 712-3004A 7 712-3083 8 714-0104

9 714-0145 10 716-0106 11 720-0311 12 732-0874 13 732-1184 14 736-0275 15 736-0921 16 736-3019 17 736-3084 18 738-0138A 19 738-0143

20 741-0225 21 741-0715 22 746-0968 23 747-1111 24 756-1154 25 783-0678A 26 783-0720A 27 710-0260A 28 710-0604A

DESCRIPTION REP. PART

NO. NO.

Deck Stabilizer Rod 29 710-0895 Lift Shaft Assembly 30 731-1990

Clevis Pin, .5 x .78 31 731-2104B Hex Nut, 1/2-13 32 736-3078

Flange Lock Nut, 3/8-16 33 783-0677 Flange Lock Nut, 5/16-18 34 783-0685B

Hex Nut, 1/2-13 35 783-1489 Internal Cotter Pin 36 710-1268

Internal Cotter Pin 37 712-3027 E-ring 38 720-0309A

Handle Grip 39 731-1989 Torsion Spring 40 732-0499 Extension Spring, .872 x 3.4 41 736-0175 Flat Washer, 5/16 42 736-0204

Lock Washer, 1/2 43 738-0137A Flat Washer, .31 x 1.062 x .134 44 738-1007 Flat Washer, .51 x 1.12 x .06 45 783-0611

Hex Cap Screw, 5/16-18 x .62 46 783-0738 Shoulder Screw, 3/8-16 47 783-0739

Hex Flange Bearing 48 783-0753 Snap Flange Bearing 49 757-0348A

Lift Cable, 16.16 50 735-0656 Lift Handle 51 735-0657

Roller Pulley 726-3046 Arm Lift 52 714-0111

Deck Stabilizer Bracket 53 731-0511 Carriage Bolt, 5/16 x .62 54 783-0209A

Self-tapping Screw, 5/16-18 x.625 55 726-0201

DESCRIPTION

Self-tapping Screw, 1/4-15 x .75 Lift Lever Cover

Shift Lever Cover w/Cup Holder Flat Washer, .349 x 1.0 x .063

Lift Adjustment Bracket Fender

Seat Mounting Bracket Screw, #10-16 x .375

Hex Flange Lock Nut, 1/4-20 Seat Adjuster Grip

Spacer

Compression Spring, .41 x 1.5

Spring Washer, .265 x .562 x .025 Flat Washer, .344 x .62 x .03

Shoulder Screw, .340 x .285,1/4-20 Shoulder Screw, .50 x .50, 3/8-16

Seat Stop Seat Pivot Bracket

Seat Adjustment Lever Seat Adjustment Selector

High Back Seat, Black RH Foot Pad

LH Foot Pad Foot Pad Clips (Not Shown)

Cotter Pin Trim Strip

Seat Lift Bracket Speed Nut

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

Page 28

ModelsD609,G609,U609&X609

42 46

21 38

37,

.30

Page 29

ModelsD609,G609,U609&X609

REF.

NO.

9 10 11 12 13 14 15 16

17 18

20 21

22 23

PART

NO. 731-1291A 710-1238 783-0726B 783-0727A 783-0728 710-0723

DESCRIPTION

Pivot Bar End Cap Self4apping Screw, 16-18 x .625

RH Pivot Support Bracket LH Pivot Support Bracket

Pivot Bar Bracket Hex Cap Screw, 3/8-16 x 1

REE PART

NO. NO.

25 638-0019A 26 638-0020A

27 683-0128A

28 712-0431 29 714-0162

30 726-0214

DESCRIPTION

LH Axle Assembly, .625 Diameter RH Axle Assembly, .625 Diameter

Pivot Bar Flange Lock Nut, 3/8-16

Cotter Pin

Push Cap, .625 711-1408 711-1655 712-0240 712-0241 712-0431 712-0459 712-3004A

RH Drag Link LH Drag Link Jam Nut, 7/16-20

Hex Nut, 3/8-24 Flange Lock Nut, 3/8-16

Flange Lock Nut, 7/16-20 Flange Lock Nut, 5/16-18

31 736-0162 33 736-0285

34 738-1011 35 741-0659

36 634-0105A

634-0172

734-0255

Flat Washer, .64 x 1.0 x .12

Flat Washer, .635 x 1.589 x .06

Shoulder Screw, .5 x 2.2, 3/8-16

Flange Bearing, .632 ID x .937 OD

Wheel Assembly Complete, 15 x 6 x 6

Rim Only w/Plastic Bearing

Air Valve (Not Shown) 717-1550D 717-1554 723-0448A 736-0169 736-3084 738-1001A 741-0475 741-0656 738-0372B 731-2624 731-2625

