Poulan Pro P624ES Owner'S Manual Download Page 38

Page: 38 / 40

26A

22A

Electric Start Only

52*

53*

*Included

with part# 40

20A

10 10A

GENII 208 HOP SNOW ENGINE SERVICE KIT

PW2HK18650178EABGJOQUVYE1M

PW2HK18650178PABGOQUVE1M

PW2HK18650178EABGOQUVE1M

PW2HK18650178ZABGOQUVZE7M

NOTE:

All component dimensions given in U.S. inches. 1 inch = 25.4 mm

IMPORTANT:

Use only Original Equipment Manufacturer (O.E.M.) replacement parts.

Failure to do so could be hazardous, damage your snow thrower and void your warranty.

REPAIR PARTS

SNOW THROWER - MODEL P624ES (96198004302)

COMPLETE ENGINE-532436067

Summary of Contents for P624ES

Page 1: ...t Throw Away WARNING Read the Owner s Manual and follow all Warnings and Safety Instructions Failure to do so can result in serious injury 585 22 97 27 Rev 1 Gasoline containing up to 10 ethanol E10 is acceptable for use in this machine The use of any gasoline exceeding 10 ethanol E10 will void the product warranty ...

Page 2: ... the machine Operation 1 Do not put hands or feet near or under rotating parts Keep clear of the discharge opening at all times 2 Exercise extreme caution when operating on or cross ing gravel drives walks or roads Stay alert for hidden hazards or traffic 3 After striking a foreign object stop the engine motor remove the wire from the spark plug disconnect the cord on electric motors thoroughly in...

Page 3: ...ondition 2 Never store the machine with fuel in the fuel tank inside a building where ignition sources are present such as hot water heaters space heaters or clothes dryers Allow the engine to cool before storing in any enclosure 3 Always refer to operator s manual for important details if the snow thrower is to be stored for an extended period 4 Maintain or replace safety and instruction labels a...

Page 4: ... the factory with the exception of those parts left unassembled for ship ping purposes All parts such as nuts washers bolts etc necessary to complete the assembly have been placed in the parts bag To ensure safe and proper operation of your snow thrower all parts and hardware you assemble must be tightened securely Use the correct tools as necessary to ensure proper tightness ASSEMBLY PRE OPERATIO...

Page 5: ...to secure upper handle to lower handle Install in lower holes in handles INSTALL SPEED CONTROL ROD See Figs 1 and 2 1 Remove plastic tie securing rod to lower handle 2 Insert rod into speed control bracket and secure with retainer spring SPEED CONTROL ROD HANDLE KNOB LOWER HANDLE PLASTIC TIE UPPER HANDLE FIG 1 INSTALL TRACTION DRIVE CONTROL ROD See Figs 3 and 4 Thetractiondrivecontrolrodisinstalle...

Page 6: ...now thrower were overinflated at the fac tory for shipping purposes Correct and equal tire pressure is important for best snow throwing performance Reduce tire pressure to 14 17 PSI CHUTE ROTATER HEAD 3 8 WASHER 3 8 LOCKNUT THREADED STUD PIN ROTATER HEAD MOUNTING BRACKET CHUTE BRACKET FIG 7 ALIGN BEFORE TIGHTENING LOCKNUT INSTALL AUGER CONTROL ROD See Figs 5 and 6 The auger control rod is installe...

Page 7: ...s Save this manual for future reference These symbols may appear on your snow thrower or in literature supplied with the product Learn and understand their meaning FORWARD PRIMER IGNITION KEY INSERT TO START AND RUN PULL OUT TO STOP READ AND FOLLOW ALL SAFETY INFORMATION AND INSTRUCTIONS BEFORE USE OF THIS PRODUCT KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE DANGER OR WARNING REVERSE SNOW DISCHARG...

Page 8: ... shear bolts locknuts and wrench Safety ignition key must be inserted for the engine to start and run Remove when snow thrower is not in use Electric start button used for starting the engine Recoil auxiliary starter handle used for starting the engine Primer pumps additional fuel from the carburetor to the cylinder for use when starting a cold engine ON OFF switch used to STOP the engine MEETS A ...

Page 9: ...se severe injury from contact or from ma terial thrown from the discharge chute Keep the area of operation clear of all persons small children and pets at all times including startup WARNING If the discharge chute or augerbecomeclogged shut offengine andwaitforallmovingpartstostop Use the clean out tool NOT YOUR HANDS to unclog the chute and or auger The DIRECTION in which snow is to be thrown is ...

