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Troy-Bilt 604 Lawn Mower User Manual

1. Drive System REF PART REF PART NO NO DESCRIPTION NO NO DESCRIPTION 1 17839 Shift Lever Bracket 44 748 0416 Shoulder Spacer 38 ID 2 117840 Transaxle Mounting Bracket 45 754 0467 Variable speed Belt 3 618 0386 Single speed Transmission Assembly 46 754 0468 Drive Belt 4 631 0009 Shifter Knob 47 756 0981 Flat Idler 2 75 OD 5 1647 0041 Shift Lever 48 783 0637 Shift Lever Support 6 656 0048 Variable speed Pulley Assembly 49 783 0667 Transmission Torque Bracket 7 656 0051 Transmission Pulley 8 5 x 5 36 50 783 0669 Idler Bracket 8 1683 0251 Double idler Bracket 51 1783 0714 Adjustable Shift Bracket 9 710 0189 Hex Cap Screw 5 16 18 x 3 52 647 0031 Brake Control Assembly 10 1710 0227 Self Tapping Screw 48 18 x 5 53 647 0032 Speed Control Assembly 11 710 0347 Hex Cap Screw 3 8 16 x 1 75 54 683 0266 AutoDrive Pedal Assembly 12 1710 0599 Self Tapping Screw 1 4 20 x 5 55 710 1135 Self Tapping Screw 5 16 18 x 2 5 13 1710 0604 Self Tapping Screw 5 16 18 x 625 56 711 0736 Ferrule 1 4 20 14 1710 0642 Self Tapping Screw 1 4 20 x 75 57 711 1363 Pin 3 8 16 x 2 43 15 1710 3011 Hex Cap Screw 3 8 16 2 25 58 714 0104 Cotter Pin 16 1711 0677 Ferrule 5 16 18 59 732 0437 Compression Spring 34 OD x 1 0 17 712 0241 Hex Nut 3 8 24 60 732 0955 Extension Spring 50 OD x 1 41 18 712 0378 Hex Nut 7 16 20 61 1735 0662 AutoDrive Pedal Pad 19 1712 0431 Flange Lock Nut 3 8 16 62 735 3049 Brake Pedal P
2. Mowing should always be done with the engine at full throttle Do not mow at high ground speed especially if a mulch kit or grass collector is installed Under heavier conditions it may be necessary to go back over the cut area a second 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 Keep the blades sharp and replace the blades when worn Refer to the MAINTENANCE section of this manual for proper blade sharpening instructions taken should be between 1 4 and 3 8 less than the second measurement Determine the approximate distance necessary for proper adjustment and proceed if necessary to the next step Loosen the two jam nuts on the rear side of the deck stabilizer bracket See Figure 7A Locate the two lock nuts on the 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 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 tractors engine A off remove the key from the ignition switch and apply the tractors parking brake before making any adjustments to the cutting deck With the tractor parked on a firm
3. The cruise control button is located on the tractor dash panel to the left of the ignition switch Push the cruise control button while traveling forward at a desired speed While holding the button in release pressure from the AutoDrive pedal This will engage the cruise control and allow the tractor to remain at that speed without applying pressure to the AutoDrive pedal Depress the brake pedal or the AutoDrive pedal to deactivate cruise control Refer to the OPERATION section of this manual for detailed instructions regarding the cruise control feature id SECTION 8 OPERATION SAFETY INTERLOCK SWITCHES This tractor is equipped with a safety interlock system for the protection of the operator If the interlock system should ever malfunction do not operate the tractor Contact an authorized MTD Service Dealer in your area The safety interlock System prevents the engine from cranking or starting unless the brake pedal is fully depressed and the PTO lever is in the disengaged OFF position The safety interlock system will automatically shut off the engine if the operator leaves the seat before engaging the brake lock 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 The safety interl
4. 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 Lock A Nuts T co eU Deck f Stabilizer Bracket Deck Jam Nuts Front to Rear SEAT ADJUSTMENT To adjust the position of the seat move the seat adjustment lever located under the seat to the left and slide the seat forward or backwards See Figure 8 Make sure seat is locked into one of the six adjustment positions before operating the tractor E E d lt Seat oo Lu Seat Adjustment Lever Figure 8 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 side and the ball joint on the right side Loosen the jam nut found on the drag link at the rear of the ball joint See Figure
5. should feel the cruise latch engage If properly engaged the cruise control button and the AutoDrive pedal should lock in the down position and the tractor will maintain the same forward speed Disengage the cruise control using one of the following methods Depress the brake pedal to disengage the cruise control and stop the tractor Lightly depress the AutoDrive pedal To change to the reverse direction when operating with cruise control depress the brake pedal to disengage the cruise control and bring the tractor to a complete stop Then place the shift lever in the REVERSE position and depress the AutoDrive pedal DRIVING ON SLOPES Refer to the SLOPE GAUGE on page 6 to help determine slopes where you may not operate safely WARNING Do not mow on inclines with A 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
6. 9 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 Deck Hanger Bracket Side to Side Figure 7 15 Remove the hex nut and lock washer on the top of ball joint See Figure 9 Zerk Fittting if so equipped Pivot Bar Hex Nut and Lock Washer Drag Link Jam Nut Ball jun es Figure 9 Thread the ball joint toward the jam nut to shorten the drag link Thread the ball joint away from the jam nut to lengthen the drag link Replace hex nut and lock washer and retighten the jam nut after proper adjustment is achieved NOTE Threading the ball joints too far onto the 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 10 e fuse m N Drag Links a Insert Dowel Steering Gear Here Support 1 Plate o2 F Steering Cl Shaft NOTE View shown from beneath tractor Figure 10 In front of the axle measure the distance horizontally from the inside of the left rim to the inside of t
7. Refer to the MAINTENANCE section of this manual for the proper battery charging procedure The hour meter operates whenever the ignition key is in the On or On Lights position and records the actual hours of tractor operation LIFT LEVER SP A The lift lever is used to change the operating position height of the cutting deck To operate move the lever to the left then place in the notch best suited for your application PTO POWER TAKE OFF LEVER ON f OFF The PTO lever is located on the left side of the dashboard next to the steering wheel Move the PTO lever forward to engage the power to the cutting deck or other attachments move the PTO lever backward toward the rear of the tractor to disengage the power to the attachments a PTO 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 AUTODRIVE PEDAL The AutoDrive pedal is located below the brake pedal on the right front side of the tractor along the running board Depress the AutoDrive 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 AutoDrive pedal The further down the pedal is depressed the faster the tractor will travel The p
8. Use slow speed Always keep machine in gear when going down slopes to take advantage of engine braking action Follow the manufacturers recommendations for wheel weights or counterweights to improve stability Use extra care with grass catchers or other attachments These can change the stability of the machine Keep all movement on the slopes slow and gradual Do not make sudden changes in speed or direction Rapid engagement or braking could cause the front of the machine to lift and rapidly flip over backwards which could cause serious injury Avoid starting or stopping on a slope If tires lose traction disengage the blade s and proceed slowly straight down the slope DO NOT Do not turn on slopes unless necessary then turn slowly and gradually downhill if possible Do not mow near drop offs ditches embankments The mower could suddenly turn over if a wheel is over the edge of a cliff or ditch or if an edge caves in Do not mow on wet grass Reduced traction could cause sliding Do not try to stabilize the machine by putting your foot on the ground Do not use grass catcher on steep slopes 3 CHILDREN Tragic accidents can occur if the operator is not alert to the presence of children Children are often attracted to the machine and the mowing activity Never assume that chil dren will remain where you last saw them Keep children out of the mowing area and in watchful care of an adult other than the
