Yard-Man 549 User Manual

Operator’s Manual
21” Mulching Mower
Model 549
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.
PRINTED IN U.S.A.
This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-covered, brush-
MTD LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019
Form No.
769-00964A (4/5/2004)
TABLE OF CONTENTS
Content Page
Important Safe Operation Practices 3 Slope Gauge 6 Assembling Your Lawn Mower 7 Know Your Lawn Mower 9 Operating Your Lawn Mower 10
Content Page
Maintaining Your Lawn Mower 12 Servicing Your Mower 12 Troubleshooting 13 Illustrated Parts List 14 Warranty 16
Making Adjustments 11
FINDING MODEL NUMBER
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 r ead and understand wh at it says.
Before you start assembling your new equipment, please locate the mod el plate on th e 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:
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, operation or maintenance of this unit, you can seek help from the experts. Choose from the op tions below:
Visit yardman.com for many useful suggest ions. Click on Customer Support butt on 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!
To reach a Customer Support Representative, 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 r efer to the engine manufacturer’s Owner’s/Operator’s Manual, packed separately with your unit, for more information.
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SECTION 1: IMPORTANT SAFE OPERATION PRACTICES
WARNING: This symbol points out important safety instructions which, if not follo wed, could endanger
the personal safety and/or property of yourself and others. Read and follow all inst ructions in this manual before attempting to operate this m achine. Failure to comply with these instructions may r esult in personal injury. When you see this symbol—HEED ITS WARNING.
WARNING: Engine exhaust, some of its constituents , and certain vehi cle components contain or emit
chemicals known to State of California to cause cancer and birt h defects or other reproductive ha rm.
WARNING: This machine was built to be operated according to the rule s for safe operation in this
manual. As with any type of power equipment , carelessness or error on the part o f the operator can result in serious injury. This machine is capable of amputating hands and feet and th rowing objects. Failure to observe the following safety instructions could result in serious injury or death.
General Operation
1. Read this operator’s manual carefully in its entirety before attempting to assemble this machine. Read , understand, and follow all instructions on t he 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 thi s manual in a safe place for future and regular reference and for ordering replacement par ts.
2. This machine is a precision piece of power equipment, not a plaything. Therefor e, 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 beh ind 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 p erforming an adjustment or repair. Thrown objects which ricochet can cause serious injury to the eyes.
7. Wear sturdy, rough-soled work shoes a nd close­fitting slacks and shirts. Shirts and pants that cover the arms and legs and steel-toed shoes are recommended. Never operate this ma chine 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 yo u 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 inf luence of alcohol or drugs.
6. Do not engage the self-prop elled 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 ma y 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 co ntrol handle
3
immediately and the blade will stop rotating within three seconds.
9. Mow in daylight or good artificial light; walk, not run.
10. Stop the blade when crossing gravel drives, walkways or roads.
11. If the equipment should start to vibrate abnormally, stop the engine and check immediately for the cause. Vibration is generally a warning of troub le.
12. Shut the engine off and wait until the blade comes to a complete stop before removing the grass catcher or unclogging the chute. The cutting blade continues to rotate for a few seconds after the engine is shut off. Never place any part of the body in the blade area until you are sure the blade has stopped rotating.
13. Never operate mower without proper trail shield, discharge cover, grass catcher, blade control handle or other safety protective devices in place and working. Never operate mower with damaged safety devices. Failure to do so can result in personal injury.
14. Muffler and engine become hot and ca n cause a burn. Do not touch.
15. Only use parts and accessories made by the original equipment manufacturer (O.E.M). Failure to do so can result in personal injury.
16. If situations occur which are not covered in this manual, use care and good judgment. Contact your dealer for assistance. Call 1-800-800-7310 for the name of your nearest dealer.
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 oft en attracted to the mower and the mowing activit y. They do not understand the dangers. Never assume that ch ildren 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 tha n 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 in to 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 operat e a power mower. 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 p arent.
Service
Slope Operation
Slopes are a major factor related to slip and fall accidents which can result in severe injury. Operation on slopes requires extra caution. If you feel unea sy 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 deg rees, do not mow it.
Do:
1. Mow across the face of slopes; never up an d down. Exercise caution when changing direction.
2. Watch for holes, ruts, rocks, hidden objects, or bumps which can cause you to slip or trip. Tall grass can hide obstacles.
3. 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.
Do Not:
1. Do not mow near drop-offs, dit ches or embankments, you could lose your footing or balance.
2. Do not mow slopes greater than 15 degrees as shown on the slope gauge.
Safe Handling of Gasoline:
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 fro m 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 fr om 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.
