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OTRO_ BILT

OPERATOR'S MANUAL

Pedal Drive Lawn Tractor

Model 609

Model Z609H 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 forest-cov-

ered, brush-covered or grass-covered land unless the engine's exhaust system is equipped with a spark attester meeting applicable

local or state laws (if any). If a spark arrester is used, it should be maintained in effective working order by the operator. In the State of

California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws.

Federal laws apply on federal lands. A spark arrester for the muffler is available through your nearest engine authorized service dealer

or contact the service department, P.O. Box 368022 Cleveland, Ohio 44136-9722.

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

TROY-BILT® is a registered trademark owned by Garden Way Incorporated of Troy, New York.

PRINTED IN U.S.A. FORM NO. 770-10250A

(10/99)

Summary of content (44 pages)

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OTRO_ BILT OPERATOR'S MANUAL Pedal Drive Lawn Tractor Model 609 Model Z609H 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 forest-covered, brush-covered or grass-covered land unless the engine's exhaust system is equipped with a spark attester meeting applicable local or state laws (if any).
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SECTION 1: TABLE OF CONTENTS FINDING YOUR MODEL NUMBER ....................................................... CALLING CUSTOMER SUPPORT ........................................................ IMPORTANT SAFE OPERATION PRACTICES.............................................. SAFETY LABLES FOUND ON YOUR UNIT................................................. SLOPE GAUGE ...................................................................... ATTACHMENTS & ACCESSORIES .............................................
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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.
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• Disengage all attachment clutches,thoroughly 3. CHILDREN depressthe brakepedal,andshiftinto neutral Tragic accidents can occur if the operator is not alert to the before attempting tostartengine. presence of children. Children are often attracted to the • Yourmoweris designed tocutnormalresidential machine and the mowing activity. Never assume that chilgrassofa heightnomorethan10".Donotattempt dren will remain where you last saw them. to mowthroughunusually tall, dry grass(e.g.
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• Keepallnuts,boltsandscrews tightto besurethe equipment isinsafeworking condition. • Nevertamperwith safetydevices.Checktheir properoperationregularly.Use all guardsas instructed inthismanual. • Afterstrikinga foreignobject,stopthe engine, remove thewirefromthesparkplugandthoroughly inspectthe mowerfor anydamage.Repairthe damage before restarting andoperating themower. • Grasscatchercomponents are subjectto wear, damageanddeterioration, whichcouldexpose movingpartsor allowobjectsto bethrown.
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USE THIS PAGE AS A GUIDE TO DETERMINE SLOPES WHERE YOU MAY NOT OPERATE SAFELY. SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE ,11 _ _ _ _ _! A POWER POLE A CORNER OF A BUILDING m4 i "'"" !_ OR A FENCE POST oo.-', Lo 0 m 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.
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SECTION 5: ATTACHMENTS 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 & ACCESSORIES 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) TracPac" Storage Container (mounts on rear of tractor) FastAttach" 46-inch Front Dozer Blade 42-
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SECTION 7: CONTROLS D B M A C G J K L NOTE: Steering Wheel not shown for clarity. Figure 3 A B Ignition Switch Throttle Control Lever C Choke Control (if so equipped) D E Systems Indicator Monitor Uft Lever F G PTO (Power Take-Off) Lever* Drive Pedal H Brake Pedal I J Parking Brake Button Shift Lever K Seat Adjustment Lever L M Cup Holder Cruise Control Button N PTO (Power Take-Off) Knob* * Tractors vary by model and are equipped with either a PTO lever or a PTO knob, NEVER both.
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IGNITION SWITCH CHOKE 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.
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ELECTRIC (POWER BRAKE PTO TAKE-OFF) PEDAL KNOB k BRAKE _ To engage the power to the cutting deck or other attachments, pull outward on the PTO knob. Push the PTO knob inward to disengage the power to the attachments. II1 The brake pedal is located on the right front side of the tractor above the drive pedal along the running board. The brake pedal can be used for sudden stops or setting the parking brake.
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SHIFT LEVER CRUISE The shift lever is located on the left side of the fender and has three positions, FORWARD, NEUTRAL and REVERSE. the moving IMPORTANT: SAFETY 6 het d cto stot 0ane e;r, ignition switch. Push the cruise control button while traveling forward at a desired speed. While holding the button in, release pressure from the drive pedal. This will engage the cruise control and allow the tractor to shift Never Jl_ remain at that speed without applying pressure to the drive pedal.
