MTD Yard-Man 203 User Manual

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OPERATOR’S MANUAL

Chipper Shredder

Vacuum

Model Number

203

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 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 arrester for the muffler is available through your nearest engine authorized service dealer or contact the service department, P.O. Box 361131 Cleveland, Ohio 44136-0019.

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

PRINTED IN U.S.A.

FORM NO.

770-10023D.fm (5/02)

TABLE OF CONTENTS

Content Page

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

Assembling Your Chipper Shredder Vacuum .................................................... 5

Know Your Chipper Shredder Vacuum .............................................................. 6

Operating Your Chipper Shredder Vacuum ....................................................... 7

Adjusting Your Chipper Shredder Vacuum ........................................................ 9

Maintaining Your Chipper Shredder Vacuum..................................................... 10

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

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

FINDING MODEL NUMBER

This Operator’s Manual is an important part of your new chipper shredder vacuum. 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 behind the unit and looking down at the frame below the engine. A sample model plate is explained below. For future reference, please copy the model number and the serial number of the equipment in the space below.

Copy the model number here:

Copy the serial number here:

ENGINE INFORMATION

The engine manufacturer is responsible for all engine-related issues with regards to performance, powerrating, specifications, warranty and service. Please refer to the engine manufacturer’s Owner’s/Operator’s Manual packed separately with your unit for more information.

CALLING CUSTOMER SUPPORT

Please do NOT return the unit to the retailer from which it was purchased, without first contacting Customer Support.

Should 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.

For more details about your unit, visit our website at www.yardman.com

SECTION 1: IMPORTANT SAFE OPERATION PRACTICES

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.

WARNING: The Engine Exhaust from this product contains chemicals known to the

State of California to cause cancer, 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.

TRAINING

1. Read, understand, and follow all instructions on the machine and in the manual(s) before attempting to assemble and operate. Keep this manual in a safe place for future and regular reference and for ordering replacement parts.

2. Be familiar with all controls and their proper operation. Know how to stop the machine and disengage them quickly.

3. Never allow children under 16 years old to operate this machine. Children 16 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.

4. Never allow adults to operate this machine without proper instruction.

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

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

7. Do not put hands and feet near rotating parts or in the feeding chambers and discharge opening. Contact with the rotating impeller can amputate fingers, hands, and feet.

8. Never attempt to unclog either the feed intake or discharge opening, remove or empty vacuum bag, or inspect and repair the machine while the engine is running. Shut the engine off and wait until all moving parts have come to a complete stop. Disconnect the spark plug wire and ground it against the engine.

PREPARATION

1. Thoroughly inspect the area where the equipment is to be used. Remove all rocks, bottles, cans, or other foreign objects which could be picked up or thrown and cause personal injury or damage to the machine.

2. Always wear safety glasses or safety goggles during operation or while performing an adjustment or repair, to protect eyes. Thrown objects which ricochet can cause serious injury to the eyes.

3. Wear sturdy, rough-soled work shoes and closefitting slacks and shirts. Loose fitting clothes or jewelry can be caught in movable parts. Never operate this machine in bare feet or sandals. Wear leather work gloves when feeding material in the chipper chute.

4. Before starting, check all bolts and screws for proper tightness to be sure the machine is in safe working condition. Also, visually inspect machine for any damage at frequent intervals.

5. Maintain or replace safety and instructions labels, as necessary.

6. 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.

a. Use only an approved gasoline container. b. Extinguish all cigarettes, cigars, pipes, and

other sources of ignition. c. Never fuel machine indoors. d. Never remove gas cap or add while the

engine is hot or running. e. Allow engine to cool at least two minutes

before refueling. f. Never over fill fuel tank. Fill tank to no more

than 1/2 inch below bottom of filler neck to

provide space for fuel expansion. g. Replace gasoline cap and tighten securely. h. If gasoline is spilled, wipe it off the engine

and equipment. Move machine to another

area. Wait 5 minutes before starting the

engine. i. Never store the machine or fuel container

inside where there is an open flame, spark,

or pilot light (e.g. furnace, water heater,

space heater, clothes dryer, etc.)

j. To reduce a 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.

k. Allow machine to cool at least 5 minutes

before storing.

OPERATION

1. Do not put hands and feet near rotating parts or in the feeding chambers and discharge opening. Contact with the rotating impeller can amputate fingers, hands, and feet.

2. Before starting the machine, make sure the chipper chute, feed intake, and cutting chamber are empty and free of all debris.

3. Thoroughly inspect all material to be shredded and remove any metal, rocks, bottles, cans, or other foreign objects which could cause personal injury or damage to the machine.

4. If the impeller strikes a foreign object or if your machine should start making an unusual noise or vibration, immediately shut the engine off. Allow the impeller to come to a complete stop. Disconnect the spark plug wire, ground it against the engine and perform the following steps:

a. Inspect for damage. b. Repair or replace any damaged parts. c. Check for any loose parts and tighten to

assure continued safe operation.

