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Bolens 420 Tiller User Manual

1. REF PART REF PART NO NO DESCRIPTION NO NO DESCRIPTION 1 1683 0195 Bracket Assembly 29 712 3004A Flange Lock Nut 5 16 18 2 1710 0528 Hex Cap Screw 5 16 18 x 1 25 30 712 3027 Hex Flange Lock Nut 1 4 20 3 1710 0599 Self tapping Screw 1 4 20 x 5 31 731 1857 Throttle Control Rnob 4 710 0751 Hex Cap Screw 1 4 20 x 62 32 731 2122 Dash Panel 5 1710 0895 Self tapping Screw 1 4 15 x 75 33 731 2227 Parking Brake Button 6 1710 0896 Screw 1 4 15 x 75 34 731 2228 Plastic Plug 7 710 0924 Phillips Pan Screw 1 4 20 x 75 35 736 3078 Flat Washer 349 x 1 0 x 063 8 1712 0271 Hex Sems Nut 1 4 20 36 747 1196 Pivot Rod 9 1712 0292 U type Speed Nut 1 4 20 37 749 1087 Dash Support Tube 10 1712 0431 Flange Lock Nut 3 8 16 38 751 0659 Two gallon Fuel Tank shown 11 726 0211 U nut 5 16 18 751 0658 Three gallon Fuel Tank 12 1726 0293 Retainer Nut 3 8 39 751 0603 Fuel Cap Fits Either Tank 13 731 1854 Headlight Lens 40 1710 1268 Screw 10 16 x 375 14 731 2300 Hood 7 style Red 41 783 0478A Hood 8 style 731 2301 Hood 7 style Green 42 783 0551A Hood Hinge Bracket 8 style 731 2302 Hood 7 style Black 43 783 0553A Hood Support Bracket 8 style 731 2303 Hood 7 style Charcoal Grey 44 1731 2247 Heat Shieldt 15 731 2306 Hood Plenum 7 style Units w B amp S OHV Twin 16 735 0126 Rubber Washer 87 x 33 731 2248 Heat Shieldt 17 736 0105 Bell Washer 401 x 87 x 063 Units w B amp S Opposed Twin 18 783 0475 LH Side Panel 45 747
2. 31 Models 607 608 amp 60 32 Steering Assembly REF PART REF PART NO NO DESCRIPTION NO NO DESCRIPTION 1 683 0304 Lower Frame Assembly 28 712 0431 Flange Lock Nut 3 8 16 2 710 0604A Self tapping Screw 16 18 x 625 29 1714 0470 Cotter Pin 3 783 0726A RH Pivot Support Bracket 30 726 0214 Push Cap 625 4 783 0727 LH Pivot Support Bracket 726 0341 Push Cap 750 5 1783 0728 Pivot Bar Bracket 31 736 0162 Flat Washer 64 x 1 0 x 12 6 1710 0514 Hex Cap Screw 3 8 16 x 1 Grade 5 32 1736 0187 Flat Washer 64 x 1 24 x 06 7 711 1409A LH Drag Link 736 0316 Flat Washer 78 x 1 59 x 06 8 1711 1408 RH Drag Link 33 736 0285 Flat Washer 635 x 1 589 x 06 9 712 0240 Jam Nut 7 16 20 Grade 2 34 1738 1011 Shoulder Screw 5 x 2 2 3 8 16 10 712 0241 Hex Nut 3 8 24 Grade 2 35 1741 0659 Flange Bearing 632 ID x 937 OD 11 1712 0431 Flange Lock Nut 3 8 16 741 0660 Flange Bearing 760 ID x 937 OD 12 1712 0459 Flange Lock Nut 7 16 20 36 634 0105A Wheel Assembly Complete 13 712 3004A Flange Lock Nut 5 16 18 15 x 6 x 6 Square Shoulder 14 717 1550A Steering Gear 11 90 Ratio 634 0056A Wheel Assembly Complete 15 1717 1554 Steering Pinion Gear 15 x 6 x 6 Round Shoulder 16 723 0448A Ball Joint 7 16 20 634 0172 Rim Only 17 1736 0169 Lock Washer 3 8 734 0255 Air Valve Not Shown 18 1736 3084 Flat Washer 51 x 1 12 x 06 734 1731 Tire Only Square Shoulder 19 738 1001A Steering Shaft 625 OD x 24 4 734 0
3. To change or replace the deck belt s on your tractor proceed as follows NOTE Removing the deck from the tractor as instructed earlier in this section will ease the following steps but is not necessary 42 inch decks Lower the deck by moving the lift lever into the bottom notch on the right fender Remove the belt guards by removing the self tapping screws that fasten them to the deck surface Move the PTO lever into the disengaged OFF position to relieve tension on the belt Remove the PTO belt from around the bottom portion of the engine pulley and from around the two idler pulleys found on the PTO engagement plate See Figure 14 Route the new belt as shown in Figure 14 around the deck pulleys idler pulleys and engine pulley OEM belt part numbers are listed in the table on the following page e Remount the belt guards removed earlier Engine Pulley Belt Guard mounted on tractor P ll Pro bet T 2 Deck Stop mounted on tractor PTO Engagement Plate Idler Pulleys y mounted on tractor Right Hand Pull a ig nd Pulley A RP Left Hand Pulley NOTE Belt covers not shown for clarity Figure 14 46 inch decks Lower the deck by moving the lift lever into the bottom notch on the right fender Remove the belt guards by removing the self tapping screws that fasten them to the deck surface Move the PTO lever into the disengaged OFF positio
4. To reduce fire hazard keep the machine free of grass leaves or other debris build up Clean up oil or fuel spillage Allow machine to cool at least 5 minutes before storing Before cleaning repairing or inspecting make certain the blade and all moving parts have stopped Disconnect the spark plug wire and keep the wire away from the spark plug to prevent accidental starting Check the blade and engine mounting bolts at frequent intervals for proper tightness Also visually inspect blade for damage e g excessive wear bent cracked Replace with blade which meets original equipment specifications Keep all nuts bolts and screws tight to be sure the equipment is in safe working condition Never tamper with safety devices Check their proper operation regularly Use all guards as instructed in this manual After striking a foreign object stop the engine remove the wire from the spark plug and thoroughly inspect the mower for any damage Repair the damage before restarting and operating the mower Grass catcher components are subject to wear damage and deterioration which could expose moving parts or allow objects to be thrown For your safety protection frequently check components and replace with manufacturer s recommended parts when necessary e Mower blades are sharp and can cut Wrap the blade s or wear gloves and use extra caution when servicing blade s e Check brake operation frequently Adjus
5. Deck Stabilizer Bracket NOTE On units equipped with a 46 inch deck the bottommost belt on the deck does NOT need to be removed in order to remove the deck Looking at the cutting deck from the right side of the tractor locate the deck support pin on the rear right side of the deck Pull the deck support pin outward to release the deck from the deck lift arm See Figure 13 Rotate the pin slightly toward the rear of the tractor and release the pin into the hole provided Repeat the above steps on the left side of the tractor Move the lift lever into the top notch on the right fender to raise the deck lift arms out of the way Carefully move the cutting deck toward the front of the tractor allowing the hooks on the deck to release themselves from the deck stabilizer rod Do NOT let the deck fall to the ground Gently slide the cutting deck from the right side out from underneath the tractor NOTE To properly remount the cutting deck perform the above steps in reverse order Having a second person assist you will ease this procedure 17 CHANGING THE DECR BELT S All belts on your tractor are subject to wear and should be replaced if any signs of cracking shredding or rotting are present IMPORTANT The V belts found on your tractor are specially designed to engage and disengage safely A substitute non OEM V belt can be dangerous by not disengaging completely For a proper working machine use factory approved belts
6. REMOVE OBJECTS THAT COULD BE THROWN BY THE BLADE S KNOW LOCATION AND FUNCTION OF ALL CONTROLS BE SURE BLADE S AND ENGINE ARE STOPPED BEFORE PLAC ING HANDS OR FEET NEAR BLADE S BEFORE LEAVING OPERATOR S POSITION DISENGAGE BLADE S PLACE THE SHIFT LEVER IN NEUTRAL ENGAGE BRAKE LOCK SHUT ENGINE OFF AND REMOVE KEY READ OPERATOR S MANUAL 11 SETTING THE CUTTING HEIGHT Select the height position of the cutting deck by placing the deck lift lever in any of the six different cutting height notches on the right side of the fender Then adjust the deck wheels so that they are at least 1 4 inch to 1 2 inch above the ground when the tractor is on a smooth flat surface such as a driveway A NOTE The deck wheels are an anti scalp feature of the deck and are not designed to support the weight of the cutting deck Refer to the ADJUSTMENTS section of this manual for more detailed instructions regarding various deck adjustments WARNING Keep hands and feet away from the discharge chute opening of the cutting deck STARTING THE ENGINE NOTE Refer to the TRACTOR SET UP section of this manual for gasoline and oil fill up instructions Insert the tractor key into the ignition switch Place the PTO lever in the disengaged OFF position Depress the brake pedal and set the parking brake Place the shift lever in the NEUTRAL position Move the throttle control lever into the FAST or CHOKE if so equipped positio
7. see an authorized MTD service dealer to have the belt changed IMPORTANT Note the routing of the lower drive belt around both the pulleys and the belt keepers BEFORE performing the following steps Locate the variable speed pulley by looking through the battery tray opening See Figure 16 Remove the variable speed pulley by loosening the hex bolt that secures it to the transmission Use a second wrench to hold the hex nut on the bottom side of the pulley Slide the belt off of the variable speed pulley as you lift the pulley up and out through the battery tray opening Battery Tra I 7 Opening Shift Lever Drive belt Lower Idler Pull Rex e EB Drive belt Upper Variable ao pulley Engine Pulley Single esas Transmission NOTE View shown from above tractor M Transmission Pulley Front of Tractor Figure 16 Remove the hex bolt from the center of the Reassemble by following the above steps in engine pulley See Figure 17 reverse order Lower the engine pulley far enough to be able Reroute the new belt around the pulleys to remove the upper drive belt from around it keeper pins and belt keepers EXACTLY as the old one was routed Refer to Figure 16 IMPORTANT When remounting the engine The drive pedal is properly adjusted when the hole pulley torque the c
8. Brake 8 1725 1741 Ignition Switch 9 725 1742 Systems Indicator Monitor 10 725 1745 Ignition Key w plastic cover 725 1744 Ignition Key w o plastic cover 11 1725 1747 Safety Plunger Switch Seat 12 725 3007A Positive Terminal Cover Boot 13 736 0329 Lock Washer 1 4 14 1629 0309 Headlight Harness 15 729 0357 Fuse Holder 16 1725 1381 20 amp Fuse 24 Electrical System 10 nndud NE W Old Old VE Dyed wists is O O TI Wwe Mu BH t wee Nu AI wig 30 HL SOLMS KN ed r g NS 3883138 il 0 0 SND TH 4 9 TE iis HLL GIONTIOS Vio Sal 3405534410 HOLIMS vag II o i s Bo xl WOLYNEALTY JAWA LU XVI 03d E UND E VN V Gi IONS zu ES Eb ld e dd MOTE qu ai ag OLIN Wo aN ua 28 iH y Houle m NOYTERONYHO EE Se 3LIHMGONYUO YIVO ae PN bol FOND El vna m HOUNS Old es ET o S 3 Me Y INNO RS E US PETI g 90119 HOLMS LYS T DEDNO 4149 SLHONGVSH 25 Models 607 amp 608 26 Tractor Body
