Bolens 609 770 10130B User Manual To The 90ca15c3 6e7d 4e16 B5ba A20406793c3a
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OPERATOR’S MANUAL Automatic Lawn Tractor Models 607 608 609 Model 608 Shown IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forestcovered, 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 dealer or contact the service 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. 770-10130B (10/99) 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 WARRANY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover SECTION 2: FINDING YOUR MODEL NUMBER This Operator’s Manual is an important part of your new rider. It will help you assemble, prepare and maintain your rider. Please read and understand what it says. Before you start to prepare your rider for its first use, please locate the model plate and copy the information from it in this Operator’s Manual. The information on the model plate is very important 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. • Although yours may vary slightly, 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 — Record this information in the space 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 (4683) or 1- (800)-800-7310 • Please have your model number and serial number ready when you call. • Although both numbers are important, you will be asked to enter only your serial number before your call can be processed. 2 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 California to cause cancer, birth defects or other reproductive harm. DANGER: Your lawn mower was built to be operated according to the rules for safe operation in this manual. As with any type of power equipment, carelessness or error on the part of the operator can result in serious injury. This 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. 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. • 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. • Only allow responsible individuals familiar with the instructions to operate the machine. Know controls and how to stop the machine quickly. • 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. • Turn off blade(s) when not mowing. • Do not put hands or feet under cutting deck or near rotating parts. • Mow only in daylight or good artificial light. • 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. • 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. • Be sure the area is clear of other people before mowing. Stop machine if anyone enters the area. • Never carry passengers. • 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. • 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. • 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 injury. • Slow down before turning. Operate the machine smoothly. Avoid erratic operation and excessive speed. 3 3. CHILDREN • Disengage all attachment clutches, thoroughly depress the brake pedal, and shift into neutral before attempting to start engine. 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. • 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. • 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. 2. SLOPE OPERATION • Before and when backing, look behind and down for small children. 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° as shown on the slope gauge, do not operate this unit on that area or serious injury could result. • Never carry children, even with the blades off. They may fall off and be seriously 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. DO: • Use extra care when approaching blind corners, shrubs, trees or other objects that may obscure your vision of a child or other hazard. • 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. 4. SERVICE • Use extreme care in handling gasoline and other fuels. They are extremely flammable and the vapors are explosive. • Use slow speed. Always keep machine in gear when going down slopes to take advantage of engine braking action. • Use only an approved container. • Follow the manufacturer’s recommendations for wheel weights or counterweights to improve stability. • Never remove fuel cap or add fuel with the engine running. Allow engine to cool at least two minutes before refueling. • Use extra care with grass catchers or other attachments. These can change the stability of the machine. • Replace fuel cap securely and wipe off any spilled fuel before starting the engine as it may cause a fire or explosion. • 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. • Extinguish all cigarettes, cigars, pipes and other sources of ignition. • 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. • Avoid starting or stopping on a slope. If tires lose traction, disengage the blade(s) and proceed slowly straight down the slope. • 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. 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. • 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. • Do not mow on wet grass. Reduced traction could cause sliding. • 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 original equipment specifications. • Do not try to stabilize the machine by putting your foot on the ground. • Do not use grass catcher on steep slopes. 4 • Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition. • Do not change the engine governor settings or overspeed the engine. Excessive engine speeds are dangerous. • Never tamper with safety devices. Check their proper operation regularly. Use all guards as instructed in this manual. • Observe proper disposal laws and regulations. Improper disposal of fluids and materials can harm the environment and the ecology. • 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. • 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 environmentally safe fashion. • 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 parts when necessary. • 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. • Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves and use extra caution when servicing blade(s). • 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 harmful waste. • 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. 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, SHIELDS, AND SWITCHES, ETC.) IN PLACE AND WORKING. • REMOVE OBJECTS THAT COULD BE THROWN BY THE BLADE(S). • KNOW LOCATION AND FUNCTION OF ALL CONTROLS. • BE SURE BLADE(S) AND ENGINE ARE STOPPED BEFORE PLACING HANDS OR FEET 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 5 Slope Gauge LINE , RE P R E SEN TIN G A 1 5 ° SL OPE OR A FENCE POST A CORNER OF A BUILDING A POWER POLE SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE USE THIS PAGE AS A GUIDE TO DETERMINE SLOPES WHERE YOU MAY NOT OPERATE SAFELY. FOL DO N D OTT ED 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 cause serious injury. If operating a walk-behind mower on such a slope, it is extremely difficult to maintain your footing and you could slip, resulting in serious injury. Operate RIDING mowers up and down slopes, never across the face of slopes. 6 SECTION 5: ATTACHMENTS & ACCESSORIES MODEL NUMBER OEM-190-601 OEM-190-602 OEM-190-112 OEM-190-118 OEM-190-603 OEM-190-604 OEM-190-822 OEM-190-823 DESCRIPTION FastAttach Twin Bagger Grass Collector (For 42-inch Decks Only) FastAttach Twin Bagger Grass Collector (For 46-inch Decks Only) Mulch Kit (For 42-inch Decks Only) Mulch Kit (For 46-inch Decks Only) FastAttach Grille Guard (mounts on front of tractor) YardMate Storage Container (mounts on rear of tractor) FastAttach 46-inch Front Dozer Blade 42-inch Two-stage Snow Thrower ™ ™ ™ ™ ™ NOTE: Your tractor is NOT designed for use with any type of ground-engaging attachments (e.g. tiller, plow). Use of this type of equipment WILL void the tractor’s warranty. SECTION 6: TRACTOR SET-UP ATTACHING THE BATTERY CABLES GAS AND OIL FILL-UP NOTE: The positive battery terminal is marked Service the engine with gasoline and oil as instructed in the separate engine manual packed with your tractor. Read instructions carefully. Pos. (+). The negative battery terminal is marked Neg. (–). IMPORTANT: Your tractor is shipped with oil; • The positive cable (heavy red wire) is secured to the positive battery terminal (+) with hex bolt and hex nut at the factory. Make certain that the rubber boot covers the terminal to help protect it from corrosion. however, you MUST check the oil level before operating. Be careful not to overfill. WARNING: Overfilling with oil may cause the engine to smoke. This will result in poor engine performance and could cause permanent engine damage. • 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. The gasoline tank is located under the hood and has a capacity of approximately two gallons. Do not overfill. • Place the hold-down strap in position over the battery to secure it in place. See Figure 2. Positive Terminal Rubber Boot WARNING: Never fill fuel tank indoors, gasoline produces noxious fumes. Always fill the fuel tank in a well ventilated area to avoid inhalation of gasoline fumes. Battery WARNING: Never fill the fuel tank while Wing Nut engine is running or while engine is hot. Tray WARNING: Never smoke while fueling Negative Terminal Bolt your tractor. Gasoline produces combustible fumes which can ignite and cause personal injury. Hold-down Strap WARNING: Do not fill closer than 1/2 Figure 2 inch from the top of the fuel tank to prevent spills and to allow for fuel expansion. If gasoline is accidently spilled, move tractor away from area of spill. Avoid creating any source of ignition until gasoline vapors have disappeared. 