Toro 38560, 1028 power shift, 38592, 1332 power shift, 924 power shift Operator's Manual

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Page 1

Form No. 3326-376 Rev A

924, 1028, and 1332 Power Shift

Snowthrower

Model No. 38547—220000001 and Up Model No. 38560—220000001 and Up Model No. 38592—220000001 and Up



Operator’s Manual

Domestic English (EN)

Page 2

Warning

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Important This engine is not equipped with a spark

arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest–covered, brush–covered or grass–covered land. Other states or federal areas may have similar laws.

This spark ignition system complies with Canadian ICES-002.

Ce système d’allumage par étincelle de véhicule est conforme à la norme NMB-002 du Canada.

The enclosed Engine Owner’s Manual is supplied for information regarding The U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty.

Keep this engine Owner’s Manual with your unit. Should this engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered through the engine manufacturer.

Contents

Page

Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .

Toro Snowthrower Safety 4. . . . . . . . . . . . . . . . . . .

Safety and Instruction Decals 6. . . . . . . . . . . . . . . . .

Assembly 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Installing the Auger/Impeller Housing 8. . . . . . . . .

Installing the Shift Rod 9. . . . . . . . . . . . . . . . . . . . .

Installing the Discharge Chute 9. . . . . . . . . . . . . . . .

Installing the Chute Control Gear 10. . . . . . . . . . . . .

Installing the Skids 10. . . . . . . . . . . . . . . . . . . . . . . . .

Before Starting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling the Engine Crankcase with Oil 11. . . . . . . . . .

Filling the Fuel Tank with Gasoline 11. . . . . . . . . . . .

Checking the Tire Pressure 12. . . . . . . . . . . . . . . . . .

Reviewing the Maintenance Schedule 12. . . . . . . . . .

Operation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Controls 12. . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Carburetor Heater Box 14. . . . . . . . . .

Installing the Carburetor Heater Box 14. . . . . . . . . . .

Page

Starting the Engine 14. . . . . . . . . . . . . . . . . . . . . . . . .

Stopping the Engine 15. . . . . . . . . . . . . . . . . . . . . . . .

Operating the Power Shift Feature 15. . . . . . . . . . . . .

Freewheeling or Self-propel Drive 16. . . . . . . . . . . .

Operating the Differential 16. . . . . . . . . . . . . . . . . . .

Snowthrowing Tips 17. . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 18. . . . . . . . .

Checking the Engine Oil Level 19. . . . . . . . . . . . . . .

Checking the Auger Gearbox Oil Level 19. . . . . . . .

Adjusting the Skids and the Scraper 19. . . . . . . . . . .

Adjusting the Traction Drive Belt 20. . . . . . . . . . . . .

Adjusting the Auger/Impeller Drive Belt 20. . . . . . . .

Replacing the Drive Belts 21. . . . . . . . . . . . . . . . . . .

Changing the Engine Oil 22. . . . . . . . . . . . . . . . . . . .

Lubricating the Drive Chain 23. . . . . . . . . . . . . . . . .

Adjusting the Drive Chain 23. . . . . . . . . . . . . . . . . . .

Replacing the Spark Plug 24. . . . . . . . . . . . . . . . . . . .

Emptying the Fuel Tank 24. . . . . . . . . . . . . . . . . . . . .

Storage 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparing the Fuel System 24. . . . . . . . . . . . . . . . . . .

Preparing the Engine 24. . . . . . . . . . . . . . . . . . . . . . .

Preparing the Snowthrower 25. . . . . . . . . . . . . . . . . .

Accessories 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Toro Total Coverage Guarantee 28. . . . . . . . . . . . . .

Introduction

Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely.

Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 illustrates the location of the model and serial numbers on the product.

Figure 1

1. Location of the model and serial numbers

181

 2001 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Printed in the USA

Page 3

Write the product model and serial numbers in the space below:

Model No.

Training

• Read the operator’s manual carefully. Be thoroughly

familiar with the controls and the proper use of the equipment. Know how to stop the unit and disengage the controls quickly.

Serial No.

This manual identifies potential hazards and has special safety messages that help you and others avoid personal injury and even death. Danger, Warning, and Caution are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful.

Danger signals an extreme hazard that will cause serious injury or death if you do not follow the recommended precautions.

Warning signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.

Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions.

This manual uses two other words to highlight information.

Important calls attention to special mechanical

information and Note: emphasizes general information worthy of special attention.

Safety

This two-stage snowthrower meets or exceeds the B71.3 specifications of the American National Standards Institute in effect at the time of production.

To ensure maximum safety and best performance, and to gain knowledge of the product, it is essential that you and any other operator of the snowthrower read and understand the contents of this manual before the engine is ever started.

This is the safety alert symbol. It is used to alert you

to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Improperly using or maintaining this snowthrower could result in injury or death. To reduce this potential, comply with the following safety instructions.

• Never allow children to operate the snowthrower. Never

allow adults to operate the snowthrower without proper instruction.

• Keep the area of operation clear of all persons

(particularly small children) and pets.

• Exercise caution to avoid slipping or falling, especially

when operating the snowthrower in reverse.

Preparation

• Thoroughly inspect the area where you will use the

snowthrower. Remove all doormats, sleds, boards, wires, and other foreign objects.

• Before starting the engine, disengage all clutches. For

Power Shift neutral as well.

• Do not operate the snowthrower without wearing

adequate winter garments. Wear footwear that will improve your footing on slippery surfaces.

• Handle fuel with care; it is highly flammable.

– Use an approved fuel container. – Never add fuel to a running or hot engine. – Fill the fuel tank outdoors with extreme care. Never

fill the fuel tank indoors.

– Replace the fuel tank cap securely and wipe up any

spilled fuel.

• Use only the power cord supplied with the snowthrower

and a receptacle appropriate for use with the power cord for electric-starting motors.

• Adjust the auger housing height to clear gravel or

crushed rock surface.

• Never attempt to make any adjustments while the

engine is running, except where specifically recommended by Toro.

• Let the engine and the snowthrower adjust to the

outdoor temperature before starting to clear snow.



models, shift the snowthrower into

Safe Operating Practices

The following instructions have been adapted from the ANSI/OPEI B71.3–1995 standard and the ISO 8437:1989 standard. Information or terminology specific to Toro snowthrowers is enclosed in parenthesis.

• Operating any powered machine can result in foreign

objects being thrown into the eyes. Always wear safety glasses or eye shields while operating, adjusting, or repairing the snowthrower.

Page 4

Operation

• Do not put hands or feet near or under rotating parts.

Keep clear of the discharge opening at all times.

• Never operate the snowthrower without good visibility

or light. Always be sure of your footing, and keep a

firm hold on the handle. Walk; never run.

• Exercise extreme caution when operating on or crossing

gravel drives, walks, or roads. Stay alert for hidden hazards or traffic.

• After striking a foreign object, stop the engine, remove

the wire from the spark plug, thoroughly inspect the snowthrower for any damage, and repair the damage before operating the snowthrower.

• If the unit should start to vibrate abnormally, stop the

engine and check immediately for the cause. Vibration is generally a warning of trouble.

• Stop the engine whenever you leave the operating

position, before unclogging the auger/impeller housing or discharge chute, and when making any repairs, adjustments, or inspections.

• When cleaning, repairing, or inspecting, make certain

that the auger/impeller and all moving parts have stopped. Disconnect the spark-plug wire, and keep the wire away from the spark plug to prevent someone from accidentally starting the engine.

• Do not run the engine indoors, except when starting it

and for moving the snowthrower in or out of the building. Open the outside doors; exhaust fumes are dangerous.

• Do not clear snow across the face of slopes. Exercise

extreme caution when changing direction on slopes. Do not attempt to clear steep slopes.

• Never operate the snowthrower without proper guards

or other safety devices in place.

• Never operate the snowthrower near glass enclosures,

automobiles, window wells, and drop-offs without properly adjusting the snow discharge angle. Keep children and pets away.

• Do not overload the machine capacity by attempting to

clear snow at too fast a rate.

• Never operate the machine at high transport speeds on

slippery surfaces. Look behind and use care when moving in reverse.

• Never direct the discharge at bystanders or allow

anyone in front of the unit.

• Disengage the power to the auger/impeller when the

snowthrower is being transported or when not in use.

• Use only attachments and accessories approved by

Toro, such as wheel weights, counterweights, and cabs. (Contact your Authorized Service Dealer for accessories available for your snowthrower.)

Maintenance and Storage

• Check all fasteners at frequent intervals for proper

tightness to be sure that the equipment is in safe

working condition.

• Never store the machine with fuel in the fuel tank inside

a building where ignition sources are present, such as

hot water and space heaters and clothes dryers. Allow

the engine to cool before storing in any enclosure.

• Always refer to this operator’s manual for important

details if the snowthrower is to be stored for an

extended period.

• Maintain or replace safety and instruction labels when

necessary.

• Run the engine run for a few minutes after clearing the

snow to prevent the auger/impeller from freezing.

Toro Snowthrower Safety

The following list contains safety information specific to Toro products or other safety information that you must know.

• Rotating auger/impeller can cut off or injure fingers or

hands. Stay behind the handles and away from the

discharge opening while operating the snowthrower.

Keep your face, hands, feet, and any other part of your

body or clothing away from moving or rotating parts.

• Before adjusting, cleaning, repairing, and inspecting the

snowthrower, and before unclogging the dischar ge

chute, stop the engine, remove the key, and wait for all

moving parts to stop. Also, disconnect the wire from the

spark plug and keep it away from the spark plug to

prevent someone from accidentally starting the engine.

• Use a stick, not your hands, to remove obstructions

from the discharge chute.

• Before leaving the operating position, stop the engine,

remove the key, and wait for all moving parts to stop.

• Do not wear loose-fitting clothing that could get caught

in moving parts.

• If a shield, safety device, or decal is damaged, illegible,

or lost, repair or replace it before beginning operation.

Also, tighten any loose fasteners.

• Do not smoke while handling gasoline.

• When operating the snowthrower on slopes, use the

lower gear. For Power Shift

rear wheel position.



snowthrowers, use the

Page 5

• Do not use the snowthrower on a roof.

• Do not touch the engine while it is running or soon after

it has stopped because the engine may be hot enough to cause a burn. Do not add oil or check the oil level in the crankcase while the engine is running.

• Perform only those maintenance instructions described

in this manual. Before performing any maintenance, service, or adjustment, stop the engine, remove the key and disconnect the wire from the spark plug. Keeping the wire away from the spark plug to prevent someone

from accidentally starting the engine. If major repairs are ever needed, contact your Authorized Service Dealer.

• Do not change the governor settings on the engine.

• When storing the snowthrower for more than 30 days,

drain the fuel from the fuel tank to prevent a potential hazard. Store fuel in an approved fuel container. Remove the key from the ignition switch before storing the snowthrower.

• To ensure the best performance and safety, purchase

only genuine Toro replacement parts and accessories.

Before Operating

Read and understand the contents of this manual before operating the snowthrower. Become familiar with all controls and know how to stop the engine quickly.

Operator's

Position

472

Caution: Improper use may result in loss of fingers, hands, or feet.

There is a highspeed

impeller within two inches

of the opening.

1508

The lowspeed auger has a moving pinch point close to the opening.

Page 6

Safety and Instruction Decals

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.

53-7670

1. Cutting/dismemberment hazard in auger

63-3050

1. Move wheels to the rear

2. Shift the transmission to neutral

68-9390

3. Push the lock spring up to disengage from the shaft groove; then slide the coupling to the desired position.

66-6860

1. Chute direction control

2. Forward drive speed settings

99-3230

3. Neutral setting 4. Reverse drive speed settings

94-8079

5. Start the engine

6. Stop the engine

Page 7

1. Primer

Tecumseh Part No. 36501

Tecumseh Part No. 37119

1. Warning—hot surface; do not touch

1. Key ignition

2. Engage to start the engine

3. Disengage to stop the engine

Tecumseh Part No. 37226

Assembly

Note: Determine the left and right sides of the machine from the normal operating position.

Loose Parts

DESCRIPTION QTY. USE

Flange-head bolts—3/4 in. (1.9 cm) 6 Lower belt cover 1 Flange-head bolts—1/2 in. (1.3 cm) 5 Cable cover 1

Installing the auger/impeller housing

4. Fast

5. Increasing scale

6. Slow

7. Stop the engine

Shift rod 1

Installing the shift rod

Locknuts 2 Discharge chute 1 Installing the discharge chute Worm gear 1 Gear bracket 1 Carriage bolt 1 Installing the chute control gear Flat washer 1 Locknut 1

Page 8

DESCRIPTION USEQTY.

Skids 2 Flange-head bolts—3/4 in. (1.9 cm) 2 Flat washers 2

Installing the skids

Locknuts 3 Ignition key 1 Starting and stopping the engine

Installing the Auger/Impeller Housing

1. Remove the two flange-head bolts that secure the idler

pulley assembly to the engine frame, and remove the idler pulley assembly (Fig. 2).

1. Latch arm 2. Latch rod

Figure 3

m5009

163

Figure 2

1. Idler pulley assembly

2. Flange-head bolts

3. Impeller pulley

4. Engine frame

5. Auger housing

Important Remove the idler pulley assembly to

prevent damaging it.

2. Align the holes in the auger/impeller housing with the

holes in the engine frame (Fig. 2).

3. Route the auger/impeller drive belt around the impeller

pulley (Fig. 2).

4. Secure the auger/impeller housing to the engine frame

with six 3/4-inch (1.9 centimeters) flange-head bolts.

5. Install the idler pulley assembly, aligning the idler

pulleys with the belts (Figs. 2 and 31).

6. Tip the snowthrower up on the front edge of the

auger/impeller housing, and block it in place.

7. Move the wheels to the rear position. Refer to

Operating the Power Shift Feature on page 15.

8. Push the latch arm to release the axle (Fig. 3).

9. Pull up on the axle while holding in the latch arm

(Fig. 3).

10.Continue pulling the axle forward until the latch rod

springs into the locked position (Fig. 3).

11. Install the lower belt cover on the underside of the

auger/impeller housing and the engine frame with two 1/2-inch (1 millimeter) flange-head bolts (Fig. 4).

164

Figure 4

1. Flange-head bolt (2)

2. Mounting tabs

3. Lower belt cover (shown from bottom)

Note: Position the belt cover mounting tabs to the rear of the engine frame member.

12.Lower the snowthrower onto its wheels.

13.Check the adjustment of the impeller cable; refer to

steps 4 through 8 of Adjusting the Auger/Impeller Drive Belt on page 20.

Page 9

14.Mount the upper belt cover to the engine frame with

three 1/2-inch (1.3 centimeters) flange-head bolts (Fig. 4).

3. Shift the snowthrower into second gear and check the

shift rod alignment with the Power Shift slot (see inset in Fig. 6).

166

Figure 5

1. Cable cover

2. Upper belt cover

3. Flange-head bolt (3)

15.Slide the cable cover onto the cables and into the hole in

the belt cover (Fig. 5).

Installing the Shift Rod

1. Insert the upper ball joint stud through the front of the

shift bracket and secure it with a locknut (Fig. 6).

Note: If the gear shift lever does not align with the Power Shift slot in the control panel, adjust the shift rod length as follows:

A. Disconnect the ball joint from the transmission lever

and loosen the jam nut (Fig. 6).

B. Rotate the ball joint up or down until the gear shift

lever aligns with the Power Shift slot (Fig. 6).

C. Install the ball joint to the transmission lever and

tighten the jam nut (Fig. 6).

Installing the Discharge Chute

1. Apply a light coat of low-temperature grease to the

chute ring (Fig. 7).

1. Discharge chute

2. Chute retainer (3)

3. Chute retainer plate (3)

Figure 7

4. Chute ring

5. Screw (3)

6. Locknut (3)

m-168

167

Figure 6

1. Gear shift lever

2. Power Shift slot

3. Locknut

4. Shift bracket

5. Upper ball joint

6. Jam nuts

7. Shift rod

8. Transmission lever

9. Lower ball joint

Note: Position the shift rod with the bend rearward.

2. Insert the lower ball joint stud through the right side of

the transmission lever and secure it with a locknut (Fig. 6).

2. Set the discharge chute (open side forward) onto the

discharge opening so that the chute retainers are on the chute ring (Fig. 7).

Note: Ensure that the chute retainer guide pins are in the holes in the chute gear.

3. Tighten the screw and the locknut on the left side to

position the chute retainer against the chute retainer plate and to secure the discharge chute to the chute ring (Fig. 7).

4. Push the other chute retainers toward the discharge

chute (slotted), and tighten the screws (Fig. 7).

5. Ensure that the chute rotates freely on the chute ring. If

the chute binds, move the right-hand retainer outward (Fig. 7).

Page 10

Installing the Chute Control Gear

1. Insert the one-inch (2.5 centimeters) carriage bolt into

the mounting hole of the gear bracket (Fig. 8).

170

Figure 8

1. Gear bracket

2. Carriage bolt, flat washer, and locknut

3. Mounting flange

4. Chute gear rod

5. Worm gear

2. Position the worm gear into the bracket, align the holes, and insert the chute gear rod through the bracket and the gear (Fig. 8).

3. Loosely mount the worm gear and the bracket to the mounting flange with a carriage bolt, a flat washer, and a locknut (Fig. 8).

4. Slide the worm gear into the teeth of the chute gear and tighten the locknut.

5. Operate the chute control. If the chute control binds, apply a light coat of grease to the worm gear and move it slightly outward if it binds; move it slightly inward if it is too loose.

Installing the Skids

1. Check the air pressure in the tires; refer to Checking the Tire Pressure on page 12.

2. Move the snowthrower to a flat surface and ensure that the scraper (Fig. 9) is parallel to the ground. If it is not, adjust the scraper; refer to Adjusting the Skids and the Scraper on page 19.

171

Figure 9

1. Scraper

3. Remove the two flange bolts and flat washers that

secure the ends of the scraper to the side plates (Fig. 10).

m-4932

Figure 10

1. Side plate (2)

2. Flange bolts (4)

3. Skid (2)

4. Flat washers (4)

5. Locknut (2)

4. Insert a flange bolt through the rear slot in each skid.

5. Insert a washer between each skid and the side plate

(Fig. 10). Do not tighten the bolts.

6. Install a flange bolt through the front slot of each skid

and the side plate.

7. Insert a washer and a locknut behind (on the inside of)

the side plate (Fig. 10). Do not tighten the bolts.

Note: The following steps describe how to adjust the skids for paved surfaces. For gravel or crushed rock surfaces, refer to Adjusting the Skids and the Scraper on page 19.

8. Manually move the wheels to the rear Power Shift

position by lifting up on the handgrips and moving the shift control fully forward (Fig. 11).

Page 11

m4058

Figure 11

9. Support the scraper 1/8 inch (3 millimeters) above a

level surface if you use the snowthrower on smooth pavement.

Note: The scraper should be higher than 1/8 inch (3 millimeters) above the pavement if it is cracked, rough, or uneven. Setting the scraper too low may result in

damage to the snowthrower that is not covered by the warranty.

m5008

Figure 12

1. Dipstick

2. Spark-plug wire

2. Clean around the dipstick (Fig. 12).

3. Remove the dipstick by rotating the cap

counterclockwise and pulling it out (Fig. 12).

4. Slowly pour about three-fourths of the crankcase

capacity of oil into the crankcase.

5. Wipe the dipstick clean with a clean cloth.

6. Install the dipstick into the filler neck, then remove it.

3. Fuel tank cap

10.Move the skids down to sit flat on the ground and

tighten the four flange bolts that secure both skids to the side plates.

Before Starting

Filling the Engine Crankcase with Oil

The engine comes from the factory with only a few ounces of oil in the crankcase. Before starting the engine, add oil. The crankcase in models 38547 and 38560 holds 26 ounces (0.77 liters) of oil, and the crankcase in model 38592 holds 28 ounces (0.83 liters) of oil. However, because there is some oil in the crankcase, do not add the full amount at one time. Use only a high-quality, SAE 5W–30 or SAE 10 weight detergent oil that has the American Petroleum Institute (API) service classification SF, SG, SH, or SJ. For extremely cold conditions (below 0°F or –18°C), use 0W–30 weight detergent oil that has the American Petroleum Institute (API) service classification SF, SG, SH, or SJ.

To add oil:

1. Move the snowthrower to a level surface to ensure an

accurate oil level reading.

Note: To ensure an accurate oil level reading, you must fully install the dipstick.

7. Read the oil level on the dipstick.

8. If the oil level is below the Add mark on the dipstick,

slowly pour only enough oil into the filler hole to raise the oil level to the Full mark on the dipstick.

Important Do not overfill the crankcase with oil and

run the engine; engine damage will result. Drain the excess oil until the oil level on the dipstick reads Full.

9. Insert the dipstick into the filler neck and rotate the cap

clockwise until it is tight.

Filling the Fuel Tank with Gasoline

For best results, use clean, fresh, lead-free gasoline, including oxygenated or reformulated gasoline, with an octane rating of 87 or higher. To ensure freshness, purchase only the quantity of gasoline that you expect to use in 30 days. Using unleaded gasoline results in fewer combustion deposits and longer engine life. You may use leaded gasoline if unleaded gasoline is not available.

Important Do not add oil to the gasoline. Important Do not use methanol, gasoline containing

methanol, gasohol containing more than 10% ethanol, premium gasoline, or white gas. Using these fuels can damage the engine’s fuel system.

Page 12

Important Do not use gasoline that is more than 30

days old.

Important Do not use fuel additives other than a fuel

stabilizer/conditioner. Do not use fuel stabilizers with an alcohol base such as ethanol, methanol, or isopropanol.

Danger

In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property.

• Fill the fuel tank outdoors, in an open area, and

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 level is 1/4 to 1/2 in. (6 to 13 mm) below the bottom of the filler neck. This empty space in the tank allows the gasoline to expand.

• Never smoke when handling gasoline, and stay

away from an open flame or where a spark may ignite the gasoline fumes.

• Store gasoline in an approved fuel container and

keep it out of the reach of children.

• Never buy more than a 30-day supply of

gasoline.

Danger

When fueling, under certain circumstances, a static charge can develop, igniting the gasoline. A fire or explosion from gasoline can burn you and others and damage property.

1. Clean around the fuel tank cap (Fig. 12).

2. Remove the fuel tank cap.

3. Fill the fuel tank with unleaded to within 1/4 to 1/2 inch

(6 to 13 millimeters) from the top of the tank. Do not fill into the filler neck.

Important Do not fill the fuel tank more than 1/4 inch

(6 millimeters) from the top of the tank because the gasoline must have room to expand.

4. Install the fuel tank cap and wipe up any spilled

gasoline.

Checking the Tire Pressure

Check the pressure of the tires because they are overinflated at the factory for shipping. Reduce the pressure equally in both tires to between 12 and 15 psi (82 and 103 kPa).

Reviewing the Maintenance Schedule

Review the Recommended Maintenance Schedule on page 18. You may need to perform one or more additional procedures before or soon after you begin operating the snowthrower.

• Always place gasoline containers on the ground

and away from your vehicle before filling.

• Do not fill gasoline containers inside a vehicle or

on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge.

• When practical, remove gasoline-powered

equipment from the truck or trailer and refuel the equipment with its wheels on the ground.

• If this is not possible, then refuel such

equipment on a truck or trailer from a portable container, not from a gasoline dispenser nozzle.

• If you must use a gasoline dispenser nozzle, keep

the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

Use a fuel stabilizer/conditioner regularly during operation and storage. A stabilizer/conditioner cleans the engine during operation and prevents gum-like varnish deposits from forming in the engine during periods of storage.

Operation

Note: Determine the left and right sides of the machine from the normal operating position.

Operating Controls

• Auger/Impeller Drive Control Lever (Fig. 13)—To

engage both the auger and impeller, press the lever against the right handgrip. To disengage, release the lever.

Page 13

m-4059

Figure 13

1. Auger/impeller drive control lever

2. Traction control lever

3. Speed shift control

4. Discharge chute control

• Traction Control Lever (Fig. 13)—To engage the traction (wheel drive), press the lever against the left handgrip. To stop the traction, release the lever.

• Speed Shift Control (Fig. 13)—This control has a neutral position, four forward speeds, and two reverse speeds. It also controls the power shifting of the wheels. To select a speed, move the shift control to the desired position.

Note: Before shifting the gears into or out of reverse, or when using the Power Shift feature, release the traction drive control. You man shift between any of the forward speeds without releasing the traction control lever.

• Discharge Chute Control (Fig. 13)—Rotate the discharge chute control clockwise to move the discharge chute to the right; counterclockwise to move the chute to the left.

• Auger/Impeller Lockup—When you press both the auger/impeller drive control lever and traction control lever, the traction control lever locks the auger/impeller drive control lever down. Release the traction control lever to release both levers.

• Ignition Switch (Fig. 14)—Insert the key before starting the engine. To stop the engine, remove the key.

• Choke (Fig. 14)—Rotate the choke to the On position

to start a cold engine. As engine warms up, gradually rotate the choke counterclockwise to the Off position.

• Throttle (Fig. 14)—Move the throttle upward to

increase the engine speed; move it downward to decrease the engine speed. Move the throttle to the Stop position to stop the engine.

• Primer (Fig. 14)—Press the primer to pump a small

amount of gasoline into the engine for improved cold-weather starting.

• Fuel Shutoff Valve (Fig. 15)—Close the valve by

rotating it clockwise. Open the valve by rotating it counterclockwise. Close the valve when you do not use the snowthrower.

2236

Figure 15

1. Fuel shutoff valve

2. Hose clamp

3. Fuel line

• Chute Deflector Handle (Fig. 16)—Move the deflector

handle forward to move the snow stream down and rearward to move the snow stream up.

176

Figure 16

1. Deflector handle 2. Discharge chute

1. Ignition switch

2. Choke

Figure 14

3. Throttle

4. Primer

• Recoil Starter (Fig. 17)—The recoil starter is on the

back side of the engine. Pull the recoil starter to start the engine.

m-4034

934

Figure 17

1. Recoil starter

Page 14

• Electric Starter (Fig. 18)—Push the starter button to

start the engine.

Figure 18

1. Electric starter

2. Starter button

• Power Cord (Fig. 18)—Connect the power cord to the

electric starter and to an electrical outlet when starting the engine.

m–4516

3. Receptacle

4. Power cord

Removing the Carburetor Heater Box

If you operate the engine when the air temperature is above 40F (4C), remove the carburetor heater box (Fig. 19).

m4947

Figure 20

1. Green ground wire clip

7. Install the choke knob.

8. Insert the ignition key.

9. Connect the wire to the spark plug.

Important Use the heater box as a reference for the

choke and throttle positions.

Installing the Carburetor Heater Box

To install the carburetor heater box, reverse steps 1 through 9 of Removing the Carburetor Heater Box on page 14. Remove the fasteners from their holes before installing the carburetor heater box.

m5006

Figure 19

1. Carburetor heater box

1. Disconnect the wire from the spark plug and ensure that

the wire does not contact the plug (Fig. 19).

2. Remove the key from the ignition switch (Fig. 14).

3. Pull the choke knob off (Fig. 14).

4. Remove two screws and the three bolts that secure the

carburetor heater box in place (Fig. 19). Note: Install these fasteners in their holes for safe

keeping.

5. Lift the carburetor heater box up and away from the

engine.

6. Disconnect the green ground wire clip under the throttle

(Fig. 20).

Starting the Engine

Important Ensure that there are no obstructions in the

auger/impeller and the discharge chute before you operate the snowthrower. Use a stick, not your hand, to remove an

obstruction from the auger/impeller or the discharge chute.

1. Connect the wire to the spark plug.

2. Move the speed shift control to the N (Neutral) position

and the throttle to the Fast position.

3. Release the auger/impeller drive control lever and the

traction control lever (Fig. 13).

4. Open the fuel shutoff valve below the fuel tank

(Fig. 15).

5. Rotate the choke (Fig. 14) to the On position.

6. Insert the ignition key (Fig. 14).

Important Do not use the primer or the choke if the

engine has been running and is hot. Excessive priming may flood the engine and prevent it from starting.

7. Cover the hole in the center of the primer (Fig. 14) with

your thumb and slowly push in the primer three times, pausing a moment between pushes.

8. For the recoil starter:

Page 15

A. Grasp the recoil starter handle (Fig. 17) and pull it

out slowly until positive engagement results; then pull the handle vigorously to start the engine.

B. Keep a firm grip on the starter handle and return the

rope slowly.

For the electric starter:

A. Connect the power cord to the snowthrower

(Fig. 18) and to a standard household power outlet.

Caution

If you leave the snowthrower plugged into a power outlet, someone can inadvertently start the snowthrower and injure people or damage property.

Unplug the power cord whenever you do are not starting the snowthrower.

Auger/Impeller Drive Belt on page 20. If the problem persists, take the snowthrower to an Authorized Service Dealer for service.

Figure 21

1. Large screw head

m-2680

Stopping the Engine

B. Push the starter button. Note: Run the electric starter no more than ten times at

intervals of five seconds on, then five seconds off.

Important Running the electric starter extensively can

overheat and damage the starter.

Note: If the engine does not start after this series of attempts, wait at least 40 minutes to allow the starter to cool before attempting to start it again.

Note: If the engine does not start after the second series of attempts, take the snowthrower to an Authorized Service Dealer for service.

C. When the engine starts, disconnect the power cord

from the snowthrower and the outlet.

Note: If engine does not start or if the air temperature is –10F (–23C) or colder, the engine may need additional priming. After pushing in the primer, try to start the engine before priming again.

9. After the engine starts, immediately rotate the choke (Fig. 14) to the 3/4 position. As the engine warms up, rotate the choke to the 1/2 position. When the engine warms up sufficiently, rotate the choke to the Off position.

1. Engage the auger to clear any remaining snow from

inside the housing.

2. Run the engine for a few minutes to dry off any

accumulated moisture.

3. Release the auger/impeller drive control lever and the

traction control lever (Fig. 13).

4. Shift the traction drive into the N (Neutral) position.

5. Stop the engine by doing one of the following:

A. Move the throttle to the Slow position and remove

the ignition key.

B. Move the throttle to the Stop position.

6. Close the fuel shutoff valve (Fig. 15).

7. Pull the recoil starter with a rapid, continuous, full-arm

stroke three or four times. This prevents the recoil starter from freezing up.

8. Wait for all moving parts to stop before leaving the

operating position.

Operating the Power Shift Feature

Important Ensure that the auger and impeller do not

rotate while the auger/impeller drive control lever is in the Disengaged position. Stand in the operating position and look around to the side of the auger housing (Fig. 21). A large screw head on the side of the auger housing rotates when the auger and impeller rotate (Fig. 21). If the auger

and impeller rotate while the engine runs and the auger/impeller drive control lever is disengaged, stop the snowthrower immediately. Refer to Adjusting the

Move the wheels to the rear Power Shift position in heavy or drifted snow. Leave the wheels in the front position for light snow or for transporting the snowthrower.

