How to use this file...(dealer Setup & Adjustment Guides)

Transcription

1 How to use this file...(ealer Setup & djustment Guides) Instructions for Print Vendors (Paper Manuals) Paper Size: * 8-1/2 x 11 * ody 50 lbs brilliant white offset or equivalent. Press: indery: OVRS: OY: General: * ody 1-color, 2-sided * 3-Hole rill (ealer Setup Guides must LWYS be 3-Hole rilled!) UL orner Stitch (Unless being prined as part of a complete set of Guides with Tabs). * This document is a self-covered piece. heck the front cover for the individual document number (a TP 300-XXXX-XX-XX-SM number). * RMMR: O number pages are LWYS right hand pages, and VN number are LWYS left hand pages. * This instruction page is NOT part of the manual and must NOT be printed. Pages labeled with the text THIS PG INTNTIONLLY LNK are placement pages ONLY, and should NOT be printed.

2 THIS PG INTNTIONLLY LNK

3 ealer Setup & djustment Instructions Large Frame Snowthrowers This ealer Setup Instruction applies to the following units: Mfg. No. escription LX, 8HP Snowthrower LX, 8HP Snowthrower (xport) , 9HP Snowthrower , 9HP Snowthrower (xport) , 11HP Snowthrower , 11HP Snowthrower (xport) TTNTION STUP PRSONNL: The safety warnings provided in this guide and in the operator's manual included with the unit contain important information that must be obeyed when assembling, setting-up, operating, servicing, transporting, or storing the unit. These warnings are highlighted by the safety alert triangle symbol shown above, which signifies that an important safety message is being provided. You must read, understand, and follow these warnings and instructions, and use safe shop and work practices at all times while working on or around this unit and all other outdoor power equipment. Sections and items denoted by the Setup symbol provide the information necessary to fully assemble, test, and prepare the units described above for delivery to your customers. Quick Setup List is provided on page 3 of this booklet to help you identify and check that the items have been performed. dditional information concerning functional tests, general adjustment procedures, and the location of normal lubrication points are included in these instructions. lthough all required lubrication and normal adjustments on factory-assembled components are done at the factory, this additional information is provided to assist you in ensuring that each unit is delivered to the customer in proper working order. Mfg. No. escription LX, 8HP Snowthrower , 9HP Snowthrower , 11HP Snowthrower , 13HP Snowthrower M, 13HP Snowthrower TL OF ONTNTS: SFTY RULS...2 STUP PROURS Quick Setup List...3 Uncrating...4 Reduce and heck Tire Pressures...4 ssembly...4 Install rift utters...4 Install Handle ars and ontrol Panel (optional)...5 heck Fluid Levels & Fill...6 Lubricate the Snowthrower...6 Perform Safety hecks...8 JUSTMNT PROURS uger rive Linkage djustments...9 Traction rive Linkage djustment...10 Speed Selector djustment...10 ischarge ontrol djustment...10 hute irection ontrol Rod Gear djustment...11 asy Turn able djustment...11 Scraper ar & Skid Shoe djustment...12 rive elt Replacement...13 uger elt Replacement...13 Traction rive elt Replacement / TP LW-S

4 860LX, 970, 1180, & 1390 Large Frame Snowthrowers SFTY RULS Read these safety rules and follow them closely. Failure to obey these rules could result in loss of control of equipment, severe personal injury or death to you, yourself or bystanders, or damage to property or equipment. This auger is capable of amputating hands and feet and throwing objects. The triangle in text signifies important cautions or warnings which must be followed. General Read the Operator s Manual carefully. e thoroughly familiar with all controls and proper equipment use. Never allow children to operate the machine. o not allow adults to operate it without proper instruction. Keep the area of operation clear of all persons, particularly small children and pets. Never discharge material toward any person or pet. Make sure: a. Snowthrower is in good operating condition; b. ll safety devices and shields are in place and working; c. ll adjustments are correct. Preparation Never attempt to make any adjustment while engine is running. Thoroughly inspect the area where the snowthrower is to be used and remove all objects such as door mats, sleds, boards, wires and sticks. isengage all clutches (release uger ontrol lever) before starting engine. o not operate snowthrower without wearing proper winter clothing. Wear footwear which improves footing on slippery surfaces. Handle gasoline with care - it is highly flammable. a. Use approved gasoline container. b. Never remove the fuel tank cap or add gasoline to a running or hot engine. c. Never fill the fuel tank indoors. d. Wipe up spilled gasoline. o not run engine indoors. xhaust fumes are deadly. Operation Keep hands and feet away from rotating parts. Keep clear of discharge opening at all times. lways clear snow up and down the face of slopes, never across the face. Use extreme caution when changing direction on slopes. o not attempt to clear slopes over 17.7% (10 ). Use extreme caution when operating on or crossing drives, walks or roads. Stay alert for hidden hazards and traffic. e especially careful not to touch snowthrower parts which might be hot from operation. llow such parts to cool before attempting to maintain, adjust or service. If unit starts to vibrate abnormally, disengage drives and stop the engine. heck immediately for the cause. Vibration is generally a warning of trouble. Never operate machine at high transport speeds on slippery surfaces. Use care when backing up. efore leaving operator s position for any reason: - shut off engine, - remove the ngine Key and - wait for all moving parts to stop. efore cleaning, repairing or inspecting the unit, make certain all moving parts have stopped. Remove the key to prevent accidental starting. lways use a grounded, 3-wire plug receptacle for electric starting. djust snow discharge angle for safe flow when operating near glass enclosures, automobiles, window wells, dropoffs, etc. WRNING To avoid serious injury, do not put your hands into the auger housing or discharge chute. If auger stalls or chute becomes plugged, use the following procedure to remove objects or clear the chute: 1. Release both the rive and uger ontrol levers. 2. Shut off the engine. 3. Remove the ngine Key. 4. Wait for moving parts to stop. 5. isconnect spark plug wire. 6. Use a narrow board to remove foreign objects and clear the chute or auger. Never put your hands into the auger or discharge chute. WRNING This unit is a two-stage snowthrower. The first stage is the auger, which feeds the snow back into the impeller housing. The second stage is the impeller, which throws the snow out the discharge chute. If bodily contact is made with the auger or impeller when they are rotating, severe personal injury will occur. To avoid injury, keep others and yourself away from the auger and the discharge chute whenever the engine is running. Read and follow all of the safety rules and warnings in this manual. o not overload machine capacity by clearing snow at too fast a ground speed. isengage uger ontrol when transporting or not in use. Never operate the snowthrower without good visibility or light. lways be sure of your footing. o not change the engine governor settings or over-speed the engine. Never direct the discharge chute at bystanders; nor allow anyone in front of the unit while it is operational. Never operate this machine without all of the proper guards or other safety protective devices in place. Maintenance & Storage Keep all nuts, bolts and screws tight to ensure that the equipment is in safe operating condition. Never store equipment with gasoline in the tank in a building where fumes may reach an open flame or spark. llow the engine to cool before storing in any enclosure. lways refer to the Operator s Manual for important details if snowthrower is to be stored for an extended period. Run auger drive a few seconds after completion of throwing snow to help clear out snow and prevent icing and freeze-up on unit. TP LW-S 2 8/2002

5 Quick Setup List - Page Setup Procedure Steps to Perform 4 Uncrating 860LX, 970, 1180, & 1390 Large Frame Snowthrowers 4 Reduce Tire Pressures Reduce Tire Pressure to 20 psi (137 kpa) & heck 4 ssembly Install rift utters Install Handle ars to Snowthrower Frame 6 heck Fluid Levels & Fill uger Gearcase ngine rankcase Fuel Tank 6 Lubricate Snowthrower Lubricate all grease & oil points 8 Perform Safety hecks Functional hecks heck that all Safety Guards are in place. heck Scraper ars & Skid Shoe Height heck rive ontrol & uger ontrol heck hute irection ontrol heck hute eflector ontrol heck Speed Selector ontrol Operational hecks Start ngine & Test LL ontrols Test uger Stopping Time (uger MUST stop within 5 seconds after the control is released.) Test rive ontrols heck For Fluid Leaks 8/ TP LW-S

