Troy-Bilt J609 Operator's Manual
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Troy-Bilt J609 Operator's Manual

Auto drive lawn tractors
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Operator's Manual
Auto Drive Lawn Tractors
Super Bronco™
Bronco™
(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. 770-10490D.fm
(4/2004)

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  • 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.

  • Page 2: Table Of Contents

    This information will be necessary to use the manufacturer’s web site and/or help from the Customer Support Department or an authorized service dealer. Copy the model number here: Copy the serial number here: TROY-BILT LLC P. O. BOX 3 6 1 1 3 1 www.troybilt.com CLEVELAND, OH 44136...

  • Page 3: Important Safe Operation Practices

    SECTION 1: 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 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. or trailer bed with a plastic liner. Always place Check brake operation frequently as it is subjected to containers on the ground away from your vehicle wear during normal operation.
  • Page 6 SECTION 2: SLOPE GAUGE...

  • Page 7: Tractor Set-Up

    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 Wheel Cap stated. Attaching The Steering Wheel Hex Bolt & Washer • The hardware for attaching the steering wheel has been packed within the steering wheel, beneath steering wheel cap.

  • Page 8: Operation

    SECTION 4: OPERATION Know the Controls 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.
  • Page 9 Throttle Control Lever Choke The throttle control lever controls the speed of the engine. When set in a (Model only) given position, the throttle will maintain a uniform engine speed. Fast Choke Control Bronco: Moving the throttle lever all the way forward activates the engine’s choke control.
  • 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: Safety Interlock Switches

    AVOID SERIOUS INJURY OR DEATH and the PTO lever is in the “Blades Stop” position. If this system should ever malfunction, do not operate the tractor, immediately contact a Troy-Bilt dealer. • GO UP AND DOWN SLOPES, NOT ACROSS. • AVOID SUDDEN TURNS.

  • Page 12: Starting The Engine

    Starting the Engine NOTE: Refer to the TRACTOR SET-UP on page 7 manual for gasoline and oil fill-up instructions. IMPORTANT 1. Insert the tractor key into the ignition switch. 2. Place the PTO (Blade Engage) Lever in the disengaged (Blade Stop) position. 3.

  • Page 13: Making Adjustments

    • 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: Leveling The Deck

    Steering Hex Nut and Grease Fitting Pivot Bar Lock Washer • 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.

  • Page 15: Maintenance

    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: 1. 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 Pivot Points & Linkage • Lubricate all pivot points on the drive system, parking brake and lift linkage at least once a season with light oil. Rear Wheels • 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 Front Wheels •...

  • Page 17: Service

    5. Thread hose coupler (packaged with this manual) onto the end of your garden hose. See Figure 12. 6. Attach the hose coupler to the water port on your decks surface. See Figure 12. Turn the water on. 7. While sitting in the operator’s position, re-start the engine and place throttle lever in FAST (rabbit) position.

  • Page 18: Cutting Deck Removal

    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: Cutting Blades

    7. Repeat the above steps on the right side of the tractor. 8. Using a pair of needle nose pliers, pull out the cotter pin holding the deck cable. This will disconnect the cable. 9. Move the deck lift lever into the top notch on the right fender to raise the deck lift arms out of the way. 10.
  • Page 20 2. Grasp the bracket and pivot the transmission idler successfully complete it. Otherwise, see your pulley toward the rear of the tractor to release Troy-Bilt dealer . tension on the upper drive belt. 3. Remove the belt from around the transmission idler pulley.
  • Page 21 Battery Tray Variable-Speed Drive belt (Lower) Shift Lever Opening Pulley Rear Idler Pulley Drive belt (Upper) Belt Keeper Front Idler Pulley Idler Bracket Keeper Pins to drive pedal Double-Idler Bracket Engine Pulley Transmission Idler Pulley Single-Speed Transmission Pulley Transmission Front of Tractor NOTE: View shown from above tractor.

  • Page 22: Off-Season Storage

    NOTE: Recharge the battery before returning it to service after storage. Even if the tractors starts, the engine charging system may not bring the battery upto a full charge, unless it is recharged. Attachments & Accessories The following attachments and accessories are available for your lawn tractor. See your local Troy-Bilt dealer for price and availability. MODEL...

  • Page 23: Troubleshooting

    SECTION 9: TROUBLESHOOTING Trouble Possible Cause(s) Corrective Action Engine fails to start PTO lever engaged. Place PTO lever 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.

  • Page 24: Illustrated Parts List

    SECTION 10: PARTS LIST FOR MODELS J609 & 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...
  • Page 25 Models J609 & T609 Ref. 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...
  • Page 26 Models J609 & 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 Models J609 & T609 Ref. Part Description Ref. Part Description 747-1130B Deck Stabilizer Rod 783-0720A Deck Stabilizer Bracket 683-0197B Lift Shaft Assembly 710-0260A Carriage Bolt, 5/16 x .62 711-0332 Clevis Pin, .5 x .78 710-0604A Self-tapping Screw, 5/16-18 x .625...
  • Page 28 Models J609 & 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 Models J609 & T609 Ref. Part Ref. Part Description Description 710-1260A Self-tapping Screw, 5/16-18 x .75 638-0019A LH Axle Assembly, (Model LTX-1842) 710-0604A Self-tapping Screw, 16-18 x .625 638-0021 LH Axle Assembly(Model LTX-2146) 783-0726B RH Pivot Support Bracket 638-0020A RH Axle Assembly (Model LTX-1842)
  • Page 30 Models J609 & 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 Models J609 & T609 Ref. Part Ref. Part Description Description 17840 Mounting Bracket 710-1611B TT Screw 5/16-18 x 0.75 618-04133 Drive Assembly 711-04159 618-04147 Variable Spd. Pulley Assembly 712-0130 Hex Lock Nut 3/8-16 647-04020 Shift Lever Assembly 712-3004A Flange Lock Nut 710-0607 TT Screw 5/16-18 x 0.5...
  • Page 32 Models J609 & T609...
  • Page 33 Models J609 & T609 Ref. Part Description 732-0614 Ring, Wire 716-0231 Ring, E Type, .750 736-0336 Flat Washer, 5/8 x 1.0 x .030* 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...
  • Page 34 Models J609 & 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 35 Lock Washer, 1/4 712-3010 Hex Nut, 5/16-18 683-0304C Lower Frame Assembly 714-0470 Cotter Pin, 1/8 x 1.25 725-1737A 12-volt Battery, 190 CCA (Model J609) 726-0201 Speed Nut, .3125 731-2111A PTO Knob 725-1706A 12-volt Battery, 270 CCA (Model T609) 710-0751 Hex Cap Screw, 1/4-20 x .62 732-1170 Extension Spring, .75 x 6.75...
  • Page 36 Models J609 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 T 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...
  • Page 37 Models J609 & T609 SYSTEMS INDICATOR MONITOR YEL/WHT ORG/BLK...
  • Page 38 Models J609 & 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 39 Models J609 & T609 Ref. Part No. Description Ref. Part No. Description 711-04069 Grass Catcher Pin, 1/4-20 736-0162 Flat Washer, .64 x 1.0 x .12 618-0565 Spindle Assy., 5.75 Dia. w/ Fitting 736-0270 Bell Washer, .265 x .75 x .062 738-0373 Shoulder Screw, .498 x 1.53...

  • Page 40: Warranty

    MANUFACTURER’S LIMITED WARRANTY FOR: The limited warranty set forth below is given by Troy-Bilt LLC d. Troy-Bilt does not extend any warranty for products sold with respect to new merchandise purchased and used in the or exported outside of the United States, its possessions United States, its possessions and territories.

This manual is also suitable for:

T609Super bronco

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