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Operator’s Manual

FORM NO. 3321–378

824 and 1028 Power Shift �

SnowthrowersModel No. 38542–9900001 & UpModel No. 38558–9900001 & Up

The engine exhaust from this productcontains chemicals known to the State ofCalifornia to cause cancer, birth defects,

or other reproductive harm.

WARNING:

�The Toro Company – 1998All Rights ReservedPrinted in USA i

Figures

1

181

1. Model and serial number decal

1631

2

3

5

5

4

1. Auger housing2. Engine frame3. Impeller pulley

4. Idler pulley assembly5. Mounting screws (2)

1641

2

3

1. Lower belt cover (shownfrom bottom)

2. Mounting tabs3. Flange head capscrew

1663

2

1

1. Upper belt cover2. Cable cover

3. Flange head capscrew

1

2

3

4

ii

7

8

167

1

4

5 2

6

6

23

5

1. Shift rod2. Ball joint3. Shift bracket4. Transmission lever

5. Locknut6. Jam nut7. Gear shift lever8. Power Shift slot

168

1

2

3

41. Discharge chute2. Plastic chute retainer

3. Chute retainer plate4. Chute ring

1

2 5

4

3

170

1. Gear bracket2. Carriage bolt, flat washer

& locknut

3. Worm gear4. Chute gear rod5. Mounting flange

5 6

7

iii

1 1712 3

1. Scraper2. Carriage bolt

3. Auger blades

5

4742

1

3

3

4

1. Flange bolts2. Skid3. Flat washers

4. Locknut5. Sideplate

m–4064

1 171

1. Pipe plug

2

1

m–4063

1. Dipstick and filler hole 2. Fuel tank cap

4

21

3

173

1. Auger/impeller control2. Traction drive control

3. Speed shift control4. Discharge chute control

8

9

10

11

12

13

iv

3

1m-40674 2

6

5

1. Throttle2. Choke3. Primer

4. Ignition switch5. Heater box6. Mounting screw

1

m–4065

2

3

1. Fuel shut-off valve2. Hose clamp

3. Fuel line

2

1

176

1. Deflector handle 2. Discharge chute

934

1

1. Recoil starter

m–4066

1

2

1. Mounting screw 2. Heater box

m–4064

14

15

16

17

18

19

v

179

�

�

�

��

1. Axle pin2. Inner axle hole

3. Outer axle hole and wheelhub

1

181

1. Drive chain

�

m-4036

1. Drain plug

20

21

22

23

vi

��

�

�

1. Feeler gauge 2. Center of spring

1

3

4 2

183

1. Auger/impeller cable(outer cable)

2. Traction cable (innercable)

3. Mounting bracket4. Jam nut

1

1842

1/8” min.(3 mm)

1. Impeller idler arm 2. Brake arm

1

3

4576

2

8185

1. Idler pulley assembly2. Flange head capscrews

(2)3. Capscrew & lockwasher4. Half sheave

5. Auger/impeller belt6. Traction belt7. Middle pulley section8. Idler pulley (2)

24

25

26

27

vii

1/8” – 3/8”DEFLECTION

186

1 2

187

1. Transmission 2. Transmission frame

189

1

1. Flange head capscrews

��

�

1. Spark plug wire

0.30”(0.76 mm)

110

28

29

30

31

32

1

ContentsPage

Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before Operating 2. . . . . . . . . . . . . . . . . . . .

While Operating 3. . . . . . . . . . . . . . . . . . . . .

Maintaining Snowthrower 4. . . . . . . . . . . . .

Safety Decals and Instructions 6. . . . . . . . . .

Loose Parts 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessories 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mount Auger/impeller Housing 8. . . . . . . . .

Install Shift Rod (Fig. 5) 8. . . . . . . . . . . . . .

Install Discharge Chute (Fig. 6) 8. . . . . . . . .

Install Chute Control Gear (Fig. 7) 9. . . . . .

Check Tire Pressure 9. . . . . . . . . . . . . . . . . .

Install Skids 9. . . . . . . . . . . . . . . . . . . . . . . .

Check Auger Gear Box Oil 9. . . . . . . . . . . .

Before Starting 10. . . . . . . . . . . . . . . . . . . . . . . . . .

Fill Crankcase With Oil 10. . . . . . . . . . . . . . .

Fill Fuel Tank With Gasoline 10. . . . . . . . . . .

Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controls 11. . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting/Stopping Engine 12. . . . . . . . . . . . . .

Power Shift Operation 13. . . . . . . . . . . . . . . .

Free Wheeling Or Self–propelled Drive 13. .

Snowthrowing Tips 13. . . . . . . . . . . . . . . . . .

Adjusting Scraper (Fig. 8) 14. . . . . . . . . . . . .

Adjusting Skids (Fig. 9) 14. . . . . . . . . . . . . . .

Maintenance 15. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Draining Gasoline 15. . . . . . . . . . . . . . . . . . .

Lubricating Snowthrower 15. . . . . . . . . . . . .

Changing Crankcase Oil 15. . . . . . . . . . . . . .

Auger Gear Box Oil 16. . . . . . . . . . . . . . . . . .

Adjusting Auger/Impeller Drive Belt 16. . . .

Adjusting Traction Drive Belt (Fig. 25) 17. . .

Replacing Drive Belts (Fig. 27) 17. . . . . . . . .

Adjusting Drive Chain (Fig. 28–30) 18. . . . .

Replacing Spark Plug 19. . . . . . . . . . . . . . . . .

Storage 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty Back Cover. . . . . . . . . . . . . . . . . . . . . . . .

IntroductionThank you for purchasing a Toro product.

All of us at Toro want you to be completely satisfiedwith your new product, so feel free to contact yourlocal Authorized Service Dealer for help with service,genuine Toro parts, or other information you mayrequire.

Whenever you contact your Authorized ServiceDealer or the factory, always know the model andserial numbers of your product. These numbers willhelp the Service Dealer or Service Representativeprovide exact information about your specificproduct. You will find the model and serial numberdecal located in a unique place on the product(Fig. 1).

