Yard-Man 203 User Manual

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-
MTD LLC P.O. BOX 361131 CLEVELAND, OHIO 44136-0019
PRINTED IN U.S.A.
FORM NO.
770-10023F.fm (4/04)
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
Content Page
Maintaining Your Chipper Shredder Vacuum 9 Trouble Shooting 13 Illustrated Parts List 14 Warranty 20
Adjusting Your Chipper Shredder Vacuum 8
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 u nit for best perform ance. Please read and u nderstand what it says.
Before you start assembling your new equipment, please locate the model plate on t he equipment and copy the information from it in the space pr ovided below. A sample model plate is also given below. You can locate the model plate by standing behin d the unit and looking down at the frame below the engine. This information will be necessary to use the manufacturer’s web site and/or help from the Customer Support Departme nt or an authorized service dealer.
Copy the model number here:
www.yardman.com
MTD LLC P. O. BOX CLEVELAND,OH 330-220-4683 800-800-7310
361131
44136
Copy the serial number here:
CUSTOMER SUPPORT
Please do NOT return the unit to the retailer from where it was purchased, without first contacting Customer Support.
If you have difficulty assembling this product or have any questions regarding the controls, opera tion or maintenance of this unit, you can seek help from the experts. Choose from the options below:
Visit yardman.com for many useful suggest ions. Click on Customer Support but ton and you will get the four options reproduced here. Click on the appropriate button and help is immediately available.
The answer you are looking for could be just a mouse click away!
If you prefer to reach a Customer Support Representat ive, please call 1-800-800-7310.
The answer you are looking for could be just a mouse click away!
Engine
Manual
The engine manufactur er is responsible for all engine-related issu es with regards to performance, power-rating, specifica tions, warranty and service. Please re fer to the engine manufacturer’s Owner’s/Operator’s Manual, packed separately with your unit, for more information.
2
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 your self and others. Read and follow all instructions in this manual before attempting to operate this machine. Failur e 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 oper ation in this
manual. As with any type of power equipment, carelessne ss or error on the part of the operator can result in serious injury. This machine is capable of amputating hands and feet and thro wing 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 regu lar reference a nd 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 m achine without proper instruction.
5. Keep bystanders, helpers, pets, and childre n 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 discharg e opening. Contact with the rotating impeller can amputate fingers, hands, and feet.
8. Never attempt to unclog either th e 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 a nd 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 containe r. b. Extinguish all cigarettes, cigars, pipes, and
other sources of ignition. c. Never fuel machine indoors. d. Never remove gas cap or add while t he
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.).
3
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 discharg e opening. Contact with the rotating impeller can amputate fingers, hands, and feet.
2. Before starting the machine, make sure t he chipper chute, feed intake, and cutting chamber are empt y 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 re sult.
8. Never attempt to unclog either th e 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 disch arge 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 attache d to the machine. Never attempt to attach or change eit her attachment while the engine is running.
11. Keep all guards, deflectors and safety device s 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 mach ine in safe working condition. Also, visually inspect machine for any damage and repair, if needed.
3. Before cleaning, repairing, or inspecting, sto p 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 outdoor s.
10. Observe proper disposal laws and regulations for gas, oil, etc. to protect the environment.
4
WARNING: - YOUR RESPONSIBILITY: Restrict the use of this power machine to persons who read, understand and follow the warnings and instructions in this ma nual and on the mac hine.
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 wi th 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 fl at, 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
Nozzle
Figure 1
Bag
5
Attaching The Nozzle
Remove three wing nuts from the front of the chipper shredder vacuum.
Place nozzle in position over the three st uds on unit and secure with wing nuts just removed. See Figure 2.
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 asse mbly 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.
Discharge Chute
Place the four straps on the top of the bag over upper handle, hooking them on the studs to se cure in place. Squeeze the clamp on the drawstr ing and pull the drawstring tight. Release the clamp. See Figure 4.
