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OPERATOR’S MANUAL
21” Two-in-One
Mulching Mower
540 Series
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 o
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Table of Contents Content Page Safe Operation Practices.........................................................................3 Slope Guage............................................................................................5 Finding Model Number.............................................................................6 Unpacking................................................................................................6 Setting Up Mower ....................................
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SECTION 1: IMPORTANT SAFE OPERATION PRACTICES 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 your lawn mower. Failure to comply with these instructions may result in personal injury. When you see this symbol—heed its warning. Your lawn mower was built to be operated according to the rules for safe ope
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DO: • Keep all nuts, bolts, and screws tight to be sure the equipment is in safe working condition. • Mow across the face of slopes; never up and down. • Never tamper with safety devices. Check their Exercise extreme caution when changing direction proper operation regularly. on slopes. • After striking a foreign object, stop the engine, • Watch for holes, ruts, hidden objects, or bumps. remove the wire from the spark plug, and Tall grass can hide obstacles. thoroughly inspect the m
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o FOLD ON DOTTED LINE, REPRESENTING A 15 SLOPE SIGHT AND HOLD THIS LEVEL WITH A VERTICAL TREE A POWER POLE A CORNER OF A BUILDING OR A FENCE POST 15o WARNING Do not mow on inclines with a slope in excess of 15 degrees (a rise of approximately 2-1/2 feet every 10 feet). A riding mower could overturn and cause serious injury. If operating a walk-behind mower on such a slope, it is extremely difficult to maintain your footing and you could slip, resulting in serious injury. Operate RIDING mowers up
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SECTION 3: FINDING MODEL NUMBER This owner’s guide is an important part of your new Yard-Machine lawn mower. It will help you to assemble, prepare and maintain your mower. Please read and understand what it says. Before you start assembling the mower for its first use, please locate its model plate and copy the information on to this owner’s guide. The information on the model plate is very important if you contact a service center or the Yard-Machine customer support department.
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SECTION 5: SETTING UP MOWER Tools Required • Pair of Pliers • Funnel • Set of adjustable wrenches Disconnecting Spark Plug • Before setting up your lawn mower, disconnect the spark plug wire from the spark plug, and ground it against the engine. See Figure 3. • If the engine is equipped with the optional rubber boot, attach the boot to a bolt on the engine to ground. Rubber Boot Spark Plug Wire Spark Plug Engine with rubber boot FIGURE 3 Assembling Handle NOTE: If your mower is
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• Raise the lower handle in the direction shown in Figure 4 (step 2) till it snaps into place. • Raise the upper handle in the direction shown in Figure 4 (step 3). Tighten the wing nuts which are already on the handle. See Figure 5A. Note: Make sure to route the cables inside the lower handle. Also do not crimp the cables while lifting the handle up. • For shipping purposes, the hairpin clip is placed in the outer hole of the weld pin on the lower handle. Remove the hairpin clip from
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Following parts are included with a hard top grass bag: front frame, rear frame, grass bag, hardtop cover, mounting bracket, phillips screw and hex lock nut. Assemble soft grass bag as follows: NOTE: Make certain bag is turned right side out before assembling (warning label will be on the outside). • Join the rear frame and front frame assembly following Figure 7A. • Insert frame into grass bag as shown in Figure 7B (black plastic side is the bottom of bag). • Slip the openings in
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Attaching Grasscatcher to Mower NOTE: Your mower was shipped with the rear mulching baffle in place on the mower. Remove the mulching baffle in order to install and use the grass catcher. For instructions on how to bag the grass clippings, please refer to page 14 of this manual. • Lift the rear discharge door and remove the rear mulching baffle from the mower. See Figure 9. Rear Mulching Baffle FIGURE 9 • Hard Top Grass Bag: Holding open the rear discharge door as shown below, pla
