Troy-Bilt 5210R Snow Blower User Manual
Contents
1. E The keyswitch is located in the center of the lip on the rear of the handlebar control panel There are two positions of this keyswitch RUN and STOP Turning the key to the RUN position allows you to start the engine with the recoil starter or optional electric starting motor Turning the key to STOP will shut the engine off Always remove the engine ignition key when storing cleaning or performing any maintenance on the snowthrower BrentChalmers com SNOW THROWER AND ENGINE CONTROLS Figure 3 5 Engine Control Lever Figure 3 5 Item F This lever is located on the rear of the left hand side of the engine It is used to increase or decrease the engine speed This lever also will effect the speed of the wheels and auger when those handlebar control levers are engaged Moving the engine control lever upward increases engine speed Moving the lever downward decreases engine speed Engine Choke Knob Figure 3 5 Item G The engine choke knob is located on the left rear side of the engine on the carburetor s heat box The choke knob is used to enrich the gasoline mixture when starting This makes starting easier when the engine is cold Before starting a cold engine rotate the choke knob clockwise to its FULL CHOKE position After the engine starts gradually rotate the choke knob counterclockwise to its CHOKE OFF position If the engine is still warm from a previous run you may not have2. BrentChalmers com SECTION 3 SNOW THROWER AND ENGINE CONTROLS This Section describes the location and function of the various controls you will need to use when oper ating the snowthrower For complete step by step operating instructions please refer to Section 4 Operation SNOW THROWER CONTROLS Figure 3 1 Auger Drive Control Lever Figure 3 1 A This lever is located on the top of the right hand handlebar tube in front of the grip It is used to engage and disengage drive to the auger Moving this lever down and holding it against the handlebar will make the auger rotate To stop the auger simply release the lever Wheel Drive Control Lever Figure 3 1 This lever is located on the top of the left hand handlebar tube in front of the grip It is used to engage or disengage drive to the wheels Moving this lever down and holding it against the handlebar will make the wheels turn when the shift handle is not in N Neutral To stop the wheels from turning simply release the lever Discharge Chute Control Crank Figure 3 1 Item C The discharge chute control crank is located on the left hand side of the rear lip of the handlebar control panel Turning the discharge chute control crank clock wise will turn the discharge chute to the right Turning the discharge chute control crank counterclockwise will turn the discharge chute to the left It will take approximately 81
3. SNOWTHROWER Model 5210R OWNER OPERATOR MANUAL Safety Assembly Controls Operation Maintenance BrentChalmers com FEATURES AND CONTROLS ENGINE IGNITION KEYSWITCH WHEEL DRIVE AUGER DRIVE A CONTROL LEVER CONTROL LEVER a gt N i DISCHARGE CHUTE K CONTROL CRAN SHIFT HANDLE DEFLECTOR CHUTE CAP DEFLECTOR CHUTE CHUTE GUARD IMPELLER INSIDE HOUSING f i A X N _ SKID SHOE gt ADJUSTABLE SCRAPER BLADE AUGER BrentChalmers com TABLE OF CONTENTS Page Page SECTION 1 Safety 4 SECTION 4 Operation 14 TONG nak ads wie ee ne 4 Pre Start Checklist 14 Preparation eee os 4 Starting a ok RET 14 s Son Mee 5 e sin ose rang odes 16 Maintenance and Storage 6 Moving the Snowthrower in Reverse 16 ee ee ee 6 Changing Speeds 17 Snowthrowing Tips 17 SECTION 2 Easy Assembly 7 SECTION 5 Engine and Snowthrower SECTION 3 Snowthrower and Engine Controls 11 Maintenance Ree 19 Snowthrower Controls 11 Checking Engine Oil Level and 11 Adding Oil to Engine 19 inlaid awe Changing the Engine Oil 19 Wheel Drive Control Lever 11
4. t throw snow well Discharge chute impeller or auger clogged with snow slush or ice Stop engine disconnect spark plug wire Use a long stick to unclog chute auger and or impeller continued BrentChalmers com ENGINE AND SNOWTHROWER MAINTENANCE Trouble TROUBLESHOOTING Possible Problem Snowthrower doesn t throw snow well continued Snow sticks to auger or chute Incorrect wheel speed setting on shift handle Auger drive belt is loose Skid shoes set too high Scraper blade adjusted incorrectly Snowthrower makes sloping cut in snow Electric start motor won t crank engine 28 Skid shoes not set at equal height Scraper blade is incorrectly adjusted Electrical cord not plugged in Fuse or circuit breaker for outlet is blown Faulty electrical cord or plug Overheated starter Solution Spray auger and chute with silicone lubricant When throwing snow generally use faster speeds Use slower speeds on heavier snow Adjust auger drive belt Adjust skid shoes equally so that the scraper blade is 1 8 inch above the surface being cleared Readjust scraper blade so that it is 1 8 inch above the surface being cleared Readjust skid shoes to an equal height Re level scraper blade Plug electrical cord into outlet Replace fuse or re set circuit breaker Replace electrical cord Starter is t
5. When the top of the shift handle is moved all the way to the left the snowthrower will be in 3 High speed There is a detent a stop for each of the speeds between R Reverse and 3 High speed As you slowly move the shift handle sideways you can feel these detents These speeds refer only to the wheel speed not the auger speed To use the shift handle release the wheel drive handlebar control lever Allow all forward or reverse motion of the snowthrower to stop Move the shift handle into the desired speed and re engage the wheel drive handlebar control lever When familiarizing yourself with the various speeds or when moving the snowthrower near obstacles use 1 Low or 2 Medium speed Auger is shown upside down Figure 3 4 Skid Shoes Figure 3 4 A skid shoe is located at the bottom of each side of the auger housing These skid shoes are used to raise or lower the height of the auger housing This allows you to lower the auger housing when throwing snow off smooth surfaces so you can get a cleaner path If you re throwing snow from clear level ground adjust the skid shoes so that the scraper blade clears the ground by approximately 1 8 inch When throwing snow from rough surfaces such as those covered by gravel the skid shoes allow you to raise the auger housing so that the scraper blade clears the gravel and doesn t pick it up and throw it If you re throwing snow from a gravel covered area adj
6. 16 18 Two spacers Two extra 5 16 18 shear bolts for auger Four 5 16 18 x 3 4 hex flange screws U N gt BrentChalmers com EASY ASSEMBLY Figure 2 1 Step 1 Attach the Handlebars 1 Remove the four loosely installed 5 16 18 x 7 8 flange screws from holes A Place the lower ends of the handlebar assembly on the outside of the upper rear corner of the frame as shown in Figure 2 1 Item A Align the two holes in the left side of the lower end of the handlebars with the two holes in the left side of the frame Loosely install a 5 16 18 x 3 4 hex flange screw into each of these holes Repeat the previous two steps for the right side of the lower handlebars Evenly tighten all four screws Use the two 7 16 inch wrenches to check the four handlebar control panel mounting screws Figure 2 1 CC for tightness Step 2 Connect the Ignition Ground 1 Run the black ignition ground wire down the left hand handlebar tube as shown in Figure 2 1 and 2 2 Item B 2 Plug the connector at the lower end of the black ignition ground wire into the terminal beneath the Engine Control Lever See Figure 2 1 Item B 3 Attach the black ground wire to the lower left handlebar with the two tie straps See Figure 2 1 and 2 2 Item C BrentChalmers com N AA Ae C Figure 2 2 Step 3 Attach the Deflector Chute Assembly 1 Use a 3 8
