MTD 11A 546B029 User Manual LAWN MOWER Manuals And Guides 1107385L
User Manual: MTD 11A-546B029 11A-546B029 MTD LAWN MOWER - Manuals and Guides View the owners manual for your MTD LAWN MOWER #11A546B029. Home:Lawn & Garden Parts:MTD Parts:MTD LAWN MOWER Manual
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Safety • Assembly • Operation • Tips & Techniques • Maintenance • Troubleshooting • Parts Lists • Warranty
AOA AL
21" Hi=Wheel Mower- Model Series 540
iMPORTANT
READ SAFETY RULES AND iNSTRUCTiONS CAREFULLY BEFORE OPERATION
Warning: Thisunit is equippedwithan internalcombustionengineandshouldnot beusedon or nearany unimprovedforest-covered,brush-
coveredor grass-coveredlandunlesstheengine'sexhaustsystemisequippedwitha sparkarrestermeetingapplicablelocalor statelaws(if any).
If a sparkarresteris used,it shouldbemaintainedineffectiveworkingorderby the operator.In theStateof Californiathe aboveis requiredbylaw
(Section4442of the CaliforniaPublicResourcesCode).Otherstatesmayhavesimilarlaws.Federallawsapplyonfederallands.A sparkarrester
for the muffleris availablethroughyour nearestengineauthorizedservicedealeror contactthe servicedepartment,RO.Box361131Cleveland,
Ohio44136-0019.
PRINTEDIN U.S.A MTD LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019
FORMNO.769-00447F
3/22/2007
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.
Table of Contents
Slope Gauge ........................................................ 3
Safe Operation Practices ................................... 4
Setup and Adjustment ....................................... 6
Operating Your Lawn Mower .............................. 8
Maintaining Your Lawn Mower ......................... 10
Troubleshooting ................................................ 12
Safety Labels .................................................... 13
Parts List ........................................................... 14
Warranty ............................................. Back Cover
MTDLLCreservesthe rightto changeproductspecifications,designs,andequipmentwithoutnoticeandwithoutincurringobligation.
Finding and Recording Model Number
BEFOREYOU BEGINTO ASSEMBLEYOURNEW
EQUIPMENT,pleaselocate the model plateon the
equipmentand copythe informationto the sample
model plateprovidedto the right.Youcanlocate the
modelplate bystanding at the operatingpositionand
lookingdown at the rearof the deck. This information
will benecessaryto usethe manufacturer'sweb
site, to obtainassistancefrom the CustomerSup-
port Department,or when contactingan authorized
service dealer.
f
Model Number Serial Number
MTD LLC
P.O. BOX 361131
CLEVELAND, OH 44136
330-220-4683
, www.mtdproducts.com 800-800-731
Customer Support
Please do NOTreturn the unit to the retailer from which it was
purchased, without first contacting Customer Support.
If you havedifficulty assemblingthis productor have anyquestionsregardingthe controls,operation,or
maintenanceof this unit,youcan seekhelp fromthe experts.Choosefrom the optionsbelow:
• Visitwww.mtdproducts.com
• Phonea CustomerSupport Representativeat 1.800.800.7310.Spanishspeakingagents areavailable.
• The engine manufacturer is responsiblefor all engine-relatedissueswith regardsto performance,power-
rating,specifications,warrantyand service. Pleasereferto the enginemanufacturer'sOwner's/Operator's
Manual,packedseparatelywith your unit,for moreinformation.
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WARNING
This symbolpoints
out importantsafety
instructionswhich, if
notfollowed,could
endangerthe personal
i safetyand/or property
I ofyourselfand others.
Readandfollowall
instructionsinthis
manualbeforeat-
temptingto operate
i this machine. Failure
I to complywith these
instructionsmay result
i in personalinjury.When
you see this symbol.
i HEED ITS WARNING!
i Your Responsibility
Restrictthe use
of this power machine
to personswho read.
i understand
andfollow the warnings
and instructions
I. =nthis manual
and on the machine.
WARNING: Engine Exhaust,some of its constituents, and certain vehicle compo-
nentscontain or emit chemicals known to State of Californiato cause cancer and
birth defects or other reproductiveharm.
DANGER: This machine was built to be operatedaccordingto the rulesfor safe operation in this
manual.As with any type of powerequipment, carelessnessor error on the part of the operator
can result in serious injury.This machine is capable of amputating handsand feet and throwing
objects. Failure to observe the following safety instructions could result in serious injury or death.
Children
Tragicaccidentscanoccur ifoperatorisnotalert to presence
of children.Childrenare oftenattractedto mowerand mowing
activity.Theydonot understandthe dangers.Neverassume
thatchildrenwill remainwhereyou lastsawthem.
1. Keepchildrenoutof the mowingareaand underwatchful
careof a responsibleadultotherthanthe operator.
2. Bealert andturn moweroffif a childentersthearea.
3. Beforeand whilemovingbackwards,look behindanddown
forsmallchildren.
4. Useextremecare whenapproachingblind corners,
doorways,shrubs,trees,or otherobjectsthat mayobscure
yourvisionof a child whomayrun intothe mower.
5. Keepchildrenawayfromhotor runningengines.Theycan
sufferburnsfroma hotmuffler.
6. Neverallowchildrenunder14yearsoldto operatea power
mower.Children14yearsoldand overshouldreadand
understandoperationinstructionsandsafetyrulesinthis
manualandshouldbetrainedandsupervisedbya parent.
General Operation
1. Readthis operator'smanualcarefullyin its entiretybefore
attemptingto assemblethis machine.Read,understand,
andfollowall instructionsonthe machineandin the
manual(s)beforeoperation.Becompletelyfamiliarwith
thecontrols andthe properuseof this machinebefore
operatingit. Keepthis manualin a safeplaceforfuture
and regularreferenceand for orderingreplacementparts.
