Troy-Bilt T609 User Manual

Download

Page 1

Operator’s Manual

Auto Drive Lawn Tractors

Super Bronco™

Bronco™

(Models J609 & T609)

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

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

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

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

PRINTED IN U.S.A.

FORM NO.

770-10490D.fm (4/2004)

Page 2

TABLE OF CONTENTS

Content Page

Customer Support 2 Important Safe Operation Practices 3 Tractor Set-Up 7 Operation 8 Making Adjustments 13 Maintenance 15

Content Page

Service 17 Off-Season Storage 22 Attachments & Accessories 22 Troubleshooting 23 Illustrated 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, pl ease locate the model plate under th e seat of the tractor and copy the informa tion in the space provided below. A sample m odel 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 serv ice 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, opera tion 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 manufactur er is responsible for all engine-related issu es with regards to performance, power-rating, specifica tions, warranty and service. Please re fer to the engine manufacturer’s Owner’s/Operator’s Manual, at the end of this manual, for more information.

Page 3

SECTION 1: IMPORTANT SAFE OPERATION PRACTICES

WARNING: This symbol points out important safety instructions which, if not follo wed, could endanger

the personal safety and/or property of yourself and others. Read and follow all inst ructions in this manual before attempting to operate this m achine. Failure to comply with these instructions may r esult in personal injury. When you see this symbol—heed its warning.

DANGER: This machine was built to be operat ed 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 oper ator can result in serious injury. This machine is capable of amputating hands and feet and throwing ob jects. Failure to observe the following safety instructions could result in serious injury or death.

California Proposition 65 Warning: Engine exhaust, some of its constituents, and certain vehicle

components contain or emit chemicals known to the State of California to cause cance r 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 ca n 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. Throw n 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 disch arge direction and do not point it at anyone. Do not operate the mower without the discharge cover or entire grass catcher in its proper place.

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

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

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

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

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

16. Mow only in daylight or good artificial light.

17. Never carry passengers.

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

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

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

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

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

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

24. Check overhead clearances carefully before driving under low 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.

Page 4

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 mowerrelated 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 your Troy-Bilt dealer for assistance.

Slope Operation

Slopes are a major factor related to loss of control and tipover accidents which can result in severe injury or death. All slopes require extra caution. If you cannot back up the slope or if you feel uneasy on it, do not mow it.

For your safety, use the slope gauge included as part of this manual to measure slopes before operating this unit on a sloped or hilly area. If the slope is greater than 15 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. 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” feature is a reminder not to cut in reverse and to help 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.

2. 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

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.

Page 5

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 wi th 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:

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 your Troy-Bilt dealer.

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

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

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

7. Keep all nuts, bolts, and screws tight to be sure the

equipment is in safe working condition

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

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

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

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

12. Do not change the engine governor settings or overspeed 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.

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.

Page 6

SECTION 2: SLOPE GAUGE

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 main tain

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

A CORNER OF A BUILDING

OR A FENCE POST

SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE

A POWER POLE

WARNING

15°

Page 7

SECTION 3: TRACTOR SET-UP

NOTE: Any reference to right, left, front or back of the tractor is from the operating position, unless otherwise stated.

Steering

Wheel Cap

Attaching The Steering Wheel

• The hardware for attaching the steering wheel has been packed within the steering wheel, beneath steering wheel cap. Carefully pry off the steering wheel cap and remove the hardware.

• With the wheels of the trac tor pointing st raight forward, place steering wheel over steering shaft.

• Place the washer (with the cupped sid e down) over the steering shaft and secure with the hex bolt. See Figure 2.

• Place steering wheel cap over the center of steering wheel and push downward until it “clicks” into place.

Attaching The Seat

NOTE: For shipping reasons, seats are mounted

backward to the pivot bracket. Release the seat form its shipping position and remove the two hex screws from the bottom of the seat before proceeding.

• Pull out the tab found on the seat stop and hold it open while sliding the seat off the seat pivot bracket. See Figure 3.

• Line up the plastic seat spacers with the slots in seat pivot bracket.

• Slide seat in until front seat spacer engages the seat stop. See Figure 3.

WARNING: Before operating, stand behind

the machine and pull back on seat until fully engaged into stop.

Hex Bolt

& Washer

Steering

Shaft

Figure 1

Seat Stop

Tab

Pivot Bracket

Figure 2

Remove Shipping Brace

IMPORTANT:

discarded before operating your riding mower.

• Locate the shipping brace and accompanying warning tag on the right side of the mower, between discharge chute and cutting deck. See Figur e 3.

• While holding the discharge chute up, ro tate the shipping brace clockwise and remove.

• Discard the shipping brace.

Gas and Oil Fill-Up

The gasoline tank is located under the hood and dep ending on the model of tracto r, has a capacity of either two or three gallons. Do not overfill.

IMPORTANT:

operating. The capacity of your engine’s sump and oil filter is 62 oz (1.8 liters). Be careful not to overfill.

The shipping brace must be removed and

Shipping Brace

Warning Tag

Figure 3

WARNING: Use extreme ca re when handling gasoline. Gaso line is extremely flammable and the vapors

are explosive. Never fuel machine indoors or while the engine is hot or runnin g. 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

Page 8

SECTION 4: OPERATION

Know the Controls

Read this owner’s manual and safety rules before operat ing your lawn mower. Compare figure below with your lawn tractor to learn about the loction and purpose of various controls and adjustments. Save this manual for future reference. It is very important to follow the instructions and operate t he controls properly.

Steering Wheel not shown for clarity.

AMPS

Figure 4

A PTO (Blade Engage) Lever H Cruise Control Button B Choke Control (Super Bronco only) I Ignition Switch C Parking Brake Button J Brake Pedal D Shift Lever K Drive Pedal E Cup Holder L Cargo Net (not shown) F Ammeter M Deck Lift Lever G Throttle Control Lever

NOTE: Any reference in this manual to the RIGHT or LEFT side of the t ractor is observed from operator ’s position.

Page 9

Throttle Control Lever

The throttle control lever controls the speed of th e engine. When set in a given position, the throttle will maintain a uniform engine speed.

Choke

(Model only)

Fast

Choke Control

Bronco: Moving the throttle lever all the way for ward activates the engine’s choke control.

Super Bronco: The choke control knob is on the left side of th e dash panel and is activated by pulling outward. Activating the choke control closes the choke plate on the carburetor and aids in starting the engine.

IMPORTANT:

throttle control lever must alway s be in the FAST (rabbit) position.

When operating the tractor with the cutting deck engage d,

Slow

Brake Pedal

The brake pedal is used for sudden stops or setting the parking brake. This pedal must be fully depressed to activate the safety interlock switch when starting the tractor

Parking Brake Button

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

• To set the parking brake, fully depress the brake pe dal and push the parking brake button in. Hold the button in while taking your foot of f the brake pedal. Both parking button an d brake pedal will stay depressed.

• To release the parking brake, depress the brake pedal slightly. The parking brake button will then return to its original position.

IMPORTANT:

Always set the parking brake when leaving the tractor unattended.

