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Operator's Manual
Pedal Drive Lawn Tractor
Models D609G
G609G
U609H
X609G
IMPORTANT:
Read safety rules and instructions
carefully
before operating
equipment.
Warning:
This unit is equipped with an internal combustion engine and should net 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.BOX361131, CLEVELAND, OHIO 44136-0019
PRINTED IN U.S.A.
FORM NO. 770-10490A
(12/2001)
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Summary of Contents for Troy-Bilt D609G
- Page 1 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.BOX361131, CLEVELAND, OHIO 44136-0019 PRINTED IN U.S.A. FORM NO. 770-10490A...
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Page 2: Table Of Contents
TABLEOFCONTENTS Content Page Important Safe Operation Practices ..............Slope Gauge ...................... Tractor Set-up ....................Know Your Lawn Tractor ................... Operating Your Lawn Tractor ................Making Adjustments ..................Maintaining Your Lawn Tractor ................Service ......................Off-Season Storage ................... Troubleshooting ....................Parts List ......................FINDINGMODELNUMBER This Operator's Manual is an important part of your new lawn tractor. -
Page 3: Important Safe Operation Practices
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 23. Muffler a ndengine become hotandcancausea Keep all movement on the slopes slow and gradual. burn.Donottouch. Do not make sudden changes in speed or direction. 24. Check overhead c learances carefully before driving Rapid engagement or braking could cause the front under lowtreebranches, wires, d ooropenings e tc., of the machine to lift and rapidly flip over backwards where theoperator m ay bestruck orpulled from the...
- Page 5 Never over fill fuel tank. Fill tank to no more feature emphasises not to cut in reverse and than ½ inch below bottom of filler neck to to avoid back-over accidents; do not defeat it. Keep children away from hot or running allow space for fuel expansion.
- Page 6 10. Never a ttempt tomakeadjustments orrepairs to maximum safe operating speed of the engine. themachine while theengine is running. 13. Maintain or replace safety and instruction labels, as 11.Grass catcher c omponents andthedischarge necessary. coveraresubject towearanddamage which could 14. Observe proper disposal laws and regulations for expose moving partsorallowobjects tobethrown.
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Page 7: Slope Gauge
SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE A POWER POLE A CORNER OFA BUILDING OR A FENCE POST I,LI 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 8: Tractor Set-Up
SECTION 3: SETTING UPYOUR TRACTOR NOTE: Any reference in this manual to the RIGHT or LEFT side of the tractor is observed from operator's WARNING: Use extreme care when position. handling gasoline. Gasoline is extremely flammable and the vapors are explosive. Never Attaching the BatteryCables fuel machine indoors or while the engine is hot or running. -
Page 9: Know Your Lawn Tractor
SECTION 4: KNOW YOUR LAWNTRACTOR Compare the illustration below with the controls on your tractor; get familiar with these features before you start to operate the tractor. This manual covers two models. So follow the descriptions and instructions pertaining to your tractor model only. - Page 10 Throttle ControlLever The throttle control lever is WARNING: unattended. Always disengage PTO, move Never leave a running machine / Choke* located on the right side of shift lever into neutral position, set parking the tractor's dash panel. brake, stop engine and remove key to prevent This lever controls the unintended starting.
- Page 11 amperage. Refer to Battery charging Parking Brake Button procedure on page 21 or have the To set the parking brake, engine's charging system checked by fully depress the brake an authorized dealer. pedal and push the parking brake button in. Hold the Cup Holder button in while taking your The tractor's cup holder is located on the fender to the...
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Page 12: Operating Your Lawn Tractor
SECTION 5: OPERATING Y OUR LAWNTRACTOR • Insert the tractor key into the ignition switch. WARNING: • Place PTO lever in the disengaged (OFF) position. Read, understand, and follow all • Engage the tractor's parking brake. instructions and warnings on the machine and in this manual before operating. - Page 13 Driving theTractor Avoid turns when driving on a slope. If a turn must be made, turn down the slope. Turning up a slope IMPORTANT: Avoid sudden starts, high speed and greatly increases the chance of a roll-over. sudden stops. Avoid stopping when driving up a slope. If it is necessary to stop while driving up a slope, start up smoothly and carefully to reduce the possibility of WARNING:...
