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Operator’s Manual
21” Mulching Mower
Model 544
IMPORTANT: Read safety rules and instructions carefully before operating equipment.
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 worki
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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....................................................................................... 10 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 components
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immediately and the blade will stop rotating within 3. Do not mow on wet grass. Unstable footing could three seconds. cause slipping. 9. Mow in daylight or good artificial light; walk, not run. 10. Stop the blade when crossing gravel drives, Children walkways or roads. Tragic accidents can occur if the operator is not alert to 11. If the equipment should start to vibrate abnormally, the presence of children. Children are often attracted to stop the engine and check immediately for the the
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10. Never over fill fuel tank. Fill tank to no more than ½ 4. Mower blades are sharp and can cut. Wrap the inch below bottom of filler neck to provide space for blade or wear gloves, and use extra caution when fuel expansion. servicing them. 11. Replace gasoline cap and tighten securely. 5. Keep all nuts, bolts, and screws tight to be sure the 12. If gasoline is spilled, wipe it off the engine and equipment is in safe working condition. equipment. Move unit to another area. Wait 5 6. Never ta
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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 Removing Unit From Carton Remove staples, break glue on top flaps, or cut Spark Plug tape at carton end and open carton. Remove loose parts if included with unit (i.e., Wire operator’s manual, etc.) Cut along corners, lay the carton down flat, and remove all packing material. Roll or slide unit out of carton and check carton thoroughly for loose parts. Spark Plug Loose Parts in Carton Figure 2 Grass Bag Side Discharge Chute NOTE: Reference t
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Remove hairpin clip from the outer hole of the weld pin on each handle brackets. Using a pair of pliers, squeeze one leg of the lower handle against the handle bracket. Insert the hairpin clip into the inner hole on the weld pin. Repeat on the other side. See Spring Washer Figure 5. After moving the hairpin clip, insert the carriage Wave Washer bolt, from Group A of the hardware pack, in the upper hole on the handle mounting bracket and Shoulder secure with plastic wing nut from the
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IMPORTANT: Make sure cable is routed to the outside Grass Catcher Insert frame of the handle so that it is not in the way when attaching Frame into bag the grass catcher. Lift the rear discharge door on the mower. Place the hooks, found on both sides of the grass catcher frame, over the chute door pivot rod at the rear of the mower. Release the rear discharge door. See Figure 11. Discharge Door Grass Bag Grass Catcher Plastic Assembly Channel Complete Grass Catcher Figure 11 To re
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SECTION 4: KNOW YOUR LAWN MOWER Read this operator’s manual and safety rules before Cutting Height Adjustment Levers operating your lawn mower. Compare the illustration in These levers are located on each wheel and are used Figure 13 with your lawn mower to familiarize yourself to adjust the cutting height. These levers have to be at with the location of various controls and adjustments. the same relative position to ensure uniform cut. Save this manual for future reference. Recoil Start
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SECTION 5: OPERATING YOUR LAWN MOWER Standing behind the mower, depress the blade WARNING: Read, understand, and follow all control handle and hold it against the upper handle. instructions and warnings on the machine and Grasp starter handle and pull rope out slowly until in this manual before operating. engine reaches the start of compression cycle (rope will pull slightly harder at this point). Let the NOTE: For shipping purposes your mower is set with rope rewind slowly. Pull rope
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Operate the mower till the grass bag is full. Bagging Grass Clippings Stop engine completely by releasing the blade You can use the grass catcher bag to collect clippings control handle. Make sure that the unit has come to while you are operating the mower. a complete stop. Attach grass catcher following instructions on page Lift discharge door and pull grass bag up and away 9 of this manual. Grass clippings will automatically from the mower to dispose of the grass clippings. co
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SECTION 7: MAINTAINING YOUR LAWN MOWER Clean the spark plug and reset the gap to .030” at WARNING: Always stop the engine and least once a season. Refer to the engine manual for disconnect the spark plug wire before correct spark plug type. performing any maintenance work or Inspect muffler periodically, and replace if adjustments on your lawn mower. necessary. Damaged mufflers or spark arresters can create a fire hazard. Make sure to avoid muffler and surrounding areas while the mowe
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SECTION 8: SERVICING THE MOWER Sharpening the Blade Replacing Rear Flap The blade can be sharpened with a file or on a To remove rear flap, cut off the flat end of the wire grinding wheel. Do not attempt to sharpen the rod which secures it to the deck. See Figure 17. blade while it is still on the mower. Attach the new flap and new rod to deck, bending Follow the original angle of grind as a guide. Make the ends of the new rod over to secure to deck. sure that each cutting edge r
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SECTION 9: OFF-SEASON STORAGE Coat mower’s cutting blade with chassis grease to Storing Your Lawn Mower prevent rusting. The following steps should be taken to prepare your Store mower in a dry, clean area. Do not store next lawn mower for storage. to corrosive materials, such as fertilizer. Clean and lubricate mower thoroughly as described NOTE: When storing any type of power equipment in a in the lubrication instructions. poorly ventilated or metal storage shed, care should be IMPOR
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SECTION 11: PARTS LIST FOR MODEL 544 1 2 13 3 4 14 12 6 7 5 11 9 8 23 10 22 15 16 31 6 17 64 47 A 32 21 24 A 20 18 34 46 36 19 33 39 25 28 41 40 30 26 23 27 43 35 45 49 37 29 42 38 50 51 52 32 44 31 60 40 59 54 53 55 61 62 56 41 65 57 47 63 58 16
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Model 544 Ref. Ref. Part No. Part Description Part No. Part Description No. No. 1. 749-1092A Upper Handle 34. 710-0703 Hex Carriage Screw 1/4-20 2. 747-1161A Control Handle 35. 682-3056A Handle Bracket Assembly - RH 3. 710-1270 C-Sunk Screw 1/4-20 x 1.3” 682-3057A Handle Bracket Assembly - LH 4. 746-0883 Throttle Housing 36. 710-0286 Machine Screw 1/4-20 x .500 5. 712-0324 Hex Lock Nut 1/4-20 37. 710-0896 Hex Washer Screw 1/4-14 x .625 6. 720-0279 Handle Knob 38. 710-0514 Hex Cap Screw 3/8-16
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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