Steering Gear, 11/90 Ratio Steering Pinion Gear

Ball Joint, 7/16-20 Lock Washer, 3/8 Flat Washer, .51 x 1.12 x .06

Steering Shaft, .625 OD x 24.4 Plastic Bushing, .38 ID Hex Flange Bearing, 5/8 Shoulder Spacer, .38 ID Steering Wheel, 13.25 Steering Wheel Cap

734-1731

37 734-2290A 38 783-0653D 39 738-0143

40 736-0331

41 710-1260A

42 736-0242 43 710-0643

44 783-0656A 45 783-0657A 46 736-3004

Tire Only, Square Shoulder

Hub Cap Steering Support Bracket Shoulder Screw, 3/8-16 Bell Washer, .39 x 1.13 x .062 Self4apping Screw, 5/16-18 x .75 Bell Washer, .34 x .872 Hex Bolt, 5/16-18 X 1

Axle Bracket RH

Axle Bracket LH

Flat Washer

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

Page 30

ModelsD609,G609,U609& X609

39j

_16

•73

_-23

81\

Page 31

ModelsD609,G609,U609&X609

REE PART

NO. NO.

1 783-1015 2 17840 3 618-0551 4 631-0009 5 647-0045 6 656-0048 7 656-0051A 8 683-0251

9 710-0176 10 710-0227 11 710-0347 12 736-0272 13 710-0604A 14 710-0642 15 710-3011 16 711-0677 17 712-0241 18 712-0378 19 712-0431 20 712-3017 21 712-3004A 22 712-3008 23 714-0111 24 714-0149B 25 723-3018 26 725-1644 27 726-0320 28 732-0384 29 732-0525

30 732-0716 31 732-0963

32 736-0105 33 736-0140 34 736-0169 35 736-3OO8

36 736-0407 37 736-3010 38 738-0322 39 747-1122

40 747-1123A 41 747-1127

42 747-0047A 43 711-0736 44 738-0372B 45 754-0467 46 754-0468

DESCRIPTION

Shift Lever Support Transaxle Mounting Bracket Single-speed Transmission Assembly

Shifter Knob Shift Lever Variable-speed Pulley Assembly

Transmission Pulley, 8.5 x .5-36 Double-idler Bracket

Hex Cap Screw, 5/16-18 x 2.75 Self-tapping Screw, #8-18 x .5 Hex Cap Screw, 3/8-16 x 1.75

Flat Washer, .51 x 1.0 x .060 Self-tapping Screw, 5/16-18 x .625

Self-tapping Screw, 1/4-20 x .75 Hex Cap Screw, 3/8-16 x 2.25

Ferrule, 5/16-18 Hex Nut, 3/8-24

Hex Nut, 7/16-20 Flange Lock Nut, 3/8-16 Hex Nut, 3/8-16 Flange Lock Nut, 5/16-18 Jam Nut, 3/8-16

Cotter Pin Internal Cotter Pin

Ball Joint Short Spring Switch

Insulator Nut Plate Extension Spring, .62 Dia. x 6.12

Compression Spring Clip

Extension Spring, .59 OD x 4 Extension Spring, .50 Dia. x 6.37 (hooks to flange, 783-0650, in frame)

Bell Washer, .401 x .87 x .063 Flat Washer, .385 x .62 x .063 Lock Washer, 3/8 Flat Washer, .344 x .760 x .120 Bell Washer, .46 x 1.0 x .602 Flat Washer, .407 x .812 x .136 Shoulder Screw, .625 x .217 Brake Rod Belt Guard

Idler Adjustment Rod, 3/8

Shift Rod Adjustment Ferrule, 1/4-20 x 1.0

Shoulder Spacer, .38 ID Lower Drive Belt

Upper Drive Belt

REE PART

NO. NO.

