Troy-Bilt J609 User Manual

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Operator’s Manual

Automatic Lawn Tractors

Super Bronco™

Bronco™

(Models T609 & J609)

IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY

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.

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

PRINTED IN U.S.A.

FORM NO.

770-10490F.fm

(12/1/2004)

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TABLE OF CONTENTS

Content Page

Customer Support 2 Important Safe Operation Practices 3 Slope Gauge 7 Tractor Set-Up 8 Know Your Lawn Tractor 9 Operating Your Lawn Tractor 12 Making Adjustments 16

Content Page

Maintaining Your Lawn Tractor 18 Service 19 Off Season Storage 22 Attachments & Accessories 22 Troubleshooting 23 Parts List 24 Warranty 40

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 under the seat of the tractor and copy the information in the space provided below. A sample model plate is also given below. This information will be necessary to use the manufacturer’s web site and/or help from the Customer Support Department or an authorized service dealer.

Copy the model number here:

Copy the serial number here:

TROY-BILT LLC

www.troybilt.com

P. O. BOX CLEVELAND, OH 44136 330-558-7220 866-840-6483

361131

CUSTOMER SUPPORT

Please do NOT return the unit to the retailer from where it was purchased, without first contacting Customer Support.

If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenance of this unit, you can seek help from the experts. Choose from the options below:

Visit troybilt.com for many useful suggestions. Click on Customer Support button and you will get the four options reproduced here. Click on the appropriate button and help is immediately available.

The answer you are looking for could be just a mouse click away!

To reach the Customer Support Line, please call 1-866-840-6483 or 1-330-558-7220.

The answer you are looking for could be just a mouse click away!

Engine

Manual

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, at the end of this manual, for more information.

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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.

DANGER: This machine was built to be operated according to the rules for safe operation in this man-

ual. 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.

California Proposition 65 Warning:

WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain

or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

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.

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

24. Check overhead clearances carefully before driving under low hanging 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 approved accessory or attachment.

28. Data indicates that operators, age 60 years and above, are involved in a large percentage of riding mower-related injuries. These operators should evaluate their ability to operate the riding mower 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 an authorized MTD Service 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 on it, do not mow it.

For your safety, use the slope gauge included as part of this manual to measure slopes before operating this unit on a sloped or hilly area. If the slope is greater than 15 degrees as shown on the slope gauge, do not operate this unit on that area or serious injury could result.

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.

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

6. 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.

7. 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.

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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. To avoid back-over accidents, always

disengage the cutting blade(s) before shifting into reverse. The “Reverse Caution Mode” should not be used when children or others are around.

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.

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 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 MTD Service 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.

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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.

WARNING: YOUR RESPONSIBILITY Restrict the use of this power machine to persons who read,

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

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

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 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.

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SECTION 2: SLOPE GAUGE

Use this page as a guide to determine slopes where you may not operate safely.

on such slopes.

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

your footing and you could slip, resulting in serious injury.

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

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Page 8

SECTION 3: TRACTOR SET-UP

Attaching the Battery Cables

NOTE: The positive battery terminal is marked Pos.

(+). The negative battery terminal is marked Neg. (–).

• The positive cable (heavy red wire) is secured to the positive battery terminal (+) with a hex bolt and hex nut at the factory. Make certain that the rubber boot covers the terminal to help protect it from corrosion.

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

• 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 wing nut.

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

Rubber Boot

Service the engine with gasoline and oil as instructed in the separate Briggs & Stratton Operator/Owner Manual packed with your tractor. Read instructions carefully.

IMPORTANT:

engine. However, you MUST check the oil level before operating. Be careful not to overfill.

Your tractor is shipped with motor oil in the

Shipping Brace Removal

WARNING: Make sure the riding mower’s

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

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

Wing Nut

Hex 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 19 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. Do not overfill.

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.

Shipping Brace

Warning Tag

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.

WARNING: The shipping brace, used for

packaging purposes only, must be removed and discarded before operating your riding mower.

WARNING: The mowing deck is capable of

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

Page 9

SECTION 4: KNOW YOUR LAWN TRACTOR

Figure 3

A PTO (Blade Engage) Lever G Throttle Lever B Ammeter H Ignition Switch Module C Choke Knob (Super Bronco Only) I Brake Pedal D Parking Brake Button J Drive Pedal E Shift Lever K Cruise Control Button F Cup Holder L Deck Lift Lever

NOTE: Steering Wheel not shown for clarity.

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

Page 10

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 and, on the Bronco models, when pushed all the way forward, the choke control also. When set in a given position, the throttle will maintain a uniform engine speed. See Figure 4.

(Bronco) Choke

Position

Fast

Position

Slow

Position

Figure 4

IMPORTANT:

deck engaged, be certain that the throttle lever is always in the FAST (rabbit) position.

When operating the tractor with the cutting

(Super Bronco)

Fast

Position

Slow

Position

Ignition Switch Module

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.

To start the engine, insert the key into the ignition switch and turn clockwise to the START position. Release the key into the NORMAL MOWING MODE position once the engine has fired.

To stop the engine, turn the ignition key counterclockwise to the OFF position. See Figure 5.

.ORMAL

$RIVING-ODE

3TOP

0OSITION

3TART

0OSITION

Choke Control

On Super Bronco models, 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 13 of this manual for detailed starting instructions.

Brake Pedal

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

NOTE: The brake pedal must

be fully depressed to activate the safety interlock switch when

starting the tractor

Figure 5

IMPORTANT:

Safety Interlock Switches on page 12 and Starting The Engine on page 13 of this manual for detailed instructions regarding the Ignition Switch Module and operating the tractor in REVERSE CAUTION MODE.

Prior to operating the tractor, refer to both

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 cause the tractor to move. Ground speed is also controlled with the drive pedal. The further down the pedal is depressed, the faster the tractor will travel. The pedal will return to its original position when it’s not depressed.

IMPORTANT:

leaving the tractor unattended.

Always set the parking brake when

Page 11

Ammeter

The ammeter measures the electrical output of the engine’s charging system. Under normal operating conditions, with engine at full throttle, the ammeter should indicate positive charge.

AM PS

PTO (Blade Engage) Lever

OFF

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The PTO (Blade Engage) lever is located on the left side of the dashboard next to the steering wheel. Move the PTO (Blade Engage) lever forward to engage the power to the cutting deck or other (separately available) attachments; move the PTO (Blade Engage) lever rearward to disengage the power to the attachments.

NOTE: The PTO (Blade Engage) lever must be in the

disengaged (OFF) position when starting the engine, when traveling in reverse and if the operator leaves the seat.

