Kmart 11A-544A020, 01758270-1 Owner’s Manual

Safe Operation Practices • Set-Up • Operation • Maintenance • Service • Troubleshooting • Warranty

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Push Mower m Moclel Series 540

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

PrintedIn USA FormNo.769-05618

(November3,2009)

ToTheOwner

ThankYou

1

Thank you for purchasing a Lawn Mower manufactured by MTD.
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. We reserve

the right to change product specifications, designs and
equipment without notice and without incurring obligation.

Table of Contents

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

Assembly & Set-Up .................................................. 9

Controls & Features ................................................ 12

Operation ................................................................ 13

Maintenance &Adjustment. ................................. 15

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 manufacturer 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 ..................................................................... 17

Troubleshooting ..................................................... 18

Replacement Parts ................................................. 19

Warranty ................................................................ 20

Spanish .................................................................... 21

RecordProductinformation

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.

MODEL NUMBER

DNDNDNDNDND

SERIAL NUMBER

DDDDDDDDDDD

CustomerSupport

Please do NOTreturn the machine to the retailer or dealer without first contacting the 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:

0 Visit us on the web at www.mtdproducts.com

0 Call a Customer Support Representative at [phone] or [phone]
0 Write us at MTD LLC • RO. Box 361131 • Cleveland, OH • 44136-0019

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!

CALIFORNIA PROPOSITION 65

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: Battery posts, terminals, and related accessories contain lead and lead

,A

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.

2

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. Keep this manual in a safe
place for future and regular reference and for ordering

replacement parts.

2. Be completely familiar with the controls and the proper use
of this machine before operating it.

3. 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 purpose.

4. 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.

5. Only responsible individuals who are familiar with these
rules of safe operation should be allowed to use this

machine.

6. 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.

7. 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.

8. 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.

9. 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.

10. 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.

11. 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. Amissingordamageddischargecovercancauseblade 27.
contactorthrownobjectinjuries.

13. Manyinjuriesoccurasaresultofthemowerbeingpulled
overthefootduringafallcausedbyslippingortripping.

Donotholdontothemowerifyouarefalling;releasethe
handleimmediately. 28.

14. Neverpullthemowerbacktowardyouwhileyouare
walking.Ifyoumustbackthemowerawayfromawallor

obstructionfirstlookdownandbehindtoavoidtripping
andthenfollowthesesteps:

a. Stepbackfrommowertofullyextendyourarms.
b. Besureyouarewellbalancedwithsurefooting.
c. Pullthemowerbackslowly,nomorethanhalfway

towardyou.

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.

d. Repeatthesestepsasneeded.

15. Do not operate the mower while under the influence of
alcohol or drugs. 1.

16. Do not engage the self-propelled mechanism on machines
so equipped while starting engine. 2.

17. The blade control is a safety device. Never attempt to
bypass its operation. Doing so makes the safety device
inoperative and may result in personal injury through 3.
contact with the rotating blade. The blade control must
operate easily in both directions and automatically return

to the disengaged position when released.

18. Never operate the mower in wet grass. Always be sure of Do Not:
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.

19.

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

20.

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

21.

If the equipment should start to vibrate abnormally, stop
the engine and check immediately for the cause. Vibration

is generally a warning of trouble.

22.

Shut the engine off and wait until the blade comes to
acomplete stop before removing the grasscatcher or

unclogging the chute. The cutting blade continues to
rotate for afew seconds after the blade control is released.

Never place any part of the body in the blade area until you
are sure the blade hasstopped rotating.

23.

Never operate mower without proper trail shield,
discharge cover, grasscatcher, blade control or other safety

protective devices in place and working. Never operate
mower with damaged safety devices. Failure to do socan
result in personal injury.

24.

Muffler and engine become hot and can causea burn. Do
not touch.

25.

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

26.

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

Do:

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

2. Do not mow slopes greater than 15 degrees asshown on

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

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.

2.

3.

4.

5.

6.

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.
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.

Mow across the face of slopes; never up and down. Exercise
extreme caution when changing direction on slopes.

Watch for holes, ruts, rocks, hidden objects, or bumps
which can cause you to slip or trip. Tall grass can hide

obstacles.

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.

could lose your footing or balance.

the slope gauge.

slipping.

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.
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.

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

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.

4 I SECTION 2 -- IMPORTANT SAFE OPERATION PRACTICES

Service

SafeHandling OfGas01ine:

I. 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. Wash your skin and change clothes
immediately.

2. Use only an approved gasoline container.

3. 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.

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 overfill fuel tank. Filltankto no more than I inch
below bottom of filler neck to provide for fuel expansion.

I0. Replace gasoline cap and tighten securely.
1I. 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 free 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.

GeneralService:

I. Never run an engine indoors or in a poorly ventilated area.

Engine exhaust contains carbon monoxide, an odorless
and deadly gas.

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

3. Check the blade and engine mounting bolts at frequent
intervals for proper tightness. Also, visually inspect blade
for damage (e.g., bent, cracked, worn) Replace blade with
the original equipment manufacture's (O.E.M.) blade only,

listed in this manual. "Use of parts which do not meet the
original equipment specifications may lead to improper
performance and compromise safety!"

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

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

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

7. After striking a foreign object, stop the engine, disconnect
the spark plug wire and ground against the engine.

Thoroughly inspect the mower for any damage. Repair the
damage before starting and operating the mower.

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

9. Grass catcher components, discharge cover, and trail shield
are subject to wear and damage which could expose
moving parts or allow objects to be thrown. For safety
protection, frequently check components and replace
immediately with original equipment manufacturer's

(O.E.M.) parts only, listed in this manual. "Use of parts
which do not meet the original equipment specifications
may lead to improper performance and compromise
safety!"

10. Do not change the engine'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.

15. 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 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.

Donot 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.

SECTION 2 -- IMPORTANT SAFE OPERATION PRACTICES S

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 include the following emission control systems: Engine
Modification (EM), Oxidizing Catalyst (OC), Secondary Air
Injection (SAI) and Three Way Catalyst (TWC) if so equipped.

SparkArrestor

i_ll WARNING: This machine is equipped with an

Ira 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 attester for the muffler is available through your

nearest engine authorized service dealer or contact the service
department, RO. Box 361131 Cleveland, Ohio 44136-0019.

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).

6 I SECTION 2 -- IMPORTANT SAFE OPERATION PRACTICES

Safety Symbols

This page depicts and describes safety symbols that may appear on this product. Read, understand, and follow all instructions on the
machine before attempting to assemble and operate.

READ THE OPERATOR'S MANUAL(S)
Read, understand, and follow all instructions in the manual(s) before attempting to

assemble and operate

DANGER -- ROTATING BLADES

To reduce the risk of injury, keep hands and feet away. Do not operate unless discharge cover
or grass catcher is in its proper place. If damaged, replace immediately.

®

i|1_

Do not mow when children or others are around.

IRFS

_1_ DANGER-- HAND/FOOT CUT

Keep hands and feet away from rotating parts.

DANGER -- THROWN DEBRIS
Remove objects that can be thrown by the blade in any direction. Wear safety glasses.

DANGER -- SLOPES
Use extra caution on slopes. Do not mow slopes greater than 15°.

,_ _ WARNING--GASOLINEIS FLAMMABLE

__\_%._ and muffler to cool before touching.

Allow the engine to cool at least two minutes before refueling.

WARNING-- CARBON MONOXIDE

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

WARNING-- HOT SURFACE

Engine parts, especially the muffler, become extremely hot during operation. Allow engine

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

Ii_ WARNING: Your Responsibility--Restrict the use of this power machine to persons who read, understand and |

SAVETHESEINSTRUCTIONS!

SECTION 2 -- IMPORTANT SAFE OPERATION PRACTICES 7

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SECTION 2 -- IMPORTANT SAFE OPERATION PRACTICES

AssembJy&Set-Up

Contents of Carton

3

One Lawn Mower
One Grass Catcher

One Lawn Mower Operator's Manual
One Engine Operator's Manual

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.

One Bottle of Oil
One Side Discharge Chute

2.

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.

Handle Hardware

Figure 3-1

b. Tighten star knobs to secure upper handle to lower

handle. Make sure that each carriage bolt is seated
properly in the handle.

Figure 3-2

2.

Insert a carriage bolt found in the manual bag into the
upper hole on the handle mounting bracket. Secure with
one plastic wing nut, also included in the manual bag. See
Fig. 3-2. Repeat on other side with remaining hardware.

3.

The rope guide is attached to the right side of the upper
handle. See Fig. 3-3. Loosen the wing nut which secures the
rope guide.

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.

RearWheels

Install rear wheels as follows in Fig. 3-4 (wheels maybe already
installed at factory, if so disregard this step):

\

1.

Place rear of the mower deck on raised blocks.

2.

Remove lock nut from pivot arm assembly (on select
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.

GrassCatcher

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 fra me so that its black plastic side is

at the bottom.

b.

Slip plastic channel of grass bag over hooks on the
frame. See Fig. 3-5. All the plastic channels except
center top of bag attach from outside of bag.

Figure 3-5

c. Attach center top of bag from inside of bag.

Figure 3-4

SECTION 3 -- ASSEMBLY& SET-UP

2. Follow the steps below to attach the grass catcher:

a. Lift rear discharge door. See Fig. 3-6.

,p

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.

2_

Slide two hooks of side discharge chute under hinge pin on
mulching plug assembly. Lower the mulching plug. Do not
remove side mulching plug at any time, even when you are

not mulching.

Adjustments

CuttingHeight

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.

J

SideDischargeChute

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.

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Figure 3-7

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.

Set-Up

GasandOilFill-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.

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.

J

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

SECTION3 -- ASSEMBLY& SET-UP 11

ControlsandFeatures

Recoil Starter

Grass

Catcher

Side Discharge

Chute

4

Control

Plug

BladeControl

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.

_ ARNING: This blade control is a safety device.

Never attempt to bypass its operations.

Cutting HeightAdjustmentLevers

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.

MulchPlug

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.

Cutting Height

Adjustment Levers

Figure 4-1

GrassCatcher

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.

SideDischargeChute

Your mower is shipped as a mulcher. To discharge the grass
clippings to the side instead, follow the instructions in the

Assembly & Set-Up section to attach the side discharge chute.

_lb ARNING: Keep hands and feet away from the

chute area on cutting deck. Refer to warning label
on the unit.

RecoilStarter

The recoil starter is attached to the right upper handle. Stand
behind the unit and pull the recoil starter rope to start the unit.

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