Troy-Bilt J609 manual

Oper ator’ s Man ual PRINTED IN U .S .A. FORM NO . 770-10490D. fm (4/2004) IMPOR T ANT : Read saf ety rules and instr uctions carefully bef ore 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-co vered land unless the engi[...]

2 TABLE OF CONTENTS FINDING MODEL NUMBER This Operator’s M anual is an important part of your new lawn tractor. It will help you assemble, prepare and maintain the unit fo r best performance. Please read and understand what it says. Before you star t assembling your new equipment , please locate the model plate under th e seat of the tra ctor and[...]

3 SECTION 1: IMPORTANT SAFE OPERATION PRACTICES General Operation 1. Read, understand, and follow all instructions on the machine and in the manual(s) before attempti ng to assemble and ope rate. Keep this manual in a safe place for future and regular re ference and for o rdering replacement parts. 2. Be familiar with all controls and their proper [...]

4 27. Use only acce ssories and attachments approved for this machine by the machine manufacturer. Read, understand and follow all in structions provided with the approved accessory or attachmen t. 28. Data indicates th at operators, age 60 years and above, are involved in a large percentage of ridi ng mower- related injuries. These opera to rs sho[...]

5 b. Never fill containers inside a vehicle or on a truck or trailer bed with a pla stic liner. Always pla ce containers on the ground away from your vehicle before filling. c. When practical, remove gas-powered equipment from the truck or trailer and refue l it on the ground. If this is not possible, then refuel such equip ment on a trailer with a[...]

6 SECTION 2: SLOPE GAUGE 15° SIGHT AND HOLD THIS LEVEL WITH A VER TICAL TREE A POWER POLE A CORNER OF A BUILDING OR A FENCE POST F O L D O N DO T T E D L I N E , RE P RE S E NT I NG A 1 5 ° S L O P E Do not mow on inclines with a slope in excess of 15 de grees (a rise of appr oximately 2-1/2 feet every 10 fee t). A riding mower could overturn a n[...]

7 SECTION 3: TRACTOR SET-UP NOTE: Any referenc e to right, left, front or back of the tractor is from the operating positio n, unless otherwise stated. Attaching The Steering Wheel • The hardware for att aching the steering wh eel has been packed within the ste ering wheel, beneath steering wheel cap. Care fully pry off the steering wheel cap and[...]

8 SECTION 4: OPERATION Know the Controls Read this owner’s manual and safety rules befor e operating your lawn mower. Compare figure below with your lawn tractor to lear n about the loction and purpose of various controls and adjustments. Save th is manual for future reference. It is very important to follow the instructions and operate the con t[...]

9 Throttle Control Lever The throttle contr ol lever controls the speed of the en gine. When set in a given position, the throttle will maintain a uniform engine speed. Choke Control Bronco : Moving the th rottle lever all the way forward activates the engine’s choke control. Super Bronco : The choke con trol knob is on the left side of th e dash[...]

10 Headlights • To turn on the hea dlights, rotate the same igni tion key from ON position to ON/LIGHTS position of th e ignition switch. • To turn off th e 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). Ammeter The ammeter measures th e e[...]

11 NOTE: The deck wheels ar e an anti-scalp feature of the deck a nd are not designed to support the weig ht of the cutting deck. Cargo Net Conveniently locate d on the tractor’s dash panel, the carg o net can be used to store personal ite ms while operating the lawn tract or. Cup Holder The tractor’s cup holder is located on the fender to th e[...]

12 Starting the Engine NOTE: Re fer to the TRACTOR SET-UP o n page 7 manual f or gasoline and oil f ill-up instructions. 1. Insert the tractor key in to the ignition switch. 2. Place the PTO (Blade Engag e) Lever in the disengaged (Blade Stop) position. 3. Engage the t ractor’s parking brake. 4. Move the throttle control leve r into the CHOK E po[...]

