Troy-Bilt 547cc Pony 42-inch Gas Riding Lawn Mower User Manual

Troy-Bilt 547cc Pony 42-inch Gas Riding Lawn Mower

Important Safe Operation Practices

General Operation

1. Read, understand, and follow all instructions on the machine and in the manual(s) before attempting to assemble and operate. Keep this manual in a safe place for future and regular reference, and for ordering replacement parts.
2. Be familiar with all controls and their proper operation. Know how to stop the machine and disengage it quickly.
3. Never allow children under 14 years of age to operate this machine. Children 14 and over should read and understand the instructions and safe operation practices in this manual and on the machine and should be trained and supervised by an adult.
4. Never allow adults to operate this machine without proper instruction.
5. To help avoid blade contact or a thrown object injury, keep bystanders, helpers, children, and pets at least 75 feet from the machine while it is in operation. Stop the machine if anyone enters the area.
6. Thoroughly inspect the area where the equipment is to be used. Remove all stones, sticks, wire, bones, toys, and other foreign objects that could be picked up and thrown by the blade(s). Thrown objects can cause serious personal injury.
7. Plan your mowing pattern to avoid discharge of material toward roads, sidewalks, bystanders, and the like. Also, avoid discharging material against a wall or obstruction, which may cause discharged material to ricochet back toward the operator.
8. Always wear safety glasses or safety goggles during operation and while performing an adjustment or repair to protect your eyes. Thrown objects that ricochet can cause serious injury to the eyes.
9. Wear sturdy, rough-soled work shoes and close-fitting slacks and shirts. Loose-fitting clothes and jewelry can get caught in movable parts. Never operate this machine in bare feet or sandals.
10. Be aware of the mower and attachment discharge direction and do not point it at anyone. Do not operate the mower without the discharge cover or the entire grass catcher in its proper place.
11. Do not put hands or feet near rotating parts or under the cutting deck. Contact with the blade(s) can amputate hands and feet.
12. A missing or damaged discharge cover can cause blade contact or thrown object injuries.
13. Stop the blade(s) when crossing gravel drives, walks, or roads and while not cutting grass.
14. Watch for traffic when operating near or crossing roadways. This machine is not intended for use on any public roadway.
15. Do not operate the machine while under the influence of alcohol or drugs.
16. Mow only in daylight or good artificial light.
17. Never carry passengers.
18. Disengage blade(s) before shifting into reverse. Back up slowly. Always look down and behind before and while backing to avoid a back-over accident.
19. Slow down before turning. Operate the machine smoothly. Avoid erratic operation and excessive speed.
20. Disengage blade(s), set parking brake, stop engine, and wait until the blade(s) come to a complete stop before removing the grass catcher, emptying the grass, unclogging the chute, removing any grass or debris, or making any adjustments.
21. Never leave a running machine unattended. Always turn off the blade(s), place the transmission in neutral, set the parking brake, stop the engine, and remove the key before dismounting.
22. Use extra care when loading or unloading the machine into a trailer or truck. This machine should not be driven up or down ramp(s), because the machine could tip over, causing serious personal injury. The machine must be pushed manually on the ramp(s) to load or unload properly.
23. The muffler and engine become hot and can cause a burn. Do not touch.

Assembly & Set-Up

Tractor Set-Up

Connecting the Battery Cables

CAUTION: When attaching battery cables, always connect the POSITIVE (Red) wire to its terminal first, followed by the NEGATIVE (Black) wire.

For shipping reasons, both battery cables on your equipment may have been left disconnected from the terminals at the factory. To connect the battery cables, proceed as follows:

NOTE: The positive battery terminal is marked Pos. (+). The negative battery terminal is marked Neg. (–).

1. Remove the plastic cover, if present, from the positive battery terminal and attach the red cable to the positive battery terminal (+) with the bolt and hex nut.
2. Remove the plastic cover, if present, from the negative battery terminal and attach the black cable to the negative battery terminal (–) with the bolt and hex nut.
3. Position the red rubber boot over the positive battery terminal to help protect it from corrosion.

NOTE: If the battery is put into service after the date shown on the top/side of the battery, charge the battery as instructed in the Maintenance section of your Operator’s Manual prior to operating the tractor.

Shipping Brace Removal

WARNING! Make sure the riding mower’s engine is off, remove the ignition key, and set the parking brake before removing the shipping brace. Refer to the Controls and Features section for instructions on how to set the parking brake.

• Locate the shipping brace, if present, and the accompanying warning tag found on the right side of the mower, between the discharge chute and the cutting deck.
• Place the deck lift lever in the highest cutting position. Refer to Setting the Cutting Height in the Operation section of this manual.
• While pushing the discharge chute towards the machine with your left hand, remove the shipping brace with your right hand by grasping it between your thumb and index finger and rotating it clockwise.

WARNING! The shipping brace, used for packaging purposes only, must be removed and discarded before operating your riding mower.

WARNING! The mowing deck is capable of throwing objects. Failure to operate the riding mower without the discharge cover in the proper operating position could result in serious personal injury and/or property damage.

Attaching The Steering Wheel

If the steering wheel for your tractor did not come attached, the hardware for attaching it has been packed within the steering wheel, beneath the steering wheel cap. Carefully pry off the steering wheel cap and remove the hardware.

1. With the wheels of the tractor pointing straight forward, place the steering wheel over the steering shaft.
2. Place the washer (with the cupped side down) over the steering wheel and secure with the hex bolt.
3. Place the steering wheel cap over the center of the steering wheel and push downward until it “clicks” into place.

Attaching The Seat

If the seat for your tractor was not attached at the factory, refer to the following steps.

NOTE: For shipping reasons, seats are either fastened to the tractor seat’s pivot bracket with a plastic tie or mounted backward to the pivot bracket. In either case, free the seat from its shipping position and remove the adjustment knob from the bottom of the seat before proceeding with the instructions below.

1. Position the shoulder screws (found on the base of the seat) inside the slot openings in the seat pivot bracket.
2. Slide the seat slightly rearward in the seat pivot bracket, lining up the center rear slot in the pivot bracket with the remaining hole in the seat’s base.
3. Select the desired position for the seat, and secure it with the adjustment knob removed earlier.
4. To adjust the position of the seat on models so equipped, loosen the adjustment knob on the bottom of the seat. Slide the seat forward or backward as desired. Retighten the adjustment knob.

Controls & Features

WARNING! Read and follow all safety rules and instructions in this manual, including the entire Operation section, before attempting to operate this machine. Failure to comply with all safety rules and instructions may result in personal injury.

Throttle / Choke Control

The throttle control lever is located on the left side of the tractor’s dash panel. This lever controls the speed of the engine, as well as the choke when it is pushed all the way forward. When set in a given position, the throttle will maintain a uniform engine speed.

IMPORTANT: When operating the tractor with the cutting deck engaged, be certain that the throttle lever is always in the FAST (rabbit) position.

Moving the throttle lever all the way forward activates the engine’s choke control. Activating the choke control closes the choke plate on the carburetor and aids in starting the engine.

Ignition Switch

The ignition switch is activated to start the engine. Insert the key into the ignition switch and turn clockwise to the START position. Release the key into the ON position once the engine has fired.

WARNING! Never leave a running machine unattended. Always disengage PTO, move the shift lever into the neutral position, set the parking brake, stop the engine, and remove the key to prevent unintended starting.

IMPORTANT: Prior to operating the tractor, refer to both Safety Interlock Switches and Starting The Engine in the Operation section of this manual for detailed instructions regarding the Ignition Switch Module.

Clutch-Brake Pedal

The clutch-brake pedal is located on the left side of the lawn tractor, along the running board. Depress the clutch-brake pedal partway down when slowing the tractor by changing speeds (Refer to Speed Control Lever). Depress the pedal all the way down to engage the disc brake and bring the tractor to a complete stop.

NOTE: The clutch-brake pedal must be depressed to start the engine. Refer to Safety Interlock Switches in the Operation section of this manual.

Shift Lever

The shift lever is located on the left side of the fender and has three positions: FORWARD, NEUTRAL, and REVERSE. The brake pedal must be depressed, and the tractor must not be in motion when moving the shift lever.

IMPORTANT: Never force the shift lever. Doing so may result in serious damage to the tractor’s transmission.

Maintenance & Adjustments

Maintenance

WARNING: Before performing any maintenance or repairs, disengage PTO, move shift lever into neutral position, set parking brake, stop engine, and remove key to prevent unintended starting.

Engine

Refer to the Engine Owner’s Manual for engine maintenance instructions.

Check engine oil level before each use as instructed in the Engine Owner’s Manual packed with your unit. Follow the instructions
carefully.

Changing Engine Oil On Briggs & Stratton Models

For draining oil from the engine’s crankcase, a plastic oil drain sleeve is packed with this Operator’s Manual. To drain the oil, proceed as follows:

1. Run the engine for a few minutes to allow the oil in the crankcase to warm up. Warm oil will flow more freely and carry away more of the engine sediment, which may have settled at the bottom of the crankcase. Use care to avoid burns from hot oil.
2. Open the tractor’s hood and locate the oil drain port on the right side of the engine and the oil fill cap on the topside of the engine.
3. Unscrew the oil fill cap and remove the dipstick from the oil fill tube.
4. Snap the small end of the oil drain sleeve onto the space provided around the oil drain plug.
5. Remove the drain plug and drain oil into a suitable container with a capacity of no less than 64 oz.
6. Reinstall the oil drain plug securely. Be careful not to overtighten.
7. Refill the engine with new motor oil as instructed in the Engine Owner’s Manual packed with your unit.

IMPORTANT: Refer to the Engine Owner’s Manual packed with your unit for information regarding the quantity and proper viscosity of motor oil.

