POWERSMART DB7659H-22 (01) PDF Document

It is your responsibility to restrict the use of this power machine to persons who read, understand and follow the warnings and instructions in this manual and on the machine.

• ROTATING PARTS! Only use the clean-out tool to clear blockages. NEVER use your hands. This machine is capable of amputating fingers, hands, toes, and feet.

• Thrown Objects: NEVER direct the discharge chute towards persons or property that may be injured or damaged by thrown objects.

• Bystanders: Keep people away from the unit while operating. Keep children out of the work area and under the watchful care of a responsible adult. Bystanders, pets, and children should be at least 75 feet from the machine while it is in operation.

Before attempting to assemble and operate the snow thrower, you should:

• Read, understand, and follow all instructions on the machine and in the manual.

• Be familiar with all controls and their proper operation. Know how to stop the machine and disengage the controls quickly.

• Never allow children under 14 years of age to operate this machine. Children 14 and over should read and understand the instructions and be trained and supervised by an adult.

• Never allow adults to operate this machine without proper instruction.

• Plan your snow-throwing pattern to avoid discharging material toward roads, bystanders, and the like, as thrown objects can cause serious personal injury.

• Exercise caution to avoid slipping or falling, especially when operating in reverse.

Thoroughly inspect the area where the equipment is to be used. Remove all doormats, newspapers, sleds, boards, wires, branches, and other foreign objects which could be tripped over or thrown by the auger/impeller.

• Always wear safety glasses or eye shields during operation and while performing an adjustment or repair.

• Do not operate without wearing adequate winter outer garments. Avoid jewelry, long scarves, or other loose clothing. Wear footwear that will improve footing on slippery surfaces.

• Adjust the housing height to clear gravel or crushed rock surfaces.

• Disengage all control levers before starting the engine.

• Never attempt to make any adjustments while the engine is running, except where specifically recommended.

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

To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and its vapors are explosive.

• Use only an approved gasoline container.

• Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

• Never fuel the machine indoors.

• Never remove the gas cap or add fuel while the engine is hot or running.

• Allow the engine to cool at least two minutes before refueling.

• Never overfill the fuel tank.

• Replace the gasoline cap and tighten it securely.

• If gasoline is spilled, wipe it off the engine and equipment. Move the machine to another area and wait 5 minutes before starting the engine.

• Never store the machine or fuel container inside where there is an open flame, spark, or pilot light (e.g., furnace, water heater, space heater, clothes dryer).

• Allow the machine to cool for at least 5 minutes before storing.

• When filling containers, always place them on the ground away from your vehicle. If possible, remove gas-powered equipment from the truck or trailer and refuel it on the ground.

• Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device.

• Do not put hands or feet near rotating parts, in the auger impeller housing, or in the chute assembly.

• The auger impeller control lever is a safety device. Never bypass its operation.

• Never operate with a missing or damaged chute assembly. Keep all safety devices in place and working.

• Never run an engine indoors or in a poorly ventilated area. Engine exhaust contains carbon monoxide, an odorless and deadly gas.

• Do not operate the machine while under the influence of alcohol or drugs.

• The muffler and engine become hot and can cause a burn. Do not touch. Keep children away.

• Exercise extreme caution when operating on or crossing gravel surfaces and when operating on slopes.

• Plan your snow-throwing pattern to avoid discharge towards windows, walls, cars, etc.

• Never direct discharge at children, bystanders, or pets.

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

• Never operate this machine without good visibility or light. Always be sure of your footing and keep a firm hold on the handles. Walk, never run.

• Disengage power to the auger impeller when transporting or not in use.

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

• If the machine vibrates abnormally, stop the engine, disconnect the spark plug wire, and inspect thoroughly for damage.

• Wait until the auger/impeller comes to a complete stop before unclogging the chute, making adjustments, or inspections. Use the provided clean-out tool.

• Never tamper with safety devices. Check their proper operation regularly.

• Before cleaning, repairing, or inspecting, disengage all control levers and stop the engine.

• Wait until the auger impeller comes to a complete stop and disconnect the spark plug wire to prevent unintended starting.