9. bad GOOD BAD Figure 24 TIRES The recommended operating tire pressure is manufacturers recommended psi Do approximately 10 psi for the rear tires and 14 psi for overinflate Uneven tire pressure could cause the the front tires Refer to the tire sidewall for exact tire cutting deck to mow unevenly SECTION 11 LUBRICATION WARNING Always stop the engine and disconnect the spark plug wire s and ground against the A engine before performing any maintenance ENGINE Lubricate the engine with motor oil as instructed in the separate engine manual packed with your unit PIVOT POINTS Lubricate all pivot points AutoDrive pedal brake pedal etc at least once a season with light oil LINKAGE Lubricate all the pivot points on the drive brake and lift linkage at least once a season with SAE 30 engine oil STEERING GEAR Lubricate the teeth of the steering gear with an all purpose automotive grease every 25 hours of operation or once a season WHEELS Both the front wheels and the rear wheels should be removed from the axles once a season Lubricate the axles and the rims well with an all purpose automotive grease before re installing them FRONT AXLES Your tractor may be equipped with zerk fittings on the ends of the front pivot bar See Figure 9 Lubricate both the left and the right front axles with a grease gun at least once a season 2
10. compression spring and brake disc See Figure 11 Compression Spring Brake NOTE View shown from beneath tractor Transmission Figure 11 Loosen but do NOT remove the hex nut found on the right side of the brake assembly See Figure 11 Using a feeler gauge set the gap between the brake disc and the brake puck at 011 Re tighten the hex nut loosened earlier PTO POWER TAKE OFF ADJUSTMENT If your tractor s engine fails to crank when following the starting instructions found earlier in this manual the PTO may be in need of adjustment With the PTO lever in the disengaged OFF position the lever must go back far enough so that a metal tab that is bolted to the base of the lever can fully depress a plunger saftey switch mounted to the tractors frame beneath the fuel tank Adjust if necessary as follows WARNING If the blades on your A tractor s cutting deck continue to turn with the PTO lever in the disengaged OFF postion stop the tractor immediately and perform the following steps Turn the tractors engine off remove the key from the ignition switch and apply the tractor s parking brake Locate the PTO engagement rod and the PTO adjuster link by looking at the tractors underside See Figure 12 Remove the cotter pin that affixes the lower end of the PTO engagement rod to the PTO adjuster link Save the pin See Figure 12 Take the lower end of the PTO engag
11. discharge chute to relieve tension on the belt Remove the deck belt from the bottom portion of the engine pulley and from around the PTO idler pulley Remove and discard old belt Route the new belt s as shown in Figure 15 OEM belt part numbers shown below 19 IMPORTANT t is recommended that the PTO be readjusted after replacing the deck belt Refer to PTO POWER TAKE OFF ADJUSTMENT in the ADJUSTMENTS section of this manual for the proper procedure Remount the belt guards removed earlier 42 Inch Deck 46 Inch Deck PTO Top Belt 754 0472 754 0476 Bottom Belt N A 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 R
12. drain valve in slightly then rotate counterclockwise and pull outward to begin draining oil See Figure 13 Service the oil filter if so equipped as instructed in the separate engine manual packed with your unit Perform the above steps in the opposite order after oil has finished draining Refill the engine with new motor oil IMPORTANT Refill the engine with the proper capacity and weight of motor oil as instructed in the separate engine manual Service air cleaner every 25 hours under normal conditions Clean every few hours under extremely dusty condition To service the air cleaner refer to the separate engine manual packed with your unit The spark plug s should be cleaned and the gap reset once a season Spark plug replacement is recommended at the start of each mowing season check engine manual for correct plug type and gap specifications CLEANING THE ENGINE AND DECK Any fuel or oil spilled on the machine should be wiped off promptly Do NOT 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 IMPORTANT Do NOT use a garden hose to clean the cutting deck The ball bearings in the blade spindles are sealed at the factory and cannot be re lubricated Spraying water near the spindles can significantly
13. free of grass leaves or other debris build up Clean up oil or fuel spillage Allow machine to cool at least 5 minutes before storing Before cleaning repairing or inspecting make certain the blade and all moving parts have stopped Disconnect the spark plug wire and keep the wire away from the spark plug to prevent accidental starting Check the blade and engine mounting bolts at frequent intervals for proper tightness Also visually inspect blade for damage e g excessive wear bent cracked Replace with blade which meets original equipment specifications ASSEMBLE CHUTE DEFLECTOR BEFORE OPERATING MACHINE Keep all nuts bolts and screws tight to be sure the equipment is in safe working condition Never tamper with safety devices Check their proper operation regularly Use all guards as instructed in this manual After striking a foreign object stop the engine remove the wire from the spark plug and thoroughly inspect the mower for any damage Repair the damage before restarting and operating the mower Grass catcher components are subject to wear damage and deterioration which could expose moving parts or allow objects to be thrown For your safety protection frequently check components and replace with manufacturer s recommended parts when necessary Mower blades are sharp and can cut Wrap the blade s or wear gloves and use extra caution when servicing blade s Check brake operation frequently Adjus
14. operator Be alert and turn machine off if children enter the area Before and when backing look behind and down for small children Never carry children even with the blades off They may fall off and be 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 Use extra care when approaching blind corners shrubs trees or other objects that may obscure your vision of a child or other hazard 4 SERVICE Use extreme care in handling gasoline and other fuels They are extremely flammable and the vapors are explosive Use only an approved container Never remove fuel cap or add fuel with the engine running Allow engine to cool at least two minutes before refueling Replace fuel cap securely and wipe off any spilled fuel before starting the engine as it may cause a fire or explosion Extinguish all cigarettes cigars pipes and other Sources of 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 Never run a machine inside a closed area To reduce fire hazard keep the machine
15. pug es e Slow Slow Position Position 2 Figure 5 IMPORTANT When using operated equipment such as the cutting deck or other attachments always operate the tractor with the throttle lever in the FAST rabbit position CHOKE CONTROL On some units moving the throttle lever all the way forward activates the engine s choke control On all other units the choke control can be found on the left side of the dash panel and is activated by pulling the knob outward Activating the choke control closes the choke 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 INDICATOR MONITOR HOUR METER Your tractor is equipped with four indicator lights and an hour meter located on the left side of the dash panel See Figure 6 Battery Oil VOL e Meter 8 Figure 6 If a 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 OIL Check the crankcase oil level and add oil as required The BATTERY indicator light will illuminate any time the ignition key is the On position and the engine is not running If it illuminate s while the engine is running it indicates that the battery is in need of a charge