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. 7 SECTION 7: CONTROLS D B F C A AMPS P H I G J E NOTE: Steering Wheel not shown for clarity Figure 3 A B C D E Ignition Switch Throttle Control Lever Choke Control (if so equipped) Indicator Monitor Lift Lever F G H I J PTO (Power Take-Off) Lever Drive Pedal Brake Pedal Parking Brake Button Shift Lever NOTE: Any reference in this manual to the RIGHT or LEFT side of the tractor is observed from operator’s position. 8 IGNITION SWITCH IMPORTANT: When To start the engine, insert key into the ignition switch and turn clockwise to the START position. Release 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 also used to operate the headlights. Refer to OPERATING THE HEADLIGHTS in the OPERATION section of this manual for detailed instructions CHOKE CONTROL using PTO operated equipment such as the cutting deck or other attachments, ALWAYS operate the tractor with the throttle lever in the FAST (rabbit) position. 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 plate on the carburetor and aids in starting the engine. Refer to STARTING THE ENGINE in the OPERATION section of this manual for detailed starting instructions. WARNING: Remove the key from the tractor when the tractor is not in use to prevent accidental starting. Off On/Lights On SYSTEMS INDICATOR MONITOR Your tractor is equipped with an ammeter as part of its systems indicator monitor and is located on the left side of your tractor’s dash panel. See Figure 6. Start AMPS Figure 4 THROTTLE CONTROL LEVER Brake The throttle lever is located on the right side of the tractor’s dash panel. This lever controls the speed 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 Ammeter PTO Figure 6 If the Brake light or PTO light illuminates when attempting to start the unit, proceed as follows: BRAKE — Depress the brake pedal. PTO — Move PTO lever into the disengaged (OFF) position. Throttle Symbol Fast Position Fast Position Slow Position Oil It is normal for the Oil light to illuminate while the engine is cranking, but if it illuminates while the engine is running, proceed as follows: OIL— Stop the tractor immediately and check the crankcase oil level as instructed in the seperate engine manual packed with your unit. Add oil as required. The ammeter measures the the electrical output of the engine’s charging system. Under normal operating conditions, with the engine running at full throttle, the ammeter’s needle should measure a positive charge. Slow Position Figure 5 9 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. The brake pedal is located on the right front side of the tractor above the drive pedal along the running board. The brake pedal can be used for sudden stops or for setting the parking brake. PTO (POWER TAKE-OFF) LEVER NOTE: The brake pedal must be fully depressed to activate the safety interlock switch when starting the tractor. PARKING BRAKE BUTTON P 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. The PTO lever is located on the left side of the dash 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: The PTO lever must be in the disengaged (OFF) position when starting the engine, when shifting into reverse and if the operator leaves the seat. NOTE: The parking brake must be set if the operator leaves the seat with the engine running or the engine will automatically shut off. DRIVE PEDAL IMPORTANT: Always set the parking brake when leaving the tractor unattended. SHIFT LEVER F The shift lever is located on the left side of the fender and has three positions, FORWARD, NEUTRAL and REVERSE. The brake pedal must be depressed and the tractor must not be in motion when moving the shift lever. The drive pedal is located below the brake pedal on the right front side of the tractor along the running board. Depress the drive pedal with your right foot when the tractor shift lever is in either forward or reverse to cause the tractor to move. Ground speed is also controlled with the drive pedal. The further down the pedal is depressed, the faster the tractor will travel. The pedal will return to its original position when it’s not depressed. N IMPORTANT: Never force the shift lever. Doing so may result in serious damage to the tractor’s transmission. IMPORTANT: Always set the parking brake when leaving the tractor unattended. 10 Shift Knob R SECTION 8: OPERATION SAFETY INTERLOCK SWITCHES SETTING THE CUTTING HEIGHT 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 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. Select the height position of the cutting deck by placing the deck lift lever in any of the six different cutting height notches on the right side of the fender. Then adjust the deck wheels so that they are 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. • The safety interlock system will automatically shut off the engine if the operator leaves the seat before engaging the brake lock. WARNING: Keep hands and feet away from the discharge chute opening of the cutting deck. • The safety interlock system will automatically shut off the engine if the operator leaves the seat with the PTO lever in the engaged (ON) position, regardless of whether the brake lock is engaged. The PTO lever must be in the disengaged (OFF) position to restart the engine. 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 section of this manual for more detailed instructions regarding various deck adjustments. • 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. STARTING THE ENGINE NOTE: Refer to the TRACTOR SET-UP section of this manual for gasoline and oil fill-up instructions. WARNING: Do NOT attempt to bypass • Insert the tractor key into the ignition switch. or disconnect the tractor’s safety interlock. Doing so could result in serious personal injury or death. • Place the PTO lever in the disengaged (OFF) position. • Depress the brake pedal and set the parking brake. IMPORTANT: Tampering with or attempting to bypass the tractors Safety Interlock Switches in any way WILL void your warranty. • Place the shift lever in the NEUTRAL position. • Move the throttle control lever into the FAST (or CHOKE, if so equipped) position. WARNING • Pull out the choke control knob, if so equipped (a warm engine may not require choking). AVOID SERIOUS INJURY OR DEATH • • • • • • • • • • • • • Turn the ignition key clockwise to the START position. After the engine starts, release the key. It will return to the ON position. 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 AND BEHIND BEFORE AND WHILE BACKING. KEEP SAFETY DEVICES (GUARDS, SHIELDS, AND SWITCHES) IN PLACE AND WORKING. REMOVE OBJECTS THAT COULD BE THROWN BY THE BLADE(S). KNOW LOCATION AND FUNCTION OF ALL CONTROLS. BE SURE BLADE(S) AND ENGINE ARE STOPPED BEFORE PLACING HANDS OR FEET NEAR BLADE(S). BEFORE LEAVING OPERATOR’S POSITION, DISENGAGE BLADE(S), PLACE THE SHIFT LEVER IN NEUTRAL, ENGAGE BRAKE LOCK, SHUT ENGINE OFF AND REMOVE KEY. IMPORTANT: Do NOT hold the key in the START position for longer than ten seconds at a time. Doing so may cause damage to your engine’s starter. NOTE: If starting problems are encountered, refer to the TROUBLESHOOTING section of this manual. 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) to open up the choke plate on the engine’s carburetor. READ OPERATOR’S MANUAL 11 NOTE: Do NOT leave the choke control out while DRIVING ON SLOPES operating the tractor. Doing so will result in a "rich" fuel mixture and cause the engine to run poorly. Refer to the SLOPE GAUGE on page 6 to help determine slopes where you may not operate safely. STOPPING THE ENGINE WARNING: Do not mow on inclines with a slope in excess of 15 degrees (a rise of approximately 2-1/2 feet every 10 feet). The tractor could overturn and cause serious injury. 