7. Figure 5 8 Item S to the back of the engine and move the belt guide out of the way 6 Loosen the bolts that attach the belt guides to the front of the chassis below the transmission pulley Turn these belt guides to give you room to take the wheel drive belt off the transmission pulley 7 You may have to loosen the bolt that secures the engine pulley belt guide Figure 5 5 Item R in place and turn this belt guide out of the way 8 Take the wheel drive belt off the transmission pulley and engine wheel drive pulley To install the wheel drive belt 1 Place the wheel drive belt on the engine wheel drive pulley and transmission pulley 2 If you had to loosen the bolt that secures the engine pulley belt guide Figure 5 5 Item R in place position the leg of this belt guide approxi mately 1 16 inch from the outer surface of the wheel drive belt and tighten the bolt that secures it to the back of the engine 3 Rotate one of the two belt guides that is below the transmission pulley so that its leg is 1 16 inch away from the outer surface of the wheel drive belt Hold the belt guide in this position and 22 tighten the bolt that holds the belt guide in place Repeat this step for the remaining belt guide Retighten bolt that attaches belt guide Figure 5 8 Item S to engine Move the rear half of the snowthrower close to the front half Place the auger drive belt onto the engine auger drive pulley Figur
8. days from the date of purchase This LIMITED 3 YEAR WARRANTY also applies to all parts except the engine which is warranted separately by the engine manufacturer Call or write us for a free copy of the engine warranty All transportation and shipping costs for returned and replacement parts and for making the product available for service must be paid by you This warranty presumes you will provide reasonable care for the product and does not cover defects malfunctions or failure caused by misuse neglect ac cidents or unauthorized attachments or parts This warranty does not cover incidental or consequential damages or expense of any kind including but not limited to cost of equipment rental Any implied warranties including but not limited to any implied warranty of merchantibility or fitness for a particular purpose are limited in duration to the warranty period specified above How to Get Service To obtain warranty service write to Troy Bilt Manufacturing Company 102nd Street amp 9th Avenue Troy NY 12180 or call toll free 1 800 833 6990 or consult your Yellow Pages for the name of your closest authorized Troy Bilt Dealer Your Rights Under State Law Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also
9. have other rights which vary from state to state Troy Bilt Manufacturing Co 102nd Street amp 9th Ave Troy NY 12180 Call Toll Free 1 800 833 6990 Garden Way Canada inc 1515 Matheson Blvd Unit B11 Mississauga Ontario L4W 2 5 Local calls only 416 Area Code 624 8423 From Ontario and Quebec Provinces call Toll Free 1 800 387 3351 From Western Canada amp Maritime Provinces call Toll Free 1 800 387 3316 ener Piwan sa BrentChalmers com
10. inch wrench anda 5 16 inch wrench to remove two of the three sets of shims and clips Figure 2 3 Items D amp E from the lower rear part of the deflector chute assembly Don t remove the shim and clip that is in front of the chute opening 2 Apply multipurpose automotive grease all around the surface of the deflector chute flange Figure 2 3 Item F 3 Place the deflector chute onto the flange as shown in Figure 2 3 4 Reinstall the two sets of shims and clips you previously removed Make sure that the shims Figure 2 3 Item D are above the deflector chute flange Figure 2 3 Item F 5 Connect the chute crank Figure 2 1 G to the plastic universal joint Figure 2 1 Item H by using the hammer and block of wood to gently tap the roll pin into the universal joint and chute crank 6 Move the discharge chute deflector cap Fig 2 3 upward 7 Rotate the chute control crank at the handlebar console to make sure that the deflector chute turns without binding If the deflector chute binds readjust bracket Figure 2 1 Item J as follows A Loosen screw Figure 2 1 Item Adjust bracket Figure 2 1 J by moving it inward or outward as necessary C Retighten screw Figure 2 1 Item D Repeat Step 7 Step 4 Attach Cables to Control Levers 1 Place one of the hex screws Figure 2 1 Item L through the hole in the right hand handlebar lever Hold the screw in
11. it Failure to obey the safety message could result in personal injury or property damage TRAINING 1 Very carefully read this Owner Operator Manual and any other literature you receive Be thoroughly familiar with the controls and proper use of the equipment Know how to stop the snowthrower and disengage its controls quickly 2 Never allow children to operate the snowthrower Never allow uninstructed or irresponsible adults to operate the snowthrower 3 Keep the area of operation clear of all persons particularly small children and pets PREPARATION 1 Thoroughly inspect the area where the snow thrower will be used Remove all doormats sleds boards wires and other foreign objects 2 Disengage all clutches and shift into neutral before starting the engine 3 Do not operate the snowthrower without wearing adequate winter outer garments Wear footwear that will improve footing on slippery surfaces 4 Handle gasoline with care it is highly flammable and its vapors are explosive 5 Adjust the collector housing height to clear gravel or crushed rock surfaces 6 Never attempt to make any adjustments while the snowthrower is running unless otherwise specified in this Manual 7 Let the engine and snowthrower adjust to out door temperatures before starting to clear snow 8 Always wear safety glasses or eye shields during operation or while performing an adjustment or repair to protect your eyes from o
12. or drugs Never attempt to carry children on the snow thrower They could fall off and be seriously injured or they could interfere with the safe oper ation of the snowthrower Use extra care when using the snowthrower near blind corners shrubs trees and any other objects that may obscure vision Keep children out of the area of operation Keep children under the watchful eye of an adult other than the person operating the snowthrower Never assume that children will remain where you last saw them BrentChalmers com SAFETY 27 Do not use the snowthrower near drop ofts ditches or embankments If the snowthrower s wheel should go over the edge or if the edge would cave in the snowthrower could suddenly overturn 28 Do not wear loose clothing such as scarves that could get caught in the rotating parts of the snowthrower 29 Exercise caution to avoid slipping or falling especially when operating in R Reverse MAINTENANCE AND STORAGE 1 Never perform any maintenance while the engine is running or when the spark plug wire is connected to the spark plug except when specif ically instructed to do so in this Manual 2 Check shear bolts and other fasteners at fre quent intervals for proper tightness to be sure the snowthrower is in safe working condition 3 Never store the snowthrower with gas in its gas tank inside a building where ignition sources such as hot water heaters space heaters clothes dry
13. read Section 2 Easy Assembly all the way through These assembly instructions will tell you how to assemble your new snowthrower with a minimum of tools time and fuss Before starting or operating the snowthrower read Section 1 Safety Section 3 Snow Thrower and Engine Controls and Section 4 Operation Make sure that you know how to safely operate the snowthrower If you lend the snowthrower to another person be sure he or she reads understands and follows the safety and operating instructions given in this Manual Of course if you should have any questions about your snowthrower we are never farther away than your telephone Our telephone numbers and business hours are on Page 3 and on the back cover of this Manual if you should ever need replacement parts for your snowthrower you can either stop by your local dealer or order the part directly from us Please remember we are here to help you TROY BILT Manufacturing Company This TROY BILT Snowthrower has passed the safety standards of the Outdoor Power Equipment Institute and an individual testing laboratory ANS B71 3 1984 SAFETY STANDARD 2 BrentChalmers com FOR SERVICE OR PARTS For service questions operating questions or addresses hours and telephone numbers are listed replacement parts you can either contact us at the below for your convenience factory or see your local servicing dealer Our factory ADDRESS HOUR