4
10. Never over fill fuel tank. Fill tank to no more than ½ inch below bottom of filler neck to provide space for fuel expansion.
11. Replace gasoline cap and tighten securely.
12. If gasoline is spilled, wipe it off the engine and equipment. Move unit to another area. Wait 5 minutes before starting the engine.
13. Never store the machine or fuel container inside where there is an open flame, spark or pilot light as on a water heater, space heater, furnace, cloth es dryer or other gas appliances.
14. To reduce fire hazard, keep mowe r free of grass, leaves, or other debris build-up. Clean up oil or fuel spillage and remove any fuel soaked debris.
15. Allow mower to cool 5 minutes before storing.
General Service:
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.) blad e 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 befor e starting an d 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 origin al 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 safet y.
10. Do not change the engine governor set ting 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.
Your Responsibility
Restrict the use of this power machine to pe rsons who read, understan d and follow the warnings a nd instructions in this manual and on the machine.
1299 AC
5
SECTION 2: SLOPE GAUGE
Use this page as a guide to determine slopes where you may not operate safely. Do not operate your lawn mower on such slopes.
Operate WALK-BEHIND mowers across the face of slopes, never up and down slopes.
Operate RIDING mowers up and down slopes, never across the face of slopes.
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 inju ry. If operatin g a walk-beh ind mower on such a slop e, it is extre mely difficult to maintain your footing
and you could slip, resulting in serious injury.
F
O
L
D
O
N
D
O
T
T
E
D
L
I
N
E
,
R
E
P
R
E
S
E
N
T
I
N
G
A CORNER OF A BUILDING
OR A FENCE POST
SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE
A POWER POLE
WARNING
15°
A
1
5
°
S
L
O
P
E
6
SECTION 3: ASSEMBLING YOUR LAWN MOWER
Removing Unit From Carton
Remove staples, break glue on top flaps, or cut
tape at carton end and open carton.
Remove loose parts if included with unit (i.e.,
operator’s manual, etc.)
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.
Loose Parts in Carton
•Grass Bag
Side Discharge Chute
Rear Wheels
Hardware Pack
Bottle of Oil
Hardware Pack
Please identify each piece of the hardware pack as shown here.
Carriage Bolt
Wing Nut
Before Assembly
Before setting up your lawn mower, disconnect the
spark plug wire from the spark plug. See Figure 1.
Lower Handle
Upper Handle
Figure 2
Make sure that carriage bolt through the uppe r and lower handles on each side is properly seated. Tighten the wing nuts. See Figur e 3.
Tighten these wing nuts
Carriage Bolt
Handle Bracket
Carriage Bolt
Spark Plug Wire
Spark Plug
Figure 1
NOTE: Reference to ri ght or left hand side of t he mower
is observed from the operating position.
Setting Up Your Lawn Mower
Assembling Handle
Lift up and pull back on the upper handle to raise the handle into the operating position. See Figure
2. Make certain the lower handle is seated securely into the handle bracket assemblies.
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 th e other side. See Figure 4.
Carriage Bolt
Wing Nut
Hairpin Clip
Figure 4
After moving the hairpin clip, insert th e carriage bolt, from the hardware pack, in the upper hole on the handle mounting bracket and secure with plastic wing nut from the hardware pack. See Figure 4. Repeat on the other side.
Weld Pin
7
Fasten the cable to the lower handle with the two cable ties found on the lower handle. Pu ll the cable ties tight and trim off the excess. See Figure 5.
Cable Tie
Assembling Grass Catcher
NOTE: If the grass catcher came pre-assembled,
proceed to the next section. If it came unassembled, follow the steps below to assemble it first, before attaching to the mower.
Lower Handle
Figure 5
NOTE: Your mower is shipped with the handle in the
higher position. If you wish to lower the height of the handle, refer to the Adjustment Section at this time.
Attaching Rear Wheels
Remove the hex flanged nut on the rear axle from each side (leave the spring washer in place) and place the rear wheel on the axle. See Figure 6. Reinsert the flanged nut into the axle as shown, and tighten securely. Repeat on other side.
Wheel
Hex Nut
Rear Axle
Insert frame into grass bag with the black plastic side on the bottom of bag. See Figure 8.
Slip the openings in the side of the plastic channel on bag over the hooks on the grass catcher frame. Secure bag to the frame by working the six plastic channels on bag over frame. All of the plastic chan­nels except the center top of the bag attach from the outside of bag. The center top of the bag attaches from inside the bag. See Figure 8.
Grass Catcher Frame
Grass Bag
Plastic Channel
Insert frame into bag
Grass Catcher Assembly Complete
Spring Washer
Figure 6
Attaching Starter Rope
The rope guide is already attached to the right side of the upper handle of your mower. See Figure 7.