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 any 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 driving up a slope, start up smoothly and carefully to reduce the possibility of flipping the tractor over backward. • Place the PTO lever in the disengaged (OFF) position • Move the throttle control into the SLOW (turtle) position and allow the engine to "idle down" for ten seconds. Failure 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. IMPORTANT: If you think you’ve struck a foreign object, stop the engine immediately. Remove the wire(s) from the spark plug(s), thoroughly inspect the unit for any damage, and repair the damage before restarting and operating the tractor. DRIVING THE TRACTOR WARNING: Avoid OPERATING THE HEADLIGHTS sudden starts, excessive speed and sudden stops. To turn the tractor’s headlights on: • Start the engine following the instructions earlier in this section. WARNING: Do not leave the seat of the tractor without first placing the PTO lever in the disengaged (OFF) position, depressing the brake pedal and engaging the parking brake. If leaving the tractor unattended, also turn the ignition key off and remove the key. • Turn the key one notch counterclockwise into the On/Lights position of the ignition switch. Refer to Figure 4. 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. • Depress the brake pedal to release the parking brake and let the pedal up. Move the throttle lever into the FAST (rabbit) position. IMPORTANT: Never move the key into the Start IMPORTANT: Do NOT use the shift lever to position while the engine is running. Doing so may cause damage to your engine’s starter. 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 shifting. STOPPING THE ENGINE • Place the PTO lever in the disengaged (OFF) position. • To move forward, place the shift lever in the FORWARD position, then slowly depress the drive pedal until the desired speed is achieved. • 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. • 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. • Remove the key from the ignition switch to prevent accidental starting. IMPORTANT: If you think you’ve struck a foreign object, stop the engine immediately. Remove the wire(s) from the spark plug(s), thoroughly inspect the unit for any damage, and repair the damage before restarting and operating the mower. 12 USING THE LIFT LEVER WARNING: To avoid possible injury, do 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 earlier in this section. 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. ENGAGING THE PTO (POWER TAKE-OFF) LEVER WARNING: Never direct the discharge of material toward bystanders or allow anyone near the machine while in operation. • Move the throttle control lever to the FAST (rabbit) position. • For best results it is recommended that the first two laps be cut with the discharge thrown towards the center. After the first two laps, reverse the direction to throw the discharge to the outside for the balance of cutting. This will give a better appearance to the lawn. • 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. • Do not cut the grass too short. Short grass invites weed growth and yellows quickly in dry weather. IMPORTANT: The PTO lever cannot be in the • Do not mow at high ground speed, especially if a mulch kit or grass collector is installed. • Mowing should always be done with the engine at full throttle. 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 SAFETY INTERLOCK SWITCHES earlier in this section. • Under heavier conditions it may be necessary to go back over the cut area a second time to get a clean cut. • Do NOT attempt to mow heavy brush and weeds and extremely tall grass. Your tractor is designed to mow lawns, NOT clear brush. MOWING • Keep the blades sharp and replace the blades when worn. Refer to the MAINTENANCE section of this manual for proper blade sharpening instructions. This tractor comes equipped with a cutting deck. The following information will be helpful when using the cutting deck with your tractor. SECTION 9: ADJUSTMENTS LEVELING THE DECK WARNING: Turn the tractor’s engine off, remove the key from the ignition switch and apply the tractor’s parking brake before making any adjustments to the cutting deck. WARNING: Cutting blades are sharp. Always protect hands by wearing heavy leather work gloves to grasp blades. NOTE: Check the tractor’s tire pressure before • 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. performing any deck leveling adjustments. Refer to TIRES in the maintenance section of this manual for further information regarding tire pressure. Front to Rear • Measure the distance from the front of the blade tip to the ground and from the rear of the blade tip to the ground. The first measurement taken should be between 1/4" and 3/8" less than the second measurement. 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: 13 • Determine the approximate distance necessary for proper adjustment and proceed, if necessary, to the next step. • Locate the two lock nuts on the opposite 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. • Loosen the two jam nuts on the rear side of the deck stabilizer bracket. See Figure 7A. • Retighten the two jam nuts loosened earlier when proper adjustment is achieved. Side to Side If the cutting deck appears to be mowing unevenly, a side-to-side adjustment can be performed. Adjust if necessary as follows: WARNING: Turn the tractor’s engine off, remove the key from the ignition 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. • Measure the distance from the outside of the left blade tip to the ground and the distance from the outside of the right blade tip to the ground. Both measurements taken should be equal. If they’re not, proceed to the next step. • Loosen, but do NOT remove, the hex cap screw on the left deck hanger bracket. See Figure 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 Nuts A B Deck Stabilizer Bracket Deck Jam Nuts Hex Cap Screw Deck Hanger Bracket Front to Rear Side to Side Figure 7 SEAT ADJUSTMENT To adjust the position of the seat, loosen, but do NOT remove the four screws which secure the seat to the seat pivot bracket. Slide the seat forward or backward until desired position is reached. Retighten the four screws. See Figure 8. Screws Seat Pivot Bracket Figure 8 14 BRAKE ADJUSTMENT Hex Nut and Lock Washer 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: Pivot Bar Axle • Looking at the transmission from the right side of the tractor, locate the compression spring and brake disc. See Figure 9. Drag Link • Loosen, but do NOT remove, the hex nut found on the right side of the brake assembly. See Figure 9. Jam Nut Ball Joint Figure 10 • Using a feeler gauge, set the gap between the brake disc and the brake puck at .011". • Replace hex nut and lock washer and retighten the jam nut after proper adjustment is achieved. • Re-tighten the hex nut loosened earlier. NOTE: Threading the ball joints too far onto the Hex Nut drag links will cause the front tires to "toe-in" too far. Proper toe-in is between 1/16" and 5/16". Front tire toe-in can be measured as follows: • Place the steering wheel in position for straight ahead travel. Insert a 1/4" dowel up through aligning holes in both the steering gear and support plate. See Figure 11. Set Gap at .011" Brake Disc NOTE: • 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. Compression Spring View shown from beneath tractor. • Behind the axle, measure the distance horizontally from the inside of the left rim to the inside of the right rim. Note the distance. Transmission Figure 9 • The measurement taken in front of the axle should be between 1/16" and 5/16" less than the measurement taken behind the axle. STEERING ADJUSTMENT • Adjust if necessary. If the tractor turns tighter in one direction than the other, or if the ball joints are being replaced due to damage or wear, the steering drag links may need to be adjusted. Adjust the drag links so that equal lengths are threaded into the ball joint on the left side and the ball joint on the right side: • Remove the dowel inserted earlier before attempting to operate the tractor. Drag Links Insert Dowel Here • Loosen the jam nut found on the drag link at the rear of the ball joint. See Figure 10. • Remove the hex nut and lock washer on the top of ball joint. See Figure 10. Steering Gear Support Plate • 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. NOTE: Steering Shaft View shown from beneath tractor. Figure 11 15 CARBURETOR ADJUSTMENT NOTE: A dirty air cleaner will cause an engine to 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. WARNING: If any adjustments are 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. Refer to separate engine manual packed with your unit for carburetor adjustment information or see an authorized Briggs & Stratton service dealer. SECTION 10: MAINTENANCE WARNING: Disconnect the spark plug • Push the oil drain valve in slightly, then rotate counterclockwise and pull outward to begin draining oil. See Figure 12. wire(s) and ground against the engine before performing any adjustments, repairs or maintenance. • Service the oil filter (if so equipped) as instructed in the separate engine manual packed with your unit. Perform the above steps in the opposite order after oil has finished draining. ENGINE Refer to the separate engine manual for engine maintenance instructions. • Refill the engine with new motor oil. Check engine oil level before each use as instructed in the separate engine manual packed with your unit. Read and follow instructions carefully. 