14. to move the choke knob all the way to its FULL CHOKE position You may only have to move the choke knob to a partial choke postion between CHOKE OFF and FULL CHOKE positions Or you may not have to move the choke knob away from its CHOKE OFF position Pre Starting Primer Button Figure 3 5 Item H The pre starting primer button is located on the upper left hand side of the rear of the engine Pressing this button pumps small amounts of gaso line into the engine to improve cold weather starting Make sure that your finger covers the small hole in the center of the button when you press it Engine Recoil Starter Figure 3 5 Item The recoil starter is located on the rear of the engine It is used to pull start the engine To use the recoil starter slowly pull the recoil starter s black plastic handle until you feel some resistance from engine compression Look behind you to make sure there are no obstacles in the way and then rapidly pull the handle Allow the rope to slowly be pulled back into the recoil starter mechanism Repeat as necessary until the engine starts TO OPEN TURN THE LEFT VALVE COUNTERCLOCKWISE IF SO EQUIPPED Figure 3 6 Fuel Shutoff Valve Figure 3 6 The fuel shutoff valve is located beneath the gas tank It is located in the fuel line between the gas tank and the carburetor Turning the fuel shutoff valve clockwise will shut off the fuel flow to th
15. without proper adjustment of the snow discharge angle and direction Keep chil dren and pets away Do not overload the snowthrower capacity by attempting to clear snow at too fast a rate Never operate the machine at high transport speeds on slippery surfaces Look behind and use care when backing Never direct discharge at bystanders Never allow anyone in front of the snowthrower Disengage power to the auger when the snow thrower is transported or not in use Use only attachments and accessories that are recommended by Troy Bilt Manufacturing Company Never operate the snowthrower without good visibility or light Always be sure of your footing and keep a firm hold on the handles Walk never run If the auger impeller or discharge chute should clog with snow NEVER use your hands or feet to remove the snow Shut the engine off and dis connect the spark plug wire Then use a long stick at least 3 feet long to clear the blockage Do not change the engine governor setting or overspeed the engine Stop both the wheel drive and the auger drive if you are approached by any child inattentive adult or pet Do not touch engine parts which may be hot from operation Allow the engine to cool before inspecting cleaning or repairing it If you have to pull the snowthrower rearward release both handlebar levers Always check behind you for hazards Do not operate the snowthrower while under the influence of alcohol
16. 2 turns of the discharge chute con trol crank to move the discharge chute from full left to full right When throwing snow turn the discharge chute so that it throws the snow downwind as long as down wind is in a safe direction When you begin a turn while throwing snow remember to move the discharge chute so that the snow is always being discharged downwind Figure 3 2 Discharge Chute Deflector Cap Figure 3 2 D This control is used to direct the vertical angle of snow discharge This angle is adjusted by moving the lever on the side of the deflector cap outward mov ing the deflector cap up or down as required and then releasing the lever Usually keep the angle of snow discharge low especially in windy conditions Shift Handle Figure 3 3 DD The shift handle is located on the right hand side of the rear of the chassis It is used to select one of three forward speeds 3 High 2 Medium or 1 Low N Neutral or R Reverse In the N Neutral position the wheels are free to turn and you can eas ily push the Bren almers corm SNOW THROWER AND ENGINE CONTROLS snowthrower when the shift handle is in any of the forward or reverse gears It will take increased effort because you are also turning the wheel drive system by way of the wheels When the top of the shift handle is moved all the way to the right the snowthrower will be in R Reverse
17. 5 to 20 PSI Pounds per Square Inch Step 6 Add Oil to the Engine 1 Unscrew the dipstick oil filler cap Figure 2 1 Item O 2 Insert a clean funnel into the oil filler tube 3 Slowly pour engine oil into the oil fill tube The engine should hold approximately 21 ounces of oil While pouring pause frequently to check the oil level by reinstalling the dipstick firmly screw it in place and then removing it Don t over fill the engine with oil stop adding oil when it reaches the mark on the dipstick Step 7 Check the Transmission Gear Oil Level Although we filled your snowthrower s transmission with the correct SAE 90 weight gear oil at the factory be sure to double check the gear oil s level Please refer to Lubrication on Page 20 of this Manual for instructions Step 8 Attach the drift slicers to the snowthrower s auger housing Use four 5 16 18 x 3 4 flange screws and lock nuts to secure the drift slicers to the outside of the snowthrower s auger housing Use bolt holes Figure 2 1 BB when attaching the drift slicers You ve now finished assembling your snowthrower Please read Section 1 Safety Section 3 Controls and Section 4 Operation before you start the snowthrower s engine Note Store the two extra shear bolts and nuts in an easily remembered location If an auger shaft bolt should break simply replace it with one of these bolts 10
18. ANCE TROUBLESHOOTING Trouble Engine won t start Solution Ignition key in OFF position Spark plug wire disconnected Gas tank empty Fouled spark plug Engine Control Lever is in idle position Engine not primed enough Engine primed too much Fuel shutoff valve closed Engine is difficult to start Turn key to ON position Reconnect spark plug wire to spark plug Fill gas tank Remove clean inspect or replace re gap and reinstall spark plug Move Engine Control Lever to its FAST position Push primer button several more times Move choke knob to its OFF position and Engine Control Lever to idle Attempt to start engine this should burn up excess gas in carburetor Then proceed with normal starting procedure Open fuel shutoff valve Incorrect Choke Knob setting Engine Control Lever is in incorrect position Fuel shutoff valve closed Engine not primed enough Stale gas in tank Faulty spark plug Reposition Choke Knob Move Engine Control Lever to its FAST position Open fuel shutoff valve Push primer button several times Drain gas Refill with fresh gas Remove clean inspect re gap and reinstall spark plug Engine idles rough k S Faulty or fouled spark plug Incorrect choke setting Remove clean inspect re gap and reinstall spark plug After engine starts move engine choke knob gradu
19. C When connecting or disconnecting the elec trical cord stand on dry ground do not stand in puddles or on wet ground Make sure that your hands or gloves are not wet Do not use the electric starter if it is raining D When connecting the electrical cord first connect the cord to the electric starting switchbox on top of the engine Then connect the electri cal cord to a properly grounded 120V wall outlet This will help prevent any sparks from occurring near the engine BrentChalmers com To prevent a shock hazard use the electric starting system only with an electrical cord rated for outdoor use Be sure this electrical cord is of a sufficient gauge F Do not abuse the electrical cord Never pull the snowthrower by the cord Never yank the cord to disconnect it from the outlet Keep the cord away from oil sharp edges and excessive heat OPERATION 1 Before each use check the operation of the snowthrower s controls Do not operate the snowthrower unless all controls are functioning properly 2 Do not put hands or feet near or under rotating parts Keep clear of the intake and discharge openings at all times 3 Exercise extreme caution when operating or crossing gravel drives walks or roads Stay alert for hidden hazards or traffic 4 After striking a foreign object stop the engine disconnect the spark plug wire from the spark plug and thoroughly inspect the snowthrower for any damage Repair any