47 756-0981 48 783-1016B 49 783-0667B 50 783-0669 51 736-0430 52 647-0031 53 647-0032 54 683-0266 55 714-0470 56 711-0736 57 711-1363 58 714-0104 59 732-0437 60 732-0955 61 735-0662 62 735-3049 63 736-0142 64 736-0187 65 736-0204 66 738-0155 67 738-0507B 68 741-0225 69 741-3065A 70 747-1137 71 747-1138 72 748-0413 73 736-0275 74 783-0653D 75 783-0732 76 783-0773 77 783-0780A 78 683-0304 79 783-1031A 80 736-0242 81 710-0627 82 634-0105A

634-0177 634-0070 734-0255

734-1730 83 734-2290A 84 710-0809 85 750-0556 86 710-0650 87 710-1260A 88 747-1285 89 748-0415B

DESCRIPTION

Flat Idler, 2.75 OD Speed Control Rod Bracket Transmission Torque Bracket

Idler Bracket Flat Washer, .350 x 1.59 x .062

Brake Control Assembly Speed Control Assembly Drive Pedal Assembly

Cotter Pin, 1/8x 1.25 Ferrule, 1/4-20

Pin, 3/8-16 x 2.43 Cotter Pin

Compression Spring, .34 OD x 1.0 Extension Spring, .50 OD x 1.41

Drive Pedal Pad Brake Pedal Pad Flat Washer, .281 x .5 x .063 Flat Washer, .64 x 1.24 x .06 Flat Washer, .344 x .062 x .03 Shoulder Screw, .437 x 1.62 Shoulder Screw, .5 x .434

Hex Flange Bearing Split Hex Flange Bearing

Cruise Control Rod Brake Lock Control Rod

Cruise Latch Flat Washer, .344 x .688 x .065

Stearing Support Bracket Drive Lock-out Bracket

Brake Pedal Neutral Return Bracket

Lower Frame Assembly Hitch Plate

Bell Washer, .34 x .872 Hex Cap Screw, 5/16-24 x .75

Wheel Assembly (Model D609G) Wheel Assembly (Model U609H) Rim Only Air Valve (Not Shown) Tire Only, 20 x 8 x 8, Square Shoulder Hub Cap Self-tapping Screw, 1/4-20 x 1.25 Spacer Self-tapping Screw, 5/16-18 x .875 Self-tapping Screw, 5/16-18 x .75

Shift Rod Spacer

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

Page 32

ModelsD609,G609,U609& X609

REE PART

NO. NO.

1 716-0231 2 721-0338 3 711-1431 4 741-0340 5 736-0495 6 717-1362 7 717-1363 8 750-1234 9 718-0228

10 741-0525

11 719-0394 12a 736-0336 12b 736-0337 12c 736-0349

13 736-0519

14 741-0336

15 741-0337

16 750-1238

17 611-0133

18 618-0424

19 661-0006

20 710-1325 21 710-1206 22 717-0678 23 732-0863 24 741-0862 25 761-0202 26 711-1430 27 716-0108 28 717-1464 29 719-0391A 30 736-0723

DESCRIPTION

E-Ring, .75 Seal, .75 x 1.0 x .125

Drive Shaft Sleeve Bearing, .75 x .1.0 x 1.0

Thrust Washer, 1.0 x .632 x .0 42-Tooth Bevel Gear

42-Tooth Bevel Gear

Spacer, .633 x 1.0 x .513

Clutch Collar

Needle Bearing, .625 x .875 Lower Housing

Flat Washer, 5/8 x 1.0 x .030* Flat Washer, 5/8 x 1.0 x .040* Flat Washer, 5/8 x 1.0 x .020* Flat Washer, .70 x 1.125 x .031

Flange Bearing, 5/8 x 3/4 x 3/4 Flange Bearing, 5/8 x 3/4 x 15/16

Spacer, .635 x 1.0 x .27 Detent Shaft Assembly

Differential Assembly Brake Assembly Self-tapping Screw, 1/4-20 x 1.625 Self-tapping Screw, 1/4-20 x 2.375

Brake Pad

Compression Spring

Detent Ball Brake Disc

Input Shaft Retaining Ring, .437

14-Tooth Bevel Pinion Upper Housing

Thrust Washer, .635 x 1.25 x .042

j "

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

Page 33

ModelsD609,G609,U609&X609

I (for choke)

_13

4 27

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

REF.

