Troy-Bilt Series 540 manual

Safety • Assembl y • Operation • Tips & T echniques • Maintenance • T roubleshooting • P ar ts Lists • Warranty Warning : This un it is equi pped wi th an internal c ombu stion en gine and s hould not be u sed on or near any unim proved forest-c overed, brush- covered or grass -c overed land unles s the eng ine’ s exhaus t syste[...]

2 Finding and Recor ding Model Number T ab le of Contents BE FO RE Y OU BE GIN T O ASSE MBLE Y OUR NEW E QUIP MENT , please loca te the m odel plat e on the equipm ent and cop y the info rmatio n to the samp le model pla te p rov ided to the righ t. Y ou can loca te the model pla te b y standing a t the opera ting position and looking do wn at th e[...]

3 1 Slope Gauge W ARNING Do not mo w on inclines with a slope in e xcess of 1 5 degre es (a rise of appro ximat ely 2- 1/ 2 feet e very 1 0 fee t) . A riding mow er could o ve r turn and cause s erious inj ury . If opera ting a w alk - behind mo wer on such a slope , it is extrem ely difficult to main tain y our footi ng and y ou could slip , resul[...]

4 2 Safe Operat ion Practices Children T ragic accidents can occur if operator is not aler t to presence of children. Children are often attracted to mow er and mowing activity . They do not understand the dangers . Nev er assume that children will remain where you last sa w them. 1. K eep children out of the mowing area and under watchful care of [...]

5 1 9. Shu t the en gine o ff a nd wait un til th e blad e com es to a com plete s top be fore rem oving t he gra ss cat cher or u nc log - ging t he c hute. The c ut ting b lade c ont inues t o rotate for a few s eco nds af ter the e ngin e is shu t off. Never pl ace any par t o f the b ody in the b lade are a unti l you are sure t he bla de has s[...]

6 3 Setup and Adjustment 1 . Remove any packing materi al whic h may be between upper an d lower handle s. a. Pull up and b ack on up per hand le as shown in Figure 3 - 1 . M ake cert ain the lower hand le is seated securel y into the hand le mount ing brackets. Do n ot crim p cabl e while lif ti ng the han dle up. b. Tig hten star kno bs to secure[...]

7 7 . Y our mower is ship ped as a mul cher . T o conver t to side d ischar ge, make sure grass c atcher is of f of the unit and rear d isch arge do or is clos ed. a. On t he side of t he mower , li ft t he mulc hing plug. See Figure 3 - 7 . b. Sli de t wo hooks of sid e disc harge c hute under hinge p in on mulc hing plu g assemb ly . Lower the mu[...]

8 4 Operating Y our Lawn Mo wer Now that you have set up your lawn mower for opera- tion, read t his sec tion to be come ac quainted wi th its contro ls and features. Thi s knowled ge will a llow you to use your new equip ment to its full est potenti al. Blade Control The blad e control i s att ached to th e upper ha ndle. Depres s and squeeze it a[...]

9 4 Operating Y our Lawn Mo wer W ARNING The op eration of any lawn mower can result in foreign obje cts b eing thrown into the eyes, which can dam age your eyes se verely. A lways wear safet y glasse s while ope rating the mower or while per form - ing any adjustments or repair s on it. Be sure no one ot her than the o perator is standing ne ar th[...]

10 5 Maintaining Y our Lawn Mo wer W ARNING Alwa ys stop engi ne, disconnect spark plug, and grou nd against eng ine before per formi ng any type of maint enance on yo ur machine. Do not us e a pressu re wash er or garde n hose to cle an yo ur unit. The se ma y cause damage t o electric components , spindles, pulle ys, beari ngs, or the engine . Th[...]

11 5 Maintaining Y our Lawn Mo wer W ARNING When remov ing the cutting blade for sharpenin g or replacement , protect yo ur hands with a pair of heavy glo ves or use a heavy rag to hold the blade. An unbalanced blade will ca use ex ce ssiv e vibration when ro tat- ing at hi gh spee ds. It may cau se damage to mo wer and could break causing per- son[...]

12 For repairs bey ond the minor adj ustments listed here, contact an authorized service dealer . 6 T r ouble Shooting Cause Pr oblem Remedy Engine fails to st ar t 1 . Blad e co ntrol d isen gage d. 2. Spar k plug w ire di sco nnec ted. 3. Fuel tank e mpt y or st ale fu el. 4. Engin e not ch oked. 5. Fault y spar k plug. 6. Blo cked fu el lin e. 7[...]

13 7 Safety Labels W ARNING DO NOT remov e safet y (or any) labels from mower f or any reason. Safety Labels Found On Y our Lawn Mo wer T O N O D , Y R U J N I F O K S I R E H T E C U D E R O T S S E L N U E T A R E P O R O R E V O C E G R A H C S I D A C S S A R G . E C A L P R E P O R P S T I N I S I R E H C T . Y L E T A I D E M M I E C A L P E [...]

14 Wheel T reads K2 Bar Bar S-Wave 50 28 24 37 24 39 40 41 24 43 45 44 26 27 28 36 25 35 34 24 23 14 13 11 18 17 16 15 29 30 32 31 24 33 46 49 6 2 5 1 51 3 12 22 21 20 19 38 47 42 4 7 10 8 9 48 Model Series 540[...]

15 8 P ar ts List Ref. Part No. Descr iptio n 1 7 4 7 - 1 1 61 A Blade C ontrol 2 7 49 - 1 09 2A Up per Handl e 3 7 46 - 1 1 3 0 Control Ca ble, 40 ” 4 726- 0 240 Cable Ti e 5 66 4- 0 401 1 Gra ss Bag Asse mbly 6 7 4 7 - 0 408 0 Grass B ag F rame 7 720 - 0279 Handl e Knob 8 73 1-05 642 T rail shi eld 9 7 4 7 - 0 458 8 Pivot Rod 1 0 631 - 0 4225 R[...]

The limi ted warranty s et fort h below is gi ven by T roy- Bilt LLC with re spec t to new merchan dise purc hased an d used in t he United St ates, its pos ses- sions an d territori es. “T roy- Bilt ” warr ants this pr oduc t against d efects i n material and wor kman - ship for a per iod of t wo ( 2) years c ommen cing on t he date of orig in[...]