6. Do not allow an accumulation of processed material to build up in the discharge area. This can prevent proper discharge and result in kickback of material through the feed opening.

7. Do not attempt to shred or chip material larger than specified on the machine or in this manual. Personal injury or machine damage could result.

8. Never attempt to unclog either the feed intake or discharge opening while the engine is running. Shut the engine off, wait until all moving parts have stopped, disconnect the spark plug wire and ground it against the engine before clearing debris.

9. Never operate without vacuum bag and discharge chute properly attached to the machine. Never empty or change vacuum bag while the engine is running. Zippered end of vacuum bag must be kept closed at all times during operation.

10. Never operate without either the inlet nozzle or optional hose attachment properly attached to the machine. Never attempt to attach or change either attachment while the engine is running.

11. Keep all guards, deflectors and safety devices in place and operating properly.

12. Keep your face and body back and to the side of the chipper chute while feeding material into the machine to avoid accidental kickback injuries.

13. Never operate this machine without good visibility or light. Always be sure of your footing and keep a firm hold on the handles.

14. Do not operate this machine on a gravel surface.

15. Do not operate this machine while under the influence of alcohol or drugs.

16. Muffler and engine become hot and can cause a burn. Do not touch.

17. Never pick up or carry machine while the engine is running.

MAINTENANCE AND STORAGE

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

2. Check bolts and screws for proper tightness at frequent intervals to keep the machine in safe working condition. Also, visually inspect machine for any damage and repair, if needed.

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

4. Do not change the engine governor settings or overspeed the engine. The governor controls the maximum safe operating speed of the engine.

5. Maintain or replace safety and instruction labels, as necessary.

6. Follow this manual for safe loading, unloading, transporting, and storage of this machine.

7. Never store the machine or fuel container inside where there is an open flame, spark or pilot light such as a water heater, furnace, clothes dryer, etc.

8. Always refer to the operator’s manual for proper instructions on off-season storage.

9. If the fuel tank has to be drained, do this outdoors.

10. Observe proper disposal laws and regulations for gas, oil, etc. to protect the environment.

WARNING: - YOUR RESPONSIBILITY: Restrict the use of this power machine to persons who read, understand and follow the warnings and instructions in this manual and on the machine.

NOTE: Not all safety labels shown may apply to your chipper shredder vacuum.

SECTION 2: ASSEMBLING YOUR CHIPPER SHREDDER VACUUM

IMPORTANT:

in the engine. Be certain to service engine with gasoline and oil as instructed in the separate engine manual before operating your machine.

NOTE: Reference to right or left hand side of the chipper shredder vacuum is observed from the operating position.

Removing Unit From Carton

• Remove staples, break glue on top flaps, or cut tape at carton end and peel along top flap to open carton.

• Remove loose parts if included with unit (i.e., operator’s manual, etc.)

• Cut along corners, lay carton down flat, and remove packing material.

• Roll or slide unit out of carton and check carton thoroughly for loose parts.

Loose Parts In Carton (See Figure 1)

• Nozzle

• Bag

This unit is shipped without gasoline or oil

WARNING: Before setting up your chipper shredder vacuum, disconnect the spark plug wire from the spark plug and ground against the engine.

Nozzle

Bag

Figure 1

Attaching The Nozzle

• Remove three wing nuts from the front of the chipper shredder vacuum.

• Place nozzle in position over the three studs on unit and secure with wing nuts just removed. See Figure 2.

Discharge Chute

Bag Opening

Bag

Wing Nut

Figure 2

NOTE: The metal tab on the nozzle must depress the

safety switch button attached to the front of chipper shredder vacuum or the engine will not start.

Wing Nuts

Nozzle

Attaching The Bag

• Place bag under of upper handle assembly and slip the front opening on the bag over the discharge chute, making certain it is over the rim on the discharge chute. See Figure 3.

Figure 3

• Place the four straps on the top of the bag over

upper handle, hooking them on the studs to secure in place. Squeeze the clamp on the drawstring and pull the drawstring tight. Release the clamp. See Figure 4.

Bag Straps

Figure 4

SECTION 3: KNOW YOUR CHIPPER SHREDDER VACUUM

WARNING: Be familiar with all controls and their proper operation. Know how to stop the machine and disengage them quickly.

Bag

Collects shredded or chipped material fed through the chipper chute or vacuumed up through the nozzle. See Figure 5.

Chipper Chute

Allow twigs and small branches up to 2” in diameter to be fed into the impeller for chipping. See Figure 5.

Caster Locks

The caster locks are located on top of each front caster wheel. Refer to the Adjustment Section to position wheel locks. See Figure 5.

Nozzle Door Adjustment Levers

The nozzle adjustment levers are located on each side of the nozzle door. They are used to adjust the nozzle door for ground clearance that will provide the best performance for the operating conditions. See Figure 5.

