Safety • Set-Up • Operation • Adjustments • Maintenance • Troubleshooting • Warranty OPERATOR’S MANUAL Hydrostatic Lawn Tractor — Model 616 IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY BEFORE OPERATING EQUIPMENT. PRINTED IN U.S.A. P. O. Box 1386, KITCHENER, ONT. N2G 4J1 769-02796 1.9.
This Operator’s Manual is an important part of your new equipment. It will help you assemble, prepare and maintain the unit for best performance. Please read and understand what it says. Table of Contents Slope Gauge........................................................ 3 Safe Operation Practices.................................... 4 Setting Up Your Lawn Tractor............................. 8 Operating Your Lawn Tractor............................ 12 Adjusting Your Lawn Tractor...........................
Use this page as a guide to determine slopes where you may not operate safely. Do not operate your lawn mower on such slopes. 1 Slope Gauge Sight and hold this level with a vertical tree... 15° Fo or a fence post or a corner of a building... ot ld alo ng d ted lin e (r e p r e sents a 15 ° s l o pe) 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.
2 Safe Operation Practices This symbol points out important safety instructions which, if not followed, could endanger the personal safety and/or property of yourself and others. Read and follow all instructions in this manual before attempting to operate this machine. Failure to comply with these instructions may result in personal injury. When you see this symbol, HEED ITS WARNING.
General Operation: 14. Watch for traffic when operating near or crossing roadways. This machine is not intended for use on 1. Read, understand, and follow all instructions on the any public roadway. machine and in the manual(s) before attempting to 15. Do not operate the machine while under the influassemble and operate. Keep this manual in a safe ence of alcohol or drugs. place for future and regular reference and for ordering 16. Mow only in daylight or good artificial light. replacement parts. 2.
2 Safe Operation Practices This symbol points out important safety instructions which, if not followed, could endanger the personal safety and/or property of yourself and others. Read and follow all instructions in this manual before attempting to operate this machine. Failure to comply with these instructions may result in personal injury. When you see this symbol, HEED ITS WARNING.
Service 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Never attempt to make adjustments or repairs to the machine while the engine is running. Never run an engine indoors or in a poorly ventilated 11. Grass catcher components and the discharge area. Engine exhaust contains carbon monoxide, an cover are subject to wear and damage which could odorless, and deadly gas. expose moving parts or allow objects to be thrown.
3 Attaching the Battery Cables Rubber Boot NOTE: The positive battery terminal is marked Pos. (+). The negative battery terminal is marked Neg. (–). • The positive cable (heavy red wire) is secured to the positive battery terminal (+) with a hex bolt and hex nut at the factory. Make certain that the rubber boot covers the terminal to help protect it from corrosion. Retaining Rod Setting Up Your Lawn Tractor • Remove the hex bolt and wing nut from the negative cable.
3 Shipping Brace Removal WARNING: Make sure the riding mower’s engine is off, remove the ignition key, and set the parking brake before removing the shipping brace. Setting Up Your Lawn Tractor • Locate the shipping brace, if present, and accompanying warning tag found on the right side of the mower, between the discharge chute and the cutting deck. See Figure 3-2.
3 Attaching The Seat Seat styles vary by tractor model and there are three different styles available: • Standard Adjustment • Quick Adjustment Setting Up Your Lawn Tractor • Knob Adjustment If the seat for your tractor did not come attached, refer to Figure 3-4, Figure 3-5, and Figure 3-6 to identify your tractor’s seat style and follow the applicable instructions below to attach it.
3 Identifying the Mulch Plug (if so equipped) On tractor models so equipped, a mulch plug can either be found within the cutting deck’s discharge opening or packed separately with your unit. Setting Up Your Lawn Tractor NOTE: Refer to Mulching on page 19 for more detailed information. If you’d prefer to operate the cutting deck without mulching, simply remove the mulch plug by unthreading the plastic wing nut which fastens it to the cutting deck.