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. Changing Engine Oil • Unscrew oil fill cap and remove dipstick from the oil fill tube. See Figure 12. Oil Fill Cap Protective Cap The spark plug(s) should be cleaned and the gap reset once a season. Replacement is recommended at the start of each mowing season; check engine manual for correct plug type and gap specifications. Oil Drain Hose CLEANING THE ENGINE AND DECK Oil Fill Tube Any fuel or oil spilled on the machine should be wiped off promptly. Do NOT allow 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 deck with a wisk broom, putty knife or forced air after each mowing. Oil Drain Valve Oil Drain Port IMPORTANT: The use a pressure washer or NOTE: Single-cylinder engine shown. garden hose to clean your tractor is NOT recommended. It may cause damage to electrical components, spindles, pulleys, bearings or the engine. The use of water will result in a shortened life of the tractor and reduce its serviceability. Valve location will vary with engine style. Figure 12 • Pop open the protective cap on the end of the oil drain valve to expose the oil drain port. See Figure 12. • Push oil drain hose (packed with unit) onto the oil drain port. Route the opposite end of the hose into an appropriate oil collection container with a capacity great enough to collect the used oil. 16 CUTTING DECK REMOVAL WARNING: Do NOT remove deck WARNING: immediately after operating the tractor. Allow the engine and other moving parts ample time to cool down. Before performing any maintenance, move the PTO 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 attachments and in order to perform certain maintenance procedures, the deck must be removed from the tractor. To properly remove the cutting deck, proceed as follows: • Engage the parking brake. • Move the PTO lever into the disengaged (OFF) position to relieve tension on the belt. • Lower the deck by moving the lift lever into the bottom notch on the right fender. • Remove the PTO belt from around the lower portion of the engine pulley and from around both PTO idler pulleys on the PTO engagement plate. Deck Lift Arms To Lift Assembly PTO Idler Pulleys PTO Belt Deck Support Pins Engine Pulley Deck Stabilizer Bracket Hooks PTO Engagement Plate (mounted on tractor) Deck Stabilizer Rod Front of Tractor NOTE: 42-inch deck shown Figure 13 NOTE: On units equipped with 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 13. • Rotate the pin slightly toward the rear of the tractor and release the pin into the hole provided. • Repeat the above steps on the left side of the tractor. • Move the lift lever into the top notch on the right fender to raise the deck lift arms out of the way. • Carefully move the cutting deck toward the 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. 17 CHANGING THE DECK BELT(S) All belts on your tractor are subject to wear and should be replaced if any signs of cracking, shredding or rotting are present. IMPORTANT: The V-belts found on your tractor are specially designed to engage and disengage safely. A substitute (non-OEM) V-belt can be dangerous by not disengaging completely. For a proper working machine, use factory approved belts. To change or replace the deck belt(s) on your tractor, proceed as follows: NOTE: Removing the deck from the tractor as instructed earlier in this section will ease the following 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. • Move the PTO lever into the disengaged (OFF) position to relieve tension on the belt. • Remove the PTO belt from around the bottom portion of the engine pulley and from around the two idler pulleys found on the PTO engagement plate. See Figure 14. • Route the new belt as shown in Figure 14, around the deck pulleys, idler pulleys and engine pulley. OEM belt part numbers are listed in the table on the following page • Remount the belt guards removed earlier. Engine Pulley Deck Stop (mounted on tractor) Belt Guard (mounted on tractor) PTO belt PTO Engagement Plate (mounted on tractor) Idler Pulleys Right Hand Pulley Left Hand Pulley NOTE: Belt covers not shown for clarity. Figure 14 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 surface. • Move the PTO lever into the disengaged (OFF) position to relieve tension on the belt. • Remove the PTO belt from around the bottom portion of the engine pulley and from around the two PTO idler pulleys found on the PTO engagement plate. See Figure 15. • Route the new belt as shown in Figure 15, around the upper portion of the left hand deck pulley, PTO idler pulleys and the lower portion of the engine pulley. OEM belt part numbers are listed in the table on the following page. • Remount the belt guards removed earlier. 18 Belt Guard (mounted on tractor) Deck Stop (mounted on tractor) Engine Pulley PTO Engagement Plate (mounted on tractor) PTO Idler Pulleys Deck belt (Bottom) PTO belt (Top) Right Hand Pulley (beneath belt guard) Deck Idler Pulley Left Hand Double Pulley Center Pulley NOTE: Left hand belt cover not shown for clarity. 46-inch deck shown. Self-Tapping Screws Figure 15 PTO (Top) Belt Bottom Belt 42-Inch Deck 754-0485 N/A 46-Inch Deck 754-0486 754-0349 CHANGING THE TRANSMISSION DRIVE BELT(S) All belts on your tractor are subject to wear and should be replaced if any signs of cracking, shredding or rotting are present. IMPORTANT: The V-belts found on your tractor are specially designed to engage and disengage safely. A substitute (non-OEM) V-belt can be dangerous by not disengaging completely. For a proper working machine, use factory approved belts. To change or replace the drive belt(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: When removing the battery, disconnect the NEGATIVE (Black) wire from it’s terminal first, followed by the POSITIVE (Red) wire. Re-install in reverse order. Upper Drive Belt • Locate the transmission idler pulley on the upper drive belt by looking through the battery tray opening. See Figure 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: 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. 19 Lower Drive Belt NOTE: Proper removal of the lower drive belt requires the removal of several tractor components. Read through the following procedure prior to attempting it to determine if you feel you could successfully complete it. If you don’t, see an authorized MTD service dealer to have the belt changed. IMPORTANT: Note the routing of the lower drive belt around both the pulleys and the belt keepers BEFORE performing the following steps. • Locate the variable-speed pulley by looking through the battery tray opening. See Figure 16. • 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. • Slide the belt off of the variable-speed pulley as you lift the pulley up and out through the battery tray opening. Variable-speed Pulley Battery Tray Opening Drive belt (Lower) Shift Lever Rear Idler Pulley Belt Keeper Drive belt (Upper) Front Idler Pulley Idler Bracket Belt Keeper Engine Pulley to drive pedal Double-Idler Bracket Transmission Idler Pulley Single-speed Transmission NOTE: Transmission Pulley Front of Tractor View shown from above tractor. Figure 16 • Remove the hex bolt from the center of the engine pulley. See Figure 17. • Reassemble by following the above steps in reverse order. • Lower the engine pulley far enough to be able to remove the upper drive belt from around it. • Reroute the new belt around the pulleys and belt keepers EXACTLY as the old one was routed. Refer to Figure 16. The drive pedal is properly adjusted when the hole found in the double-idler bracket has approximately 1-3/8" of travel with ten pounds of pressure applied to the drive pedal. See Figure 17. IMPORTANT: When remounting the engine pulley, torque the center hex bolt to between 38 footpounds and 50 foot-pounds. • Remove the drive belt by feeding it from both ends toward the front idler pulley on the double-idler bracket. See Figure 16. 