Yard Machines E645E, 615, E665E, E6A5E User Manual

Operator’s Manual

Snow Thrower

Models

615, E6A5E,

E645E, E665E

IMPORTANT: Read safety rules and instructions carefully before operating equipment.

Warning:

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 ma y 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 368022 Cleveland, Ohio 44136-9722.

PRINTED IN U.S.A.

This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forest-

MTD PRODUCTS INC. P.O. BOX 368022 CLEVELAND, OHIO 44136-9722

FORM NO.

770-10025A

(6/99)

TABLE OF CONTENTS

Content Page

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

Contents of Hardware Pack...............................................................................5

Assembling Your Snow Thrower........................................................................6

Know Your Snow Thrower .................................................................................10

Operating Your Snow Thrower...........................................................................11

Making Adjustments ..........................................................................................13

Maintaining Your Snow Thrower........................................................................14

Service...............................................................................................................15

Off-Season Storage...........................................................................................17

Troubleshooting.................................................................................................18

Parts List............................................................................................................19

FINDING MODEL NUMBER

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

Before you start assembling your new equipment, 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)

CLEVELAND, OHIO 44136

(Serial Number)

MTD PRODUCTS INC

Copy the model number here:

Copy the serial number here:

CALLING CUSTOMER SUPPORT

If you have difficulty assembling this product or have any questions regarding the controls, operation or maintenance of this unit, please call the Customer Support Department.

Call 1- (330) 220-4MTD (4683) or 1- (800)-800-7310 to reach a Customer Support representative. 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

This Warning 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 your Snow Thrower. Failure to comply with these instructions may result in personal injury. When you see this symbol, heed its warning.

DANGER: Your Snow Thrower 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 seriou s injury . 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 or death.

TRAINING

• Read this operator's manual carefully in its entirety

before attempting to assemble or operate this machine. Be completely familiar with the controls and the proper use of this machine before operating it. Keep this manual in a safe place for future and regular reference an d for ordering replacement parts.

• Never allow children under 14 years old to operate a

snow thrower. Children 14 years old and over should only operate snow thrower under close parental supervision. Only persons well acquainted with these rules of safe ope ration sh ould be al lowed to us e your snow thrower.

• No one should operate this unit while intoxicated or

while taking medication that impairs the senses or reactions.

• Keep the area of operation clear of all persons,

especially small children and pets.

• Exercise caution to avoid slipping or falling, especially

when operating in reverse.

PREPARATION

• Thoroughl y inspect the area where the equipmen t is

to be used and remove all door mats, sleds, boards, wires and other foreign objects.

• Disengage all clutches and shift into neutral before

starting engine.

• Do not operate equipment without wearing adequate

winter outer garments. Do not wear jewelry, long scarfs or other loose clothing which could become entangled in moving parts. Wear footwear which will improve footing on slippery surfaces.

• Before working with gasoline, extinguish all cigarettes

and other sources of ignition. Check the fuel before starting the engine. Gasoline is an extremely flammable fuel. Do not fill the gasoline tank indo ors, while the engine is running, or until engine has been allowed to cool at least two minutes. Replace gasoline cap securely and wipe off any spilled gasoline before starting the engine as it may cause a fire or explosion.

• Use a grounded three wire plug-in for all units with electric drive motors or electric starting motors.

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

• Never atte mpt to make any adj ustme nts wh ile en gine is running (except where specifically recommended by manufacturer).

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

• 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 in any direction.

OPERATION

• Do not put hands or feet near or under rotating parts. Keep clear of discharge opening and auger at all times.

• Exercise extreme caution when operating on or crossing g ravel driv es, walks, or roads. Sta y alert for hidden hazards or traffic. Do not carry passengers.

• After striking a foreign object, stop the engine, remove wire from spark plug, and thoroughly inspect the snow thrower for any damage. Repair the damage before restarting and operating the snow thrower.

• If the snow thrower should start to vibrate abnormally, stop the engine and check immediately for the cause. Vibration is generally a warning of trouble.