For your convenience, write the product model andserial numbers in the space below.

Model No.

Serial No.

Read this manual carefully to learn how to operateand maintain your product correctly. Reading thismanual will help you and others avoid personal injuryand damage to the product. Although Toro designs,produces and markets safe, state-of-the-art products,you are responsible for using the product properlyand safely. You are also responsible for trainingpersons who you allow to use the product about safeoperation.

2

The Toro warning system in this manual identifiespotential hazards and has special safety messages thathelp you and others avoid personal injury, even death.DANGER, WARNING and CAUTION are signalwords used to identify the level of hazard. However,regardless of the hazard, be extremely careful.

DANGER signals an extreme hazard that will causeserious injury or death if the recommendedprecautions are not followed.

WARNING signals a hazard that may cause seriousinjury or death if the recommended precautions arenot followed.

CAUTION signals a hazard that may cause minor ormoderate injury if the recommended precautions arenot followed.

Two other words are also used to highlightinformation. “Important” calls attention to specialmechanical information and “Note” emphasizesgeneral information worthy of special attention.

SafetyThe 824 POWER SHIFT� SNOWTHROWER meetsor exceeds the Outdoor Power Equipment Institute’ssafety standards for snowthrowers; thus, Toro proudlydisplays the OPEI safety seal. To assure maximumsafety, optimum performance, and to gain knowledgeof the product, it is essential that you or any otheroperator of the snowthrower read and understand thecontents of this manual before the engine is everstarted. Pay particular attention to the safety alert

symbol which means CAUTION, WARNING OR

DANGER — “personal safety instruction.” Read andunderstand the instruction because it has to do withsafety. Failure to comply with instruction may result inpersonal injury.

The following instructions are comparable to theInstructions For Safe Snowthrowing adopted by theAmerican National Standards Institute (ANSI). Thesnowthrower is designed and tested to offer

reasonably safe service; however, failure to complywith the following instructions MAY RESULT INPERSONAL INJURY.

Before Operating

1. Read and understand the contents of this manualbefore operating the snowthrower. Becomefamiliar with all controls and know how to stopengine and snowthrower quickly.

2. Never allow children to operate thesnowthrower. Adults should operate thesnowthrower only after reading this manual.

3. Keep everyone, especially children and pets,away from snowthrower and area of operation.

4. Inspect area thoroughly where snowthrower willbe used. Remove doormats, sleds, boards, sticks,wire, and any other foreign objects which mightbe picked up and thrown by the snowthrower.

5. Keep all shields and safety devices in place. If ashield, safety device or decal is illegible,damaged or lost, repair or replace it beforebeginning operation. Also, tighten any loosenuts, bolts or screws.

6. Wear adequate winter clothing and rubber bootsthat will ensure proper footing on slipperysurfaces. Do not wear loose-fitting clothing thatcould possibly get caught in moving parts.

7. Always wear safety glasses or eye shields duringoperation or while performing an adjustment orrepair to protect eyes from foreign objects thatmay be thrown from the machine.

8. Adjust both skids so auger/impeller housingclears gravel or crushed rock surfaces.

9. Before starting the engine, move speed shiftcontrol to N (neutral) and ensure thatauger/impeller control and traction (wheel drive)control are in disengaged position.

3

10. Always use a grounded, three wire plug and cordto start snowthrower equipped with an electricstarter. Extension cord must be connected to aproperly grounded outlet.

11. Fill fuel tank with gasoline before starting theengine. Avoid spilling any gasoline. Becausegasoline is highly flammable, handle it carefully.DO NOT SMOKE WHILE HANDLINGGASOLINE.

A. Use an approved gasoline container.

B. Fill fuel tank outdoors, not indoors.NEVER ADD FUEL T O AN ENGINETHAT IS RUNNING OR HOT. Enginemust be cool to reduce potential fire hazard.

C. Open doors if engine will be started in thegarage because exhaust fumes aredangerous and could possibly be deadly. Donot run engine indoors.

D. Wipe up any spilled gasoline. Reinstallgasoline container cap and snowthrowerfuel tank cap securely before starting theengine.

While Operating

12. ROTATING IMPELLER OR AUGER CANCUT OFF OR INJURE FINGERS ORHANDS. STAY BEHIND THE HANDLESAND AWAY FROM DISCHARGEOPENING WHILE OPERA TING THESNOWTHROWER. KEEP FACE, HANDS,FEET, AND ANY OTHER PART OF YOURBODY OR CLOTHING A WAY FROMCONCEALED, MOVING OR ROT ATINGPARTS.

13. BEFORE ADJUSTING, CLEANING,REPAIRING, AND INSPECTING THESNOWTHROWER, AND BEFOREUNCLOGGING THE DISCHARGECHUTE, SHUT ENGINE OFF AND WAITFOR ALL MOVING PAR TS TO STOP.ALSO, PULL WIRE OFF SPARK PLUG

AND KEEP WIRE AWAY FROM THEPLUG TO PREVENT ACCIDENT ALSTARTING. USE A STICK, NOT YOURHAND, TO REMOVE OBSTRUCTIONSFROM DISCHARGE CHUTE.

14. Before leaving the operator’s position (behindhandles), remove key from switch.

15. Allow engine to warm up outdoors beforeclearing snow.

16. Operate the snowthrower only when there isgood visibility or light. Always maintain securefooting and balance and keep a firm grip on thehandles, especially when operating in reverse.Walk; never run.

17. Be attentive when using the snowthrower, andstay alert for holes in the terrain and otherhidden hazards. Be careful when clearing snowfrom a gravel drive because stones could bepicked up and thrown if skids are not adjusted soauger/impeller housing clears all rocks.

18. Do not make any adjustments while the engine isrunning.

19. Never direct discharge of snow or operatesnowthrower near bystanders, glass enclosures,automobiles and trucks, window wells or adrop–off without proper adjustment of the snowchute and deflector angle.