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• Slide the two hooks on the side discharge chute under the hinge pin on the mulching plug assembly. See Figure 11. Lower the mulching plug. Do not remove the mulching plug at any time, even when you are not mulching. Mulching Plug Hinge Pin Deflector Side discharge Hook (Slide hooks under the two sides of hinge pin) FIGURE 11 WARNING: Never operate the mower unless the hooks on the grass catcher are firmly seated in the slots on the handle bracket assemblies, and the rear discha
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Recoil Starter The recoil starter is attached to the handle. Stand behind the unit and pull the recoil starter to start the unit. Primer The primer is used to pump gas into the carburetor. Use it to start a cold engine, but do not use it to restart a warm engine after short shutdown. Refer to engine manual for illustration. Blade Control Handle WARNING: This control mechanism is a safety device. Never attempt to bypass its operations. The blade control handle is
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Hold control lever firmly against upper handle Pull starter rope FIGURE 13 • Attach spark plug wire to spark plug. Make certain the metal cap on the end of the spark plug wire is fastened securely over the metal tip on the spark plug. • To prevent the unit from sliding, place your foot firmly against the tire. • Move throttle control all the way forward. This step is not applicable in case of mowers with fixed throttle. o • Push primer three times. Wait about two secon
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Bagging Grass Clippings Hold firmly and carry Remove bag AB FIGURE 14 You can use the grasscatcher bag to collect clippings while you are operating the mower. Attach the grasscatcher following instructions on page 10 of this manual. Operate the mower till the grass bag is full, or the job is completed whichever is earlier. Stop the engine completely by releasing the control lever. Make sure that the unit has come to a complete stop. To empty the grass bag proceed as follows: • Lif
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WARNING: Never tip the mower more than 90 degrees 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. Lubrication For complete lubrication chart, see Figure 15. Wheels • Lubricate the wheels and bearings, if so equipped, at least once a season with light oil or engine oil. Also, if the wheels are removed for any reason, lubricate the surface of the axle bolt and the inner surface of the wheel wit
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• Clean the engine periodically. Remove dirt and debris with a cloth or brush. We do not recommend using a garden hose to clean mower unless the muffler, air filter and the carburetor are covered to keep water out. Water in engine can shorten engine life. • Clean the spark plug and reset the gap to .030” at least once a season or every 50 hours of operation. Spark plug replacement is recommended at the start of each season. Refer to the engine manual for correct spark plug type.
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IMPORTANT: The bolt, used to secure the blade to the engine, is specially heat-treated. Do not substitute. To order replacement bolt, refer to the Parts List section of this manual. WARNING: To ensure safe operation of your unit, all nuts and bolts must be checked periodically for correct tightness. To Sharpen Blade: • The blade can be sharpened with a file or on a grinding wheel. Do not attempt to sharpen while operator is on the mower. • Follow the original angle of grind a
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• Push the throttle control lever on the handle all the way forward as far as it will go, then back it off one “click.” Make certain the throttle control lever remains in this position. • Push the control lever on the engine as far toward the rear of the engine as it will go. Secure the cable in this position with the cable clamp and screw. Screw Cable Clamp Control Lever on Engine FIGURE 18 Adjusting Carburetor If the engine is running rough, minor adjustments t
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Other • Do not store gasoline from one season to another. • Replace your gasoline can if it starts to rust. Rust and/or dirt in the gasoline will cause problems. Store unit in a clean, dry area. Do not store next to corrosive materials, such as fertilizer. NOTE: If storing in an unventilated or metal storage shed, be certain to rustproof the equipment by coating with a light oil or silicone. SECTION 11: TROUBLE-SHOOTING GUIDE PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Engine fails to
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SECTION 12: REPAIR PARTS 1 74 12 11 10 25 Remote Throttle Assembly Fixed Throttle Assembly 3 15 7 16 8 9 26 4 19 2 68 6 24 14 69 53 17 67 54 20 13 23 61 30 92 31 56 39 58 82 87 89 80 39 88 55 18 50 87 81 59 45 90 94 40 76 84 47 51 86 83 42 73 43 44 85 41 44 63 32 70 36 64 71 34 75 33 60 93 72 20
