Troy-Bilt 42012 Snow Blower User Manual
Contents
1. 7 speeds 5 Forward 2 Reverse 30 Specifications ON DIODE RECTIFIER Wiring Diagram OFF ENGINE CONNECTOR Light GREEN neo 3 f X i ARED lt BLUE CHEATER hi IGNITION SWITCH BLACK YELLOW RED 229 YELLOW NNECT CONNECTOR RED Ree En HANDLEBAR HANDLEBAR HEATER ENGINE SHROUD GROUND SCREW 31 For customer assistance contact your nearest authorized dealer or GARDEN WAY INCORPORATED 1 Garden Way Troy New York U S A 12180 Customer Service 1 800 437 8686 Technical Service 1 800 520 5520 Parts Service 1 800 648 6776 FAX 518 391 7332 Outside the U S A and Canada Customer Service 518 391 7007 For Technical Service 518 391 7008 Parts Service 518 391 7006 or FAX 518 391 7332 Form 1774200 Rev B 9 98 Printed in U S A 1998 GARDEN WAY INCORPORATED2. Rotate the chute control crank Z Fig 2 6 The deflector chute should turn freely Adjust the worm gear assembly bracket L Fig 2 4 as necessary to prevent binding Attach Auger Drive Control Rod Remove the plastic cable tie that secures the auger drive control arm AD Fig 2 8 to the transmission shift arm AB The auger drive control rod AA Fig 2 8 has been pre adjusted at the factory To avoid misadjustment do not rotate the jam nut AT Fig 2 8 while completing the following steps Hold the jam nut AT in place with a 7 16 wrench and use another 7 16 wrench to thread the adjusting thimble AS downward a total of 12 turns Raise auger drive control handle X Fig 2 6 all the way up Then hook the spring AC Fig 2 8 at the lower end of the auger drive control rod AA into the hole in the auger drive control arm AD Thread the adjusting thimble AS Fig 2 8 upward until it contacts the jam nut AT Using two wrenches tighten the jam nut against the adjusting thimble When the engine is started as described in the Operation section you will be given a functional check to make sure the auger drive control rod is properly adjusted Section 2 Assembly Attach Wheel Drive Control Rod 1 Remove the plastic cable tie that secures the wheel drive control rod AE Fig 2 8 and the gear shift control rod AF to the left handlebar 2 Hook the spring AG
3. c Check for and tighten any loose parts Section 1 Safety 13 14 15 20 21 Before inspecting the unit or making any adjustments or if the unit jams or becomes clogged shut the engine off immediately and allow all moving parts to come to a stop Disconnect the spark plug wire from the spark plug and secure the wire away from the spark plug Use only a wooden stick at least 3 feet long to clear away any blockage Keep all guards covers shields and safety devices in place and in good working condition Do not attempt to defeat the purpose of any safety device Exercise extreme caution on slopes Do not attempt to clear steep slopes Do not clear snow across the face of slopes Exercise extreme caution when changing direction on slopes Always observe the terrain Watch for and avoid obstacles Stay away from holes ditches soft or steep embankments and other potentially dangerous terrain Deep snow can hide obstacles and drop offs Do not use the unit near drop offs ditches or embankments If a wheel goes over an edge or if an edge caves in the unit could overturn Do not operate the unit at high transport speeds on slippery surfaces Wet surfaces reduce traction and stability Look behind and use care when operating the unit in reverse If you have to pull the unit backward disengage the auger and wheel drives Always check behind you for hazards Be extremely c
4. choke a cold engine when starting Refer to the following section Operation for proper operation information M Fig 3 5 Skid shoes Controls the distance between the auger housing scraper blade and the ground This distance should be adjusted to clear any uneven or gravel surfaces Refer to the Maintenance section for proper adjustment information N Fig 3 5 Scraper blade Located at lower front bottom edge of the auger housing the scraper blade is designed to contact the ground and to clear snow down to the pavement Refer to the Maintenance section for proper adjustment information Section 3 Controls Handlebar Warmer Feature The unit is equipped with handlebar warmers that are automatically activated when the engine is running Allow a few minutes perhaps longer in extremely cold temperatures for the handlebars to warm to the touch Fig 3 4 Fig 3 5 Section Operation Pre operation checklist 1 Review Section 1 Safety and Section 3 Controls in this manual 2 Check the unit for any loose or missing hardware Tighten or replace as needed 3 Check inside the auger housing and the discharge chute and remove any debris 4 Check the engine oil level a Move the unit onto a level surface b Remove the engine oil dipstick O Fig 4 1 c Wipe the oil from the dipstick with a clean cloth d Screw the dipstick back int
5. contacting the factory Speed rotating parts Keep hands or any other part of the body or clothing away from the inside 2 not wear loose fitting clothing of the auger housing discharge such as scarves which could be opening or moving parts caught by moving parts Tie up or restrain long hair Never allow children or untrained adults to use the unit 7 Before inspecting servicing or adjusting any part of the unit shut the Before starting the engine check the 6 tightness of all screws nuts bolts and other fasteners Replace or clean any damaged or unreadable safety and operating labels Wear adequate winter outer garments when operating the unit Wear footwear that will improve footing on slippery surfaces Exercise caution to avoid slipping or falling especially when operating in reverse Use extra care when handling gasoline and other fuels Gasoline and its vapors are highly flammable and explosive To help prevent a fire or explosion a Store gasoline only in an approved gasoline storage container safely out of the reach of children b Never remove the fuel fill cap on the fuel tank or add fuel while the engine is running or hot c Keep matches smoking materials open flames and sparks away from the fuel tank and gasoline storage container d Fill the fuel tank outdoors and with extreme care Never fill the fuel tank indoors 10 7 Adjust the skid shoes and scraper e Repla
6. d Rotate the fuel shut off valve K Fig 4 5 to the position Auger drive engagement A WARNING STOP THE ENGINE AND REMOVE THE SPARK PLUG WIRE FROM THE SPARK PLUG BEFORE REMOVING ANY DEBRIS FROM THE AUGER HOUSING 1 Remove any debris from inside the auger housing 2 Adjust the discharge chute deflector cap RR Fig 4 6 angle with adjustment lever SS Fig 4 6 The discharge chute deflector cap should usually be adjusted to alow angle so it is not pointing at any persons animals buildings or vehicle especially in windy conditions NOTE If the auger does not start or stop rotating as described in Steps 3 and 4 below an adjustment is required Refer to Auger Drive Belt Adjustment in the Maintenance section 3 Engage the auger drive by squeezing the auger drive control lever H Fig 4 4 down against the handlebar The auger should immediately begin to rotate 4 Disengage the auger drive by releasing the auger drive control lever H The auger should stop within five 5 seconds Wheel drive engagement 1 Clear all obstructions from in front of the unit 2 Stand behind the unit in the operating position 3 Movethe gearshift lever B Fig 4 4 into the 1 or first gear position NOTE If the wheels do not start or stop rotating as described in Steps 4 and 5 below an adjustment is required Refer to Wheel Drive Disc Adjustment in the Maintenance sectio
7. adjust the skid shoes so the scraper blade clears the rough or gravel surface Use low travel speeds for safety and to prevent overloading the unit A WARNING THOROUGHLY INSPECT THE AREA WHERE THE UNIT WILL BE USED BEFORE THE FIRST SNOWFALL REMOVE ALL DOORMATS SLEDS BOARDS WIRES AND OTHER DEBRIS TO PREVENT INJURY FROM THROWN OBJECTS 20 Snowthrowing Patterns A DANGER DO NOT USE YOUR HANDS OR FEET TO DISLODGE SNOW FROM INSIDE THE AUGER HOUSING OR THE DISCHARGE CHUTE ANY CONTACT WITH THE MOVING PARTS WILL CAUSE SERIOUS INJURY STOP THE ENGINE AND REMOVE THE SPARK PLUG WIRE FROM THE SPARK PLUG AND USE A LONG AT LEAST 3 100 CM LONG WOODEN STICK TO UNCLOG THESE AREAS Use pattern in Fig 4 7 when snow can only be thrown to one side Begin throwing snow closest to the side opposite where it can be thrown and direct the discharge away from that side When turning the unit around after each pass rotate the discharge chute as you proceed so snow continues to be thrown in the proper direction Use pattern in Fig 4 8 to throw snow to both sides When turning the unit rotate the discharge chute as necessary to throw snow in the proper direction As you turn rotate the discharge chute so that the snow is always thrown in this direction SNOW IS NOT THROWN HERE EC SE Sa ee EN SNOW IS THROWN HERE NR or fay Fig 4 7 The discharge chute stays the same direction
