PoulanPRO 96194001003 User Manual

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IMPORTANT MANUAL Do Not Throw Away

OWNER'S MANUAL

MODEL NUMBER:

WARNING:

96194001003

SNOW THROWER

Always Wear Eye Protection During Operation

Gasoline containing up to 10% ethanol (E10) is acceptable for use in this machine. The use of any gasoline exceeding 10% ethanol (E10) will void the product warranty.

581 45 59-27

Read the Owner's Manual and fol low all Warnings and Safety In struc tions. Fail ure to do so can result in serious injury.

IMPORTANT

Safe Operation Practices for Walk-Behind Snow Throwers

This snow thrower is capable of amputating hands and feet and throwing objects.

Failure to observe the following safety instructions could result in serious injury.

Look for this symbol to point out im por tant safety precautions. It means CAUTION!!! BE COME ALERT!!! YOUR SAFE TY IS IN VOLVED.

WARNING: Always disconnect spark plug wire and place it where it can not con tact plug in order to pre vent ac ci den tal start ing when setting up, trans port ing, ad just ing or making re pairs.

WARNING: This snow thrower is for use on sidewalks, driveways and other ground level surfaces. Caution should be exercised while using on sloping surfaces. Do not use snow thrower on surfaces above ground level such as roofs of residences, garages, porch es or other such structures or buildings.

Training

1. Read, understand and follow all instructions on the machine and in the manual(s) before operating this unit. Be thoroughly familiar with the controls and the proper use of the equipment. Know how to stop the unit and disengage the controls quickly.

2. Never allow children to operate the equipment. Never allow adults to operate the equipment without proper instruction.

3. Keep the area of operation clear of all persons, particularly small children.

4. Exercise caution to avoid slipping or falling, especially when operating the snow thrower in reverse.

Preparation

1. Thoroughly inspect the area where the equipment is to be used and remove all doormats, sleds, boards, wires, and other foreign objects.

2. Disengage all clutches and shift into neutral before starting the engine (motor).

3. Do not operate the equipment without wearing adequate winter garments. Avoid loose fitting clothing that can get caught in moving parts. Wear footwear that will improve footing on slippery surfaces.

4. Handle fuel with care; it is highly flammable (a) Use an approved fuel container. (b) Never add fuel to a running engine or hot en-

gine.

fuel tank indoors.

(d) 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.

(e) When practical, 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.

WARNING: Snow throwers have ex posed rotating parts, which can cause severe injury from contact, or from material thrown from the discharge chute. Keep the area of operation clear of all persons, small children and pets at all times including startup.

CAUTION: Muffler and other engine parts become extremely hot during operation and remain hot after engine has stopped. To avoid severe burns on contact, stay away from these areas.

WARNING: Engine exhaust, some of its con stit u ents, and certain vehicle com po nents contain or emit chem icals known to the State of Cal i for nia to cause can cer and birth defects or oth er re pro duc tive harm.

(f) Keep the nozzle in contact with the rim of the fuel

tank or container opening at all times, until refueling is complete. Do not use a nozzle lock-open device.

(g) Replace gasoline cap securely and wipe up spilled

fuel.

(h) If fuel is spilled on clothing, change clothing im-

mediately.

5. Use extension cords and receptacles as specified by the manufacturer for all units with electric drive motors or electric starting motors.

6. Adjust the collector housing height to clear gravel or crushed rock surface.

7. Never attempt to make any adjustments while the engine (motor) is running (except when specifically recommended by manufacturer).

8. Always wear safety glasses or eye shields during operation or while performing an adjustment or repair to protect eyes from foreign objects that may be thrown from the machine.

Operation

1. Do not put hands or feet near or under rotating parts. Keep clear of the discharge opening at all times.

2. Exercise extreme caution when operating on or crossing gravel drives, walks, or roads. Stay alert for hidden hazards or traffic.

3. After striking a foreign object, stop the engine (motor), remove the wire from the spark plug, disconnect the cord on electric motors, thoroughly inspect the snow thrower for any damage, and repair the damage before restarting and operating the snow thrower.

4. If the unit should start to vibrate abnormally, stop the engine (motor) and check immediately for the cause. Vibration is generally a warning of trouble.

5. Stop the engine (motor) whenever you leave the operating position, before unclogging the collector/impeller housing or discharge chute, and when making any

repairs, adjustments or inspections.

6. When cleaning, repairing or inspecting the snow thrower, stop the engine and make certain the collector/impeller and all moving parts have stopped. Disconnect the spark plug wire and keep the wire away from the plug to prevent someone from accidentally starting the engine.

7. Do not run the engine indoors, except when starting the engine and for transporting the snow thrower in or out of the building. Open the outside doors; exhaust fumes are dangerous.

8. Exercise extreme caution when operating on slopes.

9. Never operate the snow thrower without proper guards, and other safety protective devices in place and working.

10. Never direct the discharge toward people or areas where property damage can occur. Keep children and others away.

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

12. Never operate the machine at high transport speeds on slippery surfaces. Look behind and use care when operating in reverse.

13. Disengage power to the collector/impeller when snow thrower is transported or not in use.

14. Use only attachments and accessories approved by the manufacturer of the snow thrower (such as wheel weights, counterweights, or cabs).

15. Never operate the snow thrower without good visibility or light. Always be sure of your footing, and keep a firm hold on the handles. Walk; never run.

16. Never touch a hot engine or muffler.

Clearing a Clogged Discharge Chute

Hand contact with the rotating impeller inside the discharge chute is the most common cause of injury associated with snow throwers. Never use your hand to clean out the discharge chute. To clear the chute:

1. SHUT THE ENGINE OFF!

2. Wait 10 seconds to be sure the impeller blades have stopped rotating.

3. Always use a clean-out tool, not your hands.

Maintenance and Storage

1. Check shear bolts and other bolts at frequent intervals for proper tightness to be sure the equipment is in safe working condition.

2. Never store the machine with fuel in the fuel tank inside a building where ignition sources are present such as hot water heaters, space heaters, or clothes dryers. Allow the engine to cool before storing in any enclosure.

3. Always refer to operator’s manual for important details if the snow thrower is to be stored for an extended period.

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

5. Run the machine a few minutes after throwing snow to prevent freeze-up of the collector/impeller.

CONGRATULATIONS on your purchase of a new snow thrower. It has been designed, engineered and man u fac tured to give best possible dependability and per for mance.

Should you experience any problem you cannot easily remedy, please contact your nearest authorized service center. We have competent, well-trained tech ni cians and the proper tools to service or repair this unit.

Please read and retain this manual. The instructions will enable you to assemble and maintain your snow thrower prop er ly. Always observe the “SAFETY RULES”.

SERIAL NUMBER: ___________________________

DATE OF PURCHASE: _______________________

THE MODEL AND SERIAL NUMBERS WILL BE FOUND ON A DECAL ATTACHED TO THE REAR OF THE SNOW THROWER HOUSING.

YOU SHOULD RECORD BOTH SERIAL NUMBER AND DATE OF PURCHASE AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

TABLE OF CONTENTS

PRODUCT SPECIFICATIONS

Gasoline Capacity .5 Gal (1,89 Liters) and Type: Unleaded Regular only

Oil Type SAE 30 (above 50°F) (API SG–SL): SAE 5W-30 or 10W-30

(32° to 50°F) SAE 5W-30 (below 32°F)

Oil Capacity: 16 Ounces (0,47 Liters)

Spark Plug: F6RTC Gap: 0.030" (0,762 mm)

CUSTOMER RESPONSIBILITIES

• Read and observe the safety rules.

• Follow a regular schedule in maintaining, caring for and using your snow thrower.

• Follow the instructions under “Maintenance” and “Stor age” sec tions of this own er’s manual.

SAFETY RULES ........................................................ 2-3

PRODUCT SPECIFICATIONS ...................................... 3

CUSTOMER RESPONSIBILITIES ................................ 3

ASSEMBLY / PRE-OPERATION ............................... 4-7

OPERATION ............................................................ 8-12

MAINTENANCE SCHEDULE ..................................... 13

MAINTENANCE ..................................................... 13-14

SERVICE AND AD JUST MENTS ........................... 15-17

STORAGE ................................................................... 18

TROU BLE SHOOT ING ................................................ 19

REPAIR PARTS ..................................................... 20-37

WARRANTY ............................................ BACK COVER

PARTS PACKED SEPARATELY IN CARTON

(1) AUGER CONTROL ROD

(1) MULTI-

WRENCH

(180684)

(1) DISCHARGE CHUTE

ROTATOR HEAD MOUNTING

(1) WASHER 3/8

(19131316)

(2) SHEAR BOLTS 1/4-20 x 1-3/4

(1) POWER CORD

(198563)

SAFTEY IGNITION KEY(S)

(1) LOCKNUT 3/8

(73800600)

EXTRA SHEAR BOLTS AND NUTS

(192090)

(443059)

(2) LOCKNUTS

1/4-20

(73800400)

(3) RETAINER SPRINGS

(169675)

(2) FLAT WASHERS

(2) CARRIAGE BOLTS

3/8-16 x 2.25

(2) HANDLE KNOBS

ASSEMBLY / PRE-OPERATION

Read these instructions and this manual in its entirety before you attempt to assemble or operate your new snow thrower. Reading the entire manual will familiarize you with the unit, which will assist you in assembly, operation and maintenance of the product.

