Bolens 546 Operator's Manual
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Bolens 546 Operator's Manual

Bolens 546 Operator's Manual

21” rear & side discharge mulching mower
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Operator's Manual
IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY
Warning:
This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-
covered, brush-covered or grass-covered land unless the engine's exhaust system is equipped with a spark arrester meeting
applicable local or state laws (if any). If a spark arrester is used, it should be maintained in effective working order by the 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.O. BOX 361131 CLEVELAND, OHIO 44136-0019
PRINTED IN U.S.A.
21" Rear & Side
Discharge
Mulching Mower
Model 546
769-00574.fm
FORM NO.
(11/02)

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Summary of Contents for Bolens 546

  • Page 1 Operator’s Manual 21” Rear & Side Discharge Mulching Mower Model 546 IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest- covered, brush-covered or grass-covered land unless the engine’s exhaust system is equipped with a spark arrester meeting applicable local or state laws (if any).

  • Page 2: Table Of Contents

    See previous section to locate this information. You will be asked to enter the serial number in order to process your call. For more details about your unit, visit our website at www.bolens.com...

  • Page 3: Important Safe Operation Practices

    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.

  • Page 4: Slope Operation

    continues to rotate for a few seconds after the 2. Be alert and turn mower off if a child enters the engine is shut off. Never place any part of the body area. in the blade area until you are sure the blade has 3.
  • Page 5 14. To reduce fire hazard, keep mower free of grass, 7. After striking a foreign object, stop the engine, leaves, or other debris build-up. Clean up oil or fuel disconnect the spark plug wire and ground against spillage and remove any fuel soaked debris. the engine.

  • Page 6: Slope Gauge

    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.

  • Page 7: Assembling Your Lawn Mower

    SECTION 3: ASSEMBLING YOUR LAWN MOWER This unit is shipped without gasoline or oil IMPORTANT: in the engine. Be certain to service engine with gasoline and oil as instructed in the separate engine manual before operating your mower. NOTE: Reference to right or left hand side of the mower is observed from the operating position.

  • Page 8: Grass Catcher Assembly

    Attaching Rear Wheels • Secure bag to frame by working the plastic channels on bag over frame as shown in Figure 7B. • Remove hardware from hardware pack. All of the plastic channels except the center top of • Insert shoulder screw through wave washer, flat the bag attach from the outside of bag.

  • Page 9: Know Your Lawn Mower

    Attaching Grass Catcher To Mower Removing Grass Catcher • Lift the rear discharge door and place the grass • Lift the rear discharge door on the mower, and lift catcher on the pivot rod. Let go of discharge door the grass catcher up. so that it rests on the grass catcher.

  • Page 10: Operating Your Lawn Mower

    Mulching Plug Cutting Height Adjustment Levers The mulching plug is used only for mulching purposes. These levers are located on each wheel and are used Instead of collecting the grass clippings in a grass to adjust the cutting height. These levers have to be at catcher, some mower models have the option of the same relative position to ensure uniform cut.See recirculating the clippings back to the lawn.

  • Page 11: Making Adjustments

    Using Your Lawn Mower WARNING: If you strike a foreign object, stop the engine. Remove wire from the Be sure that the lawn is clear of stones, sticks, wire, or spark plug, thoroughly inspect the mower other objects which could damage the lawn mower or for any damage, and repair the damage the engine.

  • Page 12: Maintaining Your Lawn Mower

    All wheels must be placed in the same IMPORTANT: Height Adjustment relative position. For rough or uneven lawns, move the Lever height adjustment lever to a higher position. This will help stop scalping of the grass. Engine Adjustments See the separate engine manual packed with your unit for adjustments to the engine.
  • Page 13 Lubrication Always stop engine and disconnect spark Rear Discharge plug wire before cleaning, lubricating or Door doing any kind of service work on the lawn Handle mower. Bracket Blade Control: Lubricate the pivot points on the blade control handle and the brake cable at least once a season with light oil.

  • Page 14: Storing Your Lawn Mower

    • Remove the blade and the adapter from the • Be sure to install the blade with the side of the crankshaft. blade marked “Bottom” (or with part number) facing the ground when the mower is in the operating position. Blade •...

  • Page 15: Troubleshooting

    SECTION 8: TROUBLESHOOTING Problem Cause Remedy Engine fails to start 1. Blade control handle disengaged. 1. Engage blade control handle. 2. Spark plug wire disconnected. 2. Connect wire to spark plug. 3. Fuel tank empty or stale fuel. 3. Fill tank with clean, fresh gasoline. 4.

  • Page 16: Parts List

    Model 546...
  • Page 17 Model 546 Ref. Ref. Part No. Part Description Part No. Part Description 749-1092A Upper Handle 738-0507B Shoulder Screw 747-1161A Control Handle 736-0105 Spring Washer.375 ID x.870 OD 720-0279 Handle Knob 732-0866 Spring Lever 710-1205 Rope Guide 736-0182 Wave Washer.500 ID x 1.0 OD 710-1174 Carriage Bolt 5/16-18 x 2”...
  • Page 18 NOTES...
  • Page 19 NOTES...
  • Page 20 MANUFACTURER’S LIMITED WARRANTY FOR: The limited warranty set forth below is given by Troy-Bilt LLC 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.

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