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-  
covered, brush-covered or grass-covered land unless the engine’s exhaust system is equipped with a spark arrester meeting  
applicable local or state laws (if any). If a spark arrester is used, it should be maintained in effective working order by the operator.  
In the State of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have  
similar laws. Federal laws apply on federal lands. A spark arrester for the muffler is available through your nearest engine authorized  
service dealer or contact the service department, P.O. Box 361131 Cleveland, Ohio 44136-0019.  
MTD LLC P.O. BOX 361131 CLEVELAND, OHIO 44136-0019  
PRINTED IN U.S.A.  
770-10023F.
FORM NO.  
(4/04)  
SECTION 1: IMPORTANT SAFE OPERATION PRACTICES  
WARNING: This symbol points out important safety instructions which, if not followed, could  
endanger the personal safety and/or property of yourself and others. Read and follow all instructions in  
this manual before attempting to operate this machine. Failure to comply with these instructions may  
result in personal injury. When you see this symbol - heed its warning.  
WARNING: The Engine Exhaust from this product contains chemicals known to the  
State of California to cause cancer, birth defects or other reproductive harm.  
DANGER: This machine was built to be operated according to the rules for safe operation in this  
manual. As with any type of power equipment, carelessness or error on the part of the operator can  
result in serious injury. This machine is capable of amputating hands and feet and throwing objects.  
Failure to observe the following safety instructions could result in serious injury or death.  
2. Always wear safety glasses or safety goggles  
TRAINING  
during operation or while performing an adjustment  
1. Read, understand, and follow all instructions on the  
or repair, to protect eyes. Thrown objects which  
machine and in the manual(s) before attempting to  
ricochet can cause serious injury to the eyes.  
assemble and operate. Keep this manual in a safe  
3. Wear sturdy, rough-soled work shoes and close-  
place for future and regular reference and for  
ordering replacement parts.  
2. Be familiar with all controls and their proper  
fitting slacks and shirts. Loose fitting clothes or  
jewelry can be caught in movable parts. Never  
operate this machine in bare feet or sandals. Wear  
operation. Know how to stop the machine and  
leather work gloves when feeding material in the  
disengage them quickly.  
chipper chute.  
3. Never allow children under 16 years old to operate  
4. Before starting, check all bolts and screws for  
this machine. Children 16 years old and over  
should read and understand the operation  
proper tightness to be sure the machine is in safe  
working condition. Also, visually inspect machine  
instructions and safety rules in this manual and  
for any damage at frequent intervals.  
should be trained and supervised by a parent.  
4. Never allow adults to operate this machine without  
proper instruction.  
5. Keep bystanders, helpers, pets, and children at  
least 75 feet from the machine while it is in  
operation. Stop machine if anyone enters the area.  
6. Never run an engine indoors or in a poorly  
ventilated area. Engine exhaust contains carbon  
monoxide, an odorless and deadly gas.  
7. Do not put hands and feet near rotating parts or in  
5. Maintain or replace safety and instructions labels,  
as necessary.  
6. To avoid personal injury or property damage use  
extreme care in handling gasoline. Gasoline is  
extremely flammable and the vapors are explosive.  
Serious personal injury can occur when gasoline is  
spilled on yourself or your clothes which can ignite.  
Wash your skin and change clothes immediately.  
a. Use only an approved gasoline container.  
b. Extinguish all cigarettes, cigars, pipes, and  
the feeding chambers and discharge opening.  
other sources of ignition.  
Contact with the rotating impeller can amputate  
fingers, hands, and feet.  
8. Never attempt to unclog either the feed intake or  
c. Never fuel machine indoors.  
d. Never remove gas cap or add while the  
engine is hot or running.  
discharge opening, remove or empty vacuum bag,  
e. Allow engine to cool at least two minutes  
or inspect and repair the machine while the engine  
before refueling.  
is running. Shut the engine off and wait until all  
f. Never over fill fuel tank. Fill tank to no more  
moving parts have come to a complete stop.  
than 1/2 inch below bottom of filler neck to  
Disconnect the spark plug wire and ground it  
against the engine.  
provide space for fuel expansion.  
g. Replace gasoline cap and tighten securely.  
h. If gasoline is spilled, wipe it off the engine  
PREPARATION  
and equipment. Move machine to another  
area. Wait 5 minutes before starting the  
engine.  
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.  
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.  
11. Keep all guards, deflectors and safety devices in  
place and operating properly.  