Bag Opening
Figure 3
Bag Straps
Bag
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 ne edles 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 whe el 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.
6
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
Caster Lock
Engine Controls
See the separate engine manual for the location an d function of the controls on the engine.
Nozzle
Nozzle Door Adjustment Lever
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 instr ucted in the separate engine manual packed with your chipper shredder vacuum. Read instructions carefully.
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.
NOTE: See your engine manual packed with your unit
for more detailed instructions.
Starting Engine
Attach spark plug wire to spark plug. Make certain the metal cap on the end of the spark plug is fastened securely over the metal tip on the spark plug.
Make certain drive clutch control is in the disengaged (released) position.
Engines with choke lever: 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.
7
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.
Stopping Engine
Move throttle control lever to STOP or OFF position.
Disconnect spark plug wire from spark plug and ground against the engine.
To Empty Bag
The bag is designed to be emptied without being removed from unit. Open the large zipper in th e rear of the bag to empty the contents. If bag is rem oved for any reason, follow the instructions for attaching the bag in the ASSEMBLY section. Be certain the zipper is clo sed completely when operating the unit.
into catcher bag. Do not attempt to shred or chip any material other than vegetation found in a no rmal yard (i.e. branches, leaves, twigs, etc.) Avoid fibrous plan ts 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.Se e 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.
Chipper Chute
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.
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
IMPORTANT:
housing in the discharge area. If t he 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.
Figure 6
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 ahea d operation. Place pins in smaller holes to allow casters to rotate freely. Lock wheels in straight position when operating on slopes. See Figure 7.
8
Smaller Hole (Rotate Freely)
Larger Hole (Locked)
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.
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 clut ch 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
Loosen
Figure 9
Engine Adjustments
Refer to the separate engine manual for engine adjustment instructions.
Nozzle Door Adjustment Lever
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.
Lubrication (Refer to Figure 5)
Wheels: Lubricate the rear wheels with ligh t oil once a season.
Nozzle Door Adjustment Levers: Lubricate each adjustment lever once a season with light oil.
Front Caster Wheels: Grease fi ttings are located on the front caster wheels to provide easy lubrica tion of the swivel pins once a season.
9
Customer Responsibilities
MAINTENANCE
SCHEDULE
Lubricate Wheels
T C
Lubricate Adjustment Levers
U D O
Lubricate Caster Wheels
R P
Check Chipper Blades Check Oil
Change Oil
E
Check Air Filter
N
I G N
Clean Engine
E
Check Spark Plug
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SERVICE
DATES
Maintenance
Engine
Refer to the separate engine manual for all engine maintenance instructions.
Check engine oil leve l before each use as instructed in the separate engine manual packed with your unit. Read and follow instructions carefully.
Clean air cleaner ever y 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 pl ug 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 b olt, 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 fla il screen from the inside the housing. See Figure 10.
Clean the screen by scraping or washing with wate r 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
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.
10
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 gro und 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 scre ws. 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.
Access Plate
Self-Tapping
Hex Lock Nuts
Screws
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 th e 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.
Safety Switch
Self-Tapping Screw
Lower Belt Guard
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.
Self-Tapping Screws
Figure 12
Remove the safety switch from the fron t 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
Disconnect the spark plug wire and gro und it away from the spark plug.
Figure 13
11
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 mo unting adapter by removing the five hex bolts and two hex nuts. See Figure 14.
Hex Bolts
Hex Bolts
Place the mounting adapter ag ainst the engine and make sure the hole in the mountin g 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. Tur n 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.
Inner Housing
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
Transmission Pulley
Mounting Adapter
Idler Bracket
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.
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.
Reassemble following the previous steps in reverse order.
Outer Housing
Holes for Screwdrivers
Figure 17
12
Storing Your Chipper Shredder Vacuum
Clean the equipment thoroughly.
Wipe equipment with an oiled rag to prevent rust.
Refer to engine manual for correct engin e 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.
