Troy-Bilt AutoDrive 604, Operator'S Manual

Page 1: ...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...

Page 2: ... 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 SECTION 3 CALLING CUSTOMER SUPPORT 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 If you are having difficul...

Page 3: ...g 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 reverse and backing up Always look down and behind before and while backing Be aware of the mower and attachment dischar...

Page 4: ...ur 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 in watchful care of an adult other than the operator Be alert and tur...

Page 5: ...g 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 othe...

Page 6: ... MAY NOT OPERATE SAFELY 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...

Page 7: ... approximately two gallons Do not overfill WARNING Gasoline produces noxious fumes Never fill fuel tank indoors Always fill the fuel tank in a well ventilated area to avoid inhalation of gasoline fumes WARNING Never smoke while fueling your tractor or fill the fuel tank while engine is running or while engine is hot WARNING Do not fill closer than 1 2 inch from the top of the fuel tank to prevent ...

Page 8: ...ft 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 Steering Wheel not shown for clarity P 1 10 P NOTE Any reference in this manual to the RIGHT or LEFT side of the tractor is observed from operator s position ...

Page 9: ... 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 INDICATOR MONITOR HOUR METER Your tractor is equipped with four in...

Page 10: ...RTANT Always set the parking brake when leaving the tractor unattended BRAKE PEDAL The brake pedal is located on the right front side of the tractor above the AutoDrive pedal along the running board The brake pedal can be used for sudden stops or setting the parking brake NOTE The brake pedal must be fully depressed to activate the safety interlock switch when starting the tractor PARKING BRAKE BU...

Page 11: ...vents 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 ...

Page 12: ... 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...

Page 13: ...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 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 start...

Page 14: ...TIRES in the maintenance section of this manual for further information regarding tire pressure 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 WARNING Turn the tractor s engine off remove the key from the ign...

Page 15: ...on 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 Loosen the jam nut found on the drag link at the rear of the ball joint See Figure 9 Remove the hex nut and lock washer on the top of ball j...

Page 16: ...en 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 11 Figu...

Page 17: ... cap on the end of the oil drain valve to expose the oil drain port See Figure 13 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 Push the oil drain valve in slightly then rotate counterclockwise and pull outward to begin draining oil See Figure 13 Servi...

Page 18: ...ottom notch on the right fender Grasp the PTO idler pulley bracket and pivot it toward the discharge chute to relieve tension on the belt Remove the deck belt from the bottom portion of the engine pulley and from around the PTO idler pulley 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 ...

Page 19: ...ulley and from around the PTO idler pulley Route the new belt as shown in Figure 14 around the deck pulleys idler pulley and engine pulley IMPORTANT It is recommended that the PTO be readjusted after replacing the deck belt Refer to PTO POWER TAKE OFF ADJUSTMENT in the ADJUSTMENTS section of this manual for the proper procedure Remount the belt guards removed earlier Figure 15 46 inch decks Lower ...

Page 20: ...r 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 ...

Page 21: ...ley at this time See Figure 18 Figure 18 IMPORTANT When remounting the engine pulley torque the center hex bolt to between 38 foot pounds and 50 foot pounds Drive belt Lower Drive belt Upper Front of Tractor Rear Idler Pulley Front Idler Pulley Variable speed Pulley Battery Tray Belt Keeper Transmission Idler Pulley Transmission Pulley Engine Pulley Belt Keeper Single speed Transmission Shift Leve...

Page 22: ...ee Figure 21 Remove the AutoDrive pedal return spring Using two 9 16 wrenches remove the pin from the speed control assembly See Figure 21 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 IMPORTANT After replacing the drive belts perform the PT...

Page 23: ... 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 IMPORTANT If 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 bat...

Page 24: ...NTS Lubricate all pivot points AutoDrive pedal brake pedal etc at least once a season with light oil LINKAGE Lubricate all the pivot points on the drive brake and lift linkage at least once a season with SAE 30 engine oil STEERING GEAR Lubricate the teeth of the steering gear with an all purpose automotive grease every 25 hours of operation or once a season WHEELS Both the front wheels and the rea...

Page 25: ...ched between body panels burned by the exhaust pipe or muffler or rubbed against a moving part Engine cranks but will not start Throttle or choke not in starting position No fuel to the carburetor No spark to spark plug s Dirty aircleaner Refer to the OPERATION section of this manual for the correct position of the throttle control and choke for starting Gasoline tank empty Fill Fuel line or in li...

Page 26: ...4 710 0599 Self Tapping Screw 1 4 20 x 5 5 712 3006 Hex Nut 1 4 20 6 725 1426 Solenoid 12 volt 100 Amp 7 725 1657A Snap Mount Safety Interlock Switch 8 725 1741 Ignition Switch 9 725 1743 Indicator Monitor Hour Meter 10 725 1745 Ignition Key 11 725 1747 Safety Plunger Switch 12 736 0222 External Lock Washer 1 4 13 736 0329 Lock Washer 1 4 Model 604 9 3 8 10 1 7 7 5 11 5 13 13 6 4 5 2 ...