20 The blades may be removed for sharpening or replacement as follows. Double-idler Bracket • 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. Hole Idler Adj. Rod 1-3 • Place a block of wood between the center deck housing baffle and the cutting blade to act as a stabilizer. See Figure 19. /8" Front of Tractor NOTE: • Use a 15/16" wrench to remove the hex flange nut that secures the blade to the spindle assembly. See Figure 19. View shown from above tractor. Figure 17 Adjust the drive pedal after replacing the drive belts on your tractor, if necessary, as follows: 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. • Locate the speed control assembly on the underside of the steering support bracket. See Figure 18. Idler Adj. Rod Place Wrenches Here Block of Wood Hex Flange Nut Neutral Return Bracket Pin Hairpin Clips Spindle Assembly Cutting Blade Figure 19 To properly sharpen the cutting blades, remove equal amounts of metal from both ends of the blades along the cutting edges. See Figure 20. Speed Control Assembly Drive Pedal Return Spring Figure 18 Sharpen the cutting edge straight across, parallel to the trailing edge, at a 25° to 30° angle. See Figure 20. • 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. 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 20. • Remove the drive pedal return spring. • Using two 9/16" wrenches, remove the pin from the speed control assembly. See Figure 18. Thread the idler adjustment rod inward or outward to lengthen or shorten the travel of the double-idler bracket until proper adjustment is achieved. Worn Blade Edge • Reassemble by following the above steps in reverse order. Blade Separation Wind Wing CUTTING BLADES WARNING: Cutting blades are sharp. Always protect hands by wearing heavy leather work gloves to grasp blades. Sharpen Edge Evenly Figure 20 21 5/8" minim um IMPORTANT: If removing the battery for any It is extremely important that each cutting blade edge be ground equally to maintain proper blade balance. An unbalanced blade will cause excessive vibration when rotating at high speeds, may cause damage to the tractor and result in personal injury. The blade can be tested by balancing it on a blade balancer or round shaft screwdriver. Grind metal from the heavy side until it balances evenly. reason, disconnect the NEGATIVE (Black) wire from it’s terminal first, followed by the POSITIVE (Red) wire. When re-installing the battery, always connect the POSITIVE (Red) wire its terminal first, followed by the NEGATIVE (Black) wire. Be certain that the wires are connected to the correct terminals, reversing them could change the polarity and cause damage to your engine’s alternating system. When replacing the blade, be sure to install the blade with the side of the blade marked ‘‘Bottom’’ (or with a part number stamped in it) facing the ground when the mower is in the operating position. 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. IMPORTANT: Use a torque wrench to tighten the blade spindle hex flange nut to between 70 footpounds and 90 foot-pounds. 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. TIRES The recommended operating tire pressure is approximately 10 psi for the rear tires and 14 psi for the front tires. Refer to the tire sidewall for exact tire manufacturer’s recommended psi. Do not overinflate. Uneven tire pressure could cause the cutting deck to mow unevenly. 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 for 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 21 to determine if it is good or bad. BATTERY The battery is sealed and is maintenance-free. Acid levels cannot be checked. • Always keep the battery cables and terminals clean and free of corrosive build-up. • After cleaning the battery and terminals, apply a light coat of petroleum jelly or grease to the terminals and over the positive terminal boot. • Always keep the boot positioned over the positive terminal to prevent shorting. GOOD BAD Figure 21 SECTION 11: LUBRICATION WARNING: Always stop the engine and WHEELS disconnect the spark plug wire(s) and ground against the engine before performing any maintenance. 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. ENGINE STEERING GEAR Lubricate the engine with motor oil as instructed in the separate engine manual packed with your unit. Lubricate the teeth of the steering gear with an allpurpose automotive grease every 25 hours of operation or once a season. LINKAGE Lubricate all the pivot points on the drive, brake and lift linkage at least once a season with SAE 30 engine oil. PIVOT POINTS Lubricate all pivot points (drive pedal, brake pedal, etc.) at least once a season with light oil. 22 SECTION 12: TROUBLESHOOTING GUIDE Trouble Possible Cause(s) Corrective Action Engine will Safety switch not crank button not depressed. There are two safety switches in the starting circuit of your unit: the brake pedal switch and the seat switch. Make certain the actuator on the brake control is fully depressing the button on the brake pedal switch and that the operator is seated on the tractor. The PTO lever must be in the disengaged (OFF) position, also. Battery installed The battery must be installed with negative terminal attached to black ground wire. incorrectly. Negative terminal is identified at the post by “NEG”, “N” or “-”. The positive terminal, identified by “POS”, “P” or “+”, must be attached to the thick red wire which goes to the solenoid. Battery is dead Charge at six amps with a 12-volt automotive-type battery charger for one hour or until or weak. fully charged. Blown fuse Refer to page 23 for fuse location. Replace fuse with automotive type fuse of 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 repair with electrician's tape if the wire strands have not been damaged. Note: Look for a wire pinched between body panels, burned by the exhaust pipe or muffler or rubbed against a moving part. Engine Throttle or choke Refer to the OPERATION section of this manual for the correct position of the throttle cranks but not in starting control and choke for starting. will not start position. No fuel to the Gasoline tank empty. Fill with clean, fresh fuel. carburetor. Fuel line or in-line fuel filter plugged. Remove and clean fuel line. Replace fuel filter (if so equipped) if necessary. No spark to Spark plug lead disconnected. Connect lead. Using a spark tester, check for spark. If spark plug(s). no spark is present, have engine’s magneto serviced by an authorized engine dealer. Dirty aircleaner. Engine smokes If the air cleaner is dirty, the engine may not start. Refer to the engine manual packed with your unit. Check oil level. Excessive vibration Engine oil has been overfilled. Engine loses crankcase vacuum. Bent blade or damaged pulley. Mower won’t discharge grass or leaves uncut strips Engine speed low. Speed selection. Use lower ground speed. The slower your ground speed, the better the quality of cut. Cutting height Raise deck. set too low. Sharpen or replace blades (uncut strip problem only). Blades dull. Dipstick not seated or broken. Replace defective part. Engine breather defective. Replace. Stop engine immediately. Check all pulleys, blade adapters, keys and bolts for tightness and spindle damage. Tighten or replace any loose or damaged parts. Always replace damaged blade. Only use original equipment blades. Throttle must be set at full throttle. 23 Models 607, 608 & 609 1 8 14 10 9 15/16 AMPS 3 11 5 13 4 2 12 6 5 13 5 7 REF. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 PART NO. 625-0051 629-0944 629-0126 710-0599 712-3006 725-1426 725-1657A 725-1741 725-1758 725-1745 725-1744 725-1747 725-3007A 736-0329 629-0309 729-0357 725-1381 DESCRIPTION Bulb/Socket Headlight Assembly Wiring Harness w/o Ref. 14 Harness Adapter, #18 x 5 Self-tapping Screw, 1/4-20 x .5 Hex Nut, 1/4-20 Solenoid, 12-volt, 100 Amp Snap Mount Safety Interlock Switch (Brake) Ignition Switch Systems Indicator Monitor w/ Ammeter Ignition Key w/ plastic cover Ignition Key w/o plastic cover Safety Plunger Switch (Seat) Positive Terminal Cover (Boot) Lock Washer, 1/4 Headlight Harness Fuse Holder 20-amp Fuse 24 GREEN BLUE 25 STARTER ALTERNATOR AFTERFIRE SOLENOID ALTERNATOR MAGNETO HEADLIGHTS GREEN - BLUE BATTERY RED + RED/BLACK RED WHITE YELLOW GREEN RED SOLENOID 725-1426 RED ORANGE YELLOW ORANGE/BLACK ORANGE/WHITE FUSE 725-1381 BRAKE SWITCH 725-1657A KEY SWITCH 725-1741 PTO SWITCH 725-1657A L M GREEN RED A1 B ORG/BLK YEL/WHT A2 S ORANGE G ORANGE/WHITE YELLOW/BLACK ORANGE/BLACK REVERSE SW. 725-1643 RED GREEN OIL PRESSURE BLACK KEY SW 725-1741 G+M+A1 OFF RUN 1 B+A1 RUN 2 B+A1 B+S+A1 START ORANGE/BLACK WHITE ORANGE/WHITE ORANGE ORANGE/BLACK SEAT SWITCH 725-1736 L+A2 OIL GROUND +12 V A/C BRAKE + BRAKE PTO PTO + Electrical System YEL/WHT YEL/BLK ORG/BLK GREEN RED/WHT Models 607 & 608 41 46 14 46 45 31 27 28 43 44 25 15 30 47 3 42 32 21 5 3 5 22 37 22 16 10 39 35 36 38 34 23 33 17 5 7 9 18 12 24 20 24 1 8 29 13 11 2 26 9 4 6 7 19 26 Tractor Body 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 PART NO. 683-0195 710-0528 710-0599 710-0751 710-0895 710-0896 710-0924 712-0271 712-0292 712-0431 