Troy-Bilt 500 User Manual

Operator’s Manual

500 series

Snowthrowers

IMPORTANT: Read safety rules and instructions

carefully before operating equipment.

MTD Products Ltd., P. O. BOX 1386, KITCHENER, ONTARIO N2G 4J1

Printed in U.S.A.

FORM NO

772C0708

(7/2004)

TABLE OF CONTENTS

Content Page

Customer Support 2 Important Safe Operation Practices 3 Setting Up Your SnowThrower 5 Operating Your Snow Thrower 8 Maintaining Your Snow Thrower 12

Content Page

Service & Ajustments 13 Off Season Storage 17 Trouble Shooting 18 Warranty 19 Illustrated Parts List 20

FINDING MODEL NUMBER

This Operator’s Manual is an important part of your new snow thrower. It will help you to assemble, prepare and maintain the unit for best performance. Please read and understand what it says.

Before you start assembling your new snow thrower, please locate the model plate on the equipment and copy the information from it in the space provided below. The information on the model plate is very important if you need help from our Customer Support Department or an authorized dealer.

• You can locate the model number by standing behind the unit in the operating position and looking down at the dash panel . A sample model plate is explained below. For future reference, please copy the model number and the serial number of the equipment in the space below.

Model Number Numéro de modèle

Serial Number Numéro de série

Copy the model number here:

XXX-XXXXXX

XXXXXXXXXXX

Copy the serial number here:

TROYBILT - CANADA KITCHENER, ON N2G 4J1

ENGINE INFORMATION

The engine manufacturer is responsible for all engine-related issues with regards to performance, power-rating, specifications, warranty and service. Please refer to the engine manufacturer’s Owner’s/Operator’s Manual packed separately with your unit for more information.

CALLING CUSTOMER SUPPORT

Please do NOT return the unit to the retailer from which it was purchased, without first contacting Customer Support.

If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenance of this unit, please call a Customer Support Representataive. 1-800-668-1238

Please have your unit’s model number and serial number ready when you call. See previous section to locate this information. You will be asked to enter the serial number in order to process your call.

SECTION 1: IMPORTANT SAFE OPERATION PRACTICES

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—heed its warning.

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 rules for safe operation 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 hands and feet and throwing 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 old to operate this

machine. Children 14 years old and over should read and understand the operation instructions and safety rules in this manual and should be trained and supervised by a parent.

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, helpers, 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

1. Thoroughly inspect the area where the equipment is to

be used. Remove all door mats, newspapers, sleds, boards, wires and other foreign objects which could be tripped over or thrown by the auger/impeller.

2. Always wear safety glasses or eye shields during

operation and while performing an adjustment or repair to protect your eyes. Throw n objects which ricochet can cause serious injury to the eyes.

3. 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.

4. Use a grounded extension cord and receptacle for all

units with electric start engines.

5. Adjust collector housing height to clear gravel or crushed

rock surfaces.

6. Disengage the control handle before starting the engine.

7. Never attempt to make any adjustments while engine is

running, except where specifically recommended in the operator’s manual.

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

9. 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.

Operation

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

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

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

4. Never operate with a missing or damaged discharge chute. 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.

G R A P H IC S S H E E T

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.

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 patter n to avoid discharge towards windows, walls, cars etc. To avoid 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 in reverse.

16. If the machine should start t o vibrate abnormally, st op the engine, disconnect the spark plug and ground it against the engine. Inspect thoroughly for damage. Repair any damage before starting and operating.

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

18. Never put your hand in the discharge or collector openings. Always use a clearing tool to unclog the discharge opening.

19. Use only attachments and accessories approved by the manufacturer.

20. If situations occur which are not covered in this manual, use care and good judgment. Call customer assistance for the name of your nearest servicing dealer.

Maintenance And Storage

1. Never tamper with safety devices. Check their proper operation regularly.

2. Disengage the control handle and stop 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 before cleaning, repairing, or inspecting.

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 (O.E.M.) parts only. “Use of parts which do not meet the original equipment specifications may lead to improper performance and compromise safety!”

6. Check controls 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.

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.

SECTION 2: SETTING UP YOUR SNOW THROWER

NOTE: The snow thrower is shipped with oil and

WITHOUT GASOLINE. After assembly, refer to separate engine manual for proper fuel and engine oil recommendations.

NOTE: This Operator’s Manual covers several models,

handle panels, lights and chute cranks are some features that may vary by model. Not all features referenced in this manual are applicable to all snowthrower models.

Unpacking

• Cut along corners of the carton and lay it down flat. Remove packing material.

• Remove any loose parts included with unit (i. e., operator’s manual, etc.).

• Roll unit out of carton. Check carton thor oughly for any remaining loose part.

Loose Parts

Your snow thrower has been assembled at the factory except the parts shipped loose in the carton. These are listed below.

a. Electric Start Cord (optional) b. Shear Pins and Cotter Pins

Handle Knob

Figure 1

Before Assembly

Disconnect spark p lug wire and ground it against the engine to prevent unintended starting.

NOTE: All references in this manual to the left or right

side of the snow thrower is from the operating position only. Exceptions, if any, will be specified.

Setting up the Snow Thrower

1. Raise the upper handle assembly in the direction shown in Figure 1. Align the upper handles with the lower handle.

2. Tighten two handle knobs firmly to secure the upper handle to the lower handles. See Figure 1.

3. Slide the shift rod connector down over the end of the lower shift rod. Tap the connector until it locks over the lower shift rod. See Figure 2.

NOTE: If the connector is not properly assembled, the

shift rod will pivot and changing speed or direction of the snow thrower will not be possible.

Chute Assembly (all models)

1. Apply a light lubricant (i.e. 3-in-1 oil) to the base of the chute assembly.

2. Place the chute assembly on the lip of the chute adapter. See Figure 3.

Connector Shift Rod

Figure 2

Chute Assembly

Figure 3

3. One end of each chute keepe r is already att ached to the chute flange. Pivot the free end of the chut e keeper to align it with the chute flange and push it till it snaps into position. See Figure 4. Repeat with remaining chute keepers.

Chute Assembly

Chute Keeper

Figure 4

chute assembly as shown in Figure 6, cables should be towards the operator.

4. Insert the clevis pin, earlier removed, through t he holes on the chute control box and chute support tube. Secure with the hairpin clip. See Figure 5.

For All Models without Engine Covers

1. Slip the cables, running from the chute to the handle panel into the cable guide located on top of the engine. See Figure 7 .

Cable Guide

For Models with 4 Way Chute Control Box

1. Pull the hairpin clip out of the clevis pin on the chute support tube. Save this hardware. See Figure 5.

Hairpin Clip

Chute Support

Tube

4 Way Chute

Control

Box

Clevis Pin

Figure 5

Cables

Short

Tube

Chute Support

Tube

Figure 7

Lamp Wire (optional)

1. Wrap the wire from the la mp down the right handle as shown in Figure 8 .

2. Plug wire into the alternator lead wire under the fuel tank. See Figure 8 inset.

Alternator Lead

Lamp Wire

NOTE: Wheels are omitted from illustration for clarity.

Figure 8

Chute Clean-Out Tool

1. The chute clean-out tool is fastened with a cable tie to the rear of the auger housing for shipping purposes. Cut the cable tie and remove the extension cord (optional) before operating the snow thrower.

Figure 6

2. Position the chute assembly so the chute opening is facing the front of the unit.

3. Place the chute control box on the short tube of the chute assembly and the chute support tube of the

Final Adjustments

After setting up your snow thrower, check the adjustments as instructed below and make any final adjustments necessary before operating the unit .

CAUTION: Perform the following test before operating the snow thrower for the first time and at th e start of each winter season. Failure to comply with these adjustment instructions may cause damage to the unit.

Auger Control Test

1. To check the adjustment of the auger control, push forward the left hand control until the rubber bumper is compressed. There should be slack in the cable.

2. Release the control. The cable should be straight. Make certain you can depress the auger control grip against the left handle completely.

WARNING: Do not over-tighten the cable.

Over-tightening may prevent the auger fro m disengaging and compromise the safety of the snow thrower.

• If adjustment is necessary, loosen the he x jam nut and rotate the coupling end of the cable (without turning the cable) counterclockwise to provide more slack.

3. Recheck the adjustment. Tighten jam nut against the cable when correct adjustment is re ached.

Coupling

8. If the wheels can still be turned when you engage the drive control, loosen the hex jam nut and rotat e the coupling end of the cable (without turning the cable) in one turn. Recheck the adjustment and repeat if needed.

9. Tighten the jam nut to secure the cable when correct adjustment is reached.

NOTE: For further details, refer to the Adjustment

section on page 16.

Skid Shoe

Locate the shave plate and the skid shoes in Figure

12. The space between this shave plate and the

ground can be adjusted. For close snow removal, place skid shoes in the low position. Use middle or high position when area to be cleared is uneven. It is not recommended that you operate this snow thrower on gravel as loose gravel can be easily picked up and thrown by the auger causing personal injury or damage to the snow thrower. If for some reason, you have to operate the snow thrower on gravel, keep the skid sh oe in the highest position for maximum clearance between the ground and the shave plate.

Some models are equipped with reversible skid shoes and may be turned over to increase their lifespan. See Figure 11.

Jam

Nut

Auger Cable

Figure 9

Drive Control & Shift Lever

1. Tip the snow thrower forward so that it rests on the auger housing.

2. Move the shift lever all the way forward to the sixth (6) position.

3. With the drive control lever released, spin the snow thrower wheels by hand. The wheels should turn; however, you may feel some resistance.

4. Engage the drive control. The wheels should no longer turn.

5. Now release the drive control and spin the wheels again.

6. Move the shift lever back to the fast reverse position and then all the way forw ard again. There should be no resistance in the shift lever and the wheels should turn.

7. If you face resistance when moving the shift lever or the wheels stop when they should not, loosen the lock nut on the traction drive cable and unthread the cable one turn.

High

IMiddle

Low

Hex Jam Nut

Skid Shoe

Figure 10- Standard Skid Shoe

Figure 11- Reversible Skid Shoe

1. Adjust skid shoes by loosening the four hex nuts (two on each side) and carriage bolts. Move skid shoes to desired position.

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

3. Retighten the hex jam nut and repeat all three tests to verify proper adjustment has b een achieved.

Tire Pressure (Pneumatic Tires)

The tires are over-inflated for shipping purposes. Check tire pressure and reduce to 15-20 psi.

NOTE: If the tire pressure is not equal in both tires, the

unit may pull to one side or the other.

SECTION 3: OPERATING YOUR SNOW THROWER

Know The Controls

Read this owner’s manual and safety rules before operating your sn ow thrower. Compare Figure 12 with your snow thrower to familiarize yourself with the location of various controls and adjustments. Maintain safety while learning about the controls and operating th e unit. Save this man ual for future reference.

Drive Control Shift Lever

Chute Control

Auger Contr o l

Headlight

Gas Tank

Chute Assembly

Chute Clean-Out Tool

Shave Plate

Auger

Wheel Steering Control

Skid Shoe

Figure 12

Drive Control/ Auger Control Lock

The drive control is located on the right handle. Squeeze down the traction cont rol to engage the whe el drive. Release to stop.

The drive control also locks the auger control so you can operate the chute crank 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 the traction control to stop the augers and wheel drive (the aug er control must also be released).

IMPORTANT:

changing speeds.

Always release the drive control before

Auger Control

The auger control is located on the left handle. Squeeze the auger control to engage the augers. Release to stop the snow throwing action. The drive control must also be released in order to stop the auger.

IMPORTANT:

adjust the auger control. Read and follow all instructions carefully and perform all adjustments to verify your snow thrower is operating safely and properly.

Refer to Auger Control Test on page 7 to

Ignition Key

The ignition key must be fully inserted in the switch before the unit will start. Remove key when snow thrower is not in use. Do not attempt to turn the key.

Discharge Chute

The angle of the discharge chute controls the distance that the snow is thrown. Tilt the discharge chute up for greater distance; tilt down for less distance.

Four Way Chute Control

This four-way control lever is meant to control the direction and distance of snow discharge from the chute. Press the button on the knob and pivot it left or right to rotate the chute to the direction that snow will be thrown. Tilt the lever forward or rearward to adjust the distance snow will be thrown.

Shift Lever

The shift lever is located in the center of the handle panel and is used to determine ground speed and direction of travel. It can be moved into any of eight positions.

IMPORTANT:

changing speeds. Forward: The snow thrower has six forward (F)

speeds. Position one (1) is the slowest and position six (6) is the fastest.

Reverse: The snow thrower has two reverse (R) speeds—R1 is the slower of the two.

Always release traction control before

Headlight

The headlight is on whenever the engine is running.

Chute Clean-Out Tool

The chute clean-out tool is designed to clear a clogged discharge chute. Refer to page 12 for instructions on how to properly use it.

WARNING: Never use your hand to clear a

clogged discharge chute. Shut off engine and remain behind handles until all moving parts have stopped before unclogging.

Wheel Steering Controls

The left and right wheel steering controls are located on the underside of the handles. Squeeze the right control to turn right; squeeze the left control t o turn left.

NOTE: Operate the snow thrower in open areas until

you are familiar with these controls.

Skid Shoe

The skid shoe position is determined by the condition of the ground from where snow has to be removed. Higher the snow level, lower will be the skid shoe level. Adjust it accordingly.

Stopping Snow Thrower

1. To stop the wheels, release the traction drive lever of the snow thrower.

2. To stop throwing snow, release the auger drive lever.

3. To stop the engine, push throttle control lever to OFF and pull out the ignition key. Do not turn key.

Before Starting

WARNING: Read, understand, and follow

all instructions and warnings on the machine and in this manual before operating.

Gas & Oil Fill-Up

Service the engine with gasoline and oil as instructed in the separate engine manual packed with your snow thrower. Read instructions carefully.

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.

Starting The Engine

WARNING: Be sure no one other than the

operator is standing near the sn ow thrower

while starting or operating. Do not operate this snow thrower unless the discharge chute assembly has been properly installed and is secured.

• Attach spark pl ug wire to spark plug. Make certain the metal loop on the end of the spark plug wire

+ 20 hidden pages