Troy-Bilt Super Bronco J609 Operator's Manual
Auto drive lawn tractors
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TRilY RILT
Operator's Manual
Auto Drive Lawn Tractors
Super Bronco TM
Bronco
TM
(Models J609 & T609)
IMPORTANT:
Read safety rules and instructions
carefully
before operating
equipment.
Warning:
This unit is equipped with an internal combustion engine and should not be used on or near any unimproved
forest-covered,
brush-covered
or grass-covered
land unless the engine's exhaust system is equipped with a spark arrester meeting applicable local or state
laws (if any). If a spark arrester is used, it should be maintained
in effective working order by the operator. In the State of California the
above is required by law (Section 4442 of the California
Public Resources
Code). Other states may have similar laws. Federal laws apply
on federal lands. A spark arrester for the muffler is available through your nearest engine authorized service dealer or contact the service
department,
P.O. Box 361131 Cleveland, Ohio 44136-0019.
TROY-BILT LLC.P.O.BOX 361131, CLEVELAND, OHIO 44136-0019
PRINTED IN U.S.A.
FORM NO. 770-10490C
(11/2003)
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Summary of Contents for Troy-Bilt Super Bronco J609
- Page 1 A spark arrester for the muffler is available through your nearest engine authorized service dealer or contact the service department, P.O. Box 361131 Cleveland, Ohio 44136-0019. TROY-BILT LLC.P.O.BOX 361131, CLEVELAND, OHIO 44136-0019 PRINTED IN U.S.A. FORM NO. 770-10490C...
- Page 2 TABLEOFCONTENTS Content Page Content Page Customer Support Service Important Safe Operation Practices Off-Season Storage Tractor Set-Up Attachments & Accessories Operation Troubleshooting Making Adjustments Illustrated Parts List Maintenance Warranty FINDINGMODEL NUMBER This Operator's Manual is an important part of your new lawn tractor. It will help you assemble, prepare and maintain the unit for best performance.
- Page 3 SECTION 1: IMPORTANT SAFEOPERATION P RACTICES WARNING: This symbol points out important safety instructions which, if not followed, could endanger the personal safety and/or property of yourself and others. Read and follow all instructions in this manual before attempting to operate this machine. Failure to comply with these instructions may result in personal injury.
- Page 4 29. If situations occur which are not covered in this manual, the presence of children. Children are often attracted to use care and good judgment. Contact your Troy-Bilt the machine and the mowing activity. They do not dealer for assistance.
- Page 5 Never fill containers inside a vehicle or on a truck serviced professionally by your Troy-Bilt dealer. Check brake operation frequently as it is subjected to or trailer bed with a plastic liner. Always place wear during normal operation. Adjust and service as...
- Page 6 SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE A POWER POLE A CORNER OF A BUILDING OR A FENCE POST £O 15° WARNING &i 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 SECTION 3: TRACTOR SET-UP NOTE: Any reference to right, left, front or back of the Steering _ tractor is from the operating position, unless otherwise stated. A a@in Th8 SteeringWheel Hex Bolt Wheel Cap/_ The hardware for attaching the steering wheel has &...
- Page 8 SECTION 4: OPERATION Read this owner's manual and safety rules before operating your lawn mower. Compare figure below with your lawn tractor to learn about the loction and purpose of various controls and adjustments. Save this manual for future reference. It is very important to follow the instructions and operate the controls properly. Figure 4 PTO (Blade Engage) Lever Cruise Control Button...
- Page 9 ThrottleControlLever .=_Choke The throttle control lever controls the speed of the engine. When set in a given position, the throttle wilt maintain a uniform engine speed. ChokeControl Bronco: Moving the throttle lever all the way forward activates the engine's choke control. (M°_deFI °...
- Page 10 Headlights To turn on the headlights, rotate the same ignition key from ON position to ON/LIGHTS position of the ignition switch. To turn off the headlights, rotate the ignition key from ON/LIGHTS position to either ON position (to leave the engine running) or OFF position (to shut the engine off).
- Page 11 • GO UP AND DOWN SLOPES, NOT ACROSS. tractor, immediately contact a Troy-Bilt dealer. • AVOID SUDDEN TURNS. The safety interlock system will automatically shut off • DO NOT OPERATE THE UNIT WHERE IT COULD SLIP OR TIR •...
- Page 12 NOTE: Refer to the TRACTOR SET-UPon page 7 manual for gasoline and oil tiff-up instructions. Insert the tractor key into the ignition switch. Place the PTO (Blade Engage) Lever in the disengaged (Blade Stop) position. Engage the tractor's parking brake. Move the throttle control lever into the CHOKE position (a warm engine may not require choking).
- Page 13 Do not mow at high ground speed, especially if a mulch kit or grass collector is installed. For best results it is recommended that the 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.
- Page 14 Hex Nut and Grease Fitting Pivot Bar Lock Washer Ifthetractor t urns tighterinonedirection thanthe other, o riftheball j ointsarebeingreplaced dueto damage orwear, t hesteering draglinksmayneed to beadjusted. Adjust t hedraglinkssothatequal lengths arethreaded intotheball j ointsonbothsides. 1. Loosen thejamnutonthedraglinkattherearofthe Axle ball j oint.SeeFigure 7. 2.
- Page 15 Sideto Side If the cutting deck appears to be mowing unevenly, a side to side adjustment can be performed. Adjust if necessary as follows: With the tractor parked on a firm, level surface, place the deck lift lever in the top notch (highest position) and rotate both blades so that they are perpendicular with the tractor.
- Page 16 PivotPoints& Linkage Lubricate all pivot points on the drive system, parking brake and lift linkage at least once a season with light oil. RearWheels Remove rear wheels from the axles once a season; lubricate the axles and rims with an all-purpose automotive grease and re-install the wheels FrontWheels Each front wheel axle is equipped with a grease fitting;...
- Page 17 5. Thread hosecoupler ( packaged withthismanual) onto theendofyourgarden hose. S eeFigure 12. 6. Attach thehosecoupler t othewaterportonyourdecks surface. SeeFigure12.Turnthewateron. 7. While sittingintheoperator's p osition, re-start t he engine andplace throttle leverinFAST (rabbit) position. 8. MovethePTO (Blade Engage) L ever t oONposition. 9.
- Page 18 12.6 V or higher for adequate charge. Otherwise, charge the battery with an automotive-type 12-volt charger for a minimum of one hour at six amps. Follow the chart below to charge: State of Charge Charging Time Voltmeter Reading (percentage) (minutes) 12.7 12.4 12.2...
- Page 19 7. Repeat t heabove steps ontheright s ideofthetractor. 8. Using a pairofneedle nosepliers, p ulloutthecotter p inholding thedeckcable. T hiswilldisconnect thecable. 9. Movethedeckliftleverintothetopnotchontheright f ender t oraisethedeckliftarms outoftheway. 10.Gently slidethecutting decktoward thefrontofthetractor a llowing thehooks onthedecktorelease themselves fromthedeckstabilizer rod.DoNOTletthedeckfalltotheground. CuSin S adss WARNING: Shut tractor engine off, remove ignition key, disconnect the spark plug wire(s) and ground against the engine before proceeding with job.
- Page 20 Engine Pulley PTO Idler Bracket Deck belt (Bottom) tractor) PTO belt (Top) Left Hand Pulley Right Hand Pulley (beneath belt guard) Deck Idler Pulley Center Pulley Self-Tapping Screws NOTE: Left hand belt cover not shown for clarity. Figure 15 Alt belts on the tractor are subject to wear and should be replaced if cracking, shredding or rotting occurs. To change or replace the deck belts on your tractor, proceed as follows: Lower the deck by moving the deck lift lever into the bottom notch on the right fender.
- Page 21 Variable=Speed Battery Tray Opening Shift Lever Rear Idler Pulley m Drive belt (Upper) Engine Pulley Transmission Pulley Transmission Front of Tractor ---I_ NOTE: View shown from above tractor. Figure 16 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.
- Page 22 A a@ments & Accesso bs The following attachments and accessories are available for your lawn tractor. See your local Troy-Bilt dealer for price and availability.
- Page 23 SECTION 9: TROUBLESHOOTING Engine fails to start PTOlever engaged. Place PTOlever in OFF position. Parking brake not engaged. Engage parking brake. Spark plug wire(s) disconnected. Connect wire(s) to spark plug. Throttle control lever not in correct Place throttle lever to CHOKE position. starting position.
- Page 24 SECTION 10: PARTS LISTFORMODELS J609 & T609 painted parts, refer to the list of color codes below. Please add the applicable color code to the part number for a replacement part. For instance, ifa part numbered 700-xxxx is painted Red, the part number to order would be 700-xxxx-0638.
- Page 25 ModelsJ609 & T609 Re& Part Ref. Part Description Description 783-1346 Grill Support Bracket (9-style) 710-0895 Self-tapping Screw, 1/4-15 x .75 710-0599 Self-tapping Screw, 1/4-20 x.5 710-3217 Truss Phillips Screw. #8-32 x .375 710-0528 Hex Cap Screw, 5/16-18 x 1.25 712-0142 Hex Nut, #8-32 710-0924 Throttle Control Knob...
- Page 26 ModelsJ609 & T609 NOTE: For painted parts, refer to the list of color codes below. Please add the applicable color code to the part number for a replacement part. For instance, if a part numbered 700-xxxx is painted Red, the part number to order would be 700-xxxx-0638.
- Page 27 ModelsJ609 & T609 Ref. Re& Description Description 747-1130B Deck Stabilizer Rod 783-0720A Deck Stabilizer Bracket 683-0197B 710-0260A Lift Shaft Assembly Carriage Bolt, 5/16 x .62 711-0332 Clevis Pin, .5 x .78 710-0604A Self-tapping Screw, 5/16-18 x .625 712-0206 Hex Nut, 1/2-13 736-0331 Bell Washer, .390 x 1.13 x .062 712-0431...
- Page 28 ModelsJ609 & T609 NOTE: For painted parts, refer to the list of color codes below. Please add the applicable color code to the part number for a replacement part. For instance, if a part numbered 700-xxxx is painted Red, the part number to order would be 700-xxxx-0638.
- Page 29 ModelsJ609 & T609 Ref. Ref. Description Description 710-1260A 638-0019A Self-tapping Screw, 5/16-18 x .76 LH Axle Assembly, (Model LTX-1842) 710-0604A 638-0021 Self-tapping Screw, 16-18 x .625 LH Axle Assembly(Model LTX-2146) 783-0726B 638-0020A RH Pivot Support Bracket RH Axle Assembly (Model LTX-1842) 783-0727A 638-0022 LH Pivot Support Bracket...
- Page 30 ModelsJ609 & T609 IMPORTANT: For a proper working machine, use Factory Approved Parts. V-belts are designed to engage and disengage safely. A substitute (non OEM) V-belt can be dangerous by not disengaging completely.
- Page 31 ModelsJ609 & T609 Ref. Re& Part Part Description Description 17840 719-1611B TT Screw 5/16-18 x 0,75 Mounting Bracket 618-04133 711-04159 Drive Assembly 618-04147 712-0130 Hex Lock Nut 3/8-16 Variable Spd. Pulley Assembly 647-04020 712-3094A Shift Lever Assembly Flange Lock Nut Cotter Pin 710-0607 TT Screw 5/16-18 x 0,5...
- Page 32 ModelsJ609 & T609 .¢...
- Page 33 ModelsJ609 & T609 Description 732-0614 Ring, Wire 716-0231 Ring, E Type..750 736-0336 Fiat Washer, 5/8 x 1.0 x .030* 736-0337 Fiat Washer, 5/8 x 1.0 x .040* 736-0349 Fiat Washer, 5/8 x 1.Ox .020* 736-0335 Washer, Thrust .635 x 1.26 x .06 710-1325 Self-tapping Screw, 1/4-20 x 1.625 719-04017...
- Page 34 ModelsJ609 & T609 _,_ 32 NOTE: For painted parts, refer to the list of color codes below. Please add the applicable color code to the part number for a replacement part. For instance, if a part numbered 700-xxxx is painted Red, the part number to order would be 700-xxxx-0638.
- Page 35 ModelsJ609 & T609 Ref. Part Re& Description Description 732-04035 647-0064 Compression Spring, 1.28 x 3.125 PTO Engage Lever Assembly 683-0450 723-0444 PTO Engage Plate Assembly Battery Strap 738-1020 710-0276 Shoulder Screw..625 x .5, 7/16-20 Carriage Screw, 5/16-18 x 1.00 736-0407 710-0520 Bell Washer, .45 x 1.0 x .062 Hex Cap Screw, 3/8-16 x 1.5...
- Page 36 ModelsJ609 Ref. Part No. Description 710-0227 AB Screw #8-18 x 0.5 710-0599 TT Screw 1/4-20 x 0.5 710-0726 AB Screw 5/16-12 x 0.5 710-1237 ]- screw #10-32 x 0.625 710-1314A Socket Hd Scr. 5/16-18 x .750 710-1315 TT Screw 3/8-16 x 1.25 712-0271 Sems Nut Exhaust Gasket...
- Page 37 ModelsJ609 & T609 SYSTEMS tNIICATOR MONITOR I£ £...
- Page 38 ModelsJ609 & T609 NOTE: For painted parts, refer to the list of color codes below, Please add the applicable color code to the part number for a replacement part, For instance, if a part numbered 700-xxxx is painted Red, the part number to order would be 700-xxxx-0638, Red: 0638 Oyster Gray: 0662...
- Page 39 ModelsJ609 & T609 Part No. Ref. Part No. Descdption Description 711-04069 Grass Catcher Pin, 1/4-20 736-0162 Flat Washer, .64 x 1.0 x. 12 618-0565 736-0276 Bell Washer, .265 x .75 x .062 Spindle Assy., 5.75 Dia. w/Fitting 683-0198G 42-inch Deck Shell 738-0373 Shoulder Screw, .498 x 1.53 683-0254...
- Page 40 MANUFACTURER'S LIMITED WARRANTY FOR: ® The limited warranty set forth below is given by Troy-Bilt LLC Troy-Bilt does not extend any warranty for products sold or exported outside of the United States, its with respect to new merchandise purchased and used in the United States, its possessions and territories.