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Safe Operation Practices • Set-Up • Operation • Maintenance • Service • Troubleshooting • Warranty
Otraep Or ’s Mlauna
Push Mower — Model Series 540
WARNING
READ AND FOLLOW ALL SAFETY RULES AND INSTRUCTIONS IN THIS MANUAL
BEFORE ATTEMPTING TO OPERATE THIS MACHINE.
FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
MTD LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019
Printed In USA Form No. 769-03420
(August 27, 2007)
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To The Owner 1 Thank You Thank you for purchasing a Lawn Mower manufactured by This product has met the rigid safety standards of the Outdoor MTD LLC. It was carefully engineered to provide excellent Power Equipment Institute and an independent testing performance when properly operated and maintained. laboratory. If you have any problems or questions concerning the machine, phone your local authorized MTD service dealer Please read this entire manual prior to operating the equipment. or
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Important Safe Operation Practices 2 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! CALIFORNIA PROPOSITION 65 WARNING: Engine Exhaust, some of its constituents, and certain v
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12. A missing or damaged discharge cover can cause blade 27. When starting engine, pull cord slowly until resistance contact or thrown object injuries. is felt, then pull rapidly. Rapid retraction of starter cord (kickback) will pull hand and arm toward engine faster than 13. Many injuries occur as a result of the mower being pulled you can let go. Broken bones, fractures, bruises or sprains over the foot during a fall caused by slipping or tripping. could result. Do not hold on to the mow
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3. Check the blade and engine mounting bolts at frequent Service intervals for proper tightness. Also, visually inspect blade for damage (e.g., bent, cracked, worn) Replace blade with Safe Handling Of Gasoline: the original equipment manufacture’s (O.E.M.) blade only, 1. To avoid personal injury or property damage use extreme listed in this manual. “Use of parts which do not meet the care in handling gasoline. Gasoline is extremely flammable original equipment specifications may lead to i
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Spark Arrestor Average Useful Life According to the Consumer Products Safety Commission WARNING: This machine is equipped with an (CPSC) and the U.S. Environmental Protection Agency (EPA), internal combustion engine and should not be used this product has an Average Useful Life of seven (7) years, or 140 on or near any unimproved forest-covered, brush hours of operation. At the end of the Average Useful Life, buy covered or grass-covered land unless the engine’s a new machine or have the
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Fold along dotted line (represents a 15° slope) Sight and hold this level with a vertical tree... or a corner of a building... or a fence post 15° Use this page as a guide to determine slopes where you may not operate safely. WARNING: Do not operate your lawn mower on such 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. Operate riding mowers up and down slopes, neve
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Assembly & Set-Up 3 Contents of Carton • One Lawn Mower • One Lawn Mower Operator’s Manual • One Bottle of Oil • One Grass Catcher • One Engine Operator’s Manual • One Hardware Pack • One Side Discharge Chute 2. Locate the hairpin clip on the weld pin on each side of Assembly lower handle. NOTE: This unit is shipped without gasoline or oil in the engine. a. Remove hairpin clip from this hole. Using a pair of Fill up gasoline and oil as instructed in the accompanying engine pliers, insert hai
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3. The rope guide is attached to the right side of the upper 1. Place rear of the mower deck on raised blocks. handle. See Fig. 3-3. Loosen the wing nut which secures the 2. Remove lock nut from pivot arm assembly (on select rope guide. models, these may be included separately in a plastic bag). 3. Slide wheel, with hollow side in, onto pivot arm and secure with lock nut. 4. Assemble the other side in the same manner. A Grass Catcher 1. Follow steps below to assemble the grass catcher. Make
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2. Follow the steps below to attach the grass catcher: 2. Slide two hooks of side discharge chute under hinge pin on mulching plug assembly. Lower the mulching plug. Do not a. Lift rear discharge door. See Fig. 3-6. remove side mulching plug at any time, even when you are not mulching. Adjustments Each wheel has a height adjustment lever to change the cutting height of the mower. 1. Depress height adjustment lever towards wheel. B 2. Slide lever to desired position for a change in cutting h
