Bolens 546 User manual

SINCE-1850
Operator's Manual
21" Rear & Side
Discharge
Mulching Mower
Model546
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_overed land unless the engine's exhaust system is equipped with a spark arrester meeting
applicable local or state laws (if any). If e 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. FORM NO. 769-00574
(11/02)

TABLEOFCONTENTS
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
Making Adjustments .......................................................................................... 11
Maintaining Your Lawn Mower ........................................................................... 12
Troubleshooting ................................................................................................. 15
Parts List ............................................................................................................ 16
FINDINGMODELNUMBER
This Operator's Manual isan important part of your new lawn mower. It wilt 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 inthe 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.
(Model Number)
(Serial Number)
,_i__. TROY-BILT LLC
P. O. BOX 361131
CLEVELAND, OH 44136
www. bolens.com 330-558-7220
866-840-6483_,
Copy the model number here:
Copy the serial number here:
ENGINEINFORMATION
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.
CALLINGCUSTOMERSUPPORT
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
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
your call.

SECTION1: IMPORTANTSAFEOPERATIONPRACTICES
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.
DANGER: This machine was built to be operated according to the rules for safe operation in this
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.
GeneralOperation
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
rules of safe operation should be allowed to use this
machine.
4. Thoroughly inspect the area where the 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 children, bystanders, helpers and pets at
least 75 feet from the mower while it is in operation.
Stop machine if anyone enters the area.
6. Always wear safety glasses or safety goggles
during operation and while performing an
adjustment or repair to protect your eyes. Thrown
objects which ricochet can cause serious injury to
the eyes.
7. 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.
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 aresult of the mower being
pulled over the foot during afall 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 walt or obstruction first look down and behind to
avoid tripping and then follow these steps:
a. Step backfrom the mowerto fully extend your
arms.
b. Be sure you arewell balancedwith surefooting.
c. Pull the mowerback slowly, no morethanhalfway
toward you.
d. Repeat these steps as needed.
5. MOWonly in daylight or in good artificial light. Walk,
never run.
6. Stop the blade when crossing gravel drives, walks
or roads.
7. If the equipment should start to vibrate abnormally,
stop the engine and check immediately for the
cause. Vibration is generally a warning of trouble.
8. 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

continuestorotateforafewsecondsafterthe
engineisshutoff.Neverplaceanypartofthebody
inthebladeareauntilyouaresurethebladehas
stoppedrotating.
9. Neveroperatemowerwithoutpropertrailshield,
dischargecover,grasscatcher,bladecontrol
handleorothersafetyprotectivedevicesinplace
andworking.Neveroperatemowerwithdamaged
safetydevices.Failuretodoso,canresultin
personalinjury.
10.Mufflerandenginebecomehotandcancausea
burn.Donottouch.
11.Onlyusepartsand accessories made for this
machine by the manufacturer. Failure to do so, can
result in personal injury.
12. If situations occur which are not covered in this
manual, use care and good judgment. Contact your
dealer for assistance. Telephone [phone]
for the name of your nearest dealer.
SlopeOperation
Slopesare a majorfactor relatedto slip andfall accidents
which can result in severe injury. Operationon slopes
requiresextra caution. Ifyou feel uneasy on a slope, do not
mow it. For yoursafety, usethe slope gauge includedas part
ofthis manualto measure slopes beforeoperating this uniton
a slopedor hillyarea. If the slopeis greaterthan 15degrees,
do not mow it.
DO:
I. Mow acrossthe face of slopes;never up and down.
Exercise extremecaution when changingdirection on
slopes.
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.
DoNot:
1. Do notmow near drop-offs, ditches or embankments,
you could loseyourfooting 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. 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 comers,
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 bums from ahot 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
SafeHandlingOfGasoline:
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. When practical, 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. 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.Toreducefirehazard,keepmowerfreeofgrass,
leaves,orotherdebrisbuild-up.Cleanupoilorfuel
spillageandremoveany fuel soaked debds.
15. Allow a mower to cool at least 5 minutes before
storing.
GeneralService:
1. Never run an engine indoors or in apoorly
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.EM.) blade only,
listed in this manual. "Use of parts which do not
meet the odginal 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.EM.) parts only,
listed in this manual. "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.
_L WARNING -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,
NOTE: Not all safety labels shown may apply to yourlawn mower.