Wing Nut
Upper Handle
Starter Rope
Rope Guide
Figure 7
With the spark plug wire disconnected and grounded, hold the blade contro l handle against the upper handle, and pull the rope out of the engine .
Slip the rope through the rope guide as shown below. Tighten the wing nut holding the rope guide to the upper handle.
Lower Handle
Figure 8
Attaching Hard Top Cover (If Equipped)
Slide the hardtop cover under the gr ass catcher handle, positioning it so the handle rests snugly into the notch in the cover, and press the frame int o the tabs at the back of the cover. See Figure 9 .
Grass Catcher Handle
Notch in Hardtop
Cover
Mounting Bracket
Figure 9
Position the mounting bracket facing down between the front of the handle and the front of the
Self Tapping Screws
8
hardtop cover so that the holes in the cover line up with the holes in the bracket. Inse rt the self t apping screws down through the hardtop cover and mounting bracket.
Attaching Grass Catcher & Chute
WARNING: Never operate the mower
unless the hooks on the grass catcher are firmly seated on the chute pivot rod, and th e rear discharge door rests firmly against the to p of the grass catcher.
IMPORTANT:
the handle so that it is not in the way when attaching the grass catcher.
Lift the rear discharge door on the mower .
Place the hooks, found on both sides of the grass catcher frame, over the chute door pivo t rod at the rear of the mower. Release the rear discharge door. See Figure 10.
Rear Discharge Door
Make sure cable is routed to the outside of
To remove the grass catcher, lif t the rear discharg e door on the mower, lift the grass catcher up and of f
the pivot rod. Release the rear discharge door.
Attaching Side-Discharge Chute
Remove the grass catcher and let t he discharge door close.
On the right side of the mower, lift the mulching plug and slide the two hooks of the side-discharge chute under the hinge pin on the mulching plug assembly. Lower the mulching plug. See Figure 11.
IMPORTANT:
time, even when you are not mulching.
Do not remove the mulching plug a t any
Mulching
Plug
Hinge Pin
Side Chute
Deflector
Figure 11
Using Mulch Plug
Lift the mulch plug and remove th e discharge chute
Grass Catcher
Figure 10
SECTION 4: KNOW YOUR LAWN MOWER
Read this operator’s manual and safety rules before operating your lawn mower. Compare the illustration in Figure 12 with your lawn mower to familiarize yourself with the location of various controls and adjustments. Save this manual for future reference.
Blade Control Handle
The blade control handle is located on the uppe r handle of the mower. The blade control handle must be depressed in order to operate th e unit. Release bla de control handle to stop engine and blade.
9
Recoil
Starter
Side-Discharge Chute
Blade Control Handle
Grass Catcher
Rear Cutting Height Adjuster Lever
Front Cutting Height Adjuster Lever
Mulching Plug
Figure 12
up and away from the mower. Let mulch plug rest against the deck. Operate mower without the grass catcher. Refer to page 11.
WARNING: The operation o f any lawn
mower 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.
WARNING: This blade control mechanism is
a safety device. Never attempt to bypass its operations.
Cutting Height Adjustment Levers
These levers are located on each wheel and are used to adjust the cutting height. These levers have to be at the same relative position to ensure uniform cut.
Recoil Starter
The recoil starter is attached to the right upp er handle. Stand behind the unit and pull the recoil starter rope to start the unit.
Mulching Plug
Instead of collecting grass clippings in a grass catcher, this mower has the option of recirculating the clippings back to the lawn. This is called mulching. Remove the grass catcher and the side-discharge chute from the mower, and operate with the mulching plug only for this purpose.
Grass Catcher
The grass catcher, located at the rear of the mowe r, is used to bag the grass clippings for disposal at another site. Once the bag is full, it has to be removed from the mower and emptied before any further mowing.
SECTION 5: OPERATING YOUR LAWN MOWER
Grasp starter handle and pull rope out slowly until
WARNING: Read, understand, and follow all
instructions and warnings on the machine an d in this manual before operating.
NOTE: You must service the engine with oil and gasoline before starting the mower for the first time. Check oil and gasoline levels and fill up as necessary for subsequent starts.
Gas & Oil Fill-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.
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.
WARNING: Be sure no one other tha n the
operator 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, fe et, hair and
loose clothing away from any moving parts on engine and lawn mower.
NOTE: See your engine manual packed with your unit for more detailed instructions.
Before Starting Mower
Attach spark plug wire to spark plug. Make certain the metal cap on the end of the spark plug wire (inside the rubber boot) is fastened secure ly over the metal tip on the spark plug.
