Yard-Man 1040-9 User's Manual
Contents
1. determine the left or right hand side of your mower by standing behind the unit as you mow PART NAME Ass y Engine B amp S Model 60102 Type 0258 01 oo csecesesseessetees Spacer seseeseeseeresererrerereerorererenereereres Bracket Belt Keeper cccecseeees Belt Keeper Upper cesceseees Belt Keeper Lower ccccssesseeeees Nut 5 16 18 Hex 0 eecccseeseees Lockwasher 5 16 ccccccccccecessetees Bolt 5 16 18 x 1 Carriage Screw 4 20 x 1 Fillister Head MWY BOLE airea sna Set Screw 5 16 24 x 7 32 nee Pulley virvecescosesssasecosnsraiescnscenadstecesosses ROM Pin s ssseseescesesseersoeceovecssessasasessarssoe Assembly Pulley 0 cssccesescereeeers Washer 5 8 x 5 16 senere Screw 10 32 x Ph Hd Washer ssccccscsssescnscesasceresesssseseveees Belt Guard cccescescecessseeeseenesneeenes Ass y Jack Shaft Hsg amp Bearings Jackshaft Housing cccsssesreeee Bearing eesssessssorseersesssesesoessesesossoseee Oiler erinan isara aeii Ja kshaft Marsiin PUN DEEL EE aTe TT a AE A E T Sprocket esessesessesesersesesosseresscesroreerese Washer asantin iaiia Nut 7 16 24 Hex Jam cee Connector Link eesesseessereereesserrseere Retaining Ring eesssesseerererssseesseesesee PUPA EE EA EAEE T Spring oeesesesssesessesserseesesrereerenrerererseneee Rollpin seessesseroesessressereraresossessisaseseas Roller es cisedcdesesccossde2. TO ATTACH THROTTLE CABLE Remove the air cleaner with the handle mounted throttle in CHOKE position insert the throttle wire into the top hole of the speed lever on carburetor as shown Place the cable behind the cable clamp screw and washer pull the throttle cable until the choke is in Full Choke position then tighten the clamp screw securely For further adjustments follow the directions outlined on page 4 of your Engine Oper ating and Maintenance Instructions TO ATTACH CLUTCH CABLE Place the handle in the stand up position with the handle control lever in neutral Insert the control wire through the hole in the top of the actuating bracket After locating the cable under the retaining clip pull the cable to the rear as far as the actuating bracket will allow and tighten the cable clip mounting screw securely BEFORE STARTING ENGINE 1 Remove oil fill plug Fig 2 Place mower level and fill engine crankcase to top of oil plug with S A E No 30 oil Tilt mower to make sure oil flows completely into crankcase Replace fill plug and tighten 2 The air cleaner protects the engine against grit and dirt CAUTION an extremely dirty air cleaner element may cause engine to stall SEE ENGINE INSTRUCTION MANUAL FOR PROPER AIR CLEANER MAINTENANCE 3 Fill tank with good grade regular clean fresh gas oline DO NOT MIX OIL with gasoline FOR COMPLETE ENGINE INFORMATION READ ENGINE INSTRUCTION BOOKLET FURNISHED WITH YOUR
3. operating manual ana PRINTED IN U S A parts list YaRD MaNn 1410 West Ganson Street Jackson Michigan 49202 MODEL 1040 9 18 INCH POWER REEL MOWER 0611 722 IMPORTANT RULES FOR SAFE OPERATION Your Mower is a precision piece of power equipment Engineering skill and experience have been combined to provide the ultimate in safety and efficiency As with any type of power equipment carelessness or error on the part of the operator can result in injury Exercise extreme caution at all times KNOW YOUR MACHINE Read the Owner s Manual carefully learn how to operate your mower properly MAKE SURE THE LAWN IS CLEAR of sticks stones wire and other hazardous _items before mowing Such items are dangerous to both the mower and individuals in the vicinity of the mower ADD FUEL BEFORE STARTING ENGINE never when engine is hot or running KEEP AREA OF OPERATION CLEAR of all persons particularly small children and pets DISENGAGE ALL BLADE AND DRIVE CLUTCHES so equipped before starting engine ALWAYS STOP ENGINE and disconnect sparkplug wire before making cut ting height adjustments CHECK ALL NUTS BOLTS AND SCREWS occasionally to be sure mower is in good operating condition NEVER OPERATE EQUIPMENT IN WET GRASS Always be sure of your footing keep a firm hold on the handle and walk never run ALWAYS CHECK FOR DAMAGE if you should strike some foreign object with the blade while