Drive Pedal

The drive pedal controls movement and grou nd speed of the tractor. Depress the drive peda l with your right foot (when the tractor shift lever is in either forward or re verse) to cause the tractor to mo ve. The further down the pedal is depressed, the faster the tractor will travel. The pedal will return to its original position when it is not depressed.

PTO (Blade Engage) Lever

Engaging this lev er transfers power to the cu tting deck or other (separately available) attachments. The PTO (Blade Engage) lever must be disengaged when (1) starting the engine, (2) travelling in reverse or (3) if the operator leaves the seat.

• To engage the PTO, pro ceed as follows:

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

2. Grasp the PTO (Blade Engage) lever and pivot it all the way forward into the engaged (ON) position.

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

• To disengage the PTO, move the lever towards rear. This will cut off power to deck or other attachments.

IMPORTANT:

regardless of whether the parking brake is engaged, and (2 ) the PTO is engaged while the drive pedal is in position for reverse travel.

The engine will automatically shut off if (1) the operator leaves the seat while the PTO is still engaged

Ignition Switch

Ignition switch is activated to start the engine. Insert key into the ignition switch and turn clockwise to the START position. Release the key into the ON position once engine has fired.

STOP

* This may also be referrred to as

simply PTO lever.

On/Lights

Off

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.

Start

Page 10

Headlights

• To turn on the headlights, rotate the same ign ition key from ON position to ON/LIGHTS position of th e ignition switch.

• To turn off the headlights, rotate the ignition key from ON/LIGHTS position to either ON position (to leave the engine running) or OFF position (to shut the engine off) .

WARNING: Never move the key into the Start position while the engine is running. Doing so may cause

damage to your engine’s starter.

Ammeter

The ammeter measures the electrical output of the engine’s chargin g system. Under normal operating conditions, with engine a t full throttle, the ammeter should indicate positive charge.

AMPS

Shift Lever

The shift lever has three positions: FORWARD (F), NEUTRAL (N) and REVERSE (R).These control the direction of movement of the tractor. Depress the brake pedal and let the tractor stop before moving t he shift lever to one of these three positions.

IMPORTANT:

damage to the tractor’s transmission.

Never force the shift lever. Doing so may result in serious

Shift

Knob

Cruise Control Button

The cruise control feature should only be utilized while traveling in t he forward direction. To engage th e cruise control, follow t hese steps:

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

2. Lightly depress the cruise control butto n.

3. While continuing to hold the cruise button in, lift your foot from the drive pedal (you should feel the cruise latch engage) .

4. Once engaged, the cruise control button and the drive pedal will lock in the “down” position, and the tractor will maintain 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 the cruise control, lightly depress either the brake ped al or the drive pedal.

• To change to the reverse direction when opera ting with cruise control, depr ess 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.

Seat Adjustment Lever

To adjust the seat position, loosen the two seat adjustment knob s and reposition the seat to the desired position. Once a comfortable position is found, tighten the adjustment knobs to lock the seat in place.

Deck Lift Lever

The deck lift lever is used to change the height of the cutting deck. To use, move the lever to the left, then place it in one of the six notches best suited for your application.

To set the cutting height of the deck you will also have to adjust the deck wheels so that they are between ¼-inch and ½-inch above th e ground when the tractor is on a smooth, flat surface such as a driveway. refer to Deck Levelling instructions on page 14.

Page 11

NOTE: The deck wheels are an anti-scalp feature of the deck and are not designed to support the weight of the cutting deck.

Cargo Net

Conveniently located on the tractor’s dash panel, the ca rgo net can be used to store personal ite ms while operating the lawn tractor.

Cup Holder

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

Safety Interlock Switches

The safety interlock system prevents the engine from cranking or starting unless the parking brake is engaged, and the PTO lever is in the “Blades Stop” position. If this system should ever malfunction, do not operate the tractor, immediately contact a Troy-Bilt dealer.

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

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

• The safety interlock system will automatically shut off the engine if the PTO (Blade Engage) Lever is moved into the engaged (ON) position with the drive pedal in position for reverse travel.

IMPORTANT:

Tampering with or attempting to bypass the

tractors Safety Interlock Switches in any way will void your tractor’s warranty.

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 O THERS 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 EN GINE 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

WARNING

WARNING: Do not operate the tractor if the interlock system is malfunctioning. This system was

designed for your safety and protection.

Page 12

Starting the Engine

NOTE: Refe r to the TRACTOR SET-UP on page 7 manual for gasoline and oil fill-up instructions.

1. Insert the tractor key into the ignition switch.

2. Place the PTO (Blade Engage) Lever in the disengaged (Blade Stop) position.

3. Engage the tractor’s parking brake.

4. Move the throttle control lever into the CHOKE position (a warm engine may not require choking).

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

IMPORTANT:

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

6. After the engine starts, move the thrott le control lever from CHOKE to the FAST position.

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

Do not hold the key in the START position for

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 damage before restarting.

1. If the blades are engaged, place the PTO lever in the “Blades Stop” position.

2. Turn the ignition key counterclockwise to the OFF position.

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

IMPORTANT

Do not leave the seat of the tractor without

1. disengaging PTO lever

2. depressing brake pedal

3. engaging parking brake

If leaving the tractor unatte nded, also turn t he ignition key off and remove the key.

Do not use the shift lever to change the direction of travel when the tractor is in motion. Always use the brake pedal to bring the tractor to a complete stop before moving the shift lever.

Avoid sudden starts, excessive speed and sudden stops while driving the tractor.

Do not mow on slope in excess of 15 degrees ( a rise of approximately 2-1/2 feet every 10 feet).

Keep hands and feet away from the opening of the cutting deck.

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.

Driving The Tractor

• Depress the brake pedal to release the parking brake.

• Move the throttle lever into the FAST (rabbit) po sition.

• 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.

Driving On Slopes

IMPORTANT:

• Mow up and down slopes, never across.

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

• Avoid turns when driving on a slope. If a turn must be made, attempt while going downward on the slope.

• 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.

Refer to the SLOPE GAUGE on page 6 to help determine slopes where you may operate the tractor safely.

Mowing

The following information will be helpful when using the cutting deck with your tractor.

Page 13

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

(if equipped)

• For best results it is recommended that the first two laps be cu t 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 we ed growth and yellows quickly in dry weath er.

• 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 tra ctor is designed to mow lawns, NOT clear brush.

• Keep the blades sharp and replace the blades when worn. Ref er to Cutting Blades on page 19 of this manual for proper blade sharpening instru ctions.

WARNING: To help avoid blade conta ct or a thrown object injury, keep bystanders, helpers, children

and pets at least 75 feet from the machine while it is in operation. Sto p machine if anyone enters the area.

Side-Discharge

To operate the cutting deck for side-discharge of grass clippings only, remove the mulch plug by unthre ading the plastic wing nut which fastens it to the cutting deck. This will allow the clippings to discharge out the side. See Figure 5.

Bell

Washer

SECTION 5: MAKING ADJUSTMENTS

WARNING: Never attempt to make any adjustments while the engine is running, except where specified

in the operator’s manual.Disconnect spark plug wire(s) and ground aga inst the engine before performin g any adjustments, repairs or maintenance.

