Page 1
Operator’s Manual
21” Hi-Wheel Mower
Models 546 & 549
Warning:
ered, 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.
PRINTED IN U.S.A.
This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-cov-
MTD LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019
Form No.
769-00987A.fm
(11/2004)
Page 2
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 10
Content Page
Maintaining Your Lawn Mower 12
Servicing Your Lawn Mower 12
Troubleshooting 13
Illustrated Parts List 14
Warranty 16
Making Adjustments 11
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.
Before you start assembling your new equipment, please locate the model plate on the
equipment and copy the information from it in the space provided below. A sample model plate is
also given below. You can locate the model plate by standing at the operating position and
looking down at the rear of the deck. This information will be necessary to use the
manufacturer’s web site and/or help from the Customer Support Department or an authorized
service dealer.
Copy the model number here:
www.troybilt.com
TROY-BILT LLC
P. O. BOX
361131
CLEVELAND, OH 44136
330-558-7220
1-800-520-5520
Copy the serial number here:
CUSTOMER SUPPORT
Please do NOT return the unit to the retailer from where it was purchased, without first contacting Customer Support.
If you have difficulty assembling this product or have any questions regarding the controls, operation or
maintenance of this unit, you can seek help from the experts. Choose from the options below:
Visit troybilt.com for many useful suggestions. Click on Customer Support button and you will
get the four options reproduced here. Click on the appropriate button and help is immediately
available.
The answer you are
looking for could be just
a mouse click away!
To reach a Customer Support Representative, please call 1-800-520-5520.
The answer you are
looking for could be just
a mouse click away!
Engine
Manual
The engine manufacturer is responsible for all engine-related issues with regards to
performance, 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.
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SECTION 1: IMPORTANT SAFE OPERATION PRACTICES
WARNING:
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:
chemicals known to State of California to cause cancer and birth defects or other reproductive harm.
WARNING:
manual. As with 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.
This symbol points out important safety instructions which, if not followed, could endanger
Engine exhaust, some of its constituents, and certain vehicle components contain or emit
This machine was built to be operated according to the rules for safe operation in this
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.
2. 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.
3. 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.
4. 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 objects 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.
5. 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.
6. 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. Wear sturdy, rough-soled work shoes and closefitting 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.
8. Do not put hands or feet near rotating parts or
under the cutting deck. Contact with the blade can
amputate hands and feet.
9. A missing or damaged discharge cover can cause
blade contact or thrown object injuries.
10. 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.
11. Never pull the mower back toward you while you
are walking. 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.
5. Do not operate the mower while under the influence
of alcohol or drugs.
6. Do not engage the self-propelled mechanism on
units so equipped while starting engine.
7. 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.
8. 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
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immediately and the blade will stop rotating within
three seconds.
9. 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 removing 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 1-800-520-5520 for the
name of your nearest dealer.
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. Be alert 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
should be trained and supervised by a parent.
Service
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 on a
slope, do not mow it. Before operating this unit on a
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 can 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.
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.
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10. Never over fill fuel tank. Fill tank to no more than ½
inch below bottom of filler neck to provide space for
fuel expansion.
11. Replace gasoline cap and tighten securely.
12. If gasoline is spilled, wipe it off the engine and
equipment. Move unit to another area. Wait 5
minutes before starting the engine.
13. 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.
14. 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.
15. 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.
2. 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.
3. 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!”
4. Mower blades are sharp and can cut. Wrap the
blade or wear gloves, and use extra caution when
servicing them.
5. Keep all nuts, bolts, and screws tight to be sure the
equipment is in safe working condition.
6. Never tamper with safety devices. Check their
proper operation regularly.
7. 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.
8. Never attempt to make a wheel or cutting height
adjustment while the engine is running.
9. 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.
10. Do not change the engine governor setting or
overspeed the engine. The governor controls the
maximum safe operating speed of the engine.
11. Maintain or replace safety and instruction labels, as
necessary.
12. Observe proper disposal laws and regulations.
Improper disposal of fluids and materials can harm
the environment.
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 machine.
1299 AC
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SECTION 2: SLOPE GAUGE
Use this page as a guide to determine slopes where you may not operate safely. Do not operate your lawn mower
on such slopes.
Operate WALK-BEHIND mowers across the face of slopes, never up and down slopes.
Operate RIDING mowers up and down slopes, never across the face of slopes.
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.
