546 / 546R / 546HR / 546RS

546 / 546R / 546HR / 546RS
Instruction manual
Original instructions
Lawn Mowers
Read this instruction manual carefully before
first operation and strictly observe the safety
9 546 129 english
Lawn Mowers
Instruction manual
Original instructions
Dear Customer,
Congratulations for choosing this SOLO quality
The lawn mower is a high performance mower
that will contribute to a well-cared for lawn.
The owners manual comes with the
appropriate engine owners manual which
is an integral part of this owners manual.
Please read the owners manual carefully and
familiarize yourself with the correct use of the
SOLO lawn mower prior to operating the lawn
mower for the first time. Please observe all
instructions, recommendations and explanations.
Adherence to the owners manual is essential for
proper operation of the lawn mower. Do not
operate the lawn mower while other persons,
especially children or animals are within close
proximity. The operator of the lawn mower is
responsible for any personal or property damages
to third parties.
EC declaration of conformity Î The EC
declaration of conformity on a separate piece of
paper forms part of these operating instructions.
Packaging and disposal
Please keep the original packaging in order to
protect the equipment against transport damage in
case you ever need to ship it or transport it. If the
packaging materials are no longer required then
they must be disposed of properly in accordance
with applicable local regulations. Cardboard
packaging materials are raw materials which can
be recycled or reused.
At the end of the equipment’s service life, please
make sure that you dispose of it properly, in
accordance with the official directives and
regulations that apply in your area
546 / 546R / 546HR / 546RS
The following symbols are used in this manual and
on the product:
Always handle this power tool with
particular care
Read these operating instructions and
those appertaining the motor, carefully,
before initial start-up and all maintenance
or cleaning work
Wear protective gloves when servicing
and for repair
Wear protective head gear
Pay particular attention when handling
Never smoke near the power tool or
where the equipment is refuelled!
Keep open flames away from the power
tool and the fuel can
Observe mowing hours
Do not allow third parties within the
danger zone
Detach spark plug wire prior to working on
cutting device;
Stop engine
Do not spray the mower with high
pressure cleaning hose
Never place the lawnmower on its side
In the best interest of continued technological
progress we reserve the right to change the design
and configuration of any product without prior
For that reason, no claims can be accepted with
reference to text and illustrations in this manual
Index ; Type plate
1. Type plate .............................................................................................................................................. 3
2. Standard delivery.................................................................................................................................. 4
3. Control and function elements ............................................................................................................ 4
4. Technical data....................................................................................................................................... 6
5. Accessoires........................................................................................................................................... 6
6. Safty guidelines .................................................................................................................................... 7
6.1 Correct use
6.2 General safety instructions
6.3 Fuel and fuelling
6.4 Prior to Mowing
6.5 During Start-up
6.6 Handling
6.7 Information for lawn mower with electrical starter (546RS)
6.8 Service and Storage
7. Preparing the equipment for use....................................................................................................... 10
7.1 Engine
7.2 Assembly
7.3 Grass Catching Device
7.4 Adjusting cutting height
8. Starting / Stopping the engine........................................................................................................... 11
8.1 Starting
8.2 Self-propelled drive roller (546R / 546HR / 546RS)
8.3 Shutting off engine
9. Mowing hints ....................................................................................................................................... 12
9.1 Mowing with Grass catching device
9.2 Lawn Care
10. Maintenance and Care...................................................................................................................... 13
10.1 Cleaning the Mower
10.2 Wheel axles and wheel hubs
10.3 Height adjustment
10.4 Drive belt
10.5 Oil level check
10.6 Mowing Blade
10.7 Air filter Maintenance
10.8 Possible faults and troubleshooting
Guarantee ................................................................................................................................................ 17
Parts subject to wear and tear............................................................................................................... 17
1. Type plate
a: Type designation
b: Serial number
c: Build year (07 Î 2007)
d: Max. speed (operating)
Standard delivery ; Control and function elements
2. Standard delivery
Lawn mower
Grass catching device complete with frame and carrying handle
Charger, Ignition keys (only with 546RS)
Spark plug wrench
Owners manual, owners manual for engine
EC declaration of conformity on a separate piece of paper
3. Control and function elements
Fig. 1a
Model 546
Adhesive labels:
A Model 546:
Model 546R, 546HR, 546RS:
To stop the engine Î release bow handle (1)
To start the self-drive Î pull bow handle (2) against the tubular handle
To stop the engine Î release bow handle (1)
B Fill the engine with oil before taking the machine into use
Control and function elements
Controls that are subject to model:
Fig. 2a: 546R, 546HR
Engines that are subject to model_
models 546R and 546RS as per model 546
Fig. 2d: Engine 546HR
Fig. 2b: 546RS
Brake lever, engine brake
Drive lever, self-propelled (546R, 546HR, 546RS)
Throttle lever
Key for electrical start-up (546RS)
Starter grip
Grascatching device
Ejection shield
Pinning lever
Air filter
Fuel tank
Central height adjustment
Spark plug
Oil filler pipe
- Battery (546RS)
- Gear box (546R, 546HR, 546RS)
Technical data ; Accessoires
4. Technical data
Cutting width
Wheel adjustment
continuous central adjustment from 30 - 75 mm (approx. 1’’ - 3“)
Grass catching device Vol. l
Blower-blade, one piece, mounted to overload clutch
Total weight with grass
catching device
1-cyl., 4-cycle engine
Engine power
Engine capacity
kW at rpm
Series 650
2,4 / 2800
Series 650
2,4 / 2800
GCV 135E
2,1 / 2800
Lead-free reg.
