<font color="blue"> usually run it much lower than 540 rpms...and does a good job cutting at the lower speed. </font>
As mentioned in previous responses, I agree that lower rpm should have little, if any adverse impact on your gearbox.
The greater the tip speed, the more likely a blade will cut vs tear. Does it take 540 to cut? Will grass blades always tear at less than 540? If you look at different models of decks, their tip speeds will likely not be the same at 540rpm.
I believe a dull mower blade could tear a blade of grass, even at 540 rpm...while a sharp blade may cut your yard nicely at a speed below 540? Even after mowing once or twice, if you feel the edge of the mower blades, you will be able to tell that the sharpness is beginning to dull.
Then there's the question- So what if some grass blades are torn instead of cut? More prone to disease? etc. What diseases have you seen? I don't know. Most everybody has their yard cut regularly during summer. Right? Have you ever heard someone say, "Wow, look at that diesased yard. That guy must be mowing with dull blades at less than 540 rpm!!"
Anyway, my point is, keep your blades in decent shape, and if the cut of your yard is OK at less than 540 rpm, stay with it. I don't think it will hurt your gearbox.
OkieG