2. Thismachineis a precisionpieceof powerequipment,
nota plaything.Therefore,exerciseextremecautionat all
times.Yourunithas beendesignedto performonejob: to
mowgrass. Do notuseit for any otherpurpose.
3. Neverallow childrenunder 14yearsold to operatethis
machine.Children14yearsold and overshould readand
understandthe instructionsinthis manualandshould
betrainedand supervisedby a parent.Onlyresponsible
individualswho arefamiliar withthese rulesof safe
operationshould beallowedto usethis machine.
4. Thoroughlyinspectthe areawherethe equipmentisto
beused. Removeall stones,sticks,wire, bones,toys
andotherforeignobjects, whichcouldbetrippedover or
pickedup andthrownbythe blade.Thrownobjects can
causeseriouspersonalinjury.Planyour mowingpattern
to avoiddischargeof materialtowardroads,sidewalks,
bystandersandthe like.Also,avoiddischargingmaterial
againsta wall or obstruction,whichmaycausedischarged
materialto ricochetback towardthe operator.
5. Tohelpavoidbladecontact ora thrownobjectinjury,
stay inoperatorzone behindhandlesand keepchildren,
bystanders,helpersand petsat least 75feetfrom mower
whileit is inoperation.Stop machineifanyoneenters
area.
6. Alwayswearsafetyglassesor safetygogglesduringopera-
tion andwhile performingan adjustmentor repairto protect
youreyes.Thrownobjectswhich ricochetcan causeserious
injuryto the eyes.
7. Wearsturdy,rough-soledworkshoesand close-fitting
slacksandshirts. Shirtsand pantsthatcoverthe arms and
legs andsteel-toedshoesare recommended.Neveroperate
this machinein barefeet,sandals,slipperyor light-weight
(e.g.canvas)shoes.
8. Do notputhandsorfeet nearrotatingpartsor undercutting
deck.Contactwithblade can amputatehandsandfeet.
9. A missingor damageddischargecovercan cause blade
contactor thrownobject injuries.
10.Manyinjuriesoccuras a resultof the mowerbeing pulled
overthefoot duringa fall causedby slippingor tripping.
Do nothold onto the mowerifyou are falling;releasethe
handleimmediately.
11.Neverpullthe mowerback towardyouwhileyouare
walking.If youmust backthe mowerawayfroma wall or
obstructionfirstlook downand behindto avoidtrippingand
thenfollowthese steps:
a. Stepback frommowerto fully extendyourarms.
b. Be sure youare wellbalancedwithsurefooting.
c. Pullthe mowerbackslowly,no morethan halfway
towardyou.
d. Repeatthesestepsas needed.
12.Do notoperatethe mowerwhileunderthe influenceof
alcoholordrugs.
13.Do notengagetheself-propelledmechanismon unitsso
equippedwhilestartingengine.
14.The bladecontrolhandleis a safetydevice.Neverattempt
to bypassits operation.Doingso makesthe safetydevice
inoperativeandmayresult in personalinjurythrough
contactwiththe rotatingblade.The bladecontrolhandle
mustoperateeasily in bothdirectionsandautomatically
returnto the disengagedpositionwhenreleased.
15.Neveroperatethe mowerinwet grass.Alwaysbesure of
yourfooting. A slipand fall cancauseseriouspersonal
injury.If youfeel youare losing yourfooting,releasethe
bladecontrolhandleimmediatelyand the bladewillstop
rotatingwithinthreeseconds.
16.Mowonly in daylightor good artificiallight. Walk,neverrun.
17.Stopthe bladewhencrossinggraveldrives, walksor roads.
18.If the equipmentshouldstartto vibrateabnormally,stopthe
engineand checkimmediatelyfor the cause.Vibrationis
generallya warningof trouble.
4
19.Shutthe engineoff and waituntil the bladecomesto a
completestopbeforeremovingthe grasscatcherorunclog-
gingthe chute.
Thecutting bladecontinuesto rotatefora few secondsafter
the engineisshutoff. Neverplaceany partof the body in
the bladeareauntil youare surethe bladehasstopped
rotating.
20.Neveroperatemowerwithoutpropertrailshield,discharge
cover,grasscatcher,bladecontrolhandleorothersafety
protectivedevicesin placeand working.Neveroperate
mowerwith damagedsafetydevices.Failureto do so can
result in personalinjury.
21.Mufflerand enginebecomehotandcan causea burn.Do
nottouch.
22.Only use partsandaccessoriesmadeforthis machineby
manufacturer.Failureto do so can resultin personalinjury.
23. Ifsituationsoccur whichare notcoveredinthis manual,
usecare and goodjudgment.Contactyour dealerfor
assistance.
Slope Operation
Slopesare a majorfactor relatedto slip andfall accidents,which
canresult insevereinjury.Operationonslopesrequiresextra
caution.If youfeeluneasyona slope,do notmowit. Foryour
safety,use theslopegaugeincludedas part ofthis manualto
measureslopesbeforeoperatingthis uniton a slopedorhilly
area.Ifthe slopeis greaterthan 15degrees,donotmow it.
Do:
1. Mow acrossthe faceof slopes;neverupand down.Exercise
extremecautionwhenchangingdirectiononslopes.
2. Watchfor holes,ruts, rocks,hiddenobjects,or bumps
which cancauseyouto slipor trip. Tallgrasscan hide
obstacles.
3. Alwaysbe sure of yourfooting.A slipand fallcan cause
serious personalinjury.If youfeel youare losingyour
balance,releasethe bladecontrol handleimmediately,and
the bladewill stoprotatingwithin3 seconds.
Do Not:
1. Do notmow neardrop-offs,ditchesor embankments,you
could loseyourfootingor balance.
