MTD 11A-545D034 User Manual

Operator’s Manual

21” Rear & Side

Discharge

Mulching Mower

Model Number

11A-545D034

IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY

Warning:

covered, brush-covered or grass-covered land unless the engine’s exhaust system is equipped with a spark arrester meeting applicable local or state laws (if any). If a spark arrester is used, it should be maintained in effective working order by the operator. In the State of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. A spark arrester for the muffler is available through your nearest engine authorized service dealer or contact the service department, P.O. Box 361131 Cleveland, Ohio 44136-0019.

This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-

MTD LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019

PRINTED IN U.S.A.

FORM NO.

769-00584.fm (12/02)

TABLE OF CONTENTS

Content Page

Important Safe Operation Practices...................................................................3

Slope Gauge...................................................................................................... 6

Assembling Your Lawn Mower........................................................................... 7

Know Your Lawn Mower .................................................................................... 9

Operating Your Lawn Mower ............................................................................. 10

Making Adjustments ..........................................................................................11

Maintaining Your Lawn Mower........................................................................... 12

Troubleshooting ................................................................................................. 15

Parts List............................................................................................................ 16

FINDING MODEL NUMBER

This Operator’s Manual is an important part of your new lawn mower. It will help you assemble, prepare and maintain the unit for best performance. Please read and understand what it says.

Before you start assembling your new equipment, please locate the model plate on the equipment and copy the information from it in the space provided below. The information on the model plate is very important if you need help from our Customer Support Department or an authorized dealer.

• You can locate the model number by standing at the operating position and looking down at the rear of the mower deck. A sample model plate is explained below. For future reference, please copy the model number and the serial number of the equipment in the space below.

(Model Number)

Copy the model number here:

Copy the serial number here:

www.RyobiOutdoor.com

(Serial Number)

MTD LLC P. O. BOX 361131 CLEVELAND, OH 44136

330-558-7210 800-345-8746

ENGINE INFORMATION

The engine manufacturer is responsible for all engine-related issues with regards to performance, powerrating, specifications, warranty and service. Please refer to the engine manufacturer’s Owner’s/Operator’s Manual packed separately with your unit for more information.

CALLING CUSTOMER SUPPORT

If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenance of this unit, please call the Customer Support Department.

Call 1- (330) 558-7210 or 1- (800)-345-TRIM (8746) to reach a Customer Support representative. Please have your unit’s model number and serial number ready when you call. See previous section to locate this information. You will be asked to enter the serial number in order to process your call.

For more details about your unit, visit our website at www.ryobioutdoor.com

SECTION 1: IMPORTANT SAFE OPERATION PRACTICES

WARNING:

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.

This symbol points out important safety instructions which, if not followed, could

WARNING: Engine Exhaust, some of its constituents, and certain vehicle

components contain or emit chemicals known to State of California to cause cancer and birth defects or other reproductive harm.

DANGER

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.

This machine was built to be operated according to the rules for safe operation in this

General Operation

1. Read this operator’s manual carefully in its entirety before attempting to assemble this machine. Read, understand, and follow all instructions on the machine and in the manual(s) before operation. Be completely familiar with the controls and the proper use of this machine before operating it. Keep this manual in a safe place for future and regular reference and for ordering replacement parts.

2. This machine is a precision piece of power equipment, not a plaything. Therefore, exercise extreme caution at all times. Your unit has been designed to perform one job: to mow grass. Do not use it for any other purpose.

3. Never allow children under 14 years old to operate this machine. Children 14 years old and over should read and understand the operation instructions and safety rules in this manual and should be trained and supervised by a parent. Only responsible individuals who are familiar with these rules of safe operation should be allowed to use this machine.

4. Thoroughly inspect the area where the equipment is to be used. Remove all stones, sticks, wire, bones, toys and other foreign objects which could be tripped over or picked up and thrown by the blade. Thrown objects can cause serious personal injury. Plan your mowing pattern to avoid discharge of material toward roads, sidewalks, bystanders and the like. Also, avoid discharging material against a wall or obstruction which may cause discharged material to ricochet back toward the operator.

5. To help avoid blade contact or a thrown object injury, stay in the operator zone behind the handles and keep children, bystanders, helpers and pets at least 75 feet from the mower while it is in operation. Stop machine if anyone enters the area.

6. Always wear safety glasses or safety goggles during operation and while performing an adjustment or repair to protect your eyes. Thrown objects which ricochet can cause serious injury to the eyes.

7. Wear sturdy, rough-soled work shoes and closefitting slacks and shirts. Shirts and pants that cover the arms and legs and steel-toed shoes are recommended. Never operate this machine in bare feet, sandals, slippery or light weight (e.g. canvas) shoes.

8. Do not put hands or feet near rotating parts or under the cutting deck. Contact with the blade can amputate hands and feet.

9. A missing or damaged discharge cover can cause blade contact or thrown object injuries.

10. Many injuries occur as a result of the mower being pulled over the foot during a fall caused by slipping or tripping. Do not hold on to the mower if you are falling; release the handle immediately.

11. Never pull the mower back toward you while you are walking. If you must back the mower away from a 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.

5. Mow only in daylight or in good artificial light. Walk, never run.

6. Stop the blade when crossing gravel drives, walks or roads.

7. If the equipment should start to vibrate abnormally, stop the engine and check immediately for the cause. Vibration is generally a warning of trouble.

8. Shut the engine off and wait until the blade comes to a complete stop before removing the grass catcher or unclogging the chute. The cutting blade

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.

9. Never operate mower without proper trail shield, discharge cover, grass catcher, blade control handle or other safety protective devices in place and working. Never operate mower with damaged safety devices. Failure to do so, can result in personal injury.

10. Muffler and engine become hot and can cause a burn. Do not touch.

11. Only use parts and accessories made for this machine by the manufacturer. Failure to do so, can result in personal injury.

12. If situations occur which are not covered in this manual, use care and good judgment. Contact your dealer for assistance. Telephone 1- (800)-345TRIM (8746) for the name of your nearest dealer.

Slope Operation

Slopes are a major factor related to slip and fall accidents which can result in severe injury. 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:

1. Mow across the face of slopes; never up and down.

Exercise extreme caution when changing direction on slopes.

2. Watch for holes, ruts, rocks, hidden objects, or

bumps which can cause you to slip or trip. Tall grass can hide obstacles.

3. Always be sure of your footing. A slip and fall can

cause serious personal injury. If you feel you are losing your balance, release the blade control handle immediately, and the blade will stop rotating within 3 seconds.

Do Not:

1. Do not mow near drop-offs, ditches or embankments,

you could lose your footing or balance.

2. Do not mow slopes greater than 15 degrees as

shown on the slope gauge.

3. Do not mow on wet grass. Unstable footing could

cause slipping.

Children

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the mower and the mowing activity. They do not understand the dangers. Never assume that children will remain where you last saw them.

1. Keep children out of the mowing area and under the watchful care of a responsible adult other than the operator.

2. Be alert and turn mower off if a child enters the area.

3. Before and while moving backwards, look behind and down for small children.

4. Use extreme care when approaching blind corners, doorways, shrubs, trees, or other objects that may obscure your vision of a child who may run into the mower.

5. Keep children away from hot or running engines. They can suffer burns from a hot muffler.

6. Never allow children under 14 years old to operate a power mower. Children 14 years old and over should read and understand the operation instructions and safety rules in this manual and should be trained and supervised by a parent.

Service

Safe Handling Of Gasoline:

1. To avoid personal injury or property damage use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive. Serious personal injury can occur when gasoline is spilled on yourself or your clothes which can ignite.

2. Wash your skin and change clothes immediately.

3. Use only an approved gasoline container.

4. Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before filling.

5. When practical, remove gas-powered equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment on a trailer with a portable container, rather than from a gasoline dispenser nozzle.

6. Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device.

7. Extinguish all cigarettes, cigars, pipes and other sources of ignition.

8. Never fuel machine indoors because flammable vapors will accumulate in the area.

9. Never remove gas cap or add fuel while the engine is hot or running. Allow engine to cool at least two minutes before refueling.

10. Never over fill fuel tank. Fill tank to no more than ½ inch below bottom of filler neck to provide space for fuel expansion.

11. Replace gasoline cap and tighten securely.

12. If gasoline is spilled, wipe it off the engine and equipment. Move unit to another area. Wait 5 minutes before starting the engine.

13. Never store the machine or fuel container inside where there is an open flame, spark or pilot light as on a water heater, space heater, furnace,clothes dryer or other gas appliances.

14. To reduce fire hazard, keep mower free of grass, leaves, or other debris build-up. Clean up oil or fuel spillage and remove any fuel soaked debris.

15. Allow a mower to cool at least 5 minutes before storing.

General Service:

1. Never run an engine indoors or in a poorly ventilated area. Engine exhaust contains carbon monoxide, an odorless and deadly gas.

2. Before cleaning, repairing, or inspecting, make certain the blade and all moving parts have stopped. Disconnect the spark plug wire and ground against the engine to prevent unintended starting.

3. Check the blade and engine mounting bolts at frequent intervals for proper tightness. Also, visually inspect blade for damage (e.g., bent, cracked, worn) Replace blade with the original equipment manufacture’s (O.E.M.) blade only, listed in this manual. “Use of parts which do not meet the original equipment specifications may lead to improper performance and compromise safety!”

4. Mower blades are sharp and can cut. Wrap the blade or wear gloves, and use extra caution when servicing them.

5. Keep all nuts, bolts, and screws tight to be sure the equipment is in safe working condition.

6. Never tamper with safety devices. Check their proper operation regularly.

7. After striking a foreign object, stop the engine, disconnect the spark plug wire and ground against the engine. Thoroughly inspect the mower for any damage. Repair the damage before starting and operating the mower.

8. Never attempt to make a wheel or cutting height adjustment while the engine is running.

9. Grass catcher components, discharge cover, and trail shield are subject to wear and damage which could expose moving parts or allow objects to be thrown. For safety protection, frequently check components and replace immediately with original equipment manufacturer’s (O.E.M.) parts only, listed in this manual. “Use of parts which do not meet the original equipment specifications may lead to improper performance and compromise safety!”

10. Do not change the engine governor setting or overspeed the engine. The governor controls the maximum safe operating speed of the engine.

11. Maintain or replace safety and instruction labels, as necessary.

12. Observe proper disposal laws and regulations. Improper disposal of fluids and materials can harm the environment.

WARNING - YOUR RESPONSIBILITY:

understand and follow the warnings and instructions in this manual and on the machine.

NOTE: Not all safety labels shown may apply to your lawn mower.

Restrict the use of this power machine to persons who read,

SECTION 2: SLOPE GAUGE

Use this page as a guide to determine slopes where you may not operate safely. Do not operate your lawn mower on such slopes.

Operate RIDING mowers up and down slopes, never across the face of slopes.

Operate WALK-BEHIND mowers across the face of slopes, never up and down slopes.

Do not mow on inclines with a slope in excess of 15 degrees (a rise of approximately 2-1/2 feet every 10 feet). A riding mower could

overturn and cause serious injury. If operating a walk-behind mower on such a slope, it is extremely difficult to maintain your footing

and you could slip, resulting in serious injury.

A CORNER OF A BUILDING

OR A FENCE POST

SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE

A POWER POLE

WARNING

15°

SECTION 3: ASSEMBLING YOUR LAWN MOWER

IMPORTANT:

in the engine. Be certain to service engine with gasoline and oil as instructed in the separate engine manual before operating your mower.

NOTE: Reference to right or left hand side of the mower is observed from the operating position.

This unit is shipped without gasoline or oil

Removing Unit From Carton

• Remove staples, break glue on top flaps, or cut tape at carton end and peel along top flap to open carton.

• Remove loose parts if included with unit (i.e., operator’s manual, etc.)

• Cut along corners, lay carton down flat, and remove packing material.

• Roll or slide unit out of carton and check carton thoroughly for loose parts.

Loose Parts in Carton

• Grass Bag

• Side Discharge Chute

• Rear Wheels

• Hardware Pack

Disconnecting Spark Plug Wire

Before setting up your lawn mower, disconnect the spark plug wire from the spark plug and ground against the engine. See Figure 1.

Bolt

Spark Plug Wire

Figure 2

• Remove the hairpin clips from the outer hole in the weld pins on the handle mounting brackets. Using a pair of pliers, squeeze one leg of the lower handle against the handle mounting bracket. Insert the hairpin clip into the inner hole on the weld pin. Repeat on the other side. See Figure 3.

• After moving the hairpin clip, insert the carriage bolt from hardware pack in the upper hole on the handle mounting bracket and secure with plastic wing nut from the hardware pack. Repeat on other side.

Handle Mounting Bracket

Carriage Bolt

Wing Nut

Insert Hairpin Clip

Spark

Plug Wire

Spark Plug

Figure 1

Setting Up Your Lawn Mower

Assembling Handle

• Lift up and pull back on the upper handle to raise the handle into the operating position. Make certain the lower handle is seated securely into the handle bracket assemblies. Tighten the wing nuts on each side of the handle (carriage bolts must be seated properly into the handle). See Figure 2.

NOTE: Your mower is shipped with the handle in the higher position. If you wish to lower the height of the handle, refer to the Adjustment Section at this time.

