Troy-Bilt 5024 User Manual

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

OperatOr’s Manual

Two-Stage Snow Thrower — Storm 5024

WARNING

READ AND FOLLOW ALL SAFETY RULES AND INSTRUCTIONS IN THIS MANUAL

BEFORE ATTEMPTING TO OPERATE THIS MACHINE.

FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.

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

Printed In USA

Form No. 769-03576B

(December 3, 2007)

To The Owner

Thank You

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

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

All information in this manual is relative to the most recent
product information available at the time of printing. Review
this manual frequently to familiarize yourself with the unit, its
features and operation. Please be aware that this Operator’s
Manual may cover a range of product specifications for various
models. Characteristics and features discussed and/or illustrated
in this manual may not be applicable to all models. Troy-Bilt LLC
reserves the right to change product specifications, designs and
equipment without notice and without incurring obligation.

Table of Contents

Important Safe Operation Practices ..................... 3

Assembly & Set-Up .................................................. 6

Controls & Features ................................................10

Operation ................................................................13

1

This product has met the rigid safety standards of the Outdoor
Power Equipment Institute and an independent testing
laboratory. If you have any problems or questions concerning
the unit, phone a authorized Troy-Bilt service dealer or contact
us directly. Troy-Bilt’s Customer Support telephone numbers,
website address and mailing address can be found on this page.
We want to ensure your complete satisfaction at all times.

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

Maintenance & Adjustment .................................15

Service .....................................................................18

Troubleshooting .................................................... 22

Replacement Parts ................................................ 23

Record Product Information

Before setting up and operating your new equipment, please
locate the model plate on the equipment and record the
information in the provided area to the right. You can locate the
model plate by standing at the operator’s position and looking
at the lower, rear section of the frame. This information will
be necessary, should you seek technical support via our web
site, Customer Support Department, or with a local authorized
service dealer.

MOdel nuMber

serial nuMber

Customer Support

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

If you have difficulty assembling this product or have any questions regarding the controls, operation, or maintenance of
this unit, you can seek help from the experts. Choose from the options below:

Visit us on the web at www.troybilt.com

◊

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

◊

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

◊

2

Important Safe Operation Practices

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!

CALIFORNIA PROPOSITION 65

WARNING! Engine Exhaust, some of its constituents, and certain vehicle components

contain or emit chemicals known to State of California to cause cancer and birth defects
or other reproductive harm.

DANGER: This machine was built to be operated according to the safe operation practices in
this manual. As with any type of power equipment, carelessness or error on the part of the
operator can result in serious injury. This machine is capable of amputating fingers, hands,
toes and feet and throwing foreign objects. Failure to observe the following safety
instructions could result in serious injury or death.

2

Training

1.

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

2.

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

3.

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

4.

Never allow adults to operate this machine without proper
instruction.

5.

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

6.

Keep bystanders, 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

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

Always wear safety glasses or eye shields during operation

1.
and while performing an adjustment or repair to protect
your eyes. Thrown objects which ricochet can cause serious
injury to the eyes.

Do not operate without wearing adequate winter outer

2.
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.

Use a grounded three-wire extension cord and receptacle

3.
for all machines with electric start engines.

Adjust collector housing height to clear gravel or crushed

4.
rock surfaces.

Disengage all control levers before starting the engine.

5.
Never attempt to make any adjustments while engine is

6.
running, except where specifically recommended in the
operator’s manual.

Let engine and machine adjust to outdoor temperature

7.
before starting to clear snow.

3

Safe Handling of Gasoline

To avoid personal injury or property damage use extreme care
in handling gasoline. Gasoline is extremely flammable and the
vapors are explosive. Serious personal injury can occur when
gasoline is spilled on yourself or your clothes which can ignite.
Wash your skin and change clothes immediately.

Use only an approved gasoline container.

a.

Extinguish all cigarettes, cigars, pipes and other

b.

sources of ignition.
Never fuel machine indoors.

c.