9. Brake Rod 80 783 0805A RH Belt Cover 40 748 0324 Shoulder Spacer 81 753 0872 46 inch Deck Assembly Complete 41 783 1026 RH Belt Guard Bracket Manual PTO activated w o mulch kit 42 783 1027 LH Belt Guard Bracket 82 1753 0871 42 inch Deck Assembly Complete 43 731 1643A Mulch Plug 42 inch Decks Manual PTO activated w o mulch kit if so equipped 41 Models 607 608 amp 609 4 for throttle 12 Briggs amp Stratton OHV V Twin qx s 5 13 aye uet ru face forward 14 deflector must Briggs amp Stratton OHV Single deflector must face forward 14 42 Briggs amp Stratton Engine Accessories Opposed Twin 42 n 43 35 b Bed rera for choke 7 ao o gu ee 6 P pere 1 di REF PART REF PART NO NO DESCRIPTION NO NO DESCRIPTION 1 710 0148 Self tapping Screw 48 32 x 375 23 710 3206A Hex Cap Screw M8 1 25 x 25 2 1710 0599 Self tapping Screw 1 4 20 x 5 24 712 3086 Flange Nut M8 1 25 3 1710 0604A Self tapping Screw 5 16 18 x 625 25 725 0157 Cable Tie 4 710 1237 Screw 10 32 x 625 26 1736 0607 External Lock Washer 5 16 5 710 1314 Socket Cap Screw 5 16 18 x 625 27 751 0617 Muffler Single Inlet 6 1710 1315 Self tapping Screw 3 8 16 x 1 25 28 712 0271 Hex Sems Nut 1 4 20 for starter cable 7 712 3017 Hex Nut 3 8 16 29 721 0208 Exhaust Gasket OHV Single 8 1721 0460 Exhaus
10. Nut 1 2 13 8 1714 0104 Internal Cotter Pin 9 714 0111 Cotter Pin 10 1716 0106 E ring 11 720 0311 Handle Grip 12 732 0874 Torsion Spring 13 1732 0934 Lift assist Spring 1 15 x 5 99 Found on Units w 46 inch Deck Only 14 1736 0275 Flat Washer 5 16 15 736 0921 Lock Washer 1 2 16 736 3019 Flat Washer 31 x 1 062 x 134 17 736 3084 Flat Washer 51 x 1 12 x 06 18 738 0138 Hex Cap Screw 5 16 18 x 62 19 738 0380 Shoulder Screw 5 x 27 3 8 16 20 741 0225 Hex Flange Bearing 21 741 0715 Snap Flange Bearing 22 746 0968 Lift Cable 16 16 23 1747 1111 Lift Handle 24 756 1154 Roller Pulley 25 783 0678 Arm Lift 26 783 0720A Deck Stabilizer Bracket 27 710 0260 Carriage Bolt 5 16 18 x 62 28 710 0604A SSelf tapping Screw 5 16 18 x 625 29 710 0895 Self tapping Screw 1 4 15 x 75 30 783 0740 Seat Pivot Bracket 31 726 3046 Foot Pad Clips 32 738 0155 Shoulder Screw 437 x 1 62 33 783 1010 Lift Adjustment Bracket 34 783 0839 Fender 35 783 0715 Seat Mounting Bracket 36 710 0870 Hex Washer Head Screw 3 8 16 x 625 37 757 0360A Seat Medium Back 757 0348A Seat High Back if so equipped 757 0350 Seat High Back w Drain Holes if so equipped 38 723 0483 LH Abrasive Foot Pad 39 723 0484 RH Abrasive Foot Pad 40 735 0657 LH Rubber Foot Pad if so equipped 41 735 0656 RH Rubber Foot Pad if so equipped 42 710 1611 Self tapping Screw 5 16 18 x 75 43 1710 0260 Hex Cap Screw 5 16 18 x 62 44 731 0511 5 Trim Strip 1 5
11. area The safety interlock system prevents the engine from cranking or starting unless the brake pedal is fully depressed and the PTO lever is in the disengaged OFF position The safety interlock system will automatically shut off the engine if the operator leaves the seat before engaging the brake lock The safety interlock system will automatically shut off the engine if the operator leaves the seat with the PTO lever in the engaged ON position regardless of whether the brake lock is engaged The PTO lever must be in the disengaged OFF position to restart the engine The safety interlock system will automatically shut off the engine if the PTO lever is moved into the engaged ON position with the shift lever in the REVERSE position WARNING Do NOT attempt to bypass A or disconnect the tractor s safety interlock Doing so could result in serious personal injury or death IMPORTANT Tampering with or attempting to bypass the tractors Safety Interlock Switches in any way WILL void your warranty A WARNING AVOID SERIOUS INJURY OR DEATH GO UP AND DOWN SLOPES NOT ACROSS AVOID SUDDEN TURNS DO NOT OPERATE THE UNIT WHERE IT COULD SLIP OR TIP IF MACHINE STOPS GOING UPHILL STOP BLADE S AND BACK DOWNHILL SLOWLY DO NOT MOW WHEN CHILDREN OR OTHERS ARE AROUND NEVER CARRY CHILDREN LOOK DOWN AND BEHIND BEFORE AND WHILE BACKING KEEP SAFETY DEVICES GUARDS SHIELDS AND SWITCHES IN PLACE AND WORKING
12. area please check for a listing in the Yellow Pages or contact the Customer Service Department of MTD PROD UCTS INC by calling 1 800 800 7310 or writing to P O Box 368022 Cleveland Ohio 44136 9722 This limited warranty does not provide coverage in the following cases a The engine or component parts thereof These items carry a separate manufacturer s warranty Please refer to the applicable manufacturers warranty on these items b Log splitter pumps valves and cylinders have a sepa rate one year warranty c Routine maintenance items such as lubricants filters blade sharpening and tune ups or adjustments such as brake adjustments clutch adjustments or deck adjustments and normal deterioration of the exterior finish due to use or exposure d MTD does not extend any warranty for products sold or exported outside of the United States of America its possessions and territories except those sold through MTD s authorized channels of export distribu tion No implied warranty including any implied warranty of merchantability or fitness for a particular purpose applies after the applicable period of express written warranty above as to the parts as identified No other express warranty or guaranty whether written or oral except as mentioned above given by any person or entity including a dealer or retailer with respect to any product shall bind MTD During the period of the War ranty the exclusive remedy is repair or
13. engine and disconnect the spark plug wire s and ground against the engine before performing any maintenance ENGINE Lubricate the engine with motor oil as instructed in the separate engine manual packed with your unit LINKAGE Lubricate all the pivot points on the drive brake and lift linkage at least once a season with SAE 30 engine oil 22 IMPORTANT f removing the battery for any reason disconnect the NEGATIVE Black wire from it s terminal first followed by the POSITIVE Red wire When re installing the battery always connect the POSITIVE Red wire its terminal first followed by the NEGATIVE Black wire Be certain that the wires are connected to the correct terminals reversing them could change the polarity and cause damage to your engine s alternating system Charging If the unit has not been put into use for an extended period of time charge the battery with an automotive type 12 volt charger for a minimum of one hour at six amps WARNING Batteries give off an explosive gas during and for some time after charging Charge battery in a well ventilated area and do not allow a spark or an open flame near the battery FUSE A fuse is installed in your tractor s wiring harness to protect the tractor s electrical system from damage caused by excessive amperage Always use the same capacity fuse for replacement If the electrical system does not function or your tractor s engine will not crank firs
14. it may be necessary to go back over the cut area a second time to get a clean cut Do NOT attempt to mow heavy brush and weeds and extremely tall grass Your tractor is designed to mow lawns NOT clear brush Keep the blades sharp and replace the blades when worn Refer to the MAINTENANCE section of this manual for proper blade sharpening instructions WARNING Turn the tractors engine off remove the key from the ignition switch and apply the tractor s parking brake before making any adjustments to the cutting deck With the tractor parked on a firm level surface place the lift lever in the top notch highest position and rotate the blade nearest the discharge chute so that it is parallel with the tractor Measure the distance from the front of the blade tip to the ground and from 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 e Determine the approximate distance e Locate the two lock nuts on the opposite side necessary for proper adjustment and proceed of the stabilizer bracket See Figure 7A if necessary to the next step Tighten the lock nuts to raise the front of the Loosen the two jam nuts on the rear side of deck loosen the lock nuts to lower the front of the deck the deck stabilizer bracket See Figure 7A e Retighten the two jam nuts loosened earlier when proper adjustment is achieved Side to Side If the cutting d
15. overfill WARNING Overfilling with oil may cause the engine to smoke This will result in poor engine performance and could cause permanent engine damage gt The gasoline tank is located under the hood and has a capacity of approximately two gallons Do not overfill WARNING Never fill fuel tank indoors gasoline produces noxious fumes Always fill the fuel tank in a well ventilated area to avoid inhalation of gasoline fumes WARNING Never fill the fuel tank while engine is running or while engine is hot WARNING Never smoke while fueling your tractor Gasoline produces combusti ble fumes which can ignite and cause per sonal injury WARNING Do not fill closer than 1 2 inch from the top of the fuel tank to prevent spills and to allow for fuel expansion If gasoline is accidently spilled move tractor away from area of spill Avoid creating any source of ignition until gasoline vapors have disappeared PPP P SECTION 7 CONTROLS D B F C A 2 CAGA A om S SC 7 RES L A A w E CIA a CIA O g T ASISTAN YO CE E Raus O D A N y Sa EE H SIS a i G wee E J 5 L il NOTE Steering Wheel not shown for clarity Figure 3 A Ignition Switch F PTO
16. should measure a positive charge LIFT LEVER S A The lift lever is used to change the operating position height of the cutting deck To operate move the lever to the left then place in the notch best suited for your application PTO POWER TAKE OFF LEVER em ore W The PTO lever is located on the left side of the dash next to the steering wheel Move the PTO lever forward to engage the power to the cutting deck or other attachments move the PTO lever backward toward the rear of the tractor to disengage the power to the attachments a PTO NOTE The PTO lever must be in the disengaged OFF position when starting the engine when shifting into reverse and if the operator leaves the seat DRIVE PEDAL The drive pedal is located below the brake pedal on the right front side of the tractor along the running board Depress the drive pedal with your right foot when the tractor shift lever is in either forward or reverse to cause the tractor to move Ground speed is also controlled with the drive pedal The further down the pedal is depressed the faster the tractor will travel The pedal will return to its original position when it s not depressed IMPORTANT Always set the parking brake when leaving the tractor unattended 10 BRAKE PEDAL The brake pedal is located on the right front side of the trac