726-0211 726-0293 731-1854 731-2300 731-2301 731-2302 731-2303 731-2306 735-0126 736-0105 783-0475 783-0476A 783-0477 783-1034 783-1038 710-0106 710-0604A 710-1017 710-1238 710-3217 712-0142 REF. NO. 29 30 31 32 33 34 35 36 37 38 DESCRIPTION Bracket Assembly Hex Cap Screw, 5/16-18 x 1.25 Self-tapping Screw, 1/4-20 x .5 Hex Cap Screw, 1/4-20 x .62 Self-tapping Screw, 1/4-15 x .75 Screw, 1/4-15 x .75 Phillips Pan Screw, 1/4-20 x .75 Hex Sems Nut, 1/4-20 U-type Speed Nut, 1/4-20 Flange Lock Nut, 3/8-16 U-nut, 5/16-18 Retainer Nut, 3/8 Headlight Lens Hood, 7-style, Red Hood, 7-style, Green Hood, 7-style, Black Hood, 7-style, Charcoal Grey Hood Plenum, 7-style Rubber Washer, .87 x .33 Bell Washer, .401 x .87 x .063 LH Side Panel RH Side Panel Grille Hood Bracket, 7-style Hood Side Bracket, 7-style Hex Cap Screw, 1/4-20 x 1.25 Self-tapping Screw, 5/16-18 x .625 Truss Phillips Screw, 1/4-20 x .625 Hex Washer Screw, 5/16-18 x .625 Truss Phillips Screw, #8-32 x .375 Hex Nut, #8-32 39 40 41 42 43 44 45 46 47 — PART NO. 712-3004A 712-3027 731-1857 731-2122 731-2227 731-2228 736-3078 747-1196 749-1087 751-0659 751-0658 751-0603 710-1268 783-0478A 783-0551A 783-0553A 731-2247 DESCRIPTION Flange Lock Nut, 5/16-18 Hex Flange Lock Nut, 1/4-20 Throttle Control Knob Dash Panel Parking Brake Button Plastic Plug Flat Washer, .349 x 1.0 x .063 Pivot Rod Dash Support Tube Two-gallon Fuel Tank (shown) Three-gallon Fuel Tank Fuel Cap (Fits Either Tank) Screw, #10-16 x .375 Hood, 8-style Hood Hinge Bracket, 8-style Hood Support Bracket, 8-style Heat Shield‡ (Units w/ B&S OHV Twin) 731-2248 Heat Shield‡ (Units w/ B&S Opposed Twin) 747-1184 Heat Shield Support Rod 726-3046 Ratchet Clip 746-1085 Choke Cable/Knob † (Units w/ B&S Opposed Twin) OEM-190-603 Grille Guard™ Bumper Kit, Not Shown (if so equipped) AF-47442 Bumper Assembly AF-44056 Clevis Pin, .5 x 1 AF-43055 Internal Cotter Pin AF-44742 Plastic Plug †Tractors with a B&S Single-cylinder (I/C or OHV) engine have NO choke knob/cable. The choke is activated with the throttle control. ‡Tractors with a B&S Single-cylinder (I/C or OHV) engine have NO heat shield. 27 Model 609 26 9 7 25 32 6 4 3 8 24 16 12 3 20 28 33 31 4 11 14 10 20 30 2 17 20 23 29 1 1 21 15 20 15 15 1 22 21 8 5 19 18 27 18 28 Tractor Body 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 31 32 33 PART NO. 710-0604A 710-0788 710-0895 710-1017 710-1238 710-3217 712-0142 731-0511-5 731-1857 731-2122 731-2228 731-2227 736-0119 736-0142 736-3078 747-1196 749-1087 710-0924 710-3008 712-0292 712-3004A 731-2118 731-2119 736-0211 747-1162 783-0783 783-0784 783-0785 751-0659 751-0658 751-0603 746-1085 731-2270 731-2271 712-3027 DESCRIPTION Self-tapping Screw, 5/16-18 x .625 Self-tapping Screw, 1/4-20 x 1.0 Self-tapping Screw, 1/4-15 x .75 Torx Self-tapping Screw, 5/16-18 x .625 Screw, 5/16-18 x .875 (Grade 5) Torx Screw, #8-32 x .375 Hex Nut, 8-32 Five-inch Trim Strip Throttle Control Lever Dash Panel Plastic Plug Parking Brake Button Lock Washer, 5/16 Flat Washer, .281 x .5 x .063 Flat Washer, .349 x 1.0 x .063 Pivot Rod Dash Support Tube Pan Phillips Screw, 1/4-20 x .75 Hex Cap Screw, 5/16-18 x .75 U-type Speed Nut, 1/4-20 Flange Lock Nut, 5/16-18 Lens, 9-style Grille, 9-style Flat Washer, .285 x 1.25 x .08 Hood Hinge Rod Hood, 9-style RH Side Pane, 9-style LH Side Panel, 9-style Two-gallon Fuel Tank (shown) Three-gallon Fuel Tank Fuel Cap (Fits Either Tank) Choke Knob/Cable Assembly† (Units w/ B&S Opposed Twin or OHV Twin) Hood Plenum (Units w/ B&S OHV V-Twin)‡ Hood Plenum (Units w/ B&S Opposed Twin)‡ Hex Flange Lock Nut, 1/4-20 †Units with B&S Single-cylinder (I/C or OHV) engines have NO choke knob/cable. The choke is activated with the throttle control. ‡Units with B&S Single-cylinder (I/C or OHV) engines have NO hood plenum. 29 Models 607, 608 & 609 37 30 6 36 31 40 28 35 31 36 32 42 38 41 34 39 11 33 44 6 14 2 13 9 43 8 14 18 5 19 8 12 17 21 22 10 20 6 23 25 19 21 22 24 6 14 8 3 6 4 5 1 15 26 30 17 16 9 7 Lift Assembly REF. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 PART NO. 747-1130 683-0197 711-0332 712-0206 712-0431 712-3004A 712-3083 714-0104 714-0111 716-0106 720-0311 732-0874 732-0934 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 736-0275 736-0921 736-3019 736-3084 738-0138 738-0380 741-0225 741-0715 746-0968 747-1111 756-1154 783-0678 783-0720A 710-0260 710-0604A 710-0895 783-0740 726-3046 738-0155 783-1010 783-0839 783-0715 710-0870 757-0360A 757-0348A 757-0350 723-0483 723-0484 735-0657 735-0656 710-1611 710-0260 731-0511-5 38 39 40 41 42 43 44 DESCRIPTION Deck Stabilizer Rod Lift Shaft Assembly Clevis Pin, .5 x .78 Hex Nut, 1/2-13 Flange Lock Nut, 3/8-16 Flange Lock Nut, 5/16-18 Hex Nut, 1/2-13 Internal Cotter Pin Cotter Pin E-ring Handle Grip Torsion Spring Lift-assist Spring, 1.15 x 5.99 (Found on Units w/ 46-inch Deck Only) Flat Washer, 5/16 Lock Washer, 1/2 Flat Washer, .31 x 1.062 x .134 Flat Washer, .51 x 1.12 x .06 Hex Cap Screw, 5/16-18 x .62 Shoulder Screw, .5 x .27, 3/8-16 Hex Flange Bearing Snap Flange Bearing Lift Cable, 16.16 Lift Handle Roller Pulley Arm Lift Deck Stabilizer Bracket Carriage Bolt, 5/16-18 x .62 Self-tapping Screw, 5/16-18 x .625 Self-tapping Screw, 1/4-15 x .75 Seat Pivot Bracket Foot Pad Clips Shoulder Screw, .437 x 1.62 Lift Adjustment Bracket Fender Seat Mounting Bracket Hex Washer Head Screw, 3/8-16 x .625 Seat, Medium Back Seat, High Back (if so equipped) Seat, High Back w/ Drain Holes (if so equipped) LH Abrasive Foot Pad RH Abrasive Foot Pad LH Rubber Foot Pad (if so equipped) RH Rubber Foot Pad (if so equipped) Self-tapping Screw, 5/16-18 x .75 Hex Cap Screw, 5/16-18 x .62 Trim Strip, 1.5 31 Models 607, 608 & 609 24 43 42 23 19 6 38 21 14 20 4 2 20 13 22 11 18 7 13 22 8 30 13 15 12 42 41 5 28 1 30 2 32 10 17 11 32 35 3 2 35 27 39 44 40 37 34 35 32 31 33 36 29 32 9 16 26 25 Steering Assembly 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 PART NO. 683-0304 710-0604A 783-0726A 783-0727 783-0728 710-0514 711-1409A 711-1408 712-0240 712-0241 712-0431 712-0459 712-3004A 717-1550A 717-1554 723-0448A 736-0169 736-3084 738-1001A 741-0475 741-0656 738-0372 631-0027 731-0220 638-0019 638-0021 638-0020 638-0022 683-0128A DESCRIPTION Lower Frame Assembly Self-tapping Screw, 16-18 x .625 RH Pivot Support Bracket LH Pivot Support Bracket Pivot Bar Bracket Hex Cap Screw, 3/8-16 x 1 (Grade 5) LH Drag Link RH Drag Link Jam Nut, 7/16-20 (Grade 2) Hex Nut, 3/8-24 (Grade 2) Flange Lock Nut, 3/8-16 Flange Lock Nut, 7/16-20 Flange Lock Nut, 5/16-18 Steering Gear, 11/90 Ratio Steering Pinion Gear Ball Joint, 7/16-20 Lock Washer, 3/8 Flat Washer, .51 x 1.12 x .06 Steering Shaft, .625 OD x 24.4 Plastic Bushing, .38 ID Hex Flange Bearing, 5/8 Shoulder Spacer, .38 ID Steering Wheel Steering Wheel Cap LH Axle Assembly, .625 Diameter LH Axle Assembly, .625 / .750 Diameter RH Axle Assembly, .625 Diameter RH Axle Assembly, .625 / .750 Diameter Pivot Bar REF. PART NO. NO. 28 712-0431 29 714-0470 30 726-0214 726-0341 31 736-0162 32 736-0187 736-0316 33 736-0285 34 738-1011 35 741-0659 741-0660 36 634-0105A 634-0056A 37 38 39 40 41 42 43 44 634-0172 734-0255 734-1731 734-0864 741-0487A 741-0706 734-0484A 783-0653C 738-0143 736-0331 738-0140 736-0242 710-0643 731-1649 DESCRIPTION Flange Lock Nut, 3/8-16 Cotter Pin Push Cap, .625 Push Cap, .750 Flat Washer, .64 x 1.0 x .12 Flat Washer, .64 x 1.24 x .06 Flat Washer, .78 x 1.59 x .06 Flat Washer, .635 x 1.589 x .06 Shoulder Screw, .5 x 2.2, 3/8-16 Flange Bearing, .632 ID x .937 OD Flange Bearing, .760 ID x .937 OD Wheel Assembly Complete, 15 x 6 x 6 Square Shoulder Wheel Assembly Complete, 15 x 6 x 6 Round Shoulder Rim Only Air Valve (Not Shown) Tire Only, Square Shoulder Tire Only, Round Shoulder Plastic Flange (Not Shown) Plastic Flange w/ Fitting (Not Shown) Hub Cap Steering Support Bracket Shoulder Screw, 3/8-16 Bell Washer, .39 x 1.13 x .062 Shoulder Screw, .435 x .178, 5/16 x .56 Bell Washer, .34 x .872 Hex Bolt, 5/16-18 X 1 Pivot Bar End Cap NOTE: Units equipped with a 42-inch deck have axles with a .625 diameter. Units equipped with a 46-inch deck have axles with a .625 / .750 diameter. 33 Models 607, 608 & 609 4 22 13 5 29 21 21 2 2 79 58 13 35 19 78 13 60 83 57 60 11 18 36 25 41 58 19 28 58 65 83 68 56 71 55 73 23 61 6 58 77 31 7 64 33 75 33 23 54 46 38 13 47 69 45 62 40 50 8 44 43 19 26 1 42 37 27 24 30 3 32 20 9 10 19 47 34 15 17 49 23 39 14 35 66 59 76 13 35 72 12 31 21 58 63 53 21 70 52 68 64 23 69 81 63 12 80 16 34 82 Drive System 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 31 PART NO. 783-1015 17840 618-0551 631-0009 647-0045 656-0048 656-0051A 683-0251 710-0176 710-0227 710-0347 736-0272 710-0604A 710-0642 710-3011 711-0677 712-0241 712-0378 712-0431 712-0798 712-3004A 712-3008 714-0111 714-0149B 723-3018 725-1644 726-0320 732-0384 732-0525 732-0716 732-0963 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 736-0105 736-0140 736-0169 736-0275 736-0407 736-3010 738-0322 747-1122 747-1123A 747-1127 747-1156 711-0736 748-0372 754-0467 754-0468 REF. NO. 