Page 27: ...anel 4 style Red 16 731 1995 LH Head Light Reflector 17 731 1996 RH Head Light Reflector 18 736 0173 Flat Washer 28 x 74 x 063 19 736 3078 Flat Washer 349 x 1 0 x 063 20 747 1132 Hood Support Rod 21 783 0808 Heat Shield 4 style 22 710 0604 Self Tapping Screw 5 16 18 x 625 23 710 1017 Torx Self Tapping Screw 1 4 14 x 625 24 710 3217 Torx Screw 8 32 x 375 25 712 0142 Hex Nut 8 32 26 731 0069 Dash Pa...

Page 28: ...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 22 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 ...

Page 29: ...apping Screw 1 4 15 x 75 30 731 1990 Lift Lever Cover 31 731 2104 Shift Lever Cover w Cup Holder 32 738 0155 Shoulder Screw 437 x 1 62 33 783 0677 Lift Adjustment Bracket 34 783 0685 Fender 35 783 0715 Seat Mounting Bracket 36 710 1268 Screw 10 16 x 375 37 712 3027 Hex Flange Lock Nut 1 4 20 38 720 0309A Seat Adjuster Grip 39 731 1989 Spacer 40 732 0499 Compression Spring 41 x 1 5 41 736 0175 Spri...

Page 30: ...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 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 ...

Page 31: ...Pivot Bar 28 712 0431 Flange Lock Nut 3 8 16 29 714 0470 Cotter Pin 30 726 0214 Push Cap 5 8 726 0341 Push Cap 3 4 31 736 0162 Flat Washer 64 x 1 0 x 12 32 736 0187 Flat Washer 64 x 1 24 x 06 736 0316 Flat Washer 78 x 1 59 x 06 33 736 0285 Flat Washer 635 x 1 589 x 06 34 738 1011 Shoulder Screw 5 x 2 2 3 8 16 35 741 0659 Flange Bearing 632 ID x 937 OD 741 0660 Flange Bearing 760 ID x 937 OD 36 634...

Page 32: ...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 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 80 81 82 6 ...

Page 33: ...rd 41 747 1127 Idler Adjustment Rod 3 8 42 747 1156 Shift Rod 43 747 1160 Belt Guard Rod 44 748 0416 Shoulder Spacer 38 ID 45 754 0467 Variable speed Belt 46 754 0468 Drive Belt 47 756 0981 Flat Idler 2 75 OD 48 783 0637 Shift Lever Support 49 783 0667 Transmission Torque Bracket 50 783 0669 Idler Bracket 51 783 0714 Adjustable Shift Bracket 52 647 0031 Brake Control Assembly 53 647 0032 Speed Con...

Page 34: ... 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 ...

Page 35: ...gement Arm 34 783 0798 PTO Engagement Link 35 783 0799 PTO Arm 36 783 0806 Deck Stop 37 710 0561 Hex Cap Screw 7 16 20 x 2 5 Grade 5 38 710 0599 Self Tapping Screw 1 4 20 x 5 39 736 0171 Lock Washer 7 16 40 736 0322 Flat Washer 45 x 1 25 x 164 41 750 0956 Spacer 1 01 x 1 4 x 825 42 756 1158 Engine Pulley 5 56 Dia x 3 56 Dia 43 756 1164 Pulley Sheave 44 754 0472 PTO Belt 42 inch Decks 754 0476 PTO ...

Page 36: ...0 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 ...

Page 37: ...1 53 30 742 0611 Three in one Blade Star Center 16 28 31 742 0612 Three in one Blade Star Center 14 88 32 747 1116 Deck Release Pin 33 754 0349 Deck Belt 34 756 0627 Flat Idler Pulley 3 5 OD 35 783 0139 Idler Bracket 36 783 0141 Center Deck Skirt 37 783 0142 RH Deck Skirt 38 783 0747 LH Belt Cover 39 783 0805 RH Belt Cover 40 16606 Retainer Hook 41 618 0324 Spindle Assembly 5 75 Dia 756 1151 Pulle...

Page 38: ...ek Twin Single cylinder 9 7 11 for choke 13 4 9 7 11 for choke 13 9 12 for throttle 6 9 22 18 19 20 8 10 14 10 5 10 5 16 15 1 deflector must face forward 18 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 ...

Page 39: ...t Pipe Intek Twin 17 751 0651 LH Exhaust Pipe Intek Twin 18 751 3140 Oil Drain Valve 19 751 3141 Oil Drain Hose 20 751 3142 Oil Drain Cap 21 783 0615 Muffler Heat Shield 22 783 0625A Engine Heat Shield 23 710 3206A Hex Cap Screw M8 1 25 x 25 24 712 3086 Flange Nut M8 1 25 25 721 0375 Exhaust Gasket Kohler 26 736 0607 External Lock Washer 5 16 27 751 0621 Exhaust Pipe Kohler 28 751 0617 Muffler Sin...

Page 40: ... Department of MTD PRODUCTS INC Transportation charges Transportation charges for the movement of any power equipment unit or attachment are the responsibility of the purchaser Units exported out of the United States MTD PRODUCTS INC 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 PRODU...