II 9 SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE
| I, 4 A POWER POLE
-- aq A CORNER OF A BUILDING
>" " " " ", | I | 91 OR A FENCE POST
i
_ | "",, _'_'_N',--
X
_ g Do not mow on inclines with a stope in excess of 15 degrees (a rise of approximately 2-1/2 feet ever,/10 feet). A riding mower could
_ _ overturn and cause sedous injury. If operating a walk-behind mower on such a slope, it is extremely difficult to maintain your footing
m o
a. "_ and you could slip, resulting in serious injury.
.__x: Operate RIDING mowers up and down slopes, never across the face of slopes.
=°o _ Operate WALK-BEHIND mowers across the face of slopes, never up and down slopes.
_ C
cD

SECTION3: ASSEMBLINGYOURLAWNMOWER
IMPORTANT:This unit is shipped without gasoline or oil
in the engine. Be certain to service engine with gasoline
and oil as instructed in the separate engine manual
before operating your mower.
NOTE: Reference to right or left hand side of the mower
is observed from the operating position.
RemovingUnitFromCarton
Remove staples, break glue on top flaps, or cut tape
at carton end and peel along top flap to open carton.
Remove loose parts if included with unit (i.e.,
operator's manual, etc.)
Cut along comers, lay carton down flat, and remove
packing material.
Roll or slide unit out of carton and check carton
thoroughly for loose parts.
LoosePartsinCarton
Grass Bag
Side Discharge Chute
Rear Wheels
Hardware Pack
DisconnectingSparkPlugWire
Before setting up your lawn mower, disconnect the spark
plug wire from the spark plug and ground against the
engine. See Figure 1.
Bolt I/
0 0 park Plug
Spark
PlugWire Spark Plug
Figure 1
SettingUpYourLawnMower
AssemblingHandle
Lift up and pull back on the upper handle to raise the
handle into the operating position. Make certain the
lower handle is seated securely into the handle
bracket assemblies. Tighten the wing nuts on each
side of the handle (carriage bolts must be seated
properly into the handle). See Figure 2.
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. 7
Figure 2
Remove the hairpin clips from the outer hole in the
weld pins on the handle mounting brackets. Using a
pair of pliers, squeeze one leg of the lower handle
against the handle mounting bracket. Insert the
hairpin clip intothe inner hole on the weld pin.
Repeat on the other side. See Figure 3.
After moving the hairpin clip, insert the carriage bolt
from hardware pack in the upper hole on the handle
mounting bracket and secure with plastic wing nut
from the hardware pack. Repeat on other side.
_Handle Mounting
_ A JBracket
_ _X_ 41__-Carriage Bolt
Win Nut
g._ut _ _ lille _'_ _ _lnsert Hairpin
"_ "k_"_'_'_..X Clip
Hairpin._ _'°°_o WeldPin
Clip
Figure 3
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 4.
Cable Tie.
Handle
Figure 4