17. the tractor with the throttle lever in the FAST rabbit position CHOKE CONTROL On some units moving the throttle lever all the way forward activates the engine s choke control On all other units the choke control can be found on the left side of the dash panel and is activated by pulling the knob outward Activating the choke control closes the choke plate on the carburetor and aids in starting the engine Refer to STARTING THE ENGINE in the OPERATION section of this manual for detailed starting instructions SYSTEMS INDICATOR MONITOR Your tractor is equipped with an ammeter as part of its systems indicator monitor and is located on the left side of your tractor s dash panel See Figure 6 _ Oil Brake Ammeter PTO Figure 6 If the Brake light or PTO light illuminates when attempting to start the unit proceed as follows BRAKE Depress the brake pedal PTO Move PTO lever into the disengaged OFF position It is normal for the Oil light to illuminate while the engine is cranking but if it illuminates while the engine is running proceed as follows OlL Stop the tractor immediately and check the crankcase oil level as instructed in the seperate engine manual packed with your unit Add oil as required The ammeter measures the the electrical output of the engine s charging system Under normal operating conditions with the engine running at full throttle the ammeter s needle
18. 1184 Heat Shield Support Rod 19 783 0476A RH Side Panel 46 1726 3046 Ratchet Clip 20 1783 0477 Grille 47 1746 1085 Choke Cable Knob t 21 783 1034 Hood Bracket 7 style Units w B amp S Opposed Twin 22 1783 1038 Hood Side Bracket 7 style OEM 190 603 Grille Guard Bumper Kit Not Shown 23 1710 0106 Hex Cap Screw 1 4 20 x 1 25 if so equipped 24 710 0604A Self tapping Screw 5 16 18 x 625 AF 47442 Bumper Assembly 25 710 1017 Truss Phillips Screw 1 4 20 x 625 AF 44056 Clevis Pin 5 x 1 26 710 1238 Hex Washer Screw 5 16 18 x 625 AF 43055 Internal Cotter Pin 27 710 3217 Truss Phillips Screw 48 32 x 375 AF 44742 Plastic Plug 28 1712 0142 Hex Nut 48 32 T Tractors with a B amp S Single cylinder I C or OHV engine have NO choke knob cable The choke is activated with the throttle control Tractors with a B amp S Single cylinder I C or OHV engine have NO heat shield 27 Model 609 28 Tractor Body PART NO DESCRIPTION 710 0604A Self tapping Screw 5 16 18 x 625 710 0788 Self tapping Screw 1 4 20 x 1 0 710 0895 Self tapping Screw 1 4 15 x 75 710 1017 Torx Self tapping Screw 5 16 18 x 625 710 1238 Screw 5 16 18 x 875 Grade 5 710 3217 Torx Screw 48 32 x 375 712 0142 Hex Nut 8 32 731 0511 5 Five inch Trim Strip 731 1857 Throttle Control Lever 731 2122 Dash Panel 731 2228 Plastic Plug 731 2227 Parking Brake Button 736 0119 Lock Washer 5 16 736 0142 Flat Was
19. 36 SECTION 3 CALLING CUSTOMER SUPPORT e LOCATE YOUR MODEL NUMBER AND SERIAL NUMBER Record this information in the space provided To find your unit s specific model number and serial number see SECTION 2 FINDING YOUR MODEL NUMBER e If you are having difficulty assembling this product or if you have any questions regarding the controls operation or maintenance of this unit please call the Customer Support Department Customer Support can be reached by dialing 1 330 220 4MTD 4683 or 1 800 800 7310 Please have your model number and serial number ready when you call Although both numbers are important you will be asked to enter only your serial number before your call can be processed SECTION 4 IMPORTANT SAFE OPERATION PRACTICES A A A 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 YOUR LAWN MOWER FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY WHEN YOU SEE THIS SYMBOL HEED ITS WARNING WARNING The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm DANGER Your lawn mower was built to be operated according to the rules for safe operation in this manual As with any type of power equipment car
20. 372 Shoulder Spacer 38 ID 734 1730 Tire Only 20 x 8 x 8 Square Shoulder 45 754 0467 Variable speed Belt 734 1596 Tire Only 20 x 8 x 8 Round Shoulder 46 1754 0468 Drive Belt 83 750 0556 Spacer IMPORTANT The V belts found on your tractor are specially designed to engage and disengage safely A substitute non OEM V belt can be dangerous by not disengaging completely For a proper working machine use factory approved belts 35 Oo N co 1 e 6 00 86 gt IAS AVE AR 4 40 eo 21 Units with 618 0307C Transmission ONLY Models 607 608 amp 609 36 Single speed Transmission REF PART NO NO DESCRIPTION 1 1618 0318 Clutch Collart 2 1710 0788 Self tapping Screw 1 4 20 x 1 0 3 1711 1274 Drive Shaft 4 1711 1280 Counter Shaft 5 1713 0474 22 link Chain 420 6 713 0478 14 tooth Sprocket 7 717 1422 Sprocket Bevel Gear 42 10 8 1717 1565 29 tooth Spur Gear 9 1717 1569 20 tooth Spur Gear 10 718 0652 Counter Shaft Coupling 11 12a 12b 12c 18 14 15 16 17 719 0394 Lower Housing 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 0519 Flat Washer 70 x 1 125 x 031 741 0336 Flange Bearing 5 8 x 3 4 x 3 4 741 0337 Flange Bearing 5 8 x 3 4 x 15 16 750 1238 Spacer 635 x 1 0 x 27 611 0112 Detent Shaft AssemblyT 611 0133 Detent Shaft Assemblyt 18 618 0369 Di
21. 864 Tire Only Round Shoulder 20 741 0475 Plastic Bushing 38 ID 741 0487A Plastic Flange Not Shown 21 1741 0656 Hex Flange Bearing 5 8 741 0706 Plastic Flange w Fitting Not Shown 22 738 0372 Shoulder Spacer 38 ID 37 734 0484A Hub Cap 23 1631 0027 Steering Wheel 38 783 0653C Steering Support Bracket 731 1687 Steering Wheel MTD 39 1738 0143 Shoulder Screw 3 8 16 24 1731 0220 Steering Wheel Cap 40 1736 0331 Bell Washer 39 x 1 13 x 062 731 1459A Steering Wheel Cap w Icon 41 738 0140 Shoulder Screw 435 x 178 5 16 x 56 25 638 0019 LH Axle Assembly 625 Diameter 42 736 0242 Bell Washer 34 x 872 638 0021 LH Axle Assembly 625 750 Diameter 43 1710 0643 Hex Bolt 5 16 18 X 1 26 638 0020 RH Axle Assembly 625 Diameter 44 731 1649 End Cap 638 0022 RH Axle Assembly 625 750 Diameter 731 1291A End Cap w Fitting if so equipped 27 683 0128A Pivot Bar NOTE Units equipped with a 42 inch deck have axles with a 625 diameter Units equipped with a 46 inch deck have axles with a 625 750 diameter 33 Models 607 608 amp 609 Drive System REF PART REF PART NO NO DESCRIPTION NO NO DESCRIPTION 1 783 1015 Shift Lever Support 47 1756 0981 Flat Idler 2 75 OD 2 117840 Transaxle Mounting Bracket 48 783 0637 Shift Lever Support 3 1618 0307C Single speed Transmission Assembly 49 783 0667A Transmission Torque Brac
22. Labels found on your unit Slope Gauge USE THIS PAGE AS A GUIDE TO DETERMINE SLOPES VVHERE YOU MAY NOT OPERATE SAFELY L so EE AR SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE Lag A POWER POLE gg A CORNER OF A BUILDING I Lg OR A FENCE POST Al ove 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 If operating a walk behind mower on such a slope it is extremely difficult to maintain your footing and you could slip resulting in serious injury Operate RIDING mowers up and down slopes never across the face of slopes SECTION 5 ATTACHMENTS 8 ACCESSORIES MODEL NUMBER DESCRIPTION OEM 190 601 FastAttach Twin Bagger Grass Collector For 42 inch Decks Only OEM 190 602 FastAttach Twin Bagger Grass Collector For 46 inch Decks Only OEM 190 112 Mulch Kit For 42 inch Decks Only OEM 190 118 Mulch Kit For 46 inch Decks Only OEM 190 603 FastAttach Grille Guard mounts on front of tractor OEM 190 604 YardMate Storage Container mounts on rear of tractor OEM 190 822 FastAttach 46 inch Front Dozer Blade OEM 190 823 42 inch Two stage Snow Thrower NOTE Your tractor is NOT designed for use with any type of ground engaging attachments e g tiller plow Us
23. Pin 20 714 0104 Internal Cotter Pin 072 x 1 12 62 712 0271 Hex Sems Nut 1 4 20 21 714 0111 Cotter Pin 3 32 x 1 0 63 732 0429A Extension Spring 5 x 3 97 22 717 1553A Deck Adjustment Gear 64 732 0594A Extension Spring 91 x 7 33 23 710 0578 Screw 1 4 20 x 1 5 65 1738 0347 Shoulder Spacer 625 x 1 16 24 726 0233 Push Nut 25 x 5 66 738 0572 Shoulder Screw 374 x 1 16 25 731 1032B Side Discharge Chute Assembly 67 742 0611 Three in one Blade Star Center 16 28 26 731 2281A Belt Cover 68 742 0612 Three in one Blade Star Center 14 88 27 732 0306 Compression Spring 406 x 531 x 1 75 69 1746 1107 Bracket Cable 12 28 732 0428A Compression Spring 50 x 4 35 70 1750 0807 Spacer 385 x 625 x 70 29 734 0973 Deck Wheel 5 x 1 38 71 754 0349 Deck Belt 30 1736 0105 Bell Washer 401 x 87 x 063 72 1756 0627 Flat Idler Pulley 3 5 OD 31 1736 0119 Lock Washer 5 16 73 1783 0139 Idler Bracket 32 736 0270 Bell Washer 265 x 75 x 062 74 783 0141 Center Deck Skirt 33 1736 0275 Flat Washer 344 x 688 x 065 75 1783 0142 RH Deck Skirt 34 1736 0416 Flat Washer 320 x 3 0 x 125 76 1783 0747 LH Belt Cover 35 738 0373 Shoulder Screw 498 x 1 53 77 731 1636 Mulch Plug 46 inch Decks 36 1742 0616 Three in one Blade Star Center 21 23 if so equipped 37 1746 0970 Bracket Cable 5 35 78 712 0291 Hex Lock Nut 1 4 20 if so equipped 38 747 1116 Deck Release Pin 79 17116 Deck Brake Assembly 46 inch Decks 39 1747 1202 Deck
24. Power Take Off Lever B Throttle Control Lever G Drive Pedal C Choke Control if so equipped H Brake Pedal D Indicator Monitor Parking Brake Button E LiftLever J Shift Lever NOTE Any reference in this manual to the RIGHT or LEFT side of the tractor is observed from operator s position IGNITION SWITCH To start the engine insert key into the ignition switch and turn clockwise to the START position Release key to the ON position once engine has fired See Figure 4 Refer to STARTING THE ENGINE in the OPERATION section of this manual for detailed starting instructions The ignition switch is also used to operate the headlights Refer to OPERATING THE HEADLIGHTS in the OPERATION section of this manual for detailed instructions WARNING Remove the key from the tractor when the tractor is not in use to prevent accidental starting Off On Lights Start Figure 4 THROTTLE CONTROL LEVER The throttle lever is located on the right side of the tractor s dash panel This lever controls the speed of the engine and on some units the choke control also When set in a given position the throttle will maintain a uniform engine speed See Figure 5 Throttle Throttle Symbol Symbol Choke postion pocion e Fast dg Position En EH Eril EE mmm Le a Le Slow ES Slow d Position Position Figure 5 IMPORTANT When using PTO operated equipment such as the cutting deck or other attachments ALWAYS operate
