Troy-Bilt OG-4605 User manual

IMPORTANT: Read Safety Rules and Instructions Carefully
Owner’s Manual
¨SET-UP ¨OPERATION ¨MAINTENANCE
PRINTED IN U.S.A. OG-4605

2
CALLING CUSTOMER SUPPORT
•LOCATE YOUR MODEL NUMBER AND SERIAL NUMBER which appears on your unit
and record the information in the space provided below.
IMPORTANT: You must have these numbers, along with the date and proof of
purchase to receive warranty or service.
•If you are having difficulty assembling this product or if you have any questions regard-
ing the controls, operation or maintenance of this unit, please call an authorized dealer.
•Please have your model number and serial number ready when you call.
NOTE: Although both numbers are important, you will be asked to enter only
your serial number before your call can be processed.
This is where your model number will be,
record model number here:
This is where your serial number will be,
record serial number here:
TABLE OF CONTENTS
CALLING CUSTOMER SUPPORT .............................................2
TABLE OF CONTENTS .....................................................2
IMPORTANT SAFE OPERATION PRACTICES ....................................3
SLOPE GAUGE...........................................................6
UNPACKING.............................................................7
ASSEMBLY..............................................................7
CONTROLS .............................................................9
OPERATION ............................................................10
ADJUSTMENTS.........................................................12
LUBRICATION ..........................................................12
MAINTENANCE..........................................................12
OFF SEASON STORAGE INSTRUCTIONS......................................14
TROUBLE SHOOTING ....................................................15
REPLACEMENT PARTS/PIÈCES DÉTACHÉES...................................16
WARRANTY ............................................................21

GENERAL OPERATION
•Read, understand, and follow all instructions
on the machine and in the manual(s) before
attempting to assemble and operate. Keep
this manual in a safe place for future and
regular reference and for ordering replace-
ment parts.
•Be familiar with all controls and their proper
operation. Know how to stop the machine
and disengage them quickly.
•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 su-
pervised by a parent.
•Never allow adults to operate this machine
without proper instruction.
•To help avoid blade contact or a thrown ob-
ject injury, keep bystanders, helpers,
children and pets at least 75 feet from the
machine while it is in operation. Stop ma-
chine if anyone enters the area.
•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 dis-
charge of material toward roads, sidewalks,
bystanders and the like. Also, avoid dis-
charging material against a wall or
obstruction which may cause discharged
material to ricochet back toward the opera-
tor.
•Always wear safety glasses or safety gog-
gles during operation and while performing
an adjustment or repair to protect your eyes.
Thrown objects which ricochet can cause
serious injury to the eyes.
•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.
•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.
•Never pull the mower back toward you while
you are walking. If you must back the
mower away from a wall or obstruction first
look down and behind to avoid tripping and
then follow these steps:
a) Step back from the mower to fully extend
your arms.
b) Be sure you are well balanced with sure
footing.
c) Pull the mower back slowly, no more than
half way toward you.
d) Repeat these steps as needed.
•Do not operate the mower while under the
influence of alcohol or drugs.
•Do not put hands or feet near rotating parts
or under the cutting deck. Contact with the
blade can amputate hands and feet.
•A missing or damaged discharge cover can
cause blade contact or thrown object inju-
ries.
•Do not engage the self-propelled mecha-
nism on units so equipped while starting
engine.
•Never attempt to make a wheel or cutting
height adjustment while the engine is run-
ning.
•The blade control handle is a safety device.
Never attempt to bypass its operation.
Doing so makes the safety device inopera-
3
This unit has been inspected against the manufacturers quality check list. In case of a discrep-
ancy, please call us. We will make every effort to ship the part(s) by courier within one working
day of your call.
IMPORTANT SAFE OPERATION PRACTICES
WARNING: This symbol points out important safety instructions which, if not fol-
lowed, 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.
DANGER: This machine was built to be operated according to the rules for safe op-
eration 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.

tive and may result in personal injury
through contact with the rotating blade. The
blade control handle must operate easily in
both directions and automatically return to
the disengaged position when released.
•Never operate the mower in wet grass. Al-
ways be sure of your footing. A slip and fall
can cause serious personal injury. If you feel
you are losing your footing, release the
blade control handle immediately and the
blade will stop rotating within three seconds.
•Mow only in daylight or in good artificial
light. Walk, never run.
•Stop the blade when crossing gravel drives,
walks or roads.
•If the equipment should start to vibrate ab-
normally, stop the engine and check
immediately for the cause. Vibration is gen-
erally a warning of trouble.
•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 continues to rotate for a
few seconds after the engine is shut off.
Never place any part of the body in the
blade area until you are sure the blade has
stopped rotating.
•Never operate mower without proper trail
shield, discharge cover, grass catcher, blade
control handle or other safety protective de-
vices in place and working. Never operate
mower with damaged safety devices. Failure
to do so, can result in personal injury.
•Muffler and engine become hot and can
cause a burn. Do not touch.
•Only use parts and accessories made for
this machine by the manufacturer. Failure to
do so, can result in personal injury.
•If situations occur which are not covered in
this manual, use care and good judgment.
Contact your customer support department.
SLOPE OPERATION
Slopes are a major factor related to slip and
fall accidents which can result in severe in-
jury. Operation on slopes requires extra
caution. If you feel uneasy on a slope, do
not mow it. For your safety, use the slope
gauge included as part of this manual to
measure slopes before operating this unit on
a sloped or hilly area. If the slope is greater
than 15 degrees, do not mow it.
DO:
•Mow across the face of slopes; never up
and down. Exercise extreme caution when
changing direction on slopes. Watch for
holes, ruts, bumps, rocks, or other hidden
objects which can cause you to slip or trip.
Tall grass can hide obstacles. 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.
DO NOT:
•Do not mow near drop-offs, ditches or em-
bankments, you could lose your footing or
balance.
•Do not mow slopes greater than 15 degrees
as shown on the slope gauge.
•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 re-
main where you last saw them.
a) Keep children out of the mowing area
and under the watchful care of a respon-
sible adult other than the operator.
b) Be alert and turn mower off if a child en-
ters the area.
c) Before and while moving backwards, look
behind and down for small children.
d) Use extreme care when approaching
blind corners, doorways, shrubs, trees, or
other objects that may obscure your vi-
sion of a child who may run into the
mower.
e) Keep children away from hot or running
engines. They can suffer burns from a hot
muffler.
•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 su-
pervised by a parent.
SERVICE SAFE HANDLING OF GASOLINE:
•To avoid personal injury or property damage
use extreme care in handling gasoline. Gas-
oline is extremely flammable and the vapors
are explosive. Serious personal injury can
occur when gasoline is spilled on yourself or
4