4. _ Rivet 3 16 x _ _ Reel Assembly __ _ Rollpin Sprocket Anti wind Cup amp Hub Assy ________ 1 Rivet 3 16 x 13 32 Retainer Felt Washer ____ _ __ Felt Retainer Bearing _ __ Hub Cap e Screw Cutter Bar L H Thd Cotter Pin x 5 __ _ W _ Washer 2422252 ee Wheel and Tire Assembly Drive Wheel amp Bearings Less Tire cc co act a hel Bearing oe a et Pinion Gear __ __ _ _ ____ Felt Washer _ __ __ Retainer Bushing 22 22 oe ee For Illustration See Page 8 REF NO 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 PART NO NAME OF PART 2643 18 Knob Wheel Adjust 41 028 Nut oe a i a 1117 Screw 10 32 x 3 Sems 1129 139 55 End Plate with Trunnions L H __ 1723 1 1129 138 55 Scraper eor End Plate with Trunnions R H ___ 1624 138 Spacer 2 2 22 a a 1118 8 55 Gear Housing R H 1657 23 Nylon Bushing 428 Pinion Gear ________ 1539 31 NOt 20 6 2 2o2 nee 1156 6 TRUNNION neo ee ee 1513 40 SY fee ee a 453 Screw ee eE 455 Screw Cutter Bar R H Thd 2134 11 55 Cut
5. frequently to make sure all parts are operating smoothly Your mower left the factory properly adjusted and properly lubricated to assure you of a smooth clean cutting job Keep it clean The mower should be thoroughly cleaned and lubricated at the start of each mowing season for better operation and longer service life DO NOT use water to clean the mower use a broom or brush to remove grass and dirt When storing mow er for any length of time follow storage instructions in engine instruction booklet CHECKING AND ADJUSTING CUTTER BAR CLEARANCE When properly set the cutter bar should almost contact the reel blades Only on very fine grass should the reel blades touch the cutter bar and then very lightly so that only a slight scraping noise is heard It s easy to check proper cutter bar clearance j u st place a piece of newspaper about 2 wide and 6 long between reel blades and cutter bar See Step 2 below Correct cutter bar clearance should pinch but not cut the paper at both ends and the middle of the cutter bar If it doesn t adjust as follows CUTTER BAR ADJUSTMENT Fig 4 Cutter Bar bolts 2 amp 3 are tapered and extend beyond the side plate slightly When thes e tapered bolts are tight any end play or looseness is eliminated Be sure these bolts are tight before making adjust ments TO TIGHTEN CUTTER BAR Turn hex adjusting nut counterclockwise TO LOOSEN CUTTER BAR Turn hex adjusting nut c
6. moving stop your mower Inspect for and repair any damage before restarting and operating the mower STOP THE ENGINE when you leave the equipment Make certain the blades and all moving parts have stopped WHEN MOWING A TERRACE slope or incline mow lengthwise DO NOT mow up or down Be careful when turning to avoid slipping PREPARING YOUR MOWER FOR USE SET UP Your mower has been packaged with the upper and lower handle assemblies shipped loose The clutch and throttle controls are assembled to the upper handle care should be taken not to kink the control wires during set up To assemble the handle to the chassis place the lower handle through the opening in the left hand end plate and slip it over the 1 2 in dia trunnion While holding the stand up handle latch open press the right hand side of the lower handle toward the center of the mower until it will fit into the opening in the end plate place handle through the opening and slip it over the 1 2 dia trunnion With the lower handle section in the operating position the upper handle can now be assembled to the lower section with the special bolts washers and hand knobs provided After the upper and lower handle sections are assembled the throttle and clutch controls must be attached to the engine and clutch as follows ger CLUTCH CONTROL THROTTLE CONTROL iy UPPER HANDLE CLUTCH CONTROL HANDLE KNOBS THROTTLE CONTRO THROTTLE IN HOKE POSITION
7. 5 16 24 x Ye Hex Sems Label Wheel Adjust ccsssssseee Bolt 5 16 24 x 34 Hex Head Screw 6 x Rd Head eee Name Plate Clevis Pin Cotter Pin Latch seese Deck i issescscves Bolt 4 20 x osasesoseoeressevenscessesesesoooe sescesospevestesesesoasorosevasnos eresserosacpasacosoocoveseesnsosos tessesevocsecasrosososparossoseroe sesvenssasasessosoosesosssessossoe eeseusasocosseostoesocesvsepesareo sereseevosootesocsesosoesesosossas vesesesvesacosoapesospososreosenso Taruni Screw 10 32 x Ph Hd neeese Label Neutral Guard Chain Handle Lower Knob Handle Drive sesssssseesesssseee aseeoeoesossporesosoesesnepvosssane EEEETTTTTTITITILITITIITTITITTTTI Label Lower Handle c e0 Bolt 5 16 18 x 13 Special Throttle Cable Clip seuren LELTTTTTTTTETITITTITIITITITTTTITIT LEETE TITTTTITTITITITTITITTTTT TTTI Bolt 4 20 x 1 Rd Hd eee Ass y Throttle Control seese Nut 4 20 Acorn ccccssssccccsssesssesees Ass y Upper Handle eseese Bolt 14 20 x 1 Rd Hd seess Ass y Clutch Control cccseeseeeee Ass y Control Wire amp Cable Cover Lower Cover Upper seessesosoosessesesoeserosossooeso LELTTTTTITTEZITTTTTTTITITITITITTTT Label Upper Cover eessessssressee Knob Clutch Control esseere Ass y Lever LLEITITTTTTTTTTETIITITITIT
8. MOWER BEFORE STARTING OR OPERATING TO START ENGINE 1 Place clutch control lever in NEUTRAL position before starting engine Set throttle control in CHOKE position 3 Pull starter rope with a smooth quick full stroke once Move throttle lever to FAST position Pull starter rope again 4 When the engine starts move the throttle lever to SLOW Idle position until the engine warms up OPERATING CONTROLS Clutch Lever Control Move the clutch lever to forward position for direct drive operation Move rearward Neutral to stop Magic Handle Control Move clutch lever to Magic Control position Neutral To propel mower forward raise the handle To stop the mower lower the handle Adjust throttle for the most comfortable walking speeds BREAK IN PERIOD 1 During first 10 hours of operation check frequently the following Oil level in engine crankcase Belt adjustment on engine to jackshaft drive Page 6 Check all bolts nuts and screws for tightness CUTTING HEIGHT IN INCHES ROLLER BRACKET ALIGNMENT HOLE OIL FILL RECOIL STARTER TO ADJUST HEIGHT OF CUT 1 Consult the chart located below The roller adjust ing knobs A and wheel adjusting levers B must be in the positions shown for desired cutting height EXAMPLE For 1 1 2 cutting height the roller knob must be in No 2 position and the wheel adjust lever must be in No 4 position 2 Place the mower on a hard flat surface T
9. TTTTTITTS Pin Special 3 16 x 21 seess Retaining Ring Bracket asorsssesosooeessassananecsosase teseasesesosveseesoseesooseteonose Pin Special 4 x 1 15 seseeseessse Retaining Ring sesoeseresessasesrasoseesasosose Washer 5 16 x 5 x 1 16 sesse Label Caution o cccccssessereesereeeee Label Throttle Control cccececeeseeees Label Magic Handle eee Label OPEI aserossseessssasoesesatosescecesos Standard Hardware ltem Purchase Locally WARRANTY We guarantee all parts against defects in material and workmanship for a period of one 1 year from the date of purchase when used for residential 90 days for commercial We agree to repair or replace without charge to the original Purchaser including labor any part or parts upon examination by a Yard Man Authorized Dealer to be defective within the guarantee period except the engine which is warranteed separately by the manufacturer All transportation charges for replacement under this guarantee must be paid by the Purchaser This guarantee will not apply to a unit which has been subjected to misuse negligence accident or to a unit which has been altered in any way YaRD MaN Yard Man reserves the right to make engineering changes without prior notification or respon sibility to the Purchaser
10. ilt mower back on the roller until wheels are off the surface Move right hand wheel lever outward to disen gage the locating pin then move lever forward or back until it is aligned with the proper number on the deck label Release outward pressure on lever make sure the locating pin seats securely in the adjustment hole in the end plate 3 Tilt mower forward until roller is off the ground 2 q m Qe 5 1 Turn right hand roller knob counter clockwise 2 full turns and move knob up or down until alignment hole in roller bracket is in line with proper number on label at rear of end plate see illustration Turn knob clockwise until tightened securely Repeat this procedure for other side CUTTING HEIGHT IN INCHES 2 ame 1 7 aanza Yy m aaa Vy a QUALITY OF CUT Since a reel type mower does not create a lifting action like a rotary mower it CANNOT lift up and cut tall blades of grass that are bent over If cutting height is set too high grass of this nature will not be in posi tion to be drawn between the reel blades and cutter bar and in many cases will be pushed away by the revolving reel Therefore to obtain the utmost in per formance and lawn appearance cutting height ABOVE 156 IS NOT RECOMMENDED except where grass is up right and dense SERVICE INSTRUCTIONS ALWAYS REMOVE SPARK PLUG WIRE BEFORE MAKING ADJUSTMENTS NEVER MAKE ANY ADJUSTMENTS WITH ENGINE RUNNING Check your mower
11. lockwise ADJUSTING REEL AND CUTTER BAR PAPER TEST 1 Insert strip of newspaper between cutter bar and reel blades 2 Turn ree slowly backwards If the paper is held snugly by each blade then adjustment is correct 3 Adjust cutter bar so that reel blades pinch paper without cutting it SERVICE 1 Sharpening is required w h e n the mower will not cut satisfactorily without the reel blades wiping on the cutter bar NOTE When cutter bar is removed for sharpening left hand pivot bolt Item 2 fig 4 must be turned counter clock wise to be removed Right hand pivot bolt on right hand side of mower must be turned clock wise TO ADJUST CHAIN DRIVE L Set hand control lever in MAGIC CONTROL posi tion Neutral and the handle in stand up position Loosen 4 engine mounting bolts and pull engine back Loosen 4 control assembly bolts and move spacer plate under control assembly Pull the control asseembly back to tighten chain Leave enough slack to allow the chain to be de flected aprox 1 8 to 3 16 inch Tighten 3 mount ing nuts securely leaving the spacer plate nut loose TO ADJUST BELT DRIVE 1 2 Be sure the chain is properly adjusted as outlined above Be sure engine mount bolts are o o s e and spacer plate is positioned beneath control assembly Handle must be in stand up position and hand con trol lever in MAGIC CONTROL position With strip of paper between jackshaft and actuator
12. ndle 2 Move handle latch on the end plate in and move handle to upright position To transport mower in car remove handle from chassis for more conven ient handling CAUTION Always remove spark plug wire before attempting to lift the mower STORAGE Store your mower in a clean dry place and keep clean to serve you well If stored for a length of time the en gine should be drained of fuel This will prevent the forming of gum deposits on essential parts in the car buretor fuel line and tank which might affect the effi cient operation of your engine when again used Sewice Record DATE DESCRIPTION 3dI 3LISOddO HLM JTAVAONVHD AILNI SLAYd dad agwANNnN NY 6 2Bog aag jsi SHOd J04 REF NO N A BR WH 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 PARTS LIST MODEL 1040 9 When ordering parts listed as L H or R H determine the left or right hand side of your mower by standing behind the unit as you mow Do not use Reference Numbers when ordering Repair Parts always use Part Numbers PART NO 1534 8 1540 59 1112 18 55 1530 6 2135 20 55 1548 5 2121 2 55 1530 20 1629 28 104 106 3 2674 33 55 1509 86 142 141 1108 80 41 1110 27 41 2619 25 1652 52 425 109 323 1118 9 55 1631 26 1540 55 1629 41 1657 19 NAME OF PART Nut 10 32 Gripco Washer Roller __ __ Spacer Tube Assembly 18
13. roller hold control assembly down against spacer plate then move engine forward until paper is just free Retighten engine mount bolts Move space plate from under control assembly Tighten spacer plate nut TO ADJUST MAGIC CONTROL ACTION 1 2 3 4 5 Place hand lever in MANUAL position Fig 7 Lower handle to operating position Loosen adjusting screw locknuts Fig 7A With handie down adjust s c r e w so that Actuator Roller has 1 16 inch clearance between roller and jackshaft Retighten adjusting screw lock nut LUBRICATION 1 Change engine oil crankcase after first 5 hours of operating See engine operating instructions 2 Check air cleaner frequently 3 Reel bearings require no attention until m o w er is serviced Check jackshaft oiler cup frequently oil at begin ning of mowing season and as needed Oil roller shaft once or twice a year or as needed Lightly lubricate with engine oil points indicated on roller and between end plates and wheel dust cov ers Periodic lubrication at these points will insure smooth mechanical operation Fig 8 To insure continued easy operation of controls oil out side of exposed cables for full length with engine oil as required JACKSHAFT ACTUATOR ROLLER a 7 fie ENG MTG BOLT CONTROL ASS Y SPACER PLATE MAGIC CONTROL NEUTRAL Cf MANUAL CONTROL STAND UP HANDLE 1 There s no storage problem with the stand up ha
14. secoasacies ccvesteoscessuaes Bracket ccsssccccessesssssccserceressssossseese Bracket sijsstsseacsssesssscdisecetenseteucese suessies Nut 10 32 Hex Lock osese Screw 10 32 x 9 16 Rd Hd Screw 10 32 x Ph Hd Clamp Conduit cesesseeerenneneees Spring ceesceseeeesereeserecesrasesteserensoonee Control Bracket ccsesecceceseesetessees Nut 4 20 Hex 00 cecccsesessssereeeees Lockwasher 4 Split cece Spacer eseessrerseseeserosseesseseseeserenrerereoe Braik t ficssseccecetecucsesiscdecsvsheissuceeiasseae Nut 5 16 24 Hex Lock 0 0 1 REF NO 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 PART NO 2705 6 1513 23 1513 18 2616 456 1513 8 1616 114 1513 41 1020 1605 580 1545 23 1547 4 2627 21 1624 122 2642 51 1097 5690 9 55 1529 15 117 1616 441 3639 32 55 3712 135 01 1643 47 1616 442 1513 103 0171 33 1689 5 1501 31 2142 63 1537 3 0177 99 01 1501 32 2142 64 2188 66 2622 143 1622 144 1616 567 1643 49 1155 35 1547 53 1650 53 1609 532 1547 54 1650 37 151 1616 449 1616 527 1616 568 1616 111 PART NAME Perererererririe titer rrr rere Bolt 5 16 18 x 156 Step sesers Bolt 5 16 24 Hex Shoulder Label Deck esssosoeseevecooperesesoereesessse Bolt
15. ter Bar Assembly 18 __ __ 1622 50 Dust Cover esaea 1643 23 Roller Adjust Knob _ _ 2132 12 55 Roller Bracket Assembly L H _ 1529 25 Bolt 5 16 18 x _ 1548 7 Rollpin qe 1632 57 Roller Shaft ___ 10 Trunnion 2 522550 ee 1658 6 Roller sete ep etd 2132 11 55 Roller Bracket Assembly R H _ 1540 43 Washer Special ____ 1650 21 Retaining Ring 1509 38 Screw 10 32 x Hex Hd _ _ 1155 14 55 Spring amp Trunnion Assembly ____ 1616 119 Roller Adjust Label _____ 2624 113 55 Spacer End Plate _ Standard Hardware tem Purchase Locally _ ALL UNNUMBERED PARTS INTER CHANGEABLE WITH OPPOSITE SIDE For Parts List See Page 11 REF NO 1 OD ON A OM Bh WD 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 30 31 32 33 34 35 37 38 39 40 4 42 43 44 45 46 47 PART NO 1624 69 1606 48 1724 7 1724 9 70 1025 1529 11 1509 69 1651 20 1508 13 1626 40 55 1548 11 2120 34 55 1540 17 1511 9 1540 55 2639 30 55 2102 20 55 3601 64 55 1652 1 1691 2 1632 26 1546 2 1654 2 1638 16 1036 1538 16 1113 13 1650 10 1547 3 1642 30 55 1548 13 1658 8 1609 536 55 1609 83 55 1534 8 41 054 1117 1694 10 2642 52 55 1609 537 55 67 1018 1624 50 3609 82 55 41 028 PARTS LIST MODEL 1040 9 When ordering parts listed as L H or R H
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