PTO

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

Cruise Control Button

The cruise control button is located on the tractor dash panel to the left of the ignition switch. Push the cruise control button while traveling forward at a desired speed. While holding the button in, release pressure from the drive pedal. This will engage the cruise control and allow the tractor to remain at that speed without applying pressure to the drive pedal. Depress the brake pedal or the drive pedal to deactivate cruise control. Refer to Setting the Cruise Control on page 14 this manual for detailed instructions regarding the cruise control feature.

NOTE: Cruise control can NOT 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.

Seat Adjustment Lever

To adjust the seat position, loosen the two seat adjustment knobs and reposition the seat to the desired position. Once a comfortable position is found, tighten the adjustment knobs to lock the seat in place. Refer to Seat Adjustment on page 17 of this manual for more detailed instructions.

Deck Lift Lever

Found 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.

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.

Shift Lever

The shift lever is located on the left side of the fender and has three positions, FORWARD, NEUTRAL and REVERSE. The brake pedal must be depressed and the tractor must not be in motion when the moving shift lever. See Figure 6.

Shift Knob

Figure 6

IMPORTANT:

result in serious damage to the tractor’s transmission.

Never force the shift lever. Doing so may

Page 12

SECTION 5: OPERATING YOUR LAWN TRACTOR

Safety Interlock Switches

This tractor is equipped with a safety interlock system for the protection of the operator. If the interlock system should ever malfunction, do not operate the tractor. Contact an authorized Troy-Bilt service dealer.

• The safety interlock system prevents the engine from cranking or starting unless the parking brake is engaged, and the PTO (Blade Engage) lever is in the disengaged (OFF) position.

• The engine will automatically shut off if the operator leaves the seat before engaging the parking brake.

• The engine will automatically shut off if the operator leaves the tractor’s seat with the PTO (Blade Engage) lever in the engaged (ON) position, regardless of whether the parking brake is engaged.

• The engine will automatically shut off if the operator engages the the PTO with the parking brake ON.

• With the ignition key in the NORMAL MOWING position, the engine will automatically shut off if the PTO (Blade Engage) lever is moved into the engaged (ON) position with the shift lever in Reverse.

WARNING: Do not operate the tractor if the

interlock system is malfunctioning. This system was designed for your safety and protection.

3. Depress the REVERSE PUSH BUTTON (Orange, Triangular Button) at the top, right corner of the key switch module. The red indicator light at the top, left corner of the key switch module will be ON while activated. See Figure 7.

4. Once activated (indicator light ON), the tractor can be driven in reverse with the cutting blades (PTO) engaged.

5. Always look down and behind before and while backing to make sure no children are around.

6. After resuming forward motion, return the key to the

NORMAL MOWING position.

IMPORTANT:

remain activated until:

)NDICATOR

,IGHT

3TOP

0OSITION

The REVERSE CAUTION MODE will

a. The key is placed in either the NORMAL

MOWING position or STOP position.

b. The operator engages the parking brake by

fully depressing the brake pedal and holding it down while gently pushing the parking brake button inward.

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Reverse Caution Mode

WARNING: Use extreme caution while

operating the tractor in the REVERSE CAUTION MODE. Always look down and

behind before and while backing. Do not operate the tractor when children or others are around. Stop the tractor immediately if someone enters the area.

The REVERSE CAUTION MODE position of the key switch module allows the tractor to be operated in reverse with the blades (PTO) engaged.

IMPORTANT: Mowing in reverse is not recommended. To use the REVERSE CAUTION MODE:

IMPORTANT:

tractor seat.

1. Start the engine as previously instructed in this Operator’s Manual.

2. Turn the key from the NORMAL MOWING (Green) position to the REVERSE CAUTION MODE (Yellow) position of the key switch module. See Figure 7.

The operator MUST be seated in the

3TART

0OSITION

Figure 7

Engaging the Parking Brake

To engage the parking brake:

• Fully depress the brake pedal and hold it down with your foot while gently pushing the parking brake button inward.

• Hold the 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 the 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.

Page 13

Setting the Cutting Height

Select the height position of the cutting deck by placing the deck lift lever in any of the six different cutting height notches on the right side of the fender. Then adjust the deck wheels so that they are between ¼-inch and ½inch 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.

Stopping the Engine

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

• If the blades are engaged, place the PTO (Blade Engage) 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.

Refer to Leveling the Deck on page 16 of this manual for more detailed instructions regarding various deck adjustments.

Starting the Engine

WARNING: Do not operate the tractor if the

interlock system is malfunctioning. This system was designed for your safety and protection.

NOTE: Refer to the TRACTOR SET-UP on page 8 of this

manual for Gasoline and Oil fill-up instructions.

• Insert the tractor key into the ignition switch.

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

• Engage the tractor’s parking brake.

• Activate the choke control.

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

IMPORTANT:

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

• After the engine starts, deactivate the choke control and place the 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

Driving The Tractor

WARNING: Avoid sudden starts, ex-

cessive speed and sudden stops.

WARNING: Do not leave the seat of the

tractor without first placing the PTO (Blade Engage) 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:

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

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

Do NOT use the shift lever to change the

Page 14

WARNING

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 SAFETY DEVICES (GUARDS, SHIELDS, AND SWITCHES) IN PLACE AND WORKING.

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

• KNOW LOCATION AND FUNCTION OF ALL CONTROLS.

• BE SURE BLADE(S) AND ENGINE ARE STOPPED BEFORE PLACING HANDS OR FEET NEAR BLADE(S).

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

READ OPERATOR’S MANUAL

Driving On Slopes

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

Setting The 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.

• While continuing to hold the cruise 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.

NOTE: Cruise control can not 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.

Disengage the cruise control using one of the following methods:

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

• Lightly depress the drive pedal.

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

Engaging the Blades

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

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

• Grasp the PTO (Blade Engage) lever and pivot it all the way forward into 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.

IMPORTANT:

The engine will automatically shut off if the PTO is engaged with the shift lever in position for reverse travel with the ignition key in the NORMAL MOWING position. Refer to Safety Interlock Switches on page 12.

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.

Page 15

Mowing

WARNING: 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.

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, bystanders and the like. Also, avoid discharging material against a wall or obstruction which may cause discharged material to ricochet back toward the operator.

• 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.

• 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. After the first two laps, reverse the direction to throw the discharge to the outside for the balance of cutting. This will give a better appearance to the lawn.

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

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

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

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

• Keep the blades sharp and replace the blades when worn. Refer to Cutting Blades on page 20 of this manual for proper blade sharpening instructions.

Mulching

The Super Bronco™ is equipped with a mulch kit which incorporates special blades, already standard on the 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 the best results when mulching.

• 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 out the side. See Figure 8.