your clothes which can ignite. Wash your
skin and change clothes immediately.
a) Use only an approved gasoline container.
b) 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.
c) When practical, remove gas-powered
equipment from the truck or trailer and
refuel it on the ground. If this is not possi-
ble, then refuel such equipment on a
trailer with a portable container, rather
than from a gasoline dispenser nozzle.
d) 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.
e) Extinguish all cigarettes, cigars, pipes
and other sources of ignition.
f) Never fuel machine indoors.
g) Never remove gas cap or add fuel while
the engine is hot or running. Allow en-
gine to cool at least two minutes before
refueling.
h) Never over fill fuel tank. Fill tank to no
more than ½ inch below bottom of filler
neck to provide space for fuel expansion.
i) Replace gasoline cap and tighten se-
curely.
j) If gasoline is spilled, wipe it off the engine
and equipment. Move unit to another
area. Wait 5 minutes before starting the
engine.
k) 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.
l) To reduce fire hazard, keep machine free
of grass, leaves, or other debris build-up.
Clean up oil or fuel spillage and remove
any fuel soaked debris.
m) Allow machine to cool at least 5 minutes
before storing.
GENERAL SERVICE:
•Never run an engine indoors or in a poorly
ventilated area. Engine exhaust contains car-
bon monoxide, an odorless and deadly gas.
•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 pre-
vent unintended starting.
•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 manufacturer’s
(O.E.M.) blade only, listed in this manual.
“Use of parts which do not meet the original
equipment specifications may lead to im-
proper performance and compromise
safety!”
•Mower blades are sharp and can cut. Wrap
the blade(s) or wear gloves, and use extra
caution when servicing them.
•Keep all nuts, bolts, and screws tight to be
sure the equipment is in safe working condi-
tion.
•Never tamper with safety devices. Check
their proper operation regularly.
•After striking a foreign object, stop the en-
gine, disconnect the spark plug wire and
ground against the engine. Thoroughly in-
spect the mower for any damage. Repair the
damage before starting and operating the
mower.
•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 equip-
ment manufacturer’s (O.E.M.) parts only,
listed in this manual. “Use of parts which do
not meet the original equipment specifica-
tions may lead to improper performance
and compromise safety!”
•Do not change the engine governor setting
or overspeed the engine. The governor con-
trols the maximum safe operating speed of
the engine.
•Maintain or replace safety and instruction la-
bels, as necessary.
•Observe proper disposal laws and regula-
tions. Improper disposal of fluids and
materials can harm the environment. SI-102
7.23.03
5

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SLOPE GAUGE
(Keep this sheet in a safe place for future reference.)
OWNER'S
MANUAL SAFETY LABEL WARNING - Your Responsibility:
Restrict the use of this power machine to persons who
read, understand and follow the warnings and instruc-
tions in this manual and on the machine.

It is suggested that this manual be read in its
entirety before attempting to assemble or
operate. Keep this manual in a safe place for
future reference and for ordering
replacement parts.
This unit is shipped WITHOUT GASOLINE
or OIL. After assembly, service engine with
gasoline and oil as instructed in the separate
engine manual packed with your unit.
NOTE: Reference to right or left hand
side of the mower is observed from the
operating position.
UNPACKING
REMOVING UNIT FROM CARTON
•Remove staples, break glue on top flaps, or
cut tape at carton end and peel along top
flap to open.
•Remove loose parts included with unit (i.e.,
operator’s manual, oil, etc.).
•Cut corners and lay carton down flat. Re-
move packing material.
•Roll or slide unit out of carton. Check carton
thoroughly for loose parts.
CAUTION: DO NOT BEND OR KINK
CABLES.
TOOLS REQUIRED
Pair of Pliers Funnel
ASSEMBLY
CAUTION: DISCONNECT SPARK
PLUG WIRE. IF THE WIRE IS NOT
EQUIPPED WITH A RUBBER BOOT,
SEE SEPARATE ENGINE MANUAL
FOR GROUNDING PROCEDURE.
•Remove grass bag from the unit and set it
out of the way. See Figure 1, step 1.
•Remove any packing material which may be
between the upper and lower handles for
shipping purposes.
•Raise the lower handle in the direction
shown in Figure 1, step 2 till it snaps into
place.
•Raise the upper handle in the direction
shown in Figure 1, step 3. Tighten the wing
nuts which are already on the handle. See
Figure 2.
•Pull the drive control handle all the way
back.
•While holding the drive control handle, hook
the “Z” end of the drive cable into the bot-
tom hole of the drive control handle from in-
side to outside. See Figure 3.
NOTE: Make certain the drive cable is
routed around the outside and above
the lower handle so it does not interfere
with attaching the grass bag.
•Attach drive cable to the lower handle with
one cable tie. Insert peg on cable tie into the
hole on the lower handle. Pull cable tie tight
and cut off the extra.
•For shipping purposes, the hairpin clip is
placed in the outer hole of the weld pin on
the lower handle. Remove the hairpin clip
from the outer hole of the weld pin. See Fig-
ure 4.
•Using a pair of pliers, insert the hairpin clip
into the inner hole on the weld pin. Repeat
on other side.
7
Figure 1
2Lift lower handle.
3Lift
upper
handle.
1Move
bag
away.
Figure 3
Drive
Control
Handle
Insert "Z"
fittiing
Figure 2
Large
Wing Nut Saddle
Washer
Carriage
Bolt