8. y B N 1 16 1 8 M Fig 5 15 1 5 3mm Fig 5 16 Brake Arm Adjustment Skid shoes Scraper blade The brake arm adjustment is set at the factory to 1 16 1 8 for proper belt brake clearance Due to wear this may need adjustment To perform this adjustment 1 26 Remove the bolts flat washer lock washer and belt cover AB Fig 5 9 Squeeze the auger drive control lever AL Fig 5 9 against handlebar Using a flashlight look down through the pulleys and belts Fig 5 11 Check the gap between the brake arm A Fig 5 15 and the belt B The gap should measure between 1 16 and 1 8 1 5 3 mm To adjust the gap Loosen nut C Hold the bolt D in place and rotate nut E until the proper clearance is obtained Secure nut C Reinstall the bolts and belt cover 1 The unit should be adjusted so the auger housing and the scraper blade N Fig 5 16 are 1 8 above the surface to be cleared If the unit is used to clear gravel or uneven surfaces this adjustment should be increased so gravel or other foreign objects are not scooped into the auger To adjust the auger housing scraper blade height a Move the unit onto a level surface b Loosen the hardware securing the skid shoes M Fig 5 16 c Adjust the skid shoes M until they are in the correct position to support the auger housing and the scraper blade adjust both skid shoes the same to prevent uneven snow removal d Tighten
9. 16008 Tire Chain Kit Includes tire chains for added traction 1756278 Drift Slicer Kit Includes drift slicers and mounting hardware 10771 Cab Kit Includes three sided protective cab framework and hardware 42500 Light Kit Includes light mounting hardware and wire lead 16009 Blizzard Pack Includes Light Kit Cab Kit and Electric Starter Kit 110V 42501 Service Kit Includes two V belts spark plug four shear bolts and top lock nuts fuel stabilizer 1 qt motor oil and spray lubricant 1771731 The items listed above are available for your snowthrower The information is the most current available at the time this literature was printed To order the kits listed above contact your dealer or call or write to the addresses listed on page 3 of this manual 29 Specifications Specifications Below is a list of specifications for your snowthrower The information is the most current at the time this manual was printed Snowthrower Models 42010 42012 42030 amp 42031 Snowthrower Height ses To top of handlebar levers 41 5 105 3 cm das w o handlebars deflector cap down 33 83 75 cm Length etes With handlebars 70 177 6 cm Without handlebars 41 0 104 cm Weight approximate 42010 42030 295 Ibs 134 Kg 45012 3908 edna ust cst ects 315 Ibs 143 Kg Tires i E 2 ply
10. 3 From either side of the unit slide the discharge chute onto the chute mounting flange K making sure that the plastic shims G are above the flange and the plastic hold down clips H are below the flange Tighten the shim mounting hardware securely if necessary rotate the discharge chute to the right in order to tighten the left side shim and hold down clip 4 Hook the front hold down clip H under the mounting flange K and place the front plastic shim G on top of the hold down clip between the top of the flange and the toothed chute flange Using two 5 16 wrenches secure with the screws washers and locknuts 5 Remove the plastic cable tie that secures the worm gear assembly L Fig 2 4 inset B to the mounting bracket 6 Remove the washer and locknut from the screw M Fig 2 4 inset B in the worm gear assembly L Position the worm gear assembly on the mounting bracket as follows a Engage the worm gear threads 1 2 way with the teeth on the flange of the discharge chute base rotate chute as needed b The length of the worm gear should be centered with the teeth on the flange of the discharge chute base c Reinstall the washer and locknut on the screw M and tighten securely Front hold down clip H j 9 Fig 2 5 d Turn chute control rod F Fig 2 4 by hand to be sure the worm gear and discharge chute rotate freely but with enough resistance to p
11. Fig 2 8 at the lower end of the wheel drive control rod AE into the hole in the wheel drive control arm AH If necessary raise the wheel drive control arm AH while attaching the spring 3 The wheel drive control rod has been pre adjusted at the factory When the engine is started as described in the Operation section you will be given a functional check to make sure the wheel drive control rod is properly adjusted J Install Gear Shift Control Rod 1 Place the gear shift select lever T Fig 2 6 in the No 5 position Yellow 2 Gently push the transmission shift arm AB Fig 2 9 fully downward 3 Align the holes in the transmission shift arm AB and the lower end of the gear shift control rod AF If the holes do not align follow the Gear Shift Rod Adjustment procedure in the Maintenance section of this manual 4 Attach the gear shift control rod AF to the transmission shift arm AB with the two 1 4 20 x 3 4 hex head screws and 1 4 20 locknuts supplied see Fig 2 9 Yellow amp e Red Wires he Fig 2 10 K Wiring Harness Installation 1 Remove the plastic cable tie that secures the wiring harness to the right handlebar 2 Route the wiring harness to the inside of the right handlebar and over to the right side of the engine 3 Attach the ring terminal AK Fig 2 10 on the two black wires to the screw on the engine shroud as shown Th
12. oe 22 Wheel dietus cies 23 Shear Bolts cec d e tende te e Ab Ren i e Ae 23 Auger D e n e He EHE 24 Slip Differentials 4 cci on v E 25 Gear d ERR ed 25 Drive Disk Clearance stetit iei d ie dnd s 25 Brake Arm Adjustment eee ee DE 26 Skid Shoes Scraper Blade Rn ae cepe e di 26 Off S ason Storage tu e 26 Troubleshooting Cliart rrt rrt tet ee 27 Mainteriarice Schedule a oe ee ue Ue REN 29 Specifications st abt aen eet ed pt RE 30 Wiring Diagram apa a nece de Rn HR b HR Reda 31 Section Safety SPARK ARRESTER WARNING TO RESIDENTS OF CALIFORNIA AND SEVERAL OTHER STATES Under California law and under the laws of several other states you are not permitted to operate an internal combustion engine using hydrocarbon fuels on any forest brush hay grain or grass covered land or land covered by any flammable agricultural crop without an engine spark arrester in continuous effective working order The engine on the unit is an internal combustion engine which burns gasoline a hydrocarbon fuel and must be equipped with a spark arrester muffler in continuous effective working order The spark arrester must be attached to the engine exhaust system in such a manner that flames or heat from the system will not ignite flammable material Failure of the owner operator of the unit to com
13. p PeNEs 4 80 4 00 x 8 Ait Pressure ee 8 to 12 psi 55 82 kPa Clearing Width 42010 42030 24 61 cm Su A EU IE 42012 42031 26 65 6 cm Engine 42010 42030 8 H P 5 97 kW Tecumseh HMSK80 42012 42031 10 H P 7 46 kW Tecumseh HMSK100 Snow King winterized 4 cycle air cooled Displacement 42010 42090 hehe enacts 42 18 cid 0 691 L 42012 42081 rante et 49 98 cid 0 769 L Bore x Stroke 42010 42030 3 125 x 2 5312 in 79 9 x 64 31 mm 42012 42031 3 3125 x 2 5312 in 84 14 x 64 31 mm Carburetor Float type primer and choke winterized GOVERN Olt Mechanical High Speed i a n RR DERE e EU 3450 RPM Idle Speed Speed Setting Lubrication OIF Qil Drainer t re it i her t Rr reis Engine Oil Typo sete aret Refer to engine owner s manual for manufacturer s recommendations Capacity asta m ctc ener 26 U S ozs 0 77 L Igniti erre ttes Electronic Spark Plug Refer to engine owner s manual Fuel ede ive eee ier areas Unleaded Regular Tank ie 1 U S gallon 3 79 L fuel shut off valve Filter istae Fine mesh molded into tank Gear Case eas Impeller shaft with worm gear Gear arte SAE 90 weight gear oil Wheel