13 • Do not mow at high ground sp eed, especially if a mulch kit or grass collector is installed. • For best results it is recommended that the first two laps be cu t with the discharge thrown towards the center. After the first two laps, re verse the direction to throw the discharge to the outside for the bala nce of cutting. This will give a [...]

14 Steering • If the tractor t urns tighter in one direction than the other, or if the ball joint s are being replaced due to damage or wear , the steering drag links may need to be adjusted. Adjust the dr ag links so that equal lengths are threade d into the ball joints on both sides. 1. Loosen the jam nut on the drag link at the rear of t he ba[...]

15 Side to Side If the cutting deck ap pears to be mowing unevenly, a side to side adjustment can be performed. Adjust if necessary as follows: 1. With the trac tor parked on a firm, level surface, place the deck lift lever in the to p notch (highest position) and rotate bot h blades so that they are perp endicular with the tractor . 2. Measur e th[...]

16 Pivot Points & Linkage • Lubricate all pivot poin ts on the drive system, parking brak e and lift linkage at least once a season with light oil. Rear Wheels • Remove rear whee ls from the axles once a season; lubric ate the axles and rims w ith an all-purpo se automotive grease and re-install th e wheels Front Wheels • Each front wh ee[...]

17 5. Thread hose coupler (packaged with th is manual) onto the end of your gard en hose. See Figure 12. 6. Attach the hose coupler to the water port on your decks surface. Se e Figure 12. Turn the wate r on. 7. While sittin g in the operat or’s position, re- start the engine and place thro ttle lever in FAST (rabbit) position. 8. Move the PT O ([...]

18 12.6 V or higher f or adequate charge . Otherwise, charge the battery with an automotive-typ e 12-volt charger f or a minimum of one hour at six amps. Fo llow the chart below to charge: Jump-Starting IMPORT ANT : Do not jump-start a damag ed battery. Before connecting the jumpe r cables, make sure that the two equipment are no t in contact and t[...]

19 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. Gently slide the cu tting deck toward the fron t of [...]

20 • All belts on the tracto r are subject to wear and should be repla ced if cracking, shredding or rotting occurs. To change or repl ace the deck belts on you r tractor, procee d as follows: 1. Lower the deck by moving t he deck lift lever into the bottom notch on t he right fender. 2. Remove the b elt guards by removing t he self-tapping scre [...]

21 5. Remove the upper drive belt by pulling it up through the battery tray opening. 6. Reroute the new uppe r drive belt a s shown in Figure 16. Lower Drive Belt IMPORT ANT : Note the routing of the lower drive belt ar ound both the pulleys and t he belt keepers before performing the following steps. 1. Locate the variab le-speed pulley through th[...]

22 After replacing the drive belts, adjust the drive pedal on your tractor as fo llows: 1. Locate the sp eed control assem bly on the underside of the st eering support bracket. See Figure 18. 2. Remove both hair pin clips from the pin which is fastened to the speed cont rol assembly (be careful not to lose the small flat washers found on the pin).[...]

23 SECTION 9: TROUBLESHOOTING Tr o u b l e P ossible Cause(s) Corrective Action Engine fails to start 1. PTO lever engaged. 2. Parking brake not engage d. 3. Spark plug wire(s) disconnected. 4. Throttle control le ver not in correct starting position. 5. Fuel tank empty, or stale fuel. 6. Blocked fuel line. 7. Faulty spark plug. 8. Engine flooded. [...]

24 SECTION 10: PARTS LIST FOR MODELS J609 & T609 A A 15 17 21 5 27 18 1 13 26 6 5 11 28 29 30 27 34 35 16 10 8 32 33 31 45 46 23 42 38 24 25 36 44 2 4 4 3 42 22 20 41 40 37 2 9 47 23 NOTE: For painte d pa rts , refer to the list of color codes below. Please add the applicable color code to the part number for a replacement part. For instance, i[...]