Engine oil: SOLO all-season
4-stroke engine oil 0083115
SOLO gearbox oil 0083182
approx 0.6 l
ca. 0.55 l
Noise level in work area LpA (ISO 11094)
50 ml
85 dB(A)
Sound capacity level LWA (ISO 11094) measured/ garanted Î
95 dB(A) / 96 dB(A)
Weighted acceleration value avhw (EN 836)
12 m/s2 ± 0,5 x a
Measurements: a: 140 cm (~55’’), b: 105 cm (~41’’), c: 51,5 cm (~20’’), d: 92 cm (~36’’), e: 40 cm (~16’’)
5. Accessoires
Mulch set cutting deck insert and special blade
Deflector set to convert to side discharge mower
SOLO all-season 4-stroke engine oil
SOLO gearbox oil (546R, 546HR, 546RS)
SOLO bearing grease
Drive Speed Reduction Kit
Caution: An authorized specialist service centre must install the kit!
Part no.
59 00 830
59 00 800
00 83 115
00 83 182
00 83 175
59 00 862
Safty guidelines
6. Safty guidelines
6.1 Correct use
The SOLO lawn mower is intended to be used only for private home or hobby gardens. The lawn mower is
not to be used in public facilities, parks, sports centers or for agricultural and forestry purposes.
Due to potential bodily harm, the SOLO lawn mower is not to be used for the following purposes:
to trim bushes, hedges or shrubs,
to cut or chop growing vines or lawns on roof-tops or balcony window boxes,
to clean or suction-up walkways or to chop up trees and shrubbery debris,
to cut up tree and shrubbery sections.
to level elevations on the ground, for instance mole hills or other similar elevations,
a drive aggregate for other work units,
as a trailer,
as a dynamo with a self-propelled drive roller mower (for example for carrying and transporting lawn
debris), except with the intended grass catching bag. The warranty becomes invalid if these rules are
not observed.
6.2 General safety instructions
Do not allow children or other third parties who are not familiar with the functioning of the machine to
operate the lawn mower. Juveniles under age 16 should not be permitted to operate the lawn mower.
Please adhere to local ordinances which may determine the minimum age for operating the lawn
Loan the lawn mower only to individuals who are familiar with handling this model. Always make the
owners manual available to them.
Explain to the individual who is to use the lawn mower, how to avoid possible danger and accidents.
Mow only during daylight hours or with proper artificial illumination.
Individuals who have a pacemaker should stay clear off the electrical wires of the starter when engine
is started or when engine is running.
Mowers with BRIGGS+STRATTON -4-cycle engines are not suitable for inclines over 15 degrees.
Lawnmowers equipped with HONDA OHC Engines can be used on slopes with an incline of
max.20 degrees.
Store the mower in a safe manner! Mowers should be stored in a dry and locked area that is
inaccessible to children.
6.3 Fuel and fuelling
Handling gasoline requires great care.
Gasoline is highly flammable. Refuel only outdoors - never in enclosed areas.
Smoking and open fires are prohibited.
Do not spill any gasoline.
If gasoline is spilled, clean lawn mower immediately, otherwise do not start engine!
Avoid contact with gasoline. Change clothing if accidental spills occur!
