Yard-Man 12A-978Q755, 12A-978Q701 Owner’s Manual

Operator's Manual
21" Self-Propelled
Mower
Model 978Q
IMPORTANT: Read safety rules and instructions carefully before operating equipment.
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.BOX361131CLEVELAND,OHIO44136-0019
PRINTED IN U.S.A.
Form No.769-00596B
(11/2003)
TABLEOFCONTENTS
Content
Important Safe Operation Practices Slope Gauge Assembling Your Lawn Mower
Know Your Lawn Mower Operating Your Lawn Mower
Making Adjustments
Page Content Page
3 Maintaining Your Lawn Mower 13 6 Servicing Your Lawn Mower 14 7 Off-Season Storage 16 9 Troubleshooting 17
10 Illustrated Parts List 18 11 Warranty 24
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. A sample model plate is also given below. You can locate the model plate by standing at the operating position and looking down at the rear of the deck. This information will be necessary to use the manufacturer's web site and/or help from the Customer Support Department or an authorized
service dealer.
Copy the model number here:
YaRD-MaN)/2=:°.Lc
www.yardman.com 330-220-4683
P. O. BOX 361131 CLEVELAND,OH 44136
800-800-7310
Copy the serial number here:
CUSTOMERSUPPORT
Please doNOTreturntheunit totheretailer fromwhereit waspurchased,withoutfirstcontactingCustomerSupport.
If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenance of this unit, you can seek help from the experts. Choose from the options below:
Visit yardman.com for many useful suggestions. Click on Customer Support button and you will get the four options reproduced here. Click on the appropriate button and help is immediately available.
answer you are
looking for could be just
a mouse c//cA awayf
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L<}_i_kto cl_eck tie stat_ls of yo_ _l_esli<>l_
To reach a Customer Support Representative, please call 1-800-800-7310.
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En ine
The engine manufacturer is responsible for all engine-related issues with regards to
performance, power-rating, specifications, warranty and service. Please refer to the engine manufacturer's Owner's/Operator's Manual, packed separately with your unit, for more
information.
SECTION1: IMPORTANTSAFEOPERATIONPRACTICES
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" 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.
WARNING" 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 instructions on the machine and in the 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 safe operation rules should use this machine.
4. Thoroughly inspect the area where 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 bystanders, helpers, children and pets at
least 75 feet from the machine while it is in operation. Stop machine if anyone enters the area.
6. Always wear safety glasses to protect your eyes during equipment operation and while performing an adjustment or repair. 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 steel-toed 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 feet 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 a result 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. If you 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 the mower 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.
5. Do not operate the mower while under the influence of alcohol or drugs.
6. Do not engage the self-propelled mechanism on
units so equipped while starting engine.
7. 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.
8. 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
immediatelyandthebladewillstoprotatingwithin threeseconds.
9. Mowindaylightorgoodartificiallight;walk,notrun.
10.Stopthebladewhencrossinggraveldrives, walkwaysorroads.
11.Iftheequipmentshouldstarttovibrateabnormally,
stoptheengineandcheckimmediatelyforthe cause.Vibrationisgenerallyawarningoftrouble.
12.Shuttheengineoffandwaituntilthebladecomes
toacompletestopbeforeremovingthegrass catcheroruncloggingthechute.Thecuttingblade
continuestorotateforafewsecondsafterthe engineisshutoff.Neverplaceanypartofthebody
inthebladeareauntilyouaresurethebladehas stoppedrotating.
13.Neveroperatemowerwithoutpropertrailshield,
dischargecover,grasscatcher,bladecontrol handleorothersafetyprotectivedevicesinplace andworking.Neveroperatemowerwithdamaged safetydevices.Failuretodosocanresultin personalinjury.
14.Mufflerandenginebecomehotandcancausea
burn.Donottouch.
15.Onlyusepartsandaccessoriesmadebythe
originalequipmentmanufacturer(O.E.M).Failure todosocanresultinpersonalinjury.
16.Ifsituationsoccurwhicharenotcoveredinthis
manual,usecareandgoodjudgment.Contactyour dealerforassistance.Call1-800-800-7310forthe
nameofyournearestdealer.
3. Do not mow on wet grass. Unstable footing could cause slipping.
Children
Tragic accidents can occur if the 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 children
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 obscure your vision of a child who may run into the
mower.
5. Keep children away from hot or running engines. They can suffer burns from a hot muffler.
6. 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 inthis manual and
should be trained and supervised by a parent.
Service
SlopeOperation
Slopes are a major factor related to slip and fall accidents which can result in severe injury. Operation on slopes requires extra caution. Ifyou feel uneasy on a slope, do not mow it. Before operating this unit on a slope or hilly area, use the slope gauge on page 6 to measure slopes. 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 caution when changing direction.
,
Watch for holes, ruts, rocks, hidden objects, or bumps which can cause you to slip or trip. Tall grass can hide obstacles.
,
Always be sure of your footing. A slip and fall can cause serious personal injury. If you feel you are losing your balance, release the blade control handle immediately, and the blade will stop rotating
within 3 seconds.
DoNot:
1. Do not mow near drop-offs, ditches or embankments, you could lose your footing or
balance.
2. Do not mow slopes greater than 15degrees as shown on the slope gauge.
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 personal injury can occur when gasoline is spilled on yourself or your clothes which can ignite.