F
O
L
D
O
N
D
O
T
T
E
D
L
I
N
E
,
R
E
P
R
E
S
E
N
T
I
N
G
A CORNER OF A BUILDING
OR A FENCE POST
SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE
A POWER POLE
WARNING
15°
A
1
5
°
S
L
O
P
E
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SECTION 3: ASSEMBLING YOUR LAWN MOWER
Removing Unit From Carton
• Remove staples, break glue on top flaps, or cut
tape at carton end and open carton.
• Remove loose parts if included with unit (i.e.,
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.
Loose Parts in Carton
•Grass Bag
• Side Discharge Chute
• Rear Wheels
• Hardware Pack
• Bottle of Oil
Hardware Pack
Please identify each piece
of the hardware pack as
shown here.
Carriage
Bolt
Wing Nut
Before Assembly
• Before setting up your lawn mower, disconnect the
spark plug wire from the spark plug. See Figure 1.
Lower Handle
Upper
Handle
Figure 2
• Make sure that carriage bolt through the upper and
lower handles on each side is properly seated.
Tighten the wing nuts. See Figure 3.
Tighten these
wing nuts
Carriage
Bolt
Handle
Bracket
Carriage
Bolt
Spark Plug
Wire
Spark Plug
Figure 1
NOTE: Reference to right or left hand side of the mower
is observed from the operating position.
Setting Up Your Lawn Mower
Assembling Handle
• Lift up and pull back on the upper handle to raise
the handle into the operating position. See Figure
2. Make certain the lower handle is seated securely
into the handle bracket assemblies.
Figure 3
• 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 4.
Carriage Bolt
Wing Nut
Hairpin Clip
*Wheel not shown for clarity
Figure 4
• After moving the hairpin clip, insert the carriage
bolt, from the hardware pack, in the upper hole on
the handle mounting bracket and secure with
plastic wing nut from the hardware pack. See
Figure 4. Repeat on the other side.
Weld Pin
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• 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 5.
Cable Tie
Assembling Grass Catcher
NOTE:
proceed to the next section. If it came unassembled,
follow the steps below to assemble it first, before
attaching to the mower.
If the grass catcher came pre-assembled,
Lower
Handle
Figure 5
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
• Remove the hex flanged nut on the rear axle from
each side and place the rear wheel on the axle.
Make sure the wave washer is on the inside of the
wheel, between the wheel and the lawnmower. See
Figure 6. Reinsert the flanged nut into the axle as
shown, and tighten securely. Repeat on other side.
Rear Wheel
Wave Washer
Hex
Nut
(If Not Already Attached)
Rear Axle
• Insert frame into grass bag with the black plastic
side on the bottom of bag. See Figure 8.
• 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
channels 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 8.
Grass Catcher
Frame
Grass
Bag
Plastic
Channel
Insert frame
into bag
Grass Catcher
Assembly
Complete
Figure 6
Attaching Starter Rope
The rope guide is already attached to the right side of
the upper handle of your mower. See Figure 7.
Wing Nut
Upper Handle
Starter Rope
Rope Guide
Figure 7
• 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.
• Slip the rope through the rope guide as shown
below. Tighten the wing nut holding the rope guide
to the upper handle.
Lower Handle
Figure 8
Attaching Grass Catcher & Chute
WARNING:
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.
IMPORTANT:
the handle so that it is not in the way when attaching 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 9.
8
Make sure cable is routed to the outside of
Never operate the mower
Page 9
Rear Discharge Door
IMPORTANT:
Do not remove the mulching plug at any
time, even when you are not mulching.
Mulching
Plug
Grass Catcher
Figure 9
• To remove the grass catcher, lift the rear discharge
door on the mower, lift the grass catcher up and off
the pivot rod. Release the rear discharge door.
Using Mulch Plug
• Lift the mulch plug and remove the discharge chute
Attaching Side-Discharge Chute
• Remove the grass catcher and let the discharge
door close.
• On the right 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 mulching plug. See Figure 10.
SECTION 4: KNOW YOUR LAWN MOWER
Blade Control Handle
Grass Catcher
Rear Cutting
Height Adjuster
Lever
Recoil
Starter
Front Cutting
Height Adjuster
Lever
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.
Hinge
Pin
Side
Chute
Deflector
Figure 10
up and away from the mower. Let mulch plug rest
against the deck. Operate mower without the grass
catcher. Refer to page 11.
WARNING:
The operation of any lawn
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.
Side-Discharge
Chute
Mulching
Plug
Figure 11
Read this operator’s manual and safety rules before
operating your lawn mower. Compare the illustration in
Figure 11 with your lawn mower to familiarize yourself
with the location of various controls and adjustments.
Save this manual for future reference.