Seat

WARNING: Bef ore oper ating 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 6.

2. Loosen the two seat adjustment knobs located under the seat. See Figure 6.

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

Wing Nut

Figure 5

Seat

Figure 6

Knob

Page 14

Steering

• If the tractor turns tighter in one direction than the

Hex Nut and Lock Washer

Grease Fitting

Pivot Bar

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 joints on both sides.

1. Loosen the jam nut on the drag link at the rear of t he

Axle

ball joint. See Figure 7.

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

3. Thread the ball joint toward the jam nut to shorten the drag link.

4. Thread the ball joint away from the jam nut to

Jam Nut

Ball Joint

Drag Link

lengthen the drag link.

5. Replace hex nut and lock washer and retighten the

Figure 7

jam nut after proper adjustment is achieved.

NOTE: Threading the ball joints too far on to 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:

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

2. In front of the axle, measure the distance horizo ntally from the inside of the left rim to the insid e of the right rim. Note the distance.

3. Behind the axle, measure the distance horizontal ly from inside of the left rim to the inside of the right rim. Note the distance.

4. The measurement taken in front of the axle should be bet ween 1/16" and 5/16" less than the measurement taken behind the axle. Adjust if necessary.

Leveling the Deck

NOTE: Check the tractor’s tire pressure before performing any deck leveling adjustments. Refer to Tires later in this section for further information regarding tire pressure.

Front To Rear

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

1. 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.

2. Measure the distance from the f ront of the blade tip to the ground and the rear of the blade tip to the gro und. 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.

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

Deck

Stabilizer

Bracket

Dec

Lock Nut

Figure 8

Page 15

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:

1. 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 perp endicular with the tractor.

2. 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 not, proceed to the next step.

3. Loosen, but do not remove, the hex cap screw on the left deck hanger bracket. See Figur e 9.

4. To balance the deck turn the adjustment gear, located immediately behind the hex cap screw, clockwise/up or counterclockwise/down. See Figure 9. You will need an adjustable wrench for this step.

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

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

Hex Cap Scre

Figure 9

Adjus

tment Gear

Parking Brake Adjustment

WARNING: Never attempt to adjust the

brakes while the engine is running. Always disengage PTO, move shift lev er into neutra l position, stop engine and remove key to prevent unintended starting.

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:

1. Looking at the transmission from the ri ght side of the tractor, locate the compression spring and brake disc. See Figure 10.

2. Loosen, but do not remove, the hex nut found on the right side of the brake assembly. See Figure 10.

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

4. Re-tighten the hex nut loosened earlier.

Hex Nut

Set gap at .011"

Brake Disc

NOTE: View shown from beneath tractor.

Compression

Spring

Figure 10

Transmission

SECTION 6: MAINTAINING YOUR LAWN TRACTOR

WARNING: Befo re performing any maintenan ce or repairs, disengage PTO, move shift lever into neutral

position, set parking brake, stop engine and remove key to prevent unintended starting.

Lubrication

Engine

• Lubricate the engine with motor oil as instructed in the engin e manual.

Page 16

Pivot Points & Linkage

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

Rear Wheels

• Remove rear wheels from the axles once a season; lubr icate the axles and rims with an all-purpose automotive grease and re-install the wheels

Front Wheels

• Each front wheel axle is equipped with a grease fitting; lub ricate with a grease gun after every 25 hours of tractor operation or at le ast once a season.

Engine

Refer to the engine manual for engine maintenance instructions.

• Check engine oil level before each use as instructed in the engine manual. Read and follow instructions carefully. Refer to this manual for details about type and grade of oil.

Changing Engine Oil

1. Unscrew oil fill cap and remove dipstick from the oil fill tube. See Figure 11.

2. Pop open the protective cap on the end of the oil dr ain valve to expose the oil drain port. See Figure 11.

3. 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 contain er with a capacity great enough to collect the used oil (approximately 62 oz.).

4. Push the oil drain valve in slightly, then rotate counterclockwise and pull outward to begin draining o il. See Figure 11.

5. Service the oil filter as instructed in the engine manual.

6. Perform the above steps in the opposite order after oil has finished draining. Refill the engine with approximately 62 oz.(1.8 liters) of new motor oil.

Air Cleaner

Service the pre-cleaner, if so equipped, and cartridge as instructed in the engine manual at the end of this manual.

Spark Plug

Clean the spark plug and reset its gap once a season, pref erably at the start of each mowing season. Refe r to the engine manual for correct plug type and gap specifications.

Oil Fill Cap

Oil Fill Tube

Oil Drain Hose

Figure 11

Protective Cap

Oil Drain Valve

Oil Drain Port

Cleaning The Engine & Deck

• Wipe off any fuel or oil spillage on the machine promptly. Do not allow grass, leaves, and dirt to accumulate around the cooling fins or on any othe r part of the ma chine, especially the pulle ys and other moving part s.

IMPORTANT:

electrical components and the engine could reduce life of the tractor and its serviceability .

Deck Wash System™ (if equipped)

• Use the Deck Wash System™ to rinse grass clippings from the deck’s underside and prevent t he buildup of corrosive chemicals. Complete the following steps after each mowing:

IMPORTANT:

1. Drive the tractor to a level, clear spot on your lawn, near enough to a water sillcock (spigot) for your garden hose to reach.

2. Move PTO lever to “Blades Stop” position.

3. Move shift lever into neutral position.

4. Set the parking brake and stop engine.

The use of a pressure washer to clean y our tractor is not recommended. Direct w ater pressure on

Make certain the tractor’s di scharge chute is directed away from your house, garage, parked cars, etc.

Page 17

5. Thread hose coupler (packaged with this manu al) onto the end of your garden hose. See Figure 12.

6. Attach the hose coupler to the water p ort on your decks surface. See Figure 12. Turn the water on.

7. While sitting in the operator’s position, re-start the engine and place throttle lever in FAST (rabbit) position.

8. Move the PTO (Blade Engage) Le v er to ON position.

9. Remain in the operator’s position with the cutting deck engaged for a minimum of t wo minutes, allowing the underside of the cutting deck to throughly rinse.

10. Move the PT O lever all the way back into t he “Blade Stop” position.

11. Turn the ignitio n key to the STOP position to turn the tractor’s engine off.

12. Turn the water off and detach the hose coup ler from the water port on your decks surface.

SECTION 7: SERVICE

WARNING: Before servicing, repairing, or inspecting, always disengage PTO, mo v e shift le ve r into

neutral position, set parking brake, stop engine and remove key from tractor to prevent unintended starting.

Water Port

Figure 12

Hose Coupler

(Shown without Hose Attached)

Tire Pressure

IMPORTANT:

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

Never exceed the maximum inflation pressure shown on the sidewall of the tire .

Battery

The battery is sealed and maintenance-f ree. Acid levels cannot be checked. However, some care is required for long battery life:

• 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:

negative (black) wire from its terminal first, followed by

the positive (red) wir e. When re-installing the battery, always connect the positive (red) wire to its terminal first, followed by negative (black) wire.

If removing the battery, disconnect the

1. Battery wires must be connected to the correct terminals. Reversing them could change the polarity and damage engine’s alternating system.

2. Do not jump-start a damaged battery.

IMPORTANT

Charging

• If the tractor has no t been used f or an extende d period of time, use a voltmet er or load tester to measure the charge. The voltmeter should read

3. When storing the battery, disconnect the negative terminal and store with full charge.

Page 18

12.6 V or higher for adequate charge. Other wise, charge the battery with an automoti ve-type 12-volt charger for a minimum of one hour at six amps. Follow the chart below to charge:

Voltmeter Reading

12.7 100 0

12.4 75 90

12.2 50 180 12 25 280

State of Charge

(percentage)

Charging Time

(minutes)

WARNING: Batteries give off an explosive ga s while charging. Charge the bat tery in a well ventilated

area and keep away from an open flame or pilot light as on a water heater, spac e heater, furnace, clothes dryer or other gas appliances.

Jump-Starting

IMPORTANT:

equipment are not in contact and their ignitions are tu rned off. Follow the seque nce described below very closely.

1. Connect the positive (+) lead of the jumper cable t o the positive (+) post of the discharge d battery.

2. Connect the other end of the positive (+) jumper ca ble to the positive (+) post of th e good battery.

3. Connect one end of the n egative (-) ju mper cable to t he negative ( -) post of the good battery.

4. Connect the other end of the negative (-) ca ble to the engine block of the stalled tractor, away from the battery, and stand back.

5. Start the stalled tractor and leave it running to ch arge the battery.

6. Disconnect the negative (-) jumper cable from the tractor.

7. Disconnect the other end of the negative (-) jumper ca ble from the negative (-) post of th e good battery.

8. Disconnect the positive (+) jumper cable from the positive (+) post of the good battery.

9. Disconnect the other end of the positive (+) jumper cable from the formerly dead battery.

Do not jump-start a damaged battery. Before connecting the jumpe r cables, make sure that the two

Fuse

Two fuses are 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 one of the fuses has not blown. One can be found under the ho od mounted behind the top of the da sh panel on the support bar. The other fuse is mounted to the inside of the fra me, behind the battery. Pull each f use out to determine if it is good or blown. Always use a fuse with the same amperage capacity for replacement.

Cutting Deck Removal

The cutting deck will have to be removed from the tractor for a variety of service tasks. To remove the cutting deck, proceed as follows:

1. Place the PTO Lever in the “Blades Stop” position and engage the parking brake.

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

3. Remove the PTO belt from around the engine pulley and from around the PTO idler pulley(s).

4. 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 13.

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

6. Rotate the pin slightly toward the rear of th e tractor and release the pin into the hole provided.

Support Pin

Figure 13

Page 19

7. Repeat the above steps on the right side of the tractor .

8. Using a pair of needle nose pliers, pull out the cotter pin holding the deck cable. This will disconnect the cable.

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

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

Cutting Blades

WARNING: Shut tracto r engine off, rem ove ignition key, disconnect the spark plug wire(s) and grou nd

against the engine before proceeding with job. Protect your hands by using heavy gloves or a rag to grasp

the cutting blade

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

1. Remove the deck from beneath the tractor, then gently flip the deck over to expose its underside.

2. Place a block of wood between the center deck housing baffle and the cutting blade to act as a stabilizer. See Figure 14.

3. Using a 15/16" wrench, remove the hex flange nut that secures the blade to the spindle assembly. See Figure 14.

4. To properly sharpen the cutting blades, re move 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 14 .

• If the cutting edge of the b lade has already been sharpened to within 5/8" of the wind wing radius, or if any metal separation is present, replace the blade s with new ones. See Figure 14.

IMPORTANT:

Each cutting blade edge has to be ground equally to maintain proper blade balance. A poorly balanced blade will cause excessive vibration, may damage the tractor and/or result in personal injury.

5. Test the blade by balancing it on a round shaft

screwdriver. Grind metal from the heavy side until it balances evenly.

6. 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 g round when the mower is in the operating p osition.

7. Use a torque wrench to tighten the blade spindle hex

flange nut to between 70 and 90 foot-pou nds.

8. Gently slide the cutting deck (from the right side) out

from underneath the trac tor.

. Remove the blades following instructions below:

Hex Flange Nut

Wood Block

Spindle Assembly

Blade separation

Worn blade edge

Wind Wing

Sharpen edge evenly

Figure 14

Changing the Deck Belt(s)

WARNING: Shut tracto r engine off, rem ove ignition key, disconnect the spark plug wire(s) and grou nd

against the engine before proceeding with job.

IMPORTANT:

OEM) V-belt can be dangerous by not disengaging complet ely. For a proper working machine, use fact ory approved belts.

The V-belts on your tractor are specially designed to engage and diseng age safely. A substitute (non-

Page 20

Engine Pulley

Left Hand Pulley

PTO Idler Bracket

(mounted on tractor)

Deck belt (Bottom) PTO belt (Top)

Right Hand Pulley

(beneath belt guard)

Deck Idler Pulley

NOTE: Left hand belt cover not shown for clarity.

• All belts on the tractor are subject to wear and should be repla ced if cracking, shredding or rotting occurs. To

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

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

2. Remove the belt guards by removing the self-tapping screws that faste n them to the deck surface. See Figur e

15 for location of the screws.

3. Grasp the PTO idler bracket and pivot it toward the discharge chut e to relieve tension on the PTO belt.

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

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

6. Remove the belt from around all pulleys, including the deck idler pulley.

7. Route the new belts as shown in Figure 15. Remount the belt guards removed earlier.

Center Pulley

Figure 15

Self-Tapping Screws

Changing Transmission Drive Belt

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

1. Remove the cutting deck as instructed earlier in this

section.

2. After disconnecting the battery cables, r emove the

battery and battery tray from be neath the seat.

IMPORTANT:

NEGATIVE (Black) wire from its terminal first, followed by the POSITIVE (Red) wire. Re-install in reverse order.

When removing the battery, disconnect the

1. While installing replacement belts, it is essential to follow the same routing map as the original.

Upper Drive Belt

1. Locate the transmission idler pulley on the upper drive belt by looking through the batt ery tray opening. See Figure 16.

2. Grasp the bracket and pivot the transmission idler pulley toward the rear of the tracto r to release tension on the upper drive belt.

3. Remove the belt from around the transmission idler pulley.

4. Remove the upper drive belt from around the transmission pulley and the variable-sp eed pulley. Slowly rotate the pulley counterclockwise to roll the belt o ff it.

2. 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 could successfully complete it. Otherwise, see your Troy-Bilt dealer .

IMPORTANT

Page 21

Variable-Speed

Pulley

Battery Tray

Opening

Shift Lever

Rear Idler Pulley

Drive belt (Lower) Drive belt (Upper)

Single-Speed

Transmission

NOTE:

View shown from above tractor.

Idler Bracket

Transmission Idler Pulley

Transmission Pulley

Belt Keeper

Double-Idler Bracket

Front of Tractor

Front Idler Pulley

Figure 16

Keeper Pins

to drive pedal

Engine Pulley

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

6. Reroute the new upper drive belt as shown in Figure 16 .

Lower Drive Belt

IMPORTANT:

the following steps.