Your new snow thrower has been as sem bled at the factory with the ex cep tion of those parts left unassembled for shipping purposes. All parts such as nuts, washers, bolts, etc., necessary to com plete the as sem bly have been placed in the parts bag. To ensure safe and proper operation of your snow thrower, all parts and hard ware you assemble must be tightened se cure ly. Use the correct tools as nec es sary to ensure proper tightness.

REMOVE SNOW THROWER FROM CAR TON

1. Remove all accessible loose parts and parts boxes from carton.

2. Cut down all four corners of carton and lay panels flat.

3. Remove the two (2) screws securing the auger housing to the pallet.

4. Remove all packing materials ex cept plastic tie holding speed control rod to lower handle.

5. Remove the two (2) plastic ties securing the upper handle to the pallet.

6. Remove snow thrower from carton and check carton thor ough ly for ad di tion al loose parts.

HOW TO SET UP YOUR SNOW THROWER

TOOL BOX (See Fig. 8)

A toolbox is provided on your snow thrower. The toolbox is located on top of the belt cover. Store the extra shear bolts, nuts and multi-wrench provided in parts bag in the toolbox.

ASSEMBLY / PRE-OPERATION

NOTE: The multi-wrench may be used for assembly of the

chute rotator head to snow thrower and making ad just ments to the skid plates.

UNFOLD UPPER HANDLE

1. Raise upper handle to the operating position and tight en handle knobs securely. Additional carriage bolts, washers and handle knobs are in bag of parts. Use to secure upper handle to lower handle. Install in lower holes in handles.

INSTALL SPEED CONTROL ROD (See Figs. 1 and 2)

1. Remove plastic tie securing rod to lower handle.

2. Insert rod into speed control bracket and secure with retainer spring.

SPEED CONTROL ROD

PLASTIC TIE

UPPER HANDLE

HANDLE KNOB

INSTALL TRACTION DRIVE CONTROL ROD (See Figs. 3 and 4)

The traction drive control rod is installed on the snow thrower.

1. Remove plastic tie securing rod to lower handle.

2. With top end of rod positioned under left side of control panel, push rod down and insert top end of rod into hole in drive control bracket. Secure with retainer spring.

PLASTIC TIE

TRACTION DRIVE

CONTROL ROD

VINYL

SLEEVE

LOWER HANDLE

FIG. 1

SPEED CON TROL ROD

RETAINER SPRING

FIG. 3

TRACTION DRIVE CON TROL LEVER

DRIVE CONTROL BRACKET

RETAINER

SPRING

TRACTION DRIVE CON TROL ROD

SPEED CONTROL BRACKET

FIG. 2

FIG. 4

SPEED

CONTROL

LEVER

ASSEMBLY / PRE-OPERATION

INSTALL AUGER CONTROL ROD (See Figs. 5 and 6)

1. Retrieve vinyl sleeve and spring from bag of parts and retrieve the auger control rod from carton chute tray. Slide straight rod end through the small hole in the vinyl sleeve. Using the long hook end of the spring, hook spring in hole #4 in rod. (See Fig. 5).

2. Hook end of spring into control arm with loop opening up as shown. (See Fig. 5).

3. With top end of rod positioned under right side of control panel, push down on rod and insert end of rod into hole in auger control bracket. Secure with retainer spring.

AUGER

CONTROL

ROD

CONTROL ARM

VINYL SLEEVE

INSTALL DISCHARGE CHUTE / CHUTE ROTATER HEAD (See Fig. 7)

NOTE: The multi-wrench provided in your parts bag may

be used to install the chute rotater head.

1. Place discharge chute assembly on top of chute base with discharge opening toward front of snow thrower.

2. Position chute rotater head over chute bracket. If nec es sary, rotate chute assembly to align square and pin on un der side of chute rotater head with holes in chute brack et.

3. With chute rotater head and chute bracket aligned, po si tion chute rotater head on pin and threaded stud of mounting bracket.

4. Install 3/8 washer and locknut on threaded stud and tighten securely.

CHUTE ROTATER HEAD

3/8 LOCKNUT

3/8 WASHER

LOOP

OPENING

FIG. 5

AUGER CONTROL ROD

RETAINER SPRING

AUGER

CONTROL

LEVER

AUGER CONTROL BRACKET

THREADED

STUD

CHUTE BRACKET

ALIGN BEFORE

TIGHTENING LOCKNUT

FIG. 7

ROTATER HEAD

MOUNT ING

BRACKET

CHECK TIRE PRESSURE

The tires on your snow thrower were overinflated at the factory for shipping purposes. Correct and equal tire pres sure is important for best snow throwing performance.

• Reduce tire pressure to 14-17 PSI.

FIG. 6

OPERATION

FORWARD

PRIMER

IGNITION KEY.

INSERT TO START

AND RUN,

PULL OUT TO STOP.

READ AND FOLLOW ALL SAFETY INFORMATION

AND INSTRUCTIONS BEFORE USE OF THIS PRODUCT.

KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE.

DANGER

OR WARNING

REVERSE

SNOW

DISCHARGE

TRACTION

DRIVE CONTROL

DISENGAGED

ENGAGED

KNOW YOUR SNOW THROWER

READ THIS OWNER'S MANUAL AND ALL SAFETY RULES BEFORE OPERATING YOUR SNOW THROWER. Compare the illustrations with your snow thrower to familiarize yourself with the location of various controls and adjustments. Save this manual for future reference.

These symbols may appear on your snow thrower or in literature supplied with the product. Learn and understand their meaning.

OPERATION

MUF FLER

GAS O LINE FILLER CAP

CHOKE CON TROL

SAFETY IGNITION KEY

ON / OFF SWITCH

PRIM ER

FUEL SHUT-OFF VALVE

RECOIL (AUXILIARY) STARTER HANDLE

NOTE: ITEMS ABOVE

ARE SHOWN IN THEIR TYPICAL

LOCATION ON THE

ENGINE. ACTUAL

LOCATION MAY VARY

WITH THE ENGINE

ON YOUR UNIT.

ELECTRIC

START

BUTTON

DISCHARGE CHUTE

CLEAN-OUT TOOL

POWER

CORD

PLUG

AUGER CONTROL LEVER

CHUTE

DE FLEC TOR

DISCHARGE CHUTE CONTROL LEVER

DRIVE SPEED CON TROL LEVER

TRACTION

DRIVE

CONTROL

LEVER

LIGHT

CHUTE

DE FLEC TOR

KNOB

HANDLE

KNOB

MUF FLER

TOOLBOX

AU GERS

FIG. 8

MEETS A.N.S.I. SAFETY REQUIREMENTS

Our snow throwers conform to the standards of the American National Standards Institute.

Toolbox - used to store spare shear bolts, locknuts and wrench.

Safety ignition key - must be inserted for the engine to start and run. Remove when snow thrower is not in use.

Electric start button – used for starting the engine.

Recoil (auxiliary) starter handle – used for start ing the

en gine.

Primer - pumps additional fuel from the carburetor to the cylinder for use when starting a cold engine.

ON / OFF switch - used to STOP the engine.

Choke control - used for starting a cold engine.

Drive speed control lever - used to select forward or

reverse motion and speed of snow thrower.

Traction drive control lever - used to engage power-pro pelled for ward or reverse motion of snow thrower.

Auger control lever - used to engage auger motion (throw snow).

Discharge chute control lever - used to change the di rec tion the snow is thrown.

Skid plate - used to adjust height of scraper bar from the ground.

SKID PLATE

OPERATION

The operation of any snow thrower can result in foreign objects thrown into the eyes, which can result in severe eye damage. Always wear safety glasses or eye shields while operating

your snow thrower or performing any ad just ments or repairs. We recommend standard safe ty glasses or a wide vision safety mask worn over spectacles.

HOW TO USE YOUR SNOW THROWER

Know how to operate all controls before adding fuel or

attempting to start the engine.

STOPPING

TRACTION DRIVE

• Release traction drive control lever to stop the forward

or reverse movement of the snow thrower.

AUGER

• Release the auger control lever to stop throwing snow.

ENGINE

1. Move ON / OFF switch to “OFF” position.

2. Remove (do not turn) safety ignition key to prevent

unauthorized use.

NOTE: Never use choke to stop engine.

TO USE FUEL SHUT-OFF VALVE (See Fig. 9)

The fuel shut-off valve is located beneath the fuel tank on the engine. Always op er ate the snow thrower with the fuel shut-off valve in the OPEN position.

TO CONTROL SNOW DISCHARGE (See Figs. 11 & 12)

WARNING: If the discharge chute or au ger become clogged, shut-off en gine and wait for all moving parts to stop. Use the clean-out tool, NOT YOUR HANDS, to un clog the chute and/or auger.

The DIRECTION in which snow is to be thrown is controlled by the discharge chute control lever.

