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Operator’s Manual
21” Mulching Mower
Model 546
Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-cov-
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 44
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TABLE OF CONTENTS Content Page Content Page Important Safe Operation Practices 3 Maintaining Your Lawn Mower 12 Slope Gauge 6 Servicing Your Lawn Mower 12 Assembling Your Lawn Mower 7 Troubleshooting 13 Know Your Lawn Mower 9 Illustrated Parts List 14 Operating Your Lawn Mower 10 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
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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
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immediately and the blade will stop rotating within 3. Do not mow on wet grass. Unstable footing could three seconds. cause slipping. 9. Mow in daylight or good artificial light; walk, not run. 10. Stop the blade when crossing gravel drives, Children walkways or roads. Tragic accidents can occur if the operator is not alert to 11. If the equipment should start to vibrate abnormally, the presence of children. Children are often attracted to stop the engine and check immediately for the the
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10. Never over fill fuel tank. Fill tank to no more than ½ 4. Mower blades are sharp and can cut. Wrap the inch below bottom of filler neck to provide space for blade or wear gloves, and use extra caution when fuel expansion. servicing them. 11. Replace gasoline cap and tighten securely. 5. Keep all nuts, bolts, and screws tight to be sure the 12. If gasoline is spilled, wipe it off the engine and equipment is in safe working condition. equipment. Move unit to another area. Wait 5 6. Never ta
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FOLD ON DOTTED LINE, REPRESENTING A 15° SLOPE SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE A POWER POLE A CORNER OF A BUILDING OR A FENCE POST 15° WARNING 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 u
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SECTION 3: ASSEMBLING YOUR LAWN MOWER Removing Unit From Carton Lower Handle • Remove staples, break glue on top flaps, or cut tape at carton end and open carton. Handle Upper Remove loose parts if included with unit (i.e., Bracket Handle 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 Figure 2 Side Discharge Chute
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Fasten the cable to the lower handle with the two Grass Catcher Insert frame cable ties found on the lower handle. Pull the cable Frame into bag ties tight and trim off the excess. See Figure 5. Cable Tie Lower Handle Grass Bag Grass Catcher Figure 5 Plastic Assembly Channel NOTE: Your mower is shipped with the handle in the Complete higher position. If you wish to lower the height of the handle, refer to the Adjustment Section at this time. Attaching Starter Rope The rope guide is alread
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Attaching Side-Discharge Chute Using Mulch Plug Remove the grass catcher and let the discharge Lift the mulch plug and remove the discharge chute door close. up and away from the mower. Let mulch plug rest On the right side of the mower, lift the mulching against the deck. Operate mower without the grass plug and slide the two hooks of the side-discharge catcher. Refer to page 11. chute under the hinge pin on the mulching plug assembly. Lower the mulching plug. See Figure 9. IMPORTANT:
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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 grass catcher and the side-discharge chute from the mower, and operate with the mulching plug only for this purpose. SECTION 5: OPERATING YOUR LAWN MOWER WARNING: Be sure no one other than the WARNING: Read, understand, and follow all operator is standing near the lawn mower while instructions and warnings
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Attach grass catcher following instructions on page Mulching 8 of this manual. Grass clippings will automatically For effective mulching, do not cut wet grass. New or collect in the bag as you run the mower. thick grass may require a narrower cut. If the grass has Operate the mower till the grass bag is full. grown in excess of 4”, mulching is not recommended. Stop engine completely by releasing the blade Mow using the side discharge to reduce the grass control handle. Make sure t
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SECTION 7: MAINTAINING YOUR LAWN MOWER Put the mower back on its wheels on the ground. If WARNING: Always stop the engine and you had put plastic under the gas cap, make sure to disconnect the spark plug wire before remove it now. performing any maintenance work or adjustments on your lawn mower. Lubrication Blade Control Handle Cleaning Mower Lubricate the pivot points on the blade control The underside of the mower deck should be cleaned handle at least once a season with light oil
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Follow the original angle of grind as a guide. Make Place blade bell support on blade. Make sure the sure that each cutting edge receives an equal notches on the blade bell support are aligned with amount of grinding to prevent an unbalanced blade. small holes in the blade. Replace hex bolt and tighten hex bolt to torque: 450 WARNING: An unbalanced blade will cause in. lbs. min., 600 in. lbs. max. excessive vibration when rotating at high NOTE: To ensure safe operation of your mower,
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SECTION 10: PARTS LIST FOR MODEL 546 4 2 1 12 14 13 6 7 11 8 9 10 31 22 49 16 34 19 32 64 20 21 18 24 35 33 45 46 29 15 39 28 23 36 25 26 30 29 49 42 40 43 37 49 49 60 52 51 17 50 54 59 61 53 65 55 40 62 49 57 47 56 58 14
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Model 546 Ref. Ref. Part No. Part Description Part No. Part Description No. No. 1. 749-1092A Upper Handle 34. 710-0703 Hex Carriage Screw 1/4-20 2. 747-1161A Control Handle 35. 687-02033 Handle Bracket — RH 4. 731-04204 Deluxe Bail Cover 687-02031 Handle Bracket — LH 6. 720-0279 Handle Knob 36. 710-1652 TT Screw 1/4-14 x.625 7. 710-1205 Rope Guide 37. 710-0216 Hex Screw 3/8-16 x 0.75 8. 710-1174 Carriage Bolt 5/16-18 x 2” 39. 687-02039 Pivot Arm Assembly — RH 9. 736-0451 Shoulder Washer.320 I
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MANUFACTURER’S LIMITED WARRANTY FOR: The limited warranty set forth below is given by Troy-Bilt LLC e. Troy-Bilt does not extend any warranty for products with respect to new merchandise purchased and used in the sold or exported outside of the United States, its United States, its possessions and territories. possessions and territories, except those sold through Troy-Bilt’s authorized channels of export distribution. “Troy-Bilt” warrants this product against defects in material f. Replacem