12. Keep your face and body back and to the side of  
the chipper chute while feeding material into the  
machine to avoid accidental kickback injuries.  
13. Never operate this machine without good visibility  
or light. Always be sure of your footing and keep a  
firm hold on the handles.  
14. Do not operate this machine on a gravel surface.  
15. Do not operate this machine while under the  
influence of alcohol or drugs.  
16. Muffler and engine become hot and can cause a  
burn. Do not touch.  
17. Never pick up or carry machine while the engine is  
running.  
OPERATION  
1. Do not put hands and feet near rotating parts or in  
the feeding chambers and discharge opening.  
Contact with the rotating impeller can amputate  
fingers, hands, and feet.  
2. Before starting the machine, make sure the chipper  
chute, feed intake, and cutting chamber are empty  
and free of all debris.  
3. Thoroughly inspect all material to be shredded and  
remove any metal, rocks, bottles, cans, or other  
foreign objects which could cause personal injury  
or damage to the machine.  
MAINTENANCE AND STORAGE  
1. Never tamper with safety devices. Check their  
proper operation regularly.  
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:  
2. Check bolts and screws for proper tightness at  
frequent intervals to keep the machine in safe  
working condition. Also, visually inspect machine  
for any damage and repair, if needed.  
3. Before cleaning, repairing, or inspecting, stop the  
engine and make certain the impeller and all  
moving parts have stopped. Disconnect the spark  
plug wire and ground it against the engine to  
prevent unintended starting.  
4. Do not change the engine governor settings or  
overspeed the engine. The governor controls the  
maximum safe operating speed of the engine.  
5. Maintain or replace safety and instruction labels, as  
necessary.  
a. Inspect for damage.  
b. Repair or replace any damaged parts.  
c. Check for any loose parts and tighten to  
assure continued safe operation.  
6. Do not allow an accumulation of processed  
material to build up in the discharge area. This can  
prevent proper discharge and result in kickback of  
material through the feed opening.  
7. Do not attempt to shred or chip material larger than  
specified on the machine or in this manual.  
Personal injury or machine damage could result.  
8. Never attempt to unclog either the feed intake or  
discharge opening while the engine is running.  
Shut the engine off, wait until all moving parts have  
stopped, disconnect the spark plug wire and  
ground it against the engine before clearing debris.  
9. Never operate without vacuum bag and discharge  
chute properly attached to the machine. Never  
empty or change vacuum bag while the engine is  
running. Zippered end of vacuum bag must be kept  
closed at all times during operation.  
6. Follow this manual for safe loading, unloading,  
transporting, and storage of this machine.  
7. Never store the machine or fuel container inside  
where there is an open flame, spark or pilot light  
such as a water heater, furnace, clothes dryer, etc.  
8. Always refer to the operator’s manual for proper  
instructions on off-season storage.  
9. If the fuel tank has to be drained, do this outdoors.  
10. Observe proper disposal laws and regulations for  
gas, oil, etc. to protect the environment.  
10. Never operate without either the inlet nozzle or  
optional hose attachment properly attached to the  
machine. Never attempt to attach or change either  
attachment while the engine is running.  
4
WARNING: - YOUR RESPONSIBILITY: Restrict the use of this power machine to persons who read,  
understand and follow the warnings and instructions in this manual and on the machine.  
NOTE: Not all safety labels shown may apply to your chipper shredder vacuum.  
SECTION 2: ASSEMBLING YOUR CHIPPER SHREDDER VACUUM  
IMPORTANT: This unit is shipped without gasoline or oil  
in the engine. Be certain to service engine with gasoline  
and oil as instructed in the separate engine manual  
before operating your machine.  
Nozzle  
NOTE: Reference to right or left hand side of the  
chipper shredder vacuum is observed from the  
operating position.  
Removing Unit From Carton  
Remove staples, break glue on top flaps, or cut  
tape at carton end and peel along top flap to open  
carton.  
Remove loose parts if included with unit (i.e.,  
operator’s manual, etc.)  
Cut along corners, lay carton down flat, and remove  
packing material.  
Roll or slide unit out of carton and check carton  
thoroughly for loose parts.  
Bag  
Loose Parts In Carton (See Figure 1)  
Figure 1  
Nozzle  
Bag  
5
Attaching The Nozzle  
Bag Opening  
Bag  
Discharge  
Chute  
Remove three wing nuts from the front of the  
chipper shredder vacuum.  