16. pulley as you lift the pulley up and out through the battery tray opening NOTE Jacking the rear of the tractor up off the ground and securing it with jackstands at this point in the procedure will ease the following steps but is not necessary 20 Battery Tray _ Opening Shift Lever Drive belt Lower Drive belt Upper Variable speed Pulley _ Xx PROSE Line Uh Single speed Transmission Transmission Pulley NOTE View shown from above tractor Front of Tractor gt Figure 16 Remove the rear idler pulley from the double Remove the hex bolt from the center of the idler bracket while unrouting the belt from engine pulley Do NOT attempt to remove the around both the rear and the front idler pulley engine pulley at this time See Figure 18 Refer to Figure 16 7 Remove the cotter pin that affixes the lower end of the PTO engagement rod to the PTO adjuster link Save the pin for reassembly See Figure 17 i PTO Adjuster Link NOTE View shown from beneath tractor Cotter Pin Figure 18 PTO Engagement Rod IMPORTANT When remounting the engine Figure 17 pulley torque the center hex bolt to between 38 foot pounds and 50 foot pounds 21
17. this section ENGAGING THE PTO POWER TAKE OFF LEVER Move the throttle control lever to the FAST rabbit position Move the PTO lever forward into the engaged ON position Keep the throttle lever in the FAST rabbit position for the most efficient use of the cutting deck and other attachments The operator must remain in the tractor seat at all times If the operator should leave the seat without moving the PTO lever into the disengaged OFF position and setting the parking brake the engine will shut off IMPORTANT 7he PTO lever cannot be in the 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 MOWING This tractor is equipped with one of MTD s high quality cutting decks The following information will be helpful when using the cutting deck with your tractor A WARNING To avoid possible injury do not allow anyone in the area of the tractor while mowing Even if the area to be mowed has been cleared of foreign objects small objects may be picked up and discharged by the mower WARNING Never direct the discharge of material toward bystanders or allow anyone near the machine while operation A For best results it is recommended that th
18. 0 Self Tapping Screw 5 16 18 x 875 756 1151 Pulley Only 12 710 0751 Hex Cap Screw 1 4 20 x 62 42 683 0198 42 inch Deck Shell 13 710 1260A Self Tapping Screw 5 16 18 x 75 43 710 0604 Self Tapping Screw 5 16 18 x 625 14 712 3288 Hex Cap Screw 1 4 20 x 1 62 44 712 0181 Top Lock Jam Nut 3 8 16 15 1712 0241 Hex Nut 3 8 24 45 712 0271 Hex Sems Nut 1 4 20 16 1712 0291 Center Lock Nut 1 4 20 46 712 3006 Hex Nut 1 4 20 17 712 0417A Flange Nut 5 8 18 47 1731 2231 Belt Cover 18 1712 0431 Flange Lock Nut 3 8 16 48 736 0270 Bell Washer 265 x 75 x 062 19 712 3027 Hex Flange Lock Nut 1 4 20 49 742 0616 Three in one Blade Star Center 21 23 20 714 0104 Internal Cotter Pin 072 x 1 12 50 731 1636 Mulch Plug 46 inch Decks 21 1717 1553 Deck Adjustment Gear 51 731 1643A Mulch Plug 42 inch Decks 22 731 1032A Side Discharge Chute Assembly 52 712 3087 Wing Nut 1 4 20 23 732 0306 Compression Spring 406 x 531 x 1 75 53 712 0291 Center Lock Nut 1 4 20 24 732 0594A Extension Spring 91 x 7 33 54 710 0106 Hex Cap Screw 1 4 20 x 1 25 25 734 0973 Deck Wheel 5 x 1 38 55 1710 0578 Screw 1 4 20 1 5 26 1736 0105 Bell Washer 401 87 x 063 56 753 0852 46 inch Deck Assembly Complete 27 1736 0119 Lock Washer 5 16 w o mulch kit 28 738 0347 Shoulder Spacer 625 x 169 57 1753 0851 42 inch Deck Assembly Complete 29 1738 0373 Shoulder Spacer 498 x 1 53 w o mulch kit replacement part 70
19. 0 xxxx 0637 code MTD Red 0638 Oyster Gray 0662 Powder Black 0637 NOTE For painted parts please refer to the list of color codes below Please add the applicable color needed to the part number to order a For instance if a part numbered 700 xxxx is painted Powder Black the part number to order would be wherever 37 Model 604 11 7 for choke Briggs amp Stratton for throttle 12 face forward 14 deflector must for choke 11 Kohler sE or is 2 SF t 38 Engine Accessories par E Briggs amp Stratton k pe MESS Intek Single 2 n 29 deflector must 14 face forward REF PART REF PART NO NO DESCRIPTION NO NO DESCRIPTION 1 710 0148 Self Tapping Screw 8 32 x 375 19 751 3141 Oil Drain Hose 2 710 0599 Self Tapping Screw 1 4 20 x 5 20 751 3142 Oil Drain Cap 3 710 0604 Self Tapping Screw 5 16 18 x 625 21 783 0615 Muffler Heat Shield 4 1710 1237 Screw 10 32 x 625 22 783 0625A Engine Heat Shield 5 1710 1314 Socket Cap Screw 5 16 18 x 625 23 710 3206A Hex Cap Screw M8 1 25 x 25 6 710 1315 Self Tapping Screw 3 8 16 x 1 25 24 712 3086 Flange Nut M8 1 25 7 1712 0798 Hex Nut 3 8 16 25 1721 0375 Exhaust Gasket Kohler 8 721 0460 Exhaust Gasket Intek Twin 26 736 0607 External Lock Washer 5 16 9 726 0205 Hose Clamp 27 751 0621 Exhaust Pipe Kohler 10 7
20. 072 Parking Brake Button 8 712 3004A Flange Lock Nut 5 16 18 28 731 1857 Throttle Control Lever 9 712 3027 Hex Flange Lock Nut 1 4 20 29 731 2106 Cruise Control Button 10 725 1649 Head Lamp Socket 30 747 1155 Brake Cruise Pivot Rod 11 1731 1978 RH Head Light Lens 31 749 1087 Dash Support Tube 12 731 1979 LH Head Light Lens 32 731 2232 Intake Bellow Intek Single 13 1731 2238 Hood 4 style Red 731 2234 Intake Bellow Intek Twin 14 1731 2237 LH Side Panel 4 style Red 33 751 0603 Fuel Cap 15 1731 2236 RH Side Panel 4 style Red 34 751 0659 Fuel Tank Two Gallon Shown 16 731 199 LH Head Light Reflector 751 0658 Fuel Tank Three Gallon 17 1731 1996 RH Head Light Reflector 35 725 1745 Ignition Key 18 736 0173 Flat Washer 28 x 74 x 063 36 746 1084 Choke Throttle Cable Intek Single 19 736 3078 Flat Washer 349 x 1 0 x 063 746 1085 Choke Cable Intek Twin 20 747 1132 Hood Support Rod 746 1088 Choke Cable Kohler 27 Model 604 Lift Assembly REF PART REF PART NO NO DESCRIPTION NO NO DESCRIPTION 1 1647 0040 Deck Stabilizer Rod 27 710 0260 Carriage Bolt 5 16 18 x 62 2 683 0197 Lift Shaft Assembly 28 1710 0604 Self Tapping Screw 5 16 18 x 625 3 711 0332 Clevis Pin 5 x 78 29 710 0895 Self Tapping Screw 1 4 15 x 75 4 1712 0206 Hex Nut 1 2 13 30 1731 1990 Lift Lever Cover 5 712 0431 Flange Lock Nut 3 8 16 31 731 2104 Shift Lever Cov
21. 21 Remove the AutoDrive pedal return spring Using two 9 16 wrenches remove the pin from the speed control assembly See Figure 21 Thread the idler adjustment rod inward or outward to lengthen or shorten the travel of the double idler bracket until proper adjustment is achieved Reassemble by following the above steps in reverse order IMPORTANT After replacing the drive belts perform the PTO adjustment as instructed in the ADJUSTMENTS section of this manual prior to operating the tractor CUTTING BLADES WARNING Cutting blades are sharp Always protect hands by wearing heavy leather work gloves to grasp blades The blades may be removed for sharpening or replacement as follows Remove the deck from beneath the tractor refer to DECK REMOVAL earlier in this section for detailed instructions then gently flip the deck over to expose its underside Place a block of wood between the center deck housing baffle and the cutting blade to act as a stabilizer See Figure 22 Usea 15 16 wrench to remove the hex flange nut that secures the blade to the spindle assembly See Figure 22 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 Block of Wood Hex Flange Nut Y Spindle Assembly Cutting Blade Figure 22 To properly sharpen the cutting blades r
22. 3 712 3027 Hex Flange Lock Nut 1 4 20 754 0476 PTO Belt 46 inch Decks 14 1714 0111 Cotter Pin 45 683 0263 Lower Frame Assembly 15 725 1657A Snap Mount Safety Interlock Switch 46 723 0444 Battery Strap 16 1731 2111 PTO Knob 47 732 0755 Compression Spring 1 314 OD x 2 35 17 1732 0977 Extension Spring 62 OD x 2 16 48 732 0956 Compression Spring 66 OD x 1 5 18 732 0978 Extension Spring 1 2 OD x 3 638 49 738 1014 Shoulder Screw 5 x 1 25 3 8 16 19 736 0140 Flat Washer 385 x 62 x 063 50 783 0349 Battery Tray 20 736 0176 Flat Washer 25 x 93 x 12 51 783 0668 Hitch Plate 21 1736 0272 Flat Washer 51 x 1 0 x 60 52 783 0733 Spacer Cup 1 5 OD 22 738 1021 Shoulder Screw 5 x 27 3 8 16 53 725 1426 Solenoid 12 Volt 100 Amp 23 738 1125 Shoulder Nut 1 4 20 54 1736 0222 Lock Washer 1 4 24 741 0708 Hex Split Flange Bearing 50 ID 55 725 1747 Safety Interlock Plunger Switch 25 747 1112 PTO Engagement Handle 56 738 1020 Shoulder Screw 625 x 5 7 16 20 26 747 1114 PTO Engagement Lever 57 736 0407 Bell Washer 45 x 1 0 x 062 27 747 1174 PTO Actuator Adjuster Link 58 712 0459 Flange Lock Nut 7 16 20 28 748 0416 Shoulder Spacer 38 ID 59 783 0653 Steering Support Bracket 29 748 0421 Arm Spacer 68 60 725 1706 12 volt Battery 270 CCA 30 756 0627 Flat Idler Pulley 3 5 OD 61 712 3044 Wing Nut 1 4 20 31 1783 0744 Stop Bracket 62 1712 0271 Hex Sems Nut 1 4 20 32 783 0796 PTO Actuator Bracket 63 710 0751 Hex Cap Scr