20. Clear snow from slopes by going up and down,never across the face. Use caution whenchanging directions. Use lower gear and rearwheel position when operating on slopes. Neverclear snow from steep slopes.

21. Do not overload the snowthrower by clearingsnow at too fast a rate.

22. DO NOT USE SNOWTHROWER ON AROOF.

23. If a foreign object is hit or snowthrower vibratesabnormally, stop engine by turning key to OFFand wait for all moving parts to stop. Pull wireoff spark plug and check snowthrower

4

immediately for possible damage, an obstructionor loose parts. Vibration is generally a sign oftrouble. Repair any damage before startingengine and operating snowthrower again.

24. Do not touch engine while it is running or soonafter it is stopped because the engine will be hotenough to cause a burn. Do not add oil or checkoil level in crankcase when engine is running.

25. Never operate snowthrower at high transportspeeds on slippery surfaces. Use care whenbacking.

Maintaining Snowthrower

26. Perform only those maintenance instructionsdescribed in this manual. Shut engine off beforeperforming any maintenance service oradjustment. Additionally, pull wire off sparkplug and keep wire away from plug to preventaccidental starting. If major repairs are everneeded, contact your local Authorized TOROService Dealer for assistance.

27. Keep snowthrower in safe operating conditionby keeping nuts, bolts, and screws tight. Checkengine mounting bolts frequently to ensure theyare tight.

28. Maintain or replace safety and instruction labels,as necessary.

29. Do not overspeed the engine by changinggovernor settings.

30. Run the snowthrower a few minutes afterthrowing snow to prevent freeze-up of thecollector/impeller.

31. Never store snowthrower with fuel in fuel tankinside a building where ignition sources such asan open flame, sparks, hot water and spaceheaters, and clothes dryers are present. Allowengine to cool before storing. NEVER STORESNOWTHROWER IN HOUSE (LIVINGAREA) OR BASEMENT BECAUSEGASOLINE AND FUMES ARE HIGHL YFLAMMABLE, EXPLOSIVE, ANDDANGEROUS IF INHALED.

32. When storing the snowthrower for an extendedtime—off season storage or 30 days—draingasoline from fuel tank to prevent a potentialhazard. Store gasoline in a safety–approved redmetal container. Remove key from ignitionswitch when storing snowthrower. Store key in amemorable place.

33. At the time of manufacture, the snowthrowerconformed with or exceeded OPEI safetystandards in effect for snowthrowers. Therefore,to ensure best performance and safety, purchasegenuine TORO replacement parts andaccessories to keep the TORO all TORO.NEVER USE “WILL FIT” REPLACEMENTPARTS AND ACCESSORIES.

34. For safety reasons, use only those accessoriesand attachments recommended by The TOROCompany to ensure continued safety certificationof the product. Using unapproved accessoriesand attachments could contribute to a potentialhazard.

5

Read and understand the contents of this manualbefore operating the snowthrower . Becomefamiliar with all controls and know how to stopthe engine quickly.

BEFORE OPERATING

OPERATOR’SPOSITION

CAUTION: IMPROPER USE MAY RESULTIN LOSS OF FINGERS, HANDS OR FEET.

HIGH SPEED IMPELLERWITHIN 2 INCHES OF

LOW SPEED AUGERHAS MOVING PINCHPOINT, CLOSE TO OPENING.

1508

OPENING

472

6

Safety Decals and Instructions

Safety decals and instructions are easily visible to the operator and are located near any area of potential danger.Replace any decal that is damaged or lost. Decals with Tecumseh part numbers must be obtained from TecumsehProduct Company. Decals with Toro part numbers must be obtained from The Toro Company.

ON ENGINE(Tecumseh Part No. 371 19)

NEXT TO PRIMER(Tecumseh Part No. 36501)

ON ENGINE(Tecumseh Part No. 37226)

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7

Loose Parts

Part Qty Use

Flange head capscrew — 5/16–18 x 3/4” lg. 6

Lower belt cover 1Mount Auger/impeller Housing page 8

Flange head capscrew — 1/4–20 x 1/2” lg. 5Mount Auger/impeller Housing, page 8

Cable cover 1

Shift rod 1Install Shift Rod page 8

Locknut—3/8-24 2Install Shift Rod, page 8

Discharge chute 1 Install Discharge Chute, page 8

Worm gear 1

Gear bracket 1

Carriage bolt—5/16-18 x 1” lg. 1 Install Chute Control Gear, page 9

Flat washer 1

, p g

Locknut—5/16 1

Skid 2

Flange head capscrew—5/16-18 x 3/4” lg. 2Install Skids page 9

Flat washer 2Install Skids, page 9

Locknut—5/16 2

Key 1 Use in Ignition Switch

Registration card 1 Use to register product with factory

Specifications and design subject to change without notice.

Accessories

Description Part Number

110 Vac Electric Starter Kit 37–4810

Tire Chain Kit 56–2700

Snow Cab 68–9500

Weight Kit (required with Snow Cab) 74–1190

Drift Breaker 66–7960

Light Kit 66–7941

Differential Kit 38038

8

AssemblyNote: Determine left and right sides of

snowthrower by standing in the normaloperating position.

Mount Auger/impeller Housing

1. Remove (2) flange head capscrews securing idlerpulley assembly to engine frame. Remove idlerpulley assembly.

2. Align auger/impeller housing and engine framemounting holes (Fig. 2).

3. Route impeller belt around impeller pulley.

4. Secure auger/impeller housing to engine framewith (6) 5/16–18x3/4” lg. flange head capscrews.

5. Reinstall idler pulley assembly. Make sure idlerpulleys are aligned with belts when reinstallingidler pulley assembly.

6. Tip snowthrower up on front edge ofauger/impeller housing.

7. Move wheels to the rear Power Shift position.

8. Mount lower belt cover to underside ofauger/impeller housing and engine frame with(2) 1/4–20x1/2” lg. flange head capscrews (Fig.3). Make sure belt cover mounting tabs arepositioned to rear of engine frame member.