• To change the discharge chute position, press down ward on discharge chute control lever and move lever left or right until chute is in desired position. Be sure lever springs back and locks into desired position.

DISCHARGE CHUTE

CONTROL LEVER

OFF

OPEN

FIG. 9

TO USE CHOKE CON TROL (See Fig. 10)

The choke con trol is located on the en gine. Use the choke control when ev er you are starting a cold en gine. Do not use to start a warm en gine.

• To engage choke, move lever to “FULL” position.

FULL OFF

FIG. 10

FIG. 11

The DISTANCE that snow is thrown is controlled by the position of the chute deflector. Set the deflector low to throw snow a short distance; set the deflector higher to throw snow farther.

• To change the deflector position, loosen knob, move deflector to desired position and tighten knob securely.

HIGH

POSITION

KNOB

CHUTE DEFLECTOR LOW POSITION

FIG. 12

OPERATION

TO THROW SNOW (See Fig. 13)

The auger rotation is controlled by the auger control lever located on the right side handle.

• Squeeze auger control lever to handle to engage the auger and throw snow.

• Release the auger control lever to stop throwing snow.

AUGER CONTROL LEVER

FIG. 13

USING THE CLEAN-OUT TOOL (See Fig. 14)

In certain snow conditions, the discharge chute may become clogged with ice and snow. Use the clean-out tool to dislodge this blockage.

When cleaning, repairing, or in spect ing, make certain all controls are disengaged and the auger/impeller and all moving parts have stopped. Disconnect the spark plug wire and keep the wire away from the spark plug to prevent accidental starting.

• Release the auger control lever and shut off the engine.

• Remove the clean-out tool from it's mounting clip. Grasp the tool firmly by the handle and push and twist the tool into the discharge chute to dislodge the blockage.

After the packed snow has been dislodged, return the cleanout tool to it's mounting clip by pushing it into the clip.

• Make sure the discharge chute is pointed in a safe direction (no vehicles, buildings, people, or other objects are in the direction of discharge) before restarting engine.

• Restart the engine, then squeeze the auger control lever to the handle to clear snow from the auger housing and the discharge chute.

DISCHARGE CHUTE

TO MOVE FORWARD AND BACKWARD (See Fig. 15)

SELF-PROPELLING, forward and reverse movement of the snow thrower, is controlled by the traction drive control lever located on the left side handle.

• Squeeze traction drive control lever to handle to en gage the drive system.

• Release traction drive control lever to stop the forward or reverse movement of the snow thrower.

SPEED and DIRECTION are controlled by the drive speed control lever.

• Press downward on the speed control lever and move lever to de sired po si tion BE FORE engaging the trac tion drive control lever. Be sure lever springs back and locks into desired position.

CAUTION: Do not move speed con trol le ver when traction drive control lever is en gaged. Damage to the snow thrower can result.

• Slower speeds are for heavier snow and faster speeds are for light snow and transporting the snow thrower. It is recommended that you use a slower speed until you are familiar with the operation of the snow thrower.

NOTE: When both traction drive and auger control levers are engaged, the traction drive control lever will lock the auger control lever in the engaged position. This will allow you to release your right hand from the handle and adjust the discharge chute direction without interrupting the snow throwing process.

TRACTION DRIVE CONTROL LEVER

DRIVE SPEED CONTROL LEVER

FIG. 15

CLEAN-OUT TOOL

MOUNTING CLIP

FIG. 14

OPERATION

TO ADJUST SKID PLATES (See Fig. 16) NOTE: The wrench provided in your parts bag may be

used to adjust the skid plates.

Skid plates are located on each side of the auger housing and adjust the clearance between the scraper bar and the ground surface. Adjust skid plates evenly to proper height for current surface conditions. For removal of snow in normal con di tions, such as a paved driveway or side walk, place skid plates in the highest position (lowest scraper clear ance) to give a 1/8" clearance between the scraper bar and the ground. Use a middle position if the surface to be cleared is uneven.

NOTE: It is not recommended to operate the snow thrower over gravel or rocky surfaces. Objects such as gravel, rocks or other debris, can easily be picked up and thrown by the impeller, which can cause serious personal injury, property dam age or damage to the snow thrower.

• If snow thrower must be operated over gravel surface, use extra caution and be sure skid plates are adjusted to lowest (highest scraper clear ance) position.

1. Shut off engine and wait for all moving parts to stop.

2. Adjust skid plates by loosening the hex nuts, then moving skid plate to desired position. Be sure both plates are adjusted evenly. Tighten securely.

HIGH POSITION (LOW GROUND CLEARANCE)

AUGER

HOUSING

HEX NUTS

SCRAPER BAR

SKID PLATE

ADD GASOLINE (See Fig. 17)

• Fill fuel tank to bottom of tank filler neck. Do not overfill. Use fresh, clean, regular unleaded gasoline with a minimum of 87 octane. Do not mix oil with gasoline. Purchase fuel in quan ti ties that can be used within 30 days to assure fuel freshness.

WARNING: Wipe off any spilled oil or fuel. Do not store, spill or use gasoline near an open flame.

CAUTION: Alcohol blended fuels (called gas o hol or using ethanol or methanol) can attract moisture which leads to separation and for ma tion of acids dur ing storage. Acidic gas can damage the fuel system of an engine while in storage. To avoid engine problems, the fuel system should be emptied be fore stor age of 30 days or longer. Empty the gas tank, start the engine and let it run until the fuel lines and carburetor are empty. Use fresh fuel next season. See Storage In struc tions for ad di tion al information. Never use engine or car bu re tor cleaner products in the fuel tank or per ma nent damage may occur.

ON / OFF SWITCH

CHOKE CONTROL

RECOIL (AUXILIARY) STARTER HANDLE

GAS O LINE FILLER CAP

ENGINE OIL FILL

CAP / DIPSTICK

LOW POSITION (HIGH GROUND CLEAR ANCE)

FIG. 16

SCRAPER BAR (See Fig. 16)

The scraper bar is not adjustable, but is reversible. After con sid er able use it may become worn. When it has worn almost to the edge of the housing, it can be reversed, providing additional service before requiring replacement. Replace a dam aged or worn scrap er bar.

BEFORE STARTING THE ENGINE

CHECK ENGINE OIL LEVEL (See Fig. 17)

The engine on your snow thrower has been shipped from the factory already filled with oil.

1. Check engine oil with snow thrower on level ground.

2. Remove oil fill cap/dipstick and wipe clean, reinsert the dipstick and screw tight, wait for a few seconds, remove and read oil level. If necessary, add oil until “FULL” mark on dipstick is reached. Do not overfill.

• To change engine oil, see “TO CHANGE ENGINE OIL” in the Main te nance sec tion of this manual.

STARTER

BUTTON

SAFETY IG NI TION KEY

PRIM ER

POWER

CORD

FUEL SHUT-OFF VALVE

NOTE: ALL ITEMS ARE SHOWN IN THEIR TYPICAL LOCATION.

ACTUAL LOCATION MAY VARY WITH ENGINE ON YOUR UNIT.

FIG. 17

PLUG

OPERATION

TO START ENGINE

• Be sure fuel shut-off valve is in the “OPEN” position.

Your snow thrower engine is equipped with both a 120 Volt A.C. electric starter and a recoil starter. The electric starter is equipped with a three-wire power cord and plug and is designed to operate on 120 Volt A.C. household current.

• Be sure your house is a 120 Volt A.C. three-wire ground ed system. If you are uncertain, consult a li censed electrician.

WARNING: Do not use the electric start er if your house is not a 120 Volt A.C. three-wire grounded system. Se ri ous per son al injury or damage to your snow thrower could result.

COLD START - ELECTRIC STARTER

1. Insert safety ignition key (tied to recoil start cord) into ignition slot until it clicks. DO NOT turn the key. Keep the extra safety ignition key in a safe place.

2. Place ON / OFF switch in “ON” position.

3. Move choke control to “FULL” position.

4. Connect the power cord to the engine.

5. Plug the other end of the power cord into a three-hole grounded 120 Volt A.C. receptacle.

NOTE: Do not use primer when start ing en gine with the electric starter.

6. Push starter button until engine starts.

IMPORTANT: Do not crank engine more than five con tin u ous seconds between each time you try to start. Wait 5 to 10 seconds between each attempt.

7. When the engine starts, release the starter button and slowly move the choke control to the “OFF” position.

8. Disconnect the power cord from the receptacle first, then from the engine.

Allow the engine to warm up for a few minutes. Engine will not develop full power until it has reached normal operating temperature.

WARM START - ELECTRIC STARTER

Follow the steps above, keeping the choke control in the “OFF” position.

COLD START - RECOIL STARTER

1. Insert safety ignition key (tied to recoil start cord) into ignition slot until it clicks. DO NOT turn the key. Keep the extra safety ignition key in a safe place.

2. Place ON / OFF switch in “ON” position.

3. Rotate choke control to “FULL” position.

4. Push the primer four (4) times if the temperature is below 15°F, or two (2) times if temperature is between 15° and 50°F. If temperature is above 50°F, priming is not nec es sary.