Page 10: ... housing and the discharge chute CLEAN OUT TOOL FIG 14 MOUNTING CLIP DISCHARGE CHUTE TO MOVE FORWARD AND BACKWARD See Fig 15 SELF PROPELLING forward and reverse movement of the snow thrower is controlled by the traction drive control lever located on the left side handle Squeezetractiondrivecontrollevertohandletoengage the drive system Release traction drive control lever to stop the forward or re...

Page 11: ...d be emptied before storage of 30 days or longer Empty the gas tank start the engine and let it run until the fuel lines and carburetor are empty Use fresh fuel next season SeeStorageInstructionsforadditional information Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur SCRAPER BAR See Fig 16 The scraper bar is not adjustable but is reversible After con...

Page 12: ...er cord to the engine 5 Plug the other end of the power cord into a three hole grounded 120 Volt A C receptacle NOTE Do not use primer when starting engine with the electric starter 6 Push starter button until engine starts IMPORTANT Do not crank engine more than five continu ous seconds between each time you try to start Wait 5 to 10 seconds between each attempt 7 When the engine starts release t...

Page 13: ...low the maintenance schedule in this manual NOTE Use only Original Equipment Manufacturer OEM parts to service this unit Failure to do so can cause the unit to malfunction and pose a risk of injury to the operator BEFORE EACH USE 1 Check engine oil level 2 Check for loose fasteners 3 Checkcontrolstobesuretheyarefunctioningproperly LUBRICATION Keep your snow thrower well lubricated See LUBRICATION ...

Page 14: ...h plug 2 Clean area around drain plug 3 Remove drain plug and drain oil in a suitable container 4 Install drain plug and tighten securely 5 Wipe off any spilled oil from snow thrower and engine 6 Install left wheel if removed for draining oil Be sure to install wheel pin and retainer pin into proper hole in wheel axle See TO REMOVE WHEELS in the Service and Adjustments section of this manual 7 Rem...

Page 15: ...g Place wire where it cannot come in contact with spark plug 3 Align hole in auger hub with hole in auger shaft and install a new 1 4 20 x 2 shear bolt Install 1 4 20 lock nut and tighten securely CAUTION Do not substitute Use only original equipment shear bolts as supplied with your snow thrower 4 Insert safety ignition key and reconnect spark plug wire to spark plug IMPELLER SHEAR BOLTS The impe...

Page 16: ...vice center department NOTE It is recommended that both the auger and traction drive belt be replaced at the same time The V belts on your snow thrower are of special construc tion and should be replaced by original equipment manu facturer OEM belts available from your nearest service center department Using other than OEM belts can cause personal injury or damage to the snow thrower WARNING Belt ...

Page 17: ...er department ENGINE SPEED Never tamper with the engine governor which is factory set for proper engine speed Overspeeding the engine above the factory high speed setting can be dangerous and will void the warranty If you think the engine governed high speed needs adjusting contact a service center depart ment which has the proper equipment and experience to make any necessary adjustments TO ADJUS...

Page 18: ... system of an engine while in storage Empty the fuel tank by starting the engine and letting it run until the fuel lines and carburetor are empty Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur Use fresh fuel next season NOTE Fuel stabilizer is an acceptable alternative in min imizing the formation of fuel gum deposits during storage Add stabilizer to...

Page 19: ...dles or 1 Choke is in FULL position 1 Move choke to OFF position runs roughly 2 Blockage in fuel line 2 Clean fuel line 3 Stale fuel 3 Empty fuel tank carburetor refill with fresh clean gasoline 4 Water in fuel 4 Empty fuel tank carburetor refill with fresh clean gasoline 5 Carburetor is in need of 5 Contact an authorized service center department adjustment or overhaul Excessive 1 Loose parts or ...

Page 20: ... U S inches 1 inch 25 4 mm IMPORTANT Use only Original Equipment Manufacturer O E M replacement parts Failure to do so could be hazardous damage your snow thrower and void your warranty 2 EXPLODED 01 07 032 A 15 16 18 19 20 21 22 23 33 18 17 19 20 24 25 26 27 34 34 9 9 9 1 11 11 11 11 3 4 6 8 7 5 12 12 14 10 13 2 28 28 31 29 30 32 ...