9. Check adjustment of impeller cable; refer tostep 3 of Adjusting Auger/Impeller Drive Belt,page 16.

10. Mount upper belt cover to engine frame with (3)1/4–20x1/2” lg. flange head capscrews (Fig. 4).

11. Slide cable cover onto cables and into hole inbelt cover (Fig. 4).

Install Shift Rod (Fig. 5)

1. Insert upper shift rod ball joint stud throughfront of shift bracket and secure with 3/8–24locknut.

Note: Shift rod to be positioned with bendrearward.

2. Insert bottom ball joint stud through right side oftransmission lever and secure with 3/8–24locknut.

3. Shift into 2nd gear and check shift rod alignmentwith Power Shift slot.

Note: If gear shift lever is not aligned withPower Shift slot in control panel(Fig. 5, inset), shift rod length must beadjusted as follows:

A. Disconnect ball joint from transmissionlever and loosen jam nut.

B. Rotate ball joint up or down, until gear shiftlever is aligned with Power Shift slot.

C. Reinstall ball joint to transmission lever andtighten jam nut.

Install Discharge Chute (Fig. 6)

Note: Before installing discharge chute,apply a light coat of low temperaturegrease to chute ring.

1. Set discharge chute—open side forward—ontoauger/impeller discharge opening, so plasticchute retainers are positioned on chute ring.Make sure chute retainer guide pins are insertedinto holes in chute gear.

2. Tighten machine screw and locknut on left sideuntil chute retainer plate is positioned againstplastic chute retainer and discharge chute issecured to chute ring.

9

3. Push chute retainers on right side towarddischarge chute (slotted) and tighten machinescrew.

4. Make sure chute rotates freely on ring. If chutebinds, move right hand retainer outward to easeoperation.

Install Chute Control Gear(Fig. 7)

1. Insert the 5/16–18 x 1” lg. carriage bolt into gearbracket mounting hole.

2. Position worm gear into bracket, align holes andinsert chute gear rod through bracket and gear.

3. Loosely mount worm gear and bracket tomounting flange with carriage bolt, flat washer,and locknut.

4. Slide worm gear into teeth of chute gear andtighten locknut.

5. Check operation. Move gear slightly outward ifbinding is evident.

Check Tire Pressure

IMPORTANT: Check pressure of tiresbecause they are over–inflated at the factoryfor shipping. Therefore, before thesnowthrower is operated, reduce pressure inboth tires to 7–15 psi equally.

Install Skids

1. Check tire pressure; refer to Check Tire Pressure,page 9.

2. Move the snowthrower onto a flat surface andcheck if scraper (Fig. 8) is parallel to the ground.If not, adjust scraper; refer to Adjusting Scraper,page 14.

3. Remove (2) flange bolts and washers securingends of scraper to side plates (Fig. 9). Reinstallbolts through rear slots in skids. Assemble bothskids so that washers are between skids andsideplates (Fig. 9). Do not tighten bolts.

4. Install (2) flange bolts through front slots inskids and thru sideplates. Install flat washers andlocknuts on inside of sideplates. Do not tightenbolts.

Note: The following steps adjust the skids forpaved surfaces. For gravel or crushedrock surfaces, refer to Adjusting Skids,page 14.

5. Manually move wheels to the rear Power Shiftposition by lifting up on handles and moving theshift control fully forward to Power Shiftposition (Fig. 10).

6. Support the scraper to be 1/8 inch above a levelsurface if the snowthrower is to be used onsmooth pavement.

Note: The scraper should be higher than 1/8inch above the pavement if thepavement surfaces are cracked, roughor uneven.

7. Move the skids down to sit flat on the groundand tighten the (4) flange bolts securing bothskids to the auger side plates.

Check Auger Gear Box Oil

1. Move snowthrower to a level surface.

2. Clean area around pipe plug so dirt is removed.

3. Remove pipe plug from gear box (Fig. 11).

4. Check oil level in gear box. Oil must be at pointof overflowing in filler opening.

5. If level of oil is low, add GL–5 or GL–6 SAE85–95 EP transmission oil to the gear box untilpoint of overflow.

6. Reinstall pipe plug in gear box.

10

Before StartingENGINES WHICH ARE CER TIFIED T OCOMPLY WITH CALIFORNIA AND U.S. EPAEMISSION REGULA TIONS FOR ULGEENGINES: Are certified to operate on regularunleaded gasoline. Include the following emissioncontrol system(s): EM, TWC (if so equipped); Do notinclude any user adjustable features – therefore noother adjustments are needed.

Fill Crankcase W ith Oil

The engine is shipped from the factory without oil inthe crankcase. Therefore, before starting the engine,oil must be added to the crankcase.

IMPORTANT: Check level of oil every 5operating hours or each time unit is used.Initially, change oil after the first 2 hours ofoperation; thereafter, under normalconditions, change oil after every 25 hours ofoperation or annually, whichever comes first.

1. Move unit to a level surface to ensure anaccurate oil level reading.

2. Clean area around dipstick to prevent foreignmatter from entering filler hole when dipstick isremoved.

3. Remove dipstick from crankcase (Fig. 12).

4. Slowly pour 24 ounces of SAE 5W–30 orSAE 10 oil into the filler hole. The engine usesany high–quality detergent oil having theAmerican Petroleum Institute (API) “serviceclassification”—SE, SF or SG.

Note: Dipstick must be fully installed toensure accurate gauging of oil level.DO NOT OVERFILL.

Fill Fuel Tank With Gasoline

POTENTIAL HAZARD• In certain conditions gasoline is extremely

flammable and highly explosive.

WHAT CAN HAPPEN• A fire or explosion from gasoline can burn

you, others, and cause property damage.

HOW TO AV OID THE HAZARD• Use a funnel and fill the fuel tank outdoors,

in an open area, when the engine is cold.Wipe up any gasoline that spills.

• Do not fill the fuel tank completely full.Add gasoline to the fuel tank until the levelis 1/4” to 1/2” (6 mm to 13 mm) below thebottom of the filler neck. This empty spacein the tank allows gasoline to expand.