2. Do notmow slopesgreaterthan 15degreesas shownon
the slopegauge.
3. Do notmow onwet grass. Unstablefootingcouldcause
slipping.
Service
Safe Handling Of Gasoline:
1. Toavoidpersonalinjuryor propertydamageuse extreme
care in handlinggasoline.Gasolineisextremelyflammable
and thevaporsare explosive.Seriouspersonalinjury can
occur whengasolineisspilled onyourselfor your clothes,
which canignite.Washyourskin andchangeclothes
immediately.
2. Use onlyan approvedgasolinecontainer.
3. Neverfill containersinsidea vehicleor on a truck ortrailer
bed witha plasticliner.Alwaysplacecontainersonthe
groundawayfromyourvehiclebeforefilling.
4. Removegas-poweredequipmentfromthe truckor trailer
and refueliton theground.If this isnot possible,then refuel
suchequipmenton atrailer witha portablecontainer,rather
than froma gasolinedispensernozzle.
5. Keepthe nozzlein contactwiththe rimof the fueltankor
containeropeningat all times untilfueling is complete.Do
not usea nozzlelock-opendevice.
6. Extinguishallcigarettes,cigars, pipesand othersources
of ignition.
7. Neverfuel machineindoorbecauseflammablevaporswill
accumulatein thearea.
8. Neverremovegascap oradd fuel whileengineis hot or
running. Allowengineto cool at least two minutesbefore
refueling.
9. Neveroverfill fueltank. Filltankto nomorethan Y2inch
below bottomof filler neckto providefor fuel expansion.
10.Replacegasolinecapandtightensecurely.
11.If gasolineis spilled,wipe itoff theengineand equipment.
Moveunit to anotherarea.Wait 5 minutesbeforestarting
engine.
12.Neverstorethe machineorfuel containernearan open
flame,sparkor pilot light as on a water heater,space
heater,furnace,clothesdryeror othergasappliances.
13.Toreducefire hazard,keepmowerfree of grass, leaves,
orother debrisbuild-up.Cleanup oil orfuel spillageand
removeanyfuel soakeddebris.
14.Allowa mowerto cool at least5 minutesbeforestoring.
GeneralService:
1. Neverrun an engineindoorsorin a poorlyventilatedarea.
Engineexhaustcontainscarbonmonoxide,anodorless
anddeadlygas.
2. Beforecleaning,repairing,or inspecting,makecertainthe
bladeandall movingparts havestopped.Disconnectthe
sparkplugwire andgroundagainstthe engineto prevent
unintendedstarting.
3. Checkthe bladeandenginemountingbolts atfrequent
intervalsfor propertightness.Also,visuallyinspectblade
fordamage(e.g.,bent,cracked,worn)Replacebladewith
theoriginalequipmentmanufacture's(O.E.M.)bladeonly,
listedin this manual."Useof partswhichdo notmeetthe
originalequipmentspecificationsmayleadto improper
performanceand compromisesafety!"
4. Mowerbladesare sharpandcan cut.Wrapthebladeor
weargloves,anduseextracautionwhenservicingthem.
5. Keepallnuts,bolts,andscrewstightto be surethe equip-
mentis insafeworkingcondition.
6. Nevertamperwithsafetydevices.Checktheir proper
operationregularly.
7. Afterstrikinga foreignobject,stopthe engine,discon-
nectthesparkplugwire andgroundagainsttheengine.
Thoroughlyinspectthe mowerfor any damage.Repairthe
damagebeforestartingandoperatingthe mower.
8. Neverattemptto makea wheelor cuttingheightadjust-
mentwhilethe engineisrunning.
9. Grasscatchercomponents,dischargecover,andtrail
shield aresubjectto wear anddamagewhichcould
exposemovingparts or allowobjectsto be thrown.For
safetyprotection,frequentlycheckcomponentsand re-
placeimmediatelywithoriginal equipmentmanufacturer's
(O.E.M.)partsonly, listedin this manual."Use of parts
whichdo notmeetthe originalequipmentspecifications
mayleadto improperperformanceand compromise
safety!"
10.Do notchangetheenginegovernorsettingor over-revthe
engine.Thegovernorcontrolsthe maximumsafeoperating
speedof the engine.
11.Maintainor replacesafetylabels,as necessary.
12.Observeproperdisposallawsand regulations.Improper
disposalof fluidsand materialscanharmtheenvironment.
Practices
WARNING
This symbol points
out importantsafety
instructions, which if
not followed,could
endangerthe personal
safety and/or property
of yourselfand others.
Readand followall
instructions inthis man-
ual before attemptingto
operate this machine.
Failureto comply with
these instructionsmay
result in personal injury.
When you see this
symbol.
HEED iT'S WARNING!
Your Responsibility
Restrictthe use
of this power machine
to personswho read.
understand
and followthe warnings
and instructions
in this manua
and on the machine.
5
1. Removeanypackingmaterialwhichmaybebetween
Standbehindthe mower
as ifyouwere goingto
i operate it. Yourright
handcorrespondsto the
rightsideof the mower;
yourleft hand corre-
spondsto the left sideof
the mower.
Makesureto routecable
outside the lower handle.
Donotcrimpcablewhile
lifting the handleup.
IMPORTANT
IThis unit is shippedwith-
out gasoline or oil inthe
engine. Fillup gasoline
iandoil as instructed in
i the accompanying engine
; manual BEFOREoperat-
ing your mower.
iThis Operator'sManual
imaycoverarangeof
,productspecifications
i for variousmodels
ICharacteristics,features,
iandengines discussed
i and/or illustratedin
this manual may notbe
applicable to all models,
MTDLLCreservesthe
rightto changeproduct
ispecifications,designs,
Iandequipment without
inoticeand withoutincur-
iringobligation.
Figure3-1: Unfoldhandle,tightenhardware.
