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Bolens 544 Lawn Mower User Manual

1. Bolens SINCE 1850 Operators 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 working order by the operator In the State of California the above is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands A spark arrester for the muffler is available through your nearest engine authorized service dealer or contact the service department P O Box 361131 Cleveland Ohio 44136 0019 TROY BILT LLC P 0 BOX 361131 CLEVELAND OHIO 44136 0019 PRINTED IN U S A Form No 769 00447 9 2002 TABLE OF CONTENTS Content Page Important Safe Operation Practices ee eeseceeeeeenneeeeeeeaeeeeeeeaaaeeeeeeeaaeeeeeneaaas 3 Slope f 101 8 lt eoa rr nrc ere rrrtecentrrer centre teen ctr E ert reer reer terme er eee tree ce rte 6 Assembling Your Lawr MOWED ceeeeeeeeeeeeeee eee eeeeeeeeeeeeeeaeeeeteeeaeeeeteeeaeeeeteeeeeees 7 Know Your Lawn MOW6fizis ccsectessdsscceessdsanactansasaateneesvaacceetduvadeeentesddaccanabsact
2. power rating specifications warranty and service Please refer to the engine manufacturer s Owner s Operator s Manual packed separately with your unit for more information CALLING CUSTOMER SUPPORT If you have difficulty assembling this product or have any questions regarding the controls operation or maintenance of this unit please call the Customer Support Department Call 1 866 840 6483 or 1 330 558 7220 to reach a Customer Support representative Please 4 have your unit s model number and serial number ready when you call See previous section to locate this information You will be asked to enter the serial number in order to process na your call For more details about your unit visit our website at www bolens com 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 contain or emit chemicals known to State of California to cause cancer and birth defects or other reproductive harm WARNING This machine was built to be operated according to the rules for safe operation in this manual As w
3. Blade Bell Support 26 736 0270 Bell Washer 265 ID x 75 OD 58 710 1044 Hex Cap Screw 3 8 24 x 1 5 27 710 0599 Hex Washer Screw 1 4 20 x 500 59 15261A Height Adjustment Plate 28 712 0130 Hex Lock Nut 3 8 16 60 720 0426 Height Adjustment Knob 29 736 0356 Bell Washer 390 ID x 380 OD 61 15262B Pivot Bar 30 782 5004 Rear Baffle RH 62 732 0404 Spring Lever 31 782 5003 Rear Baffle LH 63 738 0102 Shoulder Bolt 32 710 1017 Tap Screw 1 4 14 x 625 64 747 0996 Chute Door Pivot Rod 33 712 3005 Flange Lock Nut 3 8 16 65 731 1409 Side Discharge Deflector 17 MANUFACTURER S LIMITED WARRANTY FOR OTROY BILT The limited warranty set forth below is given by Troy Bilt LLC with respect to new merchandise purchased and used in the United States its possessions and territories Troy Bilt LLC warrants this product against defects for a period of two 2 years commencing on the date of original purchase and will at its option repair or replace free of charge any part found to be defective in materials or workmanship This limited warranty shall only apply if this product has been operated and maintained in accordance with the Operator s Manual furnished with the product and has not been subject to misuse abuse commercial use neglect accident improper maintenance alteration vandalism theft fire water or damage because of other peril or natural disaster Damage resulting f
4. Removing Unit From Carton e Remove staples break glue on top flaps or cut tape at carton end and open carton e Remove loose parts if included with unit i e operator s manual etc e Cut along corners lay the carton down flat and remove all packing material e Roll or slide unit out of carton and check carton thoroughly for loose parts Loose Parts in Carton Grass Bag Rear Wheels Hardware Pack Bottle of Oil Hardware Pack Side Discharge Chute Please identify each piece of the hardware pack as shown in Figure 1 Carriage Bolt Wing Nut Group A TT 1 QS Wave Washer OO Flat Washer Shoulder Screw Spring Washer Group B Figure 1 Before Assembly e Before setting up your lawn mower disconnect the spark plug wire from the spark plug and ground against the engine See Figure 2 z Spark Plug Wire Spark Plug Figure 2 NOTE Reference to right or left hand side of the mower is observed from the operating position Setting Up Your Lawn Mower Assembling Handle e Lift up and pull back on the upper handle to raise the handle into the operating position See Figure 3 Make certain the lower handle is seated securely into the handle bracket assemblies Figure 3 e Tighten wing nuts on each side of the handle making sure that the carriage bolts are seated properly into the handle See Figure 4 T
5. Replace gasoline cap and tighten securely If gasoline is spilled wipe it off the engine and equipment Move unit to another area Wait 5 minutes before starting the engine Never store the machine or fuel container inside where there is an open flame spark or pilot light as on a water heater space heater furnace clothes dryer or other gas appliances To reduce fire hazard keep mower free of grass leaves or other debris build up Clean up oil or fuel spillage and remove any fuel soaked debris Allow mower to cool 5 minutes before storing General Service 1 Never run an engine indoors or in a poorly ventilated area Engine exhaust contains carbon monoxide an odorless and deadly gas Before cleaning repairing or inspecting make certain the blade and all moving parts have stopped Disconnect the spark plug wire and ground against the engine to prevent unintended starting Check the blade and engine mounting bolts at frequent intervals for proper tightness Also visually inspect blade for damage e g bent cracked worn Replace blade with the original equipment manufacture s O E M blade only listed in this manual Use of parts which do not meet the original equipment specifications may lead to improper performance and compromise safety Your Responsibility Restrict the use of this power machine to persons who read understand and follow the warnings and instructions in this manual and on the mach