• Never smoke when handling gasoline, andstay away from an open flame or wheregasoline fumes may be ignited by a spark.

• Store gasoline in an approved containerand keep it out of the reach of children.

• Never buy more than a 30-day supply ofgasoline.

Use clean, fresh lead-free gasoline, includingoxygenated or reformulated gasoline, with an octanerating of 85 or higher. To ensure freshness, purchaseonly the quantity of gasoline that can be used in 30days. Use of lead-free gasoline results in fewercombustion chamber deposits and longer spark pluglife. Use of premium grade fuel is not necessary.

IMPORTANT : NEVER USE METHANOL ,GASOLINE CONTAINING METHANOL ,GASOHOL CONTAINING MORE THAN10% ETHANOL, PREMIUM GASOLINE,OR WHITE GAS BECAUSE ENGINEFUEL SYSTEM DAMAGE COULDRESULT.

Toro also recommends that ToroStabilizer/Conditioner be used regularly in all Torogasoline powered products during operation and

11

storage seasons. Toro Stabilizer/Conditioner cleansthe engine during operation and prevents gum–likevarnish deposits from forming in the engine duringperiods of storage.

Note: A fuel stabilizer/conditioner is mosteffective when mixed with freshgasoline.

DO NOT USE FUEL ADDITIVES OTHERTHAN THOSE MANUF ACTURED FOR FUELSTABILIZA TION DURING ST ORAGE SUCHAS TORO’S STABILIZER/CONDITIONER ORA SIMILAR PRODUCT . TORO’SSTABILIZER/CONDITIONER IS APETROLEUM DISTILLA TE BASEDCONDITIONER/ST ABILIZER. T ORO DOESNOT RECOMMEND STABILIZERS WITH ANALCOHOL BASE SUCH AS ETHANOL,METHANOL OR ISOPROPYL. ADDITIVESSHOULD NOT BE USED TO TRY TOENHANCE THE POWER OR PERFORMANCEOF MACHINE.

1. Clean area around the fuel tank cap (Fig. 12).Remove cap from fuel tank. Using unleaded,regular gasoline, fill tank to within 1/4” to 1/2”(6 to 13 mm) from the top of the tank, not intothe filler neck. This space is for expansion offuel. Do not fill tank full. Reinstall fuel tank cap.

Fuel tank capacity is 4 quarts.

OperationControls

Auger/Impeller Control (Fig. 13)—Control has twopositions: ENGAGE and DISENGAGE. To engageboth auger and impeller, compress lever against righthandle grip. To disengage, release lever.

Traction Drive Control (Fig. 13)—To engagetraction (wheel drive) or activate power shift system,lever must be compressed against left handle grip. Tostop traction, release lever.

Speed Shift Control (Fig. 13)—The control has aneutral position, four speeds forward and two reverse,and also controls power shifting of wheels. To selectspeeds, move shift control to desired position.

Note: Before shifting gears into or out ofreverse or when using the Power Shiftfeature, the traction drive control mustbe released. On-the-go shifting may beaccomplished with any of theFORWARD speeds without releasingthe traction drive control.

Auger/impeller Lock–Up (Fig. 13)—When theauger/impeller control and traction drive control areboth compressed, the traction control locks theauger/impeller control down. Releasing the tractioncontrol releases the auger/impeller control.

Discharge Chute Control (Fig. 13)—Rotatedischarge chute control clockwise to move dischargechute to the right and counterclockwise to move chuteto the left.

Ignition Switch (Fig. 14)—Insert key before startingengine with the recoil starter. To stop engine, removekey.

Throttle (Fig. 14)—Move throttle upward to increasethe engine speed.

Choke (Fig. 14)—Rotate choke to ON position tostart a cold engine. As engine warms up, rotate chokegradually to OFF.

Primer (Fig. 14)—Press primer to pump a smallamount of gasoline into engine for improved coldweather starting.

Fuel Shut–Off Valve (Fig. 15)—Valve is locatedunder fuel tank. Close valve to stop fuel flow fromfuel tank and open valve to allow fuel to flow to thecarburetor. Close valve when snowthrower is notused.

Deflector Handle (Fig. 16)—Deflector handle on topof discharge chute is used to control the height of thesnow stream.

Recoil Starter (Fig. 17)—Recoil starter is on backside of engine. Pull recoil starter to start engine.

12

Starting/Stopping Engine

Starting

Note: If engine is operated when temperatureis +40� F (4� C) or higher, removecarburetor heater box. However, theheater box must be reinstalled whentemperature falls below +40� F (4� C).To remove heater box:

A. Remove (4) mounting screws securingheater box in place (Fig. 14 and 18).

B. Grasp choke knob and pull it off mountingpin.

C. Lift heater box up and away from theengine, and reinstall choke knob onmounting pin.

IMPORTANT: Check auger and impeller toensure that both parts are not frozen, but freeto rotate. Also, make sure discharge chute isnot obstructed. USE A STICK, NOT YOURHAND, TO REMOVE ANYOBSTRUCTIONS.

1. Move speed shift control to N (neutral) andthrottle to FAST (Fig. 13).

2. Ensure that auger/impeller control and tractiondrive control are in disengaged position.

3. Open fuel shut–off valve below fuel tank(Fig. 15).

4. Move choke to ON choke position (Fig. 14).

5. Insert ignition key (Fig. 14).

6. Cover hole in center of primer with thumb andpush primer three times slowly. DO NOTPRIME IF THE ENGINE HAS BEENRUNNING AND IS HOT.

Note: Excessive priming may cause floodingof engine and failure to start.

7. Grasp recoil starter handle (Fig. 17) and pull itout slowly until positive engagement results;then pull vigorously to start the engine. Keepfirm grip on starter handle and return the ropeslowly.

Note: If engine does not start or iftemperature is –10�� F or below,additional priming may be required.After each additional prime, try to startthe engine before priming again.