2. Wash your skin and change clothes immediately.
3. Use only an approved gasoline container.
4. Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place
containers on the ground away from your vehicle
before filling.
5. If possible, remove gas-powered equipment from the truck or trailer and refuel it on the ground. If this
is not possible, then refuel such equipment on a trailer with a portable container, rather than from a gasoline dispenser nozzle.
6. Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device.
7. Extinguish all cigarettes, cigars, pipes and other sources of ignition.
8. Never fuel machine indoors because flammable vapors will accumulate in the area.
9. Never remove gas cap or add fuel while the engine
is hot or running. Allow engine to cool at least two minutes before refueling.
10.Neveroverfillfueltank.Filltanktonomorethan½ inchbelowbottomoffillernecktoprovidespacefor
fuelexpansion.
11.Replacegasolinecapandtightensecurely.
12.Ifgasolineisspilled,wipeitofftheengineand equipment.Moveunittoanotherarea.Wait5 minutesbeforestartingtheengine.
13.Neverstorethemachineorfuelcontainerinside
wherethereisanopenflame,sparkorpilotlightas
onawaterheater,spaceheater,furnace,clothes dryerorothergasappliances.
14.Toreducefirehazard,keepmowerfreeofgrass, leaves,orotherdebrisbuild-up.Cleanupoilorfuel spillageandremoveanyfuelsoakeddebris.
15.Allowmowertocool5minutesbeforestoring.
GeneralService:
1. Never run an engine indoors or in a poorly ventilated area. Engine exhaust contains carbon monoxide, an odorless and deadly gas.
2. Before cleaning, repairing, or inspecting, make certain the blade and all moving parts have stopped. Disconnect the spark plug wire and ground against the engine to prevent unintended starting.
3. Check the blade and engine mounting bolts at
frequent intervals for proper tightness. Also,
visually inspect blade for damage (e.g., bent, cracked, worn) Replace blade with the original equipment manufacture's (O.E.M.) blade only, listed in this manual. "Use of parts which do not meet the original equipment specifications may lead to improper performance and compromise safety!"
4. Mower blades are sharp and can cut. Wrap the blade or wear gloves, and use extra caution when
servicing them.
5. Keep all nuts, bolts, and screws tight to be sure the equipment is in safe working condition.
6. Never tamper with safety devices. Check their
proper operation regularly.
7. After striking a foreign object, stop the engine, disconnect the spark plug wire and ground against the engine. Thoroughly inspect the mower for any damage. Repair the damage before starting and operating the mower.
8. Never attempt to make a wheel or cutting height adjustment while the engine is running.
9. Grass catcher components, discharge cover, and trail shield are subject to wear and damage which could expose moving parts or allow objects to be thrown. For safety protection, frequently check components and replace immediately with original equipment manufacturer's (O.E.M.) parts only,
listed here. Use of parts which do not meet the
original equipment specifications may lead to
improper performance and compromise safety.
10. Do not change the engine governor setting or overspeed the engine. The governor controls the
maximum safe operating speed of the engine.
11. Maintain or replace safety and instruction labels, as
necessary.
12. Observe proper disposal laws and regulations.
Improper disposal of fluids and materials can harm
the environment.
YourResponsibility
Restrict the use of this power machine to persons who read, understand and follow the warnings and instructions inthis manual and on the machine.
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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
o
and you could slip, resulting in serious injury. Operate RIDING mowers up and down slopes, never across the face of slopes. Operate WALK-BEHIND mowers across the face of slopes, never up and down slopes.
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SECTION3: ASSEMBLINGYOURLAWNMOWER
RemovingUnitFromCarton
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., grass
bag etc.), and save it appropriately.
Cut along corners, lay the carton down flat, and
remove all packing material.
Roll or slide unit out of carton and check carton
thoroughly for loose parts.
LoosePartsinCarton
1. Grass Bag
2. Grass Bag Adapter
3. Side Discharge Chute
4. Hardware Pack
HardwarePack
Please identify each piece of the hardware pack as shown in Figure 1.
Carriage Bolt
Wing Nut
Figure 1
BeforeAssembly
Before setting up your lawn mower, disconnect the
spark plug wire from the spark plug. See Figure 2.
SettingUpYourLawn Mower
AssemblingHandle
Lift up and pull back on the upper handle to raise the handle into the operating position. See Figure
3. Make certain the lower handle is seated securely
into the handle bracket assemblies.
_ Handle Assembly
/
Wing Nut
Handle Mounting Bracket
Figure 3
Tighten wing nuts on each side of the handle
making sure that the carriage bolts are seated properly into the handle. See Figure 3. Remove hairpin clip from the outer hole of the weld pin on each handle brackets. Using a pair of pliers,
squeeze one leg of the lower handle against the
handle bracket. Insert the hairpin clip into the inner hole on the weld pin. Repeat on the other side. See Figure 4.
After moving the hairpin clip, insert the carriage
bolt, from the hardware pack, in the upper hole on
the handle mounting bracket and secure with
plastic wing nut, also from the hardware pack. See Figure 4. Repeat on the other side.
\
ff !park Plug
ire X
Figure 2
NOTE: Reference to right or left side of the mower is
observed from the operating position.
_¢_Carriage Bolt
Lower Handle Hole
Wing Nut
Handle Mounting _ Hairpin Bracket Clip
Figure 4
Fasten the cable to the lower handle with the two
Bag
cable ties found on the lower handle. Pull the cable ties tight and trim off the excess. See Figure 5.