1. Locate the variable-speed pulley through the ba ttery tray opening. See Figure 16.

2. 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.

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

4. Remove the rear idler pulley from the double-idler bracket while unrouting the belt from around both the rear an d the front idler pulley. See Figure 16.

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

IMPORTANT:

center hex bolt to between 38 and 50 foot-pounds.

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

7. Reassemble by following the above steps in reverse order. Reroute the new belt aroun d the pulleys, belt keepers and keeper pins exactly as the old one was rou ted. Refer to Figure 16.

• The drive pedal is properly adjusted when the hole in the double-idler br acket has approximately 1-3/8" of travel with 10 lbs. pressure applied to the drive pedal. See Figure 17.

Note the routing of the lower drive belt around both the pulleys and the belt keepers before performin g

Double-Idler

Bracket

When remounting the engine pulley, torque the

Hole

”

NOTE:

View shown from above tractor.

Front of Tractor

Idler

Adjuster Rod

Figure 17

Page 22

After replacing the drive belts, adjust the dri ve pedal on your tractor as follows:

1. Locate the speed control assembly on the underside of the steering support bracket. See Figure 18.

2. 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 18.

3. Remove the drive pedal return spring.

4. Using two 9/16" wrenches, remove the pin from the speed control assembly. See Figure 18.

5. Thread the idler adjustment rod inward or outward to lengthen or shorten the travel of the do uble-idler bracket until proper adjustment is achieved.

6. Reassemble by following the above steps in reverse order.

SECTION 8: OFF-SEASON STORAGE

Neutral Return Bracket

Hairpin

Clips

AutoDrive™ Pedal

Return Spring

Idler

Adj. Rod

Figure 18

Place Wrenches Here

Speed Control

Assembly

WARNING: Never store the ma chine or fuel container indoors wh ere there is an open flame, spar k or

pilot light such as on water heater, furnace, clothes dryer or other gas appliance.

• Clean and lubricate the tractor as instructed on page 15 before storing for an extende d period.

WARNING: Drain fuel only into an approved container outdoors, away from an open f lame. Allow engine

to cool. Extinguish cigarettes, cigars, pipes, and other sources of ignition prior to d raining fuel.

• Follow instructions in the Seasonal Storage section of the engine manual for proper engine care prior to storing your tractor.

• It is not necessary to remove the battery from the tractor for storage. However, clean the to p fo the battery and make sure it has full charge. Disconnect t he negative termina l of the battery before storing the tractor.

NOTE: Recharge the battery before returning it to service after storage. Even if the tractors starts, the engine charging system may not bring the battery upto a full charge, unless it is recharged.

Attachments & Accessories

The following attachments and accessories are available for your lawn tractor . See your local Troy-Bilt dealer for price and availability.

MODEL DESCRIPTION

OEM-190-116 Mulch Kit OEM-190-180 FastAttach™ Twin Bagger Grass Collector OEM-190-603 FastAttach™ Grille Guard (mounts on front of tractor) OEM-190-604 FastAttach™ Yard-Mate™ Storage Container/Toolbox (mounts on rear of tractor) OEM-190-607 FastAttach™ Deluxe Tractor Sunshade OEM-190-822 FastAttach™ 46-inch Front Dozer Blade OEM-190-823 FastAttach™ 42-inch Two-stage Snow Thrower

Page 23

SECTION 9: TROUBLESHOOTING

Trouble Possible Cause(s) Corrective Action

Engine fails to start 1. PTO lever engaged.

2. Parking brake not engaged.

3. Spark plug wire(s) disconnected.

4. Throttle control lever not in correct starting position.

5. Fuel tank empty, or stale fuel.

6. Blocked fuel line.

7. Faulty spark plug.

8. Engine flooded.

Engine runs erratic 1. Unit running with CHOKE applied.

2. Spark plug wire loose.

3. Blocked fuel line or stale fuel.

4. Vent in gas cap plugged.

5. Water or dirt in fuel system.

6. Dirty air cleaner.

Engine overheats 1. Engine oil level low.

2. Air flow restricted.

Engine hesitates at high RPM

1. Spark plug gap too close. 1. Remove spark plug(s) and reset the gap at .030”.

1. Place PTO lever in OFF position.

2. Engage parking brake.

3. Connect wire(s) to spark plug.

4. Place throttle lever to CHOKE position.

5. Fill tank with clean, fresh gas.

6. Clean fuel line or replace fuel filter, if so equipped.

7. Clean, adjust gap or replace plug.

8. Crank engine with throttle in FAST position.

1. Place throttle lever in FAST position.

2. Connect and tighten spark plug wire.

3. Clean fuel line; fill tank with clean, fresh gas. Replace fuel filter, if so equipped.

4. Clear vent or replace cap if damaged.

5. Drain fuel tank. Refill with clean, fresh gas.

6. Replace air cleaner cartridge or clean precleaner, if so equipped.

1. Fill crankcase with proper capacity and weight of oil.

2. Clean grass clippings and debris from around the engine’s cooling fins and blower housing.

Idles poorly 1. Spark plug fouled, faulty or gap too

wide.

2. Dirty air cleaner.

Excessive vibration 1. Cutting blade loose, unbalanced or

damaged.

Mower will not mulch grass

Uneven cut 1. Deck not balanced properly.

1. Engine speed too low.

2. Wet grass.

3. Excessively high grass.

4. Dull blade.

2. Dull blade.

3. Uneven tire pressure.

1. Replace spark plug(s). Set plug gap at .030”.

2. Replace air cleaner cartridge or clean precleaner, if so equipped.

1. Tighten blade and spindle, balance blade and/or replace blade.

1. Place throttle in FAST (rabbit) position.

2. Do not mow when grass is wet; wait until later to cut.

3. Mow once at a high cutting height, then mow again at desired height or make a narrower cutting swath.

4. Sharpen or replace blade.

1. Perform side-to-side deck adjustment.

2. Sharpen or replace blade.

3. Check tire pressure in all four tires.

Page 24

SECTION 10: PARTS LIST FOR MODELS J609 & T609

NOTE: For painted parts, refer to the list of color codes below. Please add the applicable color code to the part number for a replacement part. For instance, if a part numbered 700-xxxx is painted Red, the part number to order would be 700-xxxx-0638.

Red: 0638

Oyster Gray: 0662

Powder Black: 0637

Page 25

Models J609 & T609

Ref.

No.

