Yard-Man 604 User Manual

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PERATOR’S

ANUAL

AutoDrive

™

Lawn Tractor

Model 604

IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY

Warning:

covered, brush-covered or grass-covered land unless the engine’s exhaust system is equipped with a spark arrester meeting applicable local or state laws (if any). If a spark arrester is used, it should be maintained in effective working order by the operator. In the State of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have simila r la w s. Fe de r al la w s ap pl y on f ed er al l an ds . A s par k ar res t er f or the muf f ler is av ai la ble t hr o ugh y ou r n ea res t e ng in e a utho r iz ed service dealer or contact the servic e department, P .O. Box 368022 Cleveland, Ohio 44136-9722.

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

PRINTED IN U.S.A. FORM NO. 770-10079

This un it is equi pp ed wi th a n in ter nal c omb ustio n en gi ne an d sh ould not be used on o r n ear an y un impr ov ed fo res t-

(12/98)

SECTION 1: TABLE OF CONTENTS

PAGE

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

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

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

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

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

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

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

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

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

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

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

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

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

PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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

SECTION 2: FINDING YOUR MODEL NUMBER

This Operator’s M anu al is an important part of y our new rider. It will help you assem ble, prepar e and m a i ntain your rider. Please read and understand what it says. Before you start to prepare your tractor for its first use, please locate the model plate and copy the information from it in this Operat or’s Manual. The inf ormation on the m odel plate is very impo rtant if you need help from your dealer or the MTD customer support department.

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

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

This is where your model number will be.

XXX-X-XXX-X-XXX XXXXXXXXXXX

This is where your serial number will be.

Copy the model number here:

MTD PRODUCTS INC

P .O. BOX 368022

CLEVELAND, OHIO 44136

Copy the serial number here:

SECTION 3: CALLING CUSTOMER SUPPORT

•

LOCATE YOUR MODEL NUMBER AND SERIAL NUMBER —

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

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

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

• Customer Support can be reached by dialing:

1- (330) 220-4MTD

(

1- (800)-800-7310

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

• Although both numbers ar e important, you will be asked to enter on ly your

call can be processed.

Record this information in the space

4683)

serial

number before your

SECTION 4: IMPORTANT SAFE OPERATION PRACTICES

WARNING:

THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH, IF NOT FOLLOWED, COULD ENDANGER THE PERSONAL SAFETY AND/OR PROPERTY OF YOURSELF AND OTHERS. READ AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL BEFORE ATTEMPTING TO OPERATE YOUR LAWN MOWER. FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. WHEN YOU SEE THIS SYMBOL, HEED ITS WARNING.

WARNING:

The Engine Exhaust from this product contains chemicals known to

the State of C alif ornia to caus e cancer, birt h defects or other reproductive harm.

DANGER:

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

Your lawn mower was built to be operated according to the ru les for safe operation in

1. GENERAL OPERATION

• Read, understand, and follow all instructions in the operator’s manual and on the machine before starting. Keep this manual in a safe place for future and regular reference and for ordering replacement parts.

• Only allow responsible individuals familiar with the instructions to operate the machine. Know controls and how to stop the machine quickly.

• Do not put hands or feet under cutting deck or near rotating parts.

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

• Be sure the area is clear of other people before mowing. Stop machine if anyone enters the area .

• Never carry passengers .

• Disengage blade(s) before shifting into reverse and backing up. Always look down and behind before and while backing.

• Be aware of the mower and attachment discharge direction and do not point it at anyone. Do not operate the mower without either the entire grass catcher or the chute guard in place.

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

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

• Turn off blade(s) when not mowing.

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

• Mow only in daylight or good artificial light.

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

• Watch for traffic when operating near or crossing roadways.

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

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

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

• Check overhead clearance carefully before driving under power lines, wires, bridges or low hanging tree branches, before entering or leaving buildings, or in any other situation where the operator may be struck or pulled from the unit, which could result in serious in ju ry .

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

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

2. SLOPE OPERATION

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

DO:

• Mow up and down slopes, not across.

• Remove obstacles such as rocks, limbs, etc.

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

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

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

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

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

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

DO NOT:

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

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

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

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

• Do not use grass catcher on steep slopes.

3. CHILDREN

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

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

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

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

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

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

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

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

4. SERVICE

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

• Use only an approved container.

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

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

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

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

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

• Never run a machine inside a closed area.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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.

WARNING

TO 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.

• LOOK DOWN & BEHIND BEFORE AND WHILE BACKING.

• KEEP SAFETY DEVICES (GUARDS, SHI ELDS, AND SWITCHES, ETC.) IN PLACE AND WORKING.

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

• KNOW LOCATION AND FUNCTION OF ALL CONTROLS.

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

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

READ OPERATOR'S MANUAL

Figure 1 Safety Labels found on your unit

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

SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE

A POWER POLE

A CORNER OF A BUILDING

OR A FENCE POST

Slope Gauge

15°

WARNING

Do not mow on inclines with a slope in excess of 15 degrees (a rise of approximately 2-1/2 feet every 10 feet). A riding mower could overturn and caus e se rious in jury. I f operat ing a wal k-behind mowe r on such a slope, it is extremely difficult to maintain your footing and you could slip, resulting in serious injury. Operate RIDING mowers up and down slopes, never across the face of slopes.

SECTION 5: ATTACHMENTS & ACCESSORIES

MODEL NUMBER DESCRIPTION

OEM-190-601 FastAttach OEM-190-602 FastAttach OEM-190-112 Mulch Kit (For 42-i nch Decks Only) OEM-190-118 Mulch Kit (For 46-i nch Decks Only, includes a set of bl ades) OEM-190-603 FastAttach OEM-190-604 TracPac OEM-190-822 FastAttach OEM-190-823 42-inch Two-stage Snowt hrower

™

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

™

Twin Bagger Grass Collector (For 46-inch Decks Only, includes a set of blades)

™

Front Bumper Kit

™

Storage Container (mounts on rear of tractor)

™

46-inch Front Dozer Blade

SECTION 6: TRACTOR SET-UP

ATTACHING THE BATTERY CABLES NOTE:

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

The positive battery terminal is marked

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

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

• Place the hold-down strap in p osition ov er the battery to secure it in place. See Figure 2.

Positive

Terminal

Rubber

Boot

GAS AND OIL FILL-UP

Service the engine with gasoline and oil as instructed in the separa te engine man ual packed with your tractor. Read instructions carefully.

IMPORTANT:

however, you MUST check the oil level before operating. B e carefu l not t o overfill. Ove rfilling with o il may cause the engine to smoke. This will result in poor engine performance and could cause permanent engine damage.

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

Your tractor is shipped with oil;

WARNING:

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

Battery

Wing

Nut

Negative

Terminal

Hold-down Strap

Bolt

Tray

Figure 2

NOTE:

If battery is put into service after date shown on top of battery, charge for minimum of one hour at 6-10 amps. Refer to the

MAINTENANCE

section of this manual for more detailed instructions regarding proper battery charging procedure.

WARNING:

Never smoke while fueling your tractor or fill the fuel tank while engine is running or while engine is hot.

WARNING:

Do not fill closer than 1/2 inch from the top of the fuel tank to prevent spills and to allow for fuel expansion. If gasoline is accidently spilled, m ove tractor away from area of spill. Avoid creat ing any source of ignition until gasoline vapors have disappeared.

INSTALLING THE MULCH KIT

On units equipped with a 46-inch deck, follow the instructions included with the mulch kit which is packaged separately within the crate. On units equipped with a 42-inch deck , the mulch kit is installed at the factory. To remove it, unfasten t he wing knob found on the top of th e cutting deck and carefully pull the mulch plug out from the di scharge area of the deck.