6. mower even when you are not mulching the grass 1 WARNING Do not remove the mulching The mulching baffle is already in place on the mower for shipping purposes e To remove the mulching baffle lift the rear discharge door on the mower Remove the mulching baffle See Figure 10 EE Rear Mulching Baffle Figure 10 IMPORTANT Make sure cable is routed to the outside of the handle so that it is not in the way when attaching the grass catcher e Lift the rear discharge door on the mower e 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 Catcher Figure 11 e To remove the grass catcher lift the rear discharge door on the mower lift the grass catcher up and off the pivot rod Reinstall the mulching baffle and release the rear discharge door WARNING Never operate the mower unless the hooks on the grass catcher are firmly seated on the chute pivot rod and the rear discharge door rests firmly against the top of the grass catcher Converting To Side Discharge e Lift the rear discharge door and install the mulching baffle See Figure 10 e On the side of the mower lift the mulching plug and slide the two hooks of the side discharge chute under the hinge pin on the mulching plug assembly Lower the side mulching plug See Figure 12 e Do not remove the side mul
7. recommended schedule for lubricating engine components Lubricate Lubricate Figure 16 Lubrication Chart SECTION 8 SERVICING THE MOWER Replacing Rear Flap To remove rear flap cut off the flat end of the wire rod which secures it to the deck See Figure 17 e Attach the new flap and new rod to deck bending the ends of the new rod over to secure to deck Rear Discharge Door Handle Bracket Handle Bracket lt lt Figure 17 Rear Flap Blade Care WARNING When removing the cutting blade for sharpening or replacement protect your hands with a pair of heavy gloves or use a heavy rag to hold the blade Periodically inspect the blade adapter for cracks especially if you strike a foreign object Replace when necessary Removing the Blade e Disconnect spark plug wire from spark plug e Turn mower on its side making sure that the air filter and the carburetor are up e Remove the bolt and the blade bell support which hold the blade and the blade adapter to the engine crankshaft See Figure 18 e Remove the blade and the adapter from the crankshaft Blade Adapter Figure 18 Sharpening the Blade e The blade can be sharpened with a file or ona grinding wheel Do not attempt to sharpen the blade while it is still on the mower e Follow the original angle of grind as a guide Make sure that each cutting edge receives an equal amount of grinding to prevent an unbalanced
8. 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 x 1 0 7 710 1205 Rope Guide 39 17488A Pivot Bar RH 8 710 1174 Carriage Bolt 5 16 18 x 2 17489A Pivot Bar LH 9 736 0451 Shoulder Washer 320 ID x 930 OD 40 738 0507B Shoulder Screw 10 720 0284 Wing Nut 41 736 0105 Spring Washer 375 ID x 870 OD 11 749 0928A Lower Handle 42 732 0866 Spring Lever 12 746 0957 Control Cable 43 736 0182 Wave Washer 500 ID x 1 0 OD 13 664 0084 Grass Bag 44 736 0456 Flat Washer 510 ID x 1 37 OD 14 747 0995A Grass Catcher Frame 45 738 0481A Shoulder Screw 15 714 0104 Hairpin Clip 46 14578 Front Height Adjuster RH 16 782 7599B Grass Bag Door 14579 Front Height Adjuster LH 17 782 5007A Rear Mulch Plug 47 734 1988 Front Wheel 7 x 2 18 732 0700 Wire Rod 49 712 0431 Flange Lock Nut 3 8 16 19 731 1236 Trailshield 50 782 5002 Front Baffle 20 750 0434 Spacer 375 O D x 50 I D x 1 02 51 732 0731 Torsion Spring 21 732 0809 Door Spring 52 747 0710 Hinge Pin 22 682 3058 Handle Bracket Assembly LH 53 782 7006 Hinge Mounting Bracket 682 3059 Handle Bracket Assembly RH 54 731 1404A Mulching Plug 23 734 1864 Rear Wheel 14 x 2 55 748 0376C Blade Adapter 24 782 0047A Deck 21 56 742 0741 Blade 21 Mulching 25 710 0654A Hex Washer Screw 3 8 16 x 1 0 57 736 0524A
9. are explosive Never fuel the machine indoors or while the engine is hot or running Extinguish cigarettes cigars pipes and other sources of ignition Before Starting Mower e Attach spark plug wire to spark plug Make certain the metal cap on the end of the spark plug wire inside the rubber boot is fastened securely over the metal tip on the spark plug Throttle Speed Your lawn mower engine is equipped with a constant speed throttle which is set at full throttle for best performance Starting Engine A WARNING Be sure no one other than the operator is standing near the lawn mower while starting engine or operating mower WARNING Never run engine indoors or in enclosed poorly ventilated areas Engine exhaust contains carbon monoxide an odorless and deadly gas WARNING Keep hands feet hair and loose clothing away from any moving parts on engine and lawn mower e Push primer three times Wait about two seconds between each push In cold weather around 55 F or below prime five times Do not prime to restart a warm engine after a short shutdown Standing behind the mower depress the blade control handle and hold it against the upper handle e Grasp starter handle and pull rope out slowly until engine reaches the start of compression cycle rope will pull slightly harder at this point Let the rope rewind slowly Pull rope with a rapid continuous full arm stroke Keeping a firm grip on the starter handle