20. INE AND SNOWTHROWER MAINTENANCE the hole Allow any excess to drain out of the gear box Wipe any excess gear oil off the gear box Reinstall the plug 8 Touch up any scratches unpainted or rusty sur faces with paint Wheel Drive Cable Adjustment CAUTION Before adjusting the wheel drive cable shut the engine off allow it to cool disconnect the spark plug A wire and prevent it from touching the spark plug and remove the engine ignition key Failure to do this could result in personal injury or property damage Figure 5 5 Figure 5 6 1 Remove the two screws that secure the sides of the belt cover Figure 5 4 Item F to the snow thrower Take the belt cover off the snowthrower 2 Push the idler pulley Figure 5 5 Item G to the left until the belt Figure 5 5 Item H is tight Adjust the idler stop Figure 5 5 Item 1 so that there is a gap of 3 8 inch between the left hand edge of the idler stop and the inner surface of the frame Make this adjustment by loosening the idler screw stop nut Figure 5 5 Item J and slid ing the idler stop right or left as needed Re tighten the idler stop nut when you have the 3 8 inch gap 4 Check the tension on the wheel drive cable It should just be taut when the Wheel Drive Lever is not engaged If it is slack or too taut adjust the cable tension at the adjustment section Figure 5 6 Item 5 Make sure that the spark plug wire is d
21. O NOT use your hands or feet to dislodge it Shut the engine off disconnect the spark plug wire and prevent it from touching the spark plug Then use a long stick at least 3 feet long to unclog thses areas For best results remove snow as soon as possible after it falls 18 Always slightly overlap each pass to make sure that all snow is removed If possible always try to throw snow downwind If you try to throw snow upwind it could be blown back on you on the snowthrower and on the area you re clearing If you re throwing snow from a smooth area adjust the skid shoes so that the scraper blade is above the ground by approximately 1 8 inch If you re throwing snow from a gravel covered area adjust the skid shoes so that the scraper blade clears the gravel BrentChalmers com SECTION 5 ENGINE AND SNOWTHROWER MAINTENANCE ENGINE MAINTENANCE Checking Engine Oil Level and Adding Oil to Engine Before each use check the engine oil level Also while using the snowthrower stop the engine and check its oil level every five hours of operation To check the engine oil level 1 Shut the engine off 2 Unscrew the dipstick Figure 5 1 A Use a clean cloth to wipe the dipstick 3 Re insert the dipstick into the oil fill tube Firmly screw the dipstick all the way back into the oil fill tube 4 Unscrew the dipstick and check the oil level It should be between the FULL and ADD m
22. S TELEPHONE NUMBERS In the U S A TROY BILT MFG CO M F 8 a m to 7 p m Toll free 1 800 833 6990 102nd St amp 9th Ave Sat 9 a m to 4 p m Troy NY 12180 In Canada GARDEN WAY CANADA INC M F 8a m to5p m Local 416 area code 624 8423 1515 Matheson Blvd Unit B11 From Ontario amp Quebec Toll free 1 800 387 3351 Mississauga Ontario L4W 2P5 From western Canada amp the Maritime Provinces Toll free 1 800 387 3316 When you contact the factory or local servicing dealer for parts or service information please provide the following information Snowthrower Serial Number See Figure at right Snowthrower Model Number Date of Delivery Engine Manufacturer Engine Model SERIAL NUMBER AND Serial Number MODEL NUMBER DECAL For the location of the engine model serial number please refer to the engine owner s manual which was included in the literature package IMPORTANT All references to left right front and rear in this Manual are determined from the operator s position standing behind the handlebars and facing the direction of for ward travel BrentChalmers com SECTION 1 SAFETY IMPORTANT Safe Practices for Walk Behind Snowthrowers This is a safety alert symbol It is used in this Manual and on snow thrower decals to alert you to poten tial hazards Whenever you see this symbol read and obey the safety message that follows
23. ally to its NO CHOKE position BrentChalmers com ENGINE AND SNOWTHROWER MAINTENANCE Trouble Engine overheats Auger drive lever does not make auger spin TROUBLESHOOTING Dirty air screen Low engine oil level Dirty cooling fins Loose spark plug Solution Remove all debris from air screen Check engine oil level Add oil as necessary Clean cooling fins Disconnect spark plug wire Re tighten spark plug Not enough tension on auger drive belt Incorrect auger drive belt adjustment Broken shear bolt s on auger drive shaft s Broken idler spring at lower end of cable Broken cable Belt guide s adjusted incorrectly Broken square key or loose setscrew on auger drive pulley Broken woodruff key and roll pin on transmission input shaft Auger spins when Auger Drive Lever is not engaged 26 Too much tension on auger drive cable Incorrect auger drive belt adjustment Belt guide s adjusted incorrectly Increase tension at auger drive cable adjustment section Re adjust auger drive cable Replace bolt s Replace spring Replace cable Belt guides should be 1 16 inch away from belt Replace key and retighten setscrew Replace woodruff key and roll pin Cable should just be taut when Auger Drive Lever is not engaged Adjust tension at auger drive cable adjustment section Adjust auger drive belt B
24. an Engine Ignition System 20 Discharge Chute Control Crank 11 BOO PUG 20 Discharge Chute Deflector Cap 11 Carburetor Adjustment 20 Shit Handl 2 ww toe cae iie 11 Snowthrower Maintenance 20 SKid NOOR eee ene Peed 12 pat S Blad 12 LUBMCAION esa kamus a 20 E a a Wheel Drive Cable Adjustment 21 ngine ontro Wh al Dive Halt and Engine Ignition Keyswitch 12 21 Engine Control Lever 13 Auger Drive Cable Adjustment 22 Engine Choke Knob 13 Auger Drive Belt Removal and Pre Starting Primer Button 13 HASTA LION 23 Engine Recoil Starter 13 Maintenance Schedule 24 Fuel Shutoff Valve 2 13 Troubleshooting 25 120V Electric Starter Optional 13 Specifications Inside Back Cover BrentChalmers com Dear TROY BILT Snowthrower Owner Congratulations You now own one of the finest snowthrowers available today To help you safely and efficiently assemble operate and service your snowthrower we ve prepared this Owner Operator Manual for you This Manual gives you important information you need to safely operate and service your snowthrower Before assembling your new snowthrower please
25. arks on the dipstick 5 If the oil level is low add oil as follows A Remove the dipstick B Insert the clean funnel into the oil fill tube C Slowly pour oil into the funnel While pouring stop frequently remove the funnel reinstall the dipstick then remove it and check the oil level Don t overfill the engine with oil D When the engine oil level is correct securely reinstall the dipstick Figure 5 1 Changing the Engine Oil After the very first two hours that you operate your snowthrower change the engine oil After this initial engine oil change change the engine oil every 25 hours of operation or at the end of the snow throwing season whichever comes first To change the engine oil 1 Start the engine Allow it to warm up to operating temperature 2 SHUT THE ENGINE OFF 3 Fold a piece of cardboard approximately 3 inches by 6 inches lengthwise into a shallow V See Figure 5 2 4 Use 3 8 inch open end wrench or an adjustable wrench to loosen not remove the engine oil drain plug Figure 5 2 5 Place the folded cardboard beneath the drain plug as shown in Figure 5 2 6 Place a container minimum capacity of 1 quart underneath the end of the cardboard to catch the draining oil Figure 5 2 BrentChalmers com ENGINE AND SNOWTHROWER MAINTENANCE 7 Slowly unscrew the drain plug Allow the oil to run down the cardboard and into the conta
26. bjects that may be thrown from the machine 9 Check the engine oil level before starting the engine 10 Check the gas level in the gas tank before start ing the engine Don t fill the gas tank when the 11 12 13 14 15 16 snowthrower is indoors or when the engine is running or hot Allow the engine to cool for sev eral minutes before filling the gas tank Use an approved fuel container Use a funnel or spout to prevent spillage After filling securely reinstall the gas tank and fuel container caps Wipe up any spilled gasoline before starting the engine Do not fill the gas tank all the way up to the top of the filler neck Fill the tank up only to within 1 2 inch of the bottom of the filler neck Before starting the engine check the auger and discharge chute to make sure that they are free of ice Do not operate the snowthrower without guards or safety devices in place Do not attempt to defeat the purpose of these safety devices Before starting the engine check the snowthrow er for loose or missing fasteners nuts screws amp bolts Keep smoking materials sparks and flame away from the gas tank and fuel container For electric starting snowthrowers A Use 3 pronged properly rated and approved electrical cord Make sure that you plug this electrical cord into a properly grounded 3 pronged outlet B Before use inspect the electrical cord to make sure that it is not damaged