23. 36 0119 Lock Washer 5 16 28 1751 0617 Muffler Single Inlet 11 1736 0221 Flat Washer 3 8 x 56 x 018 29 712 0271 Hex Sems Nut 1 4 20 for starter cable 12 751B221535 Casing Clamp 30 721 0208 Exhaust Gasket Intek Single 13 751 0535 Fuel Line Hose 31 732 0966 Extension Spring 275 x 1 25 14 1751 0564 Muffler Deflector 32 751B213146 Casing Clamp 15 1751 0616 Muffler Twin Inlet 33 1751 0619 Exhaust Pipe Intek Single 16 1751 0650 RH Exhaust Pipe Intek Twin 34 1746 1084 Throttle Choke Cable Intek Single 17 1751 0651 LH Exhaust Pipe Intek Twin 35 1746 1086 Throttle Cable Intek Twin 18 1751 3140 Oil Drain Valve 36 1746 1087 Throttle Cable Kohler 39 MANUFACTURER S LIMITED WARRANTY FOR OTROY BILT For TWO YEARS from the date of retail purchase within the United States of America its possessions and territories MTD PRODUCTS INC will at its option repair or replace for the original purchaser free of charge any part or parts found to be defective in material or workmanship This warranty covers units which have been operated and maintained in accordance with the operating instructions furnished with the unit and which have not been subject to misuse abuse commercial use neglect accident improper maintenance or alteration Normal wear parts or components thereof are subject to separate terms as noted below in the No Fault Ninety Day Consumer Warranty clause All normal wear part failures will be cov
24. 4 SECTION 12 TROUBLESHOOTING GUIDE Trouble Possible Corrective Action Cause s Engine will Safety switch There are two safety switches in the starting circuit of your unit the brake pedal switch crank button not and the PTO switch Make certain the actuator is fully depressing the buttons on each depressed switch The Operator must be seated on the tractor in order to start the engine 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 Battery is dead or weak Blown fuse identified by POS or must be attached to the thick red wire which goes to the solenoid Charge at six amps with a 12 volt automotive type battery charger for one hour or until fully charged Refer to operator s manual 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 nec essary 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
25. 5 x 6 x 6 14 717 1550 Steering Gear 11 90 Ratio 634 0172 Rim Only 15 1717 1554 Steering Pinion Gear 734 0255 Air Valve Not Shown 16 723 0448A Ball Joint 7 16 20 734 1731 Tire Only Square Shoulder 17 1736 0169 Lock Washer 3 8 741 0487A Plastic Flange Not Shown 18 736 3084 Flat Washer 51 x 1 12 x 06 741 0706 Plastic Flange w Fitting Not Shown 19 738 1001 Steering Shaft 625 OD 24 4 37 734 0484A Hub Cap 20 741 0475 Plastic Bushing 38 ID 38 783 0653 Steering Support Bracket 21 741 0656 Hex Flange Bearing 5 8 39 1738 1020 Shoulder Screw 625 x 50 7 16 20 22 748 0416 Shoulder Spacer 38 ID 40 736 0331 Bell Washer 39 x 1 13 x 062 23 631 0027 Steering Wheel 41 738 0140 Shoulder Screw 435 x 178 5 16 x 56 24 731 0220 Steering Wheel Cap 42 736 0242 Bell Washer 34 x 872 25 1638 0019 LH Axle Assembly 625 Diameter 43 710 0643 Hex Bolt 5 16 18 X 1 638 0021 LH Axle Assembly 625 750 Diameter 26 638 0020 RH Axle Assembly 625 Diameter 638 0022 RH Axle Assembly 625 750 Diameter NOTE For painted parts please refer to the list of color codes below Please add the applicable color code wherever needed to the part number to order a replacement part For instance if a part numbered 700 xxxx is painted Powder Black the part number to order would be 700 xxxx 0637 MTD Red 0638 Oyster Gray 0662 Powder Black 0637 31
26. 9 747 1122 Brake Rod 634 0104 Wheel Assembly Complete 20 x 8 x 8 40 747 1123 Belt Guard 634 0077 Rim Only 41 747 1127 Idler Adjustment Rod 3 8 734 0255 Air Valve Not Shown 42 747 1156 Shift Rod 734 1873 Tire Only 20 x 10 x 8 Square Shoulder 43 747 1160 Belt Guard Rod 734 1730 Tire Only 20 x 8 x 8 Square Shoulder 33 Model 604 34 Power Take off System REF PART REF PART NO NO DESCRIPTION NO NO DESCRIPTION 1 1683 0278 PTO Engagement Link w Weld Pin 33 783 0797 PTO Engagement Arm 2 683 0282 PTO Actuator Bracket w Weld Nut 34 783 0798 PTO Engagement Link 3 710 0514 Hex Cap Screw 3 8 16 1 0 Grade 5 35 783 0799 PTO Arm 4 710 0597 Hex Cap Screw 1 4 20 x 1 0 Grade 5 36 783 0806 Deck Stop 5 710 0604 Self Tapping Screw 5 16 18 x 625 37 1710 0561 Hex Screw 7 16 20 x 2 5 Grade 5 6 710 1260A Self Tapping Screw 5 16 18 x 75 38 1710 0599 Self Tapping Screw 1 4 20 x 5 7 1710 3011 Hex Cap Screw 3 8 16 2 25 Grade 5 39 1736 0171 Lock Washer 7 16 8 710 3180 Hex Cap Screw 5 16 18 x 1 75 Grade 5 40 736 0322 Flat Washer 45 x 1 25 x 164 9 710 3199 Hex Cap Screw 1 4 20 x 1 5 Grade 5 41 1750 0956 Spacer 1 01 x 1 4 x 825 10 712 0431 Flange Lock Nut 3 8 16 42 1756 1158 Engine Pulley 5 56 Dia x 3 56 Dia 11 712 3004A Flange Lock Nut 5 16 18 43 756 1164 Pulley Sheave 12 712 3010 Hex Nut 5 16 18 44 754 0472 PTO Belt 42 inch Decks 1
27. Bracket replacement part 700 xxxx 0637 code MTD Red 0638 Oyster Gray 0662 Powder Black 0637 NOTE For painted parts please refer to the list of color codes below Please add the applicable color needed to the part number to order a For instance if a part numbered 700 xxxx is painted Powder Black the part number to order would be wherever 29 Model 604 30 Steering Assembly REF PART REF PART NO NO DESCRIPTION NO NO DESCRIPTION 1 683 0263 Lower Frame Assembly 27 683 0128A Pivot Bar 2 1710 0604 Self tapping Screw 16 18 x 625 28 712 0431 Flange Lock Nut 3 8 16 3 783 0726 RH Pivot Support Bracket 29 714 0470 Cotter Pin 4 783 0727 LH Pivot Support Bracket 30 726 0214 Push Cap 5 8 5 1783 0728 Pivot Bar Bracket 726 0341 Push Cap 3 4 6 710 0514 Hex Cap Screw 3 8 16 x 1 Grade 5 31 736 0162 Flat Washer 64 x 1 0 x 12 7 1711 1291 LH Drag Link 32 736 0187 Flat Washer 64 x 1 24 x 06 8 711 1292 RH Drag Link 736 0316 Flat Washer 78 x 1 59 x 06 9 712 0240 Jam Nut 7 16 20 Grade 2 33 736 0285 Flat Washer 635 x 1 589 x 06 10 712 0241 Hex Nut 3 8 24 Grade 2 34 738 1011 Shoulder Screw 5 x 2 2 3 8 16 11 1712 0431 Flange Lock Nut 3 8 16 35 741 0659 Flange Bearing 632 ID x 937 OD 12 712 0459 Flange Lock Nut 7 16 20 741 0660 Flange Bearing 760 ID x 937 OD 13 712 3004A Flange Lock Nut 5 16 18 36 634 0105A Wheel Assembly Complete 1
28. ERATOR S MANUAL Figure 1 Safety Labels found on your unit USE THIS PAGE AS A GUIDE TO DETERMINE SLOPES WHERE YOU MAY NOT OPERATE SAFELY pi SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE Lag 148 CORNER OF A BUILDING au OR A FENCE POST Slope Gauge A vanno 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 SECTION 5 ATTACHMENTS amp ACCESSORIES MODEL NUMBER DESCRIPTION OEM 190 601 FastAttach Twin Bagger Grass Collector For 42 inch Decks Only OEM 190 602 FastAttach Twin Bagger Grass Collector For 46 inch Decks Only includes a set of blades OEM 190 112 Mulch Kit For 42 inch Decks Only OEM 190 118 Mulch Kit For 46 inch Decks Only includes a set of blades OEM 190 603 FastAttach Front Bumper Kit OEM 190 604 TracPac Storage Container mounts on rear of tractor OEM 190 822 FastAttach 46 inch Front Dozer Blade OEM 190 823 42 inch Two stage Snowthrower SECTION 6 TRACTOR SET UP ATTACHING THE BATTERY CABLES NOTE The positive battery terminal is marked Pos The negative
29. FAST or CHOKE if so equipped position Pull out the choke control knob if so equipped a warm engine may not require choking Turn the ignition key clockwise to the START position After the engine starts release the key It will return to the ON position 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 f 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 into the FAST position to open up the choke plate on the engine s carburetor NOTE Do NOT leave the choke control out while operating the tractor Doing so will result in a rich fuel mixture and cause the engine to run poorly 12 STOPPING THE ENGINE 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 f you think you ve struck a foreign object stop the engine immediately Remove the wire s from the spark plug s thorou
30. IN ITS PROPER PLACE ASSEMBLE CHUTE DEFLECTOR TO THIS UNIT BEFORE OPERATING 1426 ILLA DAN GER M KEEP HANDS AND FEET AWAY Ly DO NOT OPERATE MOWER UNLESS Y AVOID SERIOUS INJURY OR DEATH KEEP HANDS AND FEET AWAY FROM ROTATING PARTS REMOVE OBJECTS THAT CAN BE THROWN BY THE BLADE IN ANY DIRECTION WEAR SAFETY GLASSES ARE OT MOW WHEN CHILDREN OR OTHERS AROUND NEVER CARRY CHILDREN USE EXTRA CAUTION ON SLOPES DO NOT MOW SLOPES GREATER THAN 15 MOW UP AND DOWN OT ACROSS AVOID SUDDEN TURNS USE LOW GEAR BEAD OPERAT GRASS CATCHER IS IN ITS PROPER PLACE DANGER X KEEP HANDS and FEET AWAY OR S MANUAL KEEP SAFETY DEVICES Wo TO AVOID SERIOUS INJURY OR DEATH GO UP AND DOWN SLOPES NOT ACROSS AVOID SUDDEN TURNS DONOT OPERATE THE UNIT WHERE IT COULD SLIP OR TIP IF MACHINE STOPS GOING UPHILL STOP BLADE S AND BACK DOWNHILL SLOWLY DO MOW WHEN CHILDREN OR OTHERS ARE AROUND NEVER CARRY CHILDREN LOOK DOWN amp 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 OP