1 783-1346 Grill Support Bracket (9-style) 2 710-0599 Self-tapping Screw, 1/4-20 x .5 3 710-0528 Hex Cap Screw, 5/16-18 x 1.25 4 710-0924 Phillips Pan Screw, 1/4-20 x .75 5 710-1017 Truss Phillips Screw, 1/4-20 x .625 6 725-1741 Ignition Switch 7 735-04019 Side Panel Seal 8 710-0642 Self-tapping Screw, 1/4-20 x .75

9 712-0292 U-type Speed Nut, 1/4-20 10 736-0270 Bell Washer, .265 x .75 x .062 11 725-04156 Ammeter 12 712-3004A Hex Nut, 5/16-18 13 731-2119A Grille (9-style) 15 725-0157 Cable Tie, 3/16 x .05 x 7.4 16 746-1085 Choke Knob/Cable (Model L TX-2146) 17 783-0783 Hood (9-style) 18 783-0784 RH Side Panel (9-style) 19 783-04200 LH Side Panel (9-style) 20 731-2637 Headlight Lens (9-style) 21 747-2138 Hood Hinge Rod 22 625-0051 Headlight Assembly 23 710-0726 Self-tapping Screw, 5/16-12 x .75 24 751-0603 Fuel Cap 25 751-0658D Fuel Tank, Three-Gallon 26 725-1745 Ignition Key w/ plastic cover

Part

No. Description

725-1744 Ignition Key w/o plastic cover

Ref.

No.

27 710-0895 Self-tapping Screw, 1/4-15 x .75 28 710-3217 Truss Phillips Screw, #8-32 x .375 29 712-0142 Hex Nut, #8-32 30 731-1857 Throttle Control Knob 31 731-2122C Dash Panel 32 731-04217 Cruise Control Button 33 731-04215 Parking Brake Button 34 736-0142 Flat Washer, 9/32 x 1/2 x 1/16 35 747-1196 Brake/Cruise Pivot Rod 36 783-04285 Dash Support Plate RH

37 712-3010 Hex Nut, 5/16-18 38 710-1611B Self-tapping Screw, 5/16-18 x .75 39 726-3046 Ratchet Clip 40 736-0119 Lock Washer, 5/16 41 726-0201 Speed Nut, .3125 42 736-3078 Flat Washer, .349 x 1.0 x .063 43 710-1238 Screw, 5/16-18 x .875 (Grade 5) 44 747-04158 Fuel Tank Support RH

45 735-04023 Cargo Net 46 726-04029 Clip: Cargo Net 47 731-2228 Cover: Cruise Control — 629-0469A Headlight Wire Harness (Not Shown) — 629-04050 Tractor Wire Harne ss (Not Shown)

Part

No. Description

783-04323 Dash Support Plate LH

747-04161 Fuel tank Support LH

Page 26

Models J609 & T609

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

applicable color code to the part number for a replacement part. For instance, if a part numbered 700-xxxx is painted Red, the part number to order would be 700-xxxx-0638.

Red: 0638

Oyster Gray: 0662

Powder Black: 0637

10 20

17 21

21 22

45 43

Page 27

Models J609 & T609

Ref.

No.

1 747-1130B Deck Stabilizer Rod 2 683-0197B Lift Shaft Assembly 3 711-0332 Clevis Pin, .5 x .78 4 712-0206 Hex Nut, 1/2-13 5 712-0431 Flange Lock Nut, 3/8-16 6 712-0429 Flange Lock Nut, 5/16-18 7 712-3083 Hex Nut, 1/2-13 8 714-0104 Internal Cotter Pin

9 714-0145 Internal Cotter Pin 10 716-0106 E-Ring 11 720-0311 Handle Grip 12 732-0874 T orsion Spring 13 732-1184 Extension Spring, .84 x 4.6 14 736-0275 Flat Washer, 5/16 15 736-0921 Lock Washer, 1/2 16 736-3019 Flat Washer, .531 x 1.062 x .134 17 736-3084 Flat Washer, .51 x 1.12 x .06 18 738-0138A Hex Cap Screw, 5/16-18 x .62 19 738-0143 Shoulder Screw, 3/8-16 20 741-0225 Hex Flange Bearing 21 741-0715 Snap Flange Bear ing 22 746-0968 Lift Cable, 16.16 (LTX-1842)

23 747-1111A Lift Handle 24 756-1154 Roller Pulley 25 783-0678A Lift Arm

Part

No.

746-1144 Lift Cable, 15.62 (LTX-2146)

Description

Ref.

No.

26 783-0720A Deck Stabilizer Bracket 27 710-0260A Carriage Bolt, 5/16 x .62 28 710-0604A Self-tapping Screw, 5/16-18 x .625 29 736-0331 Bell Washer, .390 x 1.13 x .062 30 720-04009 Knob, 3/8-16 31 738-04012 Shoulder Screw 32 736-3078 Flat Washer, .349 x 1.0 x .063 33 783-1010A Lift Adjustment Bracket 34 783-04314 Fender 35 783-1489 Seat Mounting Bracket 36 738-0296 Shoulder Screw 37 726-0201 Speed Clip 38 783-0209A Seat Lift Bracket 39 757-04001 Seat: Low Back 40 735-0672 RH Foot Pad, Rubber 41 735-0673 LH Foot Pad, Rubber 42 726-3046 Foot Pad Clips 43 714-0111 Cotter Pin 44 783-04081 Seat Pivot Bracket 45 736-0204 Flat Washer, .344 x .62 46 731-0511 Trim Strip 47 731-1990 Lift Lever Cover 48 731-2104B Shift Lever Cover w/ Cup Holder 49 710-0895 Self-Tapping Screw, 1/4-15 x .75 50 731-04591 Cup Holder 51 710-0599 TT Screw, 1/4-20 x 0.5

Part

No.

Description

Page 28

Models J609 & T609

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

20 13

13 22

below. Please add the applicable color code to the part number for a replacement part. For instance, if a part numbered 700-xxxx is painted Red, the part number to order would be 700-xxxx-0638.

Red: 0638

Oyster Gray: 0662

14 20

Powder Black: 0637

Page 29

Models J609 & T609

Ref.

No.

1 710-1260A Self-tapping Screw, 5/16-18 x .75

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

3 783-0726B RH Pivot Support Bracket

4 783-0727A LH Pivot Support Bracket

5 783-0728 Pivot Bar Bracket

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

7 711-1408 RH Drag Link

8 711-1409A LH Drag Link

9 712-0240 Jam Nut, 7/16-20 (Grade 2) 10 712-0214 Hex Nut 11 712-0130 Flange Lock Nut, 3/8-24 12 712-0459 Flange Lock Nut, 7/16-20 13 712-0429 Flange Lock Nut, 5/16-18 14 717-1550D Steering Gear, 11/90 Ratio 15 717-1554 Steering Pinion Gear 16 723-0448A Ball Joint, 7/16-20 17 736-0169 Lock Washer, 3/8 18 736-3084 Flat Washer, .51 x 1.12 x .06 19 738-1001A Steering Shaft, .625 OD x 24.4 20 741-0475 Plastic Bushing, .38 ID 21 741-0656 Hex Flange Bearing, 5/8 22 738-0372B Shoulder Spacer, .38 ID 23 631-04008 Steering Wheel, Soft Grip, Three Spoke 24 731-04681 Steering Wheel Cover

Part

No. Description

Ref.

No.