25. ROLS cie Sok ras Ghee enna a EN EG hg RE UI E RR ce eR e Bad aan ciate ne RE ns 8 OPERATION oo db och fe Rabies eee il Gaye aaa ia a de IRE ep RE RE ERES 11 ADJUSTMENT Sy rreg tes a ea tata i cee a ahs sd RE ae Ries 13 MAINTENANGE 7 tpi rre treo POP td de eds ni b 16 LUBRICATION Louis is ee eet a arte ke DU VERE iiie PSC Tee de P ve 22 TROUBLESHOOTING GUIDE 2250202 nth ee lo EA edita ns Bed iur sas 23 PARES LIST 3 etuer ead i UR E ES RR EU Rete Sh Pint T ease pede abe 24 WARRANY INFORMATION ssssssse RR ll Back Cover SECTION 2 FINDING YOUR MODEL NUMBER This Operators Manual is an important part of your new rider It will help you assemble prepare and maintain your rider Please read and understand what it says Before you start to prepare your rider for its first use please locate the model plate and copy the information from it in this Operators Manual The information on the model plate is very important if you need help from your dealer or the MTD customer support department Every tractor has a model plate You can locate it by lifting the seat and looking at the seat bracket An example of what the model plate will look like is shown below This is where your model number will be XXX X XXX X XXX XXXXXXXXXXX This is where your serial number will be Copy the model number here MTD MTD PRODUCTS INC i P O BOX 368022 Copy the serial number here ForA Growing Wor CLEVELAND OHIO 441
26. T AWAY A DANGER KEEP HANDS AND FEET AWAY e DO NOT OPERATE MOWER UNLESS A THIS GUARD OR ENTIRE GRASS k CATCHER IS IN ITS PROPER PLACE ASSEMBLE CHUTE DEFLECTOR TO THIS UNIT BEFORE OPERATING 1426MW a A DANGER Bel SERIOUS INJURY OR DEATH EEP HANDS AND FEET AWAY FROM E ROTATING PARTS REMOVE OBJECTS THAT CAN BE THROWN BY THE LADE IN ANY DIRECTION WEAR SAFETY GLASSES r NOT MOW WHEN CHILDREN OR OTHERS T RE AROUND NEVER CARRY CHILDREN SE EXTRA CAUTION ON SLOPES DO NOT MOW SLOPES GREATER THAN 15 MOW UP AND DOWN NOT ACROSS AVOID SUDDEN TURNS USE LOW GEAR A WARNING TO AVOID SERIOUS INJURY OR DEATH GO UP AND DOWN SLOPES NOT ACROSS AVOID SUDDEN TURNS DO NOT OPERATE THE UNIT WHERE IT COULD SLIP OR TIP IF MACHINE STOPS GOING UPHILL STOP BLADE S AND BACK DOWNHILL SLOWLY DO NOT MOW WHEN CHILDREN OR OTHERS ARE AROUND NEVER CARRY CHILDREN LOOK DOWN amp BEHIND BEFORE AND WHILE BACRING KEEP SAFETY DEVICES GUARDS SHIELDS AND SWITCHES ETC IN PLACE AND WORKING REMOVE OBJECTS THAT COULD BE THROWN BY THE BLADE S KNOW LOCATION AND FUNCTION OF ALL CONTROLS BE SURE BLADE S AND ENGINE ARE STOPPED BEFORE PLACING HANDS OR FEET NEAR BLADE S BEFORE LEAVING OPERATOR S POSITION DISENGAGE BLADE S PLACE THE SHIFT LEVER IN NEUTRAL ENGAGE PARKING BRAKE SHUT OFF AND REMOVE KEY READ OPERATOR S MANUAL KING TOR S MANUAL KEEP SAFETY DEVICES NOS Figure 1 Safety
27. YARD MACHINES 7 by MTD OPERATOR S MANUAL Automatic Lawn Tractor Models 607 608 609 Model 608 Shown IMPORTANT READ SAFETY RULES AND INSTRUCTIONS CAREFULLY 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 dealer or contact the service department P O Box 368022 Cleveland Ohio 44136 9722 MTD PRODUCTS INC P O BOX 368022 CLEVELAND OHIO 44136 9722 PRINTED IN U S A FORM NO 770 10131A 10 99 SECTION 1 TABLE OF CONTENTS PAGE FINDING YOUR MODEL NUMBER LL LL 2 CALLING CUSTOMER SUPPORT paaa Keep eee n 2 IMPORTANT SAFE OPERATION PRACTICES LL 3 SAFETY LABLES FOUND ON YOUR UNIT 4 4 n 5 SLOPE GAUGE eoo as ee tabu edet a Dra E betreut 6 ATTACHMENTS amp ACCESSORIES LL Lu eee 7 TRACTOR SETUP ERIS eee La dani See ad esee Siue 7 CONT
28. ackward until desired position is reached Retighten the four screws See Figure 8 Seat Pivot Bracket Figure 8 14 BRARE ADJUSTMENT 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 The brake disc can be found on the right side of the transmission in the rear of the tractor Adjust if necessary as follows Looking at the transmission from the right side of the tractor locate the compression spring and brake disc See Figure 9 Loosen but do NOT remove the hex nut found on the right side of the brake assembly See Figure 9 Using a feeler gauge set the gap between the brake disc and the brake puck at 011 e Re tighten the hex nut loosened earlier Hex Nut E ae gt du Compression Spring Brake seal NOTE View shown from beneath tractor Transmission Figure 9 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 Adjust the drag links so that equal lengths are threaded into the ball joint on the left side and the ball joint on the right side e Loosen the jam nut found on the drag link at the rear of the ball joint See Figure 10 e Remove th
29. ange Nut Neutral Return Bracket Ey Hairpin PA Clips 4 e d i amp IX Assembly Cutting Blade Figure 19 To properly sharpen the cutting blades remove Drive Pedal Speed Control equal amounts of metal from both ends of the blades Return Spring Assembly along the cutting edges See Figure 20 Figure 18 Sharpen the cutting edge straight across parallel to e Remove both hairpin clips from the pin which the trailing edge at a 25 to 30 angle See Figure is fastened to the speed control assembly be 20 careful not to lose the small flat washers found on the pin See Figure 18 IMPORTANT f the cutting edge of the blade has e Remove the drive pedal return spring already been sharpened to within 5 8 of the wind wing radius or if any metal separation is present gt Using iwo 9 16 Wrenches remove the pin replace the blades with new ones See Figure 20 from the speed control assembly See Figure 18 Thread the idler adjustment rod inward or outward to lengthen or shorten the travel of the double idler bracket until proper adjustment is achieved Reassemble by following the above steps in reverse order Blade Separation Wind Wing CUTTING BLADES Always protect hands by wearing heavy Sharpen Edge Evenly leather work gloves to grasp blades Figure 20 WARNING Cutting blades are sharp 21 It is ex
30. ctly Negative terminal is identified at the post by NEG N or The positive terminal identified by POS P or must be attached to the thick red wire which goes to the solenoid Battery is dead Charge at six amps with a 12 volt automotive type battery charger for one hour or until or weak fully charged Blown fuse Refer to page 22 for fuse location Replace fuse with automotive type fuse of the proper amperage Fuses seldom fail without a reason The problem must be corrected Check for loose connections in the fuse holder Replace fuse holder if nec essary A dead short may be in the cranking or charging circuit where the insulation may have rubbed through and exposed the bare wire Replace the wire or repair with electrician s tape if the wire strands have not been damaged Note Look for a wire pinched between body panels burned by the exhaust pipe or muffler or rubbed against a moving part Engine Throttle or choke Refer to the OPERATION section of this manual for the correct position of the throttle cranks but not in starting control and choke for starting will not start position No fuel to the Gasoline tank empty Fill with clean fresh fuel carburetor Fuel line or in line fuel filter plugged Remove and clean fuel line Replace fuel filter if so equipped if necessary No spark to Spark plug lead disconnected Connect lead Using a spark tester check for spark If spark plug s no spark is present have engi
31. e hex nut and lock washer on the top of ball joint See Figure 10 e Thread the ball joint toward the jam nut to shorten the drag link Thread the ball joint away from the jam nut to lengthen the drag link Pivot Bar Hex Nut and Lock Washer Axle Ball Joint Jam Nut Figure 10 e Replace hex nut and lock washer and retighten the jam nut after proper adjustment is achieved NOTE Threading the ball joints too far onto the drag links will cause the front tires to toe in too far Proper toe in is between 1 16 and 5 16 Front tire toe in can be measured as follows e Place the steering wheel in position for straight ahead travel Insert a 1 4 dowel up through aligning holes in both the steering gear and support plate See Figure 11 e In front of the axle measure the distance horizontally from the inside of the left rim to the inside of the right rim Note the distance e Behind the axle measure the distance horizontally from the inside of the left rim to the inside of the right rim Note the distance The measurement taken in front of the axle should be between 1 16 and 5 16 less than the measurement taken behind the axle Adjust if necessary Remove the dowel inserted earlier before attempting to operate the tractor Drag Links Insert Dowel Steering Gear Here o Support A o Plate o2 Steering HT Shaft eo NOTE View shown from beneath tractor Fi
32. e of this type of equipment WILL void the tractor s warranty SECTION 6 TRACTOR SET UP ATTACHING THE BATTERY CABLES NOTE The positive battery terminal is marked Pos The negative battery terminal is marked Neg e The positive cable heavy red wire is secured to the positive battery terminal with hex bolt and hex nut at the factory Make certain that the rubber boot covers the terminal to help protect it from corrosion e Remove the hex bolt and wing nut from the negative cable Attach the negative cable heavy black wire to the negative battery terminal with the bolt and wing nut e Place the hold down strap in position over the battery to secure it in place See Figure 2 Rubber Positive Terminal Boot N y mM ce IN I T Battery a O O Wing S Nut Tray mm SA Negative Bolt Terminal Hold down Stra Figure 2 NOTE f battery is put into service after date shown on top of battery charge for minimum of one hour at 6 10 amps Refer to the MAINTENANCE section of this manual for more detailed instructions regarding proper battery charging procedure GAS AND OIL FILL UP Service the engine with gasoline and oil as instructed in the separate engine manual packed with your tractor Read instructions carefully IMPORTANT Your tractor is shipped with oil however you MUST check the oil level before operat ing Be careful not to
33. eck appears to be mowing unevenly a side to side adjustment can be performed Adjust if necessary as follows WARNING Turn the tractors engine off remove the key from the ignition switch and apply the A tractor s parking brake before making any adjustments to the cutting deck e With the tractor parked on a firm level surface place the lift lever in the top notch highest position and rotate the both blades so that they are perpendicular with the tractor Measure the distance from the outside of the left blade tip to the ground and the distance from the outside of the right blade tip to the ground Both measurements taken should be equal If they re not proceed to the next step Loosen but do NOT remove the hex cap screw on the left deck hanger bracket See Figure 7B Balance the deck so that both blade tip measurements taken earlier are equal Retighten the hex cap screw on the left deck hanger bracket when proper adjustment is achieved Al Nut B e LS H CP beep a bod DS Sir A A i ETT SS a racket LE H E v e Deck UI Hex Cap Screw Com RA Deck Hanger Bracket Front to Rear Side to Side Figure 7 SEAT ADJUSTMENT To adjust the position of the seat loosen but do NOT remove the four screws which secure the seat to the seat pivot bracket Slide the seat forward or b
