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O
PERATOR'S
IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY
Warning:
This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-cov-
ered, brush-covered or grass-covered land unless the engine's exhaust system is equipped with a spark 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.
M
ANUAL
Pedal Drive Lawn Tractor
Model 604
FORM NO. 770-10234A
(2/99)
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Table of Contents
Related Manuals for Troy-Bilt 604
Summary of Contents for Troy-Bilt 604
- Page 1 PERATOR’S ANUAL Pedal Drive 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-cov- ered, 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).
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Page 2: Table Of Contents
SECTION 1: TABLE OF CONTENTS PAGE FINDING YOUR MODEL NUMBER ............2 CALLING CUSTOMER SUPPORT. -
Page 3: Important Safe Operation Practices
SECTION 4: IMPORTANT SAFE OPERATION PRACTICES WARNING: THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH, IF NOT FOLLOWED, COULD ENDANGER THE PERSONAL SAFETY AND/OR PROPERTY OF YOURSELF AND OTHERS. READ AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL BEFORE ATTEMPTING TO OPERATE YOUR LAWN MOWER. FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. - Page 4 • Disengage all attachment clutches, thoroughly 3. CHILDREN depress the brake pedal, and shift into neutral Tragic accidents can occur if the operator is not alert to the before attempting to start engine. presence of children. Children are often attracted to the •...
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Page 5: Safety Lables Found On Your Unit
• Keep all nuts, bolts and screws tight to be sure the • Do not change the engine governor settings or equipment is in safe working condition. overspeed the engine. Excessive engine speeds are dangerous. • Never tamper with safety devices. Check their proper operation regularly. -
Page 6: Slope Gauge
USE THIS PAGE AS A GUIDE TO DETERMINE SLOPES WHERE YOU MAY NOT OPERATE SAFELY. SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE A POWER POLE A CORNER OF A BUILDING OR A FENCE POST 15° WARNING Do not mow on inclines with a slope in excess of 15 degrees (a rise of approximately 2-1/2 feet every 10 feet). A riding mower could overturn and cause serious injury. -
Page 7: Attachments & Accessories
™ OEM-190-112 Mulch Kit (For 42-inch Decks Only) OEM-190-118 Mulch Kit (For 46-inch Decks Only) 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... -
Page 8: Controls
SECTION 7: CONTROLS NOTE: Steering Wheel not shown for clarity. Figure 3 Ignition Switch Brake Pedal Throttle Control Lever Parking Brake Button PTO (Power Take-Off) Knob Shift Lever Indicator Monitor/Hour Meter Seat Adjustment Lever Lift Lever Cup Holder Choke Control (if so equipped) M Cruise Control Button G Drive Pedal NOTE:... -
Page 9: Ignition Switch
IGNITION SWITCH IMPORTANT: When using operated equipment such as the cutting deck or other To start the engine, insert key into the ignition switch attachments, always operate the tractor with the and turn clockwise to the START position. Release throttle lever in the FAST (rabbit) position. key to the ON position once engine has fired. - Page 10 LIFT LEVER BRAKE PEDAL BRAKE The brake pedal is located on the right front side of The lift lever is used to change the operating position the tractor above the drive pedal along the running (height) of the cutting deck. To operate, move the board.
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Page 11: Operation
CRUISE CONTROL BUTTON SEAT ADJUSTMENT LEVER The cruise control button is located on To adjust the seat forward or backward, slide the the tractor dash panel to the left of the seat adjustment lever to the left and reposition the ignition switch. - Page 12 SETTING THE CUTTING HEIGHT STOPPING THE ENGINE Select the height position of the cutting deck by • Place the PTO switch in the disengaged placing the deck lift lever in any of the six different (OFF) position cutting height notches on the right side of the fender. •...