Cable Tie
Lower Handle
Figure 5
AttachingStarterRope
NOTE: Make certain the drive cable is routed around
the outside and above the lower handle so it does not interfere with attaching the grass bag.
The rope guide, which is connected to the support rod, is located on the right side of the lower handle. See Figure 6. With the spark plug wire disconnected and grounded, hold the blade control handle against the upper handle, and pull the starter rope out of the engine. Release the blade control handle. Slip the starter rope into the rope guide.
Rope
Nuts
Figure 7
Lift chute door on the grass bag adapter and slide grass bag onto the adapter. See Figure 8.
NOTE: The chute door has been designed to move the
starter rope out of the way of the bag when the chute door is opened.
Chute
Door,
Grass
Bag
Figure 8
Rope Guide
Figure 6
AttachingTheGrassBag
The mower was shipped with the mulching baffle installed on the unit. You can keep this baffle on as long as you want to mulch the grass clippings. For bagging purposes, you will have to attach the grass bag and its adapter in place of the mulching baffle.
Remove three wing nuts holding the mulching baffle or side discharge chute in place and remove the accessory from the unit.
Replace with grass bag adapter, while making sure the front lip of adapter goes under the edge of
the deck. Secure with wing nuts previously removed. See Figure 7.
AttachingSideDischargeChute
Remove mulching baffle or grass bag adapter from unit by disconnecting wing nuts.
Attach side discharge chute to unit and secure with
the three wing nuts. See Figure 9.
Side Discharge
Chute
Figure 9
SECTION4: KNOWYOURLAWNMOWER
Read this operator's manual and safety rules before operating your lawn mower. Compare the illustration in Figure 10 with your lawn mower to familiarize yourself with the location of various controls and adjustments.
Save this manual for future reference.
,_ WARNING" The operation of any lawnmower can result in foreign objects being
thrown into the eyes, which can damage your eyes severely. Always wear safety glasses while operating the mower, or while performing any adjustments or repairs on it.
BladeControlHandle
The blade control handle is located on the upper handle of the mower. The blade control handle must be
depressed in order to operate the unit. Release blade control handle to stop engine and blade.
,i_ WARNING" This blade control mechanism isa safety device. Never attempt to bypass its
operations.
Cutting HeightAdjustmentLevers The cutting height adjustment lever is located above
the left rear wheel. To adjust the cutting height, refer to the Adjustment Section in this manual.
RecoilStarter
The recoil starter is attached to the support rod located on the right side of the lower handle. Stand behind the
unit and pull the recoil starter rope to start the unit. DriveClutch Control
The drive clutch control is located on the upper handle.
Squeeze the drive control to engage the drive system. Release the clutch control to disengage the drive system. Release the clutch control to slow down when approaching an obstacle, making a turn, or stopping.
ShiftLever
The shift lever is located on the drive clutch control
housing on the upper handle. This lever is used to select the forward speed of the mower. When changing speed selection, release the drive clutch control.
NOTE: Move the shift lever only when the engine is running. Changing the shift lever setting with the engine off can damage the mower.
MulchingPlug
The mulching plug is used only for mulching purposes.
Instead of collecting grass clippings in a grass catcher,
this mower has the option of recirculating the clippings
back to the lawn.
Drive Clutch
Side-Discharge Chute Mulch Plug
Shift
Recoil
-Blade Control Handle
\\\\
Figure 10
Height Adj.
SECTION5: OPERATINGYOURLAWNMOWER
StartingEngine
_ ARNING" Read, understand, and follow all
NOTE: For shipping purposes your mower is set with
the wheels in a low cutting height posfion. For best results, raise the cutting position until it is determined which height is best for your lawn. See the Adjustment
Section for details.
instructions and warnings on the machine and in this manual before operating.
Gas&OilFill-Up
Check oil level and add oil if necessary. Follow relevant instructions in the engine manual for this.
Service the engine with gasoline as instructed in the engine manual.
WARNING: Use extreme care when
handling gasoline. Gasoline is extremely flammable and the vapors are explosive. Never fuel the machine indoors or while the engine is hot or running. Extinguish cigarettes, cigars, pipes and other sources of ignition.
BeforeStartingMower
Attach spark plug wire to spark plug. Make certain the metal cap on the end of the spark plug wire is
fastened securely over the metal tip on the spark
plug.
Check for proper drive clutch operation using the neutral adjustment test described below.
Neutral AdjustmentTest To perform the neutral adjustment test, answer the
following questions.
With the drive clutch control released, push mower
forward and pull it backward. Does it move freely?
Squeeze the drive clutch control and pull the mower backward. Do the rear wheels lock?
Is the drive clutch control cable free of kinks or sharp bends?
Ifyou answered "yes" to all three questions, your mower passed the test and you can start your
mower.
Ifyou answered "no" to any of the three questions, you will have to adjust the drive clutch control as
instructed in the ADJUSTMENT SECTION.
,_ WARNING: Be sure no one other than theoperator is standing near the lawn mower while
starting engine or operating mower.
WARNING: Never run engine indoors or in
enclosed, poorly ventilated areas. Engine exhaust contains carbon monoxide, an
odorless and deadly gas.
WARNING: Keep hands, feet, hair and
loose clothing away from any moving parts on engine and lawn mower.