14. the hardware to lock the skid shoes M into the proper position The scraper blade N Fig 5 16 can also be adjusted Adjust the scraper blade N at the carriage bolts Adjust the bottom edge of the scraper blade so it is parallel with the bottom edge of the auger Off season storage When storing the unit for more than 90 days follow these procedures to help keep the unit in good condition for future use e Clean dirt grime and grease from the unit and engine Perform routine lubrication as instructed earlier in this section e Add a fuel stabilizer to the fuel tank according to the instructions provided with the stabilizer Avoid leaving non stabilized fuel in the fuel tank for longer than 30 days because gum and other deposits can form which could foul the carburetor and fuel line e If the unit is equipped with a fuel shut off valve rotate the valve to the OFF position Change the engine oil e Remove the spark plug and squirt 1 2 ounce of engine oil into the spark plug hole Hold a rag over the hole be careful to prevent the rag from entering the hole Slowly pull the recoil starter several times to coat the cylinder wall with oil Re install the spark plug but leave the spark plug wire disconnected from the spark plug e Thoroughly inspect the unit for any loose damaged or missing parts Repair or replace the parts as necessary e Check all nuts bolts and other fasteners for
15. up into the auger To adjust the auger housing scraper blade height a Move the unit onto a level surface o Loosen the bolts securing the skid shoes M Fig 4 2 e Adjust the skid shoes M until they are in the correct position to support g the auger housing and the scraper blade adjust both skid shoes the same to prevent uneven snow removal e Tighten the bolts to lock the skid shoes M into the proper position 1 10 The scraper blade N Fig 4 2 can also be adjusted Adjust the scraper blade N at the carriage bolts Z Fig 4 2 Adjust the bottom edge of the scraper blade so it is parallel to the bottom edge of the auger Adjust the discharge chute deflector cap AA Fig 4 3 with lever to the desired angle of discharge Usually keep the angle of the discharge defector cap low especially in windy conditions Rotate the discharge chute control rod crank P Fig 4 3 and check for binding Check the auger drive and wheel drive control levers H and L Fig 4 3 for freedom of movement Check the tire pressure Inflate both tires evenly to 8 to 12 PSI 55 to 82 Kpa 12 Spray silicone spray on the inside of the deflector chute the chute discharge deflector cap the auger housing and on the augers This will help prevent snow from sticking do not spray silicon spray on rubber or plastic damage can result Re connect the spark plug wire J Fig
16. 4 1 to the spark plug if needed Rotate the fuel shut off valve K Fig 4 1 to the ON position if so equipped Section 4 Operation Starting the engine 1 2 3 5 To 6 A WARNING Review the Pre operation checklist earlier in this section Move the unit outside to a well ventilated level area Move the gearshift lever B Fig 4 4 into the desired gear position Turn the ignition key C Fig 4 4 to the RUN position Turn choke knob D Fig 4 5 clockwise to FULL CHOKE warm engines require little or no choking Push the primer button E Fig 4 5 two or three times cover hole in center of bulb when pushing If the temperature is below 15 F 9 push the button 4 or 5 times Move the throttle lever F to FAST start engine with the recoil starter Before using the recoil starter G Fig 4 5 make sure there are no obstacles behind you Pull recoil starter handle rapidly to overcome engine compression prevent kick back and start engine Maintain control of rope so it slowly returns into the starter mechanism Repeat pulling actions until engine starts Turn the choke knob D Fig 4 5 counterclockwise out of the full choke position Turn the choke off as the engine warms up DO NOT USE THE 110V ELECTRIC STARTER DURING RAINY WEATHER DO NOT STAND IN WATER OR ON DAMP SURFACES WHEN CONNECTING CORD For the optional ele
17. NT Left and right sides of the unit are determined from the operator A J position facing the direction of forward travel E Install Handlebars 1 Cut the plastic cable ties securing the H handlebar ends to the chassis and remove the handlebars Remove the protective wrapping on the handlebars Hardware shown full size 2 Attach the handlebars to the sides of Be the chassis as follows use the four 3 8 16 x 3 4 hex flange screws supplied in hardware bag a Install two screws in the upper mounting holes C Fig 2 3 on each side Leave screws loose enough to allow handlebar to pivot RS b Install two screws D in the lower D lt mounting holes Fig 2 2 c Using light pressure press down on the left side handlebar and tighten the two screws Repeat on the right side handlebar 3 There are four pre installed screws E Fig 2 3 on the inside of the handlebars that secure the control panel to the handlebars Check each screw and tighten securely IN S Section 2 Assembly F Install Discharge Chute 1 Remove the cardboard packing shield from the discharge chute mount opening 2 Loosen do not remove the left and right side sets of plastic shims G Fig 2 4 inset A and plastic hold down clips H Fig 2 4 inset A on the toothed flange J of the discharge chute assembly Remove and save the remaining front hold down clip shim and mounting hardware
18. OTROV BILT Models 42010 8 HP 24 Auger 42030 8 HP 24 Auger 42012 10 HP 26 Auger 42031 10 HP 26 Auger GARDEN WAY INCORPORATED Owner Operator Manual Snowthrower e Safety Assembly Controls Operation Maintenance Dear Owner Thank you for purchasing this product The unit was carefully designed and manufactured to provide excellent performance if properly operated and maintained Read this manual This is a safety operation and general maintenance manual which does not attempt to cover major repairs This manual is considered a permanent part of the unit and it must stay with the unit if itis resold A replacement manual can be obtained from the factory All information in this manual is based on the latest product information available at the time of printing Review this manual frequently to familiarize yourself with the unit its features and safe operation Our products have met the rigid safety standards of the Outdoor Power Equipment Institute and an independent testing laboratory The warranty statement is included in the literature package Read it carefully Also please complete and return the postpaid owner registration card included with this manual The purpose of the card is to register each unit and owner at the factory to provide information and safety literature If you have any problems or questions concerning the unit contact your local authorized dealer or the fa
19. above ADD and below FULL Wait afew minutes after filling crankcase allowing oil to settle Insert dipstick and tighten securely Recheck level and adjust as necessary Section 2 Assembly M Check Auger Gear Case Oil Level The auger gear case was filled at the factory with the correct amount of SAE 90 gear oil This level should be checked before using the unit Refer to Lubrication in the Maintenance section of this manual for complete information N Check Tire Pressure Check the air pressure in both tires using an automotive type tire pressure gauge Inflate tires evenly to 8 12 psi 55 82 kPa O Install Drift Slicers optional attachment The optional drift slicers AR Fig 2 12 are designed for use in deep snow conditions To install the drift slicers 1 Position the drift slicers AR Fig 2 12 to the outside of the auger housing 2 Attach the drift slicers with the four 5 16 18 x 3 4 screws and locknuts AS provided with the drift slicers Section Controls This section defines the various controls on the unit Refer to the following section Operation for an explanation of the proper use of these controls A Fig 3 1 Wheel drive control lever Controls the engagement of the wheel drive When this lever is down against the handlebar and the engine is running the wheels will rotate Refer to the Maintenance section of this manual for the p