8. After engine starts, immediately move choke(Fig. 14) to 3/4 position. As engine warms up,move choke to 1/2 position; then to OFFposition. If engine falters, return choke to 1/2position. When engine warms sufficiently, movechoke to OFF position.

Before Stopping

1. Engage auger/impeller to clear any remainingsnow from inside the housing.

2. Run engine for a few minutes to help dry off anymoisture which may have accumulated onengine.

3. With engine running, pull recoil starter with arapid, continuous full arm stroke three or fourtimes. This helps prevent possible freeze–up ofrecoil starter due to extreme snow blowingconditions.

Note: Pulling of recoil starter rope produces aloud, clattering sound. This is notharmful to the engine or the starter.

Stopping

1. Release traction and auger/impeller drivecontrols (Fig. 13).

2. Move throttle to slow.

3. Remove key from ignition switch.

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4. Wait for all moving parts to stop before leavingthe operator’s position (behind the handles).

5. Store key in a memorable place.

Power Shift Operation

Wheels will shift forward (or rearward) with everyother movement of the shift control.

Move wheels to the rear Power Shift position inheavy and/or drifted snow.

Leave wheels in the front position for light snow orfor transporting snowthrower.

1. Release traction drive lever.

2. To move wheels to front or rear position, moveshift control fully forward to Power Shiftposition and hold (Fig. 19).

3. Fully engage traction drive lever to move wheelsinto alternate position (Figs. 19 & 20).

Note: When power shifting it may benecessary to slightly raise handle toassist wheel movement.

Note: To shift wheels manually if engine isnot running, follow steps 1 and 2 andthen lift up on handles to unlockwheels.

Note: If wheels do not move in desireddirection when power shifting, repeatprocedure.

Free Wheeling OrSelf–propelled Drive

The snowthrower can be free wheeled or engaged forself–propelled operation. There are two holes in eachend of the axle. When axle pins are thru outer axleholes and not thru wheel hub (Fig. 21), snowthrower

free wheels. By contrast, when both pins are installedthru holes in wheel hub and inner hole of axle(Fig. 21), snowthrower propels itself.

Snowthrowing Tips

1. When snowthrower is not being used, close fuelshut–off valve and remove key from the switch.

2. Remove snow as soon as possible after it falls.This produces best snow removal results.

3. When in the rear Power Shift position, pushdown on handles to increase traction ifnecessary.

4. Discharge snow downwind whenever possible,and overlap each swath to ensure complete snowremoval. If wheels slip, shift into a lower gear toreduce forward speed.

5. In some snow and cold weather conditions, somecontrols and moving parts may freeze. Therefore,when any control becomes hard to operate, stopthe engine and wait for all moving parts to stop;then check all parts for freeze up. DO NOT USEEXCESSIVE FORCE AND TRY TO OPERATETHE CONTROLS WHEN FROZEN. Free allcontrols and moving parts before operating.

6. Adjust skids to match the type of surface beingcleaned. Refer to Adjusting Skids, page 14.

7. Run snowthrower for a few minutes afterclearing snow so moving parts do not freeze.Engage auger/impeller to clear any remainingsnow from inside housing.

8. Do not overload snowthrower by clearing snowat too fast a rate. If engine slows down, shift to alower gear to reduce forward speed.

9. Move wheels to the rear Power Shift positionand shift to a lower gear in heavy and/or driftedsnow to prevent the auger/impeller housing fromriding up over the snow.

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10. Always use full throttle (maximum enginespeed) when throwing snow.

11. In wet or slushy conditions, clogging of thedischarge chute will be reduced by maintainingmaximum engine speed and by not overloadingthe engine.

POTENTIAL HAZARD• Rotating impeller or auger can cut off or

injure fingers or hands.

WHAT CAN HAPPEN• Rotating impeller or auger can cut off or


HOW TO AV OID THE HAZARD• Stay behind the handles and away from

discharge opening while operating thesnowthrower.

• Keep face, hands, feet and any other part ofyour body or clothing away fromconcealed, moving or rotating parts.

• Before adjusting, cleaning, repairing andinspecting the snowthrower, and beforeunclogging the discharge chute, shut engineoff and wait for all moving parts to stop.

• Also, pull wire off spark plug and keepwire away from the plug to preventaccidental starting.

• Use a stick, not your hands, to removeobstructions from discharge chute.

Adjusting Scraper (Fig. 8)

Adjust the scraper to compensate for wear and toensure that the auger does not contact the pavement.

1. Pull wire off spark plug and make sure wire doesnot contact plug accidentally.

2. Check the tire pressure in both tires. Make surethat they are both inflated equally between 7 and15 psi.

3. Move the snowthrower onto a flat surface andshift the wheels to the FRONT position.

4. Loosen the (4) flange bolts securing both skidsto the auger side plates.

5. Next, loosen the carriage bolts securing thescraper to the auger/impeller housing.

6. Support the auger blades so that the auger is 1/8– 1/4 inch off the ground.

7. Move the scraper so that it contacts the flatsurface all the way across, then tighten the tworear flanged cap screws securing scraper andskids to the side plates. This temporarily locksthe scraper in the proper position so that theremainder of the fasteners can be tightenedwithout affecting adjustment.

8. Secure the scraper using carriage bolts and nylonlocknuts.

9. Adjust the skids; refer to Adjusting Skids,page 14.

Adjusting Skids (Fig. 9)

For Concrete or Asphalt Surfaces

If the snowthrower is not cleaning up the snow closeenough to the pavement, adjust the skids to lower thescraper.

If the scraper catches on cracks in the pavement,adjust the skids to raise the scraper.


2. Loosen the (4) flange bolts securing both skidsto the auger side plates.

3. Check scraper adjustment to ensure that theauger does not contact the pavement; refer toAdjusting Scraper, page 14.

4. Move the wheels to the REAR Power Shiftposition.

5. Support the scraper to be 1/8 inch above a levelsurface if the snowthrower is to be used onsmooth pavement.

15

Note: The scraper should be higher than 3/16inch above the pavement if thepavement surfaces are cracked, roughor uneven.

