Troybilt 542 Owner's manual

Brand: Troybilt

Model: 542

Category: Lawnmowers

Type: Owner's manual

This manual is also suitable for

11A-542Q711

Safetyo Assembly o Operation oTips &Techniques oMaintenance *Troubleshooting o Parts Lists oWarranty

21-inch Rotary Mower- Model 542

READ SAFETY RULES AND mNSTRUCTmONS CAREFULLY BEFORE OPERATION

Warning: This unitisequippedwithan internalcombustionengineandshouldnotbeusedon or nearanyunimprovedforest-covered,brush=

coveredor grass=coveredlandunlesstheengine'sexhaustsystemisequippedwithasparkarrestermeetingapplicablelocalorstatelaws(ifany),

If a sparkarresterisused,itshouldbemaintainedineffectiveworkingorderbytheoperator,Inthe StateofCaliforniatheaboveisrequiredbylaw

(Section4442oftheCaliforniaPublicResourcesCode),Otherstatesmayhavesimilarlaws,Federallawsapplyonfederallands,A sparkarrester

forthemufflerisavailablethroughyournearestengineauthorizedservicedealeror contacttheservicedepartment,RO,Box361131Cleveland,

Ohio44136=0019,

PRINTEDiN U,S,A MTD LLC, RO. BOX 361131 CLEVELAND, OHiO 44136-0019 FORMNO,769=02232

11/29/2005

This Operator's Manua_ is an important part of your new lawn mower, mtwH_ he_p you assemble,

prepare, and maintain the unit for best performance. P_ease read and understand what it says.

Table of Contents

Smope Gauge ....................................................... 3

Safe Operation Practices ................................... 4

Setup and Adjustment ....................................... 6

Operating Your Lawn Mower .............................. 8

Maintaining Your Lawn Mower ......................... 10

Trouble Shooting .............................................. 12

Safety Labels .................................................... 13

Parts List ........................................................... 14

Warranty ............................................ Back Cover

Finding and Recording Model Number

BEFOREASSEMBLINGYOUR NEWEQUIPMENT,please

locate themodel plateon theequipmentand copythe infor=

mationto thesample modelplate providedtothe right.You

can locatethe modelplate by standingat the operatingposi=

tionand lookingdown at the rearof the deck.This information

will be necessarywhen usingthe manufacturer'swebsite, to

obtainassistancefromthe CustomerSupport Department,or

whencontactingan authorizedservice dealer.

lVlodet Number Serial Number

0 TRO_XX--T" TROY=O[LT LLC

P. 0. BOX 361131

www.troybimt.com CLEVELAND, OH44136

330=558=7220

Customer Support

P_ease do NOTreturn the unit to the retailer from which it was purchased, without first

contacting Customer Support.

if you havedifficultyassemblingthis productor haveanyquestionsregardingthecontrols, operation,or maintenanceof this

unit,youcan seek helpfrom theexperts. Choosefromthe optionsbelow:

o Visitwww.troybilt.com

Phonea CustomerSupport Representativeat 1-866-840-6483.

The enginemanufactureris responsiblefor all engine-relatedissueswith regardto performance,power=rating,specifications,

warranty,and service. Please refertothe engine manufacturer'sOwner's/Operator'sManual,packedseparatelywithyour

unit,for more information.

yourlawnmoweronsuchslopes.

WARNING

Do not mowon inclines

with a dope in excess

of 15degrees(a rise

of approximately

2-"

feet). A riding r

couldoverturnand

cause seriousinjury.

if operatinga walb

behindmoweron such

a dope, it isextremely

footing and youcould

dip, resultingin serious

injury.

OperateRiDiNG

mowersupand down

dopes, neveracross

theface of dopes.

Operate

WALK-BEHIND

mowersacrossthe

face of dopes, never

up and down slopes.

manual.Aswithanytypeofpowerequipment,carelessnessorerroronthepartoftheoperatorcan

resultinseriousinjury.Thismachineiscapableofamputatinghandsandfeetandthrowingobjects.

! Failuretoobservethefollowingsafetyinstructionscouldresultinseriousinjuryordeath.

endangerthepersonal

safetyand/orproperty

Children

Tragicaccidentscan occurifoperatorisnotalerttopresence

ofchildren.Childrenareoftenattractedto mowerandmowing

activity.Theydonot understandthedangers.Neverassume

thatchildrenwill remainwhereyoulastsawthem.

1. Keepchildrenoutofthe mowingareaandunderwatchful

careof aresponsibleadultotherthanthe operator.

2. Bealertandturnmoweroffifachildentersthearea.

3. Beforeandwhilemovingbackwards,lookbehindanddown

forsmallchildren.

4. Useextremecarewhenapproachingblindcorners,

doorways,shrubs,trees,orotherobjectsthat mayobscure

yourvisionofachildwhomayrunintothemower.

5. Keepchildrenawayfromhot orrunningengines.Theycan

sufferburnsfroma hotmuffler.

6. Neverallowchildrenunder14yearsoldto operateapower

mower.Children14yearsold andovershouldreadand

understandoperationinstructionsandsafetyrulesinthis

manualandshouldbetrainedandsupervisedbyaparent.

General Operation

1. Readthis operator'smanualcarefullyin its entiretybefore

attemptingtoassemblethismachine.Read,understand,

andfollow allinstructionsonthe machineandin the

manual(s)beforeoperation.Becompletelyfamiliarwith

thecontrolsandthe properuseofthismachinebefore

operatingit.Keepthismanualinasafeplaceforfuture

andregularreferenceandfor orderingreplacementparts.