20. areful when using the unit near blind corners shrubs trees and other objects that may obscure vision Be extremely careful when operating near or crossing gravel drives walks or roads Stay alert for hidden hazards or traffic 22 23 24 25 26 2T 28 29 30 31 Remove any hearing protection and watch for traffic when operating near or when crossing roadways Do not leave the unit unattended with the engine running Stop the engine let all moving parts come to a stop and disconnect the spark plug wire from the spark plug before leaving the unit Use only attachments and accessories that are approved for use with the unit Contact the factory customer service department at the address and phone number on page 3 if you are not sure about the use of any attachment or accessory Operate the unit only in daylight or in good artificial light Do not tamper with the engine governor settings The governor controls the maximum safe engine operating speed and protects the engine and moving parts from damage Contact your local engine dealer for service if a problem exists Shut off the engine disconnect the spark plug wire and secure the wire away from the spark plug before transporting the unit in a vehicle Do not touch the muffler or other engine parts which may be hot from operation Wait for parts to cool completely before inspecting cleaning or repairing the unit Never oper
21. ate the unit near buildings glass enclosures automobiles window wells drop offs etc without first properly adjusting the discharge angle and direction Keep children and pets away Never direct discharge at persons animals vehicles or buildings Never allow anyone in front of the unit when the engine is running Disengage the auger drive when the unit is being transported or is not in use 32 33 Disengage the auger and wheel drives if you are approached by any child inattentive person or pet Run the unit for a few minutes after use to prevent freeze up Remove any snow from the unit snow can melt re freeze and jam the unit Maintenance and Storage 1 When the unit is stopped for servicing inspection storage or to change an attachment or an accessory disconnect the spark plug wire from the spark plug and secure the wire away from the plug Let the engine cool before making inspections adjustments or performing any maintenance Maintain the unit and all attachments and accessories in safe working condition Never perform any maintenance while the engine is running or when the spark plug wire is connected to the spark plug Do not store the unit or fuel container inside an enclosure where there is an open flame or spark or where ignition Sources are present such as hot water and space heaters furnaces clothes dryers stoves electric motors etc 10 11 12 Allow the e
22. be full forward travel in gear position 5 and full reverse travel in gear position Reverse 2 f not refer to Gear Shift Rod Adjustment in the Maintenance section Reverse A WARNING USE EXTREME CAUTION WHEN OPERATING THE UNIT IN REVERSE CLEAR ALL OBSTACLES AWAY FROM THE UNIT BEFORE OPERATING IN REVERSE BE PREPARED FOR THE UNIT TO MOVE TOWARD YOU WHEN THE GEARSHIFT LEVER IS IN THE REVERSE POSITION RR SS Fig 4 6 Section 4 Operation Transporting the unit Release the auger drive control lever to disengage the auger drive whenever the unit is being transported to the work site The unit is extremely heavy Have at least one other person help you when loading or unloading the unit into a truck or trailer Use ramps when loading or unloading the unit onto a trailer or truck Securely tie the unit to prevent shifting while in transit Snowthrowing tips Remove snow as soon as possible after a snowfall Run the engine at full throttle the position Spray silicone spray onto the inside of the auger housing the discharge chute the deflector cap and also on the augers to help prevent snow from sticking Do not spray silicone on rubber or plastic damage will result Direct discharge downwind l fasmooth area is being cleared adjust the skid shoes so the scraper blade is approximately 1 8 3mm from the ground If arough or gravel area is being cleared
23. ce the fuel fill cap on the blade so the auger housing clears fuel tank the cap on the gasoline gravel or crushed rock surfaces storage container and clean up fuel spills before starting the Operation engine oe 1 The operator of the unit is responsible f Leave 1 2 inch 2 5 cm of air for the safety of all persons in the space at the top of the fuel tank operating zone of the unit to allow for fuel expansion 2 Before starting the unit disconnect g Do not store the unit or the the spark plug wire and check the gasoline storage container where auger and discharge chute to make there isa danceroran open sure they are free of ice Check the 9 h pen engine oil level Reconnect the spark flame or spark or where ignition plug wire before starting the engine sources are present such as hot water heaters Disengage all clutches and shift into furnaces clothes dryers stoves neutral before starting the engine SE eos 4 Let the unit adjust to outdoor For units equipped with the electric 5 start kit a Only use a 3 pronged UL rated and approved outdoor use electrical cord 6 b Only plug into a properly grounded 3 pronged outlet Do not use any adapters on the cord c Inspect the electrical cord for damage before use If it is damaged do not use it d Stand on dry ground when handling the electrical cord Do not handle the electrical cord with wet hands or wet gloves Do not use the
24. closest to the engine 2 Placethe belt into the groove closest to the engine Reinstall the auger drive belt in its pulley 3 Position the belt guide AC back on the engine and secure with bolts removed earlier 4 Reinstall bolt BB leaving 1 16 1 5mm clearance between underside of bolt head and front edge of pulley AE Tighten jam nut BA against engine crankcase Section 5 Maintenance JT ze ll Q HILL f S QA 5 Perform the wheel drive disc adjustment above 6 Reinstall the belt cover and bolts Shear Bolts Special shear bolts C Fig 5 7 secure the augers to auger shaft and are designed to break shear if the auger jams This prevents damage to other more vital parts Inspect the shear bolts before each use and replace them if they are worn or broken Torque shear bolts to 11 ft Ibs 15 Nm AF Fig 5 8 A CAUTION USING ANYTHING BUT ORIGINAL EQUIPMENT SHEAR BOLTS COULD RESULT IN DAMAGE TO THE UNIT USE AUGER SHAFT SHEAR BOLTS PART NUMBER 1735625 WHEN REPLACING SHEAR BOLTS Section 5 Maintenance Auger Drive Belt Adjustment Due to wear the auger drive belt may begin to slip when the auger drive lever is engaged To adjust the auger drive belt 2 If assembling a new unit raise the wheel drive control lever AP Fig 5 9 and the auger drive control lever AL 1 Perform the brake arm adjustment as described
25. ctory our telephone numbers and mailing address are listed on page 3 and on the back of this manual We want to ensure your complete satisfaction at all times A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Safety Alert Symbol This is a safety alert symbol A It is used in this manual and on the unit to alert you to potential hazards When you see this symbol read and obey the message that follows it Failure to obey safety messages could result in personal injury or property damage Owner Registration Card Please fill out and mail the enclosed Owner Registration Card The purpose of this card is to register each unit and owner at the factory to provide information and safety literature MAS Warranty Service The warranty statement is included in your unit s literature package Model Serial Numbers The model serial numbers are located on the back of the unit For quick reference record these numbers in the spaces below Date of Purchase Model Serial Numbers Left and Right Sides Left and right sides of the unit are determined from the operator position facing the direction of forward travel Customer Service and Technical Service If you have questions or problems with the unit contact your authorized dealer or call or write the factory When calling or
26. ctric starter 6 Plug the electrical cord into the electric start switch box on the engine Plug the other end of the electrical cord into a properly grounded 3 pronged 110V outlet 8 Push the starter button on the switch box When the engine starts release the button NOTE The starter is thermally protected When overheated from continuous use the starter will stop functioning Allow the starter to cool for several minutes before attempting to restart engine 9 Move the choke knob D Fig 4 5 out of the full choke position Turn the choke off as the engine warms up Stopping Emergency conditions 1 Release both control levers H and L Fig 4 4 2 Rotate the ignition key C Fig 4 4 to the STOP position Normal conditions 1 Release both control levers H and L Fig 4 4 Wait for the unit to come to a complete stop 2 Move the throttle lever F Fig 4 5 into the position Allow the engine to idle for several minutes to melt any snow on the engine 3 Rotate the ignition key C Fig 4 4 into the STOP position Remove the key 4 Disconnect the spark plug wire J Fig 4 5 from the spark plug 5 To prevent the unit from freezing up 8 Remove standing water from the floor of the auger housing b Move the throttle lever F Fig 4 5 into the lt position c Move the choke knob D Fig 4 5 into the full choke position