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SETTING THE CUTTING HEIGHT STOPPING THE ENGINE 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.
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• Whilecontinuingto holdthe cruisebuttonin, To turn the tractor's headlights off: liftyourfootfromthe drivepedal(youshould • Turn the key either into the On position (to feetthecruiselatchengage). leave the engine running) or the Off position • If properlyengaged,the cruisecontrolbutton (to shut the engine off). Refer to Figure 4. and the drivepedalshouldlockin the down position,andthetractorwillmaintainthesame IMPORTANT: Never move the key into the Start position while the engine is running.
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MOWING • The operator must remain in the tractor seat at all times. If the operator should leave the seat without pushing the PTO knob inward into the disengaged (OFF) position, the tractor's engine will shut off. IMPORTANT: This tractor is equipped with one of MTD's high quality cutting decks. The following information wilt be helpful when using the cutting deck with your tractor. The PTO knob cannot be in the engaged (ON) position when the tractor is driving in the reverse direction.
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• With the tractor parked on a firm, level surface,placethe lift leverin the top notch (highestposition)androtatethe bladenearest the dischargechuteso thatit is parallelwith thetractor. • Measurethe distancefrom the front of the bladetip to the groundand the rear of the bladetiptotheground.Thefirstmeasurement takenshouldbe between1/4"and3/8" less thanthesecondmeasurement. Determine the approximatedistancenecessaryfor proper adjustmentandproceed,if necessary, to the nextstep.
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SEAT ADJUSTMENT • Replace hex nut and lock washer and retighten the jam nut after proper adjustment is achieved. To adjust the position of the seat, move the seat adjustment lever (located under the seat) to the left and slide the seat forward or backwards. See Figure 9. Make sure seat is locked into one of the six adjustment positions before operating the tractor. NOTE: Threading the ball joints too far onto the drag links will cause the front tires to "toe-in" too far.
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• Loosen, but do NOT remove, the hex nut found on the right side of the brake assembly. See Figure 12. ! • Using a feeler gauge, set the gap between the brake disc and the brake puck at .011 ". • Re-tighten the hex nut loosened earlier. 1 Hex Nut Set Gap at NOTE: View shown from beneath tractor. Transmission Figure 12 SECTION 10: MAINTENANCE Pop open the protective cap on the end of the oil drain valve to expose the oil drain port. See Figure 13.
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CLEANING THE ENGINE AND DECK Lower the deck by moving the lift lever into the bottom notch on the right fender. 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.
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CHANGING THE DECK BELT(S) All belts on your tractor are subject to wear and should be replaced if any signs of cracking, shredding rotting are present. or 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.
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Engine Pulley h.,,---------- Deck Stop (mounted on tractor) Belt Guard PTO belt PTO Engagement Plate Idler Right Hand Pulley Left Hand Pulley NOTE: Belt covers not shown for clarity.
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Variable-speed Battery Tray Opening Drive belt (Lower) Shift Lever Rear Idler Pulley Drive belt (Upper) Electric PTO Clutch !! (if so equipped) r II Engine Pulley (Upper Portion) Transmission NOTE: Transmission Pulley Front of Tractor View shown from above tractor. -p_ Figure 17 Lower Drive Belt • Remove the rear idler pulley from the doubleidler bracket while unrouting the belt from around both the rear and the front idler pulley. Refer to Figure 16.
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• Remove the hex bolt from the center of the engine pulley (or the electric PTO clutch on units so equipped) and gently lower it off of the engine crankshaft. Be careful not to lose any washers or spacers which may be found on top of the engine pulley or the electric PTO clutch. See Figure 18. Using two 9/16" wrenches, remove the pin from the speed control assembly. See Figure 20.
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• After cleaning the battery and terminals, apply a light coat of petroleum jelly or grease to the terminals and over the positive terminal boot. NOTE: The hex flange nut has a right-handed (normal) thread pattern. Do NOT attempt to force the nut in the incorrect direction. Doing so may damage the nut and create a safety hazard. • Always keep the boot positioned over the positive terminal to prevent shorting.