10. blade WARNING An unbalanced blade will cause A excessive vibration when rotating at high speeds It may cause damage to the mower and could break causing personal injury Balancing the Blade e The blade can be tested by balancing it on a round shaft screwdriver Remove metal from the heavy side until it balances evenly It is recommended that the blade always be removed from the adapter when testing for balance Installing the Blade e Before reinstalling the blade and the blade adapter to the unit lubricate the engine crankshaft and the inner surface of the blade adapter with light oil e Be sure to install the blade with the side of the blade marked Bottom or with part number facing the ground when the mower is in the operating position e Slide the blade adapter onto the engine crankshaft e Place the blade on the adapter Be certain the blade is aligned and seated on the blade adapter flanges e Place blade bell support on blade Make sure the notches on the blade bell support are aligned with small holes in the blade e Replace hex bolt and tighten hex bolt to torque 450 in lbs min 600 in lbs max NOTE To ensure safe operation of your mower periodically check the blade bolt for correct torque SECTION 9 OFF SEASON STORAGE Storing Your Lawn Mower The following steps should be taken to prepare your lawn mower for storage e Clean and lubricate mower thoroughly as described in the lubrication inst
11. ching plug at any time even when you are not mulching IMPORTANT This unit is shipped without gasoline or oil in the engine Service engine with gasoline and oil as instructed in separate engine manual before operating Ae Mulching Plug Hinge Pin Side Chute Deflector Figure 12 SECTION 4 KNOW YOUR LAWN MOWER Read this operator s manual and safety rules before operating your lawn mower Compare the illustration in Figure 13 with your lawn mower to familiarize yourself with the location of various controls and adjustments Save this manual for future reference WARNING The operation of any lawn A mower can result in foreign objects being thrown into the eyes which can damage your eyes severely Always wear safety glasses while operating the mower or while performing any adjustments or repairs on it Blade Control Handle The blade control handle is located on the upper handle of the mower The blade control handle must be depressed in order to operate the unit Release blade control handle to stop engine and blade WARNING This blade control mechanism is a safety device Never attempt to bypass its operations Upper Handle pp EN Recoil Starter Grass ae Catcher ad NO Y Chute Mulching Plug Cutting Height Adjustment Levers These levers are located on each wheel and are used to adjust the cutting height These levers have to be at the same relative position to
12. e maintenance items such as lubricants filters blade sharpening tune ups brake adjustments clutch adjustments deck adjustments and normal deterioration of the exterior finish due to use or exposure d Troy Bilt LLC does not extend any warranty for products sold or exported outside of the United States its possessions and territories except those sold through Troy Bilt LLC s authorized channels of export distribution e Parts that are not genuine Troy Bilt parts are not covered by this warranty f Service completed by someone other than an authorized service dealer is not covered by this warranty g Transportation charges and service calls are not covered No implied warranty including any implied warranty of merchantability of fitness for a particular purpose applies after the applicable period of express written warranty above as to the parts as identified No other express warranty whether written or oral except as mentioned above given by any person or entity including a dealer or retailer with respect to any product shall bind Troy Bilt LLC During the period of the warranty the exclusive remedy is repair or replacement of the product as set forth above The provisions as set forth in this warranty provide the sole and exclusive remedy arising from the sale Troy Bilt LLC shall not be liable for incidental or consequential loss or damage including without limitation expenses incurred for substitute or rep
13. e mounting bracket e Place the hairpin clips in the inner holes in the weld pins and insert the carriage bolts the upper hole on the handle mounting bracket and secure with plastic wing nuts e Reassemble the upper handle to the lower handle e Attach the starter rope as instructed in the Assembly Section f gt Notch Lower Handle O G Figure 14 Operate the mower till the grass bag is full Stop engine completely by releasing the blade control handle Make sure that the unit has come to a complete stop Lift discharge door and pull grass bag up and away from the mower to dispose of the grass clippings Cutting Height Adjustment IMPORTANT All wheels must be placed in the same relative position For rough or uneven lawns move the height adjustment lever to a higher position This will help stop scalping of the grass An adjusting plate and thumb lever at each wheel position provides cutting height adjustment Each adjusting plate has nine height positions Height of cut will change when you move the thumb lever from one position to another Simply depress the lever towards the wheel and move the lever assembly to desired position See Figure 15 Height Adjustment Lever Figure 15 Engine Adjustments Refer to the engine manual for these adjustments SECTION 7 MAINTAINING YOUR LAWN MOWER WARNING Always stop the engine and disconnect the spark plug wire before performing any maintenance work or adj