- Page 14 • Keep the throttle lever in the FAST (rabbit) position grass clippings repeatedly beneath the cutting deck. for the most efficient use of the cutting deck or other The ultra-fine clippings are then forced back into the (separately available) attachments. lawn where they act as a natural fertilizer.
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Page 15: Making Adjustments
SECTION 6: MAKING ADJUSTMENTS • Loosen the two jam nuts on the rear side of the WARNING: deck stabilizer bracket. See Figure 5A. Disconnect the spark plug • Locate the two lock nuts on the opposite side of the wire(s) and ground against the engine before performing any adjustments, repairs or stabilizer bracket. - Page 16 SeatAdjustment Steering Adjustment If the tractor turns tighter in one direction than the other, WARNING: Before operating this machine, or ifthe ball joints are being replaced due to damage or make sure the seat is engaged in the seat stop, wear, the steering drag links may need to be adjusted.
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Page 17: Maintaining Your Lawn Tractor
SECTION 7: MAINTAINING YOUR LAWNTRACTOR Oil RII WARNING: Before performing Oil Drain maintenance or repairs, disengage PTO, move Protective Cap Hose shift lever into neutral position, set parking brake, stop engine and remove key to prevent unintended starting. Cleaning EngineandDeck •... -
Page 18: Service
SECTION 8: SERVICE if any metal separation is present, replace the blades with new ones. See Figure 10. WARNING: Before performing • Grind each blade edge equally to maintain proper maintenance or repairs, disengage PTO, move blade balance. shift lever into neutral position, set parking brake, stop engine and remove key to prevent •... - Page 19 substitute (non-OEM) V-belt can be dangerous by not disengaging completely. For a proper working machine, use factory approved belts only. All belts on your tractor are subject to wear and should be replaced if any signs of cracking, shredding or rotting are present.
- Page 20 IMPORTANT:The V-belts found on your tractor are • Remove the upper drive belt from around the specially designed to engage and disengage safely. A transmission pulley and the variable-speed pulley. substitute (non-OEM) V-belt can be dangerous by not NOTE: Slowly rotate the pulley counter-clockwise to roll disengaging completely.
- Page 21 • Slide belt off the variable-speed pulley as you lift • Reassemble by following the above steps in reverse order. the pulley up and out through battery tray opening. • Remove the rear idler pulley from the double- idler bracket while unrouting the belt from around both Idler Adj.
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Page 22: Off-Season Storage
If the electrical system does not function, or your WARNING: Batteries give off an explosive • tractor's engine will not crank, first check to be gas while charging. Charge battery in a well certain that the fuse has not blown. ventilated area and keep away from an open It can be found under the hood mounted behind the flame or pilot light as on a water heater, space... -
Page 23: Troubleshooting
SECTION 10: TROUBLESHOOTING Trouble Corrective Action Possible Cause(s) Engine fails to start PTO lever engaged. Place PTO lever in disengaged (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 FAST or CHOKE (if so equipped) starting position. -
Page 24: Parts List
SECTION 11: PARTS LISTFORMODELS D609,G609,U609 & X609 <... - Page 25 ModelsD609,G609,U609 & X609 DESCRIPTION REF. PART NO. DESCRIPTION REF. PART NO. 783-1346 Grill Support Bracket (9-style) 751-0659A Fuel Tank, Two-gallon (Model D609G) 710-0599 Self-tapping Screw, 1/4-20 x .5 Ignition Key w/plastic cover 710-0528 Hex Cap Screw, 5/16-18 x 1.25 725-1745 Ignition Key w/o plastic cover 710-0924 Phillips Pan Screw, 1/4-20 x .75...
- Page 26 ModelsD609,G609,U609 & X609 48. 37...
- Page 27 ModelsD609,G609,U609 & X609 PART DESCRIPTION REP. PART DESCRIPTION 747-1130A Deck Stabilizer Rod 710-0895 Self-tapping Screw, 1/4-15 x .75 Lift Lever Cover 683-0197 Lift Shaft Assembly 731-1990 711-0332 Clevis Pin, .5 x .78 731-2104B Shift Lever Cover w/Cup Holder 712-0206 Hex Nut, 1/2-13 736-3078 Flat Washer, .349 x 1.0 x .063 712-0431...