Place nozzle in position over the three studs on unit  
and secure with wing nuts just removed.  
See Figure 2.  
Wing  
Wing  
Nuts  
Nut  
Nozzle  
Figure 3  
Place the four straps on the top of the bag over  
upper handle, hooking them on the studs to secure  
in place. Squeeze the clamp on the drawstring and  
pull the drawstring tight. Release the clamp.  
See Figure 4.  
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.  
Bag  
Straps  
Attaching The Bag  
Place bag under of upper handle assembly and slip  
the front opening on the bag over the discharge  
chute, making certain it is over the rim on the  
discharge chute. See Figure 3.  
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.  
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.  
Bag  
Nozzle  
Collects shredded or chipped material fed through the  
chipper chute or vacuumed up through the nozzle.  
See Figure 5.  
Yard waste such as leaves and pine needles can be  
vacuumed up through the nozzle for shredding.  
See Figure 5.  
Chipper Chute  
Drive Clutch Control  
Allow twigs and small branches up to 2” in diameter to  
The drive clutch control is located on the upper handle  
assembly. Squeezing the drive clutch control against  
the upper handle engages the rear wheels. Release the  
drive clutch control to slow down or stop the wheel  
drive. See Figure 5.  
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.  
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)  
Engine Controls  
The starter handle is located on the engine. Pull the  
See the separate engine manual for the location and  
starter handle to start engine.  
function of the controls on the engine.  
Drive Clutch  
Control  
Bag  
Nozzle  
Nozzle Door  
Adjustment Lever  
Chipper  
Chute  
Caster Lock  
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.  
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.  
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.  
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.  
Gas And Oil Fill-Up  
Service the engine with gasoline and oil as instructed in  
the separate engine manual packed with your chipper  
shredder vacuum. Read instructions carefully.  
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.  
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.  
NOTE: See your engine manual packed with your unit  
for more detailed instructions.  
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.  
into catcher bag. Do not attempt to shred or chip any  
material other than vegetation found in a normal yard  
(i.e. branches, leaves, twigs, etc.) Avoid fibrous plants  
such as tomato vines until they are thoroughly dried  
out. Materials such as stalks or heavy branches up to 2”  
in diameter may be fed into the chipper chute.See  
Figure 6.  
WARNING: 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.  
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.  
Stopping Engine  
Move throttle control lever to STOP or OFF  
position.  
Disconnect spark plug wire from spark plug and  
ground against the engine.  
Chipper  
Chute  
To Empty Bag  
The bag is designed to be emptied without being  
removed from unit. Open the large zipper in the rear of  
the bag to empty the contents. If bag is removed for any  
reason, follow the instructions for attaching the bag in  
the ASSEMBLY section. Be certain the zipper is closed  
completely when operating the unit.  
To Engage Drive  
Figure 6  
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.  
IMPORTANT: The flail screen is located inside the  
housing in the discharge area. If the flail screen  
becomes clogged, remove and clean as instructed in  
MAINTAINING YOUR CHIPPER SHREDDER  
VACUUM. For best performance, it is also important to  
keep the chipper blade sharp.  
Using the Chipper Shredder Vacuum  
Tire Pressure (Pneumatic Tires Only)  
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  
WARNING: Maximum tire pressure under  
any circumstance is 30 psi. Equal tire  
pressure should be maintained at all  
times.  
SECTION 5: ADJUSTING YOUR CHIPPER SHREDDER VACUUM  
WARNING: Do not at any time make any  
adjustments without first stopping engine,  
disconnecting spark plug wire, and  
grounding it against the engine.  
Front Caster Wheels  
This chipper shredder vacuum is equipped with front  
caster wheels. The casters can be locked in a straight  
ahead position or position to swivel freely. Lift and place  
pins in the larger holes for locked or straight ahead  
operation. Place pins in smaller holes to allow casters  
to rotate freely. Lock wheels in straight position when  
operating on slopes. See Figure 7.  
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 clutch cable. In  
addition, the adjustment wheel may also be used to  
determine the position in which the drive clutch control  
is engaged. If it is more comfortable to have the drive  
engaged with the lever further away from the handle,  
tighten the clutch cable. See Figure 9.  
Smaller Hole  
(Rotate Freely)  
Larger Hole  
(Locked)  
Figure 7  
Nozzle Door Height Adjustment  
Tighten  
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.  
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 mainte-  
nance 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 unin-  
tended starting.  