NO.

1 2 3 4 5

6 7

8 9

10 11

12 13

14 15

PART

NO. DESCRIPTION

710-0227 710-0599 710-0604A

710-1237 710-1314A

710-1315 712-3017 721-0460 726-0205 736-0119 736-0300 751B221535 751-0535 751-0564 751-0616

REP.

NO.

Self-tapping Screw, #8-18 x .5 16 Self-tapping Screw, 1/4-20 x .5 17 Self-tapping Screw, 5/16-18 x .625 18

Screw, #10-32 x .625 , 19 Socket Cap Screw, 5/16-18 x .625 20

Self-tapping Screw, 3/8-16 x 1.25 21 Hex Nut, 3/8-16 (Model G609G) 22

Exhaust Gasket (Model G609G) 23 Hose Clamp 24 Lock Washer, 5/16 25 Flat Washer (Model G609G) 26

Casing Clamp (Model G609G) 27 Fuel Line Hose 28

Muffler Deflector 29 Muffler, Twin Inlet (Model G609G) 30

751-0650 751-0651 751-3140

751-3141 751-3142

783-0615B 783-0625C

722-0263 746-1086 746-1084 751-0619 751B213146 751-0617 712-0271 721-0208

PART

NO. DESCRIPTION

RH Exhaust Pipe (Model G609G) LH Exhaust Pipe (Model G609G)

Oil Drain Valve Oil Drain Hose

Oil Drain Cap Muffler Heat Shield

Engine Heat Shield (Model G609G) Foam (fits over fuel line)

Throttle Cable (Model G609G) Throttle Cable (Model D609G)

Exhaust Pipe (Model D609G) Casing Clamp (Model D609G) Muffler, Single Inlet (Model D609G) Hex Sems Nut, 1/4-20 (for starter cable) Exhaust Gasket (Model D609G)

Page 34

ModelsD609,G609,U609& X609

34_ _38

16. 25

Page 35

ModelsD609,G609,U609&X609

REE PART

NO. NO.

1 647-0064 2 683-0450 3 710-0276 4 710-0520 5 710-0831 6 710-1238 7 712-0229 8 712-0431

9 712-3004A 10 712-3010 11 714-0470 12 726-0201 13 731-2111A 14 732-1170 15 732-0991A 16 736-0108 17 736-0119 18 736-0140 19 736-0275

20 736-3000 21 736-0331 22 736-3039 23 738-0372B

24 741-0708 25 747-1112D 26 747-1286A 27 748-0415B 28 756-0627B 29 756-1208

DESCRIPTION REF. PART

NO. NO.

PTO Engage Lever Assembly 30 783-0744A PTO Engage Plate Assembly 31 783-0891B Carriage Screw, 5/16-18 x 1.00 32 710-0604A Hex Cap Screw, 3/8-16 x 1.5 33 732-3080A Hex Cap Screw, 3/8-16 x 5.5 34 723-0444

Hex Head Washer Screw, 5/16-18 x .875 35 738-1020 Push Nut, 3/8 36 736-0407

Flange Lock Nut, 3/8-16 37 712-0459 Flange Lock Nut, 5/16-18 38 783-1031A

Hex Nut, 5/16-18 39 783-0349 Cotter Pin, 1/8 x 1.25 40 725-1426

Speed Nut, .3125 41 710-0599 PTO Knob 42 736-0222

Extension Spring, .75 x 6.75 43 683-0304 Belt Guard 44 725-1706

Flat Washer, .510 x .750 x .033 45 710-0703 Lock Washer, 5/16 46 712-0271

Flat Washer, .385 x .62 x .063 47 712-3087 Flat Washer, 5/16 48 732-1165 Flat Washer, .406 x .875 x .059 49 710-3180 Bell Washer, .39 x 1.13 x .062 50 750-0956