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Page 13: Stopping The Engine
• While continuing to hold the cruise button in, To turn the tractor’s headlights off: lift your foot from the drive pedal (you should • Turn the key either into the On position (to feel the cruise latch engage). leave the engine running) or the Off position •... -
Page 14: Adjustments
• The operator must remain in the tractor seat • For best results it is recommended that the at all times. If the operator should leave the first two laps be cut with the discharge thrown seat without pushing the PTO knob inward towards the center. -
Page 15: Side To Side
Side to Side If the cutting deck appears to be mowing unevenly, a side to side adjustment can be performed. Adjust if necessary as follows: WARNING: Turn the tractor’s engine off, remove the key from the ignition switch and apply the tractor’s parking brake before making any adjustments to the cutting deck. -
Page 16: Carburetor Adjustment
Adjust the drag links so that equal lengths are CARBURETOR ADJUSTMENT threaded into the ball joint on the left side and the WARNING: adjustments ball joint on the right side: made to the engine while the engine is • Loosen the jam nut found on the drag link at running (e.g. -
Page 17: Maintenance
SECTION 10: MAINTENANCE WARNING: IMPORTANT: Disconnect the spark plug Refill the engine with the proper wire(s) and ground against the engine capacity and weight of motor oil as instructed in the before performing any adjustments, repairs separate engine manual. or maintenance. Service air cleaner every 25 hours under normal conditions. - Page 18 • Grasp the PTO idler pulley bracket and pivot it • Repeat the above steps on the left side of the toward the discharge chute to relieve tension tractor. on the belt. Remove the deck belt from the • Move the lift lever into the top notch on the electric PTO clutch and from around the PTO right fender to raise the deck lift arms out of idler pulley.
- Page 19 • Remove the deck belt from the electric PTO clutch and from around the PTO idler pulley. • Route the new belt as shown in Figure 14, around the deck pulleys, idler pulley and electric PTO clutch. • Remount the belt guards removed earlier. Electric PTO Clutch PTO Idler Pulley Deck belt (Bottom)
- Page 20 Battery Tray Variable-speed Drive belt (Lower) Shift Lever Opening Pulley Rear Idler Pulley Drive belt (Upper) Belt Keeper Front Idler Pulley Engine Pulley Idler Bracket Belt Keeper to drive pedal Double-Idler Bracket Electric PTO Clutch Transmission Idler Pulley Single-speed Transmission Pulley Transmission Front of Tractor NOTE:...
- Page 21 • Slide the belt off of the variable-speed pulley IMPORTANT: When remounting the electric as you lift the pulley up and out through the PTO clutch, make certain that the stud found to the battery tray opening. right of the engine crankshaft slides up through the hole found in the top of the electric PTO clutch.
- Page 22 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. Worn Blade Edge Wind Wing CUTTING BLADES Blade Separation WARNING: Cutting blades are sharp.
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Page 23: Lubrication
Charging FUSE If the unit has not been put into use for an extended A fuse is installed in your tractor’s wiring harness to period of time, charge the battery with an protect the tractor’s electrical system from damage automotive-type 12-volt charger for a minimum of caused by excessive amperage. -
Page 24: Troubleshooting Guide
SECTION 12: TROUBLESHOOTING GUIDE Possible Trouble Corrective Action Cause(s) Engine will Safety switch There is one safety switch in the starting circuit of your unit: the brake pedal switch. not crank button not Make certain the actuator is fully depressing the button on this switch. The Operator depressed. -
Page 26: Parts List
Model 604 REF. PART DESCRIPTION 625-0051 Bulb/Socket Headlight Assembly 725-1739 Bulb Only 725-1649 Socket Only 629-0928 Wiring Harness (Includes Ref 17) 629-0126 Alternator Adapter (for Intek engines) 710-0599 Self Tapping Screw, 1/4-20 x .5 712-3006 Hex Nut, 1/4-20 725-1426 Solenoid, 12-volt, 100 Amp... - Page 27 Electrical System/Tractor Body REF. PART REF. PART DESCRIPTION DESCRIPTION 710-0788 Self Tapping Screw, 1/4-20 x 1.0 710-1017 Torx Self Tapping Screw, 1/4-14 x .625 710-0599 Self Tapping Screw, 1/4-20 x .5 710-3217 Torx Screw, #8-32 x .375 710-0751 Hex Cap Screw, 1/4-20 x .62 712-0142 Hex Nut, 8-32 710-0895...