Lubrication (Refer to Figure 5)  
Wheels: Lubricate the rear wheels with light oil once a  
season.  
Nozzle Door Adjustment Levers: Lubricate each  
adjustment lever once a season with light oil.  
Front Caster Wheels: Grease fittings are located on  
the front caster wheels to provide easy lubrication of the  
swivel pins once a season.  
9
Customer Responsibilities  
MAINTENANCE  
SCHEDULE  
SERVICE  
DATES  
Lubricate Wheels  
Lubricate Adjustment Levers  
Lubricate Caster Wheels  
Check Chipper Blades  
Check Oil  
Change Oil  
Check Air Filter  
Clean Engine  
Check Spark Plug  
Clean the screen by scraping or washing with water  
and reinstall the screen.  
Maintenance  
Engine  
NOTE: Be certain to reassemble the flail screen with  
the curved side down.  
Refer to the separate engine manual for all engine  
maintenance instructions.  
Check engine oil level before each use as  
instructed in the separate engine manual packed  
with your unit. Read and follow instructions  
carefully.  
Clean air cleaner every 25 hours under normal  
conditions or once a season. Clean every few hours  
under extremely dusty conditions. To service the air  
cleaner, refer to the separate engine manual  
packed with your unit.  
Hex Bolt  
Flat Washer  
Hex Nut  
Discharge  
Chute  
The spark plug should be cleaned and the gap  
reset once a season. Check engine manual for  
correct plug type and gap specifications.  
Self-Tapping  
Screws  
Removing The Flail Screen  
If the discharge area becomes clogged, remove the flail  
screen and clean area as follows:  
Flail Screen  
Hex Bolts  
Hex Nuts  
Stop the engine and make certain the chipper  
shredder vacuum has come to a complete stop.  
Disconnect spark plug wire from spark plug and  
ground against the engine.  
Remove the vacuum bag from the unit.  
Remove the four self-tapping screws from the  
bottom of the discharge chute, and the hex bolt, flat  
washer and hex nut from the top. Remove the  
discharge chute assembly. See Figure 10.  
Remove the two hex bolts and hex nuts which  
extend through the impeller housing. Lift the flail  
screen from the inside the housing. See Figure 10.  
Figure 10  
Reattach the discharge chute assembly with the  
hardware previously removed and connect the bag  
to unit.  
10  
Drain the gasoline and oil from the chipper  
shredder vacuum.  
Remove the three wing nuts that secure the nozzle  
to the outer housing and remove the nozzle. Refer  
to Figure 2.  
Remove the vacuum bag from the unit.  
Remove the discharge chute as instructed in the  
previous section Removing The Flail Screen.  
Remove the plastic belt cover on the front of the  
engine by removing two self-tapping screws. Refer  
to Figure 11.  
Sharpening Or Replacing Chipper Blades  
NOTE: When tipping the unit, empty the fuel tank and  
keep spark plug side up.  
Disconnect the spark plug wire and ground it  
against the engine.  
Remove the flail screen as instructed in the  
previous section.  
Remove the plastic belt cover on the front of the  
engine by removing the two self-tapping screws.  
See Figure 11.  
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.  
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.  
Safety  
Switch  
Remove other blade in the same manner to replace  
or sharpen.  
Self-Tapping  
Screw  
Access Plate  
Lower  
Belt Guard  
Self-Tapping  
Screws  
Hex  
Lock Nuts  
Self-Tapping  
Screws  
Figure 12  
Remove the safety switch from the front of the outer  
housing by removing the two self-tapping screws.  
See Figure 12.  
Remove the two hex bolts and hex lock nuts which  
extend through the housing. Lift the flail screen out  
of the housing. Refer to Figure 10.  
Remove the outer housing and housing blades by  
removing the fourteen self-tapping screws.  
Remove the hex bolt, lock washer, and flat washer  
that secures the impeller assembly to the  
crankshaft. See Figure 13.  
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.  
Hex Bolt  
Lock Washer  
Flat Washer  
Impeller  
Assembly  
NOTE: Make certain blades are reassembled with the  
sharp edge facing upward.  
Belt Removal And Replacement  
NOTE: Because the engine on this has a tapered  
crankshaft, a special impeller removal tool (part number  
753-0638) is required to remove impeller assembly.  
Contact your local service dealer.  
Disconnect the spark plug wire and ground it away  
from the spark plug.  
Figure 13  
11