Operator`s manual

ManualsBrandsYard-Man ManualsDo-It-Yourself toolsModel Series 420

Safety • Assembly • Operation • Adjustment • Maintenance • Troubleshooting • Parts Lists • Warranty

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

covered or grass-covered land unless the engine’s exhaust system is equipped with a spark arrester meeting applicable local or state laws (if any).

If a spark arrester is used, it should be maintained in effective working order by the operator. In the State of California the above is required by law

(Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. A spark arrester

for the muffler is available through your nearest engine authorized service dealer or contact the service department, P.O. Box 361131 Cleveland,

Ohio 44136-0019.

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

PRINTED IN U.S.A.

READ SAFETY RULES AND INSTRUCTIONS CAREFULLY BEFORE OPERATION

IMPORTANT

OPERATOR’S MANUAL

Automatic Lawn Tractor — Model Series 604

2/8/2006

FORM NO. 769-02352

Summary of content (56 pages)

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Safety • Assembly • Operation • Adjustment • Maintenance • Troubleshooting • Parts Lists • Warranty OPERATOR’S MANUAL Automatic Lawn Tractor — Model Series 604 IMPORTANT READ SAFETY RULES AND INSTRUCTIONS CAREFULLY BEFORE OPERATION Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-covered, brushcovered or grass-covered land unless the engine’s exhaust system is equipped with a spark arrester meeting applicable local or state laws (if
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This Operator’s Manual is an important part of your new lawn tractor. It will help you assemble, prepare and maintain the unit for best performance. Please read and understand what it says. 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 .......................
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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 �� 3 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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2 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 this machine. Failure to comply with these instructions may result in personal injury. When you see this symbol.
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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.
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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.
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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.
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3 Setting Up Your Lawn Tractor 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. MTD LLC reserves the right to change product specifications, designs and equipment without notice and without incurring obligation. Rubber Boot Attaching the Battery Cables NOTE: The positive battery terminal is marked Pos. (+). The negative battery terminal is marked Neg. (–).
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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 2.
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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 4, Figure 5, and Figure 6 to identify your tractor’s seat style and follow the applicable instructions below to attach it.
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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.
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4 Know Your Lawn Tractor Operating Your Lawn Tractor Any reference in this manual to the RIGHT or LEFT side of the tractor is observed from operator’s position. 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.
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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 9.
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4 Operating Your Lawn Tractor Ammeter �� Figure 11 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. Systems Indicator Monitor (If Equipped) LCD Located in the center of the tractor’s console, the systems indicator monitor records, and displays on its LCD, hours of tractor operation whenever the ignition key is rotated out of the STOP position.
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Parking Brake Button To set the parking brake, fully depress the brake pedal and push the parking brake button in. Hold the button in while taking your foot off the brake pedal. Both the parking button and the brake pedal will then stay depressed. To release the parking brake, depress the brake pedal slightly. The parking brake button will then return to its original position.
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4 Operating Your Lawn Tractor WARNING �� 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, EVEN WITH BLADES OFF. • LOOK DOWN AND BEHIND BEFORE AND WHILE BACKING.
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WARNING: Keep hands and feet away from the discharge opening of the cutting deck. Stopping the Engine WARNING: If you strike a foreign object, stop the engine, disconnect the spark plug wire(s) and ground against the engine. Thoroughly inspect the machine for any damage. Repair the damage before restarting and operating NOTE: The deck wheels are an anti-scalp feature of the deck and are not designed to support the weight of the cutting deck.