Never remove gas cap or add fuel while the engine is

d.

hot or running.
Allow engine to cool at least two minutes before

e.

refueling.
Never over fill fuel tank. Fill tank to no more than ½

f.

inch below bottom of filler neck to provide space for
fuel expansion.

Replace gasoline cap and tighten securely.

g.

If gasoline is spilled, wipe it off the engine and

h.

equipment. Move machine to another area. Wait 5
minutes before starting the engine.

Never store the machine or fuel container inside

i.

where there is an open flame, spark or pilot light
(e.g. furnace, water heater, space heater, clothes
dryer etc.).

Allow machine to cool at least 5 minutes before

j.

storing.
Never fill containers inside a vehicle or on a truck

k.

or trailer bed with a plastic liner. Always place
containers on the ground away from your vehicle
before filling.

If possible, remove gas-powered equipment from

l.

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.

Keep the nozzle in contact with the rim of the fuel

m.

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

Operation

Do not put hands or feet near rotating parts, in the auger/

1.
impeller housing or chute assembly. Contact with the
rotating parts can amputate hands and feet.

The auger/impeller control lever is a safety device. Never

2.
bypass its operation. Doing so makes the machine unsafe
and may cause personal injury.

The control levers must operate easily in both directions

3.
and automatically return to the disengaged position when
released.

Never operate with a missing or damaged chute assembly.

4.
Keep all safety devices in place and working.

Never run an engine indoors or in a poorly ventilated area.

5.
Engine exhaust contains carbon monoxide, an odorless
and deadly gas.

Do not operate machine while under the influence of

6.
alcohol or drugs.

Muffler and engine become hot and can cause a burn. Do

7.
not touch. Keep children away.

Exercise extreme caution when operating on or crossing

8.
gravel surfaces. Stay alert for hidden hazards or traffic.

Exercise caution when changing direction and while

9.
operating on slopes.

Plan your snow-throwing pattern to avoid discharge

10.
towards windows, walls, cars etc. Thus, avoiding possible
property damage or personal injury caused by a ricochet.

Never direct discharge at children, bystanders and pets or

11.
allow anyone in front of the machine.

Do not overload machine capacity by attempting to clear

12.
snow at too fast of a rate.

Never operate this machine without good visibility or light.

13.
Always be sure of your footing and keep a firm hold on the
handles. Walk, never run.

Disengage power to the auger/impeller when transporting

14.
or not in use.

Never operate machine at high transport speeds on

15.
slippery surfaces. Look down and behind and use care
when backing up.

If the machine should start to vibrate abnormally, stop

16.
the engine, disconnect the spark plug wire and ground it
against the engine. Inspect thoroughly for damage. Repair
any damage before starting and operating.

Disengage all control levers and stop engine before you

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

Never put your hand in the discharge or collector

18.
openings. Always use the clean-out tool provided to
unclog the discharge opening. Do not unclog chute
assembly while engine is running. Shut off engine and
remain behind handles until all moving parts have stopped
before unclogging.

Use only attachments and accessories approved by the

19.
manufacturer (e.g. wheel weights, tire chains, cabs etc.).

When starting engine, pull cord slowly until resistance

20.
is felt, then pull rapidly. Rapid retraction of starter cord
(kickback) will pull hand and arm toward engine faster than
you can let go. Broken bones, fractures, bruises or sprains
could result.

If situations occur which are not covered in this manual, use

21.
care and good judgment. Contact Customer Support for
assistance and the name of your nearest servicing dealer.

4 sectiOn 2 — iMpOrtant safe OperatiOn practices

Maintenance & Storage

Never tamper with safety devices. Check their proper

1.
operation regularly. Refer to the maintenance and
adjustment sections of this manual.

Before cleaning, repairing, or inspecting machine

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

Check bolts and screws for proper tightness at frequent

3.
intervals to keep the machine in safe working condition.
Also, visually inspect machine for any damage.

Do not change the engine governor setting or over-speed

4.
the engine. The governor controls the maximum safe
operating speed of the engine.