Hardware Pack _*_
Wing Nuts (2) Carriage Bolts (2) ..........................................
upperandlowerhandles.
a. Pullupand backon upperhandleas shownin
Figure3-1.Makecertainthe lowerhandleis seated
securelyintothe handlemountingbrackets.Donot
crimpcablewhile liftingthe handleup.
b. Tightenstarknobsto secureupperhandleto
lowerhandle.Makesurethateachcarriagebolt is
seatedproperlyinthe handle.
2. Locatethe hairpinclipon the weldpinon eachsideof
lowerhandle.
a. Removehairpinclipfromthis hole.Usinga pair
of pliers,inserthairpinclip intothe holeon pin
closestto the bracket.SeeFigure3-2. Repeaton
otherside.
.
b. inserta carriagebolt fromthe hardwarepackinto
the upperholeonthe handlemountingbracket.
Securewithone plasticwing nut,also included
inthe hardwarepack.Repeatonother sidewith
remainingitemsfromhardwarepack.
The ropeguideis attachedto the right sideof the
upperhandle.SeeFigure3-3. Loosenthe wing nut
whichsecuresthe ropeguide.
a. Holdbladecontrolagainstupperhandle.
b. Pullstarterropeout of the engine.Releaseblade
control.
.
c. Slipstarterropeinto ropeguide.
d. Tightenwingnut.
insertpostoncable tie intoholeprovidedon thelower
handle.Pullcabletie tightandtrimexcess.SeeFigure
3-4.
Figure3-2:Securelowerhandleto mountingbrackets.
f
Figure3-3:Pullrecoilstarterthroughropeguide andtighten. Figure3-4:Securecablesto handleusingcabletie.
6
.Followstepsbelowto assemblethe grasscatcher.
Makecertainbagis turned rightsideout before
assembling(warninglabelwill be onthe outside)
a. Placebagoverframesothat itsblackplasticside
is at the bottom.
b. Slip plasticchannelof grassbagoverhookson
the frame.SeeFigure3-5. All theplasticchannels
exceptcentertop of bagattachfromoutsideof
bag.
c. Attachcentertop of bagfrominsideof bag.
Yourmoweris shippedas a mulcher.Toconvertto
sidedischarge,makesuregrasscatcheris off of the
unitand reardischargedooris closed.
a. Onthe sideof the mower,lift the mulchingplug.
SeeFigure3-7.
b. Slidetwohooksof side dischargechuteunder
hingepinonmulchingplugassembly.Lowerthe
mulchingplug. Do not removesidemulchingplug
at anytime,evenwhenyou arenot mulching.
Figure3-7:Lift mulchplugandinstallside dischargechute.
Figure3-5:Assemblethegrasscatcher.
6. Followthe stepsbelowto attachthe grasscatcher:
a. Liftreardischargedoor.SeeFigure3-6.
b. Placegrasscatcheron thepivotrod. Letgo
of dischargedoorsothat it restson thegrass
catcher.
_ARNING:Neveroperate mowerunless
the hooksonthe grass catcher are
firmly seated on the pivotrod and the
rear discharge door restsfirmly against
top of the grass catcher.
Adjustments
Anadjustingplateandthumbleverat eachwheel
providescuttingheightadjustment.
1. Depresslevertowardswheel.
2. Moveitto any oneof the positionsfor desiredcutting
height.SeeFigure3-8. Makesurethateachwheelis
positionedat the sameheight.
3. Releaselevertowardsmowerdeck.
/
S
Figure3-6:Attachthegrasscatcher. Figure3-8:Use leversto adjustcuttingheight.
7
setupand
WARNING
withoutthe mulching
plug, the grass catcher,
or the discharge chute
NOTE:When adjusting
the cutting height,
all wheels must be
positioned at the same
height.
M0Wer
WARNING
The blade control is a
safety device. Never
attempt to bypass its
operations.
Use extreme care when
handling gasoline.
Gasoline is extremely
flammable and the
vapors are explosive.
iNeverfuel themachine
indoors or while the
engine is hot or running.
Extinguish cigarettes,
,cigars, pipes, and other
sources of ignition.
Keep hands and feet
iaway from the cutting
deck. Refer to warning
label on the unit.
/
Know Your Lawn Mower
f BladeControl
Recoil Starter
CuttingHeight
Adjustment
front
andrear)
MulchPlug
SideDischargeChute ..=======__
Figure4-1:Themajorparts onthelawnmower.
Nowthatyou havesetupyour lawnmowerfor opera-
tion,readthis sectionto becomeacquaintedwithits
controlsandfeatures.Thisknowledgewill allowyouto
useyour newequipmentto itsfullestpotential.
Blade Control
Thebladecontrolisattachedto the upperhandle.
Depressandsqueezeit againstthe upperhandleto
operatethe unit.Releaseit to stopengineandblade.
__k WARNING:Thisblade controlis
asafetydevice. Donot bypass its
operations.
Cutting Height Adjustment Levers
Oneadjustmentleveris locatedon eachwheelandis
usedto adjustthe cuttingheight.All fourwheelsmust
beat the samepositionto ensurea uniformcut.
Recoil Starter
The recoilstarteris attachedto the rightupperhandle.
Standbehindthe unitand pullthe recoilstarterropeto
startthe unit.
Mulch Plug
Themulchplugis usedfor mulchingpurposes.Insteadof
collectingthe grassclippingsinagrasscatcheror using
the sidedischargechute,somemowermodelshavethe
optionof recirculatingthe clippingsbackto the lawn.This
is calledmulching.
Grass Catcher
Thegrasscatcher,locatedat the rearof the mower,is
usedto bagthe grassclippingsfor disposalat another
site.Oncethe bagisfull, ithasto beremovedfromthe
mowerandemptiedbeforeanyfurthermowing.