•Insert the carriage bolt, included in the
hardware pack, in the upper hole on the
handle mounting bracket (carriage bolt must
go to the inside of handle).See Figure 4. Se-
cure with one plastic wing nut, also included
in the hardware pack. Repeat on the other
side with remaining items from the hardware
pack.
ATTACHING DRIVE ADJUSTER BLOCK
•The drive adjuster block is attached to the
drive cable.
•Remove bolt attached to the lower right han-
dle.
•Align the drive adjuster block, curved side
against handle, with hole in handle.
•Secure drive adjuster block with bolt previ-
ously removed. See Figure 5.
ATTACHING STARTER ROPE
•The rope guide and wing nut are attached to
the starter rope, on top of the engine. Re-
move the wing nut from rope guide. Remove
the rope guide from the starter rope.
•With the spark plug wire disconnected and
grounded as instructed in the separate en-
gine manual, hold the blade control handle
against the upper handle, and pull the starter
rope out of the engine. Hold the rope guide
as shown so the opening in the rope guide
is toward the front of mower. Slip the rope
guide around the starter rope and into the
right side of lower handle using the hole
shown. Secure using the small wing nut. See
Figure 5.
•Make certain all nuts and bolts are tightened
securely.
ASSEMBLY OF GRASS CATCHER
NOTE: If your mower's grass catcher is
assembled, proceed to the next sec-
tion. If not, follow these steps.
Soft Grass Bag
NOTE: Make certain the grass bag is
turned right side out before assembling
(warning label will be on the outside).
•Place bag over frame (black plastic side is
the bottom of bag.) Insert the hooks on the
frame through the holes in the side plastic
channels of the bag. See Figure 6.
•Secure bag to frame by working the plastic
channels on bag over frame as shown in
Figure 6. All of the plastic channels except
center top of bag attach from the outside of
bag. Center top of bag attaches from the in-
side of bag.
ATTACHING GRASS CATCHER TO
MOWER
•Lift the rear discharge door on the mower,
and place the grass catcher on the pivot rod.
Let go of discharge door so that it rests on
the grass catcher. See Figure 7.
NOTE: Make certain cables are routed
to the outside of the handle so they are
not in the way when attaching the grass
catcher.
TO REMOVE THE GRASS CATCHER
•Lift the rear discharge door on the mower as
shown in Figure 7. Lift the grass catcher up
8
Figure 4
Carriage
Bolt
Wing Nut
Upper Hole
Place the hairpin clips in the inner hole.
Weld Pin
Lower Handle
Figure 5
Bolt
Drive Adjuster
Block
Starter
Handle
Rope Guide
Small Wing Nut
Figure 6
Hole in
Plastic
Channel
Plastic
Channels
Hook
Bag

and off the pivot bar. Release the rear dis-
charge door.
WARNING: Never operate the
mower unless the hooks on the
grass catcher are seated on the
pivot rod, and the rear discharge
door rests firmly against the top of
the grass catcher.
CONVERTING TO SIDE DISCHARGE
If your unit is equipped with a side discharge
deflector, you can convert to a side dis-
charge mower as follows:
•Remove the grass catcher as previously de-
scribed.
•On the side of the mower deck, lift the
hinged mulching plug. See Figure 8.
•Slide the two hooks on the side discharge
deflector under the hinge pin on the hinged
mulching plug assembly.
•Lower the hinged mulching plug.
NOTE: Do not remove the hinged mulch-
ing plug at any time, even when you are
not mulching.
WARNING: All mowers are equipped
with a rear protective guard. The guard
helps eliminate projectiles thrown by
the blade from injuring the operator.
DO NOT REMOVE THIS GUARD.
CONVERTING TO MULCHER
•Remove the grasscatcher.
•If the unit was set up for side discharge, lift
the hinged mulching plug on the side of the
deck and remove the side discharge chute.
Lower the hinged mulch plug. See Figure 8.
CAUTION: Do not run your lawn
mower without chute deflector,
mulching plug or an approved
grass catcher in place. The
deflector will deflect a projectile
thrown by the blade into the lawn.
FINAL ASSEMBLY
•Check all nuts and bolts for correct tight-
ness.
CONTROLS
Read this owner’s manual and safety rules
before operating your lawn mower. Compare
Figure 9 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 oper-
ator’s eyes thus causing severe eye
damage. Always wear safety
glasses while operating the mower,
or while performing any adjust-
ments or repairs on it.
Drive Control Handle
This mower is equipped with Smart Speed™
transmission which enables the drive control
handle to adjust the mowing speed automat-
ically with your walking. The drive control
handle is located on the upper handle. Push
the handle forward to engage drive, pull it
backwards to stop. The farther the handle is
pushed forward, the faster the mower will
propel.
Blade Control Handle
The blade control handle is located on the
upper handle of the mower. See Figure 9.
The blade control handle must be de-
pressed in order to operate the unit.
Release the blade control handle to stop the
engine and blade.
WARNING: The blade control han-
dle is a safety device. Never at-
tempt to bypass its operations.
9
Figure 8
Hinged Mulching Plug
Side
Chute
Deflector
Figure 7
Rear Discharge
Door
Grass
Catcher
Pivot Rod