34. elessness or error on the part of the operator can result in serious injury This lawn mower is capable of amputating hands and feet and throwing objects Failure to observe the following safety instructions could result in serious injury or death 1 GENERAL OPERATION Read understand and follow all instructions in the operators manual and on the machine before starting Keep this manual in a safe place for future and regular reference and for ordering replacement parts Only allow responsible individuals familiar with the instructions to operate the machine Know controls and how to stop the machine quickly Do not put hands or feet under cutting deck or near rotating parts Clear the area of objects such as rocks toys wire etc which could be picked up and thrown by the blade A small object may have been overlooked and could be accidentally thrown by the mower in any direction and cause injury to you or a bystander To help avoid a thrown objects injury keep children bystanders and helpers at least 75 feet from the mower while it is in operation Always wear safety glasses or safety goggles during operation or while performing an adjustment or repair to protect eyes from foreign objects Stop the blade s when crossing gravel drives walks or roads Be sure the area is clear of other people before mowing Stop machine if anyone enters the area Never carry passengers Disengage blade s before shifting into rever
35. enoid 12 Volt 100 Amp 47 736 0171 Lock Washer 7 16 18 710 0599 Self tapping Screw 1 4 20 x 5 48 1750 0956 Spacer 19 712 0459 Flange Lock Nut 7 16 20 49 756 0982A Engine Pulley 20 1683 0304 Lower Frame Assembly 50 732 0735 Extension Spring 1 318 x 2 37 21 736 3010 Flat Washer 407 x 812 x 135 51 647 0053 Belt Guard 22 710 0831 Hex Cap Screw 3 8 16 x 5 5 52 711 1044 Keeper Pin 23 1736 0275 Flat Washer 344 x 688 x 065T 53 731 2111A PTO Knob 24 732 0944 Extension Spring 75 x 5 39 54 1736 0108 Flat Washer 510 x 750 x 033 25 1736 0140 Flat Washer 385 x 62 x 063 55 747 1112A PTO Handle 26 710 0642 Self tapping Screw 1 4 20 x 750 56 647 0046 PTO Lever 27 1736 0322 Flat Washer 45 x 1 25 x 164 57 710 0650 Self tapping Screw 15 16 18 x 875 28 712 3004A Flange Lock Nut 5 16 18 58 732 0995 Extension Spring 5 x 6 0 29 783 0653C Steering Support Bracket 59 741 0708 Hex Split Flange Bearing 30 754 0485 PTO Belt 42 inch Decks w Manual PTO 754 0486 PTO Belt 46 inch Decks w Manual PTO 39 Models 607 608 amp 609 a 46 inch Deck xm G 16 See PTO breakdown UN 25 D 46 inch Deck Brake Assembly NK 44 D DEN a s Qi l ma 29 30 42 inch Deck BE cb Cutting Decks REF PART REF PART NO NO DESCRIPTION NO NO DESCRIPTION 1 116606 Re
36. enter hex bolt to between 38 foot found in the double idler bracket has approximately pounds and 50 foot pounds 1 3 8 of travel with ten pounds of pressure applied e Remove the drive belt by feeding it from both to the drive pedal See Figure 17 ends toward the front idler pulley on the double idler bracket See Figure 16 20 The blades may be removed for sharpening or Double idler AGS Bracket replacement as follows 2 Q e Remove the deck from beneath the tractor Hole oro refer to DECK REMOVAL earlier in this Idler section for detailed instructions then gently e Adj Rod flip the deck over to expose its underside 1 3 e Place a block of wood between the center e deck housing baffle and the cutting blade to Front of Tractor act as a stabilizer See Figure 19 Use a 15 16 wrench to remove the hex flange nut that secures the blade to the spindle Figure 17 assembly See Figure 19 Adjust the drive pedal after replacing the drive belts on your tractor if necessary as follows NOTE View shown from above tractor NOTE The hex flange nut has a right handed normal thread pattern Do NOT attempt to force the nut in the incorrect direction Doing so may damage the nut and create a safety hazard Locate the speed control assembly on the underside of the steering support bracket See Figure 18 Idler Adj Rod Place Wrenches Here Block of Wood NJ Hex Fl
37. fferential AssemblyT 618 0424 Differential Assemblyt 19 1661 0006 Brake Assembly 20 1710 1325 Self tapping Screw 1 4 20 x 1 625 21 1710 1206 Self tapping Screw 1 4 20 x 2 375 22 717 0678 Brake Pad 23 732 0863 Compression Spring 24 741 0862 Detent Ball 25 761 0202 Brake Disc 26 711 1331 Input Shaftt 711 1430 Input Shaft 27 716 0385 Retaining Ring 394T 716 0108 Retaining Ring 437t 28 1717 1571 12 tooth Bevel Piniont 717 1464 14 tooth Bevel Piniont 29 719 0391A Upper Housing 30 1736 0335 Thrust Washer 63 x 1 24 x 062T 736 0723 Thrust Washer 635 x 1 25 x 042 31 1741 0525 Needle Bearing 625 x 875 32 1718 0228 Clutch Collart 33 1711 1431 Drive Shaftt 34 1750 1234 Spacer 633 x 1 0 x 513 35 1717 1362 42 tooth Bevel Geart 36 1717 1363 42 tooth Bevel Geart 37 1736 0495 Thrust Washer 1 0 x 632 x 0 38 741 0340 Sleeve Bearing 75 x 1 0 x 1 0 39 721 0338 Seal 75 x 1 0x 125 40 716 0231 E ring 75 41 618 0551 Transmission Assembly Complete If rebuilding transmission for any reason use applicable flat washer 12a 12b or 12c in this application allowing proper end play as instructed in MTD s Service Manual IMPORTANT One of two different transmissions may be found on your lawn tractor 618 0307B amp 618 0307C Refer to the model plate found on the rear right portion of the transmission s lower housing before ordering replacement service parts TUsed on Single speed transm
38. gure 11 CARBURETOR ADJUSTMENT WARNING if any adjustments are made to the engine while the engine is running e g carburetor disengage all clutches and blades Keep clear of all moving parts Be careful of heated surfaces and muffler SECTION 10 MAINTENANCE WARNING Disconnect the spark plug A wire s and ground against the engine ENGINE before performing any adjustments repairs or maintenance Refer to the separate engine manual for engine maintenance instructions Check engine oil level before each use as instructed in the separate engine manual packed with your unit Read and follow instructions carefully Changing Engine Oil e Unscrew oil fill cap and remove dipstick from the oil fill tube See Figure 12 Oil Fill Cap Oil Drain Hose A Protective Cap Oil Drain Valve Cil Drain Port NOTE Single cylinder engine shown Valve location will vary with engine style Figure 12 Pop open the protective cap on the end of the oil drain valve to expose the oil drain port See Figure 12 Push oil drain hose packed with unit onto the oil drain port Route the opposite end of the hose into an appropriate oil collection container with a capacity great enough to collect the used oil 16 NOTE A dirty air cleaner will cause an engine to run rough Be certain it is clean and properly attached before adjusting carburetor Refer to separate engine manual packed with your unit for informati
39. her 281 x 5 x 063 736 3078 Flat Washer 349 x 1 0 x 063 747 1196 Pivot Rod 749 1087 Dash Support Tube 710 0924 Pan Phillips Screw 1 4 20 x 75 710 3008 Hex Cap Screw 5 16 18 x 75 712 0292 U type Speed Nut 1 4 20 712 3004A Flange Lock Nut 5 16 18 731 2118 Lens 9 style 731 2119 Grille 9 style 736 0211 Flat Washer 285 x 1 25 x 08 747 1162 Hood Hinge Rod 783 0783 Hood 9 style 783 0784 RH Side Pane 9 style 783 0785 LH Side Panel 9 style 751 0659 Two gallon Fuel Tank shown 751 0658 Three gallon Fuel Tank 751 0603 Fuel Cap Fits Either Tank 746 1085 Choke Knob Cable Assemblyt Units w B amp S Opposed Twin or OHV Twin 32 731 2270 Hood Plenum Units w B amp S OHV V Twin t 731 2271 Hood Plenum Units w B amp S Opposed Twin 33 1712 3027 Hex Flange Lock Nut 1 4 20 XJ Co C2 NNNNNNNDNNNA 2 bobo a a dodo od z 20 Qo do ga amp owm oooo doomsrowvaoooudoogsrom om TUnits with B amp S Single cylinder I C or OHV engines have NO choke knob cable The choke is activated with the throttle control tUnits with B amp S Single cylinder I C or OHV engines have NO hood plenum 29 Models 607 608 amp 609 30 Lift Assembly REF PART NO NO DESCRIPTION 1 1747 1130 Deck Stabilizer Rod 2 1683 0197 Lift Shaft Assembly 3 1711 0332 Clevis Pin 5 x 78 4 1712 0206 Hex Nut 1 2 13 5 1712 0431 Flange Lock Nut 3 8 16 6 712 3004A Flange Lock Nut 5 16 18 7 712 3083 Hex
40. ission 618 0307B ONLY jUsed on Single speed transmission 618 0307C ONLY 37 Models 607 608 amp 609 42 deck shown 30 PTO belt for 38 Power Take off System REF PART REF PART NO NO DESCRIPTION NO NO DESCRIPTION 1 712 0431 Flange Lock Nut 3 8 16 31 1732 0991 Belt Guard 2 1732 0996 Compression Spring 1 31 x 3 0 32 732 0990 Belt Guard 3 1783 0733 Spacer Cup 1 5 OD 33 1714 0470 Cotter Pin 1 8 x 1 25 4 1732 0997 Compression Spring 66 OD x 1 5 34 683 0302 PTO Engagement Plate 5 710 0604A Self tapping Screw 5 16 18 x 625 35 1738 0372 Shoulder Spacer 6 1710 0751 Hex Cap Screw 1 4 20 x 62 36 1710 3011 Hex Cap Screw 3 8 16 x 2 25 Grade 5 7 1712 0271 Hex Sems Nut 1 4 20 37 756 0627 Flat Idler Pulley 3 5 OD 8 1712 3044 VVing Nut 1 4 20 38 783 0349 Battery Tray 9 1725 1706 12 volt Battery 270 CCA 39 748 0415A Spacer 3 8 x 1 54 10 738 1014 Shoulder Screw 5 x 1 25 3 8 16 40 783 0744A Engagement Stop Bracket 11 1738 1020 Shoulder Screw 625 x 5 7 16 20 41 1712 0229 Push Nut 3 8 12 736 0407 Bell Washer 45 x 1 0 x 062 42 1736 0105 Bell Washer 401 x 870 x 063 13 723 0444 Battery Strap 43 1710 0376 Hex Cap Screw 5 16 18 x 1 0 14 783 1031 Hitch Plate 44 1712 3006 Hex Nut 1 4 20 15 725 1747 Safety Interlock Plunger Switch 45 1736 0119 Lock Washer 5 16 16 736 0222 Lock Washer 1 4 46 1710 3029 Hex Cap Screw 7 16 20 x 1 25 17 725 1426 Sol
41. ket 4 631 0009 Shifter Knob 50 1783 0669 Idler Bracket 5 647 0045 Shift Lever 51 783 0714 Adjustable Shift Bracket 6 1656 0048 Variable speed Pulley Assembly 52 647 0031 Brake Control Assembly 7 656 0051A Transmission Pulley 8 5 x 5 36 53 647 0032 Speed Control Assembly 8 1683 0251 Double idler Bracket 54 1683 0266 Drive Pedal Assembly 9 1710 0176 Hex Cap Screw 5 16 18 x 2 75 55 712 0431 Flange Lock Nut 3 8 16 10 1710 0227 Self tapping Screw 48 18 x 5 56 711 0736 Ferrule 1 4 20 11 710 0347 Hex Cap Screw 3 8 16 x 1 75 57 711 1363 Pin 3 8 16 x 2 43 12 1736 0272 Flat Washer 51 x 1 0 x 060 58 714 0104 Cotter Pin 13 710 0604A Self tapping Screw 5 16 18 x 625 59 732 0437 Compression Spring 34 OD x 1 0 14 710 0642 Self tapping Screw 1 4 20 x 75 60 1710 0778 Self tapping Screw 1 4 20 x 1 5 15 710 3011 Hex Cap Screw 3 8 16 x 2 25 61 735 0662 Drive Pedal Pad 16 711 0677 Ferrule 5 16 18 62 1735 3049 Brake Pedal Pad 17 712 0241 Hex Nut 3 8 24 63 710 1650 Self tapping Screw 5 16 18 x 875 18 712 0378 Hex Nut 7 16 20 64 736 0187 Flat Washer 64 x 1 24 x 06 19 712 0431 Flange Lock Nut 3 8 16 65 736 0204 Flat Washer 344 x 062 x 03 20 712 0798 Hex Nut 3 8 16 66 738 0155 Shoulder Screw 437 x 1 62 21 712 3004A Flange Lock Nut 5 16 18 67 738 0507B Shoulder Screw 5 x 434 22 712 3008 Jam Nut 3 8 16 68 741 0225 Hex Flange Bearing 23 714 0111 Cotter Pin 69 741 3065A Split Hex Flange Bearing 24 714 0149B Inte