WARNING:
This blade control mechanism is
a safety device. Never attempt to bypass its
operations.
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 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.
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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.
grass catcher and the side-discharge chute from the
mower, and operate with the mulching plug only for this
purpose.
Mulching Plug
Instead of collecting grass clippings in a grass catcher,
this mower has the option of recirculating the clippings
back to the lawn. This is called mulching. Remove the
SECTION 5: OPERATING YOUR LAWN MOWER
(rope will pull slightly harder at this point). Let the
WARNING:
instructions and warnings on the machine and
in this manual before operating.
NOTE: You must service the engine with oil and gasoline before starting the mower for the first time. Check oil and gasoline levels and fill up as necessary for subsequent starts.
Read, understand, and follow all
rope rewind slowly.
• Pull rope with a rapid, continuous, full arm stroke.
Keeping a firm grip on the starter handle, let the
rope rewind slowly.
WARNING:
operator is standing near the lawn mower while
starting engine or operating mower.
Be sure no one other than the
Gas & Oil Fill-Up
• Check oil level and add oil if necessary. Follow
relevant instructions in the engine manual for this.
• Service the engine with gasoline as instructed in
the engine manual.
WARNING:
handling gasoline. Gasoline is extremely
flammable and the vapors are explosive. Never
fuel the machine indoors or while the engine is
hot or running. Extinguish cigarettes, cigars,
pipes and other sources of ignition.
Use extreme care when
Before Starting Mower
• 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.
Starting Engine
• (On Model 549 only, Model 546 skip to next bullet
point) 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.
• Grasp starter handle and pull rope out slowly until
engine reaches the start of compression cycle
WARNING:
enclosed, poorly ventilated areas. Engine
exhaust contains carbon monoxide, an
odorless and deadly gas.
WARNING:
loose clothing away from any moving parts on
engine and lawn mower.
NOTE: See your engine manual packed with your unit for more detailed instructions.
Never run engine indoors or in
Keep hands, feet, hair and
Stopping Engine
• Release blade control handle to stop the engine
and the blade.
• Disconnect spark plug wire and move away from
spark plug to prevent accidental starting.
Using Your Lawn Mower
• You can use your mower as a mulching mower or a
rear bagger.
• Be sure that the lawn is clear of stones, sticks, wire,
or other objects which could damage lawn mower
or engine.
WARNING:
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.
• For best results, do not cut wet grass. New grass or
thick grass may require a narrower cut.
If the mower strikes a foreign
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• For a healthy lawn, always cut off one-third or less
of the total length of the grass.
Mulching
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.
SECTION 6: MAKING ADJUSTMENTS
Bagging Grass Clippings
You can use the grass catcher bag to collect clippings
while you are operating the mower.
• Attach grass catcher following instructions on page
8 of this manual. Grass clippings will automatically
collect in the bag as you run the mower.
• 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.
WARNING:
adjustments without first stopping engine and
disconnecting spark plug wire.
Do not at any time make any
Handle Height Adjustment
Your mower is shipped with the handle in the higher
height position. To lower the height proceed as follows:
• Remove the starter rope from the rope guide.
• 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.
• 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.
• Turn lower handle around so the notch on the
bottom of the lower handle is facing forward.
See Figure 12A.
• Reassemble the handle, placing the bottom holes
in the handle over the weld pins in the handle
mounting bracket.
• Place the hairpin clips in the inner holes in the weld
pins and insert the carriage bolts though the upper
hole on the handle mounting bracket and secure
with plastic wing nuts. Repeat on the other side.
Height
Notch
Lower
Handle
A
• Reassemble the upper handle to the lower handle.
• Attach the starter rope as instructed in the
Assembly Section.
B
Figure 12
Adj.
Lever
Cutting Height Adjustment
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 12B. All wheels must be placed in the same
relative position.
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SECTION 7: MAINTAINING YOUR LAWN MOWER
• Put the mower back on its wheels on the ground. If
WARNING:
disconnect the spark plug wire before
performing any maintenance work or
adjustments on your lawn mower.
Always stop the engine and
you had put plastic under the gas cap, make sure to
remove it now.
Lubrication
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.
NOTE: We do not recommend the use of pressure washers or garden hose to clean your unit. These may cause damage to bearings or the engine. The use of water will result in shortened life and reduce serviceability.
• Disconnect spark plug wire. Drain the gasoline from
the lawn mower, or place a piece of plastic under
the gas cap.
• Tip the mower so that it rests on the housing. Keep
the side with the air cleaner facing up. Hold the
mower firmly.
WARNING:
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.