NOTE: Over priming may cause flooding, preventing the engine from starting. If you do flood the engine, wait a few minutes be fore at tempt ing to start and DO NOT push the primer.

5. Pull recoil starter handle quickly. Do not allow starter rope to snap back.

6. When the engine starts, release the recoil starter han dle and slowly move the choke control to the “OFF” position.

Allow the engine to warm up for a few minutes. Engine will not develop full power until it has reached normal operating temperature.

WARM START - RECOIL STARTER

Follow the steps above, keeping the choke in the “OFF” position. DO NOT push the primer.

BEFORE STOPPING

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

IF RECOIL STARTER HAS FROZEN

If the recoil starter has frozen and will not turn the engine, proceed as follows:

1. Grasp the recoil starter handle and slowly pull as much rope out of the starter as possible.

2. Release the recoil starter handle and let it snap back against the starter.

If the engine still fails to start, repeat the above steps or use the electric starter.

SNOW THROWING TIPS

• Go slower in deep, freezing or heavy wet snow. Use the drive speed control, NOT the ON / OFF switch, to adjust speed.

• It is easier and more efficient to remove snow im me di ate ly after it falls.

• The best time to remove snow is the early morning. At this time the snow is usually dry and has not been exposed to the direct sun and warming tem per a tures.

• Slightly overlap each successive path to ensure all snow will be removed.

• Throw snow downwind whenever possible.

• Ad just the skid plates to proper height for current snow con di tions. See “TO ADJUST SKID PLATES” in this section of this manual.

• For extremely heavy snow, re duce the width of snow removal by over lap ping previous path and moving slowly.

• Keep engine clean and clear of snow during use. This will help air flow and extend engine life.

• After snow-throwing is completed, allow engine to run for a few minutes to melt snow and ice off the engine.

• Clean the entire snow thrower thoroughly after each use and wipe dry so it is ready for next use.

WARNING: Do not operate snow thrower if weather conditions im pair visibility. Throwing snow dur ing a heavy, windy snowstorm can blind you and be hazardous to the safe operation of the snow thrower.

MAINTENANCE

The warranty on this snow thrower does not cover items that have been sub ject ed to operator abuse or negligence. To receive full value from the warranty, operator must maintain snow thrower as in struct ed in this manual. Some ad just ments will need to be made periodically to properly maintain your snow thrower.

At least once a season, check to see if you should make any of the adjustments described in the Service and Ad just ments section of this manual.

• At least once a year, you should replace the spark plug and check belts for wear. A new spark plug will help your engine run better and last longer.

• Follow the maintenance schedule in this manual.

NOTE: Use only Original Equipment Manufacturer (OEM) parts to service this unit. Failure to do so can cause the unit to malfunction and pose a risk of injury to the operator.

LUBRICATION CHARTGENERAL REC OM MEN DA TIONS

➀ SAE 30 Motor Oil

See “ENGINE” in

➁

Maintenance section

General

➂

Purpose Grease

➀ Pivot points

BEFORE EACH USE

1. Check engine oil level.

2. Check for loose fasteners.

3. Check controls to be sure they are functioning properly.

LUBRICATION

Keep your snow thrower well lubricated (See “LU BRI CA TION CHART”).

SNOW THROWER

Always observe the safety rules when performing any main te nance.

TIRES

• Maintain proper air pressure in both tires (14–17 P.S.I.).

➁ Engine

➂ Auger

grease fittings

• Keep tires free of gasoline and oil, which can harm rubber.

NOTE: To seal tire punctures and prevent flat tires due to slow leaks, tire sealant may be purchased from your local parts dealer. Tire sealant also prevents tire dry rot and cor ro sion.

oil

MAINTENANCE

BELTS

Check belts for deterioration and wear after every 50 hours of operation and replace if necessary. The belts are not ad just able. Replace belts if they begin to slip from wear. (See “TO REMOVE BELT COVER” in the Service and Adjustments section of this manual).

The belts on your snow thrower are of special con struc tion and should be replaced by original equipment man u fac tur er (OEM) belts avail able from your nearest dealer. Using other than OEM belts can cause personal injury or damage to the snow thrower.

AUGER GEAR CASE

• The gear case was filled with lubricant to the proper level at the factory. The only time the lubricant needs attention is if service has been performed on the gear case.

• If lubricant is required, use only Ronex ED #1 grease.

TRACTION DRIVE SYSTEM

DO NOT lubricate the drive components inside the snow thrower. The sprockets, hex shafts, drive disc and friction wheel require no lubrication. The bearings and bushings are lifetime lubricated and require no maintenance.

CAUTION: Any lubricating of the above com po nents can cause contamination of the friction wheel and damage to the drive system of your snow thrower.

ENGINE

See engine manual.

LUBRICATION

Use only high quality detergent oil rated with API service classification SG–SL. Select the oil's SAE viscosity grade according to your expected operating temperature.

TO CHANGE ENGINE OIL

Determine temperature range anticipated before next oil change. All oil must meet API service classification SG–SL.

• Be sure snow thrower is on level surface.

• Oil will drain more freely when warm.

• Catch oil in a suitable container.

NOTE: The left side wheel may be removed from snow thrower for easier access to the oil drain plug and place ment of a suitable container. The unit tilted, resting on the frame with the left wheel removed, will help drain any oil trapped inside the engine. (See “TO REMOVE WHEELS” in the Service and Adjustments section of this manual).

1. Remove safety ignition key and disconnect spark plug wire from spark plug and place wire where it cannot come in contact with plug.

2. Clean area around drain plug.

3. Remove drain plug and drain oil in a suitable container.

4. Install drain plug and tighten securely.

5. Wipe off any spilled oil from snow thrower and engine.

6. Install left wheel (if removed for draining oil). Be sure to install wheel pin and retainer pin into proper hole in wheel axle (See “TO REMOVE WHEELS” in the Service and Adjustments section of this manual).

7. Remove oil fill cap/dipstick. Be careful not to allow dirt to enter the engine.

8. Refill engine with oil through oil dipstick tube. Pour slowly. Do not overfill. For approximate capacity see “PRODUCT SPECIFICATIONS” section of this man u al.

9. Use gauge on oil fill cap/dipstick for checking level. Be sure dipstick cap is tightened securely for accurate reading. Keep oil at “FULL” line on dipstick.

10. Wipe off any spilled oil.

MUFFLER

Inspect and replace corroded muffler as it could cre ate a fire haz ard and/or dam age.

SPARK PLUG

Replace spark plug at the beginning of each season or after every 100 hours of operation, whichever occurs first. Spark plug type and gap setting are shown in the “PROD UCT SPEC I FI CA TIONS” section of this manual.

NOTE: Although multi-viscosity oils (5W30, 10W30 etc.) improve starting in cold weather, these multi-viscosity oils will result in increased oil consumption when used above 32°F. Check your engine oil level more frequently to avoid possible engine damage from running low on oil.

Change the oil after every 25 hours of operation or at least once a year if the snow thrower is not used for 25 hours in one year.

Check the crankcase oil level before starting the engine and after each five (5) hours of continuous use. Tighten oil fill cap / dipstick securely each time you check the oil level.

CLEANING

IMPORTANT: For best performance, keep snow thrower

housing free of any dirt or trash. Clean the outside of your snow thrower after each use.

WARNING: Remove safety ignition key and disconnect spark plug wire from spark plug. Place wire where it can not come in contact with spark plug.

• Keep finished surfaces/wheels free of gasoline, oil, etc.

• We do not recommend using a garden hose to clean your snow thrower unless the electrical system, muffler and carburetor are covered to keep water out. Water in engine can result in shortened engine life..

SERVICE AND ADJUSTMENTS

WARNING: To avoid serious injury, before performing any service or ad just ments:

1. Be sure the on/off switch is in the OFF position.

2. Remove safety ignition key.

3. Make sure the augers and all mov ing parts have completely stopped.

4. Disconnect spark plug wire from spark plug and place wire where it can not come in contact with plug.

SNOW THROWER

TO ADJUST SNOW THROWER HEIGHT

See “TO ADJUST SKID PLATES” and “SCRAPER BAR” in the Operation section of this manual.

CHUTE DEFLECTOR

The chute deflector, attached to the top of the discharge chute, is provided to direct discharging snow away from the operator. If the deflector becomes damaged, it should be re placed.

WARNING: To avoid serious injury, nev er operate your snow thrower with the deflector removed or damaged.

To replace the capscrew/shear bolts:

1. Disengage all controls and move throttle control to STOP position. Wait for all moving parts to stop.

2. Remove safety ignition key and disconnect spark plug wire from spark plug. Place wire where it cannot come in contact with spark plug.

3. Align holes in impeller hub with holes in impeller shaft and install two (2) new 1/4-20 x 1-5/8" capscrew/shear bolts. Install 1/4-20 locknuts and tighten securely.

CAUTION: Do not substitute. Use only original equip ment capscrew/shear bolts as sup plied with your snow thrower.

4. Insert safety ignition key and reconnect spark plug wire to spark plug.

1/4-20 LOCKNUT

1/4-20 x 1-5/8 CAPSCREW / SHEAR BOLT

IMPELLER HUB

IMPELLER

SHAFT

1/4-20 x 2

SHOULDER /

SHEAR BOLT

• To change direction and/or distance snow is dis charged, see “TO CONTROL SNOW DISCHARGE” in the Op er a tion section of this manual.

