Yard-Man 604 series Operator's Manual

Automatic lawn tractor

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

OPERATOR'S MANUAL

Automatic Lawn Tractor — Model Series 604

IMPORTANT

READ SAFETY RULES AND INSTRUCTIONS CAREFULLY BEFORE OPERATION

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

FORM NO. 769-02352

PRINTED IN U.S.A.

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

2/8/2006

Table of Contents

Summary of Contents for Yard-Man 604 series

Page 1 Safety • Assembly • Operation • Adjustment • Maintenance • Troubleshooting • Parts Lists • Warranty OPERATOR’S MANUAL Automatic Lawn Tractor — Model Series 604 IMPORTANT READ SAFETY RULES AND INSTRUCTIONS CAREFULLY BEFORE OPERATION Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-covered, 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).
Page 2: Table Of Contents
This Operator’s Manual is an important part of your new lawn tractor. It will help you assemble, prepare and maintain the unit for best performance. Please read and understand what it says. Table of Contents Slope Gauge ............3 Maintaining Your Lawn Tractor ......24 Safe Operation Practices ........
Page 3: Slope Gauge
Use this page as a guide to determine slopes where you may not operate safely. Do not operate your lawn mower on such slopes. Slope Gauge 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).
Page 4: Safe Operation Practices
WARNING: Engine Exhaust, some of its constituents, and certain vehicle compo- nents contain or emit chemicals known to State of California to cause cancer and birth defects or other reproductive harm. DANGER: This machine was built to be operated according to the rules for safe operation in this Safe manual.
Page 5 General Operation: 14. Watch for traffic when operating near or crossing roadways. This machine is not intended for use on 1. Read, understand, and follow all instructions on the any public roadway. machine and in the manual(s) before attempting to 15.Do not operate the machine while under the influ- assemble and operate.
Page 6 Slope Operation: Do Not: 1. Do not turn on slopes unless necessary; then, turn Slopes are a major factor related to loss of control and slowly and gradually downhill, if possible. tip-over accidents which can result in severe injury or 2.
Page 7 Service 10.Never attempt to make adjustments or repairs to the machine while the engine is running. 1. Never run an engine indoors or in a poorly ventilated 11. Grass catcher components and the discharge area. Engine exhaust contains carbon monoxide, an cover are subject to wear and damage which could odorless, and deadly gas.
Page 8: Setting Up Your Lawn Tractor
NOTE: This Operators Manual covers a range of product specifications for various models. Characteristics and fea- tures discussed and/or illustrated in this manual may not Rubber Boot be applicable to all models. MTD LLC reserves the right to change product specifications, designs and equipment without notice and without incurring obligation.
Page 9: Shipping Brace Removal
Shipping Brace Removal WARNING: Make sure the riding mower’s engine is off, remove the ignition key, and set the parking Setting Up brake before removing the ship- Your Lawn ping brace. Tractor • Locate the shipping brace, if present, and accompany- ing warning tag found on the right side of the mower, between the discharge chute and the cutting deck.
Page 10 Attaching The Seat Seat styles vary by tractor model and there are three different styles available: • Standard Adjustment • Quick Adjustment & Setting Up • Knob Adjustment If the seat for your tractor did not come attached, refer to Your Lawn Figure 4, Figure 5, and Figure 6 to identify your tractor’s seat style and follow the applicable instructions below to...
Page 11 Identifying the Mulch Plug (if so equipped) On tractor models so equipped, a mulch plug can either be found within the cutting deck’s discharge opening or packed separately with your unit. Setting Up NOTE: Refer to Mulching on page 19 for more detailed Your Lawn information.
Page 12: Operating Your Lawn Tractor
Know Your Lawn Tractor Operating Your Lawn Tractor Any reference in this manual to the RIGHT or LEFT side of the tractor is observed from operator’s position. This Operators Manual covers a range of product specifications for various models. Characteristics and features discussed and/or illustrated in this manual may not...
Page 13: Throttle Control Lever
Throttle Control Lever The throttle control lever is located on the right side of �� the tractor’s dash panel. This lever controls the speed �� of the engine and, on some models, when pushed all �� the way forward, the choke control also. When set in a ��...
Page 14 Ammeter The ammeter measures the electrical output of the engine’s charging system. Under normal operating conditions, with engine at full throttle, the ammeter should indicate positive charge. Electric PTO (Blade Engage) Knob Equipped) Operating �� To engage the power to the cutting deck or other Your Lawn (separately available) attach-...