27. ces clothes dryers stoves electric motors etc are present Never refuel the gas tank when the electrical cord is connected to the snowthrower on electric start models Failure to follow these instructions could result in personal injury or property damage BrentChalmers com A Unscrew the gas tank cap from the engine s gas tank B Insert a clean funnel into the gas tank or use a fuel container that has a flexible pour spout C Pour the gas into the tank Don t fill the tank all the way Leave approximately 1 4 inch of air space between the top of the fuel and the bottom of the gas tank s filler neck D Wipe up any spilled gas Securely reinstall the gas tank cap 2 Move the shift handle Figure 3 3 Item D to its Neutral position N 3 Turn the engine ignition key Figure 3 1 E to its RUN position 4 Move the choke knob Figure 3 4 Item G to its FULL CHOKE position if the engine is cold to a partial choke position if the engine is warm from a previous run 5 Push the pre starting primer button Figure 3 4 Item H two or three times Omit this step if you are using the 120V electric starter If the engine is still warm from a previous run push the pre start primer button one time only If the temperature is below 15 F you may have to push the pre starting primer button more than three times 6 Move the engine control lever to its FAST position 7 Make sure tha
28. ch box As soon as the engine starts release the button D Gradually move the choke knob to its NO CHOKE position and allow the engine to warm up E After the engine is warmed up unplug the electrical cord from the 120V wall outlet Then unplug the electrical cord from the switchbox on top of the engine 10 Check operation of the Auger Drive Lever as follows A Quickly squeeze and release the Auger Drive Lever B The auger should begin spinning when you squeeze the lever It should stop spinning when you release the lever A WARNING the auger spins before you squeeze the Auger Drive Lever or if the auger continues to spin after you release the Auger Drive Lever do not use the snowthrower Shut the snow thrower s engine off disconnect the spark plug wire and prevent it from touching the spark plug Adjust or repair the auger drive mechanism See Auger Drive Cable Adjustment Failure to follow this instruction could result in personal injury or property damage 11 Check the operation of the Wheel Drive Lever as follows BrentChalmers com 16 OPERATION A Move the shift handle to its LOW position B Quickly squeeze and release the Wheel Drive Lever C The wheels should begin turning when you squeeze the lever They should stop turning when you release the lever WARNING If the wheels turn before you squeeze the Wheel Drive Lever or if the wheels continue to turn afte
29. ct electrical cord to switchbox then to a 120V wall outlet B While engine is running push the starter button and spin the engine s starter for several seconds the unusual sound made by the spinning starter won t harm the engine or starter C Disconnect the electrical cord from the 120V wall outlet Then disconnect the electrical cord from the switchbox 5 Turn the engine ignition key to its OFF position Remove key 6 Disconnect the spark plug wire and prevent it from touching the spark plug 7 To help avoid possible freezing of the controls A Wipe all snow and moisture from the engine in the vicinity of the engine control lever and the choke knob B Move the engine control lever and the choke knob back and forth several times C Move the choke knob to FULL and leave it in this position D Move the engine control lever to the start position and leave it there E Close the fuel valve beneath the engine s gas tank Moving the Snowthrower in Reverse 1 Release both handlebar levers Auger Drive and Wheel Drive If the snowthrower was moving for ward allow its forward motion to stop 2 Move the shift handle into R Reverse the top of the shift handle will be all the way to the right CAUTION Before engaging the Wheel Drive Lever when the snowthrower is in Reverse R look behind you to make sure that there are no obstacles Failure to follow this instruction could result in personal injury or
30. d ordering instructions BrentChalmers com SECTION 2 EASY ASSEMBLY Before you begin assembly read this Section all the way through to familiarize yourself with the assembly steps Then gather the tools you ll need To assemble your snowthrower you ll need 1 One quart of clean high quality engine oil Refer to Specifications on the inside back cover for the recommended types and viscosities 2 Two 7 16 inch wrenches 3 Two 1 2 inch wrenches one of these should be an open end wrench 4 One 3 8 inch wrench small amount of multipurpose automotive grease One 5 16 inch wrench One automotive type tire pressure gauge One 9 16 inch wrench A clean funnel 10 A hammer and block of wood to tap the roll pin into the plastic universal joint You can substitute adjustable wrench es Compare the parts you received the shipping carton with the list below to make sure you received everything If you are missing any parts please con tact your local servicing dealer or call the factory for replacements Your shipping carton should contain The snowthrower engine auger assembly The handlebar assembly The discharge chute assembly The hardware package which consists of One roll pin Two 10 24 x 7 8 hex screws Two 10 flat washers Two 10 24 locknuts Two ignition keys One tie strap Two cable brackets Six locknuts 5
31. damage before restart ing and operating the snowthrower 5 If the snowthrower should start to vibrate abnor mally stop the engine disconnect the spark plug wire and check immediately for the cause Vibra tion is generally a warning of trouble 6 Stop the engine and disconnect the spark plug wire whenever you leave the operating position before unclogging the auger impeller housing or discharge chute and when making any repairs adjustments or inspections 7 When clearing repairing or inspecting make sure that the auger impeller and all other mov ing parts have stopped Stop the engine discon nect the spark plug wire and keep it away from the spark plug to prevent accidental starting 8 Do not run the engine indoors except when starting the engine and transporting the snow thrower into or out of the building Open the buillding s outside doors exhaust fumes con tain carbon monoxide a deadly poison that is odorless and colorless 9 Do not clear snow across the face of slopes Exercise extreme caution when changing direc tion on slopes Do not attempt to clean steep slopes 10 Never operate the snowthrower without proper guards plates or other safety protective devices in place 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 SAFETY Never operate the snowthrower near buildings glass enclosures automobiles window wells drop offs etc
32. e 5 8 Item Q Move the snowthrower halves together Align the four attachment holes two in each side of the frame Loosely install the four screws Figure 5 8 Item Q that secure the halves of the snowthrower together Then firmly tighten the screws Reinstall the worm gear and support Figure 5 7 Item M to the left hand side of the snowthrower Firmly tighten the bolt Figure 5 7 Item N that holds it in place Rotate the chute control crank to make sure that the deflector chute turns freely If it doesn t loosen the bolt Figure 5 7 Item N and adjust the support inward or outward so that the chute doesn t bind Adjust the wheel drive cable See Wheel Drive Cable Adjustment Reinstall the belt cover on the snowthrower Auger Drive Cable Adjustment CAUTION Before adjusting the auger drive cable shut the engine off allow it to cool disconnect the spark plug wire and prevent it from touching the spark plug and remove the engine ignition key Failure to follow this instruction could result in personal injury or property damage Figure 5 9 BrentChalmers com ENGINE AND SNOWTHROWER MAINTENANCE 1 Remove the two screws that secure the sides of the belt cover Figure 5 4 F to the snow thrower Take the belt cover off the snowthrower 2 Push the idler Figure 5 9 Item T sideways to tighten the auger drive belt 3 Look at the brake arm hole Figure 5 9 Ite