• Stop engine whenever you leave the operating position, before unclogging the collector/impeller housing or discharge guide, and making any repairs, adjustments, or inspections. Never place your hand in the discharge or collector openings. Use a stick or wooden broom handle to unclog the discharge opening.

• Take all possible precautions when leaving the unit unattended. Disengage the collector/impeller, shift into neutral, stop the engine, and remove the key.

• When cleaning, repairing, or inspecting, make certain collector/impeller and all moving parts have stopped. Disconnect spark plug wire and keep away from plug to prevent accidental starting.

• Do not run engine indoors, except when starting engine and transporting snow thrower in or out of building. Open doors. Exhaust fumes are dangerous.

• Do not clear snow across the face of slopes. Exercise extreme caution when changing direction on slopes. Do not attempt to clear steep slopes.

• Never operate snow thrower without guards, plates, or other safety protection devices in place.

• Never operate snow thrower near glass enclosure, automobiles, window wells, drop off, etc., without proper adjustments of snow thrower discharge angle. Keep children and pets away.

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

• Never operate the machine at high transport speeds on slippery surfaces. Look behind and use care when backing.

• Never direct discharge at bystanders or allow anyone in front of unit.

• Disengage power to collector/impeller when transporting or not in use.

• Use only attachments and accessories approved by the manufacturer of snow thrower (such as wheel weights, counter weights, cabs, etc.).

• 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.

• Muffler and engine become hot and can cause a burn. Do not touch.

MAINTENANCE AND STORAGE

• Check shear bolts, engine mounting bolts, etc., at frequent intervals for proper tightness to be sure equipment is in safe working condition.

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

• Always refer to operator's manual instructions for important details if snow thrower is to be stored for an extended period.

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

• Check clutch controls periodically to verify they engage and disengage properly and readjust if necessary. Refer to operator's manual for adjustment instructions.

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.

DANGER

AVOID INJURY FROM ROTA TING AUGER KEEP HANDS, FEET AND CLOTHING AWAY .

W ARNING

STOP ENGINE BEFORE REMOVING DEBRIS AND SERVICING UNIT

KEEP CLEAR OF IMPELLER WHILE ENGINE IS RUNNING

NEVER DIRECT DISCHARGE AT BYSTANDERS OR WINDOWS OR ALLOW ANYONE IN FRONT OF UNIT

THOROUGHLY INSPECT THE AREA WHERE THE EQUIPMENT IS TO BE USED AND REMOVE ALL DOO R MATS, SLEDS, BOARDS, WIRES AND OTHER FOREIGN OBJECTS

REFER TO OWNERS MANUAL FOR

5. FULL INSTRUCTIONS

Safety Labels Found on Snow Thrower

SECTION 2: CONTENTS OF HARDWARE PACK

Lay out the hardware according to the illustration for identification purposes. Part numbers are shown in parentheses. (Hardware pack may contain extra items which are not used on your unit.)

ATTACHING THE HANDLES

(2) Hex Bolts

5/16-18 x 1-3/4” Long

(710-3180)

(2) Hex Bolts

5/16-18 x 3/4” Long

(710-3008)

ATTACHING THE SPEED SELECTOR PLATE AND SHIFT LEVER

(2) Hex Bolts

1/4-20 x 3/4” lg.

(710-3015)

(2) Handle Tabs

(784-5599)

(4) Lock Washers

5/16” I.D.

(736-0119)

(4) Self-Tapping

Screws

1/4-20 x 1/2” Lg.

(710-0599)

(2) Hex Lock Nuts

1/4” Thread

(712-3027)

ATTACHING THE HANDLE PANEL

(4) Carriage Bolts

5/16-18 x 1-1/2” Long

(710-0262)

(4) Hex Nuts

5/16” Thread

(712-3010)

ATTACHING THE CLUTCH CABLES

(2) “Z” Fitting

(746-0778)

ATTACHING THE CHUTE ASSEMBLY

(4) Lock Washers

5/16” I.D.

(736-0119)

(2) Hex Nuts

#10-24 Thread

(712-0121)

ATTACHING THE CHUTE DIRECTIONAL CONTROL ASSEMBLY

(1) Hair Pin Clip

(714-0104)

(1) Cupped Washer

5/16” I.D.

(736-0242)

AUGER SHEAR BOLTS (SPARES)

(2) Flat Washers

3/8” I.D. x 5/8” O.D.

(2)Hex Nut

5/16” Thread

(712-3010)

(2) Shear Bolts

(710-0890A)

(736-0185)

(6) Hex Lock Nuts

(6) Hex Bolts

1/4-20 x 3/4” Lg.

(710-3015)

(2) Hex Lock Nuts

5/16” Thread

(712-0429)

1/4” Thread

(712-3027)

(3) Chute Flange Keepers

(Not Shown) (731-0851)

SECTION 3: ASSEMBLING YOUR SNOW THROWER

IMPORTANT:

gasoline, and check oil level as instructed in the separate engine manual packed with your unit.

NOTE:

thrower are determined from behind the unit in the operating position.

After asse mbly , serv ice en gine with

References to right or left side of the snow

Unpacking

• Remove staples or break glue on th e top flaps of the carton. Remove any loose par ts included with unit (i.e., operator’s manual, etc.).

• Cut corner’s and lay end of carton down flat. Remove packing material.

• Roll unit out of carton. Che ck carton thoroughly for loose parts before discarding.

Tools r equired for assembly

• Pair of Pliers

• Two adjustable wrenches

Loose parts in carton See Figure 1

A (2) Handles (Right and Left) B (1) Handle Panel Assembly C (1) Speed Selector Plate D (1) Shift Lever E(1)Chute Directional Control Ass’y.

F (1) Chute Assembly

(1) Hardware Pack

Figure 1

Assembling the handles and handle

Carriage Bolts

Lock Washers

Hex Nuts

Clutch Grip

Pivot Rod

Left Handle (A)

Handle Panel Assembly(B)

panel (hardware a and b)

• Raise both clutch grips.

• Lower left and right handles (A) down through handle panel (B) between the pivot rod and the clutch grips and attach using hardware B. See Figure 2.

Lock Washer

Handle Tabs

Hex Bolt

Lock Washer

Figure 4

Attaching speed selector plate and shift lever (hard ware c)

• Assemble the speed selector plate (C) to the outside of the handles as shown in Figure 5. Secure using four self-ta pping scr ews. See Figur e

• Insert the shift lever (D) through slot in the speed selector plate.

Figure 2

• Do not tighten at this time.

• Lay handle panel assembly behind snow thrower. See Figure 3.

Figure 3

• Insert 3/4” long hex bolts and lock washers through bottom holes in handles and bottom holes in snow thrower. Do not tighten.

• Raise handles up until upper holes in handles and upper holes in snow thrower frame line up.

• Secure with 1 3/4” long hex bolts, lock washers and handle tabs. See Figure 4.

NOTE:

The bend in the lever should be towards the operator. Secure shift lever to the shift lever spring using two hex bolts and hex lock nuts. Tighten both bolts finger tight. At this poi nt the shift lever and shift lever spring are not against each other. As you tighten the bolts and nuts with two wrenches they will pull together. See Figure 5.

Speed

Selector

Plate (C)

Shift Lever (D)

Self-Tapping

Screw

Hex Bolts

Shift Lever

Spring

Hex Lock Nuts

Figure 5

• Tighten all hardware assembled to this point.

CLUTCH GRIPS MUST MOVE FREELY.

Attaching the clutch cables (hardw are d)

Hex

Nut

“Z” Fitting

• Thread hex nuts onto the “Z” fittings (see insert,). Insert “Z” fitting into hole in clutch grips. See Figure

Chute

Assembly (F)

Hex Bolt

Hex Lock Nut

Figure 6

• Route the left cable between engine and speed selector plate and then between handle panel and clutch lever pivot rod before threading onto the left “Z” fitting. Assemble the right cable using the same route.

• Correct a djustme nt on cable s is mi nimal slack but not tight. Tighten hex nuts when adjustment is correct.

NOTE:

If the right hand lo ckout cable is not adjusted correctly, the wheels wil l tend to turn. If the left hand lockout cable is not adjus ted correctly, the augers will not stop rotating.

WARNING: There must not be any

tension on either clutch cable with the drive or auger clutch grip in the disengaged (up) position. These clutches are a safety feature, and their function can be overridden if there is tension on either cable with the clutches disengaged.

Attaching the chute assembly (hardwar e e)

• Place chute assembly (F) over chute opening, with

the opening in the chute assembly facing the front of the unit. Place chute flange keepers beneath lip of chute assembly, with the flat side of chute flange keeper facing downward.

• Insert hex bolt up through chute flange keeper and

chute assembly as shown in Figure 7. Secure with hex lock nut. After assembling all three chute flange keepers, tighten all nuts and bolts securely. Do not overtighten.

NOTE:

hand. Tighten with two adjustable wrenches. This type of nut is used where vibration occurs.

Lock nuts cannot be threade d onto a bolt by

Chute Flange

Keeper

Figure 7

Attaching the chute directional cont rol (hardware f)

• Loosen the two hex nuts which secure the chute directional control bracket (see Figure 8) to the snow thrower housing.

Hex Nuts

Chute Directional Control Bracket

Figure 8

• Place one flat washer over the end of the chute directional control, then insert the end of the control into the hole in the plastic bushing in the chute directional control bracket. See Figure 9. Place second flat washer on chute directional control, and secure with hairpin clip.

Flat

Washers

Hairpin Clip

Chute Directional Control

Bracket

Figure 9

Chute Directional

Control

Cup Side

Crown

Side

Left

Handle

Hex Nut

2” of

Threads

Eyebolt

Hex Nut

Cupped Washer

Lamp Wire

Alternator Lead

Right Handle

• Thread one hex nut onto the eyebolt on the chute directional control assembly until there is at least two inches of threads showing between the nut and the head of the eyebolt. See Figure 10.

Figure 10

• Place the eyebolt into the hole located half way up the left handle. Secure with cupped washer (cupped side against the handle, see insert, Figure

10) and hex nut.

• Adjust the chute directional control support bracket (see Figure 9) so that the spiral on the chute directional control fully engages the teeth on the chute assembly. Tighten the nuts on the chute directional control bracket securely. Tighten the hex nuts on the eyebolt.

• Check to make sure all nuts and bolts on the control panel and all four bolts which secure the handles to the frame are tight.

Lamp wiring (Models E645 and E665 only)

Wrap the wire from the lamp down the right handle until the wire can be plugged into the alternator lead wire under the fuel tank . Be sure the lamp wire does not interfere with the movement of any controls or cables.

Figure 11

Final assembly and adjustments Auger control clutch

To check the adjustment of the auger control clutch, push forward on the left hand clutch grip (depress the rubber bumper). There should be slack in the cable. Release the clutch grip. The cable shoul d be straight. Make certain you can de press th e auger contr ol clutch grip against the left handle completely. If necessary, loosen the hex lock nut and thread the cable in (for less slack) or out (for more slack) as necessary. Refer to Figure 12. Recheck the adjustment. Tighten the lock nut against the cable when correct adjustment is reached.

“Z” Fitting

Hex Nut

Cable

Figure 12

Tr action control clutch an d shift lever adjustment

To check the adjustm ent of the traction control clutch and shift lever, move the shift le ver all the way ove r to fifth (5) position. With the traction control lever released, push the snow thrower forward. The unit should move forwar d freely. Then engage the tract ion control clutch grip. The wheels should stop turning. Now release the tr action control clutch grip, and push the unit again. Move the shift lever back to the fast reverse position, then all the way over again. There should be no resi stance in the sh ift lever, and the and the wheels should keep turning If you have resis tance when moving the shift lever or the wheels stop when t hey should not, loos en the jam nut on the traction control cable and unthread the cable one turn. If the wheels do not stop when you engage the traction contr ol clutch grip, loosen the jam nut on the traction control cab le and thread the cable in one turn. Recheck the adjustment and repeat as necessary. Tighten the jam nut to secure the cable when correct adjustment is reached.

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