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 DESCRIPTION Shift Lever Support Transaxle Mounting Bracket Single-speed Transmission Assembly Shifter Knob Shift Lever Variable-speed Pulley Assembly Transmission Pulley, 8.5 x .5-36 Double-idler Bracket Hex Cap Screw, 5/16-18 x 2.75 Self-tapping Screw, #8-18 x .5 Hex Cap Screw, 3/8-16 x 1.75 Flat Washer, .51 x 1.0 x .060 Self-tapping Screw, 5/16-18 x .625 Self-tapping Screw, 1/4-20 x .75 Hex Cap Screw, 3/8-16 x 2.25 Ferrule, 5/16-18 Hex Nut, 3/8-24 Hex Nut, 7/16-20 Flange Lock Nut, 3/8-16 Hex Nut, 3/8-16 Flange Lock Nut, 5/16-18 Jam Nut, 3/8-16 Cotter Pin Internal Cotter Pin Ball Joint Short Spring Switch Insulator Nut Plate Extension Spring, .62 Dia. x 6.12 Compression Spring Clip Extension Spring, .59 OD x 4 Extension Spring, .50 Dia. x 6.37 (hooks to flange, 783-0650, in frame) Bell Washer, .401 x .87 x .063 Flat Washer, .385 x .62 x .063 Lock Washer, 3/8 Flat Washer, 5/16 Bell Washer, .45 x 1.0 x .602 Flat Washer, .407 x .812 x .135 Shoulder Screw, .625 x .217 Brake Rod Belt Guard Idler Adjustment Rod, 3/8 Shift Rod Adjustment Ferrule, 1/4-20 x 1.0 Shoulder Spacer, .38 ID Variable-speed Belt Drive Belt PART NO. 756-0981 783-0637 783-0667A 783-0669 783-0714 647-0031 647-0032 683-0266 712-0431 711-0736 711-1363 714-0104 732-0437 710-0778 735-0662 735-3049 710-1650 736-0187 736-0204 738-0155 738-0507B 741-0225 741-3065A 710-0859 747-1138 710-1260A 748-0415A 783-0653C 783-0732 783-0773 783-0780A 683-0304 783-1031 736-0242 710-0627 634-0177 634-0104 734-1675 83 634-0070 734-0255 734-1873 734-1730 734-1596 750-0556 DESCRIPTION Flat Idler, 2.75 OD Shift Lever Support Transmission Torque Bracket Idler Bracket Adjustable Shift Bracket Brake Control Assembly Speed Control Assembly Drive Pedal Assembly Flange Lock Nut, 3/8-16 Ferrule, 1/4-20 Pin, 3/8-16 x 2.43 Cotter Pin Compression Spring, .34 OD x 1.0 Self-tapping Screw, 1/4-20 x 1.5 Drive Pedal Pad Brake Pedal Pad Self-tapping Screw, 5/16-18 x .875 Flat Washer, .64 x 1.24 x .06 Flat Washer, .344 x .062 x .03 Shoulder Screw, .437 x 1.62 Shoulder Screw, .5 x .434 Hex Flange Bearing Split Hex Flange Bearing Hex Cap Screw, 3/8-16 x 2.5 Brake Lock Control Rod Self-tapping Screw, 5/16-18 x .75 Spacer, 5/16 x 1.54 Stearing Support Bracket Drive Lockout Bracket Brake Pedal Neutral Return Bracket Lower Frame Assembly Hitch Plate Bell Washer, .34 x .872 Hex Cap Screw, 5/16-24 x .75 Wheel Assembly Complete 20 x 10 x 8 Square Shoulder Wheel Assembly Complete 20 x 8 x 8 Square Shoulder Wheel Assembly Complete 20 x 8 x 8 Round Shoulder Rim Only Air Valve (Not Shown) Tire Only, 20 x 10 x 8, Square Shoulder Tire Only, 20 x 8 x 8, Square Shoulder Tire Only, 20 x 8 x 8, Round Shoulder Spacer IMPORTANT: The V-belts found on your tractor are specially designed to engage and disengage safely. A substitute (non-OEM) V-belt can be dangerous by not disengaging completely. For a proper working machine, use factory approved belts. 35 Models 607, 608 & 609 40 12* 31 41 21 20 29 22 26 25 19 31 30 28 27 15 12c 18 39 38 21 13 38 39 1 3 7 16 8 14 5 23 12c 6 14 12* Units with 618-0307C Transmission ONLY 10 4 17 24 2 9 37 3 13 36 32 37 12* 11 34 12* 14 36 12c Single-speed Transmission REF. NO. 1 2 3 4 5 6 7 8 9 10 11 12a 12b 12c 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 PART NO. 618-0318 710-0788 711-1274 711-1280 713-0474 713-0478 717-1422 717-1565 717-1569 718-0652 719-0394 736-0336 736-0337 736-0349 736-0519 741-0336 741-0337 750-1238 611-0112 611-0133 618-0369 618-0424 661-0006 710-1325 710-1206 717-0678 732-0863 741-0862 761-0202 711-1331 711-1430 716-0385 716-0108 717-1571 717-1464 719-0391A 736-0335 736-0723 741-0525 718-0228 711-1431 750-1234 717-1362 717-1363 736-0495 741-0340 721-0338 716-0231 618-0551 DESCRIPTION Clutch Collar† Self-tapping Screw, 1/4-20 x 1.0 Drive Shaft Counter Shaft 22-link Chain, #420 14-tooth Sprocket Sprocket Bevel Gear, 42/10 29-tooth Spur Gear 20-tooth Spur Gear Counter Shaft Coupling Lower Housing Flat Washer, 5/8 x 1.0 x .030* Flat Washer, 5/8 x 1.0 x .040* Flat Washer, 5/8 x 1.0 x .020* Flat Washer, .70 x 1.125 x .031 Flange Bearing, 5/8 x 3/4 x 3/4 Flange Bearing, 5/8 x 3/4 x 15/16 Spacer, .635 x 1.0 x .27 Detent Shaft Assembly† Detent Shaft Assembly‡ Differential Assembly† Differential Assembly‡ Brake Assembly Self-tapping Screw, 1/4-20 x 1.625 Self-tapping Screw, 1/4-20 x 2.375 Brake Pad Compression Spring Detent Ball Brake Disc Input Shaft† Input Shaft‡ Retaining Ring, .394† Retaining Ring, .437‡ 12-tooth Bevel Pinion† 14-tooth Bevel Pinion‡ Upper Housing Thrust Washer, .63 x 1.24 x .062† Thrust Washer, .635 x 1.25 x .042‡ Needle Bearing, .625 x .875 Clutch Collar‡ Drive Shaft‡ Spacer, .633 x 1.0 x .513 42-tooth Bevel Gear‡ 42-tooth Bevel Gear‡ Thrust Washer, 1.0 x .632 x .0 Sleeve Bearing, .75 x .1.0 x 1.0 Seal, .75 x 1.0 x .125 E-ring, .75 Transmission Assembly Complete *If rebuilding transmission for any reason, use applicable flat washer (12a, 12b, or 12c) in this application allowing proper end play as instructed in MTD ’s Service Manual. IMPORTANT: One of two different transmissions may be found on your lawn tractor (618-0307B & 618-0307C). Refer to the model plate found on the rear right portion of the transmission’s lower housing before ordering replacement service parts. †Used on Single-speed transmission 618-0307B ONLY. ‡Used on Single-speed transmission 618-0307C ONLY. 37 Models 607, 608 & 609 57 2 1 50 3 4 42 13 53 10 14 54 15 55 17 16 5 12 11 5 6 7 8 44 19 6 45 9 18 43 40 56 38 16 26 48 A 28 20 28 Hook spring, Ref. 58, here 51 45 52 29 39 41 36 25 33 35 24 21 31 A 1 34 58 25 33 59 23 33 32 37 21 30 (PTO belt for 42" deck shown) 49 27 47 22 38 46 Power Take-off System 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. 712-0431 732-0996 783-0733 732-0997 710-0604A 710-0751 712-0271 712-3044 725-1706 738-1014 738-1020 736-0407 723-0444 783-1031 725-1747 736-0222 725-1426 710-0599 712-0459 683-0304 736-3010 710-0831 736-0275 732-0944 736-0140 710-0642 736-0322 712-3004A 783-0653C 754-0485 754-0486 DESCRIPTION Flange Lock Nut, 3/8-16 Compression Spring, 1.31 x 3.0 Spacer Cup, 1.5 OD Compression Spring, .66 OD x 1.5 Self-tapping Screw, 5/16-18 x .625 Hex Cap Screw, 1/4-20 x .62 Hex Sems Nut, 1/4-20 Wing Nut, 1/4-20 12-volt Battery, 270 CCA Shoulder Screw, .5 x 1.25, 3/8-16 Shoulder Screw, .625 x .5, 7/16-20 Bell Washer, .45 x 1.0 x .062 Battery Strap Hitch Plate Safety Interlock Plunger Switch Lock Washer, 1/4 Solenoid, 12-Volt, 100 Amp Self-tapping Screw, 1/4-20 x .5 Flange Lock Nut, 7/16-20 Lower Frame Assembly Flat Washer, .407 x .812 x .135 Hex Cap Screw, 3/8-16 x 5.5 Flat Washer, .344 x .688 x .065† Extension Spring, .75 x 5.39 Flat Washer, .385 x .62 x .063 Self-tapping Screw, 1/4-20 x .750 Flat Washer, .45 x 1.25 x .164 Flange Lock Nut, 5/16-18 Steering Support Bracket PTO Belt (42-inch Decks w/ Manual PTO) PTO Belt (46-inch Decks w/ Manual PTO) 39 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. 732-0991 732-0990 714-0470 683-0302 738-0372 710-3011 756-0627 783-0349 748-0415A 783-0744A 712-0229 736-0105 710-0376 712-3006 736-0119 710-3029 736-0171 750-0956 756-0982A 732-0735 647-0053 711-1044 731-2111A 736-0108 747-1112A 647-0046 710-0650 732-0995 741-0708 DESCRIPTION Belt Guard Belt Guard Cotter Pin, 1/8 x 1.25 PTO Engagement Plate Shoulder Spacer Hex Cap Screw, 3/8-16 x 2.25 (Grade 5) Flat Idler Pulley, 3.5 OD Battery Tray Spacer, 3/8 x 1.54 Engagement Stop Bracket Push Nut, 3/8 Bell Washer, .401 x .870 x .063 Hex Cap Screw, 5/16-18 x 1.0 Hex Nut, 1/4-20 Lock Washer, 5/16 Hex Cap Screw, 7/16-20 x 1.25 Lock Washer, 7/16 Spacer Engine Pulley Extension Spring, 1.318 x 2.37 Belt Guard Keeper Pin PTO Knob Flat Washer, .510 x .750 x .033 PTO Handle PTO Lever Self-tapping Screw,15/16-18 x .875 Extension Spring, .5 x 6.0 Hex Split Flange Bearing Models 607, 608 & 609 46-inch Deck 16 57 See PTO breakdown 40 34 19 57 51 15 19 57 76 61 71 17 72 66 57 50 70 63 80 17 69 79 19 50 81 32 24 25 7 31 22 38 21 60 55 32 64 65 32 24 73 54 35 29 30 15 15 19 52 27 12 38 46-inch Deck Brake Assembly 4 74 44 78 77 19 15 49 1 9 62 35 23 29 62 9 56 30 53 75 49 58 59 68 67 67 14 14 42-inch Deck 8 26 2 24 25 82 17 35 29 19 24 32 38 27 21 22 4 32 13 20 17 11 31 30 42 15 44 45 47 15 33 12 6 30 41 19 46 43 35 29 9 12 36 37 1 14 14 9 17 40 39 34 5 36 18 Cutting Decks 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 31 32 33 34 35 36 37 38 39 40 41 42 43 PART NO. 16606 618-0324 683-0198C 683-0254 683-0303 710-0520 710-0528 710-0604A 710-0751 710-0817 710-1122 710-1260A 711-0677 712-0417A 712-0431 712-3004A 712-3006 