Yard-Man E663H, E643E User Manual

Operator’s Manual
Snow Thro wer
Warning: This unit 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.
MTD LLC P.O. BOX 361131 CLEVELAND, OHIO 44136-0019
770-10020E.fm (6/2003)
Content Page
Important Safe Operation Practices ........................................................................ 3
Loose Parts............................................................................................................. 5
Assembling Your Snow Thrower ............................................................................. 5
Know Your Snow Thrower....................................................................................... 7
Operating Your Snow Thrower................................................................................ 8
Making Adjustments................................................................................................ 11
Maintaining Your Snow Thrower ............................................................................. 13
Service.................................................................................................................... 13
Troubleshooting ...................................................................................................... 17
Parts List ................................................................................................................. 18
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 pla te 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 looking at the lower frame cover in the re ar of your snow thrower. A sample model plate is explained below. For future refe rence, please copy the model number and th e serial number of the equipment in the space below.
(Model Number)
(Serial Number)
MTD LLC P. O. BOX CLEVELAND,OH 330-220-4683 800-800-7310
Copy the model number here:
Copy the serial number here:
The engine manufacturer is responsible for all engine-rel ated issues with regard to performance, power-rating, specifications, warranty and service. Please refer to the eng ine manufacturer’s Owner’s/ Operator’s Manual packed separately with your unit for more information.
Please do NOT return the unit to the retailer from which it was purchased, without first contacting Customer Support.
Should you have difficulty assembling this product or have any questions regarding the controls, opera tion or maintenance of this unit, please call the Customer Support Depart ment.
Call 1- (330) 220- 4MTD (4683) or 1- (80 0)-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.
For more details about your unit, visit our web site at www.yardman.com
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 the State of California to cause cancer, 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.
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.
1. 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.
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 three-wire 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 all clutch levers 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
1. Do not put hands or feet near rotating parts, in the auger/ impeller housing or discharge chute. Contact with the rotating parts can amputate hands and feet.
2. The auger/impeller clutch lever is a safety device. Never bypass its operation. Doing so makes the machine unsafe and may cause personal injury.
3. The clutch levers 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.
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 pattern to avoid discharge towards windows, walls, cars etc. Thus, avoiding possible 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 to vibrate abnormally, stop the engine, disconnect the spark plug wire and ground it against the engine. Inspect thoroughly for damage. Repair any damage before starting and operating.
17. Disengage all clutch levers and stop engine before you leave the operating position (behind the handles). Wait until the auger/impeller 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 the clean-out tool provided to unclog the discharge opening. Do not unclog discharge chute while engine is running. Shut off engine and remain behind handles until all moving parts have stopped before unclogging.
19. Use only attachments and accessories approved by the manufacturer (e.g. wheel weights, tire chai ns, cabs etc.).
20. If situations occur which are not covered in this manual, use care and good judgment. Contact your dealer or telephone 1-800-800-7310 for
assistance and the name of your nearest servicing dealer.
1. Never tamper with safety devices. Check their proper operation regularly. Refer to the maintenance and adjustment sections of this manual.
2. Before cleaning, repairing or inspecting machine disengage all clutch levers 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.
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 (OEM) parts only. “Use of parts which do not meet the original equipment specifications may lead to improper performance and compromise safety!”
6. Check clutch 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.
Restrict the use of this power machine t o persons who read, understand and follow the warnings and instructions in this manual and on the machine. The safety labels are shown below for your reference.
The snow thrower is shipped with following loose parts in the carton. Plea se remove all loose parts from the carton before discarding it. See Figure 1 to identify the par ts noting that these parts may be refe rred to again in the following sections of this manual. Part numbers are shown in parentheses.
Shear Bolts (710-0890A)
Hex Lock Nuts (712-0429)
Figure 1
The augers are secured to the auger shaft wit h two shear bolts and hex lock nuts. If you hit a foreign object or ice jam, the snow thrower is designed so that the bolts may shear. Two replacement shear bolts and nuts are provided for your convenience. Store in a safe place until needed.
hex bolts. Any damage to the auger gearbox or other components as a result of doing so will NOT be covered by your snow thrower’s warranty.
NEVER replace the auger shear bolts with standard
NOTE: Any reference in this manual to the left or right
side of the snow thrower is observed from the operator’s position.
later on in this section BEFORE operating your snow thrower.
Make any final adjustments as instructed
WARNING: Disconnect the spark plug wire
and ground it against the engine to prevent unintended starting.
Raise the upper handle assembly until it locks over the lower handle. See Figure 2 and Figure 3.
Look at the lower rear of snow thrower frame to be sure both cables are aligned with roller guides.
Secure the upper handle and lower handle with the two plastic wing knobs, cupped washers and carriage bolts previously removed. See Figure 3.
Remove the lower two plastic wing knobs, cupped washers and carriage bolts from the lower handle. See Figure 2.
Wing Knobs,
Washers and Bolts
Figure 2
Wing Knobs
Figure 3
Slide the shift rod connector down over the end of the lower shift rod. See Figure 3. Tap the conn ector until it locks on the lower shift rod.
NOTE: If the conne ctor is not properly assembled, the
shift rod will pivot and you will not be able to change speeds or change directions.
Attaching Chute Directional Control
For packaging purposes, the two-piece chute directional control was attached to the snow thrower on the two ends, but was kept loose at the middle. Assemble as follows:
Remove the hairpin clip from the chute directional control. Align holes on the upper and lower pieces of the chute directional control before r einserting the hairpin clip. See Figure 4.
Hairpin Clip
Figure 4
If not already attached, slip the cables that run from
the handle panel to the chute into the cable guide located on top of the engine. See Figure 5.
Cable Guide
Figure 5
Unwrap the headlight wire which is attached to the
headlight, beneath the handle panel. Wind the headlight wire around the right ha ndle until excess slack is removed.
Plug the headlight wire into the wire lead found on
the right side of the engine, beneath the fu el tank.
Chute Clean-Out Tool
This tool is fastened with a cable tie to the rear of the auger housing for shipping purposes. Cut the cable tie and remove tool before operating the snow thrower.
Final Adjustments
Traction Control and Shift Lever Adjustment
To check the adjustment of the traction control and shift lever, proceed as follows:
Move the shift lever into sixth (6) position.
a. With the traction control (refer to Figure 6)
released, gently push the snow thrower forward, then pull it back. Disregarding the overall weight of the snow thrower, the machine should otherwise move freely.
b. Engage the traction control, and attempt to
move the machine both forward and rearward. You should experience resistance as the wheels should not be turning.
Move the shift lever into the fast reverse (R2) position and repeat the previous steps (a & b).
If you experienced resistance either when repositioning the shift lever from 6 to R2 or when attempting to move the machine forward or rearward with the traction control released, your snow thrower’s traction control is in need of adjustment and you should NOT operate the machine before completing the adjustment as follows:
Loosen the jam nut on the traction control ca ble and UNTHREAD the cable one full turn.
Recheck the adjustment.
Retighten the jam nut to secure the cable when correct adjustment is reached.
If the machine can be moved freely both fo rward and rearward when the traction co ntrol fully depr essed, proceed as follows:
Loosen the jam nut on the traction drive cable and THREAD the cable in one full turn.
Recheck the adjustment and repeat as necessary.
Retighten the jam nut to secure the cable when correct adjustment is reached.
If you are unsure that you have reached the correct adjustment, refer to Traction Control Adjustment on page. 11 of this manual.
Tire Pressure Adjustment
The tires are over-inflated for shipping purposes. Check tire pressure and reduce to between 15 psi and 20 psi.
NOTE: If the tire pressure is not equal in both tires,
the unit may pull to one side or the other.
WARNING: Be familiar with all the controls
on the snow thrower and their proper operation. Know how to stop the machine and disengage them quickly.
Auger Control
The auger drive clutch is located on the left handle. Squeeze the clutch grip to engage the augers. Release to stop the snow throwing action. (Traction control must also be released.) See Figure 6.
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.
Traction Control / Auger Control Lock
The traction control is located on t he right handle. Squeeze the traction control to enga ge the wheel drive. Release to stop.
This lever also locks the auger control so you can turn the chute directional control without interrupting the snow throwing process. If the auger control is engaged along with the traction control, the operator can release the auger control (the left handle) and the augers will remain engaged. Release the traction control to stop both the augers and wheel drive.
changing speeds.
Shift Lever
The shift lever is located in the center of the handle panel and is used to establish both ground speed and direction of travel. It can be moved into any of eight positions. See Figure 6.
Your snow thrower has six forward (F) speeds. Position number one (1) is the slowest. Position number six (6) is the fastest.
Your snow thrower has two reverse (R) speeds. R1 is the slower, while R2 is the faster of the two.
Always release tractional control before
changing speeds.
Always release tractional control before
Chute Tilt Control
The distance snow is thrown can be varied by adjusting the pitch of the chute assembly. Move the chute tilt control forward to decrease the distance, or toward th e rear to increase the distance. See Figure 6.
Fuel Shut-off Valve (if so equipped)
The fuel shut-off valve, located under fuel t ank, controls fuel flow from the tank. Always make certain it is in the Open (vertical) position before atte mpting to start the engine. See Figure 6.
The headlight is on whenever the engine is running.
Throttle Control
The throttle control is located on the engine. I t regulates the speed of the engine.
Ignition Key
The ignition key must be fully inserted in the switch before the unit will start. Remove the ignition key when snow thrower is not in use.
Do NOT attempt to turn the key.
Chute Clean-out Tool
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.
designed to clear a clogged discharge chute. Refer to Operating Your Snow Thrower on page 10 for detailed instructions on how to properly use the chute clean-out tool.
The chute clean-out tool (see Figure 6) is
Traction/Auger Shift Lever Control Lock
Discharge Chute
Chute Tilt Control
Auger Control
Fuel Shut-Off Valve
(If So Equipped)
Clean-Out Tool
Chute Directional Control
Ignition Key
Figure 6
Before Starting
WARNING: Read, unde rstand, and follow
all instructions and warnings on the machine and in this manual before operating.
Gas And Oil Fill-up
Check oil level and add oil if necessary. Service the engine with gasoline as instructed in the separate engine manual packed with your snow thrower.
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 Engine
thrower, read, understand and follow ALL instructions to perform adjustments found under the heading Auger Control Test on page 9 of this manual.
Attach spark plug wire to spark plug. Make certain the metal loop on end of the spark plug wire (inside
Prior to operating your snow
the boot) is fastened securely over the metal tip on the spark plug.
Make certain the fuel cut-off valve, if your snow thrower is so equipped, is in OPEN position.
Make certain the auger and drive clutch levers are in the disengaged (released) position.
Move throttle control to FAST (Rabbit) position. Insert ignition key into slot. Be certain it snaps into place. Do not t urn key.
NOTE: Engine will not start unless ignition key is
inserted into ignition slot in carbur etor cover.
Electric Starter
Determine that your house wiring is a three-wire grounded system. Ask a licensed electrician if you are not certain.
If your house wiring system is not a three-wire grounded system, do not use this electric starter under any conditions.
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.
Throttle Control
Rope Starter Handle
If your home electrical system is grounded, but a three-hole receptacle is not available, one should be installed by a licensed electrician before using the electric starter.
If you have a grounded three-prong receptacle, proceed as follows:
Connect power cord to switch box on engine. Plug the other end of power cord into a three-hole , grounded 120 volt AC receptacle.
Rotate choke knob to FULL position.
Move throttle control to FAST (Rabbit) position.
Fully depress the primer three times, making sur e to cover the vent hole went pushing.
NOTE: Do NOT use the primer when restarting a
warm engine. Doing so will cause the engine to “flood.”
Push starter button on top of the engine .
When engine starts, release starter but ton, and move choke gradually to OFF. If engine falters, move choke momentarily to FULL and then gradually to OFF.
When disconnecting the power cord, always unplug from the three-prong receptacle fir st and then from the snow thrower.
Recoil Starter
Rotate choke knob to FULL choke position (cold engine start). If engine is warm, place choke in OFF position instead of FULL.
Push primer button two or three times. If engine is warm, push primer button once only.
NOTE: Always cover vent hole in primer button when
pushing. Additional priming may be necessary for first start if temperature is below 15°F.
Grasp starter handle and pull rope out slowly, until it pulls slightly harder. Let rope rewind slowly.
Pull starter handle rapidly. Do not allow handle to snap back. Allow it to rewind slowly while keeping a firm hold on the starter handle.
As engine warms up and begins to operate evenly, rotate choke knob slowly to OFF position. If engine falters, return to FULL choke, then slowly move to OFF position.
To Stop Engine
Run engine for a few minutes before stopping to help dry off any moisture on the engine.
Move the throttle control to the STOP or OFF position.
To help prevent starter freeze-up: Electric Starter
Connect power cord to switch box on engine, then to 120 volt AC receptacle. With the engine running, push starter button and sp in the starter for several seconds. The unusual sound made by spinning the
starter will not harm engine or starter. Disconnect the power cord from receptacle first, and then from snow thrower’s switch box.
Recoil Starter
With engine running, pull starter r ope with a rapid, continuous full arm stroke three or four times. Pulling the starter rope will produce a loud clattering sound, which is not harmful to the engine or starter.
Remove the ignition key. Do not turn key. Disconnect the spark plug wire from the spark plug to prevent accidental starting while equipment is unattended.
NOTE: Keep the ignition key in a safe place. The
engine will not start without the ignition key.
Wipe all the snow and moisture from the carburetor cover in the area of the control levers. Also, move the control levers back and forth several times.
To Engage Drive
NOTE: Use the slower speeds until you are familiar
with the operation of the snow thrower.
With the engine running near top sp eed, move shift lever into one of the six FORWARD positions or two REVERSE positions. Select a speed appropriate for the snow conditions that exist.
Squeeze the traction control against the right handle and the snow thrower will move. Release it and the drive motion will stop.
releasing the traction control. Doing so will cause premature wear to drive system’s friction wheel rubber.
NEVER move shift lever without first
To Engage Augers
To engage the augers and start the snow thr owing action, squeeze the auger control aga inst the left handle.
To disengage power to the augers, release both the auger control and the traction control, if engaged,
Auger Control Test
operating the snow thrower for the first ti me and at the start of each winter season.
Check the adjustment of the auger control as follows:
When the auger control is released and in the disengaged “up” position, the cable should ha ve very little slack, but should NOT be tight .
Perform the following test before
WARNING: Do not over-tighten the cable.
Over-tightening may prevent the auger from disengaging and compromise the safety of the snow thrower.
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