6 860LX, 970, 1180, & 1390 Large Frame Snowthrowers Uncrating 1. Using a reciprocating saw, cut crate sides from bottom skid. Lift crate from bottom skid. 2. Remove screws securing skid shoes to bottom skid. Roll snowthrower from bottom skid backwards. 3. Make sure klik-pin is inserted through hole in wheel and axle shaft and secured. Figure 1. Klik-pin-locked. Klik-Pin Reduce and heck Tire Pressure The tires are over inflated for shipping purposes. It is very important to reduce the tire pressure to the following pressure: Pressure 20 psi (137 kpa) Figure 2. hecking Tire Pressure ssembly Install rift utters rift cutters (if equipped) are mounted to snowthrower auger housing backwards. Refer to Figure 3. Remove hardware and install drift cutters with hardware as shown. Figure 3. ssemble Handle ars. Screws, 5/16-18 x 3/4. Lockwasher, 5/16. rift utter. Nut, 5/16 TP LW-S 4 8/2002

7 860LX, 970, 1180, & 1390 Large Frame Snowthrowers ssembly ontinued Install Handle ars and ontrol Panel (If Required) 1. Locate handle bar assembly and attachment bolts. See Figure ttach handle bar assembly to snowblower frame using the 6 nuts, washers and bolts provided. See Figure Install upper hute irection ontrol Rod. See Figures 4 and Install ushing into bracket. See Figure Slide hute irection ontrol rod through bushing (, Figure 5) and install gear () onto the end of the upper hute ontrol Rod (). See Figure 5. Secure gear to control rod with otter Pin (). 6. ttach rive lutch able to clutch cable support. Secure cable to clutch lever assembly. 7. ttach Upper Speed Selector Shift Rod to lower shift rod. NOT: shift rod assembly must pivot freely on pivot blocks. 8. ttach Upper uger lutch Rod to lower clutch rod. Note: Refer to the djustments section of this manual for linkage adjustments. Figure 4. Handle ssembly. hute ontrol Rod. Handle ttachment bolt, Washer and Nut. Figure 5. ontrol Rod Gear. Plastic ushing. Roll Pin / otter Pin. hute irection ontrol Rod. Gear 8/ TP LW-S

8 860LX, 970, 1180, & 1390 Large Frame Snowthrowers heck Fluid Levels & Fill 1. heck auger gear case lubrication. Place the snowthrower on a level surface. Remove the pipe plug (, Figure 6). The lubricant should be level with the hole. If not, add Simplicity Winter Weight Worm Gear Oil 2. Fill the engine crankcase with oil as described in the engine Owner's Manual. WRNING Gasoline is highly flammable and must be handled with care. o not allow open flame, smoking or matches in the area. void overfilling. Figure 6. uger Gear ase Lubrication. Pipe Plug 3. Fill the fuel tank with gasoline. e sure to check your engine Owner's Manual for gasoline recommendations. o not overfill; allow space for gasoline expansion. Lubricate the Snowthrower UTION It is very important that grease fittings on auger shaft (see Figure 7) are lubricated regularly. If auger rusts to shaft, damage to worm gear may occur if shear pins do not break. With an oil can, apply medium weight (10W) oil to points shown in Figures 8 thru 12. There are two grease fittings in the auger shaft (Figure 7). Wipe fittings clean and apply two or three shots of grease. lso, use grease on points shown in Figure 9. Generally, all moving metal parts should be oiled where contact is made with other parts. Keep oil and grease off belts and pulleys NOT: Make sure auger shaft grease fittings have been lubricated to prevent shaft rusting. pply grease until it comes out both sides of shaft (gear box side and housing bearing side). Grease may be squeezed out at shear pin locations. Figure 7. Lubricate uger Shaft Figure 8. Lubricate eflector ap hinges (Remote ontrol Model Shown) TP LW-S 6 8/2002

9 860LX, 970, 1180, & 1390 Large Frame Snowthrowers Figure 9. Lubricate Points Where chute ontacts Flange (Oil); Lubricate Ring Gear and Pinion Gear While Rotating Spout (Grease) Figure 11. Lubricate ontrol Levers & Lube xles o Not Lubricate deflector cap control. Figure 12. Lubricate Points Where Free-Hand ontrol Linkage Pivots Figure 10. Lubricate Points Where ontrol Rods Pass Thru racket 8/ TP LW-S

10 860LX, 970, 1180, & 1390 Large Frame Snowthrowers Perform Safety hecks heck ngine ontrols 860 / 970 / Make sure all safety guards are in place and all nuts, bolts, clips, cotter pins and wires are secure. 2. heck to make sure spark plug wire is attached. 3. heck all controls for proper operation: a. The engine should stop when the key is removed. b. The throttle should control the engine speed and stop the engine when moved to the STOP position. c. The fuel shut-off valve should stop the flow of fuel to the engine d. The recoil starter or electric starter (if equipped) should crank the engine when activated. 4. heck the engine area for oil or gasoline leaks. orrect any problems in accordance with the engine manufacturers instructions. F 1390 F Figure 13. heck ngine ontrols. Primer. Fuel Shut-Off Valve. Recoil Starter. Throttle. hoke F. Key TP LW-S 8 8/2002

11 860LX, 970, 1180, & 1390 Large Frame Snowthrowers heck Snowthrower ontrols 1. heck the skid shoes to make sure they are set at the desired height. djust if necessary. 2. heck the traction drive control (, Figure 14). Snowthrower motion should stop when the control is released. 3. heck the auger control (). uger movement should stop when the control is released. 4. heck the chute direction control () for proper operation. The discharge chute should rotate freely in both directions. 5. heck the remote deflector control () for proper operation. The deflector should pivot freely up and down when the chute deflector control (F) is either pulled or pushed. 6. heck the speed selector () for smooth operation. The control must move freely into each speed position gate and remain in position when released. If controls do not function properly, perform the appropriate adjustment as shown in the djustment Section. 7. The auger is secured to the shaft by shear pins, which will break if the auger strikes an object. xtra shear pins are provided. Keep these pins with the Operators Manual. Lubricate the auger shaft. 860 / 970 / 1180 G 1390 Operational hecks 1. With engine at full speed, engage the auger control and release. o this ten (10) times. uger should come to a complete stop within five seconds each time. If not, perform uger djustments. 3. ngage traction control and release. o this ten times. Unit should come to a complete stop each time. If it does not, perform the Traction rive djustments. 4. Remove the engine key. The engine must stop. 5. Move the throttle to STOP. The engine must stop. G Figure 14. Snowthrower ontrols. Traction ontrol. ischarge hute ontrol. Speed Selector. uger ontrol. eflector ontrol F. Hand Warmer ontrol (Select Models) G. asy Turn ontrol F 8/ TP LW-S

12 860LX, 970, 1180, & 1390 Large Frame Snowthrowers djustments uger rive Linkage djustment Power oost Models For models with Power oost, adjust traction drive and auger drive linkages (same procedure): 1. With the drive lever engaged, the bottom end of lower rod () should be flush with bottom of spring (). If not, go to next step. Refer to Figure Loosen the two turnbuckle nuts () if tightened. Note that top turnbuckle nuts are left-hand threads and bottom turnbuckle nuts are right-hand threads. 3. While holding the lower rod, turn the turnbuckle () toward the right to lower the rod or toward the left to raise the rod. 4. ngage the drive lever to check the adjustment. When correct, hold the turnbuckle with a screwdriver and tighten the nuts against the turnbuckle. Figure 15. Traction and uger rive djustment. Upper Rod. Lower Rod. Nuts. Spring. Turnbuckle Standard Models (Without Power oost ) 1. With drive lever released, there should be 1/32" (.79 mm) clearance between the spring hook () and bottom of the lever (F). If not go to next step. Refer to Figure Loosen the two turnbuckle nuts () if tightened. Note that top turnbuckle nuts are left-hand threads and bottom turnbuckle nuts are right-hand threads. 3. Hold the lower rod to keep from turning and turn the turnbuckle toward the right to lower the spring or toward the left to raise the spring. 4. When correct, tighten the two nuts against the turnbuckle while holding turnbuckle in position with screwdriver. F Figure 16. uger rive djustment. Upper Rod. Lower Rod. Turnbuckle. Spring Hook. Nuts F. Lever TP LW-S 10 8/2002

13 860LX, 970, 1180, & 1390 Large Frame Snowthrowers Traction rive Linkage djustment 1. With the traction drive lever engaged, the bottom end of lower rod () should be flush with bottom of spring (). If not, go to next step. Refer to Figure Loosen the two turnbuckle nuts () if tightened. Note that top turnbuckle nuts are left-hand threads and bottom turnbuckle nuts are right-hand threads. 3. While holding the lower rod, turn the turnbuckle () toward the right to lower the rod or toward the left to raise the rod. 4. ngage the drive lever to check the adjustment. When correct, tighten the nuts against the turnbuckle. Rods flush with bottom of spring (lever engaged) Figure 17. Traction rive Linkage djustment. Upper Rod. Lower Rod. Nuts. Spring. Turnbuckle Speed Selector djustment 1. Loosen the two nuts (, Figure 18). 2. Place the shift lever (, Figure 14) in 5th gear. The lower speed selector rod (, Figure 18) will properly locate itself due to an integral spring. 3. Grasp upper speed selector rod (, Figure 18), and pull up, then tighten the two nuts (, Figure 18) while maintaining the position of the upper rod. Make sure the shoulders of the carriage bolts are in the slots. 4. lways check traction drive tension and auger drive tension after adjusting speed selector. Figure 18. rive Linkage. Nut. Lower Speed Selector Rod. Upper Speed Selector Rod 8/ TP LW-S

14 860LX, 970, 1180, & 1390 Large Frame Snowthrowers ischarge ontrol djustment If the discharge control is difficult to operate, first lubricate the pinion gear (, Figure 19) and ring gear (F). The pinion gear can be adjusted by loosening the nut (G) which holds the pinion gear bracket in the slotted hole. If the pinion gear is too tight against the ring gear, move it away slightly and then retighten the nut. heck operation again. If discharge control is still difficult to operate, see hute irection ontrol Rod Gear djustment. F G Figure 19. ischarge ontrol. Pinion Gear. U-Shaped racket. ontrol Rod F. Ring Gear. arriage bolt G. Nut. Slotted racket hute irection ontrol Rod Gear djustment If the discharge chute becomes difficult to rotate or begins to operate erratically, the chute direction control rod gears may require adjustment: See Figure Loosen the gear bracket mounting nuts (Figure 20). 2. Slide the gear bracket into the position that provides the best engagement between the gears. 3. Tighten the bracket mounting nuts, and check for smooth operation. 4. Readjust if necessary. 5. Lubricate the hute irection ontrol rod gears with lithium grease. Mounting Nuts Figure 20. hute irection Gear djustments lectric hute Rotator Motor djustment (Select Units) If the electric chute rotator does not function properly, check the electrical connections and then perform the procedure below. 1. Remove the rotator motor cover. 2. Lubricate the chute ring gear. 3. Loosen the capscrews (, Figure 21) securing the rotator motor and adjust so that the motor gear and chute ring gear mesh. Tighten the capscrews. 4. Reinstall the rotator motor cover. Figure 21. hute Rotator Motor djustment. apscrews TP LW-S 12 8/2002

15 860LX, 970, 1180, & 1390 Large Frame Snowthrowers asy Turn able djustment If the asy Turn cable has stretched, the gears will not disengage when the control lever is activated. djust the cable using the following procedure. 1. Turn the engine off and disconnect the spark plug wire. 2. Loosen the jam nut (, Figure 22). 3. Turn the adjustment nut () to lengthen or shorten the cable. The cable should be tightened just until all slack is removed from the lever, however it must not engage the asy Turn release without depressing the control lever. 4. Tighten the jam nut. Figure 22. able djustment. djustment Nut. Jam Nut Scraper ar & Skid Shoe djustment On smooth surfaces such as concrete or asphalt, the scraper bar should scrape the surface. On surfaces such as gravel, the scraper bar should be high enough so that it will not pick up gravel or debris. The height of the scraper bar is controlled by raising or lowering the Skid Shoes (See Figure 23). 1. To raise the scraper bar height, rest the scraper bar on a strip of wood equal in thickness to the desired height. 2. Make sure the scraper bar is parallel to the ground surface. 3. Loosen the skid shoe nuts and let the skid shoes drop to the surface. 4. Tighten the nuts, making sure the Skid Shoes are adjusted equally and are parallel to the surface. 5. To lower the height of the scraper bar, raise the Skid Shoes. 6. If the scraper bar becomes worn, it can be replaced by removing the mounting nuts and bolts attaching it to the snowthrower. Figure 23. Skid Shoe djustment. Scraper ar Mounting olt. Scraper ar. Skid Shoe Nuts. Skid Shoe 8/ TP LW-S

16 860LX, 970, 1180, & 1390 Large Frame Snowthrowers elt over Figure 24. elt over rive elt Replacement uger elt Replacement Screws 1. Rotate the spout full right. Loosen the two screws (one on each side) (Figure 24) securing the belt cover. 2. Tilt the cover forward and remove it. 3. Remove the belt guide (, Figure 25) by removing the two capscrews (), lockwashers and washers. 4. Remove the auger drive belt as follows: a. Slip the auger drive belt (, Figure 25) from the idler pulley by pushing it away from the pulley and then toward the rear. b. Remove the belt from the engine pulley. Slip the belt from under the brake pad. c. Remove six capscrews from bottom cover and remove from snowthrower frame. Loosen nuts (, Figure 26 on each side to release auger pulley belt stops (, Figure 26). Move belt stops and remove belt from pulley (, Figure 26). d. elt can be removed from top or bottom. For more clearance to remove the belt, engage the traction drive lever. It is usually necessary to rotate the drive wheels to help pass the belt between the auger pulley and final drive gear. 5. Reverse the procedure to install the belt. e sure there are no twists and the belts are properly seated in the grooves. djust the belt stops so there is 1/8 (3mm) clearance between belt and stop. The pattern for the belt is shown in Figure heck the auger drive tension. Follow the procedures under uger rive System djustments. 7. Make sure the auger stops when the auger drive lever is released (must stop in 5 seconds or less). Make sure traction drive stops when the traction drive lever is released. If not, check the drive tension. F Figure 25. uger rive elt and Pulleys. apscrews. uger Pulley. elt Guide F. Idler Pulley, uger. uger rive elt. ngine Pulley Figure 26. uger Pulley elt Stops (shown with bottom cover removed). Nuts. Gear ssy. olts. elt Stops. Set ollar. uger Pulley 8. Replace and secure bottom cover and belt cover. TP LW-S 14 8/2002

17 860LX, 970, 1180, & 1390 Large Frame Snowthrowers elt over Figure 28. elt over Screws Figure 27. uger rive elt Pattern. ngine Pulley. riven Pulley. rive elt. elt Stops, uger. Idler Pulley Pulley only Traction rive elt Replacement 1. Rotate the spout full right. Loosen the two screws (Figure 28) securing the belt cover. 2. Tilt the cover forward and work it off the snowthrower. 3. Remove the belt guide (, Figure 29) by removing the two capscrews (), lockwashers and washers. 4. Remove the traction drive belt as follows: a. Pull the idler pulley (F, Figure 29) away from the belt and slip the belt from the pulley. b. Slip the belt off the traction pulley and then the engine pulley. The arm for the front idler pulley (G, Figure 29) may have to be pivoted to provide clearance for removing the belt from the traction pulley. c. Pull the belt out between the auger pulley (H, Figure 29) and traction pulley. 5. Reverse the procedure to install the belt. e sure there are no twists and the belts are properly seated in the grooves. djust the belt stops so there is 1/8 (3mm) clearance between belt and stop. The belt routing is shown in Figure Perform the Traction rive System djustments. 7. Replace and secure belt cover. F Figure 29. Traction rive elt and Pulleys. Nuts. Traction Pulley. elt Guide F. Idler Pulley, Traction. Traction rive elt G. Idler Pulley uger. ngine Pulley H. uger Pulley G H Figure 30. Traction rive elt Pattern (From Front). ngine Pulley. Idler Pulley. rive elt. riven Pulley 8/ TP LW-S

18 860LX, 970, 1180, & 1390 Large Frame Snowthrowers NOTS MNUFTURING, IN. 500 N Spring Street / PO ox 997 Port Washington, WI US 2002 Simplicity Manufacturing, Inc. ll Rights Reserved 16