MTD 540, 11A-544C062 Owner’s Manual

OPERATOR'S MANUAL

21" Rear & Side

Discharge

Mulching Mower

Model Series 540

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IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY

Warning: This unit 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 attester is used, it should be maintained in effective working order by the operator,

Inthe 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 368022 Cleveland, Ohio 44136_9722.

MTD PRODUCTS INC. P.O. BOX 368022 CLEVELAND, OHIO 44136-9722

PRINTED IN U.S.A. FORM NO. 770-10006B

(1woo)

TABLEOFCONTENTS

Content Page

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

Slope Gauge ...................................................................................................... 6

Assembling Your Lawn Mower ........................................................................... 7

Know Your Lawn Mower .................................................................................... 9

Operating Your Lawn Mower ............................................................................. 9

Making Adjustments .......................................................................................... 10

Maintaining Your Lawn Mower ........................................................................... 11

Troubleshooting ................................................................................................. 14

Parts List ............................................................................................................ 16

FINDINGMODELNUMBER

This Operator's Manual is an important part of your new lawn mower. It will help you assemble, prepare and
maintain the unit for best performance. Please read and understand what it says.

Before you start assembling your new equipment, please locate the model plate on the

equipment and copy the information from it in the space provided below. The information on
the model plate is very important if you need help from our Customer Support Department or
an authorized dealer.

You can locate the model number by standing at the operating position and looking down at the rear
of the mower deck. A sample model plate is explained below. For future reference, please copy the
model number and the serial number of the equipment inthe space below.

w.-

(Model Number)

MTD PRODUCTS INC

CLEVELAND, OHIO 44136

(Serial Number)

Copy the model number here:

Copy the serial number here:

CALLINGCUSTOMERSUPPORT

If you have difficulty assembling this product or have any questions regarding the controls, operation or

maintenance of this unit, please call the Customer Support Department.

Call 1- (330) 220-4MTD (4683) or 1- (800)-800-7310 to reach a Customer Support
representative. Please have your unit's model number and serial number ready when you

call. See previous section to locate this information. You will be asked to enter the serial
number in order to process your call.

SECTION1: IMPORTANTSAFEOPERATIONPRACTICES

WARNING: This symbol points out important safety instructionswhich, if not followed, could

endanger the personal safety and!or property of yourself and others. Read and follow all instructions in
this manual before attempting to operate this machine. Failure to comply with these instructions may

result in personal injury. When you see this symbol - heed its warning.

WARNING: Engine Exhaust, some of its constituents, and certain vehicle
components contain or emit chemicals known to State of California to cause cancer

and birth defects or other reproductive harm.

DANGER: This machine was built to be operated according to the rules; for safe operation in this

manual. As with any type of power equipment, carelessness or error on the part of the operator can
result in serious injury. This machine is capable of amputating hands and feet and throwing objects.

Failure to observe the following safety instructions could result in serious injury or death.

GeneralOperation

1. Read this operator's manual carefully in its entirety
before attempting to assemble this machine. Read,

understand, and follow all instructionson the machine
and inthe manual(s) before operation. Be completely
familiar with the controls and the proper use of this

machine before operating it. Keep this manual in a safe
place for future and regular reference and for ordering

replacement parts.

2. This machine is a precision piece of power equipment,
not a plaything. Therefore, exercise extreme caution at all

times. Your unit has been designed to perform one job; to

mow grass. Do not use it for any other purpose.

3. Never allow children under 14 years old to operate this
machine. Children 14 years old and over should read and
understand the operation instructions and safety rules in
this manual and should be trained and supervised by a
parent. Only responsible individuals who are familiar with
these rules of safe operation should be allowed to use

this machine.

4. 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.

5. To help avoid blade contact or a thrown object injury, stay
in the operator zone behind the handles and keep

children, bystanders, helpers and pets at least 75 feet
from the mower while it is in operation. Stop machine if
anyone enters the area.

6. Always wear safety glasses or safety goggles during

operation and while performing an adjustment or repair to

protect your eyes. Thrown objects which ricochet can

cause serious injury to the eyes.

7. Wear sturdy, rough-soled work shoes and close-fitting

slacks and shirts. Shirts and pants that cover the arms

and legs and steeFtoed shoes are recommended. Never
operate this machine in bare feet, sandals, slippery or
light weight (e.g. canvas) shoes.

8. Do not put hands or feel near rotating parts or under the
cutting deck. Contact with the blade can amputate hands

and feet.

9. A missing or damaged discharge cover can cause blade
contact or thrown object injuries,

10. Many injuries occur as _Lresult 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.

11. Never pull the mower back toward you while you are
walking. Ifyou must back the mower away from a wall or
obstruction first look down and behind to avoid tripping

and then follow these steps:

a, Step back from tlnemower to fully extend your

arms.

b. Be sure you are well balanced with sure footing.

c. Pull the mower back slowly, no more than half way

toward you.

d. Repeat these steps as needed.

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

13. Do not engage the self-propelled mechanism on units so
equipped while starting engine.

14. The blade control handle is a safety device. Never
attempt to bypass 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
automatically return to the disengaged position when

released,

15, Never operate the mower in wet grass. Always be sure of

your footing. A slip and fall can cause serious personal
injury. If you feel you are losing your footing, release the
blade control handle immediately and the blade will stop

rotating within three seconds.

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

run.

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

roads.

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

Vibration is generally a warning of trouble.

19,

Shut the engine off and wait until the blade comes to a
complete stop before re,moving the grass catcher or

3

uncloggingthechute.Thecuttingbladecontinuesto
rotateforafewsecondsaftertheengineisshutoff.

Neverplaceanypartofthebodyinthebladeareauntil 5.
youaresurethebladehasstoppedrotating.

20.Neveroperatemowerwithoutpropertrailshield, 6.
dischargecover,grasscatcher,bladecontrolhandleor
othersafetyprotectivedevicesinplaceand working.

Never operate mower with damaged safety devices.
Failure to do so, can result in personal injury.

21. Muffler and engiee become hot and can cause a burn. Do

not touch. Service

22. Only use parts and accessories made for this machine by

the manufacturer. Failure to do so, can result in personal

injury.

23. If situations occur which are not covered in this manual,

use care and good judgment. Contact your dealer for
assistance. Telephone [phone] for the name of
your nearest dealer.

2. Wash your skin and change clothes immediately.

SlopeOperation

SIopes 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 unit 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 ceuse
serious personal injury. If you feel you are losing your
balance, release the blade controI handle immediately,
and the blade will stop rotating within 3 seconds.

Do Not:

1. Do not mow near drop-off& ditches or embankments,
you could lose your footing or balance.

2. Do not mow slopes greater than 15 degrees as shown on
the slope gauge.

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

3. Use only an approved gasoline container.

4. Never fill containers inside a vehicle or on a truck or

5. When practical, remove gas-powered equipment from

6, Keep the nozzle in contact with the rim of the fueI tank or

7. Extinguish all cigarettes, cigars, pipes and other sources

8. Never fuel machine indoors because flammable vapors

9. Never remove gas cap or add fuel whiIe the engine is hot

10. Neveroverfillfueltank. Filltanktonomorethan V2inch

11. Replace gasoline cap and tighten securely.

12. If gasoline is spilled, wipe it off the engine and

13. Never store the machine or fuel centainer inside where

Children

Tragic accidents can occur ifthe operator is not alert to the
presence of children. Children are often attracted to the
mower and the mowing activity. They do not understand the
dangers. Never assume that chiIdren will remain where you

last saw them.
1, Keep children out of the mowing area and under the

watchful care of a responsible adult other than the
operator.

2. Be alert and turn mower off if a child enters the area.

3. Before and while moving backwards, look behind and
down for small children.

4. Use extreme care when approaching blind corners,
doorways, shrubs, trees, or other objects that may

14. To reduce fire hazard, keep mower free of grass, leaves,

15. Allow a mower to cool at Ieast 5 minutes before storing.

GeneralService:

1. Never run an engine indoors or in a poorly ventilated

2. Before cleaning, repairing, or inspecting, make certain

3. Check the blade and engine mounting bolts at frequent

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 old to operate a
power mower. Children 14 years old and over should

read and understand the operation instructions and
safety rules in this manual and should be trained and
supervised by a parenL

SafeHandlingOfGasoline:

1. To avoid personal injury or property damage use extreme
care in handling gasoline. Gasoline is extremely

flammable and the vapors are explosive. Serious
personar injury can occur when gasoline is spilled on

yourself or your clothes which can ignite.

trailer bed with a plastic liner. Always place containers on

the ground away from your vehicle before filling.

the truck or trailer and refuel it on the ground. If this is net

possible, then refuel such equipment on a trailer with a
portable container, rather than from a gasoline dispenser

nozzle.

container opening at all times until fueling iscomplete. Do
not use a nozzle lock-open device.

of ignition.

will accumulate in the area.

or running. Allow engine to cool at least two minutes
before refueling.

below bottom of filler neck to provide space for fuel
expansion.

equipment. Move unit to another area. Wait 5 minutes
before starting the engine.

there is an open flame, spark or pilot light as on a water

heater, space heater, furnace ,clothes dryer or other gas

appliances.

or other debds build-up. Clean up oil or fueI spillage and

remove any fuel soaked debris.

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

the blade and all moving parts have stopped. Disconnect
the spark plug wire and ground against the engine to

prevent unintended starting.

intervalsforpropertightness.Also,visuallyinspectblade

9. Grass catcher components, discharge cover, and trail

fordamage(e.g.,bent,cracked,worn)Replaceblade
withtheoriginalequipmentmanufecture's(O.E.M.)blade

only,listedinthismanual."Useofpartswhichdonot
meettheoriginalequipmentspecificationsmayleadto
improperperformanceandcompromiseeafetyF

4. Mowerbladesaresharpandcancut.Wrapthebladeor
weargloves,anduseextracautionwhenservicingthem.

5. Keepallnuts,bolts,andscrewstighttobesurethe
equipmentisinsafeworkingcondition.

10. Do not change the engine governor setting or overspeed

6. Nevertamperwithsafetydevices.Checktheirproper
operationregularly.

7. Afterstrikingaforeignobject,stoptheengine,disconnect

11. Maintain or replace safety and instruction labels, as

thesparkplugwireandgroundagainsttheengine.
Thoroughlyinspectthemowerforanydamage.Repair

12. Observe proper disposs.I laws and regulations. Improper

thedamagebeforestartingandoperatingthemower.

8. Neverattempttomakeawheelorcuttingheight

adjustment while the engine is running.

understand and follow the warnings and instructions in this manual and on the roach ne.

WARNING - YOU R RESPONSIBILITY; Restrict the use of this power machine to persons who read,

NOTE: Not all safety labels shown may apply to your lawn mower.

shield are subject to wear and damage which could
expose moving parts or alIow 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 safetyF

the engine. The governor controls the maximum safe
operating speed of the engine.

necessary.

disposal of fluids and materials can harm the
environment.

DANGER

SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE

A POWER POLE

!

!

A CORNER OF A BUILDING

OR A FENCE POST

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15°

_WARNING

Do not mow on inclines with a slope in excess of 15 degrees (a rise of approximately 2-1/2 feet every 10 feet). A riding mower could

overturn and cause serious injury. If operating a walk-behind mower on such a slope, it is extremely difficult to maintain your footing
and you could slip, resulting in serious injury.

Operate RIDING mowers up and down slopes, never across the face of slopes.

;:3

Operate WALK-BEHIND mowers across the face of slopes, never up and down slopes.

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