42. machine Tall grass can hide obstacles Use slow speed Always keep machine in gear when going down slopes to take advantage of engine braking action Follow the manufacturers recommendations for wheel weights or countenveights to improve stability Use extra care with grass catchers or other attachments These can change the stability of the machine Keep all movement on the slopes slow and gradual Do not make sudden changes in speed or direction Rapid engagement or braking could cause the front of the machine to lift and rapidly flip over backwards which could cause serious injury Avoid starting or stopping on a slope If tires lose traction disengage the blade s and proceed slowly straight down the slope DO NOT Do not turn on slopes unless necessary then turn slowly and gradually downhill if possible Do not mow near drop offs ditches or embankments The mower could suddenly turn over if a wheel is over the edge of a cliff or ditch or if an edge caves in Do not mow on wet grass Reduced traction could cause sliding Do not try to stabilize the machine by putting your foot on the ground Do not use grass catcher on steep slopes 3 CHILDREN Tragic accidents can occur if the operator is not alert to the presence of children Children are often attracted to the machine and the mowing activity Never assume that chil dren will remain where you last saw them Keep children out of the mowing area and i
43. mediately Remove the wire s from the spark plug s thoroughly inspect the unit for any damage and repair the damage before restarting and operating the mower USING THE LIFT LEVER To raise the cutting deck move the lift lever to the left then place it in the notch best suited for your application Refer to SETTING THE CUTTING HEIGHT earlier in this section ENGAGING THE PTO POWER TAKE OFF LEVER Move the throttle control lever to the FAST rabbit position Move the PTO lever forward into the engaged ON position Keep the throttle lever in the FAST rabbit position for the most efficient use of the cutting deck and other attachments The operator must remain in the tractor seat at all times If the operator should leave the seat without moving the PTO lever into the disengaged OFF position and setting the parking brake the engine will shut off IMPORTANT The PTO lever cannot be in the engaged ON position when the tractor is driving in the reverse direction The safety interlock system will automatically shut off the engine if the PTO lever is moved into the engaged ON position with the shift lever in the REVERSE position Refer to SAFETY INTERLOCK SWITCHES earlier in this section MOWING This tractor comes equipped with a cutting deck The following information will be helpful when using the cutting deck with your tractor SECTION 9 ADJUSTMENTS LEVELING THE DECK A NOTE Check the tract
44. n Pull out the choke control knob if so equipped a warm engine may not require choking Turn the ignition key clockwise to the START position After the engine starts release the key It will return to the ON position IMPORTANT Do NOT hold the key in the START position for longer than ten seconds at a time Doing so may cause damage to your engine s starter NOTE f starting problems are encountered refer to the TROUBLESHOOTING section of this manual After the engine starts slowly release the brake pedal As the engine warms up gradually push the choke control knob inward or move the throttle control lever out of the CHOKE position to open up the choke plate on the engine s carburetor NOTE Do NOT leave the choke control out while operating the tractor Doing so will result in a rich fuel mixture and cause the engine to run poorly STOPPING THE ENGINE Place the PTO lever in the disengaged OFF position Move the throttle control into the SLOW turtle position and allow the engine to idle down for ten seconds Failure to do so may result in an engine afterfire Turn the ignition key counterclockwise to the OFF position Remove the key from the ignition switch to prevent accidental starting IMPORTANT f you think you ve struck a foreign object stop the engine immediately Remove the wire s from the spark plug s thoroughly inspect the unit for any damage and repair the damage before re
45. n watchful care of an adult other than the operator Be alert and turn machine off if children enter the area Before and when backing look behind and down for small children Never carry children even with the blades off They may fall off and be seriously injured or interfere with the safe machine operation Never allow children under 14 years old to operate the machine Children 14 years and over should only operate machine under close parental supervision and proper instruction Remove key when machine is unattended to prevent unauthorized operation Use extra care when approaching blind corners shrubs trees or other objects that may obscure your vision of a child or other hazard 4 SERVICE Use extreme care in handling gasoline and other fuels They are extremely flammable and the vapors are explosive Use only an approved container Never remove fuel cap or add fuel with the engine running Allow engine to cool at least two minutes before refueling Replace fuel cap securely and wipe off any spilled fuel before starting the engine as it may cause a fire or explosion Extinguish all cigarettes cigars pipes and other sources of ignition Never refuel the machine indoors because fuel vapors will accumulate in the area Never store the fuel container or machine inside where there is an open flame or spark such as a gas hot water heater space heater or furnace Never run a machine inside a closed area
46. n to relieve tension on the belt Remove the PTO belt from around the bottom portion of the engine pulley and from around the two PTO idler pulleys found on the PTO engagement plate See Figure 15 Route the new belt as shown in Figure 15 around the upper portion of the left hand deck pulley PTO idler pulleys and the lower portion of the engine pulley OEM belt part numbers are listed in the table on the following page e Remount the belt guards removed earlier 18 Belt Guard x 4 Deck Stop mounted on tractor mounted on tractor Deck belt Bottom Engine Pulle g y PTO Sandeman FE HE PTO belt Top PTO Idler Pulleys mounted on tractor Right Hand Pulley Deck Idler Pulley FS o beneath belt guard o o o og A OE SS o ALS c SS o I o e o j Left Hand i a Double Pulley P Center Pulley i NOTE Left hand belt cover not shown for clarity 46 inch deck shown Self Tapping Screws Figure 15 42 Inch Deck 46 Inch Deck PTO Top Belt 754 0485 754 0486 Deck Bottom Belt N A 754 0349 CHANGING THE TRANSMISSION DRIVE BELT S All belts on your tractor are subject to wear and should be replaced if any signs of cracking shredding or rotting are present IMPORTANT The V belts found on your tractor are specially designed to engage and disengage safely A substitute non OEM V belt can be dangerous by not disengagi
47. ne s magneto serviced by an authorized engine dealer Dirty aircleaner If the air cleaner is dirty the engine may not start Refer to the engine manual packed with your unit Engine Engine oil has Check oil level smokes been overfilled Engine loses Dipstick not seated or broken Replace defective part crankcase Engine breather defective Replace vacuum Excessive Bent blade or Stop engine immediately Check all pulleys blade adapters keys and bolts for vibration damaged pulley tightness and spindle damage Tighten or replace any loose or damaged parts Always replace damaged blade Only use original equipment blades Mower Engine speed Throttle must be set at full throttle won t low discharge Speed selection Use lower ground speed The slower your ground speed the better the quality of cut grass or Cutting height Raise deck leaves set too low uncut strips Blades dull Sharpen or replace blades uncut strip problem only 23 Models 607 608 amp 609 _8 10 249 n Th 7 ha 2 m 12 REF PART NO NO DESCRIPTION 1 1625 0051 Bulb Socket Headlight Assembly 2 1629 0944 Wiring Harness w o Ref 14 3 1629 0126 Harness Adapter 18 x 5 4 1710 0599 Self tapping Screw 1 4 20 x 5 5 1712 3006 Hex Nut 1 4 20 6 1725 1426 Solenoid 12 volt 100 Amp 7 725 1657A Snap Mount Safety Interlock Switch
48. ng completely For a proper working machine use factory approved belts To change or replace the drive belt s on your tractor proceed as follows NOTE t s recommended that both drive belts be replaced at the same time Remove the cutting deck as instructed earlier in this section After disconnecting the battery cables remove the battery and battery tray from beneath the seat IMPORTANT When removing the battery disconnect the NEGATIVE Black wire from it s terminal first followed by the POSITIVE Red wire Re install in reverse order Upper Drive Belt Locate the transmission idler pulley on the upper drive belt by looking through the battery tray opening See Figure 16 Grasp the bracket and pivot the transmission idler pulley toward the rear of the tractor to release tension on the upper drive belt Remove the belt from around the transmission idler pulley Remove the upper drive belt from around the transmission pulley and the variable speed pulley NOTE Slowly rotate the pulley counterclockwise to roll the belt off of it 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 19 Lovver Drive Belt NOTE Proper removal of the lower drive belt requires the removal of several tractor components Read through the following procedure prior to attempting it to determine if you feel you could successfully complete it If you don t
49. on regarding air cleaner maintenance Refer to separate engine manual packed with your unit for carburetor adjustment information or see an authorized Briggs amp Stratton service dealer Push the oil drain valve in slightly then rotate counterclockwise and pull outward to begin draining oil See Figure 12 e Service the oil filter if so equipped as instructed in the separate engine manual packed with your unit Perform the above steps in the opposite order after oil has finished draining e Refill the engine with new motor oil IMPORTANT Refill the engine with the proper capacity and weight of motor oil as instructed in the separate engine manual Service air cleaner every 25 hours under normal conditions Clean every few hours under extremely dusty condition To service the air cleaner refer to the separate engine manual packed with your unit The spark plug s should be cleaned and the gap reset once a season Replacement is recommended at the start of each mowing season check engine manual for correct plug type and gap specifications CLEANING THE ENGINE AND DECK Any fuel or oil spilled on the machine should be wiped off promptly Do NOT allow grass leaves and dirt to accumulate around the cooling fins of the engine or on any other part of the machine especially the pulleys and other moving parts Clean the underside of the deck with a wisk broom putty knife or forced air after each mowing IMPORTANT The u