Snow thrower shave plates and skid shoes are subject to

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

Check control levers periodically to verify they engage

6.
and disengage properly and adjust, if necessary. Refer
to the adjustment section in this operator’s manual for
instructions.

Maintain or replace safety and instruction labels, as

7.
necessary.

Observe proper disposal laws and regulations for gas, oil,

8.
etc. to protect the environment.

Prior to storing, run machine a few minutes to clear snow

9.
from machine and prevent freeze up of auger/impeller.

Never store the machine or fuel container inside where

10.
there is an open flame, spark or pilot light such as a water
heater, furnace, clothes dryer etc.

Always refer to the operator’s manual for proper

11.
instructions on off-season storage.

Check fuel line, tank, cap, and fittings frequently for cracks

12.
or leaks. Replace if necessary.

Do not crank engine with spark plug removed.

13.

Do not modify engine

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

Notice Regarding Emissions

Engines which are certified to comply with California and federal
EPA emission regulations for SORE (Small Off Road Equipment)
are certified to operate on regular unleaded gasoline, and
may include the following emission control systems: Engine
Modification (EM) and Three Way Catalyst (TWC) if so equipped.

Spark Arrestor

WARNING! This machine is equipped with an

internal combustion engine and should not be used
on or near any unimproved forest-covered, brush
covered or grass-covered land unless the engine’s
exhaust system is equipped with a spark arrester
meeting applicable local or state laws (if any).

If a spark arrester is used, it should be maintained in effective
working order by the operator. In the State of California the
above is required by law (Section 4442 of the California Public
Resources Code). Other states may have similar laws. Federal laws
apply on federal lands.
A spark arrester for the muffler is available through your
nearest engine authorized service dealer or contact the service
department, P.O. Box 361131 Cleveland, Ohio 44136-0019.

Average Useful Life

According to the Consumer Products Safety Commission
(CPSC) and the U.S. Environmental Protection Agency (EPA),
this product has an Average Useful Life of seven (7) years, or 60
hours of operation. At the end of the Average Useful Life, buy a
new machine or have the machine inspected annually by an
authorized service dealer to ensure that all mechanical and
safety systems are working properly and not worn excessively.
Failure to do so can result in accidents, injuries or death.

WARNING! Your Responsibility—Restrict the use of this power machine to persons who read, understand and

follow the warnings and instructions in this manual and on the machine.

SAVE THESE INSTRUCTIONS!

5sectiOn 2 — iMpOrtant safe OperatiOn practices

Assembly & Set-Up

Contents of Carton

One Snow Thrower• Two Replacement Auger Shear Pins• One Chute Assembly•

One Snow Thrower Operator’s

• One Product Registration Card•
Manual

Assembly

Handle

Place the shift lever in the forward-6 position.

1.
Observe the lower rear area of the snow thrower to be sure

2.
both cables are aligned with roller guides before pivoting
the handle upward. See Fig. 3-1.

3

Figure 3-1

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

Secure the handle by tightening the plastic knob located

2.
on both the left and right sides of the handle. Remove
and discard any rubber bands, if present. They are for
packaging purposes only.

Chute Assembly

Position the chute assembly over the base. See Fig. 3-2.

1.
Close the flange keepers to secure the chute assembly

2.
to the chute base. The flange keepers will click into place
when properly secure. See Fig. 3-3.

NOTE: If the flange keepers will not easily click into place,
use the palm of your hand to apply swift, firm pressure to
the back of each.

Figure 3-2

Figure 3-3

6

Chute Directional Control

A

B

Chute Clean-out Tool

Remove the plastic cap (if present), flat washer and hairpin

1.
clip from the end of the chute directional control. See Fig.
3-4.

Chute Clean-Out Tool

The chute clean-out tool is fastened to the top of the auger
housing with a mounting clip and a cable tie at the factory. Cut
the cable tie before operating the snow thrower. See Fig. 3-6.

Figure 3-4

Insert the end of the chute directional control into the

2.
lower bracket and secure with the flat washer and hairpin
clip just removed. If necessary, the lower bracket can be
adjusted. Refer to Chute Bracket Adjustment on Page 16.