Be careful that fuel does not spill onto the ground (environmental protection!)
Transport and store gasoline only in authorized and marked containers.
If damages occur, replace fuel tank, cap and fuel lines
Check for any visible damage.
Lead-free, regular gasoline is to be used.
• Refuel only with the recommended fuels which are listed in the separate engine owners manuals.
• Let mower cool off prior to refueling.
• Thoroughly clean the surrounding areas of the fuel tank. Remove fuel tank cap and fill tank to the
lower edge of the filler pipe. Firmly close fuel tank cap.
Gasoline may contain solvent-like substances.
Avoid hand and eye contact with gasoline.
Wear protective gloves when refueling.
Do not inhale gasoline fumes.
Store fuel in areas inaccessible to children.
Safty guidelines
6.4 Prior to Mowing
Check the area completely prior to mowing and during mowing. Remove any foreign matter such as
pebbles, stones, wooden pieces, bones, etc. prior to mowing.
Never mow without sturdy shoes and without wearing long pants. Never mow bare-footed or with
open-toe sandals.
Attach the ejection shield and the grass catching device. Make certain that these are properly secured.
It is prohibited to use the mower without the ejection shield or with a damaged shield.
Check the mower for
a) secure fit of fastening parts,
b) damage or severe wear and tear.
Observe installation hints and specified torque when replacing parts.
Check the grass catching device frequently for wear and tear.
Lawn mowers with 4-cycle engine need to be serviced with engine oil prior to first-time usage (observe
the hints in the separate engine owners manual).
Check the oil level prior to each mowing.
6.5 During Start-up
The drive has to be disengaged when starting a self-propelled drive roller mower.
The mower needs to be positioned on level ground when starting.
Do not start-up in deep grass.
When starting mower it is important that feet are away from the cutting unit.
Never place hands or feet near moving parts. Be careful that neither hands nor feet will be caught
below the deck.
6.6 Handling
Do not run the engine in enclosed areas where dangerous exhaust fumes may collect. Danger of
The engine/exhaust becomes very hot: Do not touch!
Always position yourself firmly on the ground when mowing on a slope.
Move at a walking pace when mowing.
Mow diagonally on a slope, never in a straight upward or downward motion.
Be especially careful when changing directions on a slope.
Be especially careful when turning mower around or when pulling mower towards you.
Do not walk backwards with the mower. Danger of stumbling. Avoid walking backwards.
Avoid abnormal body positions. Assure solid positioning on the ground, and at all times, keep your
Always keep sufficient distance which is established by the length of the handle.
Turn off engine and remove spark plug cap,
• Prior to checking the mower,
• prior to removing blockages of ejected material,
• or prior to cleaning the mower and for other maintenance work, and
when you mount the Assembly mulching Set
when the mower is temporarily left alone,
when the mower is lifted or tilted during transport.
Turn engine off when,
• Opening the ejection shield and when removing grass catching device,
• when removing the upper handle section from the lower handle section,
when pushing mower outside the lawn,
when the cutting height is to be adjusted,
prior to refueling.
when crossing areas other than grass
when transporting the mower to or from the grass area
Safty guidelines
Never lift or carry the mower when engine is running.
Never use the mower when ejection shield is damaged or missing. Mow only with the proper grass
catching device which has to be correctly installed, and with a completely closed ejection shield.
Do not alter the engine‘s initial settings.
If the mower becomes blocked, for example when running over an obstacle, the mower needs to be
checked by a specialist to see if parts are damaged or deformed.
Immediate checking is required if the mower vibrates at an unusual high level.
6.7 Information for lawn mower with electrical starter (546RS)
Note the battery-manufacturer‘s information which is included with each new machine.
Attention: To protect against battery discharging during shipping, the plug on the red cable of the
battery connection is equipped with a protective hose. This hose is to be removed prior to connecting
the battery.
Charge the battery 24 hours prior to operating the mower. It is possible that the batteries have become
discharged due to extended storage.
Never charge the battery with a charger intended for other purposes (such as a charger for an
automobile) since the battery may become damaged.
The battery is located under the lid next to the ejection passageway of the lawn mower deck. Make
certain that the charger is connected to the battery and not to the engine‘s main cable; otherwise the
charger may become damaged.
Frequent starting and stopping may lead to a discharged battery (complete discharging is damaging to
the battery). In this situation it is necessary to quickly charge the battery with the charger.
Never store a discharged battery since the battery may become permanently damaged.