Page 15: Safety Interlock Switches
Parking Brake Button Safety Interlock Switches To set the parking brake, fully This tractor is equipped with a safety interlock system depress the brake pedal and for the protection of the operator. If the interlock system push the parking brake button in. should ever malfunction, do not operate the tractor.
Page 16: Engaging The Parking Brake
WARNING �� AVOID SERIOUS INJURY OR DEATH �� • GO UP AND DOWN SLOPES, NOT ACROSS. �� Operating • AVOID SUDDEN TURNS. �� • DO NOT OPERATE THE UNIT WHERE IT COULD SLIP OR TIP. Your Lawn ��...
Page 17: Stopping The Engine
WARNING: Keep hands and feet Stopping the Engine away from the discharge opening of the cutting deck. WARNING: If you strike a foreign object, stop the engine, discon- NOTE: The deck wheels are an anti-scalp feature of the nect the spark plug wire(s) and deck and are not designed to support the weight of the ground against the engine.
Page 18: Driving On Slopes
4. To move in reverse, place the shift lever in the Disengage the cruise control using one of the following REVERSE position, check that the area behind is methods: clear then slowly depress the drive pedal. 1. Depress the brake pedal to disengage the cruise control and stop the tractor.
Page 19 The following information will be helpful when using the cutting deck with your tractor: WARNING: Plan your mowing pattern to avoid discharge of materials toward roads, side- Operating walks, bystanders and the like. Also, avoid discharging material Your Lawn against a wall or obstruction which may cause discharged Tractor material to ricochet back toward...
Page 20: Adjusting Your Lawn Tractor
Front To Rear The front of the cutting deck is supported by a stabilizer bar that can adjusted to level the deck from front to rear. The front of the deck should be between 1/4-inch and 3/8-inch lower than the rear of the deck. Adjust if neces- sary as follows: Adjusting 1.
Page 21: Parking Brake Adjustment
Parking Brake Adjustment WARNING: Never attempt to ad- just the brakes while the engine is running. Always disengage PTO, Adjusting move shift lever into neutral posi- Your Lawn tion, stop engine and remove key to prevent unintended starting. Tractor 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.
Page 22: Seat Adjustment
Seat Adjustment Quick Adjust Seat (If so equipped) WARNING: Before operating this Adjusting machine, make sure the seat is engaged in the seat stop, stand Your Lawn behind the machine and pull back on seat until fully engaged into Tractor stop.
Page 23: Steering Adjustment
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. Adjusting Adjust the drag links so that equal lengths are threaded into the ball joint on the left and right side: Your Lawn 1.
Page 24: Maintaining Your Lawn Tractor
IMPORTANT: Refer to the Engine Operator/Owner Manual packed with your unit for information regarding the quantity and proper weight of motor oil. Air Cleaner Service the pre-cleaner, if so equipped, and cartridge/air Maintaining cleaner element as instructed in the Engine Operator/ Owner Manual packed with your unit.
Page 25: Product Specifications
Deck Wash System™ (If equipped) Your tractor’s deck may be equipped with a water port on its surface as part of its deck wash system. Use the Deck Wash System™ to rinse grass clippings from the deck’s underside and prevent the buildup of corrosive chemicals.
Page 26 5. Looking at the cutting deck from the left side of the Charging tractor, locate the deck support pin on the rear left If the tractor has not been put into use for an extended side of the deck. See Figure 23. period of time, charge the battery with an automotive-type 12-volt charger for a minimum of one hour at six amps.
Page 27: Cutting Blades
Cutting Blades WARNING: Be sure to shut the engine off, remove ignition key, disconnect the spark plug wire(s) and ground against the Maintaining engine to prevent unintended starting before removing the cut- Your Lawn ting blade(s) for sharpening or Tractor replacement.
Page 28: Changing The Deck Belt
Changing the Deck Belt 4. Carefully loosen, but do not remove, the deck idler pulleys. 5. Remove the deck belt from around all pulleys, including WARNING: Be sure to shut the deck idler pulleys and the electric PTO clutch (units the engine off, remove ignition with electric PTO).
Page 29 42” Deck (Electric PTO) Electric PTO Clutch Right Hand Spindle Pulley Maintaining Your Lawn Tractor Idler Pulleys Left Hand Spindle Pulley Figure 26 �� Figure 27...
Page 30: Off-Season Storage / Attachments
Clean and lubricate the tractor as instructed in Section Follow the instructions in the Service, Storage & 6: MAINTAINING YOUR LAWN TRACTOR of this Specifications section of the Engine Operator/Owner manual before storing for an extended period. Manual for proper engine care prior to storing your tractor. WARNING: Drain fuel only into WARNING: Never store the an approved container outdoors,...