Gas and Oil Fill-Up
1. Checkoillevelandaddoil if necessary.Followengine
owner'smanualforthis.
2. Servicethe enginewithgasolineas instructedinthe
engineowner'smanual.
_ARNING:Useextremecarewhenhan-
dling gasoline.Gasoline is extremely
flammable and the vapors areexplosive.
Neverfuel the machine indoorsor while
the engine is hot or running. Extinguish cigarettes,
cigars, pipes,and other sources of ignition.
8
Starting Engine
__k ARNING:Besurenoone otherthan
the operatoris standingnearthe lawn
mowerwhilestartingengineor operat-
ing mower.Neverrun engineindoorsor
in enclosed,poody ventilatedareas.Engineexhaust
containscarbonmonoxide,an odorlessand deadly
gas. Keephands,feet, hairand looseclothingaway
from any moving partsonengine and lawnmower.
Follow the set of instructionspertainingto your unit.
Referto engine manual for helpwith the engine.
Briggs & Stratton/Kawasaki Engine:
1. Ifequipped,pushprimerthreetimes(Kawasaki-one
time).Waitabouttwo secondsbetweeneach push.
See Figure4-2. In temperaturearound550F or below,
primefivetimes.Do notprimeto restarta warm
engine.
2. Standingbehindthe mower,squeezethe bladecontrol
againstupperhandle.SeeFigure4-2.
3. Holdingthesetwo handlestogetherfirmly,grasp recoil
starterhandleand pullropeout witha rapid,continu-
ous,full arm stroke.SeeFigure4-2. Keepinga firm
gripon the starterhandle,let the roperewindslowly.
Repeatuntil enginecranks.Letthe roperewindeach
timeslowly.
Honda Engine:
1. Placethe fuel valveleverfoundonthe left sideof the
engineintothe ON (OPEN)position.See Figure4-3.
2. Movethechokelever(if equipped)all the way
backwardintothe chokeposition.
3. Standingbehindthe mower,squeezethe bladecontrol
againstupperhandle.SeeFigure4-3.The chokewill
now beginto slowly returnto the offchokeposition
afteractivatingthe bladecontrol.Therefore,quickly
moveontostepfourbelow.
4. Holdingthesetwo handlestogetherfirmly,grasp recoil
starterhandleand pullropeout witha rapid,continu-
ous,full arm stroke.SeeFigure4-3. Keepinga firm
gripon the starterhandlelet the roperewindslowly.
Repeatuntil enginecranks.Letthe roperewindeach
timeslowly.
__1= ARNING:Waitfor the blade to stop
completelybefore performingany work
on the mower or to removethe grass
catcher.
Stopping Engine
1. Releasebladecontrolto stoptheengineand blade.
2. Disconnectsparkplugwirefromsparkplugand
groundagainstthe engine.
Figure4-2:StartingtheBriggs&Strattonengine.
Figure4-3:StartingtheHondaengine.
anydirectionandcauseseriouspersonalinjuryto the
operatorandothers.
__k ARNING:if you strikeaforeign
object, stop the engine. Remove
wire from the spark plug,thoroughly
inspectmowerfor any damage,and
repairdamage before restarting andoperating.
Extensive vibration of mowerduring operation is an
indicationof damage.The unit should be promptly
inspectedand repaired.
Using as Mulcher
Formulchinggrass,removethe grasscatcherandside
dischargechutefromthe mower.Foreffectivemulching,
do notcutwetgrass.If the grasshasbeenallowedto
growin excessof fourinches,mulchingis not recom-
mended.Usethe grasscatcherto bagclippingsinstead.
Using Your Lawn Mower Using Grass Catcher
Besurelawnisclearof stones,sticks,wire,or other Youcan usethe grasscatcherto collectclippingswhile
objectswhichcoulddamagelawnmowerorengine, youareoperatingthe mower.Referto setupsectionfor
Such objectscouldbe accidentlythrownby the mowerin instructionson attachingthe grasscatcher.
9
Operating
Mower
WARNING
The operation of any
lawn mower can result
n foreign objects being
thrown into the eyes,
which can damage your
eyes severely. Always
wear safety glasses
while operating the
mower or while perform-
ing any adjustments or
repairs on it.
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
ventilated 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,
/" Deck Care
lVloWer
Do not use apressure
Washer or garden
hoseto Cleanyour
uniL These may Cause
damageto eleCtric
componentsi spindles;
pu,eys,bearings;or
theenginel The use
Ofwater Willresu!tin
shortened lifeand
reduce serviceability:
This Operator'sManual
covers several models;
Lawn Mowerfeatures
vary by model: Not
all features disCussed
(Orengnespictur
in this manual are
app!icableto all Lawn
Figure5-1:Areasto lubricateonmower.
General Recommendations
• Alwaysobservesafetyruleswhen performing
anymaintenance.
• Thewarrantyon thislawnmowerdoesnot cover
itemsthathavebeensubjectedto operatorabuse
ornegligence.To receivefull valuefromwarranty,
operatormustmaintainthelawn moweras
instructedhere.
• Changingof engineigovernedspeedwill void
enginewarranty.
• Alladjustmentsshouldbecheckedat leastonce
eachseason.
• Periodicallycheckallfastenersand makesurethese
aretight.
__i ARNING:Alwaysstopengine,discon-
nect spark plug, and ground against
engine before performing any type of
maintenance on your machine.
Lubrication
1. Lubricatepivotpointson thebladecontrolat least
oncea seasonwithlightoil. The bladecontrolmust
operatefreelyinboth directions.SeeFigure5il.
2. Lubricatethe wheelsat leastoncea seasonwith
lightoil (ormotoroil). If wheelsareremovedfor any
reason,lubricatesurfaceof the pivotarm andinner
surfaceof thewheelwithlight oil. SeeFigure5il.