Carriage Screw

Plastic Wing Nut

Figure 8

Mulch Plug

Headlights

On some models, the lamps are ON whenever the tractor’s engine is running. On other models, the lamps are ON whenever the ignition key is moved out of the STOP position.

On all models, the lamps turn OFF when the ignition key is moved to the STOP position.

Page 16

SECTION 6: MAKING ADJUSTMENTS

WARNING: Never attempt to make any

adjustments while the engine is running, except where specified in the operator’s manual.

Leveling the Deck

NOTE: Check the tractor’s tire pressure before

performing any deck leveling adjustments. Refer to

Tires on page 19 for information regarding tire pressure.

Front To Rear

The front of the cutting deck is supported by a stabilizer bar that can adjusted to level the deck from front to rear. The front of the deck should be 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 the front of the blade tip to the ground and the rear of the blade tip to the ground.

• The first measurement taken should be between 1/4" and 3/8" less than the second measurement. Determine the approximate distance necessary for proper adjustment and proceed, if necessary, to the next step.

• Loosen the two jam nuts, if present, on the rear side of the deck stabilizer bracket.

• Locate the lock nut on the front side of the stabilizer bracket. See Figure 9. Tighten the lock nut to raise the front of the deck; loosen the lock nut to lower the front of the deck.

NOTE: Models with a 42-inch deck have only ONE

jam nut, washer, and lock nut.

• 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 10.

Adjustment Gear

Hex Bolt

Figure 10

• 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.

,OOSEN

TOLOWERDECK

Figure 9

4IGHTEN

TORAISEDECK

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.

Page 17

If the tractor does not come to a complete stop when the brake pedal is completely depressed, or if the tractor’s rear wheels can roll with the parking brake applied, the brake is in need of adjustment. The brake disc can be found on the right side of the transmission in the rear of the tractor. Adjust if necessary as follows:

• Looking at the transmission from the right side of the tractor, locate the compression spring and brake disc. See Figure 11.

Hex Nut

Set Gap at.011"

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 13.

Hex Nut

Axle

Pivot Bar

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 11.

• 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 11

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.

1. Flip the seat up as shown in Figure 12.

2. Loosen the two seat adjustment knobs located under the seat. See Figure 12.

3. Slide the seat forward or rearward, then tighten the knobs to lock the seat at the desired position. Put the seat down to the operating position.

Seat Knob

Drag Link

Jam Nut

Ball Joint

Figure 13

• Remove the hex nut on the top of ball joint. See Figure 13.

• 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 retighten the jam nut after proper adjustment is achieved.

NOTE: Threading the ball joints too far onto the drag

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

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.

Figure 12

Page 18

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.

Engine

Refer to the Briggs & Stratton Operator/Owner Manual for engine maintenance instructions.

Check engine oil level before each use as instructed in the Briggs & Stratton Operator/Owner Manual packed with your unit. Follow the instructions carefully.

Changing Engine Oil

NOTE: Depending on the engine model found on your

tractor, it may be necessary to remove the tractor’s side panel in order to replace the oil filter (if so equipped).

• Unscrew oil fill cap and remove dipstick from the oil fill tube. See Figure 14.

Oil Fill Cap

Oil Drain Hose

Oil Fill Tube

Figure 14

• Pop open the protective cap on the end of the oil drain valve to expose the drain port. See Figure 14.

• 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 of no less than 64 oz.

• Push the oil drain valve in slightly, then rotate counterclockwise and pull outward to begin draining oil. See Figure 14.

• Service the oil filter (if so equipped) as instructed in the separate Briggs & Stratton Operator/Owner Manual packed with your unit.

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

Protective Cap

Oil Drain Valve

Drain Port

• Refill the engine with new motor oil.

IMPORTANT:

Owner Manual packed with your unit for information regarding the quantity and proper weight of motor oil.

Refer to the Briggs & Stratton Operator/

Air Cleaner

Service the pre-cleaner, if so equipped, and cartridge/ air cleaner element as instructed in the Briggs & Stratton Operator/Owner Manual packed with your unit.

Spark Plug(s)

The spark plug(s) should be cleaned and the gap reset once a season. Spark plug replacement is recommended at the start of each mowing season. Refer to the Briggs & Stratton Operator/Owner Manual for correct plug type and gap specifications.

Lubrication

WARNING: Before lubricating, repairing, or

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

Engine

Lubricate the engine with motor oil as instructed in the Briggs & Stratton Owner Manual packed with your unit.

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 Axles

Each end of the tractor’s front pivot bar may be equipped with a grease fitting. Lubricate with a grease gun after every 25 hours of tractor operation.

Cleaning the Engine And Deck

Any fuel or oil spilled on the machine should be wiped off promptly. Do NOT allow debris to accumulate around the cooling fins of the engine or on any other part of the machine.

IMPORTANT:

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

The use of a pressure washer or garden

Page 19

SECTION 8: SERVICE

Cutting Deck Removal

To remove the cutting deck, proceed as follows:

• Place the PTO (Blade Engage) 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 deck belt from around the tractor’s engine pulley and idler pulleys (Refer to Changing the Deck Belt).

• 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. See Figure 15.

Support Pin

IMPORTANT:

manufacturer’s recommended or maximum psi. Do not overinflate. Uneven tire pressure could cause the cutting deck to mow unevenly.

Refer to the tire sidewall for exact tire

Battery

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

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

• After cleaning the battery and terminals, 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.

IMPORTANT:

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

If removing the battery for any reason,

Figure 15

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

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

• Repeat the above steps on the tractor’s right side.

• 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.

Tires

WARNING: Never exceed the maximum

inflation pressure shown on the sidewall of the tire.

The recommended operating tire pressure is:

• Approximately 10 psi for the rear tires

• Approximately 14 psi for the front tires

Charging

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

amps.

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.

Jump Starting

WARNING: When removing or installing

the battery, follow these instructions to prevent the screwdriver from shorting against the frame.

IMPORTANT:

with the battery of a running vehicle.

• Connect end of one jumper cable to the positive terminal of the good battery, then the other end to the positive terminal of the dead battery.

• Connect the other jumper cable to the negative terminal of the good battery, then to the frame of the unit with the dead battery.

Never jump your tractor’s dead battery

Page 20

WARNING: Failure to use this procedure

could cause sparking, and the gas in either battery could explode.

Cleaning

Clean the battery by removing it from the tractor and washing with a baking soda and water solution. If necessary, scrape the battery terminals with a wire brush to remove deposits. Coat terminals and exposed wiring with grease or petroleum jelly to prevent corrosion.

Battery Failures

Some common causes for battery failure are:

• incorrect initial activation • undercharging

• overcharging • corroded connections

• freezing

These failures are NOT covered by your tractor’s warranty.

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

• To properly sharpen the cutting 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 17.