Hairpin Clip

Figure 3

• Fasten the cable to the lower handle with the two cable ties found on the lower handle. Pull the cable ties tight and trim off the excess. See Figure 4.

Cable Tie

Lower Handle

Figure 4

Weld Pin

Attaching Rear Wheels

• Remove hardware from hardware pack.

• Insert shoulder screw through wave washer, flat

washer, rear wheel, and spring washer.

• Secure shoulder screw with hardware to rear pivot bar. See Figure 5.

Spring Washer

Wave Washer

• Secure bag to frame by working the plastic channels on bag over frame as shown in Figure 7B. All of the plastic channels except the center top of the bag attach from the outside of bag. The center top of the bag attaches from inside the bag.

Plastic Channels

Frame

Hook

Shoulder Screw

Flat Washer

Rear Wheel

Figure 5

Attaching Starter Rope

• The rope guide is attached to the right side of upper handle. Loosen the wing nut which secures the rope guide. See Figure 6.

Starter Rope

Rope Guide

Upper Handle

Wing Nut

Lower Handle

Figure 6

• With the spark plug wire disconnected and grounded, hold the blade control handle against the upper handle, and pull the starter rope out of the engine. Release the blade control handle. Slip the starter rope into the rope guide. Tighten the wing nut.

Grass Catcher Assembly

NOTE: Make certain the grass bag is turned right side out before assembling (warning label will be on the outside).

Frame

Assembly

Bag

Plastic

Channels

Figure 7

Attaching Hardtop Cover

• Slide the hardtop cover under the grass catcher handle, positioning it so the handle rests snugly into the notch in the cover, and press the frame into the tabs at the back of the cover.

• Position the mounting bracket facing down between the front of the handle and the front of the hardtop cover so that the holes in the cover line up with the holes in the bracket. Insert the self tapping screws down through the hardtop cover and mounting bracket. See Figure 8.

Grass Catcher Handle

Self Tapping

Notch in Hardtop

Cover

Screws

1. Frame Assembly

2. Bag

3. Hardtop Cover*

4. Mounting Bracket *

5. Two self Tapping Screws* *Hardtop Cover only.

Assembling Soft Top Grass Catcher

• Place the bag over the frame (black plastic side is the bottom of bag). Slip the openings in the side of the plastic channels on the bag over the hooks on the grass catcher frame.

Mounting Bracket

Figure 8

Attaching Grass Catcher To Mower

• Lift the rear discharge door and place the grass catcher on the pivot rod. Let go of discharge door so that it rests on the grass catcher. See Figure 9.

Figure 9

IMPORTANT:

outside of the handle so they are not in the way when attaching the grass catcher.

Make sure cables are routed to the

WARNING: Never operate the mower unless the hooks on the grass catcher are firmly seated on the chute pivot rod, and the rear discharge door rests firmly against the top of the grass catcher.

Removing Grass Catcher

• Lift the rear discharge door on the mower, and lift the grass catcher up.

• Release the rear discharge door.

Converting To Side Discharge

• Your mower has been shipped as a mulcher. To convert it to a side-discharge mower, lift the mulching plug. Slide the two hooks on the side-discharge deflector under the hinge pin on the mulching plug assembly. Lower the mulching plug.See Figure 10.

Mulching Plug

Hinge Pin

Side Chute Deflector

Figure 10

• Do not remove the side mulching plug at any time, even when you are not mulching.

WARNING: Never operate the mower without the mulching cover, the grass catcher bag, or the discharge chute properly installed.

SECTION 4: KNOW YOUR LAWN MOWER

Read this operator’s manual and safety rules before operating your lawn mower. Compare the illustration in Figure 11 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 eyes, which can damage your eyes severely. Always wear safety glasses while operating the mower, or while performing any adjustments or repairs on it.

Grass Catcher

The grass catcher, located at the rear of the mower, is used to bag the grass clippings for disposal at another site. Once the bag is full, it has to be removed from the mower and emptied before any further mowing. See Figure 11.

Recoil Starter

Grass Catcher

Blade Control Handle

Cutting Height Adjustment Lever

Mulching Plug

Figure 11

Mulching Plug

The mulching plug is used only for mulching purposes. Instead of collecting the grass clippings in a grass catcher, some mower models have the option of recirculating the clippings back to the lawn. See Figure

11.

Recoil Starter

The recoil starter is attached to the right handle. Stand behind the unit and pull the recoil starter to start the unit. See Figure 11.

Cutting Height Adjustment Levers

These levers are located on each wheel and are used to adjust the cutting height. These levers have to be at the same relative position to ensure uniform cut.See Figure 11.

Blade Control Handle

The blade control handle is located on the upper handle of the mower. The blade control handle must be depressed in order to operate the unit. Release blade control handle to stop engine and blade. See Figure 11.

This blade control mechanism is a safety device. Never attempt to bypass its operations.

SECTION 5: OPERATING YOUR LAWN MOWER

WARNING: Keep hands and feet away from chute area on the cutting deck. The operation of any lawn mower can result in foreign objects being thrown into the eyes, which can result in severe eye damage. Always wear safety glasses or eye shields.

NOTE: For shipping purposes your mower is set with

the wheels in a low cutting height position. For best results raise the cutting position until it is determine which height is best for your lawn. See the Adjustment Section for details.

Gas and Oil Fill-Up

Service the engine with gasoline and oil as instructed in the separate engine manual packed with your mower. Read instructions carefully.

Never fill fuel tank indoors with engine running or until the engine has been allowed to cool for at least two minutes after running.

Starting Engine

• Attach spark plug wire to spark plug. Make certain the metal cap on the end of the spark plug is fastened securely over the metal tip on the spark plug.

• Prime engine as instructed in the separate engine manual packed with your unit.

• Your lawn mower may be equipped with a constant speed throttle, which is set at full throttle for best performance.

• Stand behind the mower and squeeze the blade control handle against the upper handle.

• Grasp recoil starter handle and pull rope out slowly until engine reaches the start of compression cycle (rope will pull slightly harder at this point). Let the rope rewind slowly. Pull rope with a rapid, continuous, full arm stroke. Keeping a firm grip on the starter handle, let the rope return to the starter slowly.

Using Your Lawn Mower

Be sure that the lawn is clear of stones, sticks, wire, or other objects which could damage the lawn mower or the engine. Such objects could be accidently thrown by the mower in any direction and cause serious personal injury to the operator and others.

For best results, do not cut wet grass because it tends to stick to the underside of the mower, preventing proper discharge of grass clippings, and could cause you to slip and fall. New grass, thick grass, or wet grass may require a narrower cut.

For a healthier lawn, never cut off more than one-third of the total length of the grass. Your lawn should be cut in the fall as long as there is growth. This mower is designed to be operated at full throttle to give you the best cut and do the most effective job of mowing or mulching.

SECTION 6: MAKING ADJUSTMENTS

WARNING: If you strike a foreign object, stop the engine. Remove wire from the spark plug, thoroughly inspect the mower for any damage, and repair the damage before restarting and operating the mower. Extensive vibration of the mower during operation is an indication of damage. The unit should be promptly inspected and repaired.

Mulching

For effective mulching, do not cut wet grass because it tends to stick to the underside of the deck, preventing proper mulching of grass clippings. New or thick grass may require a narrower cut. The ground speed should be adjusted to the condition of the lawn. If mowing has been delayed and the grass has been allowed to grow in excess of 4”, mulching is not recommended. Mow using the side discharge to reduce the grass height to 3 1/4” maximum before mulching.

WARNING: Do not at any time make any adjustments without first stopping engine and disconnecting spark plug wire.

Handle Height Adjustment

Your mower is shipped with the handle in the higher height position. To lower the height proceed as follows:

• Remove the starter rope from the rope guide.

• Remove the upper handle by removing the hand

knobs and carriage bolts. Lay the upper handle out of the way, being careful not to bend or kink the cables.

• Remove the hairpin clips from the weld pins on the handle brackets and remove the wing nuts and carriage bolts from the upper hole on the handle mounting bracket. Press out on the legs of the lower handle and remove lower handle from the mower.

• Turn lower handle around so the notch on the bottom of the lower handle is facing forward. See Figure 12.

• Reassemble, placing the bottom holes in the handle over the weld pins in the handle mounting bracket.

• Place the hairpin clips in the inner holes in the weld pins and insert the carriage bolts the upper hole on the handle mounting bracket and secure with plastic wing nuts.

• Reassemble the upper handle to the lower handle.

• Attach the starter rope as instructed in the

Assembly Section

Notch

Lower Handle

Figure 12

Cutting Height Adjustment

An adjusting plate and spring lever at each wheel position provides cutting height adjustment. Each adjusting plate has assorted height positions. When the spring lever is moved from one location to another the height of cut will be changed. Simply depress the lever towards wheel and move lever assembly to desired position. See Figure 13.

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