- Page 28 ModelsD609,G609,U609 & X609...
- Page 29 ModelsD609,G609,U609 & X609 REF. PART DESCRIPTION PART DESCRIPTION 638-0019A 731-1291A LH Axle Assembly, .625 Diameter Pivot Bar End Cap 710-1238 638-0020A Self4apping Screw, 16-18 x .625 RH Axle Assembly, .625 Diameter 683-0128A Pivot Bar 783-0726B RH Pivot Support Bracket 712-0431 783-0727A LH Pivot Support Bracket Flange Lock Nut, 3/8-16...
- Page 30 ModelsD609,G609,U609 & X609 •73 _-23...
- Page 31 ModelsD609,G609,U609 & X609 PART DESCRIPTION PART DESCRIPTION 783-1015 756-0981 Shift Lever Support Flat Idler, 2.75 OD 17840 783-1016B Transaxle Mounting Bracket Speed Control Rod Bracket 618-0551 783-0667B Single-speed Transmission Assembly Transmission Torque Bracket Shifter Knob 631-0009 783-0669 Idler Bracket 647-0045 Shift Lever 736-0430 Flat Washer, .350 x 1.59 x .062...
- Page 32 ModelsD609,G609,U609 & X609 PART DESCRIPTION 716-0231 E-Ring, .75 721-0338 Seal, .75 x 1.0 x .125 711-1431 Drive Shaft 741-0340 Sleeve Bearing, .75 x .1.0 x 1.0 736-0495 Thrust Washer, 1.0 x .632 x .0 717-1362 42-Tooth Bevel Gear 717-1363 42-Tooth Bevel Gear 750-1234 Spacer, .633 x 1.0 x .513 718-0228...
- Page 33 ModelsD609,G609,U609 & X609 I (for choke) NOTE: Engine accessory parts are applicable to all models except otherwise noted. REF. PART REP. PART DESCRIPTION DESCRIPTION 710-0227 751-0650 RH Exhaust Pipe (Model G609G) Self-tapping Screw, #8-18 x .5 710-0599 751-0651 Self-tapping Screw, 1/4-20 x .5 LH Exhaust Pipe (Model G609G) 710-0604A Self-tapping Screw, 5/16-18 x .625...
- Page 34 ModelsD609,G609,U609 & X609...
- Page 35 ModelsD609,G609,U609 & X609 PART DESCRIPTION REF. PART DESCRIPTION 647-0064 PTO Engage Lever Assembly 783-0744A Engagement Stop 683-0450 PTO Engage Plate Assembly 783-0891B Deck Stop 710-0276 Carriage Screw, 5/16-18 x 1.00 710-0604A Self-tapping Screw, 5/16-18 x .625 710-0520 Hex Cap Screw, 3/8-16 x 1.5 732-3080A Compression Spring, 1.28 x 3.5 710-0831...
- Page 36 ModelsD609G, G 609G & X609G 1235 50 11 21 e...
- Page 37 ModelsD609G, G 609G& X609G REF. PART NO. DESCRIPTION REF. PARTNO. DESCRIPTION 16606 Bracket: Retainer Hook 732-O3O6 Compression Spring 618-0565 Spindle Assembly: Pulley 732-0470A Extension Spring 683-0198E Deck Assembly 732-1165 Extension Spring 683-0254 734-0973 Deck Wheel Deck Hanger Bracket LH Bell Washer 683-0440 Brake Assembly: deck 736-0105...
- Page 38 ModelU609H •...
- Page 39 ModelU609H REF. PART NO. DESCRIPTION REF. PART NO. DESCRIPTION 16606 Retainer hook: bracket 726-0233 Push Nut 17116 Deck Brake Assembly 732-0306 Compression Spring Belt Cover RH 17258C 732-0429A Extension Spring 17982 732-594A Spindle Plate Extension Spring 618-0240A Spindle Assembly 732-0934 Extension Spring 618-0594 732-1165...
- Page 40 MANUFACTURER'S LIMITED WARRANTY FOR: The limited warranty set fodh below is given by Troy-Bilt LLC Troy-Bilt LLC does net extend any warranty for products sold or exported outside of the United States, with respect to new merchandise purchased and used in the United States, its possessions and territories.