Disconnect the battery from the main cable of the mower if the mower is not used for more than 14
Prior to storing the mower at the end of a season, charge the battery for 24 hours with the supplied
charger. Do not reconnect the battery, store in a cool and dry place (never above 23oC (73o F ). The
battery needs to be recharged within 6 months of the last charge.
Recharge the battery for 24 hours with the supplied charger prior to operating the mower in the Spring.
The battery is completely enclosed and does not require any additional servicing.
Defective batteries need to be disposed off properly in accordance with local regulations. Some local
shops may accept and dispose off defective batteries.
6.8 Service and Storage
Caution: Before every Service, Cleaning and Storage stop the engine and remove spark plug cap.
• Take care that all screw connections are tightened.
• Never store the mower with gasoline in fuel tank in a building where gasoline vapors may come in
contact with open fires or where sparks could ignite fumes.
• The fuel tank should be emptied outdoors. Use suitable containers for draining gasoline.
• Let the engine run until the gasoline remaining in the carburetor is depleted.
• Let the engine cool off prior to storage in an enclosed area.
• To avoid danger of fire, clean grass, leaves or escaping grease (oil) off engine, muffler and fuel tank.
• On a regular basis, check the grass catching device and check the ejection shield for wear and tear
and sound operation.
• For safety reasons, replace worn or damaged parts.
• Always wear protective gloves when working near the cutting device‘s vicinity.
• Servicing and repairs are only to be conducted when engine is turned off and when spark plug cap is
• For warranty purposes and safety reasons only SOLO replacement parts should be used.
Ensure that the tank is fully drained before any assembly, disassembly or modification.
Preparing the equipment for use
7. Preparing the equipment for use
7.1 Engine
Prior to start up, carefully read the engine
operating manual and the following instructions.
Adhere to all instructions to assure the engine‘s
long life and to keep the warranty valid.
7.3 Grass Catching Device
Caution! Assemble and disassemble grass
catching device only when engine is shut off!
Fig. 3
7.2 Assembly
Your lawnmower will be ready for use in only a few
Securing the handle:
• Open locking screws (8)
• Pivot the upper handle into the required position
– if required, release locking screws (8) a little.
• Turn the open locking screw far enough
inwards to ensure that both handle parts sit
closely together when the locking levers are
closed. If required, either tighten or relax the
locking screws by one full turn.
Tip: Lock the locking screw levers upwards to
ensure that, whilst mowing, the screws do not
catch on shrubs.
Secure the Bowden and other cables in the cable
Folding the handle again for transport or storage:
When folding the handle, open both locking
screws upwards and tilt the upper handle forward.
Note: On lawnmowers with self-drive, push the
control bar (2) against the handle, before folding
the handle over, to prevent damaging the spark
To install grass catching device, lift ejection shield
(7), with one hand. With the other hand, hold grass
catching device (6), at the carrying grip and link
into mower deck at an angle from above.
7.4 Adjusting cutting height
Fig. 4
Starter handle inserted in the cable guide
Release the engine brake by bushing brake lever,
A (1), to the handle. Put the starter grip (5) in the
cable guide which is located on the upper handle
Attention: When folding and unfolding the handle,
pay special attention that the Bowden cables are
not bent and run smoothly..
Caution! Assure that Bowden cables are not
caught up anywhere and that they have not
become damaged during transport!
The mower is equipped with a continuously
adjustable cutting height of approx. 30 - 75 mm
(approx. 1 - 3 inches). The height adjustment for all
wheels is accomplished by the central adjustment
(position 11). Turning to the right reduces the
cutting height, and turning to the left increases the
height. The height can be read from the markings.
Attention: The cutting height is to be set so that
the blade does not touch the ground when the
ground is not level. Only mow with the lowest
cutting adjustment when lawns are flat.
Starting / Stopping the engine
8. Starting / Stopping the engine
During start up with self-propelled drive roller
mower, the drive has to be disengaged.
When starting the mower, position yourself on the
side or behind the mower. The safety distance
which is given by the handle is always to be
adhered to.
Caution! The cutter operates as soon as the
engine starts! Never reach with your hands under
the deck and never slide a foot under the deck!
8.1 Starting
Model 546HR
Fig. 5
Cold start:
Move throttle control
(3) to the choke
symbol . After the
engine starts, put
throttle lever (3) on
position “max”.