• Scrape and clean the underside of the deck with a
suitable tool. Do not spray with water.
Never tip the mower more than
Blade Control Handle
• 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
• 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 pivot arm axle and the
inner surface of the wheel with light oil.
Rear Discharge Door
• 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 Care
Follow the accompanying engine manual for detailed
list and instructions.
WARNING:
surrounding areas while the mower engine is
hot because temperature of these areas of the
engine may exceed 150
Make sure to avoid muffler and
o
F.
SECTION 8: SERVICING YOUR LAWN MOWER
Blade Care
WARNING:
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
• Disconnect spark plug wire from spark plug.
• Turn mower on its side making sure that the air filter
and the carburetor are up.
• Remove the bolt and the blade bell support which
hold the blade and the blade adapter to the engine
crankshaft. See Figure 13.
When removing the cutting
• Remove the blade and the adapter from the
crankshaft.
Blade
Adapter
Sharpening the Blade
• The blade can be sharpened with a file or on a
grinding wheel. Do not attempt to sharpen the
blade while it is still on the mower.
12
Figure 13
Blade Bell
Support
Hex Bolt
Page 13
• 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 blade.
WARNING:
An unbalanced blade will cause
excessive vibration when rotating at high
speeds. It may cause damage to the mower,
and could break causing personal injury.
• Place blade bell support on blade. Make sure the
notches on the blade bell support are aligned with
small holes in the blade.
• 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.
Balancing the Blade
• 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
• 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.
• 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.
• Slide the blade adapter onto the engine crankshaft.
• Place the blade on the adapter. Be certain the
blade is aligned and seated on the blade adapter
flanges.
Replacing Rear Flap
• To remove rear flap, cut off the flat end of the wire
rod which secures it to the deck.
• Attach the new flap and new rod to deck, bending
the ends of the new rod over to secure to deck.
Storing Your Lawn Mower
The following steps should be taken to prepare your
lawn mower for storage.
• Clean and lubricate mower thoroughly as described
in the lubrication instructions.
• Refer to engine manual for correct engine storage
instructions.
• Coat mower’s cutting blade with chassis grease to
prevent rusting.
• Store mower in a dry, clean area. Do not store next
to corrosive materials, such as fertilizer.
SECTION 9: TROUBLESHOOTING
Problem Cause Remedy
Engine fails to start 1. Blade control handle disengaged.
2. Spark plug wire disconnected.
3. Fuel tank empty or stale fuel.
4. Blocked fuel line.
5. Faulty spark plug.
6. Engine flooded
Engine runs erratic 1. Spark plug wire loose.
2. Blocked fuel line or stale fuel.
3. Vent in gas plugged.
4. Water or dirt in fuel system.
5. Dirty air cleaner.
6. Carburetor out of adjustment.
Engine overheats 1. Engine oil level low.
2. Air flow restricted.
3. Carburetor not adjusted properly.
Excessive vibration 1. Cutting blade loose or unbalanced.
2. Bent cutting blade.
Mower will not mulch grass 1. Wet grass.
2. Excessively high grass.
3. Dull blade.
Uneven cut 1. Wheels not positioned correctly.
2. Dull blade.
NOTE: For repairs beyond the minor adjustments listed above, contact your local authorized service dealer.
1. Engage blade control handle.
2. Connect wire to spark plug.
3. Fill tank with clean, fresh gasoline.
4. Clean fuel line.
5. Clean, adjust gap, or replace.
6. Wait a few minutes to restart. (do not prime
model 549).
1. Connect and tighten spark plug wire.
2. Clean fuel line; fill tank with fresh gasoline
3. Clear vent.
4. Drain fuel tank. Refill with fresh fuel.
5. Clean air cleaner.
6. Adjust carburetor.
1. Fill crankcase with proper oil.
2. Remove blower housing and clean.
3. Adjust carburetor.
1. Tighten blade and adapter. Balance blade.
2. Replace blade.
1. Do not mow when grass is wet; wait until
later to cut.
2. Mow once at a high cutting height, then mow
again at desired height.
3. Sharpen or replace blade.
1. Place all four wheels in same position.
2. Sharpen or replace blade.
13
Page 14
SECTION 10: PARTS LIST FOR MODELS 546 & 549
30
1
2
10
3
40
25
54
37
57
59
60
31
13
8
18
19
53
17
27
14
15
55
42
36
44
47
26
25
45
16
23
35
22
21
25
25
33
20
24
46
5
6
11
52
40
38
25
28
43
41
34
47
9
49
7
50
4
56
51
12
32
39
58
48
25
29
14
Page 15
PARTS LIST FOR MODELS 546 & 549
Ref.