Flat Washer, .407 x .812 x .135 51 710-3029 Shoulder Spacer, .380 52 736-0171 Hex Split Flange Bearing 53 736-0322 PTO Engagement Handle 54 756-0982B Belt Keeper Rod 55 754-0497 Spacer, 3/8 x 1.54 56 783-0653D Idler Pulley, 3.5 57 711-1044 Idler Pulley, 4.0 58 738-1132

DESCRIPTION

Engagement Stop Deck Stop Self-tapping Screw, 5/16-18 x .625 Compression Spring, 1.28 x 3.5 Battery Strap

Shoulder Screw, .625 x .5, 7/16-20 Bell Washer, .45 x 1.0 x .062

Flange Lock Nut, 7/16-20 Hitch Plate

Battery Tray Solenoid, 12-Volt, 100 Amp

Self-tapping Screw, 1/4-20 x .5 Lock Washer, 1/4

Lower Frame Assembly 12-Volt Battery, 270 CCA Carriage Screw 1/4-20 x 0.75

Hex Sems Nut, 1/4-20 Wing Nut, 1/4-20

Extension Spring, .50 x 5.0 Hex Cap Screw, 5/16-18 x 1.75

Spacer Cup Hex Head Cap Screw, 7/16-20 x 1.25

Lock Washer, 7/16 Flat Washer, .450 x 1.25

Engine Pulley, 3.56 OD x 5.56 PTO Belt

Steering Support Bracket Keeper Pin, 5/16 x 4.75

Shoulder Screw 1/4-20

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

Page 36

ModelsD609G,G609G& X609G

21 e

1235

29 50 11

37 51

Page 37

ModelsD609G,G609G&X609G

REF. PART NO.

NO.

1. 16606

2. 618-0565

3. 683-0198E

4. 683-0254

5. 683-0440

6. 710-0520

7. 710-0528

8. 710-0604A

9. 710-0650

10. 710-0751

11. 710-1238

12. 710-1830

13. 710-3151

14. 710-3180

15. 711-1534

16. 712-0337

17. 712-0417A

18. 712-0431

19. 712-3004A

20. 712-3006

21. 712-3010

22. 712-3027

23. 714-047O

24. 716-3020

25. 717-1553A

26. 726-O233

27. 731-2486

DESCRIPTION

Bracket: Retainer Hook Spindle Assembly: Pulley

Deck Assembly Deck Hanger Bracket LH Brake Assembly: deck

Hex Screw 3/8-16 x 1.5

Hex Screw 5/16-18 x 1.25 TT Screw 5/16-18 x 0.625 TT Screw 5/16-18 x 0.875

Hex Screw 1/4-20 x 0.620

Hex Washer Head Screw TT Screw 1/4-20 x 4.0

Hex Screw 5/8-18 x 4.25

Hex Screw 5/16-18 x 1.75

Hex Nut 5/8-18

Flange Nut 5/8-18

REF. PARTNO.

NO.

28. 732-O3O6

29. 732-0470A

30. 732-1165

31. 734-0973

32. 736-0105

33. 736-0119

34. 736-0140

35. 736-0158

36. 736-0162

37. 736-0270

38. 738-0373

39. 741-0524

40. 742-0616

41. 746-0970

42. 747-1116

43. 748-0331

44. 750-0932A

DESCRIPTION

Compression Spring Extension Spring Extension Spring

Deck Wheel Bell Washer Lock Washer Flat Washer Lock Washer Flat Washer Bell Washer

Sholder Spacer Bearing

Blade Brake Cable Deck Release Rod

Shoulder Spacer

Spacer Flange Lock Nut Flange Lock Nut

Hex Nut 1/4-20 Hex Nut 5/16-18 Lock Nut 1/4-20

Cotter Pin

Snap Ring

Gear: Deck Adjustment

Push Nut Belt Cover

45. 754-O497

46. 754-O498

47. 756-0627B

48. 756-1202

49. 783-1025

50. 783-1291

51. 712-3087

52. 710-0134

53. 731-2363

V-Belt

Idler Pulley

Double Pulley

Chute Stop

Idler Bracket

Wing Nut

Carriage Screw

Mulch Plug

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

Page 38

ModelU609H

50\

29 14

38 39 • 9

1_ 4 16 9

16 55 18

60_ 59 _g g

62 _ 19 24

Page 39

ModelU609H

REF. PART NO. NO.