IMPORTANT:

If the cutting edge of the blade has already been sharpened to within 5/8" of the wind wing radius, or if any metal separation is present, replace the blades with new ones. See Figure 17.

Blade Separation

Worn Blade Edge

Cutting Blades

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 cutting blade(s) for sharpening or replacement. Protect your hands by using heavy gloves or a rag to grasp the cutting blade.

WARNING: Periodically inspect the blade

spindles for cracks or damage, especially if you strike a foreign object. Replace immediately if damaged

The blades may be removed as follows.

• Remove the deck from beneath the tractor, (refer to

Cutting Deck Removal on page 19) 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 16.

Hex Flange Nut

Wood Block

Wind Wing

Sharpen Edge Evenly

Figure 17

It is important that each cutting blade edge be ground equally to maintain proper blade balance.

A poorly balanced blade will cause excessive vibration and may cause damage to the tractor and result in personal injury. The blade can be tested by balancing it on a round shaft screwdriver. Grind metal from the heavy side until it balances evenly.

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

IMPORTANT:

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

Spindle Assembly

Fuses

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.

WARNING: Always use a fuse with the

same amperage capacity for replacement.

Figure 16

Page 21

Changing the Deck Belt

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).

WARNING: Avoid the possibility of a

pinching injury. Do not place your fingers on the idler spring or between the belt and a pulley while removing the belt.

All belts on your tractor are subject to wear and should be replaced if any signs of wear are present.

• Insert a 3/8”-drive ratchet wrench (set to loosen)

into the square hole found in the idler bracket on the left side of the deck’s surface. See Figure 18.

Idler Bracket

Belt Guard

3/8” Square Hole

IMPORTANT:

specially designed to engage and disengage safely. A substitute (non-OEM) V-belt can be dangerous by not disengaging completely. For a proper working machine, use factory approved belts.

To change or replace the deck belt 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.

• Remove the belt keeper rod from around the engine pulley.

The V-belts found on your tractor are

Left Hand Spindle Pulley

Figure 18

• Grasp the ratchet’s handle and pivot it toward the front of the tractor to relieve tension on the belt.

• With belt tension relieved, carefully remove the

belt from around the left-hand spindle pulley.

IMPORTANT:

rearward before removing it from the square hole.

• Remove the deck belt from around all pulleys, including the deck idler pulleys and the engine pulley.

• Route the new belt as shown on the following page.

• Remount the belt guards removed earlier.

Engine Pulley

Carefully allow the ratchet to pivot

Right Hand Spindle Pulley

Idler Pulleys

Figure 19

Changing the Transmission Drive Belts

NOTE: Several components must be removed and

special tools (i.e. air/impact wrench) in order to change

the tractor’s drive belts. See an authorized Troy-Bilt Service Dealer to have your drive belts replaced or phone Customer Support as instructed on page 2 for information on ordering an Troy-Bilt Service Manual.

Page 22

SECTION 9: OFF-SEASON STORAGE

Clean and lubricate the tractor as instructed in Section 7: MAINTAINING YOUR LAWN TRACTOR on page 18 of this

manual 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.

Follow the instructions in the Service, Storage & Specifications section of the Briggs & Stratton Operator/Owner Manual for proper engine care prior to storing your tractor.

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.

SECTION 10: ATTACHMENTS & ACCESSORIES

The following attachments and accessories are compatible for Model T609 and J609 Lawn Tractors. See the retailer from which you purchased your tractor, an authorized Troy-Bilt Service Dealer or phone 1-866-840-6483 for information regarding price and availability.

NOTE: Model T609 and J609 Lawn Tractors are NOT designed for use with any type of ground-engaging

attachments (e.g. tiller or plow). Use of this type of equipment WILL void the tractor’s warranty.

MODEL DESCRIPTION

OEM-190-116 Mulch Kit OEM-190-180 FastAttach™ Twin Bagger Grass Collector OEM-190-604 FastAttach™ Yard-Mate™ Storage Container/Toolbox (mounts on rear of tractor) OEM-190-607* FastAttach™ Deluxe Tractor Sunshade OEM-190-672 FastAttach™ Grille Guard Bumper Kit (mounts on front of tractor) OEM-190-823 FastAttach™ 42-inch Two-stage Snow Thrower OEM-190-833 FastAttach™ 46-inch Front Dozer Blade

* Not compatible with tractors equipped with a Grass Collector

Page 23

SECTION 11: TROUBLESHOOTING

Trouble Possible Cause(s) Corrective Action

Engine fails to start PTO 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(s) 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(s) gap too close. Remove spark plug(s) and reset the gap. Idles poorly Spark plug(s) 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(s). Place throttle lever to FAST position.

Pull out the CHOKE control (if so equipped) or place the throttle control in CHOKE position. 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. Push CHOKE control (if so equipped) in, or move the throttle control out of the CHOKE position. Connect and tighten spark plug wire(s). 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(s). Set plug(s) gap.

Replace air cleaner cartridge/element or clean precleaner, if so equipped. Tighten blade and spindle. Balance blade. Replace blade. Place throttle control 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

SECTION 12: PARTS LIST

14 24

18 36

15 12

Page 25

Models J609 & T609

REF.

NO.

1 710-04095 Hex Screw, 3/8-16, 1.00, Gr5 2 710-0514 Hex Screw, 3/8-16, 1.00, Gr5 3 710-0643 Hex Screw, 5/16-18, 1.00, Gr5 4 711-1408 Link, Drag, RH 5 711-1409A Link, Drag, LH 6 712-0214 Nut, Hex Lock, 3/8-24 7 712-04065 Nut, Flange Lock, 3/8-16, Grf, Nylon 8 712-0459 Nut, Flange Lock, 7/16-20

9 712-3004A Nut, Flange Lock, 5/16-18, Gr5 10 712-0240 Nut, Jam, 7/16-20, Gr2 11 717-1550E Gear, Steering, 11/90 Ratio 12 717-1554 Gear, Pinion, Steering 13 723-0448A Ball Joint, 7/16-20, Lock 14 736-3004 Washer, Flat,.406 x.875 x.105 15 736-3084 Washer, Flat,.51 x 1.12 x.06 16 710-0726 Screw, 5/16-12, 0.750 17 738-04154 Spacer, Shoulder,.38 x 1.00 x.31 18 738-1001A Shaft, Steering,.625 OD x 24.25 Lg 19 741-0475 Plastic Bushing.380 ID 20 738-0143 Screw, Shoulder,.498 x.340, 3/8-16 21 783-0726D Pivot Bracket, Support RH 22 783-0727C Pivot Bracket, Support LH 23 783-0728 Pivot Bracket, Bar 24 631-04008 Steering Wheel, 3 Spoke, Soft Grip