33. e carburetor Turning the fuel shutoff valve counterclockwise will allow fuel to flow between the gas tank and the carburetor After shutting the engine off turn the fuel shutoff valve off Before starting make sure that you turn the fuel shutoff valve on or else the engine will stop and you will not be able to re start it until you turn the fuel shutoff valve back on 120V Electric Starter Optional The 120V electric starter switch is mounted on top of the engine To function the electric starter must first be con nected to a 120V wall outlet After this connection is made you simply push the starter button on top of the electric starter switch to start the engine As soon as the engine starts release the starter button The electric starter is thermally protected If over heated it will automatically stop Allow the starter to cool before attempting to use the electric starter Be sure to review the operating instructions that come with the electric start kit BrentChalmers com SECTION 4 OPERATION Pre start Checklist 1 Review Section 1 Safety and Section 3 Controls 2 Check the snowthrower for any loose or missing hardware 3 Check the engine oil level 4 Check the level of the gas in the gas tank 5 Check the skid shoe Figure 4 1 Item A adjust ment See Skid Shoes in Section 3 6 Check the scraper blade Figure 4 1 Item for wear and adjustment 7 Check the discharg
34. e chute crank Figure 3 1 Item C for freedom of movement Then adjust the discharge chute and deflector cap Figure 4 2 Item to the desired direction and angle discharge 8 Make sure that the chute guard Figure 4 2 D is installed 9 Check the handlebar control levers Figure 3 1 Items A amp B for freedom of movement Check the tire pressure Make sure both tires are inflated equally Correct tire pressure is 15 to 20 PSI HINT To help prevent snow from sticking to the inside of the deflector discharge chute and auger impeller housing spray these areas with a silicone spray 10 Figure 4 1 Figure 4 2 Starting 1 Fill the snowthrower s gas tank as follows Gasoline is highly flammable and its vapors are explosive Never fill gas tank when engine is running or still hot from operation Allow engine and muf fler to cool at least 2 minutes before refueling Do not allow open flames sparks matches or smoking in the area e Fill fuel tank outdoors in a well ventilated area e Wipe up any spills and move the snowthrower away from gasoline fumes before starting the engine e Use only an approved gasoline container Store it safely out of the reach of children 14 Store gasoline in a well ventilated area Do not store where vapors may reach an open flame or spark or where ignition sources such as a hot water heater or space heater furna
35. elt guides should be 1 16 inch away from belt BrentChalmers com ENGINE AND SNOWTHROWER MAINTENANCE TROUBLESHOOTING Trouble Wheel Drive Lever does not make wheels turn Possible Problem Shift Handle is in N Neutral Not enough tension on wheel drive belt Incorrect wheel drive belt adjustment Broken or excessively worn wheel drive belt Broken wheel drive cable Broken wheel drive spring on end of cable Broken square key or loose setscrew on wheel drive pulley Broken wheel drive chain Broken woodruff key and or loose setscrew on wheel drive pulley s Wheels turn when Wheel Drive Lever is not engaged Too much tension on wheel drive cable Incorrect wheel drive belt adjustment Belt guide s adjusted incorrectly Cable should just be taut when Release Wheel Drive Lever move Shift Handle to desired speed re engage Wheel Drive Lever Cable should just be taut when Wheel Drive Lever is not engaged Adjust tension at wheel drive cable adjustment section Re adjust wheel drive belt Replace wheel drive belt Replace wheel drive cable Replace spring Replace key retighten setscrew Replace chain Replace woodruff key and tighten setscrew Wheel Drive Lever is not engaged Adjust tension at wheel drive cable adjustment section Re adjust wheel drive cable Belt guides should be 1 16 inch away from belt Snowthrower doesn
36. ers etc are present Allow the engine to cool before storing the snowthrower in any enclosure 4 Refer to Storage in this Manual and to the Engine Owner s Manual for important details if the snowthrower is to be stored for an extended period 5 Maintain or replace safety and instructional labels as necessary See the Snowthrower Parts Catalog for location of labels 6 Run the snowthrower a few minutes after you ve finished throwing snow to prevent freeze up of the auger Brush off snow build up on the snowthrower 7 Remember the end of the winter is a good time to inspect your snowthrower and order any replacement parts 8 Use only genuine Troy Bilt replacement parts Replacement parts manufactured by others could present safety hazards even though they may fit on this snowthrower 9 Store gasoline in a cool well ventilated area safely away from any sparks or flame producing equipment Store gasoline in an approved con tainer safely out of the reach of children 10 Touch up scratches unpainted or rusted areas with paint DECALS For your personal safety and the safety of others a number of safety message decals have been affixed to your snowthrower Keep them clean and legible at all times Contact your local servicing dealer or the factory for replacements if any of these decals is missing or becomes illegible Refer to the separate Snowthrower Parts Catalog for decal locations part numbers an
37. he belt guide Figure 5 9 Item S to the back of the engine and move the belt guide out of the way 6 Loosen the two belt guides that are located on the back of the auger housing below the auger drive pulley Rotate the belt guides out of the way 7 Take the old auger drive belt off the engine pulley and auger drive pulley To install the auger drive belt 1 Adjust the Auger Drive Cable See Auger Drive Reinstall the belt cover on the snowthrower Place the new auger drive belt into the groove in the auger drive pulley Move one of the belt guides on the back of the auger housing below the auger drive pulley so that its leg is 1 16 inch away from the auger drive belt Hold the belt guide in this position Tighten the bolt that secures this belt guide to the back of the auger housing Repeat this step for the remaining belt guide Retighten the bolt that secures the belt guide Figure 5 9 Item S to the engine Move the rear half of the snowthrower close to the front half Place the auger drive belt into the the groove in the engine auger drive pulley Move the snowthrower halves together Align the four attachment bolt holes two on each side Loosely intall the screws Figure 5 9 Item X that secure the halves of the snowthrower together Firmly tighten these screws Reinstall the worm gear and support Figure 5 7 Item M to the left hand side of the snowthrower Firmly tigh
38. hermally protected If overheated it will stop auto matically Allow starter to cool before again trying to restart engine BrentChalmers com SPECIFICATIONS Snowthrower HEIGHT To top of handlebar lever 421 2 inches Without handlebars 2914 inches WIDTH At tires 1934 inches At handlebars 23 inches LENGTH With handlebars 591 inches Without handlebars 40 inches TIRES 2 ply 4 10 4 Pressure 15 20 PSI AUGER WIDTH 21 inches TRANSMISSION GEAR OIL SAE 90W gear oil OPTIONAL EQUIPMENT Electric Start Kit 120 Volt Tire chains Single Cylinder Tecumseh 5 horsepower Oil recommendations Use a high quality 4 cycle engine oil rated SD SE or SF Viscosities Below 0 SAE 0 30 or SAE 10W diluted with 10 kerosene Between 0 32 F SAE 5W30 or SAE 10W Above 32 F SAE 30 or SAE 10W30 Fuel recommendations Use a fresh clean unleaded regular gasoline Do not mix any oil with the gasoline Spark plug type See Engine Owner s Manual Spark plug gap 0 030 inch BrentChalmers com LIMITED THREE YEAR WARRANTY What is Covered Your TROY BILT Snowthrower is carefully inspected and tested at the Factory We or your Dealer will repair or replace at our option and at no cost to you any part which we find to be defective in materials or workman ship for a period of 3 years from the date you purchase your Snowthrower Note Warranty for commercial use is limited to ninety 90
39. hrown to this side BEGIN Figure 4 3 Snow throwing pattern when snow can only be thrown to one side Use the pattern shown in Figure 4 4 when you wish to throw snow to both the right and left sides of the area being cleared When using this pattern you have to change the direction of the discharge chute only when making a turn at the end of a pass eS SNOW IS THROWN TO EITHER SIDE 9 lt z N Fg N a a _ ar PATYA gt lt SS vsi S gt Discharge chute direction stays the same except when turning Snow is thrown to each side lt Bin as SSS lt Se SNOW IS THROWN TO EITHER SIDE Seat gs oS Figure 4 4 Throwing snow when snow be thrown to either side of the area being cleared BrentChalmers com OPERATION Run the engine at full throttle when throwing snow Use a lower wheel speed in heavy wet snow Spray the auger inside of auger housing inside of discharge chute and inside of deflector chute with silicone spray to prevent snow from sticking to these areas Before the first snowfall inspect the area in which you ll be using the snowthrower Remove any door mats sleds boards wires and other foreign objects If snow should stick in the deflector chute or auger D
40. ighten the adjustment section s two nuts to prevent the cable from pulling free of the adjustment section You ll tighten these nuts later after you ve checked the cable tension C Repeat Steps 5 A and 5 B for the remaining cable bracket and cable Check the tautness of the cables The cables should just barely be taut when the handlebar levers are not engaged If the cables have to be adjusted proceed as follows A Unscrew the upper nut on the adjustment sec tion several turns B If the cable tension is too loose screw the lower adjustment section nut counterclockwise as viewed from above until the cable is taut If the cable is too taut screw the lower adjust ment section nut clockwise as viewed from above until the cable is just taut C Use a 2 inch open end wrench to hold the lower nut in place Screw the upper nut clockwise until it touches the cable bracket Use another 1 2 inch open end wrench to securely tighten the adjustment section s upper nut tight against the cable bracket D Again check the tension of the cable to make sure that the tightening procedure did not upset the cable s adjustment BrentChalmers com EASY ASSEMBLY Step 5 Check the Tires Air Pressure 1 Use an automotive type tire pressure gauge to check the air pressure in the tires 2 Make sure that both tires are evenly inflated or else the snowthrower could pull to one side The correct tire pressure is 1
41. iner 8 After the oil has drained reinstall the drain plug and very securely tighten it 9 Add clean oil to the engine See Checking Engine Oil Level and Adding Oil to Engine Engine Ignition System The snowthrower engine has an electronic ignition system This system eliminates the traditional set of points and condensor The electronic ignition system also eliminates the yearly tune up The only sched uled maintenance you need to perform on the engine s ignition system concerns the spark plug which is discussed next Spark Plug Yearly or every 100 hours of operation remove the engine s spark plug clean it and inspect it Clean the spark plug by scraping it don t wire brush it or sand blast it Replace the spark plug with a new one if its electodes were pitted or burned or if its por celain was cracked Before installing the spark plug set its electrode gap at 0 030 inch COMPLIANCE WITH RADIO INTERFERENCE REGULATIONS CERTI FIED REPLACE SPARK PLUG WITH RESISTOR 030 8 mm SPARK PLUG FEELER GAUGE Figure 5 3 Carburetor Adjustment Your carburetor has been set for proper operation If you believe that it has come out of adjustment please refer to the engine owner s manual for the correct carburetor adjustment procedure SNOWTHROWER MAINTENANCE Lubrication Refer to Figure 5 4 and the numbered items follow ing it to determine which areas on your snowthrower should be
42. iscon nected and not touching the spark plug Pull the recoil starter rope while watching the engine wheel drive pulley Figure 5 8 Item L The belt should not move on this pulley If the belt does move decrease the 3 8 inch gap you set in Step 3 6 Reinstall the belt cover Figure 5 4 Item F on the snowthrower Wheel Drive Belt Removal and Installation CAUTION Before removing or install ing the wheel drive belt shut the engine off allow it to cool disconnect A the spark plug wire and prevent it from touching the spark plug and remove the engine ignition key Failure to do this could result in personal injury or property damage To remove the wheel drive belt 1 Remove the two screws that secure the sides of the belt cover Figure 5 4 Item F to the snow thrower Take the belt cover off the snowthrower 2 Remove the worm gear and support Figure 5 7 Item M from the left hand side of the snowthrower by removing the bolt Figure 5 7 Figure 5 7 BrentChalmers com ENGINE AND SNOWTHROWER MAINTENANCE 3 Remove the two each side flange screws Figure 5 8 Item O from the snowthrower Figure 5 8 4 Slowly pivot the rear half of the snowthrower back Rest the handlebars on a stable object 5 Take the auger drive belt Figure 5 8 off the engine auger drive pulley Figure 5 8 You may have to loosen the bolt that secures the belt guide
43. lubricated At the beginning and end of each snow throwing season be sure to lubricate the snow thrower as recommended This will help prevent any corrosion at 20 friction points during the off season It will also ensure that the snowthrower will be ready to use when the first snow falls Figure 5 4 1 Use clean engine oil or a silicone spray to lubri cate the handlebar levers pivot points Be careful not to get any oil or silicone spray on the levers 2 Clean any dirt off the toothed part of the flange on the bottom of the discharge chute Apply fresh grease to the worm gear and toothed part of the flange 3 Apply fresh engine oil to the bearing on each side of the auger shaft Wipe off any excess oil 4 Sparingly oil the discharge chute control crank where it enters the control panel Also oil it at the support on top of the left hand rear side of the frame 5 Sparingly apply oil to the two pivot points on the deflector cap 6 One at a time remove the wheels and apply fresh grease to the wheel shaft and clevis pin This makes future wheel removal easier 7 Check the auger gear box s gear oil level Move the snowthrower to a level area Unscrew the plug Figure 5 4 Item 7 from the front of the gear box Oil should just begin to flow out of the hole If it doesn t add SAE 90 gear oil to the gear box Fill the gear box until the oil just begins to flow from BrentChalmers com ENG
44. m U This hole should be flush with the outside of the right hand side of the frame 4 Ifthe brake arm hole is not flush with the outside of the right hand side of the frame loosen the two screws Figure 5 9 V and move arm Figure 5 9 Item W sideways as necessary Tighten the two screws and then repeat Steps 2 and 3 5 Check auger drive cable tension It should be taut when the auger drive handle is not engaged when it is not squeezed down Adjust tension at the auger drive cable e adjustment section at the lower end of the handlebar Figure 5 6 Auger Drive Belt Removal and Installation CAUTION Before removing or install ing the auger drive belt shut the engine off allow it to cool disconnect A the spark plug and remove the engine ignition key Failure to follow this instruction could result in personal injury or property damage 1 Remove the two screws that secure the sides of the belt cover Figure 5 4 F to the snow thrower Take the belt cover off the snowthrower 2 Remove the screw Figure 5 7 Item N worm gear and support Figure 5 7 Item M 3 Remove the two each side flange screws Figure 5 9 Item X from the snowthrower 4 Slowly pivot the rear half of the snowthrower back Rest the handlebars on a stable object 5 Take the auger drive belt Figure 5 8 Item P off the engine auger drive pulley Figure 5 8 Item Q You may have to loosen the bolt that secures t
45. place and put a spacer Figure 2 1 Item M over the threaded end of the hex screw Run the auger drive cable from the right hand side of the snowthrower upward beneath the handlebar control panel and place the upper end of the cable over the spacer 2 Place a flat washer and nut onto the threaded end of the hex screw Use a 5 16 inch and a 3 8 inch wrench to securely tighten the nut and hex screw 3 Repeat Steps 4 1 and 4 2 for the left hand handle bar lever and wheel drive cable Secure the adjustment section Figure 2 2 Item N EASY ASSEMBLY Attach the cable brackets to the lower inner side of the handlebar tubes as follows A Remove 74 20 x 3 4 screw from the inside bottom of the handlebar and insert it into one of the cable brackets Figure 2 2 Item AA B Place the legs of the bracket and screw on the lower inside of the handlebar tube See Figure 2 2 Use a 3 8 inch wrench to securely tighten the screw Make sure that the bracket is positioned as shown in Figure 2 2 with the horizontal leg of the bracket above the screw head C Repeat Steps 4 A and 4 B for the remaining bracket and screw of the cable to the cable bracket as follows A Pull downward on the cable and insert the adjustment section of the cable into the slot in the cable bracket The horizontal leg of the cable bracket should fit between the two nuts that are on the threaded portion of the cable s adjustment section B Loosely t
46. property damage A 3 Slowly squeeze the Wheel Drive Lever and guide the snowthrower rearward 4 Before shifting into one of the forward speeds release the Wheel Drive Lever and let the rear ward motion of the snowthrower stop BrentChalmers com Changing Speeds You can engage the Wheel Drive Lever when the shift handle is in any of the speeds R Reverse 1 First 2 Second or 3 Third You do not have to begin in 1 First and then shift up through 2 Second and then into 3 Third You can begin in 3 Third if you wish In 2 Second or 3 Third the snowthrower will move forward faster than in 1 First OPERATION Before moving the shift handle to another speed release the handlebar levers and let the forward or rearward motion of the snowthrower stop Then move the shift handle to the desired speed and re engage the Wheel Drive Lever Snow Throwing Tips Use the pattern shown in Figure 4 3 when snow cannot be thrown to one side of the area being cleared Begin throwing snow close to this side mak ing sure that the discharge chute directs the snow away from this side When you turn the snowthrower around at the end of each pass you ll have to gradu ally crank the discharge chute so that it always throws the snow away from the area where no snow can be thrown As you turn rotate the discharge chute so that snow is always thrown in this direction aa Snow is not t
47. r you release the Wheel Drive Lever do not use the snowthrower Shut the snow thrower s engine off disconnect the spark plug wire and prevent it from touching the spark plug Adjust or repair the Wheel Drive Mechanism See Wheel Drive Cable Adjustment Failure to follow this instruction could result in personal injury or property damage A 12 Move the shift handle into the desired speed range You do not have to start in 1 LOW See Changing Speeds 13 If both handlebar levers operate properly re engage the levers and begin operation NOTE If you only want to move the snowthrower but not throw snow simply engage the Wheel Drive Lever Leave the Auger Drive Lever disengaged released Stopping To quickly stop the snowthrower 1 Release both handlebar levers 2 Turn the engine ignition key to its OFF position To stop the snowthrower under normal conditions 1 Release both handlebar levers 2 Move the shift handle to its Neutral N position 3 Move the engine control lever to its idle position Allow the engine to run at idle for several minutes to melt any snow off the engine 4 To help avoid possible freezing of starter when snowthrower is not being used For standard start engines With engine running pull recoil starter rope all the way out 3 4 times the unusual sound made by the starter rope won t harm the engine or the starter For 120V electric start engines A Conne
48. t both handlebar levers Auger Drive and Wheel Drive are released WARNING Engine exhaust contains carbon monoxide an odorless and A deadly poison Do not run the engine indoors or in a poorly ventilated area Failure to follow this instruction could result in personal injury 8 To start the engine with the recoil starter A Grasp the black plastic handle of the recoil starter rope Figure 3 5 Item Look behind you to make sure there are no obstacles in the way Place your other hand on the right hand handle bar to stabilize the snowthrower when you pull the recoil starter rope B Pull the recoil starter rope handle out slowly until you feel some resistance from engine compression C Then pull the handle rapidly Allow the start er rope to rewind slowly Repeat as necessary until the engine starts OPERATION D Gradually move the choke knob to its NO CHOKE position and allow the engine to warm up 9 To start the engine with the optional 120V electric starter WARNING To prevent personal injury from electrical shocks Do not use the 120V electric starter in the rain Do not stand in puddles or on damp ground when using the electric starter or when connecting the electrical cord A Plug the electrical cord into the switchbox on top of the engine B Plug the other end of the electrical cord into a properly grounded 120V wall outlet C Push the starter button on top of the swit
49. ten the bolt that holds it in place Rotate the chute control crank to make sure that the deflector chute turns freely If it doesn t loosen the bolt Figure 5 7 and move the support inward or outward as necessary so that the dis charge chute does not bind when you rotate the chute control crank Cable Adjustment BrentChalmers com ENGINE AND SNOWTHROWER MAINTENANCE 24 MAINTENANCE SCHEDULE Check operation of Auger Drive Lever and Wheel Drive Lever Apply oil to handlebar control levers and linkages Check auger gear box oil level Add SAE 90 gear oil as required Check and clean engine cowling air screen on engine Check clean and re gap or simply replace spark plug Apply a light coating of multipurpose grease to axle shaft bearing Check wheel drive belt and auger drive belt for adjustment Sand and re paint any rusted areas Check engine oil level Check all fasteners a for tightness Change engine oil Check tire pressure Clean all snow slush and ice off snowthrower Check both belts for wear Apply a light coating of oil to drive chain Check belts for wear and damage Every 25 Every 50 At the each hours of hours of end of the use operation operation season BrentChalmers com ENGINE AND SNOWTHROWER MAINTEN
50. ust the skid shoes so that the scraper is above the gravel 12 To adjust the skid shoes 1 2 Move the snowthrower to a level area Shut the snowthrower s engine off Disconnect the spark plug wire and prevent it from touching the spark plug Use 9 16 inch wrench to loosen the two bolts that secure the skid shoe to the side of the auger housing Move the skid shoe up or down as necessary to obtain the desired gap between the scraper blade and the ground Repeat Steps 3 and 4 for the other skid shoe Be sure to adjust this skid shoe the same amount or else you ll get a sloping cut when you throw snow Scraper Blade Figure 3 4 The scraper blade is located at the lower rear of the auger housing It is attached to the auger hous ing by 5 bolts and nuts The scraper blade is adjusta ble for height and is replaceable in case it becomes worn out or damaged Since the scraper blade will contact the ground it will gradually wear and will be subject to damage At the beginning and end of each season check the scraper blade for excessive wear and damage You can adjust the scraper blade by loosening the 5 nuts that attach it to the auger housing The nuts are located in the lower inner surface of the auger housing When all the nuts are loose move the scraper blade up or down as necessary Hold the scraper blade in this position and re tighten the nuts ENGINE CONTROLS Engine Ignition Keyswitch Figure 3 1
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