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Controls and Features 4 Blade Control Recoil Starter Grass Catcher Side Discharge Chute Mulch Plug Cutting Height Adjustment Levers Figure 4-1 Grass Catcher Blade Control The grass catcher, located at the rear of the mower, is used to bag The blade control is attached to the upper handle of the mower. the grass clippings for disposal at another site. Once the bag is Depress and squeeze it against the upper handle to operate the full, it has to be removed from the mower and emptied before
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Operation 5 Starting Engine WARNING: Be sure no one other than the operator is standing near the lawn mower while starting 2 engine or operating mower. Never run engine indoors or in enclosed, poorly ventilated areas. Engine exhaust contains carbon monoxide, an odorless and deadly gas. Keep hands, feet, hair and 3 loose clothing away from any moving parts on engine and lawn mower. Follow the set of instructions pertaining to your unit. Refer to 1 engine manual for help with the engine. B
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Using Your Lawn Mower Using Grass Catcher Be sure lawn is clear of stones, sticks, wire, or other objects You can use the grass catcher to collect clippings while you are which could damage lawn mower or engine. Such objects could operating the mower. Refer to the Assembly & Set-Up section for be accidently thrown by the mower in any direction and cause instructions on attaching the grass catcher. serious personal injury to the operator and others. WARNING: If you strike a foreign object, stop
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Maintenance & Adjustments 6 2. Lubricate the wheels at least once a season with light oil (or Maintenance motor oil). If wheels are removed for any reason, lubricate surface of the pivot arm and inner surface of the wheel General Recommendations with light oil. See Fig. 6-1. • Always observe safety rules when performing any 3. Lubricate the torsion spring and pivot points on the rear maintenance. discharge door and side mulch plug periodically with light • The warranty on this lawn mower d
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Engine Care Replacing Rear Flap A list of key engine maintenance jobs required for good 1. To remove rear flap, lift rear door, and press flap in on performance by the mower is given below. Follow the either side to remove from hole. See Fig. 6-2. accompanying engine manual for a detailed list and instructions. • Maintain oil level as instructed in engine manual. • Service air cleaner every 25 hours under normal conditions. Clean every few hours under extremely dusty conditions. Poor engine
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Service 7 WARNING: An unbalanced blade will cause Blade Care excessive vibration when rotating at high speeds. It WARNING: When removing the cutting blade for may cause damage to mower and could break sharpening or replacement, protect your hands with causing personal injury. a pair of heavy gloves or use a heavy rag to hold the 5. Lubricate the engine crankshaft and the inner surface of blade. the blade adapter with light oil. Slide the blade adapter Periodically inspect the blade adapt
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Troubleshooting 8 Problem Cause Remedy Engine Fails to start 1. Blade control disengaged. 1. Engage blade control. 2. Spark plug boot disconnected. 2. Connect wire to spark boot. 3. Fuel tank empty or stale fuel. 3. Fill tank with clean, fresh gasoline. 4. Engine not primed (if equipped with primer). 4. Prime engine as instructed in the Operation section. 5. Faulty spark plug. 5. Clean, adjust gap, or replace. 6. Blocked fuel line. 6. Clean fuel line. 7. Engine flooded. 7. Wait a few minutes to
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Model Series 540 51 5 3 1 6 2 7 38 4 42 47 8 49 52 10 48 9 46 44 45 11 43 12 24 33 41 40 13 32 24 37 39 31 50 34 35 14 30 28 36 24 29 25 53 15 26 24 16 23 24 17 54 27 18 21 22 19 20 Wheel Treads 55 Zag Pin Bar K2 Bar Bar 18
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Model Series 540 Ref Ref Part Number Description Part Number Description No. No. 1. 747-1161A Blade Control 734-1987 Front Wheel, 8 x 1.8, Bar 734-2005A Front Wheel, 8 x 2.125, Zag 2. 749-1092A Upper Handle 734-04087 Front Wheel, 8 x 1.8, Pin Bar 3. 746-1130 Control Cable, 40” 746-04104 Control Cable, 40”, Snap-On, Kaw 28. 738-0507B Shoulder Scr., .5D x .434 - LH Rear 746-1137 Control Cable, 53” 738-04266 Shoulder Scr., .5D x .385 - RH Rear 29. 732-0404 Front Spring Lever 4. 726-0240 Cable Tie
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MANUFACTURER’S LIMITED WARRANTY FOR The limited warranty set forth below is given by MTD LLC with c. Routine maintenance items such as lubricants, filters, blade respect to new merchandise purchased and used in the United States sharpening, tune-ups, brake adjustments, clutch adjustments, and/or its territories and possessions, and by MTD Products Limited deck adjustments, and normal deterioration of the exterior finish with respect to new merchandise purchased and used in Canada and/ due to