Starting Engine
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.
Standing behind the mower, depre ss the blade control handle and hold it against the upper handle.
Stopping Engine
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.
Using Your Lawn Mower
You can use your mower as a mulching mower or a rear bagger.
Be sure that the lawn is clear of st ones, sticks, wire, or other objects which could damage lawn mower
or engine.
For best results, do not cut wet grass. New grass or thick grass may require a narrower cut.
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WARNING: If the mower strikes a foreign
object, 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 mowe r.
For a healthy lawn, always cut off one-third or less of the total length of the grass.
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.
SECTION 6: MAKING ADJUSTMENTS
Bagging Grass Clippings
You can use the grass catcher bag to collect clippings while you are operating the mower.
Attach grass catcher following instructions on page 9 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.
Lift discharge door and pull grass bag up and away from the mower to dispose of the grass clippings.
WARNING: Do not at any ti me make any
adjustments without first stopping engine and disconnecting spark plug wire.
Handle Height Adjustment
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 upper handle by removing the hand knobs and carriage bolts. 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 h andle from the mower.
Turn lower handle around so the notch on the bottom of the lower handle is facing forward. See Figure 13A.
Reassemble the handle, 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 though the upper hole on the handle mounting bracket and secure with plastic wing nuts. Repeat on the other side.
Height
Notch
Lower Handle
A
Reassemble the upper handle to the lower handle.
Attach the starter rope as instructed in the Assembly Section.
B
Figure 13
Adj. Lever
Cutting Height Adjustment
For rough or uneven lawns, move the height adjustment lever to a higher position. This will help stop scalping of the grass.
An adjusting plate and thumb lever at each wheel position provides cutting height adjustment. Each adjusting plate has nine height positions. Height of cut will change when you move the thumb lever from one position to another.
Simply depress the lever towards the wheel a nd move the lever assembly to desired position. See Figure 13B. All wheels must be placed in the same relative position.
11
SECTION 7: MAINTAINING YOUR LAWN MOWER
Put the mower back on its wheels on the ground. If
WARNING: Always stop the engine and
disconnect the spark plug wire before performing any maintenance work or adjustments on your lawn mower.
you had put plastic under the gas cap, make sure to remove it now.
Lubrication
Cleaning Mower
The underside of the mower deck should be cleaned after each use to prevent any build-up of grass clippings, leaves, dirt, or other debris.
NOTE: We do not recommend the use of pressure washers or garden hose to clean your unit. These may cause damage to bearings or the e ngine. 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.
WARNING: Never tip the mower more than
90 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.
Scrape and clean the underside of the deck with a suitable tool. Do not spray with water.
Blade Control 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.
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 pivot arm axle and the inner surface of the wheel with light oil.
Rear Discharge Door
Lubricate the torsion spring and the pivot point on each end of the rear discharge door using a light oil. This will prevent rusting of the discharge door.
Engine Care
Follow the accompanying engine manual for detailed list and instructions.
WARNING: Make sure to avoid muf fler and
surrounding areas while the mower engine is hot because temperature of these areas of the engine may exceed 150
o
F.
SECTION 8: SERVICING THE MOWER
Blade Care
WARNING: When removing the cu tting
blade for sharpening or replacement, pro tect 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.
Removing the 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 14.
Remove the blade and the adapter from the crankshaft.
Blade
Adapter
Blade Bell
Support
Hex Bolt
Figure 14
Sharpening the Blade
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.
12
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.
WARNING: An unbalanced blade will cause
excessive vibration when rotating at high speeds. It may cause damage to the mower, and could break causing personal injury.
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 to rque: 450 in. lbs. min., 600 in. lbs. max.
NOTE: To ensure safe operation of your mower, periodically check the blade bolt for correct torque.
Balancing the 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
Replacing Rear Flap
To remove rear flap, cut off the flat end of the wire
Attach the new flap and new rod to deck, bend ing
when testing for balance.
Installing the 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.
Be sure to install the blade with the side of the
Storing Your Lawn Mower
The following steps should be taken to prepare your lawn mower for storage.
Clean and lubricate mower thoroughly as describe d blade marked “Bottom” (or with part number) facing the ground when the mower is in the operating
Refer to engine manual for correct engin e storage position.
Slide the blade adapter onto the engine cran kshaft.
Coat mower’s cutting blade with chassis grease to
Place the blade on the adapter. Be cert ain the blade is aligned and seated on the blade adapter
Store mower in a dry, clean area. Do not store next
flanges.
