Troy-Bilt 604 manual

O PERA T OR’S M ANU AL IMPORT ANT : READ SAFETY RULES AND INSTR UCT IONS CAREF ULL Y MTD PR ODUCTS INC. P .O . BO X 368022 CLEVELAND , OHIO 44 136-9722 PRINTED I N U. S .A. FORM NO . 770-10187 Wa rn in g: Th is un it is equi pped wi th a n in ter nal c omb ustio n en gi ne an d sh ould not be used on o r n ear an y un impr ov ed fo res t- cover e[...]

2 SECTION 1: TABL E OF CO NTENTS PAGE FIN DI N G YO UR MO DE L N UM B ER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CA LLI NG CU STO ME R S UP P ORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 IMP O RTA NT S A F[...]

3 SECTION 4: IMPOR TANT SAFE OPERAT ION PRACTICES WARNING: THIS SY M BOL POINT S OUT IMPORTANT SAFET Y I N STRUCTIO NS WHICH, IF NOT F OLLOWED, C OULD EN DANGER THE P ERSONAL SAF ETY AND/O R PROPERT Y OF YOURSELF AND OTHERS. READ AND FOLLOW ALL INSTRUCTIONS IN T HIS MANUAL BEFORE ATTEMPT ING TO OPERATE Y OUR LAWN M OWER. FAILURE TO CO MPLY W ITH TH[...]

4 • Diseng age all att achment cl utches, thor oughly depres s the br ake pedal, and shi ft into neutr al befor e att em pt ing to start engi ne. • You r mower is design ed to cut normal residen tial grass of a height no m ore than 10". Do not attempt to mow th rough unus ually ta ll, dry grass ( e. g . , pastur e) or p i l es of dry l eav[...]

5 • Kee p all n uts, bol ts and screws tight to be sure t h e equipmen t is in safe work ing conditi on. • Nev er tam per with safety devi ces. Chec k t heir proper operation regul arl y. Use all guar ds as inst ructed in thi s m anua l. • Afte r striki ng a for eign object , sto p the engi ne, remove the wir e fr om the spark plug and thorou[...]

6 Slope G auge 15 ° SIGHT AND HOLD THIS L E VEL WITH A VERTICAL TREE A POWE R PO LE A CO R NER O F A BU ILDING OR A FENCE PO ST F O L D O N D O T T E D L I N E , R E P R E S E N T I N G A 1 5 ° S L O P E USE THIS PA GE AS A GUIDE TO DETERMI NE SLOPES WHERE YOU M A Y NOT OPERAT E SAFELY. Do not mow on inclines with a slope i n excess of 15 degrees[...]

7 SECTION 5: ATTACHM ENTS & ACCESSORIES SECTION 6: T RACTOR SET-UP A TT A CHING THE B A TTER Y CABLE S NOTE: The positive bat tery terminal is marked Pos. (+). T he negativ e battery terminal is marked Neg. (–). • The positive c able (heavy red wire) is secured to the posit i ve battery terminal ( + ) wi t h a hex bolt and hex nut a t the f[...]

8 SECTION 7: CONTRO LS Fig ure 3 A Ignition Switch H Brake Pedal B Throttle Control Lever I Parking Brake Button C Cho ke Control (if so equip ped) J Shift Lever D Indicator Monitor/Hour Meter K Seat Adjustment Lever E Lift Lever L Cup Holder F PTO (Power Take-Off) Lever M Cruise Control Button G AutoDrive ™ Pedal A B D C F M I J L E G H K NOTE: [...]

9 IGNITION SW IT CH To start the engin e, i nsert key i nt o the ignition switch and turn clockw ise to the S TART position. Release key to the ON p os it i on once en gine h as fired. See Figure 4. Refer to STAR TING THE ENGI NE in the OP ERATION se ction of this manual for detailed starting in structions. The ignitio n switch is al so used to o p[...]

10 LI FT LE VER The li ft lever i s used to ch ange th e o perating pos ition (height) of the cutting deck. To operate, move the lever to the left , then place i n the notc h best suit ed for your application. PT O (PO WER T AKE-O FF) L EVER The PTO lever is located on t he left sid e of the das hboard next to the steering wheel. Move the PTO lever[...]

11 CRUISE CONTR OL BUTT ON The cru ise control button is locat ed on the trac tor dash panel to the left of th e ignition swit ch. Push the cruise c ontrol button while traveling forward at a des ired speed. While holding the button in, release pressure from the AutoD rive ™ pedal. This w ill engag e the cruise control an d allow the tractor to r[...]

12 SETT ING THE CUT TING HEIGHT Select the height position of the cutting deck by placing t he dec k lift lever in a ny of the s ix different cutt ing height not ches on the righ t sid e of the fen der. Then adj us t the deck wheels s o that they are at least 1/4 inch to 1/2 inch abo ve the ground when the tracto r is on a sm ooth, flat surfac e su[...]

13 • While cont inuing to hold the cruise bu tton i n, lift your foot from the AutoDrive ™ pe dal (you should feel the cruise latch engage ). • If properly engaged, t he cruise contro l button and the AutoDrive ™ pedal s h ould lock in the down pos ition, and t he trac tor will maintain the same f orward s peed. • Disenga ge the cruise co[...]

14 MO W IN G This tractor is equipp ed with one of MTD ’s high q ualit y c utting d ecks . The foll ow ing info r mation w ill be helpful whe n using the cutting d eck with your tract or. WARNING : To avoi d poss ible injury, do not allow anyone in the area of the tractor while mowing. E ven if the area to be mowed has been cleared of foreign obj[...]

15 • Measure the distance from the outside of the left blade tip t o the ground and the distance from the outside o f the right b lade tip to the g round. B oth measu rements tak en should be e qual. I f 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. • Ba[...]

16 Front tire toe-in can b e measured as follows: • Place the steering wheel in position for straight ahead travel. Insert a 1/4" dowel up through aligning hole s in both t he steering gear and support plate. See Figu re 10. Figure 10 • In front o f the ax le, measure t he distance horizontally from the inside of th e le ft rim to the i ns[...]

17 • Locate th e PTO e ngagem ent rod an d the PT O adjuster link by looking at the t ractor’s undersi de. See Figure 12. • Remov e the cotter pin that af fixes the lower end of the P TO engagement ro d to the PTO adjuster link. Sav e th e pin. See Figure 12 . • Take the lower end of the PTO engag ement rod out o f the hole in the PTO adjus[...]

18 CLEANING THE ENGINE AND DE CK Any fu el or oil spilled on the m achine s hould be wiped o ff prom pt ly. Do NOT all ow grass , leaves, and dirt to acc umulate aroun d the c ooling fins of the engine or on any othe r part of the machine, esp ecially the pulleys and other mov ing parts. Clean the unde rside of t he dec k with a w isk broom, putty [...]

19 CHANGING THE DECK BEL T(S) All belts on your tractor are subje ct to wear an d should be replaced if any signs of c racking, shreddin g or rotting are present. IMPORTANT: The V-be lts found on your tractor are s pe cially designe d to engage and disengage safe ly. A substitute (non - OEM) V-belt c an be dang erous by not dise ngaging com pletely[...]

20 IMPORTANT: It is rec ommend ed that the PT O be read justed after replacing t he deck belt. Refer to PTO (POWER TAKE- O FF ) ADJUSTM ENT in the ADJ U ST M EN TS section of this m anual for the proper procedure. • Remount the belt guards removed earlier. CHANGING THE TRANSMISSION DRIVE BEL T(S) All belts on your tractor are subje ct to wear an [...]

21 Figure 1 6 • Remov e the rear idler pu lley from the double- idler bracket while unrouting t h e belt fr o m around bot h the rear and the front idler pulley. Refer to F igure 16. • Remov e the cotter pin that af fixes the lower end of the P TO engagement ro d to the PTO adjuster link. Save the pin for reassembly. See Figure 17 . Figure 17 ?[...]

22 • Remov e the two h ex bolts (from both sides of the tractor) that aff ix the PTO actuat or bracket to the tractor frame. See Figure 19. Figure 19 • Carefully lower the PTO actuator bracket and the engine pul ley as an a ssembly wh ile removing the d rive belt f rom the upper portion of the engin e p ulley. • Remov e the drive belt by feed[...]

23 NOTE: The hex flange n ut has a right-handed thread pa ttern. Do NOT attempt to force the nut in the i ncorrect direction. Doing so m ay damage t he nut and create a safety hazard. Figure 22 To prope rly sharpe n t he c utting b lades, rem ove equal am ount s of met al from both end s of the blades along th e cutting edges. See Figure 23. Sharpe[...]

24 TIR E S The recom mended op erating tire p ressure is approx imately 10 psi for the rear tires and 14 psi for the front tires. Refer to the ti re sidew al l for exact tire manufac turer’s recommend ed psi. Do not overinflate. Unev en tire pressure could cause t he cutting deck to mow unevenly. SECTION 11: LUBRICAT ION WARNING: Alwa ys stop t h[...]

25 SECTION 12 : TROUBLESHO OTING GUIDE T rouble Possible Cause(s) Corrective Action Engine will not cr ank Sa fety swit ch but ton not depress ed. Battery ins talled in corr ectl y . Battery is dead or w eak. Blown f use There are t wo saf et y swi t ches in the starting circ uit of your uni t: the br ake pedal s wit ch and the PT O s witch. M ak e[...]

26 REF . NO . PA R T NO . DESCRIPTION 1 625-0051 Bulb/Soc ket Headlight Assem b ly 725-17 39 Bul b Onl y 725-16 49 Sock et Only 2 629-0913 Wiring Ha r ness 3 629-0924 Harness Adapter ( fo r K ohler engines ) 4 710-0599 Self T apping Scre w , 1/4 -20 x . 5 5 712-3006 He x Nut, 1/4-20 6 725-1426 Solenoi d, 12-v ol t, 100 Amp 7 725-1657A Snap Mount Sa[...]

27 El ectr ica l Sy st em/ Trac tor Body 1 4 21 10 4 2 32 2 12 16 2 13 22 14 3 6 8 9 18 19 6 22 22 22 22 22 22 15 33 31 34 26 35 23 24 28 25 30 29 4 27 36 20 4 REF . NO . PA R T NO . DESCRIPTION 1 710-078 8 Self T apping Scre w , 1/4- 20 x 1.0 2 710-059 9 Self T apping Scre w , 1/4- 20 x .5 3 710-075 1 He x Cap Screw , 1/4- 20 x .62 4 710-089 5 Sel[...]

28 Model 604 49 39 46 6 45 45 41 37 43 42 36 47 48 44 16 30 28 35 32 38 33 27 31 34 50 51 11 28 29 14 8 13 9 17 21 22 10 20 12 23 21 2 2 24 6 2 8 14 18 25 19 4 5 3 16 4 1 16 9 7 17 15 5 19 8 14 6 6[...]

29 REF . NO . PA R T NO . DESCRIPTION 1 647-004 0 Dec k Stabil ize r Rod 2 683-019 7 Lift Shaf t Ass embly 3 711-033 2 Cle vis Pi n, .5 x . 78 4 712-020 6 He x Nut, 1/2-13 5 712-043 1 Flang e Loc k Nut, 3/8-16 6 712-300 4A Flang e Loc k Nut, 5/1 6-18 7 712-308 3 He x Nut, 1/2-13 8 714-010 4 Internal Cotter Pin 9 714-011 1 Cotter Pi n 10 716-010 6 E[...]

30 Model 604 1 2 2 2 5 3 9 6 38 8 10 12 1 3 11 13 14 15 16 17 18 19 21 20 22 20 24 23 4 25 26 27 28 29 33 31 31 30 29 32 35 34 30 32 35 36 33 37 39 40 11 41 42 13 7 43 42[...]

31 REF . NO . PA R T NO . DESCRIPTION 1 683-026 3 Low er F rame Asse m b l y 2 710-060 4 Self-t apping Scre w , 16-18 x .625 3 783-072 6 RH Pivot Support Brack et 4 783-072 7 LH Piv ot Su ppor t Brac k et 5 783-072 8 Pivo t Bar Brack et 6 710-051 4 He x Cap Screw , 3/8- 16 x 1 (Gr ade 5) 7 711-129 1 LH Drag Link 8 711-129 2 RH Drag Link 9 712-024 0[...]

32 Model 604 4 22 13 5 1 12 2 21 2 21 13 19 13 18 36 11 28 31 7 38 46 47 40 8 44 43 12 43 12 37 47 15 17 19 19 50 26 27 24 10 49 19 33 23 30 32 20 42 14 3 9 16 61 3 9 13 76 62 13 69 53 54 25 41 57 58 19 23 64 68 73 71 70 58 65 56 56 58 33 77 72 58 63 55 69 60 66 59 21 75 33 52 3 1 68 64 23 23 35 78 79 34 80 81 82 6[...]

33 REF . NO . PA R T NO . DESCRIPTION 1 1783 9 Shif t Le ver Brac ket 2 1784 0 T ransaxle Mounti ng Br ack et 3 618-038 6 Single- speed T ransmi ssion Assemb ly 4 631-000 9 Shifte r Knob 5 647-004 1 Shift Le ver 6 656-004 8 V ariabl e-spee d Pulle y Asse mbly 7 656-005 1 T ransmi ssion Pulle y , 8.5 x .5- 36 8 683-025 1 Doub le -idler Br ac ke t 9 [...]

34 Model 604 33 22 13 23 17 1 10 28 5 13 29 4 35 36 34 10 23 20 9 32 3 19 27 10 18 14 2 12 5 59 5 24 6 45 15 21 25 11 26 31 16 56 5 5 49 57 55 58 38 54 53 51 49 10 47 52 48 46 7 44 30 41 39 37 38 43 40 60 61 62 63 63 8[...]

35 REF . NO . PA R T NO . DESCRIPTION 1 683-027 8 PT O Engageme nt Li nk w/ W eld Pin 2 683-028 2 PT O Actu ator Brac ket w/ Wel d Nut 3 710-051 4 He x Cap Screw , 3/8- 16 x 1.0 (Gr ade 5) 4 710-059 7 He x Cap Screw , 1/4- 20 x 1.0 (Gr ade 5) 5 710-060 4 Self T apping Scre w , 5/16 -18 x .6 25 6 710-126 0A Self T apping Scre w , 5/16 -18 x .75 7 71[...]

36 Model 604 42-inc h Deck 46-inc h Deck 5 1 1 17 13 17 11 30 37 30 31 8 6 19 12 26 25 29 52 22 53 55 50 36 19 26 25 29 23 32 20 23 32 21 27 9 18 7 35 28 26 15 24 16 14 2 34 18 3 33 38 10 3 10 10 10 17 40 11 13 42 17 19 26 25 44 29 23 32 20 4 23 21 9 27 32 52 53 54 51 19 48 48 12 45 26 25 29 44 43 47 41 22 49 49 56 57[...]

37 REF . NO . PA R T NO . DESCRIPTION 1 1798 2 Reinf orcemen t Spindle Plate 2 618-024 0 Spindle Ass embly , 5 Di a. 756-095 9 Pulle y Only 3 618-024 1 Doub le Pull ey Spindl e Assemb ly 756-060 3 Doub le Pull ey O nly 4 683-025 4 Dec k Adjus tment Brac ket w / W eld Nut 5 683-026 5 46-inch Dec k Shell 6 710-016 7 Carriage Scre w , 1/4-20 x .5 7 71[...]

38 Model 604 Kohler Briggs & Stratto n In tek Twin Single-c ylinder 9 7 11 (f or c hoke) 13 4 9 7 11 (f or ch oke) 13 9 12 (fo r t hrot tl e) 6 9 22 18 19 20 8 10 14 10 5 10 5 16 15 1 (def l ect or must fac e forw ard ) 18 20 19 14 1 ( def l ect o r m ust face for w ar d ) 24 27 28 21 23 26 17 5 35 3 2 21 3 2 21 25 36[...]

39 Engine Accessories Briggs & Str atton Intek Si ngle 3 2 18 19 2 0 REF . NO . PA R T NO . DESCRIPTION 1 710-014 8 Self T apping Scre w , # 8-32 x .375 2 710-059 9 Self T apping Scre w , 1/4- 20 x .5 3 710-060 4 Self T apping Scre w , 5/16 -18 x .6 25 4 710-123 7 Scre w , #10-32 x .625 5 710-131 4 Soc ket Cap Scre w , 5/1 6-18 x .625 6 710-131[...]

MANUF A CTURER’S LIMITED W ARRAN TY FOR: For TWO YEARS f rom t he date of retail purcha se within the Un i ted S tates of America, its posse ssions and territories, M TD PRODUCTS INC will, at its option, repa ir or replace, for the original purchaser, free o f charge, any part or pa rts found t o be defective in material or workmanship. This warr[...]