Set-Up

Shear Pins

A pair of replacement auger shear pins and bow tie cotter pins
are included with your snow thrower. See Fig. 3-5 Store them in a
safe place until needed..

Figure 3-6

Tire Pressure

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

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

Fuel Recommendations

Use automotive gasoline (unleaded or low leaded to minimize
combustion chamber deposits) with a minimum of 87 octane.
Gasoline with up to 10% ethanol or 15% MTBE (Methyl Tertiary
Butyl Ether) can be used. Never use an oil/gasoline mixture or
dirty gasoline. Avoid getting dirt, dust, or water in the fuel tank.
DO NOT use E85 gasoline.

Refuel in a well-ventilated area with the engine stopped.

•
Do not smoke or allow flames or sparks in the area where
the engine is refueled or where gasoline is stored.

Do not overfill the fuel tank. After refueling, make sure the

•
tank cap is closed properly and securely.

Be careful not to spill fuel when refueling. Spilled fuel or

•
fuel vapor may ignite. If any fuel is spilled, make sure the
area is dry before starting the engine.

Avoid repeated or prolonged contact with skin or

•
breathing of vapor.

Figure 3-5

7sectiOn 3 — asseMbly & set-up

Adding Fuel

Fill
between
high
and low
marks

Fuel Level Indicator

Top View

WARNING! Use extreme care when handling

gasoline. Gasoline is extremely flammable and the
vapors are explosive. Never fuel the machine
indoors or while the engine is hot or running.
Extinguish cigarettes, cigars, pipes and other
sources of ignition.

WARNING! Always keep hands and feet clear of

equipment moving parts. Do not use a pressurized
starting fluid. Vapors are flammable.

Clean around fuel fill before removing cap to fuel.

1.
A fuel level indicator is located in the fuel tank. Fill tank

2.
until fuel reaches the fuel level indictor, Fig. 3-7. Be careful
not to overfill.

Figure 3-8

Replace and tighten cap/dipstick firmly before starting

4.
engine.

Adjustments

Figure 3-7

Checking Oil Level

CAUTION: The engine is shipped with oil in the

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

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

Remove the oil filler cap/dipstick and wipe the dipstick

1.
clean. See Fig. 3-8.

Insert the cap/dipstick into the oil filler neck, but do not

2.
screw it in.

Remove the oil filler cap/dipstick. If the level is low, slowly

3.
add oil until oil level registers between high (H) and low
(L), Fig. 3-8. Refer to the Engine Maintenance section for
correct oil viscosity and engine oil capacity.

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

8 sectiOn 3— asseMbly & set-up

Skid Shoes

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

CAUTION: It is not recommended that you operate

this snow thrower on gravel as it can easily pick up
and throw loose gravel, causing personal injury or
damage to the snow thrower and surrounding
property.

For close snow removal on a smooth surface, raise skid

•
shoes higher on the auger housing.

Use a middle or lower position when the area to be cleared

•
is uneven, such as a gravel driveway

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

To adjust the skid shoes:

Loosen the four hex nuts (two on each side) and carriage

1.
bolts. Move skid shoes to desired position. See Fig. 3-9.

Make certain the entire bottom surface of skid shoe is

2.
against the ground to avoid uneven wear on the skid
shoes.

Retighten nuts and bolts securely.

3.

Figure 3-9

Chute Assembly

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

Stop the engine by removing the ignition key and loosen

1.
the plastic knob found on the left side of the chute
assembly.

Pivot the chute upward or downward before retightening

2.
the wing knob. See Fig. 3-10.

Auger Control

WARNING! Prior to operating your snow thrower,

carefully read and follow all instructions below.
Perform all adjustments to verify your snow thrower
is operating safely and properly.

Check the adjustment of the auger control as follows:

1.

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

2.

In a well-ventilated area, start the snow thrower engine.
Refer to Starting the Engine on page 13. Make sure the
throttle is set in the FAST position.

3.

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

4.

Allow the auger to remain engaged for approximately ten
(10) seconds before releasing the auger control. Repeat this
several times.

5.

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

6.

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

7.

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

Figure 3-10

Figure 3-11

8.

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

9.

Retighten the upper hex nut.

10.

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

9sectiOn 3 — asseMbly & set-up

Recoil Starter

Handle

Oil Drain

Muer

Electric Start

Button

Electric Outlet

Primer

Ignition

Key

Throttle

Control

Choke

Control

Drive Control

Oil Fill

Chute Assembly

Gas Cap

Shift Lever

Auger Control

Chute Directional Control

Clean Out

Tool

Augers

Skid Shoe

Controls and Features

4

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

Shift Lever

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

Forward

There are six forward (F) speeds. Position one (1) is
the slowest and position six (6) is the fastest.

Reverse

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

Figure 4-1

Choke Control

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

Ignition Key

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

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

10

Throttle Control

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

Primer

Pressing the primer forces fuel directly
into the engine’s carburetor to aid in cold­weather starting.

Auger Control

Oil Fill

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

Oil Drain

Engine oil can be drained through the oil drain.

Muffler

Engine exhaust exists the engine via the muffler.

Skid Shoes

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

Electric Starter Outlet

Requires the use of a three-prong outdoor extension cord and a
120V power source/wall outlet.

Recoil Starter Handle

This handle is used to manually start the engine.

Electric Starter Button

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

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

Drive Control

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

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

Augers

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

Chute Assembly

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

Gas Cap

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

11sectiOn 4 — cOntrOls and features

Chute Directional Control

The chute directional control is located on left side of the snow
thrower. To change the direction in which snow is thrown, turn
chute directional control as follows:

Crank clockwise to discharge to the left.

•
Crank counterclockwise to discharge to the right.

•

Chute Clean-Out Tool

WARNING! Never use your hands to clear a

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

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

1.

Release both the Auger Control and the Drive Control.

2.

Stop the engine by removing the ignition key.

3.

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

4.

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

5.

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

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

12 sectiOn 4— cOntrOls and features

Operation

Starting the Engine

WARNING! Always keep hands and feet clear of

moving parts. Do not use a pressurized starting
fluid. Vapors are flammable.

NOTE: Allow the engine to warm up for a few minutes after

starting. The engine will not develop full power until it reaches
operating temperatures.

Electric Starter

WARNING! The electric starter is equipped with a

grounded three-wire power cord and plug, and is
designed to operate on 120 volt AC household
current. It must be used with a properly grounded
three-prong receptacle at all times to avoid the
possibility of electric shock. Follow all instructions
carefully prior to operating the electric starter.
DO NOT use electric starter in rain.

Determine that your home’s wiring is a three-wire

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

Insert ignition key fully into slot, Fig. 5-1. Make sure it snaps

2.
into place. DO NOT turn ignition key. The engine cannot
start unless the key is inserted into ignition switch.

Plug the extension cord into the electric outlet located

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

Figure 5-2

Move throttle control to FAST (rabbit) position.

4.
Move choke to the ON position (cold engine start). If

5.
engine is warm, place choke in OFF position.

Push primer three to five (3-5) times, making sure to cover

6.
vent hole when pushing. If engine is warm, push primer
only once. Always cover vent hole when pushing. Cool
weather may require priming to be repeated.

Push starter button to start engine. Once the engine

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

As the engine warms, slowly rotate the choke control to

8.
OFF position. If the engine falters, restart engine and run
with choke at half-choke position for a short period of time,
and then slowly rotate the choke into OFF position.

After engine is running, disconnect power cord from

9.
electric starter. When disconnecting, always unplug the
end at the wall outlet before unplugging the opposite end
from the engine.

5

Figure 5-1

13

Recoil Starter

CAUTION! Do not pull the starter handle while the

engine running.

WARNING: To avoid unsupervised engine

operation, never leave the engine unattended while
running. Turn the engine off after use and remove
ignition key

1.

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

2.

Move throttle control to FAST (rabbit) position.

3.

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

4.

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

5.

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

6.

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

To Engage Drive

1.

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

2.

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

To Engage Augers

1.

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

Replacing Shear Pins

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

CAUTION: NEVER replace the auger shear pins

with anything other than OEM Part No.738-04124A
replacement shear pins. Any damage to the auger
gearbox or other components as a result of failing to
do so will NOT be covered by your snow thrower’s
warranty.

WARNING! Always turn off the snow thrower’s

engine and remove the key prior to replacing shear
pins.

Stopping the Engine

WARNING: To avoid unsupervised engine

operation, never leave the machine unattended
with the engine running. Turn the engine off after
use and remove ignition key

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

1.

Move throttle control to STOP position.

2.

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

3.

Wipe any moisture away from the controls on the engine.

Figure 5-3

14 sectiOn 5— OperatiOn

r

Maintenance & Adjustments

6

Maintenance

Engine

Refer to the Engine Maintenance section.

Shave Plate and Skid Shoes

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

To remove skid shoes:

Remove the four carriage bolts and hex flange nuts which

1.
secure them to the snow thrower.

Reassemble new skid shoes with the four carriage bolts

2.
(two on each side) and hex flange nuts. Refer to Fig. 6-1.

Lubrication

Gear Shaft

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

Carefully pivot the snow thrower up and forward so that it

1.
rests on the auger housing.

Remove the frame cover from the underside of the snow

2.
thrower by removing four self-tapping screws which secure
it. Refer to Fig 7-3.

Apply a light coating of engine oil (or 3-in-1 oil) to the hex

3.
shaft. See Fig. 6-2.

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

Figure 6-1

To remove shave plate:

Remove the carriage bolts and hex nuts which attach it to

1.
the snow thrower housing.

Reassemble new shave plate, making sure heads of

2.
carriage bolts are to the inside of housing. Tighten
securely.

Tire Pressure

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

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

Figure 6-2

Wheels

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

Chute Directional Control

Once a season, lubricate the eye-bolt bushing and the spiral with
3-in-1 oil.

15

Auger Shaft

At least once a season, remove the shear pins from the auger
shaft. Spray lubricant inside the shaft and around the spacers
and the flange bearings found at either end of the shaft.
See Fig. 6-3.

Figure 6-3

Adjustments

Shift Cable

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

Place the shift lever in the fastest forward speed position.

1.
Loosen the hex nut on the shift cable index bracket. See

2.
Fig. 6-4.

Figure 6-4

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

3.
Retighten the hex nut.

4.

Auger Control

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

Chute Assembly

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

Skid Shoes

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

16 sectiOn 6— Maintenance & adjustMents

Drive Control

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

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

Check the adjustment of the drive control as follows:

With the drive control released, push the snow thrower

1.
gently forward. The unit should roll freely.

Engage the drive control and gently attempt to push the

2.
snow thrower forward. The wheels should not turn. The
unit should not roll freely.

With the drive control released, move the shift lever back

3.
and forth between the R2 position and the F6 position
several times. There should be no resistance in the shift
lever.

If any of the above tests failed, the drive cable is in need of

4.
adjustment. Proceed as follows:

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

5.
Fig. 6-5.

Chute Bracket Adjustment

If the spiral at the bottom of the chute directional control is not
fully engaging with the chute assembly, the chute bracket can be
adjusted. To do so:

Loosen the two nuts which secure the chute bracket and

1.
reposition it slightly. See Fig. 6-6.

Figure 6-5

Position the bracket upward to provide more slack (or

6.
downward to increase cable tension).

Retighten the upper hex nut.

7.

Figure 6-6

Retighten the nuts.

2.

Off-Season Storage

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

Lubricate the machine as instructed earlier in this section.

1.
Store in a clean, dry area.

2.
If storing the snow thrower in an unventilated area,

3.
rustproof the machine using a light oil or silicone to coat
the snow thrower.

Clean the exterior of the engine and the snow thrower.

4.

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

17sectiOn 6 — Maintenance & adjustMents