25 731-04681 Steering Wheel Cap 26 738-04128 Shoulder Screw,.5 x 2.380, 3/8-16 27 734-2290A Deluxe Hub Cap 28 736-0316 Flat Washer,.78 x 1.589 x.06 29 714-04039 Cotter Pin, 5/32 x 1.25 30 719-04105 Cast Iron Pivot Bar 31 731-04693 Hub Cap 32 638-04006 LH Axle Assembly,.750 33 638-04005 RH Axle Assembly,.750 34 726-04035 Push Nut 35 783-04568 Deck Hanger Bracket, Front 36 741-0656A Hex Flange Bearing 37 634-04086 Wheel Assembly Complete, 15 x 6

PART

NO. DESCRIPTION

631-04028 Steering Wheel, 3 Spoke, Standard Grip

734-1731 Tire Only 15 x 6 x 6 634-04081 Rim Only w/ Valve Stem

NOTE: Tractor features vary by model. NOT all parts listed above and pictured on the previous page are standard equipment.

Page 26

Model

s J609 & T609

Page 27

Models J609 & T609

REF.

NO.

1 783-1346 Bracket, Grill Support 2 710-0528 Screw, 5/16-18 x 1.25 3 710-0599 Screw, 1/4-20, 0.500 4 712-3010 Hex Nut, 5/16-18 5 710-0895 Screw, 1/4-15, 0.750 6 710-0924 Screw, Machine, 1/4-20, 0.750 7 725-0157 Cable Tie (Not Shown) 8 712-0292 Nut, Clip, 1/4-20

9 731-04960 Grill, 9 Style 10 735-04019 Panel Seal 11 726-0201 Nut, Speed,.3125 ID 12 783-0783 Hood 13 731-2637 Lens 14 783-04200 Side Panel, LH 15 783-0784A Side Panel, RH 16 731-2269A Plenum, Bronco (Model J609)

17 736-0119 Washer, Lock, 5/16 18 747-2138 Hinge Rod 19 710-0642 Screw, 1/4-20 x.75 20 736-0270 Washer, Bell,.265 x.75 x.062 21 751-0603 Fuel Cap 22 710-0726 Screw, 5/16-12, 0.750 23 710-1017 Screw, 1/4-14, 0.625 24 710-1611B Screw, 5/16-18, 0.750 25 710-3217 Screw, Machine, #8-32, 0.375

PART

NO. DESCRIPTION

731-2270A Plenum, Super Bronco (Model T609)

REF.

NO.

26 712-0142 Nut, Hex, #8-32 27 731-04728 Brake Lever 28 731-04729 Cruise Control Lever 29 731-05001 Dash Panel 30 731-1857 Control Knob 31 736-0142 Washer, Flat,.281 x.50 x.063 32 747-1196 Rod, Brake / Cruise Pivot 33 783-04285A Support Plate, Dash, RH 34 783-04323A Support Plate, Dash, LH 35 747-04158 Fuel Tank Support - RH

36 751-3213A Fuel Tank, 3 Gal. 37 725-04227 Ignition Switch Module 38 725-04156 Ammeter 39 725-0963 Miniature Lamp, 12V 40 725-1649 Socket, Lamp 41 725-1744 Key, Ignition

42 746-1086 Throttle Cable, 39”, Super Bronco

43 746-04132 Choke Knob w/ Cable, 37.5” Super Bronco 44 736-3078 Washer, Flat,.344 x 1.0 x.063 45 731-1999 Choke Plug (Not Shown), Bronco — 629-04083 Headlight Wire Harness — 629-04103 Tractor Wire Harness — 629-04144 Jumper Wire Harness

PAR T

NO. DESCRIPTION

747-04161 Fuel Tank Support - LH

725-1745 Key w/ Plastic Cover, Ignition

746-1084 Throttle/Choke Cable, Bronco

NOTE: Tractor features vary by model. NOT all parts listed above and pictured on the previous page are standard equipment.

Page 28

Model

s J609 & T609

Left Hand Transmission

Bolt Mounting

29 12

Page 29

Models J609 & T609

REF.

NO.

1 17840 Mounting Bracket, Transaxle 2 736-0430 Flat Washer,.350 x 1.59 x.062 3 731-2290A Hub Cap 4 647-04020 Lever Assembly, Shift 5 710-0607 Screw, 5/16-18, 0.500 6 710-0726 Screw, 5/16-12, 0.750 7 710-0809 Screw, 1/4-20, 1.250 8 710-1007 Screw, Sems, 3/8-16, 1.500

9 710-1266 Screw, 5/16-18, 3.50, Gr5 10 710-3144 Screw, 3/8-16, 2.00, Gr5 11 711-0736 Adjustment Ferrule 1/4-20 x 1. 12 712-0241 Nut, Hex, 3/8-24, Gr5 13 712-04063 Nut, Flange Lock, 5/16-18, GrF, Nylon 14 712-04065 Nut, Flange Lock, 3/8-16, GrF, Nylon 15 712-0700 Nut, Flange, 9/16-18, Gr2 16 714-0104 Pin, Cotter,.072 Dia. x 1.13 17 714-0111 Pin, Cotter, 3/32, 1.0 18 714-0209 Cotter Pin, Internal,.125 Dia. 19 714-0470 Pin, Cotter, 1/8 x 1.25 20 718-0758A Pulley Hub, 5/8 Spline 21 720-04028 Knob, Shift 22 723-3018 Ball Joint 23 731-04602 Sleeve,.758 x.821 x 3.3125 24 731-04604 Sleeve,.758 x.821 x 2.4375 25 732-0384 Spring, Extension,.62 Dia x 6.12 26 732-0525 Spring Clip, Shifter 27 732-0716 Spring, Extension,.59 OD x 4.00 28 732-0963 Spring, Extension,.50 Dia x 6.37 29 736-0169 Washer, Lock, 3/8 30 736-0242 Washer, Bell,.340 x.872 x.060 31 738-0372B Spacer, Shoulder, 1.00 x.38 x.38 32 747-04146 Rod, Shift 33 747-04164 Rod, Brake 34 747-1127 Idler Rod, Adjustable, 3/8 35 748-0334 Spacer,.68 36 750-0566A Spacer,.260 x.372 x 1.030 37 754-0467 Belt, V-Type 38 754-0468 Belt, V-Type 39 756-04002 Pulley, V-Type, 7.25 Dia. 40 756-0981B Idler Pulley, Flat 2.75 OD 41 783-04283 Bracket, Shift 42 783-04360 Bracket, Shift, F-N-R 43 783-04442 Idler Bracket, Center Double

44 647-0031B Control Assembly, Brake 45 647-0032A Control Assembly, Speed 46 683-0266 Pedal Assembly

PART

NO. DESCRIPTION

REF.