3. Lubricatethe torsionspringsandpivotpointonthe
reardischargedoorandside mulchplugperiodically
withlightoil to preventrust.SeeFigure511.
4. Followtheaccompanyingenginemanualfor lubrica-
tion scheduleandinstructionfor enginelubrication.
Cleanundersideof the mowerdeckaftereachuse to
preventbuild-upof grassclippingsorotherdebris.Follow
stepsbelowfor thisjob.
1. Disconnectsparkplugwire.Draingasolinefromlawn
mowerorplacea pieceof plasticunderthegas cap.
2. Tip mowersothat it restsonthe engine.Keepthe side
withthe aircleanerfacingup. Holdmowerfirmly.
_ARNING:Nevertip the mower more
than 90° in any direction anddo not
leavethe mower tipped for any lengthof
time. Oil can drain intothe upper partof the engine
causing a starting problem.
3. Scrapeand cleanthe undersideof the deckwith a
suitabletool.Do notspraywithwater.
4. Putthe mowerbackonits wheelsonthe ground.If
youhad putplasticunderthe gas capearlier,make
sureto removeit now.
Engine Care
A listof keyenginemaintenancejobs requiredfor good
performanceby the moweris given below.Followthe
accompanyingenginemanualfor adetailedlist and
instructions.
• Maintainoil levelas instructedin enginemanual.
•Serviceaircleanerevery25 hoursundernormal
conditions.Cleaneveryfewhoursunderextremely
dustyconditions.Poorengineperformanceand
floodingusuallyindicatesthatthe aircleanershould
beserviced.Toservicethe aircleaner,referto the
enginemanual.
• Cleansparkplugand resetthegaponce a season.
Sparkplugreplacementis recommendedat the start
of eachmowingseason.Checkenginemanualfor
correctplugtypeand gapspecifications.
• Cleanengineregularlywitha clothorbrush.Keepthe
top of theengineclean to permitproperair circulation.
Removeallgrass,dirt,andcombustibledebrisfrom
mufflerarea.
10
Blade Care
_i= ARNING:Whenremovingthe cutting
bladefor sharpeningor replacement,
protectyourhandswith a pairof heavy
gloves or use a heavy ragto hold the
blade.
Periodicallyinspectthe bladeadapterfor cracks,
especiallyif youstrikea foreignobject. Replacewhen
necessary.Followthe stepsbelowfor bladeservice.
1. Disconnectsparkplugwirefromsparkplug.Turn
moweron itsside makingsurethatthe airfilterand
the carburetorarefacingup.
2. Removethe boltandthe bladebellsupportwhich
holdthe bladeand the bladeadapterto the engine
crankshaft,Figure5-2.
3. Removebladeandadapterfromthe crankshaft,
Figure5-2.
4. The bladecan be sharpenedwitha fileor on a grind-
ingwheel.Do notattemptto sharpenthe bladewhileit
is stillonthe mower.
Whensharpeningthe blade,followthe originalangle
of grind. Grindeachcuttingedgeequallyto keepthe
bladebalanced.
5. Totest for balance,removebladeand balanceon
a roundshaftscrewdriver.Removemetalfromthe
heavysideuntil itbalancesevenly.
f
J
Figure5-2:Removethebolt,support,andadaptertoaccess
theblade.
_ WARNING:Anunbalanced bladewill
causeexcessivevibration when rotating
at high speeds. It maycausedamage to
mower and could break causing personal
injury.
6. Lubricatetheenginecrankshaftandthe innersurface
of the bladeadapterwithlightoil. Slidethe blade
adapteronto the enginecrankshaft.
7. Placethe bladeon the adaptersuchthatthe side
of the blademarked"Bottom"(orwithpart number)
facesthe groundwhenthe mowerisintheoperating
position.Makesurethatthe bladeisalignedand
seatedon the bladeadapterflanges.
8. Placebladebellsupportonthe blade.Alignnotches
on the bladebell supportwith smallholesinblade.
9. Replacehex boltandtightenhex boltto torque:450
in.Ibs. rain.,600 in.Ibs.max.
Toensuresafeoperationof yourmower,periodically
checkthe bladeboltfor correcttorque.
Replacing Rear Flap
1. To removerearflap,lift reardoor,andpressflap in on
eitherside to removefromhole. SeeFigure5-3.
2. Removeflap fromoppositeholeand replacewith new
flap intheoppositeorderandmannerof removal.
Figure5-3:Removerearflap.
Off-Season Storage
Thefollowingstepsshouldbetakento prepareyour
lawnmowerfor storage.
• Cleanandlubricatemowerthoroughlyas described
inthe lubricationinstructions.
• Do not usea pressurewasherorgardenhoseto
cleanyourunit.
Referto enginemanualforcorrectengine
storageinstructions.
Coatmower'scuttingbladewithchassisgreaseto
preventrusting.
Storemowerina dry,cleanarea. Donot storenext
to corrosivematerials,suchas fertilizer.
Whenstoringanytypeof powerequipmentina poorly
ventilatedor metalstorageshed,careshouldbetaken
to rust-prooftheequipment.Usinga lightoil or silicone,
coattheequipment,especiallycablesandall moving
partsof yourlawnmowerbeforestorage.
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.
An unbalanced blade
will cause excessive
vibration when rotat-
ingat high speeds. It
may cause damage
to mower and could
break causing per-
sonal injury.
11
Shooting
For repairsbeyond
the minoradjustments
listedhere; contact
an authorized service
dealer'
NOTE: Specficationsaid
subjectto changewith0ut
notificationo[ ob!igation,
Imagesrnayn0treflect
yourexact modeland are
iiiI i_I _ii_iii_iii_!i_ii_i _ _i i_ _ i
Problem Cause Remedy
Engine fails to start ii B!adeControidisengaged, ii EngagebladeC0ntr0
2 Spa[kplugWiredisconnected. 2 connect wireto spark plugl
3: Fuel tankemptYorstaidfuel &Fill tankWithcleanl freshgasoiine:
4. Enginenot primed(if equippedwith 4. Primeengineas instr,u,ctedin operat_
primer)i I ingYourLawnMower:
5. FaultySparkp ugl 15 cleanl adjustgaP,0rreP!ace.
6, clean fuellinel
7: Enginefl0oded. Waita few minutest0 restart bUtdo
I& Fue! yalve (if equipped)CloSed. I Open fuel va!ve, see enginemanna!.
9. EnginenotChoked(if equippedw/choke). & Chokeenginel Seeengine manual.
Engine runs erratic 1. Sparkplugwire loose. 1. Connect andtightensparkplugwire.
2. Blockedfuel lineor stalefuel. 2. Cleanfuelline; fill tank withclean,
3. Ventingas cap plugged.
4. Wateror dirt infuel system.
5. Dirtyair cleaner.
6. Carburetorout of adjustment.
freshgasoline.
3. Clearvent.
4. Drainfueltank. Refillwithfresh fuel.
5. Referto enginemanual.
6. Referto enginemanual.
Engine overheats 1. Engineoil levellow, 1. Fillcrankcasewith properoil.
2. Airflow restricted. 2. Cleanaccumulateddebrisfromengine.
3. Carburetornotadjustedproperly. 3. Referto enginemanual.
Occasional skips 1. Sparkpluggap tooclose. 1. Adjustgap to .030-inch.
(hesitates) at high speed 2. Carburetoridlemixtureadjustment 2. Referto enginemanual.
improperlyset.
I I
Idles poorly 1. Sparkplugfouled,faultyor gaptoo wide. 1. Resetgapto .030-inchor replace
spark plug.
2. Carburetorimproperlyadjusted. 2. Referto enginemanual.
3. Dirtyair cleaner. 3. Referto enginemanual.
Excessive Vibration 1. Cuttingbladelooseor unbalanced. 1. Tighten bladeandadapter.Balance
blade.
2. Bentcutting blade. 2. See anauthorizedservicedealer.
Mower wil not mulch grass 1. Wetgrass. 1 Donot mowwhengrass is wet wait
untillater to cut.
2 Excessivelyhighgrass. 2. Mowonce at a highcutting height,
then mowagainat desiredheight or
makea narrowercurt ngpath.
, 3. Dullblade. , 3. Sharpenor replaceblade,
Uneven cut 1. Wheelsnotpositionedcorrectly. 1. Placeallfour wheelsin same
heightposition.
2. Dullblade. _ 2. Shar en or re! laceblade.
12
Safety Labels Found On Your Lawn Mower
13
iVlodel Series 540
Zag
14
747-1161A BladeControl 734-04215 FrontWheel,8 x 1.8,K2 Bar
2 749-1092A UpperHandle 734-1988 FrontWheel,7 x 1.8,Bar
3 746-1130 ControlCable,40" 734-1987 FrontWheel,8 x 1.8,Bar
746-04104 ControlCable,40",Snap-On,Kaw 734-2005A FrontWheel,8 x 2.125,Zag
746-1137 ControlCable,53" 734-04086 FrontWheel,7 x 1.8,PinBar
726-0240 CableTie 28 738-0507B
664-04007A GrassBagAssembly 29 732-0404
664-04034A GrassBagAssembly-Gray 30 720-0426
664-04027 GrassBagAssembly-Yardman 31 710-0599
747-04080 GrassBagFrame 32 736-0270
720-0279 HandleKnob 33 710-0654A
731-05642 Trailshield 34 710-0216
6
7
8
9 747-04588 PivotRod 35 710-1652
10 731-05865 RearDischargeDoor 36 720-0312
11 687-02280 RearHandleBracketAssy.- LH 37 734-04217
687-02279 RearHandleBracketAssy.-RH 734-04082
12 787-01279 Deck21-inch 734-04093
13 687-02075B FrontHgt.Adj.Assy.,8" Whl.-LH 734-04089
ShoulderScrew,.5Dx.434
FrontSpringLever
HeightAdjustKnob
TT Screw,1/4-20x .500
BellWasher
TT Screw,3/8-16x 1.0
HexScrew,3/8-16x .75
TT Screw,1/4-20x .625
FoamGrip
RearWheel,12x 1.8,K2 Bar
RearWheel,12x 1.8,Bar
RearWheel,12x 2.125,Zag
RearWheel,12x 1.8,PinBar
Parts Li
_FACTORY PARTS
To order replacement
parts, contact
1,800-800'7310
or visit
687-02074B FrontHgt.Adj.Assy.,811Whl.-RH 38 710-1205 EyeBolt www.mtdproducts;com
_687-02099B _ FrontHgt.Adj.Assy.,7 Whl.-LH 39 _ 732-0866 _ RearHi-WheelSpringLever
687-02100B FrontHgt.Adj.Assy.,7"Whl.-RH 40
14 782-5002B FrontBaffle
15 748-0377C BladeAdapterw/Star 41
748-04082 BladeAdapter- 25ram 42
16 742-0741 21-inchMulchingBlade 43
17 736-0524B BellBladeSupport 44
18 710-1257 HexScrew,3/8-24x2.5 45
19 731-04177 SideDischargeChute 46
20 17032A DeflectorChuteAdaptor 47
21 732-1014 TorsionSpring 48
22 747-0710 HingePin 49
687-02039A RearPivotArmAssy- RH
687-02040A RearPivotArmAssy- LH
714-0104 HairpinClip
720-04072 StarKnob
710-0703 CarriageBolt ,1/4-20x .75
731-04150C RearBaffle
710-1241 ScrewHL, 1/4-15x 1.00
732-04090A TorsionSpring- RH
710-1174 CarriageBolt,5/16-18x 2
712-0397 Wing Nut
749-0928A LowerHandle
23 687-02055 HingedMulchPlugAssembly 50 736-0182t SpringWasher
24 712-04065 FlangeLockNut3/8-16 51 731-04204t DeluxeBailCover- Red
25 787-01290 HeightAdjustmentPlate 731-04859t DeluxeBailCover- Gray
26 687-02337 PivotArmAssyLH (7"wheel) 52 732-04089A TorsionSpring- LH
687-02338 PivotArmAssyRH(7" wheel) 53 738-04266 ShoulderScrew,.500Dia.X .385
687-02337 PivotArmAssyRH(8" wheel) 54 731-0981At HubCap
687-02338 PivotArmAssyLH (8"wheel)
t If Equipped
Mowerfeatures/componentsvaryby model.NOTall partslistedaboveand picturedon the previouspageare
standardequipment.