14. emoving the grass catcher or unclogging the chute The cutting blade continues to rotate for a few seconds after the engine is shut off Never place any part of the body in the blade area until you are sure the blade has stopped rotating 13 Never operate mower without proper trail shield discharge cover grass catcher blade control handle or other safety protective devices in place and working Never operate mower with damaged safety devices Failure to do so can result in personal injury 14 Muffler and engine become hot and can cause a burn Do not touch 15 Only use parts and accessories made by the original equipment manufacturer O E M Failure to do so can result in personal injury 16 If situations occur which are not covered in this manual use care and good judgment Contact your dealer for assistance Call 1 866 840 6483 for the name of your nearest dealer Slope Operation Slopes are a major factor related to slip and fall accidents which can result in severe injury Operation on slopes requires extra caution If you feel uneasy ona slope do not mow it Before operating this unit ona slope or hilly area use the slope gauge on page 6 to measure slopes If the slope is greater than 15 degrees do not mow it Do 1 Mow across the face of slopes never up and down Exercise caution when changing direction 2 Watch for holes ruts rocks hidden objects or bumps which can cause you to slip or trip Tall grass ca
15. engine every time e Service foam filter in the air cleaner every 25 hours of use and replace the paper filter component every 100 hours You may have to service the air filter more frequently if you are operating the mower under extremely dusty conditions e Clean the engine periodically Remove dirt and debris with a cloth or brush Clean the spark plug and reset the gap to 030 at least once a season Refer to the engine manual for correct spark plug type e Inspect muffler periodically and replace if necessary Damaged mufflers or spark arresters can create a fire hazard Make sure to avoid muffler and surrounding areas while the mower engine is hot because temperature of these areas of the engine may exceed 150 F Lubrication Refer to the lubrication chart in Figure 16 Blade Control Handle e Lubricate the pivot points on the blade control handle at least once a season with light oil The blade control must operate freely in both directions Wheels e Lubricate the wheels and bearings if so equipped at least once a season with light oil or engine oil Also if the wheels are removed for any reason lubricate the surface of the axle bolt and the inner surface of the wheel with light oil Rear Discharge Door e Lubricate the torsion spring and the pivot point on each end of the rear discharge door using a light oil This will prevent rusting of the discharge door Engine e Follow the engine manual instructions and
16. ensure uniform cut Recoil Starter The recoil starter is attached to the right upper handle Stand behind the unit and pull the recoil starter rope to start the unit Grass Catcher The grass catcher located at the rear of the mower is used to bag the grass clippings for disposal at another site Once the bag is full it has to be removed from the mower and emptied before any further mowing Mulching Plug Both the mulching baffle and the mulching plug are used only for mulching purposes Instead of collecting grass clippings in a grass catcher this mower has the option of recirculating the clippings back to the lawn Blade Control Handle Rear Cutting Height Adjustment Lever Front Cutting Height Adjustment Lever Figure 13 SECTION 5 OPERATING YOUR LAWN MOWER WARNING Read understand and follow all instructions and warnings on the machine and in this manual before operating A NOTE For shipping purposes your mower is set with the wheels in a low cutting height position For best results raise the cutting position until it is determined which height is best for your lawn See the Adjustment Section for details Gas amp Oil Fill Up e Check oil level and add oil if necessary Follow relevant instructions in the engine manual for this e Service the engine with gasoline as instructed in the engine manual WARNING Use extreme care when A handling gasoline Gasoline is extremely flammable and the vapors
17. g For effective mulching do not cut wet grass New or thick grass may require a narrower cut If the grass has grown in excess of 4 mulching is not recommended Mow using the side discharge to reduce the grass height to 3 25 maximum before mulching Bagging Grass Clippings You can use the grass catcher bag to collect clippings while you are operating the mower e Attach grass catcher following instructions on page 9 of this manual Grass clippings will automatically collect in the bag as you run the mower SECTION 6 MAKING ADJUSTMENTS adjustments without first stopping engine and disconnecting spark plug wire Handle Height Adjustment Your mower is shipped with the handle in the higher height position To lower the height proceed as follows T WARNING Do not at any time make any e Remove the starter rope from the rope guide e Remove the upper handle by removing the hand knobs and carriage bolts Lay the upper handle out of the way being careful not to bend or kink the cables e Remove the hairpin clips from the weld pins on the handle brackets and remove the wing nuts and carriage bolts from the upper hole on the handle mounting bracket Press out on the legs of the lower handle and remove lower handle from the mower e Turn lower handle around so the notch on the bottom of the lower handle is facing forward See Figure 14 e Reassemble placing the bottom holes in the handle over the weld pins in the handl
18. g If you must back the mower away from a wall or obstruction first look down and behind to avoid tripping and then follow these steps a Step back from the mower to fully extend your arms b Be sure you are well balanced with sure footing c Pull the mower back slowly no more than half way toward you d Repeat these steps as needed Do not operate the mower while under the influence of alcohol or drugs Do not engage the self propelled mechanism on units so equipped while starting engine The blade control handle is a safety device Never attempt to bypass its operation Doing so makes the safety device inoperative and may result in personal injury through contact with the rotating blade The blade control handle must operate easily in both directions and automatically return to the disengaged position when released Never operate the mower in wet grass Always be sure of your footing A slip and fall can cause serious personal injury If you feel you are losing your footing release the blade control handle immediately and the blade will stop rotating within three seconds Mow in daylight or good artificial light walk not run 10 Stop the blade when crossing gravel drives walkways or roads 11 If the equipment should start to vibrate abnormally stop the engine and check immediately for the cause Vibration is generally a warning of trouble 12 Shut the engine off and wait until the blade comes to a complete stop before r
19. geesesanacs 10 Operating Your LAWN MOWED ccecceeeeeeennee eee e ence eee eeeaaeeeeeeeaaaeeeeeeeaaeeeeeeeaaeeeenees 11 Making ACjUStme int sessionerna EEE EEEE 12 Maintaining Your Lawn MOWET ccccececeeceeeeeeeeeeeeeeeeaeeeeeeeaeeeeeeeaaaeeeeeseaeeeeeneaaas 13 Troubleshooting eraeun SAE NESESER ERRER EAE 15 Pana EiS tosin on n na E E E E E E E 16 FINDING MODEL NUMBER This Operator s Manual is an important part of your new lawn mower It will help you assemble prepare and maintain the unit for best performance Please read and understand what it says equipment and copy the information from it in the space provided below The information on the model plate is very important if you need help from our Customer Support Department or an authorized dealer You can locate the model number by standing at the operating position and looking down at the rear of the mower deck A sample model plate is explained below For future reference please copy the model number and the serial number of the equipment in the space below amp Before you start assembling your new equipment please locate the model plate on the Model Number Serial Number Copy the model number here Copy the serial number here TROY BILT LLC Bolens 2 2 CLEVELAND OH 44136 www bolens com 330 558 7220 866 840 6483 ENGINE INFORMATION The engine manufacturer is responsible for all engine related issues with regards to performance
20. he engine Maintain or replace safety and instruction labels as necessary Observe proper disposal laws and regulations Improper disposal of fluids and materials can harm the environment AVOID SERIOUS INJURY OR DEATH KEEP HANDS AND FEET AWAY FROM ras THE e REMOVE OBJECTS THAT CAN BE THR BLADE IN ANY DIRECTION WEAR SAFETY seat DO NOT MOW WHEN CHILDREN OR OTHERS AE AROUYE USE EXTRA CAUTION ON SLOPES DO NOT MOW SLOPES OWN GREATER THAN 15 MOW ACROSS NEVER UP AND D NEVER PULL MOWER CLOSE TO YOUR FEET LOOK DOIN RDS BEHIND BEFORE AND WHILE MOVING BA S MA AFET ELD DISCHARGE COVER ETC IN PLAC SLOPE GAUGE SECTION 2 Use this page as a guide to determine slopes where you may not operate safely Do not operate your lawn mower on such slopes es SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE i Ia POWER POLE l 1 og A CORNER OF A BUILDING a OR A FENCE POST 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 up and down slopes never across the face of slopes Operate WALK BEHIND mowers across the face of slopes never up and down slopes SECTION 3 ASSEMBLING YOUR LAWN MOWER
21. hould be trained and supervised by a parent Service Safe Handling of Gasoline 1 To avoid personal injury or property damage use extreme care in handling gasoline Gasoline is extremely flammable and the vapors are explosive Serious personal injury can occur when gasoline is spilled on yourself or your clothes which can ignite 2 Wash your skin and change clothes immediately 3 Use only an approved gasoline container 4 Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner Always place containers on the ground away from your vehicle before filling 5 If possible remove gas powered equipment from the truck or trailer and refuel it on the ground If this is not possible then refuel such equipment on a trailer with a portable container rather than from a gasoline dispenser nozzle 6 Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete Do not use a nozzle lock open device 7 Extinguish all cigarettes cigars pipes and other sources of ignition 8 Never fuel machine indoors because flammable vapors will accumulate in the area 9 Never remove gas cap or add fuel while the engine is hot or running Allow engine to cool at least two minutes before refueling 10 11 12 13 14 15 Never over fill fuel tank Fill tank to no more than 12 inch below bottom of filler neck to provide space for fuel expansion
22. ighten this wing nut aT Carriage Bolt Figure 4 e 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 Figure 5 e After moving the hairpin clip insert the carriage bolt from Group A of the hardware pack in the upper hole on the handle mounting bracket and secure with plastic wing nut from the hardware pack See Figure 5 Repeat on the other side Carriage Bolt Wing Nut Handle Mounting Bracket Weld Pin F 5 Hairpin Clip Figure 5 e Fasten the cable to the lower handle with the two cable ties found on the lower handle Pull the cable ties tight and trim off the excess See Figure 6 Cable Tie S5 vA a gt a Lower Handle Figure 6 NOTE Your mower is shipped with the handle in the higher position If you wish to lower the height of the handle refer to the Adjustment Section at this time Attaching Rear Wheels The necessary hardware is included in Group B of the hardware pack Refer to Figure 1 e Insert shoulder screw through flat washer wave washer rear wheel and spring washer as shown in Figure 7 Insert this assembly into the corresponding hole on the rear pivot bar and secure Spring Washer Wave Washer Figure 7 Attaching Starter Rope The rope guide is already attached t
23. ine TO REDUCE THE RISK OF INJURY DO NOT OPERATE MOWER UNLESS DISCHARGE CHUTE COVER OR GRASS CATCHER IS IN ITS PROPER PLACE KEEP HANDS and FEET AWAY 4 WARNING TO REDUCE THE RISK OF INJURY DO NOT OPERATE MOWER UNLESS THIS GUARD OR ENTIRE GRASS CATCHER IS IN ITS PROPER PLACE 10 11 12 Mower blades are sharp and can cut Wrap the blade or wear gloves and use extra caution when servicing them Keep all nuts bolts and screws tight to be sure the equipment is in safe working condition Never tamper with safety devices Check their proper operation regularly After striking a foreign object stop the engine disconnect the spark plug wire and ground against the engine Thoroughly inspect the mower for any damage Repair the damage before starting and operating the mower Never attempt to make a wheel or cutting height adjustment while the engine is running Grass catcher components discharge cover and trail shield are subject to wear and damage which could expose moving parts or allow objects to be thrown For safety protection frequently check components and replace immediately with original equipment manufacturer s O E M parts only listed here Use of parts which do not meet the original equipment specifications may lead to improper performance and compromise safety Do not change the engine governor setting or overspeed the engine The governor controls the maximum safe operating speed of t
24. ine overheats 1 Engine oil level low 1 Fill crankcase with proper oil 2 Air flow restricted 2 Remove blower housing and clean 3 Carburetor not adjusted properly 3 Adjust carburetor Occasional skip hesitates at 1 Spark plug gap too close 1 Adjust gap to 030 high speed Idles poorly 1 Spark plug fouled faulty or gap too 1 Reset gap to 030 or replace spark plug wide 2 Adjust carburetor 2 Carburetor improperly adjusted 3 Clean air cleaner 3 Dirty air cleaner Excessive vibration 1 Cutting blade loose or unbalanced 1 Tighten blade and adapter Balance blade 2 Replace blade 2 Bentcutting blade Mower will not mulch grass 1 Wet grass 1 Do not mow when grass is wet wait until later to cut 2 Excessively high grass 2 Mowonce ata high cutting height then mow again at desired height or make a narrower cutting path 3 Dull blade 3 Sharpen or replace blade Uneven cut 1 Wheels not positioned correctly 1 Place all four wheels in same height position 2 Dull blade 2 Sharpen or replace blade SECTION 11 PARTS LIST FOR MODEL 544 Model 544 ee Part No Part Description T Part No Part Description 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
25. ith any type of power equipment carelessness or error on the part of the operator can result in serious injury This machine is capable of amputating hands and feet and throwing objects Failure to observe the following safety instructions could result in serious injury or death General Operation 1 Read this operator s manual carefully in its entirety before attempting to assemble this machine Read understand and follow all instructions on the machine and in the manual s before operation Be completely familiar with the controls and the proper use of this machine before operating it Keep this manual in a safe place for future and regular reference and for ordering replacement parts This machine is a precision piece of power equipment not a plaything Therefore exercise extreme caution at all times Your unit has been designed to perform one job to mow grass Do not use it for any other purpose Never allow children under 14 years old to operate this machine Children 14 years old and over should read and understand the operation instructions and safety rules in this manual and should be trained and supervised by a parent Only responsible individuals who are familiar with these safe operation rules should use this machine Thoroughly inspect the area where equipment is to be used Remove all stones sticks wire bones toys and other foreign objects which could be tripped over or picked up and thrown by the blade Thrown objec
26. lacement lawn care services or for rental expenses to temporarily replace a warranted product Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts so the above exclusions or limitations may not apply to you In no event shall recovery of any kind be greater than the amount of the purchase price of the product sold Alteration of safety features of the product shall void this warranty You assume the risk and liability for loss damage or injury to you and your property and or to others and their property arising out of the misuse or inability to use the product This limited warranty shall not extend to anyone other than the original purchaser or to the person for whom it was purchased as a gift HOW STATE LAW RELATES TO THIS WARRANTY This limited warranty gives you specific legal rights and you may also have other rights which vary from state to state Troy Bilt LLC P 0 BOX 361131 CLEVELAND OHIO 44136 0019 Phone 1 866 840 6483 1 330 558 7220
27. let the rope rewind slowly Stopping Engine e Release blade control handle to stop the engine and the blade e Disconnect spark plug wire and move away from spark plug to prevent accidental starting Using Your Lawn Mower A e You can use your mower as a mulching mower or a rear bagger e Donot operate the mower without the rear mulching baffle or the grasscatcher bag properly installed e Be sure that the lawn is clear of stones sticks wire or other objects which could damage lawn mower or engine Such objects could be accidently thrown by the mower in any direction and cause serious personal injury to the operator and others e For best results do not cut wet grass It may stick to the underside of the mower preventing proper discharge of grass clippings and could cause you to slip and fall New grass or thick grass may require a narrower cut e Fora healthy lawn always cut off one third or less of the total length of the grass Lawn should be trimmed in fall as long as there is growth 1 WARNING If the mower strikes a foreign WARNING Never operate the mower unless the hooks on the grasscatcher are seated in the slots on the handle bracket assemblies and the rear discharge door rests firmly against the top of the grasscatcher object stop the engine Remove spark plug wire from the spark plug and thoroughly inspect for any damage Repair the damage promptly before restarting and operating the mower Mulchin
28. n hide obstacles 3 Always be sure of your footing A slip and fall can cause serious personal injury If you feel you are losing your balance release the blade control handle immediately and the blade will stop rotating within 3 seconds Do Not 1 Do not mow near drop offs ditches or embankments you could lose your footing or balance 2 Do not mow slopes greater than 15 degrees as shown on the slope gauge 3 Do not mow on wet grass Unstable footing could cause slipping Children Tragic accidents can occur if the operator is not alert to the presence of children Children are often attracted to the mower and the mowing activity They do not understand the dangers Never assume that children will remain where you last saw them 1 Keep children out of the mowing area and under the watchful care of a responsible adult other than the operator 2 Bealert and turn mower off if a child enters the area 3 Before and while moving backwards look behind and down for small children 4 Use extreme care when approaching blind corners doorways shrubs trees or other objects that may obscure your vision of a child who may run into the mower 5 Keep children away from hot or running engines They can suffer burns from a hot muffler 6 Never allow children under 14 years old to operate a power mower Children 14 years old and over should read and understand the operation instructions and safety rules in this manual and s
29. o the right side of the upper handle of your mower See Figure 8 e With the spark plug wire disconnected and grounded hold the blade control handle against the upper handle and pull the rope out of the engine e Slip the rope through the rope guide as shown below Tighten the wing nut holding the rope guide to the upper handle Starter Wing Nut Upper Handle Lower Handle Figure 8 Assembling Grass Catcher NOTE f the grass catcher came pre assembled proceed to the next section If it came un assembled follow the steps below to assemble it first before attaching to the mower e Insert frame into grass bag with the black plastic side on the bottom of bag See Figure 9 e Slip the openings in the side of the plastic channel on bag over the hooks on the grass catcher frame Secure bag to the frame by working the six plastic channels on bag over frame All of the plastic chan nels except the center top of the bag attach from the outside of bag The center top of the bag attaches from inside the bag See Figure 9 Grass Catcher Frame Insert frame into bag Grass Bag Grass Catcher Plastic Assembly Channel Complete Figure 9 Attaching Grass Catcher To Mower NOTE Your lawn mower is equipped with both a mulching baffle and a mulching plug While the mulching baffle is located at the rear of the mower the mulching plug is located on the right of the cutting deck plug from the