25 638-0019A LH Axle Assembly, (Model LTX-1842) 26 638-0020A RH Axle Assembly (Model LTX-1842) 27 719-0399B Pivot Bar w/ Fittings (Model LTX-1842) 28 712-0431 Flange Lock Nut, 3/8-16

29 714-0162 Cotter Pin 30 726-0214 Push Cap, .625 (Model LTX-1842)

32 736-0430 Flat Washer 33 736-0331 Bell Washer, .39 x 1.13 x .062 34 738-1011 Shoulder Screw, .5 x 2.2, 3/8-16 35 710-0643 Hex Bolt, 5/16-18 X 1 36 634-04086 Wheel Assembly Complete, 15 x 6 x 6

— 634-04081 Rim Only — 734-0255 Air Valve (Not Shown) — 734-1731 Tire Only, Square Shou lder — 741-0516A Flange Bearing (Not Shown)

— 741-0990A Flange Bearing (Not Shown) 37 734-2290A Hub Cap 38 783-0653F Steering Support Bracket 39 738-0143 Shoulder Screw, 3/8-16 40 736-3004 Flat Washer, .406 x .875 x .105

Part

No. Description

638-0021 LH Axle Assembly(Model LTX-2146) 638-0022 RH Axle Assembly(Model LTX-2146) 719-0525B Pivot Bar w/ Fittings (Model LTX-2146)

726-0341 Push Cap, .750 (Model LTX-2146)

Page 30

Models J609 & T609

IMPORTANT:

working machine, use

For a proper

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 17840 Mounting Bracket 2 618-04133 Drive Assembly 3 618-04147 Variable Spd. Pulley Assembly 4 647-04020 Shift Lever Assembly 5 710-0607 TT Screw 5/16-18 x 0.5 6 710-0726 AB Screw 5/16-12 x 0.75 7 710-0809 TT Screw 1/4-20 x 1.25 8 710-1007 TT Sems Screw 3/8-16 x 1.5

9 710-1266 Hex Bolt 5/16-18 x 3.5 10 710-3144 Hex Bolt 3/8-16 x 2.0 11 711-0736 Ferrule 12 712-0241 Hex Nut 3/8-24 13 712-0429 Hex Lock Nut 5/16-18 14 712-0431 Flange Lock Nut 3/8-16 15 714-0104 Hairpin Clip 16 714-0111 Cotter Pin 17 714-0209 Hairpin Clip 18 714-0470 Cotter Pin 19 720-04028 Shift Knob 20 723-3018 Ball Joint 21 732-0384 Extension Spring 22 732-0525 Spring Clip 23 732-0716 Extension Spring 24 732-0963 Extension Spring 25 736-0169 Lock Washer 3/8 26 737-3007 Grease 27 738-0372B Shoulder Spacer 28 747-04146 Shift Rod 29 747-04164 Brake Rod 30 747-1127 Idler Adj. Rod 31 748-0334 Spacer: Transaxle 32 750-0566A Spacer 33 754-0467 V Belt 34 754-0468 V Belt 35 756-0981A Flat Idler Pulley 36 783-04283 Shift Bracket 37 783-04360 Shift Bracket 38 783-04442 Double Idler Bracket: Center 39 647-0031C Brake Control Assembly 40 647-0032A Speed Control Assembly 41 683-0266 Drive Pedal Assembly 42 710-0650 TT Screw 5/16-18 x 0.875 43 710-0726 AB Screw 5/16-12 x 0.75 44 710-1260A LD Screw 5/16-18 x 0.75

Part

No. Description

Ref.

No.

45 710-1611B TT Screw 5/16-18 x 0.75 46 711-04159 Pin 47 712-0130 Hex Lock Nut 3/8-16 48 712-3004A Flange Lock Nut 49 714-0104 Cotter Pin 50 726-04028 Push Nut 51 732-0335 Compression Spring 52 732-0955 Extension Spring 53 732-0963 Extension Spring 54 735-0662 Control Pad 55 735-3049 Brake Pad 56 736-0262 Flat Washer 57 736-3008 Flat Washer 58 738-0155 Shoulder Screw 59 738-0380 Shoulder Screw 60 741-0225 Hex Flange Bearing 61 741-3065B Hex Flange Bearing: Split 62 747-04093 Brake Lock Rod 63 747-04096 Cruise Control Rod 64 748-04039 Cruise Latch 65 783-0653F Steering Support Bracket 66 783-0732 Lock-Out Bracket 67 783-0773A Brake Pedal 68 783-0780B Neutral Return Bracket 69 756-04002 Transmission Pulley 70 712-0700 Flange Nut 9/16-18 71 718-0758A Pulley Hub 72 683-04055 Transmission Torque Bracket 73 683-04130 Idler Bracket 74 710-0227 AB Screw #8-18 x 0.5 75 725-1644 Spring Switch 76 750-0736 Shoulder Spacer 77 710-0514 Hex Bolt 3/8-16 x 1.0 78 747-04146 Shift Rod 79 726-0320 Insulator Nut Plate 80 736-0242 Bell Washer 81 710-0627 Hex Cap Screw 82 634-0104 Wheel Assembly

83 734-2290A Hub Cap 84 736-0430 Flat Washer

Part

No. Description

634-0070 Rim Assembly 734-0255 Air Valve 734-1730 Tire

Page 32

Models J609 & T609

3 8

22 23

Page 33

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 15 717-1362 42-tooth Bevel Gear 16 717-1363 42-tooth Bevel Gear 17 718-0228 Clutch Collar 18 736-0519 Flat Washer, .70 x 1.125 x .031 19 711-04053 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*

*Use applicable flat washer (12a, 12b or 12c) in this application allowing .0150/.0020 in end-play

NOTE: If rebuilding the upper housing of the transmission, add

two ounces of Unirex input shaft cavity.

N3 grease (Part No. 737-0289) in the

Page 34

Models J609 & T609

36 35

45 46

Red: 0638

Oyster Gray: 0662

Powder Black: 0637

59 58

59 60

7 27 23

11 18

8 18 11

NOTE: #63 (battery hold-down rod) is not shown in picture.

52 51

Page 35

Models J609 & T609

Ref.

No.

1 647-0064 PTO Engage Lever Assembly 2 683-0450 PTO Engage Plate Assembly 3 710-0276 Carriage Screw, 5/16-18 x 1.00 4 710-0520 Hex Cap Screw, 3/8-16 x 1.5 5 710-0831 Hex Cap Screw, 3/8-16 x 5.5 6 710-0726 AB Screw 5/16-12 x 0.75 7 712-0229 Push Nut, 3/8 8 712-0431 Flange Lock Nut, 3/8-16

9 712-3004A Flange Lock Nut, 5/16-18 10 712-3010 Hex Nut, 5/16-18 11 714-0470 Cotter Pin, 1/8 x 1.25 12 726-0201 Speed Nut, .3125 13 731-2111A PTO Knob 14 732-1170 Extension Spring, .75 x 6.75 15 732-0991A Belt Gu ard 16 736-0108 Flat Washer, .510 x .750 x .033 17 736-0119 Lock Washer, 5/16 18 736-0140 Flat Washer, .385 x .62 x .063 19 736-0275 Flat Washer, 5/16 20 736-3000 Flat Washer, .406 x .875 x .059 21 736-0242 Bell Washer 22 736-3039 Flat Washer 23 738-0372B Shoulder Spacer, .380 24 741-0708 Hex Split Flange Bearing, .5 25 747-1112D PTO Engage Handle 26 747-1286A Belt Keeper Rod 27 748-0415A Spacer, 3/8 x 1.54 28 756-0627B Idler Pulley, 3.5 29 756-1208 Idler Pulley, 4.0 30 783-0744A Engagement Stop 31 783-0891B Deck Stop 32 710-0604A Self Tapping Screw, 5/16-18 x .625

Part

No. Description

Ref.