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4 Operating Your Lawn Tractor 4. 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. Disengage the cruise control using one of the following methods: 1. Depress the brake pedal to disengage the cruise control and stop the tractor. Driving On Slopes 2. Lightly depress the drive pedal. Refer to the SLOPE GAUGE on page 3 to help determine slopes where you may operate the tractor safely.
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4 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. Also, avoid discharging material against a wall or obstruction which may cause discharged material to ricochet back toward the operator. Operating Your Lawn Tractor • Do not mow at high ground speed, especially if a mulch kit or grass collector is installed.
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5 Front To Rear The front of the cutting deck is supported by a stabilizer bar that can adjusted to level the deck from front to rear. The front of the deck should be between 1/4-inch and 3/8-inch lower than the rear of the deck. Adjust if necessary as follows: 1. With the tractor parked on a firm, level surface, place the deck lift lever in the top notch (highest position) and rotate the blade nearest the discharge chute so that it is parallel with the tractor.
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5 Parking Brake Adjustment WARNING: Never attempt to adjust the brakes while the engine is running. Always disengage PTO, move shift lever into neutral position, stop engine and remove key to prevent unintended starting. If the tractor does not come to a complete stop when the brake pedal is completely depressed, or if the tractor’s rear wheels can roll with the parking brake applied, the brake is in need of adjustment.
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5 Seat Adjustment Quick Adjust Seat (If so equipped) WARNING: Before operating this machine, make sure the seat is engaged in the seat stop, stand behind the machine and pull back on seat until fully engaged into stop. Adjusting Your Lawn Tractor Figure 17 • To adjust the position of the seat on models equipped with a seat adjustment lever, move the lever to the left and slide the seat forward or rearward. Refer to the Setting Up Your Lawn Tractor section.
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5 Steering Adjustment 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 and right side: 1. Loosen the jam nut found on the drag link at the rear of the ball joint. See Figure 19. �� 2. Remove hex nut on the top of ball joint. See Figure 19. �� 3.
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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.
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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™ 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.
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6 Maintaining Your Lawn Tractor 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 23. 6. Pull the deck support pin outward to release the deck from the deck lift arm. 8. Repeat the above steps on the tractor’s right side. 9. Move the deck lift lever into the top notch on the right fender to raise deck lift arms up and out of the way. 10.
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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.
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6 Maintaining Your Lawn Tractor 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). 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).
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42” Deck (Electric PTO) Electric PTO Clutch Right Hand Spindle Pulley 6 Maintaining Your Lawn Tractor Left Hand Spindle Pulley Idler Pulleys Figure 26 �� Figure 27 29 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.
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7 Clean and lubricate the tractor as instructed in Section 6: MAINTAINING YOUR LAWN TRACTOR of this manual before storing for an extended period. Follow the instructions in the Service, Storage & Specifications section of the Engine Operator/Owner Manual 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.
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8 Safety Labels ��
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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.
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NOTES 33
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Model Series 604 �� 34 ��
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Ref. No. Part No. Description Ref. No. Part No. Description 1 710-1268† Screw #10-16 x .375 30 783-04333A Fender 2 712-04063 Nut, Flange Lock 5/16-18 31 783-0677B Adjust. Brkt., Lift 3 712-04064† Nut, Flange Lock 1/4-20 32 783-1489B Mounting Bracket, Seat 4 720-0309A† Seat Adjuster Grip 33 710-0227 Screw, #8-18 x.50 5 726-0201† Nut, Speed .3125 ID 34 726-0279 Plate, Insulator 6 731-04074† Spacer 35 725-1303 Spring Switch, Outer 7 732-0499† Compression Spring .
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Model Series 604 �� 36
