Bolens 11A-546I763 Owner’s 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 isused, 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. Itwilt 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
¢
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.
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.
(Model Number)
(Serial Number)
,_i__. TROY-BILT LLC
www. bolens.com 330-558-7220
P. O. BOX 361131
CLEVELAND, OH44136
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 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 walt or obstruction first look down and behind to
avoid tripping and then follow these steps:
a. Step backfrom the mowerto fullyextend your
arms.
b. Besure you arewell balanced with surefooting.
c. Pull the mowerback slowly, no more thanhalfway
toward you.
d. Repeatthese 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. Ifsituations occur which are not covered in this
manual, use care and good judgment. Contact your
dealer for assistance. Telephone 1-866-840-6483
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 your safety, use the slope gauge included as part
ofthis manualto measure slopes before operating this unit on
a slopedor hilly area. If the slopeis greater than 15degrees,
do not mow it.
DO:
I. Mow across the face of slopes;never up and down.
Exercise extremecautionwhen changingdirectionon
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 orbalance.
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 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
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 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.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,
NOTE: Not all safety labels shown may apply to yourlawn mower.
understand and follow the warnings and instructions in this manual and on the machine,
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
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_ | " ",, _'_'_N',--
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_ 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
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