31. OTROY BILT OPERATOR S MANUAL AutoDrive Lawn Tractor Model 604 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 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 368022 Cleveland Ohio 44136 9722 MTD PRODUCTS INC P O BOX 368022 CLEVELAND OHIO 44136 9722 PRINTED IN U S A FORM NO 770 10187 12 98 SECTION 1 TABLE OF CONTENTS PAGE FINDING YOUR MODEL NUMBER 2 CALLING CUSTOMER SUPPORT setea pn a oi aa o E a ee 2 IMPORTANT SAFE OPERATION PRACTICES 3 SAFETY LABLES FOUND ON YOUR eee 5 SLOPE GAUGE tet ttre tae Race Des bees dd ume ee eade ee endete o d ede I e repe 6 ATTACHMENTS 8 ACCESSORIES LL 7 TRACTOR ii ei us A icu eee eet kane peius 7 CONTROLS erate ads ao qe
32. PPORT 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 f 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 AMTD 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 SECTION 4 IMPORTANT SAFE OPERATION PRACTICES A A A 1 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 t
33. Remove the two hex bolts from both sides of the tractor that affix the PTO actuator bracket to the tractor frame See Figure 19 PTO Actuator C Bracket 12 SC Figure 19 Carefully lower the PTO actuator bracket and the engine pulley as an assembly while removing the drive belt from the upper portion of the engine pulley Remove the drive belt by feeding it from both ends toward the front idler pulley on the double idler bracket See Figure 16 Reassemble by following the above steps in reverse order Reroute the new belt around the pulleys and belt keepers EXACTLY as the old one was routed Refer to Figure 16 The AutoDrive pedal is properly adjusted when the hole found in the double idler bracket has approximately 1 3 8 of travel with ten pounds of pressure applied to the AutoDrive pedal See Figure 20 Double idler Bracket Hole Front of Tractor p NOTE View shown from above tractor Figure 20 Adjust the AutoDrive pedal after replacing the drive belts on your tractor if necessary as follows Locate the speed control assembly on the underside of the steering support bracket See Figure 21 22 AutoDrive Pedal Speed Control Return Spring Assembly Figure 21 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
34. Steering Wheel not shown for clarity Figure 3 A Ignition Switch H Brake Pedal B Throttle Control Lever I Parking Brake Button C Choke Control if so equipped J Shift Lever D Indicator Monitor Hour Meter K Seat Adjustment Lever E Lift Lever L Cup Holder F PTO Power Take Off Lever M Cruise Control Button G AutoDrive Pedal NOTE Any reference in this manual to the RIGHT or LEFT side of the tractor is observed from operator s position 8 IGNITION SWITCH 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 A WARNING Remove the key from the tractor when the tractor is not in use to prevent accidental starting Off On Lights On Start Figure 4 THROTTLE CONTROL LEVER The throttle lever is located on the right side of the tractor s dash panel This lever controls the 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 Throttle Symbol Symbol Choke Position N kgs Position Fast 4 Position EX
35. WITCHES 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 PLAC ING 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 READ OPERATOR S MANUAL SETTING THE CUTTING HEIGHT 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 A 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 WARNING Keep hands and feet away from the discharge chute opening of the cutting deck STARTING THE ENGINE NOTE Refer to the TRACTOR SET UP section of this manual for Gasoline and Oil fill up instructions Insert the tractor key into the ignition switch Place the PTO lever in the disengaged OFF position Depress the brake pedal and set the parking brake Place the shift lever in the NEUTRAL position Move the throttle control lever into the
36. a moving part Engine Throttle or choke Refer to the OPERATION section of this manual for the correct position of the throttle cranks but in starting control and choke for starting will not start position No fuel to the Gasoline tank empty Fill 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 If the air cleaner is dirty the engine may not start Refer to the engine manual packed with your unit Engine Engine oil has Check oil level smokes been overfilled Engine loses Dipstick not seated or broken Replace defective part crankcase Engine breather defective Replace vacuum Excessive Bent blade or Stop engine immediately Check all pulleys blade adapters keys and bolts for vibration damaged pulley tightness and spindle damage Tighten or replace any loose or damaged parts Always replace damaged blade Only use original equipment blades Mower Engine speed Throttle must be set at full throttle won t low discharge Speed selection Use lower ground speed The slower your ground speed the better the quality of cut grass or Cutting height Raise deck leaves set too low uncut strips Blades dull Sharpen or replace bla
37. ad 20 712 0798 Hex Nut 3 8 16 63 736 0140 Flat Washer 281 x 5 x 0625 21 712 3004A Flange Lock Nut 5 16 18 64 736 0187 Flat Washer 64 x 1 24 x 06 22 712 3008 Jam Nut 3 8 16 65 736 0204 Flat Washer 344 x 062 x 03 23 714 0111 Cotter Pin 66 738 0155 Shoulder Screw 437 x 1 62 24 714 0149B Internal Cotter Pin 67 738 0507B Shoulder Screw 5 x 434 25 723 0156 Ball Joint 3 8 24 68 741 0225 Hex Flange Bearing 26 725 1644 Short Spring Switch 69 741 3065A Split Hex Flange Bearing 27 726 0320 Insulator Nut Plate 70 747 1137 Cruise Control Rod 28 732 0384 Extension Spring 62 Dia x 6 12 71 1747 1138 Brake Lock Control Rod 29 732 0525 Compression Spring Clip 72 748 0413 Cruise Latch 30 732 0716 Extension Spring 59 OD x 4 73 748 0415 Spacer 5 16 x 1 54 31 732 0963 Extension Spring 50 Dia x 6 37 74 1783 0653 Stearing Support Bracket hooks to flange 783 0650 in frame 75 1783 0732 AutoDrive Lockout Bracket 32 1736 0105 Bell Washer 401 x 87 x 063 76 783 0773 Brake Pedal 33 736 0140 Flat Washer 385 x 62 x 063 77 783 0780 Neutral Return Bracket 34 736 0169 Lock Washer 3 8 78 1683 0263 Lower Frame Assembly 35 736 0275 Flat Washer 5 16 79 783 0668 Hitch Plate 36 736 0407 Bell Washer 45 x 1 0 x 602 80 736 0242 Bell Washer 34 x 872 37 1736 3010 Flat Washer 407 x 812 x 135 81 1710 0627 Hex Cap Screw 5 16 24 x 75 38 738 0322 Shoulder Screw 625 x 217 82 634 0177 Wheel Assembly Complete 20 x 10x 8 3
38. ate a unit in bare feet sandals or sneakers Check overhead clearance carefully before driving under power lines wires bridges or low hanging tree branches before entering or leaving buildings or in any other situation where the operator may be struck or pulled from the unit which could result in serious injury Disengage all attachment clutches thoroughly depress the brake pedal and shift into neutral before attempting to start engine Your mower is designed to cut normal residential grass of a height no more than 10 Do not attempt to mow through unusually tall dry grass e g pasture or piles of dry leaves Debris may build up on the mower deck or contact the engine exhaust presenting a potential fire hazard 2 SLOPE OPERATION Slopes are a major factor related to loss of control and tip over 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 DO Mow up and down slopes not across Remove obstacles such as rocks limbs etc Watch for holes ruts or bumps Uneven terrain could overturn the machine Tall grass can hide obstacles
39. ath dnl sube MATA latina Re ae REN ase di aah et Cae 8 OPERATION Z ay O dee a oat ale iS doe Gy dete a Duet ela ento 11 ADJUSTMENTS ds a iios E nka eed eed ea xe Rt eth a io ed ek ve 14 MAINTENANGE et sets ie an Di 17 LUBRICATION uode dec get Ret iad ahah etitm nones a cete ite a e brane aa etas Paes edes deg 24 TROUBLESHOOTING GUIDE hen 25 PARTS LISE iena ei ie Ue o ee re int 27 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 tractor 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 An example of what the model plate will look like is shown below This is where your model number will be XXXXXXXXXXX This is where your serial number will be Copy the model number here MTD PRODUCTS INC MTD BOX 368022 Copy the serial number here CLEVELAND OHIO 44136 SECTION 3 CALLING CUSTOMER SU
