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Troy-Bilt J609 manual

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Table of contents for the manual

  • Page 1

    PRINTED IN U.S .A. FORM NO . 770-10490F.f m (12/1/20 04) IMPOR T ANT : READ SAFETY R ULES AND INSTR UCTIONS CAREFULL Y 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 gras s-covered land unless the engine’s exhaust system is equipped with a spark [...]

  • Page 2

    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. Plea se read and understand what it says. Before you star t assembling your new equipment , please locate the model plate un der the seat of the tra ctor an[...]

  • Page 3

    3 SECTION 1: IMPORTANT SAFE OPERATION PRACTICES WARNING: This symbol points out import ant safety instructions wh ich, if not followed, could endan ger the personal safe ty and/or propert y of yourself and ot hers. Read and follow all instructions in this manual before attemptin g to operate this machine . Failure to comply with these instructions [...]

  • Page 4

    4 23. Muf fler and engine become hot an d can cause a burn. Do not touch. 24. Check overhead cle arances carefully before driving under low hang ing tree branches, wire s, door openings etc ., where the oper ator may be stru ck or pulled from the unit, which could re sult in serious injury. 25. Disenga ge all attachment clutches, depress t he brake[...]

  • Page 5

    5 e. Use extreme car e when approaching blind corners, doorways, sh rubs, trees or other objects that may block your vision of a child who may run into th e machine. f. To avoid back-over ac cidents, always disengage the cutting blad e(s) before shifting i nto reverse. The “Reverse Caution Mode” should not be used when children or others are ar[...]

  • Page 6

    6 8. Never tamper with the sa fety interlock system or other safety device s. Check their proper oper ation regularly. 9. After striking a foreign object , stop the engine, disconnect the spark plug wire(s) and ground against the engine. Tho roughly inspect the machine for any damage. Re pair the damage before starti ng and operating. 10. Never att[...]

  • Page 7

    7 SECTION 2: SLOPE GAUGE 3IGHTANDHOLDTHISLEVELWITHAVERTICALTREE ORACORNEROFABUILDING ORAFENCEPOST &OLDALONGDOTTEDLINEREPRESENTSASLOPE  Do not mow on inclines with a slope in excess of 15 degrees ( a rise of approximately 2-1/2 feet eve[...]

  • Page 8

    8 SECTION 3: TRACTOR SET-UP Attaching the Battery Cables NOTE: The positive ba ttery termin al is marked Pos. (+). The negative ba ttery terminal is marked Neg. (–). • The positive cable (heavy red wire ) is secured to the positive battery terminal (+) with a hex bolt and hex nut at the facto ry. Make ce rtain that the rubb er boot covers th e [...]

  • Page 9

    9 SECTION 4: KNOW YOUR LAWN TRACTOR Figure 3 NOTE: Any reference in this manual to the RI GHT or LEFT side of the tractor is observed from operat or’s position. A PTO (Blade Engage) Lever G Throttle Lever B Ammeter H Ignition Switch Module C Choke Knob (Super Bronco Only) I Brake Pedal D Parking Brake Button J Drive Pedal E Shift Lever K Cruise C[...]

  • Page 10

    10 Thro tt l e C on t rol L eve r The throttle control lever is located on the right side of the tractor’s dash pane l. This lever controls the speed of the engine and , on the Bronco model s, when pushed all the way forward, the choke control also. Wh en set in a given position, the throttle will maintain a uniform engine speed. See Figure 4. Fi[...]

  • Page 11

    11 Ammeter The ammeter measures th e electrical output of the engine’s charging system. Under normal operating cond itions, with engine at full throttle, the ammeter shou ld indicate positive charge. PTO (Blade Engage) Lev er The PTO (Blade Engage) leve r is located on the left side of the d ashboard next to the st eering wheel. Move the PTO (Bla[...]

  • Page 12

    12 SECTION 5: OPERATING YOUR LAWN TRACTOR Safety Interlock Switches This tractor is equipped with a safet y interlock system for the pr otection of the ope rator. If the interlock system should ever malfunction, do not operate the tractor . Contact an authorized Troy-Bilt service dealer. • The safety interlock syste m prevents the engine from cra[...]

  • Page 13

    13 Setting the Cutting Height Select the height posit ion of the cutting deck by placing the deck lift lever in any of the six d ifferent cutting height notches on the ri ght side of the fender. The n adjust the deck wheels so that they are between ¼-inch and ½- inch above the gr ound when the tractor is on a smooth , flat surface such as a dr iv[...]

  • Page 14

    14 Driving On Slopes Refer to th e SLOPE GAUGE on page 7 to help determine slopes where you may operate the tracto r safely. WARNING: Do not mow on inclines with a slope in excess of 15 deg rees (a rise of approximatel y 2-1/2 feet every 1 0 feet). The tractor could overturn and cause ser ious injury. • Mow up and down slopes, NEVER across. • E[...]

  • Page 15

    15 Mowing WARNING: To help avoid blade contact or a thrown object injury, keep bystanders, helpers, child ren and pets at least 75 feet from the machine while it is in operation. Stop machine if anyone ente rs the area. The following information will be helpful when using the cutting deck with your tr actor. WARNING: Plan your mowing pattern to avo[...]

  • Page 16

    16 SECTION 6: MAKING ADJUSTMENTS WARNING: Ne v er attempt to make an y adjustments while the engine is running, e xcept where specified in th e operator’ s manual . Leveling the Deck NOTE: Check the tractor’ s tire pressure before performing any de ck leveling adjustments. Refer to Tires on page 19 for informati on regarding tire pressure. Fron[...]

  • Page 17

    17 If the tractor doe s not come to a comp lete stop when the brake ped al is completely de pressed, or if the tractor’s rear wheels can roll with the park ing brake applied, the brak e is in need of adjustment. The brake disc can be found on the right side of the transmission in the rear of the tr actor. Ad just if necessary as follow s: • Loo[...]

  • Page 18

    18 SECTION 7: MAINTAINING YOUR LAWN TRACTOR WARNING: Before performing any maintenance or repair s, disengage PTO, move shift leve r into neutra l position, s et parking brake, st op engine and remove ke y to prevent unint ended starting. Engine Refer to the Briggs & Stratton Operator/Owner Manual for engine maintenan ce instructions. Check eng[...]

  • Page 19

    19 SECTION 8: SERVICE Cutting Deck Removal To remove t he cutting deck, proc eed as fo llows: • Place the PTO (Blade Engage) lever in the disengage d (OFF) position and en gage the parking brake. • Lower the deck by movin g the deck lift lever into the bottom notch on the right fender. • Remove the deck belt fr om around the tractor’s engin[...]

  • Page 20

    20 WARNING: Failure to use this procedure could cause sparkin g, and the gas in either battery could explode. Cleaning Clean the battery by re moving it from the tractor and washing with a baking so da and water solution. If necessary, scrape the battery t erminals wi th a wire brush to remove depo sits. Coat terminals and expo sed wiring with grea[...]

  • Page 21

    21 Changing the Deck Belt WARNING: Be sure to shut t he engine off, remove igniti on key, discon nect the spa rk plug wire(s) and ground against the engine to prevent unintende d starting before remo ving the belt(s). WARNING: Avoid the possibility of a pinching injury. Do not pla ce your fingers on the idler spring o r between the belt an d a pull[...]

  • Page 22

    22 SECTION 9: OFF-SEASON STORAGE Clean and lubricate the tr actor as instructed in Section 7: MAINTAINING YOUR LAWN TRACTOR on page 18 of this manual before sto ring for an extended period . WARNING: Drain fuel only into an approved containe r outdoors, away from an open flame. Allow engine to cool. Extinguish cigarettes, cigars, pipes, and other s[...]

  • Page 23

    23 SECTION 11: TROUBLESHOOTING T r ouble P ossible Cause(s) Corrective Actio n Engine fails to start PT O engaged. P arking brake not engaged. Spark pl ug wire(s) disconnected. Throttle control le v er not in correct star ting positio n. Chok e not activ ated Fuel tank empty , or stale fuel. Bloc ked fuel line. F aulty spark pl ug. Engine flooded. [...]

  • Page 24

    24 25 3 14 24 15 12 8 4 19 9 6 17 1 22 17 7 29 13 10 33 37 28 29 5 11 28 32 21 16 7 16 20 7 2 7 18 36 23 24 30 31 28 34 27 35 26 26 SECTION 12: PARTS LIST[...]

  • Page 25

    25 Models J609 & T609 REF . NO . PA R T NO . DESCRIPTION 1 710-04095 Hex Screw, 3/8-16, 1 .00, Gr5 2 710-0514 Hex Screw, 3/8-16, 1.00, Gr5 3 710-0643 Hex Screw, 5/16-18, 1.00, Gr5 4 711-1408 Link, Drag, RH 5 711-1409A Link, Drag, LH 6 712-0214 Nut, Hex Lock, 3/8-24 7 712-04065 Nut, Fl ange Lock, 3/8-16, Grf, Nyl on 8 712-0459 Nut, Flange Lock, [...]

  • Page 26

    26 Model s J609 & T609 5 31 32 27 23 5 10 12 19 34 28 20 25 23 42 41 37 24 22 19 36 21 22 29 26 38 43 30 16 35 3 33 11 44 2 44 17 18 9 40 39 13 1 4 8 15 6 6 6 3 14 16[...]

  • Page 27

    27 Models J609 & T609 REF . NO . PA R T NO . DESCRIPTION 1 783-1346 Bracket, Grill Support 2 710-0528 Screw, 5/16-18 x 1.25 3 710-0599 Screw, 1/4-20, 0.500 4 712-3010 Hex Nut, 5/ 16-18 5 710-0895 Screw, 1/4-15, 0.750 6 710-0924 Screw, Machine, 1/4-20, 0.750 7 725-0157 Cable Tie (Not Shown) 8 712-0292 Nut, Clip, 1/4-20 9 731-04960 Grill, 9 Style[...]

  • Page 28

    28 B B A A C D E G G F F E D C Left Hand T ran s mi ss ion Bolt Mounting 21 4 26 16 19 14 6 42 11 9 13 6 6 6 39 40 10 75 73 28 8 82 77 20 18 40 71 80 5 76 79 81 78 46 48 64 17 44 51 47 60 49 69 54 56 64 41 55 45 17 61 63 57 52 51 70 58 66 16 16 85 3 30 2 90 68 16 59 14 53 50 16 67 62 14 72 25 74 32 24 23 27 33 17 9 22 12 6 29 12 31 36 36 37 7 65 7 [...]

  • Page 29

    29 Models J609 & T609 REF . NO . PA R T NO . DESCRIPTION 1 17840 Mounting Bracket, Transaxle 2 736-0430 Flat Washer,.350 x 1.59 x.062 3 731-2290A Hub Cap 4 647-04020 Lever Asse mbly, Shift 5 710-0607 Screw, 5/16-18, 0.500 6 710-0726 Screw, 5/16-12, 0.750 7 710-0809 Screw, 1/4-20, 1.250 8 710-1007 Screw, Sems, 3/8-16, 1.500 9 710-1266 Screw, 5/1[...]

  • Page 30

    30 Model s J609 & T609 To D e c k A A B B 8 37 18 48 47 33 8 8 39 40 31 29 27 30 36 13 34 50 42 41 35 32 46 49 38 9 12 13 17 9 44 5 28 34 1 43 16 22 23 4 42 26 10 3 45 14 25 15 20 2 6 21 24 26 11 19 7 IMPORT ANT: For a proper working machine, use Factory Approved Par ts. V-belts are designed to engage and disenga ge safely. A substitu te (non O[...]

  • Page 31

    31 Models J609 & T609 REF . NO . PA R T NO . DESCRIPTION 1 17962 Plate, Switch 2 647-04036 Lever Assemb ly, Engagement 3 710-0809 Screw, 1/4-20 x 1.250 4 710-0859 Screw, 3/8-16, 2.50 5 710-0276 Screw, Carriage, 5/16-18, 1.00 6 710-1260A Screw, 5/16-18 x.750 7 710-3157A Screw, 7/16-20, 3.25, Gr5 8 710-0726 Screw, 5/16-12, 0.750 9 714-0145 Click [...]

  • Page 32

    32 Models J 609 & T609 A B B A 18 19 20 15 39 45 5 11 12 4 3 6 36 3 40 10 13 9 23 21 31 30 41 1 35 38 44 42 37 2 14 26 32 25 8 7 28 29 17 16 43 1 33 27 1 24 34 22[...]

  • Page 33

    33 Models J609 & T609 REF . NO . PA R T NO . DESCRIPTION 1 712-04063 Nut, Flange Lock, 5/16-18, GrF, Nylon 2 757-04009A Mediu m Back Seat, Super Bronco 757-04001 Low Back Seat, Bronco 3 726-3046 Ratchet Clip 4 735-0656 RH F oot P ad, Rubber , Super Bronco 735-0672 RH F oot P ad, Bronco 5 735-0657 LH Foot P ad, Rubber , Super Bronco 735-0673 LH [...]

  • Page 34

    34 Model s J609 & T609 8 3 2 1 5 6 8 4 10 9 7 12 1 1 11 12 13 14 3 17 15 20 19 20 21 22 23 24 25 28 29 27 26 3[...]

  • Page 35

    35 Models J609 & T609 NO TE: If rebuilding the upper housing, include two ounces (2 oz.) of Unirex ® N3 grease (P ar t No. 737-0289) in the input shaft cavity . REF . NO . PA R T NO . DESCRIPTION 1 732-0614 Ring, Wire 2 716-0231 Ring, E Type,.750 3 736-0336* Flat Washer, 5/8 x 1.0 x.030 736-0337* Flat Washer, 5/8 x 1.0 x.040 736-0349* Flat Was[...]

  • Page 36

    36 47 5 14 53 48 50 51 30 28 37 8 29 24 35 9 46 1 1 11 41 43 54 22 55 32 56 32 45 44 2 36 57 10 31 18 4 23 39 11 27 56 43 34 17 33 19 52 38 15 42 21 20 26 46 9 49 16 13 6 7 12 3 58 40 25 Model s J609 & T609[...]

  • Page 37

    37 NOTE: Tractor features vary by mode l. NOT all pa rts listed above and pictured on the previous page are standard equip ment. IMPORT ANT: For a proper working machine, use Factory Approved Par ts. V-belts are designed to engage and disenga ge safely. A substitu te (non OEM) V-belt can be dangerous by not disengaging co mpletely. NOTE: Tractor fe[...]

  • Page 38

    38 11 11 15 4 14 12 9 19 21 20 7 10 6 5 17 16 1 18 8 22 2 3 Oil Ref. No. Pa r t 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[...]

  • Page 39

    39 NOTES[...]

  • Page 40

    40 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 purch ased 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 d[...]