Formodelsequippedwith Hondaengine:
Make sure the fuel valve lever found on the left side of
the engine is in the ON position. See Figure 11.
Recoil
Starter
Fuel Valve
Choke Leverf
Figure 11
Move the choke lever all the way backward into the choke position. Once the engine is warm, the lever will automatically revert to the RUN position. Refer to the engine manual for further details.
Formodelsequippedwith Briggs& Strattonengine:
Push primer three times. Wait about two seconds
between each push. In cold weather around 55° F or below, prime five times. Do not prime to restart a warm engine after a short shutdown.
ForAll Models:
Standing behind the mower, depress the blade control handle and hold it against the upper handle.
Grasp starter handle and pull rope out slowly until engine reaches the start of compression cycle
(rope will pull slightly harder at this point). Let the
rope rewind slowly. Pull rope with a rapid, continuous, full arm stroke. Keeping a firm grip on the starter handle, let the rope rewind slowly.
NOTE: See your engine manual packed with your unit
for more detailed instructions.
10
StoppingEngine
Release blade control handle to stop the engine and the blade.
Disconnect spark plug wire and move away from spark plug to prevent accidental starting.
UsingYourLawnMower
Do not operate the mower without any one of the mulching baffle, discharge chute or grass catcher properly installed.
,i_ WARNING" Be sure that the lawn is clear of
Forbestresults, donotcutwetgrass. It may stickto
For a healthy lawn, always cut off one-third or less
IMPORTANT:Move the shift lever only when the engine is running. Changing the shift lever setting with the engine off can cause damage to the mower.
stones, sticks, wire, or other objects which could damage lawn mower or engine. Such objects could be accidently thrown by the mower in any direction and cause serious personal injury to the operator and others.
the underside of the mower, preventing proper discharge of grass clippings, and could cause you to slip and fall. New grass or thick grass may require a narrower cut.
of the total length of the grass. Lawn should be trimmed in fall as long as there is growth.
Mulching
For effective mulching, do not cut wet grass. New or thick grass may require a narrower cut. If the grass has grown in excess of 4", mulching is not recommended.
Mow using the side discharge to reduce the grass
height to 3.25" maximum before mulching.
BaggingGrassClippings
You can use the grass catcher bag to collect clippings while you are operating the mower.
Attach grass catcher following instructions on page 8 of this manual. Grass clippings will automatically collect in the bag as you run the mower.
Operate the mower till the grass bag is full.
Stop engine completely by releasing the blade control handle. Make sure that the unit has come to
a complete stop.
While holding the grass bag by both the rear handle and the lower handle, lift the grass bag straight up off the adapter. The chute door will move the rope out of the way of the bag.
Continue to hold the lower handle and raise the
rear of the grass bag up toward your chest. The grass bag will open and the grass clippings will disperse.
When replacing the grass bag, be sure the top of the bag rests on the wire support between the
handles.
,_ WARNING" If the mower strikes a foreignobject, stop the engine. Remove spark plug
wire from the spark plug and thoroughly inspect for any damage. Repair the damage promptly before restarting and operating the mower.
SECTION6: MAKINGADJUSTMENTS
,_ WARNING" Do not at any time make anyadjustments without first stopping engine and
disconnecting spark plug wire.
CuttingHeight
Your mower is shipped with the cutting height in the lowest position. The cutting height adjustment lever is located above the left rear wheel. To adjust the cutting height, proceed as follows:
Pull the lever out and away from the mower and then move it forward or backward to another slot.
See Figure 12.
NOTE: For rough or uneven lawns, move the height adjustment lever to a higher position. This will help stop scalping.
Cutting Height Adjustment Lever
11
Figure 12
HandleHeight
Your mower is shipped with the handle in the higher height position. To lower the height, proceed as follows:
Remove the starter rope from the rope guide.
Remove the wing nuts and carriage bolts securing the upper handle. Remove and lay the upper handle out of the way, being careful not to bend or
kink the cables.
Remove the hairpin clips from the weld pins on the handle brackets and remove the wing nuts and carriage bolts from the upper hole on the handle mounting bracket.
Press out on the legs of the lower handle and remove lower handle from the mower.
Turn lower handle around so the notch on the bottom of the lower handle is facing forward.
See Figure 13.
Notch
Lower Handle
To resolve the above problems, rotate the adjustment wheel with your fingers clockwise to tighten the cable and counter-clockwise to loosen the cable. See Figure 14.
BottomView
Adjustment
Wheel_.
Shift Lever D Clutch
Figure 14
NOTE: For some people, the drive clutch control may
not be in a comfortable position. You can adjust the handle out by tightening the adjustment wheel.
Handle
Control
Shift LeverCable
Figure 13
Reassemble the handles, placing the bottom holes in the handle over the weld pins in the handle mounting bracket.
Place the hairpin clips in the inner holes in the weld pins and insert the carriage bolts through the upper hole on the handle mounting bracket and secure
with plastic wing nuts.
Reassemble the upper handle to the lower handle.
Attach the starter rope as instructed on page 8.
DriveClutchControl
The adjustment wheel is located in the drive clutch control handle housing and is used to tighten or loosen the drive belt. You will have to adjust the drive clutch control if any of the following happens:
1. The mower does not propel itself with the drive clutch engaged.
2. The mower's drive wheels hesitate with the drive clutch engaged.
Periodic adjustment of the six speed shift cable may be necessary due to normal wear on the cable. Adjustment is needed if all six speeds do not work.