40. 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 Remove the hex bolt and wing nut from the negative cable Attach the negative cable heavy black wire to the negative battery terminal with the bolt and wing nut Place the hold down strap in position over the battery to secure it in place See Figure 2 Rubber Boot Positive Negative Terminal Bolt Figure 2 NOTE f 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 GAS AND OIL FILL UP Service the engine with gasoline and oil as instructed in the separate engine manual packed with your tractor Read instructions carefully IMPORTANT Your tractor is shipped with oil however you MUST check the oil level before operat ing Be careful not to overfill Overfilling with oil may cause the engine to smoke This will result in poor engine performance and could cause permanent engine damage The gasoline tank is located under the hood and has a capacity of approximately two gallons Do not overfill WARNING Gasol
41. des uncut strip problem only 25 Model 604 9 3 7 2 fa 7 NO NO DESCRIPTION 1 625 0051 Bulb Socket Headlight Assembly 725 1739 Bulb Only 725 1649 Socket Only 2 629 0913 Wiring Harness 3 1629 0924 Harness Adapter for Kohler engines 4 1710 0599 Self Tapping Screw 1 4 20 x 5 5 1712 3006 Hex Nut 1 4 20 6 725 1426 Solenoid 12 volt 100 Amp 7 725 1657A Mount Safety Interlock Switch 8 725 1741 Ignition Switch 9 725 1743 Indicator Monitor Hour Meter 10 1725 1745 Ignition Key 11 1725 1747 Safety Plunger Switch 12 736 0222 External Lock Washer 1 4 13 736 0329 Lock Washer 1 4 26 Electrical System Tractor Body REF PART REF PART NO NO DESCRIPTION NO NO DESCRIPTION 1 1710 0788 Self Tapping Screw 1 4 20 x 1 0 21 783 0808 Heat Shield 4 style 2 1710 0599 Self Tapping Screw 1 4 20 x 5 22 710 0604 Self Tapping Screw 5 16 18 x 625 3 710 0751 Hex Cap Screw 1 4 20 x 62 23 1710 1017 Torx Self Tapping Screw 1 4 14 x 625 4 710 0895 Self Tapping Screw 1 4 15 x 75 24 710 3217 Torx Screw 8 32 x 375 5 1710 0924 Pan Phillips Screw 1 4 20 x 75 25 1712 0142 Hex Nut 8 32 6 710 3008 Hex Cap Screw 5 16 18 x 75 26 731 0069 Dash Panel Manual PTO 4 style 7 1712 0292 U type Speed Nut 1 4 20 27 731 0
42. e 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 SECTION 9 ADJUSTMENTS LEVELING THE 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 performing any deck leveling adjustments Refer to TIRES in the maintenance section of this manual for further information regarding tire pressure Front to Rear The front of the cutting deck is supported by a stabi lizer bar that can adjusted to level the deck from front to rear The front of the deck should be 1 4 to 3 8 lower than the rear of the deck Adjust if necessary as follows WARNING Turn the tractors engine A 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 blade nearest the discharge chute so that it is parallel with the tractor Measure the distance from the front of the blade tip to the ground and the rear of the blade tip to the ground The first measurement 14 Do not cut the grass too short Short grass invites weed growth and yellows quickly in dry weather
43. ed 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 S owly 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 Lower Drive Belt NOTE Proper removal of the lower drive belt requires special tools and 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 affixes it to the transmission Use a second wrench to hold the hex nut on the bottom side of the pulley Slide the belt off of the variable speed
44. edal will return to its original position when it s not depressed IMPORTANT Always set the parking brake when leaving the tractor unattended 10 BRAKE PEDAL The brake pedal is located on the right front side of the tractor above the AutoDrive pedal along the running board The brake pedal can be used for sudden stops or setting the parking brake NOTE The brake pedal must be fully depressed to activate the safety interlock switch when starting the tractor PARKING BRAKE BUTTON To set the parking brake fully depress the brake pedal and push the parking brake button in Hold the button in while taking your foot off the brake pedal Both the parking button and the brake pedal will then stay depressed To release the parking brake depress the brake pedal slightly The parking brake button will then return to its original position NOTE The parking brake must be set if the operator leaves the seat with the engine running or the engine will automatically shut off IMPORTANT Always set the parking brake when leaving the tractor unattended SHIFT LEVER The shift lever is located on the left side of the fender and has three positions FORWARD NEUTRAL and REVERSE The brake pedal must be depressed and the tractor must not be in motion when the moving shift lever IMPORTANT Never force the shift lever Doing so may result in serious damage 1o the tractor s transmission CRUISE CONTROL BUTTON
45. ement rod out of the hole in the PTO adjuster link and move the rod as far back into the disengaged OFF position as possible Thread the PTO adjuster link outward until the hole in the end of it is aligned with the PTO engagement rod SECTION 10 MAINTENANCE A ENGINE Refer to the separate engine manual for engine maintenance instructions Check engine oil level before each use as instructed in the separate engine manual packed with your unit Read and follow instructions carefully WARNING Disconnect the spark plug wire s and ground against the engine before performing any adjustments repairs or maintenance Changing Engine Oil Unscrew oil fill cap and remove dipstick from the oil fill tube See Figure 13 Oil Fill Cap T a Protective Cap Oil Drain Valve Oil Drain Port NOTE Single cylinder engine shown Valve location will vary with engine style Figure 13 17 Reinsert the PTO engagement rod into the hole in the PTO adjuster link and reinsert the cotter pin removed earlier if undamaged PTO Adjuster Link Cotter Pin PTO Engagement Rod Figure 12 Pop open the protective cap on the end of the oil drain valve to expose the oil drain port See Figure 13 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 Push the oil
46. emove equal amounts of metal from both ends of the blades along the cutting edges See Figure 23 Sharpen the cutting edge straight across parallel to the trailing edge at a 25 to 30 angle See Figure 23 IMPORTANT f the cutting edge of the blade has already been sharpened to within 5 8 of the wind wing radius or if any metal separation is present replace the blades with new ones See Figure 23 Wind Wing Blade Separation Sharpen Edge Evenly Figure 23 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 round shaft screwdriver Grind metal from the heavy side until it balances evenly When replacing the blade be sure to install the blade with the side of the blade marked Bottom with a part number stamped in it facing the ground when the mower is in the operating position 23 IMPORTANT Use a torque wrench to tighten the blade spindle hex flange nut to between 70 foot pounds and 90 foot pounds 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 o
47. er w Cup Holder 6 712 3004A Flange Lock Nut 5 16 18 32 738 0155 Shoulder Screw 437 x 1 62 7 1712 3083 Hex Nut 1 2 13 33 783 0677 Lift Adjustment Bracket 8 714 0104 Internal Cotter Pin 34 783 0685 Fender 9 714 0111 Cotter Pin 35 783 0715 Seat Mounting Bracket 10 716 0106 E ring 36 710 1268 Screw 10 16 x 375 11 1720 0311 Handle Grip 37 1712 3027 Hex Flange Lock Nut 1 4 20 12 732 0874 Torsion Spring 38 720 0309A Seat Adjuster Grip 13 732 0934 Lift assist Spring 1 15 x 5 99 39 731 1989 Spacer Found on Units w 46 inch Decks Only 40 732 0499 Compression Spring 41 x 1 5 14 736 0275 Flat Washer 5 16 41 736 0175 Spring Washer 265 x 562 x 025 15 1736 0921 Lock Washer 1 2 42 736 0204 Flat Washer 344 x 62 x 03 16 736 3019 Flat Washer 31 x 1 062 x 134 43 738 0137A Shoulder Screw 340 x 285 1 4 20 17 1736 3084 Flat Washer 51 x 1 12 x 06 44 738 1007 Shoulder Screw 50 x 50 3 8 16 18 1738 0138 Hex Screw 5 16 18 x 62 45 1783 0611 Seat Stop 19 738 0380 Shoulder Screw 5 x 27 3 8 16 46 783 0738 Seat Pivot Bracket 20 741 0225 Hex Flange Bearing 47 783 0739 Seat Adjustment lever 21 741 0715 Snap Flange Bearing 48 783 0753 Seat Adjustment Selector 22 746 0968 Lift Cable 16 16 49 1757 0348 Seat Black w Drain Holes 23 747 1111 Lift Handle 50 735 0657 LH Foot Pad 24 756 1154 Roller Pulley 51 1735 0656 RH Foot Pad 25 783 0678 Arm Lift 726 3046 Foot Pad Clips Not Shown 26 783 0720 Deck Stabilizer