SHEAR BOLTS (See Fig. 18)

AUGER SHEAR BOLTS Both right and left-hand augers are secured to the auger

shaft with a shear bolt and hex nut. Should a foreign object or ice become lodged in the augers, the shear bolts are designed to break, preventing damage to any other com po nents. If one or both augers do not turn when auger control lever is engaged, check to see if one or both of the bolts have sheared. To replace the shear bolts:

1. Disengage all controls and move throttle control to STOP position. Wait for all moving parts to stop.

2. Remove safety ignition key and disconnect spark plug wire from spark plug. Place wire where it cannot come in contact with spark plug.

3. Align hole in auger hub with hole in auger shaft and install a new 1/4-20 x 2" shear bolt. Install 1/4-20 lock nut and tighten securely.

CAUTION: Do not sub sti tute. Use only original equip ment shear bolts as sup plied with your snow thrower.

4. Insert safety ignition key and reconnect spark plug wire to spark plug.

IMPELLER SHEAR BOLTS The impeller is secured to the impeller shaft with two (2)

capscrew/shear bolts and hex nuts. Should a foreign object or ice become lodged in the impeller, the capscrews are de signed to break, preventing damage to any other com po nents. If impeller does not turn when auger control lever is engaged, check to see if the capscrews have sheared.

1/4-20 LOCK NUT

AUGER HUB

FIG. 18

AUGER SHAFT

TO REMOVE BELT COVER (See Fig. 19)

1. Loosen the two (2) screws securing belt cover to frame.

2. Remove belt cover.

• Replace belt cover by installing cover and tightening screws.

SCREWSFRAME

FIG. 19

AUGER

HUB

BELT

COVER

SERVICE AND ADJUSTMENTS

TO REPLACE BELTS (See Fig. 20)

The auger and traction drive belts are not adjustable. If the belts are damaged or begin to slip from wear, they should be replaced. It is recommended that the belt(s) be replaced by a service center/department.

NOTE: It is recommended that both the auger and traction drive belt be replaced at the same time.

The V-belts on your snow thrower are of special con struc tion and should be replaced by original equipment man u fac tur er (OEM) belts avail able from your nearest service center/department. Using other than OEM belts can cause personal injury or damage to the snow thrower.

WARNING: Belt replacement requires separation of the snow thrower. While separating the auger housing from the frame assembly, it is important that an assistant stand in the operating po si tion and hold the snow thrower han dles. Serious personal injury and/ or damage to the unit could occur if the snow thrower should fall during the belt chang ing process.

FRAME ASSEMBLY

HANDLES

AUGER

HOUS ING

8. RELIEVE TENSION ON TRACTION DRIVE BELT IDLER and remove traction drive belt from around pulleys.

HINT: Insert a 3/8" drive ratchet (in the “ON” position) into the square hole in idler arm and rotate ratchet clockwise to relieve tension.

9. With tension relieved on idler, install new traction drive belt around pulleys and inside belt keepers.

10. Install clutch rod in swing plate; secure with hairpin.

11. Place auger belt around and inside the groove of auger pulley only.

12. While your assistant slowly raises handles to rejoin the auger hous ing and frame assembly, pull up on the auger belt and squeeze sides together above pulley so belt is fully seated in groove of pulley.

13. Move idler arm so it does not hit impeller pulley as you bring snow thrower completely together and check carefully for proper routing of belts. If auger belt has become dislodged from the pulley (by catching the idler arm bracket while bringing snow thrower together), separate the snow thrower and re peat step 12. Belt must be fully seated in pulley groove when bring ing the snow thrower together.

14. Install the two (2) hex bolts and tighten securely.

15. INSTALL ENGINE PULLEY - Place belt in pulley groove and slide pulley on crankshaft. Install flat washer, bolt and tighten securely (41-47 N-m torque). Make sure belt is inside belt keeper.

16. INSTALL BELT COVER and two (2) screws. Tighten securely.

17. INSTALL DISCHARGE CHUTE – See “INSTALL DIS CHARGE CHUTE / CHUTE ROTATER HEAD” in the As sem bly / Pre-Operation section of this manual.

1. REMOVE GASOLINE FROM FUEL TANK - Drain gasoline from fuel tank into a suitable container, out doors, away from fire or flame. Wipe up any spilled gasoline.

2. REMOVE DISCHARGE CHUTE - Loosen locknut se cur ing chute rotator head to mounting bracket only enough to allow chute rotator head to be raised and dis charge chute to be removed from snow thrower.

3. REMOVE BELT COVER - See “TO REMOVE BELT COVER” in this section of this manual.

4. REMOVE ENGINE PULLEY - Remove bolt, flat washer securing pulley to engine crankshaft. Remove outside (auger) pulley only from crank shaft.

5. SEPARATE SNOW THROWER - With your assistant standing in the operating position holding the handles, re move the two (2) bolts holding the auger housing and frame together.

WARNING: As the last bolt is removed, have your assistant carefully lower the han dles down to the ground.

6. REMOVE HAIRPIN FROM CLUTCH ROD and remove clutch rod from swing plate. Tip swing plate forward.

7. REMOVE AUGER BELT from around pulley.

IDLER ARM

SQUARE

HOLE

FRAME

TRACTION DRIVE BELT

CLUTCHING IDLER ARM BRACKET

AUGER PULLEY

BELT KEEPER

ENGINE PULLEY

FIG. 20

FLAT WASHER

BOLT

AUGER

BELT

AUGER

HOUSING

BOLTS

SERVICE AND ADJUSTMENTS

TO REMOVE WHEELS (See Fig. 21)

• Remove the wheel pin and retainer pin and remove wheel from axle.

IMPORTANT: When installing wheel, be sure to use the inner most hole in axle and the wheel hub hole. To disengage drive system from the wheels (for pushing or transporting the snow thrower) remove wheel pin and retainer pin from wheel hub and insert wheel pin and retainer into the outer hole in axle only.

NOTE: To seal punctures or prevent flat tires due to slow leaks, tire sealant may be purchased from your local parts dealer. Tire sealant also prevents tire dry rot and cor ro sion.

WHEEL PIN

RETAINER PIN

WHEEL

FIG. 21

OUTER HOLE

INNER

HOLE

WHEEL HUB

ENGINE

See engine manual.

CARBURETOR

Your carburetor is not adjustable. Engine performance should not be affected at altitudes up to 7,000 feet (2,134 meters). If your engine does not operate properly due to suspected carburetor problems, take your snow thrower to a qualified service center.

ENGINE SPEED

Never tamper with the engine governor, which is factory set for proper engine speed. Overspeeding the engine above the factory high speed setting can be dangerous and will void the warranty. If you think the engine-governed high speed needs adjusting, contact a qualified service center, which has proper equipment and experience to make any necessary ad just ments.

TO ADJUST CABLE TENSION (See Fig. 22)

Adjust cable tension by turning the adjuster turn buckle, located on the right hand cable. Grasp the long section tightly and turn the short section to lengthen the adjuster. Adjust until cable is snug.

ADJUSTER TURN

BUCKLE

FIG. 22

TO ADJUST TRACTION BELT AND AUGER BELT TENSION

If the traction or auger belt is slipping because it is not tight enough when engaged, the tension can be increased by adjusting the spring location in the control rod. Unhook the rod from the control lever and move the spring at the bottom of the rod one or two holes closer to the top of the rod. This effectively shortens the rod and increases the belt tension. (See "INSTALL AUGER CONTROL ROD" in the Assembly section of this manual.)

STORAGE

Immediately prepare your snow thrower for storage at the end of the season or if the unit will not be used for 30 days or more.

WARNING: Never store the snow thrower with gaso line in the tank in side a build ing where fumes may reach an open flame, spark or pilot light as on a fur nace, water heater, clothes dryer or gas ap pli ance. Allow the engine to cool be fore storing in any enclosure.

SNOW THROWER

When snow thrower is to be stored for a period of time, clean it thor oughly, re move all dirt, grease, leaves, etc. Store in a clean, dry area.

1. Clean entire snow thrower (See “CLEANING” in the Main te nance section of this manual).

2. Inspect and replace belts, if necessary (See “TO RE PL ACE BELTS” in the Service and Adjustments sec tion of this manual).

3. Lubricate as shown in the Main te nance sec tion of this man u al.

4. Be sure that all nuts, bolts, screws, and pins are securely fas tened. Inspect moving parts for damage, breakage and wear. Replace if nec es sary.

5. Touch up all rusted or chipped paint surfaces; sand lightly before painting.

ENGINE

See engine manual.

FUEL SYS TEM IMPORTANT: It is important to prevent gum deposits from

forming in essential fuel system parts such as carburetor, fuel hose, or tank during storage. Also, alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage.

• Empty the fuel tank by starting the engine and letting it run until the fuel lines and car bu re tor are empty.

• Never use engine or carburetor cleaner prod ucts in the fuel tank or permanent damage may occur.

• Use fresh fuel next season.

NOTE: Fuel stabilizer is an acceptable alternative in min i miz ing the formation of fuel gum deposits during stor age. Add stabilizer to gasoline in fuel tank or storage container. Always follow the mix ratio found on stabilizer container. Run engine at least 10 min utes after adding stabilizer to allow the stabilizer to reach the carburetor. Do not empty the gas tank and carburetor if using fuel stabilizer.

ENGINE OIL

Drain oil (with engine warm) and replace with clean engine oil. (See “ENGINE” in the Maintenance section of this man ual).

CYLINDER

1. Remove spark plug.

2. Pour one ounce (29 ml) of oil through spark plug hole into cylinder.

3. Pull recoil starter handle slowly a few times to dis trib ute oil.

4. Replace with new spark plug.

OTHER

• Remove safety ignition key; store it in a safe place.

• Do not store gasoline from one season to another.

• Replace your gasoline can if your can starts to rust. Rust and/or dirt in your gasoline will cause problems.

• If possible, store your snow thrower indoors and cover it to protect it from dust and dirt.

• Cover your snow thrower with a suitable pro tec tive cover that does not retain moisture. Do not use plastic. Plastic cannot breathe, which allows con den sa tion to form and will cause your snow thrower to rust.

IMPORTANT: Never cover snow thrower while engine/exhaust area is still warm.

TROUBLESHOOTING

See appropriate section in manual unless directed to an authorized service center/department.

PROBLEM CAUSE CORRECTION

Does not start 1. Fuel shut-off valve (if so 1. Turn fuel shut-off valve to OPEN position.

equipped) in OFF position.

2. Safety ignition key 2. Insert safety ignition key. is not inserted.

3. Out of fuel. 3. Fill fuel tank with fresh, clean gasoline.

4. Throttle in STOP position 4. Move throttle to FAST position (or ON/OFF switch is OFF). (or ON/OFF switch to ON position).

5. Choke in OFF position. 5. Move to FULL position.

6. Primer not depressed. 6. Prime as instructed in the Operation section of this manual.

7. Engine is flooded. 7. Wait a few minutes before restarting, DO NOT prime.

8. Spark plug wire is 8. Connect wire to spark plug. disconnected.

9. Bad spark plug. 9. Replace spark plug.

10. Stale fuel. 10. Empty fuel tank & carburetor, refill with fresh, clean gasoline.

11. Water in fuel. 11. Empty fuel tank & carburetor, refill with fresh, clean gasoline.

Loss of power 1. Spark plug wire loose. 1. Reconnect spark plug wire.

2. Throwing too much snow. 2. Reduce speed and width of swath.

3. Fuel tank cap is covered 3. Remove ice and snow on and around fuel tank cap. with ice or snow.

4. Dirty or clogged muffler. 4. Clean or replace muffler.

Engine idles or 1. Choke is in FULL position. 1. Move choke to OFF position. runs roughly 2. Blockage in fuel line. 2. Clean fuel line.

3. Stale fuel. 3. Empty fuel tank & carburetor, refill with fresh, clean gasoline.

4. Water in fuel. 4. Empty fuel tank & carburetor, refill with fresh, clean gasoline.

5. Carburetor is in need of 5. Contact an authorized service center/department. adjustment or overhaul.

Excessive 1. Loose parts or damaged 1. Tighten all fasteners. Replace damaged parts. If vibration vibration augers or impeller. remains, contact an authorized service center/department.

Recoil starter 1. Frozen recoil starter. 1. See “IF RECOIL STARTER HAS FROZEN” is hard to pull in the Operation section of this manual.

Loss of traction 1. Drive belt is worn. 1. Check / replace drive belt. drive / slowing 2. Drive belt is off of pulley. 2. Check / reinstall drive belt. of drive speed 3. Friction drive wheel is worn. 3. Contact an authorized service center/department.

Loss of snow 1. Auger belt is off of pulley. 1. Check / reinstall auger belt. discharge or 2. Auger belt is worn. 2. Check / replace auger belt. slowing of 3. Clogged discharge chute. 3. Clean snow chute. snow discharge 4. Augers / impeller jammed. 4. Remove debris or foreign object from augers / impeller.

REPAIR PARTS SNOW THROWER - - MODEL NUMBER 961940010 (96194001003) AUGER HOUSING / IMPELLER ASSEMBLY

NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm

IMPORTANT: Use only Original Equipment Manufacturer (O.E.M.) replacement parts.

Failure to do so could be hazardous, damage your snow thrower and void your warranty.

01.07.026-F

2 (EXPLODED)

REPAIR PARTS SNOW THROWER - - MODEL NUMBER 961940010 (96194001003) AUGER HOUSING / IMPELLER ASSEMBLY

KEY PART NO. NO. DESCRIPTION

1 532 18 41-05 IMPELLER 2 532 42 71-48 GEARBOX ASSEMBLY 3 532 18 89-09 BEARING 4 532 42 71-46 IMPELLER PULLEY 5 532 44 24-38 DISCHARGE BASE 6 532 18 40-95 CORNER BRACKET 7 532 19 21-99 CLEAN OUT TOOL 8 532 40 54-00 TOOL CLIP 9 873 80 04-00 NUT 1/4-20 10 874 78 04-26 SCREW 1/4-20 X .625 11 532 42 79-42 NUT 5/16-18 12 532 16 31-83 SCREW 5/16-18 X .625 13 532 42 71-45 IMPELLER HUB 14 532 42 71-54 IMPELLER SLEEVE 15 532 14 52-12 FLANGE NUT 3/8-16 16 532 18 03-55 CARRIAGE BOLT 17 532 19 41-89 SCREW 13-16 X .625 18 532 40 77-60 PLUG 19 532 42 73-02 GEARBOX COVER RH 20 532 42 73-45 GASKET 21 532 40 77-70 SEAL 22 532 40 77-62 BEARING 23 532 17 46-97 THRUST WASHER 1.00 24 532 40 77-63 WORM GEAR 25 532 40 77-64 AUGER SHAFT 26 532 18 92-82 SQUARE KEY 27 532 40 77-58 BEARING 28 532 17 46-83 THRUST WASHER 29 532 42 71-47 IMPELLER SHAFT 30 532 18 42-05 ROLL PIN 31 532 17 46-81 THRUST WASHER 32 532 17 46-84 THRUST BEARING 33 532 40 77-69 BEARING 34 532 40 77-68 O-RING 35 532 40 77-67 SCREW 5/16-18 X .750 36 532 42 73-17 GEARBOX COVER LH 37 532 19 20-90 SHEAR BOLT

NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm

IMPORTANT: Use only Original Equipment Manufacturer (O.E.M.) replacement parts.

Failure to do so could be hazardous, damage your snow thrower and void your warranty.

REPAIR PARTS SNOW THROWER - - MODEL NUMBER 961940010 (96194001003) AUGER HOUSING / IMPELLER ASSEMBLY

KEY PART NO. NO. DESCRIPTION

1 532 43 88-28 AUGER HOUSING 2 532 40 78-25 SCRAPER BAR 3 872 27 05-05 CARRIAGE BOLT 5/16−18 X .625 4 532 15 53-77 NUT 5/16−18

3 (5x)

4 (5x)

01.07.001-A

KEY PART NO. NO. DESCRIPTION

1 532 42 10-72 AUGER ASSEMBLY LH 24 2 532 42 10-73 AUGER ASSEMBLY RH 24

01.07.017-A

NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm

IMPORTANT: Use only Original Equipment Manufacturer (O.E.M.) replacement parts.

Failure to do so could be hazardous, damage your snow thrower and void your warranty.

REPAIR PARTS SNOW THROWER - - MODEL NUMBER 961940010 (96194001003) AUGER HOUSING / IMPELLER ASSEMBLY

01.07.024-B

KEY PART NO. NO. DESCRIPTION

1 532 42 04-78 AUGER BEARING 2 532 41 19-39 BEARING PLUG 3 532 17 95-82 SCREW 5/16−18 X 1.00

KEY PART NO. NO. DESCRIPTION

01.11.001-C

1 532 18 40-93 SKID PLATE LH 2 532 18 40-94 SKID PLATE RH 3 872 27 05-06 CARRIAGE BOLT 5/16−18 X .75 4 532 42 79-42 NUT 5/16−18

NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm

IMPORTANT: Use only Original Equipment Manufacturer (O.E.M.) replacement parts.

Failure to do so could be hazardous, damage your snow thrower and void your warranty.

REPAIR PARTS SNOW THROWER - - MODEL NUMBER 961940010 (96194001003) CONTROL PANEL / CHUTE

01.09.005-E

KEY PART NO. NO. DESCRIPTION

1 532 44 42-39 CHUTE WELDMENT 2 532 43 88-32 DEFLECTOR WELDMENT 3 532 42 03-25 DEFLECTOR SEAL 4 532 18 41-14 STRAP 5 532 44 50-19 KNOB BLACK 6 532 12 84-15 POP RIVET 7 532 18 56-00 SHOULDER BOLT 1/4−20 X .704 8 872 27 05-05 CARRIAGE BOLT 5/16−18 X .625 9 532 19 17-30 NUT 1/4−20 10 532 15 54-15 WASHER 11 532 17 92-46 PLASTIC WASHER 12 532 43 03-24 CHUTE SNOW SHIELD 13 532 42 17-28 SHIELD RETAINER STRAP

NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm

IMPORTANT: Use only Original Equipment Manufacturer (O.E.M.) replacement parts.

Failure to do so could be hazardous, damage your snow thrower and void your warranty.

REPAIR PARTS SNOW THROWER - - MODEL NUMBER 961940010 (96194001003) CONTROL PANEL / CHUTE

KEY PART NO. NO. DESCRIPTION

1 532 42 82-72 LEVER/CABLE ROTATOR ASSEMBLY 2 817 50 10-10 SCREW 10-24 X .625 *3 532 42 06-78 ROTATOR HEAD *4 532 40 59-32 ROTATOR PIVOT BRACKET *5 532 42 06-75 PULLEY PIVOT *6 532 42 82-73 CABLE ASSEMBLY ADJUSTABLE *7 532 42 83-10 CABLE ASSEMBLY HEAT SHIELD

01.09.010-B

NOTES:

1. ITEMS INDICATED WITH AN * ARE LISTED AS REFERENCE FOR SERVICE PARTS ONLY.

NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm

IMPORTANT: Use only Original Equipment Manufacturer (O.E.M.) replacement parts.

Failure to do so could be hazardous, damage your snow thrower and void your warranty.

REPAIR PARTS SNOW THROWER - - MODEL NUMBER 961940010 (96194001003) HANDLES

01.08.003-B

KEY PART NO. NO. DESCRIPTION

1 532 42 10-69 PLOW HANDLE LH 2 532 42 10-70 PLOW HANDLE RH 3 532 42 91-48 PANEL BRACKET LH 4 532 42 91-49 PANEL BRACKET RH 5 532 19 95-13 HANDLE GRIP 6 874 78 05-12 SCREW 5/16−18 X .750 7 874 78 05-24 SCREW 5/16−18 X 1.50 8 532 75 11-53 NUT 5/16−18 9 532 15 54-15 WASHER 10 532 05 38-47 WASHER

KEY PART NO. NO. DESCRIPTION

1 532 42 15-36 LOWER HANDLE 2 532 44 36-17 PIVOT SUPPORT WELDMENT 3 817 00 05-10 SCREW 5/16−18 X .750 4 817 00 06-16 SCREW 3/8−16 X 1.00 5 532 85 10-74 WASHER HARDENED

01.05.013-C

NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm

IMPORTANT: Use only Original Equipment Manufacturer (O.E.M.) replacement parts.

Failure to do so could be hazardous, damage your snow thrower and void your warranty.

REPAIR PARTS SNOW THROWER - - MODEL NUMBER 961940010 (96194001003) HANDLES

01.08.002-J

KEY PART NO. NO. DESCRIPTION

1 532 41 55-39 CONTROL PANEL 2 580 68 78-02 CONTROL LEVER LH 3 580 68 77-02 CONTROL LEVER RH 4 532 41 55-46 TRACTION ROD ARM 5 532 42 90-98 IMPELLER ROD ARM 6 532 41 26-77 INTERLOCK BAIL 7 532 42 16-13 SPACER 8 532 16 96-75 RETAINER 9 817 06 04-10 SCREW 1/4-20 X .62 10 532 41 42-80 KNOB BLACK 11 532 41 42-81 KNOB RED 12 532 17 88-99 HANDLE KNOB 13 819 13 13-16 WASHER 3/8 14 872 12 06-18 CARRIAGE BOLT 3/8-16 X 2.25

NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm

IMPORTANT: Use only Original Equipment Manufacturer (O.E.M.) replacement parts.

Failure to do so could be hazardous, damage your snow thrower and void your warranty.

REPAIR PARTS SNOW THROWER - - MODEL NUMBER 961940010 (96194001003) HANDLES

KEY PART NO. NO. DESCRIPTION

1 580 79 77-01 IMPELLER ROD ASSEMBLY

2 580 79 79-01 TRACTION ROD ASSEMBLY 3 532 18 04-45 SHIFTER ROD TOP 4 532 18 77-16 SHIFTER ROD BOTTOM 5 532 18 04-47 SPRING SLEEVE 6 580 79 62-01 SPRING CONTROL ROD 7 580 80 21-01 SPRING TRACTION ROD 8 872 27 05-05 CARRIAGE BOLT 5/16-18 X .750 9 532 15 53-77 NUT 5/16-18 10 532 16 96-75 RETAINER

01.12.010-A

NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm

IMPORTANT: Use only Original Equipment Manufacturer (O.E.M.) replacement parts.

Failure to do so could be hazardous, damage your snow thrower and void your warranty.

REPAIR PARTS SNOW THROWER - - MODEL NUMBER 961940010 (96194001003) HANDLES

KEY PART

01.10.003-D

NO. NO. DESCRIPTION

1 532 18 33-46 CONSOLE PANEL 2 532 17 86-68 HEADLIGHT BEZEL 3 532 18 09-27 FLOOD HEADLIGHT 4 532 18 44-71 SCREW 10−24 X .625 5 532 17 52-62 SCREW 10−24 X 1.25 6 532 44 50-29 WIRE HARNESS 7 532 18 37-84 BULB

KEY PART NO. NO. DESCRIPTION

1 532 41 62-88 INTERLOCK SPRING 2 532 44 52-91 INTERLOCK CAM 3 532 44 32-15 TORSION SPRING 4 532 16 96-75 RETAINER 5 817 06 04-10 SCREW 1/4−20 X .625 6 532 42 18-14 INTERLOCK STOP

01.08.007-D

NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm

IMPORTANT: Use only Original Equipment Manufacturer (O.E.M.) replacement parts.

Failure to do so could be hazardous, damage your snow thrower and void your warranty.

REPAIR PARTS SNOW THROWER - - MODEL NUMBER 961940010 (96194001003) DRIVE

ITEM 42 EXPLODED

53 7

11 53

IMPORTANT: Use only Original Equipment Manufacturer (O.E.M.) replacement parts.

Failure to do so could be hazardous, damage your snow thrower and void your warranty.

NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm

01.02.013-C

REPAIR PARTS SNOW THROWER - - MODEL NUMBER 961940010 (96194001003) DRIVE

KEY PART NO. NO. DESCRIPTION

1 532 19 88-75 SPEED SELECTOR ASSEMBLY 2 817 50 10-10 SCREW 10-24 X .625 3 532 43 88-37 END PLATE 4 817 49 05-08 SCREW 5/16-18 X .50 5 532 05 70-79 WASHER 6 532 40 54-85 CONTROL ARM 7 532 19 85-80 CLEVIS PIN 8 532 41 54-50 SHIFTER PLATE 9 532 40 28-81 SHOULDER BOLT 10 532 41 54-33 SHIFTER BRACKET 11 532 19 17-30 NUT 1/4-20 12 532 41 54-35 CLUTCH PLATE 13 532 41 68-64 CLUTCH BRACKET 14 532 18 71-01 SHIFTER LINK 15 532 70 02-79 RETAINER 16 532 42 75-42 CONTROL SHAFT 17 532 40 25-68 CLUTCH ROD 18 532 16 96-75 RETAINER 19 581 42 25-01 SHIFTER YOKE 20 532 40 23-10 PIVOT ROD 21 812 00 00-36 RETAINER 22 532 40 28-78 RETURN SPRING 23 532 75 11-53 NUT 5/16-18 24 532 40 89-81 BEARING 25 873 93 05-00 NUT 5/16-18 26 532 19 95-09 RUBBER WHEEL PLATE 27 532 44 06-20 RUBBER RING

KEY PART NO. NO. DESCRIPTION

28 532 17 53-44 BEARING 29 532 17 86-13 WHEEL HUB 30 874 76 05-14 SCREW 5/16-18-.875 31 812 00 00-12 RETAINER RING 32 532 40 21-87 SPROCKET SHAFT 33 532 40 16-19 CHAIN 34 532 43 73-03 SPROCKET WELDMENT 35 532 41 54-29 SHIFTER BRACKET 36 532 18 01-35 SPRING 37 532 40 26-52 PLATE PIVOT ROD 38 532 42 82-88 E-RING .375 39 532 18 44-71 SHOULDER SCREW 40 532 41 08-77 BOTTOM PAN 41 532 41 66-82 SPRING BRACKET 42 532 40 26-89 DRIVE PLATE ASSEMBLY 43 532 41 45-57 IDLER SPRING 44 532 17 88-28 IDLER SPRING 45 532 40 25-04 PULLEY SHAFT 46 532 40 18-20 DRIVE PLATE 47 532 19 87-91 BEARING 48 532 40 23-93 PULLEY HALF 49 817 54 10-08 SCREW 10-24 X .50 50 532 40 25-11 SPACER BEARING 51 532 42 29-41 SWING PLATE 52 532 13 20-10 NUT 3/8-16 53 532 42 88-67 SCREW 5/16-18 X .750 54 817 00 05-10 BOLT 5/16-18 X .625

NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm

IMPORTANT: Use only Original Equipment Manufacturer (O.E.M.) replacement parts.

Failure to do so could be hazardous, damage your snow thrower and void your warranty.

REPAIR PARTS SNOW THROWER - - MODEL NUMBER 961940010 (96194001003) DRIVE

01.03.005-C

KEY PART NO. NO. DESCRIPTION

1 532 18 82-26 AXLE ASSEMBLY (assy of 1a,1b) 1a 532 17 93-52 AXLE SHAFT 1b 532 18 42-06 ROLL PIN 3/16 2 532 40 26-91 SPROCKET 3 532 44 49-49 THRUST WASHER 4 532 17 98-30 BEARING 5 817 49 05-08 BOLT 5/16−18 X .500 6 532 17 12-71 PIN 7 532 18 92-82 SQUARE KEY 8 532 12 47-88 RETAINER PIN

NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm

IMPORTANT: Use only Original Equipment Manufacturer (O.E.M.) replacement parts.

Failure to do so could be hazardous, damage your snow thrower and void your warranty.

REPAIR PARTS SNOW THROWER - - MODEL NUMBER 961940010 (96194001003) CHASSIS / ENGINE / PULLEYS

KEY PART

01.00.034-A

NO. NO. DESCRIPTION

- - 580 42 60-01 COMPLETE LCT ENGINE PW2HK18650178E 1 532 43 88-40 FRAME 2 532 15 04-06 BOLT 3/8-16 3 532 42 88-67 SCREW 5/16-18 X .750

KEY PART NO. NO. DESCRIPTION

1 532 43 88-42 ENGINE MOUNTING PLATE

01.01.004-A

KEY PART NO. NO. DESCRIPTION

1 532 44 30-30 COVER ASSEMBLY

01.21.013-C

NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm

IMPORTANT: Use only Original Equipment Manufacturer (O.E.M.) replacement parts.

Failure to do so could be hazardous, damage your snow thrower and void your warranty.

REPAIR PARTS SNOW THROWER - - MODEL NUMBER 961940010 (96194001003) CHASSIS / ENGINE / PULLEYS

01.21.003-D

KEY PART NO. NO. DESCRIPTION

1 532 40 80-07 IMPELLER BELT 2 532 41 97-44 TRACTION BELT 3 532 42 92-71 IDLER ARM BRACKET 4 532 18 05-23 IDLER PULLEY 5 532 42 65-89 NUT 5/16-18 6 874 78 05-24 SCREW 5/16-18 X 1 .50 7 532 42 92-70 IDLER BRACKET 8 817 00 05-10 SCREW 5/16-18 HEX 9 532 42 42-97 SHOULDER BOLT 5/16-18 X .500 10 532 75 11-53 NUT 5/16-18 NYLOCK 11 532 18 77-86 TRACTION IDLER ARM 12 532 18 05-22 TRACTION PULLEY 13 874 78 05-20 SCREW 5/16-18 X 1 .00

KEY PART NO. NO. DESCRIPTION

14 532 05 92-89 WASHER 15 873 80 05-00 NUT 5/16-18 16 532 85 10-84 SCREW 3/8-24 X 1.375 17 532 40 00-26 WASHER 18 532 42 64-91 PULLEY ENG IMPELLER 19 532 42 64-90 PULLEY ENG TRACTION 20 874 61 05-16 SCREW 5/16-18 X 1 .00 21 810 04 05-00 LOCKWASHER 5/16 22 532 15 54-52 BELT GUIDE 23 811 05 05-00 LOCKWASHER 5/16 24 532 17 53-31 IDLER BUSHING

NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm

IMPORTANT: Use only Original Equipment Manufacturer (O.E.M.) replacement parts.

Failure to do so could be hazardous, damage your snow thrower and void your warranty.

REPAIR PARTS SNOW THROWER - - MODEL NUMBER 961940010 (96194001003) WHEELS

KEY PART NO. NO. DESCRIPTION

1 532 43 70-83 WHEEL ASSEMBLY LH 2 532 43 70-84 WHEEL ASSEMBLY RH

01.06.018-A

NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm

IMPORTANT: Use only Original Equipment Manufacturer (O.E.M.) replacement parts.

Failure to do so could be hazardous, damage your snow thrower and void your warranty.

REPAIR PARTS SNOW THROWER - - MODEL NUMBER 961940010 (96194001003) BAG OF PARTS

01.14.004-B

01.14.009-B

KEY PART NO. NO. DESCRIPTION

1 532 19 85-63 POWER CORD 2 532 16 96-75 RETAINER PIN 3 532 42 91-12 WRENCH 4 873 80 06-00 LOCKNUT 3/8−16 5 819 13 13-16 WASHER 3/8 6 532 19 20-90 SHEAR BOLT 1/4−20 X 1−3/4 7 873 80 04-00 LOCKNUT 1/4−20

KEY PART NO. NO. DESCRIPTION

1 532 44 30-59 SAFETY IGNITION KEY KIT

KEY PART NO. NO. DESCRIPTION

1 532 18 04-45 SHIFTER ROD TOP 2 532 18 77-16 SHIFTER ROD BOTTOM 3 872 27 05-05 CARRIAGE BOLT 5/16-18 X .75 4 532 15 53-77 NUT 5/16-18

NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm

IMPORTANT: Use only Original Equipment Manufacturer (O.E.M.) replacement parts.

Failure to do so could be hazardous, damage your snow thrower and void your warranty.

REPAIR PARTS SNOW THROWER - - MODEL NUMBER 961940010 (96194001003) DECALS

KEY PART NO. NO. DESCRIPTION

1 532 18 10-37 DECAL, DANGER 3 532 18 10-35 DECAL, DANGER, DEFLECTOR 4 532 18 10-42 DECAL, DANGER 6 532 18 10-33 DECAL, INSTRUCTION 9 581 43 01-01 DECAL, CON RT SPD/LEV/PWST 11 581 43 01-02 DECAL, CON LT WD/DEF

- - 581 45 59-27 OWNER’S MANUAL, ENGLISH

- - 581 45 60-32 OWNER’S MANUAL, FRENCH

NOTE: All component dimensions given in U.S. inches. 1 inch = 25.4 mm

IMPORTANT: Use only Original Equipment Manufacturer (O.E.M.) replacement parts.

Failure to do so could be hazardous, damage your snow thrower and void your warranty.

SERVICE NOTES

LIMITED WARRANTY

The Manufacturer warrants to the original consumer purchaser that this product as manufactured is free from defects in materials and work man ship. For a period of two (2) years from date of purchase by the original consumer purchaser, we will repair or replace, at our option, without charge for parts or labor incurred in replacing parts, any part which we find to be defective due to materials or workmanship. This Warranty is subject to the following limitations and exclusions.

1. This warranty does not apply to the engine, transaxle/transmission components, battery (except as noted below) or components parts thereof. Please refer to the applicable manufacturer's warranty on these items.

2. Transportation charges for the movement of any power equipment unit or attachment are the responsibility of the pur chaser. Transportation charges for any parts submitted for replacement under this warranty must be paid by the purchaser unless such return is requested by the manufacturer.

3. Battery Warranty: On products equipped with a Battery, we will replace, without charge to you, any battery which we find to be defective in manufacture, during the first ninety (90) days of ownership. After ninety (90) days, we will exchange the Battery, charging you 1/12 of the price of a new Battery for each full month from the date of the original sale. Battery must be maintained in accordance with the instructions furnished.

4. The Warranty period for any products used for rental or commercial purposes is limited to 90 days from the date of original purchase.

5. This Warranty applies only to products which have been properly assembled, adjusted, operated, and main tained in ac cor dance with the instructions furnished. This Warranty does not apply to any product which has been subjected to alteration, misuse, abuse, improper assembly or installation, delivery damage, or to normal wear of the product.

6. Exclusions: Excluded from this Warranty are belts, blades, blade adapters, normal wear, normal adjustments, stan dard hardware and normal maintenance.

7. In the event you have a claim under this Warranty, you must return the product to an authorized service dealer.

Should you have any unanswered questions concerning this Warranty, please contact:

HOP Outdoor Products Customer Service Dept. 9335 Harris Corners Parkway Charlotte, NC 28269 USA

giving the model number, serial number and date of purchase of your product and the name and address of the authorized dealer from whom it was purchased.

THIS WARRANTY DOES NOT APPLY TO INCIDENTAL OR CONSEQUENTIAL DAMAGES AND ANY IMPLIED WAR RAN TIES ARE LIMITED TO THE SAME TIME PERIODS STATED HEREIN FOR OUR EXPRESSED WARRANTIES. Some areas do not allow the limitation of consequential damages or limitations of how long an implied Warranty may last, so the above limitations or exclusions may not apply to you. This Warranty gives you specific legal rights, and you may have other rights which vary from locale to locale.

This is a limited Warranty within the meaning of that term as defined in the Magnuson-Moss Act of 1975.

In Canada contact:

HOP 5855 Terry Fox Way Mississauga, Ontario L5V 3E4

08.09.12 SR Printed in the U.S.A.

PoulanPRO 96194001003 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual