Poulan PP521ES User Manual

IMPORTANT MANUAL Do Not Throw Away

OWNER'S MANUAL

MODEL NUMBER:

PP521ES

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.

WARNING:

SNOW THROWER

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.

Always Wear Eye Protection During Operation

532 44 36-08 Rev. 2 07.22.11 TH/SR Printed in the U.S.A.

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”.

Safe Operation Practices for Walk-Behind Snow Throwers

IMPORTANT: 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. Ensure the control bar is released before starting the engine.

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 engine. (c) Fill fuel tank outdoors with extreme care. Never fill

fuel tank indoors.

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 be-

come 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 i cals known to the State of Cal i for nia to cause can cer and birth defects or oth er re pro duc tive harm.

(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.

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

7. 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.

8. Let engine and machine adjust to outdoor temperatures before starting to clear snow.

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), 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. Remove key.

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 auger 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 auger blades and all moving parts have stopped. Remove key.

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 auger blades when snow thrower is transported or not in use.

14. Use only attachments and accessories approved by the manufacturer of the snow thrower.

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.

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.

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 (Figure 1).

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

PRODUCT MAINTENANCE LEVEL

MODEL

CATALOG

FOR SERVICE CALL 1-800-849-1297

ASSEMBLED IN U.S.A. Orangeburg, SC 29118

CONFORMS TO ANSI B71.3-2005 SAFETY STANDARDS

SERIAL

407435

Figure 1

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 manual.

Clearing a Clogged Discharge Chute

Hand contact with the rotating auger blades

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 auger blades have stopped rotating.

3. Always use a clearing tool at least 15 inches long.

PRODUCT SPECIFICATIONS

Gasoline Capacity 1.6 Quarts (1,5 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: 18 Ounces (0,53 Liters)

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

TABLE OF CONTENTS

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

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

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

SAFETY AND INSTRUCTIONAL DECALS ................. 4

SETUP........................................................................ 5-6

OPERATION ............................................................7-11

MAINTENANCE ..................................................... 12-16

STORAGE ................................................................... 17

TROUBLESHOOTING ................................................ 18

REPAIR PARTS ..................................................... 20-31

WARRANTY ................................................................ 32

KNOW YOUR SNOW THROWER

READ THIS OWNER'S MANUAL AND ALL SAFETY RULES BEFORE OPERATING YOUR SNOW THROWER. Com-

pare 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.

IMPORTANT: Safety and instruction decals are located near areas of potential danger. Replace damaged decals.

DANGER

OR WARNING

CHOKE

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.

Setup

Loose Parts

Use the chart below to verify that all parts have been shipped.

Procedure Description Qty. Use

No parts required – Unfold the handle.

Carriage bolts Flange nuts Washers Knob Chute Deflector

5 4 2 1 1 1

Install the discharge chute. Install the discharge chute. Install the discharge chute. Install the discharge chute.

1. Unfolding the Handle

Procedure

1. Loosen the two handle knobs and pull out the two handle bolts until you can move the handle freely and rotate the handle to the operating position (Figure 2).

Figure 2

1. Handle knobs 2. Handle bolt

2. Installing the Discharge Chute

5 Carriage bolts 4 Flange nuts 2 Washers 1 Knob 1 Chute 1 Deflector

Procedure

1. Install the chute deflector to the discharge chute using two screws, washers, nut and deflector knob (Figure 4).

2. Install the discharge chute to the chute base using three screws and nuts (Figure 4).

2. Tighten the handle knobs until they are snug (Figure 3).

Figure 3

Figure 4

1. Deflector

2. Carriage bolts

3. Flange nuts

IMPORTANT: Do not overtighten the flange nuts; otherwise you may damage the discharge chute.

4. Washer

5. Knob

6. Discharge chute

3. Filling the Engine with Oil

ENGINE

See engine manual.

LUBRICATION NOTE: SAE 10W30 or SAE 5W30 oil is acceptable for

use in cold temperatures if engine is difficult to start. 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.

1. Move the snowthrower to a level surface.

2. Clean around the dipstick (Figure 5). NOTE: Dipstick location may vary depending on engine

type.

3. Remove either side mounted filler cap dipstick or high oil fill dipstick and wipe it clean.

Product Overview

*11

Figure 6

Fill if oil is below “Add” on the

GLSVWLFN

Fill if oil is below letter “L” on the

¿OOHUFDS

Figure 5

1. Oil filler cap/dipstick

4. Insert the dipstick into the filler neck and turn clockwise until fully seated. Then remove the dipstick by turning it counter-clockwise.

5. Fill oil to "FULL" on dipstick with the recommended oil.

6. Securely screw in the oil filler cap/dipstick.

1. Discharge chute

2. Chute deflector handle

3. Fuel tank cap

4. Control bar

5. Recoil start handle

6. Primer

7. Choke lever

8. Electric-start button (if equipped)

9. Oil drain plug

10. Drive belt cover

*11. Oil fill cap/dipstick

12. Ignition key

13. Chute deflector

* Dipstick location may vary depending on engine type.

Operation

NOTE: Determine the left and right sides of the machine

from the normal operating position.

NOTE: For best results, purchase only the quantity of gasoline that you expect to use in 30 days. Otherwise, you may add fuel stabilizer to newly purchased gasoline to keep it fresh for up to 6 months.

Checking the Engine Oil

• Gasoline is extremely flammable and explosive. A fire or explosion from gasoline can burn you and others.

• To prevent a static charge from igniting the gasoline, place the container and/or snowthrower on the ground before filling, not in a vehicle or on an object.

• Fill the tank outdoors when the engine is cold. Wipe up spills.

• Do not handle gasoline when smoking or around an open flame or sparks.

• Store gasoline in an approved fuel container, out of the reach of children.

• Do not tip the snowthrower with fuel in the fuel tank.

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.

IMPORTANT: Know how to operate all controls before adding fuel or attempting to start the engine.

Filling the Fuel Tank

Fill the fuel tank with fresh unleaded gasoline (minimum 87 AKI octane rating) (Figure 7).

Level

1. Move the snowthrower to a level surface.

2. Clean around the dipstick (Figure 8). NOTE: Dipstick location may vary depending on engine

type.

3. Remove either side mounted filler cap dipstick or high oil fill dipstick and wipe it clean.

Fill if oil is below “Add” on the

GLSVWLFN

Fill if oil is below letter “L” on the

¿OOHUFDS

Figure 8

1. Oil filler cap/dipstick

4. Insert the dipstick into the filler neck and turn clockwise until fully seated. Then remove the dipstick by turning it counter-clockwise.

5. Fill oil to "FULL" on dipstick with the recommended oil.

6. Securely screw in the oil filler cap/dipstick.

NOTE: Running the engine with a low oil level can cause engine damage. Always check the engine oil before start up.

NOTE: Running the engine with too much oil may cause engine damage and excess smoke in the exhaust. Always check the engine oil level before start up.

Figure 7

IMPORTANT: Do not add oil to the gasoline. IMPORTANT: Do not use E85 blended fuels. This engine

is not E20/E30/E85 compatible. Alternative fuels with high alcohol content can cause hard starting, poor engine performance, and may cause internal engine damage.

Starting the Engine

1. Push key in (Figure 9).

Figure 9

1. Key

2. Move choke lever to left position (Figure 10).

3. Firmly push in the primer 2 times with your thumb, holding the primer in a for a second before releasing it each time (Figure 11).

Figure 11

1. Primer

NOTE: Remove your glove when you push in the primer so that air cannot escape from the primer hole.

IMPORTANT: It may not be necessary to use the primer or the choke if the engine has been running and is hot. Excessive priming may flood the engine and prevent it from starting.

4. Pull the recoil starter or if your snow thrower is equipped with an electric starter, connect an extension cord to the snow thrower and plug the other end into a threehole grounded 110 volt A.C. receptacle and push the electric-start button (Figure 12).

1. Choke lever

Figure 10

Figure 12

1. Electric start button

NOTE: Use an extension cord recommended for outdoor use that is not longer than 50 feet (15 m).

Engaging the Auger Blades

The electrical cord can become damaged, causing

a shock or fire.

Thoroughly inspect the electrical cord before plug-

ging it into a power source. If the cord is damaged, do not use it to start the snowthrower. Replace or repair the damaged cord immediately. Contact an Authorized Service Dealer for assistance.

To engage the auger blades, hold the control bar against the handle (Figure 14).

Figure 14

Figure 13

1. Recoil start handle

IMPORTANT: Run the electric starter no more than 10 times at intervals of 5 seconds on, then 5 seconds off. Running the electric starter extensively can overheat and damage it. If the engine does not start after this series of attempts, wait at least 40 minutes to allow the starter to cool before attempting to start it again. If the engine does not start after the second series of attempts, take the snowthrower to an Authorized Service Dealer for service.

NOTE: If you pull the recoil handle and feel no resistance, the starter may be frozen. Thaw out the starter before attempting to start the snowthrower.

5. While the engine is running, move the choke lever slowly to the right position.

6. Unplug the extension cord from the power source and the snowthrower (Figure 12).

Unplug the power cord whenever you are not start-

ing the snowthrower.

1. Control bar

Disengaging the Auger Blades

To disengage the auger blades, release the control bar (Figure 15).

Figure 15

1. Control bar

IMPORTANT: During initial operation there may be wear between the auger blades and the scraper bar. Maximum performance, both snow throwing and driving, occurs when there is zero clearance between these two parts (Figure 16).

During initial break-in period of the auger blades it

is normal for the auger blades to build up excessive heat if not operated in the snow.

Do not operate without snow or water for lubricating

the auger blades. This will cause excessive heat build up in the auger blades which could cause damage to the auger blades and scrapper bar.

Adjusting the Discharge Chute and Chute Deflector

To adjust the discharge chute, move deflector chute handle left or right to desired position (Figure 18).

Figure 16

1. Rub Area 2. Wear Areas

Stopping the Engine

To stop the engine, pull key out (Figure 17).

Figure 18

1. Chute deflector knob

2. Chute deflector

3. Chute handle

To raise or lower the angle of the chute deflector, loosen the chute deflector knob on the chute deflector and move the chute deflector up or down (Figure 18).

1. Key Figure 17

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