Safety • Assembly • Operation • Tips & Techniques • Maintenance • Troubleshooting • Parts Lists • Warranty A O A 21" Hi=Wheel Mower- AL Model Series 540 iMPORTANT READ SAFETY RULES AND iNSTRUCTiONS CAREFULLY BEFORE OPERATION Warning: This unit is equippedwith an internalcombustionengineand shouldnot be usedon or nearany unimprovedforest-covered,brushcoveredor grass-coveredland unlesstheengine'sexhaustsystemis equippedwith a sparkarrestermeetingapplicablelocalor statelaws(if any).
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 Customer Support .............................................. Slope Guage ........................................................ Safe Operation Practices ................................... Setup And Adjustment ....................................... Operating Your Lawn Mower ........................
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WARNING: Engine Exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to State of Californiato cause cancer and birth defects or other reproductiveharm. 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.
19.Shut the engine off andwait untilthe bladecomesto a completestop before removingthe grasscatcheror unclogging the chute. The cuttingbladecontinuesto rotatefor a fewseconds after the engine is shut off. Neverplaceany part of the bodyin the bladearea untilyou are surethe blade hasstopped rotating. 20. Neveroperate mowerwithoutpropertrail shield, discharge cover,grass catcher,bladecontrol handleor othersafety protectivedevices in placeand working.Neveroperate mowerwithdamagedsafetydevices.
1. Removeanypackingmaterialwhich may be between upperand lowerhandles. a. Pull up and backon upperhandleas shownin Figure3-1.Makecertain the lowerhandleis seated securelyintothe handle mountingbrackets.Donot crimpcablewhile liftingthe handleup. b. Tightenstar knobsto secureupper handleto lowerhandle.Make surethat eachcarriagebolt is seatedproperlyin the handle. c. Placea blockunderthemowerdeck to raisethe unitoff of thegroundand removethe flangelock nutfromthe axle.
5. Followstepsbelowto assemblethe grasscatcher. Makecertainbag is turned rightsideout before assembling(warninglabelwill be on the outside) 7. Yourmoweris shippedas a mulcher.Toconvertto sidedischarge,makesuregrass catcherisoff of the unitand reardischargedoor isclosed. a. Placebag overframe sothat its black plasticside is at the bottom. a. On the sideof the mower,lift the mulchingplug, Figure3-7. b. Slip plasticchannelof grass bagoverhooks on the frame,Figure3-5.
/ Know Your Lawn Mower f BladeControl Recoil Starter =====_, Mower GrassCatcher_ WARNING The blade control is a MulchPlug -- safety device. Never attempt to bypass its operations. Side Discharge Chute _,.__ i Use extreme care when ; handling gasoline. Gasoline is extremely flammable and the vapors are explosive. Neverfuel the machine i indoors or while the ; engine is hot or running. ; Exhngwsh c_garettes, cigars, pipes, and other sources of ignition. Figure4-1:The majorparts on the lawnmower.
mowercan result in foreign objects being ARNING:The operationof any lawn thrownintothe eyeswhichcan damage youreyes severely.Alwayswear safetyglasses whileoperatingthe moweror while performingany adjustmentsor repairson it. _ Starting Engine You r LaWn operatoris standingnear lawn mower WARNING:Be sure no onethe otherthan the whilestartingengineor operatingmower. Never runengineindoorsor in enclosed,poorly ventilatedareas. Engineexhaustcontainscarbon monoxide, an odorlessand deadly gas.
Deck Care Cleanundersideof the mowerdeck after eachuse to preventbuild-upof grass clippingsor otherdebris. Follow stepsbelowfor this job. 1. Disconnectsparkplug wire. Draingasolinefrom lawn moweror placea pieceof plasticunderthegas cap. Lubricate these q points before reassembly. 2. Tip mowersothat itrestson the housing.Keepthe sidewith the air cleanerfacingup. Hold mowerfirmly. than 90° in any direction do not WARNING:Never tip the and mower more leavethe mower tipped for any length of time.
F Blade Care bladefor sharpeningor replacement, ARNING:Whenremovingthe cutting protectyourhandswith a pairof heavy gloves or use a heavy rag to hold the blade. _ Periodicallyinspectthe bladeadapterfor cracks, especiallyif youstrikea foreignobject. Replacewhen necessary.Followthe stepsbelowfor blade service. 1. Disconnectsparkplug wirefrom spark plug.Turn moweron itsside makingsurethat the air filter and the carburetorare facing up. Your LaWn MoWer 2.
Problem Cause Engine fails to Start i ade controldisengagedl 21 spark plug Wire disconnected• 31 Fueltank empty OrStalefuel• 4. Enginenot pr reed. 5: Faultyspark pug 6. BloCkedfuel linel 7: Engineflooded. Enginerunserratic 1. Sparkplug wire loose. 2. Blockedfuel lineor stale fuel. 3. 4. 5. 6. _i _ 1. Adjust gapto .030-inch. 2. Referto engine manual. Idles poorly 1. Sparkplug fouled, faulty or gaptoo wide. 1. Resetgapto .030-inchor replace spark pug. 2. Referto engine manual• 3.
WARNING DO NOT remove safety (or any)labels from mower for any reason: ii i _iI_ ii 13
747-1161A Blade Control 732-0404 FrontSpring Lever 2 749-1092A UpperHandle 30 720-0426 HeightAdjustKnob 3 746-1130 Cntrl.Cable,40" Model 546&549 31 710-0599 TT Screw,1/4-20x .500 746-1137 Cntrl Cable,53"Model 543 32 736-0270 Bell Washer 4 726-0240 CableTie 33 710-0654A TT Screw,3/8-16x 1.0 5 664-04080 Grass BagAssembly 34 710-0216 Hex Screw,3/8-16x .75 6 747-04080 Grass Bag Frame 35 710-1652 TT Screw,1/4-20x .
MANUFACTURER'S LiMiTED WARRANTY The limitedwarrantyset forth belowisgivenby MTDLLCwith respect to newmerchandisepurchasedand usedin the UnitedStates,its possessionsand territories. "MTD"warrantsthis productagainstdefectsin materialand workmanshipfor a periodof two (2) years commencingon the date of original purchaseand will, at its option,repairor replace,freeof charge,any part foundto be defectiveinmaterialsor workmanship.