• Check bolts and screws for proper tightness at frequent intervals.

• Do not change the engine governor setting or overspeed the engine.

• Shave plates and skid shoes are subject to wear. Frequently check all components and replace them with original equipment manufacturer (OEM) parts only.

• Check control levels periodically to verify they engage and disengage properly.

• Maintain or replace safety and instruction labels as necessary.

• Prior to storing, run the machine for a few minutes to clear snow and prevent the auger impeller from freezing up.

• Check the fuel line, tank, cap, and fittings frequently for cracks or leaks.

• Have the machine inspected annually by an authorized service dealer.

No. To avoid serious injury or death, do not modify the engine in any way. Tampering with the governor setting can lead to a runaway engine and cause it to operate at unsafe speeds. Never tamper with the factory setting of the engine governor.

• Drive Control Handle: Used to engage and disengage the drive wheels. Pull up to engage the wheels; release to disengage.

• Speed Control Lever: Located on the right side, it is used to set the drive speed and direction of travel. It has six positions (4 forward, 2 reverse).

• Auger Control Handle: Used to engage and disengage the augers. Pull back to engage the augers; release to disengage.

• Chute Rotation Handle: Manually rotate the handle clockwise or counter-clockwise to adjust the snow discharge direction.

• Skid Shoe: Position the shoes based on surface conditions. Adjust upward for hard-packed snow and downward for gravel or crushed rock surfaces.

• Auger: When engaged, the augers rotate to cut snow and direct it into the impeller housing to be discharged out the chute.

• Clean-out Tool: Fastened to the rear of the auger housing, it is used to clean the chute assembly when snow and ice become lodged. Never use your hands.

• Discharge Chute: Provides a discharge path for snow being thrown. It is adjustable.

• Shave Plate: Maintains contact with the pavement as the snow thrower is propelled, allowing snow close to the pavement’s surface to be discharged.

WARNING: This snow thrower is heavy. Assembly procedures may require lifting equipment or two people.

1. Attach the lower handle to the main frame using four (4) bolts. Each side will require two (2) bolts.

2. Attach the upper handle to the lower handle using four (4) knobs, washers, and bolts.

To attach the drive cable:

1. Push the drive control handle inward to detach it from the upper handle.

2. Attach the drive cable to the hole on the drive control handle bar.

3. Re-attach the drive control handle to the upper handle.

To attach the auger cable:

4. Repeat steps 1-3 to attach the auger cable to the auger control handle.

NOTICE: Do not bend or kink the control cables. The cables should be routed under the handle assembly and not wrapped around the handle or knobs. The cables must move freely and not bind.

1. Loosen and remove the three sets of screws, locknuts, and washers on the discharge chute base.

2. Hold the discharge chute and handle to align the mounting holes with the chute base mount holes. Insert the screws and washers and secure them with locknuts. Do not over-tighten the screws.

Note: Make sure all fasteners are tightened.

1. Locate the pair of skid shoes from the parts bag and remove the bolts.

2. Loosely install the skid shoes using the bolts and hex nuts on each side of the auger housing. Make sure the skid shoe tip faces out.

The adjustment of the skid shoes sets the height of the auger shave plate above the ground.

• For smooth surfaces (concrete, asphalt), set the auger shave plate so that the bottom of the plate is just above the ground.

• For rough surfaces (gravel, dirt), set the auger shave plate slightly above the ground to avoid picking up debris.

To adjust:

3. Move the Snow Thrower to a solid, smooth, and level surface.

4. Place a spacer board (e.g., a piece of wood) on the ground underneath the auger shave plate. The thickness of the board should be the same as the desired clearing height. The skid shoes should not touch the board.

5. With the two (2) nuts loose on each skid shoe, allow the skid shoe to slide down to the ground, then tighten the nuts to secure it in place.

Before using your Snow Thrower for the first time, check the following:

• Have you read and followed all setup and operation procedures for the engine as outlined in the ENGINE manual?

• Has the engine been filled with oil and gasoline to the proper level?

• Are all snow thrower components properly attached and assembled?

• Are there any broken or damaged parts?

• Are all fasteners tight?

• Are the tires inflated to the proper pressure?

1. To engage the auger, push back the auger control handle. Release it to disengage.

2. To engage the drive, pull up on the drive control handle. The machine will start moving in the direction and speed set by the speed control lever.

3. When finished clearing a snow path, release the auger control handle and the drive control handle.

Note: Always release (disengage) the auger and drive control handles before adjusting the drive speed control lever. Never change the drive speed while the snow thrower is moving, as it could damage the drive mechanism and void the warranty.

Move the drive speed control lever to the desired speed. There are six (6) settings:

• Forward Speeds: Four (4) settings. 1 is the slowest forward speed, and 4 is the fastest.

• Reverse Speeds: Two (2) settings. R1 is the slowest reverse speed, and R2 is the fastest.

Note: There is no neutral drive setting on the lever. Neutral is achieved when the drive control handle is disengaged.

WARNING – Never direct the snow discharge chute at the operator, bystanders, vehicles, or nearby windows.

Direction Adjustment:

The discharge chute can be adjusted 180°. Rotate the chute rotation handle to change the direction.

• Rotate the handle clockwise to move the discharge chute to the left.

• Rotate the handle counterclockwise to move the chute to the right.

Angle Adjustment:

WARNING! Always disengage the drive and auger control handles before making adjustments. The angle of the chute deflector controls the discharge distance.

1. Loosen the knobs on both sides of the chute deflector and adjust the deflector to the desired angle. Raising the angle increases the distance; lowering it decreases the distance.

2. Retighten the knobs. Do not over-tighten.

Do not advance the chute deflector too far forward, as this can cause an opening to appear between the deflector and discharge chute.

1. Start the engine (refer to the ENGINE manual) and let it run outside for several minutes.

2. Adjust the chute outlet to the desired direction.

3. Engage/Push back the auger control handle to start the augers and impeller turning.

4. Set the desired direction and speed using the speed control lever.

5. Engage/Pull up the drive control handle and direct the snow thrower into the snow to be cleared.

NOTICE: Do not change speed positions while the drive is engaged. Disengage the drive control handle BEFORE changing speeds. If snow is deeper than the auger height, remove it in several passes, taking narrower swaths. Wet, heavy snow can be a challenge; keep the auger engaged as much as possible to help prevent clogging.

1. Engage the auger and impeller for 30 seconds to clear any remaining snow inside the machine.

2. Stop the auger by releasing the left control handle.

3. Set the engine switch to the OFF position (see ENGINE manual for stopping procedures).

4. Remove snow from all snow thrower surfaces, including the auger housing and chute areas.

If the snow discharge chute or auger housing becomes clogged, STOP the engine and make sure that all rotating parts have come to a complete stop.

Use the supplied snow clean-out tool to clear the obstruction. After unclogging, wipe the tool clean and place it back in its holder on top of the auger housing.

WARNING! NEVER use your hands to clear a clog.

Proper maintenance will help prolong the life of your snow thrower. Always turn OFF the engine before performing any maintenance.

• After Each Use: Run the snow thrower for a few minutes to prevent the collector/impeller from freezing. Stop the engine, wait for parts to stop, and wipe residual ice and snow off the unit. Rotate the chute handle several times to remove excess snow.

• Tire Inflation: Before each use, check the tire pressure. The pressure should be in the range of 20-24 psi for best performance.

• Shave Plate Replacement: Remove both skid shoes and the hardware attaching the shave plate to the housing. Reassemble with the new shave plate, making sure the heads of the carriage bolts are on the inside of the housing.

• Auger or Impeller Jams: Always turn OFF the engine before clearing jams. Keep hands and feet away from rotating parts. Use the clean-out tool to clear visible jams after the auger and impeller have come to a full stop.

Shear pins are a safety mechanism designed to break under high load to protect the auger drive system. Replacement shear pins and locknuts are provided.

1. Turn off the engine and wait for all moving parts to come to a complete stop. Remove any remnants of the broken shear pin. You may need to unscrew the nut from the broken pin and drive it out.

2. Insert a new shear pin through the hole in the auger shaft and tighten using the shear pin nylon locknut. Do not over-tighten the nylon locknut.

NOTICE: Never replace shear pins with standard pins or fasteners, as this can cause damage to the snow blower and drive systems.

WARNING! Use caution when performing this adjustment.

1. With the engine running, engage the drive control handle and move the speed control lever between F1 (forward 1) and R1 (reverse 1) to determine which way the cables need to be adjusted. Release the drive control handle when shifting between gears.

2. Loosen the jam nuts on each cable (only one or two threads) and move each cable up or down as required until a positive direction change is achieved when the lever is shifted between F1 and R1. The goal is to find the neutral position between these two settings. This may take multiple attempts.

3. Tighten the cable jam nuts once the proper setting has been achieved.

WARNING! Ensure the engine is off and the spark plug wire is removed before starting.

1. Push the auger control handle inward to detach it from the upper handle, then disconnect the auger cable from the auger control handle.

2. Remove the 2 hex head screws and remove the belt cover.

3. Loosen the belt guide pin hex head screw (on the engine crankcase) and rotate the pin away from the pulley.

4. On the left side, loosen the hex nuts attaching the auger housing to the main frame.

5. On the right side, remove the hex nuts, lock washers, and flat washers attaching the auger housing to the main frame.

6. Pull the right side of the auger housing away from the main frame just enough to access the belt and auger pulley, then remove the belt from the drive pulley.

7. Push the auger tension pulley arm to move the auger brake away from the belt.

8. Remove the auger belt.

WARNING! Ensure the engine is off and the spark plug wire is removed before starting.

1. Push the auger tension pulley arm to move the auger brake, allowing access for belt installation into the auger pulley.

2. Route the belt to the inside of the tension pulley and install the auger belt onto the drive pulley while pulling the auger housing back into position with the main frame.

3. Install and/or tighten the hex nuts attaching the auger housing to the main frame. Tighten all fasteners securely, but do not over-tighten.

4. With the belt installed, move the belt guide pin to within 3/16 to 3/8 in. from the belt and tighten the pin in position. The pin should be loose enough to allow the belt to spin freely but not jump off the pulley.

5. Connect the lower auger cable to the cable adjustment plate.

6. Install the belt cover using 2 hex head screws. Ensure the auger cable is routed outside the belt cover.

NOTICE: After initial installation, belt tension should be checked periodically. A loose belt can cause premature wear, slipping, or poor performance. A tight belt can cause premature wear, overheating, and damage to pulleys and bearings.

To avoid repeated failures, inspect related components when replacing a belt.

Inspect the old belt for:

• Correct size and type

• Missing pieces, burning, general damage

• Fraying, peeling, cracks, tears

• Uneven wear patterns

• Foreign material (oil, grease, dirt)

Inspect the auger pulleys for:

• Broken sheave or hub, loose mounting bolts

• Bent or “out-of-round” condition

• Misalignment

• Foreign material

• Loose, damaged, or misaligned tension pulley

• Free movement of the tension pulley and arm assembly

Inspect the auger engagement handle and cable for:

• Cable and connection damage

• Free movement and proper routing (no binding)

• Damaged handle or pivot

Cleaning:

1. To clean your Snow Thrower, use a damp cloth and mild detergent on the surfaces only. Never get soap or water inside the working mechanisms.

Note: Do not clean with water. Water will freeze and damage the machine.

2. Clean the Snow Thrower of snow and ice buildup before storing or transporting.

3. Inspect the unit for worn, loose, or damaged parts. Check and tighten connections and screws if necessary.

Storage:

WARNING! Never store your Snow Thrower for extended periods with fuel in the tank. A fuel stabilizer can be added to extend its shelf life.

Store the unit in a locked, dry place out of the reach of children. Cover loosely with a tarp for added protection.

WARNING: Before any inspections, stop the engine, wait for all parts to stop, and disconnect the spark plug wire.

This is likely caused by a broken or missing auger tension pulley arm return spring. You will need to replace the tension arm return spring.