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Operator’s Manual
21” Mulching Mower
Model Series 544
IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY
Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-
covered, brush-covered or grass-covered land unless the engine’s exhaust system 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 opera
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TABLE OF CONTENTS Content Page Important Safe Operation Practices................................................................... 3 Slope Gauge...................................................................................................... 6 Assembling Your Lawn Mower........................................................................... 7 Know Your Lawn Mower .................................................................................... 9 Operating Your Lawn Mower ...........
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SECTION 1: IMPORTANT SAFE OPERATION PRACTICES WARNING: This symbol points out important safety instructions which, if not followed, could endanger the personal safety and/or property of yourself and others. Read and follow all instructions in this manual before attempting to operate this machine. Failure to comply with these instructions may result in personal injury. When you see this symbol - heed its warning. WARNING: Engine Exhaust, some of its constituents, and certain vehicle componen
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continues to rotate for a few seconds after the 2. Be alert and turn mower off if a child enters the engine is shut off. Never place any part of the body area. in the blade area until you are sure the blade has 3. Before and while moving backwards, look behind stopped rotating. and down for small children. 9. Never operate mower without proper trail shield, 4. Use extreme care when approaching blind corners, discharge cover, grass catcher, blade control doorways, shrubs, trees, or other objec
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14. To reduce fire hazard, keep mower free of grass, 7. After striking a foreign object, stop the engine, leaves, or other debris build-up. Clean up oil or fuel disconnect the spark plug wire and ground against spillage and remove any fuel soaked debris. the engine. Thoroughly inspect the mower for any 15. Allow a mower to cool at least 5 minutes before damage. Repair the damage before starting and storing. operating the mower. 8. Never attempt to make a wheel or cutting height General Serv
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FOLD ON DOTTED LINE, REPRESENTING A 15° SLOPE SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE A POWER POLE A CORNER OF A BUILDING OR A FENCE POST 15° WARNING 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 u
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SECTION 3: ASSEMBLING YOUR LAWN MOWER IMPORTANT: This unit is shipped without gasoline or oil in the engine. Be certain to service engine with gasoline and oil as instructed in the separate engine manual before operating your mower. NOTE: Reference to right or left hand side of the mower is observed from the operating position. Removing Unit From Carton Remove staples, break glue on top flaps, or cut tape at carton end and peel along top flap to open carton. Remove loose parts if includ
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Secure bag to frame by working the plastic Attaching Rear Wheels channels on bag over frame as shown in Figure 7B. Remove hardware from hardware pack. All of the plastic channels except the center top of Insert shoulder screw through wave washer, flat the bag attach from the outside of bag. The center washer, rear wheel, and spring washer. top of the bag attaches from inside the bag. Secure shoulder screw with hardware to rear pivot bar. See Figure 5. Plastic B A Channels Frame Sp
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Do not remove the side mulching plug at any time, Converting To Side Discharge even when you are not mulching. Your mower has been shipped as a mulcher. To convert it to a side-discharge mower, lift the mulch- Mulching ing plug. Slide the two hooks on the side-discharge Plug deflector under the hinge pin on the mulching plug assembly. Lower the mulching plug.See Figure 9. Hinge Pin Side Chute Deflector Figure 9 WARNING: Never operate the mower without the mulching cover, the grass catcher
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Cutting Height Adjustment Levers Blade Control Handle These levers are located on each wheel and are used The blade control handle is located on the upper handle to adjust the cutting height. These levers have to be at of the mower. The blade control handle must be the same relative position to ensure uniform cut.See depressed in order to operate the unit. Release blade Figure 10. control handle to stop engine and blade. See Figure 10. This blade control mechanism is a safety device. Never a
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SECTION 6: MAKING ADJUSTMENTS WARNING: Do not at any time make any Cutting Height Adjustment adjustments without first stopping engine An adjusting plate and spring lever at each wheel and disconnecting spark plug wire. position provides cutting height adjustment. Each adjusting plate has assorted height positions. When the Handle Height Adjustment spring lever is moved from one location to another the Your mower is shipped with the handle in the higher height of cut will be changed. Simpl
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SECTION 7: MAINTAINING YOUR LAWN MOWER Some adjustments will have to be made General Recommendations periodically to maintain your unit properly. All Always observe safety rules when performing any adjustments in the Making Adjustments section of maintenance. this manual should be checked at least once each The warranty on this lawn mower does not cover season. items that have been subjected to operator abuse Periodically check all fasteners and make sure or negligence. To rece
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Lubrication Always stop engine and disconnect spark Rear Discharge plug wire before cleaning, lubricating or Door doing any kind of service work on the lawn Handle mower. Bracket Blade Control: Lubricate the pivot points on the blade control handle and the brake cable at least once a season with light oil. The blade control must operate freely in both directions. See Figure 13. Handle Rear & Side Discharge Doors: The torsion springs Bracket and pivot points should be lubricated periodical
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Remove the blade and the adapter from the Be sure to install the blade with the side of the crankshaft. blade marked “Bottom” (or with part number) facing the ground when the mower is in the operating position. Blade Slide the blade adapter onto the engine crankshaft. Adapter Place the blade on the adapter. Be certain the blade is aligned and seated on the blade adapter flanges. Blade Bell Support Place blade bell support on blade. Make sure the notches on the blade bell suppor
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SECTION 8: TROUBLESHOOTING Problem Cause Remedy Engine fails to start 1. Blade control handle disengaged. 1. Engage blade control handle. 2. Spark plug wire disconnected. 2. Connect wire to spark plug. 3. Fuel tank empty or stale fuel. 3. Fill tank with clean, fresh gasoline. 4. Blocked fuel line. 4. Clean fuel line. 5. Faulty spark plug. 5. Clean, adjust gap, or replace. 6. Engine flooded 6. Wait a few minutes to restart, but do not prime. Engine runs erratic 1. Spark plug wire loose. 1. Conn
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Model Series 544 1 2 10 9 3 4 11 8 6 5 19 7 12 13 18 28 61 57 41 59 14 17 20 16 40 60 30 15 33 21 24 35 34 25 19 22 38 23 29 39 31 36 62 42 32 44 27 45 43 37 26 53 36 52 47 46 48 54 55 49 35 50 41 58 56 51 16
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Model Series 544 Ref. Ref. Part No. Part Description Part No. Part Description No. No. 749-1092A Upper Handle 710-0216 Hex Cap Screw 3/8-16 x 1.0 1. 32. 747-1161A Control Handle 17488A Pivot Bar - RH 2. 33. 720-0279 Handle Knob 17489A Pivot Bar - LH 3. 710-1205 Rope Guide 738-0507B Shoulder Screw 4. 34. 710-1174 Carriage Bolt 5/16-18 x 2” 736-0105 Spring Washer.375 ID x.870 OD 5. 35. 736-0451 Shoulder Washer.320 ID x.930 OD 732-0866 Spring Lever 6. 36. 720-0284 Wing Nut 736-0182 Wave Washer.
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NOTES 18
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NOTES 19
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MANUFACTURER’S LIMITED WARRANTY FOR: The limited warranty set forth below is given by Troy-Bilt LLC d. Troy-Bilt LLC does not extend any warranty for with respect to new merchandise purchased and used in the products sold or exported outside of the United States, United States, its possessions and territories. its possessions and territories, except those sold through Troy-Bilt LLC’s authorized channels of export Troy-Bilt LLC warrants this product against defects for a distribution. period