Nozzle

Yard waste such as leaves and pine needles can be vacuumed up through the nozzle for shredding. See Figure 5.

Drive Clutch Control

The drive clutch control is located on the upper handle assembly. Squeezing the drive clutch control against the upper handle engages the rear wheels. Release the drive clutch control to slow down or stop the wheel drive. See Figure 5.

Throttle Control Lever (Not Shown)

The throttle control lever is located on the engine. It controls the engine’s speed and stops the engine. See separate engine manual packed with unit for details.

Starter Handle (Not Shown)

The starter handle is located on the engine. Pull the starter handle to start engine.

Drive Clutch Control

Bag

Chipper Chute

Engine Controls

See the separate engine manual for the location and function of the controls on the engine.

Stopping Engine

• Move throttle control lever to STOP or OFF position.

• Disconnect spark plug wire from spark plug and ground against the engine.

Nozzle

Nozzle Door Adjustment Lever

Caster Locks

Figure 5

SECTION 4: OPERATING YOUR CHIPPER SHREDDER VACUUM

WARNING: Read, understand, and follow all instructions and warnings on the machine and in this manual before operating.

Always wear the safety glasses provided with this machine during operation or while performing any adjustments or repairs. Thrown objects which ricochet can cause serious injury to the eyes.

Gas And Oil Fill-Up

Service the engine with gasoline and oil as instructed in the separate engine manual packed with your chipper shredder vacuum. Read instructions carefully.

Starting Engine

• Attach spark plug wire to spark plug. Make certain

• Make certain drive clutch control is in the

• Engines with choke lever:

WARNING: Use extreme care when handling gasoline. Gasoline is extremely flammable and the vapors are explosive. Never fuel machine indoors or while the engine is hot or running. Extinguish cigarettes, cigars, pipes, and other sources of ignition.

the metal cap on the end of the spark plug is fastened securely over the metal tip on the spark plug.

disengaged (released) position.

Move choke lever on engine to CHOKE position. (A warm engine may not require choking).

• Engines with primer:

Prime engine as instructed in separate engine manual.

• The throttle control lever is located on the engine. Move engine throttle control lever to FAST or START position.

• Place one foot on the left rear wheel to prevent the unit from skidding while starting.

• Grasp starter handle and pull rope out slowly until engine reaches start of compression cycle (rope will pull slightly harder at this point).

NOTE: A noise will be heard when at the start of the compression cycle. This noise should be expected until the impeller reaches full speed.

• Pull rope with a rapid, continuous, full arm stroke. Keep a firm grip on starter handle. Let rope rewind slowly.

• Repeat the previous steps until engine fires. When engine starts, move choke control (if equipped) gradually to RUN position.

WARNING: Keep bystanders, helpers, pets, and children at least 75 feet from the machine before starting and while operating. Do not operate this machine unless the discharge chute and bag have been properly installed and secured to the machine.

Using the Chipper Shredder Vacuum

Place both hands on top of upper handle to push unit over yard waste. Yard waste such as leaves and pine needles can be vacuumed up through the nozzle for shredding. After material has been shredded by the blades on the impeller assembly, it will be discharged into catcher bag. Do not attempt to shred or chip any material other than vegetation found in a normal yard (i.e. branches, leaves, twigs, etc.) Avoid fibrous plants such as tomato vines until they are thoroughly dried out. Materials such as stalks or heavy branches up to 2” in diameter may be fed into the chipper chute. See Figure 6.

WARNING: Do not attempt to shred, chip, or vacuum any material larger than specified on the machine or in this manual. Personal injury or damage to the machine could result.

To Empty Bag

The bag is designed to be emptied without being removed from unit. Open the large zipper in the rear of the bag to empty the contents. If bag is removed for any reason, follow the instructions for attaching the bag in the ASSEMBLY section. Be certain the zipper is closed completely when operating the unit.

To Engage Drive

To engage the wheel drive, hold the drive clutch control against the upper handle. Releasing the drive clutch control stops the rear wheels from driving. Release the drive clutch control to slow down when negotiating an obstacle, making a turn, or stopping. Engage control slowly to prevent the front wheels from lifting up.

Figure 6

IMPORTANT:

housing in the discharge area. If the flail screen becomes clogged, remove and clean as instructed in MAINTAINING YOUR CHIPPER SHREDDER VACUUM. For best performance, it is also important to keep the chipper blade sharp.

The flail screen is located inside the

Tire Pressure (Pneumatic Tires Only)

WARNING: Maximum tire pressure under any circumstance is 30 psi. Equal tire pressure should be maintained at all times.

SECTION 5: ADJUSTING YOUR CHIPPER SHREDDER VACUUM

WARNING: Do not at any time make any adjustments without first stopping engine, disconnecting spark plug wire, and grounding it against the engine.