SECTION 7: CONTROLS

NOTE:

Steer ing Wheel not shown for clarity.

NOTE:

Figure 3

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

™

Pedal

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

IGNITION SWITCH

To start the engine, insert key into the ignition switch and turn clockwise to the

START

key to the ON position once engine has fired. See Figure 4. Refer to STARTING THE ENGINE in the OPERATION section of this manual for detailed starting instructions. The ignition switch is als o used to operate the headlights. Refer to OPERATING THE HEADLIGHTS in the OPERATION section of this manual for detailed instructions

WARNING:

Rem ove th e key from th e tractor when the tractor is not in use to prevent accidental starting.

position. Release

Off On/Lights

IMPORTANT:

When using PTO operated equipment such as the cutting deck or other attachments, always operate the tractor with the throttle le ve r in t he FA ST (rabbit) position.

CHOKE CONTROL

On some units, moving the throttle lever all the way forward activates the engine’s choke control. On all other units, the choke control can be found on the left side of the dash panel and is activated by pulling the knob outward. Activating the choke control closes the choke p late o n the c arburetor and aids in starting the engine. Refer to STAR TING THE ENGINE in the OPERATION s ection of this manual for detailed starting instructions.

Start

Figure 4

THROTTLE CONTROL LEVER

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

Throttle Symbol

Choke

Position

Fast

Position

Slow

Position

Throttle

Symbol

Fast

Position

Slow

Position

INDICATOR MONITOR

HOUR METER

Your tractor is equipped with four in dicat or lights a nd an hour meter located on the left side of the dash panel. See Figure 6.

Battery

Hour

Meter

1/10

PTO

Oil

Brake

Figure 6

If a light illuminates when attemp tin g to s tart t he uni t, proceed as follows: BRAKE — Depress the brake pedal. PTO — Move PTO lever into the disengaged

(OFF) position.

OIL— Check the crankcase oil level, and a dd

oil as required. The BATTERY indicator ligh t will illuminate any time the ignition key is the On position and the engine is not running. If it illuminate’s while the engine is running, it indicates that the bat tery is in need of a charge. Refer to the MAINTENA NCE section of this manual for the proper battery charging procedure.

Figure 5

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

LIFT LEVER

BRAKE PEDAL

BRAKE

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

PTO (POWER TAKE-O FF) LEVER

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

NOTE:

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

he PTO lever must be in the disengaged

AUTODRIVE™ PEDAL

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

NOTE:

activate the safety interlock switch when starting the tract or

The brake pedal must be fully dep ressed t o

™

pedal along the

PARKING BRAKE BUTTON

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

NOTE:

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

IMPORTANT:

when leaving the tractor unattended.

The parking brake must be set if the

Always set the parking brake

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

IMPORTANT:

when leaving the tractor unattended.

Always set the parking brake

™

pedal with

SHIFT LEVER

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

™

IMPORTANT:

force the s hift lever. Doin g so may result in serious damage to the tractor’s transmission.

Never

Shift

Knob

CRUISE CONTROL BUTTON

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

™

pedal. This w ill engag e the cruise control and allow the tractor to remain at that speed without applying pressure to the AutoDrive

™

pedal. Depress the brake pedal or the AutoDrive

™

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

SECTION 8: OPERATION

SAFETY INTERLOCK SWITCHES

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

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

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

• The safety interlock system wil l automatically shut off the e ngine if the PTO lever is moved into the engaged (ON) position with the shift lever in the REVERSE position.

MTD

SEAT ADJUSTMENT LEVER

To adjust the seat forward or backward, slide the seat adjustment lever to the left and reposition the seat to the desired position. Once a comfortable position is found, release the seat adjustm ent lever to lock the seat in place. Refer to the ADJUSTMENTS section of this manual for more detailed instructions.

CUP HOLDER

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

WARNING:

Never operate the tractor under the influe nce of alcoholic b everages or drugs of any kind. Doing so can result in serious personal injury or death.

IMPORTANT:

Tampering with or attempting to bypass the tractors Safety Interlock Switches in any way WILL void your warranty.

WARNING

• GO UP AND DOWN SLOPES, NOT ACROSS.

• AVOID SUDDEN TURNS.

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

• IF MACHINE STOPS GOIN G UPHILL, STOP BLADE(S) AND BACK DOWNHILL SLOWLY.

• DO NOT MOW WHEN CHILDREN OR OTHERS ARE AROUND.

• NEVER CARRY CHILDREN.

• LOOK DOWN AND BEHIND BEFORE AND WHILE BACKING.

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

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

• KNOW LOCATION AND FUNCTION OF ALL CONTROLS.

• BE SUR E BLADE( S) AND ENGIN E ARE STOP PED BEF ORE 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.

A VOID SERIOUS INJURY OR DEATH

READ OPERATOR’S MANUAL

WARNING:

Do NOT attempt to bypass or disconnect the tractor’s safety interlock. Doing so could result in serious personal injury or death.

SETTING THE CUTTING HEIGHT

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

WARNING:

from the discharge chute opening of the cutting deck.

Keep hands and f eet away

STOPPING THE ENGINE

• Place the PTO lever in the disengaged (OF F) position

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

• Turn the ignition key counterclockwise to the OFF position.

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

NOTE:

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

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

STARTING THE ENGINE NOTE:

this manual for Gasoline and Oil fill-up instructions.

IMPORTANT:

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

NOTE:

to the

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

NOTE:

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

Refer to the TRACTOR SET-UP section of

• Insert the tractor key into the ignition switch.

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

• Depress the brake pedal and set the parking brake.

• Place the s hif t lev e r in the NEUTR AL pos i tion.

• Move the throttle control lever into the FAST (or CHOKE, if so equipped) position.

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

• Turn the ignition key clockwise to the START position. After the engine starts, release the key. It will ret u r n to the ON position.

Do NOT hold the key in the START

If starting problems are encountered, refer

TROUBLESHOOTING

section of this manual.

Do NOT leave the choke cont rol out while

IMPORTANT:

If yo u thin k you’ ve str uck a for eign object, stop the engine immediately. Remove the wire(s) from the spark plug(s), thoroughly inspe ct the unit for any damage, and repair the damage before restarting and operating the tractor

DRIVING THE TRACTOR

WARNING

excessive speed and sudden stops.

WARNING

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

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

IMPORTANT:

change the directio n 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 d epress the AutoDr ive achieved.

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

™

pedal until the desired speed is

™

pedal.

Avoid sudden starts,

Do not leave the seat of the

Do NOT use the shift lever to

SETTING THE CRUISE CONTROL NOTE:

utilized in th e for wa r d dir e c t ion .

The cruise control feature should only be

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

• Lightly depress the cruise control button.

™

• While continuing to hold the cruise button i n,

™

lift your foot from the AutoDrive

pedal (you

should feel the cruise latch engage).

• If properly engaged, the cruise control button and the AutoDrive

™

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

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

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

• Lightly depress the

AutoDrive

™

pedal.

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

To turn the tractor’s headlights off:

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

IMPORTANT:

Never move the key into the Start position while the engine is running. Doing so may cause damage to your engine’s starter.

STOPPING THE ENGINE

• Place the PTO lever in the disengaged (OF F) position.

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

™

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

DRIVING ON SLOPES

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

WARNING

Do not mow on inclines with

a slope in excess of 15 degrees (a rise of approximately 2-1/2 feet every 10 feet). The tractor could overturn and cause serious inju r y.

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

OPERATING THE HEADLIGHTS

To turn the tractor’s headlights on:

• Start the engine following the instructions earlier in this section.