15
ii i _iI_ ii
MANUFACTURER'S LiMiTED WARRANTY FOR
The limitedwarrantysetforthbelowisgivenby MTDLLCwithrespect
to newmerchandisepurchasedandusedin the UnitedStates,its
possessionsandterritories.
"MTD"warrantsthisproductagainstdefectsinmaterialandworkman-
shipfor a periodof two (2)yearscommencingonthe date of original
purchaseandwill,at itsoption,repairor replace,freeof charge,any
part foundto bedefectiveinmaterialsorworkmanship.Thislimitedwar-
rantyshallonlyapply if thisproducthasbeenoperatedand maintained
inaccordancewiththe Operator'sManualfurnishedwiththe product,
andhas notbeensubjectto misuse,abuse,commercialuse,neglect,
accident,impropermaintenance,alteration,vandalism,theft,fire,water,
ordamagebecauseof otherperilor naturaldisaster.Damageresulting
fromthe installationor useof any part,accessoryor attachmentnot
approvedby MTDfor use withthe product(s)coveredbythis manual
willvoid yourwarrantyas to any resultingdamage.
Normalwearpartsarewarrantedto befree fromdefectsinmaterialand
workmanshipfor a periodof thirty (30)daysfromthe dateof purchase.
Normalwearpartsinclude,butare notlimitedto itemssuchas: batter-
ies,belts,blades,bladeadapters,grassbags,riderdeckwheels,seats,
snowthrowerskidshoes,shaveplates,augerspiralrubberandtires.
HOW TO OBTAIN SERVICE: Warranty service is available,WITH
PROOFOF PURCHASE, through your local authorized service
dealer. To locate the dealer in your area, check your Yellow Pages,
or contact MTD LLC at RO. Box 361131,Cleveland, Ohio 44136-
0019, or call 1-800-800-7310or 1-330-220-4683 or log on to our
Web site at www.mtdproducts.com.
Thislimitedwarrantydoesnot providecoverageinthe followingcases:
a. Theengineor componentpartsthereof.Theseitemsmaycarrya
separatemanufacturer'swarranty.Referto applicablemanufacturer's
warrantyfor termsandconditions.
b. Logsplitterpumps,valves,andcylindershavea separateoneyear
warranty.
c. Routinemaintenanceitemssuchas lubricants,filters,blade
sharpening,tune-ups,brakeadjustments,clutchadjustments,deck
adjustments,andnormaldeteriorationof the exteriorfinishdueto
useor exposure.
d. Servicecompletedby someoneotherthananauthorizedservice
dealer.
e. MTDdoesnot extendanywarrantyfor productssoldor exported
outsideof the UnitedStates,its possessionsandterritories,except
thosesoldthroughMTD'sauthorizedchannelsof exportdistribution.
f. ReplacementpartsthatarenotgenuineMTDparts.
g. Transportationchargesandservicecalls.
No impliedwarranty,includingany impliedwarranty of mer-
chantabilityof fitness for a particular purpose,applies after the
applicable periodof express written warranty above as to the
partsas identified.No otherexpresswarranty, whetherwrittenor
oral, except as mentioned above,givenby any personor entity,
includingadealeror retailer, withrespect to any product,shall
bindMTD.Duringthe periodof the warranty,the exclusiveremedy
is repairor replacementof the productas setforth above.
Theprovisionsas set forth inthis warrantyprovidethe soleand
exclusiveremedy arising from the sale.MTDshallnot be liable
for incidentalor consequentiallossor damage including,without
limitation, expensesincurredfor substituteor replacementlawn
careservicesor for rentalexpensesto temporarily replacea
warranted product.
Somestatesdo notallowthe exclusionor limitationof incidentalor
consequentialdamages,or limitationsonhowlongan impliedwarranty
lasts,sothe aboveexclusionsor limitationsmaynot applyto you.
In noeventshallrecoveryof any kindbegreaterthanthe amountof the
purchasepriceof the productsold.Alterationof safetyfeatures of
the productshallvoid this warranty. Youassumethe riskandliability
for loss,damage,or injuryto you andyourpropertyand/orto othersand
theirpropertyarisingout of the misuseor inabilityto usethe product.
Thislimitedwarrantyshallnot extendto anyoneotherthan theoriginal
purchaserorto the personfor whomitwas purchasedas a gift.
HOWSTATELAWRELATESTOTHIS WARRANTY:This limited
warrantygivesyou specificlegalrights,and youmayalsohaveother
rightswhichvaryfromstateto state.
IMPORTANT:OwnermustpresentOriginalProofof Purchaseto obtain
warrantycoverage.
IVITDLLC, P.O. BOX 361131 CLEVELAND, OHiO 44136-0019; Phone: 1=800=800-7310, 1-330=220-4683
GDOO-lO0015 REV.A