2. Thismachineisa precisionpieceof powerequipment,

nota plaything.Therefore,exerciseextremecautionat all

times.Yourunithasbeendesignedto performonejob: to

mowgrass.Donotuseitfor anyotherpurpose.

3. Neverallowchildrenunder14yearsoldto operatethis

machine.Children14yearsoldand overshouldreadand

understandthe instructionsinthis manualandshould

betrainedand supervisedbya parent.Onlyresponsible

individualswhoarefamiliarwiththeserulesofsafe

operationshouldbeallowedtousethismachine.

4. Thoroughlyinspectthe areawherethe equipmentisto

beused.Removeall stones,sticks,wire,bones,toysand

otherforeignobjectswhichcould betrippedoveror picked

upand thrownbythe blade.Thrownobjectscancause

seriouspersonalinjury.Planyourmowingpatternto avoid

dischargeofmaterialtowardroads,sidewalks,bystanders

andthe like.Also,avoiddischargingmaterialagainsta

wallorobstructionwhichmaycausedischargedmaterial

toricochetbacktowardtheoperator.

6. Alwayswearsafetyglassesor safetygogglesduringopera-

tionandwhileperforminganadjustmentorrepairtoprotect

youreyes.Thrownobjectswhichricochetcancauseserious

injurytothe eyes.

7. Wearsturdy,rough-soledworkshoesandclose-fitting

slacksandshirts.Shirtsand pantsthatcoverthe armsand

legsandsteel-toedshoesarerecommended.Neveroperate

thismachineinbarefeet,sandals,slipperyor lightweight

(e.g.canvas)shoes.

8. Donotputhandsorfeetnearrotatingpartsor undercutting

deck.Contactwithbladecanamputatehandsandfeet.

9. Amissingor damageddischargecovercancauseblade

contactor thrownobjectinjuries.

10.Manyinjuriesoccurasa resultofthe mowerbeingpulled

overthefootduringafall causedbyslippingortripping.

Do notholdontothe mowerifyouarefalling;releasethe

handleimmediately.

11.Neverpullthe mowerbacktowardyouwhileyouare

walking.Ifyoumustbackthe mowerawayfromawallor

obstructionfirstlookdownandbehindtoavoidtrippingand

thenfollowthesesteps:

a. Stepbackfrommowertofully extendyourarms.

b. Besureyou arewellbalancedwithsurefooting.

c. Pullthemowerbackslowly,no morethanhalfway

towardyou.

d. Repeatthesestepsasneeded.

12.Donotoperatethe mowerwhileunderthe influenceof

alcoholor drugs.

13.Donotengage theself-propelledmechanismon unitsso

equippedwhilestartingengine.

14.Thebladecontrolhandleis asafetydevice.Neverattempt

tobypassits operation.Doingsomakesthe safetydevice

inoperativeandmay resultinpersonalinjurythrough

contactwiththe rotatingblade.The bladecontrolhandle

mustoperateeasilyin bothdirectionsandautomatically

returntothe disengagedpositionwhenreleased.

15.Neveroperatethe mowerinwetgrass.Alwaysbesureof

yourfooting. Aslipand fallcan causeseriouspersonal

injury.If youfeelyouarelosingyourfooting,releasethe

bladecontrolhandleimmediatelyandthe bladewillstop

rotatingwithinthreeseconds.

16.Mowonlyindaylightorgoodartificiallight.Walk,neverrun.

17.Stopthe bladewhencrossinggraveldrives,walksor roads.

18.Ifthe equipmentshouldstarttovibrateabnormally,stopthe

engineandcheckimmediatelyforthe cause.Vibrationis

and followthe warnings 5. Tohelpavoidbladecontactora thrownobjectinjury, ._ generallya'_arningof!rouble.........

]_ _nutthe engne errandwar unl: me Daaecomes-coa

and i..struction2 stayinoperatorzonebehindhandlesandkeepchildren, "

u _ competestop beforeremovngthe grasscatcheror uncog

, ,; bystanders,helpers,andpetsat least75feet frommower .

un_nusmanuau glngthechute

whileit isin operation.Stopmachineifanyoneenters

and onthe machine, area.

..... ,J

Thecuttingbladecontinuesto rotatefora fewsecondsafter

the engineisshutoff. Neverplaceanypartofthe bodyin

the bladeareauntilyouaresurethe bladehasstopped

rotating.

20.Neveroperatemowerwithoutpropertrailshield,discharge

cover,grasscatcher,bladecontrolhandle,or othersafety

protectivedevicesin placeandworking.Neveroperate

mowerwithdamagedsafetydevices.Failuretodo socan

resultin personalinjury.

21.Mufflerandenginebecomehotandcancausea burn.Do

nottouch.

22.Onlyusepartsandaccessoriesmadeforthismachineby

manufacturer.Failureto dosocanresultinpersonalinjury.

23.Ifsituationsoccurwhicharenot coveredinthismanual,

usecareand goodjudgment.Contactyourdealerfor

assistance.Telephone1-866-840-6483forthe nameofyour

nearestdealer.

SJope Operation

Slopesarea majorfactorrelatedto slipandfallaccidentswhich

canresultinsevereinjury.Operationonslopesrequiresextra

caution.Ifyoufeeluneasyonaslope,donotmowit.Foryour

safety,usethe slopegaugeincludedaspartofthis manualto

measureslopesbeforeoperatingthisunitonaslopedor hilly

area.Iftheslopeis greaterthan15degrees,do notmowit.