Page 21: ...4 00 TOOL CLIP 9 873 80 04 00 NUT 1 4 20 10 874 78 04 26 SCREW 1 4 20 X 625 11 532 42 79 42 NUT 5 16 18 12 532 16 31 83 SCREW 5 16 18 X 625 13 532 18 03 55 CARRIAGE BOLT 14 532 19 41 89 SCREW 13 16 X 625 15 532 40 77 60 PLUG 16 532 42 73 02 GEARBOX COVER RH 17 532 42 73 45 GASKET 18 532 40 77 70 SEAL 19 532 40 77 62 BEARING 20 532 17 46 97 THRUST WASHER 1 00 21 580 36 41 01 WORM GEAR 22 532 40 77 ...

Page 22: ...nd void your warranty KEY PART NO NO DESCRIPTION REPAIR PARTS SNOW THROWER MODEL NUMBER P624ES 96198004302 AUGER HOUSING IMPELLER ASSEMBLY KEY PART NO NO DESCRIPTION 1 2 3 5x 4 5x 01 07 001 A 1 532 41 52 95 AUGER HOUSING 2 532 41 62 15 SCRAPPER BAR 3 872 27 05 05 CARRIAGE BOLT 5 16 18 X 625 4 532 15 53 77 NUT 5 16 18 1 2 01 07 017 A 1 532 42 10 72 AUGER ASSEMBLY LH 24 2 532 42 10 73 AUGER ASSEMBLY...

Page 23: ... Failure to do so could be hazardous damage your snow thrower and void your warranty REPAIR PARTS SNOW THROWER MODEL NUMBER P624ES 96198004302 AUGER HOUSING IMPELLER ASSEMBLY 1 1 2 3 2 3 01 07 024 B 1 532 42 04 78 AUGER BEARING 2 532 41 19 39 BEARING PLUG 3 532 17 95 82 SCREW 5 16 18 X 1 00 1 532 43 59 51 PLATE SKID PLASTIC HDPE 2 532 42 65 89 NUT 5 16 18 LARGE HEX FLANGE BLK 3 872 11 05 10 CARRIA...

Page 24: ... P624ES 96198004302 CONTROL PANEL CHUTE 10 11 11 11 1 2 3 4 5 6 6 6 7 9 8 12 13 01 09 005 E 1 532 44 36 24 CHUTE WELDMENT 2 532 18 45 11 DEFLECTOR WELDMENT 3 532 42 03 25 DEFLECTOR SEAL 4 532 18 41 14 STRAP 5 532 19 19 38 KNOB BLACK 6 532 12 84 15 POP RIVET 7 532 18 56 00 SHOULDER BOLT 1 4 20 X 704 8 872 27 05 05 CARRIAGE BOLT 5 16 18 X 625 9 532 19 17 30 NUT 1 4 20 10 532 15 54 15 WASHER 11 532 1...

Page 25: ...CRIPTION REPAIR PARTS SNOW THROWER MODEL NUMBER P624ES 96198004302 CONTROL PANEL CHUTE 1 2 2 3 4 5 6 7 01 09 010 C 1 532 42 82 72 LEVER CABLE ROTATOR ASSEMBLY 2 817 54 10 08 SCREW 10 24 X 625 3 532 42 06 78 ROTATOR HEAD 4 532 40 59 32 ROTATOR PIVOT BRACKET 5 532 42 06 75 PULLEY PIVOT 6 532 42 82 73 CABLE ASSEMBLY ADJUSTABLE 7 532 42 83 10 CABLE ASSEMBLY HEAT SHIELD NOTES 1 ITEMS INDICATED WITH AN ...

Page 26: ...6198004302 HANDLES 1 2 3 4 5 5 6 6 7 7 9 9 8 8 8 01 08 003 C 1 532 42 10 69 PLOW HANDLE LH 2 532 42 10 70 PLOW HANDLE RH 3 532 42 91 48 PANEL BRACKET LH 4 532 42 91 49 PANEL BRACKET RH 5 532 19 95 13 HANDLE GRIP 6 874 78 05 12 SCREW 5 16 18 X 750 7 874 78 05 24 SCREW 5 16 18 X 1 50 8 532 75 11 53 NUT 5 16 18 9 532 15 54 15 WASHER 1 2 3 3 4 4 5 5 01 05 013 E 1 585 23 81 02 LOWER HANDLE 2 532 42 75 ...