- Page 28 Model 604...
- Page 29 Lift Assembly REF. PART REF. PART DESCRIPTION DESCRIPTION 647-0040 Deck Stabilizer Rod 710-0260 Carriage Bolt, 5/16-18 x .62 683-0197 Lift Shaft Assembly 710-0604A Self Tapping Screw, 5/16-18 x .625 711-0332 Clevis Pin, .5 x .78 710-0895 Self Tapping Screw, 1/4-15 x .75 712-0206 Hex Nut, 1/2-13 731-1990...
- Page 30 Model 604...
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Page 31: Steering Assembly
Steering Assembly REF. PART REF. PART DESCRIPTION DESCRIPTION 683-0263A Lower Frame Assembly 683-0128A Pivot Bar 710-0604A Self-tapping Screw, 16-18 x .625 712-0431 Flange Lock Nut, 3/8-16 783-0726 RH Pivot Support Bracket 714-0470 Cotter Pin 783-0727 LH Pivot Support Bracket 726-0214 Push Cap, 5/8 783-0728 Pivot Bar Bracket... - Page 32 Model 604...
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Page 33: Drive System
Drive System REF. PART REF. PART DESCRIPTION DESCRIPTION 17839 Shift Lever Bracket 748-0416 Shoulder Spacer, .38 ID 17840 Transaxle Mounting Bracket 754-0467 Variable-speed Belt 618-0307 Single-speed Transmission Assembly 754-0468 Drive Belt 631-0009 Shifter Knob 756-0981 Flat Idler, 2.75 OD 647-0041 Shift Lever 783-0637 Shift Lever Support... - Page 34 Model 604...
- Page 35 Power Take-off System REF. PART REF. PART DESCRIPTION DESCRIPTION 712-0431 Flange Lock Nut, 3/8-16 711-0640 Stud, 3/8-16 x 2.68 732-0735 Compression Spring, 1.318 x 2.37 712-3010 Hex Nut, 5/16-18 783-0733 Spacer Cup, 1.5 OD 710-3180 Hex Cap Screw, 5/16-18 x 1.75 (Grade 5) 732-0956 Compression Spring, .66 OD x 1.5 732-0978...
- Page 36 Model 604 46-inch Deck 42-inch Deck...
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Page 37: Cutting Decks
Cutting Decks REF. PART REF. PART DESCRIPTION DESCRIPTION 17982 Reinforcement Spindle Plate 742-0611 Three-in-one Blade, Star Center, 16.28 618-0240 Spindle Assembly, 5 Dia. 742-0612 Three-in-one Blade, Star Center, 14.88 756-0959 Pulley Only 747-1116 Deck Release Pin 618-0241 Double Pulley Spindle Assembly 754-0349 Deck Belt 756-0603... - Page 38 Model 604 (for choke) Briggs & Stratton Intek Twin (for throttle) (deflector must face forward) (for choke) Kohler Single-cylinder (deflector must face forward)
- Page 39 Engine Accessories Briggs & Stratton Intek Single (deflector must face forward) REF. PART REF. PART DESCRIPTION DESCRIPTION 710-0148 Self Tapping Screw, #8-32 x .375 751-3141 Oil Drain Hose 710-0599 Self Tapping Screw, 1/4-20 x .5 751-3142 Oil Drain Cap 710-0604A Self Tapping Screw, 5/16-18 x .625 783-0615 Muffler Heat Shield...
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Page 40: Cleveland, Ohio
MANUFACTURER’S LIMITED WARRANTY FOR: For TWO YEARS from the date of retail purchase Units exported out of the United States: MTD within the United States of America, its possessions PRODUCTS INC does not extend any warranty for and territories, MTD PRODUCTS INC will, at its products sold or exported outside of the United option, repair or replace, for the original purchaser, States of America, its possessions and territories,...