No.

33 732-04035 Compression Spring, 1.28 x 3.125 34 723-0444 Battery Strap 35 738-1020 Shoulder Screw, .625 x .5, 7/16-20 36 736-0407 Bell Washer, .45 x 1.0 x .062 37 712-0459 Flange Lock Nut, 7/16-20 38 783-1031A Hitch Plate 39 783-0349 Battery Tray 40 725-1426 Solenoid, 12-Volt, 100 Amp 41 710-0599 Self Tapping Screw, 1/4-20 x .5 42 736-0222 Lock Washer, 1/4 43 683-0304C Lower Frame Assembly 44 725-1737A 12-volt Battery, 190 CCA (Model J609)

45 710-0751 Hex Cap Screw, 1/4-20 x .62 46 712-0271 Hex Sems Nut, 1/4-20 47 712-3044 Wing Nut, 1/4-20 48 732-1165 Extension Spring, .50 x 5.0 49 710-3180 Hex Cap Screw, 5/16-18 x 1.75 50 750-0596 Spacer Cup 51 710-3029 Hex Head Cap Screw, 7/16-20 x 1.25 52 736-0171 Lock Washer, 7/16 53 736-0322 Flat Washer, .450 x 1.25 54 756-0982B Engine Pulley, 3.56 OD x 5.56 55 754-0497 PTO Belt 56 783-0653F Steering Support Bracket 57 711-1044 Keeper Pin, 5/16 x 4.75 58 725-1657A Switch 59 17962 Switch Plate 60 710-0224 Screw, #10-16 x .5 61 732-1013 Belt Guard 62 736-0300 Flat Washer 63 747-04121A Battery Hold-Down Rod (not shown)

Part

No. Description

725-1706A 12-volt Battery, 270 CCA (Model T609)

Page 36

Models J609

Ref.

No.

Oil

1 2 3 4

5 6 7

9 10 11 12 13 14

8 18

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 Hose Extension 751-3142 Oil Drain Cap 783-0615C 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 751-0650A Exhaust Pipe RH 751-0651A Exhaust Pipe LH 751-3140 Oil Drain 751-3141 Extension Hose: Oil Drain 751-3142 Oil Drain Cap 783-0615B Heat Shield: Muffler 783-0625C Heat Shield: Single

Page 37

Models J609 & T609

OIL SENSOR

BLK

725-1439

725-1303

SEAT SWITCH

SYSTEMS INDICATOR MONITOR

RED/WHT

ORG

SWITCH

BRAKE

725-1741

KEY SWITCH

725-1657A

OFF

G+M+A1

B+S+A1

START

DESCRIPTION

Conditions as shown:

KEY SWITCH OFF

ITEM

PTO OFF

BRAKE SWITCH OFF

TRACTOR UNOCCUPIED

RUN 1

Rev. Kill

B+A1

L+A2

Mechanical

RUN 2

B+A1

GRN

HEADLIGHTS

YEL/BLK

YEL/WHT

ORG/BLK

PTO SWITCH

725-1716

20 AMP

FUSE

ORG/WHT

RED

BLU

WHT

ALTERNATOR

YEL

AFTERFIRE SOLENOID

ALTERNATOR

MAGNETO

RED

725-1426

SOLENOID

STARTER

FUSE

20 AMP

RED

BLK

Page 38

Models J609 & T609

Red: 0638

Oyster Gray: 0662

Powder Black: 0637

20 38

57 31

5 46

32 48

Page 39

Models J609 & T609

Ref.

No.

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Part No. Description

711-04069 Grass Catcher Pin, 1/4-20 618-0565 Spindle Assy., 5.75 Dia. w/ Fitting 683-0198G 42-inch Deck Shell 683-0254 Deck Adj. Bracket w/ Weld Nut 736-0140 Flat Washer, .385 x .62 x .063 710-0520 Hex Cap Screw, 1/4-20 x 1.5 710-0528 Hex Cap Screw, 5/16-18 x 1.25 710-0726 Self-tapping Screw, 5/16-12 x .75 710-0751 Hex Cap Screw, 1/4-20 x .62 710-1238 Hex Hd. Washer Scr., 5/16-18 x .875 710-0650 Self-tapping Screw, 5/16-18 x .875 710-3151 Hex Cap Screw, 5/8-18 x .875 712-0337 Hex Nut, 5/8-18 712-0417A Hex Flange Nut, 5/8-18 712-0431 Flange Lock Nut, 3/8-16 712-0429 Flange Lock Nut, 5/16-18 712-3006 Hex Nut, 1/4-20 712-0324 Hex Lock Nut, 3/8-16 714-0470 Cotter Pin, 1/8 x 1.25 716-3020 Internal Snap Ring 717-04074 Deck Adjustment Gear 726-0233 Push Nut. .25 x .5 731-1032B Side Discharge Chute Assembly 731-2486A Belt Cover 732-0306A Comp. Spring, .406 x .531 x 1.75 732-0470A Extension Spring, .50 x 4.74 734-0973 Deck Wheel, 5 x 1.38 710-0134 Carriage Screw, 1/4-20 x .5 736-0119 Lock Washer, 5/16 736-0158 Lock Washer, 5/8

Ref.

No.

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59

Part No. Description

736-0162 Flat Washer, .64 x 1.0 x .12 736-0270 Bell Washer, .265 x .75 x .062 738-0373 Shoulder Screw, .498 x 1.53 741-0524 Bearing, .625 x 1.574 x .470 742-0616A Blade, Star Center, 21.23" 747-1116 Deck Release Pin 748-0331 Shoulder Spacer, .625 x .324 750-0932A Spacer, .635 x .88 x 1.72 683-0440 Deck Brake Assembly 754-0498 Deck Belt 756-0627B Idler Pulley, 3.5 756-1202 Double Pulley, 5.0 710-1830 Self-tapping Screw, 1/4-20 x 4.0 746-0970 Brake Cable, 5.05 783-1291 Idler Bracket 711-1534 Pin, 3/8-16, 3/8 x 3.27 731-2363 Mulch Plug 712-3087 Wing Nut 710-0599 Self-Tapping Screw, 1/4-20 x .5 783-1146A Deck Skirt 712-0641 Hex Nut, M-16 x 1.5 721-0417 O-Ring 737-04003B Water Nozzle (if equipped) 736-0760 Lock Washer 710-3180 Hex Bolt, 5/16-18 x 1.75 732-1165 Extension Spring 783-04013A Stab. Bracket: Pulley 712-3010 Hex Nut 783-1025 Chute Stop (not shown)

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. Th ese 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 retaile r, with respect to any pro duct, 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 T609 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual