MTD Push Mower Lawn Mower User Manual
Contents
1. SECTION 2 IMPORTANT SAFE OPERATION PRACTICES 27 When starting engine pull cord slowly until resistance is felt then pull rapidly Rapid retraction of starter cord kickback will pull hand and arm toward engine faster than you can let go Broken bones fractures bruises or sprains could result 28 If situations occur which are not covered in this manual use care and good judgement Contact Customer Support for assistance or the name of the nearest service 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 machine 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 three 3 seconds Do Not i Do not mow near drop offs ditches or embankments you could lose your footing or b2. Safe Operation Practices Set Up Operation Maintenance Service Troubleshooting Warranty OPERATOR S MANUAL Push Mower Model Series 540 A 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 To The Owner Thank You Thank you for purchasing a Lawn Mower manufactured by MTD LLC It was carefully engineered to provide excellent performance when properly operated and maintained Please read this entire manual prior to operating the equipment It instructs you how to safely and easily set up operate and maintain your machine Please be sure that you and any other persons who will operate the machine carefully follow the recommended safety practices at all times Failure to do so could result in personal injury or property damage All information in this manual is relative to the most recent product information available at the time of printing Review this manual frequently to familiarize yourself with the machine its features and operation Please be aware that this Operator s Manual may cover a range of product specifications for various models Characteristics and features discussed and or illustrated in this manual may not be applicable to all models MTD LLC res
3. Remove wire from the spark plug thoroughly inspect mower for any damage and repair damage before restarting and operating Extensive vibration of mower during operation is an indication of damage The unit should be promptly inspected and repaired Section 5 OPERATION 13 Maintenance amp Adjustments Maintenance General Recommendations Always observe safety rules when performing any maintenance The warranty on this lawn mower does not cover items that have been subjected to operator abuse or negligence To receive full value from warranty operator must maintain the lawn mower as instructed here Changing of engine governed speed will void engine warranty All adjustments should be checked at least once each season Periodically check all fasteners and make sure these are tight WARNING Always stop engine disconnect spark plug and ground against engine before performing any type of maintenance on your machine Lubrication 1 Lubricate pivot points on the blade control at least once a season with light oil The blade control must operate freely in both directions See Fig 6 1 Figure 6 1 2 Lubricate the wheels at least once a season with light oil or motor oil If wheels are removed for any reason lubricate surface of the pivot arm and inner surface of the wheel with light oil See Fig 6 1 3 Lubricate the torsion spring and pivot points on the rear discharge door and side mulch p
4. belts blades blade adapters tines grass bags wheels rider deck wheels seats snow thrower skid shoes friction wheels shave plates auger spiral rubber and tires Attachments MTD warrants attachments for this product against defects in material and workmanship for a period of one 1 year commencing on the date of the attachment s original purchase or lease Attachments include but are not limited to items such as grass collectors and mulch kits HOW TO OBTAIN SERVICE Warranty service is available WITH PROOF OF PURCHASE through your local authorized service dealer To locate the dealer in your area In the U S A Check your Yellow Pages or contact MTD LLC at P O Box 361131 Cleveland Ohio 44136 0019 or call 1 800 800 7310 1 330 220 4683 or log on to our Web site at www mtdproducts com In Canada Contact MTD Products Limited Kitchener ON N2G 4J1 or call 1 800 668 1238 or log on to our Web site at www mtdcanada com This limited warranty does not provide coverage in the following cases a The engine or component parts thereof These items may carry a separate manufacturer s warranty Refer to applicable manufactur er s warranty for terms and conditions b Log splitter pumps valves and cylinders have a separate one year warranty c Routine maintenance items such as lubricants filters blade sharpening tune ups brake adjustments clutch adjustments deck adjustments and normal deterioration of
5. 738 0507B 738 04266 732 0404 720 0426 710 0599 736 0270 710 0654A 710 0216 710 1652 720 0312 734 04217 734 04082 734 04093 734 04089 710 1205 732 0866 687 02335 687 02040A 714 0104 720 04072 710 0703 731 04150C 710 1241 732 04090A 710 1174 712 0397 749 0928A 736 0182t 731 04204t 731 04859T 732 04089A 738 04266 731 0981AT 736 0504t t If Equipped Front Wheel 8 x 1 8 Bar Front Wheel 8 x 2 125 Zag Front Wheel 8 x 1 8 Pin Bar Shoulder Scr 5D x 434 LH Rear Shoulder Scr 5D x 385 RH Rear Front Spring Lever Height Adjust Knob TT Screw 1 4 20 x 500 Bell Washer TT Screw 3 8 16 x 1 0 Hex Screw 3 8 16 x 75 TT Screw 1 4 20 x 625 Foam Grip Rear Wheel 12 x 1 8 K2 Bar Rear Wheel 12 x 1 8 Bar Rear Wheel 12 x 2 125 Zag Rear Wheel 12 x 1 8 Pin Bar Eye Bolt Rear Hi Wheel Spring Lever Rear Pivot Arm Assy RH Rear Pivot Arm Assy LH Hairpin Clip Star Knob Carriage Bolt 1 4 20 x 75 Rear Baffle Screw HL 1 4 15 x 1 00 Torsion Spring RH Carriage Bolt 5 16 18 x 2 Wing Nut Lower Handle Spring Washer Deluxe Bail Cover Red Deluxe Bail Cover Gray Torsion Spring LH Shoulder Screw 5 D x 385 Front Hub Cap Wave Washer 510 x 750 x 017 NOTE Mower features components vary by model NOT all parts listed above and pictured on the previous page are standard equipment 19 MANUFACTURER S LIMITED WARRANTY FOR ForA For A Growing World Wo
6. Never operate this machine in bare feet sandals slippery or light weight e g canvas shoes Do not put hands or feet near rotating parts or under the cutting deck Contact with blade can amputate fingers hands toes and feet 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 A missing or damaged discharge cover can cause blade contact or thrown object injuries 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 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 Step back from 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 Do not operate the mower while under the influence of alcohol or drugs Do not engage the self propelled mechanism on machines so equipped while starting engine The blade control handle is a safety device Never attempt to bypass its operation Doing so makes the safety device inoperative and may result in personal injury through contact with the rotating blade The blade control handle must operate easily in both directions and auto
7. the exterior finish due to use or exposure d Service completed by someone other than an authorized service dealer e MTD does not extend any warranty for products sold or exported outside of the United States and or Canada and their respective possessions and territories except those sold through MTD s authorized channels of export distribution f Replacement parts that are not genuine MTD parts g Transportation charges and service calls h MTD does not warrant this product for commercial use No implied warranty including any implied warranty of merchantability of fitness for a particular purpose applies after the applicable period of express written warranty above as to the parts as identified No other express warranty whether written or oral except as mentioned above given by any person or entity including a dealer or retailer with respect to any product shall bind MTD During the period of the warranty the exclusive remedy is repair or replacement of the product as set forth above The provisions as set forth in this warranty provide the sole and exclusive remedy arising from the sale MTD shall not be liable for incidental or consequential loss or damage including without limitation expenses incurred for substitute or replacement lawn care services or for rental expenses to temporarily replace a warranted product Some states do not allow the exclusion or limitation of incidental or consequential damages or
8. Bar Part Number Ref No Description Part Number Model Series 540 Description 747 1161A 749 1092A 746 1130 746 04104 746 1137 726 0240 764 04065 747 04728 720 0279 731 05642 747 04588 731 05865 687 02280A 687 02279A 787 01279 687 02075B 687 02074B 687 02099B 687 02100B 782 5002B 748 0377C 748 04082 742 0741 736 0524B 710 1257 731 04177 17032A 732 1014 747 0710 687 02055 712 04065 787 01290 687 02337 687 02338 687 02337 687 02338 734 04215 734 1988 Blade Control Upper Handle Control Cable 40 Control Cable 40 Snap On Kaw Control Cable 53 Cable Tie Grass Bag Assembly Grass Bag Frame Handle Knob Trailshield Pivot Rod Rear Discharge Door Rear Handle Bracket Assy LH Rear Handle Bracket Assy RH Deck 21 inch Front Hgt Adj Assy 8 Whl LH Front Hat Adj Assy 8 Whl RH Front Hgt Adj Assy 7 Whl LH Front Hat Adj Assy 7 Whl RH Front Baffle Blade Adapter w Star Blade Adapter 25mm 21 inch Mulching Blade Bell Blade Support Hex Screw 3 8 24 x 2 5 Side Discharge Chute Deflector Chute Adaptor Torsion Spring Hinge Pin Mulch Plug Assembly Flange Lock Nut 3 8 16 Height Adjustment Plate Pivot Arm Assy LH 7 wheel Pivot Arm Assy RH 7 wheel Pivot Arm Assy RH 8 wheel Pivot Arm Assy LH 8 wheel Front Wheel 8 x 1 8 K2 Bar Front Wheel 7 x 1 8 Bar 734 1987 734 2005A 734 04087
9. ING 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 Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling DANGER This machine was built to be operated according to the safe operation practices 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 fingers hands toes and feet and throwing objects Failure to observe the following safety instructions could result in serious injury or death Operation 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 manuals before operation Keep this manual in a safe place for future and regular reference and for ordering replacement parts Be completely familiar with the controls and the proper use of this machine before operating it This machine is a precision piece of power equipment not a plaything Therefore exercise extreme caution at all times This machine has been designed to perform one job to mow grass Do not use it for any other purpo
10. ade adapter to the engine crankshaft See Fig 7 1 Figure 7 1 3 Remove blade and adapter from the crankshaft See Fig 7 1 4 Remove blade from the adapter for testing balance Balance the blade on a round shaft screwdriver to check Remove metal from the heavy side until it balances evenly When sharpening the blade follow the original angle of grind Grind each cutting edge equally to keep the blade balanced WARNING An unbalanced blade will cause excessive vibration when rotating at high speeds It may cause damage to mower and could break causing personal injury 5 Lubricate the engine crankshaft and the inner surface of the blade adapter with light oil Slide the blade adapter onto the engine crankshaft Place the blade on the adapter such that the side of the blade marked Bottom or with part number faces the ground when the mower is in the operating position Make sure that the blade is aligned and seated on the blade adapter flanges 6 Place blade bell support on the blade Align notches on the blade bell support with small holes in blade Z Replace hex bolt and tighten hex bolt to torque 450 in Ibs min 600 in Ibs max To ensure safe operation of your mower periodically check the blade bolt for correct torque Off Season Storage The following steps should be taken to prepare your lawn mower for storage Clean and lubricate mower thoroughly as described in the lubricati
11. alance 2 Do not mow slopes greater than 15 degrees as shown on the slope gauge 3 Donot 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 watchful care of a responsible adult other than the operator Be alert and turn mower off if a child enters the area 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 of age to operate this machine Children 14 and over should read and understand the instructions and safe operation practices in this manual and on the machine and be trained and supervised by an adult 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 Wa
12. ated areas Engine exhaust contains carbon monoxide an odorless and deadly gas Keep hands feet hair and loose clothing away from any moving parts on engine and lawn mower Follow the set of instructions pertaining to your unit Refer to engine manual for help with the engine Briggs amp Stratton Kawasaki Engine 1 If equipped push primer three times Kawasaki one time Wait about two seconds between each push See Fig 5 1 In temperature around 55 F or below prime five times Do not prime to restart a warm engine 2 Standing behind the mower squeeze the blade control against upper handle 3 Holding these two handles together firmly grasp recoil starter handle and pull rope out with a rapid continuous full arm stroke See Fig 5 1 Keeping a firm grip on the starter handle let the rope rewind slowly Repeat until engine cranks Let the rope rewind each time slowly Honda Engine 1 Place the fuel valve lever found on the left side of the engine into the ON OPEN position See Fig 5 2 2 Move the choke lever if equipped all the way backward into the choke position 3 Standing behind the mower squeeze the blade control against upper handle The choke will now begin to slowly return to the off choke position after activating the blade control Therefore quickly move onto step four below 4 Holding these two handles together firmly grasp recoil starter handle and pull rope out with a rapid con
13. 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 s governor setting or over speed the engine The governor controls the maximum safe operating speed of the engine 11 Check fuel line tank cap and fittings frequently for cracks or leaks Replace if necessary 12 Do not crank engine with spark plug removed 13 Maintain or replace safety and instruction labels as necessary 14 Observe proper disposal laws and regulations Improper disposal of fluids and materials can harm the environment Do not modify engine To avoid serious injury or death do not modify engine in any way Tampering with the governor setting can lead to a runaway engine and cause it to operate at unsafe speeds Never tamper with factory setting of engine governor Notice Regarding Emissions Engines which are certified to comply with California and federal EPA emission regulations for SORE Small Off Road Equipment are certified to operate on regular unleaded gasoline and may inc
14. de control is a safety device Never attempt to bypass its operations Cutting Height Adjustment Levers One adjustment lever is located on each wheel and is used to adjust the cutting height All four levers have to be at the same relative position to ensure a uniform cut Mulch Plug The mulch plug is used for mulching purposes Instead of collecting the grass clippings in a grass catcher or using the side discharge chute some mower models have the option of recirculating the clippings back to the lawn This is called mulching 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 Side Discharge Chute Your mower is shipped as a mulcher To discharge the grass clippings to the side instead follow the instructions in the Assembly amp Set Up section to attach the side discharge chute WARNING Keep hands and feet away from the chute area on cutting deck Refer to warning label on the unit Recoil Starter The recoil starter is attached to the right upper handle Stand behind the unit and pull the recoil starter rope to start the unit 11 12 Operation Starting Engine WARNING Be sure no one other than the operator is standing near the lawn mower while starting engine or operating mower Never run engine indoors or in enclosed poorly ventil
15. erves the right to change product specifications designs and equipment without notice and without incurring obligation Table of Contents Safe Operation Practices ii 3 Assembly amp Set Up RESTINO pui 8 Controls amp Features sacro EE se OperatiON sssssssssssssissssssssssss basssssossdssi Sesbbvsedasbsnsesees 2512 Maintenance amp Adjustment Weeer 14 Record Product Information Before setting up and operating your new equipment please locate the model plate on the equipment and record the information in the provided area to the right You can locate the model plate by standing at the operator s position and looking down at the rear of the deck This information will be necessary should you seek technical support via our web site Customer Support Department or with a local authorized service dealer Customer Support This product has met the rigid safety standards of the Outdoor Power Equipment Institute and an independent testing laboratory If you have any problems or questions concerning the machine phone your local authorized MTD service dealer or contact us directly MTD s Customer Support telephone numbers website address and mailing address can be found on this page We want to ensure your complete satisfaction at all times Throughout this manual all references to right and left side of the machine are observed from the operating position The engine manufac
16. limitations on how long an implied warranty lasts so the above exclusions or limitations may not apply to you In no event shall recovery of any kind be greater than the amount of the purchase price of the product sold Alteration of safety features of the product shall void this warranty You assume the risk and liability for loss damage or injury to you and your property and or to others and their property arising out of the misuse or inability to use the product This limited warranty shall not extend to anyone other than the original purchaser or to the person for whom it was purchased as a gift HOW STATE LAW RELATES TO THIS WARRANTY This limited warranty gives you specific legal rights and you may also have other rights which vary from state to state IMPORTANT Owner must present Original Proof of Purchase to obtain warranty coverage MTD LLC P O BOX 361131 CLEVELAND OHIO 44136 0019 Phone 1 800 800 7310 1 330 220 4683 MTD Canada Limited KITCHENER ON N2G 4J1 Phone 1 800 668 1238 GDOC 100015 REV B
17. lude the following emission control systems Engine Modification EM and Three Way Catalyst TWC if so equipped SECTION 2 IMPORTANT SAFE OPERATION PRACTICES Spark Arrestor WARNING This machine is equipped with an internal 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 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 Average Useful Life According to the Consumer Products Safety Commission CPSC and the U S Environmental Protection Agency EPA this product has an Average Useful Life of seven 7 years or 140 hours of operation At the end of the Average Useful Life buy anew machine or have the machine inspected annually by an authorized service dealer to ensure that all mechanical and safety systems are working properly and not worn excessively Failure to do so can result in accidents injuries or death WARNING Your Responsibilit
18. lug periodically with light oil to prevent rust See Fig 6 1 4 Follow the accompanying engine manual for lubrication schedule and instruction for engine lubrication Deck Care Clean underside of the mower deck after each use to prevent build up of grass clippings or other debris Follow steps below for this job 1 Disconnect spark plug wire Drain gasoline from lawn mower or place a piece of plastic under the gas cap 2 Tip mower so that it rests on the housing Keep the side with the air cleaner facing up Hold mower firmly WARNING Never tip the mower more than 90 in any direction and do not leave the mower tipped for any length of time Oil can drain into the upper part of the engine causing a starting problem 3 Scrape and clean the underside of the deck with a suitable tool Do not spray with water IMPORTANT Do not use a pressure washer or garden hose to clean your unit These may cause damage to bearings or the engine The use of water will result in shortened life and reduce serviceability 4 Put the mower back on its wheels on the ground If you had put plastic under the gas cap earlier make sure to remove it now Engine Care A list of key engine maintenance jobs required for good performance by the mower is given below Follow the 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 co
19. matically return to the disengaged position when released Never operate the mower in wet grass Always be sure of your footing A slip and fall can cause serious personal injury If you feel you are losing your footing release the blade control handle immediately and the blade will stop rotating within three seconds Mow only in daylight or good artificial light Walk never run Stop the blade when crossing gravel drives walks or roads If the equipment should start to vibrate abnormally stop the engine and check immediately for the cause Vibration is generally a warning of trouble 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 blade control is released Never place any part of the body in the blade area until you are sure the blade has stopped rotating 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 Muffler and engine become hot and can cause a burn Do not touch Never attempt to make a wheel or cutting height adjustment while the engine is running Only use parts and accessories made for this machine by the manufacturer Failure to do so can result in personal injury
20. nditions Clean every few hours under extremely dusty conditions Poor engine performance and flooding usually indicates that the air cleaner should be serviced To service the air cleaner refer to the engine manual Clean spark plug and reset the gap once a season Spark plug replacement is recommended at the start of each mowing season Check engine manual for correct plug type and gap specifications Clean engine regularly with a cloth or brush Keep the top of the engine clean to permit proper air circulation Remove all grass dirt and combustible debris from muffler area Replacing Rear Flap 1 2 To remove rear flap lift rear door and press flap in on either side to remove from hole See Fig 6 2 Figure 6 2 Remove flap from opposite hole and replace with new flap in the opposite order and manner of removal SECTION 6 MAINTENANCE amp ADJUSTMENTS 15 Service Blade Care WARNING When removing the cutting blade for sharpening or replacement protect your hands with a pair of heavy gloves or use a heavy rag to hold the blade Periodically inspect the blade adapter for cracks especially if you strike a foreign object Replace when necessary Follow the steps below for blade service 1 Disconnect spark plug boot from spark plug Turn mower on its side making sure that the air filter and the carburetor are facing up 2 Remove the bolt and the blade bell support which hold the blade and the bl
21. on instructions Do not use a pressure washer or garden hose to clean your unit Coat mower s cutting blade with chassis grease to prevent rusting Refer to engine manual for correct engine storage instructions Store mower in a dry clean area Do not store next to corrosive materials such as fertilizer When storing any type of power equipment in a poorly ventilated or metal storage shed care should be taken to rust proof the equipment Using a light oil or silicone coat the equipment especially cables and all moving parts of your lawn mower before storage 16 17 Troubleshooting Problem Engine Fails to start Blade control disengaged Spark plug boot disconnected Fuel tank empty or stale fuel Engine not primed if equipped with primer Faulty spark plug Blocked fuel line Engine flooded Fuel valve if equipped closed Engine not choked if equipped with choke Engage blade control Connect wire to spark boot Fill tank with clean fresh gasoline Prime engine as instructed in the Operation section Clean adjust gap or replace Clean fuel line Wait a few minutes to restart but do not prime Open fuel valve See engine manual Choke engine See engine manual Engine runs erratic Spark plug boot loose Blocked fuel line or stale fuel Vent in gas cap plugged Water or dirt in fuel system Dirty ai
22. over hooks on the frame See Fig 3 5 All the plastic channels except center top of bag attach from outside of bag Figure 3 3 a Hold blade control against upper handle b Pull starter rope out of the engine Release blade control c Slip starter rope into rope guide d Tighten wing nut 4 Insert post on cable tie into hole provided on the lower handle Pull cable tie tight and trim excess Rear Wheels Install rear wheels as follows in Fig 3 4 wheels maybe already installed at factory if so disregard this step Figure 3 5 c Attach center top of bag from inside of bag Figure 3 4 Section 3 AssemBLY amp Set Up 10 2 Follow the steps below to attach the grass catcher a Lift rear discharge door See Fig 3 6 Figure 3 6 b Place grass catcher on the pivot rod Let go of discharge door so that it rests on the grass catcher WARNING Never operate mower unless the hooks on the grass catcher are firmly seated on the pivot rod and the rear discharge door rests firmly against top of the grass catcher Side Discharge Chute Your mower is shipped as a mulcher To convert to side discharge make sure grass catcher is off of the unit and rear discharge door is closed 1 On the side of the mower lift the mulching plug See Figure 3 7 Figure 3 7 Section 3 AssemBLY amp Set Up 2 Slidetwo hooks of side discharge chute under hinge pin on mulching plug assembly L
23. ower the mulching plug Do not 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 2 Slide lever to desired position for a change in cutting height See Fig 3 8 Figure 3 8 3 Release lever towards deck IMPORTANT All wheels must be placed in the same relative position For rough or uneven lawns move the height adjustment lever to a higher position This will stop scalping of grass Gas and Oil Fill Up Refer to the separate engine owner s manual for additional engine information 1 Add oil provided before starting unit for the first time out of the box 2 Service the engine with gasoline as instructed in the separate engine owner s manual WARNING Use extreme care when handling gasoline Gasoline is extremely flammable and the vapors are explosive Never fuel the machine indoors or while the engine is hot or running Extinguish cigarettes cigars pipes and other sources of ignition Controls and Features Recoil Starter Grass Catcher e Side Discharge Chute Blade Control Cutting Height Adjustment Levers Figure 4 1 Blade Control The blade control is attached to the upper handle of the mower Depress and squeeze it against the upper handle to operate the unit Release it to stop engine and blade WARNING This bla
24. r cleaner Unit running with CHOKE if equipped applied Connect and tighten spark plug boot Clean fuel line fill tank with clean fresh gasoline Clear vent Drain fuel tank Refill with fresh fuel Referto engine manual Push CHOKE knob in Engine overheats Engine oil level low Air flow restricted Fill crankcase with proper oil Clean area around and on top of engine Occasional skips hesitates at high speed Spark plug gap too close Adjust gap to 030 Idles poorly Spark plug fouled faulty or gap too wide Dirty air cleaner Reset gap to 030 or replace spark plug Referto engine manual Excessive Vibration Cutting blade loose or unbalanced Bent cutting blade Tighten blade and adapter Balance blade See an authorized service dealer Mower will not mulch grass Wet grass Excessively high grass Dull blade Do not mow when grass is wet wait until later to cut Mowonceata high cutting height then mow again at desired height or make a narrower cutting path Sharpen or replace blade Uneven cut Wheels not positioned correctly Dull blade Place all four wheels in same height position if equipped with individual height adjusters Sharpen or replace blade 18 Model Series 540 3 Pin
25. ree of grass leaves or other debris build up Clean up oil or fuel spillage and remove any fuel soaked debris 14 Allow machine 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 Checkthe 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
26. rld MID The limited warranty set forth below is given by MTD LLC with respectto new merchandise purchased and used in the United States and or its territories and possessions and by MTD Products Limited with respect to new merchandise purchased and used in Canada and or its territories and possessions either entity respectively MTD MTD warrants this product excluding its Normal Wear Parts and Attachments as described below against defects in material and workmanship for a period of two 2 years commencing on the date of original purchase and will at its option repair or replace free of charge any part found to be defective in materials or workmanship This limited warranty shall only apply if this product has been operated and maintained in accordance with the Operator s Manual furnished with the product and has not been subject to misuse abuse commercial use neglect accident improper maintenance alteration vandalism theft fire water or damage because of other peril or natural disaster Damage resulting from the installation or use of any part accessory or attachment not approved by MTD for use with the product s covered by this manual will void your warranty as to any resulting damage Normal Wear Parts are warranted to be free from defects in material and workmanship for a period of thirty 30 days from the date of purchase Normal wear parts include but are not limited to items such as batteries
27. se Never allow children under 14 years of age to operate this machine Children 14 and over should read and understand the instructions and safe operation practices in this manual and on the machine and should be trained and supervised by an adult Only responsible individuals who are familiar with these rules of safe operation should be allowed to use this machine 11 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 To help avoid blade contact or a thrown object injury stay in operator zone behind handles and keep children bystanders helpers and pets at least 75 feet from mower while it is in operation Stop machine if anyone enters area 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 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
28. sh your skin and change clothes immediately 2 Use only an approved gasoline container 3 Neverfill 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 4 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 5 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 6 Extinguish all cigarettes cigars pipes and other sources of ignition 7 Never fuel machine indoors because flammable vapors will accumulate in the area 8 Never remove gas cap or add fuel while engine is hot or running Allow engine to cool at least two minutes before refueling 9 Never over fill fuel tank Fill tank to no more than 1 inch below bottom of filler neck to provide for fuel expansion 10 Replace gasoline cap and tighten securely 11 If gasoline is spilled wipe it off the engine and equipment Move machine to another area Wait 5 minutes before starting engine 12 Never store the machine or fuel container near an open flame spark or pilot light as on a water heater space heater furnace clothes dryer or other gas appliances 13 To reduce fire hazard keep machine f
29. tinuous full arm stroke See Fig 5 2 Keeping a firm grip on the starter handle let the rope rewind slowly Repeat until engine cranks Let the rope rewind each time slowly Stopping Engine 1 Release blade control to stop the engine and blade WARNING Wait for the blade to stop completely before performing any work on the mower or to remove the grass catcher Figure 5 1 Figure 5 2 Using Your Lawn Mower Be sure lawn is clear of stones sticks wire or other objects which could damage lawn mower or engine Such objects could be accidently thrown by the mower in any direction and cause serious personal injury to the operator and others 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 Using as Mulcher For mulching grass remove the grass catcher and side discharge chute from the mower For effective mulching do not cut wet grass If the grass has been allowed to grow in excess of four inches mulching is not recommended Use the grass catcher to bag clippings instead Using Grass Catcher You can use the grass catcher to collect clippings while you are operating the mower Refer to the Assembly amp Set Up section for instructions on attaching the grass catcher WARNING If you strike a foreign object stop the engine
30. to secure upper handle to lower handle Make sure that each carriage bolt is seated properly in the handle One Lawn Mower Operator s Manual One Engine Operator s Manual One Bottle of Oil One Hardware Pack Locate the hairpin clip on the weld pin on each side of lower handle a Remove hairpin clip from this hole Using a pair of pliers insert hairpin clip into the hole on pin closest to the bracket See Fig 3 2 Repeat on other side Hardware Pack e Wing Nuts 2 Figure 3 2 b Insert a carriage bolt from the hardware pack into the upper hole on the handle mounting bracket Secure with one plastic wing nut also included in the hardware pack Repeat on other side with remaining items from hardware pack 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 securesthe gt 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 Grass Catcher 1 Follow steps below to assemble the grass catcher Make certain bag is turned right side out before assembling warning label will be on the outside a Place bag over frame so that its black plastic side is at the bottom b Slip plastic channel of grass bag
31. turer is responsible for all engine related issues with regards to performance power rating specifications warranty and service Please refer to the engine manufacturer s Owner s Operator s Manual packed separately with your machine for more information Service PRESO ssevessssseacssssoes dese ET Troubleshooting rante ann IZ Illustrated Parts List RZ ET Warranty SEAN sicilia vun 20 MobeL NUMBER IO OO SERIAL NUMBER UU OO Please do NOT return the machine to the retailer or dealer without first contacting our Customer Support Department If you have difficulty assembling this product or have any questions regarding the controls operation or maintenance of this machine you can seek help from the experts Choose from the options below D Visit us on the web at www mtdproducts com Calla Customer Support Representative at 800 800 7310 or 330 220 4683 D Write us at MTD LLC P O Box 361131 Cleveland OH 44136 0019 A 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 WARN
32. y 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 SAVE THESE INSTRUCTIONS SECTION 2 IMPORTANT SAFE OPERATION PRACTICES lt q Sight and hold this level with a vertical tree LL AT AO AAA ALADO 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 never across the face of slopes Operate walk behind mowers across the face of slopes never up and down slopes IMPORTANT SAFE OPERATION PRACTICES SECTION 2 Assembly amp Set Up Contents of Carton One Lawn Mower One Grass Catcher One Side Discharge Chute Assembly NOTE This unit is shipped without gasoline or oil in the engine Fill up gasoline and oil as instructed in the accompanying engine manual BEFORE operating your mower Handle 1 Remove any packing material which may be between upper and lower handles a Pull up and back on upper handle as shown in Fig 3 1 Make certain the lower handle is seated securely into the handle mounting brackets Do not crimp cable while lifting the handle up Figure 3 1 b Tighten star knobs
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