Do:

1. Mowacrossthe faceof slopes;neverup anddown.

Exerciseextremecautionwhenchangingdirectionon

slopes.

2. Watchfor holes,ruts,rocks,hiddenobjects,or bumpswhich

can causeyou toslipor trip.Tallgrasscan hideobstacles.

3. Alwaysbesureofyourfooting.Aslip andfall cancause

seriouspersonalinjury.If youfeelyouarelosingyour

balance,releasethe bladecontrolhandleimmediately,and

the bladewillstop rotatingwithin 3seconds.

Do Not:

1. Donotmowneardrop-offs,ditchesorembankments,where

you couldloseyourfootingorbalance.

2. Donotmowslopesgreaterthan15degreesasshownon

the slopegauge.

3. Donotmowon wetgrass.Unstablefootingcouldcause

slipping.

Service

Safe HandlingOf Gaso%e:

1. Toavoidpersonalinjury orpropertydamageuseextreme

carein handlinggasoline.Gasolineisextremelyflammable

andthevaporsareexplosive.Seriouspersonalinjurycan

occurwhengasolineis spilledonyourselforyourclothes

whichcanignite.

2. Washyourskinandchangeclothesimmediately.

3. Useonlyanapprovedgasolinecontainer.

4. Neverfill containersinsideavehicleor onatruckor trailer

bedwith aplasticliner.Alwaysplacecontainersonthe

groundawayfromyourvehiclebeforefilling.

5. Removegas-poweredequipmentfromthe truckortrailer

andrefuelit onthe ground.Ifthisis notpossible,then refuel

suchequipmentonatrailerwitha portablecontainer,rather

thanfroma gasolinedispensernozzle.

6. Keepthe nozzlein contactwith therim ofthefueltank or

containeropeningat alltimesuntilfuelingis complete.Do

notusea nozzlelock-opendevice.

7. Extinguishallcigarettes,cigars,pipesandothersources

ofignition.

8. Neverfuel machineindoorsbecauseflammablevaporswill

accumulatein the area.

9. Neverremovegascap oradd fuelwhileengineishot or

running. Allowengineto coolatleasttwominutesbefore

refueling.

10.Neveroverfillfueltank. Filltankto nomorethan_ inch

belowbottomoffillerneckto provideforfuelexpansion.

11.Replacegasolinecapandtightensecurely.

12.Ifgasolineis spilled,wipeit offthe engineandequipment.

Moveunitto anotherarea.Wait5minutesbeforestarting

engine.

13.Neverstorethe machineorfuel containernearanopen

flame,sparkorpilotlightas onawaterheater,space

heater,furnace,clothesdryer,orothergas appliances.

14.Toreducefire hazard,keepmowerfreeofgrass,leaves,

or otherdebrisbuild-up.Cleanupoil orfuel spillageand

removeanyfuel soakeddebris.

15.Allowamowertocoolat least5 minutesbeforestoring.

General Service:

1. Neverrunanengineindoorsor ina poorlyventilatedarea.

Engineexhaustcontainscarbonmonoxide,an odorlessand

deadlygas.

2. Beforecleaning,repairing,or inspecting,makecertainthe

bladeandall movingpartshavestopped.Disconnectthe

sparkplugwireandgroundagainsttheengineto prevent

unintendedstarting.

3. Checkthe bladeandenginemountingboltsatfrequent

intervalsfor propertightness.Also,visuallyinspectbladefor

damage(e.g.,bent,cracked,worn)Replacebladewiththe

originalequipmentmanufacture's(O.EM.) bladeonly,listed

inthismanual."Useofpartswhichdo notmeettheoriginal

equipmentspecificationsmayleadto improperperformance

andcompromisesafety!"

4. Mowerbladesaresharpandcancut.Wrapthebladeorwear

gloves,anduseextracautionwhenservicingthem.

5. Keepallnuts,bolts,andscrewstight tobesurethe equip-

mentisin safeworkingcondition.

6. Nevertamperwithsafetydevices.Checktheirproperopera-

tionregularly.

7. Afterstrikingaforeignobject,stopthe engine,discon-

nectthe sparkplugwireandgroundagainsttheengine.

Thoroughlyinspectthe mowerforanydamage.Repairthe

damagebeforestartingandoperatingthemower.

8. Neverattempttomakeawheelorcuttingheightadjustment

whilethe engineis running.

9. Grasscatchercomponents,dischargecover,andtrail

shieldaresubjecttowear anddamagewhichcould expose

movingpartsorallow objectsto bethrown.Forsafety

protection,frequentlycheckcomponentsand replaceim-

mediatelywithoriginalequipmentmanufacturer's(O.EM.)

partsonly,listedin thismanual."Useof partswhichdo

not meettheoriginalequipmentspecificationsmayleadto

improperperformanceandcompromisesafety!"

10.Donot changetheenginegovernorsettingor overspeedthe

engine.Thegovernorcontrolsthe maximumsafeoperating

speedofthe engine.

11.Maintainor replacesafetylabels,asnecessary'.

12.Observeproperdisposallawsandregulations.Improper

disposaloffluidsand materialscanharmtheenvironment.

w o°,°o

ThisSymbolpoints

ua! before attemptingto

resuUt in personalinjury_

::When you see th s

_symbol

,EEDMTSWARNmNG

Responsibility

Restrictthe use

of this powermachine

to personswhoread

understand

Standbehinathe

moweras ifyou were

goingb operateit,

Your righthandcor-

respondsto the right

sideof the mower;your

left handcorresponds

to the left sideof the

mower.