25 Models J609 & T609 Ref. No. Par t No. Description 1 783-1346 Grill Supp or t Brac ket (9-style) 2 710-0599 Self-tapping Screw , 1/4-20 x .5 3 710-0528 Hex Ca p Screw , 5/16-18 x 1.25 4 710-0924 Phillips P an Screw , 1/4-20 x .75 5 710-1017 T russ Phillips Screw , 1/4-20 x .625 6 725-1741 Ignition Switch 7 735-04019 Side P anel Seal 8 710-064[...]

26 48 33 27 47 34 4 1 40 11 49 28 46 39 44 28 14 8 43 17 21 10 20 12 23 21 22 24 6 2 43 45 18 25 1 9 5 3 4 1 16 9 7 17 15 6 26 13 35 38 32 18 24 6 29 30 31 6 6 36 14 37 51 50 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 i [...]

27 Ref. No. Pa r t No. Description 1 747-1130B Deck Stabilizer Rod 2 683-0197B Lift Shaft Assembly 3 711-0332 Clevis Pin, .5 x .78 4 712-0206 Hex Nut, 1/2-13 5 712-0431 Flange Lock Nut, 3/8-16 6 712-0429 Flange Lock Nut, 5/16-18 7 712-3083 Hex Nut, 1/2-13 8 714-0104 Inter nal Cotter Pin 9 714-0145 Inter nal Cotter Pin 10 716-0106 E-Ring 11 720-0311[...]

28 24 2 1 2 5 3 9 6 38 7 10 12 13 11 13 14 15 16 17 18 19 21 20 22 20 25 26 27 28 30 29 34 30 36 32 37 39 33 11 8 22 4 23 35 40 32 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 i nstance, if a part numbered 700-xxxx is pain[...]

29 Ref. No. Pa r t No. Description 1 710-1260A Self-tapping Screw , 5/16-18 x .75 2 710-0604A Self-tapping Screw , 16-18 x .625 3 783-0726B RH Pivot Suppor t Brac k et 4 783-0727A LH Pivot Suppor t Brack et 5 783-0728 Pivot Bar Br ac ket 6 710-0514 He x Cap Screw , 3/8-16 x 1 (Grade 5) 7 711-1408 RH Drag Link 8 711-1409A LH Drag Link 9 712-0240 Jam[...]

30 IMPORT ANT : For a proper working machine, use Factory App roved Parts. V-belts are designed to engage and diseng age safely. A substitute (non OEM) V-belt ca n be dangerous by not disengaging compl etely. B B A A C D E E D C 19 6 4 22 37 34 9 6 18 15 11 14 26 38 3 13 1 24 25 33 12 35 31 35 27 6 8 10 12 30 20 35 21 16 29 23 36 2 5 39 40 41 42 43[...]

31 Ref. No. Par t No. Description 1 178 40 Mounting Bracke t 2 618 -04133 Drive Assembly 3 618 -04147 Variable Spd. Pulley Assembly 4 647 -04020 Shift Lever Assembly 5 710 -0607 TT Screw 5/16-18 x 0.5 6 710 -0726 AB Screw 5/16-12 x 0.75 7 710 -0809 TT Screw 1/4-20 x 1.25 8 710 -1007 TT Se ms Screw 3/8-16 x 1.5 9 710 -1266 He x Bolt 5/16-18 x 3.5 10[...]

32 8 3 2 5 6 8 4 10 9 7 12 1 1 11 12 1 3 14 3 17 15 16 18 19 20 21 22 23 24 25 28 29 27 26 Models J609 & T609[...]

33 *Use applic ab le flat washer (12a, 12b or 12c) in this application allowing .0150/.0020 in end-pla y NOTE: If rebuilding the upper housing of the transmission, add two ounces of Unirex ® N3 grease (Part No. 73 7-0289) in the input shaft cavity. Ref. No. Par t No. Description 1 732-0614 Ring, Wire 2 716-0231 Ring, E Type, .750 3 736-0336 Flat W[...]