4 Know Your Lawn Tractor Operating Your Lawn Tractor A* E B F A* G H + 1/10 P NOTE: Any reference in this manual to the RIGHT or LEFT side of the tractor is observed from operator’s position. P I J C NOTE: This Operators Manual covers a range of product specifications for various models. Characteristics and features discussed and/or illustrated in this manual may not be applicable to all models.
4 Throttle Control Lever The throttle control lever is located on the right side of the tractor’s dash panel. This lever controls the speed of the engine and, on some models, when pushed all the way forward, the choke control also. When set in a given position, the throttle will maintain a uniform engine speed. See Figure 4-1.
4 Operating Your Lawn Tractor Electric PTO (Blade Engage) Knob (If Equipped) Figure 4-4 The PTO (Blade Engage) knob (or lever) must be in the disengaged (OFF) position when starting the engine, when traveling in reverse and if the operator leaves the seat. the MAINTENANCE section of this manual for the proper battery charging procedure or have the charging system checked by your service dealer. The ammeter (if so equipped) measures the electrical output of the engine’s charging system.
Deck Lift Lever Found on your tractor’s right fender, the deck lift lever is used to change the height of the cutting deck. To use, move the lever to the left, then place in the notch best suited for your application. Parking Brake Button • The safety interlock system prevents the engine from cranking or starting unless the parking brake is engaged, and the PTO (Blade Engage) knob (or lever) is in the disengaged (OFF) position.
4 2EVERSE #AUTION -ODE 0OSITION 3TOP 0OSITION Keep hands and feet away from the discharge opening of the cutting deck. Do not operate the tractor if the interlock system is malfunctioning. This system was designed for your safety and protection. Use extreme caution while operating the tractor in the REVERSE CAUTION MODE. Always look down and behind before and while backing. Do not operate the tractor when children or others are around. Stop the tractor immediately if someone enters the area.
NOTE: Refer to the TRACTOR SET-UP on page 8 of this manual for Gasoline and Oil fill-up instructions. Drive Pedal Brake Pedal 1. Insert the tractor key into the ignition switch. 2. Place the PTO (Blade Engage) knob (or lever) in the disengaged (OFF) position. 3. Engage the tractor’s parking brake. Operating Your Lawn Tractor 4. Activate the choke control. 5. Turn the ignition key clockwise to the START position. After the engine starts, release the key. It will return to the ON position.
4 Operating Your Lawn Tractor Moving the Tractor Manually Your tractor’s transmission is equipped with a hydrostatic relief valve for occasions when it is necessary to move the tractor manually. Activating this valve forces the fluid in the transmission to bypass its normal route, allowing the rear tires to “freewheel.” To engage the hydrostatic relief valve, proceed as follows: • Locate the hydrostatic bypass rod in the rear of the tractor. See Figure 4-7.
Mowing Mulching (If Equipped) WARNING: To help avoid blade contact or a thrown object injury, keep bystanders, helpers, children and pets at least 75 feet from the machine while it is in operation. Stop machine if anyone enters the area. The following information will be helpful when using the cutting deck with your tractor: WARNING: Plan your mowing pattern to avoid discharge of materials toward roads, sidewalks, bystanders and the like.
5 WARNING: Never attempt to make any adjustments while the engine is running, except where specified in the operator’s manual. Leveling the Deck Adjusting Your Lawn Tractor NOTE: Check the tractor’s tire pressure before performing any deck leveling adjustments. Refer to Tires on page 24 for information regarding tire pressure. Front To Rear Loosen to lower deck Figure 5-1 WARNING Never attempt to make any adjustments while the engine is running, except where specified in the operator’s manual.
Steering Adjustment 4. Balance the deck by using a wrench to turn the adjustment gear (found immediately behind the hex cap bolt just loosened) clockwise/up or counterclockwise/down. The deck is properly balanced when both blade tip measurements taken earlier are equal. 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.
6 IMPORTANT: Refer to the Engine Operator/Owner Manual packed with your unit for information regarding the quantity and proper weight of motor oil. Air Cleaner Service the pre-cleaner, if so equipped, and cartridge/air cleaner element as instructed in the Engine Operator/ Owner Manual packed with your unit. Maintaining Your Lawn Tractor Spark Plug(s) *Kohler Single Shown Figure 6-1 Engine Refer to the Engine Operator/Owner Manual for engine maintenance instructions.
