MTD 440 THRU E459, 12A-459S762 Owner’s Manual
Operator's Manual
21" Rear-Discharge
Lawn Mower
Model Series
440 Thru E459
IMPORTANT: Read safety rules and instructions carefully before operating equipment.
"Warning: This unit is equipped with an intemaI combustion engine and should not be used on or near any unimproved forest-
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 C,ode). 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 368022 Cleveland, Ohio 44136-9722.
MTD PRODUCTS INC. P.O. BOX 368022 CLEVELAND, OHIO 44136-9722
ECO # 2844
PRINTED IN U.S.A. FORM NO. 770-10134B
(11/2000)
TABLEOFCONTENTS
Content Page
Important Safe Operation Practices ................................................................... 3
Slope Gauge ...................................................................................................... 6
Assembling Your Lawn Mower ........................................................................... 7
Know Your Lawn Mower .................................................................................... 11
Operating Your Lawn Mower ............................................................................. 12
Maintaining Your Lawn Mower ........................................................................... 13
Service ............................................................................................................... 14
Making Adjustments .......................................................................................... 16
Off- Season Storage .......................................................................................... 17
Troubleshooting ................................................................................................. 18
Parts List ............................................................................................... _............ 19
FINDINGMODELNUMBER
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 inthe 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 behind the unit in the operating position and looking
down at the rear of the 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.
r
(Model Number)
(Serial Number)
Copy the model number here:
Copy the serial number here:
MTD / .TDP.ooucTs,NC
111/ ,,
If you have difficulty assembling this product or have any questions regarding the controls, operation or
maintenance of this unit, please ca]] the Customer Support Department.
CLEVELAND, OHIO 44136
CALLINGCUSTOMERSUPPORT
Call 1- (330) 220-4MTD (4683) or 1- (800)-800-7310 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.
SECTION1: IMPORTANTSAFEOPERATIONPRACTICES
WARNING: This symbol points out important safety instructions which, if not followed, could endanger
the personal safety and/or property of yourself and others. Read and follow all instructions in this manual
before attempting to operate this machine. Failure to comply with these instructions may result in personal
injury. When you see this symbol--HEED ITS WARNING.
WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain or emit
chemicals known to State of California to cause cancer and birth defects or other reproductive harm.
WARNING: This machine was built to be operated according to the rules for safe operation 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.
GeneralOperation
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 unithas 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 safe operation rules should use this machine.
4. Thoroughly inspect the area where the equipment isto
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
bystanders, helpers, children and pets at least 75 feet
from the machine white 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 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.
8. Do not put hands or feet near rotating parts or under the
cuffing 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 _ result of the mower being puffed
over the foot during a f_LIIcaused by slipping or tripping.
Do not hold on to the mswer if you are falling; release the
handle immediately.
11. Never pull the mower back toward you while you are
walking. Ifyou must baok the mower away from a wall or
obstruction first look down and behind to avoid tdpping
and then follow these s!eps:
a. Step back from ':he 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.
12. Do not operate the mo\ver while under the influenoe of
alcohol ordrugs.
13. Do not engage the self-propelled mechanism on units
so equipped while starting engine.
14, The blade control handle is a safety device. Never
attempt to bypass itsoperation. Doing so makes the
safety device inoperative and may result in personal
injurythrough contact with the rotating blade. The blade
control handle must operate easily in both directions and
automatically return to the disengaged position when
released.
15. Never operate the mower in wet grass. Always be sure of
your footing. A slip and fall can cause serious personal
injury. Ifyou feel you are losing your footing, release the
blade control handle immediately and the blade will stop
rotating within three se_nds.
16. Mow in daylight or good artificial light.Walk, never run.
17. Stop the blade when crossing gravel drives, walkways
or roads.
18. ifthe equipment should statt to vibrate abnormally, stop
the engine and check immediately for the cause.
Vibration is generally awarning of trouble.
19. Shut the engine off and wait until the blade comes to a
complete stop before removing the grass catcher or
unclogging the chute. "_hecutting 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.
20. Never operate mower without proper trail shield,
discharge cover, grass catcher, blade control handle or
3
other safety protective devices inplace and working.
Never operate mower with damaged safety devices.
Failure to do so, can result in personal injury.
21. Muffler and engine become hot and can cause a burn. Do
not touch.
22. Only use parts and accessories made for this machine by
the original equipment manufacturer (O.EM). Failure to
do so can result in personal injury.
23. If situations occur which are not covered in this manual,
use care and good judgment. Contact your dealer for
assistance. Telephone 1-800-800-7310 for the name of
your nearest dealer.
SlopeOperation
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. Before operating this unit on a slope or hilly area, use
the slope gauge on page 6 to measure slopes. 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. Ifyou feel you are losing your
balance, release the blade control handle immediately,
and the blade will stop rotating within 3 seconds.
DoNot:
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 ifthe 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 chiZdwho 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 Handlingof 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 spi!led 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. If possible, remove gas-powered equipment from the
truck or trailer and refuel it on the ground. Ifthis 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 iscomplete. 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. Neverover fillfueltank. FilltanktonomorethanY2inch
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.
GeneralService:
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
meettheoriginalequipmentspecificationsmayleadto
improperperformanceandcompromisesafety!"
4. Mowerbladesaresharpandcancut.Wrapthebladeor
weargloves,anduseextra caution when servicing them.
5. Keep al! nuts, bolts, and screws tight to be sure the
equipment is in safe working condition;
6. Never tamper with safety devices. Checktheir 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
YourResponsibility
Restrict the use of this power machine to persons who read, understand and follow the warnings and instructions in
this manual and on the machine.
DANGER
expose moving parts el' 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 eng ne governor setting or overspeed
the engine. The governor controls the maximum safe
operating speed of the engine.
11. Maintain or replaos safety and instruction labels, as
necessary.
12. Observe proper disposal laws and regulations. Improper
disposal of fluids and materials can harm the
environment.
/ WARNING
.II
SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE
A POWER POLE
A CORNER OF A BUILDING
I
OR A FENCE POST
I
{.o
=,
Do not mow on inclines with a slope in excess of 15 degrees (a rise of approximately 2-1/2 feet every 10 feet). A riding mower
==
could overturn and cause serious injury, if operating a walk-behind mower on such a slope, it is extremely difficult to maintain
your footing and you could slip, resulting in serious injury.
Operate RIDING mowers up and down slopes, never across the face of slopes.
Operate WALK-BEHIND mowers across the face of slopes, never up and down slopes.
SECTION3: ASSEMBLINGYOURLAWNMOWER
RemovingUnitFromCarton
• Remove staples, break glue on top flaps or cut tape
at carton end and peel along top flap to open
carton.
• Remove loose parts ifincluded with unit (i.e.,
operator's manual, hardware pack etc.).
• Cut corners and lay carton down flat. Remove
packing matedaL
• Roll or slide unit out of carton. Check carton
thoroughly for loose parts.
NOTE: Make sure not to crimp the cables while
removing the loose parts or the entire unit from the
carton.
NOTE: Reference to right or left hand side of the mower
is observed from the operating position.
ToolsRequired
• Pair of Pliers
• Funnel
• Set of adjustable wrenches
DisconnectingSparkPlug
• Before setting up your lawn mower, disconnect the
spark plug wire from the spark plug, and ground it to
a bolt, retaining post or V-slot on the engine. See
Figure 1.
AssemblingHandle
• For shipping purposes, the grass bag was placed
on top of the unit. Remove itfrom the unit and set it
out of the way. See Figure 2.
Lower Liftlower handle
Grass Bag
Upper
Lift
handl_
Figure 2
• Raise the lower handle, as shown inFigure 2, till it
snaps into place.
• Raise the upper handle as shown inFigure 2.
• Tighten the two wing nuts which are already on the
handle. See Figure 5.
_/U Pper HLotlwdle_Harldle
f
t Iftltl tfjl/lt
All Engines with Rubber Boot
Briggs & Stratton Engines
Figure 1
Spark Plug
,/
Tecumseh Engines
Figure 3
NOTE: Make sure to route the cables outside the lower
handle. Also do not crimp the cables while lifting the
handle up.
• For shipping purposes, the hairpin clip is placed in
the outer hole of the weld pin on the lower handle.
Remove the hairpin (:lip from the outer hole of the
weld pin.
° Using a pair of pliers insert the hairpin clip into the
inner hole in the wels pin. Repeat on the other side.
See Figure 4.
Move hairpin _,lip to
this h01e
Weld Handle
Pin
Figure 4
7
Insert post of cable ties that are on lower handle
into the holes provided on the lower handle. The
holes may be on the inside or outside. Pull cable
ties tight and cut off the extra, See Figure 5 below,
Cable Tie
\
Poston
Assembling soft grass bag:
• Join the rear frame and front frame assembly as
shown in Figure 7A.
• 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.
• Secure bag to frame by working the plastic
channets 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.
Figure 5
AttachingStarterRope
The rope guide is already attached to the right side of
the upper handle of your mower. See Figure 6,
• With the spark plug wire disconnected and
grounded, hold the blade control handle against the
upper handle, and pull the starter rope up to the
rope guide. See Figure 6.
• Slip the rope through the rope guide as shown
below, Tighten the wing nut holding the rope guide
to the upper handle.
BladeControl
Handle
Upper Handle
/
/
Rope Guide
/
Figure 6
Hook
Frame
Assembly
Rear
Frame
Plastic
Channels
Figure 7
HardtopGrassBag
Parts for hardtop grass bag:
1, Rear Frame (packed inside hardtop cover)
2. Front Frame
3. Bag
4. Hardtop Cover
5. Mounting Bracket
6. Hex LockNut
7. Phillips Screw
Assembling hardtop grass bag:
• insert one end of the rear frame into the slit in the
cloth channel on the edge of the grass bag (slits are
approximately 6 inches from the end of the bag).
See Figure 8A. Feed all the bag material on one
side of the frame before working it around frame.
Make certain the other end of rear frame comes out
the slit in the other side. See Figure 8B,
Slit
/
GrassCatcherAssembly
NOTE: Make certain the grass bag is turned right side
out before assembling (warning label will be on the
outside).
SoftGrassBag
Parts for soft grass bag:
1. Front Frame
2. Rear Frame
3. Bag
Rear []
Frame
Figure 8
8
• Slide the ends of the front frame assembly into the
ends of the rear frame as shown in Figure 9A. The
handle of the front frame assembly should be away
from the black plastic bottom of the bag. Push the
two frames together until the cross piece on the
front frame contacts the rear frame.
• Slip the openings in the side of the plastic channel
on the bag over hooks on the grass catcher frame.
See Figure 9B.
• Secure front of bag to front frame by working the
five plastic channels on bottom, sides and top of
bag over frame.
A
Handle
L
Plastic
Hook
Bottom
Phillips
Heed
Screw
Mounting
Bracket
Hex Lock
Nut
Figure 11
AttachingGrassCatcher
• If your mower is equipped with a muIching plug,
and it is in place on tl3e mower, lift the rear
discharge door and remove the rear mulching plug
from the mower. See Figure 12.
Figure 9
Hold the bag and frame so the bag hangs from the
frame (is not bunched around the frame). Slide the
handle on the grass catcher frame down into the
slot in the hardtop cover as shown in Figure 10,
Slot ln
Hardtop
Cover
Grass
Catcher
Handle
Figure 10
Press the rear frame intothe two tabs at the back of
the hardtop cover and the cross bar on the front
frame into the channel on the front of the hardtop
cover. Some force may be required.
Place the mounting bracket under the front of the
handle, with the tabs on the bracket facing up.
Insert phillips head screws down through the
hardtop cover and mounting bracket. Secure with
hex lock nuts. See Figure 11,
Rear
Mulching
Plug
Figure 12
NOTE: Make sum that the cables are routed to the
outside of the handle when attaching the grass catcher.
• Lift the rear discharge door.
• Place the hooks of the grass catcher into the slots
in the handle bracket assemblies on both sides.
See Figure 13, Release the rear discharge door.
harge Door
Figure 13
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