48. ered on this product for a period of 90 days regardless of cause After 90 days but within the two year period normal wear parts failures will be covered ONLY IF caused by defects in material or workmanship of OTHER component parts Normal wear parts are defined as batteries belts blades blade adapters grass bags rider deck wheels seats snow thrower skid shoes shave plates and tires 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 the yellow pages or contact the Customer Support Department of MTD PRODUCTS INC P O Box 368022 Cleveland Ohio 44136 9722 Phone 1 830 273 4683 The return of a complete unit will not be accepted by the factory unless prior written permission has been extended by the Customer Support Department of MTD PRODUCTS INC Transportation charges Transportation charges for the movement of any power equipment unit or attachment are the responsibility of the purchaser Units exported out of the United States MTD PRODUCTS INC does not extend any warranty for products sold or exported outside of the United States of America its possessions and territories except those sold through MTD PRODUCTS INC s authorized channels of export distribution Other Warranties 1 The engine or component parts thereof carry separate warranties from their manufacturers Please refer to the app
49. ew 1 4 20 x 62 NOTE For painted parts please refer to the list of color codes below Please add the applicable color code wherever needed to the part number to order a replacement part For instance if a part numbered 700 xxxx is painted Powder Black the part number to order would be 700 xxxx 0637 MTD Red 0638 Oyster Gray 0662 Powder Black 0637 35 Model 604 AS 46 inch Deck 42 inch Deck Cutting Decks REF PART REF PART NO NO DESCRIPTION NO NO DESCRIPTION 1 17982 Reinforcement Spindle Plate 30 742 0611 Three in one Blade Star Center 16 28 2 618 0240 Spindle Assembly 5 Dia 31 742 0612 Three in one Blade Star Center 14 88 756 0959 Pulley Only 32 1747 1116 Deck Release Pin 3 618 0241 Double Pulley Spindle Assembly 33 754 0349 Deck Belt 756 0603 Double Pulley Only 34 756 0627 Flat Idler Pulley 3 5 OD 4 683 0254 Deck Adjustment Bracket w Weld Nut 35 783 0139 Idler Bracket 5 683 0265 46 inch Deck Shell 36 783 0141 Center Deck Skirt 6 710 0167 Carriage Screw 1 4 20 x 5 37 783 0142 RH Deck Skirt 7 1710 0347 Hex Cap Screw 3 8 16 x 1 75 38 1783 0747 LH Belt Cover 8 1710 0514 Hex Cap Screw 3 8 16 x 1 0 39 783 0805 RH Belt Cover 9 710 0528 Hex Cap Screw 5 16 18 x 1 25 40 116606 Retainer Hook 10 1710 0599 Self Tapping Screw 1 4 20 x 5 41 618 0324 Spindle Assembly 5 75 Dia 11 1710 065
50. ghly inspect the unit for any damage and repair the damage before restarting and operating the tractor DRIVING THE TRACTOR WARNING Avoid sudden starts excessive speed and sudden stops 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 Depress the brake pedal to release the parking brake and let the pedal up Move the throttle lever into the FAST rabbit position IMPORTANT Do NOT use the shift lever to 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 To move forward place the shift lever in the FORWARD position then slowly depress the AutoDrive pedal until the desired speed is achieved To move in reverse place the shift lever in the REVERSE position check that the area behind is clear then slowly depress the AutoDrive pedal SETTING THE CRUISE CONTROL NOTE The cruise control feature can only be operated in the forward direction Place the shift lever in the FORWARD position then slowly depress the AutoDrive pedal until the desired speed is achieved Lightly depress the cruise control button While continuing to hold the cruise button in lift your foot from the AutoDrive pedal you
51. he 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 GENERAL OPERATION Read understand and follow all instructions in the operators manual and on the machine before starting Keep this manual in a safe place for future and regular reference and for ordering replacement parts Only allow responsible individuals familiar with the instructions to operate the machine Know controls and how to stop the machine quickly Do not put hands or feet under cutting deck or near rotating parts Clear the area of objects such as rocks toys wire etc which could be picked up and thrown by the blade A small object may have been overlooked and could be accidentally thrown by the mower in any direction and cause injury to you or a bystander To help avoid a thrown objects injury keep children bystanders and helpers at least 75 feet from the mower while it is in operation Always wear safety glasses or safety goggles during operation or while performing an adjustment or repair to protect eyes from foreign objects Stop the blade s when crossing gravel drives walks or roads Be sure the area is clear of other people before mowing Stop machine if anyone enters the area Never carry passengers Disengage blade s before shifting into reverse and backing up Always look down and beh
52. he right rim Note the distance Behind the axle measure the distance horizontally from the inside of the left rim to the inside of the right rim Note the distance The measurement taken in front of the axle should be between 1 16 and 5 16 less than the measurement taken behind the axle Adjust if necessary Remove the dowel inserted earlier before attempting to operate the tractor CARBURETOR ADJUSTMENT A WARNING If any adjustments 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 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 Refer to separate engine manual packed with your unit for carburetor adjustment information or see an authorized engine service dealer 16 BRAKE ADJUSTMENT 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 Looking at the transmission from the right side of the tractor locate the
53. ind before and while backing Be aware of the mower and attachment discharge direction and do not point it at anyone Do not operate the mower without either the entire grass catcher or the chute guard in place Slow down before turning Operate the machine smoothly Avoid erratic operation and excessive speed Never leave a running machine unattended Always turn off blade s place transmission in neutral set park brake stop engine and remove key before dismounting Turn off blade s when not mowing Stop engine and wait until blade s comes to a complete stop before a removing grass catcher or unclogging chute or b making any repairs adjusting or removing any grass or debris Mow only in daylight or good artificial light Do not operate the machine while under the influence of alcohol or drugs Watch for traffic when operating near or crossing roadways Use extra care when loading or unloading the machine into a trailer or truck This unit should not be driven up or down a ramp onto a trailer or truck under power because the unit could tip over causing serious personal injury The unit must be pushed manually on a ramp to load or unload properly Never make a cutting height adjustment while engine is running if operator must dismount to do so Wear sturdy rough soled work shoes and close fitting slacks and shirts Do not wear loose fitting clothes or jewelry They can be caught in moving parts Never oper
54. ine produces noxious fumes Never fill fuel tank indoors Always fill the fuel tank in a well ventilated area to avoid inhalation of gasoline fumes WARNING Never smoke while fueling your tractor or fill the fuel tank while engine is running or while engine is hot WARNING Do not fill closer than 1 2 inch from the top of the fuel tank to prevent spills and to allow for fuel expansion If gasoline is accidently spilled move tractor away from area of spill Avoid creating any source of ignition until gasoline vapors have disappeared gt gt gt INSTALLING THE MULCH KIT On units equipped with a 46 inch deck follow the instructions included with the mulch kit which is packaged separately within the crate On units equipped with a 42 inch deck the mulch kit is installed at the factory To remove it unfasten the wing knob found on the top of the cutting deck and carefully pull the mulch plug out from the discharge area of the deck SECTION 7 CONTROLS B i 22 SS 222 SS I C 227 SS M F A SEES 2325 SO ARIA PCI VO CIA Q GN A 5 2 v N A AIRA 3826348 pt Lc cae Me ETS eio O 200 202002 J 22 Boe gr a Y dl ux K L NOTE