The adjustable cable bracket is located on the left side of the mower beside the engine. See Figure 15.
Adjustable Cable
Bracket
Hex Nut
PUSH
Figure 15
Start engine and place shift lever in the sixth speed position. Refer to Figure 14.
Stop engine and disconnect spark plug wire and
ground it against engine.
Loosen hex nut which secures the adjustable cable bracket. See Figure 15.
Push back on the adjustable cable bracket and
tighten hex nut.
EngineAdjustments
Refer to the engine manual for these adjustments.
12
SECTION7: MAINTAININGYOURLAWNMOWER
Inspect muffler periodically, and replace if necessary. Damaged mufflers or spark arresters
,i_ WARNING" Always stop the engine and
disconnect the spark plug wire before performing any maintenance work or adjustments on your lawn mower.
CleaningMower
The underside of the mower deck should be cleaned after each use to prevent any build-up of debris. If
allowed to accumulate, it will cause rust and corrosion.
NOTE: We do not recommend the use of pressure washers or garden hose to clean your unit. These may cause damage to pulleys, bearings, or the engine. The
use of water will result in shortened life and reduce serviceability.
Disconnect spark plug wire.
Drain the gasoline from the lawn mower, or place a piece of plastic under the gas cap.
Tip the mower so that it rests on the housing. Keep the side with the air cleaner facing up. Hold the mower firmly.
Scrape and clean the underside of the deck with a suitable tool. Do not spray with water.
Put the mower back on its wheels on the ground. If you had put plastic under the gas cap, make sure to
remove it now.
,_ WARNING" Never tip the mower more than90 degrees in any directions and do not leave
the mower tipped for any length of time. Oil can drain into the upper part of the engine causing a starting problem.
can create a fire hazard. Make sure to avoid muffler and surrounding areas while the mower engine is
hot because temperature of these areas of the
engine may exceed 150° F.
Lubrication
Refer to the lubrication chart in Figure 16. BladeControl Handle
Lubricate the pivot points on the blade control handle at least once a season with light oil. The blade control must operate freely in both directions.
ChuteDoor
Lubricate the torsion spring and the pivot point on
each end of the chute door using a light oil. This will
prevent rusting of the chute door.
Wheels
Lubricate the wheels and bearings, if so equipped,
at least once a season with light oil or engine oil. Also, if the wheels are removed for any reason,
lubricate the surface of the axle bolt and the inner
surface of the wheel with light oil.
Engine
Follow the engine manual instructions and recommended schedule for lubricating engine
components.
Lubricate
EngineCare
A list of key maintenance jobs required for good performance by the mower is given below. Follow the accompanying engine manual for a detailed list and
instructions.
Change engine oil regularly, as instructed in the engine manual. Check oil level before starting engine every time.
Service foam filter in the air cleaner every 25 hours of use and replace the paper filter component every 100 hours. You may have to service the air filter more frequently if you are operating the mower under extremely dusty conditions.
Clean the engine periodically. Remove dirt and debris with a cloth or brush.
Clean the spark plug and reset the gap to.030" at least once a season. Refer to the engine manual for correct spark plug type.
Lubricate
Lubricate
Figure 16: Lubrication Chart
13
SECTION8: SERVICINGYOURLAWNMOWER
Be sure to install the blade with the side of the WARNING: Always stop the engine and disconnect the spark plug wire before
performing any maintenance work or adjustments on your lawn mower.
BladeCare
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.
Periodically inspect the blade adapter for cracks, especially if you strike a foreign object. Replace when necessary.
Removingthe Blade
Disconnect spark plug wire from spark plug.
Turn mower on its side making sure that the air filter and the carburetor are up.
Remove the bolt and the blade bell support which hold the blade and the blade adapter to the engine crankshaft. See Figure 17.
Remove the blade and the adapter from the crankshaft.
SharpeningtheBlade
The blade can be sharpened with a file or on a grinding wheel. Do not attempt to sharpen the
blade while it is still on the mower.
Follow the original angle of grind as a guide. Make sure that each cutting edge receives an equal amount of grinding to prevent an unbalanced blade.
_b ARNING" An unbalanced blade will causeexcessive vibration when rotating at high
speeds. It may cause damage to the mower, and could break causing personal injury.
Balancingthe Blade
The blade can be tested by balancing it on a round shaft screwdriver. Remove metal from the heavy side until it balances evenly. It is recommended that the blade always be removed from the adapter
when testing for balance.
Installingthe Blade
Before reinstalling the blade and the blade adapter
to the unit, lubricate the engine crankshaft and the
inner surface of the blade adapter with light oil.
blade marked "Bottom" (or with part number) facing the ground when the mower is in the operating position.
Slide the blade adapter onto the engine crankshaft.
Place the blade on the adapter. Be certain the blade is aligned and seated on the blade adapter flanges.
Place blade bell support on blade. Make sure the notches on the blade bell support are aligned with
small holes in the blade.
Replace hex bolt and tighten hex bolt to torque: 450 in. Ibs. min., 600 in. Ibs. max.
NOTE: To ensure safe operation of your mower,
3eriodically check the blade bolt for correct torque.
Blade Adapter---_
DriveBeltReplacement
Disconnect the spark plug wire and ground it against the engine.
Drain the fuel tank or place a piece of plastic
beneath the cap to prevent gasoline leakage.