Makesureto route

cane outsidethe lower

handle. Do not crimp

cane while liftingthe

handleup.

IMPORTANT

This unitis shipped

up gasolineand oil

as instructedinthe

accompanyingengine

manual BEFORE

operating yourmower.

Figure3-1:Unfoldhandleandtightenhardware.

HardwarePack )1

WingNuts(2) CarriageBelts(2

1. Removeanypackingmaterialwhichmaybebetween

upperand lowerhandles.

a. Pullupand backon upperhandleasshownin

Figure34. Makecertainthelowerhandleisseated

securelyintothe handlemountingbrackets.Donot

crimpcane whileliftingthehandleup.

b. Tightenstarknobstosecureupperhandleto

lowerhandle.Makesurethateachcarriageboltis

seatedproperlyin thehandle.

2. Locatethehairpinclipon theweldpinon eachsideof

lowerhandle.

a. Removehairpinclipfromthis hole.Usinga pair

ofpliers,inserthairpinclipintotheholeon pin

closesttothebracket,Figure3-2.Repeatonother

side.

b. Inserta carriageboltfromthehardwarepackinto

theupperholeon thehandlemountingbracket.

Securewithoneplasticwingnut,alsoincluded

inthe hardwarepack.Repeatonothersidewith

remainingitemsfromhardwarepack.

3. Theropeguideisattachedtotherightsideofthe

upperhandle,Figure3-3.Loosenthewingnutwhich

securestheropeguide.

a. Holdbladecontrolhandleagainstupperhandle.

b. Pullstarterropeoutoftheengine.Releaseblade

controlhandle.

c. Slipstarterropeintoropeguide.

d. Tightenwingnut.

4. Insertpostoncane ties intoholesprovidedon the

lowerhandle.Pullcane tiestightandtrimexcess,

Figure3-4.

Figure3-2:Securelowerhandletomountingbrackets.

Figure3-3:Pull recoilstarterthroughropeguideandtighten. Figure3-4:Securecablestohandleusingcableties.

5. Followstepsbelowtoassemblethegrasscatcher.

Makecertainbagisturnedrightsideoutbefore

assembling(warninglabelwillbe ontheoutside)

a. Placebagoverframesothatitsblackplasticside

isatthebottom.

b. Slipplasticchannelofgrassbagoverhooksonthe

frame,Figure3-5.All theplasticchannelsexcept

centertopof bagattachfromoutsideof bag.

c. Attachcentertopofbagfrominsideofbag.

7. Yourmowerisshippedasa mulcher.Toconvertto

sidedischarge,makesuregrasscatcherisoffofthe

unitand reardischargedoorisclosed.

a. Onthesideof themowerlift themulchingplug,

Figure3-7.

b. Slidetwohooksofsidedischargechuteunder

hingepin onmulchingplugassembly.Lowerthe

mulchingplug.Donotremovesidemulchingplug

atanytime,evenwhenyouarenotmulching.

Figure 3-5: Assemble the grass catcher.

6. Followthestepsbelowtoattachthegrasscatcher:

a. Liftreardischargedoor,Figure3-6.

b. Placegrasscatcheron thepivotrod.Letgo

ofdischargedoorsothat itrestson thegrass

catcher.

_jliL WARNING:Neveroperate mower unless the

hooks on the grass catcher are firmly seated

on the pivotrod and the rear discharge door rests

firmly against top of the grass catcher.

Figure3-6:Attachthegrasscatcher.

Figure3-7:Liftmulchplugandinstallsidedischargechute.

Adj ustments Whenadjustingthe !

Anadiusfingplateandthumbleverateachwheel cuttungheught,aHHwheeHs!

providescuttingheightadiustment, must bepositionedat

1. Depresslevertowardswheel, the same height, i

2. Moveitto anyoneofthepositionsfordesiredcutting

height,Figure3-8.Makesurethateachwheelis /}

positionedatthesameheight. I

3. Releaselevertowardsmowerdeck.

Figure3-8:Useleversto adjustcuttingheight.

WARNING

Know Your Lawn Mower

Grass Catcher--_

Cutting Height

Adjustment

Levers (front

J and rear)

The blade control is a

safety device. Never

attempt to bypass its

operations.

Use extreme care when

handling gaaomine.

Gasemineis extremely

flammable and the

vapors are expbaMve.

Never fuel the machine

indoors or while the

engine is hot or running.

Extinguish cigarettes,

cigars, pipes, and other

sources of ignition.

Keep hands and feet

away from the cutting

deck. Refer to warning

label on the unit.

Side DischargeChute

Figure4-1:Themajorpartsonthelawnmower.

Now that you have set up your lawn mower for

operation, read this section to become acquainted

with its controls and features. This knowledge will

allow you to use your new equipment to its fullest

potential

Blade Control

The biade control is attached to the upper handle.

Depress and squeeze it against the upper handle

to operate the unit=Release it to stop engine and

blade=

,_ WARNING:This Madecontrol isa safety

device. Donot bypass itsoperations.

Cutting Height Adjustment Levers

One adjustment lever is located on each wheel and

is used to adjust the cutting height. All four wheels

must be at the same position to ensure a uniform

cut.

