Asus 136-480A User Manual
Owner's Operating
Service Instruction
Manual
• ASSEMBLY
lOtfc
Model Nos
136-480A
•OPERATION
• REPAIR PARTS
136-485A
MTD PRODUCTS INC
PRINTED IN U.S.A.
• 5389 tlEST 130th STREET •
P. 0. BOX 2741 CLEVELAND OHIO 44111
FORM NO. 770-6037
IMPORTANT
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, see operating section of this manuai for
proper fuel and amount.
SAFE OPERATION PRACTICES FOR RIDING VEHICLES
1. Know the controls and how to stop quickly—
READ THE OWNER’S MANUAL.
2. Do not allow children to operate vehicle. Do
not allow adults to operate it without proper
instruction.
3. Do not carry passengers. Keep children and
pets a safe distance away.
4. Clear work area of objects which might be
picked up and thrown.
5. Disengage all attachment clutches and shift
into neutral before attempting to start engine.
6. Disengage power to attachment(s) and stop
engine before leaving operator position.
7. Disengage power to attachment(s) and stop
engine before making any repairs or adjust
ments.
8. Disengage power to attachment(s) when
transporting or not in use.
9. Take all possible precautions when leaving
vehicle unattended such as disengaging
power-take-off, lowering attachments, shift
ing into neutral, setting parking brake,
stopping engine and removing key.
10. Do not stop or start suddenly when going
uphill or downhill. Mow up and down face of
steep slopes; never across the face.
11. Reduce speed on slopes and in sharp turns to
prevent tipping or loss of control. Exercise ex
treme caution when changing direction on
slopes.
12. Stay alert for holes in terrain and other hidden
hazards.
13. Use care when pulling loads or using heavy
equipment.
A. Use only approved drawbar hitch points.
B. Limit loads to those you can safely
control.
C. Do not turn sharply. Use care when
backing.
D. Use counterweight(s) or wheel weights
when suggested in owner’s manual.
14. Watch out for traffic when crossing or near
roadways.
15. When using any attachments never direct dis
charge of material toward bystanders nor
allow anyone near vehicle while in operation.
16. Handle gasoline with care—it is highly
flammable.
A. Use approved gasoline container.
B. Never remove cap or add gasoline to a run
ning or hot engine or fill fuel tank indoors.
Wipe up spilled gasoline.
C. Open doors if engine is run in garage—ex
haust fumes are dangerous. Do not run
engine indoors.
17. Keep the vehicle and attachments in good
operating condition, and keep safety devices
in place. Use guards as instructed in owner’s
manual.
18. Keep all nuts, bolts, and screws tight to be
sure the equipment is in safe working
condition.
19. Never store the equipment with gasoline in
the tank inside a building where fumes may
reach an open flame or spark. Allow engine to
cool before storing in any enclosure.
20. To reduce fire hazard keep engine free of
grass, leaves or excessive grease.
21. The vehicle and attachments should be
stopped and inspected for damage after
striking a foreign object, and the damage
should be repaired before restarting and
operating the equipment.
22. Do not change the engine governor settings or
overspeed the engine.
23. When using the vehicle with mower, proceed
as follows:
(1) Mow only in daylight or in good artificial
light.
(2) Never make a cutting height adjustment
while engine is running if operator must
dismount to do so.
(3) Shut engine off when removing grass
catcher and/or unclogging chute.
(4) Check blade mounting bolts for proper
tightness at frequent intervals.
24. Check grass catcher bags frequently for wear
or deterioration. Replace with new bags for
safety protection.
25. Look behind to make sure the area is clear
before placing the transmission in reverse and
backing up.
INDEX
Safe Operation Practices.....
Index......................................................................... 3
Assembly and Battery Instructions
Controis.....................................................................6
Operating Instructions.............................................9
Maintenance
Lubrication............................................................. 10
Adjustments...........................................................11
Belt Replacement
Off-Season Storage................................................15
Trouble Shooting Chart for Recoil Start
Trouble Shooting Chart for Electric Start
Schematic for Recoil Start Unit.............................19
Schematic for Electric Start Unit
GRASS CATCHER Model No. 196-015A is
available as optional equipment for the mowers
shown in this manual.
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2
4
10
13
16
17
20
\ warning )
The mower should not be operated
without the entire grass catcher or
chute deflector in place.
NOTE
Under normal usage bag material is
subject to wear, and should be
checked periodically. Be sure any
replacement bag complies with the
mower manufacturer’s recommen
dations.
For replacement bags, use only fac
tory authorized replacement bag No.
764-0121.
Differential Breakdown and Parts List
Deck Linkage
Transmission Breakdown......................................23
Transmission Parts List.........................................24
Wheel Chart.
Illustrated Parts for R.H. Side of Rider
Parts List for R.H. Side of Rider
Illustrated Parts for L.H. Side of Rider
Parts List for L.H. Side of Rider............................29
Illustrated Parts for Frame View
Parts List for Frame View
Illustrated Parts for Deck View
Parts List for Deck View
Parts Information....................................Back Cover
TIRE PRESSURE
FOR SHIPPING PURPOSES, THE TIRES ON
YOUR UNIT MAY BE OVER-INFLATED. TIRE
PRESSURE SHOULD BE REDUCED BEFORE
UNIT IS PUT INTO OPERATION. PRESSURE
SHOULD BE APPROXIMATELY 15 P.S.I. EQUAL
TIRE PRESSURE SHOULD BE MAINTAINED ON
ALL TIRES. MAXIMUM TIRE PRESSURE IS 30
P.S.I.
Reference to right-hand or left-hand
side of machine is from the driver’s
seat facing forward.
Lockwasher 1/2”
..........................................................
........................................................
...........
.............................
........................................
NOTE
Hex Nut
1/2—13
................
.25
................
..........
..................27
.................
...........................
...........................31
Wing Nut 1/4—20
21
22
26
28
30
32
33
IMPORTANT
After striking a foreign object, stop
the engine. Remove wire from spark
plug, thoroughly inspect the mower
for any damage, and repair the dam
age before restarting and operating
the mower.
The steering wheel and seat, with the necessary
hardware, are easily assembled to the machine.
On the electric starter models, the battery must be
activated and installed as outlined in this section.
D
Lock Washer 1 /4”
Hex Bolt
1/4—20x5/8
(ED
Hex Lock Nut
3/8—16 Belleville Washer 3/8”
FIGURE 1. HARDWARE SUPPLIED
¿D
Hex Nut
1/4—20
H
ASSEMBLY
Step 1. Remove the lawn mower and all parts
from the carton. Make certain that all
loose parts and literature have been
removed before the carton is discarded.
Step 2. Place steering wheel over steering shaft.
Step 3. Secure with Believille washer and hex
nut. See figure 2.
Step 4. Press the cap on the steering wheei by
hand. See figure 2.
Steering Wheel Cap—
NOTE
Check ALL nuts and bolts for cor
rect tightness.
BATTERY INFORMATION
FOR ELECTRIC START
MODELS
Hex Nut-
Belleville Washer ’
FIGURE 2. STEERING WHEEL ASSEMBLY
mounting bolt molded in the seat.
A. Select one of three hole locations on
seat spring.
B. Place seat on spring and secure with
lockwasher (A) and hex nut (B). See
figures 1 and3.
■G
■H
\ WARNING (
Battery acid must be handled with great care
A.
as it will blister the skin and damage clothing.
It is advisable to wear goggles, rubber gloves,
and a protective apron when working with it.
B.
Neutralize acid spilled on clothing with dilute
ammonia water or a water solution of baking
soda. If acid gets on clothes, dilute it with
clean water first, then neutralize.
C. If for any reason acid should be spattered in
the eyes, wash it out immediately with clean
cold water. Seek medical aid if discomfort
continues.
D. Since battery acid is corrosive to metals, do
not pour into any sink or drain. Rinse empty
theStep 5. Your molded seat comes with
electrolyte containers and mutilate before
discarding.
I DANGER \
BATTE-RIES CONTAIN SULFURIC
ACID AND MAY CONTAIN EXPLO
SIVE GASES (when electrolyte has
been added)
FIGURE 3. SEAT ASSEMBLY
A. Keep sparks, flame, cigarettes away.
B. Hydrogen gas is generated during charging
and discharging.
C. Ventilate when charging or using in enclosed
space.
D. When using a charger—to avoid sparks,
NEVER connect or disconnect charger clips to
battery while charger is turned on.
E. Always shield eyes, protect skin and clothing
when working near batteries.
ACTIVATING THE
BATTERY
1. Place battery to be filled on bench or
workbench. NEVER activate battery in unit.
Remove vent caps from all cells.
2. Fill each cell carefully using battery grade
1.250-1.265 specific gravity. Sulfuric acid to
be 3/8” above the top of the separators or to
split ring.
3-. Allow battery to set for 20 minutes to I/2 hour.
Add additional acid if necessary to bring it up
to the proper levei.
4. Repiace the vent caps.
5. The battery can now be charged after the 20
minutes setting period. Battery can be SLOW
CHARGED (DO NOT FAST CHARGE) at a
maximum bench rate of 4-5 amperes until the
specific gravity reading is 1.265-1.275. A
charging rate in excess of this will buckle and
warp the positive plates and perforate the
separators. If electrolyte bubbles violently
while charging, reduce charging rate until
excessive bubbling action subsides, then
continue charging until specific gravity is
reached.
CAUTION
A
After battery has been in service,
add only approved water. DO NOT
ADD ACID.
B. TO INSTALL BATTERY
To install the battery in this unit, refer to next
column.
C. MAINTENANCE
1. Check periodically (every two weeks or
before and after charging) to be sure elec
trolyte level is 9/16” above separator
plates. Add only distilled water or good
quality drinking water. NEVER add addi
tional acid or other chemicals to battery
after initial activation.
2. The battery should be checked with a
hydrometer after every 25 hours of
operation. If the specific gravity is less than
1.225 remove battery and recharge.
3. Coat the terminals and exposed wiring with
a thin coat of grease or petroleum jelly for
longer service and protection against
electrolyte corrosion.
4. The battery should be kept clean. Any
deposits of acid should be neutralized with
soda and water. Be careful not to get this
solution in the cells.
D. STORAGE
1. Charge battery using normal methods.
NEVER store discharged battery as it will
not recover.
2. Store in cold, dry place.
3. Recharge battery whenever the specific
gravity is less than 1.225 before returning to
service or every two months, whichever
comes first.
E.
COMMON CAUSES FOR BATTERY FAILURE
ARE:
1. Overcharging
2. Undercharging
3. Lack of water
4. Loose hold downs and/or corroded con
nections
5. Excessive loads
6. Battery electrolyte substitutes
7. Freezing of electrolyte
NOTE
THESE FAILURES DO NOT CON
STITUTE WARRANTY.
LIMITED WARRANTY
For ninety (90) days of original retail purchase, the
battery carries a limited warranty against faulty
material or workmanship by the battery manufac
turer.
INSTALLING THE
BATTERY
1. Open the hood of the riding mower.
2. Place the battery in the battery case with the
terminal to the front. See figure 4.
FIGURE 4.
3. Cut the black rubber tubing approximately 4
Inches long.
4. Push the rubber tubing into the manifold of
the battery and place the other end into the
drain tube. See figure 4.
Dov.n
Neg.
i . .. .■,<
FIGURES.
CONTROLS
The controls on both models may be considered
as the Drive Control and the Cutting Control as
follows:
a. Throttle Control. The throttle control is used to
regulate the engine speed and choke the engine.
The engine should be operated from % to full
throttle when operating the cutting deck or snow
thrower (optional). See figure 6.
NOTE
The vented battery allows any gases
or liquid from the battery to be car
ried to the rear of the mower through
the drain tube.
5. Hook the hold down rods under the battery
case and place the hold down over the
manifold of the battery as shown In figure 5.
6. Secure the hold down with the wing nuts.
7. Attach the positive cable (from the starter
solenoid) and the small wire (from the
ammeter) to the positive battery terminal with
the bolt, lockwasher and nut in the assembly
pack.
8. Attach the negative cable, grounded, to the
negative battery terminal with the bolt,
lockwasher and nut in the assembly pack.
FIGURE 6. CONTROLS
b. Gear Shift Lever. The gear shift lever is used to
shift into one of four Forward Gears, NEUTRAL or
REVERSE. See figures 6 and 7.
c. Brake. The brake pedal is located on the right
hand side of the mower and is operated by
depressing it with your right foot. See figure 8.
d. Brake Lock. The brake lock is located on the
right hand side of the mower. To lock the brake,
depress the brake pedal and lift up the lock
button. The pedal will stay depressed. To release,
depress the pedal. See figure 8.
e. Clutch Pedal. The clutch pedal is used to
disengage the drive mechanism. Depressing the
clutch pedal at any time will reduce mower speed.
If depressed all the way, it will stop the mower.
See figure 9.
f. Clutch Lockout. When the clutch pedal is
depressed all the way it can be locked by placing
the clutch lockout in the START position as
shown in figure 9. The clutch lockout must be in
this position before the engine will start.
g. Ammeter. (Electric Start Model Only.) The
ammeter registers the rate of battery charge or
discharge. The ammeter should register on the
plus ( + ) side when the engine is running in the
fast position until the battery is completely
charged. With a fully charged battery or with the
engine idling the ammeter will not show a charge.
See figure 10.
h. Light Switch. (Electric Start Only.) Pull the
light switch out to turn on the lights. The lights
will only operate when the engine is running. See
figure..
FIGURE 8. RIGHT HAND CONTROLS.
FIGURE 7. SHIFT PATTERN
FIGURE 9. LEFT HAND CONTROLS
Ammeter
• L * \
\ Gauge
Throttle ^ ,
Control Ignition Switch
’^¿iLift Disengagement
7 FIGURE 10. ELECTRIC START MODEL
' Lever ,
R«coil Sta^qr
iShoiWH taeWrtjc”
k ^ Ignition Switch
I. Cutting Controls. The cutting controls consist
of the height of cut stop and the wheel height
adjusters.
Height of Cut Stop. See figure 12. Lift the stop
and set it at the desired cutting height.
r
Height of Cut Stop
FIGURE 11. RECOIL START MODEL.
i. Ignition Switch. The ignition switch is iocated
on the right side of the dashboard.
Recoil Model. See figure 11. Turn the key to the
ON position when starting the engine. To stop the
engine turn the key to the left to the OFF position
and remove the key to prevent accidental starting.
Electric Start. See figure 10. Turn the key to the
START positon to start the engine. When the
engine is running, let the key return to the ON
position. To stop the engine, turn the key to the
left to the OFF position and remove it to prevent
accidental starting.
The engine will not start unless the
clutch lockout is in the START posi
tion and the lift lever is in the DIS
ENGAGED position.
j. Recoil Starter. The recoil starter is located on
the right side of the dashboard. The recoil starter
can either be pulled while seated on the rider or
pulled while standing behind the rider. The
ignition key must be on before the engine will
start. After the engine starts, the recoil starter
handle must be returned and locked into the
dashboard before the blades or clutch are
engaged. The engine will stop if you do not follow
these instructions. See figure 11.
FIGURE 12. HEIGHT OF CUT SETTINGS
Wheel Height Adjuster. See figure 13. Move the
lever towards the wheel and set it in the desired
cutting height.
The cutting height of the mower can be set in two
different ways; FULL FLOAT position where the
deck follows the contour of the ground, and the
SUSPENDED position where the deck hangs
from the frame of the rider. The suspended
position is normally used for cutting rough
uneven ground.
To set the cutting deck in the full float position,
set the wheel height adjusters in the desired
cutting height as indicated in figure 13. Set height
of cut stop in the 1 Vz position. See figure 12.
To set the cutting deck in the suspended position,
set the height of cut stop in the desired cutting
height and then set the deck wheel so they just
dearths ground.
k. Lift and Disengagement Lever. It is used to
raise the cutting deck. Pulling it all the way back
and locking it disengages the blades. The engine
will not start unless the lift and disengagement
lever is in the disengaged position. See figure 10
S FIGUREIS. WHEEL HEIGHT ADJUSTER
Parking Brake MUST be disengaged
before unit is put into motion.
Unit is equipped with separate brake
and ciutch pedals. To efficiently
stop, it is necessary to disengage
ciutch when applying brakes.
OPERATING
INSTRUCTIONS
STARTING THE ENGINE
Electric Start.
See figure 10. Turn the ignition key to
the START position. When the engine is
running, let the key return to the ON
position.
To stop either model, turn the key to the left to the
OFF position and remove the key to prevent
accidental starting.
A brief break-in period is essential
to ensure maximum engine and
mower life. This consists of running
the engine at half speed for a period
of time required to use one tank of
gasoline. It is also recommended to
change crankcase oil after the first 2
hours of operation.
Be sure to follow the instructions for the oil and
gasoline as described in the engine manual.
Step 1. Be sure the fuel shut-off valve is open.
See figure 14.
Step 2. Place the clutch lockout in the START
position. See figure 9.
Step 3. Place the lift and disengagement lever in
the DISENGAGED position. See figure
12.
FIGURE 14. FUEL SHUT-OFF VALVE
Step 4. Set the throttle control in the CHOKE
position. See figure 10.
Step 5. Recoil Starter.
a. Turn the ignition key to the ON
position. See figure 11.
b. Grasp the recoil starter, unlock it by
twisting it V4 turn and pull it out
sharply and hold it in the out position.
c. Slowly release the recoil starter and
lock it into the dashboard as shown in
figure 11.
STOPPING THE ENGINE
Turn the ignition key to the left to the OFF
position and remove the key to prevent accidental
starting.
OPERATING THE MOWER
Step 1. Set the desired cutting height.
Step 2. Start the engine as outlined on page 9.
Step 3. Select gear and shift.
As you become familiar with the op
eration of the mower you can move
the stop lever to a faster position.
Step 4. While holding down the clutch pedal,
move the clutch lockout lever forward.
Step 5. Put the gear shift lever into either
FORWARD or REVERSE.
'NOTE
DO NOT force the gear shift lever! If
the lever cannot be moved from
NEUTRAL to one of the drive posi
tions, release the clutch pedal slow
ly, depress it again, and then move
the gear shift lèveras required.
Step 6. Once the machine is in motion, remove
foot from the pedal. The mower will now
move ahead or to the rear, and the use of
the steering wheel will provide direction
al control.
step 7. The mower is brought to a stop by
pressing your right foot against the brake
pedal and your left foot against the
clutch pedal. The drive belt will be disen
gaged and the brake will be applied.
A
Gear changing should be done only
after the mower has been brought to
a full stop. If the mower Is not to be
used for a long period, place the
gear shift lever in NEUTRAL and
stop the engine. DO NOT leave the
machine on an incline.
OPERATING THE CUTTER BLADE
The cutting blades may be engaged while the
mower is moving or standing still. DO NOT en
gage the cuttting blades abruptly as the sudden
belt tension on the pulley may cause the engine to
stall.
CAUTION
After the first five hours of operating a new
engine, drain the oil (see figure 15) from the
crankcase while engine is still hot and refill
crankcase with new oil; thereafter change the oil
every 25 hours of operation. This procedure
ensures for minimum wear of engine parts and
provides for virtually trouble-free operation. To
change the oii, proceed as foliows:
Step 1. With the machine on level ground, place
a suitable metal container under the oil
drain plug, then remove the drain plug.
See figure 15.
Step 2. After the oil has been drained complete-
iy from the crankcase, replace the drain
plug and tighten.
Step 3. Refill crankcase with IVa pints of good
quality, type MS, Engine oil into the
crankcase. Summer use SAE 30; Winter
(Below 40°F) use SAE 5W-20 or SAE
low.
WARNING
t
When the blade drive is engaged,
keep feet and hands away from the
discharge opening and from the
blade.
To stop the blades, move the lift and
disengagement lever (figure 10) into the DISEN
GAGED position. This raises the deck and
disengages the blades.
NOTE
When the machine is used for other
than mowing operations the blade
drive should be disengaged.
MAINTENANCE
CRANKCASE OIL
To ensure maximum engine performance, perform
the following periodic maintenance:
Oil Check
Check the oil level in the crankcase before each
use of the machine and after every five hours of
operation. Oil should b.e kept between the add and
full marks on the dipstick.
LUBRICATION
Lubricate the wheel bearings (2 per wheel) and the
upper and lower spindle bearings with SAE 30 oil
once a season. See figure 16.
FIGUREIS.
10
The chain can be lubricated by wiping it with an
oily rag.
The differential and transmission are sealed at the
factory and require no further lubrication.
FIGURE 17. REAR AXLE ASSEMBLY
CHAIN ADJUSTMENT
To tighten the chain, loosen two locknuts on each
side of rear axie as shown in figure 17.
Tighten the adjusting nuts (figure 18) equally on
both sides. Tighten until the chain has Va inch
siack between the sprockets.
The adjusting nuts can be tightened individuaiiy
to aiign the axle.
Tighten the 4 locknuts after the adjustment is
made.
When assembling the air cleaner, make certain
the iip of the foam element extends over edge of
the air cleaner body. The foam element will form a
protective seal.
Step 1. Remove two screws and lift off complete
air cleaner assembly.
Step 2. Remove screen and spacers from foam
element.
Step 3. Remove foam element from air cleaner
body.
Step 4. a. Wash foam element in kerosene or
liquid detergent and water to remove
dirt.
b. Wrap foam in cloth and squeeze dry.
c. Saturate foam in SAE 30 engine oil,
then squeeze out excess oil.
d. Assemble parts, fasten to carburetor
with screw.
FIGURE 18. CHAIN ADJUSTMENT
AIR CLEANER
Under normal operating conditions, the air
cleaner, located on top of the carburetor, must be
serviced after every ten hours of use. Under
extremely dusty operating conditions the air
cleaner must be serviced after every hour of
operation. Refer to figure 19.
CLEANING ENGINE AND BLADE HOUSING
Any fuel or oil spilled on the machine should be
wiped off promptly. Grass, leaves, and other dirt
mustoot be left to accumulate around the cooling
fins of the engine or on any part of the machine.
Clean the underside of the blade housing after
each mowing.
BELTS
Check that belts are free of oil or dirt. Wipe the
belts periodically with a clean rag.
NOTE
Belt tension is automatically main
tained by the spring on the variable
speed bracket on the drive belts and
the belt tension on the deck belt is
maintained by the two deck springs.
11
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