Troy-Bilt Super Bronco 60TG Operator's Manual

Automatic lawn tractor

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Operator's manual (48 pages)

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

OPERATOR'S MANUAL

Automatic Lawn Tractor — Super Bronco™ (Model 60TG)

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. 770-10490I

PRINTED IN U.S.A

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

1/06/2006

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Summary of Contents for Troy-Bilt Super Bronco 60TG

Page 1 (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. 770-10490I PRINTED IN U.S.A Troy-Bilt LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019 1/06/2006...
Page 2: Table Of Contents
You can locate the model plate by looking beneath the seat. This information will be necessary to use the manufacturer’s web site and/or obtain assistance from the Customer Support Department or an authorized service dealer. TROY-BILT LLC P. O. BOX 3 6 1 1 3 1 www.troybilt.com CLEVELAND, OH 44136...
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 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 Attaching The Steering Wheel The hardware for attaching the sterring wheel has been packed within the steering wheel, beneath the steering wheel cap. Carefully pry off the steering wheel cap and remove the hardware. Setting Up NOTE: There are two different styles of steering wheel cap.
Page 10: Operating Your Lawn Tractor
Know Your Lawn Tractor Operating � Your Lawn � Tractor � � NOTE: Any reference in this manual to the �� RIGHT or LEFT side of � the tractor is observed from operator’s position. � � � � � � NOTE: Steering wheel not shown for clarity Figure 5 PTO (Blade Engage) Lever...
Page 11: 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 when pushed all the way forward, the �� choke control also. When set in a given position, the ��...
Page 12: Seat Adjustment Knobs
PTO (Blade Engage) Lever �� Operating Your Lawn The PTO (Blade Engage) lever is located on the left side of the dashboard next to the steering wheel. Move the Tractor PTO (Blade Engage) lever forward to engage the power to the cutting deck or other (separately available) attach- ments;...
Page 13: Shift Lever
Cruise Control Button • The engine will automatically shut off if the operator leaves the tractor’s seat with the PTO (Blade Engage) The cruise control button is lever in the engaged (ON) position, regardless of located on the tractor dash whether the parking brake is engaged.
Page 14: Setting The Cutting Height
WARNING �� AVOID SERIOUS INJURY OR DEATH �� • GO UP AND DOWN SLOPES, NOT ACROSS. �� • AVOID SUDDEN TURNS. Operating �� • DO NOT OPERATE THE UNIT WHERE IT COULD SLIP OR TIP. Your Lawn ��...
Page 15: Starting The Engine
NOTE: The deck wheels are an anti-scalp feature of the 1. If the blades are engaged, place the PTO (Blade deck and are not designed to support the weight of the Engage) lever in the disengaged (OFF) position. cutting deck. 2.
Page 16: Driving On Slopes
Driving On Slopes To change to the reverse direction when operating with cruise control, depress the brake pedal to disengage the Refer to the SLOPE GAUGE on page 3 to help deter- cruise control and bring the tractor to a complete stop. mine slopes where you may operate the tractor safely.
Page 17 WARNING: Plan your mowing pattern to avoid discharge of materials toward roads, side- walks, bystanders and the like. Also, avoid discharging material against a wall or obstruction Operating which may cause discharged material to ricochet back toward Your Lawn the operator. Tractor •...
Page 18: Adjusting Your Lawn Tractor
2. 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 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 Adjusting next step.
Page 19 2. Loosen, but do NOT remove, the hex nut found on the right side of the brake assembly. See Figure 13. 3. Using a feeler gauge, set the gap between the brake disc and the brake puck at .011”. 4. Re-tighten the hex nut loosened earlier. Adjusting Seat Adjustment Your Lawn...
Page 20: Maintaining Your Lawn Tractor
6. Refill the engine with new motor oil as instructed in the Kohler Operator/Owner Manual packed with your unit. IMPORTANT: Refer to the Kohler Operator/Owner Manual packed with your unit for information regarding the quantity and proper weight of motor oil. Maintaining Air Cleaner Your Lawn...
Page 21 Deck Wash System™ Your tractor’s deck may be equipped with a water port on its surface as part of its deck wash system. If equipped, use the Deck Wash System™ to rinse grass clippings from the deck’s underside and prevent the buildup of corrosive chemicals.
Page 22 WARNING: Batteries give off an 6. Pull the deck support pin outward to release the deck from the deck lift arm. explosive gas while charging. 7. Rotate the pin slightly toward the rear of the tractor Charge battery in a well ventilated and release the pin into the hole provided.
Page 23: 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 24 Changing the Deck Belt 3. Remove the belt guards by removing the self-tapping screws that fasten them to the deck. 4. Carefully loosen, but do not remove, the deck idler WARNING: Be sure to shut pulleys. the engine off, remove ignition 5.
Page 25 �� Maintaining �� Your Lawn �� Tractor �� Figure 23...
Page 26: 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 on page 20 Specifications section of the Kohler Operator/Owner of this manual before storing for an extended period. Manual for proper engine care prior to storing your tractor.
Page 27: Safety Labels
�� ...
Page 28: Trouble Shooting
Problem Cause Remedy 1. Place PTO knob (or lever) in Engine fails to start 1. PTO engaged. disengaged (OFF) position. 2. Connect wire(s) to spark plug(s). 2. Spark plug wire(s) disconnected. 3. Fill tank with clean, fresh gasoline. 3. Fuel tank empty or stale fuel. 4.
Page 29 Problem Cause Remedy Engine overheats 1. Engine oil level low. 1. Fill crankcase with proper oil. 2. Air flow restricted. 2. Clean grass clippings and debris from around the engine’s cooling fins and blower housing. Engine hesitates at 1. Spark plug(s) gap too close. 1.
Page 30 Model 60TG �� ...
Page 31: Parts List
Ref. Part No. Description Ref. Part No. Description 710-1268† Screw, #10-16 x.375 783-0677B Adjust. Brkt., Lift 712-04063 Nut, Flange Lock, 5/16-18, GrF 783-1489B Mounting Bracket, Seat 712-3027† Nut, Flange Lock, 1/4-20 710-0227 Screw, #8-18 x.50 Illustrated 720-0309A† Seat Adjuster Grip 726-0279 Plate, Insulator 726-0201†...
Page 32 Model 60TG �� ...
Page 33 Ref. Part No. Description 710-04095 Hex Screw, 3/8-16, 1.00, Gr5 710-0514 Hex Screw, 3/8-16, 1.00, Gr5 710-0643 Hex Screw, 5/16-18, 1.00, Gr5 Illustrated 711-1408 Link, Drag, RH 711-1409A Link, Drag, LH Parts List 712-0214 Nut, Hex Lock, 3/8-24 712-04065 Nut, Flange Lock, 3/8-16, Grf 712-0459 Nut, Flange Lock, 7/16-20 712-3004A Nut, Flange Lock, 5/16-18, Gr5...
Page 34 Model 60TG �� ...
Page 35 Ref. Part No. Description Ref. Part No. Description 710-0726 Screw, 5/16-12 x.750 731-1857 Throttle Control Knob 710-0599 Self-tapping Screw, 1/4-20 x.5 731-05001A Dash Panel 783-04829 Side Panel - LH 731-04729 Cruise Control Button Illustrated 746-1084 Throttle Control/Cable 731-04728 Parking Brake Button 731-1999 Choke Plug 747-04161...
Page 36 Model 60TG �� ...
Page 37 Ref. Part No. Description Ref. Part No. Description 17840 Mounting Bracket, Transaxle 783-04360 Bracket, Shift, F-N-R 725-04039 Switch, Interlock 783-04442 Idler Bracket, Center Double 17962 Plate, Switch 647-0031B Control Assembly, Brake Illustrated 647-04020 Lever Assembly, Shift 647-0032A Control Assembly, Speed 710-0607 Screw, 5/16-18, 0.500 683-0266...
Page 38 Model 60TG Ref. Part No. Description 656-04015 Pulley Ass’y, Variable Speed 683-04129 Bracket, Pulley Illustrated 710-0627 Screw, 5/16-24,.750 Parts List 710-1652 Screw, 1/4-20,.625 718-04012 Cup, Bearing 736-0362 Washer, Flat 741-0600 Ball Bearing 783-04722 Switch Bracket, Parking Brake 736-0242 Washer, Bell,.340 x.872 x.060 712-04065 Nut, Flange Lock, 3/8-16, GrF 710-0599...
Page 39 �� Illustrated �� Parts List �� To order replacement � parts, call the Customer Service Line at 1-800-648-6776, or visit �� www.troybilt.com. �� ...
Page 40 Model 60TG �� ...
Page 41 Ref. Part No. Description Ref. Part No. Description 17962 Plate, Switch 756-04196 Pulley, Engine, 3.39 x 6.12 Dia. 647-04036 Lever Assembly, Engagement 783-0744A Stop Bracket, Engagement 710-0778 Screw, 1/4-20 x 1.500 683-04173 Frame Assembly, Lower Illustrated 710-0859 Screw, 3/8-16, 2.50 710-0607 Screw, 5/16-18, 0.500 710-0276...
Page 42 Model 60TG � � � � � � � � � � �� ...
Page 43 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 44 Model 60TG �� ...
Page 45 Ref. Part No. Description Ref. Part No. Description 618-0624 Spindle Assembly, Pul, 6.23” Dia 736-0300 Washer, Flat, .406 x .875 x .059 683-04138A Brake Assembly, Deck 736-0760 Washer, Lock 683-04261 Deck Shell, 42” 737-04003C Deck Water Nozzle Illustrated 683-04167 Brake Assembly, Deck 738-04166 Spacer, Shoulder, .5000 x .1475 683-0254B...
Page 46 NOTES: Use this page to make notes and write down important information.
Page 47 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 48 MANUFACTURER’S LIMITED WARRANTY FOR The limited warranty set forth below is given by Troy-Bilt LLC with respect Troy-Bilt does not extend any warranty for products sold or to new merchandise purchased and used in the United States, its posses- exported outside of the United States, its possessions and sions and territories.

Troy-Bilt Super Bronco 60TG Operator's Manual

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