50. or s tire pressure before performing any deck leveling adjustments Refer to TIRES in the maintenance section of this manual for further information regarding tire pressure WARNING Cutting blades are sharp Always protect hands by wearing heavy leather work gloves to grasp blades Front to Rear The front of the cutting deck is supported by a stabi lizer bar that can adjusted to level the deck from front to rear The front of the deck should be 1 4 to 3 8 lower than the rear of the deck Adjust if necessary as follows 13 A A A WARNING To avoid possible injury do not allow anyone in the area of the tractor while mowing Even if the area to be mowed has been cleared of foreign objects small objects may be picked up and discharged by the mower WARNING Never direct the discharge of material toward bystanders or allow anyone near the machine while in operation 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 Do not cut the grass too short Short grass invites weed growth and yellows quickly in dry weather Mowing should always be done with the engine at full throttle Do not mow at high ground speed especially if a mulch kit or grass collector is installed Under heavier conditions
51. purchase and will at its option repair or replace free of charge any part found to be defective in material or workmanship This limited warranty shall only apply if this product has been operated and maintained in accordance with the Operators Manual furnished with the product and has not been subject to misuse abuse com mercial use neglect accident improper maintenance alteration vandalism theft fire water or damage because of other peril or natural disaster Damage resulting from the installation or use of any accessory or attachment not approved by MTD Products Inc for use with the product s covered by this manual will void your warranty as to any resulting damages Normal wear parts or components thereof are subject to separate terms as follows All normal wear part or compo nent failures will be covered on the product for a period of 90 days regardless of cause After 90 days but within the two year period normal wear part failures will be covered ONLY IF caused by defects in material or workmanship of OTHER component parts Normal wear parts and compo nents include but are not limited to belts blades blade adapters grass bags rider deck wheels seats snow thrower skid shoes shave plates and tires Batteries are covered by a 90 day limited replacement warranty HOW TO OBTAIN SERVICE Warranty service is available WITH PROOF OF PURCHASE THROUGH YOUR LOCAL AUTHORIZED SERVICE DEALER To locate the dealer in your
52. replacement of the product as set forth above Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you The provisions as set forth in this Warranty provide the sole and exclusive remedy arising from the sales MTD shall not be liable for incidental or consequential loss or damages including without limitation expenses incurred for substitute or replacement lawn care ser vices for transportation or for related expenses or for rental expenses to temporarily replace a warranted product Some states do not allow the exclusion or limita tion of incidental or consequential damages so the above exclusion or limitation may not apply to you In no event shall recovery of any kind be greater than the amount of the purchase price of the product sold Alteration of the safety features of the product shall void this War ranty You assume the risk and liability for loss damage or injury to you and your property and or to others and their property arising out of the use or misuse or inability to use the product This limited warranty shall not extend to anyone other than the original purchaser original lessee or the person for whom it was purchased as a gift How State Law Relates to this Warranty This limited warranty gives you specific legal rights and you may also have other rights which vary from state to state
53. rnal Cotter Pin 70 710 0859 Hex Cap Screw 3 8 16 x 2 5 25 723 3018 Ball Joint 71 747 1138 Brake Lock Control Rod 26 1725 1644 Short Spring Switch 72 710 1260A Self tapping Screw 5 16 18 x 75 27 726 0320 Insulator Nut Plate 73 748 0415A Spacer 5 16 x 1 54 28 732 0384 Extension Spring 62 Dia x 6 12 74 783 0653C Stearing Support Bracket 29 732 0525 Compression Spring Clip 75 783 0732 Drive Lockout Bracket 30 1732 0716 Extension Spring 59 OD x 4 76 1783 0773 Brake Pedal 31 732 0963 Extension Spring 50 Dia x 6 37 77 783 0780A Neutral Return Bracket hooks to flange 783 0650 in frame 78 1683 0304 Lower Frame Assembly 32 1736 0105 Bell Washer 401 x 87 x 063 79 783 1031 Hitch Plate 33 736 0140 Flat Washer 385 x 62 x 063 80 736 0242 Bell Washer 34 x 872 34 1736 0169 Lock Washer 3 8 81 710 0627 Hex Cap Screw 5 16 24 x 75 35 736 0275 Flat Washer 5 16 82 634 0177 Wheel Assembly Complete 36 736 0407 Bell Washer 45 x 1 0 x 602 20 x 10 x 8 Square Shoulder 37 1736 3010 Flat Washer 407 x 812 x 135 634 0104 Wheel Assembly Complete 38 738 0322 Shoulder Screw 625 x 217 20 x 8 x 8 Square Shoulder 39 747 1122 Brake Rod 734 1675 Wheel Assembly Complete 40 747 1123A Belt Guard 20 x 8 x 8 Round Shoulder 41 747 1127 Idler Adjustment Rod 3 8 634 0070 Rim Only 42 747 1156 Shift Rod 734 0255 Air Valve Not Shown 43 711 0736 Adjustment Ferrule 1 4 20 x 1 0 734 1873 Tire Only 20 x 10 x 8 Square Shoulder 44 748 0
54. se a pressure washer or garden hose to clean your tractor is NOT recommended It may cause damage to electrical components spindles pulleys bearings or the engine The use of water will result in a shortened life of the tractor and reduce its serviceability CUTTING DECR REMOVAL A WARNING Before performing any maintenance move the PTO lever into the disengaged OFF position engage the parking brake turn the ignition key to the OFF position and remove the key from the Switch to avoid accidental starting Several attachments are available for your tractor To mount some of these attachments and in order to perform certain maintenance procedures the deck must be removed from the tractor To properly remove the cutting deck proceed as follows Deck Support Pins PTO Engagement Plate mounted on tractor NOTE 42 inch deck shown Deck Stabilizer Rod A Figure 13 WARNING Do NOT remove deck immediately after operating the tractor Allow the engine and other moving parts ample time to cool down Engage the tractor s parking brake Move the PTO lever into the disengaged OFF position to relieve tension on the belt Lower the deck by moving the lift lever into the bottom notch on the right fender Remove the PTO belt from around the lower portion of the engine pulley and from around both PTO idler pulleys on the PTO engagement plate Deck Lift Arms PTO Idler Pulleys PTO Belt Engine Pulley
55. se and backing up Always look down and behind before and while backing Be aware of the mower and attachment discharge direction and do not point it at anyone Do not operate the mower without either the entire grass catcher or the chute guard in place Slow down before turning Operate the machine smoothly Avoid erratic operation and excessive speed Never leave a running machine unattended Always turn off blade s place transmission in neutral set park brake stop engine and remove key before dismounting Turn off blade s when not mowing Stop engine and wait until blade s comes to a complete stop before a removing grass catcher or unclogging chute or b making any repairs adjusting or removing any grass or debris Mow only in daylight or good artificial light Do not operate the machine while under the influence of alcohol or drugs Watch for traffic when operating near or crossing roadways Use extra care when loading or unloading the machine into a trailer or truck This unit should not be driven up or down a ramp onto a trailer or truck under power because the unit could tip over causing serious personal injury The unit must be pushed manually on a ramp to load or unload properly Never make a cutting height adjustment while engine is running if operator must dismount to do SO Wear sturdy rough soled work shoes and close fitting slacks and shirts Do not wear loose fitting clothes or jewelry The
56. starting and operating the tractor DRIVING THE TRACTOR WARNING Avoid sudden starts excessive speed and sudden stops WARNING Do not leave the seat of the tractor without first placing the PTO lever in the disengaged OFF position depressing the brake pedal and engaging the parking brake If leaving the tractor unattended also turn the ignition key off and remove the key Depress the brake pedal to release the parking brake and let the pedal up Move the throttle lever into the FAST rabbit position IMPORTANT Do NOT use the shift lever to change the direction of travel when the tractor is in motion Always use the brake pedal to bring the tractor to a complete stop before shifting To move forward place the shift lever in the FORWARD position then slowly depress the drive pedal until the desired speed is achieved To move in reverse place the shift lever in the REVERSE position check that the area behind is clear then slowly depress the drive pedal 12 DRIVING ON SLOPES Refer to the SLOPE GAUGE on page 6 to help determine slopes where you may not operate safely WARNING Do not mow on inclines with A a slope in excess of 15 degrees a rise of approximately 2 1 2 feet every 10 feet The tractor could overturn and cause serious injury Operate the tractor up and down slopes never across slopes Do not drive so that the tractor may tip over sideways Before operating the tractor on any slope walk