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Ref. No. Part No. Description Ref. No. Part No. Description 1 710-04095 Hex Screw, 3/8-16, 1.00, Gr5 23 783-0728 2 710-0514 Hex Screw, 3/8-16, 1.00, Gr5 24 631-04008A Steering Wheel 3 710-0643 Hex Screw, 5/16-18, 1.00, Gr5 25 731-04065 4 711-1408 Link, Drag, RH 26 738-04128† Shoulder Screw, .5 x 2.380, 3/8-16 5 711-1409A Link, Drag, LH — 738-1011A Shoulder Screw, .5 x 2.
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Model Series 604 � �� 38
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Ref. No. Part No. Description Ref. No. Part No. Description 1 731-1980B Hood 4 Style 25 747-04301 Side Panel Support 2 731-1979 Headlight Lens - LH 26 712-0292 Clip Tinn Nut 1/4-20 — 731-1978 Headlight Lens - RH 27 783-04323D Plate Dash Support - LH 3 725-1649 Headlight Socket 28 731-04213 Brake Dash Lever 4 725-0963 Lamp 30 710-1611B TT Screw 5/16-18 x .75 5 710-1652 TT Screw 1/4-20 x .
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Model Series 604 � � � � � � � �� 40 ��
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Ref. No. Part No. Description Ref. No. Part No. Description 1 710-0726 AB Screw 5/16-12 x .750 38 683-0266 Pedal Assembly 2 783-04360 Shift Bracket F-N-R 39 735-0662 Control Pad 3 720-04028 Shift Knob 40 647-0031B Brake Control Assembly 4 647-04020 Shift Lever Assembly 41 736-0119 Lock Washer 5/16 5 732-0525 Shifter Spring Clip 42 710-0650 TT Screw 5/16-18 x .875 6 714-0104 Cotter Pin .072 dia. x 1.13 lg. 43 710-1611B TT Screw 5/16-18 x .
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10 Illustrated Parts List To order replacement parts, call the Customer Service Line at 1-800-800-7310 or visit www.yardman.com Model Series 604 Ref. No. Part No.
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�� 10 �� Illustrated Parts List �� For Choke �� Ref. No. Part No. Description Ref. No. Part No. Description 1 710-0227 AB Screw #8-18 x 0.5 12 783-0615D Muffler Bracket, Kohler V-Twin 2 751-0564A Muffler Deflector 13 710-0599 TT Screw 1/4-20 x 0.5 3 726-0205 Hose Clamp 14 710-0726 AB Screw 5/16-12 x 0.
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Model Series 604 (Electric PTO) �� 44 ��
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Ref. No. Part No. Description 1 710-0726 AB Screw 5/16-12 x .750 2 710-3011 HH Cap Screw 3/8-16 x 2.25 3 710-04379A HH Cap Screw 7/16-20 x 3.50 — 710-3157A† HH Cap Screw 7/16-20 x 3.25 4 712-04065 Flange Lock Nut 3/8-16 5a 717-04174 PTO Clutch, Electric 46/50 5b 717-04163† PTO Clutch, Electric RMS 6 736-0277 Flat Washer (used w/ref. #5a) 7 748-0415B Spacer .385 ID x .635 OD x 1.
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Model Series 604 � � � � � � � � � � �� 46 ��
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Ref. No. Part No. Description 1 732-0614 Ring, Wire 2 716-0231 Ring, E Type,.750 3 736-0336* Flat Washer, 5/8 x 1.0 x.030 — 736-0337* Flat Washer, 5/8 x 1.0 x.040 — 736-0349* Flat Washer, 5/8 x 1.0 x.020 4 736-0335 Washer, Thrust.635 x 1.26 x.06 5 710-1325 Self-tapping Screw, 1/4-20 x 1.625 6 719-04017 Upper Housing 7 711-1109 Input Shaft 8 741-0335 Needle Bearing,.625 x.813 x.495 9 717-1464 14-tooth Bevel Pinion 10 716-0108 Retaining Ring,.
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Model Series 604 (42-inch Deck - Electric PTO) �� 48 ��
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Ref. No. Part No. Description Ref. No. Part No. Description 1 618-0624 Pulley Spindle Assy 6.3 Dia. 32 736-0187 Flat Washer .64 x 1.24 x .06 2 683-0254B Deck Bracket Assembly 33 736-0225 Lock Washer 5/8 3 683-04252 Idler Assembly 34 736-0270 Bell Washer .265 x .75 x .062 4 683-04261 Deck Assembly 42” w/SD 35 736-0300 Flat Washer .406 x .875 x .059 5 710-0347 HH Cap Screw 3/8-16 x 1.75 36 736-0322 Flat Washer .450 x 1.250 x .164 6 710-0510 HH Cap Screw 7/16-20 x 3.
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Model Series 604 (46-inch Deck - Electric PTO) �� C � � B �� A � �� B �� A C �� 50 ��
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Ref. No. Part No. Description Ref. No. Part No. Description 1 618-0625 Spindle Assembly, Pulley 5.75 Dia 26 732-0826 Spring, Extension, .865 OD x 4.68 2 683-0254B Deck Hanger Bracket Ass’y, LH 27 736-0322 Washer, Flat .450 x 1.25 x .164 3 683-04104A Deck Weldment 28 734-0973 Wheel, Deck 5.0 x 1.38 4 710-0347 Screw, 3/8-16, 1.75, Gr5 29 736-0119 Washer, Lock, 5/16, Regular Duty 5 710-0520 Screw, 3/8-16, 1.50, Gr5 30 736-0270 Washer, Bell, .265 x .75 x .
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NOTES 52
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NOTES 53
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NOTES 54
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CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and MTD Consumer Group Inc are pleased to explain the evaporative emission control system warranty on your 2006 lawn mower. In California, new lawn mower must be designed, built and equipped to meet the State’s stringent anti-smog standards.
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MANUFACTURER’S LIMITED WARRANTY FOR The limited warranty set forth below is given by MTD LLC 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 materials or workmanship.