SECTION 9: TROUBLESHOOTING
Problem Cause Remedy
Engine fails to start 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
Engine runs erratic 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.
Engine overheats 1. Engine oil level low.
2. Air flow restricted.
3. Carburetor not adjusted properly.
Excessive vibration 1. Cutting blade loose or unbalanced.
2. Bent cutting blade.
Mower will not mulch grass 1. Wet grass.
2. Excessively high grass.
3. Dull blade.
Uneven cut 1. Wheels not positioned correctly.
2. Dull blade.
rod which secures it to the deck. the ends of the new rod over to secure to deck.
in the lubrication instructions. instructions. prevent rusting. to corrosive materials, such as fertilizer.
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 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. 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.
3. Sharpen or replace blade.
1. Place all four wheels in same position.
2. Sharpen or replace blade.
13
SECTION 10: PARTS LIST FOR MODEL 549
1
2
3
36
11
13
31
49
5
14
12
6
7
8
9
10
34
16
49
65
23
18
28
54
19
39
29
40
52
36
45
42
35
15
43
53
21
51
37
20
49
66
33
30
17
60
47
40
26
62
49
57
58
61
64
59
32
22
24
46
25
29
4
49
50
55
56
14
Model 549
Ref.
No.
1. 749-1092A Upper Handle
2. 747-1161A Control Handle
3. 731-04302 Hardtop Cover
4. 731-1506 Front End Cover
5. 787-01113 Grass Bag Mounting Bracket
6. 720-0279 Handle Knob
7. 710-1205 Rope Guide
8. 710-1174 Carriage Bolt 5/16-18 x 2”
9. 736-0451 Shoulder Washer.320 ID x.930 OD
10. 720-0284 Wing Nut
11. 749-0928A Lower Handle
12. 746-1130 Control Cable 40”
13. 664-04027 Grass Bag
14. 747-04080 Grass Bag Frame
15. 714-0104 Hairpin Clip
16. 731-04134 Grass Bag Door
17. 736-0504 Wave Washer.510 x.750 x.017
18. 732-0700 Wire Rod
19. 731-1236 Trail shield
20. 750-04162 Spacer.375 O.D. x.50 I.D. x 1.02”
21. 732-04090 Torsion Spring — RH
22. 687-02066 Handle Bracket Assembly — RH
23. 734-2043 Wheel, Zag Tread, Yellow 14 x 2.125
24. 787-01104 Deck 21”
25. 710-0654A Hex Washer Screw 3/8-16 x 1.0
26. 736-0270 Bell Washer.265 ID x.75 OD
28. 736-0182 Spring Washer.500 x 1.00 x.022
29. 710-0599 Screw 1/4-20 x.500
30. 782-5004A Rear Baffle - RH
31. 782-5003 Rear Baffle - LH
32. 710-1017 Tap Screw 1/4-14 x.625.
Part No. Part Description
732-04089 Torsion Spring — LH
687-02065 Handle Bracket Assembly — LH
Ref.
No.
33. 712-3005 Flange Lock Nut 3/8-16
34. 710-0703 Hex Carriage Screw 1/4-20
35. 687-02033 Handle Bracket — RH
36. 710-1652 Self-tapping Screw 1/4-14 x.625
37. 710-0216 Hex Screw 3/8-16 x 0.75
39. 687-02039 Pivot Arm Assembly — RH
40. 738-0507B Shoulder Screw
42. 732-0866 Spring Lever
43. 720-0312 Spring Lever Grip
45. 712-0397 Wing Nut
46. 687-02074 Front Height Adjuster Assembly — RH
47. 734-2004A Front Wheel, Zag Trd. 8 x 2.125
49. 712-0431 Flange Lock Nut 3/8-16
50. 782-5002A Front Baffle
51. 732-1014 Torsion Spring
52. 747-0710 Hinge Pin
53. 17032A Chute Deflector Adapter
54. 687-02055 Mulching Plug
55. 748-0376C Blade Adapter
56. 742-0741 21” Mulching Blade
57. 736-0524A Blade Bell Support
58. 710-1044 Hex Cap Screw 3/8-24 x 1.5
59. 15261A Height Adjustment Plate
60. 720-0426 Knob
61. 687-02077 Pivot Arm Assembly — RH
62. 732-0404 Spring Lever
64. 747-0996 Chute Door Pivot Rod
65. 731-04177 Side Discharge Deflector
66. 731-1426A Hubcap Radial Spoke Yellow
Part No. Part Description
687-02031 Handle Bracket — LH
687-02040 Pivot Arm Assembly — LH
687-02075 Front Height Adjuster Assembly — LH
687-02076 Pivot Arm Assembly — LH
15
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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