4. Choke not in CHOKE position (If Equipped).
5. Engine (if equipped with a primer) not primed properly.
6. Blocked fuel line.
7. 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 pro perly.
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 beyo nd the minor a djustments liste d above, contact your nea rest authorized service dea ler.
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. Prime engine.
6. Clean fuel line.
7. 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.
13
SECTION 8: PARTS LIST FOR MODEL 203
1
2
3
2
3
9
10
8
6
4
5
11
13
14
16
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 5 764-04001 Bag 6 631-0069 Nozzle Assembly 7 731-1831 Nozzle Flap 8 710-0969 Screw
PART
NO. DESCRIPTION
15
12
7
9
10
14
13
REF.
NO.
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 1.120 x.060 15 712-0431 Hex Flange Lock Nut 3/8-16 16 631-0047 Door Assembly
PART
NO. DESCRIPTION
8
14
Model 203
2
3
5
12
11
10
38
1
2
3
4
7
6
18
8
9
5
3
2
26
25
6
22
13
14
15
13
14
16
17
15
14
30
31
30
34
35
Ref.
No.
1. 681-0108 Impeller Assembly 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
18. 681-0098 Inner Flail Housing Assembly
Part No. Part Description
36
33
19
23
24
36
32
Ref.
No.
19. 781-0599 Upper Shredder Blade
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 Outer Flail Housing Assembly
27. 629-0241A Wire Harness
28. 710-0896 Hex Washer Screw 1/4-14 x.625
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
36. 710-1260A Screw 5/16-18 x.750
37. 723-0400 Safety Glasses (Not Shown)
38. 781-0735 Retaining Pin Clip
Part N o. Part Description
28
27
29
17
15
Model 203
10
9
11
2
5
6
4
6
5
1
52
54
41
19
13
49
16
33
18
44
15
56
35
8
3
7
4
8
30
24
27
34
36
40
31
39
38
23
22
42
48
45
55
32
37
51
50
57
17
17
14
12
27
29
25
28
26
21
46
50
53
43
47
16
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 Self Tapp. Screw 1/4-14 x.625
9. 710-0603 Hex Washer Screw 5/16
10. 618-0256 Chipper Shredder Trans. Assembly
11. 611-0063 Axle Shaft 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 6T Shredder Transmission Assy.
22. 16500A Hex Bearing Cup
23. 711-1118 6T Sprocket Output Shaft
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
29. 741-0414 Flange Bearing.629 ID
Part No. Part Description
748-0381 Pawl RH.345 ID (Not Shown)
Ref.
No.
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. 756-0558 Idler Pulley
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 Assembly
56. 731-1825 Hub Cap
57. 656-0008 Idler Pulley Assembly w/Bearing
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.
17
Model 203
34
22
20
5
6
4
7
8
9
10
8
21
12
18
29
30
31
32
26
12
26
28
13
2
3
3
11
13
13
14
18
12
26
12
19
26
12
14
27
30
15
1
2
17
13
18
39
40
41
45
47
38
37
48
35
43
39
36
45
37
47
48
44
38
42
46
29
34
40
13
35
36
37 38
38
29
32
13
33
20
29
37
44
46
18
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 Cable Mounting 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. 712-0380 Hex Nut 1/4-28
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 Self Tapp. Screw 1/4-14 x.625
21. 731-1646 Belt Cover
22. 719-0359 Engine Mounting Adapter
26. 710-3103 Hex Cap Screw 5/16-18 x 1.75
Part No. Part Description
Ref.
No.
27. 749-1094 Lower 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. 734-1804A Wheel 6.0 x 2.0
Part N o. 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
19
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” warrants this product against defects in material and workmanship 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 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. g. Transportation charges and service calls.
No implied warranty, including any implied w arranty 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 gre ater 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 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.
IMPORTANT:
Owner must present Original Proof of
Purchase to obtain warranty coverage.
MTD LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019; Phone: 1-800-800-7310
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