6. Move the skids down to sit flat on the groundand tighten the (4) flange bolts securing bothskids to the auger side plates.

For Gravel Surfaces

For gravel or crushed rock surfaces, adjust the skidsto prevent picking up rocks.


2. Loosen the (4) flange bolts securing both skidsto auger side plates. Next, slide skids down asfar as possible so auger will be supported as farfrom the level surface as skid adjustment allows:then tighten flange bolts.

Maintenance

POTENTIAL HAZARD• If you leave the wire on the spark plug,

someone could start the engine.

WHAT CAN HAPPEN• Accidental starting of engine could

seriously injure you or other bystanders.

HOW TO AV OID THE HAZARD• Pull wire off spark plug and remove key

from switch before you do anymaintenance. Also push wire aside so itdoes not accidentally contact spark plug.

Draining Gasoline

1. Close fuel shut–off valve located under fuel tank(Fig. 15).

POTENTIAL HAZARD• Gasoline is highly flammable.

WHAT CAN HAPPEN• Gasoline can be ignited and cause serious

personal injury.

HOW TO AV OID THE HAZARD• Drain gasoline outdoors.• Drain gasoline from a cold engine only.• Wipe up any gasoline that may have

spilled.• Do not drain gasoline near any open flame

or where gasoline fumes may be ignited bya spark.

• DO NOT SMOKE a cigar, cigarette or pipewhen handling gasoline.

2. Place a clean drain pan under shut–off valve.

3. Loosen hose clamps securing fuel line to valveand slide line off valve (Fig. 15).

4. Open valve allowing fuel to flow into drain pan.

5. Reinstall fuel line and secure with hose clamp.

Lubricating Snowthrower

1. Annually lubricate drive chain with chainlubricant (Fig. 22). Wipe up any excess oil.

Changing Crankcase Oil

Initially, change oil after the first 2 hours of engineoperation; thereafter, under normal conditions, changeoil after every 25 hours of engine operation or

16

annually. If possible, run engine just before changingoil because warm oil flows better and carries morecontaminants than cold oil.


2. Clean area around oil drain cap. Next, slide oildrain pan below drain extension; then remove oildrain cap (Fig. 23).

3. After all oil is drained, reinstall oil drain capsecurely.

4. Position snowthrower on a level surface. Next,fill crankcase with oil: see Fill Crankcase WithOil, page 10. Wipe up any oil that may havespilled.

Auger Gear Box Oil

The auger gear box oil level must be checked atsetup, after every 10 hours of use, and upon removalfrom annual storage. To check the auger gear box oillevel:

1. Position snowthrower on a level surface.

2. Clean area around pipe plug so dirt is removed.

3. Remove pipe plug from gear box (Fig. 11).

4. Check level of oil in gear box. Oil must be atpoint of overflowing in filler opening.

5. If level of oil is low, add GL–5 or GL–6 SAE85–95 EP transmission oil to the gear box untilpoint of overflow.

6. Reinstall pipe plug in gear box.

Adjusting Auger/Impeller DriveBelt

If auger/impeller belt slips, resulting in decreasedsnowthrowing performance, an adjustment isrequired. WHENEVER A NEW BEL T ISINSTALLED, AN ADJUSTMENT ISREQUIRED. USE ONLY GENUINE T OROREPLACEMENT PARTS.


2. Remove (3) flange head capscrews securing beltcover to engine frame and slide belt cover upcables (Fig. 4).

3. CHECKING IMPELLER CABLEADJUSTMENT—Depress the auger/impellercontrol lever on the right hand grip. Hold thelever and insert a .010” (.25 mm) feeler gaugebetween a coil in the center of the spring(Fig. 24). Adjust the cable to achieve .010” (.25mm) gap between the coils.

4. Loosen upper jam nut securing auger/impellercable to mounting bracket (Fig. 25).

5. Rotate bottom jam nut upward to increase belttension.

6. Tighten upper jam nut against bracket.

7. Recheck idler adjustment: refer to step 3

8. Check impeller brake arm clearance by releasingthe auger/impeller lever. With the lever released,there should be more than 1/8” clearancebetween tab on impeller idler arm and brake arm(Fig. 26). If there is less than 1/8” clearance,belt must be replaced.

17

POTENTIAL HAZARD• Improper adjustment may cause injury if

auger/impeller turns when disengaged.



HOW TO AV OID THE HAZARD• Keep face, hands, feet and any other part of

your body or clothing away fromconcealed, moving or rotating parts.

• Make certain that impeller brake armclearance is maintained.

• Do not adjust the auger/impeller drive belttoo tight because it may cause theauger/impeller to turn when the controllever is in the disengaged position. If thisoccurs, decrease belt tension.

9. Reinstall belt cover and cable cover.

10. Check tension of belt by operating theauger/impeller. If belt still slips, replace thebelt.

Adjusting Traction Drive Belt(Fig. 25)

If the wheels do not turn when the traction lever isdepressed, the traction belt tension should beincreased. Whenever the belt is replaced, anadjustment is required.

1. Loosen upper jam nut securing traction cable tomounting bracket.

2. Rotate bottom jam nut upward to increase belttension.

Note: When adjusting cable, always rotatenut one full turn at a time.

3. Tighten upper jam nut against bracket.

4. Check tension of belt by operating machine.Machine should begin to move forward whentraction lever is depressed approximatelyhalfway down toward handle grip. Turn engineoff and repeat steps until proper adjustment isachieved.

IMPORTANT: Do not adjust the belt too tightbecause it may cause snowthrower to creepwhen traction lever is in disengaged position.If this occurs, decrease belt tension.

Replacing Drive Belts (Fig. 27)

If auger/impeller belt or traction belt becomes worn,glazed, stretched, oil–soaked or otherwise defective,belt replacement is required.

1. Pull wire off spark plug and make sure it doesnot contact the plug accidentally.

2. Remove (3) flange head capscrews holding beltcover in place, and slide belt cover up cables(Fig. 4).

3. Move speed shift control to N (neutral).

4. Remove (2) flange head capscrews securing idlerpulley assembly to engine frame. Remove idlerpulley assembly.

5. Remove capscrew and lockwasher securing halfsheave to front of pulley assembly.

6. Slide half sheave and auger/impeller belt offcrankshaft and remove belt from impeller pulley.

7. If replacing traction belt, slide middle pulleysection and belt off crankshaft and remove beltfrom transmission pulley.

8. On control cable which corresponds to belt beingreplaced, loosen jam nuts securing cable tobracket (Fig. 25). Cable must be free to slide inbracket when changing belt(s).

18

9. Reinstall belts by reversing procedure. Makesure tabs in half sheave are inserted intomounting grooves in middle pulley sectionwhen reinstalling.

Note: Make sure idler pulleys are alignedwith belts when reinstalling idlerpulley assembly.

10. Readjust belts, refer to Adjusting Auger/ImpellerDrive Belt or Adjusting Traction Drive Belt.

POTENTIAL HAZARD• Improper adjustment may cause injury if

auger/impeller turns when disengaged.



HOW TO AV OID THE HAZARD• Keep face, hands, feet and any other part of

your body or clothing away fromconcealed, moving or rotating parts.

• Make certain that impeller brake armclearance is maintained.

• Do not adjust the auger/impeller drive belttoo tight because it may cause theauger/impeller to turn when the controllever is in the disengaged position. If thisoccurs, decrease belt tension.

Adjusting Drive Chain(Fig. 28–30)

The drive chain must be adjusted to maintain 1/8–3/8of an inch deflection mid span between transmissionand axle sprocket. Check chain deflection after every25 hours of operation.

1. Pull wire off spark plug and make sure wire doesnot contact plug accidentally (Fig. 31).

2. Make sure wheels are positioned in rear position,move shift control into 2nd gear, and tipsnowthrower up onto front edge ofauger/impeller housing.

IMPORTANT: To adjust drive chain, thesnowthrower must be tipped up on front edgeof auger/impeller housing. However, beforethe snowthrower is tipped, drain all gasolinefrom fuel tank. Refer to Draining Gasoline,page 15.

3. Check deflection of chain by lifting up on chainwith moderate pressure at mid span. Thereshould be 1/8–3/8” deflection (Fig. 28). Ifdeflection is not as specified, an adjustment isrequired.

4. Loosen (4) flange head capscrews (2 each side)securing transmission frame to engine frame(Fig. 30).

5. Pivot rear of transmission frame until 1/8–3/8”chain deflection is attained. Retighten flangehead capscrews.

6. Recheck chain deflection.

IMPORTANT: Excessive chain tension maycause transmission damage.

7. Chain adjustment will affect gearshift leveralignment. If gear shift lever is not aligned withPower Shift slot in control panel (Fig. 5, inset),shift rod length must be adjusted as follows:

A. Disconnect ball joint from transmissionlever and loosen jam nut.

B. Rotate ball joint up or down until gear shiftlever is aligned with Power Shift slot.

C. Reinstall ball joint to transmission lever andtighten jam nut.

19

Replacing Spark Plug

Use a Champion RJ–19LM spark plug or equivalent.Set air gap at 0.030” (0.76 mm). Check spark plugyearly or every 100 operating hours. If electrodes incenter of plug are dark or have deteriorated, install anew plug.

1. Clean area around spark plug so foreign mattercannot fall into cylinder when plug is removed.

2. Pull wire off spark plug (Fig. 31) and removeplug from cylinder head.

IMPORTANT: A cracked, fouled or dirtyspark plug must be replaced. Do not sandblast, scrape or clean electrodes because gritmay eventually release from the plug and fallinto the cylinder. The result will likely beengine damage.

3. Set air gap between electrodes of new spark plugat 0.030” (0.76 mm) (Fig. 32). Next, installspark plug in cylinder head. Tighten plug to 15ft–lb (20.4 N�m).

4. Push the wire onto the spark plug.

Storage1. FUEL SYSTEM PREPARATION–

Note: A fuel stabilizer/conditioner is mosteffective when mixed with freshgasoline.

• Add Toro Stabilizer/Conditioner to the fuel tank(one ounce per gallon of fuel).

• Run engine for ten minutes to distributeconditioned fuel through fuel system.

• Stop engine, allow it to cool, and drain fuel tank.

• Restart the engine again and run it until it stops.

• Either choke or prime the engine, restart it athird time and run engine until it will not restart.

• Dispose of fuel properly. Recycle per localcodes.

• DO NOT store STABILIZED gasoline over 90days.

2. Remove spark plug from cylinder head. Next,pour two teaspoons of engine oil into spark plughole in cylinder head. Install spark plug incylinder head, but do not install wire on theplug. Then pull recoil starter slowly to distributeoil on inside of cylinder.

3. Lubricate the snowthrower: refer to LubricatingSnowthrower, page 15. Change crankcase oil:see Changing Crankcase Oil, page 15.

4. Clean the snowthrower. Touch up chippedsurfaces with paint. Toro Re–Kote paint isavailable from an Authorized TORO ServiceDealer. Sand affected areas before painting, anduse a rust preventative to prevent metal partsfrom rusting.

5. Tighten all screws and nuts. If any part isdamaged, repair or replace it.

6. Cover snowthrower and store in a clean, dryplace out of the reach of children. NEVERSTORE SNOWTHROWER IN HOUSE(LIVING AREA) OR BASEMENT WHEREIGNITION SOURCES MA Y BE PRESENTSUCH AS HOT WATER AND SPACEHEATERS, CLOTHES DRYERS, AND THELIKE BECAUSE GASOLINE AND FUMESARE HIGHL Y FLAMMABLE,EXPLOSIVE, AND DANGEROUS IFINHALED. Allow engine to cool before storingin any enclosure.

20

If you have a general understanding of internal combustion engines and wish to repair and service your engineyourself, refer to the Warranty and Repair section in your engine owner’s manual for information on how toobtain a “MECHANICS HANDBOOK” from Tecumseh Products Company.

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