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

IMPORTANT:

USING THE LIFT LEVER

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

ENGAGING THE PTO (POWER TAKE-OFF) LEVER

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

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

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

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

IMPORTANT:

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

INTERLOCK SWITCHES

The PTO lever cannot be in the

SAFETY

earlier in this section.

MOWING

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

WARNING

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

WARNING

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

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

To avoid possib le injury, do

Never direct the discharge

MTD

’s high

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

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

• Do not mow a t high ground speed, especia lly if a mulch kit or grass collector is installed.

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

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

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

SECTION 9: ADJUSTMENTS

LEVELING THE DECK

WARNING:

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

NOTE:

performing any deck leveling adjustments. Refer to

TIRES

further information regarding tire pressure.

Check the tractor’s tire pressure before

in the maintenance section of this manual for

Front to Rear

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

WARNING:

off, remove the key from the i gnition swi tch and apply the tractor’s parking brake before making any adjustments to the cutting deck.

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

• Measure the distance from the front of the blade tip to the ground and the rear of the blade tip to the ground. The first measureme nt

Cutting blades are sharp.

Turn the tractor’s engine

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

• Loosen the two jam nuts on the rear side of the deck stabilizer bracket. See Figure 7A.

• Locate the two lock nuts on the opp osite side of the stabilizer bracket. See Figure 7A. Tighten the lock nuts to raise the front of the deck; loosen the lock nuts to lower the front of the deck.

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

Side to Side

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

WARNING:

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

• With the tractor parked on a firm, level surface, place the lift lever in the top notch (highest position) and rotate the both blades so that they are perpendicular with the tractor.

Turn the tractor’s engine

• 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 measuremen ts taken should be equal. If they’re n ot, proceed to the next step.

• Loosen, but do NOT remove, the hex cap screw on the left deck hanger bracket. See Figure 7B.

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

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

Lock

Deck

Stabilizer

Bracket

Nuts

Deck

ront to Rear

Jam Nuts

Figure 7

SEAT ADJUSTMENT

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

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

Seat

Seat Adjustment Lever

Hex Cap Screw

Deck Hanger Bracket

Side to Side

• Remove the hex nut and lock washer on the top of ball joint. See Figure 9.

Hex Nut and Lock Washer

Axle

Ball Join t

Zerk Fittting

(if so equipped)

Jam Nut

Pivot Bar

Drag Link

Figure 8

STEERING ADJUSTMENT

If the tractor turns tighter in one direction than the other, or if the b all joints are being replaced due to damage or wear, the steering drag links may nee d 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 9.

Figure 9

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

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

NOTE:

Threading the ball joints too far onto the drag links will cause the fron t 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. Insert a 1/4" dowel up through aligning holes in both the steering gear and support plate. See Figure 10.

Drag Links

Insert Dowel

Here

Support Plate

View shown from beneath tractor.

NOTE:

Figure 10

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

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

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

• Adjust if necessary.

• Remove the dowel inserted earlier before attempting to operate the tractor.

Steering Gear

Steering

Shaft

CARBURETOR ADJUSTMENT

BRAKE ADJUSTMENT

If the tractor does not come to a c om ple te stop wh en 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 t rans missio n fr om the right s i de of the tractor, locate the compression spring and brake disc. See Figure 11.

Hex Nut

Set Gap

at .011"

Brake Disc

View shown from beneath tractor.

NOTE:

• Loosen, but do NOT remove, the hex nut found on the right side of the brake assembly. See Figure 11.

• Using a feeler gaug e, 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

NOTE:

WARNING:

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

A dirty air cleaner will cause an engine to

If any adjustments are

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

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

PTO (POWER TAKE-OFF) ADJUSTMENT

If your tractor’s engine fails to crank when following the starting instructions found earlier in this manual, the PTO may be in need of adjustment. With the PTO lever in the disengaged (OFF) position, the lever must go back far enough so that a metal tab that is bolted to the base of the lever can fully depress a plunger saftey switch mounted to the tractor’s frame beneath the fuel tank. Adjust, if necessary, as follows:

WARNING:

tractor’s cutting deck continue to turn with the PTO lever in the disengaged (OFF) postion, stop the tractor immediately and perform the following steps.

• Turn the tractor’s engi ne off, remove the key from the ignition switch and apply the tractor’s parking brake.

If the blades on your

• Locate the PTO engagem ent rod and the PTO adjuster link by looking at the tractor’s underside. See Figure 12.

• Remove the cotter pin that affixes the lower end of the PT O engagement rod to the PTO adjuster link. Save the pin. See Figure 12.

• Take the lower end of the PTO engagement rod out of the hole in the PTO adjuster link and move the rod as far back into the disengaged (OFF) position as possible.

• Thread the PTO adjuster link outwa rd un til t he hole in the end of it is aligned w ith the PTO engagement rod.

SECTION 10: MAINTENANCE

• Reinsert the PTO engagement rod into the hole in the PTO adjuster link and reinsert the cotter pin removed earlier (if undamaged).

PTO Adjuster Link

Cotter Pin

PTO Engagement Rod

Figure 12

WARNING:

Disconnect the spark plug wire(s) and ground against the engine before performing any adjustm ents, repairs or maintenance.

ENGINE

Refer to the separate engine manual for engine maintenance instruction s.

Check

engine oil level

instructed in the separate engine manual packed with your unit.

Read and follow instructions

carefully. Changing Engine Oil

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

Oil Fill Cap

Oil Drain Hose

before each use as

Protective Cap

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

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

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

• Service the

oil filter

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

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

• Refill the engine with new motor oil.

IMPORTANT:

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

Service

air cleaner

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

Oil Fill Tube

NOTE:

Single-cylinder engine shown. Valv e location will vary wi th engi ne style.

Figure 13

Oil Drain V a lv e

Oil Drain Port

The

spark plug(s)

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

CLEANING THE ENGINE AND DECK

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

IMPORTANT:

Do NOT use a garden hose to clean the cutting deck. The ball bearin gs in the blade spindles are seal ed at the factory an d cannot be relubricated. Spraying water near the spindles can significantly reduce the life of the bearings.

CUTTING DECK REMOVAL

WARNING:

maintenance, move the PT O lever into the disengaged (OFF) position, engage the parking brake, turn the ignition key to the OFF position and remove the key from the

switch to avoid accidental starting

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

WARNING:

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

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

Before performing any

Do NOT remove deck

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

• Grasp the PTO id ler pulley brac ket and pivot it toward the discharge chute to relieve tension on the belt. Remove the deck belt from the bottom portion of the engine pulley a nd from around the PTO idler pulley.

NOTE:

On units equipped wi th a 46-inch deck, the bottommost belt on the deck does NOT need to be removed in order to remove the deck.

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

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

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

• Repeat the above s teps o n the left side o f t he tract o r.

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

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

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

NOTE:

To properly remount the cutting deck, perform the above steps in reverse order. Having a second person assist you will ease this procedure.

NOTE:

To Lift Assembly

Deck Support Pins

PTO Idler Pulley Bracket

(mounted on tractor)

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

Deck Stabilizer Rod

Figure 14

Deck Lift Arms

PTO Idler Pulley

PTO Belt

Engine Pulley

Deck

Stabilizer

Bracket

Hooks

Front of Trac tor

CHANGING THE DECK BELT(S)

All belts on your tractor are subject to wear and should be replace d if any signs of cracking, shreddin g or rotting are present.

IMPORTANT:

The V-belts found on your tractor are specially designed to engage and disengage safely. A substitute (non-OEM) V-belt can be dangerous by not disengaging com plet ely. For a proper working machine, use factory approved belts.

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

NOTE:

Removing the deck from the tractor as instructed earl ier in this section wi ll ease the foll owing steps,

but is not necessary.

42-inch decks

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

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

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

• Remove the deck belt from the bottom portion of the engine pulley and from around the PTO idler pulley.

• Route the new belt as shown in Figure 14, around the deck pulleys, idler pulley and engine pulley.

IMPORTANT:

(POWER TAKE-OFF) ADJUSTM EN T

It is recommended th at the PTO be readjusted after replacing the deck belt. Refer to

in the

ADJUSTMENTS

section of this manual for the proper procedure.

PTO

• Remount the belt guards removed earlier.

Engine Pulley

Deck Idler Pulley

PTO Idler Pulley

(mounted on tractor)

Deck belt (Bottom)

PTO belt (Top)

Right Hand

Double Pulley

(beneath belt guard)

Left Hand

Double Pu lley

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

NOTE:

Center Pulley

Self-Tapping Scre ws

Figure 15

46-inch decks

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

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

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

• Remove the deck belt from the bottom portion of the engine pulley and from around the PTO idler pulley.

• Remove and discard old belt.

• Route the new belt(s) as shown in Figure 15. OEM belt part numbers are listed on the following page.

IMPORTANT:

(POWER TAKE-OFF) ADJUSTM EN T

• Remount the belt guards removed earlier.

It is recommended th at the PTO be readjusted after replacing the deck belt. Refer to

in the

ADJUSTMENTS

42-Inch Deck 46-Inch Deck PTO (Top) Belt 754-0472 754-0476 Bottom Belt N/A 754-0349

section of this manual for the proper procedure.

PTO

CHANGING THE TRANSMISSION DRIVE BELT(S)

All belts on your tractor are subject to wear and should be replace d if any signs of cracking, shreddin g or rotting are present.

IMPORTANT:

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

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

NOTE:

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

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

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

IMPORTANT:

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

Upper Drive Belt

• Locate the transmission idler pulley on the upper drive belt by looking through t he battery tray opening. See Figure 16.

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

• Remove the belt from around the transmission idler pulley.

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

NOTE:

Lower Drive Belt

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

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

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

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

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

NOTE:

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

IMPORTANT:

BEFORE performing the following steps.

NOTE:

proce du re will e as e the following s teps , b ut is not ne c es s a ry .

Proper removal of the lower drive belt requires special tools and the removal of several tractor

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

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

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

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

Jacking the rear of the tractor up off the ground and securing it with jackstands at this point in the

Variable-speed

Pulley

Battery Tray

Opening

Shift Lever

Rear Idler Pulley

Drive belt (Lower)

Drive belt (Upper)

Idler Bracket

Transmission Idler Pulley

Single-speed

Transmission

View shown from above tractor.

NOTE:

Transmission Pulley

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

• Remove the cotter pin that affixes the lower end of the PT O engagement rod to the PTO adjuster link. Save the pin for reassembly. See Figure 17.

Belt Keeper

Double-Idler Bracket

Front Idler Pulley

Front of Tract or

Figure 16

• Remove the hex bolt from the center of the

Belt Keeper

to AutoDrive™ pedal

Engine Pulley

Belt Keeper

engine pulley. Do NOT a ttempt to remove the engine pulley at this time. See Figure 18.

PTO Engagement Rod

Cotter Pin

Figure 17

PTO Adjuster Link

Hex Bolt

Engine Pulley

View shown from beneath tractor.

NOTE:

Figure 18

IMPORTANT:

When remounting the engine pulley, torque the center hex bolt to between 38 footpounds and 50 foot-pounds.

• Remove the two h ex bolts (from both s ides of the tractor) that affix the PTO actuat or bracket to the tractor frame. See Figure 19.

Idler

Adj. Rod

Place Wrenches Here

Hex Bolts

PTO Actuator

Bracket

Deck Stop

Figure 19

• Carefully lower the PTO actuator bracket and the engine pulley as an assembly while removing the d rive belt f rom the upper portion of the engine pulley.

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

• Reassemble by following the above steps in reverse order.

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

The AutoD rive

™

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

™

pedal. See

Figure 20.

Double-idler

Bracket

Hole

Idler

Adj. Rod

Front of Tr act or

View shown from above tractor.

NOTE:

Figure 20

Adjust the AutoDrive

™

pedal after replacing the drive

belts on your tractor, if necessary, as follows:

• Locate the speed control assembly on the underside of the steering support brack et. See Figure 21.

Neutral

Return

Bracket

Hairpin

Clips

AutoDrive™ Pedal

Return Spring

Speed Control

Assembly

Figure 21

• Remove both hairpin clips from the pin which is fastened to the spee d control assembly (be careful not to lose the small flat washers found on the pin). See Figure 21.

• Remove the AutoDrive

™

pedal return spring.

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

21.

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

• Reassemble by following the above steps in reverse order.

IMPORTANT:

After replacing the drive belts,

perform the PTO adjustment as instructed in the

ADJUSTMENTS

section of this manual prior to

operating the tractor.

CUTTING BLADES

WARNING:

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

The blades may be removed for sharpening or replacement as follows.

• Remove the deck from beneath the tractor, (refer to DECK REMOVAL earlier in this section for detailed instructions) then gently flip the deck over to expose its underside.

• Place a block of wood between the center deck housing baffle and the cutting blade to act as a stabiliz er . See Fi g ur e 2 2.

• Use a 15/16" wrench to remove the h ex flange nut that secures the blade to the spindle assembly. See Figure 22.

Cutting blades are sharp.

NOTE:

The hex flange nut has a right-handed thread pattern. Do NOT attempt to force the nut in the incorrect direction. Doing so may damage the nut and create a safety hazard.

Hex Flange Nut

Spindle

Assembly

Cutting Blade

Block of Wood

IMPORTANT:

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

BATTERY

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

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

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

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

Figure 22

To properly sharpen the cutting blades, remove equal amounts of metal from bot h end s of the blades along the cutting edges. See Figure 23. Sharpen the cutting edge straight acros s, parallel to the trailing edge, at a 25° to 30° angle. See Figure

23.

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 23.

Worn Blade Edge

Blade Separation

Sharpen Edge Evenly

Wind Wing

Figure 23

It is extremely important that each cutting blade edge be ground equally to maintain proper blade balance. An un balanced blade will cause excessive vibration when rotating at high speeds, may cause damage to the tractor and result in persona l 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 sid e of t he blade marked ‘‘Bottom ’’ (or with a part number stamped in it) facing the ground when the mower is in the operating position.

IMPORTANT:

If removing the battery for any reason, disconnect the NE GATIVE (B lack) wire from it’s terminal first, followed by the POSITIVE (Red) wire. When re-installin g the battery, always connect the NE G ATIVE (Bl a ck) w ire its te rmin al firs t , follow ed by the POSITIVE (Red) wire. Be certain that the wires are connected to the correct terminals. reversing them could change the polarity and cause damage to your engine’s alternating system.

Charging

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

WARNING:

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

FUSE

A fuse is installed in your tractor’s wiring harness to protect the tractor’s electrical system from damage caused by excessive amperage. Always use the same capacity fuse f or replacement. If the electrical system does not function, or your tractor’s engine will not crank, first check to be certain that the fuse has not blown. It can be found under the hood mounted behind the top of dash panel on the support bar. Pull the fuse out and compare it with Figure 24 to determine if it is good or bad.

GOOD BAD

Figure 24

TIRES

The recommended operating tire pressure is approximately 10 psi for the rear tires and 14 ps i for the front tires. Refer to the tire sidewall for exact tire

SECTION 11: LUBRICATION

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

WARNING:

engine before performing any maintenance.