AttachingRearWheels
Remove hardware from hardware pack.
Insert shoulder screw through wave washer, flat
washer, rear wheel, and spring washer.
Secure shoulder screw with hardware to rear pivot
bar. See Figure 5.
Sprin!
Nave Washer
Figure 5
AttachingStarter Rope
The rope guide isattached tothe dght side of upper
handle. Loosen the wing nut which secures the
rope guide. See Figure 6.
Sta_er
Rope Nut
Rope
Guide Lower
Handle
Figure 6
With the spark plug wire disconnected and
grounded, hold the blade control handle against the
upper handle, and pullthe starter rope out of the
engine. Release the blade control handle. Slip the
starter rope into the rope guide. Tighten the wing
nut.
GrassCatcherAssembly
NOTE: Make certain the grass bag is turned right side
out before assembling (warning label will be on the
outside).
1. Frame Assembly
2. Bag
3. Hardtop Cover*
4. Mounting Bracket*
5. Two self Tapping Screws*
*Hardtop Cover only.
AssemblingSoft TopGrassCatcher
Place the bag over the frame (black plastic side is
the bottom of bag). Slip the openings inthe side of
the plastic channels on the bag over the hooks on
the grass catcher frame.
Secure bag to frame by working the plastic
channels on bag over frame as shown in Figure 7B.
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.
Plastic
Channels
Figure 7
AttachingHardtopCover(If Equipped)
Slide the hardtop cover under the grass catcher
handle, positioning it so the handle rests snugly into
the notch in the cover, and press the frame into the
tabs at the back of the cover.
Position the mounting bracket facing down
between the front of the handle and the front of the
hardtop cover so that the holes in the cover line up
with the holes in the bracket. Insert the self tapping
screws down through the hardtop cover and
mounting bracket. See Figure 8.
Grass
Catcher
Notch in
Hardtop
Cover
Self Tappin
Screws
Mountin
Bracket
Figure 8

AttachingGrassCatcherToMower
Lift the rear discharge door and place the grass
catcher on the pivot rod. Let go of discharge door
so that itrests on the grass catcher. See Figure 9.
Figure 9
IMPORTANT:Make sure cables are routed tothe
outside of the handle so they are not in the way when
attaching the grass catcher.
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.
RemovingGrassCatcher
Lift the rear discharge door on the mower, and lift
the grass catcher up.
Release the rear discharge door.
ConvertingToSideDischarge
Your mower has been shipped as a mulcher. To
convert itto a side-discharge mower, lift the mulch-
ing plug. Slide the two hooks on the side-discharge
deflector under the hinge pin on the mulching plug
assembly. Lower the mulching plug.See Figure 10.
Mulching
Plug
Pin
/'Side
,Chute
Deflector
Figure 10
Do not remove the side mulching plug at any time,
even when you are not mulching.
WARNING: Never operate the mower
without the mulching cover, the grass
catcher bag, or the discharge chute
properly installed.
SECTION4: KNOWYOURLAWNMOWER
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: 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.
GrassCatcher
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 isfull, ithas to be removed from the
mower and emptied before any further mowing. See
Figure 11.
Starter
Catcher
Mulchir
Figure 11
Blade Control
Handle
Cutting Height
Adjustment Lever

MulchingPlug
The mulching plug is used only for mulching purposes.
Instead of collecting the grass clippings in a grass
catcher, some mower models have the option of
recirculating the clippings back to the lawn. See Figure
11.
RecoilStarter
The recoil starter isattached to the right handle. Stand
behind the unit and pull the recoil starter to start the
unit. See Figure 11.
Cutting HeightAdjustmentLevers
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.See
Figure 11.
BladeControlHandle
The blade controlhandle islocated on the upper handle
ofthe mower. The blade controlhandle must be
depressed in order to operate the unit. Release blade
controlhandle to stop engine and blade. See Figure 11,
This blade control mechanism is a safety
device. Never attempt to bypass its
operations.
SECTION5: OPERATINGYOURLAWN
&WARNING: Keep hands and feet away from
chute area on the cutting deck. The
operation of any lawn mower can result in
foreign objects being thrown into the eyes,
which can result in severe eye damage.
Always wear safety glasses or eye shields.
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 determine
which height is best for your lawn. See the Adjustment
Section for details.
GasandOilFill-Up
Service the engine with gasoline and oil as instructed in
the separate engine manual packed with your mower.
Read instructions carefully.
Never fill fuel tank indoors with engine
running or until the engine has been
allowed to cool for at least two minutes
after running.
MOWER
StartingEngine
Attach spark plug wire tospark plug. Make certain
the metal cap on the end of the spark plug is
fastened securely over the metal tip on the spark
plug.
Prime engine as instructed in the separate engine
manual packed with your unit.
Your lawn mower may be equipped with a constant
speed throttle, which is set at fult throttle for best
performance.
Stand behind the mower and squeeze the blade
control handle against the upper handle.
Grasp recoil 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, let the rope return to the starter
slowly.
10