Page 31: Safety Labels
Safety Labels �� ...
Page 32: Troubleshooting
Cause Problem Remedy 1. PTO engaged. 1. Place PTO knob (or lever) in disengaged Engine fails to (OFF) position. start 2. Spark plug wire(s) disconnected. 2. Connect wire(s) to spark plug(s). 3. Fuel tank empty or stale fuel. 3. Fill tank with clean, fresh gasoline. Trouble 4.
Page 33 NOTES...
Page 34 Model Series 604 �� ...
Page 35: Parts List
Ref. Part No. Description Ref. Part No. Description 710-1268† Screw #10-16 x .375 783-04333A Fender 712-04063 Nut, Flange Lock 5/16-18 783-0677B Adjust. Brkt., Lift 712-04064† Nut, Flange Lock 1/4-20 783-1489B Mounting Bracket, Seat Illustrated 720-0309A† Seat Adjuster Grip 710-0227 Screw, #8-18 x.50 726-0201†...
Page 36 Model Series 604 �� ...
Page 37 Ref. Part No. Description Ref. Part No. Description 710-04095 Hex Screw, 3/8-16, 1.00, Gr5 783-0728 Pivot Bracket, Bar 710-0514 Hex Screw, 3/8-16, 1.00, Gr5 631-04008A Steering Wheel 710-0643 Hex Screw, 5/16-18, 1.00, Gr5 731-04065 Wheel Cover Illustrated 711-1408 Link, Drag, RH 738-04128†...
Page 38 Model Series 604 � � �� ...
Page 39 Ref. Part No. Description Ref. Part No. Description 731-1980B Hood 4 Style 747-04301 Side Panel Support 731-1979 Headlight Lens - LH 712-0292 Clip Tinn Nut 1/4-20 — 731-1978 Headlight Lens - RH 783-04323D Plate Dash Support - LH Illustrated 725-1649 Headlight Socket 731-04213 Brake Dash Lever...
Page 40 Model Series 604 � � � � � �� ...
Page 41 Ref. Part No. Description Ref. Part No. Description 710-0726 AB Screw 5/16-12 x .750 683-0266 Pedal Assembly 783-04360 Shift Bracket F-N-R 735-0662 Control Pad 720-04028 Shift Knob 647-0031B Brake Control Assembly Illustrated 647-04020 Shift Lever Assembly 736-0119 Lock Washer 5/16 732-0525 Shifter Spring Clip 710-0650...
Page 42 Model Series 604 Ref. Part No. Description 712-0241 Hex Nut 3/8-24 736-0169 Lock Washer 3/8 Illustrated 747-1127 Idler Adjustment Rod Parts List 723-3018 Ball Joint 783-04442 Center Idler Bracket 656-04015 Pulley Assembly, Var Speed 756-04002 Pulley, V-Type 754-0468 Belt, V-Type 712-0700 Flange Nut 9/16-18 748-0334...
Page 43 �� Illustrated Parts List �� For Choke �� To order replacement parts, call the Customer Service Line at 1-800-800-7310 �� or visit �� www.yardman.com � �� ...
Page 44 Model Series 604 (Electric PTO) �� ...
Page 45 Ref. Part No. Description 710-0726 AB Screw 5/16-12 x .750 710-3011 HH Cap Screw 3/8-16 x 2.25 710-04379A HH Cap Screw 7/16-20 x 3.50 Illustrated — 710-3157A HH Cap Screw 7/16-20 x 3.25 † 712-04065 Flange Lock Nut 3/8-16 Parts List 717-04174 PTO Clutch, Electric 46/50 717-04163...
Page 46 Model Series 604 � � � � � � � � � � �� ...
Page 47 Ref. Part No. Description 732-0614 Ring, Wire Illustrated 716-0231 Ring, E Type,.750 736-0336* Flat Washer, 5/8 x 1.0 x.030 Parts List — 736-0337* Flat Washer, 5/8 x 1.0 x.040 — 736-0349* Flat Washer, 5/8 x 1.0 x.020 736-0335 Washer, Thrust.635 x 1.26 x.06 710-1325 Self-tapping Screw, 1/4-20 x 1.625 719-04017 Upper Housing...
Page 48 Model Series 604 (42-inch Deck - Electric PTO) �� ...
Page 49 Ref. Part No. Description Ref. Part No. Description 618-0624 Pulley Spindle Assy 6.3 Dia. 736-0187 Flat Washer .64 x 1.24 x .06 683-0254B Deck Bracket Assembly 736-0225 Lock Washer 5/8 683-04252 Idler Assembly 736-0270 Bell Washer .265 x .75 x .062 Illustrated 683-04261 Deck Assembly 42”...
Page 50 Model Series 604 (46-inch Deck - Electric PTO) �� ...
Page 51 Ref. Part No. Description Ref. Part No. Description 618-0625 Spindle Assembly, Pulley 5.75 Dia 732-0826 Spring, Extension, .865 OD x 4.68 683-0254B Deck Hanger Bracket Ass’y, LH 736-0322 Washer, Flat .450 x 1.25 x .164 683-04104A Deck Weldment 734-0973 Wheel, Deck 5.0 x 1.38 Illustrated 710-0347 Screw, 3/8-16, 1.75, Gr5...
Page 52 NOTES...
Page 53 NOTES...
Page 54 NOTES...
Page 55 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and MTD Consumer Group Inc are pleased to explain the evaporative emission control system warranty on your 2006 lawn mower. In California, new lawn mower must be designed, built and equipped to meet the State’s stringent anti-smog standards. MTD Consumer Group Inc must warrant the EECS on your lawn mower for the period of time listed below provided there has been no abuse, neglect or improper maintenance of your lawn mower.
Page 56 MANUFACTURER’S LIMITED WARRANTY FOR The limited warranty set forth below is given by MTD LLC with respect to e. MTD does not extend any warranty for products sold or exported new merchandise purchased and used in the United States, its posses- outside of the United States, its possessions and territories, except sions and territories.

Yard-Man 604 series Operator's Manual

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