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

ENGINE

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

PIVOT POINTS

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

LINKAGE

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

STEERING GEAR

Lubricate the teeth of the st eering gear wi th an all-purpose a utomotive g rease every 25 hours of operation or once a season.

WHEELS

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

FRONT AXLES

Your tractor may be equipped wi th zerk fit tings on t he ends of the front pivot bar. See Figu re 9. L ubricate bot h the left and the right front axles with a grease gun at least once a season.

SECTION 12: TROUBLESHOOTING GUIDE

Trouble

Engine will not crank

Engine cranks b u t will not start

Possible

Cause(s)

Safety switch button not depressed. Battery installed incorrectly.

Battery is dead or weak. Blown fuse

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

No spark to spark plug(s).

Corrective Action

There are two saf ety s wi tches i n the starting circ uit of you r unit: the brak e pedal s witch and the PTO switch. Make certain the actu ator is fully depressing the buttons on each switch. The Operator must be seated on the tractor in order to start the engine, also. The battery must be install ed wit h negative te rminal attached to black ground wire . Negative terminal is identified at the post by “NEG”, “N” or “-”. The positive terminal, identified b y “POS” , “P” or “+”, mus t be att ached to the thic k r ed wire which goe s to the solenoid. Charge at six amps with a 12- v olt automoti v e-ty pe batte ry charger f or one hour or until fully charged. Refer to ope rator ’s manual for fuse locat ion. Repl ace fuse wi th automot iv e t ype fuse o f the proper amperage. Fuses seldom fail without a reason. The problem must be corrected. Check for loose connections in the fuse holder. Replace fuse holder if necessary. A dead short may be in the cranking or charging circuit where the insulation may have rubbed through and exposed the bare wire. Replace the wire or repa ir with electrician's tape i f the wire strands have not been damaged. Note: Look for a wire pinched between body panel s, burned by the exhaust pipe or muffler or rubbed against a moving part. Refer to the OPERATION section of this m anual for the correct position of the thrott le control and choke for starting..

Gas o li n e tank empty. Fill. Fuel line or in-line fuel filter plugged. Remove and cl ean fuel line. Repl ace fuel filter (if so equipped) if necessary. Spark plug lead disconnected. Connect lead. Usi ng a spark tester, check for spark. If no spark is present, have engine’s magneto serviced by an authorized engine dealer.

Engine smokes

Excessive vibrati on

Mower won’t discharge grass or leaves uncut strips

Dirty aircleaner .

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

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

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

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

Stop engine immediat ely. Check all pul leys, blade adapters, k eys and bolts for tightness and spindle damage. Tight en or replace any loose or damaged parts. Alwa ys replace damaged bl ade. Only use original equipment blades. Throttle must be set at full throttle.

Use lower ground speed. The slow er your ground speed, the better the qual it y of cut. Raise deck.

Sharpen or replace blades (uncut strip problem only).

Model 604

8 10

REF.

NO.

1 625-0051 Bulb/Socket Headlight Assembly

2 629-0913 Wiring Harness 3 629-0924 Harness Adapter (for K ohler engines) 4 710-0599 Self Tapping Screw, 1/4-20 x .5 5 712-3006 Hex Nut, 1/4-20 6 725-1426 Solenoid, 12-volt, 100 Amp 7 725-1657A Snap Mount Safety Interlock Switch 8 725-1 74 1 I g n i tion S w it c h

9 725-1743 Indicator Monitor / Hour Meter 10 725-1745 Ignition Key 11 725-1747 Safety Plunger Switch 12 736-0222 External Lock Washer, 1/4 13 736-0329 Lock Washer, 1/4

PART

NO. DESCRIPTION

725-1739 Bulb Only 725-1649 Socket Only

Electrical System/Trac t or Body

28 24

30 29

26 33 31 34

4 2

22 14

12 16

REF.

NO.

1 710-0788 Self Tapping Screw, 1/4-20 x 1.0 2 710-0599 Self Tapping Screw, 1/4-20 x .5 3 710-0751 Hex Cap Screw, 1/4-20 x .62 4 710-0895 Self Tapping Screw, 1/4-15 x .75 5 710-0924 Pan Phillips Screw, 1/4-20 x .75 6 710-3008 Hex Cap Screw, 5/16-18 x .75 7 712-0292 U-type Speed Nut, 1/4-20 8 712-3004A Flange Lock Nut, 5/16-18

9 712-3027 Hex Flange Loc k Nut, 1/4-20 10 725-1649 Head Lamp Socket 11 731-1978 RH Head Light Lens 12 731-1979 LH Head Light Lens 13 731-1980 Hood, Yellow, 4-style 14 731-1981 LH Side P anel, Yellow, 4-style 15 731-1982 RH Side P anel, Yellow, 4-style 16 731-1995 LH Head Light Re fl ector 17 731-1996 RH Head Light Refl ector 18 736-0173 Flat Washer, .28 x .74 x .063 19 736-3078 Flat Washer, .349 x 1.0 x .063 20 747-1132 Hood Support Rod

PART

NO. DESCRIPTION

REF.

NO.

21 783-0808 Heat Shield, 4-style 22 710-0604 Self T apping Screw, 5/16-18 x .625 23 710-1017 Torx Self Tapping Screw, 1/4-14 x .625 24 710-3217 Torx Screw, #8-32 x .375 25 712-0142 Hex Nut, 8-32 26 731-0069 Dash Panel (Manual PTO), 4-style 27 731-0072 Parking Brake Button 28 731-1857 Throttle Control Lever 29 731-2106 Cr uise Control Button 30 747-1155 Brake/Cruise Pivot Rod 31 749-1087 Dash Support Tube 32 731-2232 I ntake Bellow (Intek Single)

33 751-0603 Fuel Cap 34 751-0659 Fuel Tank (Two Gallon, Shown)

35 725-1745 Ignition Key 36 746-1084 Choke/Throttle Cable (Intek Single)

PART

NO. DESCRIPTION

731-2234 Intake Bellow (Intek Twin)

751-0658 Fuel Tank (Three Gallon)

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

Model 604

43 42

45 41

37 48

44 30

39 46

6 45

36 47 16

38 28

35 32

17 21

22 10

11 33 29

2 9

2 24

12 23

25 19

9 7

Lift Assembly

REF.

NO.

1 647-0040 Deck Stabilizer Rod

2 683-0197 Lift Shaft Assembly

3 711-0332 Clevis Pin, .5 x .78

4 712-0206 Hex Nut, 1/2-13

5 712-0431 Flange Lock Nut, 3/8-16

6 712-3004A Flange Lock Nut, 5/16-18

7 712-3083 Hex Nut, 1/2-13

8 714-0104 Internal Cotter Pin

9 714-0111 Cotter Pin 10 716-0106 E-ring 11 720-0311 Handle Grip 12 732-0874 Tor sion Spring 13 732-0934 Lift-assist Spring, 1.15 x 5.99

14 736-0275 Flat Washer, 5/16 15 736-0921 Lock Washer, 1/2 16 736-3019 Flat Washer, .31 x 1.062 x .134 17 736-3084 Flat Washer, .51 x 1.12 x .06 18 738-0138 Hex Cap Screw, 5/16-18 x .62 19 738-0380 Shoul der Screw, .5 x .27, 3/8-16 20 741-0225 Hex Flange Bearing 21 741-0715 Snap Flange Bearing 22 746-0968 Lift Cable, 16.16 23 747-1111 Lift Handle 24 756-1154 Roller Pulley 25 783-0678 Arm Lift 26 783-0720 Deck Stabilizer Bracket

PART

NO. DESCRIPTION

(Found on Unit s w/ 46-inch Decks Only)

REF.

NO.

27 710-0260 Carr iage Bolt, 5/16-18 x .62 28 710-0604 Self T apping Screw, 5/16-18 x .625 29 710-0895 Self T apping Screw, 1/4-15 x .75 30 731-1990 Lift Lever Cover 31 731-2104 Shift Lever Cover w/ Cup Holder 32 738-0155 Shoulder Screw, .437 x 1.62 33 783-0677 Lift Adjustment Bracket 34 783-0685 Fender 35 783-0715 Seat Mounting Bracket 36 710-1268 Screw, #10-16 x .375 37 712-3027 Hex Flange Lock Nut, 1/4-20 38 720-0309A Seat Adjuster Grip 39 731-1989 Spacer 40 732-0499 Compression Spring, .41 x 1.5 41 736-0175 Spring Washer, .265 x .562 x .025 42 736-0204 Flat Washer , .344 x .62 x .03 43 738-0137A Shoulder Screw, .340 x .285,1/4-20 44 738-1007 Shoulder Screw, .50 x .50, 3/8-16 45 783-0611 Seat Stop 46 783-0738 Seat Pivot Bracket 47 783-0739 Seat Adjustment lever 48 783-0753 Seat Adjustment Selector 49 757-0365 Seat, Radiant Yel low

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

PART

NO. DESCRIPTION

757-0372 Seat, Radiant Yellow w/ Drain Holes

726-3046 Foot P ad Clips (Not Show n)

NOTE:

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

painted parts

For

Yard-Man Green: 0665

Yard-Man Yellow: 0674

Powder Black: 0637

, please refer to

Model 604

24 43

14 20

13 42

20 1

10 17

33 31

Steering Assembly

REF.

NO.

1 683-0263 Lower Frame Assembly

2 710-0604 Self-tapping Scr ew, 16-18 x .625

3 783-0726 RH Pivot Support Bracket

4 783-0727 LH Pivot Support Bracket

5 783-0728 Pivot Bar Brac ket

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

7 711-1291 LH Drag Link

8 711-1292 RH Drag Link

9 712-0240 Jam Nut, 7/16-20 (Grade 2) 10 712-0241 Hex Nut, 3/8-24 (Grade 2) 11 712-0431 Flang e Lock Nut, 3/8-16 12 712-0459 Flang e Lock Nut, 7/16-20 13 712-3004A Flange Lock Nut, 5/16-18 14 717-1550 Steering G ear, 11/90 Ratio 15 717-1554 Steering Pinion Gear 16 723-0448A Ball Joint, 7/16-20 17 736-0169 Lock Washer, 3/8 18 736-3084 Flat Washer, .51 x 1.12 x .06 19 738-1001 Steering Shaft, .625 OD x 24.4 20 741-0475 Plast ic Bushing, .38 ID 21 741-0656 Hex Flange Bearing, 5/8 22 748-0416 Shoul der Spacer, .38 ID 23 731-1869 Steering Wh eel, .625 Spline 24 731-1904 Steering Wheel Cap w/ Logo 25 638-0019 LH Axle Asse mb ly, .625 Diameter

26 638-0020 RH Axle Assemb ly, .625 Diameter

PART

NO. DESCRIPTION

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

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

REF.

NO.

27 683-0128A Pivot Bar 28 712-0431 Flange Lock Nut, 3/8-16 29 714-0470 Cot ter Pin 30 726-0214 Push Cap, 5/8

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

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

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

37 734-1787A Hub Cap, Yellow w/ Sprig Logo

38 783-0653 St eering Support Bracket 39 738-1020 Shoulder Screw, .625 x .50, 7/16-20 40 736-0331 Bell Washer , . 39 x 1.13 x .062 41 738-0140 Shoulder Screw, .435 x .178, 5/16 x .56 42 736-0242 Bell Washer , . 34 x .872 43 710-0643 Hex Bolt, 5/16-18 X 1 44 737-3000 Grease Fittting (if so equipped) 45 710-0525 Cast Iron Pivot Bar (if so equipped)

PART

NO. DESCRIPTION

726-0341 Push Cap, 3/4

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

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

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

727-0425A Spring Clip (Not Shown)

NOTE:

painted parts

For

Yard-Man Green: 0665

Yard-Man Yellow: 0674

Powder Black: 0637

, please refer to

Model 604

5 1

11 18

31 54

47 34

15 17

49 10

56 71

66 59

32 20

27 24

50 19

33 23

Drive System

REF.

NO.

1 17839 Shift Lever Bracket

2 17840 Transaxle Mounting Bracket

3 618-0386 Single-speed Transmission Assembly

4 631-0009 Shifter Knob

5 647-0041 Shift Lever

6 656-0048 Variable-speed Pulley Assembly

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

8 683-0251 Double-idler Bracket

9 710-0189 Hex Cap Screw, 5/16-18 x 3 10 710-0227 Self Tapping Screw, #8-18 x .5 11 710-0347 Hex Cap Screw, 3/8-16 x 1.75 12 710-0599 Self Tapping Screw, 1/4-20 x .5 13 710-0604 Self Tapping Screw, 5/16-18 x .625 14 710-0642 Self Tapping Screw, 1/4-20 x .75 15 710-3011 Hex Cap Screw, 3/8-16 x 2.25 16 711-0677 Ferrule, 5/16-18 17 712-0241 Hex Nut, 3/8-24 18 712-0378 Hex Nut, 7/16-20 19 712-0431 Flang e Lock Nut, 3/8-16 20 712-0798 Hex Nut, 3/8-16 21 712-3004A Flange Lock Nut, 5/16-18 22 712-3008 Jam Nut, 3/8-16 23 714-0111 Cott er Pi n 24 714-0149B Internal Cotter Pin 25 723-0156 Ball Joint, 3/8-24 26 725-1644 Short Spring Switch 27 726-0320 Insulator Nut Plate 28 732-0384 Extension Spring, .62 Dia. x 6.12 29 732-0525 Compression Spring Clip 30 732-0716 Exten sion Spring, .59 OD x 4 31 732-0963 Extension Spring, .50 Dia. x 6.37

32 736-0105 Bell Washer, .401 x .87 x .063 33 736-0140 Flat Washer, .385 x .62 x .063 34 736-0169 Lock Washer, 3/8 35 736-0275 Flat Washer, 5/16 36 736-0407 Bell Washer, .45 x 1.0 x .602 37 736-3010 Flat Washer, .407 x .812 x .135 38 738-0322 Shoul der Screw, .625 x .217 39 747-1122 Brake Rod 40 747-1123 Belt Guard 41 747-1127 Idler Adjustment Rod, 3/8 42 747-1156 Shif t Rod 43 747-1160 Belt Guard Rod 44 748-0416 Shoul der Spacer, .38 ID

PART

NO. DESCRIPTION

(hooks to flang e, 783-0650, in frame)

REF.

NO.

45 754-0467 Variable-speed Belt 46 754-0468 Dr ive Belt 47 756-0981 Flat Idler, 2.75 OD 48 783-0637 Shift Lever Support 49 783-0667 Transmission Torque Bracket 50 783-0669 I dler Bracket 51 783-0714 Adjustable Shift Bracket 52 647-0031 Brake Control Assembly 53 647-0032 Speed Control Assembly 54 683-0266 AutoDrive 55 710-1135 Self T apping Screw, 5/16-18 x 2.5 56 711-0736 Ferrule, 1/4-20 57 711-1363 Pi n, 3/8-16 x 2.43 58 714-0104 Cot ter Pin 59 732-0437 Compression Spring, .34 OD x 1.0 60 732-0955 Extension Spring, .50 OD x 1.41 61 735-0662 AutoDrive 62 735-3049 Brake Pedal Pad 63 736-0140 Flat Washer , .281 x .5 x .0625 64 736-0187 Flat Washer , .64 x 1.24 x .06 65 736-0204 Flat Washer , .344 x .062 x .03 66 738-0155 Shoulder Screw, .437 x 1.62 67 738-0507B Shoulder Screw, .5 x .434 68 741-0225 Hex Flange Bearing 69 741-3065A Split Hex Flange Beari ng 70 747-1137 Cruise Control Rod 71 747-1138 Brake Lock Control Rod 72 748-0413 Cruise Latch 73 748-0415 Spacer, 5/16 x 1.54 74 783-0653 St earing Support Bracket 75 783-0732 AutoDrive 76 783-0773 Brake Pedal 77 783-0780 Neutral Return Bracket 78 683-0263 Lower Frame Assembly 79 783-0668 Hitch Plate 80 736-0242 Bell Washer , . 34 x .872 81 710-0627 Hex Cap Screw, 5/16-24 x .75 82 634-0177 Wheel Assembly Complete, 20 x 10 x 8

83 734-1788A Hub Cap, Yellow w/ Sprig Logo

PART

NO. DESCRIPTION

™

Pedal Assembly

™

Pedal Pad

™

Lockout Bracket

634-0104 Wheel Assembly Complete, 20 x 8 x 8 634-0077 Rim Only 734-0255 Air Valve (Not Shown) 734-1873 Tire Only, 20 x 10 x 8, Square Shoulder 734-1730 Tire Only, 20 x 8 x 8, Square Shoulder

727-0425A Spring Clip (Not Shown)

Model 604

47 52

46 49

63 62

53 38

12 18

10 19

36 35

5 8

28 10

11 26

13 33

17 13

9 20 34

23 10

41 43

38 39

Power Take-off System

REF.

NO.

1 683-0278 PTO Engageme nt Li nk w/ Weld Pin 2 683-0282 PTO Actuator Bracket w/ Weld Nut 3 710-0514 Hex Cap Screw, 3/8-16 x 1.0 (Grade 5) 4 710-0597 Hex Cap Screw, 1/4-20 x 1.0 (Grade 5) 5 710-0604 Self Tapping Screw, 5/16-18 x .625 6 710-1260A Self Tapping Screw, 5/16-18 x .75 7 710-3011 Hex Cap Screw, 3/8-16 x 2.25 (Grade 5) 8 710-3180 Hex Cap Screw, 5/16-18 x 1.75 (Grade 5)

9 710-3199 Hex Cap Screw, 1/4-20 x 1.5 (Grade 5) 10 712-0431 Flang e Lock Nut, 3/8-16 11 712-3004A Flange Lock Nut, 5/16-18 12 712-3010 Hex Nut, 5/16-18 13 712-3027 Hex Flange Lock Nut , 1/ 4-20 14 714-0111 Cott er Pi n 15 725-1657A Snap Mount Safety Interl ock Switch 16 731-2111 PTO Knob 17 732-0977 Exten sion Spring, .62 OD x 2.16 18 732-0978 Exten sion Spring, 1.2 OD x 3.638 19 736-0140 Flat Washer, .385 x .62 x .063 20 736-0176 Flat Washer, .25 x .93 x .12 21 736-0272 Flat Washer, .51 x 1.0 x .60 22 738-1021 Shoul der Screw, .5 x .27, 3/8-16 23 738-1125 Shoul der Nut, 1/4-20 24 741-0708 Hex Split Flange Bearing, .50 ID 25 747-1112 PTO Engagement Handle 26 747-1114 PTO Engagement Lever 27 747-1174 PTO Actuator Adjuster Link 28 748-0416 Shoul der Spacer, .38 ID 29 748-0421 Arm Spacer, .68 30 756-0627 Flat Idler Pulley, 3.5 OD 31 783-0744 Stop Br acket 32 783-0796 PTO Actuator Br acket

PART

NO. DESCRIPTION

REF.

NO.

33 783-0797 PTO Engagement Arm 34 783-0798 PTO Engagement Link 35 783-0799 PTO Arm 36 783-0806 Deck Stop 37 710-0561 Hex Cap Screw, 7/16-20 x 2.5 (Grade 5) 38 710-0599 Self T apping Screw, 1/4-20 x .5 39 736-0171 Lock Washer, 7/16 40 736-0322 Flat Washer , .45 x 1.25 x .164 41 750-0956 Spacer, 1.01 x 1.4 x .825 42 756-1158 Engine Pulley, 5.56 Dia. x 3.56 Dia. 43 756-1164 Pulley Sheave 44 754-0472 PTO Belt (42-inch Decks)

45 683-0263 Lower Frame Assembly 46 723-0444 Battery Strap 47 732-0755 Compression Spring, .1.314 OD x 2.35 48 732-0956 Compression Spring, .66 OD x 1.5 49 738-1014 Shoulder Screw, .5 x 1.25, 3/8-16 50 783-0349 Battery Tray 51 783-0668 Hitch Plate 52 783-0733 Spacer Cup, 1.5 OD 53 725-1426 Solenoid, 12-Volt, 100 Amp 54 736-0222 Lock Washer, 1/4 55 725-1747 Safety Interlock Plunger Switch 56 738-1020 Shoulder Screw, .625 x .5, 7/16-20 57 736-0407 Bell Washer , . 45 x 1.0 x .062 58 712-0459 Flange Lock Nut, 7/16-20 59 783-0653 St eering Support Bracket 60 725-1706 12-volt Battery, 270 CCA 61 712-3044 Wing Nut, 1/4-20 62 712-0271 Hex Sems Nut, 1/4-20 63 710-0751 Hex Cap Screw, 1/4-20 x .62

PART

NO. DESCRIPTION

754-0476 PTO Belt (46-inch Decks)

NOTE:

painted parts

For

Yard-Man Green: 0665

Yard-Man Yellow: 0674

Powder Black: 0637

, please refer to

Model 604

46-inch Deck

27 21 32

14 16 24 26 28 35

29 25 26

42-inch Deck

27 21 23

25 26

52 53

Cutting Decks

REF.

NO.

1 17982 Reinforcement Spindle Plate

2 618-0240 Spindle Assembly, 5 Dia.

3 618-0241 Double Pulley Spindle Assembly

4 683-0254 Deck Adjustment Br acket w/ Weld Nut

5 683-0265 46-inch Deck Shell

6 710-0167 Carriage Screw, 1/4-20 x .5

7 710-0347 Hex Cap Screw, 3/8-16 x 1.75

8 710-0514 Hex Cap Screw, 3/8-16 x 1.0

9 710-0528 Hex Cap Screw, 5/16-18 x 1.25 10 710-0599 Self Tapping Screw,1/4-20 x .5 11 710-0650 Self Tapping Screw, 5/16-18 x .875 12 710-0751 Hex Cap Screw, 1/4-20 x .62 13 710-1260A Self Tapping Screw , 5/16-18 x .75 14 712-3288 Hex Cap Screw, 1/4-20 x 1.62 15 712-0241 Hex Nut, 3/8-24 16 712-0291 Center Lock Nut, 1/4-20 17 712-0417A Hex Flange Nut, 5/8-18 18 712-0431 Flang e Lock Nut, 3/8-16 19 712-3027 Hex Flange Lock Nut , 1/ 4-20 20 714-0104 Internal Cot ter Pin, .072 x 1.12 21 717-1553 Deck Adjustment Gear 22 731-1032A Side Discharge Chute Assemb ly 23 732-0306 Compression Spring, .406 x .531 x 1.75 24 732-0594A Extension Spring, .91 x 7.33 25 734-0973 Deck Wheel, 5 x 1.38 26 736-0105 Bell Washer, .401 x .87 x .063 27 736-0119 Lock Washer, 5/16 28 738-0347 Shoul der Spacer, .625 x .169 29 738-0373 Shoul der Spacer, .498 x 1.53 30 742-0611 Three-in-one Blade, Star Center, 16.28

PART

NO. DESCRIPTION

756-0959 Pulley Only

756-0603 Double Pulley Only

REF.