57. t Gasket OHV V Twin 30 732 0966 Extension Spring 275 x 1 25 9 1726 0205 Hose Clamp 31 751B213146 Casing Clamp 10 1736 0119 Lock Washer 5 16 32 751 0619 Exhaust Pipe OHV Single 11 1736 0300 Lock Washer 406 x 875 x 059 33 746 1084 Throttle Choke Cable OHV Single 12 751B221535 Casing Clamp 34 1746 1086 Throttle Cable 13 751 0535 Fuel Line Hose OHV V Twin amp Opposed Twin 14 1751 0564 Muffler Deflector 35 722 0263 Foam 625 x 1 5 x 10 fits over fuel line 15 751 0616 Muffler Twin Inlet 36 783 0357A Heat Shield Opposed Twin 16 751 0650 RH Exhaust Pipe OHV V Twin 37 1710 0751 Hex Cap Screw 1 4 20 x 620 Grade 5 17 751 0651 LH Exhaust Pipe OHV V Twin 38 1736 0329 Lock Washer 1 4 18 751 3140 Oil Drain Valve 39 721 0346 Exhaust Gasket Opposed Twin 19 751 3141 Oil Drain Hose 40 1751 0623 LH Exhaust Pipe Opposed Twin 20 751 3142 Oil Drain Cap 41 751 0624 RH Exhaust Pipe Opposed Twin 21 783 0615 Muffler Heat Shield 42 712 0779A Screw 1110 16 x 5 22 783 0625B Engine Heat Shield 43 1726 0272 Clamp 9 16 43 MANUFACTURER S LIMITED VVARRANTY FOR YARD MACHINES ff The limited warranty set forth below is given by MTD PRODUCTS INC MTD with respect to new merchandise purchased and used in the United States its possessions and territories MTD warrants this product against defects in material and workmanship for a period of two 2 years commencing on the date of original
58. t and service as required Muffler engine and belt guards become hot during operation and can cause a burn Allow to cool down before touching Do not change the engine governor settings or overspeed the engine Excessive engine speeds are dangerous Observe proper disposal laws and regulations Improper disposal of fluids and materials can harm the environment and the ecology Prior to disposal determine the proper method to dispose of waste from your local Environmental Protection Agency Recycling centers are established to properly dispose of materials in an environmentally safe fashion Use proper containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them Properly dispose of the containers immediately following the draining of fluids DO NOT pour oil or other fluids into the ground down a drain or into a stream pond lake or other body of water Observe Environmental Protection Agency regulations when disposing of oil fuel coolant brake fluid filters batteries tires and other harmful waste WARNING YOUR RESPONSIBILITY Restrict the use of this power machine to persons who read understand and follow the warnings and instructions in this manual and on the machine TO REDUCE THE RISK OF INJURY DO NOT OPERATE MOWER UNLESS REAR TRAILING SHIELD AND THIS GUARD OR ENTIRE GRASS CATCHER IS IN ITS PROPER PLACE DANGER KEEP HANDS and FEE
59. t check to be certain that the fuse has not blown It can be found under the hood mounted behind the top of dash panel on the support bar Pull the fuse out and compare it with Figure 21 to determine if it is good or bad mu GOOD BAD Figure 21 WHEELS Both the front wheels and the rear wheels should be removed from the axles once a season Lubricate the axles and the rims well with an all purpose automotive grease before re installing them STEERING GEAR Lubricate the teeth of the steering gear with an all purpose automotive grease every 25 hours of operation or once a season PIVOT POINTS Lubricate all pivot points drive pedal brake pedal etc at least once a season with light oil SECTION 12 TROUBLESHOOTING GUIDE Trouble Fos sible Corrective Action Cause s Engine will Safety switch There are three safety switches in the starting circuit of your unit the brake pedal not crank X button not switch the PTO switch and the seat switch Make certain the actuator on the brake depressed control is fully depressing the button on the brake pedal switch and that the actuator at the base of the PTO engagement lever is fully depressing the button on the PTO switch The operator must be seated on the tractor to activate the seat switch Battery installed The battery must be installed with negative terminal attached to black ground wire incorre
60. tainer Hook 44 712 3087 Wing Nut 1 4 20 if so equipped 2 618 0324 Spindle Assembly 5 75 Dia 45 712 3006 Hex Nut 1 4 20 if so equipped 3 683 0198C 42 inch Deck Shell 46 1710 0597 Hex Cap Screw 1 4 20 x 1 0 4 683 0254 Deck Adjustment Bracket w Weld Nut if so equipped 5 1683 0303 Deck Brake Assembly 42 inch Decks 47 736 0173 Flat Washer 28 x 74 x 063 6 1710 0520 Hex Cap Screw 3 8 16 x 1 5 48 17258A RH Belt Cover Bracket 7 1710 0528 Hex Cap Screw 5 16 18 x 1 25 49 17928 Reinforcement Spindle Plate 8 710 0604A Self tapping Screw 5 16 18 x 625 50 1618 0240 Spindle Assembly 5 0 Dia 9 1710 0751 Hex Cap Screw 1 4 20 x 62 51 618 0241 Double Pulley Spindle Assembly 10 7710 0817 Self tapping Screw 5 16 18 x 1 25 52 683 0265C 46 inch Deck Shell 11 710 1122 Hex Cap Screw 1 4 20 x 2 5 53 710 0167 Carriage Screw 1 4 20 x 50 12 710 1260A Self tapping Screw 5 16 18 x 75 54 710 0347 Hex Cap Screw 3 8 16 x 1 75 13 711 0677 Ferrule 5 16 18 55 710 0501 Hex Cap Screw 1 4 20 x 2 0 14 712 0417A HexFlange Nut 5 8 18 56 710 0514 Hex Cap Screw 3 8 16 x 1 0 15 712 0431 Flange Lock Nut 3 8 16 57 710 0599 Self tapping Screw 1 4 20 x 5 16 712 3004A Flange Lock Nut 5 16 18 58 1710 0650 Self tapping Screw 15 16 18 x 875 17 712 3006 Hex Nut 1 4 20 59 710 0703 Hex Screw 1 4 20 x 75 18 712 3009 Hex Lock Nut 5 16 18 60 710 0805 Hex Cap Screw 5 16 18 x 1 5 19 1712 3027 Hex Flange Lock Nut 1 4 20 61 711 0993 Belt Keeper
61. the slope to look for possible hazards such as rocks mounds ruts stumps or other surface irregularities which could cause the tractor to be upset Avoid turns when driving on a slope If a turn must be made turn down the slope Turning up a slope greatly increases the chance of a roll over 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 flipping the tractor over backward OPERATING THE HEADLIGHTS To turn the tractor s headlights on e Start the engine following the instructions earlier in this section Turn the key one notch counterclockwise into the On Lights position of the ignition switch Refer to Figure 4 To turn the tractor s headlights off e Turn the key either into the On position to leave the engine running or the Off position to shut the engine off Refer to Figure 4 IMPORTANT Never move the key into the Start position while the engine is running Doing so may cause damage to your engine s starter STOPPING THE ENGINE e Place the PTO lever in the disengaged OFF position e Move the throttle control into the SLOW position and allow the engine to idle down for ten seconds then turn the ignition key counterclockwise to the OFF position e Remove the key from the ignition switch to prevent accidental starting IMPORTANT f you think you ve struck a foreign object stop the engine im
62. tor above the drive pedal along the running board The brake pedal can be used for sudden stops or for setting the parking brake NOTE The brake pedal must be fully depressed to activate the safety interlock switch when starting the tractor PARKING BRAKE BUTTON To set the parking brake fully depress the brake pedal and push the parking brake button in Hold the button in while taking your foot off the brake pedal Both the parking button and the brake pedal will then stay depressed To release the parking brake depress the brake pedal slightly The parking brake button will then return to its original position NOTE The parking brake must be set if the operator leaves the seat with the engine running or the engine will automatically shut off IMPORTANT Always set the parking brake when leaving the tractor unattended SHIFT LEVER The shift lever is located on the left side of the fender and has three positions FORWARD NEUTRAL and REVERSE The brake pedal must be depressed and the tractor must not be in motion when moving the shift lever IMPORTANT Never force the shift lever Doing so may result in serious damage to the tractors transmission SECTION 8 OPERATION SAFETY INTERLOCR SVVITCHES This tractor is equipped with a safety interlock system for the protection of the operator If the interlock system should ever malfunction do not operate the tractor Contact an authorized dealer in your
63. tremely important that each cutting blade edge be ground equally to maintain proper blade balance An unbalanced blade will cause excessive vibration when rotating at high speeds may cause damage to the tractor and result in personal injury The blade can be tested by balancing it on a blade balancer or round shaft screwdriver Grind metal from the heavy side until it balances evenly When replacing the blade be sure to install the blade with the side of the blade marked Bottom or with a part number stamped in it facing the ground when the mower is in the operating position IMPORTANT Use a torque wrench to tighten the blade spindle hex flange nut to between 70 foot pounds and 90 foot pounds TIRES The recommended operating tire pressure is approximately 10 psi for the rear tires and 14 psi for the front tires Refer to the tire sidewall for exact tire manufacturers recommended psi Do not overinflate Uneven tire pressure could cause the cutting deck to mow unevenly BATTERY The battery is sealed and is maintenance free Acid levels cannot be checked Always keep the battery cables and terminals clean and free of corrosive build up After cleaning the battery and terminals apply a light coat of petroleum jelly or grease to the terminals and over the positive terminal boot Always keep the boot positioned over the positive terminal to prevent shorting SECTION 11 LUBRICATION A WARNING Always stop the
64. y can be caught in moving parts Never operate a unit in bare feet sandals or sneakers Check overhead clearance carefully before driving under power lines wires bridges or low hanging tree branches before entering or leaving buildings or in any other situation where the operator may be struck or pulled from the unit which could result in serious injury Disengage all attachment clutches thoroughly depress the brake pedal and shift into neutral before attempting to start engine Your mower is designed to cut normal residential grass of a height no more than 10 Do not attempt to mow through unusually tall dry grass e g pasture or piles of dry leaves Debris may build up on the mower deck or contact the engine exhaust presenting a potential fire hazard 2 SLOPE OPERATION Slopes are a major factor related to loss of control and tip over accidents which can result in severe injury or death All slopes require extra caution If you cannot back up the slope or if you feel uneasy on it do not mow it For your safety use the slope gauge included as part of this manual to measure slopes before operating this unit on a sloped or hilly area If the slope is greater than 15 as shown on the slope gauge do not operate this unit on that area or serious injury could result DO Mow up and down slopes not across Remove obstacles such as rocks limbs etc Watch for holes ruts or bumps Uneven terrain could overturn the

Bolens 420 Tiller User Manual

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