Place shift lever in the first position and tip the
mower on its side with air filter facing up.
Remove the center bolt which secures the blade to the crankshaft followed by blade bell support,
blade, and blade adapter.
Move the cutting height adjustment to the highest
position.
Bolt
Figure 17
14
Remove the three hex screws holding the baffle to the deck and pivot baffle towards the rear of the mower. See Figure 18.
Baffle
Figure 18
Remove the hex bolt from the rear of unit holding the transmission to the mower housing. See Figure 19.
jHex Bolt
Cutting Height
Adjustmen_
Wheel
S
Figure 19
Tilt the transmission forward and loosen the idler pulley bolt and lock nut half a turn. See Figure 20.
Transmission Pulley
Squeeze the belt together and push it forward, while pressing the control arm inward towards the deck and remove the six speed cable from the slot. See Figure 21.
Six-Speed Cable Slot Belt
Control Arm
Figure 21
Pivot the control arm down away from the pulley and belt.
Lift off the lower pulley assembly and remove the old belt from around the crankshaft.
Place the new belt over the transmission pulley. Start the belt in the pulley groove and rotate the
pulley until the belt is seated in the transmission pulley.
Place the belt between the idler pulley and the belt
keeper bracket.
Using pliers, rotate the belt keeper bracket so that it snaps into slot on the idler bracket.
Tighten the idler pulley bolt and lock nut half a turn.
Place the belt between the two pulley halves on the crankshaft. Make sure to route the belt inside the
belt guard pin. See Figure 22.
Belt Bracket
Idler Bracket
Idler
Bolt and Locknut
Transmission
Figure 20
Using a pair of pliers, pull back and rotate belt keeper bracket from the slot on the idler pulley.
Slide the belt out from between the belt keeper bracket and the idler pulley.See Figure 20.
HalfUpperPulle_
_ ,. \_ _Lower Pulley
o,_ Half
Figure 22
IMPORTANT:When replacing the belt, do not disas-
semble the lower pulley assembly.
15
Pinch both sides of the belt together so that the belt is not in the pulley groove, and the lower pulley can be pushed towards the engine. See Figure 23.
Lower Pulley Half_ o o
Belt
Figure 23
Pivot the control arm back to its original position and reinstall the six-speed cable into the slot. See Figure 24.
Six-Speed Cable Slot
Make sure the belt is routed inside the pulley halves and the belt guard pin. Reinstall the bolt securing transmission to rear
I
mower housing. Pivot the baffle back to its original position and
secure with three hex screws removed earlier.
Lightly lubricate the inside of the blade adapter and reinstall the spacer, wave washer, blade adapter assembly, and blade in the correct order.
Tighten the hex bolt to secure the blade to torque: 450-600 in. Ibs.
ReplacingRearFlap
To remove rear flap, cut off the flat end of the wire rod which secures it to the deck.
Attach the new flap and new rod to deck, bending the ends of the new rod over to secure to deck.
Control Arm
SECTION9: 0FF-SEASONSTORAGE
StoringYourLawnMower
The following steps should be taken to prepare your
lawn mower for storage:
Clean and lubricate mower thoroughly as described in the lubrication instructions.
IMPORTANT:We do not recommend the use of a pressure washer or garden hose to clean your unit.
Refer to engine manual for correct engine storage instructions.
Coat mower's cutting blade with chassis grease to prevent rusting.
Store mower in a dry, clean area. Do not store next to corrosive materials, such as fertilizer.
NOTE: When storing any type of power equipment in a
poorly ventilated or metal storage shed, care should be
taken to rust-proof the equipment. Using a light oil or silicone, coat the equipment, especially cables and all moving parts.
16
SECTION10: TROUBLESHOOTING
Problem Cause Remedy
Engine fails to start
Engine runs erratic
Engine overheats
Occasional skip (hesitates) at high speed
Idles poorly
Excessive vibration
Mower will not mulch grass
Uneven cut
NOTE: For repairs beyond the minor adjustments listed above, contact your local authorized service dealer.
1. Blade control handle disengaged.
2. Spark plug wire disconnected.
3. Fuel tank empty or stale fuel.
4. Blocked fuel line.
5. Faulty spark plug.
6. Engine flooded.
1. Spark plug wire loose.
2. Blocked fuel line or stale fuel.
3. Vent in gas plugged.
4. Water or dirt in fuel system.
5. Dirty air cleaner.
6. Carburetor out of adjustment.
1. Engine oil level low.
2. Air flow restricted.
3. Carburetor not adjusted properly.
1. Spark plug gap too close.
1. Spark plug fouled, faulty or gap too wide.
2. Carburetor improperly adjusted.
3. Dirty air cleaner.
1. Cutting blade loose or unbalanced.
2. Bent cutting blade.
1. Wet grass.
2. Excessively high grass.
3. Dull blade.
1. Wheels not positioned correctly.
2. Dull blade.
1. Engage blade control handle.
2. Connect wire to spark plug.
3. Fill tank with clean, fresh gasoline.
4. Clean fuel line.
5. Clean, adjust gap, or replace.
6. Wait a few minutes to restart, do not prime.
1. Connect and tighten spark plug wire.
2. Clean fuel line; fill tank with clean, fresh gasoline
3. Clear vent.
4. Drain fuel tank. Refill with fresh fuel.
5. Clean air cleaner.
6. Adjust carburetor.
1. Fill crankcase with proper oil.
2. Remove blower housing and clean.
3. Adjust carburetor.
1. Adjust gap to.030".
1. Reset gap to.030" or replace spark plug.
2. Adjust carburetor.
3. Clean air cleaner.
1. Tighten blade and adapter. Balance blade.
2. Replace blade.
1. Do not mow when grass is wet; wait until later to cut.
2. Mow once at a high cutting height, then mow again at desired height or make a narrower cutting path.
3. Sharpen or replace blade.
1. Place all four wheels in same height position.
2. Sharpen or replace blade.
17
SECTION11:PARTSLISTFORMODEL978Q
17
2O
19
91
88
35
37
38
48
45
\
@
27
28
.9
45
31
73
72
76
57
3O
IMPORTANT: For a proper working machine, use Factory Approved Parts.
V-BELTS are specially designed to engage
and disengage safely. A substitute (non OEM) V-Belt can be dangerous by not
disengaging completely.
95-----_
85
18
86
80
82
87
Model978Q
Ref. Part No.
No.
1. 747-0824 647-0004_
2. 731-0904A
3. 16864
4. 731-0620
5. 713-0397
6. 732-0627
7. 731-0924
8. 731-0905A
9. 710-1667A
10. 731-0906
11. 746-0711B
12. 712-0324
13. 746-0883
14. 710-1270
15. 746-0557
16. 749-0439D
17. 720-0284
18. 736-0451
19. 710-1174
20. 726-0240
21. 749-0907B
27. 731-1901
28. 732-0842
29. 631-0066
30. 731-1832
31. 731-1833A
32. 782-0078B
33. 712-0397
34. 710-0703
35. 746-0939A
36. 782-7574A
37. 736-0270
38. 712-3006
39. 710-0167
40. 712-0138
41. 782-7575A
42. 736-0329
43. 756-0625
44. 738-0924
45. 714-0104
46. 736-0286
47. 782-0565
48. 734-2044
49. 712-0414
50. 16855
51. 10622B
Description
Control Lever Deluxe Control Lever
Upper Control Housing 6 Speed Rack Cable Bracket
Drive Control Lever Gear Insert
Shift Lever Spring 6 Speed Shift Lever Lower Control Housing C Sunk Tap Screw #10 x.75 Lg Cable Mounting Cover
Drive Cable 51.0 Top Lock Nut 1/4-20
Control Housing Oval C-Sunk Screw
Control Cable - 47" Upper Handle
Wing Nut
Saddle Washer.320 ID x.830 OD Carriage Bolt 5/16-18 x 2.0
Cable Tie Lower Handle
Trail Shield
Trail Shield Wire Chute Assembly
Side Discharge Chute Mulch Cover
21" Deck
Wing Nut
Carriage Bolt 1/4-20 x.75
6 Speed Cable
Cable Adjustment Bracket Bell Washer.265 ID x.75 OD
Hex Nut 1/4-20 Carriage Screw 1/4-20 x.50
Hex Nut 1/4-28 Cable Mounting Bracket
Lock Washer 1/4 Roller Cable Shoulder Screw.375 ID x 1/4-14 Cotter Pin Bowed Washer
Single Lever Control Arm Wheel 9x 2.125
Top Lock Tab Weld Nut 1/4-20
Ratchet Pawl Plate Plastic Spring Ratchet
Ref.
No.
52. 748-0381
53. 738-0137A
54. 748-0318
55. 736-0270
56. 710-0751
57. 731-1426A
58. 738-0102
59. 736-0504
60. 734-2004A
61. 736-0105
62. 710-1348
63. 710-1652
64. 710-0654A
65. 611-0064
66. 726-0233
68. 710-1242
69. 741-0492A
70. 710-1241
71. 731-1829
72. 754-0460
73. 656-0613
74. 750-1071
75. 750-1070
76. 782-7597
78. 782-7596
79. 732-0807
80. 711-1114
81. 736-0526
82. 731-1828
83. 710-0653
84. 748-0377C
85. 742-0741
86. 736-0524A
87. 710-1257
88. 731-1874
89. 732-0819
90. 726-0111
91. 747-0965
92. 731-1713B
94. 682-3052
95. 710-0969
96. 725-0157
97. 710-0134
If Equipped
Part No.
748-0188B
753-0609
682-3053
Description
Pawt RH Pawt LH Shld Screw.340 ID x.285 OD Wheel Rachet Bell Washer.265 ID x.75 OD
Hex Cap Screw 1/4-20 x.620 Hubcap
Shoulder Screw.498 x 1.445 Wave Washer.510 ID x.750 OD Wheel 8 x2.125
Spring Washer.401 ID x.870 OD Screw 1/4-14 x.500
Screw 1/4-20 x.625 Hex Washer Screw 3/8-16 x 1.0
Front Axle Assembly Push Nut.251D x.50OD
Torx Screw Block Bushing
Hex Washer Screw Front Axte Cover Belt 3/8 x 39.24
Pulley Assembly Sleeve Spacer.88 ID x 1.13 OD Sleeve Spacer.88 ID x 1.00 OD
Pivot Bracket Control Arm
Torsion Spring Pivot Shaft
Wave Washer 1.38 ID x.88 OD Baffle Screw 1/4-20 x 3.75
Blade Adapter Blade Adapter Kit 21" Mulching Blade Blade Belt Support
Hex Bolt 3/8-24 x 2.5 Chute Door
Torsion Spring Push Cap
Pivot Rod Discharge Chute
Handle Bracket Assembly-- RH Handle Bracket Assembly-- LH
Screw #12-16 x 1.00 Cable Tie
Carriage Screw 1/4-20 x.62
19
Model978Q
24
21
25
60 49
26
17 16
_81
15
11
\
\8
12
4
7
4
5
31
64
]1 I
46\
47_
14
51
62
20
Model978Q
Ref,
No.
1. 720-0223
2. 732-0803A
3. 738-0529
4. 710-0751
5. 736-0270
6. 748-0318
7. 736-0369
8. 682-0531
9. 750-0515
10. 741-0978
11. 750-1056
12. 710-0653
13. 682-7528
14. 741-0324A
15. 682-7526
16. 618-0263A
17. 710-0604A
18. 713-0453
19. 638-0012
20. 741-0522
21. 732-0832
22. 750-0151
23. 710-1315
24. 711-0835
25. 750-0807
26. 782-0568
27. 710-1652
28. 714-0474
29. 712-3025
30. 736-0425
31. 756-0656
32. 736-3084
Part No.
Part Description
Grip Spring Lever Shoulder Nut.825 x.165 Lg. Cap Screw 1/4-20 x.620
Belt Washer.285 ID x.75 OD Wheel Rachet Flat Washer.508 ID x 1.00D
Pivot Arm Assembly Spacer.510 ID x.70 OD Sleeve Bearing.504 ID x.830 OD Shoulder Spacer Tap Screw 1/4-20 x.375 Chain Cover Assembly Flange Bearing.506 ID x.590 Lg Transmission Axle Assembly Transmission Assembly
Hex Screw 5/16-18 Chain
Rear Axle Assembly Flange Bearing.506 ID x.715 Lg Torsion Spring Spacer.550 ID x.750 OD
Screw 3/8-16 x.25 Clevis Pin.50 Dia x 4.82 Lg.
Spacer.385 ID x.624 OD Height Adjustment Spring Bracket
Screw 1/4-20 x.625 Cotter Pin
Hex Jam Nut 5/16-24 Bell Washer.325 ID x.930 OD Pulley
Flat Washer.510 ID x 1.120 OD
Ref.
No,
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
Part No.
712-0896 782-7598 741-0124 732-0849A
750-1050 682-0027A
710-0299 741-0682A 736-0570 721-0329
618-0253 782-7601A
741-0690 736-0616 782-7595 712-0429
711-1168 717-1469
741-0674 717-1487 736-0314 736-0569 618-0252 710-0642 611-0066 664-0074 747-0940A 747-0939 747-0937 631-0071 726-0106 741-0673
Part Description
Hex Jam Nut 1/4-28 Belt Keeper
Bearing Extension Spring Flange Spacer
Idler Bracket Assembly Hex Cap Screw 1/4-28 x 1.0 Bearing Sleeve
Flat Washer.885 ID x 1.45 OD Oil Seal
Upper Housing Assembly Cable Bracket
Bearing Thrust Washer.504 ID x.70 OD
Pivot Bracket Hex Nut 5/16-18
Output Shaft 6T Gear 34T
Bearing Pinion Shaft 10T
Thrust Washer 3/8 x.70 Thrust Washer.388 x.625
Lower Housing Assembly Hex Screw 1/2-20 x.75
Shaft Assembly Grass Bag Support Rod w/Rope Guide
Pivot Rod Grass Bag Frame
Grass Bag Cover Cap Nut Bearing
21
Safety& DecorativeLabels
777S30116
(MODEL PLATE ON RIGHT SIDE)
777120291
777120067
777S30128
777S30145
TF/DO
22
NOTES
23
MANUFACTURER'S LIMITED WARRANTY FOR:
YaRD.MaNTM
®
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" warrants this product against defects in material and workmanship for a period of two (2) years commencing on the date of original purchase and wilt, 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 part, accessory or attachment not approved by MTD for use with the product(s) covered by this manual will void your warranty as to any resulting damage.
Normal wear parts are warranted to be free from defects in material and workmanship for a period of thirty (30) days from the date of purchase. Normal wear parts include, but not limited to items such as: batteries, belts, blades, blade adapters, grass bags, rider deck wheels, seats, snow thrower skid shoes, shave plates, auger spiral rubber and tires.
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, or call 1-800-800-7310 or log on to our Web site at www.mtdproducts.com.
This limited warranty does not provide coverage in the following cases:
a,
The engine or component parts thereof. These items
may carry a separate manufacturer's warranty. Refer to applicable manufacturer's warranty for terms and
conditions.
b,
Log splitter pumps, valves, and cylinders have a
separate 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.
d,
Service completed by someone other than an
authorized service dealer.
e,
MTD does not extend any warranty for products sold or
exported outside of the United States, its possessions and territories, except those sold through MTD's authorized channels of export distribution.
f,
Replacement parts that are not genuine MTD parts. Transportation charges and service calls.
g.
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. 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 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.
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 safety features of the product shall void this warranty.
You assume the risk and liability for toss, 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.
IMPORTANT:Owner must present Original Proof of Purchase to obtain warranty coverage.
MTD LLC, P.O.BOX361131CLEVELAND,OHIO44136-0019; Phone:1-800-800-7310
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