With the engine running at full speed:

1. Release the traction control lever (Fig. 13).

2. Move the speed shift control fully forward to the Power

Shift position and hold it there (Fig. 22).

Page 16

m-4060

Figure 22

3. Fully engage the traction drive lever to move the wheels

into the alternate position (Figs. 22 and 23). Note: When shifting, you may need to slightly raise the

handle assembly to assist the wheel movement.

179

Figure 23

4. Release the speed shift control. Note: To shift the wheels manually when the engine is not

running, follow steps 1 and 2 and then lift up on the handles to unlock the wheels.

473

Figure 24

1. Inner axle hole

2. Outer axle hole and wheel hub

3. Axle pin

Operating the Differential

For maximum maneuverability, leave the differential in the unlocked position. When you need additional traction, shift the differential to the locked position.

Important Ensure that the snowthrower is not on a

steep slope or an incline when performing this procedure.

1. Move the wheels to the rear position. Refer to decal 63-9390 in Safety and Instruction Decals on page 6 and to Operating the Power Shift Feature on page 15.

2. Shift the speed shift control to the N (Neutral) position.

3. Push lightly on the release tab of the lock spring to

disengage it from the shaft groove, and slide the coupling to the desired position.

• Locked position—Slide the coupling lock spring

into the left-hand shaft groove (Fig. 25).

Freewheeling or Self-propel Drive

You can operate the snowthrower with the self-propel feature engaged or disengaged (freewheeling). When you insert the axle pins through the outer axle holes and not through the wheel hubs (Fig. 24), the snowthrower freewheels. When you insert the axle pins through the holes in the wheel hubs and the inner axle holes (Fig. 24) and engage the traction control lever, the snowthrower propels itself.

1. Differential

2. Coupling

3. Left-hand shaft groove (locked position)

Figure 25

2163

4. Lock spring

5. Right-hand shaft groove (unlocked position)

6. Release tab—lock spring

Page 17

• Unlocked position—Slide the coupling lock spring

into the right-hand shaft groove (Fig. 25).

• Always use the Fast throttle position when throwing

snow.

Note: When sliding the coupling from the unlocked to the locked position, you may need to swivel the snowthrower slightly to allow the coupling to clear the differential body bolt heads.

Snowthrowing Tips

Danger

When the snowthrower is in operation, the impeller and auger can be rotating and cut off or injure hands and feet.

• Before adjusting, cleaning, repairing and

inspecting the snowthrower, and before unclogging the discharge chute, stop the engine and wait for all moving parts to stop. Disconnect the wire from the spark plug and keep it away from the plug to prevent someone from accidentally starting the engine.

• Use a stick, not your hands, to remove an

obstruction from the discharge chute.

• Stay behind the handles and away from the

discharge opening while operating the snowthrower.

• Keep face, hands, feet, and any other part of

your body or clothing away from concealed, moving, or rotating parts.

• Overlap each swath to ensure complete snow removal.

• Discharge the snow downwind whenever possible.

• Do not overload the snowthrower by clearing snow at

too fast a rate. If the engine slows down, shift the snowthrower into a lower gear to reduce the forward speed.

• In wet or slushy conditions, maintain maximum engine

speed, and do not overload the engine to prevent clogging the discharge chute.

• If the front of the snowthrower tends to ride up, reduce

the forward speed by shifting the snowthrower into a lower gear. If the front still tends to ride up, lift up on both handgrips to hold down the front of snowthrower.

• If the wheels slip, shift the snowthrower into a lower

gear to reduce the forward speed.

• After clearing the snow, let the engine run for a few

minutes to prevent moving parts from freezing. Engage the auger/impeller to clear any remaining snow from inside the housing. Shut off the engine, wait for all moving parts to stop, and remove all ice and snow from the snowthrower.

• With the engine shut off, pull the recoil starter handle

several times to prevent the recoil starter from freezing up.

• When you are not using the snowthrower, close the fuel

shutoff valve and remove the key.

Warning

The auger/impeller may pick up and throw stones, toys, and other foreign objects, causing serious personal injury to the operator or to bystanders.

• Keep the area to be cleared free of all objects

that could be picked up and thrown by the auger/impeller.

• Keep all children and pets away from area of

operation.

• Adjust the skids to match the type of surface being

cleaned. Refer to Adjusting the Skids and the Scraper on page 19.

• In snowy and cold conditions, some controls and

moving parts may freeze. Do not use excessive force when trying to operate frozen controls. If you have difficulty operating any control or part, start the engine and let it run for a few minutes.

• Remove snow as soon as possible after it falls. This

produces the best snow removal results.

Page 18

Maintenance

Note: Determine the left and right sides of the machine from the normal operating position.

Recommended Maintenance Schedule

Maintenance Service

Interval

Initially

1 Hour

2 Hours • Change the engine oil. Refer to Changing the Engine Oil on page 22.

5 Hours

10 Hours 15 Hours • Lubricate the drive chain. Refer to Lubricating the Drive Chain on page 23.

Maintenance Procedure

• Check the engine oil level.1 Refer to Checking the Engine Oil Level on page 19.

• Check the auger gearbox oil level and add oil if necessary. Refer to Checking the

Auger Gearbox Oil Level on page 19.

• Adjust the skids and the scraper.2 Refer to Adjusting the Skids and the Scraper on page 19.

• Inspect and adjust the traction drive belt. Refer to Adjusting the Traction Drive Belt on page 20.

• Inspect and adjust the auger/impeller drive belt. Refer to Adjusting the Auger/Impeller Drive Belt on page 20.

• Inspect and adjust or replace the traction drive belt if necessary. Refer to Adjusting the Traction Drive Belt on page 20, or to Replacing the Drive Belts on page 21.

• Inspect and adjust or replace the auger/impeller drive belt if necessary. Refer to Adjusting the Auger/Impeller Drive Belt on page 20, or to Replacing the Drive Belts on page 21.

• Check the auger gearbox oil level and add oil if necessary. Refer to Checking the Auger Gearbox Oil Level on page 19.

• Change the engine oil. Refer to Changing the Engine Oil on page 22.

25 Hours

100 Hours

Annually

Check the engine oil level

Adjust the skids and the scraper as needed.

Important Refer to your engine operator’s manual for additional maintenance procedures.

before each use

• Inspect and adjust the drive chain if necessary. Refer to Adjusting the Drive Chain on page 23.

• Inspect and gap the spark plug. Replace it if necessary. Refer to Replacing the Spark Plug on page 24.

• Check the auger gearbox oil level after removing the snowthrower from storage and add oil if necessary. Refer to Checking the Auger Gearbox Oil Level on page 19.

• Change the engine oil at the end of the snowthrowing season. Refer to Changing the Engine Oil on page 22.

• Lubricate the drive chain. Refer to Lubricating the Drive Chain on page 23.

• Drain the gasoline and run the engine to dry out the fuel tank and the carburetor

at the end of the snowthrowing season. Refer to Emptying the Fuel Tank on page 24.

and add oil if necessary.

Page 19

Caution

If you leave the wire on the spark plug, someone could accidently start the engine and seriously injure you or other bystanders.

Disconnect the wire from the spark plug before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug.

Checking the Engine Oil Level

Every time you use the snowthrower, first ensure that the oil level is between the Add and the Full marks on the dipstick.

1. Stop the engine and wait for all moving parts to stop.

2. Move the snowthrower to a level surface to ensure an

accurate oil level reading.

3. Clean around the dipstick (Fig. 12).

4. Remove the dipstick by rotating the cap

counterclockwise and pulling it out (Fig. 12).

5. Wipe the dipstick clean with a clean cloth.

6. Install the dipstick into the filler neck, then remove it. Note: To ensure an accurate oil level reading, you must

fully install the dipstick.

7. Read the oil level on the dipstick.

8. If the oil level is below the Add mark on the dipstick,

slowly pour only enough oil into the filler hole to raise the oil level to the Full mark on the dipstick.

Note: Use only a high-quality, SAE 5W–30 or SAE 10 weight detergent oil that has the American Petroleum Institute (API) service classification SF, SG, SH, or SJ. For extremely cold conditions (below 0°F or –18°C), use 0W–30 weight detergent oil that has the American Petroleum Institute (API) service classification SF, SG, SH, or SJ.

2. Move the snowthrower to a level surface.

3. Disconnect the wire from the spark plug and ensure that

the wire does not contact the spark plug (Fig. 12).

4. Clean the area around the pipe plug (Fig. 26).

Figure 26

1. Pipe plug

5. Remove the pipe plug from the gearbox (Fig. 26).

6. Check the oil level in the gearbox. The oil should be at

the point of overflowing in the filler opening.

7. If the oil level is low, add GL-5 or GL-6, SAE 85–95 EP

transmission oil to the gearbox until the point of overflow. Do not use synthetic gear oil.

8. Install the pipe plug in the gearbox.

9. Connect the wire to the spark plug.

171

Adjusting the Skids and the

Important Do not overfill the crankcase with oil and

run the engine; engine damage will result. Drain the excess oil until the oil level on the dipstick reads Full.

9. Insert the dipstick into the filler neck and rotate the cap clockwise until it is tight.

Checking the Auger Gearbox Oil Level

Check the oil level in the auger gearbox initially, after every ten operating hours, and when you remove the snowthrower from annual storage.

1. Stop the engine and wait for all moving parts to stop.

Scraper

Adjust the skids and the scraper initially and then as needed to ensure that the auger does not contact the paved or gravel surface. Also, adjust them as needed to compensate for wear.

1. Stop the engine and wait for all moving parts to stop.

2. Move the snowthrower to a level surface and shift the

wheels to the front position.

3. Disconnect the wire from the spark plug and ensure that

the wire does not contact the plug (Fig. 12).

4. Check the tire pressure in the tires. Refer to Checking

the Tire Pressure on page 12.

Page 20

5. Loosen the four flange bolts that secure both skids to

the auger side plates (Fig. 10) until the skids slide up and down easily.

6. Support the auger blades so that they are at least

1/8 inch (3 millimeters) off the ground (Fig. 27).

171

Figure 27

1. Scraper

2. Carriage bolt (6)

3. Auger blades

Note: Setting the auger blades too low may result in damage to the snowthrower that is not covered by the warranty.

1. Loosen the upper jam nut that secures the traction cable

to the mounting bracket (Fig. 28).

183

Figure 28

1. Jam nut

2. Mounting bracket

3. Auger/impeller cable (outer cable)

4. Traction cable (inner cable)

2. Rotate the bottom jam nut upward to increase the belt

tension (Fig. 28). Note: When you adjust the cable, always rotate the jam

nut one full turn at a time.

7. Check the scraper adjustment. The scraper should be

1/8 inch (3 millimeters) above and parallel to a level surface.

Note: Setting the scraper too low may result in damage to the snowthrower that is not covered by the warranty.

For Concrete and Asphalt Surfaces:

If the snowthrower does not clear the snow close enough to the pavement, adjust the skids to lower the scraper; if the pavement surfaces are cracked, rough, or uneven, adjust the skids to raise the scraper.

For Gravel Surfaces:

Support the auger blades a few inches (centimeters) above the ground, and adjust the skids to prevent the snowthrower from picking up rocks.

8. To adjust the scraper, loosen the carriage bolts that

secure the scraper to the auger housing (Fig. 27), level the scraper, and tighten the carriage bolts.

9. Move the skids down as far as possible.

10.Tighten the two front flange bolts that secure both skids

to the auger side plates.

11. Connect the wire to the spark plug.

3. Tighten the upper jam nut against the bracket.

4. Check the tension of the belt by operating the

snowthrower. Note: The snowthrower should begin to move forward

when you press the traction control lever about halfway down toward the handgrip.

5. Stop the engine and repeat steps 1 through 4 until you

achieve the proper adjustment.

Important Do not adjust the belt too tightly; a tight

belt can cause the snowthrower to creep even after you release the traction control lever. If this occurs, decrease the belt tension.

Adjusting the Auger/Impeller Drive Belt

Operating the snowthrower with an auger/impeller drive belt that slips decreases the snowthrowing performance and damages the belt. Check the auger/impeller drive belt for the proper tension after the first operating hour, after every five operating hours thereafter. Adjust the belt when necessary.

1. Stop the engine and wait for all moving parts to stop.

Adjusting the Traction Drive Belt

Check the traction drive belt for the proper tension after the first operating hour, after every five operating hours thereafter. Adjust the belt when necessary or whenever you replace it.

2. Disconnect the wire from the spark plug and ensure that

the wire does not contact the plug (Fig. 32).

3. Remove the three flange-head bolts that secure the belt

cover to the engine frame and slide the belt cover up the cables (Fig. 5).

4. Depress the auger/impeller drive control lever (Fig. 13).

Page 21

5. Hold the lever and insert a 0.010 in. (0.25 mm) feeler

gauge between a coil in the center of the spring (Fig. 29).

Danger

Improperly adjusting the auger/impeller drive belt may cause injury if the auger/impeller continues to turn after you release the control lever. A rotating impeller or auger can cut off or injure fingers or hands.

907

Figure 29

1. Center of spring 2. Feeler gauge

6. If the space between the coils is not 0.010 in.

(0.25 mm), adjust the cables as follows: A. Loosen the upper jam nut that secures the

auger/impeller cable to the mounting bracket (Fig. 28).

B. Rotate the bottom jam nut upward to increase the

belt tension.

C. Tighten the upper jam nut against the bracket.

7. Repeat steps 4 through 6.

8. Check the impeller brake arm clearance by releasing the

auger/impeller drive control lever. Note: With the lever released, there should be at least

1/8 in. (3 mm) clearance between the tab on the impeller idler arm and the brake arm (Fig. 30).

• Keep your face, hands, feet, and any other part

of your body or clothing away from moving or rotating parts.

• Maintain the proper impeller brake arm

clearance.

• Do not adjust the auger/impeller drive belt too

tightly. If the auger/impeller continues to turn after you release the control lever, decrease the belt tension.

9. Install the belt and the cable covers.

10.Check the belt tension by operating the auger/impeller.

11. If belt still slips, replace it. Refer to Replacing the

Drive Belts on page 21.

12.Connect the wire to the spark plug.

Replacing the Drive Belts

If the auger/impeller drive belt or the traction drive belt (Fig. 31) becomes worn, oil-soaked, or otherwise damaged, replace the belt.

184

Figure 30

1. Impeller idler arm

2. Brake arm

3. 1/8 in. (3 mm) minimum

Important If there is less than 1/8 in. (3 mm) clearance

between the tab on the impeller idler arm and the brake arm, replace the belt. Refer to Replacing the Drive Belts on page 21.

185

Figure 31

1. Idler pulley assembly

2. Flange-head bolts

3. Idler pulley

4. Traction drive belt

5. Middle pulley section

6. Auger/impeller drive belt

7. Half sheave

8. Bolt and lock washer

1. Stop the engine and wait for all moving parts to stop.

2. Disconnect the wire from the spark plug and ensure that

the wire does not contact the plug (Fig. 32).

Page 22

3. Remove the three flange-head bolts that secure the belt

cover to the engine frame and slide the belt cover and the cable cover up the cables (Fig. 5).

4. Move the speed shift control to the N (Neutral) position.

5. Remove the two-flange bolts that secure the idler pulley

assembly to the engine frame and remove idler pulley assembly (Fig. 31).

6. Remove the bolt and the lock washer that secure the

half sheave to the front of the pulley assembly (Fig. 31).

7. Slide the half sheave and auger/impeller drive belt off

the crankshaft and remove the belt (Fig. 31).

8. If you need to replace the traction drive belt, slide the

middle pulley section and the belt off the crankshaft, and remove the belt from the pulley (Fig. 31).

9. On the control cable that corresponds to the belt you are

replacing, loosen the jam nuts that secure the cable to the bracket (Fig. 28).

Note: The cable must slide freely in the bracket when you change the belts.

10.If you replace the traction drive belt, install it around

the traction drive and the middle pulley section, and slide the middle pulley section onto the crankshaft (Fig. 31).

11. Install the traction drive belt on the idler pulley

(Fig. 31).

12.Install the auger/impeller drive belt around the half

sheave, and slide the half sheave onto the crankshaft (Fig. 31).

Note: Ensure that the tabs on the half sheave are inserted into the mounting grooves in the middle pulley.

13.Install the bolt and the lock washer that secure the half

sheave to the front of the pulley assembly.

14.Install the idler pulley assembly on the engine frame

and secure it with the two flange-head bolts (Fig. 31).

1. Stop the engine and wait for all moving parts to stop.

2. Disconnect the wire from the spark plug and ensure that

the wire does not contact the plug (Fig. 32).

m-4068

Figure 32

1. Spark plug wire

3. Clean the area around the oil drain plug (Fig. 33).

182

Figure 33

1. Drain plug

4. Slide an oil drain pan under the drain extension and

remove the oil drain plug.

5. Drain the oil.

6. Install the oil drain plug.

7. Fill the crankcase with oil. Refer to Filling the Engine

Crankcase with Oil on page 11.

8. Wipe up any spilled oil.

9. Connect the wire to the spark plug.

Note: Ensure that the idler pulleys align with the belts

when you install the idler pulley assembly.

15.Install the belt and the cable covers.

16.To adjust the belts, refer to Adjusting the Traction Drive

Belt on page 20 or Adjusting the Auger/Impeller Drive Belt on page 20.

17.Connect the wire to the spark plug.

Changing the Engine Oil

Change the engine oil after the first two operating hours, after every 25 operating hours, and at the end of the snowthrowing season. If possible, run the engine just before changing the oil because warm oil flows better and carries more contaminants.

Page 23

Lubricating the Drive Chain

Lightly lubricate the drive chain after every 15 operating hours and at the end of the snowthrowing season.

1. Disconnect the wire from the spark plug and ensure that

the wire does not contact the plug (Fig. 32).

2. Lightly lubricate the drive chain with a chain lubricant

(Fig. 34).

181

Figure 34

1. Drive chain

8. If the deflection is not between 1/8 and 3/8 in. (3 and

10 mm), go to step 9; otherwise, return the snowthrower to its upright position.

9. Loosen the four flange-head bolts (two on each side)

that secure the transmission frame to the engine frame (Figs. 36 and 37).

187

Figure 36

1. Transmission 2. Transmission frame

3. Wipe up any excess oil.

4. Connect the wire to the spark plug.

Adjusting the Drive Chain

Check the chain deflection after every 25 operating hours. If the deflection mid span between the transmission and the axle sprocket is not between 1/8 and 3/8 in. (3 and 10 mm), adjust the drive chain.

1. Stop the engine and wait for all moving parts to stop.

2. Disconnect the wire from the spark plug and ensure that

the wire does not contact the plug (Fig. 32).

3. Drain the gasoline from the fuel tank. Refer to

Emptying the Fuel Tank on page 24.

4. Shift the wheels into the rear position.

5. Move the speed shift control into second gear.

6. Tip the snowthrower forward onto its auger housing and

block it so that it cannot fall.

7. Check the deflection of the chain by lifting up on it with

moderate pressure at the mid span. There should be a 1/8 to 3/8 in. (3 to 10 mm) deflection (Fig. 35).

189

Figure 37

1. Flange head bolts

10.Pivot the rear of the transmission frame until the chain

deflection is between 1/8 and 3/8 in. (3 and 10 mm).

11. Tighten the flange-head bolts.

12.Check the chain deflection.

Important Excessive chain tension may cause

transmission damage.

13.Check the speed shift control alignment with the Power

Shift slot. If the gear shift lever does not align with the Power Shift slot in the control panel (see inset in Fig. 6), adjust the shift rod length as follows:

A. Disconnect the ball joint from the transmission lever

and loosen the jam nut.

B. Rotate the ball joint up or down until the gear shift

lever aligns with the Power Shift slot.

Figure 35

1. 1/8 to 3/8 in. (3 to 10 mm) deflection

C. Install the ball joint to the transmission lever and

tighten the jam nut.

186

14.Connect the wire to the spark plug.

Page 24

Replacing the Spark Plug

Use a Champion RN4C or equivalent spark plug. Install a new plug after every 100 operating hours.

1. Stop the engine and wait for all moving parts to stop.

2. Clean any debris from around the base of the spark

plug.

3. Disconnect the wire from the spark plug (Fig. 12).

4. Remove the spark plug.

5. Examine the spark plug and replace it if it is cracked,

fouled, dirty, or if the electrodes are worn.

Important Do not clean the electrodes because grit

could enter the cylinder and damage the engine.

6. Set the gap between the electrodes on the spark plug at

0.030 in. (0.76 mm) as shown in Figure 38.

5. Loosen the hose clamp that secures the fuel line to the

valve and slide the fuel line off the fuel shutoff valve (Fig. 15).

6. Open the fuel shutoff valve and allow the fuel to drain

out of the fuel tank into the drain pan.

7. Install the fuel line onto the fuel shutoff valve and

secure it with a hose clamp.

8. Connect the wire to the spark plug.

9. Start the snowthrower and run the engine until it stops.

Repeat this step two more times to ensure that the fuel tank and the carburetor are empty.

Storage

Warning

110

Figure 38

1. 0.030 in. (0.76 mm)

7. Install the spark plug by hand and then torque it to

15 ft-lb (20.4 Nm). If you do not have a torque wrench, tighten the plug firmly.

8. Connect the wire to the spark plug.

Emptying the Fuel Tank

1. Stop the engine and wait for all moving parts to stop.

2. Disconnect the wire from the spark plug (Fig. 12)

3. Close the fuel shutoff valve (Fig. 15).

Danger

Gasoline is highly flammable; it can ignite and cause serious personal injury.

• 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 by a spark.

• Do not smoke a cigar, a cigarette, or a pipe when

handling gasoline.

4. Place a clean drain pan under the fuel shutoff valve.

Gasoline fumes are highly flammable, explosive, and dangerous if inhaled. If the product is stored in an area with an open flame, the gasoline fumes may ignite and cause an explosion.

Do not store the snowthrower in a house (living area), basement, or any other area where ignition sources may be present, such as hot water and space heaters, clothes dryers, furnaces, and other like appliances.

Preparing the Fuel System

1. Add stabilizer/conditioner to the fuel in the fuel tank as

directed.

2. Run the engine for ten minutes to distribute conditioned

fuel through the fuel system.

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

or run the engine until it stops. Refer to Emptying the Fuel T ank on page 24.

4. Start the engine and run it until it stops.

5. Choke or prime the engine, start it a third time, and run

the engine until it will not start.

6. Dispose of unused fuel properly. Recycle it according to

local codes, or use it in your automobile.

Note: Do not store stabilized gasoline for more than 90 days.

Preparing the Engine

1. While the engine is still warm, change the engine oil.

Refer to Changing the Engine Oil on page 22.

2. Remove the spark plug.

Page 25

3. Use an oil can to squirt two teaspoons of oil into the

Engine does not start or starts

1.The key is not in the ignition or

1.Insert the key into the ignition

spark plug hole.

4. Install the spark plug by hand and then torque it to 15 ft-lb (20.4 Nm). If you do not have a torque wrench, tighten the plug firmly. Do not connect the wire to the

plug.

4. Cover the snowthrower and store it in a clean, dry place out of the reach of children. Allow the engine to cool before storing it in any enclosure.

Accessories

5. Pull the recoil starter slowly to distribute the oil on the

inside of the cylinder.

Preparing the Snowthrower

1. Clean the snowthrower.

2. Touch up chipped surfaces with paint available from an

Authorized Service Dealer. Sand affected areas before painting, and use a rust preventative to prevent the metal parts from rusting.

3. Tighten all screws and nuts. Repair or replace any

damaged parts.

You can obtain the following snowthrower accessories from your Authorized Service Dealer:

• Tire Chain Kit (for the standard axle; not for use with the Differential Kit)

• Drift Breaker Kit

• Snow Cab Kit

• Weight Kit

• Heavy-Duty Skids Kit

• Light Kit

Troubleshooting

Toro designed and built your snowthrower for trouble-free operation. Check the following components and items carefully, and refer to Maintenance on page 18 for more information. If a problem continues, see an Authorized Service Dealer.

Problem Possible Causes Corrective Action

Electric starter does not turn (electric-start models only)

1. The power cord is disconnected at the outlet or the snowthrower.

1. Connect the power cord to the outlet and/or the snowthrower.

2. The power cord is worn, corroded, or damaged.

3. The power outlet is not energized.

Engine does not start or starts 1. The key is not in the ignition or 1. Insert the key into the ignition hard

is in the

2. The choke is in the and the primer has not been pressed.

3. The fuel shutoff valve is not open.

4. The throttle is not in the position.

5. The fuel tank is empty or the fuel system contains stale fuel.

6. The spark plug wire is loose or disconnected.

Off

position.

Off

position

Fast

2. Replace the power cord.

3. Have a qualified electrician energize the power outlet.

and turn it to the On position.

2. Move the choke to the position and press the primer three times.

3. Open the fuel shutoff valve.

4. Move the throttle to the position.

5. Drain and/or fill the fuel tank with fresh gasoline (not more than 30 days old). If the problem persists, contact your Authorized Service Dealer.

6. Connect the wire to the spark plug.

Fast

Page 26

Problem Corrective ActionPossible Causes

7. The spark plug is pitted, fouled, or the gap is incorrect.

8. The fuel cap vent is restricted. 8. Remove the vent restriction or

9. The engine oil level in the engine crankcase is too low or too high.

10.The air temperature is above 40°F (4°C) and the carburetor heater box is on the snowthrower.

Engine runs rough 1. The choke is in the On position. 1. Move the choke to the

2. The fuel shutoff valve is not completely open.

3. The fuel tank is nearly empty or contains stale fuel.

7. Check the spark plug and adjust the gap if necessary. Replace the spark plug if it is pitted, fouled, or cracked.

replace the fuel cap.

9. Add or drain oil to adjust the oil level in engine crankcase to the

Full

mark on the dipstick.

10.Remove the carburetor heater box.

position.

2. Open the fuel shutoff valve.

3. Drain and fill the fuel tank with fresh gasoline (not more than 30 days old). If the problem persists, contact an Authorized Service Dealer.

Off

Engine runs, but the snowthrower discharges snow poorly or not at all

4. The spark plug wire is loose. 4. Connect the wire to the spark plug.

5. The spark plug is pitted, fouled,

or the gap is incorrect.

6. The engine oil level in the

engine crankcase is too low or too high.

7. The air temperature is above

40°F (4°C) and the carburetor heater box is on the snowthrower.

1. The throttle is not in the

position when throwing snow.

2. The snowthrower is moving too

fast to clear the snow.

3. You are trying to remove too

much snow per swath.

4. You are trying to remove

extremely heavy or wet snow.

Fast

5. Check the spark plug and adjust the gap if necessary. Replace the spark plug if it is pitted, fouled, or cracked.

6. Add or drain the oil level in the engine crankcase to the mark on the dipstick.

7. Remove the carburetor heater box.

1. Move the throttle to the position.

2. Shift the snowthrower into a lower gear.

3. Reduce the amount of snow removed for per swath.

4. Don’t overload the snowthrower with extremely heavy or wet snow.

Full

Fast

5. The discharge chute is plugged.

5. Stop the engine, wait for all moving parts to stop, and use a stick to remove the snow from the discharge chute.

Page 27

Problem Corrective ActionPossible Causes

Snowthrower does not properly clear the snow off the surface

6. The auger/impeller drive belt is loose or is off the pulley.

7. The auger/impeller drive belt is worn or broken.

1. The tire pressure is low. 1. Check the pressure in the tires

2. The skids and/or the scraper is not properly adjusted.

6. Install and/or adjust the auger/impeller drive belt.

7. Replace the auger/impeller drive belt.

and adjust it if necessary.

2. Adjust the skids and the scraper.

Page 28

Gas Powered Snow Products

The Toro Total Coverage Guarantee

A Two-Year Full Warranty

(Limited Warranty for Commercial Use)

Conditions and Products Covered

The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair any Toro Product used for normal residential purposes* if defective in materials or workmanship for a period of two years from the date of purchase.

This warranty includes the cost of parts and labor, but you must pay transportation costs. Transportation within a fifteen mile radius of the servicing dealer is covered under this warranty for two-stage snowthrowers only.

This warranty applies to all gasoline powered snow products. * Normal residential purposes means use of the product on the

same lot as your home. Use at more than one location is considered commercial use, and the commercial use warranty would apply.

Limited Warranty for Commercial Use

Toro Consumer Products used for commercial, institutional, or rental use are warranted against defects in materials or workmanship for 45 days from the date of purchase.

Instructions for Obtaining Warranty Service

If you think that your Toro Product contains a defect in materials or workmanship, follow this procedure:

1. Contact any Toro Authorized or Master Service Dealer to arrange service at their dealership. To locate a dealer convenient to you, refer to the Yellow Pages of your telephone directory (look under “Lawn Mowers”) or access our website at www.Toro.com. U.S. Customers may also call 800-421-9684 to use our 24-hour Toro dealer locator system.

2. Bring the product and your proof of purchase (sales receipt) to the Service Dealer.

If for any reason you are dissatisfied with the Service Dealer’s analysis or with the assistance provided, contact us at:

Customer Care Department, Consumer Division Toro Warranty Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196 800-348-2424 (U.S. customers) 877-484-9255 (Canada customers)

Y ou must maintain your Toro Product by following the maintenance procedures described in the operator’s manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense.

There is no other express warranty except for special emission system coverage on some products and the Toro Starting Guarantee on GTS engines. This express warranty does not cover:

• Cost of regular maintenance service or parts, such as filters, fuel, lubricants, tune-up parts, blade sharpening, brake and clutch adjustments

• Any product or part which has been altered or misused or required replacement or repair due to normal wear, accidents, or lack of proper maintenance

• Repairs necessary due to improper fuel, contaminants in the fuel system, or failure to properly prepare the fuel system prior to any period of non-use over three months

All repairs covered by this warranty must be performed by an Authorized Toro Service Dealer using Toro approved replacement parts.

Repair by an Authorized Toro Service Dealer is your sole remedy under this warranty.

Neither The Toro Company nor Toro Warranty Company is liable for indirect, incidental or consequential damages in connection with the use of the Toro Products covered by this warranty, including any cost or expense of providing substitute equipment or service during reasonable periods of malfunction or non-use pending completion of repairs under this warranty.

Some states d o n o t a l l o w exclusions of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions and limitations may not apply to you.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Owner Responsibilities

Items and Conditions Not Covered

General Conditions

Countries Other than the United States or Canada

Customers who have purchased Toro products exported from the United States or Canada should contact their T oro Distributor (Dealer) to obtain guarantee policies for your country , province, or state. If for any reason you are dissatisfied with your Distributor’s service or have difficulty obtaining guarantee information, contact the Toro importer. I f all other remedies fail, you may contact us at Toro Warranty Company.

Part No. 374-0011 Rev. A