Recoil Starter

The recoi[ starter is attached to the right upper

handle= Stand behind the unit and pui[ the recoil

starter rope to start the unit=

Mulch Plug

The mulch plug is used for mulching purposes=

Instead of collecting the grass clippings in a grass

catcher or using the side discharge chute, some

mower models have the option of recirculating the

clippings back to the lawn. This is called mulching=

Grass Catcher

The grass catcher, located at the rear of the mower,

is used to bag the grass clippings for disposai at an-

other site=Once the bag is fuiL it has to be removed

from the mower and emptied before any further

mowing.

Gas and Oil Fill°Up

1, Check oi{ {eve{and add oil if necessary, Follow engine

manual for this,

2, Service the engine with gasoline as instructed in the

engine manual

WARNING: Use extreme care when handling

gasoline. Gasoline is extremely flammable

and the vapors are explosive. Never fuel the machine

indoors or while the engine is hot or running.Extin-

guish cigarettes, cigars, pipes, and other sources of

ignition.

while operating the moweror while performing any

adjustments or repairs on it.

Starting Engine

_lb WARNING:Besure nooneother thanthe

operator isstanding near the lawn mower

while starting engine or operating mower.

Never run engine indoorsor inenclosed, poorly

ventilated areas. Engine exhaustcontains carbon

monoxide, an odorless and deadlygas. Keephands,

feet, hair and looseclothing awayfrom anymoving

parts on engineand lawnmower.

NOTE:Referto the engine manualfor help with

engine relatedoperations.

1, Placethefuelvalveleverfoundontheleft sideofthe

engineintotheON(OPEN)position,Figure4-2,

2, Movethechokeleverall thewaybackwardintothe

chokeposition,Figure4-2,

3, Standingbehindthe mower,squeezethebladecontrol

againstupperhandle,Figure4=2,Thechokewillnow

begintoslowlyreturntotheoff chokepositionafter

activatingthe bladecontrol Therefore,quicklymove

ontostepfourbelow,

4, Holdingthesetwo handlestogetherfirmly,grasprecoil

starterand pullropeoutwitha rapid,continuous,full

armstroke,Figure4-2,Keepinga firmgripon the

starterhandle,lettheroperewindslowly,Repeatuntil

enginecranks,Lettheroperewindeachtimeslowly,

Stopping Engine

1, Releasebladecontroltostoptheengineandblade,

2, Disconnectsparkplugwirefromsparkplugand

groundagainsttheengine,

WARNING:Waitfor the bladeto stop

completely before performing anywork

on the mower or to removethe grass

catcher.

Using Your Lawn Mower

WARNING:Neveroperateyour mower

without eitherthe reardoor or the entire

grass catcher assembly firmly secured.

Be surelawnisclearofstones,sticks,wire,or other

obiectswhichcoulddamagelawnmowerorengine,

Suchobiectscouldbe accidentlythrownbythemower

in anydirectionandcauseseriouspersonaliniurytothe

operatorandothers,

Figure 4-2: Starting the mower.

1, Oncetheengineisrunning,squeezetheblade

controlagainsttheupperhandletoengagethe

blade,

• Forbestresults,do notcut wetgrassand never

cutoff morethanone-thirdofthetotallengthofthe

grass,

Using as Muncher

FormulcNnggrass,removethegrasscatcherorside

dischargechutefromthemower,Thereardischarge

doorshouldbeclosed,

Foreffectivemulching,do notcut wetgrass,New

orthickgrassmayrequirea narrowercut,Adjust

groundspeedaccordingtoconditionoflawn,

• If thegrasshasbeenallowedto growinexcessof

fourinches,mulcNngisnotrecommended,Usethe

grasscatchertobagclippingsinstead,

Using Grass Catcher

YoucanusethegrasscatchertocollectclippingswNle

youareoperatingthemower,

1, AttachgrasscatcherfollowinginstructionsinSetup

section,Grassclippingswillautomaticallycollectin

bagasyourunmower,Operatemowerfillgrassbag

isfull

2, Stopenginecompletelybyreleasingtheblade

control Makesurethattheunithascometo a

completestop,

3, Liftdischargedoorand pullgrassbagup andaway

fromthemowertoremovethebag,Disposeofthe

grassclippingsandreinstallthebagwhencomplete,

WARNING

The operation of any

lawn mower can result

in foreign objects being

thrown intothe eyes,

which can damage your

eyes severely. Always

wear safety glasses

while operating the

mower or while perform°

ing any adjustments or

repairs on it.

Be sure no one other

than the operator is

standing near the

lawn mower while

starting engine or

operating mower. Never

run _ngine indoors or

in enclosed, pooHy

ventilated areas. Engine

exhaust contains carbon

monoxide, an odormess

and deadmygas. Keep

hands, feet. hair and

loose clothing away

from any moving parts

on engine and lawn

mower.

Deck Care

Cban undersideofthe mowerdeckaftereachuseto

preventbuild-upofgrassclippingsorotherdebris.Follow

stepsbelowforthisiob.

1. Disconnectsparkplugwire.Draingasolinefromlawn

mowerorplacea pieceof plasticunderthegascap.

2. Tipmowersothat itrestson thehousing.Keepthe

sidewiththeaircleanerfacingup.Holdmowerfirmly.

WARNING:Nevertip the mower more

than 900in anydirection and do not

leavethe mower tipped for anylength of

time. Oil candrain into the upper part of the engine

causing a starting problem.

3. Scrapeandcban theundersideofthedeckwitha

suitabb tool Donotspraywithwater.