55. licable manufacturer s warranty on these items 2 Batteries are covered by a 90 day replacement warranty 3 Log splitter pumps valves and cylinders or component parts thereof are covered by a one year warranty 4 All other warranties express implied including any implied warranty of merchantability or fitness for a particular purpose are hereby expressly disclaimed in their entirety 5 The provisions as set forth in this warranty provide the sole and exclusive remedy of MTD PRODUCTS INC s obligations arising from the sales of its products MTD PRODUCTS INC will not be liable for incidental or consequential loss or damage How state law relates to this warranty This limited warranty gives you specific legal rights and you may also have other rights which vary from state to state Certain disclaimers are not allowed in some states and therefore they may not apply to you under all circumstances NOTE This warranty does not cover routine maintenance items such as lubricants filters blade sharpening and tune ups or adjustments such as brake adjustments clutch adjustments or deck adjustments Nor does this warranty cover normal deterioration of the exterior finish due to use or exposure
56. ock 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 WARNING Do NOT attempt to bypass A or disconnect the tractor s safety interlock Doing so could result in serious personal injury or death 11 SEAT ADJUSTMENT LEVER To adjust the seat forward or backward slide the seat adjustment lever to the left and reposition the seat to the desired position Once a comfortable position is found release the seat adjustment lever to lock the seat in place Refer to the ADJUSTMENTS section of this manual for more detailed instructions CUP HOLDER The tractor s cup holder is located on the fender to the left of the seat just to the rear of the shift lever WARNING Never operate the tractor A under the influence of alcoholic beverages or drugs of any kind Doing so can result in serious personal injury or death IMPORTANT Tampering with or attempting to bypass the tractors Safety Interlock Switches in any way WILL void your warranty A 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 LOOK DOWN AND BEHIND BEFORE AND WHILE BACKING KEEP SAFETY DEVICES GUARDS SHIELDS AND S
57. r locate the deck support pin on the rear right side of the deck Pull the deck support pin outward to release the deck from the deck lift arm See Figure 14 Rotate the pin slightly toward the rear of the tractor and release the pin into the hole provided Repeat the above 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 Gently slide 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 7o properly remount the cutting deck perform the above steps in reverse order Having a second person assist you will ease this procedure Deck Lift Arms PTO Idler Pulley Deck Stabilizer Bracket 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
58. r grease to the terminals and over the positive terminal boot Always keep the boot positioned over the positive terminal to prevent shorting IMPORTANT f removing the battery for any reason disconnect the NEGATIVE Black wire from its terminal first followed by the POSITIVE Red wire When re installing the battery always connect the NEGATIVE Black wire its terminal first followed by the POSITIVE Red wire Be certain that the wires are connected to the correct terminals reversing them could change the polarity and cause damage to your engine s alternating system Charging If the unit has not been put into use for an extended period of time charge the battery with an automotive type 12 volt charger for a minimum of one hour at six amps WARNING Batteries give off an explosive gas during and for some time after charging Charge battery in a well ventilated area and do not allow a spark or an open flame near the battery FUSE A fuse is installed in your tractor s wiring harness to protect the tractor s electrical system from damage caused by excessive amperage Always use the same capacity fuse 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 24 to determine if it is good or
59. reduce the life of the bearings CUTTING DECK REMOVAL WARNING 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 WARNING Do NOT remove deck A immediately after operating the tractor Allow the engine and other moving parts ample time to cool down Move the PTO lever into the disengaged OFF position and engage the parking brake To Lift Assembly Deck Support Pins mounted on tractor NOTE Belt covers and other tractor components not shown for clarity 42 inch deck shown Figure 14 Lower the deck by moving the lift lever into the bottom notch on the right fender Grasp the PTO idler pulley bracket and pivot it toward the discharge chute to relieve tension on the belt Remove the deck belt from the bottom portion of the engine pulley and from around the PTO idler pulley 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 tracto
60. 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 Grasp the PTO idler pulley bracket and pivot it toward the discharge chute to relieve tension on the belt Remove the deck belt from the bottom portion of the engine pulley and from around the PTO idler pulley Route the new belt as shown in Figure 14 around the deck pulleys idler pulley and engine pulley IMPORTANT t is recommended that the PTO be readjusted after replacing the deck belt Refer to PTO POWER TAKE OFF ADJUSTMENT in the ADJUSTMENTS section of this manual for the proper procedure Remount the belt guards removed earlier Engine Pulle 2 5 PTO Idler Pulley Deck belt Bottom mounted on tractor Deck Idler Pulley PTO belt Top 4 Right Hand 1 Double Pulley beneath belt guard Left Hand Double Pulley Center Pulley Self Tapping Screws NOTE Left hand belt cover not shown for clarity 46 inch deck shown Figure 15 46 inch decks Lower the deck by moving the lift lever into the bottom notch on the right fender Remove the belt guards by removing the self tapping screws that fasten them to the deck Grasp the PTO idler pulley bracket and pivot it toward the
61. stop while driving up a slope start up smoothly and carefully to reduce the possibility of flipping the tractor over backward OPERATING THE HEADLIGHTS To turn the tractor s headlights on e Start the engine following the instructions earlier in this section Turn the key one notch counterclockwise into the On Lights position of the ignition switch Refer to Figure 4 18 To turn the tractor s headlights off Turn the key either into the On position to leave the engine running or the Off position to shut the engine off Refer to Figure 4 IMPORTANT Never move the key into the Start position while the engine is running Doing so may cause damage to your engine s starter STOPPING THE ENGINE Place the PTO lever in the disengaged OFF position Move the throttle control into the SLOW position and allow the engine to idle down for ten seconds then turn the ignition key counterclockwise to the OFF position Remove the key from the ignition switch to prevent accidental starting IMPORTANT f 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 USING THE LIFT LEVER To raise the cutting deck move the lift lever to the left then place it in the notch best suited for your application Refer to SETTING THE CUTTING HEIGHT earlier in
62. t and service as required Muffler engine and belt guards become hot during operation and can cause a burn Allow to cool down before touching Do not change the engine governor settings or overspeed the engine Excessive engine speeds are dangerous Observe proper disposal laws and regulations Improper disposal of fluids and materials can harm the environment and the ecology Prior to disposal determine the proper method to dispose of waste from your local Environmental Protection Agency Recycling centers established to properly dispose of materials in an environmentally safe fashion Use proper containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them Properly dispose of the containers immediately following the draining of fluids DO NOT pour oil or other fluids into the ground down a drain or into a stream pond lake or other body of water Observe Environmental Protection Agency regulations when disposing of oil fuel coolant brake fluid filters batteries tires and other harmful waste 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 TO REDUCE THE RISK OF INJURY DO NOT OPERATE MOWER UNLESS REAR TRAILING SHIELD AND THIS GUARD OR ENTIRE A DANGER TO THIS UNIT THIS GUARD OR ENTIRE GRASS CATCHER IS

Troy-Bilt 604 Lawn Mower User Manual

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