No.
1. 747-1161A Control Handle
2. 749-1092A Upper Handle
3. 747-04080 Grass Bag Frame
4. 749-0928A Lower Handle
5. 720-0279 Wing Nut
6. 710-1205 Rope Guide
7. 710-1174 Carriage Bolt 5/16-18 x 2”
8. 664-04011 Grass Bag
9. 720-0284 Wing Nut
10. 746-1130 Control Cable 40”
11. 726-0240 Cable Ties
12. 714-0104 Hairpin Clip
13. 732-04090A Torsion Spring — RH
14. 732-04089A Torsion Spring — LH
15. 731-04134A Grass Bag Door
16. 732-1014 Torsion Spring
17. 747-0710 Hinge Pin
18. 732-0700 Wire Rod
19. 731-04998 Trail shield
20. 748-0377C Blade Adapter
21. 710-1257 Hex Cap Screw 3/8-24 x 2.5
22. 736-0524B Blade Bell Support
23. 17032A Chute Deflector Adapter
24. 742-0741 21” Mulching Blade
25. 712-0431 Flange Lock Nut 3/8-16
26. 15261C Height Adjustment Plate
27. 687-02077 Pivot Arm Assembly — RH
28. 732-0404 Spring Lever
29. 738-0507B Shoulder Screw
30. 731-04204 Deluxe Bail Cover
31. 720-0426 Spring Lever Knob
32. 710-0216 Hex Screw 3/8-16 x 0.75
Part No. Part Description
687-02076 Pivot Arm Assembly — LH
Ref.
No.
33. 687-02074 Front Height Adjuster Assembly — RH
34. 687-02039 Pivot Arm Assembly — RH
35. 782-5002B Front Baffle
36. 710-0654A Hex Washer Screw 3/8-16 x 1.0
37. 731-04150 Rear Baffle 21” Rd.
38. 710-0286 Machined Screw 1/4-20
39. 710-1652 TT Screw 1/4-14 x .625
40. 710-04371 Hex Screw1/4-15
41. 712-04064 Flange Lock Nut 1/4-20
42. 787-01231 Deck 21”
43. 734-04014 Front Wheel 8x2.125 Gray IDL
44. 736-0270 Bell Washer.265 ID x.75 OD
45. 687-02055 Mulching Plug
46. 731-04177 Side Discharge Deflector
47. 710-0599 Screw 1/4-20 x.500
48. 710-0514 Hex Cap Screw 3/8-16 x 1.0
49. 736-0451 Shoulder Washer.320 ID x.930 OD
50. 710-0703 Hex Carriage Screw 1/4-20
51. 712-0397 Wing Nut
52. 750-04162 Spacer.375 O.D. x.50 I.D. x 1.02”
53. 747-0996 Chute Door Pivot Rod
54. 734-04127 Rear Wheel 12x2.125 Gray IDL
55. 687-02056 Handle Bracket Assembly — RH
56. 687-02033 Handle Bracket — RH
57. 732-0866 Spring Lever
58. 720-0312 Spring Lever Grip
59. 736-0182 Spring Washer.500 x 1.00 x.022
60. 736-0504 Wave Washer.510 x.750 x.017
Part No. Part Description
687-02075 Front Height Adjuster Assembly — LH
687-02040 Pivot Arm Assembly — LH
687-02057 Handle Bracket Assembly — LH
687-02031 Handle Bracket — LH
15
Page 16
MANUFACTURER’S LIMITED WARRANTY FOR:
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” warrants this product against defects in material
and workmanship 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 from the
installation or use of any part, accessory or attachment not
approved by Troy-Bilt for use with the product(s) covered by
this manual will void your warranty as to any resulting
damage.
Normal wear parts are warranted to be free from defects in
material and workmanship for a period of thirty (30) days from
the date of purchase. Normal wear parts include, but are not
limited to items such as: 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 1-800-520-5520 or 1330-558-7220, 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
may 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
separate one year warranty.
c. Routine 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. Service completed by someone other than an
authorized service dealer.
e. Troy-Bilt 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’s authorized channels of export distribution.
f. Replacement parts that are not genuine Troy-Bilt parts.
g. Transportation charges and service calls.
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. 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
shall not be liable for incidental or consequential loss or
damage including, without limitation, expenses incurred
for substitute or replacement 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.
IMPORTANT:
Owner must present Original Proof of
Purchase to obtain warranty coverage.
Troy-Bilt LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019; Phone: 1-866-840-6483, 1-330-558-7220
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