Starter Rope
The starter rope is attached to the handle.
Stand behind the unit and pull the starter
rope to start the unit.
Throttle Control
The engine is equipped with a constant
speed throttle which is set at full throttle for
maximum engine and cutting performance.
Cutting Height Adjustment Lever
These levers are located on each wheel and
they are used to adjust the cutting height. All
four levers have to be at the same relative
position to ensure uniform cut.
OPERATION
Service the engine with gasoline and oil as
instructed in the separate engine manual
packed with your mower. Read instructions
carefully.
WARNING: Never fill fuel tank in-
doors, with engine running or until
the engine has been allowed to
cool for at least two minutes after
running.
BEFORE STARTING
•Attach spark plug wire to spark plug. If unit
is equipped with a rubber boot over the end
of the spark plug wire, make certain the
metal loop on the end of the spark plug wire
(inside the rubber boot) is fastened securely
over the metal tip on the spark plug. See
Figure 10.
TO START ENGINE AND ENGAGE BLADE
WARNING: Be sure no one other
than the operator is standing near
the lawn mower while starting en-
gine or operating mower.
WARNING: Never run engine in-
doors or in enclosed, poorly venti-
lated areas. Engine exhaust con-
tains carbon monoxide, an odorless
and deadly gas.
WARNING: Keep hands, feet, hair
and loose clothing away from any
moving parts on engine and lawn
mower.
•If your unit is equipped with a primer, prime
engine as instructed in the separate engine
manual packed with your unit.
•If your unit is equipped with a two speed
control on engine refer to separate engine
manual packed with your unit.
•Standing behind the mower, depress the
blade control handle and hold it against the
drive control handle. Make sure the drive
control handle is pulled all the way back.
WARNING: If the drive control han-
dle is not pulled all the way back,
the mower will propel forward when
started.
•Grasp the recoil starter handle and pull
slowly until resistance is felt, then pull rapidly
to start engine and avoid kickback. Return it
slowly to the rope guide bolt.
•After the engine starts, push the handle for-
ward to engage drive, pull it backwards to
stop. Release the drive clutch control to slow
down when negotiating an obstacle, making
a turn, or stopping. The farther the handle is
pushed forward, the faster the mower will
propel.
10
Figure 10
Metal
Loop
on Spark
Plug
Wire Rubber Boot
Figure 9 - The left rear wheel
has been left out of the picture for clarity
Recoil
Starter
Blade Control
Handle
Grass
Catcher
Mulching
Plug
Height
Adjustment
Lever
Drive Clutch
Control

NOTE: The blade control handle must
be depressed in order to operate the
unit. Release the blade control handle
to stop the engine and blade.
TO STOP ENGINE
•Release the blade control handle to stop the
engine and blade.
•Disconnect the spark plug wire as instructed
in the separate engine manual to prevent ac-
cidental starting while equipment is
unattended.
WARNING: The blade continues to
rotate for a few seconds after the
engine is shut off.
WARNING: If you strike a foreign ob-
ject, stop the engine. Remove wire
from spark plug, thoroughly inspect
the mower for any damage, and repair
the damage before restarting and op-
erating the mower. Extensive vibration
of the mower during operation is an
indication of damage. The unit should
be promptly inspected and repaired.
USING YOUR MULCHER (Optional)
Mulching mowers use a specially designed
blade to chop the grass clippings extra fine
and then blow them back down into the
lawn. The small clippings decompose
quickly becoming a natural fertilizer that re-
turns much of the needed nutrients to the
soil. Continuous mulching means continuous
free natural fertilization, no messy clippings
to worry about ever again and the end result
for you is a much greener healthier lawn.
WARNING: Your mower is designed
to cut normal residential grass of a
height no more than 10". Do not at-
tempt to mow through unusually
tall, dry grass (e.g., pasture) or
piles of dry leaves. Debris may
build up on the mower deck or con-
tact the engine exhaust presenting
a potential fire hazard.
FOR THE BEST RESULTS WHEN
MULCHING:
•Clear lawn of debris. Be sure that the lawn
is clear of stones, sticks, wire or other for-
eign objects which could damage the
lawnmower. Such objects could be acciden-
tally thrown out by the mower in any
direction and cause serious personal injury
to the operator and others as well as dam-
age to property and surrounding objects.
•Do not cut wet grass. For effective mulch-
ing do not cut wet grass because it tends to
stick to the underside of the deck preventing
proper mulching of the grass clippings.
•Cut no more than 1/3 the length of the
grass. The recommended cut for mulching
is 1/3 the length of the grass. Ground speed
will need to be adjusted so the clippings can
be dispersed evenly into the lawn. For espe-
cially heavy cutting in thick grass it may be
necessary to use one of the slowest speeds
in order to get a clean well mulched cut.
When mulching long grass you may have to
cut the lawn in two passes, lowering the
blade another 1/3 of the length for the sec-
ond cut and perhaps cutting in a different
pattern than was used the first time. Over-
lapping the cut a little on each pass will also
help to clean up any stray clippings left on
the lawn. The mower should always be oper-
ated at full throttle to get the best cut and
allow it to do the most effective job of mulch-
ing.
•Clean underside of deck. Be certain to
clean the underside of the cutting deck after
each use to avoid a build-up of grass, which
would prevent proper mulching.
•Mulching Leaves. The mulching of leaves
can also be beneficial to your lawn. When
mulching leaves make sure they are dry and
are not laying too thick on the lawn. Do not
wait for all the leaves to be off the trees be-
fore you mulch.
•It is recommended keeping driveways and
sidewalks on the operators right while mov-
ing. Continue mowing using this pattern,
having the left side of your lawnmower next
to the uncut grass. Mulching with the cutting
area of the mower on the lawn avoids grass
clippings in undesirable areas.
DECK
The underside of the mower deck should be
cleaned after each use to prevent a buildup of
grass clippings, leaves, dirt or other matter. If
this debris is allowed to accumulate, it will invite
rust and corrosion, and may prevent proper
mulching.
The deck may be cleaned by tilting the mower
and scraping clean with a suitable tool (make
certain the spark plug wire is disconnected).
NOTE: We do not recommend the use
of pressure washers or garden hose to
clean your unit. These may cause dam-
age to electric components, spindles,
pulleys, bearings, or the engine. The
use of water will result in shortened life
and reduce serviceability.
11

ADJUSTMENTS
CAUTION: DO NOT AT ANY TIME
MAKE ANY ADJUSTMENT TO
LAWNMOWER WITHOUT FIRST
STOPPING THE ENGINE AND
DISCONNECTING THE SPARK
PLUG WIRE
Adjusting Cutting Height
•Stop mower and disconnect spark plug ca-
ble before changing mower cutting height.
•The wheel adjusters give you nine (9) differ-
ent cutting positions.
Medium is the best for
most mowers.
•To change the height
of cut, squeeze ad-
juster lever toward the
wheel, moving up or
down to selected
height. See Figure 11.
NOTE: All wheels
must be in the same
height of cut.
•When cutting in heavy or moist grass, the
rear of lawnmower may be raised higher to
allow better discharge of the grass.
Adjusting Drive Clutch
The drive clutch adjustment wheel is located
on the lower right handle and is used to
tighten or loosen tension on the drive cable.
Adjust this cable if:
a) the mower does not propel itself; or
b) the wheels hesitate with the drive control
handle pushed forward.
•To adjust, rotate the adjustment wheel with
your fingers, see Figure 12. Turn the wheel
to the left to tighten the drive cable. Turn the
wheel to the right to loosen the drive cable.
LUBRICATION
CAUTION: DISCONNECT SPARK
PLUG WIRE BEFORE SERVICING
WHEELS - Lubricate the ball bearings (if so
equipped) in each wheel at least once a sea-
son with a light oil. Also, if the wheels are
removed for any reason, lubricate the sur-
face of the axle bolt and the inner surface of
the wheel with light oil. Engine oil may also
be used.
ENGINE - Follow engine manual for lubrica-
tion instructions.
BLADE CONTROL - Lubricate the pivot
points on the blade control handle and the
brake cable at least once a season with light
oil. The blade control must operate freely in
both directions.
DISCHARGE DOORS - The torsion springs
and pivot points should be lubricated period-
ically with light oil to prevent any rust or
binding. Door must work freely.
TRANSMISSION - The transmission is
pre-lubricated and sealed at the factory and
does not require lubrication on a regular ba-
sis as part of maintenance.
MAINTENANCE
For best results your blade should be sharp.
The blade may be resharpened by removing it
and either grinding or filing the cutting edge
keeping as close to the original bevel as possi-
ble.
Improper blade balance will result in excessive
vibration causing eventual damage to the en-
gine and mower. Be sure to carefully balance
blade after sharpening.
After prolonged use, especially in sandy soil
conditions, the blade will become worn and
lose some of the original shape. Cutting effi-
ciency will be reduced and the blade should be
replaced. Replace with an approved factory re-
placement blade only. Possible damage
resulting from blade unbalance condition is not
the responsibility of the manufacturer.
NOTE: Tip mower as specified in sep-
arate engine manual. If not specified
tip with carburetor up.
CUTTING BLADE
CAUTION: Cutting grass in sandy
soil condition causes abrasive wear
to the blade.
12
Figure 12
Drive Clutch
Adjustment
Figure 11

WARNING: When removing the cut-
ting blade for sharpening or replace-
ment, protect hands by using heavy
gloves or a rag to grasp the cutting
blade.
•Remove the bolt which hold the blade
adapter-pulley assembly to the engine crank-
shaft. Remove the pulley assembly and the
bell support from the crankshaft. See Figure
13.
•Remove the blade from the blade adaptor and
pulley.
Installing the blade
•Before reassembling the blade-pulley assem-
bly to the unit, lubricate the engine
crankshaft and the inner surface of the blade
adapter with light oil (or engine oil).
•Lubricating the bolt hole and hex bolt.
•Insert the hex bolt, earlier removed, through
the center holes on the blade bell support
and the blade adapter-pulley assembly re-
spectively.
•Install the blade assembly up on the crank-
shaft. Tighten the hex bolt to the torque
listed below.
IMPORTANT: The bolt, used to secure the
blade to the engine, is especially
heat-treated. Do not substitute. To order
replacement bolt, refer to the parts listed in
the middle of this manual.
Blade Mounting Torque
Center Bolt: 450 in. lbs. min., 600 in. lbs.
max.
To ensure safe operation of your unit, all
nuts and bolts must be checked periodically
for correct tightness.
ENGINE
Refer to the separate engine manual for engine
maintenance instructions.
Maintain engine oil as instructed in the sepa-
rate engine manual packed with your unit.
Read and follow instructions carefully.
Under normal conditions service air cleaner
as instructed in the separate engine manual
packed with your unit. Clean every few
hours under extremely dusty conditions.
Poor engine performance and flooding usu-
ally indicates that the air cleaner should be
serviced.
The spark plug should be cleaned and the
gap reset once a season. Spark plug replace-
ment is recommended at the start of each
mowing season; check engine manual for
correct plug type and gap specifications.
NOTE: This spark ignition system meets
all requirements of the Canadian Interfer-
ence-Causing Equipment Regulations.
Clean the engine regularly with a cloth or
brush. Keep the cooling system (blower hous-
ing area) clean to permit proper air circulation
which is essential to engine performance and
life. Be certain to remove all grass, dirt and
combustible debris from muffler area.
REAR FLAP REPLACEMENT
The rear flap is attached to the back of the
mower deck, and is designed to minimize the
possibility that objects will be thrown from the
rear of the mower toward the operator. If the
rear flap becomes damaged, replace as fol-
lows.
To remove the old rear flap, cut off the flat end
of the wire rod which secures it to the deck us-
ing a pair of side-cutters. Attach the new rear
flap using the new rod provided with the rear
flap, bending the ends of the rod over to secure.
13
Figure 13
Blade
Blade Bell
Support
Adapter-Pulley
Assembly
Hex Bolt

BELT REMOVAL AND REPLACEMENT
•Remove the two shoulder screws from on top of
the deck which secures the front drive cover to
the mower deck. See Figure 14.
•Remove the front drive cover from the unit by
lightly pressing inward on the sides of the front
drive cover. This will release the tabs that secure
the front drive cover to the height adjuster
brackets. See Figure 14.
•Remove the idler from idler bracket using
7/16” wrench and socket. See Figure 14.
•Remove the belt from the transmission. See
Figure 1.
•Remove the belt from the engine pulley and
around the blade. See Figure 15.
•Reassemble in reverse order with new belt.
NOTE: Begin idler reassembly by insert-
ing bolt up through the idler bracket
hole.
•Adjust the Drive Clutch as instructed in "Ad-
justing Drive Clutch" Section.
OFF SEASON STORAGE
INSTRUCTIONS
The following steps should be taken to pre-
pare lawn mower for storage.
•Clean and lubricate mower thoroughly as de-
scribed in the lubrication instructions.
•Refer to engine manual for correct engine
storage instructions.
•Coat mower’s cutting blade with chassis
grease to prevent rusting.
•Store mower in a dry, clean area.
NOTE: When storing any type of power
equipment in an unventilated or metal
storage shed, care should be taken to
rust-proof the equipment. Using a light
oil or silicone, coat the equipment, es-
pecially cables and all moving parts.
NOTE: Be careful not to bend or kink
cables.
NOTE: If the starter rope becomes dis-
connected from rope guide on handle,
disconnect and ground the spark plug
wire. Depress the blade control handle
and pull the starter rope out from en-
gine slowly. Slip the starter rope into
the rope guide bolt on handle.
14
Figure 15
Remove belt from around
pulley and blade
Engine
Pulley
Right
Front Left Front
Figure 15
Drive Belt
Belt Keeper
Lock nut
Idler Bracket
Idler
Shoulder
Screws
Spacer
Bolt
Front Drive Cover
Pulley

TROUBLE SHOOTING
PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION
Engine fails to start 1. Blade control handle disen-
gaged.
2. Spark plug wire disconnected.
3. Fuel tank empty, or stale fuel.
4. Blocked fuel line.
5. Faulty spark plug.
6. Engine flooded.
1. Engage blade control handle.
2. Connect spark plug wire.
3. Fill tank with clean, fresh gasoline.
4. Clean the fuel line.
5. Clean, adjust gap or replace.
6. Wait a few minutes to restart, but
do not prime.
Engine runs erratic 1. Spark plug wire loose.
2. Blocked fuel line or stale fuel.
3. Vent in gas plugged.
4. Water or dirt in fuel system.
5. Dirty air cleaner.
6. Carburetor out of adjustment.
1. Connect and tighten spark plug wire.
2. Clean the fuel line; fill the tank
with clean, fresh gasoline.
3. Clear vent.
4. Drain the fuel tank and carbure-
tor. Refill with fresh fuel.
5. Clean air cleaner.
6. Adjust carburetor.
Engine overheats 1. Engine oil level low.
2. Air flow restricted.
3. Carburetor not adjusted prop-
erly.
1. Fill crankcase with proper oil.
2. Remove blower housing and
clean.
3. Adjust carburetor.
Idles poorly 1. Spark plug fouled, faulty or gap
too wide.
2. Carburetor improperly adjusted.
3. Dirty air cleaner.
1. Reset gap to .030" or replace
spark plug.
2. Adjust carburetor.
3. Clean air cleaner.
Excessive vibration 1. Cutting blade loose or unbal-
anced.
2. Bent cutting blade.
1. Tighten blade and adapter. Bal-
ance blade.
2. Replace blade.
Mower will not mulch grass 1. Wet grass.
2. Excessively high grass.
3. Dull blade.
1. Do not mow when gras is set;
wait until later to cut.
2. Mow once at a high cutting
height, then mow again at de-
sired height or make a narrower
cutting path.
3. Sharpen or replace blade.
Uneven cut 1. Wheels not positioned correctly.
2. Dull blade.
1. Place all four wheels in same
hight position.
2. Sharpen or replace blade.
Wheels will not propel 1. Belt not installed properly.
2. Debris clogging drive operation.
1. Check belt for proper pulley in-
stallation and movement.
2. Clean out debris.
NOTE: For repairs beyond the minor adjustments listed above, contract your nearest authorized
service dealer.
15

16
51
78
31
58
56
55
59
57
18
72
52
57
26
26
26
26
43
28
68
25
26
3
11
4
5
224
37
34
76
38
32
33
40
60
73
43
12
61
54
65
47
46
77
45
67
39
41
31
29
28
35
30
69
23
48
53
31
81
66
64
63
62
9
10
36
44
53
16
22
79
84
1
3
14
20
19
19
19
49
7
82
13
15
42
8
17
85
19
6
21
27
80
71
Engine Shroud (not shown)
751B699869 with screw 710-1256/
Capots de moteur (non illustrée)
751B699869 avec vis 710-1256.
REPLACEMENT PARTS/PIÈCES DÉTACHÉES

REF PART
NO. NO.
N° DE N° DE
RÉF PIÈCE DESCRIPTION DESCRIPTION
1731-2647 Drive Control Handle Poignée de commande d’embrayage de
l’entraînement
2710-0599 Hex Wash S-Tapp Scr 1/4-20 x .50 Vis autotaraudeuse à rondelle
hex. 1/4-20 x 0,50
3736-0270 Cupped Washer .265 ID x Rondelle creuse 0,265 DI x 0,75 DE
.75 OD x .062 x 0,062
417032A Chute Hinge Charnière de déflecteur
5732-1014 Torsion Spring Ressort de torsion
6710-0809 Hex TT Scr 1/4-20 X 1.250 Vis autotaraudée 1/4-20 X 1,250
7747-2133A Blade Control Handle Poignée de commande de la lame
8749-1507 Upper Handle Guidon supérieur
9731-04177 Chute Deflector Déflecteur de la goulotte
10 687-02055 Complete Mulch Plug Plaque de déchiquetage complet
11 747-0710 Hinge Pin Axe de charnière
12 682-0015 Front Bearing Ass’y Roulement - avant
13 720-0279 Knob - ERS Guide 1/4-20 Bouton - 1/4-20
14 720-0284 Handle Knob Assembly Bouton
15 710-1205 Rope Guide Bolt Boulon de guidage de cordon
16 746-1114 Blade Control Cable Câble de commande de la lame
16 746-1141 Control Cable 58.25" Lg. Câble de la commande 58,25 po de lg.
17 710-0487 Carriage Bolt 5/16-18 x 2.0 Boulon ordinaire 5/16-18 x 2,0
18 787-01144A RH Handle Bracket Support de guidon CD
18 787-01143A LH Handle Bracket Support de guidon CG
19 726-0240 Cable Tie Attache câble
20 714-0104 Int. Cotter Pin .072 x 1.13" Lg. Goupille fendue int. 0,072 x 1,13 po de lg.
21 710-0654A Hex Wash HD Tap Scr 3/8-16 x .88 Vis autotaraudée 3/8-16 x 0,88
22 746-1250 Drive Cable Câble de la commande
23 664-04007 Grass Bag Sac à herbe
23 664-04011 Grass Bag (Troy-Bilt) Sac à herbe (Troy-Bilt)
24 710-1650 Self-tapping Scr., 5/16-18 x .875 Vis autotaraudeuse de 5/16-18 x 0,875 po
25 710-0286 Truss Mach Scr 1/4-20 x .50 Vis de renforcement à tête cintrée 1/4-20 x
0,50
26 710-04371 Hex Lock Screw 1/4-15 Vis à tête hex. 1/4-15
27 787-01278 21" Deck Plateau de coupe de 21 po
28 731-04150 Rear Baffle 21" Rear Discharge Déflecteur arrière 21 po éjection arrière
29 710-0216 Hex Cap Screw 3/8-16 x .75 Vis à chapeau à six pans de 3/8-16 x 0,75
30 732-04090A Torsion Spring RH Ressort de torsion CD
31 712-0431 Hex. Flanged L-Nut 3/8-16 Gr. F Contre-écrou à embase 3/8-16 Qual. F
32 731-05013 Transmission Cover (Black) Couvercle de la transmission (noir)
32 731-05020 Transmission Cover (Troy-Bilt) Couvercle de la transmission (Troy-Bilt)
33 782-5002B Front Baffle Déflecteur avant
34 754-0465 V-Belt Courroie trapézoïdale
35 736-0447 Wave Washer Rondelle ondulée
36 750-01165 Sleeve Spacer 10.1" Lg. Entretoise 10,10 po de lg.
37 748-04015A Blade Adapter w/Pulley Adaptateur de la lame avec poulie
38 742-0741 21" Mulching Blade Lame déchiquetage 21 po
39 736-0524B Blade Bell Support Support de la lame
40 687-02044 Height Adjuster Pivot Plate Ass'y Plaque de pivot - réglage de hauteur
41 710-1257 Hex Bolt 3/8-24 x 2.5" Lg. Boulon hex. 3/8-24 x 2,50 po de lg.
42 749-0907B Lower Handle Guidon inférieur
43 750-1166 Sleeve Spacer 2.1" Lg. Entretoise 2,10 po de lg.
44 732-04089A Torsion Spring LH Ressort de torsion CG
45 634-0190 Wheel Ass’y Complete 8 x 1.8 Ensemble de roue complet 8 x 1,80
45 734-04018A Wheel Ass'y 8 x 2.125, Ensemble de roue 8 x 2,125, pignon
Gear S-Wave
46 716-0865 Snap Ring Joint
47 717-1762 Spur Gear 14T RH Engrenage 14 dents droite
47 717-1761 Spur Gear 14T LH Engrenage 14 dents gauche
48 747-04080 Grass Bag Frame Bâti de sac à herbe
Continued on next page/Suite à la page prochaîne
17

REF PART
NO. NO.
N° DE N° DE
RÉF PIÈCE DESCRIPTION DESCRIPTION
49 736-0451 Saddle Wash. .320 ID x .937 OD Rondelle selle 0,320 DI x 0,937 DE
50 710-0606 Hex Scr 1/4-20 x 1.50 Vis à tête hexagonale 1/4-20 x 1,50
51 710-1652 Hex Wash Hd TT Scr. 1/4-20 x .625 Vis taraudée 1/4-20 x 0,625
52 687-02068 RH Handle Bracket Assembly Ensemble de support du guidon CD
52 687-02069 LH Handle Bracket Assembly Ensemble de support du guidon CG
53 715-0221 Pin Goupille
54 736-0474 Flat Washer 1.5 OD x .03 Rondelle plate 1,50 DE x 0,03
55 687-02071 Pivot Arm Assembly - RH Ensemble de bras de pivot - CD
55 687-02070 Pivot Arm Assembly - LH Ensemble de bras de pivot - CG
56 732-04175 Rear Spring Lever Levier de ressort arrière
57 720-0426 Height Adjuster Knob Bouton
58 738-0507B Shoulder Screw .50 Dia. Vis à épaulement 0,50 dia.
59 734-1987 Wheel Ass'y 8 x 1.8 Spoke Ensemble de roue 8 x 1,80 gris
Bar Grey
59 734-04033 Wheel Ass’y 8 x 2 Idle Ensemble de roue 8,0 x 2,0
S-Wave, Ball Brg. roulement à billes
60 782-0512A Height Adjuster Plate - RH Plaque de réglage de hauteur - CD
60 782-0511A Height Adjuster Plate - LH Plaque de réglage de hauteur - CG
61 732-0706 Spring Lever Front RH Levier de ressort avant - CD
61 732-0707 Spring Lever Front LH Levier de ressort avant - CG
62 732-0700 Wire Fil
63 731-04998 Trail Shield Abattant de protection arrière
64 747-04035 Pivot Rod Tige de pivot
65 716-0102 Snap Ring for 1.0" shaft Jonc d’arrêt pour arbre 1,0 PO
66 731-04134A Rear Discharge Door Porte d’éjection arrière
67 782-7551A Wheel Dust Cap Chapeau de moyeu
68 712-04064 Hex L-FlangeNut 1/4-20 Gr. F, Contre-écrou à embase 1/4-20
Nylon Qual. F, nylon
69 750-04162 Spacer .375 x .50 x 1.02" Lg. Entretoise 0,375 x 0,50 x 1,02 po de lg.
70 715-04011 Roll Pin Goupille
71 710-0703 Carriage Bolt 1/4-10 x .75 Boulon ordinaire 1/4-20 x 0,75
72 712-0397 Wing Nut Écrou à oreilles
73 618-04006 Transmission Assembly Ensemble de la transmission
74 732-1043 Belt Tension Spring Ressort de tension de la courroie
75 756-04017 Input Pulley Poulie
76 682-0512A RH Height Adjustment Assembly Ensemble de réglage de hauteur - CD
76 682-0511A LH Height Adjustment Assembly Ensemble de réglage de hauteur - CG
77 731-0981A Hub Cap Grey Radial Moyeu de chapeau - gris
78 736-0504 Wave Washer .51" ID Rondelle ondulée 0,51 DI
79 731-2646 Bail Stop Arrêt de la poignée de commande
80 782-9063 Engine Belt Keeper Bracket Support de la courroie
81 738-1002 Shoulder Scr. .375 x .25 AT 1/4-14 Vis à épaulement
82 726-0106 Speed Cap Nut Écrou rapide
83 728-0199 Rivet Rivet
84 731-2628A Handle Panel Panneau
85 747-2132A Control Rod Tige de commande
12AD466
12.16.04
18

19
Model/Modèle Shroud/Capot Hardware/Quincaillerie
12A-463E500 751A1432613 7510042823
12A-465D515 751A1433513 7510042823
12AD466A563 751B699869 710-1256
12A-558O552 751B281440 710-1256
12AD565C501 731-04525 7510042823
12AD569R565 751B281440 710-1256

20