6 Deck Wash System™ (If equipped) Your tractor’s deck may be equipped with a water port on its surface as part of its deck wash system. Use the Deck Wash System™ (sold separately) to rinse grass clippings from the deck’s underside and prevent the buildup of corrosive chemicals. Complete the following steps AFTER EACH MOWING: 1. Drive the tractor to a level, clear spot on your lawn, near enough to a water sillcock (spigot) for your garden hose to reach.
6 Maintaining Your Lawn Tractor NOTE: On models with a 46-inch deck, it may be necessary to remove the belt keepers from around the engine pulley, on order to remove the PTO belt. 5. Looking at the cutting deck from the left side of the tractor, locate the deck support pin on the rear left side of the deck. See Figure 6-4. 6. Pull the deck support pin outward to release the deck from the deck lift arm.
6 Cutting Blades WARNING: Be sure to shut the engine off, remove ignition key, disconnect the spark plug wire(s) and ground against the engine to prevent unintended starting before removing the cutting blade(s) for sharpening or replacement. Protect your hands by using heavy gloves or a rag to grasp the cutting blade. Maintaining Your Lawn Tractor WARNING: Periodically inspect the blade spindles for cracks or damage, especially if you strike a foreign object. Replace immediately if damaged.
6 Maintaining Your Lawn Tractor Changing the Deck Belt WARNING: Be sure to shut the engine off, remove ignition key, disconnect the spark plug wire(s) and ground against the engine to prevent unintended starting before removing the belt(s). All belts on your tractor are subject to wear and should be replaced if any signs of wear are present. IMPORTANT: The V-belts found on your tractor are specially designed to engage and disengage safely.
6 Maintaining Your Lawn Tractor Belt Cover Idler Pulleys Figure 6-8 46” Deck (Electric PTO) Electric PTO Clutch Idler Pulleys Figure 6-9 27 This Operators Manual covers a range of product specifications for various models. Characteristics and features discussed and/or illustrated in this manual may not be applicable to all models. MTD LLC reserves the right to change product specifications, designs and equipment without notice and without incurring obligation.
7 Off-Season Storage / Attachments Clean and lubricate the tractor as instructed in the MAINTAINENCE section of this manual before storing for an extended period. Follow the instructions in the separate engine manual packed with your unit for proper engine care prior to storing your tractor. WARNING: Drain fuel only into an approved container outdoors, away from an open flame. Allow engine to cool. Extinguish cigarettes, cigars, pipes, and other sources of ignition prior to draining fuel.
8 Safety Labels R R WARNING MAX 20% This symbol points out important safety instructions which, if not followed, could endanger the personal safety and/or property of yourself and others. Read and follow all instructions in this manual before attempting to operate this machine. Failure to comply with these instructions may result in personal injury. When you see this symbol.
9 Cause Problem Engine fails to start Trouble Shooting Engine runs erratic For repairs beyond the minor adjustments listed here, contact an authorized service dealer. Remedy 1. PTO engaged. 1. Place PTO knob (or lever) in disengaged (OFF) position. 2. Spark plug wire(s) disconnected. 2. Connect wire(s) to spark plug(s). 3. Fuel tank empty or stale fuel. 3. Fill tank with clean, fresh gasoline. 4. Choke not activated. 4.
TWO YEAR SUPREME WARRANTY: For two years from date of retail purchase within Canada, MTD PRODUCTS LIMITED 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.
11 Replacement Parts NOTE: Download a complete Parts Manual free of charge at www.mtdcanada.ca or phone (800) 668-1238 to purchase a Parts Manual. Be sure to have your model number and serial number ready. These can be found on the model plate located under the seat. Refer to page 2 for more information regarding locating your model and serial numbers. Automatic Lawn Tractor For parts and/or accessories refer to customer support on page 2.