1. 16606

2. 17116

3. 17258C

4. 17982

5. 618-0240A

6. 618-0594

7. 683-0254

8. 683-0265C

9. 710-0167

10. 710-0344

11. 710-0501

12. 710-0514

13. 710-0528

14. 710-0599

15. 710-0650

16. 710-0703

17. 710-0751

18. 710-0805

19. 710-1260A

20. 710-3180

21. 711-0993

22. 711-1554

23. 712-0271

24. 712-0417A

25. 712-0431

26. 712-3004A

27. 712-3006

28. 712-3010

29. 712-3027

30. 714-0470

31. 717-1553A

DESCRIPTION

Retainer hook: bracket Deck Brake Assembly

Belt Cover RH Spindle Plate

Spindle Assembly Spindle Assembly: Double Pulley Deck Hanger Bracket LH Deck Assembly

Carriage Screw 1/4-20 x 0.5

Hex Screw, Special 3/8-16 x 1.5 Hex Screw 1/4-20 x 2.0

Hex Bolt 3/8-16 x 1.0 Hex Bolt 5/16-18 x 1.25

TT Screw 1/4-20 x 0.5 TT Screw 5/16-18 x 0.875

Carriage Screw 1/4-20 x 0.75

Hex Bolt 1/4-20 x 0.620 Hex Screw 5/16-18 x 1.5 LD Screw 5/16-18 x 0.75 Hex Screw 5/16-18 x 1.75

REF. PART NO. NO.

32. 726-0233

33. 732-0306

34. 732-0429A

35. 732-594A

36. 732-0934

37. 732-1165

38. 734-0973

39. 736-0105

40. 736-0119

41. 736-0140

42. 736-0270

43. 736-0418A

44. 738-0347

45. 738-0373

46. 746-1107

47. 747-1116

48. 748-0234

49. 750-1320

50. 754-0349

51. 754-0486A

DESCRIPTION

Push Nut

Compression Spring

Extension Spring

Deck Wheel

Bell Washer .375 x .870 x .063

Lock Washer

Flat Washer

Bell Washer

Flat Washer

Shoulder Spacer

Shoulder Screw

Cable: Bracket

Rod: Deck Release Handle

Spacer

V Belt

V Belt Belt Guard Pin 52. 756-0627B

Pin 53. 783-0139A Sems Nut 54. 783-0141

Hex Flange Nut 55. 783-0142 Lock Nut 56. 783-1025

Lock Nut 57. 783-1348 Hex Nut 1/4-20 58. 710-0578 Hex Nut 5/16-18 59. 736-0173

Lock Nut 1/4-20 60. 712-3006

Cotter Pin 61. 712-3087 Gear: DeckAdjustment 62. 731-1636

Idler Pulley

Idler Bracket

Deck Skirt: Center

Deck Skirt RH

Chute Stop

Belt Cover LH

Machine Screw

Flat Washer

Hex Nut

Wing Nut

Mulch Plug

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

Page 40

MANUFACTURER'S LIMITED WARRANTY FOR:

The limited warranty set fodh 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 net 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 Trey-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 net limited to: batteries, belts,

blades, blade adapters, grass bags, rider deck wheels, seats, snow thrower skid shoes, shave plates, auger spiral rubber,

and tires. ROW 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 1- 330-558-7220, or log on to our Web site at www.troybilt.cem.

This limited warranty does net 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 net 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 net genuine Troy-Bilt parts are net

covered by this warranty.

f. Service completed by someone other than an

authorized service dealer is net 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 ofthe 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. Troy-

Biit 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 ofthe 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.

ROW 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.BOX361131CLEVELAND,OHIO44136-0019; Phone:1-866-840-6483,1-330-558-7220

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

Specifications and Main Features

Frequently Asked Questions

User Manual