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SECTION 11: LUBRICATION engine before performing WARNING: Always stopany themaintenance. engine and disconnect the spark plug wire(s) and ground against the ,_ ENGINE Lubricate the engine with motor oil as instructed in the separate engine manual packed with your unit. PIVOT POINTS Lubricate all pivot points (drive pedal, brake pedal, etc.) at least once a season with light oil. LINKAGE Lubricate all the pivot points on the drive, brake and lift linkage at least once a season with SAE 30 engine oil.
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SECTION Trouble 12: TROUBLESHOOTING GUIDE Possible Corrective Action Cause(s) Engine will not crank Safety switch button not depressed. Battery installed incorrectly. Battery is dead or weak. Blown fuse Throttle or choke Engine cranks but not in starting will not start position. No fuel to the carburetor. No spark to spark plug(s). Dirty aircleaner. Engine smokes Excessive vibration Engine oil has been overfilled. Engine loses crankcase vacuum.
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Model 609 < > A, J o J 26
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Tractor Body RED 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. 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 751-0658A 751-0603 746-1085 746-1088 32 33 731-2269 731-2270 712-3027 DESCRIPTION Self-tapping Screw, 5/16-18 x .
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Model 609 46 /.
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Lift Assembly REP. 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 714-0145 716-0106 720-0311 732-0874 732-0934 14 15 16 17 18 19 20 21 22 23 24 25 26 27 736-0275 736-0921 736-3019 736-3084 738-0138 738-0143 741-0225 741-0715 746-0968 747-1111 756-1154 783-0678 783-0720A 710-0260 REF. NO. 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 DESCRIPTION Deck Stabilizer Rod Lift Shaft Assembly Clevis Pin, .5 x .
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Model 609 32 31 27 I 25 40" 45 33 _6 29 30
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Steering Assembly RER 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 738-1001 741-0475 741-0656 738-0372 631-0027 731-0220 638-0019 638-0021 638-0020 638-0022 683-0128A REF. PART NO. NO.
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Model 609 _" 4 22 29 _58 79 \ 35 18\ 36\ _23 35 64 23 21 " > 83 91 81_ 8O < _14 _ 9 "16 32
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Drive System REP. 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.
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Model 609 20 12c 38_ 39 \8 .
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Single-speed Transmission RER 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 PART NO.
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Model 609 57 j3 2 j4 j13 J fl0 j53 /-14 z 54 . 5 15 _55 J _17 j 43 J 56 J 28 j20 Hook spring, Ref. 58, here > _51 59 j j36 _65 64 -- Units Equippedw/ ElectricPTO 68_. 74 j69 J I J I i 63 67 37 39 .70 (PTO belt for 42" deck shown) .49 .34 .
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Power Take-off System REP. 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 PART NO.
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Model 609 ,g_" "'_-,g 46-inch Deck 16 _See PTO breakdown _55 64 65 7O 23 29 30 58 :i:A double-pulley spindle is found in this location on 46-inch decks engaged by electric PTOs only. Use 618-0240 on manual PTO decks. 42-inch Deck 26. @ 2 38.
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Cutting Decks RED 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 44 PART NO.
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Model 609 Briggs & Stratton Intek Twin I 18 2o_ I 6 j (deflector must face forward) (for choke) 37_ Kohler Single-cylinder 18 _3 21 J _ 26 24 _ 23 _ _ _ 4O /28 14 (deflector face forward) must
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Engine Accessories j _9 34 Briggs & Stratton Intek Single _31 37 j3 (deflector must face forward) 28 RER NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 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 REF. NO. 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 DESCRIPTION Self-tapping Screw, #8-32 x .375 Self-tapping Screw, 1/4-20 x .
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Model 609 Electrical System j14 18/19 1 Electric PTO harness shown. Manual PTO harness will vary slightly RED NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 PART NO. 625-0051 629-0939 629-0944 629-0126 710-0599 712-3006 725-1426 725-1657A 725-1741 725-1743 725-1758 725-1745 725-1747 736-0222 736-0329 629-0309 725-1752 783-0462 725-3007A 729-0357 725-1381 629-0924 DESCRIPTION Bulb/Socket Headlight Assembly Wiring Harness w/o Ref. 14 (units w/Electric PTO) Wiring Harness w/o Ref.
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Notes 43
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MANUFACTURER'S LIMITED WARRANTY FOR: O TRO_ _ BILT'_ 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.