30. rom the installation or use of any accessory or attachment not approved by Troy Bilt LLC for use with the product s covered by this manual will void your warranty as to any resulting damage Normal wear parts or components thereof are subject to separate terms as follows All normal wear parts or component failures will be covered on the product for a period of 90 days regardless of cause After 90 days but within the two year period normal wear part failures will be covered ONLY IF caused by defects in materials or workmanship of OTHER component parts Normal wear parts and components include but are not limited to batteries belts blades blade adapters grass bags rider deck wheels seats snow thrower skid shoes shave plates auger spiral rubber and tires HOW TO OBTAIN SERVICE Warranty service is available WITH PROOF OF PURCHASE through your local authorized service dealer To locate the dealer in your area check your Yellow Pages or contact Troy Bilt LLC at P O Box 361131 Cleveland Ohio 44136 0019 or call 1 866 840 6483 or 1 330 558 7220 or log on to our Web site at www troybilt com This limited warranty does not provide coverage in the following cases a The engine or component parts thereof These items carry a separate manufacturer s warranty Refer to applicable manufacturer s warranty for terms and conditions b Log splitter pumps valves and cylinders have a sepa rate one year warranty C Routin
31. ructions IMPORTANT We do not recommend the use of a pressure washer or garden hose to clean your unit e Refer to engine manual for correct engine storage instructions SECTION 10 TROUBLESHOOTING e Coat mower s cutting blade with chassis grease to prevent rusting e Store mower in a dry clean area Do not store next to corrosive materials such as fertilizer NOTE When storing any type of power equipment in a poorly ventilated or metal storage shed care should be taken to rust proof the equipment Using a light oil or silicone coat the equipment especially cables and all moving parts 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 afew minutes to restart but do not prime Engine runs erratic 1 Spark plug wire loose 1 Connect and tighten spark plug wire 2 Blocked fuel line or stale fuel 2 Clean fuel line fill tank with clean fresh gasoline 3 Ventin gas plugged 3 Clear vent 4 Water or dirt in fuel system 4 Drain fuel tank Refill with fresh fuel 5 Dirty air cleaner 5 Clean air cleaner 6 Carburetor out of adjustment 6 Adjust carburetor Eng
32. ts can cause serious personal injury 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 To help avoid blade contact or a thrown object injury stay in the operator zone behind the handles and keep bystanders helpers children and pets at least 75 feet from the machine while it is in operation Stop machine if anyone enters the area Always wear safety glasses to protect your eyes during equipment operation and while performing an adjustment or repair Thrown objects which ricochet can cause serious injury to the eyes 7 10 11 0 Wear sturdy rough soled work shoes and close fitting slacks and shirts Shirts and pants that cover the arms and legs and steel toed shoes are recommended Never operate this machine in bare feet sandals slippery or light weight e g canvas shoes Do not put hands or feet near rotating parts or under the cutting deck Contact with the blade can amputate hands and feet A missing or damaged discharge cover can cause blade contact or thrown object injuries Many injuries occur as a result of the mower being pulled over the foot during a fall caused by slipping or tripping Do not hold on to the mower if you are falling release the handle immediately Never pull the mower back toward you while you are walkin
33. ustments on your lawn mower Cleaning Mower The underside of the mower deck should be cleaned after each use to prevent any build up of grass clippings leaves dirt or other debris If this debris is allowed to accumulate it will result in rust and corrosion NOTE We do not recommend the use of pressure washers or garden hose to clean your unit These may cause damage to electric components spindles pulleys bearings or the engine The use of water will result in shortened life and reduce serviceability e Disconnect spark plug wire e Drain the gasoline from the lawn mower or place a piece of plastic under the gas cap e Tip the mower so that it rests on the housing Keep the side with the air cleaner facing up Hold the mower firmly e Scrape and clean the underside of the deck with a suitable tool Do not spray with water e Putthe mower back on its wheels on the ground If you had put plastic under the gas cap make sure to remove it now WARNING Never tip the mower more than A 90 degrees in any directions and do not leave the mower tipped for any length of time Oil can drain into the upper part of the engine causing a starting problem Engine Care A list of key maintenance jobs required for good performance by the mower is given below Follow the accompanying engine manual for detailed list and instructions e Change engine oil regularly as instructed in the engine manual Check oil level before starting

Bolens 544 Lawn Mower User Manual

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