34 45 46 47 4 4 45 43 39 31 34 42 41 35 32 36 32 40 32 33 37 7 27 23 15 11 18 14 2 8 22 6 2 7 55 28 5 4 29 51 52 53 54 A A 21 17 10 9 3 25 24 30 16 12 9 19 11 1 13 38 50 57 56 9 10 48 49 B 11 18 22 26 58 59 60 58 59 60 61 NO TE: #63 (batter y hold-down rod) is not shown in picture . Models J609 & T609 NOTE: For painted parts , refer to the list[...]

35 Ref. No. Pa r t No. Description 1 647-0064 PT O Engag e Le ver Assembly 2 683-0450 PT O Engag e Plate Assembly 3 710-0276 Carr iage Screw , 5/16-18 x 1.00 4 710-0520 Hex Cap Scre w , 3/8-16 x 1.5 5 710-0831 Hex Cap Scre w , 3/8-16 x 5.5 6 710-0726 AB Screw 5/16-12 x 0.75 7 712-0229 Push Nut, 3/8 8 712-0431 Flange Lock Nut, 3/8-16 9 712-3004A Fla[...]

36 11 11 15 4 14 12 9 18 21 20 7 10 6 5 17 16 1 18 8 22 2 3 Oil Ref. No. Pa rt No. Description 1 710-0227 AB Screw #8-18 x 0.5 2 710-0599 TT Screw 1/4-20 x 0.5 3 710-0726 AB Screw 5/16-12 x 0.5 4 710-1237 T screw #10-32 x 0.625 5 710-1314A Sock et Hd Scr . 5/16-18 x .750 6 710-1315 TT Screw 3/8-16 x 1.25 7 712-0271 Sems Nut 8 721-0208 Exhaust Gaske[...]

37 A1 M ST ARTER AFTERFIRE SOLENOID AL TERNATOR AL TERNATOR MAGNETO BLK RED 725-1426 SOLENOID 20 AMP FUSE RED 725-1657A YEL SWITCH BRAKE WHT A2 HEADLIGHTS HEADLIGHTS RED PTO SWITCH BLU ORG/WHT 725-1716 YEL/WHT ORG/BLK L S B ORG YEL/BLK GRN Rev . Kill Mechanical G RED/WHT 725-1439 725-1303 SEA T SWITCH BLK SYSTEMS INDICA TOR MONITOR OIL SENSOR FUSE [...]

38 Models J609 & T609 12 34 20 38 20 34 31 42 15 41 26 10 45 37 6 2 24 8 21 29 7 17 22 32 23 25 36 15 30 13 27 33 19 18 1 11 14 35 16 16 3 40 9 4 17 43 C C 37 10 44 39 46 19 5 47 32 48 28 50 49 B 52 53 54 51 57 16 58 56 55 NOTE: For painted parts , refer to the list of color codes below. Please add the applicable color code to the part number f[...]

39 Models J609 & T609 Ref. No. P ar t No. Description 1 711-04069 Grass Catcher Pin, 1/4-20 2 618-0565 Spindle Assy., 5.75 Dia. w/ Fitting 3 683-0198G 42-inch Deck Shell 4 683-0254 Deck Adj. Bracket w/ Weld Nut 5 736-0140 Flat Washer, .385 x .62 x .063 6 710-0520 Hex Cap Screw, 1/4-20 x 1.5 7 710-0528 Hex Cap Screw, 5/16-18 x 1.25 8 710-0726 Se[...]

MANUF A CTURER’S LIMITED W ARRANTY FOR: The limited warranty set forth be low is given by Troy-Bilt LLC with respect to new merchandise purchased and used in the United States, its possessions an d territories. “Troy-Bilt” warrants this produc t against defects in material and workmanship for a pe riod of two (2) years commencing on the date [...]