712-3009 712-3027 714-0104 714-0111 717-1553A 710-0578 726-0233 731-1032B 731-2231A 732-0306 732-0428A 734-0973 736-0105 736-0119 736-0270 736-0275 736-0416 738-0373 742-0616 746-0970 747-1116 747-1202 748-0324 783-1026 783-1027 731-1643A DESCRIPTION Retainer Hook Spindle Assembly, 5.75 Dia. 42-inch Deck Shell Deck Adjustment Bracket w/ Weld Nut Deck Brake Assembly, 42-inch Decks Hex Cap Screw, 3/8-16 x 1.5 Hex Cap Screw, 5/16-18 x 1.25 Self-tapping Screw, 5/16-18 x .625 Hex Cap Screw, 1/4-20 x .62 Self-tapping Screw, 5/16-18 x 1.25 Hex Cap Screw, 1/4-20 x 2.5 Self-tapping Screw, 5/16-18 x .75 Ferrule, 5/16-18 Hex Flange Nut, 5/8-18 Flange Lock Nut, 3/8-16 Flange Lock Nut, 5/16-18 Hex Nut, 1/4-20 Hex Lock Nut, 5/16-18 Hex Flange Lock Nut, 1/4-20 Internal Cotter Pin, .072 x 1.12 Cotter Pin, 3/32 x 1.0 Deck Adjustment Gear Screw, 1/4-20 x 1.5 Push Nut. .25 x .5 Side Discharge Chute Assembly Belt Cover Compression Spring, .406 x .531 x 1.75 Compression Spring, .50 x 4.35 Deck Wheel, 5 x 1.38 Bell Washer, .401 x .87 x .063 Lock Washer, 5/16 Bell Washer, .265 x .75 x .062 Flat Washer, .344 x .688 x .065 Flat Washer, .320 x 3.0 x .125 Shoulder Screw, .498 x 1.53 Three-in-one Blade, Star Center, 21.23" Bracket Cable, 5.35" Deck Release Pin Deck Brake Rod Shoulder Spacer RH Belt Guard Bracket LH Belt Guard Bracket Mulch Plug, 42-inch Decks (if so equipped) 41 REF. PART NO. NO. 44 712-3087 45 712-3006 46 710-0597 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 736-0173 17258A 17928 618-0240 618-0241 683-0265C 710-0167 710-0347 710-0501 710-0514 710-0599 710-0650 710-0703 710-0805 711-0993 712-0271 732-0429A 732-0594A 738-0347 738-0572 742-0611 742-0612 746-1107 750-0807 754-0349 756-0627 783-0139 783-0141 783-0142 783-0747 731-1636 78 79 80 81 712-0291 17116 783-0805A 753-0872 82 753-0871 DESCRIPTION Wing Nut, 1/4-20 (if so equipped) Hex Nut, 1/4-20 (if so equipped) Hex Cap Screw, 1/4-20 x 1.0 (if so equipped) Flat Washer, .28 x .74 x .063 RH Belt Cover Bracket Reinforcement Spindle Plate Spindle Assembly, 5.0 Dia. Double Pulley Spindle Assembly 46-inch Deck Shell Carriage Screw, 1/4-20 x .50 Hex Cap Screw, 3/8-16 x 1.75 Hex Cap Screw, 1/4-20 x 2.0 Hex Cap Screw, 3/8-16 x 1.0 Self-tapping Screw,1/4-20 x .5 Self-tapping Screw,15/16-18 x .875 Hex Screw, 1/4-20 x .75 Hex Cap Screw, 5/16-18 x 1.5 Belt Keeper Pin Hex Sems Nut, 1/4-20 Extension Spring, .5 x 3.97 Extension Spring, .91 x 7.33 Shoulder Spacer, .625 x 1.16 Shoulder Screw, .374 x 1.16 Three-in-one Blade, Star Center, 16.28" Three-in-one Blade, Star Center, 14.88" Bracket Cable, 12" Spacer, .385 x .625 x .70 Deck Belt Flat Idler Pulley, 3.5 OD Idler Bracket Center Deck Skirt RH Deck Skirt LH Belt Cover Mulch Plug, 46-inch Decks (if so equipped) Hex Lock Nut, 1/4-20 (if so equipped) Deck Brake Assembly, 46-inch Decks RH Belt Cover 46-inch Deck Assembly Complete (Manual PTO activated, w/o mulch kit) 42-inch Deck Assembly Complete (Manual PTO activated, w/o mulch kit) Models 607, 608 & 609 34 4 (for throttle) 12 Briggs & Stratton OHV V-Twin 22 35 3 9 (for choke) 11 7 3 2 13 9 20 19 18 21 25 6 10 5 8 10 5 17 10 5 14 16 (deflector must face forward) 1 15 33 35 9 4 31 30 13 Briggs & Stratton OHV Single 9 2 3 19 20 3 18 21 28 20 18 29 32 6 14 27 42 1 (deflector must face forward) Engine Accessories 34 Briggs & Stratton Opposed Twin 28 19 20 18 36 42 43 3 35 9 (for choke) 11 7 2 3 13 21 9 6 39 38 37 40 15 41 14 1 REF. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 PART NO. 710-0148 710-0599 710-0604A 710-1237 710-1314 710-1315 712-3017 721-0460 726-0205 736-0119 736-0300 751B221535 751-0535 751-0564 751-0616 751-0650 751-0651 751-3140 751-3141 751-3142 783-0615 783-0625B REF. NO. 23 24 25 26 27 28 29 30 31 32 33 34 DESCRIPTION Self-tapping Screw, #8-32 x .375 Self-tapping Screw, 1/4-20 x .5 Self-tapping Screw, 5/16-18 x .625 Screw, #10-32 x .625 Socket Cap Screw, 5/16-18 x .625 Self-tapping Screw, 3/8-16 x 1.25 Hex Nut, 3/8-16 Exhaust Gasket (OHV V-Twin) Hose Clamp Lock Washer, 5/16 Lock Washer, .406 x .875 x .059 Casing Clamp Fuel Line Hose Muffler Deflector Muffler, Twin Inlet RH Exhaust Pipe (OHV V-Twin) LH Exhaust Pipe (OHV V-Twin) Oil Drain Valve Oil Drain Hose Oil Drain Cap Muffler Heat Shield Engine Heat Shield 35 36 37 38 39 40 41 42 43 43 PART NO. 710-3206A 712-3086 725-0157 736-0607 751-0617 712-0271 721-0208 732-0966 751B213146 751-0619 746-1084 746-1086 722-0263 783-0357A 710-0751 736-0329 721-0346 751-0623 751-0624 712-0779A 726-0272 (deflector must face forward) DESCRIPTION Hex Cap Screw, M8-1.25 x 25 Flange Nut, M8-1.25 Cable Tie External Lock Washer, 5/16 Muffler, Single Inlet Hex Sems Nut, 1/4-20 (for starter cable) Exhaust Gasket (OHV Single) Extension Spring, .275 x 1.25 Casing Clamp Exhaust Pipe (OHV Single) Throttle/Choke Cable (OHV Single) Throttle Cable (OHV V-Twin & Opposed Twin) Foam, .625 x 1.5 x 10 (fits over fuel line) Heat Shield (Opposed Twin) Hex Cap Screw, 1/4-20 x .620 (Grade 5) Lock Washer, 1/4 Exhaust Gasket (Opposed Twin) LH Exhaust Pipe (Opposed Twin) RH Exhaust Pipe (Opposed Twin) Screw, #10-16 x .5 Clamp, 9/16 MANUFACTURER’S LIMITED WARRANTY The limited warranty set forth below is given by MTD PRODUCTS INC (“MTD”) with respect to new merchandise purchased and used in the United States, its possessions and territories. MTD 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 material or workmanship. This limited warranty shall only apply if this product has been operated and maintained in accordance with the Operator’s Manual furnished with the product, and has not been subject to misuse, abuse, commercial use, neglect, accident, improper maintenance, alteration, vandalism, theft, fire, water or damage because of other peril or natural disaster. Damage resulting from the installation or use of any accessory or attachment not approved by MTD Products Inc. for use with the product(s) covered by this manual will void your warranty as to any resulting damages. Normal wear parts or components thereof are subject to separate terms as follows: All normal wear part or component failures will be covered on the product for a period of 90 days regardless of cause. After 90 days, but within the two year period, normal wear part failures will be covered ONLY IF caused by defects in material or workmanship of OTHER component parts. Normal wear parts and components include, but are not limited to, belts, blades, blade adapters, grass bags, rider deck wheels, seats, snow thrower skid shoes, shave plates and tires. Batteries are covered by a 90-day limited replacement warranty. 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, please check for a listing in the Yellow Pages or contact the Customer Service Department of MTD PRODUCTS INC by calling 1-800-800-7310 or writing to P.O. Box 368022, Cleveland, Ohio 44136-9722. This limited warranty does not provide coverage in the following cases: a. The engine or component parts thereof. These items carry a separate manufacturer’s warranty. Please refer to the applicable manufacturer’s warranty on these items. b. Log splitter pumps, valves and cylinders have a separate one year warranty. c. Routine maintenance items such as lubricants, filters, blade sharpening and tune-ups, or adjustments such as brake adjustments, clutch adjustments or deck adjustments; and normal deterioration of the exterior finish due to use or exposure. d. MTD 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’s authorized channels of export distribution. No implied warranty, including any implied warranty of merchantability or 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 or guaranty, whether written or oral, except as mentioned above, given by any person or entity, including a dealer or retailer, with respect to any product shall bind MTD. During the period of the Warranty, the exclusive remedy is repair or replacement of the product as set forth above. (Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.) The provisions as set forth in this Warranty provide the sole and exclusive remedy arising from the sales. MTD shall not be liable for incidental or consequential loss or damages including, without limitation, expenses incurred for substitute or replacement lawn care services, for transportation or for related expenses, or for rental expenses to temporarily replace a warranted product. (Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above exclusion or limitation 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 the 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 use or misuse or inability to use the product. This limited warranty shall not extend to anyone other than the original purchaser, original lessee or 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.
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