Page 27: ...ES 10 11 11 11 11 1 2 3 4 5 6 7 9 8 12 12 12 12 13 13 13 13 14 01 08 021 A 1 585 19 88 02 CONTROL PANEL 2 581 77 98 01 LH CONTROL LEVER 3 581 77 97 01 RH CONTROL LEVER 4 584 80 90 01 INTERLOCK CONTROL ROD 5 585 00 47 03 INTERLOCK BRACKET 6 874 78 04 10 1 4 20 X 625 HEX HEAD SCREW 7 532 42 16 13 SPACER 8 532 08 83 49 1 4 20 FLANGE NUT TOP LOCK 9 532 41 42 80 KNOB RED 10 532 41 42 81 KNOB BLACK 11 5...

Page 28: ...DEL NUMBER P624ES 96198004302 HANDLES 10 1 2 3 4 5 5 6 7 9 8 01 12 013 B 1 584 80 87 01 ROD IMPELLER CONTROL 2 584 80 88 01 ROD TRACTION CONTROL 3 532 18 04 45 SHIFTER ROD TOP 4 532 18 77 16 SHIFTER ROD BOTTOM 5 532 18 04 47 SPRING SLEEVE 6 580 79 62 01 SPRING CONTROL ROD 7 580 80 21 01 SPRING TRACTION ROD 8 872 27 05 05 CARRIAGE BOLT 5 16 18 X 75 9 532 15 53 77 NUT 5 16 18 10 532 16 96 75 RETAINE...

Page 29: ...RT NO NO DESCRIPTION REPAIR PARTS SNOW THROWER MODEL NUMBER P624ES 96198004302 HANDLES 01 10 001 B 1 3 3 2 2 1 532 18 33 52 CONSOLE PANEL 2 532 18 44 71 SCREW 10 24 X 625 3 532 17 52 62 SCREW 10 24 X 1 25 KEY PART NO NO DESCRIPTION 1 2 3 4 5 6 01 08 007 D 1 532 41 62 88 INTERLOCK SPRING 2 532 44 52 91 INTERLOCK CAM 3 532 44 32 15 TORSION SPRING 4 532 16 96 75 RETAINER 5 817 06 04 10 SCREW 1 4 20 X...

Page 30: ...quipment Manufacturer O E M replacement parts Failure to do so could be hazardous damage your snow thrower and void your warranty 10 11 11 11 1 2 3 4 5 6 7 9 9 9 8 12 13 14 15 15 16 17 18 19 20 21 22 23 23 23 24 24 24 4 24 25 26 26 27 28 29 30 31 32 33 33 34 35 36 37 38 39 39 40 41 42 ITEM 42 EXPLODED 43 44 45 46 47 48 49 50 51 52 01 02 013 F 53 53 53 53 53 54 ...

Page 31: ...ETAINER 19 581 42 25 01 SHIFTER YOKE 20 532 40 23 10 PIVOT ROD 21 812 00 00 36 RETAINER 22 532 40 28 78 RETURN SPRING 23 532 75 11 53 NUT 5 16 18 24 532 40 89 81 BEARING 25 873 93 05 00 NUT 5 16 18 26 532 19 95 09 RUBBER WHEEL PLATE 27 585 02 10 01 RUBBER RING 28 532 17 53 44 BEARING 29 532 17 86 13 WHEEL HUB 30 874 76 05 14 SCREW 5 16 18 875 31 812 00 00 12 RETAINER RING 32 532 40 21 87 SPROCKET ...

Page 32: ... thrower and void your warranty 1a 1b 1b 2 3 3 4 4 5 5 6 6 7 8 8 01 03 005 C REPAIR PARTS SNOW THROWER MODEL NUMBER P624ES 96198004302 DRIVE 1 532 18 82 26 AXLE ASSEMBLY assy of 1a 1b 1a 532 17 93 52 AXLE SHAFT 1b 532 18 42 06 ROLL PIN 3 16 2 532 40 26 91 SPROCKET 3 532 44 49 49 THRUST WASHER 4 532 17 98 30 BEARING 5 817 49 05 08 BOLT 5 16 18 X 500 6 532 17 12 71 PIN 7 532 18 92 82 SQUARE KEY 8 53...

Page 33: ... parts Failure to do so could be hazardous damage your snow thrower and void your warranty 532 43 60 67 COMPLETE LCT ENGINE PW2HK18650178E 1 532 42 92 75 FRAME 2 532 15 04 06 BOLT 3 8 16 3 532 42 88 67 SCREW 5 16 18 X 750 REPAIR PARTS SNOW THROWER MODEL NUMBER P624ES 96198004302 CHASSIS ENGINE PULLEYS 1 2 2 3 3 01 00 034 A 1 01 21 013 C 1 01 01 004 A 1 532 43 07 64 ENGINE MOUNTING PLATE 1 532 44 3...