NO.

31 742-0612 Three-in-one Blade, Star Center, 14.88 32 747-1116 Deck Release Pin 33 754-0349 Deck Belt 34 756-0627 Flat Idler Pulley, 3.5 OD 35 783-0139 I dler Bracket 36 783-0141 Center Deck Skirt 37 783-0142 RH Deck Skirt 38 783-0747 LH Belt Cover 39 783-0805 RH Belt Cover 40 16606 Retainer Hook 41 618-0324 Spindle Assembly, 5.75 Dia

42 683-0198 42-inch Deck Shell 43 710-0604 Self T apping Screw, 5/16-18 x .625 44 712-0181 Top Lock Jam Nut, 3/8-16 45 712-0271 Hex Sems Nut, 1/4-20 46 712-3006 Hex Nut, 1/4-20 47 731-2231 Belt Cover 48 736-0270 Bell Washer , . 265 x .75 x .062 49 742-0616 Three-in-one Blade, Star Center, 21.23 50 731-1636 Mul ch Plug, 46-inch Decks 51 731-1643A Mulch Plug, 42-inch Decks 52 712-3087 Wing Nut, 1/4-20 53 712-0291 Center Lock Nut, 1/4-20 54 710-0106 Hex Cap Screw, 1/4-20 x 1.25 55 710-0578 Screw, 1/4-20 x 1.5 56 736-0173 Flat Washer , . 28 x .74 x .063 57 753-0852 46-inch Deck Assembly Complete

58 753-0851 42-inch Deck Assembly Complete

PART

NO. DESCRIPTION

756-1151 Pulley Only

(w/o mulch kit) (w/o mulch kit)

NOTE:

painted parts

For

Yard-Man Green: 0665

Yard-Man Yellow: 0674

Powder Black: 0637

, please refer to

Model 604

(for choke)

Briggs & Stratton

Intek Twin

(for throttle)

(deflector must

face forward)

Kohler

Single-cylinder

(for choke)

24 27

(deflector must

face forw ar d )

Engine Accessories

Briggs & Stratton

Intek Single

4 31

REF.

NO.

1 710-0148 Self Tapping Screw, #8-32 x .375 2 710-0599 Self Tapping Screw, 1/4-20 x .5 3 710-0604 Self Tapping Screw, 5/16-18 x .625 4 710-1237 Screw, #10-32 x .625 5 710-1314 Socket Cap Screw , 5/16-18 x .625 6 710-1315 Self Tapping Screw, 3/8-16 x 1.25 7 712-0798 Hex Nut, 3/8-16 8 721-0460 Exhaust Gasket (Intek Twin)

9 726-0205 Hose Clamp 10 736-0119 Lock Washer, 5/16 11 736-0221 Flat Washer, 3/8 x .56 x .018 12 751B221535 Casing Clamp 13 751-0535 Fuel Line Hose 14 751-0564 Muffler Deflector 15 751-0616 Muffler, Twin Inlet 16 751-0650 RH Exhaust Pipe (I ntek Twin) 17 751-0651 LH Exhaust Pipe (I ntek Twin) 18 751-3140 Oil Drain Valve

PART

NO. DESCRIPTION

(deflector must

face forw a rd )

REF.

NO.

19 751-3141 Oil Drain Hose 20 751-3142 Oil Drain Cap 21 783-0615 Muf fler Heat Shield 22 783-0625A Engine Heat Shield 23 710-3206A Hex Cap Screw, M8-1.25 x 25 24 712-3086 Flange Nut, M8-1.25 25 721-0375 Exhaust Gasket (Kohler) 26 736-0607 External Lock Washer, 5/16 27 751-0621 Exhaust Pipe (Kohler) 28 751-0617 Muffler, Single Inlet 29 712-0271 Hex Sems Nut, 1/4-20 (for starter cab le) 30 721-0208 Exhaust Gasket (Intek Single) 31 732-0966 Extension Spring, .275 x 1.25 32 751B213146 Casing Clamp 33 751-0619 Exhaust Pipe (Intek Single) 34 746-1084 Throttle/Choke Cable (Intek Single) 35 746-1086 Throttle Cable (Intek Twin) 36 746-1087 Throttle Cable (Kohler)

PART

NO. DESCRIPTION

MANUFACTURER’S LIMITED WARRANTY FOR:

For TWO YEARS from the date of retail purchase within the United States of America, its possessions and territories, MTD PRODUCTS INC will, at its option, repair or replace, for the original purchaser, free of charge, any part or parts found to be defective in material or workmanship. This warranty covers units which have been operated and maintained in accordance with the operating instructions furnished with the unit, and which have not been subject to misuse, abuse, comm ercial use, neglect, accident, improper maintenance or alteration.

Normal wear parts or components thereof are subject to separate terms as noted be low in the “No Fault Ninety Day Consumer Warranty” clause.

All normal wear part failures will be covered on th is product for a period of 90 days regardless of c ause. After 90 days, but within the two year period, no rmal wear parts failures will be covered ONLY IF caused by defects in material or workmanship of OTHER component parts. Normal wear part s are defined as batteries*, belts, blades, blad e adapters, grass bags, rider deck wheels, seats, snow thrower skid shoes, shave plates and tires.

How to obtain service:

available, with proof of purchase, through your local authorized service dealer. To locate the dealer in your area, please check the yellow pages or contact the Customer Support Department of MTD PRODUCTS INC, P. O. Box 368022, Cleveland, Ohio 44136-9722. Phone 1 (330) 273-4683 . The return of a complete unit will not be accepted by the fa ctory unless prior written permission has been extended by the Customer Support Department of MTD PRODUCTS INC.

Transportation charges:

for the movement of any power equipment unit or attachment are the responsibility of the purchaser.

Warranty service is

Transportation charges

Units exported out of the United States:

PRODUCTS INC does not extend any warranty for products sold or exported outside of the United States of America, its possessions and territories, except those sold through MTD PRODUCTS INC’s authorized channels of export distribution.

Other Warranties:

1. The engine or component parts thereof carry separate warranties from their manufacturers. Please refer to the applicable manufacturer’s warranty on these items.

2. *Batteries are covered by a 90-day replacement warranty.

3. Log splitter pumps, valves and cylinders or component parts thereof are covered by a one year warranty.

4. All other warranties, express or implied, including any imp lied war rant y of mercha ntab ilit y or fitness for a particular purpose, are hereby expressly disclaimed in their entirety.

5. The provisions as set forth in this warranty provide the sole and exclusive remedy of MTD PRODUCTS INC’s obligations arising from the sales of its products. MTD PRODUCTS INC will not be liable for incidental or consequential loss or damage.

How state law relates to this warranty:

limited warranty gives you specific legal rights, and you may also have other rights which vary from state to state. Certain disclaimers are not allowed in some states and therefore they may not apply to you under all circumstances.

NOTE:

maintenance items such as lubricants, filters, blade sharpening and tune-ups, or adjustments such as brake adjustments, clutch adjustments or deck adjustments. Nor does this warranty cover normal deterioration of the exterior finish due to use or exposure.

This warranty does not cover routine

MTD

This

Yard-Man 604 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual