Yard-Man 604 manual

O PERA T OR’S M ANU AL IMPORT ANT : READ SAFETY RULES AND INSTRUCTIONS CAREFULL Y MTD PRO DUCTS INC. P .O . BO X 368022 CLEVELAND , OHIO 44136-9722 PRINTED IN U .S.A. FORM NO . 770- 10235A Warning: This unit is equipped with an internal c ombustion engine and should not be used on or near any unimproved f orest- covered, brush-covered or grass -c[...]

2 SECT ION 1: TABL E OF CO NTENTS PAGE FINDING Y OUR MODEL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CALLING CUSTOMER S U PPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 IMPORTANT SAFE O PERATION PRACT[...]

3 SECTION 4: IMPORTANT SAFE OPERATION PRACTICES WARN ING: THI S 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 OP E RATE YOUR LAWN MOWER. FAILURE TO COMPLY WITH THESE INSTRUCTIONS M[...]

4 • Disen gage all attachment clutche s , tho roughl y depress the bra ke pedal , and shift into neutral before attemptin g to start engi ne. • Your mow er is designed to c ut normal r esidentia l grass o f a height no mo re than 10" . Do n ot attempt to mow t hrough unu sually tall, dry grass (e.g., pasture) or p iles of dry leave s. Debr[...]

5 • Keep a ll nuts, bo lts and screws ti ght to b e sure the equipme nt is in safe work ing condition. • Never tamper with safety devic e s. Check their proper opera tion regularly. Us e all guards as instructe d in this manu al. • After st riking a foreign obj ect, stop the engin e, remove the wire from the spark plug an d thoroughly inspect[...]

6 Slope Gauge 15° SIGHT AND HOLD T HIS LEVEL W IT H A VE RTICAL TR EE A POWER PO LE A CORN ER OF A BUILDIN G OR A FE NCE POST 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 PAGE AS A GUIDE TO DETERMINE SLOP ES WHERE YOU MAY NOT O PERATE SAFELY. Do not m ow on incline s wit h a slop e in ex cess o f 15 d egree[...]

7 SECTION 5: ATTACHMENTS & ACCESSORIES SECTION 6: TRACTOR SET-UP A TT A CHING THE B A TTER Y CABLES NOTE: The posi tive b attery termi nal is m arked Pos. ( +). The neg ative bat tery ter minal is m arked Neg. (–). • The posit i ve cable (h e avy red wi re) is secu red to the pos itive batt ery term inal (+ ) with a hex bolt a nd hex nut at[...]

8 SECTI ON 7: CONT ROLS Figure 3 A Ign ition Swi tch H Bra ke Pe dal B Throttl e Control Lever I Parking B rake Butto n C Choke C ontrol ( if so equ ipped) J Shift Lev er D Indica tor Moni tor/Hou r Meter K Seat A djustme nt Leve r E Lift Lev er L Cup Holder F PTO (Pow er Take-O ff) Lever* M Cruise Control B utton G AutoDrive ™ Pe dal N PTO ( Pow[...]

9 IGNITION SWITCH To start the engine , insert key into the ignition switch and turn clockw ise to th e START po sition. Re lease key to t h e ON position o nce en gine ha s fired. See Figure 4. Refer to STA R TING THE ENGI NE in the OPERA TION sec tion of this manual for de taile d startin g instr uctions . The ignit ion swit ch is al so use d to [...]

10 ELECT RIC PTO (PO WER T AKE-OFF) KNOB T o en gage the power to th e cutting deck or other att achme nts, pull outward on th e PT O kn ob . P ush the PT O knob in ward to disenga ge the power to the attachm ents. NOTE: T he PTO knob must be i n the d isengage d (OFF) p osition whe n starti ng the en gine, whe n shift ing into revers e and if the [...]

11 SHIF T LEVER The shif t lever is locat ed on the left s ide of the fender an d has three positions, FORWARD, NEUTRAL and RE VERSE. The br ake peda l must be depres sed and the tra ctor must no t be i n motion when the mo ving shift leve r. IMPORTANT: Never force the shift lever. Doing so may re sult in seri ous damage to the tra ctor’s transm [...]

12 SETTING THE CUTTING HEIGHT Select the he ight posi tion of the cu tting deck by placin g the d eck li ft lever i n any of the six di fferent cutting hei ght notches on the right side of the fender. Then adj ust the deck wheels so that they are at le ast 1/4 inc h to 1/2 i nch abov e the ground when the tractor i s on a s mooth, flat surfac e suc[...]

13 • While co ntinui ng to hold the cruis e button in , lift your foot from the AutoDrive ™ ped al (you should feel the c ruise latc h enga ge). • If properly engaged, the cruise contr ol button and the AutoDr ive ™ p edal sho uld lo ck in the down pos ition, and the tracto r will m aintain th e same forw ard speed . • Disengag e the crui[...]

14 • The operat or mus t remain in the t ractor sea t at all times . If th e operato r shoul d lea ve the seat wi thout pus hing th e PTO knob inward into the disen gaged (OF F) posit ion, th e tractor ’ s engi ne will shut off. IMPORTANT: The PTO knob cannot be in th e engaged ( ON) positio n when the tract or is drivi ng in the rev erse di re[...]

15 • With the t ractor parked o n a firm, level surface, pl ace the lift lever in the top notch (highe st positi on) and rot ate the bla de neares t the dis charge ch ute so th at it is p arallel with the tractor . • Measur e the dist ance from t he front o f the blade ti p to t he groun d and the rear o f the blade ti p to the gro und. The f i[...]

16 SEA T ADJ USTMENT To adjus t the posit ion of the seat, m ove the sea t adjustm ent lever (locate d under the seat) to the left and sli de the sea t forward or back wards. S ee Figu re 9. Make sure seat is lo cked into on e of the six adjustm ent positi ons b efore ope rating th e tractor. Figure 9 STEERING ADJU STMENT If the tracto r turns tigh[...]

17 • Loosen, but do NOT remove, the hex nut found on the right sid e of the brak e assemb ly. See Figure 12. • Using a feele r gauge , set the gap between th e brake disc and the brake p uck at .0 11". • Re-tighte n the hex nut loo sened ear lier. Figure 12 SECTION 10: MAINTENANCE WARN ING: Di scon nect the sp ark p lug wire(s) and groun[...]

18 CLEANING THE ENGINE AND DECK Any fue l or oil spil led on the machine should be wiped off promptl y. Do NO T allo w grass, leaves, and dirt to accumu late ar ound the c ooling f ins of t he engin e or on any ot her part of the mach ine, especi ally the pulle ys and ot her m oving par ts. Clean the u nderside of the de ck with a wisk broom , putt[...]

19 CHANGING THE DECK B EL T( S) All bel ts on you r tract or are s ubject t o wear and shou ld be rep laced if any sig ns of cr acking , shredd ing or rotting are presen t. IMPORTANT: The V-bel ts found on y our trac tor are spe cially des igned to engage and disen gage safel y. A substit ute (no n-OEM) V -belt can be dange rous by not diseng aging[...]

20 Figure 16 CHANGING THE TRANSMISSION D RIVE BEL T(S) All bel ts on you r tract or are s ubject t o wear and shou ld be rep laced if any sig ns of cr acking , shredd ing or rotting are presen t. IMPORTANT: The V- belts fou nd on y our tra ctor are s peciall y desig ned to enga ge and disengag e safel y. A substit ute (n on-OEM) V-belt can b e dang[...]

21 Figure 17 Lower Drive Belt NOTE: Pro per re moval of the lo wer dr ive be lt requires the remo val o f sever al trac tor comp onents. Read throug h the followi ng proce dure prior to attempt ing it to determin e if you fee l you coul d succes sfully compl ete it. If you don ’ t, see an authoriz ed MTD service d ealer to have the belt chang ed.[...]

22 • Remove th e hex bolt from the ce nter of th e engine pul ley (or the electri c PTO clu tch on units so e quipped) and gently l ower it off o f the engin e crank shaft. Be c areful no t to lose any washe rs or spac ers which ma y be found on to p of the e ngine pulley or th e electri c PTO clutch . See Fi gure 18. • On units equi pped with [...]

23 NOTE: The h ex flan ge nut h as a right-ha nded (normal) thread pat tern. Do NOT at tempt to force th e nut in the incorr ect dire ction . Doing so may da mage the nut and create a safety h azard. To proper ly sh arpen th e cutt ing blad es, rem ove equal amou nts of metal from both ends of the blades along the cutti ng edges. See F igure 22 . S[...]

24 SECTION 11: LUBRICATION WARN ING: Alwa ys stop the engine and disco nnect the sp ark plug wire(s) an d ground ag ainst th e engine be fore p erforming any ma intenan ce. ENGI NE Lubricate the engi ne with motor oi l as ins tructed in the se parate engine ma nual p acked wi th your u nit. PIV O T POINTS Lubric ate all pi vot po ints (A utoDrive ?[...]

25 SECTION 12: TROUBLESHOOTI NG GUIDE T rouble Possible Cause(s) C orrective Action Engine wil l not cra nk Saf ety s witch bu tton not depr esse d. Battery install ed incor rect ly . Battery is dead or w eak. Blown fu se There is one saf ety sw itch in th e star ting circu it of y our unit: the brake pe dal s witch. Mak e cer tain the a c tuator i[...]

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

27 Tractor Body REF . NO . PA R T NO . DESCRIPTION 1 710- 3015 Hex Cap Scr ew , 1/4 -20 x . 75 2 710-0599 Self-tappi ng Screw , 1/4-20 x . 5 3 712-3006 He x Nut, 1/4-20 4 710-0895 Self-tappi ng Screw , 1/4-15 x . 75 5 710-0924 P an Phillips Scre w , 1/4-20 x .75 6 710-0528 He x Cap Scre w , 5/16-18 x 1 .25 7 712-0292 U-type Speed Nu t, 1/4-20 8 712[...]

28 Model 604 49 39 46 6 40 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 52 17 21 10 20 12 23 21 22 24 6 2 8 14 18 25 19 6 5 3 4 1 16 9 7 17 15 5 19 8 14 6 6 26 28 53[...]

29 REF . NO . PA R T NO . DESCRIPTION 1 747-1130 Dec k Stabiliz er Rod 2 683-0197 Lift Shaf t Assemb ly 3 711-0332 Cle vis Pin, .5 x .78 4 712-0206 He x Nut, 1/2-13 5 712-0431 Flan ge Loc k Nut, 3/8-16 6 712-3004A F lange Lock Nut, 5/16-18 7 712-3083 He x Nut, 1/2-13 8 714-0104 Internal Cotte r Pin 9 714-0145 Internal Cotte r Pin 10 716-0106 E-ring[...]

30 Model 604 1 2 2 2 5 3 9 6 38 8 10 12 13 11 13 14 15 16 17 18 19 21 20 22 20 24 23 25 26 27 28 37 33 3 1 31 3 0 29 32 35 34 30 32 35 36 33 37 39 40 11 41 42 13 7 43 42 22 4 32 35 44 46 45 29[...]

31 REF . NO . PA R T NO . DESCRIPTION 1 683-0304 Lo wer F rame Asse mbly 2 710-0604A Se lf-tapping Scr ew , 16-18 x .625 3 783-0726A RH Piv ot Suppor t Brac ket 4 783-0727 LH Piv ot Support Brack et 5 783-0728 Piv ot Bar Brac ket 6 710-0514 He x Cap Scre w , 3/8-16 x 1 (Grade 5) 7 711-1409 LH D rag L ink 8 711-1408 RH Dr ag Link 9 712-0240 Ja m N u[...]

32 Model 604 4 22 13 5 2 21 2 21 13 19 13 18 36 11 28 31 7 38 46 47 40 8 44 12 37 47 15 17 1 19 50 26 27 24 10 49 1 9 23 30 32 20 42 14 39 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 31 68 64 23 23 35 78 79 34 91 81 83 82 6 45 29 35 58 12 43 84 85 87 86 88 89 35 21 90 80[...]

33 REF . NO . PA R T NO . DESCRIPTION 1 783-1015 Shift Le ver Supp or t 2 17840 T ransaxle Mou nting Brac ket 3 618-0307C Single-s peed T ransmission As sembly 4 631-0009 Shifter Kno b 5 647-0045 Shift Le ver 6 656-0048 V ariable-s peed Pulley Assembl y 7 656-0051A T ransmiss ion Pulle y , 8.5 x .5 -36 8 683-0251 Doub le-idler Bra ck et 9 710-0189 [...]

34 Model 604 Units with 618-0307C T ransmission ONL Y 31 12* 20 40 29 21 22 25 19 26 31 30 28 27 18 39 38 38 39 3 13 12c 15 8 17 24 23 2 1 16 7 12c 14 12c 9 10 12* 4 11 37 3 13 36 32 37 12* 34 12* 14 14 6 21 5[...]

35 REF . NO . PA R T NO . DESCRIPTION 1 618-0318 Clutc h Collar † 2 710-0788 Self-t apping Screw , 1/4-20 x 1.0 3 711-1274 Driv e Shaft 4 711-1280 Count er Shaft 5 713-0474 22-l ink Chain, #420 6 713-0478 14-tooth Sprock e t 7 717-1422 Sproc ket Be vel Gear , 42/10 8 717-1565 29-to oth Spur Gear 9 717-1569 20-to oth Spur Gear 10 718-065 2 Count e[...]

36 Model 604 4 1 2 3 13 42 14 15 16 18 19 11 5 12 5 39 28 23 24 25 1 29 30 37 36 35 34 33 32 31 1 21 28 22 41 6 7 8 9 6 1 7 10 43 2 38 Units Equipped w/ Electric PTO 53 54 55 56 50 51 48 26 16 45 44 57 23 50 58 60 59 52 61 1 29 62 64 65 63 66 67 68 65 69 1 36 46 47 27 49 70 (PT O belt f or 37 71 A A 42" dec k shown) 73* 72*[...]

37 NOTE: For painted parts , please refe r to the l ist of c olo r code s be low. Ple ase add the appli cable color code , w herever needed , to the pa rt numbe r to order a replace ment part. For instance, if a part numbere d 700-xxxx is painted Yard-Man Green, th e part number to order woul d be 700- xxxx-066 5. Yard-Man Green: 0665 Yard-Man Yel [...]

38 Model 604 42-inch Deck 46-inch Deck 52 49 49 14 14 58 67 75 67 68 56 53 9 30 29 35 25 23 77 74 19 30 29 35 38 21 27 38 22 31 7 15 54 73 65 15 64 32 55 50 72 15 51 71 76 57 51 ‡ 57 57 57 17 12 17 15 59 62 62 24 2 4 32 3 2 19 19 61 †46-inch D eck Brake Assembly 44 45 46 43 47 35 29 30 15 12 14 36 9 14 36 1 19 25 9 24 24 32 32 17 35 29 30 42 5 [...]

39 REF . NO . PA R T NO . DESCRIPTION 1 16606 Retai ner Hook 2 618-0324 Spind le Assemb ly , 5.75 Dia . 3 683-0198B 42-inch Dec k Shell 4 683-0254 Dec k Adjustmen t Brac ket w/ W eld Nut 5 683-0303 Dec k Brak e Assemb ly , 42-inch D ec k s † 6 710-0520 He x Cap Scre w , 3/8-16 x 1 .5 7 710-0528 He x Cap Scre w , 5/16-18 x 1.2 5 8 710-0604A Self-t[...]

40 Model 604 Kohler Briggs & Stra tton Intek T win Single-cylin der 9 7 11 (for choke ) 13 4 9 7 38 (for ch oke) 13 9 12 (for throttle) 6 9 22 18 19 20 8 10 14 10 5 10 5 16 15 1 (deflec tor must face forward) 1 8 20 19 14 1 (deflector must face forward) 24 27 28 21 23 26 17 5 35 3 2 21 3 2 21 25 36 37 37[...]

41 Engine Accessories Briggs & Stra tton Intek Si ngle 3 2 18 19 20 REF . NO . PA R T NO . DESCRIPTION 1 710-0148 Self-t apping Scre w , #8-32 x .375 2 710-0599 Self-t apping Screw , 1/4-20 x .5 3 710-0604A Self-tapping Scre w , 5/16-18 x .6 25 4 710-1237 Scre w , #10-32 x .625 5 710-1314 Soc ket Cap Scre w , 5/16-18 x .625 6 710-1315 Self-t ap[...]

42 Model 604 REF . NO . PA R T NO . DESCRIPTION 1 625-0051 Bulb/ Socket Headlight Ass embly 2 629-0939 Wiring Harness w /o Ref . 14 (units w/ Elec tr ic PT O) 629- 0944 Wiring Harness w /o Ref . 14 (units w/ Manual PT O) 3 629-0126 Harness Adapter , #18 x 5 4 710-0599 Self T apping Screw , 1/4-20 x .5 5 712-3006 He x Nut, 1/4-2 0 6 725-1426 Solen o[...]

43 Notes[...]

MANUF A C TURER ’ S LIMITED W ARRANTY FOR: The l imit ed warr ant y set for th below is given by MTD PRODUCTS INC ( “ MTD ” ) with respe ct to new m erchandi se purchase d and used in the United Stat es, its possessions and ter ritories. MTD war rants this prod uct agains t defec ts in material and workman ship f or a period of two (2) y ears[...]