Front Caster Wheels

This chipper shredder vacuum is equipped with front caster wheels. The casters can be locked in a straight ahead position or position to swivel freely. Lift and place pins in the larger holes for locked or straight ahead operation. Place pins in smaller holes to allow casters to rotate freely. Lock wheels in straight position when operating on slopes. See Figure 7.

Smaller Hole (Rotate Freely)

Larger Hole (Locked)

Drive Clutch Cable Adjustment

Adjust the drive clutch control if the chipper shredder vacuum moves forward with the drive clutch control disengaged, if it does not self-propel with the drive clutch control engaged, or if drive belt is slipping (unit hesitates while engine maintains the same speed). Use the adjustment wheel located in the clutch control housing to tighten or loosen the clutch cable. In addition, the adjustment wheel may also be used to determine the position in which the drive clutch control is engaged. If it is more comfortable to have the drive engaged with the lever further away from the handle, tighten the clutch cable. See Figure 9.

Tighten

Adjustment Wheel

Figure 7

Nozzle Door Height Adjustment

The nozzle adjustment levers are located on each side of the nozzle door. The nozzle door can be adjusted to any of five positions, ranging from 1/2” to 3” ground clearance that will provide the best performance for the operating conditions. Slide the height adjustment lever forward or backward for adjusting the nozzle door upwards or downwards. Height must be adjusted equally. In general, raise the nozzle to vacuum a thick layer of leaves and lower the nozzle for smooth surfaces. See Figure 8.

Nozzle Door Adjustment Lever

Loosen

Figure 9

Engine Adjustments

Refer to the separate engine manual for engine adjustment instructions.

Figure 8

SECTION 6: MAINTAINING YOUR CHIPPER SHREDDER VACUUM

WARNING: Before performing any maintenance or repairs, stop the engine, wait until the machine comes to a complete stop, disconnect the spark plug wire and ground against the engine to prevent unintended starting.

Customer Responsibilities

MAINTENANCE

SCHEDULE

Lubricate Wheels

T C

Lubricate Adjustment Levers

U D O

Lubricate Caster Wheels

R P

Check Chipper Blades

Lubrication (Refer to Figure 5)

Wheels: Lubricate the rear wheels with light oil once a season.

Nozzle Door Adjustment Levers: Lubricate each adjustment lever once a season with light oil.

Front Caster Wheels: Grease fittings are located on the front caster wheels to provide easy lubrication of the swivel pins.

SERVICE

DATES

Check Oil

Change Oil

Check Air Filter

I G N

Clean Engine

Check Spark Plug

Maintenance

Engine

Refer to the separate engine manual for all engine maintenance instructions.

• Check engine oil level before each use as instructed in the separate engine manual packed with your unit. Read and follow instructions carefully.

• Clean air cleaner every 25 hours under normal conditions or once a season. Clean every few hours under extremely dusty conditions. To service the air cleaner, refer to the separate engine manual packed with your unit.

• The spark plug should be cleaned and the gap reset once a season. Check engine manual for correct plug type and gap specifications.

Removing The Flail Screen

If the discharge area becomes clogged, remove the flail screen and clean area as follows:

• Stop the engine and make certain the chipper shredder vacuum has come to a complete stop.

• Disconnect spark plug wire from spark plug and ground against the engine.

• Remove the vacuum bag from the unit.

• Remove the four self-tapping screws from the

bottom of the discharge chute, and the hex bolt, flat washer and hex nut from the top. Remove the discharge chute assembly. See Figure 10.

• Remove the two hex bolts and hex nuts which extend through the impeller housing. Lift the flail screen from the inside the housing. See Figure 10.

• Clean the screen by scraping or washing with water and reinstall the screen.

NOTE: Be certain to reassemble the flail screen with the curved side down.

Hex Bolt Flat Washer Hex Nut

Discharge Chute

Hex Lock Nuts

Access Plate

Self-Tapping Screws

Hex Bolts Hex Nuts

Flail Screen

Figure 10

• Reattach the discharge chute assembly with the hardware previously removed and connect the bag to unit.

Sharpening Or Replacing Chipper Blades

NOTE: When tipping the unit, empty the fuel tank and keep spark plug side up.

• Disconnect the spark plug wire and ground it against the engine.

• Remove the flail screen as instructed in the previous section.

• Remove the plastic belt cover on the front of the engine by removing the two self-tapping screws. See Figure 11.

• Remove the access plate by removing two hex lock nuts. See Figure 11.

• Locate one of the chipper blades in the access opening by rotating the impeller assembly by hand. Remove the chipper blade using a 3/16” allen wrench and a 1/2” wrench.

• Remove other blade in the same manner to replace or sharpen.

Belt Cover

Figure 11

WARNING: Use caution when replacing the blades, wear heavy gloves to avoid a contact injury with the weld bolts or the housing while loosening or tightening the blades.