8.2 Self-propelled drive roller
(546R / 546HR / 546RS)
On lawn mowers with self-propelled drive, the drive
lever is located in front of the guide bar. The selfpropelled drive can only be put into gear after the
engine starts. To engage the drive, the drive lever
(2), has to be pulled towards the grip bar. To stop
the drive, release drive lever. In its released state,
there is no drive and the lawn mower can be
pushed forward or backward.
8.3 Shutting off engine
• Move the throttle lever (3) to "min"
• release brake lever (1) and wait until engine
shuts off.
Note: When the brake lever is released (1), the
electrical ignition of the.engine is cut off. The
engine RPM and the blade will stop within several
546HR only
Starting a warm
Move throttle control
(3) to "max".
Model 546, 546R, 546RS
The choke position is automatically adjusted
through a bimetal sensor subject to engine
temperature (Ready-Start®). These models
require no manual adjustment for a cold start.
Attention: To release the engine brake when
starting the engine, the brake bar (1), needs to be
pushed towards the handle.
If the brake bar (1) is not pushed to the handle
during start, the electrical ignition is shorted and
the engine brake is activated. In this situation, the
engine cannot be started with manual start up and
electric start.
Model 546, 546R, 546HR:
Pull out starter rope until resistance is felt - then
pull rapidly and with force.
Electrical Starter (546RS):
Put the ignition key in the ignition (4) on the throttle
lever and turn 1/4 clock-wise.
Mowing hints
9. Mowing hints
When mowing, please observe the safety
recommendations which are part of this owners
Important Note: The time and duration
when lawn mowers can be operated may be
subject to local ordinances. These ordinances
usually vary from location to location.
Noise is damaging. During extended
mowing, we recommend wearing protective head
gear to avoid possible hearing loss.
Before mowing, search the lawn and carefully
remove any debris (stones, shards, metal objects,
twigs, etc.). Leaves, cuttings, etc. do not need to
be removed prior to mowing, but can be picked up
with the grass catcher.
Note: If, on account of the growth pattern, the full
engine power is not required, you can select the
Eco position (“Öko”) between max. and min. on
the throttle control (Fig. 5) to protect the
9.1 Mowing with Grass catching device
Short and dry grass can be easily blown in the
grass catching device (6). This is made possible
by blower-supported grass ejection (turbo effect).
Fig. 6
The shorter the cuttings, the better the grass
catcher handles them;
- excessively long or wet grass could possibly
clog-up the catcher or slow down the pick-up.
In case of long grass, therefore, first cut with a
higher setting in one direction (with generous
overlap) and then across the first pattern with a
lower or the standard cutting height (Fig. 6).
Grass height, density and grass dampness
determine cutting results. Grass that is dry and not
too long assures best cutting results. Wet grass
may be cut and collected; however, the cutting
results and the collection outcome are affected. A
sharp blade is essential for best cutting results. A
dull blade (grass stems become ragged during
cutting and the lawn turns yellow) has to be
resharpened (see chapter „Blade“).
9.2 Lawn Care
If possible, mow only when the lawn is dry and
when the ground is dry. The lawn mower‘s wheels
press into the wet ground and leave compression
A lawn looks better and appears more uniform if
cut often. Frequent cutting allows the lawn to
become healthy since the growth goes into the
Short cuttings up to 1 cm (approx. 1/2 inch) may be
left on the ground, longer cuttings need to be
collected with the grass catching device. At Spring
time, the first mowing should take place approx. 2
to 3 weeks before the grass grows at its usual
level. In order to achieve early greening of the
lawn, cut only approx. 1.5 cm (3/4 inch) of the
grass. Check lawn for foreign objects (rocks, glass,
metal pieces etc.) prior to mowing lawn. The grass
catching device can be used for any additional
clean-up (leaves etc.).
Newly seeded or thin lawns must not be cut too
short (leave 3 - 4 cm) (1 - 1 1/2 inches). Let the
grass remain at that length for 4 to 5 weeks, so that
the lawn increases in width and density.
Attention: SOLO Lawn mowers with rear eject are
especially suited for the collection of leaves.
However, this use is only permitted on lawns
where all foreign objects, such as stones,
shards, metal objects, twigs, etc. have first
been carefully removed. Leaf collection on solid
ground (for example, roads or walk-ways) is
prohibited due to inherent safety risks.
For leaf collection, the cutting height is to be set to
the middle or to the highest setting.