4. Putthemowerbackonits wheelsontheground.If

Figure5-1:Areastolubricateonmower, youhadputplasticunderthegascapearlbr, make

suretoremoveitnow.

pu!!eys, bearings,Or

General Recommendations

Alwaysobservesafetyrubs whenperforming

anymaintenance.

• Thewarrantyon thislawnmowerdoesnotcover

itemsthathavebeensubiectedtooperatorabuse

or negligence.Toreceivefullvaluefromwarranty,

operatormustmaintainthe lawnmoweras

instructedhere.

. Changingofengine=governedspeedwillvoid

enginewarranty.

• Alladjustmentsshouldbecheckedat bast once

eachseason.

. Periodicallycheckall fastenersand makesurethese

aretight.

_ ARNING:Always stop engine, discon-

nect spark plug, and ground against

engine before performing anytype of

maintenanceon your machine.

Engine Care

A listofkeyenginemaintenanceiobs requiredforgood

performancebythemowerisgivenbelow.Followthe

accompanyingenginemanualforadetaibd listand

instructions.

. Maintainoil levelasinstructedin enginemanual.

Serviceaircleanerevery25 hoursundernormal

conditions.Cban everyfewhoursunderextremely

dustyconditions.Poorengineperformanceand

floodingusuallyindicatesthattheaircbaner should

beserviced.Toservicetheaircleaner,refertothe

enginemanual

.Cban sparkplugandresetthegap oncea season.

Sparkplugreplacementisrecommendedatthestart

ofeachmowingseason.Checkenginemanualfor

correctplugtypeand gapspecifications.

• Cban engineregularlywitha clothorbrush.Keepthe

coolingsystem(Newerhousingarea)cleantopermit

properaircirculation.Removeallgrass,dirt, and

combustibbdebrisfrom mufflerarea.

Lubrication

1. Lubricatepivotpointson thebladecontrolat bast

oncea seasonwithlightoil Thebladecontrolmust

operatefreelyinbothdirections,Figure5-1.

2. Lubricatethewheelsatbast oncea seasonwith

lightoil (or motoroil). Ifwheelsare removedforany

reason,lubricatesurfaceofthepivotarmandinner

surfaceofthewheelwithlightoil,Figure5-1.

3. Lubricatethetorsionspringandpivotpointonthe

reardischargedoorandsidemulchplugperiodically

withlightoil topreventrust,Figure5-1.

4. Followtheaccompanyingenginemanualforlubrba-

tionschedub andinstructionforenginelubrication.

B_adeCare

WARNING:When removing the cutting

bladefor sharpeningor replacement,

protect your handswith a pair of heavy

gloves or usea heavy rag to hold the

blade.

Periodicallyinspectthebladeadapterforcracks,

especiallyifyoustrikea foreignobiect,Replacewhen

necessary,Followthestepsbelowforbladeservice,

1, Disconnectsparkplugwirefromsparkplug,Turn

moweron itssidemakingsurethattheairfilterand

thecarburetorarefacingup,

2, Removetheboltand thebladebellsupportwhich

holdthebladeandthebladeadaptertotheengine

crankshaft,Figure5=2,

3, Removebladeandadapterfromthecrankshaft,

Figure5=2,

4, Thebladecanbe sharpenedwitha fileoron agrind=

ingwheel Donotattempttosharpenthebladewhileit

isstillonthemower,

Whensharpeningtheblade,followtheoriginalangle

ofgrind,Grindeachcuttingedgeequallyto keepthe

bladebalanced,

5, Totestforbalance,removebladeand balanceon

a roundshaftscrewdriver,Removemetalfromthe

heavysideuntilitbalancesevenly,

WARNING:An unbalanced bladewill

causeexcessivevibration when rotating

at high speeds. It may causedamageto

mower and could breakcausing personal

injury.

6, Lubricatetheenginecrankshaftandtheinnersurface

ofthebladeadapterwithlightoil Slidetheblade

adapterontotheenginecrankshaft,

7, Placethebladeontheadaptersuchthattheside

oftheblademarked"Bottom"(orwith partnumber)

facesthegroundwhenthemowerisin theoperating

position,Makesurethatthebladeisalignedand

seatedon thebladeadapterflanges,

8, Placebladebellsupporton theblade,Alignnotches

on thebladebellsupportwithsmallholesin blade,

9, Replacehexboltandtightenhexbolttotorque:450

in,Ibs,min,,600 in,Ibs,max,

Toensuresafeoperationof yourmower,periodically

checkthebladeboltforcorrecttorque,

Replacing Rear F_ap

1, Toremoverearflap,cut off theflat endofthewirerod

whichsecuresitto thedeck,Figure5-3,

2, Attachthenewflapandnewrodto deck,bendingthe

endsof thenewrodovertosecuretodeck,

Figure5-2:Removethebolt,support,andadaptertoaccess

theblade,

Figure5-3:Cutwireto removerearflap.

Off-Season Storage

Thefollowingstepsshouldbetakento prepareyour

lawnmowerforstorage,

, Cleanandlubricatemowerthoroughlyasdescribed

in thelubricationinstructions,

, Donotusea pressurewasherorgardenhoseto

dean yourunit,

, Refertoenginemanualforcorrectengine

storageinstructions,

• Coatmower'scuttingbladewithchassisgreaseto

preventrusting,

• Storemowerina dry,dean area,Donotstorenext

tocorrosivematerials,suchasfertilizer,

Whenstoringanytypeof powerequipmentin apoorly

ventilatedor metalstorageshed,careshouldbetaken

torust-prooftheequipment,Usinga lightoil orsilicone,

coattheequipment,especiallycablesandall moving

partsofyourlawnmowerbeforestorage,

WARNING

When removing

thecutting blade

for sharpening or

replacement, protect

your handswith a pair

of heavygloves or use

a heavy rag to hold

the blade.

An unbalanced blade

will cause excessive

vibration when rotat-

ing at high speeds, it

may cause damage

to mower and could

break causing per-

serial injury.

For repairs beyond

the minor adjustments

listed here, contact

an authorized service

dealer.

Problem Cause

2_ Sparkp!ugwiredisconnected= 2, Connectwiretosparkplug.

Fueltankernptyoistale_uek 3. FilltankWithdean, freshgas01ineI

4. Enginenotpr!med. 4. Primeengineasinstructedin !'Operat-

ingYourLawnMower'!.

EaultySpa[kplug. 5. Cleanladustgapl 0i iepJace.

6. BloCkedfuel line. 6. Cleanfuel[inc.

Enginefl0oded. 7. Waitalew minutesio iestartlbut do

notprime

Enginerunserratic 1. Sparkplugwireloose.

2. Blockedfuel lineor stalefuel.

3. Ventingas capplugged.

4. Wateror dirt infuel system.

5. Dirtyaircleaner.

6. Carburetorout ofadjustment.

1. Connectandtightensparkplugwire.

2. Cleanfuelline;filltank withclean,

freshgasoline.

3. Clearvent.

4. Drainfueltank.Refillwithfreshfuel.

5. Refertoenginemanual.

6. Refertoenginemanual.

2. Air f!owrestricted. , 2. Removeblowerhousingandclean.

3. Carburetornotadjustedproperly. 3. Refertoenginemanuak

Occasional skips 1. Sparkpluggap tooclose. 1. Adjustgapto .030-inch.

(hesitates) at high speed 2. Carburetoridlemixtureadjustment 2. Refertoenginemanual.

improperlyset.

2. Carburetorirrlproperlyadjusted. 2. Refertoenginemanual.

3. Refertoenginemanual.

Excessive Vibration 1. Cuttingbladelooseor unbalanced. 1. Tightenbladeandadapter.Balance

blade.

2. Bentcuttingblade. 2. Seeanauthorizedservicedealer.

cuttingheight,

F k

Uneven cut 1. Wheelsnotpositionedcorrectly. 1. Placeall fourwheelsin same

heightposition.

2. Dullblade. 2. Sharpenorreplaceblade.

WARNING

DONOTremove safety

(or any) labeJs from

newer for any reasen,

Q Q

1 747q161A BladeControl

2 731-04204 BailCover

3 74Gl130 ControlCable,40dnchSnap-On

4 72G0240 CableTie

5 664-04011 GrassBagAssembly

6 747-04080 GrassBagFrame

7 73b0700 TrailshieldWire

8 731-04998 Trailshield

9 747-0996 PivotRod

10 731-04134A RearDischargeDoor

11 687_02057 RearHandleBracketAss}/,_LH

687-02056 RearHandleBracketAssy,- RHt

12 787-01279 Deck21dnch

13 687-02075A FrontHeightAdiustmentAssy-LH

687_02074A FrontHeightAdiustmentAssy_RHt

14 7865002B FrontBaffle

15 748-04082 BladeAdapter

16 742-0741 21dnchMulchingBlade

17 73G0524B BellBladeSupport

18 71G1257 HexScrew,3/8-24x 2,5

19 731-04177 SideDischargeChute

20 17032A DeflectorChuteAdaptor

21 7361014 TorsionSpring

22 747-0710 HingePin

23 987-02055 HingedMulchPlugAssembly

24 71b04065 FlangeLockNut3/8d6

25 787_01290 HeightAdiustmentPlate

26 687-02077A FrontPivotArmAssembly-RH

687_02076A FrontPivotArmAssembly_LHt

27 734-04014B FrontWheel,8 x2,125GWave

28 738-0507B ShoulderScrew,,5Dx ,434

29 732-0404 FrontSpringLever

30 72G0426 HeightAdiustKnob

31 71G0599 TTScrew,1/4-20x ,500

32 73G0270 BellWasher

33 71G0654A TTScrew,3/8-16x 1,0

34 71G0216 HexScrew,3/8d6 x ,75

35 71G1652 TTScrew,1/4-20x ,625

36 72G0312 FoamGrip

37 734-04127 RearWheel,12x2,125S-Wave

38 73G0182 SpringWasher

39 73b0866 RearHi-WheelSpringLever

40 687_02039A RearPivotArmAssy_RH

687_02040A RearPivotArmAssy_LHt

41 714-0104 HairpinClip

42 687-02192 HandleBracketAssy- RH

687_02191 HandleBracketAssy_LH

43 71G0703 CarriageBolt,1/4-20x ,75

44 731-04150C RearBaffle

45 71G04371 ScrewHL,1/4d5 x 1,00

46 732_04090A TorsionSpring_RH

732-04089A TorsionSpring- LHt

47 75G04162 Spacer

48 71b0397 WingNut

49 749-0928A LowerHandle

50 710d174 CarriageBolt,5/16-18x2

51 72G04072 StarKnob

52 72G0279 HandleKnob

53 710d205 EyeBolt

54 749-1092A UpperHandle

t NotPictured

List

FACTORY PARTS

To order replacement

parts, ca[J

1-800-648-6776

or visit

www.troybi[t,com

iMPORTANT

Fora proper work-

ingmachine, use

Factory Approved Parts.

VoBELT$are specially

designed to engage

and disengage safely.

A substitute (nonOEM)

VoBe[tcan bedangerous

bynot disengaging

completely.

MANUFACTURER'S LIMITED WARRANTY FOR

The limitedwarrantyset forthbelowisgivenbyTroy_BiltLLCwithrespect

tonewmerchandisepurchasedandusedin theUnitedStates,itsposses_

sionsandterritories.

"Troy_Bilt"warrantsthis productagainstdefectsinmaterialandworkmam

shipfora periodof two(2)yearscommencingon thedateoforiginal

purchaseandwill,atits option,repairorreplace,freeofcharge,anypart

foundtobedefectivein materialsor workmanship.This limitedwarranty

shallonlyapplyifthis producthasbeenoperatedand maintainedin

accordancewiththeOperator'sManualfurnishedwiththeproduct,and

hasnotbeensubiectto misuse,abuse,commercialuse,neglect,accident,

impropermaintenance,alteration,vandalism,theft,fire,water,or damage

becauseofotherperilor naturaldisaster.Damageresultingfromthe

installationor useofanypart,accessoryor attachmentnotapprovedby

Troy_Biltforusewiththeproduct(s)coveredbythis manualwillvoidyour

warrantyastoanyresultingdamage.

Normalwearpartsarewarrantedtobefreefromdefectsinmaterialand

workmanshipforaperiodofthirty(30)daysfromthedateofpurchase.

Normalwearpartsinclude,butare notlimitedto itemssuchas: batteries,

belts,blades,bladeadapters,grassbags,riderdeckwheels,seats,snow

throwerskidshoes,shaveplates,augerspiralrubberandtires.

NOWTO OBTAIN SERVICE: Warranty service is available, WITH

PROOFOF PURCHASE,through yourlocal authorizedservice

dealer.To locate the dealer in yourarea, check your YellowPages,

or contact Troy-Bilt LLC at RO. Box 361131,Cleveland,Ohio 44136-

0019,or can 1-866-840-6483 or 1-330-558-7220,or log on to our

Web site at www.troybilt.com.

This limitedwarrantydoesnot providecoverageinthefollowingcases:

a. Theengineor componentpartsthereof.Theseitemsmay

carrya separatemanufacturer'swarranty.Refertoapplicable

manufacturer'swarrantyfortermsandconditions.

b. Logsplitterpumps,valves,andcylindershaveaseparateone

yearwarranty.

c. Routinemaintenanceitemssuchaslubricants,filters,blade

sharpening,tune_ups,brakeadiustments,clutch adiustments,

deckadiustments,andnormaldeteriorationoftheexteriorfinish

duetouseorexposure.

d. Servicecompletedbysomeoneotherthananauthorizedservice

dealer.

e. Troy_Biltdoesnotextendanywarrantyforproductssoldor

exportedoutsideoftheUnitedStates,its possessionsand

territories,exceptthosesoldthroughTroy_Bilt'sauthorized

channelsofexportdistribution.

f. Replacementpartsthatare notgenuineTroy_Biltparts.

g. Transportationchargesandservicecalls.

Noimpliedwarranty, includinganyimpliedwarrantyof merchant°

ability offitness for a particular purpose, applies after the applicable

period of express written warranty aboveasto the parts as identi-

fied. Noother express warranty, whether written or oral, exceptas

mentioned above,given by anyperson or entity, includinga dealer or

retailer,with respectto any product, shall bind Troy-Bilt. Duringthe

period of the warranty,the exclusive remedy is repair or replacement

of the product as set forth above.

The provisions as set forth inthis warranty providethe sole and

exclusive remedyarising from the sale. Troy-Bilt shall not be liable

for incidental or consequential loss or damageincluding, without

limitation, expensesincurred for substitute or replacementlawncare

services or for rental expensesto temporarily replacea warranted

product.

Somestatesdo notallowtheexclusionor limitationofincidentalor

consequentialdamages,or limitationson howlonganimpliedwarranty

lasts,sotheaboveexclusionsor limitationsmaynotapplytoyou.

Innoeventshallrecoveryofanykindbegreaterthantheamountofthe

purchasepriceoftheproductsold.Alteration of safety features of the

product shall void this warranty. Youassumetheriskandliabilityfor

loss,damage,or injurytoyouand yourpropertyand/ortoothersandtheir

propertyarisingoutofthemisuseor inabilitytousetheproduct.

This limitedwarrantyshallnotextendto anyoneotherthantheoriginal

purchaseror tothepersonforwhomitwaspurchasedasa gift.

HOWSTATELAWRELATESTOTHiSWARRANTY:This limitedwar-

rantygh,'esyouspecificlegalrights,andyoumayalsohaveotherrights

whichvaryfromstatetostate.

IMPORTANT:OwnermustpresentOriginalProofofPurchasetoobtain

warrantycoverage.

TROYBILT LLC, P.O. BOX 361131 CLEVELAM D, OHIO 44136-0019; Phone: 1(866} 840-6483, 1-330-558-7220

Troybilt 542 Owner's manual

Brand: Troybilt

Model: 542

Category: Lawnmowers

Type: Owner's manual

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11A-542Q711

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Troybilt 542 Owner's manual

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Troybilt 542 Owner's manual

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