• When sharpening blades, follow the original angle of grind. Also, make sure to remove an equal amount from each blade and torque hardware 250 300 in. lbs.

NOTE: Make certain blades are reassembled with the sharp edge facing upward.

Belt Removal And Replacement

NOTE: Because the engine on this has a tapered crankshaft, a special impeller removal tool (part number 753-0638) is required to remove impeller assembly. Contact your local service dealer.

• Disconnect the spark plug wire and ground it away from the spark plug.

• Drain the gasoline and oil from the chipper shredder vacuum.

• Remove the three wing nuts that secure the nozzle to the outer housing and remove the nozzle. Refer to Figure 2.

• Remove the vacuum bag from the unit.

• Remove the discharge chute as instructed in the

previous section Removing The Flail Screen.

• Remove the plastic belt cover on the front of the engine by removing two self-tapping screws. Refer to Figure 11.

• Tip the unit backward so that it rests on the handles.

• Remove the lower belt guard by removing the two self-tapping screws. See Figure 12.

Self-Tapping Screw

Lower Belt Guard

Safety Switch

Hex Bolts

Self-Tapping Screws

Figure 12

• Remove the safety switch from the front of the outer housing by removing the two self-tapping screws. See Figure 12.

• Remove the two hex bolts and hex lock nuts which extend through the housing. Lift the flail screen out of the housing. Refer to Figure 10.

• Remove the outer housing and housing blades by removing the fourteen self-tapping screws.

• Remove the hex bolt, lock washer, and flat washer that secures the impeller assembly to the crankshaft. See Figure 13.

Hex Bolt Lock Washer Flat Washer

Impeller Assembly

Hex Bolts

Figure 14

• Insert the new belt between the frame and transmission pulley. It may be necessary to use a screwdriver to pry the frame away from the pulley in order to insert the belt. Being careful not to damage the pulley, apply a slight upward pressure and place belt around transmission pulley. See Figure 15.

Belt Guard Spring

Idler

Frame

Mounting Adapter

Idler Bracket

Figure 13

• Thread the special impeller tool into the crankshaft. Stop when the impeller assembly can move on the crankshaft.

• If the old belt is still on the unit, cut belt to remove from unit.

• Remove the impeller assembly from the crankshaft and unthread the special impeller tool from the impeller assembly.

• Remove the inner housing and mounting adapter by removing the five hex bolts and two hex nuts. See Figure 14.

Transmission Pulley

Figure 15

• Press down on the belt guard spring by the idler pulley and release spring from the slot on the idler bracket. Place the belt on the idler pulley and place belt guard spring back into the slot on the idler bracket. See Figure 15.

• Place the mounting adapter against the engine and make sure the hole in the mounting adapter is facing up.

• Place the inner housing against mounting adapter and frame. Secure with the five hex bolts and two hex nuts previously removed. Refer to Figure 14.

• Slide the impeller assembly onto the crankshaft and place a screwdriver under the belt. Turn the impeller assembly counterclockwise to seat the belt into the slot on the impeller. Make sure the belt is routed inside all belt guards.

• Secure the impeller assembly to the crankshaft using the hex bolt, lock washer, and flat washer previously removed. Torque the bolt to 550 in. lbs. to 700 in. lbs.

• Place the housing blades against the inner housing. See Figure 16.

Outer Housing

Inner Housing

Housing Blades

Figure 16

• Place the outer housing against the inner housing. Insert two screwdrivers into the holes to hold the blades in place while attaching the outer housing. See Figure 17.

• Secure with the fourteen self tapping screws that were previously removed and insert all screws first before tightening.

• Reassembled following the previous steps in reverse order.

Holes for Screwdrivers

Figure 17

Storing Your Chipper Shredder Vacuum

• Clean the equipment thoroughly.

• Wipe equipment with an oiled rag to prevent rust.

• Refer to engine manual for correct engine storage

instructions

• Store unit in a clean, dry area. Do not store next to corrosive materials such as fertilizer.

WARNING: Never store the machine or fuel container indoors where there is an open flame, spark, or pilot light such as on a water heater, furnace, clothes dryer, or other gas appliance.

SECTION 7: TROUBLESHOOTING

Problem Cause Remedy

Engine fails to start 1. Spark plug wire disconnected.

2. Fuel tank empty or stale fuel.

3. Throttle control lever not in correct starting position. (If Equipped)

4. Choke not in CHOKE position. (If Equipped)

5. Blocked fuel line.

6. Faulty spark plug.

Engine runs erratic 1. Spark plug wire loose.

2. Unit running on CHOKE. (If Equipped)

3. Blocked fuel line or stale fuel.

4. Water or dirt in fuel system.

5. Dirty air cleaner.

6. Carburetor out of adjustment.

Too much vibration 1. Loose parts or damaged impeller. 1. See authorized service dealer. Engine overheats 1. Engine oil level low.

2. Dirty air cleaner.

3. Carburetor not adjusted properly.

Occasional skip (hesitates) at high speed

Unit does not discharge 1. Discharge chute clogged.

Rate of discharge slows considerably or composition of discharged material changes.

NOTE: For repairs beyond the minor adjustments listed above, contact your nearest authorized service dealer.

1. Spark plug gap too close. 1. Adjust gap to .030”.

2. Foreign object lodged in impeller.

3. Low engine RPM

4. Vacuum bag is full.

1. Low engine RPM.

2. Chipper blade dull.

1. Connect wire to spark plug.

2. Fill tank with clean, fresh gasoline.

3. Move throttle lever to FAST position.

4. Move choke to CHOKE position.

5. Clean fuel line.

6. Clean, adjust gap, or replace.

1. Connect and tighten spark plug wire.

2. Move choke lever to OFF position.

3. Clean fuel line; fill tank with clean, fresh gasoline

4. Drain fuel tank. Refill with fresh fuel.

5. Clean or replace air cleaner.

6. See authorized service dealer.

1. Fill crankcase with proper oil.

2. Clean or replace air cleaner.

3. See authorized service dealer.

1. Stop engine immediately and disconnect spark plug wire. Clean flail screen and inside of discharge opening.

2. Stop engine and disconnect spark plug wire. Remove lodged object.

3. Always run engine at full throttle.

4. Empty bag.

1. Always run engine at full throttle.

2. Replace chipper blade or see your authorized service dealer.

Notes

Model 203

Ref.

No.

1. 681-0095 Chipper Chute

2. 712-3010 Hex Nut 5/16-18

3. 736-0242 Bell Washer .340 ID x .872 OD

4. 731-1690A Discharge Chute

5. 764-0492 Bag

6. 631-0069 Nozzle Assembly

7. 731-1831 Nozzle Flap

8. 710-0969 Screw

9. 720-0190 Height Adjustment Knob

10. 732-0754 Spring Lever

11. 781-0702 Index Bracket RH

12. 781-0703 Index Bracket LH

13. 738-0913 Shoulder Screw

14. 736-3084 Flat Washer .510 x 1.12 x .060

15. 712-0431 Hex Flange Lock Nut 3/8-16

16. 631-0047 Door Assembly

Part No. Part Description

777D00121 Label- YardMan Chipper Shredder 777D00183 Label- 5.5HP OHV 777D01301 Label- 1-800#/ Model Plate 777I20123 Label- Caster Wheel Lock 777I20373 Label- Chipper Shredder SP 777S30041 Label- Warning / Avoid Injury 777S30131 Label- Caution Do Not Operate 777S30183 Label- Flail Housing Warning

Model 203

Ref.

No.

1. 681-0108 Impeller Ass’y Complete

2. 719-0329 Flail Blade

3. 715-0166 Spiral Pin

4. 681-0107 Impeller Assembly

5. 711-0833B Clevis Pin

6. 736-0119 Lock Washer 5/16

7. 710-1054 Cap Screw 5/16-24 x 1.0

8. 781-0490 Chipper Blade

9. 712-0411 Hex Lock Nut 5/16-24

10. 736-0247 Flat Washer .406 x 1/1/4

11. 736-0217 Lock Washer 3/8

12. 710-1273 Hex Cap Screw 3/8-24 x 2.75

13. 723-0438 Rubber Seal

14. 710-0604A Hex Washer Screw 5/16-18

15. 712-0384 Hex Lock Nut 1/2-13

16. 781-0627 Chipper Blade Cover

17. 712-3004A Hex Flange Lock Nut 5/16-18

Part No. Part Description

Ref.

No.

18. 681-0098 Housing Ass’y Inner Flail

19. 781-0599 Upper Shredder Blade

21. 736-0119 Lock Washer 5/16

22. 710-0772 Hex Cap Screw 5/16-18 x 2

23. 781-0653 Flail Housing Blade

24. 710-3008 Hex Cap Screw 5/16-18 x .75

25. 719-0326 Discharge Screen

26. 681-0060 Housing Ass’y Outer Flail

27. 629-0241A Wire Harness

28. 710-0896 Hex Washer Screw 1/4-14

29. 726-0272 Clamp

30. 710-0382 Hex Cap Screw 1/2-13 x 5.0

31. 712-0421 Knob 5/16-18

32. 725-3166 Switch

33. 731-1613 Safety Switch Mounting Cover

34. 710-1268 Hex Washer Screw

35. 725-1700 Switch Cover

Part No. Part Description

Model 203

Ref.

No.

1. 781-0677 Chain Case LH

2. 781-0676 Chain Case RH

3. 754-0457 V-Belt

4. 748-0313 Spacer

5. 741-0413 Hex Flange Bearing

6. 736-0336 Flat Washer

7. 713-0422 Chain

8. 710-0896 Hex Washer Screw 1/4-14

9. 710-0603 Hex Washer Screw 5/16

10. 618-0256 Transmission Assembly

11. 611-0063 Axle Assembly

12. 10622B Plastic Spring Ratchet

13. 634-0243 Wheel Complete 10 x 4 x 4

14. 712-0456 Hex Nut 1/4-20

15. 712-3027 Hex Flanged Lock Nut 1/4-20

16. 714-0104 Cotter Pin

17. 736-0366 Flat Washer 5/8 ID x 1.0 OD

18. 748-0188B Pawl LH .345 ID

19. 748-0405 Wheel Ratchet 1.62 OD x .5 serr

21. 618-0255 Transmission Assembly Complete

22. 16500A Hex Bearing Cup

23. 711-1118 Output Shaft 6T Sprocket

24. 717-1432 Helical 34T Gear

25. 721-0213 Oil Seal

26. 736-0187 Flat Washer .64 ID x 1.24 OD

27. 736-0336 Flat Washer 5/8 x 1.0

28. 741-0413 Hex Flange Bearing .631 ID

Part No. Part Description

748-0381 Pawl RH .345 ID

Ref.

No.

29. 741-0414 Flange Bearing .629 ID

30. 741-0415 Flange Bearing .566 ID

31. 719-0325 Lower Housing

32. 748-0373 Flange Bearing .503 ID

33. 719-0324A Upper Housing

34. 748-0208A Flange Bearing .378 ID

35. 710-0589 Hex Washer Screw #10-16 x .75

36. 717-1433 Pinion Shaft 10T

37. 721-0329 Oil Seal

38. 736-0314 Thrust Washer .382 ID x .684 OD

39. 736-0520 Flat Washer .504 ID x .70 OD

40. 741-0479 Thrust Bearing .375 ID x .812 OD

41. 656-0008 Pulley Ass’y Idler w/ Bearing

42. 741-0556 Needle Bearing .375 ID x .375 OD

43. 710-0589 Hex Screw #10-16 x .75

44. 710-1062 Hex Cap Screw 1/4-20 x 1.25

45. 712-0138 Hex Nut 1/4-28

46. 712-3045 Hex Jam Nut 5/16-24 LH Thd

47. 732-0357A Extension Spring 1.12 Lg

48. 736-0270 Bell Washer .265 ID x .75 OD

49. 736-0329 Lock Washer 1/4

50. 736-0425 Bell Washer .325 ID x .930 OD

51. 738-0440 Shoulder Spacer .375 ID x .165 OD

52. 738-0826 Shoulder Bolt 1/4-28 x .375

53. 756-0656 Flat Pulley 5.06 Dia

54. 782-7569 Belt Keeper

55. 682-0054 Idler Bracket

Part No. Part Description

IMPORTANT: For a proper working machine, use Factory Approved Parts.

V-BELTS are especially designed to engage and disengage safely. A substitute (non OEM) V-Belt can be dangerous by not disengaging completely.

Model 203

37 38

Model 203

Ref.

No.

1. 749-1095 Upper Handle

2. 1539-019 Push Nut

3. 711-0737 Stud Pin .250 x 1.75

4. 746-0714 Clutch Cable 56"

5. 731-1735 Upper Clutch Cover

6. 731-0620 Drive Lever

7. 731-1736 Lower Clutch Cover

8. 710-0841 Screw #10-12 x .750

9. 731-1059 Mounting Cable Cap

10. 710-1331 Screw #10-16 x 1.25

11. 710-0805 Hex Cap Screw 5/16-18 x 1.50

12. 736-0451 Shoulder Washer .320 ID x .93 OD

13. 712-3004A Hex Flange Lock Nut 5/16-18

14. 725-0157 Cable Tie

15. 712-0138 Hex Nut 1/4-28

16. 736-0329 Lock Washer 1/4

17. 781-0647 Discharge Chute Bracket

18. 710-3008 Hex Cap Screw 5/16-18 x .75

19. 747-0815 Eye Bolt

20. 710-0896 Hex Washer Screw 1/4-14 x .625

21. 731-1646 Belt Cover

22. 719-0359 Engine Mounting Adapter

23. 747-0929A Belt Keeper

24. 736-3008 Flat Washer .344 x .75 x .12

Part No. Part Description

Ref.

No.

25. 710-0157 Hex Cap Screw 5/16-24 x .75

26. 710-3103 Hex Cap Screw 5/16-18 x 1.75

27. 749-1094 Lower Push Handle

28. 710-0502A Screw 3/8-16 x 1.25

29. 710-0604A Hex Washer Screw 5/16-18 x .625

30. 741-0413 Hex Flange Bearing .631 x .720

31. 681-0097A Frame Assembly

32. 781-0700 Axle Bracket

33. 781-0697 Transmission Cover

34. 747-0924 Lock Pin

35. 732-0306 Compression Spring

36. 726-0214 Push Cap

37. 736-0366 Flat Washer 5/8 ID x 1.0 OD

38. 741-0487A Flange Bearing .632 ID

39. 736-0264 Flat Washer .330 ID x .630 OD

40. 714-0104 Cotter Pin

41. 681-0087 Bracket Assembly

42. 737-3000 Grease Fitting 3/16

43. 736-0931 Flat Washer.203 ID x .403 OD

44. 681-0088 Bracket Assembly

45. 710-0521 Hex Cap Screw 3/8-16 x 3.0

46. 712-0431 Flange Lock Nut 3/8-16

47. 750-1042 Spacer

48. 734-1804 Wheel 6.0 x 2.0

Part No. Part Description

NOTE: For painted parts, please refer to

the list of color codes below. Please add the applicable color code, wherever needed, to the part number to order a replacement part. For instance, if a part numbered 700-xxxx is painted Yard-Man Green, the part number to order would be 700-xxxx-0665.

Yard-Man Green: 0665

Yard-Man Yellow: 0674

Powder Black: 0637

MANUFACTURER’S LIMITED WARRANTY FOR:

The limited warranty set forth below is given by MTD LLC with respect to new merchandise purchased and used in the United States, its possessions and territories.

MTD LLC warrants this product against defects for a period of two (2) years commencing on the date of original purchase and will, at its option, repair or replace, free of charge, any part found to be defective in materials or workmanship. This limited warranty shall only apply if this product has been operated and maintained in accordance with the Operator’s Manual furnished with the product, and has not been subject to misuse, abuse, commercial use, neglect, accident, improper maintenance, alteration, vandalism, theft, fire, water, or damage because of other peril or natural disaster. Damage resulting from the installation or use of any accessory or attachment not approved by MTD LLC for use with the product(s) covered by this manual will void your warranty as to any resulting damage.

Normal wear parts or components thereof are subject to separate terms as follows: All normal wear parts or component failures will be covered on the product for a period of 90 days regardless of cause. After 90 days, but within the two year period, normal wear part failures will be covered ONLY IF caused by defects in materials or workmanship of OTHER component parts. Normal wear parts and components include, but are not limited to: batteries, belts, blades, blade adapters, grass bags, rider deck wheels, seats, snow thrower skid shoes, shave plates, auger spiral rubber, tires.

d. MTD LLC does not extend any warranty for products

sold or exported outside of the United States, its possessions and territories, except those sold through MTD LLC’s authorized channels of export distribution.

e. Parts that are not genuine MTD parts are not covered by

this warranty.

f. Service completed by someone other than an authorized

service dealer is not covered by this warranty.

g. Transportation charges and service calls are not

covered.

No implied warranty, including any implied warranty of merchantability of fitness for a particular purpose, applies after the applicable period of express written warranty above as to the parts as identified. No other express warranty, whether written or oral, except as mentioned above, given by any person or entity, including a dealer or retailer, with respect to any product, shall bind MTD LLC. During the period of the warranty, the exclusive remedy is repair or replacement of the product as set forth above. The provisions as set forth in this warranty provide the sole and exclusive remedy arising from the sale. MTD LLC shall not be liable for incidental or consequential loss or damage including, without limitation, expenses incurred for substitute or replacement lawn care services or for rental expenses to temporarily replace a warranted product.

HOW TO OBTAIN SERVICE: Warranty service is available,

WITH PROOF OF PURCHASE, through your local authorized service dealer. To locate the dealer in your area, check your Yellow Pages, or contact MTD LLC at P.O. Box 361131, Cleveland, Ohio 44136-0019, 1-800-800-7310, 1-330-2204683 or log on to our Web site at www.yardman.com.

This limited warranty does not provide coverage in the following cases: a. The engine or component parts thereof. These items

carry a separate manufacturer’s warranty. Refer to the applicable manufacturer’s warranty for terms and conditions.

b. Log splitter pumps, valves, and cylinders have a sepa-

rate one year warranty.

c. Routine maintenance items such as lubricants, filters,

blade sharpening, tune-ups, brake adjustments, clutch adjustments, deck adjustments, and normal deterioration of the exterior finish due to use or exposure.

MTD LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019 1-800-800-7310

Some states do not allow the exclusion or limitation of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions or limitations may not apply to you. In no event shall recovery of any kind be greater than the amount of the purchase price of the product sold. Alteration

of the safety features of the product shall void this warranty. You assume the risk and liability for loss, damage, or

injury to you and your property and/or to others and their property arising out of the misuse or inability to use the product. This limited warranty shall not extend to anyone other than the original purchaser or to the person for whom it was purchased as a gift.

HOW STATE LAW RELATES TO THIS WARRANTY: This limited warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

MTD Yard-Man 203 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual