Troy-Bilt 2620 User Manual

Safe OperationPractices•Set-Up•Operation• Maintenance•Service•Troubleshooting• Warranty

Operator’s Manual

Two-StageSnowThrower—Storm2620

WARNING

READ AND FOLLOWALLSAFETYRULES AND INSTRUCTIONSIN THIS MANUAL

BEFOREATTEMPTINGTO OPERATETHISMACHINE.

FAILURETO COMPLYWITH THESE INSTRUCTIONS MAY RESULTIN PERSONAL INJURY.

TROY-BILT LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019

Printed In USA	Form No. 769-04038
	(May 23, 2008)

To The Owner	1
Thank You

Thank you for purchasing a Snow Thrower manufactured by Troy-Bilt LLC. It was carefully engineered to provide excellent performance when properly operated and maintained.

Please read this entire manual prior to operating the equipment.

It instructs you how to safely and easily set up, operate and maintain your machine. Please be sure that you, and any other persons who will operate the machine, carefully follow the recommended safety practices at all times. Failure to do so could result in personal injury or property damage.

All information in this manual is relative to the most recent product information available at the time of printing. Review this manual frequently to familiarize yourself with the unit, its features and operation. Please be aware that this Operator’s

Manual may cover a range of product specifications for various models. Characteristics and features discussed and/or illustrated in this manual may not be applicable to all models. Troy-Bilt LLC reserves the right to change product specifications, designs and equipment without notice and without incurring obligation.

If you have any problems or questions concerning the unit, phone a authorized Troy-Bilt service dealer or contact us directly. Troy-Bilt’s Customer Support telephone numbers, website address and mailing address can be found on this page. We want to ensure your complete satisfaction at all times.

Throughout this manual, all references to right and left side of the machine are observed from the operating position.

Table of Contents

Important Safe Operation Practices......................	3	Engine Maintenance	...............................................19
Assembly & Set-Up...................................................	7	Service......................................................................	21
Controls & Features................................................	11	Troubleshooting.....................................................	25
Operation................................................................	14	Replacement Parts.................................................	26
Maintenance & Adjustment..................................	16

Record Product Information

Model Number

Before setting up and operating your new equipment, please

locate the model plate on the equipment and record the

information in the provided area to the right. You can locate the

model plate by standing at the operator’s position and looking

Serial Number

at the lower, rear section of the frame. This information will be

necessary, should you seek technical support via our web site,

Customer Support Department, or with a local authorized service

dealer.

Customer Support

Please do NOT return the unit to the retailer or dealer without first contacting our Customer Support Department.

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 options below:

◊Visit us on the web at www.troybilt.com

◊Call a Customer Support Representative at [phone] or [phone]

◊Write us at Troy-Bilt LLC • P.O. Box 361131 • Cleveland, OH • 44136-0019

2

Important Safe Operation Practices	2

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. HEEDITSWARNING!

California Proposition 65

WARNING!Engine Exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to State of California to cause cancer and birth defects or other reproductive harm.

DANGER:This machine was built to be operated according to the safe operation practices 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 fingers, hands, toes and feet and throwing foreign objects. Failure to observe the following safety instructions could result in serious injury or death.

Training

1.Read, understand, and follow all instructions on the machine and in the manual(s) before attempting to assemble and operate. Keep this manual in a safe place for future and regular reference and for ordering replacement parts.

2.Be familiar with all controls and their proper operation. Know how to stop the machine and disengage them quickly.

3.Never allow children under 14 years of age to operate this machine. Children 14 and over should read and understand the instructions and safe operation practices in this manual and on the machine and be trained and supervised by an adult.

4.Never allow adults to operate this machine without proper instruction.

5.Thrown objects can cause serious personal injury. Plan your snow-throwing pattern to avoid discharge of material toward roads, bystanders and the like.

6.Keep bystanders, pets and children at least 75 feet from the machine while it is in operation. Stop machine if anyone enters the area.

7.Exercise caution to avoid slipping or falling, especially when operating in reverse.

Preparation

Thoroughly inspect the area where the equipment is to be used. Remove all doormats, newspapers, sleds, boards, wires and other foreign objects, which could be tripped over or thrown by the auger/impeller.

1.Always wear safety glasses or eye shields during operation and while performing an adjustment or repair to protect your eyes. Thrown objects which ricochet can cause serious injury to the eyes.

2.Do not operate without wearing adequate winter outer garments. Do not wear jewelry, long scarves or other loose clothing, which could become entangled in moving parts. Wear footwear which will improve footing on slippery surfaces.

3.Use a grounded three-wire extension cord and receptacle for all machines with electric start engines.

4.Adjust collector housing height to clear gravel or crushed rock surfaces.

5.Disengage all control levers before starting the engine.

6.Never attempt to make any adjustments while engine is running, except where specifically recommended in the operator’s manual.

7.Let engine and machine adjust to outdoor temperature before starting to clear snow.

3

Safe Handling of Gasoline

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 other sources of ignition.

c.Never fuel machine indoors.

d.Never remove gas cap or add fuel while the engine is hot or running.

e.Allow engine to cool at least two minutes before refueling.

f.Never over fill fuel tank. Fill tank to no more than ½ inch below bottom of filler neck to provide space for fuel expansion.

g.Replace gasoline cap and tighten securely.

h.If gasoline is spilled, wipe it off the engine and equipment. Move machine to another area. Wait 5 minutes before starting the engine.

i.Never store the machine or fuel container inside where there is an open flame, spark or pilot light (e.g. furnace, water heater, space heater, clothes dryer etc.).

j.Allow machine to cool at least 5 minutes before storing.

k.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.

l.If possible, remove gas-powered equipment from 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 from a gasoline dispenser nozzle.

m.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.

Operation

1.Do not put hands or feet near rotating parts, in the auger/ impeller housing or chute assembly. Contact with the rotating parts can amputate hands and feet.

2.The auger/impeller control lever is a safety device. Never bypass its operation. Doing so makes the machine unsafe and may cause personal injury.

3.The control levers must operate easily in both directions and automatically return to the disengaged position when released.

4.Never operate with a missing or damaged chute assembly. Keep all safety devices in place and working.

5.Never run an engine indoors or in a poorly ventilated area. Engine exhaust contains carbon monoxide, an odorless and deadly gas.

6.Do not operate machine while under the influence of alcohol or drugs.

7.Muffler and engine become hot and can cause a burn. Do not touch. Keep children away.

8.Exercise extreme caution when operating on or crossing gravel surfaces. Stay alert for hidden hazards or traffic.

9.Exercise caution when changing direction and while operating on slopes.

10.Plan your snow-throwing pattern to avoid discharge towards windows, walls, cars etc. Thus, avoiding possible property damage or personal injury caused by a ricochet.

11.Never direct discharge at children, bystanders and pets or allow anyone in front of the machine.

12.Do not overload machine capacity by attempting to clear snow at too fast of a rate.

13.Never operate this machine without good visibility or light. Always be sure of your footing and keep a firm hold on the handles. Walk, never run.

14.Disengage power to the auger/impeller when transporting or not in use.

15.Never operate machine at high transport speeds on slippery surfaces. Look down and behind and use care when backing up.

16.If the machine should start to vibrate abnormally, stop the engine, disconnect the spark plug wire and ground it against the engine. Inspect thoroughly for damage. Repair any damage before starting and operating.

17.Disengage all control levers and stop engine before you leave the operating position (behind the handles). Wait until the auger/impeller comes to a complete stop before unclogging the chute assembly, making any adjustments, or inspections.

18.Never put your hand in the discharge or collector openings. Always use the clean-out tool provided to unclog the discharge opening. Do not unclog chute assembly while engine is running. Shut off engine and remain behind handles until all moving parts have stopped before unclogging.

19.Use only attachments and accessories approved by the manufacturer (e.g. wheel weights, tire chains, cabs etc.).

20.When starting engine, pull cord slowly until resistance is felt, then pull rapidly. Rapid retraction of starter cord

(kickback) will pull hand and arm toward engine faster than you can let go. Broken bones, fractures, bruises or sprains could result.

21.If situations occur which are not covered in this manual, use care and good judgment. Contact Customer Support for assistance and the name of your nearest servicing dealer.

4		Section 2 — Important Safe Operation Practices

Maintenance & Storage

1.Never tamper with safety devices. Check their proper operation regularly. Refer to the maintenance and adjustment sections of this manual.

2.Before cleaning, repairing, or inspecting machine disengage all control levers and stop the engine. Wait until the auger/impeller come to a complete stop. Disconnect the spark plug wire and ground against the engine to prevent unintended starting.

3.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.

4.Do not change the engine governor setting or over-speed the engine. The governor controls the maximum safe operating speed of the engine.

5.Snow thrower shave plates and skid shoes are subject to wear and damage. For your safety protection, frequently check all components and replace with original equipment manufacturer’s (OEM) parts only. “Use of parts which do not meet the original equipment specifications may lead to improper performance and compromise safety!”

6.Check control levers periodically to verify they engage and disengage properly and adjust, if necessary. Refer to the adjustment section in this operator’s manual for instructions.

7.Maintain or replace safety and instruction labels, as necessary.

8.Observe proper disposal laws and regulations for gas, oil, etc. to protect the environment.

9.Prior to storing, run machine a few minutes to clear snow from machine and prevent freeze up of auger/impeller.

10.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.

11.Always refer to the operator’s manual for proper instructions on off-season storage.

12.Check fuel line, tank, cap, and fittings frequently for cracks or leaks. Replace if necessary.

13.Do not crank engine with spark plug removed.

14.According to the Consumer Products Safety Commission (CPSC) and the U.S. Environmental Protection Agency (EPA), this product has an Average Useful Life of seven (7) years,

or 60 hours of operation. At the end of the Average Useful Life have the machine inspected annually by an authorized service dealer to ensure that all mechanical and safety systems are working properly and not worn excessively. Failure to do so can result in accidents, injuries or death.

Do not modify engine

To avoid serious injury or death, do not modify engine in any way. Tampering with the governor setting can lead to a runaway engine and cause it to operate at unsafe speeds. Never tamper with factory setting of engine governor.

Notice Regarding Emissions

Engines which are certified to comply with California and federal

EPA emission regulations for SORE (Small Off Road Equipment) are certified to operate on regular unleaded gasoline, and may include the following emission control systems: Engine

Modification (EM), Oxidizing Catalyst (OC), Secondary Air

Injection (SAI) and Three Way Catalyst (TWC) if so equipped.

Spark Arrestor

Warning!This machine 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.

Section 2 — Important Safe Operation Practices		5

Safety Symbols

This page depicts and describes safety symbols that may appear on this product. Read, understand, and follow all instructions on the machine before attempting to assemble and operate.

Symbol

Description

READ THE OPERATOR’S MANUAL(S)

Read, understand, and follow all instructions in the manual(s) before attempting to assemble and operate

WARNING— ROTATING BLADES

Keep hands out of inlet and discharge openings while machine is running. There are rotating blades inside

WARNING— ROTATING BLADES

Keep hands out of inlet and discharge openings while machine is running. There are rotating blades inside

WARNING— ROTATING AUGER

Do not put hands or feet near rotating parts, in the auger/impeller housing or chute assembly. Contact with the rotating parts can amputate hands and feet.

WARNING—THROWN OBJECTS

This machine may pick up and throw and objects which can cause serious personal injury.

WARNING—GASOLINE IS FLAMMABLE

Allow the engine to cool at least two minutes before refueling.

WARNING— CARBON MONOXIDE

Never run an engine indoors or in a poorly ventilated area. Engine exhaust contains carbon monoxide, an odorless and deadly gas.

WARNING— ELECTRICAL SHOCK

Do not use the engine’s electric starter in the rain

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.

SAVE THESE INSTRUCTIONS!

6		Section 2 — Important Safe Operation Practices

Assembly & Set-Up	3
Contents of Carton

• One Snow Thrower • Two Replacement Auger Shear Pins • One Product Registration Card

•One Snow Thrower Operator’s

Manual

Assembly

Handle

1.Place the shift lever in the Forward-6 position

2.Observe the lower rear area of the snow thrower to be sure both cables are aligned with roller guides before pivoting the handle upward. See Fig. 3-1.

Figure3-1

NOTE: Make certain the upper ends of each cable are seated properly in its bracket.

3.Secure the handle by tightening the plastic knob located on both the left and right sides of the handle. Remove and discard any rubber bands, if present. They are for packaging purposes only.

Chute Assembly

1.Remove wing nut and hex screw from chute control assembly and clevis pin and cotter pin from chute support bracket. Position the chute assembly (forward-facing) over the chute base. See Fig. 3-2.

2.Place chute assembly onto chute base and secure chute control assembly to chute support bracket with clevis pin and cotter pin removed earlier. See See Fig. 3-3.

Figure3-2

Figure3-3

7

3.Finish securing chute control assembly to chute support bracket with wing nut and hex screw removed earlier.

See Fig. 3-4.

Figure3-4

Set-Up

Shear Pins

A pair of replacement auger shear pins and bow tie cotter pins are included with your snow thrower. Store them in your snow thrower’s dash panel until needed. See Fig. 3-6.

4.	Check that all cables are properly routed through the cable	Figure3-6
	guide on top of the engine. See Fig. 3-5.

Chute Clean-Out Tool

The chute clean-out tool is fastened to the top of the auger housing with a mounting clip and a cable tie at the factory. Cut the cable tie before operating the snow thrower. See Fig. 3-7.

ChuteClean-outTool

Figure3-5

Figure3-7

8		Section 3— Assembly & Set-Up

Fuel Recommendations

Use automotive gasoline (unleaded or low leaded to minimize combustion chamber deposits) with a minimum of 87 octane.

Gasoline with up to 10% ethanol or 15% MTBE (Methyl Tertiary

Butyl Ether) can be used. Never use an oil/gasoline mixture or dirty gasoline. Avoid getting dirt, dust, or water in the fuel tank.

DO NOT use E85 gasoline.

•Refuel in a well-ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where the engine is refueled or where gasoline is stored.

•Do not overfill the fuel tank. After refueling, make sure the tank cap is closed properly and securely.

•Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before starting the engine.

•Avoid repeated or prolonged contact with skin or breathing of vapor.

Adding Fuel

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.

WARNING!Always keep hands and feet clear of equipment moving parts. Do not use a pressurized starting fluid. Vapors are flammable.

1.Clean around fuel fill before removing cap to fuel.

2.A fuel level indicator is located in the fuel tank. Fill tank until fuel reaches the fuel level indictor, Fig. 3-8. Be careful not to overfill.

Fuel Level Indicator

Top View

Figure3-8

Checking Oil Level

CAUTION:The engine is shipped with oil in the engine. You must, however, check the oil level prior to operating the snow thrower. Running the engine with insufficient oil can cause serious engine damage and void the engine warranty.

NOTE: Be sure to check the engine on a level surface with the engine stopped.

1.Remove the oil filler cap/dipstick and wipe the dipstick clean. See Fig. 3-9.

2.Insert the cap/dipstick into the oil filler neck, butdonot screw it in.

Fill between high and low marks

Figure3-9

3.Remove the oil filler cap/dipstick. If the level is low, slowly add oil until oil level registers between high (H) and low (L), Fig. 3-9. Refer to the Engine Maintenance section for correct oil viscosity and engine oil capacity.

NOTE: Do not overfill. Overfilling with oil may result in engine smoking, hard starting or spark plug fouling.

4.Replace and tighten cap/dipstick firmly before starting engine.

Tire Pressure

Before operating, check tire pressure and reduce pressure in both tires to between 15 psi and 20 psi.

NOTE: If the tire pressure is not equal in both tires, the machine may not travel in a straight path and the shave plate may wear unevenly.

Section 3 — Assembly & Set-Up		9

Adjustments

Skid Shoes

The snow thrower skid shoes are adjusted upward at the factory for shipping purposes. Adjust them downward, if desired, prior to operating the snow thrower.

Caution:It is not recommended that you operate this snow thrower on gravel as it can easily pick up and throw loose gravel, causing personal injury or damage to the snow thrower and surrounding property.

•For close snow removal on a smooth surface, raise skid shoes higher on the auger housing.

•Use a middle or lower position when the area to be cleared is uneven, such as a gravel driveway

NOTE: If you choose to operate the snow thrower on a gravel surface, keep the skid shoes in position for maximum clearance between the ground and the shave plate.

To adjust the skid shoes:

1.Loosenthefourhexnuts(twooneachside)andcarriagebolts.

Move skid shoes to desired position. See Fig. 3-10.

Figure3-10

2.Make certain the entire bottom surface of skid shoe is against the ground to avoid uneven wear on the skid shoes.

3.Retighten nuts and bolts securely.

Chute Assembly

The distance snow is thrown can be adjusted by changing the angle of the chute assembly. To do so:

1.Stop the engine by removing the ignition key and loosen the plastic knob found on the left side of the chute assembly.

2.Pivot the chute upward or downward before retightening the wing knob.

Auger Control

Warning! Prior to operating your snow thrower, carefully read and follow all instructions below.

Perform all adjustments to verify your snow thrower is operating safely and properly.

Check the adjustment of the auger control as follows:

1.When the auger control is released and in the disengaged

“up” position, the cable should have very little slack. It should NOT be tight.

2.In a well-ventilated area, start the snow thrower engine.

Refer to Starting the Engine on page 14. Make sure the throttle is set in the FAST position.

3.While standing in the operator’s position (behind the snow thrower), engage the auger.

4.Allow the auger to remain engaged for approximately ten

(10) seconds before releasing the auger control. Repeat this several times.

5.With the throttle control in the FAST (rabbit) position and the auger control in the disengaged “up” position, walk to the front of the machine.

6.Confirm that the auger has completely stopped rotating and shows NO signs of motion. If the auger shows ANY signs of rotating, immediately return to the operator’s position and shut off the engine. Wait for ALL moving parts to stop before re-adjusting the auger control.

7.To readjust the control cable, loosen the upper hex nut on the auger cable bracket. See Fig. 3-11.

Figure3-11

8.Position the bracket upward to provide more slack (or downward to increase cable tension).

9.Retighten the upper hex nut.

10.Repeat steps 2-6 above to verify proper adjustment has been achieved.

10 Section 3— Assembly & Set-Up

Controls and Features	4

Drive Control

Gas Cap

Chute Assembly

Oil Fill

Clean Out

Tool

Augers

Shift Lever

Chute Directional Control

Auger Control

	Mu er	Recoil Starter
		Handle
	Primer
	Ignition
	Key
	Throttle
	Control
	Choke
	Control	Electric Start
Skid Shoe	Oil Drain	Button
		Electric Starter Outlet
	Figure4-1

Snow thrower controls and features are described below and illustrated in Fig. 4-1.

Shift Lever

The shift lever is located in the right side of the handle panel and is used to determine ground

speed and direction of travel.

Forward

There are six forward (F) speeds. Position one (1) is

the slowest and position six (6) is the fastest.

Reverse

There are two reverse (R) speeds. One (1) is the slower and two (2) is the faster.

Choke Control

The choke control is found on the rear of the engine and is activated by rotating the knob clockwise. Activating the choke control closes the choke plate on the carburetor and aids in starting the engine.

Ignition Key

The ignition key is a safety device. It must be fully inserted in order for the engine to start. Remove the ignition key when the snow thrower is not in use.

Note: Do not turn the ignition key in an attempt to start the engine. Doing so may cause it to break.

11

Throttle Control

Auger Control

The throttle control is located on the rear of the engine. It regulates the speed of the engine and will shut off the engine when moved into the STOP position.

Primer

Pressing the primer forces fuel directly into the engine’s carburetor to aid in cold-

weather starting.

Oil Fill

Engine oil level can be checked and oil added through the oil fill.

Oil Drain

Engine oil can be drained through the oil drain.

Muffler

Engine exhaust exists the engine via the muffler.

Skid Shoes

Position the skid shoes based on surface conditions. Adjust upward for hard-packed snow. Adjust downward when operating on gravel or crushed rock surfaces.

Electric Starter Outlet

Requires the use of a three-prong outdoor extension cord and a

120V power source/wall outlet.

Recoil Starter Handle

This handle is used to manually start the engine.

Electric Starter Button

Pressing the electric starter button engages the engine’s electric starter when plugged into a 120V power source.

Augers

When engaged, the augers rotate and draw snow into the auger housing.

Chute Assembly

Snow drawn into the auger housing is discharged out the chute assembly.

Gas Cap

Unthread the gas cap to add gasoline to the fuel tank.

The auger control is located on the left handle. Squeeze the control grip against the handle to engage the augers and start snow throwing action. Release to stop.

Drive Control / Auger Clutch Lock

The drive control is located on the right handle. Squeeze the control grip against the handle to engage the wheel drive. Release to stop.

The drive control also locks the auger control so that you can operate the chute directional control without interrupting the snow throwing process. If the auger control is engaged

simultaneously with the drive control, the operator can release the auger control (on the left handle) and the augers will remain engaged. Release both controls to stop the augers and wheel drive.

Note: Always release the drive control before changing speeds. Failure to do so will result in increased wear on your machine’s drive system.

12 Section 4 — Controls and Features

Chute Directional Control

ADJUSTABLE

CHUTE TILT

PUSH	PUSH
BUTTON	BUTTON
CHUTE	CHUTE
ROTATE	ROTATE
LEFT	RIGHT

The chute directional control is located on the left side of the dash panel.

•To change the direction in which snow is thrown, squeeze the button on the joy-stick and pivot the joy-stick to the right or to the left.

Chute Clean-Out Tool

Warning!Never use your hands to clear a clogged chute assembly. Shut off engine and remain behind handles until all moving parts have stopped before unclogging.

The chute clean-out tool is conveniently fastened to the rear of the auger housing with a mounting clip. Should snow and ice become lodged in the chute assembly during operation, proceed as follows to safely clean the chute assembly and chute opening:

1.Release both the Auger Control and the Drive Control.

2.Stop the engine by removing the ignition key.

3.Remove the clean-out tool from the clip which secures it to the rear of the auger housing.

4.Use the shovel-shaped end of the clean-out tool to dislodge and scoop any snow and ice which has formed in and near the chute assembly.

5.Refasten the clean-out tool to the mounting clip on the rear of the auger housing, reinsert the ignition key and start the snow thrower’s engine.

While standing in the operator’s position (behind the snow thrower), engage the auger control for a few seconds to clear any remaining snow and ice from the chute assembly.

Section 4 — Controls and Features		13

Operation	5

Starting the Engine

WARNING!Always keep hands and feet clear of moving parts. Do not use a pressurized starting fluid. Vapors are flammable.

NOTE: Allow the engine to warm up for a few minutes after starting. The engine will not develop full power until it reaches operating temperatures.

Electric Starter

WARNING!The electric starter is equipped with a grounded three-wire power cord and plug, and is designed to operate on 120 volt AC household current. It must be used with a properly grounded three-prong receptacle at all times to avoid the possibility of electric shock. Follow all instructions carefully prior to operating the electric starter.

DO NOT use electric starter in rain.

1.Determine that your home’s wiring is a three-wire grounded system. Ask a licensed electrician if you are unsure. If you have a grounded three-prong receptacle, proceed as follows. If you do not have the proper house wiring, DO NOT use the electric starter under any conditions.

2.Insert ignition key fully into slot, Fig. 5-1. Make sure it snaps into place. DO NOT turn ignition key. The engine cannot start unless the key is inserted into ignition switch.

Figure5-1

3.Plug the extension cord into the electric outlet located on the engine. Plug the other end of extension cord into a three-prong 120-volt, grounded, AC outlet in a wellventilated area. See Fig. 5-2.

Figure5-2

4.Move throttle control to FAST (rabbit) position.

5.Move choke to the ON position (cold engine start). If engine is warm, place choke in OFF position.

6.Push primer three to five (3-5) times, making sure to cover vent hole when pushing. If engine is warm, push primer only once. Always cover vent hole when pushing. Cool weather may require priming to be repeated.

7.Push starter button to start engine. Once the engine starts, immediately release starter button. Electric starter is equipped with thermal overload protection; system will temporarily shut-down to allow starter to cool if electric starter becomes overloaded.

8.As the engine warms, slowly rotate the choke control to

OFF position. If the engine falters, restart engine and run with choke at half-choke position for a short period of time, and then slowly rotate the choke into OFF position.

9.After engine is running, disconnect power cord from electric starter. When disconnecting, always unplug the end at the wall outlet before unplugging the opposite end from the engine.

14

Recoil Starter

Caution!Do not pull the starter handle while the engine running.

WARNING:To avoid unsupervised engine operation, never leave the engine unattended while running. Turn the engine off after use and remove ignition key

1.Insert ignition key fully into slot, Figure 5-5. Make sure it snaps into place. DO NOT turn ignition key. The engine cannot start unless the key is inserted into ignition switch.

2.Move throttle control to FAST (rabbit) position.

3.Move choke to the ON position (cold engine start). If engine is warm, place choke in OFF position.

4.Push primer three to five (3-5) times, making sure to cover vent hole when pushing. If engine is warm, push primer only once. Always cover vent hole when pushing. Cool weather may require priming to be repeated.

5.Pull gently on the starter handle until it begins to resist, then pull quickly and forcefully to overcome the compression. Do not release the handle and allow it to snap back. Return rope SLOWLY to original position. If required, repeat this step.

6.As the engine warms, slowly rotate the choke control to

OFF position. If the engine falters, restart engine and run with choke at half-choke position for a short period of time, and then slowly rotate the choke into OFF position.

Stopping the Engine

WARNING:To avoid unsupervised engine operation, never leave the machine unattended with the engine running. Turn the engine off after use and remove ignition key

Run engine for a few minutes before stopping to help dry off any moisture on the engine.

1.Move throttle control to STOP position.

2.Remove the ignition key. Removing the key will reduce the possibility of unauthorized starting of the engine while equipment is not in use. Keep the key in a safe place. The engine cannot start without the ignition key.

3.Wipe any moisture away from the controls on the engine.

To Engage Drive

1.With the throttle control in the Fast (rabbit) position, move shift lever into one of the six forward (F) positions or two reverse (R) positions. Select a speed appropriate for the snow conditions and a pace you’re comfortable with.

2.Squeeze the drive control against the handle the snow thrower will move. Release it and drive motion will stop.

To Engage Augers

1.To engage the augers and start throwing snow, squeeze the auger control against the left handle. Release to stop the augers.

Replacing Shear Pins

The augers are secured to the spiral shaft with two shear pins and cotter pins. If the auger should strike a foreign object or ice jam, the snow thrower is designed so that the pins may shear. If the augers will not turn, check to see if the pins have sheared. See Fig. 5-3.

caution:NEVER replace the auger shear pins with anything other than OEM Part No. 738-04124A replacement shear pins. Any damage to the auger gearbox or other components as a result of failing to do so will NOT be covered by your snow thrower’s warranty.

warning!Always turn off the snow thrower’s engine and remove the key prior to replacing shear pins.

Figure5-3

Section 5 — Operation		15

Maintenance & Adjustments	6

Maintenance

Engine

Refer to the Engine Maintenance section.

Shave Plate and Skid Shoes

The shave plate and skid shoes on the bottom of the snow thrower are subject to wear. They should be checked periodically and replaced when necessary.

To remove skid shoes:

1.Remove the four carriage bolts and hex flange nuts which secure them to the snow thrower.

2.Reassemble new skid shoes with the four carriage bolts (two on each side) and hex flange nuts. Refer to Fig. 6-1.

To remove shave plate:

r

Figure 6-1

Lubrication

Gear Shaft

The gear (hex) shaft should be lubricated at least once a season or after every twenty-five (25) hours of operation.

1.Allow the engine to run until it is out of fuel.

2.Carefully pivot the snow thrower up and forward so that it rests on the auger housing.

3.Remove the frame cover from the underside of the snow thrower by removing four self-tapping screws which secure it. Refer to Fig 7-3.

4.Apply a light coating of engine oil (or 3-in-1 oil) to the hex shaft. See Fig. 6-2.

NOTE: When lubrication the hex shaft, be careful not to get any oil on the aluminum drive plate or the rubber friction wheel. Doing so will hinder the snow thrower’s drive system. Wipe off any excess or spilled oil.

1.Remove the carriage bolts and hex nuts which attach it to the snow thrower housing.

2.Reassemble new shave plate, making sure heads of carriage bolts are to the inside of housing. Tighten securely.

Tire Pressure

Before operating, check tire pressure and reduce pressure to between 15 psi and 20 psi.

If the tire pressure is not equal in both tires, the unit may pull to one side or the other.

Figure 6-2

Wheels

At least once a season, remove both wheels. Clean and coat the axles with a multipurpose automotive grease before reinstalling wheels.

16

Auger Shaft

At least once a season, remove the shear pins from the auger shaft. Spray lubricant inside the shaft and around the spacers and the flange bearings found at either end of the shaft.

See Fig. 6-3.

Figure6-3

Adjustments

Shift Cable

If the full range of speeds (forward and reverse) cannot be achieved, refer to the figures to the right and adjust the shift cable as follows:

1.Place the shift lever in the fastest forward speed position.

2.Loosen the hex nut on the shift cable index bracket. See

Fig. 6-4.

Figure6-4

3.Pivot the bracket downward to take up slack in the cable.

4.Retighten the hex nut.

Auger Control

Refer to the Assembly and Set-up section for instructions on adjusting the auger control cable.

Chute Assembly

Refer to the Assembly and Set-up section for instructions on adjusting the skid shoes chute assembly.

Skid Shoes

Refer to the Assembly and Set-up section for instructions on adjusting the skid shoes.

Section 6 — Maintenance & Adjustments		17

Drive Control

When the drive control is released and in the disengaged “up” position, the cable should have very little slack. It should NOT be tight.

NOTE: If excessive slack is present in the drive cable or if the snow thrower’s drive is disengaging intermittently during operation, the cable may be in need of adjustment.

Check the adjustment of the drive control as follows:

1.With the drive control released, push the snow thrower gently forward. The unit should roll freely.

2.Engage the drive control and gently attempt to push the snow thrower forward. The wheels should not turn. The unit should not roll freely.

3.With the drive control released, move the shift lever back and forth between the R2 position and the F6 position several times. There should be no resistance in the shift lever.

4.If any of the above tests failed, the drive cable is in need of adjustment. Proceed as follows:

Chute Directional Control

If the chute assembly does not have full range from left-to-right, the chute control cables can be adjusted to take up slack:

1.Using a ½” wrench, loosen the upper and lower hex nuts found on one cable adjuster.

2.Grasp the metal cable housing and gently pull downward to take up slack (usually no more than 1⁄4-inch) in the cable before retightening both hex nuts.

3.Repeatontheothercableadjusteruntilthechuteassemblyhas full range from left-to-right. See Fig. 6-6.

Figure6-5

5.Loosen the lower hex nut on the drive cable bracket. See

Fig. 6-5.

6.Position the bracket upward to provide more slack (or downward to increase cable tension).

7.Retighten the upper hex nut.

Figure6-6

Off-Season Storage

If the snow thrower will not be used for 30 days or longer, follow the storage instructions below.

1.Lubricate the machine as instructed earlier in this section.

2.Store in a clean, dry area.

3.If storing the snow thrower in an unventilated area, rustproof the machine using a light oil or silicone to coat the snow thrower.

4.Clean the exterior of the engine and the snow thrower.

NOTE: Refer to the Engine Maintenance section for information on storing your engine.

18 Section 6 — Maintenance & Adjustments