Page 34: ...EY 5 532 42 65 89 NUT 5 16 18 6 874 78 05 24 CAPSCREW 5 16 18 X 1 50 7 585 28 49 01 IDLER BRACKET 8 817 00 05 10 SCREW 5 16 18 HEX 9 532 42 42 97 SHOULDER BOLT 5 16 18 X 500 10 532 75 11 53 NUT 5 16 18 TOP LOCK 11 585 23 84 01 TRACTION IDLER ARM ASM 12 532 85 10 84 CAPSCREW 3 8 24 X 1 375 10 11 1 2 3 4 5 6 7 9 8 12 13 21 15 16 17 18 18 19 20 20 22 01 21 003 F 14 13 532 40 00 26 WASHER 14 532 05 92...

Page 35: ...ipment Manufacturer O E M replacement parts Failure to do so could be hazardous damage your snow thrower and void your warranty REPAIR PARTS SNOW THROWER MODEL NUMBER P624ES 96198004302 WHEELS KEY PART NO NO DESCRIPTION 1 2 01 06 018 A 1 581 18 53 01 WHEEL ASSEMBLY LH 2 581 18 54 01 WHEEL ASSEMBLY RH ...

Page 36: ...Failure to do so could be hazardous damage your snow thrower and void your warranty 01 14 012 B 1 1 2 2 3 4 4 1 532 18 04 45 SHIFTER ROD TOP 2 532 18 77 16 SHIFTER ROD BOTTOM 3 872 27 05 05 CARRIAGE BOLT 5 16 18 X 75 4 532 15 53 77 NUT 5 16 18 1 2 3 4 5 6 7 01 14 004 B 1 532 19 85 63 POWER CORD 2 532 16 96 75 RETAINER PIN 3 532 42 91 12 WRENCH 4 873 80 06 00 LOCKNUT 3 8 16 5 819 13 13 16 WASHER 3 ...

Page 37: ...us damage your snow thrower and void your warranty REPAIR PARTS SNOW THROWER MODEL NUMBER P624ES 96198004302 DECALS 1 532 18 10 37 DECAL DANGER 3 532 18 10 35 DECAL DANGER DEFLECTOR 4 532 18 10 42 DECAL DANGER 6 532 18 10 33 DECAL INSTRUCTION 9 581 43 01 01 DECAL CON RT SPD LEV PWST 11 581 43 01 02 DECAL CON LT WD DEF 585 22 97 27 OWNER S MANUAL ENGLISH 585 22 97 31 OWNER S MANUAL FRENCH 1 3 4 9 1...

Page 38: ...NGINE SERVICE KIT PW2HK18650178EABGJOQUVYE1M PW2HK18650178PABGOQUVE1M PW2HK18650178EABGOQUVE1M PW2HK18650178ZABGOQUVZE7M 54 NOTE All component dimensions given in U S inches 1 inch 25 4 mm IMPORTANT Use only Original Equipment Manufacturer O E M replacement parts Failure to do so could be hazardous damage your snow thrower and void your warranty REPAIR PARTS SNOW THROWER MODEL P624ES 96198004302 C...

Page 39: ... 28 532 42 05 86 FLYWHEEL FAN 29 532 44 39 34 IGNITION COIL ASSY CDI 30 532 42 06 06 CRANKCASE COVER ASSY 31 532 42 09 61 BLACK OIL DIPSTICK 32 532 42 49 59 CHARGING COIL DC 34 532 43 69 66 SPARK PLUG BOOT 36 532 42 06 01 GOVERNOR ARM ASSY 37 532 42 06 02 GOVERNOR SHAFT 38 532 42 96 46 GOVERNOR GEAR ASSY 39 532 42 05 84 CAMSHAFT 40 532 42 05 78 CYLINDER HEAD ASSY 41 532 42 49 39 SPARK PLUG 44 532 ...

Page 40: ...r any products used for rental or commercial purposes is limited to 90 days from the date of origi nal purchase 5 This Warranty applies only to products which have been properly assembled adjusted operated and maintained in ac cordance with the instructions furnished This Warranty does not apply to any product which has been subjected to altera tion misuse abuse improper assembly or installation d...

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