NO.

47 710-0650 Screw, 5/16-18, 0.875 48 710-1260A Screw,5/16-18, 0.750 49 710-1611B Screw, 5/16-18, 0.750 50 711-04159B Pin, 3/8-16 x 2.68 51 712-3004A Nut, Flange Lock, 5/16-18, Gr5 52 732-0335 Spring, Compression,.405 x 1.17 53 732-0955 Spring, Extension,.50 OD x 1.41 54 732-0963 Spring, Extension,.50 OD x 6.37 55 735-0662 Pad 56 735-3049 Pad, Brake 57 736-0187 Washer, Flat,.64 x 1.24 x.06, Ht 58 736-0262 Washer, Flat,.385 x.870 x.092 59 736-0300 Washer, Flat,.406 x.875 x.059 60 736-3008 Washer, Flat,.344 x.750 x.120 61 738-0155 Screw, Shoulder.437 Dia x.162 62 738-0380 Screw, Shoulder,.50 x.27 Lg, 3/8-16 63 741-0225 Bearing, Hex Flange 64 741-3065B Split Bearing, Hex Flange 65 747-04093 Rod, Brake Lock 66 747-04096 Rod, Cruise Control 67 748-04039B Latch, Cruise Control 68 683-04186 Bracket, Lockout 69 783-0773A Ped, Brake 70 783-0780B Bracket, Neutral Return 71 618-04034 Transmission, Single Speed 72 683-04055A Bracket Assembly, Torque 73 683-04130 Bracket, Idler 74 710-0227 Screw, #8-18 x.50 75 710-0514 Screw, 3/8-16, 1.00 76 710-0604A Screw, 5/16-18,.625 77 710-1315 Screw, 3/8-16, 1.250 78 712-0130 Nut, Lock, 3/8-16, Nylon 79 725-1644 Switch Spring, Short 80 726-0320 Plate, Insulator 81 750-04294 Spacer, Shoulder 82 756-0116A Pulley, V-Type, 3.06 83 656-04015 Pulley Assembly, Variable Speed 84 683-04129 Bracket, Pulley 85 710-0627 Screw, 5/16-24,.750 86 710-0642 Screw, 1/4-20,.750 87 718-04012 Cup, Bearing 88 736-0362 Washer, Flat 89 741-0600 Ball Bearing 90 634-0104 Wheel Assembly Complete, 20 x 8 x 8

PAR T

NO. DESCRIPTION

734-1730 Tire Only 20 x 8 x 8 634-0070 Rim Only w/ Valve Stem

NOTE: Tractor features vary by model. NOT all parts listed above and pictured on the previous page are standard equipment.

Page 30

Model

s J609 & T609

To Deck

IMPORTANT:

For a proper working machine, use Factory Approved Parts. V-belts are designed to engage and disengage safely. A substitute (non OEM) V-belt can be dangerous by not disengaging completely.

Page 31

Models J609 & T609

REF.

NO.

1 17962 Plate, Switch 2 647-04036 Lever Assembly, Engagement 3 710-0809 Screw, 1/4-20 x 1.250 4 710-0859 Screw, 3/8-16, 2.50 5 710-0276 Screw, Carriage, 5/16-18, 1.00 6 710-1260A Screw, 5/16-18 x.750 7 710-3157A Screw, 7/16-20, 3.25, Gr5 8 710-0726 Screw, 5/16-12, 0.750

9 714-0145 Click Pin 10 732-04248 Extension Spring,.38OD x 3.9LG 11 736-0171 Lock Washer, 7/16 12 746-04092 Deck Engagement Cable 13 712-04065 Nut, Flange Lock, 3/8-16, GrF, Nylon 14 750-0566A Spacer,.260 x.372 x 1.030LG 15 714-0470 Pin, Cotter, 1/8 x 1.25 16 726-0201 Nut, Speed,.3125 ID 17 731-2111A Knob, PTO 18 783-04590 Cable Bracket 19 736-0322 Washer, Flat,.450 x1.250 x.164 20 741-0708 Bearing, Flange, Hex Split.500 ID 21 747-04307 Keeper Rod, Belt 22 747-1112D Engagement Handle, Deck 23 748-0415B Spacer,.385 ID x.635 OD x 1.54 24 750-0956 Spacer, 1.010 x 1.400 x.825 25 756-04064A Pulley, Engine, 3.39 x 6.12 Diameter 26 783-0744A Stop Bracket, Engagement

PART

NO. DESCRIPTION

REF.

NO.

27 683-04173 Frame Assembly, Lower 28 710-0607 Screw, 5/16-18, 0.500 29 710-0642 Screw, 1/4-20, 0.750 30 710-3005 Screw, 3/8-16, 1.25, Gr5 31 712-04064 Nut, Flange Lock, 1/4-20, GrF, Nylon 32 712-3006 Nut, Hex, 1/4-20, Gr5 33 732-04035 Spring, Compression, 1.28 OD x 3.125 34 736-0222 Washer, Lock, 1/4, External 35 736-0329 Washer, Lock, 1/4 36 738-04058 Spacer, Shoulder,.38 x 1.0 x.70 37 747-04121A Hold Rod, Battery 38 783-0349 Battery Tray 39 783-04329A Seat Bracket, Frame 40 783-04375A Frame, Upper 41 710-0599 Screw, 1/4-20, 0.50 42 725-1426 Solenoid, 12V, 100 Amp 43 725-04039 Switch, Interlock 44 710-0224 Screw, #10-16,.50 45 712-04063 Nut, Flange, Lock Nut, 5/16-18 46 712-0271 Nut, Sems, 1/4-20 47 725-1750A Battery, 235 CCA, Super Bronco

48 738-1132 Screw, Shoulder,.250 x.15, 1/4-20 49 710-0703 Screw, Carriage, 1/4-20,.75 50 712-3087 Nut, Wing, 1/4-20

PAR T

NO. DESCRIPTION

725-1737A Battery, 190 CCA, Bronco

NOTE: Tractor features vary by model. NOT all parts listed above and pictured on the previous page are standard equipment.

Page 32

Models J

609 & T609

Page 33

Models J609 & T609

REF.

NO.

1 712-04063 Nut, Flange Lock, 5/16-18, GrF, Nylon 2 757-04009A Medium Back Seat, Super Bronco

3 726-3046 Ratchet Clip 4 735-0656 RH Foot Pad, Rubber, Super Bronco

5 735-0657 LH Foot Pad, Rubber, Super Bronco

6 710-0260A Bolt, Carriage, 5/16-18,.62, Gr1 7 710-0599 Screw, 1/4-20, 0.500 8 710-0726 Screw, 5/16-12, 0.750, Super Bronco

9 710-0895 Screw, 1/4-15, 0.750, Super Bronco Only 10 731-1990 Cover, Lift Lever, Super Bronco Only 11 731-2104C Cover, w/ Cup Holder, Super Bronco Only 12 731-04591A Cup Holder, Bronco Only 13 783-04333A Fender, Super Bronco

14 783-0677 Deck Lift Plate, Super Bronco

15 783-1489A Mounting Bracket, Seat 16 710-0227 Screw, #8-18 x.50 17 726-0279 Plate, Insulator 18 725-1303 Spring Switch, Outer 19 725-1439 Spring Switch, Inner 20 726-0278 Plate, Insulator Boss 21 683-04079 Shaft Assembly, Lift 22 712-04065 Nut, Flange Lock, 3/8-16, GrF, Nylon 23 714-0104 Pin, Cotter,.072 Dia. X. 1.13 24 714-0111 Pin, Cotter, 3/32, 1.0 25 716-0106A Ring, E Type,.625 Dia. 26 720-0311 Grip, Handle, 1/2 27 732-0874 Spring, Torsion 28 738-0138A Screw, 5/16-18 x.620 Gr2 29 738-04130 Screw, Shoulder,.625 x.165, 3/8-16 30 741-0225 Bearing, Hex Flange 31 746-0968 Cable, Lift, 16.16 32 747-04155 Handle, Lift 33 756-1154 Pulley, Roller 34 783-04494 Arm, Lift - RH

35 710-0726 Screw, 5/16-12, 0.750 36 736-3078 Washer, Flat,.344 x 1.0 x.063 37 783-04081A Seat Pivot Bracket 38 720-04009 Knob, 3/8-16 39 726-0201 Nut, Speed,.3125 ID 40 732-1184 Spring, Extension,.84 Dia. x 4.6 41 736-0275 Washer, Flat,.344 x.688 x.065 42 736-0101 Washer, Flat,.406 x 1.00 x.030 43 738-0296 Screw, Shoulder,.437 x.268, 5/16-18 44 738-04012 Shoulder Screw 45 783-0209C Seat Bracket, Lift

PART

NO. DESCRIPTION

757-04001 Low Back Seat, Bronco

735-0672 RH Foot Pad, Bronco

735-0673 LH Foot Pad, Bronco

710-1611B Screw, 5/16-18 x.750, Bronco

783-04314A Fender, Bronco

783-1010A Deck Lift Plate, Bronco

783-04711 Arm, Lift - LH

NOTE: Tractor features vary by model. NOT all parts listed above and pictured on the previous page are standard equipment.

Page 34

Model

s J609 & T609

23 24

Page 35

Models J609 & T609

REF.

NO.

1 732-0614 Ring, Wire

2 716-0231 Ring, E Type,.750

3 736-0336* Flat Washer, 5/8 x 1.0 x.030

4 736-0335 Washer, Thrust.635 x 1.26 x.06

5 710-1325 Self-tapping Screw, 1/4-20 x 1.625

6 719-04017 Upper Housing

7 711-1109 Input Shaft

8 741-0335 Needle Bearing,.625 x.813 x.495

9 717-1464 14-tooth Bevel Pinion 10 716-0108 Retaining Ring,.437 11 741-0340 Sleeve Bearing,.75 x.1.0 x 1.0 12 721-0338 Seal,.75 x 1.0 x.125 13 618-04041 Differential Assembly 14 741-0336 Flange Bearing, 5/8 x 3/4 x 3/4 15 717-04056 42-tooth Bevel Gear 17 718-04045 Clutch Collar 19 711-04134 Drive Shaft 20 736-0495* Thrust Washer, 1.0 x.632 x.0

21 741-0337 Flange Bearing, 5/8 x 3/4 x 15/16 22 611-0011 Detent Shaft Assembly 23 741-0862 Detent Ball 24 732-0863 Compression Spring 25 719-04018 Lower Housing 26 717-0678 Brake Puck 27 761-0202 Brake Disc 28 710-1206 Self-tapping Screw, 1/4-20 x 2.375 29 661-0001 Brake Assembly — 737-0148 Grease (19 oz.)

PART

NO. DESCRIPTION

736-0337* Flat Washer, 5/8 x 1.0 x.040 736-0349* Flat Washer, 5/8 x 1.0 x.020

736-0494* Flat Washer,.632 x 1.00 x.035

*Use applicable washers (ref. no.’s 3 or 20) in this application allowing.0150/.0020 in. end-play.

NOTE: If rebuilding the upper housing, include two ounces (2 oz.) of Unirex® N3 grease (Part No. 737-0289) in the input shaft cavity.

Page 36

Model

s J609 & T609

Page 37

Models J609 & T609

REF.

NO.

1 618-0624 Pulley/ Spindle Assembly 2 683-04138 Deck Brake Assembly 3 683-04162 42” Deck Assembly 4 683-04167 Deck Brake Assembly 5 683-0254B Deck Hanger Bracket Assembly 6 710-0751 Screw, 1/4-20 x.620 7 710-0650 Screw, 5/16-18 x.875 8 710-0528 Screw, 5/16-18 x 1.25

9 710-0726 Screw, 5/16-12 x.750 10 710-1260A Screw, 5/16-18 x.750 11 710-0778 Screw, 1/4-20 x 1.500 12 710-3085 Screw, 3/8-16 x 3.50 13 711-04069 Grass catcher Pin 14 712-3006 Hex Nut, 1/4-20 15 712-0417A Flange Nut, 5/8-18 16 712-04064 Flange Lock Nut, 1/4-20 17 712-04063 Flange Lock Nut, 5/16-18 18 712-04065 Flange Lock Nut, 3/8-16 19 712-0641 Hex Nut, M16-1.5 20 712-3083 Hex Lock Nut, 1/2-13 21 712-0206 Hex Nut, 1/2-13 22 714-0470 Cotter Pin, 1/8 x 1.25 23 714-0104 Cotter Pin,.072 Dia. x 1.13 Lg. 24 717-04074 Deck Adjustment Gear 25 726-0233 Push Nut,.25 ID x.50 OD 26 732-0306A Compression Spring,.531 OD x 1.75 Lg. 27 732-0308A Extension Spring,.50 Dia. x 6.37 Lg. 28 734-0973 Deck Wheel 29 736-0119 Lock Washer, 5/16

PART

NO. DESCRIPTION

REF.

NO.

30 736-0270 Bell Washer,.265 x.75 x.062 31 736-0289 Shoulder Bushing,.320 ID x.135 Lg. 32 736-0267 Flat Washer,.385 x.87 x.06 33 736-0225 Lock Washer, 5/8 34 750-04446 Spacer, 3/8 ID x .68 OD x 1.46 Lg 35 738-0373 Shoulder Screw,.498 x 1.53 x 3/8-16 36 738-04162 Shoulder Spacer,.8540 x.200 37 738-04146 Plug 38 742-0616A Blade, 21.23”, Star 3-in-One 39 747-1116 Deck Release Handle Rod 40 747-04269A Front Deck Adjustment Rod 41 747-04379 Brake Control Rod 42 748-04069 Deck Lift Pivot Cup 43 750-0566A Spacer,.260 x.372 x 1.030 Lg. 44 754-04060B V-Belt, 96.3 Lg. 45 756-04129 Idler Pulley, 4.25” Dia. 46 783-04327 Belt Cover 47 783-1025 Chute Stop 48 710-0134† Carriage Screw, 1/4-20 x.62 49 710-0599† Screw, 1/4-20 x.500 50 712-3087† Wing Nut, 1/4-20 51 731-2363† Mulch Plug 52 783-1146A† Deck Skirt 53 731-1032B Discharge Chute 54 732-04287 Extension Spring, .500 Dia. x 6.375 Lg 55 710-3144 Screw, 3/8-16 x 2.00 56 712-0431 Flange Lock Nut, 3/8-16 57 712-0229 Push Nut, 3/8 58 736-0187 Flat Washer, .64 x 1.24 x .06

† If Equipped

PAR T

NO. DESCRIPTION

IMPORTANT:

working machine, use

working machine, use Factory Approved Parts.

Factory Approved Parts.

V-belts are designed to

engage and disengage

engage and disengage safely. A substitute (non

safely. A substitute (non OEM) V-belt can be

OEM) V-belt can be dangerous by not

dangerous by not disengaging completely.

disengaging completely.

NOTE: Tractor features vary by model. NOT all parts listed above and pictured on the previous page are standard equipment.

For a proper

Page 38

Model J609

Ref.

No.

Oil

1 2 3 4

5 6 7

9 10 11 12 13 14

15 16 17 18 19 20

21 22

Part No. Description

710-0227 AB Screw #8-18 x 0.5 710-0599 TT Screw 1/4-20 x 0.5 710-0726 AB Screw 5/16-12 x 0.5 710-1237 T screw #10-32 x 0.625 710-1314A Socket Hd Scr. 5/16-18 x.750 710-1315 TT Screw 3/8-16 x 1.25 712-0271 Sems Nut 721-0208 Exhaust Gasket 721-0331 Sealant: Loctite™ 725-0157 Cable Tie 726-0205 Hose Clamp 732-0966 Extension Spring 737-0169 SAE 30W Oil 751B213146 Throttle Clamp 751-0535 Fuel Line Hose 751-0564A Muffler Deflector 751-0617A Muffler 751-0619A Exhaust Pipe 751-3140 Oil Drain 751-3141 OIl Drain Extension Hose 751-3142 Oil Drain Cap 783-0615D Muffler Bracket

Model T609

Oil

Ref.

8 16

No.

10 11

12 13 14 15 16 17 18

19 20

21 22 23

24 25

Part No. Description

710-0227 AB Screw 38-18 x 0.5 710-0599 TT Screw 1/4-20 x 0.5 710-0726 AB Screw 5/16-20 x 0.75 710-1237 T Screw #10-32 x 0.625 710-1314A Socket Hd. Scr. 5/16-18 x 0.75 710-1315 TT Screw 3/8-16 x 1.25 712-0271 Sems Nut 712-3017 Hex Nut 721-0331 Pipe Sealant 721-0460 Exhaust Gasket 725-0157 Cable Tie(not shown) 726-0205 Hose Clamp 736-0300 Flat Washer 737-0169 Oil: SAE 30W 751B221535 Clamp: Casing 751-0535 Fuel Line Hose 751-0564A Deflector: Muffler 751-0616A Dual Inlet Muffler 751-0650B Exhaust Pipe RH 751-0651B Exhaust Pipe LH 751-3140 Oil Drain 751-3141 Oil Drain Extension Hose 751-3142 Oil Drain Cap 783-0615D Muffler Bracket 783-0625C Heat Shield

Page 39

NOTES

Page 40

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” warrants this product against defects in material and workmanship for a period of two (2) years commencing on the date of original purchase and will, at its option, repair or replace, free of charge, any part found to be defective in 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 part, accessory or attachment not approved by Troy-Bilt 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 30 days regardless of cause. After 30 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. Engine or components thereof. These items may 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 separate

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 does not extend any warranty for products sold

or exported outside of the United States, its possessions and territories, except those sold through Troy-Bilt’s

authorized channels of export distribution. e. Replacement parts that are not genuine Troy-Bilt parts. f. Service completed by someone other than an authorized

service dealer. g. Transportation charges and service calls.

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. 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. Troy-Bilt 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.

IMPORTANT:

Owner must present Original Proof of

Purchase to obtain warranty coverage.

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

Troy-Bilt J609 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SECTION 1: IMPORTANT SAFE OPERATION PRACTICES

SECTION 2: SLOPE GAUGE

SECTION 3: TRACTOR SET-UP

Attaching the Battery Cables

Shipping Brace Removal

Gas and Oil Fill-up

SECTION 4: KNOW YOUR LAWN TRACTOR

Throttle Control Lever

Ignition Switch Module

Choke Control

Brake Pedal

Drive Pedal

Ammeter

PTO (Blade Engage) Lever

Cruise Control Button

Seat Adjustment Lever

Deck Lift Lever

Parking Brake Button

Shift Lever

SECTION 5: OPERATING YOUR LAWN TRACTOR

Safety Interlock Switches

Reverse Caution Mode

Engaging the Parking Brake

Setting the Cutting Height

Stopping the Engine

Starting the Engine

Driving The Tractor

Driving On Slopes

Setting The Cruise Control

Engaging the Blades

Using the Deck Lift Lever

Mowing

Mulching

Headlights

SECTION 6: MAKING ADJUSTMENTS

Leveling the Deck

Parking Brake Adjustment

Steering Adjustment

Seat Adjustment

SECTION 7: MAINTAINING YOUR LAWN TRACTOR

Engine

Lubrication

Cleaning the Engine And Deck

SECTION 8: SERVICE

Cutting Deck Removal

Battery

Tires

Cutting Blades

Fuses

Changing the Deck Belt

Changing the Transmission Drive Belts

SECTION 9: OFF-SEASON STORAGE

SECTION 10: ATTACHMENTS & ACCESSORIES

SECTION 11: TROUBLESHOOTING

SECTION 12: PARTS LIST

Models J609 & T609