MTD 136-390A Manual

Owner's Operating
Service Instruction
Manual Model Nos.
136-390A
• ASSEMBLY 136-395A
• OPERATION
• REPAIR PARTS
30 ” RIDING MOWERS
lOcfc
MTD PRODUCTS INC • 5389 WEST 130th STREET • P. 0. BOX 2741 CLEVELAND OHIO 441II
PRINTED IN U.S.A.
FORM NO. 770-6034

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 manual foi
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 attachments) and stop
engine before making any repairs or adjust¬
ments.
8. Disengage power to attachments) 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. 2
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 Practice.2
Index and Assembly Instructions.3
Installing the Battery.5
Controis. 6
Operating Instructions... .9
Maintenance and Adjustment.10
Lubrication. 1 1
Belt Removal.12
Trouble Shooting Chart for Recoil Start Model. 14
Trouble Shooting Chart for Electric Start
Modeis.15
Electricai Breakdown. 1 6
Differential. . 17
Transmission.18
Transmission Parts List.19
Illustrated Parts for Rider. 20, 23, 25
Parts List for Rider. 21,23, 26,
Wheel Chart. 2 7
Deck Linkage.27
Parts Information.Back Cover
GRASS CATCHER Modei No. 196-015A is
avaiiable as optionai equipment for the mowers
shown in this manuai.
\ 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 re¬
placement bag complies with the
manufacturer’s recommendations.
For replacement bags, use only fac¬
tory authorized replacement bag No.
764-0121.
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 wheei and seat, with the necessary
hardware, are easily assembled to the machine.
On the eiectric starter models, the battery must be
activated and instaiied as outiined in this section.
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.
ASSEMBLY
NOTE
Reference to right-hahd or left-hand
side of machine is from the driver’s
seat facing forward.
Hex Bolt G H
QJ)
Hex Lock Nut
H—16 Belleville Washer W
FIGURE 1. HARDWARE SUPPLIED
Step 1. Remove the iawn 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 wheei over steering shaft.
Step 3. Secure with Belleviile washer and hex nut.
See figure 2.
Step 4. Press the cap on the steering wheel by
hand. See figure 2.
3

I
Steering Wheel Cap
Step 5. Your molded seat comes with the
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 and 3.
FIGURES. SEAT ASSEMBLY
NOTE
Check all nuts and bolts for correct
tightness.
BATTERY INFORMATION FOR ELECTRIC START
MODELS
A.
\ WARNING {
Battery acid must be handled with great care
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
electrolyte containers and mutilate before dis¬
carding.
^ DANGER \
BATTERIES CONTAIN SULFURIC
ACID MAY CONTAIN EXPLOSIVE
GASES (when electrolyte has been
added)
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.
A. 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
the split ring.
3. Allow battery to set for 20 minutes to 1/2
hour. Add additional acid if necessary to
bring it up to the proper ievel.
4. Replace 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.
4

A CAUTION
After the 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 electrolyte level
is 9/16” above separator plates. Add only
distilled water or good quarrty drinking water.
NEVER add additional 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 electro¬
lyte 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
occurs first.
E. Common Causes for Battery Failure Are:
1. Overcharging
2. Undercharging
3. Lack of water
4. Loose hold downs and/or corroded
connections
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 manu¬
facturer.
INSTALL THE BATTERY
A. Open the hood of the mower.
B. Place the battery with the terminals to the
FRONT in the battery case. See figure 4.
C. Hook both hold-down rods under the battery
case and place the hold down over the battery
caps and secure with wing nuts D.
A CAUTION
Be sure the flared edge of the hold
down is facing up to avoid damage
to the battery.
D. Attach the free end of the positive cable and
the small wire from the ammeter, to the
positive battery terminai with bolt E, washer F
and nut G. The battery terminal is marked +.
E. Attach the free end of the negative cable to the
negative terminal with bolt E, washer F and
nut G. Battery terminal is marked -.
FIGURE 4. INSTALLING THE BATTERY
5

I
CONTROLS (See figure 5.)
This manual should be read in its entirety before
you operate your Riding Mower. The more you
know and understand about the machine and its
operation, the better job it will do for you. While
reading the manual, compare the illustrations
with your mower to familiarize yourself with the
locations of various controls, lubrication points,
attachments and adjustment features.
Study the operating instructions and safety
precautions thoroughly to insure proper function¬
ing of your mower and to prevent injury to yourself
and others. Be sure to save this manual for future
reference.
THROTTLE CONTROL
The throttle control is used to regulate the engine
speed and to activate the choke on the engine. To
get maximum efficiency from cutting, the throttle
should be in the FAST position when operating
the mower. Pushing the throttle all the way
forward, past FAST will choke the engine. See
figures.
IGNITION KEY
Recoil Model. The key must be turned to the ON
position before you pull the recoil handle to start
the engine. Remove the key when the mower is
not in use. Turn the key to the left to the OFF
position to stop the engine. See figure 10.
Electric Model. The key must be turned to the
START position to start the engine. After the
engine is running let the key return to the ON
position. Remove the key when the mower is not
in use. Turn the key to the OFF position to stop
the engine. See figure 5.
FIGURES. CONTROLS
INTERLOCKS (Not Shown)
An interlock safety switch is located on the clutch
pedal and the lift and disengagement lever.
The clutch pedal must be depressed all the way
down and can be locked and the lift and
disengagement lever must be in the disengaged
position before the engine can be started.
On the recoil start model, the ignition will be
grounded and on the electric start model, the
starter will not run.
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 6.
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 brake
pedal. Always lock the brake when you park the
mower. See figure 6.
CLUTCH
The clutch pedal is located on the left hand side of
the mower and is operated with your left foot.
Depress the pedal to disengage the drive
mechanism. Release the clutch slowly to engage.
The clutch and brake pedals must both be
depressed when stopping the mower. When
shifting gears, the clutch pedal must be
disengaged and the mower cannot be moving. See
figure?.
FIGURE 6. BRAKE AND BRAKE LOCK
6

CLUTCH LOCK
When the clutch pedal is depressed all the way it
can be locked by lifting up the lock button. The
pedal will stay depressed. To release, depress the
pedal. See figure?.
STARTING I KSTRUCTIONS
■ Lock-rat clHtck
■ S otthrattie
■ D isinfoii Wait
Tan koy to or position
Pill ropo to start
Rotara rapt kaadte to lock
NOTE
The clutch pedal must be depressed
to start the engine.
FIGURE?. CLUTCH AND CLUTCH LOCK
GEAR SHIFT LEVER
Four Speed—The four speed transmission has
four forward speeds, neutral and reverse. The
clutch pedal must be repressed to shift gears. It
may be necessary to release the clutch pedal
slightly to shift the gear shift lever. Do not force
the shift lever.
1 St Gear—Heavy Cutting
2nd Gear—Medium Cutting
3rd Gear-Medium Cutting
4th Gear—Light Cutting or Travel Gear
N —Neutral
R—Reverse
a
FIGURE 8. FOUR SPEED TRANSMISSION
RECOIL STARTER HANDLE
The recoil starter handle is located on the right
side of the dashboard. The recoil starter handle
cani'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 blade or clutch are engaged.
The engine will stop if you do not follow these
instructions. See figure 9.
3 a 'I
FIGURE 9. RECOIL STARTER
LIFT AND DISENGAGEMENT LEVER
It is used to raise the cutting deck. Pulling it all
the way back and locking it disengages the blade.
See figures 5 and 8.
7

I
FIGURE 10. HEIGHT OF CUT SETTINGS
FIGURE 11 WHEEL HEIGHT ADJUSTER
NOTE
The engine will not start unless the
lift and disengagement lever is in the
disengaged position. See figure 10.
CUTTING CONTROLS
To set the cutting deck in the full float position:
set the wheel height adjusters in the desired
cutting height as indicated in figure 11. Set height
of cut stop in the lowest position. See figure 10.
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 clear the ground.
The cutting controls consist of the height of cut
stop and the wheel height adjusters.
CAUTION
Height of Cut Stop. See figure 10. Lift the stop
and set it at the desired cutting height. Allow the
lift and disengagement lever to come forward to
rest against the height of cut stop.
Wheel Height Adjuster. Move the lever towards
the wheel and set it in the desired cutting height
position. See figure 11. Both wheels must be in
the same relative position.
Parking Brake must be disengaged
before unit is put into motion.
NOTE
Unit is equipped with separate brake
and clutch pedals. To efficiently
stop, it is necessary to disengage
clutch when applying brakes.
SETTING THE 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.
8

OPERATING
INSTRUCTIONS
CAUTION
3.
4.
Keep all shields and guards in place.
Before leaving operator’s position:
Shift controls into neutral
Set parking brake
Disengage attachment drive
Shut off engine
Remove ignition key
Wait for all movement to stop before servicing
machine.
Keep people and pets a safe distance away
from machine.
FIGURE 12. RECOIL STARTER
STARTING THE ENGINE
1. Be sure the crankcase is filled with oil as
recommended in the engine manual and put
regular gasoline in the gasoline tank.
2. If the engine is equipped with a fuel shut off
valve, be sure it is open.
Electric Start Model. Turn the ignition key to the
START position. As soon as the engine starts let
the key return to the ON position. See figure 5.
Slowly return the throttle to the running position
as soon as the engine starts.
8. To stop either model, turn the ignition key to
the OFF position and remove the key when
the unit is not in use.
3. Attach the wire to the spark plug.
4. Depress the clutch pedal and lock it down
with the speed control lever.
5. Move the lift and disengagement lever
backward to the disengaged position and lock
it.
6. Set the throttle control lever in the CHOKE
position.
7. Recoil Model. Turn the ignition key to the ON'
position, twist the recoil starter handle until it
is free and pull it with a quick steady motion.
After the engine starts, return the recoil
starter handle and twist it until it iocks. See
figures 9 and 12.
NOTE
The engine will stop when clutch or
blades are engaged if this procedure
is not followed.
PUTTING THE RIDER IN MOTION
1. Advance the throttle control from % to full
throttle to prevent strain on the engine and to
operate the cutting blades.
2. Depress the clutch pedal so the clutch lock
releases.
3. Place the gear shift lever in the number 1
position on the four speed unit.
4. Slowly release the clutch pedal.
5. To stop the unit, depress the clutch pedal and
the brake pedal.
6. The blade can be engaged either while moving
or while standing still. Move the lift and
disengagement lever forward slowly until the
■ blade is running.
NOTE
As you become more familiar with
the four speed transmission, stop
the unit and shift into a higher gear.
9

I
STOPPING
Engine— Turn the ignition key to the left to the
OFF position.
Rider— D epress the ciutch and brake pedals.
Blades— M o ve the lift and disengagement iever
aii the way to the rear and iock it.
The deck may be cleaned by tilting the mower on
its rear wheels. Scrape clean with a suitable tool
or by washing with a stream of water from a
garden hose.
Be sure to disconnect the spark plug wire and
ground it while performing this maintenance.
MAINTENANCE
CRANKCASE OIL
To ensure maximum engine performance, perform
the following periodic maintenance:
Check oil level before starting engine and after
every 5 hours of operation. Be sure oil level is
maintained to FULL POINT OF OVERFLOWING or
to FULL MARK on dipstick.
Change Oil after first 5 hours of operation.
Thereafter change oil every 25 hours of operation.
Remove oil drain plug and drain oil while engine is
warm. Replace drain plug. Remove dipstick or
filler plug and refill with new oil of proper grade.
Replace dipstick or plug.
FIGURE 13. CHECKING OIL
NOTE
To insure safe operation, ALL nuts
and bolts must be checked periodi¬
cally for correct tightness.
MOWER DECK
The underside of the mower deck should be
cleaned after each period of use as grass
clippings, leaves, dirt and other matter will
accumulate. This accumulation of grass clip¬
pings, etc., is undesirable as it will invite rust and
corrosion and may cause an uneven discharge of
grass clippings at the next mowing.
BLADES
{ WARNING \
Disconnect the spark plug wire and
remove the ignition key before re¬
moving the blades.
Sharp and balanced blades are essential for
efficient mowing and long mower and engine life.
When sharpening blades, file equal amounts of
metal from each side. The blades should be
balanced before they are reinstalled. An unbal¬
anced blade will cause excessive vibration and
undue wear on the mower and the engine. When
reassembling, all parts must be installed in the
proper order and fastened securely.
Remove the 3/8” bolt and lockwasher. Pull the
blade and adapter off the mower deck. To remove
the adapter form the blade, remove the two 5/16”
bolts, lockwashers and nuts. See figure 14.
BRAKE ADJUSTMENT See figure 16.
To adjust the brake tighten the locknut one half
turn and then test the brakes. After attaining the
proper adjustment, replace the cotter pin.
The brake is located by the right rear wheel inside
the frame.
10