27. e lockwasher should be next to the screw head and the ring terminal in between the lockwasher and the engine shroud 4 Connect the spade terminal AL Fig 2 10 on the black wire to the yellow wire receptacle inside the connector receptacle AM Note that there are two yellow wires extending out of the back of the receptacle AM Do not install the spade terminal AL into the receptacle for the yellow wire that is attached with a small plastic connector to the red wire 5 Plug the wiring harness connector AN into the engine connecting plug AO Note that it can only be plugged in one way 6 Using two of the plastic cable ties provided loosely to avoid stretching wires attach the upper section of the wiring harness to the right handlebar Use the third cable tie to loosely tie the black blue and red wires together at the side of the engine Be sure that the wires are positioned safely away from the wheel L Add Engine Oil to Crankcase A WARNING DO NOT START ENGINE UNTIL ENGINE CRANKCASE HAS BEEN FILLED WITH OIL FAILURE TO FOLLOW THIS INSTRUCTION WILL RESULT IN SERIOUS ENGINE DAMAGE 1 sure that the engine is level before checking or adding oil 2 To add engine oil unscrew dipstick AP Fig 2 11 Fill oil at the dipstick opening with fresh oil See the engine owner manual for correct oil specifica tions and quantity required Do not use SAE 10W40 3 Oil level on dipstick should always be
28. eated starter Plug electrical cord into outlet Replace fuse or re set circuit breaker Replace electrical cord Allow starter motor to cool before trying to start engine again 28 Section 5 Maintenance Maintenance Chart Interval Item Service Before each use Engine oil Check level and condition All fasteners Check for tightness Auger drive lever Check operation Wheel drive lever Check operation After each use Handlebar control levers and linkages Lubricate Snowthrower Remove all snow slush and ice Every 25 hours of operation Engine oil Change or annually Tires Check pressure and condition Auger gear box Check oil level Belts Check for wear Cooling air screen Check condition and clean Spark plug Check clean re gap or replace Every 50 hours of operation Drive chains Apply oil to drive chains remove excess or annually Annually Belts Check for wear damage and adjustment Brake Adjust Auger Grease through grease fittings Rusted areas Sand repaint This table describes service guidelines only and does not provide complete service information For complete service information contact your local authorized dealer Optional Kits and Accessories Kit Description Model Part Number Electric Starter Kit 110V Allows for electric starting of the unit using house current 6857 Electric Starter Kit 12V D C Allows for electric starting of the unit using battery
29. electric starter if it is raining e Connect the cord to the electric starter first and then plug the cord into a properly grounded outlet this lessens the chances of sparks from occurring near the engine f Do abuse the electrical cord Do not pull the unit by the cord Do not pull the cord to disconnect it from the outlet Keep the cord away from sharp edges oil and excessive heat temperature before use Section 1 Safety Check the operation of the controls before using the unit Do not operate the unit unless all controls are operating properly Never carry passengers on the unit They could fall off and be seriously injured or they could interfere with safe operation Keep hands other body parts and clothing away from any moving or rotating parts Keep clear of the intake and discharge openings at all times Before starting the engine inspect the area where the unit is to be used and remove all sleds boards doormats metal bottles cans or other debris Keep children out of the area of operation and under the watchful eye of an adult not operating the unit Never assume that children will remain where you last saw them If the unit makes an unusual noise or vibration immediately shut the engine off wait for all moving parts to stop disconnect the spark plug wire from the spark plug and perform the following steps a Inspect for damage b Replace or repair any damaged parts
30. en the coiled ends of the spring W Fig 5 6 3 Squeeze wheel drive control lever X Fig 5 3 against handlebar Measure length of spring W Fig 5 6 again The spring length should now measure 5 8 3 4 15 19mm longer than the measurement taken in step 2 If it does not loosen jam nut Y Fig 5 6 and turn adjuster Z Fig 5 6 to increase or decrease the spring length 1 1 4 turns of the adjuster equals 1 16 1 5mm of spring extension Hold the adjuster and tighten the jam nut Y when the correct spring length is obtained Re check measurements and adjust if needed If after completing this adjustment the wheels do not drive adequately refer to Drive Disc Clearance Adjustment on page 25 Then repeat this adjustment Wheel Drive Belt Replacement To remove the wheel drive belt 1 Remove the bolts AB Fig 5 3 and the belt cover from the unit 2 Remove the two bolts securing belt guide AC Fig 5 8 to the engine Remove the belt guide 3 Loosen jam nut BA and remove bolt BB 4 Release tension on the idler AF Remove the auger drive belt AD Fig 5 8 from the auger drive pulley AE 5 Remove wheel drive belt AG from lower drive pulley AH Squeeze the wheel drive control lever against the handlebar X Fig 5 3 to increase the gap between lower pulleys as needed 6 Remove the belt from unit To install the wheel drive belt 1 Position the belt into lower drive pulley
31. except when turning Snow is thrown to each side as Lc ELSE PA uM RE 5 EN MENTA i SNOW IS THROWN HERE TO EITHER SIDE east 2 aS eS gt ILE d E BEGIN a EN c AS S CE SNOW IS THROWN HERE TO EITHER SIDE D Fig 4 8 os Ld Engine oil Check the engine oil level each time before starting the unit and after each 5 hours of operation A WARNING BEFORE PERFORMING ANY MAINTENANCE OR ADJUSTMENTS TO THE UNIT SHUT OFF THE ENGINE AND ALLOW TO COOL REMOVE THE IGNITION KEY DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG PREVENT THE WIRE FROM CONTACTING THE PLUG To check the engine oil level 1 Move the unit onto a level surface 2 Remove the oil dipstick A Fig 5 1 3 Wipe the oil from the dipstick with a clean cloth 4 Screw the dipstick back into the engine 5 Remove the oil dipstick A Fig 5 1 again Fig 5 1 Section Maintenance 6 The oil level should be between the FULL and the ADD marks on the dipstick Refer to the engine owner manual for proper oil specifications To change the engine oil 1 Start the engine and allow it to warm up to normal operating temperature 2 Stop the engine and wait for all moving parts to stop Disconnect the spark plug wire from the spark plug 3 Move the unit onto a level surface 4 Remove the engine oil dipstick A Fig 5 1 t
32. gine Carburetor The carburetor has been adjusted at the factory and should not require additional adjustment If a black exhaust is noticed inspect the air cleaner first An over rich mixture is usually caused by a clogged air cleaner element not an improperly adjusted carburetor Refer to the engine owner manual or contact your dealer for additional carburetor information 21 Section 5 Maintenance Lubrication At the beginning and end of each season or after every 25 hours of operation lubricate the unit as recommended below 1 Lightly oil both the deflector chute cap pivot points D Fig 5 3 2 Lightly oil the discharge chute control rod pivot points where the control rod enters the control panel bearing E Fig 5 4 the support tab F Fig 5 4 and the support on the left rear of unit housing G Fig 5 6 3 Remove the left wheel H Fig 5 3 Clean the wheel shaft and apply multi purpose grease to the wheel shaft Reinstall the left rear wheel 4 Apply oil to the bearings on sides of the auger shaft J Fig 5 3 5 Clean dirt and old grease from the flange at the bottom of the discharge chute K Fig 5 3 Apply multi purpose grease to the worm gear C toothed portion of flange and the flange 6 Lightly lubricate the handlebar control levers at pivot points M Fig 5 4 with oil or anon silicone spray Do not get oil or lubricating spray on levers 7 Lightly oil the pivot p
33. ide cardboard sleeve Remove cardboard sleeve Remove the hex nut A Fig 2 1 and the shipping strap from the left side skid shoe Reinstall the hex nut tightening it securely Remove the screw B Fig 2 1 and the shipping strap from the rear cover on the right side of the unit Reinstall the screw tightening it securely The unit is heavy Use caution and obtain the help of at least one assistant Carefully remove the unit from the crate by rolling the unit off the platform Park the unit on a clean level surface D Hardware Bag Contents The hardware bag should contain the items listed below and shown in Fig 2 2 Ref Description Qty A Cabletie noeh 3 B Hex hd flange screw 3 8 16 x 3 4 4 C Hex hd screw 1 4 20 x 3 4 2 D Locknut 1 4 20 2 E Phillips hd screw 410 24 x 3 8 2 Locknut 10 24 2 9 Cotter pin sse 1 Shear bolt 5 16 18 x 1 3 4 2 Locknut 5 16 18 2 Ignition key 2 Grease Tube not illustrated For maintenance use if required 1 These items are extra auger shear bolts and locknuts if the auger catches a hard obstruction the shear bolts are designed to break to prevent damage to the auger and other parts See the Maintenance section for replacement steps Fig 2 1 Remove Rear Shipping Strap Section 2 Assembly IMPORTA
34. ive belt Broken square key on engine pulley Increase spring tension Replace chain s Re adjust drive disc Replace wheel drive belt Replace key Wheels turn with wheel drive control lever disengaged Tension too high on spring at lower end of wheel drive control rod Drive disk out of adjustment Decrease spring tension Adjust drive disc Snowthrower does not throw snow well Discharge chute impeller or auger clogged with snow slush or ice Snow sticks to auger or chute Incorrect gear setting Loose auger drive belt Stop engine disconnect spark plug wire use a long stick to unclog chute auger and or impeller Spray auger and chute with silicone lubricant When snowthrowing generally use faster speeds use slower speeds with heavier snow Adjust auger drive belt Snowthrower does not clear snow Skid shoes set too high Scraper blade adjusted incorrectly Adjust skid shoes equally until scraper blade is evenly adjusted 1 8 3 mm above surface being cleared Adjust scraper blade until blade is evenly adjusted 1 8 3 mm above surface being cleared Snowthrower makes sloping cut in snow Skid shoes not set at equal height Scraper blade adjusted incorrectly Adjust skid shoes to equal height Adjust scraper blade ends equally Electric start motor won t crank engine Electrical cord unplugged from outlet Blown fuse or thrown circuit breaker Faulty electrical cord or plug Overh
35. later in this section 3 Pull the auger drive control arm AJ Fig 5 10 down completely Lc Fig 5 11 Fig 5 10 24 4 Measure and note the length of the spring AK Fig 5 10 Squeeze the auger drive control lever AL Fig 5 9 against the handlebar Measure the length of the spring AK Fig 5 10 again The spring length should now measure 9 16 11 16 14 17mm longer than the measurement taken in step 4 If it does not loosen the jam nut AM and turn the adjuster AN to increase or decrease the length of the spring Hold the adjuster and tighten the jam nut AM when the correct spring length is obtained Re check the measurements and adjust if needed NOTE 1 1 4 turns of the adjuster equals 1 16 1 5mm of spring extension Auger Drive Belt Replacement To remove the auger drive belt 1 Remove the bolts flat washers and lockwashers securing the belt cover AB Fig 5 9 to the unit Remove the belt cover Remove the two bolts securing the belt guide AC Fig 5 11 to the engine Remove the belt guide Loosen jam nut BC and remove bolt BD Remove the auger drive belt AD from the auger drive pulley AE Section 5 Maintenance Fig 5 12 Fig 5 13 Fig 5 14 5 Remove the auger drive belt from the lower drive pulley AO 6 Remove the bel
36. ly 3 While holding the gear shift control rod down AA loosen the jam nut ZZ Fig 5 14 and thread the pivot block N up or down as needed so it fits into the hole in the gear shift lever plate AV 4 Reinstall the pivot block into the gear shift control lever hole and secure with the washer and hairpin cotter Secure the jam nut ZZ against the pivot block N 5 Move the gear shift control lever AU Fig 5 9 through the full range of travel Check for binding Refer to the drive disk clearance adjustment below if needed Drive Disc Clearance Adjustment If the gear shift rod lever does not move freely through all the gear positions adjust clearance AY Fig 5 13 as follows 1 Loosen the jam nut AW Fig 5 10 Rotate the adjusting screw AX until the rubber drive wheel T Fig 5 13 contacts the metal drive disk U 2 Turn the rubber drive wheel T and the metal drive disk U to find the point of minimum clearance AY This is where both the drive wheel T and metal disk U are touching 3 Adjust the disks at the point of minimum clearance Loosen adjusting screw AX 1 2 turn Secure the adjusting screw AX in place while tightening the jam nut AW 4 Check the clearance AY Fig 5 13 by moving gear shift lever AU Fig 5 9 through all positions Repeat step 3 as necessary 25 Section 5 Maintenance mH MS IN zn oo
37. n of this manual 4 Engage the wheel drive by squeezing the wheel drive control lever L Fig 4 4 against the handlebar The unit should immediately move forward e Disengage the wheel drive by releasing the wheel drive control lever The wheels should stop NOTE To move the unit without throwing snow engage only the wheel drive lever Auger drive Wheel drive interlock feature The auger drive wheel drive interlock feature allows the auger and the wheels to be operated with just one hand thus freeing the other hand to operate the chute control crank rod To engage both functions squeeze both the auger and the wheel drive levers all the way down Holding just the wheel drive lever will keep both levers down in the drive position To disengage release the wheel drive lever NOTE If the auger drive control lever does not disengage when you release the wheel drive lever an adjustment is required Refer to Auger Drive Belt Adjustment in the Maintenance section Section 4 Operation Shifting gears A CAUTION TRANSMISSION DAMAGE COULD OCCUR IF THE GEARSHIFT LEVER IS MOVED WHEN THE UNIT IS IN MOTION CAREFULLY FOLLOW THE SHIFTING INSTRUCTIONS BELOW 1 Release both the auger and wheel drive control levers H and L Fig 4 4 Wait for the unit to come to a complete stop 2 Move the gearshift lever B Fig 4 4 into the desired position 3 Re engage the control levers H and L NOTE There should
38. ngine to cool before storing in any enclosure Store gasoline in a cool well ventilated area safely away from any spark or flame producing equipment Store gasoline only in an approved gasoline storage container safely out of the reach of children Use only original equipment replacement parts Parts manufactured by others could present a safety hazard even though they may fit on the unit Store the unit where children will not have access to it Always disconnect the spark plug wire from the spark plug to prevent accidental starting Remove the ignition key from the ignition keyswitch Check the tightness of the auger shear bolts and other fasteners at frequent intervals Torque shear bolts to 11 ft Ibs 15 Nm Maintain or replace safety and instruction decals as needed if they are damaged or illegible Refer to the parts catalog for decal location and ordering information Refer to the engine owner manual for complete engine information Section 1 Safety Safety Decals For your personal safety and the safety of others a number of safety message decals have been affixed to your unit Keep them clean and legible at all times Contact your local service dealer or the factory for replacements if any decals are damaged or missing Refer to the separate parts catalog for decal locations part numbers and ordering instructions Se IMPORTANT Follow the assembly steps carefully Contact the factory or y
39. ntrol Rod 10 Attach Auger Drive Control Rod sse nnns 11 Install Wheel Gear Shift Control Rods sen 12 Install Wiring Harness Adding Oil to the Engine Check Gear Case Oil 13 Check Tire Pressure Install optional Drift Slicers see 13 SECTION 3 CONTROLS 7 17 ire Ten eva eau ees Ya vua ve nani aveva na waa Ya dace 14 Wheel Auger Gear Shift Control Levers sss 14 Discharge Chute Controls Ignition Keyswitch Fuel Shut Off Valve 14 Engine Thirottle Primier erc arrene regerer 15 Engine Starter ChioKe s c eit tdt te m cett dete RET 15 Skid Shoes Scraper Blade Handlebar Warmer se 15 SECTION 4 OPERATION rte ne re n va re Fa sa seb ra spa Ease xa pa 16 Pre Operatiori Clhiecklist ie cinere cage ced tei eed 16 Starting the Engirig x atten pedore v Sd ere oed ep bt 18 Stopping the Engines remet ee ned 18 Auger Drive Engagement Disengagement sssssse een 19 Wheel Drive Engagement Disengagement ssssseeee nn 19 Shifting Gears eterne REPRE OR AER ER RR 19 Transporting the Unit Snowthrowing Patterns n 20 SECTION 5 MAINTENANCE seen 21 osse A codd 21 tt
40. o allow venting for the engine crankcase 5 Place acontainer with a minimum capacity of two quarts below the oil drain opening 6 Fold apiece of cardboard or aluminum foil into a shallow V and position it so the oil will drain through it into the container 7 Remove the oil drain plug B Fig 5 1 and allow the oil to drain into the container 8 When all oil has completely drained from the crankcase securely replace the oil drain plug B 9 Refer to the engine owner manual for correct oil specifications Fill the engine through the oil dipstick opening with the correct type and amount of oil as indicated in the engine owner manual 10 Securely replace the oil dipstick A NEVER DISPOSE OF WASTE OIL ON THE GROUND DOWN A DRAIN OR INTO A LAKE POND OR STREAM CONTACT LOCAL ENVIRONMENTAL AUTHORITIES FOR PROPER OIL DISPOSAL INSTRUCTIONS Ignition system The engine has an electronic ignition system which does not use points or a condenser The spark plug is the only item requiring maintenance in this system Spark Plug Annually or every 100 hours of operation remove and inspect the spark plug Replace the spark plug if the electrode is pitted or burned or if the porcelain is cracked Refer to the engine owner manual for correct spark plug specifica tions Fig 5 2 Refer to engine manual for spark plug gap specifications Fig 5 2 Note Use of an incorrect plug can damage the en
41. o the engine Fig 4 1 Remove the engine oil dipstick Fig 4 1 again f The oil level should be between the FULL and the ADD marks on the dipstick Refer to the engine owner manual for proper engine oil specifi cations A WARNING DO NOT START ENGINE UNTIL ENGINE CRANKCASE HAS BEEN FILLED WITH OIL FAILURE TO FOLLOW THIS INSTRUCTION WILL RESULT IN SERIOUS ENGINE DAMAGE 5 Remove the gasoline tank fill cap A and check the level of gasoline in the gasoline tank Fig 4 2 Section 4 Operation WARNING GASOLINE IS HIGHLY FLAMM ABLE AND ITS VAPORS ARE EXPLOSIVE NEVER REMOVE THE GASOLINE TANK FILL CAP OR ADD FUEL WHEN INDOORS OR WHEN ENGINE IS RUNNING OR HOT WIPE UP SPILLED GASOLINE IMMEDIATELY KEEP SMOKING MATERIALS SPARKS OR FLAMES FAR FROM FUEL TANK AND CONTAINERS Fill the fuel tank with fresh clean unleaded gasoline with a minimum octane rating of 87 Leave 1 2 of space for fuel expansion DO NOT MIX OIL WITH GASOLINE Tighten the gasoline fill cap securely Refer to the engine owner manual for additional gasoline information DO NOT MIX OIL WITH GASOLINE 6 The unit should be adjusted so the auger housing and the scraper blade N Fig 4 2 are 1 8 above the surface to be cleared If the unit is used to clear gravel or uneven surfaces this adjustment should be increased so gravel or other foreign objects are not scooped
42. oints on the gear shift control lever N Fig 5 4 8 Remove the two shear bolts C Fig 5 7 from the auger shaft then lubricate the four auger grease fittings Fig 5 7 using a grease gun Rotate auger three or four times Reinstall shear bolts torque to 11 ft lbs 15Nm 9 Check the auger gear case oil level a Place the unit on a smooth level surface Unscrew the plug P Fig 5 7 from the front of gear case b Inspect plug hole Oil should just begin to seep out of the hole Add SAE 90 gear oil if necessary until oil just begins to flow out of hole Let the excess oil drain out of the gear case c Reinstall the plug P Fig 5 5 10 Remove bolts Q Fig 5 6 securing bottom cover to unit Remove bottom cover Put gear shift lever in highest speed setting and apply a coating of multi purpose grease to the shafts R and S Fig 5 5 Prevent grease from contacting rubber drive wheel T or drive disk U If grease should contact these parts wipe clean to avoid slippage and assure proper operation Move shift lever between high speed and reverse settings to spread grease along shafts Replace bottom cover Wheel Drive Disc Adjustment Due to wear the wheel drive control disc may begin to slip when wheel drive lever is engaged To adjust wheel drive disc 1 Pull the wheel drive control arm V Fig 5 6 down completely 2 Measure and note the distance betwe
43. our local authorized dealer if you have any questions or problems A Inspect Unit Inspect the unit and shipping crate for damage immediately after delivery Contact the carrier trucking company if you find or suspect damage Inform them of the damage and request instructions for filing a claim To protect your rights put your claim in writing and mail a copy to the carrier within 15 days after the unit has been delivered Contact the factory as indicated on page 3 of this manual if you need assistance B Tools Materials Required for Assembly 1 Crowbar or large screwdriver to disassemble wood crate Scissors or knife to cut plastic ties 5 16 wrench 3 8 wrench 9 16 wrench Phillips head screwdriver medium Needle nosed pliers medium Autom otive type tire pressure gauge Clean high quality motor oil Refer to the separate engine owner s manual for the exact oil specifications and amount needed for your engine Adjustable wrenches may be used IMPORTANT Motor oil must be added to the engine crankcase before the engine is started Follow the instructions in this Assembly section Assembly C Unpacking Instructions The shipping crate should contain Snowthrower engine auger assembly Handlebar assembly Discharge chute assembly 1 2 Remove top and sides of wood crate Remove discharge chute assembly with attached hardware bag from ins
44. ply with this regulation is a misdemeanor under California law and other states and may also be a violation of other state and or federal regulations laws ordinances or codes Contact your local fire marshal or forest service for specific information about which regulations apply in your area Training 3 Keep the area of operation clear of all engine off wait for all moving parts to people particularly small children and stop and disconnect the spark plug pets Keep bystanders at least 25 feet wire from the spark plug Secure the away from the area of operation wire away from the spark plug 4 Familiarize yourself with all of the 8 Do not operate the unit if you are safety and operating decals on the under the influence of alcohol unit and on any attachments or medication or when tired or ill accessories Read this owner operator manual and the separate engine owner manual carefully before operating the unit Be Do not run the engine in an enclosed Preparation area Engine exhaust contains carbon 4 Wear approved safety glasses or eye gi yeaa monoxide gas a deadly poison that is shields and hearing protection when completely familiar with the controls odorless colorless and tasteless Do operating the unit The operation of USE ole units A not operate the unit near buildings any powered machine can result in replacement manual is available by windows or air conditioners foreign objects being thrown by high
45. re times Drain gasoline from tank refill tank with fresh gasoline Remove clean inspect re gap or replace spark plug Engine idles rough Faulty or fouled spark plug Incorrect choke setting Remove clean inspect re gap or replace spark plug After the engine starts gradually rotate the choke knob to the NO CHOKE position Engine overheats Dirty air screen Low engine oil level Dirty cooling fins Loose spark plug Remove all debris from air screen Check oil add as necessary Clean cooling fins Disconnect spark plug wire re tighten plug Auger drive lever does not actuate auger Tension too low on spring at lower end of auger drive control rod Broken auger shear bolts Loose or broken spring Increase tension on spring Replace auger shear bolts Replace spring continued 27 Section 5 Maintenance Troubleshooting continued TROUBLE Auger drive control lever does not engage auger drive POSSIBLE PROBLEM Broken square key on engine drive pulley Broken woodruff key on input shaft SOLUTION Replace key Replace key Auger spins with drive lever disengaged Tension too high on spring at lower end of auger drive control rod Decrease spring tension Wheel drive control lever does not turn wheels Tension too low on spring at lower end of wheel drive control rod Broken wheel drive chain s Drive disk out of adjustment Broken or excessively worn wheel dr
46. revent free rotation of the discharge chute during snow removal operation Readjust position of worm gear assembly as necessary Insert the flexible fingers on the plastic snow deflector N Fig 2 5 inside the chute deflector cap O Close the deflector cap by pulling the lever P outward and moving the deflector cap down Release the lever to secure the deflector cap in one of the discharge angle selector holes Attach Chute Control Rod Remove the plastic cable tie that secures the auger drive control rod AA Fig 2 6 to the right handlebar Next remove the plastic cable tie that secures the chute crank rod short rod with plastic swivel blocks to the auger drive control rod Pull the chute crank rod Z Fig 2 6 up through the top of the control panel Attach the chute control rod sections S and U Fig 2 6 as follows 8 Insert the angled end of the chute control rod U Fig 2 6 inset into the hole in the swivel block V that is attached to the end of the chute crank rod S b Insert a cotter pin W through the hole in the chute control rod U and spread the ends of the cotter pin Position the chute control support Y Fig 2 7 against the underside of the handlebar console as shown Secure the support with the two 10 24 x 3 8 Phillips pan head screws and 10 24 locknuts supplied Section 2 Assembly Fig 2 8
47. roper adjustment information B Fig 3 1 Auger drive control lever Controls the engagement of the auger drive When this lever is down against the handlebar and the engine is running the auger will rotate Refer to the Maintenance section of this manual for the proper adjustment information C Fig 3 1 Gear shift control lever Controls the selection of travel speeds five forward and two reverse positions Refer to the Maintenance section of this manual for the proper adjustment information D Fig 3 1 Discharge chute control rod Controls the direction the discharge chute is facing Rotate this crank clockwise to turn the discharge to the right rotate counter clockwise to turn the discharge chute to the left Approximately ten turns of this crank will move the discharge chute all the way from one side to the other E amp F Fig 3 2 Discharge chute deflector cap and lever Controls the vertical angle of the snow discharge To adjust the discharge angle move the discharge cap by pulling lever F Fig 3 2 outward and moving the discharge deflector cap up or down The discharge chute deflector cap should usually be adjusted to a low angle especially in windy conditions G Fig 3 1 Ignition keyswitch The keyswitch has two positions RUN and STOP Rotating the key to the RUN position allows the engine to be started Rotating the key to the STOP position stops the engine Alway
48. s remove the ignition key when the unit is not in use Store the key in a safe place out of the reach of children Fig 3 3 Fuel shut off valve Located beneath the fuel tank the fuel shut off valve Fig 3 3 controls fuel flow from the fuel tank to the carburetor Refer to the engine owner manual for complete information OFF Fig 3 3 H Fig 3 4 Throttle Located on back left corner of the engine the throttle controls the speed of the engine For proper operation information refer to the following section Operation NOTE The engine lubrication and cooling systems operate best at full throttle Operating the engine at less than full throttle for extended periods can adversely affect the performance of this system J Fig 3 4 Primer button Located at the back upper left corner of the engine Pressing the primer button pumps small amounts of gasoline into the engine to improve cold weather starting Refer to the following section Operation for proper operation information K Fig 3 4 Recoil starter Located on the back of the engine the engine recoil starter is used to pull start the engine Refer to the following section Operation for proper operation information L Fig 3 4 Choke knob Controls the amount of gasoline in the air gasoline mixture that is fed into the engine This is known as choking the engine It is often necessary to
49. t from unit To install the auger drive belt 1 Position the auger drive belt AD down through gap Position the belt into the lower drive pulley AO 2 Position the auger drive belt AD into pulley AE Reinstall the belt guide AC and secure 3 Reinstall bolt BD leaving 1 16 1 5mm clearance between underside of bolt head and front edge of pulley AE Tighten jam nut BC against engine crankcase 4 Perform the auger drive belt adjustment as necessary 5 Reinstall the belt cover and bolts Slip Differential Adjustment 1 On right side of unit remove hub cap AQ Fig 5 12 at end of wheel axle shaft Remove outer AR and inner jam nuts AS and both pairs four single disk springs of disk springs AT Inspect springs and replace them if they are worn 2 Reinstall disc springs AT and inner jam nut AS Tighten jam nut AS by hand until it contacts the disc spring then tighten AS 1 to 1 1 4 turns more DO NOT force nut more than 1 1 4 turns or differential will not work 3 Secure the inner nut AS in place while tightening the outer nut AR 4 Reinstall cover AQ Gear Shift Rod Adjustment 1 Move the gear shift lever AU Fig 5 9 to position No 5 Remove the hairpin cotter and the flat washer from the pivot block N Fig 5 14 Disconnect the pivot block N from the gear shift lever plate AV Fig 5 14 2 Pull the gear shift control rod AA Fig 5 10 down complete
50. tightness and tighten as necessary e Touch up scratches and chipped paint to prevent corrosion Store the unit on a level surface out of the reach of children Troubleshooting Section 5 Maintenance TROUBLE Engine won t start POSSIBLE PROBLEM Ignition key in STOP position Choke knob in incorrect position Engine throttle lever in incorrect starting position Engine not primed enough when cold Engine primed too much when cold Spark plug wire disconnected Fouled or faulty spark plug Gasoline tank empty Fuel shutoff valve is closed Carb fuel line varnished from old gas SOLUTION Turn key to RUN position Move choke knob to FULL CHOKE position Move throttle lever to correct starting position Push primer button several more times Rotate choke knob to OFF position move throttle lever to idle position attempt to start engine then proceed with normal starting procedure DO NOT re prime Connect spark plug wire to spark plug Remove clean inspect re gap or replace spark plug Fill gasoline tank Open fuel shutoff valve Contact dealer Engine difficult to start Incorrect choke knob setting Engine throttle lever in incorrect position Fuel shutoff valve closed Engine not primed enough Stale gasoline in tank Fouled or faulty spark plug Rotate choke knob to correct setting Rotate throttle lever to correct starting position Open fuel shutoff valve Push primer button several mo
51. writing the factory provide the model serial numbers of the unit Replacement Parts Factory specified replacement parts are available from either your authorized dealer or directly from the factory For parts ordering information refer to the parts catalog Engine Service and Repair For engine service or repair contact your nearest authorized engine dealer To locate your nearest engine dealer look in the Yellow Pages under Engines Gasoline The engine on the unit is warranted by the engine manufacturer Any unauthorized work performed on the engine during the warranty period may void the warranty For complete details on the engine warranty refer to the engine owner manual To Contact the Factory Garden Way Incorporated 1 Garden Way Troy New York 12180 Customer Service 1 800 437 8686 Technical Service 1 800 520 5520 Parts Service 1 800 648 6776 FAX 518 391 7332 Outside the U S A and Canada Customer Service 518 391 7007 Technical Service 518 391 7008 Parts Service 518 391 7006 FAX 518 391 7332 Table of Contents SECTION TE SAFETY 2 0 4 A 4 Safety Decals x22 Paises aede e be p a ud 7 SECTION 2 ASSEMBLY 8 Inspect Unit Tools Required Unpacking Hardware Bag Contents 8 Install Handlebars notre tte enm rere e c te 9 Install Discharge Chute Attach Chute Co
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