Changing The Engine Oil on Kohler Engine Models

To complete an oil change, proceed as follows:

1. Run the engine for a few minutes to allow the oil in the crankcase to warm up. Warm oil will flow more freely and carry away more of the engine sediment, which may have settled at the bottom of the crankcase. Use care to avoid burns from hot oil.
2. Open the tractor’s hood and locate the oil drain port on the right side of the engine.
3. Pop open the protective cap on the end of the oil drain valve to expose the drain port.
4. Remove the oil fill cap/ dipstick from the oil fill tube.
5. Push the oil drain hose (packed with this manual) onto the oil drain port. Route the opposite end of the hose into an appropriate oil collection container with at least a 2.5-quart capacity to collect the used oil.
6. Rotate the drain valve counter-clockwise and release to drain the oil.
7. After the oil has finished draining, push the end of the oil drain valve back in until the tabs click into place. Re-cap the end of the oil drain valve to keep debris from entering the drain port.
8. Replace the oil filter as instructed in the separate engine Owner’s Manual.
9. Refill the engine with new oil. Refer to the engine Owner’s Manual for information regarding the proper volume and weight of engine oil.

Air Cleaner

Service the pre-cleaner (if equipped) and cartridge/air cleaner element as instructed in the Engine Owner’s Manual packed with your unit.

Spark Plug

The spark plug should be cleaned and the gap reset once a season. Spark plug replacement is recommended at the start of each mowing season. Refer to the Engine Owner’s Manual for the correct plug type and gap specifications.

Cleaning the Engine And Deck

Any fuel or oil spilled on the machine should be wiped off promptly. Do NOT allow debris to accumulate around the cooling fins of the engine or on any other part of the machine.

IMPORTANT: The use of a pressure washer to clean your tractor is NOT recommended. It may cause damage to electrical components, spindles, pulleys, bearings, or the engine.

Battery

The battery is sealed and is maintenance-free. Acid levels cannot be checked.

• Always keep the battery cables and terminals clean and free of corrosive buildup.
• After cleaning the battery and terminals, apply a light coat of petroleum jelly or grease to both terminals.
• Always keep the rubber boot positioned over the positive terminal to prevent shorting.

IMPORTANT: If removing the battery for any reason, disconnect the NEGATIVE (Black) wire from its terminal first, followed by the POSITIVE (Red) wire. When re-installing the battery, always connect the POSITIVE (Red) wire to its terminal first, followed by the NEGATIVE (Black) wire. Be certain that the wires are connected to the correct terminals; reversing them could change the polarity and result in damage to your engine’s alternator system.

Charging

IMPORTANT: When charging your tractor’s battery, use only a charger designed for 12V lead-acid batteries. Read your battery charger’s Owner’s Manual prior to charging your tractor’s battery. Always follow its instructions and heed its warnings.

• If your tractor has not been put into use for an extended period of time, charge the battery as follows.
• Set your battery charger to deliver a maximum of 10 amperes. If your battery charger is automatic, charge the battery until the charger indicates that charging is complete.

NOTE: If the charger is not automatic, charge for no fewer than eight hours.WARNING! Batteries give off an explosive gas while charging. Charge battery in a well-ventilated area and keep away from an open flame or pilot light as on a water heater, space heater, furnace, clothes dryer, or other gas appliances.

Jump Starting

WARNING! When removing or installing the battery, follow these instructions to prevent the screwdriver from shorting against the frame.

IMPORTANT: Never jump your tractor’s dead battery with the battery of a running vehicle.

1. Connect the end of one jumper cable to the positive terminal of the good battery, then the other end to the positive terminal of the dead battery.
2. Connect the other jumper cable to the negative terminal of the good battery, then to the frame of the unit with the dead battery.
3. Start the tractor as instructed in the Operation section.WARNING! Failure to use this procedure could cause sparking, and the gas in either battery could explode.

Service

Cutting Deck Removal

To remove the cutting deck, proceed as follows:

1. Place the PTO (Blade Engage) lever in the disengaged (OFF) position and engage the parking brake.
2. Lower the deck by moving the deck lift lever into the bottom notch on the right fender.
3. Remove the belt-keeper rod from around the tractor’s engine pulley by removing the self-tapping screw (A) that
   secures it. Note: Make a mental note which hole the other end of the beltkeeper rod is inserted in for reinstallation purposes.
4. Remove the belt (C) from around the tractor’s engine pulley and idler pulley(s).
5. Looking at the cutting deck from the left side of the tractor, locate the bow-tie pin that secures the deck support rod on the rear left side of the deck. Remove the bowtie pin that secures the deck support rod, and carefully remove the deck support from the deck lift arm.
6. Repeat the above steps on the tractor’s right side.
7. Move the deck lift lever into the top notch on the right fender to raise the deck lift arms up and out of the way.
8. Remove the bow-tie cotter pin securing the deck lift rod to the deck. Slide the deck lift rod from the mounting weldment on the deck.
9. Carefully remove the PTO cable from the rear of the cutting deck by removing the hairpin clip that secures it. Remove the spring from the deck idler bracket.
10. Gently slide the cutting deck (from the left side) out from underneath the tractor.

Troubleshooting

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Troy-Bilt 547cc Pony 42-inch Gas Riding Lawn Mower-FAQs