Troy-Bilt 42000 User Manual

Owner/Operator
Manual

21",5H.P.
Snowthrower

$7.50

Model

• Safety

• Assembly

• Controls

• Operation

• Maintenance

42000

© 1995 Garden Way Incorporated

Form 1771779 (6/95)

Dear Owner,

Thank you for purchasing this Troy-Bilt®
Snowthrower. The unit was carefully designed
and manufactured to provide excellent
performance if properly operated and
maintained.

Read this manual. This is a safety, operation
and general maintenance manual which does
not attempt to cover major repairs. This
manual is considered a permanent part of the

unit and it must stay with the unit if it is resold.
A replacement manual can be obtained from the
factory, free of charge. All information in this
manual is based on the latest product

information available at the time of printing.

Review this manual frequently to familiarize
yourself with the unit, its features and
operation.

Our products have met the rigid safety
standards of the Outdoor Power Equipment

Institute and an independent testing laboratory.

Safety alert symbol

This is a safety alert symbol.

It is used in this manual and

A

potential hazards. When you see this
symbol, read and obey the message
that follows it. Faiiure to obey safety
messages could result in personal
injury or property damage.

on the unit to alert you to

Owner registration card

Please fill out and mail the enclosed
owner registration card. The purpose
of this card is to register each unit at
the factory in order to keep the owner
informed with informational bulletins
and safety literature.

Warranty service

The warranty statement is included on
the back cover of this manual.

The warranty statement is
included on the back
cover of this manual.

Read it carefully. Also, please complete and
return the postpaid owner registration card

which is included with this manual. The

purpose of this card is to register each unit and

owner at the factory in order to provide

informational bulletins and safety literature.

If you have any problems or questions
concerning the unit, contact your local
authorized dealer. Our telephone numbers and

mailing addresses are listed on page 3.
We want to ensure your complete satisfaction at

all times.

Modei/seriai numbers

The modei/seriai numbers are located
on the back of the unit. For quick
reference, record these numbers in the
spaces below.

Date of purchase:

Modei/seriai numbers:

Engine service and repair

For engine service or repair, contact
your nearest authorized engine dealer.
To locate your nearest engine dealer,

look in the Yellow Pages under

“Engines-Gasoline”. The engine on
the unit is warranted by the engine

manufacturer. Any unauthorized work

performed on the engine during the
warranty period may void this

warranty. For complete details on the

engine warranty, refer to the engine

owner manual.

Service and repair

For factory authorized service, contact
your authorized dealer. Do not return
parts directly to the factory. When
ordering parts, provide your dealer
with the model/serial numbers and a
description of the parts required.

Replacement parts

Factory specified replacement parts
are available from either your Troy­Bilt® authorized dealer or directly
from the factory. For parts ordering
information, refer to the parts catalog.

Left and right sides

Left and right sides of the unit are
determined from the operator's
position, facing the direction of
forward travel.

Replacement owner/operator
manual

A replacement Owner/Operator
Manual is available at no charge. To
order, call or write to the address
below.

Customer service

If you have questions or problems
with your unit, contact your local
Troy-Bilt® dealer - or call or write to
the addresses listed below. When
calling or writing the factory, provide
the model/serial number of your unit.

IN THE U.S.:
Garden Way Incorporated

102nd St. and 9th Ave.
Troy, New York 12180
For Service: [phone]
For Parts: [phone]

IN CANADA:
Garden Way Incorporated

320 Van Sickle Rd„ Unit 12
Saint Catherines, Ontario L2R 6P7
For Technical Service or Parts:
[phone]

Table of Contents

Owner registration card .................................................................................................................................. 2

Warranty service ................................................................................................................................................. 2

Model/serial numbers...................................................................................................................................... 2

Engine service and repair............................................................................................................................... 2

Unit service and repair.................................................................................................................................... 3

Left and right sides ........................................................................................................................................... 3

Replacement owner/operator manual................................................................................................... 3

Customer service................................................................................................................................................ 3

SECTION 1: SAFETY............................................................................................................................................................ 4

Safely Decals ........................................................................................................................................................ 7

SECTION 2: ASSEMBLY...................................................................................................................................................... 8

Tools/additional assembly materials .................................................................................................... 8

Handlebar assembly.......................................................................................................................................... 8

Discharge chute assembly............................................................................................................................ 8

Control lever cable assembly.................................................................................................................... 10

Tire pressure........................................................................................................................................................ 11

Engine oil................................................................................................................................................................ 11

SECTION 3: CONTROLS.................................................................................................................................................. 12

Auger drive control lever............................................................................................................................... 12