Maintenance and Care
10. Maintenance and Care
For your own safety, remove the spark
plug cap from the spark plug prior to any
maintenance work or cleaning (12).
Any maintenance and care that go
beyond the described explanations need
to be left to an authorized Service Center.
10.2 Wheel axles and wheel hubs
Fig. 8
10.1 Cleaning the Mower
After each use, the mower needs to be thoroughly
cleaned. Special attention needs to be given to the
lower side, the blade and the cutting area circle.
Tip: To enable the lawnmower to be maintained
and cleaned with an empty fuel tank, fill only
enough fuel for the mowing job in hand. That way,
the tank can be quickly emptied after mowing has
been completed.
Fig. 7
Wheel axles and wheel hubs are to be lubricated
occasionally (at least once a year). Remove wheel
cap, release screw and remove wheel. During
disassembly observe the sequence for the
reassembly of the parts. We recommend SOLO
bearing grease,
part no. 00 83 175.
Maintenance of the rear wheel-self-propelled drive
Fig. 9
After releasing locking screws (8), the mower can
be raised onto its rear wheels and be supported on
the lower handle. First pull the spark plug cap. The
fuel tank should be empty, if possible, to prevent
fuel spilling from the fuel tank cap. Catch any fuel
running out of the carburettor with a suitable rag.
Dirt and grass debris is removed easily
immediately after mowing. Imbedded grass debris
and dirt on the mower deck‘s lower section
interrupt the grass collection and affect cutting
results. Imbedded dirt on the blade and on the
blower wheel lead to imbalance and consequently
to vibration. Check also for cleanliness of the duct.
The ejection air duct can be cleaned with a small
stick or with a screw driver.
Do not spray the mower with a hose or high
pressure cleaning hose. The engine has to
remain dry. The outer deck parts can simply be
kept clean by wiping the unit off with a rag. Strong
cleaning agents of any kind are not to be used.
• After removing wheel caps and loosening
fastening screws, remove drive wheels.
• Remove grass debris and dirt from all drive
wheel areas.
Attention: Do not remove neutral gear pinions
from the gear shaft; however, check if they turn
slightly counter-clockwise to the drive direction.
• Lightly lubricate the two pinions (free wheel and
plastic pinion) with water-repellent grease which
is compatible with plastic, e.g. SOLO bearing
lubricant, part no. 00 83 175.
• Fill the space inside the drive wheel between
both taper bearings with the same or a
compatible grease.
• Also lubricate the wheel axles with grease.
• When refitting the drive wheel, ensure that both
pinions engage with each other; slightly turn the
wheel on its axle, if required.
Maintenance and Care
10.3 Height adjustment
10.5 Oil level check
Before storing your lawnmower out of season
clean and lubricate the wheel adjuster spindle with
grease (this procedure is necessary at least
For this, set the wheel adjuster to its highest
position (max)
- clean and lubricate the exposed part of the
spindle with grease
- then set the wheel adjuster to its lowest position
- clean and lubricate the remaining spindle with
grease. For this, we recommend SOLO bearing
grease, part no. 00 83 175.
Attention: The engine oil affects the lawn mower‘s
efficiency and life span. Never operate the engine
without oil or with little oil. Major engine damage
can occur. The optimum viscosity depends on
where the lawn mower is used (air temperature
and altitude) and can be found in the engine
owners manual.
Checking Oil level:
10.4 Drive belt
Tensioning the drive belt
Fig. 10
Observe the notes and instructions in the typespeci.c engine operating instructions.
Fig. 11
• Place lawn mower
horizontally with all
wheels on the ground.
• Turn oil tank cap
(14), and remove. Wipe
off dipstick.
• Place dipstick back into
filler pipe.
Remove the lid from the battery/gearbox chamber
(15) after releasing both screws. Undo the fixing
screw (C) of the tensioning lever. Tension the
drive belt by moving the tensioning lever (in the
direction of the arrow).
Note: Check the belt tension every 20 hours or at
least once per mowing season.
The belt is correctly tensioned of the centre can be
deflected by approx. its own thickness.
Changing the drive belt
• Position the lawn mower on its handle and
discharge deflector (Fig. 7). First pull the spark
plug cap and ensure that the fuel tank is empty.
• First remove the blade and impeller, then the
old drive belt.
• Position the new drive belt from below onto belt
pulley A and insert to the rear into the mower
• Reposition the mower on its wheels.
• Position the drive belt onto pulley B on the
gearbox side.
• Tighten V-belt as described above.
• Screw on cap tightly.
• Assemble blower wheel and blade. Observe
sequence of assembly parts and observe the
blade‘s torque. (Fig. 12).
• Remove dipstick, hold horizontally and read oil
level. Oil level has to be between the
"MAXIMUM" and "MINIMUM" markings.
Changing Oil (Briggs&Stratton 4-cycle engine)
The engine oil may be drained via the oil drain
screw or the oil filler opening. Blade and blower
wheel need to be removed to reach the oil drain
screw (illustration 11). Observe especially the
service instructions in the separate engine owners
For the oil change with the HONDA OHC
Engine, the used oil is removed by suction
wich should only be done by a specialist
When draining via oil filler opening (14): Tilt the
warm mower (with fuel tank empty and closed oil
filler ) slowly over the side of the filler opening.
Remove oil filler cap and catch old oil in a
container. Wait several minutes until oil is drained.
Dispose off the old oil in accordance with local
After changing oil, always wash hands with a
scouring agent, soap and water.
Attention: Never simply throw away used engine
oil and gear lubricant (environmental protection).
Collect used oil in authorized containers and
submit to the proper recycling facility.
Gearbox (546R / 546HR / 546RS)
The gear is equipped with a special permanent oil
and operates completely maintenance-free.
Technical faults that cannot be resolved by
adjusting the Bowden throttle cable are only to be
corrected by an authorized Service Center.
Maintenance and Care
10.6 Mowing Blade
Special tools, such as a torque wrench for
example, are required to mount the blade to
the mower. For safety reasons we recommend
that the mowing blade is sharpened, balanced and
re-fitted by an authorized specialist workshop only.
The following notes are therefore only intended for
specialist repair shops.
To obtain best mowing results we recommend to
have the blade sharpened / balanced or at least
once every year.
Replacement of Blade
Proper gloves are to be worn when
replacing the blade. The spark plug
cap has to be removed prior to any
Damaged Blade
The engine needs to be shut off and the spark plug
cap has to be removed if the blade has come in
contact with a foreign object or other obstacle.
After the blade stops, tilt the mower and check the
blade for damage. Deformed or bent blades are not
to be re-aligned.
Damaged parts are to be replaced immediately. If
the mower has been driven over a notable
obstacle, the mower needs to be checked by an
authorized Service Center. Prior to use make
certain that blade and blade fastening parts are not
damaged. If necessary, parts need to be checked
or replaced. Never operate mower with an
unbalanced blade - this would cause vibration and
additional damage.
Sharpening of Blade
Fig. 13
Fig. 12
Attention: The blade may be sharpened with a
metal file; however, we recommend that
resharpening/sanding is done by an authorized
Service Center who will pay attention that the same
amount is sanded off on each side to avoid any
The cutting edge of the blade is only be resanded
up to the imprinted markings.
10.7 Air filter Maintenance
When replacing any blade parts only SOLO spare
parts are to be used. The identification No. on the
blade has to agree with the Order No. for the
replacement. Never install a different type of
Use the holding pin as a blocking device for the
blade. The blade fastening screw has a regular
right-handed thread. To remove the screw we
recommend using a socket wrench 21 mm (spark
plug wrench) or hex. wrench 8 mm, 5/16“. At reassembly of the overload clutch be sure and
observe the sequence in which these parts where
previously assembled. The blade screw is to be
tightened with the specified torque of 45Nm
Attention: Dirty air filters reduce the engine‘s
efficiency, the carburetor does not receive
sufficient air flow. Routine inspection, especially in
dusty conditions, is essential.
Attention: Never clean air filter parts with gasoline
or flammable solvents. Danger of fire or explosion!
Observe all instructions in the respective engine
owners manual.
Maintenance and Care
10.8 Possible faults and troubleshooting
Possible Cause
Mower runs
rough, vibrates
• Loose screws on engine or fastening screws
• Blade fastening loose
• Blade not balanced or damaged
• Overload clutch worn
• Tighten screws
Engine does not
• Is brake lever (1) pushed against handle?
• Is the throttle lever in the correct position?
(Model 546HR)
• Is the Bowden cable / the engine brake
correctly set?
• Spark plug or spark plug cap defect
• Fuel tank empty
• Push brake lever
• Select correct setting
• Air filter dirty
• Gas Bowden cable bent
• Spark plug sooty
• Clean or replace air filter
• Adjust Gas B. cable or replace
• Replace spark plug
Engine runs
Starter rope back- • Blade fastening or overload clutch loose
• Blade is dull
• Check blade fastening
• Balance blade or replace
• If needed, replace disks (in pairs)
• Check if setting is correct
• Clean or replace spark plug
• Refuel
• Check blade fastening
Lawn turns
yellow, cutting
• Cutting set too high
• RPMs too low
• RPMs too low
• Sharpen blade
• Adjust cutting height
• Set throttle lever on high
Mower collects
• Cutting height set too low when grass is too
• Blade worn out
• Lining of catching device clogged
• Gear lever not pulled
• Set throttle lever on high
• Bowden cable bent or obstructed
drive wheel does • V-belt tension loose
not run
• Gear lever not released
Drive mower
cannot be pulled
• Bowden cable bent or obstructed
• Drive wheels dirty inside or not lubricated
• Adjust cutting height
• Replace blade
• Clean or replace catching device
• Pull gear lever to handle
• Adjust Bowden cable
• Adjust V-belt tension
• Release gear lever
• Adjust Bowden cable
• Clean and lubricate wheels
Guarantee ; Parts subject to wear and tear
The manufacturer guarantees problem free quality
and will cover the cost of replacing parts which are
found to be faulty in material or show
manufacturing defects within the prescribed
guarantee period after the date of purchase.
Please note that specific guarantee conditions
may differ from country to country. When in doubt,
please ask the vendor of the goods. The vendor of
the product is responsible for guarantee
We hope you will understand that we cannot be
liable for damage resulting from these causes:
• Non-compliance with operating instructions.
• Neglecting required maintenance and repair
• Damage caused by improper carburettor
• Wear from normal use.
• Obvious overload by continuously exceeding
the upper performance limit of the product.
• Using non-approved tools.
• Use of force, improper treatment, misuse and
• Damage from excessive heat due to dirt build
up around the cooling fan housing.
• Attempted adjustments and repairs by nonqualified persons.
• Use of unsuitable spare parts or non-original
parts if such parts are the cause of the
• Use of unsuitable or stale fuel.
• Damage caused by using the product in the
hire or rental industry.
Replacement parts
Dependable operation and the safety of your
device also depend on the quality of the
replacement parts that you use. Use only original
SOLO replacement parts.
Only original parts come from the production of the
device and thus guarantee the highest possible
material quality, dimensional accuracy, function,
and safety. Original replacement parts and
accessory parts are available from your dealer. He
also maintains the requisite replacement part lists
to determine the required replacement part
numbers, and he is constantly provided with
information concerning detail improvements and
innovations in the replacement part offering.
Please note as well that guarantee performances
from SOLO are not possible if parts other than
SOLO original parts are used.
Parts subject to wear and tear
Various parts are subject to application-specific
wear or to normal wear and must be replaced in
good time if necessary. The following parts are
subject to normal wear and are not covered by the
manufacturers guarantee:
Blade and blade fixing
Friction pads
Air filter
Spark plug
Fluids, such as engine and gearbox oil
Drive belts and freewheel 5038437 / 5038438
on lawnmowers with self-drive
Normal cleaning, adjustments or maintenance jobs
cannot be claimed as part of the guarantee.
All guarantee work must be carried out by a
service centre authorized by the manufacturer.
Maintenance and repair
Maintenance and repair of modern motorized
devices, as well as their safety-relevant
assemblies, require qualified, specialized training
and a workshop equipped with special tools and
test devices.
Thus SOLO recommends that you have a
specialized SOLO workshop carry out all work that
is not described in these operating instructions.
Your SOLO specialist has the required training,
experience, and equipment at his disposal to
provide you with the most cost-effective solution
and can help you in many ways with advice and
In conformance with the product liability law we
want to clearly point out that we are not liable for
any damages which may occur due to improper
handling, or repair. Furthermore, we are not
responsible for any damage that may occur if
replacement parts other than SOLO replacement
parts, or parts that were not authorized by SOLO,
have been used. In addition we are not liable for
any damage that may occur if repair work was
performed by any source other than the Customer
Service or an authorized Service Center. This
liability exclusion applies also to accessories and
supplemental parts.
Made in Germany
Postfach 60 01 52
D 71050 Sindelfingen
Tel. 07031-301-0
Fax 07031-301-130
P.O.Box 60 01 52
D 71050 Sindelfingen
Fax +49-7031-301-149
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