Wheel drive control lever

............................................................................................................................. 12

Discharge chute control rod....................................................................................................................... 12

Discharge chute deflector cap.................................................................................................................. 12

Gear shift lever.................................................................................................................................................... 13

Skid shoes............................................................................................................................................................. 13

Scraper blade...................................................................................................................................................... 13

Engine controls................................................................................................................................................... 13

SECTION 4: OPERATION ................................................................................................................................................. 15

Pre-operation checklist................................................................................................................................. 15

Starting the engine............................................................................................................................................ 17

Stopping the engine.......................................................................................................................................... 17

Wheel drive engagement/disengagement........................................................................................ 18

Shifting gears...................................................................................................................................................... 18

Reverse................................................................................................................................................................... 18

Auger drive engagement/disengagement.......................................................................................... 19

Emergency stopping/stopping.................................................................................................................. 19

Transporting the unit....................................................................................................................................... 19

Snowthrowing tips.......................................................................................................................................... 19

SECTIONS: MAINTENANCE .......................................................................................................................................... 22

Engine oil............................................................................................................................................................... 22

Ignition system................................................................................................................................................ 22

Sparkplug.............................................................................................................................................................. 23

Engine air cleaner............................................................................................................................................ 23

Carburetor............................................................................................................................................................ 23

Lubrication........................................................................................................................................................... 23

Wheel drive cable adjustment.................................................................................................................. 24

Wheel drive belt replacement................................................................................................................... 25

Auger drive cable adjustment................................................................................................................... 25

Auger drive bel t replacement................................................................................................................... 26

Auger shear bolts............................................................................................................................................ 27

Off season storage

......

...................................................................................................................................... 27

Optional kits and specifications.............................................................................................................. 28

Troubleshooting................................................................................................................................................ 29

Maintenance schedule

WARRANTY

............................................................................................................................................

................................................................................................................................. 31

Back Cover

Section

1 Safety

SPARK ARRESTER WARNING TO RESIDENTS OF CALIFORNIA AND SEVERAL OTHER STATES

Under California law, and under the

laws of several other states, you are
not permitted to operate an internal
combustion engine using
hydrocarbon fuels on any forest,
brush, hay, grain, or grass covered
land; or land covered by any flammable agricultural crop without an engine spark arrester in continuous effective
working order.

The engine on the unit, is an internal combustion engine which burns gasoline, a hydrocarbon fuel and must be
equipped with a spark arrester muffler in continuous effective working order. The spark arrester must be attached to the
engine exhaust system in such a manner that flames or heat from the system will not ignite flammable material. Failure
of the owner/operator of the unit to comply with this regulation is a misdemeanor under California law (and other states)
and may also be a violation of other state and/or federal regulations, laws, ordinances or codes. Contact your local fire
marshal or forest service for specific information about which regulations apply in your area.

Training

Read this owner/operator manual
and the separate engine owner
manual carefully before operating the
unit. Be completely familiar with the
controls and the proper use of the
unit. A free replacement manual is
available by sending the model and
serial numbers of the unit to the
factory.

2.

Never allow children or untrained
adults to use the unit.

3. Keep the area of operation clear of all 7.
people, particularly small children

and pets. Keep bystanders at least
25 feet away from the area of
operation.

4. Familiarize yourself with all of the
safety and operating decals on the
unit and on any attachments or 8.
accessories.

5. Do not run the engine in an enclosed
area. Engine exhaust contains
carbon monoxide gas, a deadly
poison that is odorless, colorless, i _
and tasteless. Do not operate the

unit near buildings, windows, or air

conditioners.

6. Keep hands or any other part of the
body or clothing away from the
inside of the auger housing, 2.
discharge opening, and away from
any moving parts.

Before inspecting, servicing or
adjusting any part of the unit, shut
the engine off, wait for ail moving
parts to stop, and disconnect the
spark plug wire from the spark plug.
Secure the wire away from the spark
plug.

Do not operate the unit if you are
under the influence of alcohol,
medication, or when tired or ill.

Preparation

Wear approved safety glasses or
eyes shields and hearing protection
when operating the unit. The
operation of any powered machine
can result in foreign objects being
thrown by high-speed rotating parts.

Do not wear loose-fitting clothing,
such as scarves, that can get caught
by moving parts. Tie up or restrain

iong hair.

Section 1 : Safety (continued)

3. Before starting the engine, check the
tightness of all screws, nuts, bolts,
and other fasteners. Replace any
damaged or unreadable safety and
operating labels.

4. Wear adequate winter outer
garments when operating the unit.
Wear footwear that will improve
footing on slippery surfaces.
Exercise caution to avoid slipping or
falling, especially when operating in
reverse.

5. Use extra care when handling
gasoline and other fuels. Gasoline
and its vapors are highly flammable
and explosive. To help prevent a fire
or explosion:

a. Store gasoline only in an

approved gasoline storage
container, safely out of the reach
of children.

b. Never remove the fuel fill cap on

the fuel tank, or add fuel while
the engine is running or hot.

c. Keep matches, smoking

materials, open flames, and
sparks away from the fuel tank
and gasoline storage container.

d. Fill the fuel tank outdoors and

with extreme care. Never fill the
fuel tank indoors.

e. Replace the fuel fill cap on the

fuel tank, the cap on the
gasoline storage container, and
clean up fuel spills before
starting the engine.

f. Leave 1/2-inch (2.5 cm) air

space at the top of the fuel tank
to allow for fuel expansion.

g. Do not store the unit or the

gasoline storage container
where there is a danger of an
open flame or spark, or where
ignition sources are present
such as hot water and space
heaters, furnaces, clothes
dryers, stoves, electric motors,
etc.

6. For units equipped with the electric­start kit:

a. Only use a 3-pronged, UL rated

and approved, outdoor use
electrical cord.

b. Only plug into a properly

grounded, 3-pronged outlet. Do
not use any adapters on the
cord.

c. Inspect the electrical cord for

damage before using it. If it is
damaged, do not use it.

d. Stand on dry ground when

handling the electrical cord. Do
not handle the electrical cord
with wet hands or wet gloves.
Do not use the electric starter if
it is raining.

e. Connect the cord to the electric

starter first, and then plug the
cord into a properly grounded
outlet (this lessens the chances
of a spark occurring near the
engine).

f. Do not abuse the electrical cord.

Do not pull the unit by the cord.
Do not yank the cord to
disconnect it from the outlet.
Keep the cord away from sharp
edges, oil, and excessive heat.

7. Adjust the skid shoes and scraper

blade so the auger housing to clear
gravel or crushed rock surfaces.

Operation

1. The operator of the unit is

responsible for the safety of all
persons in the operating zone of the
unit.

2. Before starting the unit, disconnect

the spark plug wire and check the
auger and discharge chute to make
sure they are free of ice. Check the
engine oil level. Reconnect the spark
plug wire before starting the engine.

3. Disengage all clutches and shift into

neutral before starting the engine.

4. Let the unit adjust to outdoor
temperature before use.

5. Check the operation of the controls
before using the unit. Do not operate
the unit unless all controls are
operating properly.

6. Never carry passengers on the unit.
They could fall off and be seriously
injured, or they could interfere with
safe operation.

7. Keep hands, other body parts, and
clothing away from any moving or
rotating parts. Keep clear of the
intake and discharge openings at all
times.

8. Before starting the engine, inspect
the area where the unit is to be used
and remove all sleds, boards,
doormats, metal, bottles, cans, or
other debris.

9. Keep children out of the area of
operation and under the watchful eye
of an adult not operating the unit.
Never assume that children will
remain where you last saw them.

10. If the unit makes an unusual noise or
vibration, immediately shut the
engine off, wait for all moving parts
to stop, disconnect the spark plug""^
wire from the spark plug and
perform the following steps:

a. Inspect for damage.
b. Replace or repair any damaged

parts.

c. Check for and tighten any loose

parts.

Section 1: Safety (continued)

11. If the unit jams or becomes clogged,
shut the engine off immediately and
allow all moving parts to come to a
stop. Disconnect the spark plug wire
from the spark plug and secure the
wire away from the spark plug. Use
only a wooden stick (at least 3 feet
long) to clear away blockage.

12. Before inspecting the unit or making
any adjustments, stop the engine and
allow all moving parts to come to a
stop. Disconnect the spark plug wire
from the spark plug and secure the
wire away from the spark plug.

13. Keep ail guards, covers, shields and
safety devices in place and in good
working condition. Do not attempt to
defeat the purpose of any safety
device.

14. Exercise extreme caution on slopes.

15. Do not attempt to clear steep slopes.

16. Do not clear snow across the face of
slopes. Exercise extreme caution
when changing direction on slopes.

17. Always observe the terrain. Watch
for and avoid obstacles. Stay away
from holes, ditches, soft or steep
embankments and other potentially
dangerous terrain. Deep snow can
hide obstacles and drop-offs.

18. Do not use the unit near drop-offs,
ditches, or embankments. If a wheel
goes over an edge, or if an edge
caves in, the unit could overturn.

19. Do not operate the unit at high
transport speeds on slippery
surfaces. Wet surfaces reduce
traction and stability.

20. Look behind and use care when
operating the unit in reverse. If you

have to pull the unit backward,

disengage the auger and wheel

drives. Always check behind you for
hazards.

21. Be extremely careful when using the
unit near blind corners, shrubs,
trees, and other objects that may
obscure vision.

22. Be extremely careful when operation
or crossing gravel drives, walks or
roads. Stay alert for hidden hazards
or traffic.

23. Remove any hearing protection and
watch for traffic when operating
near, or when crossing roadways.

24. Never leave the unit unattended when
the engine is running. Before leaving
the unit unattended, stop the engine,
let all moving parts come to a stop,
and disconnect the spark plug wire
from the spark plug.

25. Use only attachments and
accessories that are approved for use
with the unit. Contact the factory
customer service department, at the
address and phone number on page
3, if you are not sure about the use
of any attachment or accessory.

26. Operate the unit only in daylight or in
good artificial light.

27. Do not tamper with the engine
governor settings. The governor
controls the maximum safe engine
operating speed and protects the
engine and moving parts from
damage. Contact your local engine
dealer for service if a problem exists.

28. Shut off the engine, disconnect the
spark plug wire and secure the wire
away from the spark plug, before
transporting the un unit a vehicle or
trailer.

29. Do not touch the muffler or other
engine parts which may be hot from
operation. Wait for parts to cool
completely before inspecting,
cleaning, or repairing the unit.

30. Never operate the unit near

buildings, glass enclosures,
automobiles, window wells, drop­offs, etc., without first properly
adjusting the discharge angle and
direction. Keep children and pets
away.

31. Never direct discharge at bystanders.
Never allow anyone in front of the
unit when the engine is running.

32. Disengage the auger drive when the
unit is being transported or not in
use.

33. Disengage the auger and wheel
drives if you are approached by any
child, inattentive person or pet.

34. Run the unit for a few minutes after
use to prevent freeze-up. Remove
any snow from the unit (snow can
melt, and then re-freeze inside the
unit).

Maintenance and Storage

1. When the unit is stopped for

servicing, inspection, storage, or to
change an attachment or accessory,
disconnect the spark plug wire from
the spark plug and secure the wire
away from the plug. Let the engine
cool before making inspections,
adjustments, or performing any
maintenance.

2. Maintain the unit and all attachments

and accessories in safe working
condition.

3. Never perform any maintenance while

the engine is running, or when the
spark plug wire is connected to the
spark plug.

4. Do not store the unit or fuel container

inside an enclosure where there is an
open flame or spark, or where ignition
sources are present, such as: Hot
water and space heaters, furnaces,
clothes dryers, stoves, electric

motors, etc.

5. Allow the engine to cool before
storing in any enclosure.

6. Store gasoline in a cool, well­ventilated area, safely away from any
spark- or flame-producing equipment.

7. Store gasoline only in an approved
gasoline storage container, safely out
of the reach of children.

8. Use only original equipment
replacement parts. Parts
manufactured by others could present
a safety hazard even though they may
fit on the unit.

Section 1: Safety (continued)

Decals

For your personal safety and the
safety of others, there are a number of
safety message decals have been affixed
to your unit. Keep them clean and legible
at all times. Contact your local service
dealer or the factory for replacements if
any of these decals are damaged or
missing.

Refer to the separate parts catalog for
decal locations, part numbers, and
ordering instructions.

9. Store the unit where children will not
have access to it. Always disconnect
the spark plug wire from the spark

plug to prevent accidental starting.
Remove the ignition key from the
ignition switch.

10. Check the tightness of the auger
shear bolts and other fasteners at
frequent intervals.

11. Maintain or replace safety and
instruction decals if they are damaged
or illegible. Refer to the parts catalog
for decal location and ordering
information.

12. Refer to the engine owner manual for
complete engine operation and
maintenance information.

Section

2

Assembly

inspect unit

Inspect the unit and carton for damage
immediately after delivery. Contact the
carrier (trucking company) if you find or

suspect damage. Inform them of the

damage and request instructions for filing
a claim, to protect your rights, put your
claim in writing and mail a copy to the

carrier within 15 days after the unit has

been delivered, Contact us at the factory
as indicated on page 3 of this manual if
you need assistance in this matter.

Shipping carton contents

The shipping carton should contain:

• Snowthrower/engine/auger assembly.

• Handlebars.

• Discharge chute assembly (including

discharge chute control rod and
control rod support bracket).

• Hardware package containing:

(2) cable brackets.
(1) 1/4”-20 X1-1/2" cap bolt
(1) 1/4“ flat washer
(1) 1/4"-20 locknut
(4) 5/16"-18 X 5/8" hex flange bolts
(2) 1/4”-20 x 3/4“ hex flange bolts.
(2) cotter pins.
(2) ignition keys (attached to choke

knob).

*(2) extra 5/16"-18 x 1-3/4" locknuts

(see note below).

*(2) extra 5/16"-18 x 1 -3/4” shear

bolts (see note below).

*Note: These Items are replacements

for the auger shear bolts and

lockwashers (If the auger jams, the
shear bolts are designed to break to
prevent damage to the auger). Tighten

these bolts and lockwasheis toll ft-lbs

(15 Nm). Only use these special bolts In

other bolts are used In this location,
damage to the unit could result.

Toois/additionai assembiy materials

Tools/materials required to assemble the
unit:

**(2) 7/16" wrenches.
**(2) 1/2" wrenches (one open-ended).
**(1) 3/8" wrench.
**(1)5/16" wrench.
**(1) 9/16" wrench.
(1) needle-nosed pliers.
(1) automotive-type air pressure gauge.
(1) clean funnel.
(1 oz.) multi-purpose grease.
(approximately 21 oz.) clean, high-quality

engine oil. Refer to the engine owner
manual for exact engine oil
specifications.

**Note: adjustable wrenches may be

substituted.

1. Position the handlebars (Z, Fig. 2-1)
as shown, so the holes In the
handlebars align with the holes in the
upper rear corners of the
snowthrower frame.

2. Loosely install four 5/16”-18 x 5/8”
hex flange bolts (A).

3. Evenly tighten all four bolts (A).

Discharge chute assembiy

1. Remove the cardboard liner and the
chute control assembly inside the
discharge opening on top of the unit.

2. Remove the shims and clips (B and D,

Fig. 2-2) from the sides of the

discharge chute. Loosen, but do not

remove the front shim and clip.

3. Apply multi-purpose grease to the top

surface of the discharge chute flange
(C).

8

4. Position the discharge chute onto the
discharge chute flange on the auger
housing, with the front hold-down clip
(Fig. 2-3) hooked under the flange,
and the nylon shim on top of the
hold-down clip against the top of the
toothed flange.

5. Rotate the discharge chute opening
so it is facing to the right. Install the
nylon shim (B, Fig. 2-2) and hold
down clip (D) on the left side of the
chute as shown in Fig. 2-3.

Section 2: Assembly (continued)

Using two 7/16” wrenches, secure the

support bracket (G) to the handlebar
with one 1/4-20 x 1-1/2 cap bolt, one
1/4 flat washer and one 1/4”-20
locknut.

3.

Move the discharge deflector cap (H,
Fig. 2-2) upward by pulling out lever

is seated in one of the positioning
holes on the discharge chute cap.

5. Rotate the discharge chute opening
so it is facing to the left. Install the
nylon shim (B, Fig. 2-2) and hold
down clip (D) on the right side of the
chute as shown in Fig. 2-3.

IMPORTANT: Engine oil must be added
to the engine crankcase before the
engine is started. Seethe engine
owner manual (included with this unit)
for more specific engine oil information.

Discharge chute control rod assembly

1. Position the hole in the swivel block
(E, Fig. 2-4) over the hooked end of
the chute control connecting rod (F).
Secure the swivel block to the
connecting rod with a cotter pin.

Bend the ends of the cotter pin over

to secure it in place.

Section 2: Assembly (continued)

b. Adjust bracket (L)-(push in to

tighten: pull out to loosen).
c. Retighten the nut backing bolt (K).
d. Check chute rotation and repeat

adjustment as needed.

,5. Apply multi-purpose grease to the

worm gear and toothed edge of
discharge chute flange (M).

Control lever cable assembly

1. Hook the control cable assembly (0,
Fig. 2-6) entering the left side of the
frame into the right control lever (P).
The control cable (0) must be routed
behind cross-member (X).

Chute control crank assembly

1. Cut the tie securing the chute control
crank bracket (L, Fig. 2-5). Remove

the locknut backing screw (K).

2. Position the chute control crank
bracket (L) on the auger housing so
the worm gear meshes with the teeth
in the discharge chute flange.

3. Secure the chute control crank
bracket the to auger housing with the
locknut removed in step 1.

4. Rotate the chute control crank and
check for binding. Adjust, if required,
as follows:

a. Loosen the nut backing bolt (K, Fig.

2-5).,

2. Hook the control cable assembly (0)
entering the right side of the frame
into the left control lever (P and Z).
Control cable (0) must be routed
behind cross-member (X).

10